A. Repl. Methanol Concentration Sensor & Install Wiring Jumper
WARNING:Wear methanol resistant gloves, eye protection and avoid breathing fumes. Do not allow the methanol/gasoline mixture to contact skin. Service the vehicle in a well-ventilated area and avoid all ignition sources.
1. With the ignition key in the "OFF" position, disconnect the battery.
Note:
To enhance customer satisfaction, record all of the radio settings before disconnecting the battery and reset all electronic memory (clock, radio settings, etc.) when you have completed the service procedure.
2. Remove and reinstall the fuel tank filler cap to release the fuel tank pressure.
3. Remove the protective cap from the pressure test port located on the fuel rai1.
4. Obtain the hose from the fuel pressure gauge tool set # C-4799-A. Position one end of the hose into an approved gasoline container. Then attach the other end of the hose to the fuel rail test port to release the fuel pressure.
WARNING:
Do not allow the fuel to spill onto the intake or exhaust manifolds. Place shop towels under and around the pressure port to absorb fuel when the pressure is released from the rail.
5. Remove the hose from the fuel rail and reinstall the test port cap,
6. Raise the vehicle on an appropriate hoist.
7. For LH vehicles: Use an appropriate jack stand to support the front of the fuel tank.
8. For LH vehicles: Remove the four fuel tank mounting strap bolts and then carefully remove the fuel tank strap and sway bar brackets (Figure 1).
9. For LH vehicles: Remove the left side fuel tank heat shield. Save the shield for later installation.
10. Disconnect the methanol sensor wiring connector (Figure 2 and 3). Remove the brown locking tab from the rear of the original wiring connector and then remove the three wire terminals from the connector using a small screw driver, Miller Special Tool 8197 or equivalent.
12. Slip one piece of heat shrink tubing (three pieces provided) over each of the terminals on the new wiring jumper harness.
13. Connect the three jumper harness wire terminals to the three original methanol sensor wiring terminals. Be sure to match the appropriate wire color on both harnesses.
NOTE:
On LH vehicles only, the YELLOW with WHITE tracer wire on the original sensor wiring must be connected to the BLACK with RED tracer wire on the new jumper harness.
14. Slide the three pieces of heat shrink tubing over the three terminal connections. Heat the tubing until sealant comes out of both ends of each piece of heat shrink tubing.
15. Disconnect the fuel inlet and outlet hose quick connect fittings from the methanol concentration sensor (Figures 2 and 3).
WARNING:
Residual fuel may remain in the fuel lines even though the fuel pressure has been released. Use extreme care when disconnecting the quick connect fittings and have an approved gasoline container available to catch any residual fuel.
16. ^ For LII vehicles: Remove the methanol concentration sensor mounting nuts. Remove and discard the old sensor.
IMPORTANT:
Avoid the use of excessive force when removing the methanol sensor retaining nuts. If a sensor retaining screw breaks replace it with PN 06502841.
^ For AA vehicles: Remove the methanol concentration sensor bracket screws. Remove and discard the old sensor and bracket assembly.
17. Install the new methanol concentration sensor.
^ For LII vehicles: Tighten the sensor mounting nuts to 20 in-lbs (2.3 N.m).
^ For AA vehicles: Tighten the bracket-to-crossmember mounting screws to 40 in-lbs (4.5 N.m).
18. Install the fuel inlet and outlet hose quick connects onto the methanol sensor as outlined below:
a. Wipe the sensor tube ends which will be inserted into the quick connects with a clean lint free cloth.
b. Check the tube surfaces for burrs. Remove any burrs as necessary.
c. Prior to connecting the fittings to the sensor tube, lightly coat the exterior surface of the sensor tube nipples with clean 30-weight engine oil.
d. Push the quick connects onto the sensor tubes until the retainers seat and a click is heard for each connection. Pull back on the quick connects to ensure that the quick connects are firmly locked in place. Do not rely only on the audible click to confirm that secure connections have been made.
WARNING:
It is extremely important that the fuel tube and quick connect seating is checked as described in Step D. If the tube and quick connect are not fully secured, normal fuel pressure could eventually unseat the joint, resulting in fuel leakage.
19. Connect the new wiring jumper harness connector to the new methanol sensor.
20. For LH vehicles: Reinstall the fuel tail heat shield that was removed in Step 9.
21. For LH vehicles: Position the fuel tail strap and the sway bar mounting brackets into place. Install and tighten the bolts to 44 ft-lbs (60 N.m) torque.
22. Lower the vehicle.
23. Reconnect the battery.
24. Start the vehicle and check the fuel system for leaks.