Service Procedure
SERVICE PROCEDUREWARNING:
Never open the cooling system when the engine is hot. Serious burns may occur from hot high-pressure engine coolant escaping from the cooling system.
1. Write down the radio station presets.
2. If equipped, write down the customer settings for the ATC (Automatic Temperature Control) system. (Refer to the Service Manual as needed.)
3. With ignition ON:
a. Perform "FUEL PRESSURE RELEASE" in "WORK SUPPORT" mode of "ENGINE" using CONSULT III plus.
b. Start engine.
c. After engine stalls, crank it two or three times to release all fuel pressure.
d. Turn ignition OFF.
4. Disconnect both battery cables; negative cable first.
5. Carefully remove the engine cover.
^ Use hand pressure to carefully pull up at the mounting locations shown in Figure 2.
CAUTION:
In cold temperatures the engine cover may be harder to remove. To prevent breakage, carefully pull up to remove.
6. Remove the plastic air inlet tube as follows (see Figure 3):
a. Remove the mounting bolt.
b. Disconnect the recirculation valve vacuum hose (disconnect this hose from the metal pipe end).
CAUTION:
Do not attempt to disconnect the vacuum hose from the recirculation valve side.
c. Disconnect air inlet hose from air recirculation valve.
d. Disconnect manifold absolute pressure sensor harness connector and harness clip.
NOTE:
Harness clip must be pinched at bottom to release.
e. Loosen clamps at each end of the air inlet air tube.
f. Remove air inlet tube and set it in a safe area.
CAUTION:
Use rags to cover engine air inlet tube to prevent debris from entering the engine.
7. Loosen spring clamp and remove brake vacuum hose from metal pipe.
8. Loosen clamp on upper air hose to rear turbo and remove hose from turbo inlet.
NOTE:
Insert rag over hose opening to prevent debris from entering hose.
9. Using 10 mm socket and 10 mm wrench, remove 3 bolts securing brake vacuum tube.
10. Disconnect connector from EVAP solenoid. Remove harness clip by pinching clip at bottom to remove from bracket.
11. Loosen spring clamp and remove only the upper vacuum hose on EVAP solenoid.
12. Loosen spring clamp and remove rear vacuum hose on EVAP valve.
13. Remove oil dipstick.
14. Using 8 mm socket:
^ Remove 3 bolts securing EVAP valve and solenoid assembly (circled in green).
^ Set aside EVAP valve and solenoid assembly.
WARNING:
^ Never remove radiator cap or engine coolant hoses when the engine is hot. Serious burns may occur from high pressure engine coolant escaping from the engine cooling system.
^ Make sure engine has cooled before proceeding with the next step.
15. Remove coolant hoses:
a. Crimp hoses with crimping pliers.
b. Loosen spring clamps and slowly remove coolant hoses from throttle body.
NOTE:
Use rags to capture coolant drips.
CAUTION:
Use face and hand personal protection equipment as coolant may be hot.
16. Disconnect harness connector from throttle body.
17. Using an 8 mm socket, remove 4 bolts (circled in green) securing the throttle body to the intake manifold.
^ Remove the throttle body and set it aside.
^ Cover the intake opening with a clean rag to prevent debris entry.
18. Using hand pressure, remove the black foam insulator from below the throttle body opening.
19. Loosen the spring clamp and remove the Positive Crankcase Ventilation (PCV) hose from the intake.
20. Using 10 mm socket, remove 5 intake manifold bolts on top of intake, shown by green arrows in Figure 17.
21. Using 10 mm socket, remove 1 intake manifold bolt (shown in Figures 18 and 19) on drivers side of intake manifold.
22. Remove intake manifold.
a. Lift up on left side of intake and remove alternator harness clips by pinching clip at bottom to remove from intake manifold.
b. Pull top of intake toward radiator and release bottom alternator harness clip (indicated by green arrows) from bottom of intake by using a long flat blade screwdriver.
c. Remove intake manifold and set aside.
d. Cover intake ports with rag to prevent debris entry.
23. Locate fuel rail pressure sensor and disconnect harness connector.
Inspect sensor for any visible leakage.
No evidence of leaking - go to next step.
Evidence of leaking is found:
a. Remove the fuel rail pressure sensor.
b. Replace the Gasket - P/N 16635-1LA0A.
c. Reinstall the fuel rail pressure sensor.
d. Go to the next step.
24. Determine the correct torque setting for your torque wrench as follows:
^ Measure the length of your torque wrench between the center of the handle and the center of the square drive as shown in Figure 24, then go to Table A below to get the torque setting.
NOTE:
^ The use of a 3 inch extension (special tool J-50991, Figure 26) requires that you use a calculated torque setting that matches the length of your torque wrench.
^ Make sure you keep the extension tool - J50991 - straight (in line) with torque wrench as shown in Figure 25.
Table A
25. Attach special tool J-50991 (shown in Figure 26) to your torque wrench.
26. Torque the fuel rail pressure sensor to the specified torque.
27. Connect fuel rail pressure sensor harness connector.
NOTE:
Connector can not be seen after intake is installed.
28. Remove breather hose from valve cover.
^ Release spring clamp and remove hose.
29. Remove fuel pump foam insulator and bracket.
a. Using 10 mm socket remove 1 bolt securing fuel pump foam insulator bracket.
b. Remove foam insulator.
30. Locate fuel supply line attached to fuel rail.
31. Torque fuel rail connector bolts and flange nut.
^ Using 19 mm crowfoot wrench, torque flange nut to 33.4 N-m (3.4 kg-m, 25 ft-lb).
^ Using 8 MM socket torque 2 fuel rail connector bolts to 10 N-m (1.0 bolts kg-m, 89 in-lb).
32. Torque fuel pump flange nut:
a. Pull EVAP hose out from underneath wiring harness and fold out of the way.
b. Using 19 mm crowfoot wrench, torque fuel pump flange nut to:
33.4 N-m (3.4 kg-m, 25 ft-lb)
Reassembly
33. Install fuel pump foam insulator and bracket.
a. Install foam insulator.
b. Install bracket and secure with 10 mm bolt.
34. Install breather hose and position clamp.
35. Install new intake manifold gasket.
NOTE:
^ For vehicles in dealer inventory (less than 125 miles), a new gasket is not needed.
^ Clean and inspect the old gasket. Make sure gasket is not torn or cut and is installed properly.
36. Remove rag covering intake ports and install intake manifold.
^ Connect lower alternator harness clip (indicated by green arrows) to bottom of intake manifold.
37. Hand start 6 intake manifold bolts (5 top bolts, 1 side bolt).
NOTE:
Side intake manifold bolt is shorter than top bolts.
a. Hand start all bolts first. Then torque 5 bolts on top in the order shown in Figure 41.
^ Torque specification:
27 N-m (2.75 kg-m, 20 ft-lb)
NOTE:
Torque the center bolt twice.
b. Torque one bolt (shown in Figure 42 and 43) on driver side.
^ Torque specification:
19.6 N-m (2.0 kg-m, 14 ft-lb)
38. Secure 2 alternator harness clips to the intake manifold.
39. Using hand pressure, install the foam insulator below the throttle body opening.
40. Reinstall the throttle body:
a. Remove rag form the throttle body opening.
b. Install a new gasket.
NOTE:
^ For vehicles in dealer inventory (less than 125 miles), a new gasket is not needed.
^ Clean and inspect the old gasket.
^ Make sure the gasket is not torn or cut and it is installed properly.
c. Install the throttle body.
d. Hand start 4 bolts (circled in green) and torque to:
10.0 N-m (21.0 kg-m, 89 in-lb)
41. Connect throttle body harness connector.
42. Secure coolant hoses to throttle body:
a. Install hoses.
b. Position clamps.
c. Remove hose crimping pliers.
d. Clean any coolant drips.
43. Secure PCV hose to intake manifold and position clamp.
44. Secure EVAP valve and solenoid assembly using three 8 mm bolts (circled in green).
45. Install EVAP valve and solenoid hoses and position clamps.
^ Route EVAP hose under wiring harness.
^ Install hoses and position clamps..
46. Align EVAP solenoid hose in slot on intake manifold.
47. Connect EVAP solenoid wiring harness connector.
48. Secure brake vacuum pipe with three 10 mm bolts.
49. Install brake vacuum hose and position clamp.
50. Perform 1st quality check:
a. Confirm brake vacuum hose and spring clamp are connected.
b. Confirm wiring harness connector, coolant hoses and spring clamps are positioned and secured to throttle body.
c. Confirm fuel pump foam and bracket are secured.
d. Confirm breather hose and spring clamp are secured to valve cover.
e. Confirm 2 hoses and their clamps are secured to EVAP assembly.
f. Confirm wiring connector is connected to EVAP solenoid.
g. Confirm 3 bolts are installed on vacuum pipe.
51. Remove rag and install rear turbo hose then secure the clamp.
52. Ensure rubber insert is positioned correctly in plastic intake pipe, shown in Figure 59.
53. Install plastic air inlet tube.
a. Remove rag and install one end to air inlet hose.
b. Install one end to throttle body.
c. Secure clamps.
d. Install one 10 mm bolt.
54. Installation of recirculation valve vacuum tube and hoses.
^ Install vacuum tube and position clamp.
^ Install hose and position clamp.
55. Connect manifold absolute pressure sensor harness connector and harness clip.
56. Install oil level dipstick.
57. Perform 2nd quality check:
a. Confirm the recirculation valve hoses and clamps are secure.
b. Confirm the harness connector and clip are secure.
c. Confirm clamps on air intake tube are secure.
d. Confirm the oil dipstick is installed.
e. Confirm bolt is installed securing air intake tube.
58. Using hand pressure, install engine cover.
59. Connect battery cables.
^ Connect positive battery cable first.
60. Cycle ignition 3 times to build pressure in fuel system.
a. Do not press brakes, push ignition start/stop button twice without pushing brake pedal.
b. After 3 seconds push start/stop button once to turn off.
c. Repeat cycle 3 times.
61. Start engine and perform checks.
^ Make sure dash warning lights are OFF.
^ Ensure engine will rev past 4,000 RPM.
62. Reinitialize each auto-up power window as follows.
a. Turn the ignition ON.
b. Open the window all the way DOWN.
c. Pull all the way UP on the switch and HOLD (close the window completely).
d. Continue to HOLD for 4 seconds.
e. Confirm that auto up/down operates correctly.
f. Repeat the process on all windows with the auto up function.
63. If equipped, reset the customer settings for the ATC (Automatic Temperature Control) system. (Refer to the Service Manual as needed.)
64. Re-set customers radio presets with those written down.