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MAINTENANCE AND REPAIR

ON-VEHICLE SERVICE


T3B11F61
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Fuel Tank

Removal Procedure

    Caution : The fuel system is under pressure. To avoid fuel spillage and the risk of personal injury or fire, it is necessary to relieve the fuel system pressure before disconnecting the fuel lines.

  1. Relieve the fuel pressure. Refer to "Fuel Pump"in this section.
  2. Disconnect the negative battery cable.
  3. Drain the fuel tank.
  4. Disconnect the parking brake cable retainer clamps and the support along the fuel tank to provide clearance for the tank.

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  5. Remove the fuel tank filler tube clamp at the fuel tank.
  6. Disconnect the fuel tank filler tube.
  7. Disconnect the fuel tank filler tube at the fuel tank.
  8. Disconnect the canister vaportube at control valve vapor tube.

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  9. Disconnect the fuel pump harness connector at the right rear corner of the fuel tank.
  10. Disconnect the fuel inlet line near the right front of the fuel tank.
  11. Disconnect the wiring harness clips and the fuel line clips as needed.

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  12. Support the fuel tank.
  13. Remove the fuel tank retaining bolts.
  14. Carefully lower the fuel tank.
  15. Remove the fuel tank.
  16. Transfer any parts as needed.

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Installation Procedure

  1. Raise the fuel tank into position.
  2. Install the fuel tank mounting bolts.

    3. Tighten
    Tighten the fuel tank retaining bolts to 20 N•m (15 lb-ft).

  3. Connect the fuel outlet line.
  4. Connect the wiring harness clips and the fuel line clips as needed.
  5. Connect the fuel pump electrical connector.
  6. Connect the fuel vapor line.
  7. Connect the fuel tank filler tube and fuel tank vent tube.
  8. Install the fuel tank filler tube clamp at the fuel tank.

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  9. Install the parking brake cable retainer clamps and the support.

    10. Tighten
    Tighten the parking brake cable retainer clamps to 10 N•m (89 lb-in ).

  10. Connect the negative battery cable.
  11. Fill the fuel tank.
  12. Perform a leak check of the fuel tank and the fuel line connections.

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Fuel Pump

Removal Procedure

    Caution : The fuel system is under pressure. To avoid fuel spillage and the risk of personal injury or fire, it is necessary to relieve the fuel system pressure before disconnecting the fuel lines.

  1. Relieve the fuel system pressure.


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  2. Disconnect the negative battery cable.
  3. Remove the rear seat Reter to Section 9H, Seats.
  4. Remove the fuel pump access cover.
  5. Disconnect the electrical connector at the fuel pump assembly.
  6. Disconnect the fuel outlet line.
  7. Turn the lock ring counterclockwise to clear the tank tabs.
  8. Remove the fuel pump assembly from the tank.
  9. Remove and discard the gasket.

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Installation Procedure

  1. Clean the gasket mating surface on the fuel tank.
  2. Position the new gasket in place.
  3. Install the fuel pump into the fuel tank in the same location as removed for ease of line and connector installation.
  4. Position the lock ring in place and turn it clockwise until it contacts the tank stop.
  5. Connect the fuel pump assembly connector.
  6. Install the fuel pump outlet line.
  7. Install the pump access cover.
  8. Connect the negative battery cable.
  9. Perform an operational check of the fuel pump.
  10. Install the rear seat. Refer to Section 9H, Seats.


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Fuel Sender

Removal Procedure

  1. Disconnect the insulator connector.

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  2. Push the terminal wedge(1) in the insulator connector.

    3. Notice : The wedge may be disconnected with severe load but can be reconnected.


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  3. Push the wedge(1) outside and then pull the wires tp disconnect from insulator.

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  4. Remove the fuel-level sensor(1) from the sender-housing(2).
  5. Remove the sender-housing(2).

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  6. Remove fuel sender assembly(3).

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Installation Procedure

  1. Wind the wires(1) the sender assembly(2).

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  2. Install the sender assembly onto the fuel pump assembly(1).

    3. Notice : Unless correctly install the sender assmembly, fuel gauge indicate inexactly.

  3. Install the fuel-level sensor onto the sender-housing.

    4. Notice : Unless correctly install the fuel-level sensor, fuel-level warning lamp indicate inexactly.


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  4. Connect the wire into the insulator connector.

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  5. Connect the insulator connector.

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Fuel Filter

Removal Procedure

  1. Disconnect the negative battery cable.

    2. Caution : The fuel system is under pressure. To avoid fuel spillage and the risk of personal injury or fire, it is necessary to relieve the fuel system pressure before disconnecting the fuel lines.

  2. Relieve the fuel system pressure. Refer to "Fuel Pump" in this section.
  3. Disconnect the inlet/outlet fuel lines by moving the line connector lock forward and pulling the hose off of the fuel filter tube.
  4. Disconnect the fuel filter ground.

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  5. Remove the fuel filter bracket bolts.
  6. Pull the fuel filter out of the retaining clamp.

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Installation Procedure

  1. Install the new fuel filter into the retaining clamp. Note the flow direction.
  2. Install the fuel filter bracket bolts.

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  3. Connect the inlet/outlet lines. Secure the lines with the connector lock.
  4. Perform a leak test of the fuel filter.

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Fuel Rail and Injectors (1.4 SOHC)

Removal Procedure

    Caution : The fuel system is under pressure. To avoid fuel spillage and the risk of personal injury or fire, it is necessary to relieve the fuel system pressure before disconnecting the fuel lines.

  1. Relieve the fuel system pressure. Refer to "Fuel Pump"in this section.
  2. Disconnect the negative battery cable.
  3. Disconnect the fuel injector harness connectors.
  4. Remove the exhaust gas recirculation valve. Refer to "Exhaust Gas Recirculation Valve (SOHC)" in this section.

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  5. Remove the fuel inlet line.
  6. Remove the fuel rail mounting bolts.

    7. Notice : Before removal, the fuel rail assembly may be cleaned with a spray-type cleaner, following package instructions. Do not immerse the fuel rails in liquid cleaning solvent. Use care in removing the fuel rail assembly to prevent damage to the electrical connectors and the injector spray tips. Prevent dirt and other contaminants from entering open lines and passages. Fittings should be capped and holes plugged during service.

    Important : If an injector becomes separated from the rail and remains in the cylinder head, replace the injector O-ring seals and the retaining clip.

  7. Remove the fuel rail with the fuel injectors attached.

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  8. Remove the fuel injector retainer clips.
  9. Remove the fuel injectors by pulling down and out.
  10. Discard the fuel injector O-rings.

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Installation Procedure

    Important : Different injectors are calibrated for different flow rates. When ordering new fuel injectors, be certain to order the identical part number that is inscribed on the old injector.

  1. Lubricate the new fuel injector O-rings with engine oil. Install the new O-rings on the fuel injectors.
  2. Install the fuel injectors into the fuel rail sockets with the fuel injector terminals facing outward.
  3. Install the fuel injector retainer clips onto the fuel injectors and the fuel rail ledge.
  4. Make sure that the clip is parallel to the fuel injector harness connector.

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  5. Install the fuel rail assembly into the cylinder head.
  6. Install the fuel rail mounting bolts.

    7. Tighten
    Tighten the fuel rail mounting bolts to 25 N•m (18 lb-ft).

  7. Connect the fuel inlet hose.
  8. Connect the fuel injector harness connectors. Rotate each fuel injector as required to avoid stretching the wireing harness.
  9. Install the exhaust gas recirculation valve, if equipped. Refer to "Exhaust Gas Recirculation Valve (SOHC)"in this section.
  10. Connect the negative battery cable.
  11. Perform a leak check of the fuel rail and fuel injectors.

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Fuel Rail and Injectors (1.2 SOHC)

Removal Procedure

    Caution : The fuel system is under pressure. To avoid fuel spillage and the risk of personal injury or fire, it is necessary to relieve the fuel system pressure before disconnecting the fuel lines.

  1. Relieve the fuel system pressure. Refer to "Fuel Pump"in this section.

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  2. Disconnect the negative battery cable.
  3. Disconnect the fuel inlet line.
  4. Disconnect the fuel injector harness connector.
  5. Remove the fuel rail mounting bolts.

    6. Notice : Before removal, the fuel rail assembly may be cleaned with a spray-type cleaner, following package instructions. Do not immerse the fuel rails in liquid cleaning solvent. Use care in removing the fuel rail assembly to prevent damage to the electrical connectors and the injector spray tips. Prevent dirt and other contaminants from entering open lines and passages. Fittings should be capped and holes plugged during service.

    Important : If an injector becomes separated from the rail and remains in the cylinder head, replace the injector O-ring seals and the retaining clip.


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  6. Remove the fuel rail with the fuel injectors attached.
  7. Remove the fuel injector retainer clips.
  8. Remove the fuel injectors by pulling down and out.
  9. Discard the fuel injector O-rings.

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Installation Procedure

    Important : Different injectors are calibrated for different flow rates. When ordering new fuel injectors, be certain to order the identical part number that is inscribed on the old injector.

  1. Lubricate the new fuel injector O-rings with engine oil. Install the new O-rings on the fuel injectors.
  2. Install the fuel injectors into the fuel rail sockets with the fuel injector terminals facing outward.
  3. Install the fuel injector retainer clips onto the fuel injectors and the fuel rail ledge.
  4. Make sure that the clip is parallel to the fuel injector harness connector.

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  5. Install the fuel rail assembly into the cylinder head.
  6. Install the fuel rail mounting bolts.

    7. Tighten
    Tighten the fuel rail mounting bolts to 25 N•m (18 lb-ft).


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  7. Connect the fuel inlet hose.
  8. Connect the fuel injector harness connectors. Rotate each fuel injector as required to avoid stretching the wiring harness.
  9. Connect the negative battery cable.
  10. Perform a leak check of the fuel rail and fuel injectors.

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Engine Coolant Temperature Sensor (1.4 SOHC)

Removal Procedure

  1. Relieve the coolant system pressure.
  2. Disconnect the negative battery cable.
  3. Disconnect the coolant temperature (ECT) sensor connector.

    4. Notice : Use care when handling the ECT sensor. Damage to the sensor will affect the proper operation of the fuel injection system.

  4. Carefully remove the ECT sensor from the cylinder head underneath the electronic ignition (EI) system ignition coil.

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Installation Procedure

  1. Coat the threads on the ECT sensor with sealer.

    2. Notice : Use care when handling the ECT sensor. Damage to the sensor will affect the proper operation of the fuel injection system.

  2. Install the ECT into the cylinder head.

    3. Tighten
    Tighten the coolant temperature sensor to 20 N•m (15 lb-ft).

  3. Connect the ECT sensor connector.
  4. Fill the cooling system.
  5. Connect the negative battery cable.

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Throttle Position Sensor (Typical)

Removal Procedure

  1. Disconnect the negative battery cable.
  2. Disconnect the throttle position (TP) sensor connector.
  3. Remove the TP sensor retaining bolts and the TP sensor.

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Installation Procedure

  1. With the throttle valve closed, position the TP sensor on the throttle shaft. Align the TP sensor with the bolt holes.
  2. Install the TP sensor retaining bolts.

    3. Tighten
    Tighten the throttle position sensor retaining bolts to 2 N•m (18 lb-in).

  3. Connect the TP sensor connector.
  4. Connect the negative battery cable.

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Throttle Body (Typical)

Removal Procedure

  1. Disconnect the negative battery cable.
  2. Remove the air intake tube from the throttle body.
  3. Disconnect the throttle cables by opening the throttle and moving the cable through the release slot.

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  4. Disconnect the vacuum hoses from the throttle body.
  5. Disconnect the throttle position (TP) sensor and the idle air control valve connectors.

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  6. Remove the coolant hoses from the throttle body.
  7. Remove the throttle body retaining bolts.
  8. Remove the throttle body and discard the gasket.
  9. Remove the TP sensor. Refer to "Throttle Position Sensor"in this section.
  10. Remove the idle air control (IAC) valve. Refer to "Idle Air Control Valve"in this section.

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Installation Procedure

    Notice : Use care in cleaning old gasket material from machined aluminum surfaces. Sharp tools may damage sealing surfaces.

  1. Clean the gasket mating surface on the intake manifold.

    2. Notice : The throttle body may be cleaned following disassembly in a cold immersion-type cleaner. The throttle position sensor and the idle air control valve should not come in contact with any solvent or cleaner as they may be damaged.

  2. Clean the throttle body.
  3. Install the TP sensor. Refer to "Throttle Position Sensor" in this section.
  4. Install the IAC valve. Refer to "Idle Air Control Valve" in this section.

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  5. Install the throttle body assembly with a new gasket to the intake manifold.
  6. Install the throttle body retaining bolts.

    7. Tighten
    Tighten the throttle body retaining bolts to 15 N•m (11 lb-ft).

  7. Install the coolant hoses.
  8. Connect the vacuum hoses to the throttle body.

    9. Important : Make sure the throttle control cables do not hold the throttle open. With the engine OFF, check to see that the accelerator pedal is free.

  9. Connect the throttle cables.

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  10. Install the air intake tube.
  11. Connect the TP sensor connector and the IAC valve connector.
  12. Connect the negative battery cable.
  13. Fill the cooling system.

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Front Heated Oxygen Sensor (HO2S1) (Typical)

Removal Procedure

  1. Disconnect the negative battery cable.

    2. Notice : The oxygen sensor uses a permanently attached pigtail and connector. This pigtail should not be removed from the oxygen sensor. Damage or removal of the pigtail or the connector could affect proper operation of the oxygen sensor. Take care when handling the oxygen sensor. Do not drop the oxygen sensor.

  2. Disconnect the front heated oxygen sensor (HO2S1) connector.

    3. Notice : The oxygen sensor may be difficult to remove when engine temperature is below 48°C (120°F). Excessive force may damage threads in the exhaust manifold.

  3. Carefully remove the HO2S1 from the exhaust manifold.

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Installation Procedure

    Important : A special anti-seize compound is used on the oxygen sensor threads. This compound consists of a liquid graphite and glass beads. The graphite will burn away, but the glass beads will remain, making the sensor easier to remove. New or service sensors will already have the compound applied to the threads. If a sensor is removed from any engine and if for any reason it is to be reinstalled, the threads must have anti-seize compound applied before reinstallation.

  1. Coat the threads of the HO2S1 with an anti-seize compound, if needed.
  2. Install the HO2S1 into the exhaust manifold.

    3. Tighten
    Tighten the oxygen sensor to 42 N•m (31 lb-ft).

  3. Connect the HO2S1 connector.
  4. Connect the negative battery cable.

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Rear Heated Oxygen Sensor (HO2S2) (Typical)

Removal Procedure

  1. Disconnect the negative battery cable.
  2. Disconnect the electrical connector.
  3. Remove the heated oxygen sensor (HO2S2).

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Installation Procedure

  1. Install the HO2S2.

    2. Tighten
    Tighten the heated oxygen sensor to 42 N•m (31 lb-ft).

  2. Connect the electrical connector.
  3. Connect the negative battery cable.

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Intake Air Temperature Sensor (Typical)

Removal Procedure

  1. Disconnect the negative battery cable.
  2. Disconnect the intake air temperature (IAT) sensor connector.
  3. Remove the IAT sensor by pulling it out of the air intake tube.

Installation Procedure

  1. Insert the IAT sensor into the air intake tube.
  2. Connect the IAT connector.
  3. Connect the negative battery cable.

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Idle Air Control Valve (Typical)

Removal Procedure

  1. Disconnect the negative battery cable.
  2. Disconnect the idle air control (IAC) valve connector.
  3. Remove the IAC valve retaining bolts.

    4. Notice : On IAC valves that have been in service, do not push on the valve pintle. The force required to move the pintle may damage the threads on the worm drive.

  4. Remove the IAC valve.
  5. Clean the IAC valve O-ring seal area, the pintle valve seat and the air passage with a suitable fuel system cleaner. Do not use methyl ethyl ketone.

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Installation Procedure

    Important : If installing a new IAC valve, be sure to replace it with an identical part. The IAC valve pintle shape and diameter are designed for the specific application. Measure the distance between the tip of the IAC valve pintle and the mounting flange. If the distance is greater than 28 mm, use finger pressure to slowly retract the pintle.

    The force required to retract the pintle will not damage the IAC valve.The purpose of the 28 mm setting is to prevent the IAC pintle from bottoming out on the pintle seat. This 28 mm setting is also an adequate setting for controlled idle on a restart.
  1. Lubricate a new O-ring with engine oil. Install the new O-ring onto the valve.
  2. Install the IAC valve into the throttle body.

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  3. Install the IAC valve retaining bolts.

    4. Tighten
    Tighten the idle air control valve retaining bolts to 3 N•m (27 lb-in).

  4. Connect the IAC valve connector.
  5. Connect the negative battery cable.
  6. Start the engine and check for the proper idle speed.

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Manifold Absolute Pressure Sensor (1.2 SOHC)

Removal Procedure

  1. Disconnect the MAP sensor connector.
  2. Remove the bolt with the MAP sensor.

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Installation Procedure

  1. Install the MAP sensor with the bolt.

    2. Tighten
    Tighten the MAP sensor bolt to 10 N•m (89 lb-in).

  2. Connect the MAP sensor connector.
  3. Connect the negative battery cable.

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Manifold Absolute Pressure Sensor (1.4 SOHC)

Removal Procedure

  1. Disconnect the negative battery cable.
  2. Disconnect the vacuum hose from the manifold absolute pressure (MAP) sensor.
  3. Disconnect the MAP connector.
  4. Remove the MAP sensor mounting bracket bolt.
  5. Remove the bolts and nuts securing the MAP sensor to the mounting bracket.

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Installation Procedure

  1. Insert the MAP sensor into the mounting bracket.
  2. Install the bolts through the MAP sensor and the bracket. Install the retaining nuts.

    3. Tighten
    Tighten the MAP sensor retaining bolts and nuts to 8 N•m (71 lb-in).

  3. Install the MAP sensor and the mounting bracket to the firewall with the mounting bracket bolt.

    4. Tighten
    Tighten the MAP sensor mounting bracket bolt to 4 N•m (35 lb-in).

  4. Connect the MAP sensor connector.
  5. Connect the vacuum hose to the MAP sensor.
  6. Connect the negative battery cable.

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Manifold Absolute Pressure Sensor (1.4 DOHC)

Removal Procedure

  1. Disconnect the negative battery cable.
  2. Diseconnect the MAP Sensor connector.
  3. Remove the bolt with the MAP sensor.

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Installation Procedure

  1. Install the MAP sensor with the bolt.

    2. Tighten
    Tighten the MAP sensor bolt to 10 N•m (89 lb-in).

  2. Connect the MAP sensor connector.
  3. Connect the negative battery cable.

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Exhaust Gas Recirculation Valve (1.4 SOHC)

Removal Procedure

  1. Disconnect the negative battery cable.
  2. Disconnect the exhaust gas recirculation (EGR) valve electrical connector.
  3. Remove the bolts and the EGR valve.

Installation Procedure

  1. Clean the cylinder head mating surface.
  2. Install a new EGR valve gasket.
  3. Install the EGR valve with the retaining bolts.

    4. Tighten
    Tighten the exhaust gas recirculation valve retaining bolts to 30 N•m (22 lb-ft).

  4. Connect the EGR valve electrical connector.
  5. Connect the negative battery cable.

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Exhaust Gas Recirculation Valve (1.4 DOHC)

Removal Procedure

  1. Disconnect the negative battery cable.
  2. Disconnect the EGR valve electrical connector.
  3. Remove the bolts and the EGR valve.

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Installation Procedure

  1. Clean the cylinder head mating surface.
  2. Install a new EGR valve gasket.
  3. Install the EGR valve with the retaining bolts.

    4. Tighten
    Tighten the exhaust gas recirculation valve retaining bolts to 30 N•m (22 lb-ft).

  4. Connect the EGR valve electrical connector.
  5. Connect the negative battery cable.

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Knock Sensor

Removal Procedure

  1. Disconnect the negative battery cable.
  2. Remove the intake manifold. Refer to Section 1B, SOHC Engine Mechanical.
  3. Disconnect the electrical connector at the knock sensor.
  4. Remove the knock sensor.

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Installation Procedure

  1. Install the knock sensor.

    2. Tighten
    Tighten the knock sensor bolt to 20 N•m (15 lb-ft).

  2. Connect the electrical connector at the knock sensor.
  3. Install the intake manifold. Refer to Section 1B, SOHC Engine Mechanical. or Section 1C, DOHC Engine Mechanical.
  4. Connect the negative battery cable.

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G Sensor

Removal Procedure

  1. Disconnect the negative battery cable.
  2. Disconnect the G sensor electrical connector and remove the G sensor.

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Installation Procedure

  1. Install the G sensor and connect the electrical connector.
  2. Connect the negative battery cable.

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Evaporative Emission Canister

Removal Procedure

    Caution : Canister and vacuum hoses contain fuel vapors. Do not smoke in the area or permit an open flame.

  1. Disconnect the evaporative (EVAP) emission canister fuel vapor hoses.
  2. Remove the bolt securing the EVAP emission canister flange to the vehicle.
  3. Slide the EVAP emission canister out of the track holder.
  4. Remove the EVAP emission canister.

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Installation Procedure

  1. Insert the EVAP emission canister into the track and slide it into position.
  2. Install the EVAP emission canister flange bolt.

    3. Tighten
    Tighten the evaporative emission canister flange bolt to 20 N•m (15 lb-ft).

  3. Connect the canister fuel vapor hoses.

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Crankshaft Position (CKP) Sensor (1.2 SOHC)

Removal Procedure

  1. Disconnect the negative battery cable.
  2. Remove the air cleaner assembly.
  3. Disconnect the crankshaft position (CKP) sensor connector.
  4. Remove the CKP sensor retaining bolt.

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Installation Procedure

  1. Install the CKP sensor.
  2. Tighten the CKP sensor retaining bolt to 6.5 N•m (58 lb-in).

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Crankshaft Position Sensor (Typical)

Removal Procedure

  1. Disconnect the negative battery cable.
  2. Disconnect the crankshaft position (CKP) sensor connector at the frame bracket.
  3. Remove the wiring tie straps as needed.
  4. Remove the CKP sensor retaining bolt.
  5. Remove the CKP sensor.

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Installation Procedure

  1. Install the CKP sensor with the retaining bolt.

    2. Tighten
    Tighten the crankshaft position sensor retaining bolt to 6.5 N•m (58 lb-in).

  2. Connect the CKP sensor connector at the frame bracket.
  3. Secure the wire with the tie straps as needed.
  4. Connect the negative battery cable.

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Camshaft Position Sensor (1.4 SOHC)

Removal Procedure

  1. Disconnect the negative battery cable.
  2. Disconnect the sensor electrical connector.
  3. Remove the camshaft position (CMP) sensor bolts and sensor.

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Installation Procedure

  1. Install the CMP sensor and bolts.

    2. Tighten
    Tighten the camshaft position bolts to 12 N•m (106 lb-in).

  2. Connect the sensor electrical connector.
  3. Connect the negative battery cable.

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Engine Control Module

Removal Procedure

  1. Disconnect the negative battery cable.
  2. Disconnect the engine control module (ECM) connectors.
  3. Remove the ECM retaining bolts.
  4. Remove the ECM from the ECM mount.

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Installation Procedure

  1. Position the ECM in place.
  2. Install the ECM to the ECM mount and install the retaining bolts.

    3. Tighten
    Tighten the ECM retaining bolts to 4 N•m (35 lb-in).

  3. Connect the negative battery cable.
  4. Perform a crankshaft position system variation learning procedure. Refer to "DTC P1336" in this section.


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