Correction
CorrectionInspect, and if necessary, replace the surge tank.
Inspection Procedure
1. Open the hood.
2. Check the surge tank neck near the coolant level sensor (inset box in picture) for the presence of coolant. Use an inspection mirror and a light. Placing a piece of plain white paper between the neck and the rest of the tank may aid in diagnosis.
Important:
Before ordering any parts, perform the inspection in Step 1 of the Surge Tank and Wiring Harness Replacement.
- If coolant is present, proceed to the section titled "Surge Tank and Wiring Harness Replacement."
- If coolant is NOT present, proceed with the inspection.
3. Locate the date code on the lower half of the surge tank under the inlet (shown by the arrow). The date code is nine digits long in purple print. The date is the last six digits of the number and is in the format of MMDDYY.
- If the date is from 030305 to 031505, proceed with inspection.
- If the date is outside this window no further action is required.
5. Disconnect the mass air flow (MAF)/intake air temperature (IAT) sensor electrical connector.
6. Loosen the outlet duct clamps at the MAF/IAT sensor.
7. Remove the air cleaner outlet duct from the MAF/IAT sensor.
8. Grasp the air filter assembly (1) and pull up on the assembly in order to disengage the retaining pins (2) from the grommets (3).
9. Remove the bolt and nut retaining the surge tank to the vehicle.
10. Lift the end of the surge tank near the fender and inspect for either a 1 or a 2 on the bottom.
- If the number is a 2, proceed to the section titled, "Surge Tank Only Replacement."
- If the number is a 1, proceed to the next step.
12. Install the coolant surge tank back into the vehicle.
13. Install the bolt and nut to the surge tank
Tighten
Tighten the bolt and nut to 9 N.m (80 lb in).
14. Position the air cleaner assembly lining up the retaining pins (2) with the grommets (3).
15. Install the air cleaner assembly until the air cleaner is seated fully on the mounts and is up against the fender apron.
16. Install the air cleaner outlet duct to the MAF/IAT sensor.
17. Tighten the outlet duct clamps at the turbocharger and the MAF/IAT sensor.
Tighten
Tighten the clamps to 4 N.m (35 lb in).
18. Connect the MAF/IAT sensor electrical connector.
19. No further action is required.
Surge Tank Only Replacement Procedure
1. Drain the coolant below the surge tank.
2. Disconnect the coolant level sensor.
3. Install the pinch tool on the surge tank inlet and outlet hoses.
4. Remove the inlet and outlet hoses from the tank.
5. Remove the surge tank from the vehicle.
6. Install the new surge tank.
7. Connect the hoses to the surge tank.
8. Remove the pinch tool from the hoses.
9. Connect the coolant level sensor.
10. Install the bolt and nut to the surge tank.
Tighten
Tighten the bolt and nut to 9 N.m (80 lb in).
11. Position the air cleaner assembly, lining up the retaining pins (2) with the grommets (3).
12. Install the air cleaner assembly until the air cleaner is seated fully on the mounts and is up against the fender apron.
13. Install the air cleaner outlet duct to the MAF/IAT sensor.
14. Tighten the outlet duct clamps at the turbocharger and the MAF/IAT sensor.
Tighten
Tighten the clamps to 4 N.m (35 lb in).
15. Connect the MAF/IAT sensor electrical connector.
16. Refill the cooling system.
Surge Tank and Wiring Harness Replacement Procedure
Important:
The fuel injection control module wiring harness is not involved.
1. Inspect the PCM connection.
A. Using a Tech 2, record the remaining engine oil life.
B. Disconnect the negative battery cable(s).
C. Disconnect the ECM electrical connectors.
D. Release the ECM cover retaining tabs.
E. Remove the ECM cover.
F. Remove the ECM.
G. Inspect ECM connector J2 and the corresponding connector in the wiring harness for signs of moisture or corrosion. Wipe the connector surfaces with a white cloth or towel. If moisture or corrosion is found replace the ECM with a new one.
H. Install the ECM.
Important:
The cover must be fully installed prior to the electrical connections being made to ensure the ECM is fully seated in the bracket.
I. Install the ECM cover to the bracket.
J. Engage the ECM cover retaining tabs.
2. Install the hose pinch tool on the surge tank inlet and outlet hoses.
3. Drain the coolant from the surge tank.
4. Disconnect the coolant level sensor.
5. Remove the inlet and outlet hoses from the tank.
6. Remove the surge tank from the vehicle.
7. Remove the intake manifold cover.
8. Remove the push-in retainers from the wheelhouse panels.
9. Remove the top clips (2) retaining the harness to the top of the wheelhouse panels.
10. Remove the wheelhouse panels from the wheelhouse.
11. Remove the cover from the under hood fuse panel.
12. Remove the fender brace.
13. Lift the fuse panel and disconnect connector C2 (15).
14. Disconnect the glow plug battery feed wire from the terminal in the power center.
15. Disconnect:
^ C100 (14)
A. C152 (17)
B. Throttle Actuator Control Module Connector (10)
C. C108 (6)
D. C107 (9)
E. A/C Compressor Clutch Connector (1)
F. A/C Refrigerant Pressure Sensor Connector (2)
G. Generator - Left Connector (4)
H. Generator - Right Connector (26)
I. A/C Low Pressure Switch Connector (7)
16. Disconnect:
^ C153 (5)
A. Glow Plug Controller Power (9)
B. Glow Plug Controller Battery Feed Electrical Connector (1)
17. Remove the TCM cover bolts (1) located on the left side of the radiator shroud
18. Pull the cover and TCM up and away from the radiator shroud.
19. Disconnect the TCM electrical connectors (2) and remove the TCM and cover from the vehicle.
20. Raise the vehicle.
21. Disconnect from the transmission:
Backup Lamp Switch Connector
A. Vehicle Speed Sensor Connectors (three connectors)
B. Main Transmission Connector
22. Disconnect any PTO connectors as required.
23. Remove wiring from any retainers used for this branch of the wiring harness.
24. Remove the engine protection shield.
25. Remove the bolts at G102 and G104 on either side of the cylinder block near the front of the engine.
26. Disconnect the starter solenoid wire.
27. Remove the wiring from any retainers used for this branch of the wiring harness.
28. All lower wiring harness branches should now hang free.
29. Lower the vehicle using care not to trap hanging wires.
30. Remove wiring from any retainers or straps still in place.
31. Remove the harness from the vehicle noting routing of harness.
32. Place the new harness and route the branches.
33. Secure the harness in the retainers used for the removed harness where they can be accessed from above.
34. Connect:
^ Fuse Panel Connector C2
A. C100
B. C152
C. Throttle Actuator Control Module Connector
D. C108
E. C107
F. A/C Compressor Clutch Connector
G. A/C Refrigerant Pressure Sensor Connector
H. Generator - Left Connector
I. Generator - Right Connector
I. A/C Low Pressure Switch Connector
K. C153
L. Glow Plug Controller Power
M. Glow Plug Controller Battery Feed Electrical Connector
N. Glow Plug controller battery feed to the terminal in the power center
0. Transmission Control Module Electrical Connectors
35. Install the Transmission Control Module and cover to the shroud.
36. Install (2) Transmission Control Module cover bolts.
Tighten
Tighten the bolts to 9 N.m (80 lb in).
37. Connect the three ECM connectors to the ECM.
38. Route the harness branches for the transmission and starter down through the engine compartment.
39. Raise the vehicle.
40. Route the appropriate wiring branch to the transmission. Secure the wiring in the appropriate retainers.
41. Connect:
^ Backup Lamp Switch Connector
A. Vehicle Speed Sensor Connectors
B. Main Transmission Connector
42. Connect any PTO connectors as required.
43. Route the other branch of the wiring around the front of the engine. Secure the wiring in the appropriate retainers.
44. Install the bolts for grounds G102 and G104. Be sure that the new harness ground wires and any other previous wires from that location are on the bolt before installation.
45. Route the wire to the starter solenoid and connect.
46. Install the engine protection shield and bolts.
Tighten
Tighten the bolts to 20 N.m (15 lb ft).
47. Check to be sure that all wires and connectors are connected.
48. Partially lower the vehicle.
49. Install the wheelhouse panels to the wheelhouse.
50. Install the top clips that are retaining the harness to the top of the wheelhouse panels.
51. Install the push-in retainers to the wheelhouse panels.
52. Lower the vehicle.
53. Install the intake manifold cover.
54. Install the fender brace and bolts.
55. Install the cover to the under hood fuse panel.
56. Install the new coolant surge tank.
57. Connect the hoses to the surge tank.
58. Remove the hose pinch tool from the hoses.
59. Install the coolant tank nut and bolt.
Tighten
Tighten the bolt and nut to 9 N.m (80 lb in).
60. Connect the coolant level sensor electrical connector.
61. Position the air cleaner assembly, lining up the retaining pins (2) with the grommets (3).
62. Install the air cleaner assembly until the air cleaner is seated fully on the mounts and is up against the fender apron.
63. Install the air cleaner outlet duct to the MAF/IAT sensor.
64. Tighten the outlet duct clamps at the turbocharger and the MAF/IAT sensor.
Tighten
Tighten the clamps to 4 N.m (35 lb in).
65. Connect the MAF/IAT sensor electrical connector.
66. Refill the coolant system.
67. Connect the negative battery cable(s).
68. If the ECM was replaced:
^ Program the ECM.
A. Perform the turbocharger learn procedure.
B. Program oil life to remaining value.