Fuel Pressure Sensor/Switch: Service and Repair
FUEL JUNCTION BLOCK REPLACEMENTREMOVAL PROCEDURE
1. Move the hood to the service position, by moving the hood hinge bolts (1) to the service positions (2).
2. Disconnect the batteries negative cables.
3. Loosen the outlet duct clamp at the upper intake manifold cover.
4. Remove the upper intake manifold cover from the outlet duct.
5. Remove the upper intake manifold cover.
6. Drain the engine coolant. Refer to Draining and Filling Cooling System in Cooling System.
7. Remove the drive belt.
8. Relocate the air conditioning (A/C) compressor using the following procedure:
8.1. Disconnect the A/C compressor clutch electrical connector.
8.2. Disconnect the A/C cut out switch electrical connector.
8.3. Remove the A/C compressor mounting bolts.
8.4. Reposition the A/C compressor with the hoses attached to the right side of the engine Component.
9. Disconnect the left front injector harness connector (1).
10. Disconnect the oil pressure sending unit harness connector.
11. Disconnect the turbocharger coolant hose and clamp from the turbocharger bypass valve.
12. Disconnect the water outlet tube using the following procedure:
12.1. Remove the 2 bolts retaining the water outlet tube to the left valve rocker arm cover.
12.2. Remove the bolt retaining the water outlet tube to the thermostat housing.
12.3. Remove the water outlet tube.
12.4. Remove and discard the O-ring seal.
13. Disconnect the positive crankcase ventilation (PCV) hose from the upper valve rocker arm cover.
IMPORTANT: Do not use a screw driver or other tool to pry the hose loose. The hose can be torn or damaged. Loosen the hose by twisting.
14. Loosen the charged air cooler inlet duct to turbocharger clamp and remove the inlet duct.
15. Disconnect the banjo bolt (1) from the junction block.
16. Disconnect the 3 fuel pipes (3) from the junction block.
17. Disconnect the other end of fuel pipe junction block to the fuel rail (1).
18. Remove the 2 nuts holding the junction block.
19. Remove the junction block.
INSTALLATION PROCEDURE
NOTE: Refer to Fastener Notice in Service Precautions.
1. Install the junction block and the 2 nuts holding the junction block.
Tighten
Tighten the nuts to 25 N.m (18 lb ft).
2. Install the fuel system return line banjo bolt (1) to the junction block.
Tighten
Tighten the fuel return line banjo bolt to 15 N.m (11 lb ft).
3. Connect the 3 fuel pipes (3) to the junction block.
Tighten
Tighten the high pressure fuel lines to 44 N.m (32 lb ft).
4. Connect the other end of the pipe (1) to the left fuel rail.
Tighten
Tighten the high pressure pipe from the junction block to the left fuel rail to 44 N.m (32 lb ft).
5. Install the charged air cooler inlet duct to turbocharger charged air cooler outlet. Align the marks on the hose and the intake manifold duct.
Tighten
Tighten the charged air cooler clamp to 6 N.m (53 lb in).
6. Install the PCV hose to the upper valve rocker arm cover.
7. Install the water outlet tube using the following procedure:
7.1 Install a new O-ring seal on the water outlet tube.
7.2. Lightly lubricate the O-ring seal with coolant.
7.3. Install the water outlet tube.
7.4. Install the bolt retaining the water outlet tube to the thermostat housing.
Tighten
Tighten the water outlet tube to thermostat housing bolt to 21 N.m (16 lb ft).
7.5. Install the 2 bolts retaining the water outlet tube to the valve rocker arm cover.
Tighten
Tighten the water outlet tube to valve rocker arm cover bolts to 21 N.m (16 lb ft)
8. Install the turbocharger coolant hose and clamp from the turbocharger bypass valve.
9. Connect the Oil pressure sending unit harness connector.
10. Connect the left front injector harness connector (1).
11. Install the A/C compressor using the following procedure:
11.1. Install the A/C compressor mounting bolts.
Tighten
Tighten the A/C compressor mounting bolts to 50 N.m (37 lb ft).
11.2. Reconnect the A/C cut out switch electrical connector.
11.3. Reconnect the A/C compressor clutch electrical connector.
12. Replace the drive belt.
13. Fill the engine coolant. Refer to Draining and Filling Cooling System in Cooling System.
14. Install the upper intake manifold cover.
15. Install the upper intake manifold cover to the outlet duct.
16. Tighten the outlet duct clamp at the upper intake manifold cover.
Tighten
Tighten the clamp to 6 N.m (53 lb in).
17. Install the fuel cap.
18. Connect the negative batteries cables to both batteries.
19. Position the hood in the normal operating position by moving the hood hinge bolts from service position (2) to normal operating position (1).
Tighten
Tighten the bolts to 25 N.m (18 lb ft).
20. Purge air from the fuel system. Refer to Fuel Feed and Fuel Return Pipe Purge Procedure.