Service Procedure

1. Place vehicle on hoist (side lift only), open hood and disconnect battery ground cable.

2. Lift vehicle with a chassis/frame hoist. Shift the transmission into neutral and release the parking brake. This is to allow free movement to the propeller shaft during the removal and installation procedure.





3. Apply alignment marks on the flanges of the following coupling points:
^ Front differential to front propeller shaft (Figure 1)





^ Front propeller shaft to front output flange of the transfer case (Figure 2)











4. Remove the (6) 8 mm Allen head bolts and the (6) 14 mm bolts from the front propeller shaft, and remove the front propeller shaft. (Figures 3, 4, and 5)

CAUTION:
Do not touch the exhaust system, it may be hot when removing Fuel Line Shield Assembly.





5a. If a Fuel Line Shield Assembly was previously installed, remove the Oxygen Sensor Harness from the Fuel Line Shield Assembly. Then Remove the Fuel Line Shield Assembly and skip to Step 6.

5b. If the Fuel Line Shield Assembly was not previously installed. remove the Oxygen Sensor Harness from the retaining clip mounted on the fuel line. You may discard the clip as it will not be reused.

6. Place drain pan under vehicle to collect any fuel that may spill.

CAUTION:
Gasoline is extremely flammable. Ensure that there are no open flames or any spark generating equipment in the general work area. Any collected fuel must be disposed of properly.





7. Carefully remove the fuel hose clips from the lower end of the Fuel Hose Assembly. Disconnect the Fuel Hose Assembly from the fuel lines. Use the drain pan to collect any fuel that may come out. Once the fuel has stopped flowing out, direct the Fuel Hose Assembly upward. through fuel hose bracket. to ease eventual removal of the Fuel Hose Assembly from the engine compartment (Figures 7 and 11).

8. Lower the vehicle from the hoist.

9. Remove the plastic engine cover.

10. Remove crankcase breather from cam cover inlet.





11. Disconnect MAF (Mass Air-Flow) Sensor connector and IAT (Intake Air Temperature) sensor connector. (Figure 8)

12. Loosen the hose clip that secures the Air Intake Pipe to the throttle body, unclip the air cleaner cap clips, pull the Air Intake Pipe away from the throttle body and remove the Air Intake Pipe Assembly. (Figure 8)

13. Disconnect the Brake Vacuum Booster Hose from the common chamber and push it aside.

14. Disconnect the TPS (Throttle Position Sensor) connector, Ion sensor connector, MAP (Manifold Absolute Pressure) sensor connector, VSV electrical connector, EGR (Exhaust Gas Recirculation) Valve connector, and all six fuel injector connectors. (Figure 8)

15. Remove the (four) throttle body fixing bolts and pull throttle body away from the common chamber. The throttle body does not need to be removed. (Figure 8)

16. Disconnect VSV vacuum lines and common chamber vacuum lines. (Figure 8)

17. Disconnect the EGR valve pipe nut using a 22 mm wrench.

18. Remove four bolts and four nuts that retain the common chamber and the ground wire connector.





19. Carefully raise the common chamber and remove the common chamber with the Fuel Hose Assembly, and place the common chamber on the bench. (Figure 9)

IMPORTANT:
Make sure the common chamber is resting securely on the bench, not on the ground.

20. Remove and discard the original Fuel Hose Assembly and fuel hose clips from the common chamber. (Figure 9)

21. Install the "NEW" Fuel Hose Assembly onto the common chamber and secure with two fuel hose clips. (Figure 10)

22. Install the common chamber in the reverse order from the way in which it was removed (from step 19 to step 9).

^ Guide the Fuel Hose Assembly through the fuel hose bracket as you position the common chamber in place. (Figure 11)

^ Install the EGR valve nut hand tight.

^ Install the common chamber nuts and bolts along with the ground connectors and apply the torque of 18 lb ft to the (four) common chamber bolts and nuts in a criss-cross pattern.

^ Torque the EGR valve nut to 18 lb ft.

^ Connect the VSV vacuum lines and common chamber vacuum lines.

^ Install throttle body and torque bolts to 87 lb in.

^ Re-connect the TPS connector. Ion sensor connector, MAP sensor connector, VSV connector, EGR Valve connector, and all (six) fuel-injector sensor connectors securely.

^ Connect the Brake Vacuum booster line to the common chamber.

^ Install the Air Intake Pipe Assembly and tighten the hose clip that secures the hose connector to the throttle body. Secure the air cleaner cap with the air cleaner clips.

^ Re-connect the MAF sensor connector, IAT sensor connector and crankcase breather into the cam cover.

23. Raise the vehicle.

24. Carefully position the Fuel Hose Assembly into and through the fuel hose bracket. Install the Fuel Hose Assembly onto the fuel lines and secure the fuel hoses with the two remaining fuel hose clips.

NOTE:
Verify the Fuel Hose Assembly installation alignment. White mark on Fuel Hose Assembly should be in alignment with the top of the fuel hose bracket. (Figure 11)

25. Inspect and determine whether the Fuel Hose Shield has already been installed from Safety Campaign # 00V-253.

a) If the Fuel Hose Shield has been installed, skip to Step 28.

b) If the Fuel Hose Shield has not been installed, then continue on the Step 26.

26. Remove the 17mm bolt and nut of the transmission housing. (Figure 13)








27. Install Fuel Hose Shield, 17mm bolt and nuts. Hold Fuel Hose Shield towards transmission while tighting bolt to specifications. Apply torque of 56 lb. ft. (Figures 12 and 13)

IMPORTANT:
Verify Fuel Hose Shield clearance from floor board or noise may occur. (Figure 13)





28. Install the Fuel Line Shield Assembly. (Figure 14)

IMPORTANT:
You must first align the fuel hose clips to the fuel lines prior to pushing Fuel Line Shield Assembly in place [all four (4) fuel hose clips must snap into place]. Use mirror to verify that all the clips have snapped into place.

CAUTION:
Do not pinch the Breather Hose when Installing Fuel Line Shield Assembly.

29. Install the Oxygen Sensor harness into the retaining clip mounted on the Fuel Line Shield Assembly. (Figures 14 and 15)

30. Ensure the connecting surfaces of the front propeller shaft and the flange coupling on each end are clean so no foreign matter will be caught in between.

31. Install the Front Propeller Shaft:

^ Align the marks, which were applied prior to removal of the front propeller shaft.

^ Install the front propeller shaft and tighten all 12 bolts to the specified torque of 46 lb. ft.

NOTE:
You must align the marks when installing the Front Propeller Shaft.

32. Lower the vehicle from the hoist.

33. Install the plastic engine cover. Reconnect the battery ground cable.

34. Start the vehicle and inspect each end of the Fuel Hose Assembly to verify no Teaks exist.

35. Close the hood and fill out and affix campaign label(s) using the following procedure(s) in the next section.

NOTE:
Some vehicles may require two campaign labels.