Fuel Delivery and Air Induction: Service and Repair
COMPONENT PARTSRemoval / Inspection / Installation
Warning: Fuel line spills and leaks are dangerous. Fuel can ignite and cause serious injuries or death and damage. Fuel can also irritate skin and eyes. To prevent this, always complete the "Fuel Line Safety Procedures".
PROCEDURE SUMMARY
1. Disconnect the negative battery cable.
2. Remove in the order shown in (Fig.1), referring to Removal note.
3. Visually check each part for damage. Replace if necessary.
4. Install in the reverse order of removal, referring to Installation note.
Level-1 Disassembly/Assembly
Fig.1:
1. Dynamic chamber cover
2. Charge air cooler air duct
3. Air cleaner assembly
4. Air duct
5. Fresh-air duct
6. Mass air flow sensor
7. Air intake hose
8. Resonator
9. Charge air cooler (RH)
10. Charge air cooler (LH)
11. Accelerator cable
12. Vacuum hose assembly
13. EGR valve
14. Air intake pipe assembly
Removal note
Dynamic chamber cover
1. Remove nuts [A].
2. Remove the dynamic chamber cover in the order shown (Fig.2).
Installation note
Charge air cooler, air intake pipe assembly
1. Hand tighten the nuts and bolts in the order shown (Fig.3) until the air intake pipe No.3 contacts the intake manifold.
2. Verify that the rubbers are not twisted or distorted.
3. Tighten the nuts and bolts to the specified torque in the order shown (Fig.3).
Fig.3:
Tightening torque
A: 7.9-10.7 N-m (8O-110 kg-cm, 70-95.4 in-lb)
Others: 19-25 N-m (1.9-2.6 kg-m, 14-18 ft-lb)
4. Hand tighten the nuts and bolts in the order shown (Fig.4) until the charge air coolers and the air intake pipes No.1 and No.2 contact the intake manifold.
5. Verify that the rubbers are not twisted or distorted.
6. Tighten the nuts and bolts to the specified torque in the order shown. (Fig.4)
Fig.4:
Tightening torque
A: 5.0-8.8 N-m (50-90 kg-cm, 44-78 in-lb)
B: 7.9-10.7 N-m (80-110 kg-cm, 70-95.4 in-lb)
Others: 19-25 N-m (1.9-2.6 kg-m, 14-18 ft-lb)
Level-2 Disassembly/Assembly
1. Charge air cooler pipe
2. Fuel hose
3. Fuel distributor connector
4. Coolant hose
5. Intake manifold assembly
6. Throttle body assembly
7. Drive belt
8. Lysholm compressor
Removal note
Fuel hose
Before disconnecting the fuel hoses, follow the "Fuel Line Safety Procedures".
Coolant hose
Before disconnecting the coolant hoses, drain the coolant from radiator.
Installation note
Lysholm compressor
Before installation, temporarily fix the rubber onto the Lysholm compressor with two-side adhesive tape.
Intake manifold assembly
1. Install the intake manifold assembly with the new gaskets.
2. Tighten the bolts and nuts in the order shown.
Tightening torque:
19-25 N-m (1.9-2.6 kg-m, 14-18 ft-lb)