MAINTENANCE AND REPAIR
ON-VEHICLE SERVICE


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.
- Relieve the fuel system pressure.
- Start the engine and remove the rear seat cushon.


- Remove the fuel pump access cover.
- Disconnect the fuel pump assembly electrical connector lock pin.
- Disconnect the fuel pump assembly electrical connector.
- Crank the engine for an additional 10 seconds.


- Disconnect the fuel lines from the fuel pump.
- Disconnect the fuel outlet line.
- Disconnect the fuel tank return line.


- Remove the fuel pump assembly from the tank.


- Remove the fuel pump assembly (2).
- Remove the fuel pump gasket (3).


Installation Procedure
- Install in the reverse order of removal.
- Install in the fuel pump.
Tighten
Tighten the fuel pump bolts to 3-4 N•m (27-35 lb-in).
- Perform an operational check of the fuel pump.
- Perform an operational check of the ignition switch ON the 2 seconds fuel pump operation.


Fuel Sender
Removal Procedure
- Disconnect the insulator connector.


- Push the terminal wedge(1) in the insulator connector.
Notice : The wedge may be disconnected with severe load but can be reconnected.


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


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


- Remove fuel sender assembly(3).


Installation Procedure
- Wind the wires(1) the sender assembly(2).


- Install the sender assembly onto the fuel pump assembly(1).
Notice : Unless correctly install the sender assmembly, fuel gauge indicate inexactly.
- Install the fuel-level sensor onto the sender-housing.
Notice : Unless correctly install the fuel-level sensor, fuel-level warning lamp indicate inexactly.


- Connect the wire into the insulator connector.


- Connect the insulator connector.


Fuel Pressure Regulator
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.
- Relieve the fuel system pressure after remove the fuel pump assembly. Refer to "Fuel Pump"
in this section.


- Remove the fuel pressure regulator from the fuel pump.
- Remove the retainer from the fuel pump assembly (1).
- Remove the fuel pressure regulator (2).
- Check the O-ring seals for the damage or the rip.
- Use a vacuum gauge to check the diaphram for damage and the spring for operation.


Installation Procedure
- Install in the reverse order of removal.
- Do not reuse the removed O-ring seals. Replace the removed O-ring seals with the new ones.


Fuel Filter
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.
- Relieve the fuel system pressure. Refer to "Fuel Pump"
in this section.
- Remove the fuel filter from the fuel tank.
- Disconnect the inlet/outlet fuel lines by pushing the line connector lock and pulling off the hose of the fuel filter tube.
- Remove the fuel filter.


Installation Procedure
- Install in the reverse order of removal.
- Install the new fuel filter into the retaining clamp. Note the flow direction.
- Connect the inlet/outlet lines. Secure the lines with the connector lock.
- Perform a leak test of the fuel filter.


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.
- Relieve the fuel system pressure. Refer to "Fuel Pump"
in this section.
- Disconnect the fuel tank ventilation tube.
- Disconnect the clamp (1).
- Disconnect the ventilation tube (2)


- Drain the fuel tank.
- Place a pan below the fuel tank to catch the draining fuel.
- Disconnect the fuel tank filter tube.
- Disconnect the evaporative emission canister line.


- Remove the fuel filter. Refer to "Fuel Filter"
in this section.
- Install the jack to remove the fuel tank.
- Install the jack on the center of the fuel tank.
- Remove the bolts.


- Remove the fuel tank.
- Lower slowly the jack to remove the fuel tank easily (1).
- Disconnect the canister hose which is connected to the roll over valve from the fuel tank removed (2).
- Inspect the fuel tank for clacks, damages, and contaminations.
- Inspect the fuel lines for cracks and damages.


Installation Procedure
- Install in the reverse order of removal.
- After the installation is complete, start the engine to prevent the vapor lock and check the hoses for leaks.
- Install the fuel tank bolts.
Tighten
Tighten the fuel tank bolts to 18-22 N•m (13-16 lb-ft).


Fuel Rail and Injectors
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.
- Relieve the fuel system pressure. Refer to "Fuel Pump" in this section.
- Remove the canister from the engine room. Refer to "Evaporative Emission Canister"
in this section.
- Disconnect the fuel inlet line.
- Disconnect the fuel injector harness connectors.




- Remove the fuel rail with the fuel injectors attached.
- Remove the bolts.
- Remove the fuel rail with the fuel injectors attached.
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.


- Remove the injectors from the fuel rail.
- Remove the fuel injector retainer clips.
- Remove the fuel injectors by pulling them down and out.
- Discard the fuel injector O-rings.
Important : Different fuel 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 fuel injector.


Installation Procedure
- Install in the reverse order of removal.
Important : If a fuel injector becomes separated from the fuel rail and remains in the cylinder head, replace the fuel injector O-ring seals and the retaining clip.
- Lubricate the new fuel injector O-rings with engine oil. Install the new O-rings on the fuel injectors.
- Install the fuel rail retaining bolts.
Tighten
Tighten the fuel rail retaining bolts to 18-22 N•m (13-16 lb-ft).
- Perform a leak check of the fuel rail and the fuel injectors.


Evaporative Emission Canister
Removal Procedure
Caution : Canister and vacuum hoses contain fuel vapors. Do not smoke in the area or permit an open flame.
- Disconnect the negative battery cable.
- Remove the canister.
- Remove the bolt (1).
- Remove the nut, then remove the cover (2).


- Disconnect the canister hoses (3).
- Remove the evaporative emission casnister (4).


Installation Procedure
- Install in the reverse order of removal.


Evaporative Emission Canister Purge Solenoid
- Disconnect the negative battery cable.
- Disconnectthe evaporative (EVAP) emission canister purge solenoid connector.
- Disconnect the vacuum hoses from the EVAP canister purge solenoid.
- Unclip the EVAP emission canister purge solenoid from the mounting bracket.
- Installation should follow the removal procedure in the reverse order.


Manifold Absolute Pressure Sensor
Removal Procedure
- Disconnect the manifold absolute pressure (MAP) sensor connector.
- Disconnect the MAP connector.
- Remove the MAP sensor.


Installation Procedure
- Install in the reverse order of removal.
- Install the MAP sensor with the bolts.
Tighten
Tighten the MAP sensor bolts/nuts to 8-12 N•m (71-106 lb-in).


Throttle Body
Removal Procedure
- Remove the air cleaner/resonator assembly and air intake tube. Refer to Section 1B, SOHC Engine Mechanical.
- Drain the engine coolant. Refer to Section 1D, Engine Cooling.


- Disconnect the throttle cable, the throttle position sensor and the idle air control valve connectors.
- Open the throttle valve.
- Disconnect the throttle cable.


- Remove the throttle body from the intake manifold.
- Remove the throttle body bolts and nuts.
- Remove the throttle body.
- Discard the throttle body gasket.
- Inspect the throttle body gasket for the deformation and the damages.


Installation Procedure
- Install in the reverse order of removal.
Important : Make sure the throttle control cable do not hold the throttle open. With the engine OFF, check to see that the accelerator pedal is free.
- Install the throttle body with the bolts.
Tighten
Tighten the throttle body bolts to 9-12 N•m (80-106 lb-in).


Engine Coolant Temperature (ECT) Sensor
Removal Procedure
- Remove the engine coolant temperature (ECT) sensor. Refer to Section 1D, Engine Cooling.


Installation Procedure
- Install the engine coolant temperature sensor.
Tighten
Tighten the engine coolant temperature sensor to 8-12 N•m (71-106 lb-ft).


Intake Air Temperature (IAT) Sensor
Removal Procedure
- Disconnect the negative battery cable.
- Remove the intake air temperature (IAT) sensor.
- Disconnect the IAT sensor connector.
- Disconnect the IAT sensor.


Installation Procedure
- Install in the reverse order of removal.
- Install the IAT sensor.
Tighten
Tighten the IAT sensor to 20-30 N•m (15-22 lb-ft).


Front Heated Oxygen Sensor (HO2S1)
Removal Procedure
- Remove the air cleaner/resonator assembly. Refer to Section 1B, SOHC Engine Mechanical.
- Remove the exhaust manifold heat shield.
- Remove the oxygen sensor.
- Disconnect the oxygen sensor connector.
- Remove the oxygen sensor.
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.


Installation Procedure
- Install in the reverse order of removal.
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.
- Install the oxygen sensor.
Tighten
Tighten the front heated oxygen sensor to 35-44 N•m (26-33 lb-ft).


Rear Heated Oxygen Sensor (HO2S2)
Removal Procedure
- Disconnect the negative battery cable.
- Remove the front center console.
- Disconnect the HO2S2 connector.
- Remove the HO2S2.
Installation Procedure
- Install in the reverse order of removal.
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.
- Install the oxygen sensor.
Tighten
Tighten the rear heated oxygen sensor to 35-44 N•m (26-33 lb-ft).


Electric Exhaust Gas Recirculation Valve
Removal Procedure
- Disconnect the negative battery cable.
- Remove the air cleaner assembly.
- Disconnect the electric exhaust gas recirculation (EEGR) valve connector.


Knock Sensor
Removal Procedure
- Disconnect the negative battery cable.
- Remove the starter. Refer to Section 1E, Engine Electrical.
- Disconnect the electrical connector at the knock sensor (1).


- Remove the knock sensor.
- Remove the knock sensor retaining bolt (1).
- Remove the knock sensor.


Installation Procedure
- Install the knock sensor with the bolt.
Tighten
Tighten the knock sensor retaining bolt to 15-25 N•m (11-18 lb-ft).
- Connect the electrical connector to the knock sensor.
- Install the starter. Refer to Section 1E, Engine Electrical.
- Connect the negative battery cable.


Electronic Ignition (EI) System Ignition Coil
Removal Procedure
- Disconnect the negative battery cable.
- Note the ignition wire location and disconnect the ignition wires from the EI system ignition coil.
- Disconnect the EI system ignition coil connector.
- Remove the EI system ignition coil retaining bolts.
- Remove the EI system ignition coil.


Installation Procedure
- Install the EI system ignition coil.
- Tighten the EI system ignition coil to 8-12 N•m (71-106 lb-in).


Crankshaft Position (CKP) Sensor
Removal Procedure
- Disconnect the negative battery cable.
- Remove the air cleaner assembly.
- Disconnect the crankshaft position (CKP) sensor connector.
- Remove the CKP sensor retaining bolt.


Installation Procedure
- Install the CKP sensor.
- Tighten the CKP sensor retaining bolt to 5-8 N•m (89-124 lb-in).


Engine Control Module (ECM)
Removal Procedure
- Disconnect the ECM connector.


- Remove the ECM.
- Remove the bolts.
- Remove the ECM.


Installation Procedure
- Install in the reverse order of removal.
Notice : If disconnecting the battery cable to the ECM, the IAC valve resetting should be proceeded.
- Install the ECM with the bolts.
Tighten
Tighten the ECM mounting bolts to 6-8 N•m (53-71 lb-in).
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