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MAINTENANCE AND REPAIR

ON-VEHICLE SERVICE



M3C11F51
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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.

  1. Relieve the fuel system pressure.


  2. M3C11F52
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    M3C11F53
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  3. Disconnect the fuel lines from the fuel pump.


  4. M3C11F54
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  5. Remove the fuel pump assembly from the tank.


  6. M3C11F55
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M3C11F56
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Installation Procedure

  1. Install in the reverse order of removal.
  2. Install in the fuel pump.
  3. Tighten
    Tighten the fuel pump bolts to 3-4 N•m (27-35 lb-in).

  4. Perform an operational check of the fuel pump.



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Fuel Sender

Removal Procedure

  1. Disconnect the insulator connector.


  2. T3B11F2E
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  3. Push the terminal wedge(1) in the insulator connector.
  4. Notice : The wedge may be disconnected with severe load but can be reconnected.



    T3B11F2F
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  5. Push the wedge(1) outside and then pull the wires tp disconnect from insulator.


  6. T3B11F2G
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  7. Remove the fuel-level sensor(1) from the sender-housing(2).
  8. Remove the sender-housing(2).


  9. T3B11F2H
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  10. Remove fuel sender assembly(3).


T3B11F2A
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Installation Procedure

  1. Wind the wires(1) the sender assembly(2).


  2. T3B11F2B
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  3. Install the sender assembly onto the fuel pump assembly(1).
  4. Notice : Unless correctly install the sender assmembly, fuel gauge indicate inexactly.

  5. Install the fuel-level sensor onto the sender-housing.
  6. Notice : Unless correctly install the fuel-level sensor, fuel-level warning lamp indicate inexactly.



    T3B11F0T
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  7. Connect the wire into the insulator connector.


  8. T3B11F2C
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  9. Connect the insulator connector.


M3C11F57
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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.

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


  2. M3C11F58
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  3. Remove the fuel pressure regulator from the fuel pump.


M3C11F59
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Installation Procedure

  1. Install in the reverse order of removal.


M3C11F60
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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.

  1. Relieve the fuel system pressure. Refer to "Fuel Pump" in this section.
  2. Remove the fuel filter from the fuel tank.


M3C11F60
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Installation Procedure

  1. Install in the reverse order of removal.


M3C11F53
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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.

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


  3. M3C11F61
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  4. Drain the fuel tank.


  5. M3C11F62
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  6. Remove the fuel filter. Refer to "Fuel Filter" in this section.
  7. Install the jack to remove the fuel tank.


  8. M3C11F63
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  9. Remove the fuel tank.


M3C11F62
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Installation Procedure

  1. Install in the reverse order of removal.
  2. Install the fuel tank bolts.
  3. Tighten
    Tighten the fuel tank bolts to 18-22 N•m (13-16 lb-ft).



M3C11F64
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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.

  1. Relieve the fuel system pressure. Refer to "Fuel Pump" in this section.
  2. Remove the canister from the engine room. Refer to "Evaporative Emission Canister" in this section.
  3. Disconnect the fuel inlet line.
  4. Disconnect the fuel injector harness connectors.


  5. M3C11F65
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    M3C11F66
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  6. Remove the fuel rail with the fuel injectors attached.
  7. 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.



    M3C11F67
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  8. Remove the injectors from the fuel rail.
  9. 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.



M3C11F68
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Installation Procedure

  1. Install in the reverse order of removal.
  2. 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.

  3. Install the fuel rail retaining bolts.
  4. Tighten
    Tighten the fuel rail retaining bolts to 18-22 N•m (13-16 lb-ft).

  5. Perform a leak check of the fuel rail and the fuel injectors.


M3C11F69
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Evaporative Emission Canister

Removal Procedure

    Caution : Canister and vacuum hoses contain fuel vapors. Do not smoke in the area or permit an open flame.

  1. Disconnect the negative battery cable.
  2. Remove the canister.


  3. M3C11F70
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M3C11F70
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Installation Procedure

  1. Install in the reverse order of removal.


M3C11F71
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Evaporative Emission Canister Purge Solenoid

  1. Disconnect the negative battery cable.
  2. Disconnectthe evaporative (EVAP) emission canister purge solenoid connector.
  3. Disconnect the vacuum hoses from the EVAP canister purge solenoid.
  4. Unclip the EVAP emission canister purge solenoid from the mounting bracket.
  5. Installation should follow the removal procedure in the reverse order.


M3C11F72
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Manifold Absolute Pressure Sensor

Removal Procedure

  1. Disconnect the manifold absolute pressure (MAP) sensor connector.
  2. Remove the MAP sensor.


M3C11F72
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Installation Procedure

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



M3C11F73
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Throttle Body

Removal Procedure

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


  3. M3C11F74
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  4. Disconnect the throttle cable, the throttle position sensor and the idle air control valve connectors.


  5. M3C11F75
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  6. Remove the throttle body from the intake manifold.


M3C11F76
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Installation Procedure

  1. Install in the reverse order of removal.
  2. 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.

  3. Install the throttle body with the bolts.
  4. Tighten
    Tighten the throttle body bolts to 9-12 N•m (80-106 lb-in).



M3C11F77
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Engine Coolant Temperature (ECT) Sensor

Removal Procedure

  1. Remove the engine coolant temperature (ECT) sensor. Refer to Section 1D, Engine Cooling.


M3C11F77
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Installation Procedure

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



M3C11F78
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Intake Air Temperature (IAT) Sensor

Removal Procedure

  1. Disconnect the negative battery cable.
  2. Remove the intake air temperature (IAT) sensor.


M3C11F78
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Installation Procedure

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



M3C11F79
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Front Heated Oxygen Sensor (HO2S1)

Removal Procedure

  1. Remove the air cleaner/resonator assembly. Refer to Section 1B, SOHC Engine Mechanical.
  2. Remove the exhaust manifold heat shield.
  3. Remove the oxygen sensor.
  4. 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.



M3C11F79
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Installation Procedure

  1. Install in the reverse order of removal.
  2. 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.

  3. Install the oxygen sensor.
  4. Tighten
    Tighten the front heated oxygen sensor to 35-44 N•m (26-33 lb-ft).



M3C11F80
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Rear Heated Oxygen Sensor (HO2S2)

Removal Procedure

  1. Disconnect the negative battery cable.
  2. Remove the front center console.
  3. Disconnect the HO2S2 connector.
  4. Remove the HO2S2.

Installation Procedure

  1. Install in the reverse order of removal.
  2. 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.

  3. Install the oxygen sensor.
  4. Tighten
    Tighten the rear heated oxygen sensor to 35-44 N•m (26-33 lb-ft).



M3C11F81
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Electric Exhaust Gas Recirculation Valve

Removal Procedure

  1. Disconnect the negative battery cable.
  2. Remove the air cleaner assembly.
  3. Disconnect the electric exhaust gas recirculation (EEGR) valve connector.


M3C11F82
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Knock Sensor

Removal Procedure

  1. Disconnect the negative battery cable.
  2. Remove the starter. Refer to Section 1E, Engine Electrical.
  3. Disconnect the electrical connector at the knock sensor (1).


  4. M3C11F83
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  5. Remove the knock sensor.


M3C11F84
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Installation Procedure

  1. Install the knock sensor with the bolt.
  2. Tighten
    Tighten the knock sensor retaining bolt to 15-25 N•m (11-18 lb-ft).

  3. Connect the electrical connector to the knock sensor.
  4. Install the starter. Refer to Section 1E, Engine Electrical.
  5. Connect the negative battery cable.


M3C11F85
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Electronic Ignition (EI) System Ignition Coil

Removal Procedure

  1. Disconnect the negative battery cable.
  2. Note the ignition wire location and disconnect the ignition wires from the EI system ignition coil.
  3. Disconnect the EI system ignition coil connector.
  4. Remove the EI system ignition coil retaining bolts.
  5. Remove the EI system ignition coil.


M3C11F85
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Installation Procedure

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


M3C11F86
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Crankshaft Position (CKP) Sensor

Removal Procedure

  1. Disconnect the negative battery cable.
  2. Remove the air cleaner assembly.
  3. Disconnect the crankshaft position (CKP) sensor connector.
  4. Remove the CKP sensor retaining bolt.


M3C11F86
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Installation Procedure

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


M3C11F88
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Engine Control Module (ECM)

Removal Procedure

  1. Disconnect the ECM connector.


  2. M3C11F89
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  3. Remove the ECM.


M3C11F90
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Installation Procedure

  1. Install in the reverse order of removal.
  2. Notice : If disconnecting the battery cable to the ECM, the IAC valve resetting should be proceeded.

  3. Install the ECM with the bolts.
  4. Tighten
    Tighten the ECM mounting bolts to 6-8 N•m (53-71 lb-in).



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