2.0L VCDi LNP DIESEL ENGINE MANUAL PDF

2-6 Clutch Piston Installation (6T40/45/50)
2011 Chevrolet Orlando

Submodel: | Engine Type: | Liters:
Fuel Delivery: | Fuel:
2-6 Clutch Piston Installation
Callout Component Name
2–6 Clutch Piston Assembly

Note:
Position the 2–6 piston air bleed and large slot toward the top of the case.
1 DT-47796 seal protector prevents the piston seal lip from damage during installation. Apply a thin coat of ATF to the I.D. of the
DT-47796 seal protector to ease installation of the piston.
Special Tool
DT-47796 Seal Protector
For equivalent regional tools, refer to Special Tools.
2 2–6 Clutch Spring
2–6 Clutch Spring Retainer

Caution: Regulate the air pressure to 276 kPa (40 psi) maximum. High pressure could cause the piston to over travel and damage
the piston seals.
Note:
Place the retainer on the 2-6 clutch spring and align the retainer opening with the largest gap in the case splines toward the
bottom of the case. The retainer opening should be supported by a spline tooth of the case.
3
Apply shop air to the clutch fluid feed hole in the case to verify proper piston operation.
Special Tools
DT-47797 Spring Installer

DT-48056 Spring Compressor Bridge
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Crankshaft and Bearing Cleaning and Inspection

Cleaning Procedure
Clean the lower crankcase (bed plate) sealing surface.

Clean the engine block sealing surface.
Clean the lower crankcase (bed plate) tightening bolts.
Clean the lower crankcase (bed plate) bolt holes.
Axial Play Measurement
Using a dial gauge (1), inspect the crankshaft end play with the crankshaft bearing installed. Refer to Engine Mechanical Specifications for recommended limits.
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Crankshaft and Bearing Installation

Note: If the old crankshaft bearing shells was reused, set it in as removed. The middle crankshaft bearing (3) contains the thrust bearing.
1. Coat the crankshaft bearing shells with engine oil.
2. Install the 5 upper crankshaft bearings.
Note: Take extreme care to prevent any scratches or damage to the crankshaft.
3. Install the crankshaft (1).
4. Install the 5 lower crankshaft bearings (2).
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Special Tools
EN-45059 Torque Angle Sensor Kit
For equivalent regional tools, refer to Special Tools
Note: Inspect the installation position.

1. Install the crankshaft bearing clips, oil bearing clips.
2. Install the crankshaft.
3. Install the crankshaft bearing caps 1-4.
Oil bearing clips.

Install the 8 NEW crankshaft bearing cap bolts.

Install the crankshaft bearing cap.
1. Apply black adhesive sealing compound to the grooves of the rear crankshaft bearing cap.
2. Install the 2 NEW crankshaft bearing cap bolts.
Caution: Refer to Fastener Caution.
Caution: Refer to Torque-to-Yield Fastener Caution.

Tighten the bolts for the crankshaft bearing caps (1) in 3 passes using the EN-45059 sensor kit:
First pass to 50 Y (37 lb ft)

Second pass to 45°
Third pass to 15°
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Install the connecting rod bearing caps 2 and 3 (1) and oil the bearing clips.
Install 4 NEW connecting rod bearing cap bolts and tighten in 3 passes use the EN-45059 sensor kit:

Second pass to 45°
Third pass to 15°
Turn the crankshaft through 180°.

Install the connecting rod bearing caps 1 and 4 (1) and oil the bearing clips.
Install 4 NEW connecting rod bearing cap bolts and tighten in 3 passes use the EN-45059 sensor kit:

Second pass to 45°
Third pass to 15°
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Crankshaft and Bearing Removal

Note: Mark the installation position of the crankshaft bearings. Set aside in order removed. The middle crankshaft bearing (3) contains the thrust bearing.
1. Remove the 5 lower crankshaft bearings.
Note: Take extreme care to prevent any scratches or damage to the crankshaft.
2. Remove the crankshaft (1).
3. Remove the 5 upper crankshaft bearings (2).
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1. Identify all the connecting rod bearing caps (1).
2. Remove the 4 bolts.

3. Remove the connecting rod bearing caps 1 and 4 (1).
4. Turn the crankshaft through 180°.

6. Remove the connecting rod bearing caps 2 and 3 (1).
7. Identify the crankshaft bearing caps.
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8. Remove the crankshaft bearing caps (1).

10. Remove the crankshaft (2).
11. Remove the crankshaft bearing clips.
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Crankshaft Balancer Cleaning and Inspection

Special Tools
EN-50431 BSM - Backlash Measure Adapter
Warning: Refer to Safety Glasses and Compressed Air Warning.

1. Remove the coating remains on the balance shaft module gear by using compressed air.
2. Check the balancer for damages.
Note: The EN-50431 adapter must be horizontal to the balancer.

3. Install the EN-50431 adapter (1) to the balancer.
4. Install the dial gauge (2), in the distance “a” of 38.217 mm (1.505 in) to the center of the balance shaft axle.
5. Using the dial gauge (2), move the balance shaft module gear by using fingers and measure the backlash.
6. Compare the measurement results with the engine mechanical specifications. Refer to Engine Mechanical Specifications.
7. If the balance shaft module is out of specification, try the procedure (1~6) again.
8. If the balance shaft module gear backlash is out of the specifications, replace the balance shaft module by a NEW balance shaft module.
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Crankshaft Balancer Installation

Special Tools
EN-652 Flywheel Holder

EN-45059 Angle Meter
1. Install the EN-652 holder (1), lock the flywheel (2) or the automatic transmission flex plate via the starter ring gear.
Note: Use care that the height (1) of the washer is facing towards the bolt.
2. Install the crankshaft balancer (2) and the washer (3).
3. Install a NEW crankshaft balancer bolt (4) and tighten the bolt in 3 passes using the EN-45059 meter
1. First pass to 95 Y (70 lb ft).

2. Second pass to an additional 45°,
3. Final pass to an additional 15°.
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Special Tools
EN-50430 Pin - Balance Shaft Module Locking

EN-50431 Adapter - Backlash Measurement
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1. Set the piston of cylinder #1 to TDC of combustion stroke.
2. Install the EN-50430 locking pin (1) and lock the gear of the balance shaft module (2).
3. Install the balance shaft module (1) to the lower crankcase.
Note: Install the balance shaft module retaining bolts in a cross sequence.
4. Install 4 NEW balance shaft module retaining bolts (2). Tighten the bolts (2) only to the extent to which the balance shaft module (1) is still sliding on the lower
crankcase.
5. Remove the EN-50430 locking pin .
6. Push the balance shaft module (1) to the exhaust side of the engine.
7. Install a dial gauge (2) to the intake side of the balance shaft module.
8. Set the dial gauge to zero.
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9. Set driver (1) into the exhaust side like graphic shown and push the balance shaft module (2) 1,1 mm (0.039 in) to the intake side.
Note: Tighten the balance shaft module retaining bolts in a cross sequence.
10. Tighten the balance shaft module bolts (2) to 20 Y (15 lb ft).
11. Check the balance shaft module backlash specifications. Refer to Crankshaft Balancer Cleaning and Inspection.
12. Tighten the balance shaft module bolts (2) to 50 Y + 90° (37 lb ft) + 90°.
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Crankshaft Balancer Removal

Special Tools
EN-652 Flywheel Holder
1. Install the EN-652 holder (1). Lock the flywheel (2) or the automatic transmission flex plate via the starter ring gear.
2. Remove and DISCARD the crankshaft balancer bolt (4).

3. Remove the crankshaft balancer washer (3).
4. Remove the crankshaft balancer (2).
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Crankshaft Balancer Removal

1. Remove 4 balancer retaining bolts (2).

2. Remove the balancer (1).
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Crankshaft Balancer Replacement (Automatic Transmission)

Special Tools
EN-6625 Crankshaft Locking Device

Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle.
2. Remove the front compartment splash shield. Refer to Front Compartment Splash Shield Replacement.
3. Remove the drive belt. Refer to Drive Belt Replacement.
4. Remove the fastener (1).
5. Install the EN–6625 locking device (2) to lock the crankshaft.

6. Install the bolt (1).

Installation Procedure
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Crankshaft Balancer Replacement (Automatic Transmission)
1. Install the crankshaft balancer (2).

2. Install a NEW crankshaft balancer bolt (1) and tighten a first pass to 95 Y (70 lb ft).
3. Tighten the NEW crankshaft balancer bolt a second pass to an additional 45 degrees, using the EN-45059 meter
4. Tighten the NEW crankshaft balancer bolt a final pass to an additional 15 degrees, using the EN-45059 meter.
5. Remove the bolt (1).

6. Remove EN–6625 locking device (2) to unlock the crankshaft.
7. Install the fastener (1) and tighten to 58 Y (43 lb ft).

8. Install the drive belt. Refer to Drive Belt Replacement.
9. Install the front compartment splash shield. Refer to Front Compartment Splash Shield Replacement.
10. Lower the vehicle.
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Crankshaft Balancer Replacement (Manual Transmission)

Special Tools

Removal Procedure
5. Install the EN–6625 locking device (2) to lock the crankshaft.

6. Install the bolt (1).

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Crankshaft Balancer Replacement (Manual Transmission)
1. Install the crankshaft balancer (2).

2. Install a NEW crankshaft balancer bolt (1) and tighten a first pass to 95 Y (70 lb ft).
3. Tighten the NEW crankshaft balancer bolt a second pass to an additional 45 degrees, using the EN-45059 meter.
4. Tighten the NEW crankshaft balancer bolt a final pass to an additional 15 degrees, using the EN-45059 meter.

6. Remove EN–6625 locking device (2) to unlock the crankshaft.
7. Install the bolt (1) and tighten to 75 Y (55 lb ft).

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Crankshaft Balancer Replacement

Special Tools
EN-50430 Pin - Balancer Locking

EN-50431 Adapter - Backlash Measurement
Removal Procedure
1. Remove upper oil pan. Refer to Upper Oil Pan Replacement.
2. Remove and DISCARD the 4 balancer retaining bolts (2).

3. Remove the balancer (1).
1. Set the piston of cylinder 1 to TDC of combustion stroke.
2. Install the EN-50430 locking pin (1) and lock the gear of the balancer (2).
3. Install the balancer (1) to the lower crankcase.

Note: Install the balancer retaining bolts in a cross sequence.
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Crankshaft Balancer Replacement
4. Install the 4 NEW balancer retaining bolts (2). Handtighten the bolts (2) so that the balancer (1) stays slidable without clearance on the lower crankcase.
5. Remove the EN-50430 locking pin .
6. Push the balancer (1) to the exhaust side of the engine.

7. Install a dial gauge (2) at the intake side of the balancer.
8. Set the dial gauge to zero.
9. Set screwdriver (1) into the exhaust side as shown and push the balancer (2) 1.1 mm (0.0433 in)to the Intake side.

Note: Tighten the balancer retaining bolts in a cross sequence.
10. Tighten the NEW balancer bolts to 20 Y (15 lb ft).
11. Check the balancer backlash specifications. Refer to Crankshaft Balancer Cleaning and Inspection.
12. Tighten the balancer bolts to 50 Y +90° (37 lb ft + 90°).
13. Install the upper oil pan. Refer to Upper Oil Pan Replacement.
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Crankshaft Front Oil Seal Installation

Special Tools
EN-6351 Mounting Sleeves
1. Clean the sealing surfaces.

2. Slide the EN-6351 sleeves (2) protective sleeve onto the crankshaft journal.
3. Slide the crankshaft front oil seal (1) over the protective sleeve on the crankshaft journal.
4. Remove the protective sleeve, and using the EN-6351 sleeves (3), press the seal ring into the pump housing.
5. Use the crankshaft drive gear bolt (1) and washer (2) to press in the crankshaft front oil seal.
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Crankshaft Front Oil Seal Installation

Special Tools
EN-50427 Installer - Crankshaft Front Oil Seal
Note: Observe the installation position of the removed crankshaft front oil seal ring to install the NEW crankshaft front oil seal ring in the same position.
Install the crankshaft front oil seal (1), using the EN-50427 installer.
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Crankshaft Front Oil Seal Removal

Special Tools
EN-45000 Remover
Caution: Clean the crankshaft sealing surface with a clean, lint-free towel. Inspect lead-in edge of crankshaft for burrs/sharp edges that could damage the rear main oil
seal. Remove burrs/sharp edges with crocus cloth before proceeding.
Using the EN-45000 remover (3), remove the crankshaft front oil seal (1) from the crankshaft (2).
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Crankshaft Front Oil Seal Removal

Special Tools
EN-45000 Remover - Oil Seal
Note: Be careful do not damage the sealing surfaces.

Note: Observe the installation position of the crankshaft front oil seal ring before removing, to install the NEW crankshaft front oil seal ring in the same position.
Remove the crankshaft front oil seal (1), using the EN-45000 remover.
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Crankshaft Front Oil Seal Replacement

Special Tools
EN-6351 Mounting Sleeves

EN-45000 Remover
Removal Procedure
1. Replace the timing belt. Refer to Timing Belt Replacement.
2. Remove the crankshaft sprocket (1).
Caution: Clean the crankshaft sealing surface with a clean, lint-free towel. Inspect lead-in edge of crankshaft for burrs/sharp edges that could damage
the rear main oil seal. Remove burrs/sharp edges with crocus cloth before proceeding.
3. Using the EN-45000 remover (3), remove the crankshaft front oil seal (1) from the crankshaft (2).

2. Slide the EN-6351 mounting sleeves (2) protective sleeve onto the crankshaft journal.
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3. Slide the crankshaft front oil seal (1) over the protective sleeve on the crankshaft journal.
4. Remove the protective sleeve, and using the EN-6351 mounting sleeves (3), press the seal ring into the pump housing.
5. Use the crankshaft drive gear bolt (1) and washer (2) to press in the crankshaft front oil seal.
Note: When installing the crankshaft sprocket, the cam and the groove must align (2).
6. Install the crankshaft sprocket (1).
7. Install the timing belt. Refer to Timing Belt Replacement.
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Special Tools

EN-50427 Installer
Removal Procedure
1. Remove the crankshaft pulley. Refer to Crankshaft Pulley Replacement.

Note: Observe the installation position of the crankshaft front oil seal ring before removing, to install the NEW crankshaft front oil seal ring in the same
position.
2. Remove the crankshaft front oil seal (1) using EN-45000 remover.
Note: Observe the installation position of the removed crankshaft front oil seal ring, to install the NEW crankshaft front oil seal ring in the same position.
1. Install the crankshaft front oil seal ring (1) using the EN-50427 installer.
2. Install the crankshaft pulley. Refer to Crankshaft Pulley Replacement.
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Crankshaft Position System Variation Learn

Note: The crankshaft position sensor system variation learn procedure is required when the following service procedures have been performed, regardless of whether
DTC P0315 00 is set:
Engine replacement
Engine control module (ECM) replacement
Crankshaft damper replacement
Crankshaft replacement
Crankshaft Position Sensor Replacement
Any engine repairs which disturb the crankshaft to crankshaft position sensor relationship
Note: The scan tool monitors certain component signals to determine if all the conditions are met to continue with the crankshaft position sensor system variation learn
procedure. The scan tool only displays the condition that inhibits the procedure. The scan tool monitors the following components:
Crankshaft Position Sensor activity – If there is a crankshaft position sensor condition, refer to the applicable DTC that set.
Camshaft position signal activity – If there is a camshaft position sensor signal condition, refer to the applicable DTC that set.
Engine coolant temperature (ECT) – If the engine coolant temperature is not warm enough, idle the engine until the engine coolant temperature reaches the
correct temperature.
1. Install a scan tool.

2. Monitor the ECM for DTCs with a scan tool. If other DTCs are set, except DTC P0315 00, refer to Diagnostic Trouble Code (DTC) List - Vehicle for the
applicable DTC that set.
3. With a scan tool, select the Crankshaft Position System Variation Learn procedure and perform the following:
1. Observe the fuel cut-off for the applicable engine.

2. Block the drive wheels.
3. Set the parking brake.
4. Place the vehicles transmission in Park or Neutral.
5. Turn the air conditioning (A/C) OFF.
6. Cycle the ignition from OFF to ON.
7. Apply and hold the brake pedal for the duration of the procedure.
8. Start and idle the engine.
9. Accelerate to wide open throttle (WOT). The engine should not accelerate beyond the calibrated fuel cut-off RPM value noted in step 3.1. Release the
throttle immediately if the value is exceeded.
Note: While the learn procedure is in progress, release the throttle immediately when the engine starts to decelerate. The engine control is returned to
the operator and the engine responds to throttle position after the learn procedure is complete.
10. Release the throttle when fuel cut-off occurs.
Accelerate to wide open throttle (WOT). The engine should not accelerate beyond the calibrated fuel cut-off RPM value noted in step 3.1. Release the throttle
immediately if the value is exceeded.
Note: While the learn procedure is in progress, release the throttle immediately when the engine starts to decelerate. The engine control is returned to the operator and
the engine responds to throttle position after the learn procedure is complete.
The scan tool displays Learn Status: Learned this Ignition. If the scan tool indicates that DTC P0315 00 only) ran and passed, the crankshaft position sensor variation
learn procedure is complete. If the scan tool indicates DTC P0315 00 failed or did not run, refer to DTC P0315. If any other DTCs set, refer to Diagnostic Trouble Code
(DTC) List - Vehicle for the applicable DTC that set.
Turn OFF the ignition for 30 s after the learn procedure is completed successfully.
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Crankshaft Rear Oil Seal Installation

Special Tools
EN-658-1 Installer
EN-235-D Installer Kit
1. Slide the crankshaft rear oil seal (2) across the EN-235-6 installer (1) contained in EN-235-D kit.
2. Install the crankshaft rear oil seal (1) with EN-235-6 installer (2) to the crankshaft.
3. Use EN-658-1 installer (2) to strike the crankshaft rear oil seal (1)
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4. Check the crankshaft rear oil seal for proper seat, the EN-658-1 installer must be flush with the cylinder block at the position (1).
5. Install the crankshaft position sensor reluctor ring (2).

Caution: Do not allow the crankshaft encoder wheel to come into contact with external magnetic fields or sharp metal objects. Do not drop the crankshaft
encoder wheel. Do not damage the rubberized encoder track. Failure to follow these precautions may cause damage to the component.
6. Install the crankshaft rear oil seal housing (1).
7. Install the crankshaft position sensor (3) to the crankshaft rear oil seal housing (1).
8. Install the crankshaft position sensor bolt (2) and tighten to 4.5 Y (40 lb in).
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Special Tools
EN-48251 Installer - Crankshaft Rear Oil Seal
Note: Observe the installation position of the removed crankshaft rear oil seal ring to install the NEW crankshaft rear oil seal ring in the same position.
Install the crankshaft rear oil seal ring (1) using the EN-48251 installer(2).
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Crankshaft Rear Oil Seal Removal

Special Tools
EN-328-B Pin Remover

EN-6624 Remover
1. Remove the crankshaft position sensor bolt (2).

2. Remove the crankshaft position sensor (3) from the crankshaft rear oil seal housing (1).
3. Remove the crankshaft rear oil seal housing (1).
4. Remove the crankshaft position sensor reluctor ring (2).
Note: The diameter of the hole must not exceed 2 mm (0.0787 in). If the diameter of the hole exceeds 2 mm (0.0787 in), the bolt of EN-6624 remover will not be
able to grip.
5. Only make a hole at the 5 o'clock and 7 o'clock positions (1), these are the only positions where is a cavity behind the seal ring.
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6. Using a suitable tool, such as a scribe (1), make a hole in the crankshaft rear oil seal.
Position the scribe (1) at the outer edge of the crankshaft rear oil seal.
7. Remove the seal ring.
8. Install EN-6624 remover (1) to the crankshaft rear oil seal and tighten the bolt.
9. Install the EN-328-B remover (1) to EN-6624 remover (2) and remove the crankshaft rear oil seal.
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Special Tools

Note: Observe the installation position of the crankshaft rear oil seal ring before removing, to install the NEW crankshaft rear oil seal ring in the same position.
Remove the crankshaft rear oil seal (1), using the EN-45000 remover.
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Crankshaft Rear Oil Seal Replacement

Special Tools

EN-48251 Installer - Crankshaft Rear Oil Seal
Removal Procedure
1. Remove the engine flywheel / automatic transmission flexplate.
Manual Transmission, refer to Engine Flywheel Replacement.

Automatic Transmission, refer to Automatic Transmission Flex Plate Replacement.

Note: Observe the installation position of the crankshaft rear oil seal ring before removing, to install the NEW crankshaft rear oil seal ring in the same position.
Remove the crankshaft front oil seal (1), using the EN-45000 remover.
Note: Observe the installation position of the removed crankshaft rear oil seal ring, to install the NEW crankshaft rear oil seal ring in the same position.
1. Install the crankshaft rear oil seal ring (1), using the EN-48251 installer (2).
2. Install the engine flywheel / automatic transmission flexplate.
Manual transmission, refer to Engine Flywheel Replacement.

Automatic transmission, refer to Automatic Transmission Flex Plate Replacement.
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Special Tools
EN-235-D Installer Kit

EN-328-B Pin Remover
EN-658-1 Installer
EN-6624 Remover
Removal Procedure
1. For vehicle with automatic transmission: remove the automatic transmission flex plate. Refer to Automatic Transmission Flex Plate Replacement.
2. For vehicle with manual transmission: remove the engine flywheel. Refer to Engine Flywheel Replacement.
3. Place the collecting basin underneath.
4. Remove the crankshaft position sensor bolt (2).

5. Remove the crankshaft position sensor (3) from the crankshaft rear oil seal housing (1).
6. Remove the crankshaft rear oil seal housing (1).
7. Remove the crankshaft position sensor reluctor ring (2).
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Note: The diameter of the hole must not exceed 2 mm (0.0787 in). If the diameter of the hole exceeds 2 mm (0.0787 in), the bolt of EN-6624 remover will
not be able to grip.
8. Only make a hole at the 5 o'clock and 7 o'clock positions (1), these are the only positions where is a cavity behind the seal ring.
9. Using a suitable tool, such as a scribe (1), make a hole in the crankshaft rear oil seal.
Position the scribe (1) at the outer edge of the crankshaft rear oil seal.
10. Remove the seal ring.
11. Install EN-6624 remover (1) to the crankshaft rear oil seal and tighten the bolt.
12. Install the EN-328-B remover (1) to EN-6624 remover (2) and remove the crankshaft rear oil seal.
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1. Slide the crankshaft rear oil seal (2) across the EN-235-6 installer (1) contained in EN-235-D kit.
2. Install the crankshaft rear oil seal (1) with EN-235-6 installer (2) to the crankshaft.
3. Use EN-658-1 installer (2) to strike the crankshaft rear oil seal (1)
4. Check the crankshaft rear oil seal for proper seat, the EN-658-1 installer (1) must be flush with the cylinder block at the position (arrow).
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5. Install the crankshaft position sensor reluctor ring (2).

6. Install the crankshaft rear oil seal housing (1).
7. Install the crankshaft position sensor (3) to the crankshaft rear oil seal housing (1).
8. Install the crankshaft position sensor bolt (2) and tighten to 4.5 Y (40 lb in).
9. Remove the collecting basin.
10. For vehicle with manual transmission: install the engine flywheel. Refer to Engine Flywheel Replacement.
11. For vehicle with automatic transmission: install the automatic transmission flex plate. Refer to Automatic Transmission Flex Plate Replacement.
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Crankshaft Sprocket Installation

Install the crankshaft sprocket (1).
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Crankshaft Sprocket Removal

Remove the crankshaft sprocket (1).
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Crankshaft Sprocket Replacement

Removal Procedure
1. Remove the camshaft timing chain. Refer to Camshaft Timing Chain Replacement.
Note: The cam (4) is only plugged into the recess (3) and may fall down.
2. Remove the crankshaft sprocket (1) from the crankshaft.
1. If necessary plug the cam (4) into the recess (3).

Note: The cam (4) and the sprocket groove (2) must align.
2. Install the crankshaft sprocket (1) to the crankshaft.
3. Check the correct seat of the sprocket (2). The sprocket must not turn independent of the crankshaft.
4. Install the camshaft timing chain. Refer to Camshaft Timing Chain Replacement.
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Cylinder Head Assemble

Special Tools
EN-46569 Valve Spring Compressor

EN-48247 Adapter - Valve Spring Compression
EN-46116 Installer - Stem Seal
1. Install 16 NEW valve stem oil seals, using the EN-46116 installer - stem seal (1).
2. Install the valve (4).

3. Install the valve spring (3).
4. Install the valve spring retainer (2).
Note: The EN-48247 adapter (2) must be aligned vertically to the valve spring retainers.
5. Install the EN-46569 compressor (1) with the EN-48247 compression adapter (2) to install the valve assembly.
6. Tension the valve spring.
7. Install both valve stem keys.
8. Release tension from the valve spring. Remove the EN-46569 compressor (1) with EN-48247 compression adapter (2).
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9. Check proper seat of the valve stem keys.

10. Repeat the steps for each other valve assembly.
11. Install the 16 valve rocker arms (1) along with the 16 hydraulic valve lash adjusters (2).
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Special Tools
EN-958 Installer for 5 mm (0.2 in) Valve Stem Sealings

EN-6086 Basic Kit, Spring and Wedge Replacer
EN-6167 Counter Holder
EN-6215-3 Locking Pins
Note: Condition: All construction units are cleaned and checked. The cylinder head is installed on the assembly fixture and stands on the head.
Note: Depending upon the combustion chamber organization, different holders must be used to protect the valves.
1. Counter holder type A (1).
2. Counter holder type B (1).

3. Coat all valve guides and valves with oil and install them in the cylinder head in sequence. Install the counter holder. For different combustion chambers you
have to use the correct counter holder to safe the valves.
4. Install the counter holder EN-6167-1 holder (1). Fasten the EN-6215-3 locking pins (3) with safety lock pins. Fasten the holding screws (2). Turn the cylinder
head baseplate again.
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5. Install the valve stem sealings (1) with the appropriate tools (2) carefully.
For 5 mm (0.2 in) use the EN-958 installer.
Note: It is necessary that the components of the assembly head are built together in correct sequence.
6. Attach the valve springs and valve retainers into the cylinder head in sequence.
The respective sizes are hit on the head of the thrust pieces.
Caution: Ensure that the assembly head and thrust piece are held together securely. Failure to secure the assembly head and thrust piece can prevent valve
stem key installation and cause damage to the thrust pieces.
7. Push the fixing case (1) downward and install the valve wedges in the assembly head. Now push the fixing case upward, through this procedure the valve
wedges are fixed.
Attach assembly head to lever EN-6086 lever.
Note: To facilitate the assembly of the valve shim, the assembly head is to touch down (1) with the thrust piece on the valve stem. This avoids damage of the
thrust pieces.
8. Adjust (align) the lever tool until the assembly head is positioned perpendicularly over the valve.
Press the assembly head with the lever tool carefully and slowly with little pressure until the valve wedges engage audibly into the valve stem.
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9. Remove the lever tool (1) and lateral took up.
Note: After the assembly of all attachments the cylinder head is to be cleaned thoroughly.
10. Remove the counter holder (1).
Detach the cylinder head from the assembly fixture.
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Cylinder Head Cleaning and Inspection

Valve Cleaning and Inspection
Warning: Bodily injury may occur if the cleaning solvent is inhaled or exposed to the skin.
Note: Do not scratch the valve stem with the wire brush.
1. Clean the valves of carbon, oil and varnish. Carbon can be removed with a wire brush. Varnish can be removed by soaking in Parts Immersion Solvent.
2. Clean the valve guides.
3. Inspect the valve stem for wear (4).
4. Inspect the valve key groove for chipping or wear (5). Replace the valve if chipped or worn.
5. Inspect the valve face for burning or cracking (1). If pieces are broken off, inspect the corresponding piston and cylinder head area for damage.
6. Inspect the valve stem for burrs and scratches. Burrs and minor scratches may be removed with an oil stone.
7. Inspect the valve stem for straightness and the valve head for bending or distortion (3) using V blocks. Bent or distorted valves must be replaced.
8. Clean the deposits from the valve face. Inspect the valve face for grooving.
9. Replace the valve if the face is grooved. Valve faces cannot be machined. If worn, or damaged, the valves must be replaced.
10. The valves may be lightly lapped to the valve seats.
Cylinder Head and Gasket Surface Cleaning and Inspection
1. Remove the spark plugs. Refer to Spark Plug Replacement.

2. Inspect the cylinder head gasket and mating surfaces for leaks, corrosion and blow-by. If the gasket has failed, use the following faults to determine the
cause:
1. Improper installation.
2. Loose or warped cylinder head.
3. Missing, off location or not fully seated dowel pins.
4. Corrosion in the seal area around the coolant passages.
5. Chips or debris in the cylinder head bolt holes.
6. Bolt holes in the cylinder block not drilled or tapped deep enough.
3. Inspect the cylinder head gasket surface.
Cylinder head may be reused if corrosion is found only outside a 4 mm (0.375 in) band around each combustion chamber (1).
Replace the cylinder head if the area between the valve seats is cracked (2).
Replace the cylinder head if corrosion has been found inside a 4 mm (0.375 in) band around each combustion chamber (3).
Clean the cylinder head bolts.
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Note: Do not use a wire brush on any gasket sealing surface.

Clean the cylinder head. Remove all varnish, soot and carbon to the bare metal.
Clean the valve guides.
Clean the threaded holes. Use a nylon bristle brush.
Clean the remains of the sealer from the plug holes.
Inspect the cylinder head bolts for damaged threads or stretching and damaged heads caused by improper use of tools.
Replace all suspect bolts.
Inspect the cylinder head for cracks. Check between the valve seats and in the exhaust ports.
Note: Do not attempt to weld the cylinder head, replace it.
Inspect the cylinder head deck for corrosion, sand inclusions and blow holes.
Inspect the cylinder head deck surface for flatness. Refer to Engine Mechanical Specifications. If the cylinder head is out of specification, replace the cylinder
head. Do not machine the cylinder head.
Inspect all the threaded holes for damage. Threads may be reconditioned with thread inserts.
Inspect the sealing surfaces.
Inspect the cylinder head plugs.
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Cleaning Procedure
Remove any old thread sealant, gasket material or sealant.

Clean all cylinder head surfaces with non-corrosive solvent.
Dry the cylinder head with compressed air.
Remove any carbon deposits from the combustion chamber.
Visual Inspection
1. Inspect the cylinder head for the following:
Cracks, damage or pitting in the combustion chambers.

Debris in the oil galleries. Continue to clean the galleries until all debris is removed.
Coolant leaks or damage to the deck face sealing surface.
Damage to any gasket surfaces.
Damage to any threaded bolt holes.
Burnt or eroded areas in the combustion chamber.
Cracks in the exhaust ports and combustion chambers.
External cracks in the water passages.
Restrictions in the intake or exhaust passages.
Restrictions in the cooling system passages.
Rusted, damaged or leaking core plugs.
If the cylinder head is cracked or damaged, it must be replaced. No welding or patching of the cylinder head is recommended.
Measure the clearance between the straight-edge and the cylinder head deck face, using a feeler gauge (1) at four points along the straight-edge.
Check the sealing surfaces for deformation and warpage. The cylinder head sealing surfaces must be flat within 0.05 mm (0.002 in) maximum.
Measure the height H of the cylinder head from sealing surface to sealing surface. The cylinder head height should be 129.9 to 130.1 mm (5.1142 to 5.1220 in).
If the cylinder head height is out of specifications, replace the cylinder head.
Measuring Procedure
Valve Inspection
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1. Inspect the valve for damage from the head to tip for the following conditions.
Inspect the valve faces for burning and cracking (1). If pieces are broken, replace the valve and inspect the corresponding piston and cylinder head area for
damage.
Inspect the valve for straightness and distortion (2).
Inspect the valve stem for wear (3).
Inspect the valve key grooves for chipping and wear (4) and (5).
Replace the valve if any of these conditions exist.
Inspect the valve springs. If the valve spring ends are not parallel, replace the valve spring.
Inspect the valve spring seating surface of the valve rotators for wear or gouges. Replace as required.
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Cylinder Head Disassemble

Special Tools
EN-46569 Valve Spring Compressor

EN-46116 Installer - Stem Seal
1. Remove the 16 valve rocker arms (1) along with 16 hydraulic valve lash adjusters (2).
Note: The EN-48247 adapter (2) must be aligned vertically to the valve spring retainers.
2. Install the EN-46569 compressor (1) with the EN-48247 compression adapter (2) to remove the valve assembly.
3. Press down the valve spring (3) and the valve spring retainer (2) with the EN-46569 compressor and the EN-48247 compression adapter until the valve keys
(1) are released from the spring load.
Note: Set the parts aside in order removed to ensure they will be installed in their original position.
4. Remove the valve stem keys (1).
5. Release tension from the valve spring. Remove the EN-46569 compressor with EN-48247 compression adapter .
6. Remove the valve spring retainer (2).
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7. Remove the valve spring.

8. Remove the valve (4).
9. Repeat the steps for each other valve assembly.
Note: Set the oil stem seals aside in order removed to ensure they will be installed in their original position.
10. Remove the 16 valve stem oil seals, using the EN-46116 installer - stem seal (1).
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Special Tools
EN-849 Assembly Tray

EN-6167 Fixing Tool
EN-6171 Release Tool
EN-6215 Mounting Equipment
EN-840 Remover
Note: Consider the appropriate screwing on points for the EN-6215-5 side mounts .
1. Fit EN-6215-5 side mounts (1) for EN-6215-4 assembly device .
2. Install EN-6215-4 assembly device (1).
3. The spark plug threads must be cleaned of combustion residues to ensure that the counterhold can be attached correctly. Insert tap M14 x 1.25 (1) in the spark
plug thread and screw in evenly.
4. Turn the cylinder head baseplate.
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Note: There are 2 kinds of counter holder. Type A and Type B. Choose the correct type for the existing combustion chamber.
5. Install the counter holder.
Note: Depending upon the combustion chamber organization, it must be used different holders to protect the valves.
6. Counter holder type A (1).
Note: Depending upon the combustion chamber organization, it must be used different holders to protect the valves.
7. Counter holder type B (1).
8. Install the EN-6167 fixing tool (1). Attach the EN-6215-3 mounting equipment (3) with safety lock pins. Install the fixing bolts (2). Turn the cylinder head
baseplate again.
9. To ensure that no special tools are damaged during the disassembly of the valve wedges, the valve retainers are to release with EN-6171 release tool (1). Put
the EN-6171 release tool on the valve retainers and with a short impact of a rubber hammer all valve retainers will loose (setting behavior).
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Note: The valve-spring depressing tool (1) must be positioned parallel onto the valve spring cap to ensure that neither tools nor components are damaged.
Select the appropriate bore in the lever for this purpose. If the valve-spring compressor cannot be positioned parallel, the lever must be adjusted accordingly.
10. Push the depressing tool (1) down with lever until the valve spring cap is released. Remove valve cotters.
11. Remove the upper valve spring cap and valve springs and place them in sequence on EN-849 assembly tray .
Release the valve stem sealings by turning with EN-840 remover (1) and remove from the valve guides.
12. Remove lower valve spring caps or valve rotators from cylinder head and also place on EN-849 valve box (1).
13. Remove lever tool.
14. Turn cylinder head baseplate. Remove wooden board EN-6215 mounting equipment and counter holder if attached.
15. Remove all valves in sequence and place on EN-849 assembly tray (1) in sequence.
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Cylinder Head Installation

Special Tools
EN-470-B Angle Meter

GE-571-B Dial Gauge
EN-50437 Height Gauge - Piston TDC
Cleaning Procedure
Note: Ensure that the cylinder head and the cylinder block sealing surfaces are clear of oil, grease and old gasket material.
Clean the engine block in order to assure a proper measurement. Refer to Engine Block Cleaning and Inspection.
Choose the Gasket
1. Align TDC of the piston 1.

2. Measure the piston projection thickness, using the EN-50437 height gauge - piston TDC .
3. Repeat the measuring process for the cylinders 2, 3, 4 and average the measured piston projection values.
4. Choose the cylinder head gasket according the specifications below.
Piston Projection (mm) Gasket Thickness (mm)
0.21–0.30 1.05 (1 U-Groove)
0.31–0.39 1.15 (2 U-Grooves)
0.40–0.49 1.25(3 U-Grooves)
1. Install the cylinder head (3) and a NEW gasket (4).

Note: DO NOT tighten the bolts yet.
2. Install the 10 NEW cylinder head retaining bolts (2).
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3. Tighten the NEW cylinder head retaining bolts (2) in 4 steps in sequence as shown in the graphic above:
1. First step 30 Y (22 lb ft)

2. Second step 100 Y (74 lb ft)
3. Third step 90°. Use the EN-470-B angle meter .
4. Fourth step 90°. Use the EN-470-B angle meter .
4. Install the camshaft seat guide (1).
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Special Tools

2. Inspect for plane surface.
Cylinder block, cylinder head

Straight-edge, feeler gauge
Install the cylinder head gasket.

Install the cylinder head.

Note: Note the correct tightening sequence.
Install NEW cylinder head bolts.
Tighten the bolts (1) in 5 passes. Use the EN-45059 sensor kit :

Second pass to 90°
Third pass to 90°
Fourth pass to 90°
Fifth pass to 45°
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Cylinder Head Removal

1. Loosen the 10 cylinder head retaining bolts in sequence as shown.
2. Remove the camshaft seat guide (1).

3. Remove the 10 cylinder head retaining bolts (2).
4. Remove the cylinder head (3) along with the gasket (4).
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Cylinder Head Removal

1. Remove the 10 cylinder head bolts in sequence as shown.
1. Loosen the 10 bolts 90°.

2. Loosen the 10 bolts 180°.
2. Remove the cylinder head and place on a suitable base.
3. Remove the cylinder head gasket.
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Cylinder Head Replacement

Special Tools
CH-904 Underframe
CH-49290 Mounting Engine/Transmission
EN-6333 Timing Belt Tensioner Locking Pin
EN-6340 Camshaft Adjuster Locking Tool
EN-6628-A Camshaft Locking Tool
Removal Procedure
1. Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection.
2. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement.
4. Drain the cooling system. Refer to Cooling System Draining and Filling.
5. Drain the engine oil. Refer to Engine Oil and Oil Filter Replacement.
6. Remove the intake manifold. Refer to Intake Manifold Replacement.
7. Loosen the radiator inlet hose clamp (2).

8. Remove the radiator inlet hose (3) from the engine coolant thermostat (1).
9. Remove the heater outlet hose from the engine coolant thermostat housing. Refer to Heater Outlet Hose Replacement.
10. Remove the heater inlet hose from the engine coolant thermostat housing. Refer to Heater Inlet Hose Replacement.
11. Disconnect the thermostat wiring harness plug (1).

12. Remove the thermostat housing bracket nut (3).
13. Hang the thermostat housing bracket (2) with attached wiring harness aside.
14. Remove the exhaust manifold. Refer to Exhaust Manifold Replacement.
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15. Remove the 2 timing belt upper front cover bolts (2).

16. Remove the timing belt upper front cover (1).
17. Remove the camshaft cover. Refer to Camshaft Cover Replacement.
18. Remove the 2 camshaft position sensor. Refer to Camshaft Position Sensor Replacement.
19. Remove the 2 camshaft position actuator solenoid valve. Refer to Camshaft Position Actuator Solenoid Valve Replacement.
20. Remove the drive belt tensioner. Refer to Drive Belt Tensioner Replacement.
21. Set the crankshaft balancer in direction of engine rotation until the markings (1) line up with the cylinder 1 at TDC.
22. Remove the crankshaft balancer. Refer to Crankshaft Balancer Replacement.
23. Remove the 4 lower timing belt cover bolts (2).

24. Remove the lower timing belt cover (1).
Note: The SPX installation manual is supplied with the special tool and is also available online from SPX directly. Go to www.spxtools-shop.com.
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25. Assemble the CH-49290 support tool (1) according to the details provided in the SPX installation manual.
26. Support the CH-904 base frame on a jack.
27. Support the CH-49290 support tool on the CH-904 base frame.
28. Install the CH-49290 support tool (1) according to the details provided in the SPX installation manual.
30. Remove the engine mount nut (3).

31. Remove the 5 engine mount bolts (1, 2).
32. Remove the engine mount (4).
33. Remove the 3 engine mount bracket bolts (1).

34. Remove the engine mount bracket (2).
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35. Remove the center front timing belt cover from the rear timing belt cover at 2 locations.
36. Remove the center front timing belt cover (1).
37. Install the EN-6340 locking tool into the camshaft adjusters.
Note: The spot type marking (4) on the intake camshaft adjuster does not correspond to the groove of EN-6340 locking tool – left during this process but must
be somewhat above as shown.
Install the EN-6340 locking tool – left (1) in the camshaft adjusters as shown.
Note: The spot type marking (3) on the exhaust camshaft adjuster must correspond to the groove on EN-6340 locking tool – right.
Install EN-6340 locking tool – right (2) in the camshaft adjusters as shown.
Apply tension to the timing belt tensioner (2) in the direction of the arrow, using an allen key (1).
Install the EN-6333 pin (3).
Note: Note the direction of the belt, if the timing belt will be reused.
Remove the timing belt (1).
Remove and DISCARD the timing belt tensioner bolt (3).
Remove the timing belt tensioner (2).
Raise the vehicle.
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Remove the timing belt idler pulley bolt (1).

Remove the timing belt idler pulley (2).
Remove the EN-6625 locking device.
Set the crankshaft in direction of engine rotation to 60 degrees (a) before TDC. Use the EN-45059 meter and the crankshaft balancer bolt.
Note: Some engine oil will run out of the camshaft and the camshaft position actuator adjuster. That is the reason for the removal of the whole timing assembly.
Lower the vehicle.
Remove the EN-6340 locking tool.
Note: Note the arrows.

Turn the camshaft by the camshaft position actuator adjuster until the groove on the end of the camshafts is horizontal.
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Install the EN-6628-A locking tool (1).

Place a collecting basin underneath the vehicle.
Remove the camshaft position actuator adjuster closure bolt (1) of the intake camshaft position actuator adjuster and the exhaust camshaft position actuator
adjuster (3).
Note: A second technician is required.
Note: Use an appropriate open-end wrench in order to counterhold the camshaft hexagon. A thin cross-section wrench is required for a better fit. The usage of
EN-6628-A locking tool is for the camshaft adjustment to prevent misalignment of the camshafts. The wrench is required to counterhold the camshafts during bolt
torque procedure.
Remove and DISCARD the intake camshaft position actuator adjuster bolt and/or the exhaust camshaft position actuator adjuster bolt (2).
Remove the intake camshaft position actuator adjuster and the exhaust camshaft position actuator adjuster (3).
Remove the timing belt rear cover. Refer to Timing Belt Rear Cover Removal.
Loosen the 10 cylinder head bolts in sequence as shown.
1. Loosen the 10 bolts 90 degrees.

2. Loosen the 10 bolts 180 degrees.
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Remove and DISCARD the 10 cylinder head bolts (1).

Remove the cylinder head (2).
Remove and DISCARD the cylinder head gasket (3).
In case of re-use, then clean and inspect the cylinder head. Refer to Cylinder Head Cleaning and Inspection.
Remove the thermostat housing. Refer to Engine Coolant Thermostat Housing Removal.
Remove the camshafts. Refer to Camshaft Removal.
Remove the valve lifter. Refer to Valve Lifter Removal.
Disassemble the cylinder head. Refer to Cylinder Head Disassemble.
1. Assemble the cylinder head. Refer to Cylinder Head Assemble.

2. Install the valve lifter. Refer to Valve Lifter Installation.
3. Install the camshafts. Refer to Camshaft Installation.
4. Install the thermostat housing. Refer to Engine Coolant Thermostat Housing Installation.
6. Inspect for plane surface.
Cylinder block, cylinder head

Straight-edge, feeler gauge
Install a NEW cylinder head gasket (3).

Install the cylinder head (2).

Install 10 NEW cylinder head bolts (1).
Tighten the bolts as shown in sequence in 5 passes, using the EN-45059 meter:
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2. Second pass to 90 degrees.

3. Third pass to 90 degrees.
4. Fourth pass to 90 degrees
5. Final pass to 45 degrees
Install the timing belt rear cover. Refer to Timing Belt Rear Cover Installation.
Align the camshafts horizontally by the hexagon arrows, until the EN-6628-A locking tool can be inserted in both camshafts.
Insert the EN-6628-A locking tool (1) into the camshafts.
Note: If the cover is contaminated with oil, you have to clean it close.
Note: A second person is required. Counterhold against the hexagon of corresponding camshaft with an open-ended wrench.
Install intake camshaft position actuator adjuster and/or the exhaust camshaft position actuator adjuster (3).
Install a NEW intake camshaft position actuator adjuster bolt and/or a NEW exhaust camshaft position actuator adjuster bolt (2).
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Install the EN-6340 locking tool into the camshaft position actuator adjusters.
Note: The spot type marking (4) on the intake camshaft position actuator adjuster does not correspond to the groove of EN-6340 locking tool – left during
this process but must be somewhat above as shown.
1. Install the EN-6340 locking tool – left (1) in the camshaft position actuator adjusters as shown.
Note: The spot type marking (3) on the exhaust camshaft position actuator adjuster must correspond to the groove on EN-6340 locking tool – right.
2. Install the EN-6340 locking tool – right (2) in the camshaft position actuator adjusters as shown.
Note: Use an appropriate open-end wrench in order to counterhold the camshaft hexagon. A thin cross-section wrench is required for a better fit. The Use of
torque procedure.
Tighten the camshaft position actuator adjuster bolts (2) in three passes use the EN-45059 meter:
Hold at the appropriate camshaft hexagon.
1. First pass tighten to 50 Y (37 lb ft).

3. Final pass to 15 degrees.
Note: Check the closure bolt seal ring.
Install the 2 camshaft position actuator adjuster closure plugs (1) and tighten to 30 Y (22 lb ft).
Remove the EN-6628-A locking tool.
Install the crankshaft sprocket (1).
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Note: The crankshaft sprocket and oil pump housing must align.
Set the crankshaft in the direction of engine rotation to TDC. Use the crankshaft balancer bolt.

Install the timing belt tensioner (2) and tighten the NEW timing belt tensioner bolt (1) in three passes use the EN-45059 meter:


Install the timing belt idler pulley (2) and tighten the NEW bolt (1) in three passes use the EN-45059 meter:

Install the timing belt (1).

Guide the timing belt past the tensioner and place it on the crankshaft sprocket wheel.
Place the timing belt on the exhaust and intake camshaft position actuator adjusters.
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Remove the EN-6333 pin (3).
Note: The timing belt tensioner moves automatically to the correct position.
Release tension on timing belt tensioner.
Lower the vehicle.
Install the engine mount bracket (2).

Install the 3 engine mount bracket bolts (1) tighten to 62 Y (46 lb ft).
Install the engine mount (4).

Install the 2 engine mount bolts (1) and tighten to 62 Y (46 lb ft).
Install the 3 engine mount bolts (2) and tighten in three passes use the EN-45059 meter.

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Lower the CH-49290 support tool (1) with the CH-904 base frame and a jack.
Remove the CH-49290 support tool from the CH-904 base frame.
Disassemble the CH-49290 support tool (1) according to the details provided in the SPX installation manual.
Lower the vehicle.
Remove EN-6340 locking tool.
Check the timing
Note: Note the marking at the camshaft sprockets.

Turn the crankshaft 720° in the direction of engine rotation by the bolt on the crankshaft balancer.
Note: The spot type marking (4) on the intake camshaft adjuster does not correspond to the groove of EN-6340 locking tool – left during this process but must
Install EN-6340 locking tool – left (1) into the camshaft adjusters as shown.
Note: The spot type marking (3) on the exhaust camshaft adjuster must correspond to the groove on EN-6340 locking tool – right.
Install EN-6340 locking tool – right (2) into the camshaft adjusters as shown.
Raise the vehicle.
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Check the crankshaft position.
Install the lower timing belt cover (1).

Install the 4 lower timing belt cover bolts (2) and tighten to 6 Y (53 lb in).
Install the crankshaft balancer. Refer to Crankshaft Balancer Replacement.
Lower the vehicle.
Remove the EN-6340 locking tool.
Install the camshaft position actuator solenoid valve. Refer to Camshaft Position Actuator Solenoid Valve Replacement.
Install the 2 camshaft position sensors. Refer to Camshaft Position Sensor Replacement.
Install the camshaft cover. Refer to Camshaft Cover Replacement.
Install the timing belt upper front cover (1).

Install the 2 timing belt upper front cover bolts (2) and tighten to 6 Y (53 lb in).
Install the exhaust manifold. Refer to Exhaust Manifold Replacement.
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Install the radiator inlet hose (3) with the radiator inlet hose clamp (2) to the engine coolant thermostat (1).
Install the heater inlet hose to the engine coolant thermostat housing. Refer to Heater Inlet Hose Replacement.
Install the heater outlet hose to the engine coolant thermostat housing. Refer to Heater Outlet Hose Replacement.
Install the engine coolant thermostat housing bracket (2).

Install the engine coolant thermostat housing bracket nut (3) and tighten to 6 Y (53 lb in).
Connect the thermostat wiring harness plug (1).
Install the intake manifold. Refer to Intake Manifold Replacement.
Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement.
Fill engine oil. Refer to Engine Mechanical Specifications.
Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection.
Fill the cooling system. Refer to Cooling System Draining and Filling.
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Special Tools
EN-470-B Anglemeter
EN-50437 Height Gauge - Piston TDC
GE-571-B Dial Gauge
Removal Procedure
1. Remove the intake manifold bracket. Refer to Intake Manifold Bracket Replacement
2. Remove the exhaust gas recirculation manifold cooling return hose from the thermostat bypass pipe. Refer to Exhaust Gas Recirculation Manifold
Cooling Return Hose Replacement
3. Remove the oil level indicator tube. Refer to Oil Level Indicator Tube Replacement
4. Remove the turbocharger. Refer to Turbocharger Replacement
5. Remove the charge air cooler outlet hose from the throttle body module. Refer to Charge Air Cooler Outlet Hose Replacement
6. Remove the engine water outlet adapter. Refer to Engine Water Outlet Adapter Replacement
7. Remove the intake camshaft. Refer to Intake Camshaft Replacement.
8. Remove the camshaft seat guide (1).
9. Loosen the 10 cylinder head retaining bolts in sequence as shown.
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10. Remove and DISCARD 10 cylinder head retaining bolts (2).

11. Remove the cylinder head (3) and the gasket (4).
12. Remove the intake manifold. Refer to Intake Manifold Replacement
13. Remove the exhaust manifold. Refer to Exhaust Manifold Replacement
14. Remove the hydraulic valve adjusters. Refer to Hydraulic Valve Lash Adjuster Replacement
Cleaning Procedure
Note: Ensure that the cylinder head and the cylinder block sealing surfaces are clear of oil, grease and old gasket material.
2. Inspect the flatness of cylinder head and cylinder block sealing surfaces.
3. Clean the piston surfaces.
Choose the Gasket
1. Align TDC of the piston 1.

2. Measure the piston projection thickness using EN-50437 height gauge .
3. Repeat the measuring process on the cylinders 2, 3, 4 and average the measured piston projection values.
4. Choose the cylinder head gasket through below the specifications. Refer to Engine Mechanical Specifications.
1. Install the hydraulic valve lash adjusters. Refer to Hydraulic Valve Lash Adjuster Replacement
2. Install the intake manifold. Refer to Intake Manifold Replacement
3. Install the exhaust manifold. Refer to Exhaust Manifold Replacement

5. Install the cylinder head (3) and a NEW gasket (4).
Note: Do not tighten the bolts.
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6. Install 10 NEW cylinder head retaining bolts (2).

7. Tighten the cylinder head retaining bolts (2) in four steps, in a sequence as shown in the graphic above:
First step 30 Y (22 lb ft).

Second step 100 Y (74 lb ft).
Third step 90°. Use EN-470-B anglemeter .
Fourth step 90°. Use EN-470-B anglemeter .
Install the camshaft seat guide (1).

Install the intake camshaft. Refer to Intake Camshaft Replacement.
Install the engine water outlet adapter. Refer to Engine Water Outlet Adapter Replacement
Install the charge air cooler outlet hose to the throttle body module. Refer to Charge Air Cooler Outlet Hose Replacement
Install the turbocharger. Refer to Turbocharger Replacement
Install the oil level indicator tube. Refer to Oil Level Indicator Tube Replacement
Install the exhaust gas recirculation manifold cooling return hose to the thermostat bypass pipe. Refer to Exhaust Gas Recirculation Manifold Cooling Return
Hose Replacement
Install the intake manifold bracket. Refer to Intake Manifold Bracket Replacement
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Engine Block Cleaning and Inspection

Special Tools
EN-8087 Gauge
Cleaning Procedure
1. Remove any old thread sealant, gasket material or sealant.

2. Clean all the following areas with solvent:
Sealing surfaces
Cooling passages
Oil passages
Bearing journals
Clean all threaded and through holes with solvent.

Dry the engine block with compressed air.
Visual Inspection
1. Inspect the crankshaft bearings journals for damage or spun bearings. The crankshaft bearing journals are not repairable, if the crankshaft bearing
journals are damaged the engine block assembly must be replaced.
2. Inspect all sealing and mating surfaces for damage, repair or replace the engine block assembly if necessary.
3. Inspect all threaded and through holes for damage or excessive debris.
4. Inspect all bolts for damage, if damaged replace with NEW bolts only.
5. Inspect the cylinder walls for cracks or damage. The cylinder sleeves must not serviced separately, if the cylinders are damaged the cylinder block
assembly must be replaced.
6. Inspect the engine block for cracks. DO NOT repair any cracks. If cracks are found, the cylinder block assembly must be replaced.
Measuring Procedure
Engine Block Flatness Inspection
1. Inspect the engine block as shown for distortion. Use a straightedge (1) and a feeler gauge.
2. Inspect the engine block as shown for deflection. Use a straightedge (1) and a feeler gauge.
3. If the deflection is less than 0.06 mm (0.0024 in), engine block replacement is not necessary.
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4. If the deflection is larger than 0.06 mm (0.0024 in), replace the engine block.

Cylinder Sleeve Diameter Inspection
1. Inspect the cylinder bores using the EN-8087 gauge (1). Inspect for the following items:
Wear of cylinder sleeve

Cylinder sleeve diameter
Tapering of cylinder sleeve
Oval status of cylinder sleeve
Measure the cylinder bore diameter 86 mm (3,39 in) from the deck face using a dial gauge.
Refer to Engine Mechanical Specifications for the correct specifications.
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Special Tools
EN-8087 Cylinder Gauge
1. Clean the sealing material from the gasket mating surfaces (2).

2. Clean the engine block (1) and lower crankcase in a cleaning tank with solvent appropriate for aluminum. Refer to Adhesives, Fluids, Lubricants, and Sealers
for the recommended solvent.
3. Flush the engine block with clean water or steam.
4. Clean the oil passages.
5. Clean the blind holes.
6. Spray the cylinder bores and the machined surfaces with engine oil.
7. Inspect the threaded holes. Clean the threaded holes with a rifle brush. If necessary, drill out the holes and install thread inserts. Refer to Thread Inserts.
Note: Do not attempt to machine the lower crankcase to engine block surfaces.
8. Inspect the engine block for sag in length and width on the sealing surfaces.
9. Inspect the engine block for distortion along the diagonals.
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If the deck surface is out of specification, replace the block. Do not machine the block.
10. Clean the sealing material from the gasket mating surfaces (1) on the lower crankcase oil pan side.
11. Inspect the crankshaft main bearing bores. Use the EN-8087 gauge (1) to measure the bearing bore concentricity and alignment.
12. Replace the engine block and bed plate if the crankshaft bearing bores are out of specification.
13. Inspect the cylinder bores using the EN-8087 gauge (1). Inspect for the following items:
Wear
Taper
Runout
Ridging
Check the cylinder bores specifications. Refer to Engine Mechanical Specifications.

If the cylinder bores are out of specification, replace the engine block.
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Engine Front Cover and Oil Pump Installation

1. Install the NEW engine cover gasket (1).

2. Install the engine cover with the included oil pump (4).
3. Install the 8 engine cover bolts (2, 3) and tighten to 20 Y (15 lb ft).
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Engine Front Cover and Oil Pump Removal

Note: Note the different screw lengths.

1. Remove the 8 bolts (2, 3).
2. Remove the engine front cover with the included oil pump (4).
3. Remove the gasket (1).
Note: Do not damage the sealing surfaces.
4. Clean the sealing surface.
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Engine Front Cover Installation

Special Tools
EN-50435 Guide Pins
Note: Do not dig old sealant filled at T-joint area (1) between cylinder head and cylinder block when removing old sealant.
1. Remove any old sealant and gasket material with a suitable tool.
2. Clean the front cover and front cover components with solvent.
Note: Ensure that the sealing surface is clear of oil, grease and old sealant material.
3. Clean out debris from the bolt holes.

4. Dry the front cover and front cover components with compressed air.
Note: The complete installation procedure of the camshaft guide should be done in 10 minutes.
Note: Do not coat sealing compound on the engine front cover bolt holes and bolt threads.
5. Apply sealing compound on sealant line (1), 2 hole faces (2) and 2 areas (3).
6. Apply sealing compound to the edge of the chamfer (4).
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Engine Front Cover Installation
Note: The alignment pins will help maintaining position while installing the bolts.
7. To aid in cover alignment, install 2 EN-50435 guide pins on the engine block.
8. Install the engine front cover (1).
9. Install the engine front cover bolts and remove the EN-50435 guide pins.
10. Install the 13 engine front cover retaining bolts (M8) (3) and tighten evenly to 22 Y (16 lb ft).
11. Install the 3 engine cover retaining bolts (M6) (2) and tighten to 9 Y (80 lb in).
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Engine Front Cover Removal

1. Remove the 16 engine front cover retaining bolts (2, 3).
Note: Carefully detach from engine block, using a suitable tool. Do not damage the sealing surfaces.
2. Remove the engine front cover (1).
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Engine Front Cover Replacement

Special Tools
EN-50435 Guide Pin
Removal Procedure
1. Remove camshaft cover. Refer to Camshaft Cover Replacement.

3. Remove the crankshaft pulley. Refer to Crankshaft Pulley Replacement.
4. Remove the oil filter adapter. Refer to Oil Filter Adapter and Oil Cooler Assembly Replacement.
5. Remove the upper oil pan. Refer to Upper Oil Pan Replacement.
6. Remove the engine mount bracket. Refer to Engine Mount Bracket Replacement.
7. Remove the charge air control vacuum hose.
8. Remove 16 engine front cover retaining bolts (2, 3).

Note: Detach carefully from engine block using suitable tool. Do not damage sealing surfaces.
1. Remove any old sealant and gasket material with a suitable tool.
2. Clean the front cover and front cover components with solvent.
Note: Ensure that the sealing surface is clear of oil, grease and old sealing material.
4. Dry the front cover and front cover components with compressed air.
Note: The complete installation procedure of the engine front cover should be done in 10 minutes.
Note: Do not coat sealing compound on the engine front cover bolt holes and bolt threads.
5. Apply sealing compound on sealant line (1), 2 hole faces (2) and 2 areas (3).
6. Apply sealing compound to the edge of chamfer (4).
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Engine Front Cover Replacement
7. To aid in cover alignment, install 2 EN-50435 guide pins on the engine block.
9. Install the engine front cover bolts and remove the EN-50435 guide pins.
10. Install 13 engine front cover retaining bolts (M8) (3). Tighten the bolts evenly to 22 Y (16 lb ft).
11. Install 3 engine cover retaining bolts (M6) (2). Tighten the bolts to 9 Y (80 lb in).
12. Install the engine mount bracket. Refer to Engine Mount Bracket Replacement.
13. Install camshaft cover. Refer to Engine Front Cover Removal.
14. Install the oil filter adapter. Refer to Oil Filter Adapter and Oil Cooler Assembly Replacement.
15. Install the crankshaft pulley. Refer to Crankshaft Pulley Replacement.
16. Install the drive belt tensioner. Refer to Drive Belt Tensioner Replacement.
17. Install the upper oil pan. Refer to Upper Oil Pan Replacement.
2 of 2
Engine Front Cover with Oil Pump Replacement

Removal Procedure
1. Open the hood.

2. Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection.
5. Remove the air conditioning compressor. Refer to Air Conditioning Compressor Replacement.
6. Remove the generator. Refer to Generator Replacement.
7. Remove the timing belt rear cover. Refer to Timing Belt Rear Cover Replacement.
8. Remove the oil pan. Refer to Oil Pan Replacement.
9. Remove the radiator outlet hose from the water pump. Refer to Radiator Outlet Hose Replacement.
10. Remove the engine oil cooler inlet pipe bolt (4).

11. Push the engine oil cooler inlet pipe (1) into the engine oil cooler housing (2).
12. Remove the 2 engine oil cooler outlet pipe bolts (5) from the water pump.
13. Push the engine oil cooler outlet pipe (3) into the engine oil cooler housing (2).
14. Remove the 8 engine front cover bolts (2, 3).

16. Remove the engine front cover seal (1).
1. Clean sealing surface.
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2. Install a NEW engine front cover seal (1).

4. Install the 8 engine front cover bolts (2, 3) and tighten to 20 Y (15 lb ft).
5. Push the engine oil cooler outlet pipe (3) to the water pump (6).
6. Install the engine oil cooler outlet pipe bolts (5) and tighten to 8 Y (71 lb in).
7. Push the engine oil cooler inlet pipe (1) into the water pump (6).
8. Install the engine oil cooler inlet pipe bolt (4) and tighten to 8 Y (71 lb in).
9. Install the radiator outlet hose to the water pump. Refer to Radiator Outlet Hose Replacement.
10. Install the oil pan. Refer to Oil Pan Replacement.
11. Install the timing belt rear cover. Refer to Timing Belt Rear Cover Replacement.
12. Install the generator. Refer to Generator Replacement.
13. Install the air conditioning compressor. Refer to Air Conditioning Compressor Replacement.
14. Install the exhaust manifold. Refer to Exhaust Manifold Replacement.
15. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection.
16. Fill the cooling system. Refer to Cooling System Draining and Filling.
17. Close the hood.
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Engine Mount Bracket Installation

1. Install the engine mount bracket (1).

2. Install the 3 engine mount bracket bolts (2) and tighten to 58 Y (43 lb ft).
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Engine Mount Bracket Removal

1. Remove the 3 engine mount bracket bolts (2).

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Engine Mount Bracket Replacement

Removal Procedure
2. Remove the engine sight shield. Refer to Engine Sight Shield Replacement.
3. Install the engine lifter to the engine lift rear bracket.
4. Remove the engine mount. Refer to Engine Mount Replacement.
5. Remove the belt idler pulley - upper. Refer to Belt Idler Pulley Replacement - Upper.
6. Remove the belt idler pulley - lower. Refer to Belt Idler Pulley Replacement - Lower.
7. Remove the 3 engine mount bracket retaining bolts (2).


2. Install the 3 engine mount bracket bolts (2) and tighten to 58 Y (43 lb ft).
3. Install the belt idler pulley - lower. Refer to Belt Idler Pulley Replacement - Lower.
4. Install the belt idler pulley - upper. Refer to Belt Idler Pulley Replacement - Upper.
5. Install the engine mount. Refer to Engine Mount Replacement.
6. Remove the engine lifter from the rear engine lift bracket.
7. Install the engine sight shield. Refer to Engine Sight Shield Replacement.
8. Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement.
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Preliminary Procedure
Remove the engine mount. Refer to Engine Mount Replacement.
Engine Mount Bracket Bolt (Qty: 3)

1
Tighten
60 Y (44 lb ft) + 45 degrees +15 degrees
2 Engine Mount Bracket
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Engine Mount Replacement


Preliminary Procedures
2. Support the engine. Install a suitable engine lifting device. Install a suitable cable at the 3 engine lift brackets and at the engine lifting device.
Engine Mount Bolt (Qty: 2)

1
Tighten
62 Y (46 lb ft)
Engine Mount Bracket Bolt (Qty: 3)

Procedure
2
Install NEW bolts, do NOT reuse old bolts
Tighten
50 Y + 60°–75° (37 lb ft + 60°–75°)
Engine Mount Nut

3 Tighten
62 Y (46 lb ft)
4 Engine Mount
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Removal Procedure
3. Install the engine lifter to the engine lift rear bracket.
4. Remove the 5 engine mount bolts (2, 3) and the engine mount nut (1).
5. Remove the engine mount (4).
1. Install the engine mount (4).

2. Install the 3 engine mount to bracket bolts (3). DO NOT reuse the engine mount to bracket bolts (3) to install the mount (4). Use NEW bolts only.
3. Install the 2 engine mount to body bolts (2) and the engine mount to body nut (1).
Tighten the 2 engine mount to body bolts (2) to 62 Y (46 lb ft).

Tighten the engine mount to body nut (1) to 62 Y (46 lb ft).
Tighten the 3 NEW engine mount to bracket bolts (3) to 50 Y + 60° − 75° (37 lb ft + 60° – 75°).
Remove the engine lifter from the rear engine lift bracket.
Install the air cleaner assembly. Refer to Air Cleaner Assembly Replacement.
Install the engine sight shield. Refer to Engine Sight Shield Replacement.
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Engine Support Fixture

Special Tools
EN–47649 Engine Bridge

EN–47649-100 Engine Bridge Feet
EN–47650 Retainer Frame
EN–47650-250 Front Adapter
EN–47650-300 Rear Adapter
EN–47650-310 Adapter to EN-47650–300
For equivalent regional tools refer to Special Tools.
Assemble EN-47649 Engine Bridge
Install EN–47649-100 feet (4) to EN 47649 bridge (1).
1. Tighten mounting bolt (2) and nut (6) on both sides.

Put washer (5) under nut on both sides.
2. Tighten adjustment screw (3) when bridge is adjusted vertical on both sides.
Assemble and Adjustment of EN-47650 – Retainer Frame
Pre-assemble EN–47650-250 adapter (1) by following manufacturer's instructions.

Note: Pre-assemble special tool assembly outside the vehicle, in accordance with the table.
Pre-assemble EN–47650 frame off vehicle.
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Measurement Dimension
a 1350 mm (53.1 in)
b 575 mm (23.6 in)
c 385 mm (15.1 in)
d 90 mm (3.5 in)
Note: EN–47650-30 extension is equipment of EN–47650 frame and enclosed in the EN–47650 frame tool kit .
1. Install EN–47650-30 extension bars (1, 6) of the frame set to EN–47650 frame .
Note: Outer bars of EN 47650 frame MUST be arranged parallel.
2. Tighten hexagons (2, 6) on both sides.
3. Adjust height of EN 47650 frame .
Tighten hexagons (3, 5) on both sides

Adjust height with hexagons (4) on both sides
1. Remove dash upper extension panel opening cover. Refer to Dash Upper Extension Panel Opening Cover Replacement.
2. Use EN–47650-310 adapter (1) for this operation.
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Caution: To avoid paint damage, use protective covers on the fenders.

Note: Do NOT tighten fasteners of EN 47650-300 adapter .
3. Install EN–47650-300 adapter (1) over hole (2) in the front compartment rail and tighten bolt (3).
4. With the aid of an assistant install EN–47650 frame (1) to the vehicle. If necessary readjust EN–47650 frame (1) for appropriate fitting.
5. Tighten rear side of EN–47650 frame :
1. Insert safety pins (2) through the EN–47650-300 adapters and the side bar to prevent movement.
2. Tighten EN–47650 frame to EN–47650-300 adapters with mounting bolts (1).
3. Tighten bolts (3, 4, 5).
4. Tighten outer bolts (1) EN–47650–300 adapters .

5. Retighten ALL hexagons of EN–47650 frame .
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Note: Left hook must not be tightened!

6. Tighten only front right side of EN–47650 frame :
1. Align the right hook (1) with thumb wheel (2) to upper tie bar.
2. Tighten the right hook (1) to upper tie bar, using the thumb wheel (4).
3. Tighten bolts at right clamping piece (3).
Note: EN–47650-50 rail is equipment of EN–47650 frame and enclosed in the EN–47650 frame tool kit .
7. Install EN–47650-50 rail (4) to EN–47650 frame .
Secure EN–47650-50 rail (4) with safety pins (3).
Note: Secure chain boxes with hook chains on the outside of engine bride.
8. Install EN–47649 bridge (5) with the aid of an assistant onto EN–47650-050 rail (4).
Secure EN–47649 bridge (5) with safety pins (2).
9. When tool assemble EN–47650 frame and EN–47649 bridge is under load, adjust complete assemble and retighten ALL fasteners.
Removal Procedure
1. Remove EN–47649 bridge (5) with the aid of an assistant.
Remove safety pins (2).
Note: EN-47650-50 rail is equipment of EN–47650 frame and enclosed in the EN–47650 frame tool kit .
2. Remove EN 47650-50 rail (4) from EN 47650 frame .
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3. Remove front right side of EN–47650 frame :
Loosen the bolts from right clamping piece (3).

Loosen the right hook (1) with thumb wheel (2) and turn the hook 90° from upper tie bar.
Loosen rear side of EN–47650 frame :
1. Loosen EN–47650 frame from EN–47650-300 adapters with mounting bolts (1).

2. Remove safety pins (2) from the EN–47650-300 adapters and the side bars.
With the aid of an assistant remove EN–47650 frame (1) from the vehicle.
Remove bolt (3) and EN–47650-300 adapter (1) from front compartment rail (2).
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Clean contact surfaces (1) from EN–47650 frame on the upper tie bar with solvent.
Remove dash upper extension panel opening cover. Refer to Dash Upper Extension Panel Opening Cover Replacement.
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Special Tools
EN–47649 Engine Bridge

EN–47649-100 Engine Bridge Feet
EN–47650 Retainer Frame
EN–47650-250 Front Adapter
EN–47650-300 Rear Adapter
EN–47650-310 Adapter to EN-47650–300
For equivalent regional tools refer to, Special Tools.
Assemble EN-47649 Engine Bridge
Install EN–47649-100 feet (4) to EN 47649 bridge (1).
1. Tighten mounting bolt (2) and nut (6) on both sides.

Put washer (5) under nut on both sides.
2. Tighten adjustment screw (3) when bridge is adjusted vertical on both sides.
Assemble and Adjustment of EN-47650 – Retainer Frame
Pre-assemble EN–47650-250 adapter (1) by following manufacturer's instructions.

Note: Pre-assemble special tool assembly outside the vehicle, in accordance with the table.
Pre-assemble EN–47650 frame off vehicle.
1 of 6
Measurement Dimension
a 1350 mm (53.1 in)
b 575 mm (23.6 in)
c 385 mm (15.1 in)
d 90 mm (3.5 in)
Note: EN–47650-30 extension is equipment of EN–47650 frame and enclosed in the EN–47650 frame tool kit.
1. Install EN–47650-30 extension bars (1, 6) of the frame set to EN–47650 frame .
Note: Outer bars of EN 47650 frame MUST be arranged parallel.
2. Tighten hexagons (2, 6) on both sides.
3. Adjust height of EN 47650 frame .
Tighten hexagons (3, 5) on both sides

Adjust height with hexagons (4) on both sides
2. Use EN–47650-310 adapter (1) for this operation.
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Caution: To avoid paint damage, use protective covers on the fenders.

Note: Do NOT tighten fasteners of EN 47650-300 adapter .
3. Install EN–47650-300 adapter (1) over hole (2) in the front compartment rail and tighten bolt (3).
4. With the aid of an assistant install EN–47650 frame (1) to the vehicle. If necessary readjust EN–47650 frame (1) for appropriate fitting.
5. Tighten rear side of EN–47650 frame :
1. Insert safety pins (2) through the EN–47650-300 adapters and the side bar to prevent movement.
2. Tighten EN–47650 frame to EN–47650-300 adapters with mounting bolts (1).
3. Tighten bolts (3, 4, 5).
4. Tighten outer bolts (1) of EN–47650–300 adapters .

5. Retighten ALL hexagons of EN–47650 frame .
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Note: Left hook must not be tightened!

6. Tighten only front right side of EN–47650 frame :
1. Align the right hook (1) with thumb wheel (2) to upper tie bar.
2. Tighten the right hook (1) to upper tie bar, using the thumb wheel (4).
3. Tighten bolts at right clamping piece (3).
Note: EN–47650-50 rail is equipment of EN–47650 frame and enclosed in the EN–47650 frame tool kit.
7. Install EN–47650-50 rail (4) to EN–47650 frame .
Secure EN–47650-50 rail (4) with safety pins (3).
8. Install EN–47649 bridge (5) with the aid of an assistant onto EN–47650-050 rail (4).
Secure EN–47649 bridge (5) with safety pins (2).
9. When tool assemble EN–47650 frame and EN–47649 bridge is under load, adjust complete assemble and retighten ALL fasteners.
Removal Procedure
1. Remove EN–47649 bridge (5) with the aid of an assistant.
Note: EN-47650-50 rail is equipment of EN–47650 frame and enclosed in the EN–47650 frame tool kit .
2. Remove EN 47650-50 rail (4) from EN 47650 frame .
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3. Remove front right side of EN–47650 frame :
Loosen the bolts from right clamping piece (3).

Loosen the right hook (1) with thumb wheel (2) and turn the hook 90° from upper tie bar.
Loosen rear side of EN–47650 frame :
1. Loosen EN–47650 frame from EN–47650-300 adapters with mounting bolts (1).

2. Remove safety pins (2) from the EN–47650-300 adapters and the side bars.
With the aid of an assistant remove EN–47650 frame (1) from the vehicle.
Remove bolt (3) and EN–47650-300 adapter (1) from front compartment rail (2).
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Clean contact surfaces (1) from EN–47650 frame on the upper tie bar with solvent.
Remove dash upper extension panel opening cover. Refer to Dash Upper Extension Panel Opening Cover Replacement.
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Front Wheel Drive Intermediate Shaft Bearing Replacement

Front Wheel Drive Intermediate Shaft Bearing Replacement
Remove intermediate shaft. Refer to Front Wheel Drive Intermediate Shaft Replacement.
Intermediate Shaft Retaining Ring

1 Procedure
DISCARD retaining ring. Use NEW only.
Intermediate Shaft Bearing

2 Procedure
Use hydraulic press to remove bearing from shaft.
Intermediate Shaft Bearing Flange

3 Procedure
Use hydraulic press to remove flange from bearing.
Retaining Ring
4 Procedure
DISCARD retaining ring. Use NEW only.
1 of 1
Front Wheel Drive Intermediate Shaft Bracket Replacement

Front Wheel Drive Intermediate Shaft Bracket Replacement
Remove intermediate shaft. Refer to Front Wheel Drive Intermediate Shaft Replacement.
Intermediate Shaft Bracket Bolt (Qty: 2)

1
Tighten
58 Y (43 lb ft )
2 Intermediate Shaft Bracket
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Front Wheel Drive Intermediate Shaft Replacement

Front Wheel Drive Intermediate Shaft Replacement
Remove the right front wheel drive shaft. Refer to Front Wheel Drive Shaft Replacement - Right Side.
Front Wheel Drive Intermediate Shaft Bearing Bolt (Qty: 3)

1
Tighten
22 Y (16 lb ft)
Front Wheel Drive Intermediate Shaft and Bracket Assembly

Procedure
1. Drain and collect the transmission fluid.
1. For vehicles equipped with GF6 transmission, refer to Transmission Fluid Drain and Fill.
2. For vehicles equipped with F40 transmission, refer to Transmission Fluid Drain and Fill.
2. The DT-6332 protector must be installed into the differential output shaft seal prior removal and installation of the
2 intermediate shaft.
3. Refill the transmission with the collected transmission fluid.
1. For vehicles equipped with GF6 transmission, refer to Transmission Fluid Drain and Fill.
2. For vehicles equipped with F40 transmission, refer to Transmission Fluid Drain and Fill.
Special Tools
1 of 1
Front Wheel Drive Shaft Replacement - Right Side (with Front Wheel Drive Intermediate Shaft)

Special Tools
CH-313 Slide Hammer

CH-6003 Axle Shaft Remover
CH-49376 Holding Wrench
CH-49400 Hub Spindle Remover
EN-956-1 Extension
Removal Procedure
Warning: To prevent personal injury and/or component damage, do not allow the weight of the vehicle to load the front wheels, or attempt to operate the
vehicle, when the wheel drive shaft(s) or wheel drive shaft nut(s) are removed. To do so may cause the inner bearing race to separate, resulting in
damage to brake and suspension components and loss of vehicle control.
Caution: Wheel drive shaft boots, seals and clamps should be protected from sharp objects any time service is performed on or near the wheel drive
shaft(s). Damage to the boot(s), the seal(s) or the clamp(s) may cause lubricant to leak from the joint and lead to increased noise and possible failure of
the wheel drive shaft.
1. Raise and suitably support the vehicle. Refer to Lifting and Jacking the Vehicle.
2. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation.
3. Using the CH-49376 holding wrench (1) with EN-956-1 extension (2).
Note: DO NOT re-use the wheel drive shaft nut. Discard the nut and replace with NEW.
4. Remove and DISCARD the wheel drive shaft nut (2) from the wheel drive shaft (1).
1 of 3
Caution: Support the brake caliper with heavy mechanic wire, or equivalent, whenever it is separated from its mount and the hydraulic flexible brake hose
is still connected. Failure to support the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper, which may cause
damage to the brake hose and in turn may cause a brake fluid leak.
5. Using the CH-49400 remover (2), separate the brake rotor and wheel bearing/hub assembly (1).
6. Remove the outer tie rod assembly from the steering knuckle. Refer to Steering Linkage Outer Tie Rod Replacement.
7. Remove the ball joint from the steering knuckle. Refer to Lower Control Arm Replacement.
8. Using the CH-313 slide hammer (2) with CH-6003 remover (1) remove the wheel drive shaft (3) from the vehicle.
Note: If there is no washer on the wheel drive shaft, install a NEW washer.
9. Remove and DISCARD the washer (1) from the wheel drive shaft (2). Do NOT re-use the washer, replace with a NEW one only!
2 of 3
1. Install a NEW washer (1) to the wheel drive shaft.
2. Carefully install the wheel drive shaft into the intermediate shaft.
3. Install the wheel drive shaft into the differential until the retaining ring is fully seated.
4. Confirm that the front wheel drive shaft retaining ring is properly seated by holding the inner housing and pull the inner housing outward.
5. Install the front wheel drive shaft into the front wheel bearing/hub.
6. Install the ball joint to the steering knuckle. Refer to Lower Control Arm Replacement.
7. Install the outer tie rod assembly at the steering knuckle. Refer to Steering Linkage Outer Tie Rod Replacement.
Warning: Refer to Torque-to-Yield Fastener Warning.

8. Install the NEW wheel drive shaft nut (2) to the wheel drive shaft (1) tighten in 3 passes.

10. Using a torque wrench and the appropriate size socket, tighten the wheel drive shaft nut to 150 Y (111 lb ft).
11. Release the wheel drive shaft nut (2) trough 45 degrees.
12. Retighten the wheel drive shaft nut (2) to 250 Y (185 lb ft).
13. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation.
14. Lower and unsupport the vehicle.
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Front Wheel Drive Shaft Replacement - Right Side (without Front Wheel Drive Intermediate Shaft)

Special Tools
CH-313 Slide Hammer

CH-6003 Axle Shaft Remover
CH-49376 Holding Wrench
CH-49400 Hub Spindle Remover
EN-956-1 Extension
Removal Procedure
Warning: To prevent personal injury and/or component damage, do not allow the weight of the vehicle to load the front wheels, or attempt to operate the
vehicle, when the wheel drive shaft(s) or wheel drive shaft nut(s) are removed. To do so may cause the inner bearing race to separate, resulting in
damage to brake and suspension components and loss of vehicle control.
Caution: Wheel drive shaft boots, seals and clamps should be protected from sharp objects any time service is performed on or near the wheel drive
shaft(s). Damage to the boot(s), the seal(s) or the clamp(s) may cause lubricant to leak from the joint and lead to increased noise and possible failure of
the wheel drive shaft.
2. Remove the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation.
3. Drain the transmission.
Refer to the Transmission Fluid Drain and Fill procedure for vehicles equipped with D16/D20 transmission.
Refer to the Transmission Fluid Drain and Fill procedure for vehicles equipped with GF6 transmission.
Using the CH-49376 holding wrench (1) with EN-956-1 extension (2).
Note: DO NOT re-use the wheel drive shaft nut. Discard the nut and replace with NEW.
Remove and DISCARD the wheel drive shaft nut (2) from the wheel drive shaft (1).
1 of 4
Caution: Support the brake caliper with heavy mechanic wire, or equivalent, whenever it is separated from its mount and the hydraulic flexible brake hose is still
connected. Failure to support the caliper in this manner will cause the flexible brake hose to bear the weight of the caliper, which may cause damage to the brake
hose and in turn may cause a brake fluid leak.
Using the CH-49400 remover (2), separate the brake rotor and wheel bearing/hub assembly (1).
Remove the outer tie rod assembly from the steering knuckle. Refer to Steering Linkage Outer Tie Rod Replacement.
Remove the ball joint from the steering knuckle. Refer to Lower Control Arm Replacement.
Caution: DT-6332 or equivalent must be installed into the front wheel drive shaft oil seal prior to removing and installing the front wheel drive shaft. Failure to use
the DT-6332 may cause the spline of the front wheel drive shaft to cut the front wheel drive shaft oil seal. Damage to the front wheel drive shaft oil seal will result in
lubricant leaks.
Install the DT-6332 protector into the differential output shaft seal.
Using the CH-313 slide hammer (2) with CH-6003 remover (1) remove the wheel drive shaft (3) from the vehicle.
2 of 4
Caution: DT-6332 or equivalent must be installed into the front wheel drive shaft oil seal prior to removing and installing the front wheel drive shaft.
Failure to use the DT-6332 may cause the spline of the front wheel drive shaft to cut the front wheel drive shaft oil seal. Damage to the front wheel drive
shaft oil seal will result in lubricant leaks.
1. Install the DT-6332 protector into the differential output shaft seal.
2. Carefully install the wheel drive shaft into the differential until the splines are past the DT-6332 protector.
3. Remove the DT-6332 protector from the differential output shaft seal.
4. Install the wheel drive shaft into the differential until the retaining ring is fully seated.
5. Confirm that the front wheel drive shaft retaining ring is properly seated by holding the inner housing and pull the inner housing outward.
6. Install the front wheel drive shaft into the front wheel bearing/hub.
7. Install the ball joint to the steering knuckle. Refer to Lower Control Arm Replacement.
8. Install the outer tie rod assembly at the steering knuckle. Refer to Steering Linkage Outer Tie Rod Replacement.
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9. Install the NEW wheel drive shaft nut (2) to the wheel drive shaft (1) tighten in 3 passes.

11. Using a torque wrench and the appropriate size socket, tighten the wheel drive shaft nut to 150 Y (111 lb ft).
12. Release the wheel drive shaft nut (2) trough 45 degrees.
13. Retighten the wheel drive shaft nut (2) to 250 Y (185 lb ft).
14. Install the tire and wheel assembly. Refer to Tire and Wheel Removal and Installation.
15. Refill the transmission.
Refer to the Transmission Fluid Drain and Fill procedure for vehicles equipped with D16/D20 transmission.
Refer to the Transmission Fluid Drain and Fill procedure for vehicles equipped with GF6 transmission.
Lower the vehicle.
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Lower Crankcase Installation

Note: The complete installation procedure of the lower crankcase should be done in 10 minutes.
Note: Do not coat sealing compound on the crankcase bolt holes and threads.
2. Apply the sealing compound (1) as shown.
3. Install the lower crankcase (1).

4. Install the 10 lower crankcase retaining bolts (2).

5. Tighten the 10 NEW lower crankcase bolts in 2 steps as shown in the sequence above.
1. First Step: Tighten the 10 lower crankcase bolts to 55 Y (41 lb ft).

2. Second Step: Tighten the 10 lower crankcase bolts 120°.
1 of 2
Lower Crankcase Installation
6. Tighten the 6 lower crankcase retaining bolts (1) to 35 Y (26 lb ft).
2 of 2
Lower Crankcase Removal

1. Remove the 6 lower crankcase retaining bolts (1).
2. Evenly loosen the 10 lower crankcase bolts in sequence as shown.
Note: The crankshaft is only loosely fitted in the cylinder block after removal of the lower crankcase retaining bolts.
3. Remove the 10 lower crankcase retaining bolts (2).
Note: Carefully detach from engine block, using a suitable tool. Do not damage sealing surfaces.
4. Remove the lower crankcase (1).
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Mode Control Cam Cover Replacement (Left Hand Drive)

Mode Control Cam Cover Replacement

1. Remove instrument panel lower trim pad cover. Refer to Instrument Panel Lower Trim Pad Cover Replacement.
2. Remove mode control cam actuator. Refer to Mode Control Cam Actuator Replacement.
Heater and Air Conditioning Mode Control Cam Cover Bolt (Qty: 3)

1
2 Heater and Air Conditioning Mode Control Cam Cover
1 of 1
Mode Control Cam Cover Replacement (Right Hand Drive)

Mode Control Cam Cover Replacement

1. Remove the instrument panel compartment. Refer to Instrument Panel Compartment Replacement.
2. Remove the floor front air outlet duct — left side. Refer to Floor Front Air Outlet Duct Replacement - Left Side.
3. Remove the radio cooling duct. Refer to Radio Cooling Duct Replacement.
4. Remove the blower motor control module. Refer to Blower Motor Control Module Replacement.
Heater and Air Conditioning Mode Control Cam Cover Bolt (Qty: 3)

1
Heater and Air Conditioning Mode Control Cam Cover

Procedure
2
Remove the mode control cam actuator from heater and air conditioning mode control cam cover. Refer to Mode Control Cam
Actuator Replacement
1 of 1
Piston and Connecting Rod Assemble

1. Install the piston rings.
Insert into the pistons with piston ring wrench and "TOP" pointing upwards.
Set the piston ring gap.
First piston ring (right-hand ring) in position (1)

Second piston ring (minute ring) in position (2)
Interim ring of oil scraper ring in position (3), steel band rings of oil scraper ring in position (4 and/or 5)
Note: Note installation position of the piston in respect of the connection rod.
Attach the piston to the connection rod.
1. Press the piston pin into the piston and the connection rod by hand.
2. Insert the retainer in the annular groove on the piston.
3. Ensure the retainer is firmly seated in the groove.
Install the piston with connection rod. Refer to Piston, Connecting Rod, and Bearing Installation.
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Piston, Connecting Rod, and Bearing Cleaning and Inspection

Special Tools
1. Remove the oil pan. Refer to Oil Pan Removal.
2. Remove the connecting rod bearing cap (1).
1. Mark the installation position (1) of the connecting rod bearing cap.

3. Degrease the connecting rod bearing cap and wet the connecting rod bearing clip with engine oil.
Note: Do not rotate the crankshaft.
3. Lay on plastigage. Refer to Adhesives, Fluids, Lubricants, and Sealers.
Lay plastigage (flexible plastic thread) over the entire width of the connecting rod bearing journal.
4. Install the connecting rod bearing cap.
Caution: Refer to Fastener Caution
5. Tighten the 2 bolts in three passes using the EN-45059 sensor kit :

2. Second pass tighten to an additional 45°
3. Third pass tighten to an additional 15°
1 of 2

7. Remove the connecting rod bearing cap (1).
Note: When reading the value, do not confuse millimeters and inches on the measuring scale (1).
8. Measure the connecting rod bearing play.
Compare the width of the flattened plastic thread with the measuring scale.
Permissible connecting rod bearing play: 0.019-0.071 mm (0.0007-0.0028 in).
Note: Check markings on parts.

Install the connecting rod bearing cap.
Wet the connecting rod bearing journal and con-rod bearing clips with engine oil.
Renew the bolts.
Tighten the 2 bolts in three passes using the EN-45059 sensor kit :
1. First pass tighten to 35 Y (26 lb ft)

2. Second pass tighten to an additional 45°
3. Third pass tighten to an additional 15°
Install the oil pan. Refer to Oil Pan Installation.
2 of 2

Visual Inspection and Cleaning Procedure

Connecting Rod
1. Clean the connecting rods (1) in solvent and dry with compressed air.
2. Inspect the connecting rods for the following:
Signs of being twisted, bent, nicked, or cracked

Scratches or abrasion on the rod bearing seating surface
If the beam of the rod is scratched or has other damage replace the connecting rod.
If there is still excessive clearance, replace the connecting rod.
Piston
1. Clean the piston skirts and the pins with a cleaning solvent. DO NOT wire brush any part of the piston.
2. Clean the piston ring grooves with a groove cleaner. Make sure that the oil ring holes and slots are clean.
3. Inspect the pistons for the following conditions:
Cracked ring lands, skirts, or pin bosses.

Ring grooves for nicks, burrs that may cause binding.
Eroded areas at the top of the piston (1).
Scuffed or damaged skirts (2).
Worn piston pin bores (3).
If there is any excessive wear, replace the piston.
Piston and Connecting Rod Measurement Procedure

Piston Pin to Connecting Rod Bore and Piston Bore Clearance
1. Measure clearance between piston pin and connecting rod bore. Use the following procedure:
2. Measure the piston pin outside diameter.
3. Measure the connecting rod bore diameter.
4. Substract the piston ring diameter from the connecting rod diameter.
Refer to Engine Mechanical Specifications.
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Piston Ring Clearance
__
1. Install the piston rings to the cylinder as shown (1) and measure the piston ring end gap. Compare the measurements with the Engine Mechanical
Specifications.
2. If the clearance is greater than the provided specifications, the piston rings must be replaced.
3. Measure the piston ring side clearance as shown (1). Compare the measurements with the Engine Mechanical Specifications.
4. If the clearance is greater than the provided specifications, replace the piston rings.
5. If the clearance is still to great, replace the pistons.
Connecting Rod Bearing Clearance
1. Inspect the connecting rod end play and refer to Engine Mechanical Specifications.
2. Measure the piston pin to connecting rod bore using the following procedure:
1. Using an outside micrometer, take 2 measurements of the piston pin in the area of the connecting rod contact.
2. Using an inside micrometer, measure the connecting rod piston pin bore (2).
3. Subtract the piston pin diameter from the piston pin bore diameter.
3. Compare the measurements with the Engine Mechanical Specifications.
4. If there is excessive clearance, replace the piston pin.
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5. Inspect the connecting rod end play (1).

6. Compare the measurements with the Engine Mechanical Specifications.
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Piston, Connecting Rod, and Bearing Installation

Special Tools
EN-50425 Compressor - Piston Ring

Note: The dot (1) on the piston skirt must point to the timing side to ensure that the notch (2) for the oil nozzle is at the correct position.
1. Displace the piston ring joints 120° to each other.
2. Coat all pistons and cylinder bores and the EN-50425 compressor with engine oil.
3. Turn the crankshaft to TDC of combustion stroke of cylinder 2.
4. Use the EN-50425 compressor (1) as shown in the graphic above.
Note: When using the old pistons, old connecting rods and old connecting rod bearing caps, install them at their original position.
5. Install the 2 pistons with the connecting rod (1) and the connecting rod upper bearing shells (2) into the cylinder 1 and 4.
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6. Install the 2 connecting rod bearing caps (2) with the connecting rod lower bearing shells (1) to the cylinder 1 and 4.
Note: Do not tighten the bearing cap retaining bolts (3).
7. Install 4 NEW connecting rod bearing shell bolts (3).
8. Tighten the 4 NEW connecting rod bearing shell bolts (3) in 2 steps.
1. First Step: 30 Y (22 lb ft)

2. Second Step: + 70°. Use the EN-470-B anglemeter .
9. Turn crankshaft through 180°and set crankshaft to TDC of combustion stroke of cylinder 1.
10. Install 2 pistons with connecting rod (1) and connecting rod upper bearing shells (2) into cylinder 2 and 3.
11. Install 2 connecting rod bearing caps (2) with connecting rod lower bearing shells (1) to cylinder 2 and 3.
13. Tighten the 4 connecting rod bearing shell bolts (3) in two steps.
1. First Step: 30 Y (22 lb ft)

2. Second Step: + 70°. Use EN-470-B anglemeter .
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Special Tools
1. Lubricate the piston rings, piston, inner cylinder bore surface and a piston ring compressor with clean engine oil.
2. Install the piston ring compressor in order to compress the piston rings.
3. Install the piston and connecting rod assembly (4).

4. Install the connecting rod bearing (3).
5. Install the connecting rod cap (1).
6. Install NEW connecting rod bolts (2) and tighten a first pass to 35 Y (26 lb ft).
7. Tighten the NEW connecting rod bolts a second pass to an additional 45 degrees, using the EN-45059 meter.
8. Tighten the NEW connecting rod bolts a final pass to an additional 15 degrees, using the EN-45059 meter.
9. Assemble the caps and connecting rods in the marked position.
10. Rotate the crankshaft to a position where the connecting rod bolts are easy accessible.
1 of 1
Piston, Connecting Rod, and Bearing Removal

1. Install the crankshaft balancer bolt.

2. Set the pistons 1 and 4 to TDC in direction of engine rotation.
Note: Note cylinder sequence.

3. Mark the connecting rod with the connecting rod bearing cover (1).
4. Remove the 4 connecting rod bearing caps bolts (2) of cylinder 1 and 4.

5. Remove the connecting rod bearing caps (1) and the connecting rod bearing (3).
6. Push the pistons 1 and 4 (1) out of the cylinder bore (2).

Note: The shear surfaces of the con-rod and the con-rod bearing cover form a unique fit and must not be swapped or damaged. Do not lay down on the shear
surfaces.
7. Remove the pistons 1 and 4 (1).
8. Turn crankshaft on crankshaft balancer through 180° in direction of rotation of engine.
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Note: Note cylinder sequence.

9. Mark the connecting rod with the connecting rod bearing cover (1).
10. Remove the 4 connecting rod bearing caps bolts (2) of cylinder 2 and 3.
11. Remove the connecting rod bearing caps (1) and the connecting rod bearing (3).
12. Push the pistons 2 and 3 (1) out of the cylinder bore (2).

Note: The shear surfaces of the con-rod and the con-rod bearing cover form a unique fit and must not be swapped or damaged. Do not lay down on the shear
surfaces.
13. Remove the pistons 2 and 3 (1).
Note: Observe correct fitting position, observe alignment.

14. Remove the connecting rod bearing (1, 2).
15. Check the components. Refer to Piston, Connecting Rod, and Bearing Cleaning and Inspection.
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1. Set the crankshaft to TDC of combustion stroke of cylinder 1.

2. Remove the 4 connecting rod bearing cap retaining bolts (3) from the cylinder 2 and 3.
Note: Set the connecting rod bearing caps aside in the order removed.
Note: The shear surfaces of the connecting rod and the connecting rod bearing cap form a unique fit and must not be swapped or damaged. Do not lay down on
the shear surfaces.
3. Remove the 2 bearing caps (2) from the cylinder 2 and 3.
Note: Set aside in the order removed.
4. Remove the 2 lower connecting rod bearings (1) from the cylinder 2 and 3.

5. Push the 2 pistons with the connecting rod (1) from the cylinder 2 and 3 upwards.
6. Remove the 2 connecting rod upper bearings (2) from the cylinder 2 and 3.
7. Turn the crankshaft through 180° and set the crankshaft to TDC of combustion stroke of cylinder 2.
8. Remove the 4 connecting rod bearing cap bolts (3) from the cylinder 1 and 4.
Note: Set the connecting rod bearing caps aside in the order removed.
Note: The shear surfaces of the connecting rod and the connecting rod bearing cap form a unique fit and must not be swapped or damaged. Do not lay down on
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the shear surfaces.

9. Remove the 2 connecting rod bearing caps (2) from the cylinder 1 and 4.
10. Remove the 2 connecting rod lower bearings (1).
Note: Note the marking (2) of the connecting rod. Set aside in the order removed.
11. Push the 2 pistons with connecting rod (1) from the cylinder 1 and 4 upwards.
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Piston, Connecting Rod, and Bearing Replacement

Special Tools

EN-50425 Compressor - Piston Ring
Removal Procedure
1. Remove intake camshaft. Refer to Intake Camshaft Replacement.

2. Remove crankshaft balancer. Refer to Crankshaft Balancer Removal.
3. Set the crankshaft to TDC of combustion stroke of cylinder 1.

4. Remove and DISCARD the 4 connecting rod bearing cap retaining bolts (3) from the cylinder 2 and 3.
5. Remove the 2 bearing caps (2) from the cylinder 2 and 3.
6. Remove the 2 lower connecting rod bearings (1) from the cylinder 2 and 3.
7. Push the 2 pistons with the connecting rod (1) from the cylinder 2 and 3 upwards.
9. Turn the crankshaft through 180° and set the crankshaft to TDC of combustion stroke of cylinder 2.
10. Remove and DISCARD the 4 connecting rod bearing cap bolts (3) from the cylinder 1 and 4.
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11. Remove the 2 connecting rod bearing caps (2) from the cylinder 1 and 4.
12. Remove the 2 connecting rod lower bearings (1).
13. Push the 2 pistons with connecting rod (1) from the cylinder 1 and 4 upwards.
Note: The dot (1) on the piston skirt must point to the timing side to ensure that the notch (2) for the oil nozzle is at the correct position.
1. Displace the NEW piston ring joints 120° to each other.
2. Coat all pistons and cylinder bores and the EN-50425 compressor with engine oil.
3. Turn the crankshaft to TDC of combustion stroke of cylinder 2.
4. Use the EN-50425 compressor (1) as shown in the graphic above.

5. Install the 2 NEW pistons with the NEW connecting rod (1) and the NEW connecting rod upper bearing shells (2) into the cylinder 1 and 4.
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6. Install the 2 connecting rod bearing caps (2) with the connecting rod lower bearing shells (1) to the cylinder 1 and 4.
8. Tighten the 4 connecting rod bearing shell bolts (3) in 2 steps.
1. First step tighten to 30 Y (22 lb ft).

2. Second step to an additional 70°, use the EN-470-B meter .
9. Turn crankshaft through 180°and set the crankshaft to TDC of combustion stroke of cylinder 1.
10. Install 2 NEW pistons with NEW connecting rod (1) and NEW connecting rod upper bearing shells (2) into cylinder 2 and 3.
11. Install 2 NEW connecting rod bearing caps (2) with NEW connecting rod lower bearing shells (1) to cylinder 2 and 3.
13. Tighten the 4 connecting rod bearing shell bolts (3) in 2 steps.
1. First step tighten to 30 Y (22 lb ft).

2. Second step to an additional 70°, use the EN-470-B meter .
14. Install crankshaft balancer. Refer to Crankshaft Balancer Installation.
15. Install intake camshaft. Refer to Intake Camshaft Replacement.
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Belt Idler Pulley Replacement - Lower

Special Tools
EN-48952 Fixing Pin
Removal Procedure
2. Remove the front compartment insulator. Refer to Front Compartment Insulator Replacement.
3. Remove the front part of the right front wheelhouse liner. Refer to Front Wheelhouse Liner Replacement.
4. Remove the drive belt and pulley cover. Refer to Drive Belt and Pulley Cover Removal.
5. Apply tension to the drive belt tensioner (1) with a suitable wrench on the holder (2) by rotating counterclockwise.
6. Install the EN-48952 fixing pin (3).
7. Remove the drive belt from the drive belt tensioner.
8. Remove the lower drive belt idler pulley bolt (2).

9. Remove the lower drive belt idler pulley (1).
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Belt Idler Pulley Replacement - Lower
1. Install the lower drive belt idler pulley (1).

2. Install the lower drive belt idler pulley bolt (2) and tighten to 58 Y (43 lb ft).
3. Install the drive belt to the drive belt tensioner.
5. Remove the EN-48952 fixing pin (3).
6. Release tension from the drive belt tensioner (1) and allow the tensioner to slide back slowly.
7. Inspect the drive belt for proper seat.
8. Install the drive belt and pulley cover. Refer to Drive Belt and Pulley Cover Installation.
9. Install the front part of the right front wheelhouse liner. Refer to Front Wheelhouse Liner Replacement.
10. Install the front compartment insulator. Refer to Front Compartment Insulator Replacement.
2 of 2
Belt Idler Pulley Replacement - Upper

Special Tools
EN-48952 Drive Belt Tensioner Holding Pin
Removal Procedure
6. Install the EN-48952 holding pin (3).
7. Remove the drive belt from the generator pulley, the upper drive belt pulley and the drive belt tensioner.
8. Remove the upper drive belt idler pulley bolt (2).

9. Remove the upper drive belt idler pulley (1).
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Belt Idler Pulley Replacement - Upper
1. Install the upper drive belt idler pulley (1).

2. Install the upper drive belt pulley bolt (2) and tighten to 58 Y (43 lb ft).
3. Install the drive belt to the generator pulley, the upper drive belt pulley and the drive belt tensioner.
5. Remove the EN-48952 holding pin (3).
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Crankshaft Pulley Installation

Special Tools
EN-50432 Adapter Flywheel Fixing
1. Install the crankshaft pulley (1).

2. Loosely install a NEW crankshaft pulley bolt (3) and the washer (2).
3. Install the EN-50432 flywheel fixing (1).

4. Tighten the crankshaft pulley bolt to 120 Y + 90° (89 lb ft + 90°).
1 of 1
Crankshaft Pulley Removal

Special Tools

EN-50436 Remover-Crankshaft Pulley Bolt .
1. Install the EN-50432 flywheel fixing (1).
2. Loosen the crankshaft pulley bolt with EN-50436 remover (1).
3. Remove the crankshaft pulley bolt (3) and washer (2).

4. Remove the crankshaft pulley (1).
5. Remove the EN-50432 flywheel fixing .
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Crankshaft Pulley Replacement

Special Tools

EN-48952 Drive Belt Tensioner Holding Pin
EN-50436 Remover-Crankshaft Pulley Bolt
Removal Procedure
1. Disconnect battery negative cable. Refer to Battery Negative Cable Disconnection and Connection.
8. Remove the drive belt from the crankshaft pulley.
9. Remove the starter. Refer to Starter Replacement.
10. Install the EN-50432 flywheel fixing (1) to counterhold the crankshaft.
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11. Loosen the crankshaft pulley bolt with the EN-50436 remover (1).
12. Remove and DISCARD the crankshaft pulley bolt (3) and washer (2).
13. Remove the crankshaft pulley (1).
1. Install the crankshaft pulley (1).

2. Install the NEW crankshaft pulley bolt (3) and washer (2).
3. Tighten the crankshaft pulley bolt (3) in 2 steps.
First step: 120 Y (89 lb ft).

Second step: +90°. Use EN-470-B meter .
Remove the EN-50432 flywheel fixing .
Install the starter. Refer to Starter Replacement.
Install the drive belt to the crankshaft pulley.
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Apply tension the drive belt tensioner (1) with a suitable wrench on the holder (2) by rotating counterclockwise.
Remove the EN-48952 holding pin (3).
Release tension from the drive belt tensioner (1) and allow the tensioner to slide back slowly.
Inspect the drive belt for proper seat.
Install the drive belt and pulley cover. Refer to Drive Belt and Pulley Cover Installation.
Install the front part of the right front wheelhouse liner. Refer to Front Wheelhouse Liner Replacement.
Install the front compartment insulator. Refer to Front Compartment Insulator Replacement.
Lower the vehicle.
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Drive Belt Idler Pulley Installation - Lower

1. Install the lower drive belt idler pulley (1).

2. Install the lower drive belt idler pulley bolt (2) and tighten to 58 Y (43 lb ft).
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Drive Belt Idler Pulley Installation - Upper

1. Install the upper drive belt idler pulley (1).

2. Install the upper drive belt pulley bolt (2) and tighten to 58 Y (43 lb ft).
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Drive Belt Idler Pulley Removal - Lower

1. Remove the lower drive belt idler pulley bolt (2).

2. Remove the lower drive belt idler pulley (1).
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Drive Belt Idler Pulley Removal - Upper

1. Remove the upper drive belt idler pulley bolt (2).

2. Remove the upper drive belt idler pulley (1).
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Drive Belt Tensioner Installation

1. Install the drive belt tensioner (1).

2. Install the drive belt tensioner bolt (2) and tighten to 45 Y (33 lb ft).
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Drive Belt Tensioner Installation

1. Clean the drive belt tensioner thread.
2. Install drive belt tensioner (2).

3. Install drive belt tensioner bolt (1) and tighten to 55 Y (41 lb ft).
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Drive Belt Tensioner Removal

1. Remove the drive belt tensioner bolt (2).

2. Remove the drive belt tensioner (1).
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Drive Belt Tensioner Removal


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Drive Belt Tensioner Replacement

Removal Procedure
1. Remove the generator and air conditioning compressor belt. Refer to Drive Belt Replacement.

1. Clean the drive belt tensioner thread.
2. Install drive belt tensioner (2).

4. Install the generator and air conditioning compressor belt. Refer to Drive Belt Replacement.
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Special Tools
EN-48952 Tensioner Spring Holding Pin
Removal Procedure
7. Remove the drive belt from the generator pulley, the upper belt idler pulley and the drive belt tensioner.

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1. Install the drive belt tensioner (1).

3. Install the drive belt to the generator pulley, the upper belt idler pulley and the drive belt tensioner.
4. Apply tension the drive belt tensioner (1) with a suitable wrench on the holder (2) by rotating counterclockwise.
5. Remove the EN-48952 holding pin (3).
11. Lower the vehicle. Refer to Lifting and Jacking the Vehicle.
2 of 2
Generator Pulley Replacement

Remove the generator. Refer to Generator Replacement.
1 Generator Pulley Nut Cap
Generator Pulley
Procedure
Remove the generator pulley nut by using EN-6372 counterhold.
Note: Be aware of the left-hand thread.
2
Tighten
80 Y (59 lb ft)
Special Tools
EN-6372 Counterhold
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Camshaft Actuator System Description

Camshaft Actuator System Overview
(1) Camshaft Actuator Vane

(2) Timing Chain Sprocket
(3) Engine Oil Pressure-For retarding the camshaft
(4) Camshaft
(5) Input Signals from Engine Sensors
(6) Engine Control Module (ECM)
(7) Camshaft Actuator Solenoid
(8) Engine Oil Pump
(9) Engine Oil Pressure Supply
(10) Engine Oil Drain
(11) Engine Oil Pressure-For advancing the camshaft
(12) Camshaft Actuator Rotor
(13) Camshaft Position Sensor Reluctor
(14) Camshaft Actuator Lock Pin
(15) Camshaft Actuator Housing
The camshaft actuator system enables the engine control module (ECM) to change camshaft timing of all 4 camshafts while the engine is operating. The camshaft
position (CMP) actuator assembly (15) varies the camshaft position in response to directional changes in oil pressure. The CMP actuator solenoid valve controls the oil
pressure that is applied to advance or retard a camshaft. Modifying camshaft timing under changing engine demand provides better balance between the following
performance concerns:
Engine power output

Fuel economy
Tailpipe emissions
The CMP actuator solenoid valve (7) is controlled by the ECM. The crankshaft position (CKP) sensor and the CMP sensors are used to monitor changes in camshaft
positions. The ECM uses the following information in order to calculate the desired camshaft positions:
Engine coolant temperature

Calculated engine oil temperature (EOT)
Mass air flow (MAF)
Throttle position (TP)
Vehicle speed
Volumetric efficiency
Operation
The CMP actuator assembly has an outer housing that is driven by an engine timing chain. Inside the assembly is a rotor with fixed vanes that is attached to the
camshaft. Oil pressure that is applied to the fixed vanes will rotate a specific camshaft in relationship to the crankshaft. The movement of the intake camshafts will
advance the intake valve timing. The movement of the exhaust camshafts will retard the exhaust valve timing. When oil pressure is applied to the return side of the
vanes, the camshafts will return to 0 crankshaft degrees, or top dead center (TDC). The CMP actuator solenoid valve directs the oil flow that controls the camshaft
movement. The ECM commands the CMP solenoid to move the solenoid plunger and spool valve until oil flows from the advance passage (11). Oil flowing thru the
CMP actuator assembly from the CMP solenoid advance passage applies pressure to the advance side of the vanes in the CMP actuator assembly. When the
camshaft position is retarded, the CMP actuator solenoid valve directs oil to flow into the CMP actuator assembly from the retard passage (3). The ECM can also
command the CMP actuator solenoid valve to stop oil flow from both passages in order to hold the current camshaft position.
The ECM operates the CMP actuator solenoid valve by pulse width modulation (PWM) of the solenoid coil. The higher the PWM duty cycle, the larger the change
1 of 2
in camshaft timing. The CMP actuator assembly also contains a lock pin (14) that prevents movement between the outer housing and the rotor vane assembly.
The lock pin is released by oil pressure before any movement in the CMP actuator assembly takes place. The ECM is continuously comparing CMP sensor inputs
with CKP sensor input in order to monitor camshaft position and detect any system malfunctions. If a condition exists in either the intake or exhaust camshaft
actuator system, the opposite bank, intake or exhaust, camshaft actuator will default to 0 crankshaft degrees.
CMP Actuator System Operation
Change in Camshaft
Driving Condition Position Objective Result
Idle No Change Minimize Valve Overlap Stabilized Idle Speed
Light Engine Load Retarded Valve Timing Decrease Valve Overlap Stabled Engine Output
Better Fuel Economy with

Medium Engine Load Advanced Valve Timing Increase Valve Overlap
Lower Emissions
Low to Medium RPM with Advance Intake Valve Improved Low to Mid-range
Advanced Valve Timing
Heavy Load Closing Torque
High RPM with Heavy Load Retarded Valve Timing Retard Intake Valve Closing Improved Engine Output
2 of 2
Camshaft Bearing Cap Installation - Rear

Note: Do not coat sealing compound on the camshaft guide bolt holes.
2. Apply sealing compound on the sealant line (1).
3. Install the camshaft guide (1).

4. Install the 3 camshaft guide retaining bolts (3) and tighten to 25 Y (18 lb ft).
5. Install the 2 camshaft guide retaining bolts (2) and tighten to 10 Y (89 lb in).
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Camshaft Bearing Cap Removal - Rear

1. Remove the 5 camshaft guide retaining bolts (2, 3).
2. Remove the camshaft guide (1).
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Camshaft Cleaning and Inspection

Cleaning Procedure
1. Clean the camshaft in solvent.

2. Dry the camshaft with compressed air.
Visual Inspection
1. Inspect the camshaft drive sprocket thread hole (1) for damage.

2. Inspect the camshaft lobes (2) and journals (5) for the following conditions:
Excessive scoring or pitting

Discoloration from overheating
Deformation from excessive wear, especially the camshaft lobes
Inspect the camshaft thrust surface (3) for damage.
Inspect the camshaft position rotator (4) for damage.
Inspect the camshaft sealing surface (6) for damage.
Camshaft Measurement
1. Measure the camshaft journals (2) for diameter and out-of-round using a micrometer gauge (1).
2. Check specifications. Refer to Engine Mechanical Specifications.
If the diameter is smaller than specifications, replace the camshaft.

If the out-of-round exceeds specifications, replace the camshaft.
1 of 1

Special Tools
EN-845 Suction Device

EN-6361 Feeler Gauge
Note: Note the identification marking on the camshaft bearing caps.

1. Install the exhaust camshaft (1).
Lubricate the exhaust camshaft with MoS 2 lubricating paste. Refer to Adhesives, Fluids, Lubricants, and Sealers for the recommended lubricating paste.
2. Tighten the camshaft bearing caps 1–4 in a spiral from the inside to the outside and tighten to 8 Y (71 lb in).
3. Install the intake camshaft (1).

Lubricate the exhaust camshaft with MoS 2 lubricating paste. Refer to Adhesives, Fluids, Lubricants, and Sealers for the recommended lubricating paste.
4. Tighten the camshaft bearing caps 1–4 in a spiral from the inside to the outside and tighten to 8 Y (71 lb in).
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Note:
Ensure no sealant reaches the camshafts.

Note the installation sequence 1–4.
5. Install the first camshaft bearing cap (1) and the 4 bolts and tighten to 8 Y (71 lb in).
6. When replacing the intake camshaft, inspect the valve lash of the intake valves.
7. Inspect the 2 valve lash, intake valve cylinder 1.
1. Turn the intake camshaft in the direction of engine rotation by the camshaft hexagon until the cams of cylinder 1 are in the test position.
2. Insert the EN-6361 gauge , inspect the valve lash.
Write down the result.
11. When replacing the exhaust camshaft, inspect the valve lash of the exhaust valves.
12. Inspect the 2 valve lash, exhaust valve cylinder 4.
1. Turn the exhaust camshaft in the direction of engine rotation by the camshaft hexagon until the cams of cylinder 4 are in the test position.
1. Turn the exhaust camshaft in the direction of engine rotation by the camshaft hexagon gear until the cams of cylinder 3 are in the test position.
Note: Note the removal sequence 1–4.

16. Remove the 4 camshaft bearing support bolts.
17. Release the bearing support by striking it gently with a plastic hammer.
18. Remove the 1st camshaft bearing support (1).
Note: Mark the exhaust camshaft bearing caps before removal.
19. Detach the camshaft bearing caps 1–4 working from outside to inside in a spiral in steps of 1/2 up to 1 turn.
20. Remove the camshaft bearing cover from the cylinder head.
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21. Remove the intake camshaft.

Note: Mark the intake camshaft bearing caps before removal.
22. Detach the camshaft bearing caps 1–4 working from outside to inside in a spiral in steps of 1/2 up to 1 turn.
23. Remove the camshaft bearing cover from the cylinder head.
24. Remove the exhaust camshaft.
25. Using the EN 845 device (1), remove the 16 valve tappets.
26. Determine valve tappet size.
1. Measurement of the cup tappet installed 3.12 mm (0.123 in), identification number 12.

2. Measured value between cams and cup tappets +0.31 mm (0.012 in) = 3.43 mm (0.135 in)
3. Required value, valve lash – 0.25 mm (0.010 in)
Note: The identification number, arrow, is on the inside of the valve tappet.
4. Measurement of the new cup tappet = 3.18 mm (0.125 in), identification number 18.
5. Use a valve tappet with this dimension or one that is nearest to it.
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Camshaft Cover Installation

1. Clean the bolt and the camshaft cover bolt (4) thread.

2. Apply sealant to the camshaft cover bolt (4). Refer to Adhesives, Fluids, Lubricants, and Sealers.
3. Insert a NEW gasket in the camshaft cover.
4. Install the camshaft cover (1).
5. Install the 11 bolts (2, 3, 4) and tighten to 8 Y (71 lb in).
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Camshaft Cover Installation

Note: The complete installation procedure of the camshaft cover should be done in 10 minutes.
Note: Do not coat sealing compound on the camshaft guide bolt holes and threads.
2. Apply sealing compound on sealant lines (1).
3. Install the camshaft cover (1) along with a NEW gasket (3).

4. Install 20 camshaft cover retaining bolts (2) and tighten to 10 Y (89 lb in).
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Camshaft Cover Removal


2. Remove the camshaft cover (1).
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Camshaft Cover Removal

1. Remove the 20 camshaft cover retaining bolts (2).

2. Remove the camshaft cover (1) along with the gasket (3).
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Camshaft Cover Replacement

Removal Procedure
2. Remove the positive crankcase ventilation. Refer to Positive Crankcase Ventilation Hose/Pipe/Tube Replacement.
3. Remove the fuel injection feed pipes - fuel rail to fuel injector. Refer to Fuel Injection Fuel Feed Pipe Replacement - Fuel Injection Pump to Fuel Rail.
4. Remove the fuel injectors. Refer to Fuel Injector Replacement.
5. Remove the turbocharger coolant return pipe. Refer to Turbocharger Coolant Return Pipe Replacement.
6. Remove the 2 wiring harness retaining bolts (1), lay the wiring harness (2) aside.
7. Remove 20 camshaft cover retaining bolts (2).

8. Remove the camshaft cover (1) along with the gasket (3).
Note: The complete installation procedure of the camshaft cover should be done in 10 minutes.
Note: Do not coat the sealing compound on the camshaft guide bolt holes and threads.
2. Apply the sealing compound on the sealant lines (1).
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Camshaft Cover Replacement
3. Install the camshaft cover (1) in conjunction with a NEW gasket (3).

4. Install the 20 camshaft cover retaining bolts (2) and tighten to 10 Y (89 lb in).
5. Install the 2 wiring harness retaining bolts (1) and tighten to 10 Y (89 lb in).
6. Install the turbocharger coolant return pipe. Refer to Turbocharger Coolant Return Pipe Replacement.
7. Install the fuel injectors. Refer to Fuel Injector Replacement.
8. Install the fuel injection feed pipes - fuel rail to fuel injector. Refer to Fuel Injection Fuel Feed Pipe Replacement - Fuel Injection Pump to Fuel Rail.
9. Install the positive crankcase ventilation. Refer to Positive Crankcase Ventilation Hose/Pipe/Tube Replacement.
2 of 2
Camshaft Installation

Special Tools
EN-422 Installer
Note: Coat with MoS 2 lubricating paste. Refer to Adhesives, Fluids, Lubricants, and Sealers.
Note: Note the identification marking on the camshaft bearing cover.

2. Install the 4 intake camshaft bearing cover number 2-5.
3. Install the 8 intake camshaft bearing cover bolts and tighten in a spiral from the inside to the outside to 8 Y (71 lb in).
Note: Coat with MoS 2 lubricating paste. Refer to Adhesives, Fluids, Lubricants, and Sealers.
Note: Note the identification marking on the camshaft bearing cover.
5. Install the 4 exhaust camshaft bearing cover number 6-9.
6. Install the 8 exhaust camshaft bearing cover bolts and tighten in a spiral from the inside to the outside to 8 Y (71 lb in).
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Note: Sealing surfaces must be free from oil and grease.

7. Clean sealing surfaces of the first camshaft bearing support and the cylinder head with a suitable tool.
Clean oil duct from any sealant residue.
Note:
Sealing surfaces (arrows) must be free from oil and grease.

It is essential to ensure that no sealant is applied outside the marked sealing areas (1).
The grooves adjacent to the sealing surfaces must remain free from sealant.
8. Apply surface sealant to sealing surfaces of the first camshaft bearing cap thinly and evenly.
9. Position the first camshaft bearing cap on the cylinder block and tighten the bolts approximately to 2 Y (18 lb in).
Note: No sealant may reach the camshafts.

10. Install the first camshaft bearing cap.
Note: Note installation sequence 1-4.
11. Install the first camshaft bearing cap (1) bolts and tighten to 8 Y (71 lb in).
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12. Install 2 NEW sealing rings to the camshafts.

13. Tighten the seal ring with EN-422 installer (3) on the camshaft until this is in contact with the cylinder head.
14. To install, use camshaft sprocket bolt (1) in conjunction with shims (2) with a total thickness of approximately 10 mm.
15. Remove the EN-422 installer (3).
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Camshaft Position Actuator Adjuster Installation

Special Tools


1. Turn the camshaft by the hexagon until the groove on the end of the camshafts is horizontal.
2. Install the EN-6628-A locking tool (1).
3. Install intake camshaft position actuator adjuster and/or the exhaust camshaft position actuator adjuster (3).
4. Install a NEW intake camshaft position actuator adjuster bolt and/or a NEW exhaust camshaft position actuator adjuster bolt (2). DO NOT tighten the bolts yet.
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Camshaft Position Actuator Adjuster Installation
5. Install the EN-6340 locking tool into the camshaft position actuator adjusters.
Note: The spot type marking (4) on the intake camshaft position actuator adjuster does not correspond to the groove of EN-6340-left locking tool - left
during this process but must be somewhat above as shown.
1. Install the EN-6340-left locking tool (1) in the camshaft position actuator adjusters as shown.
Note: The spot type marking (3) on the exhaust camshaft position actuator adjuster must correspond to the groove on EN-6340-left locking tool - right.
2. Install the EN-6340-right locking tool (2) in the camshaft position actuator adjusters as shown.

EN-6628-A locking tool is for the camshaft adjustment to prevent misalignment of the camshafts. The wrench is required to counterhold the camshafts during
bolt torque procedure.
6. Install the camshaft position actuator adjuster bolts (2) and tighten the bolts in 3 passes using the EN-45059 meter.
1. First pass to 50 Y (37 lb ft)

2. Second pass to an additional 150 degrees
3. Final pass to an additional 15 degrees
7. Install the 2 camshaft position actuator adjuster closure plugs (1) and tighten to 30 Y (22 lb ft).
8. Remove the EN-6628-A locking tool.
9. After the installation of the timing belt, rotate the engine 720 degrees and check the position of the crankshaft and camshafts, again. Refer to Timing Belt
Adjustment.
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Camshaft Position Actuator Adjuster Removal

Special Tools

Note: The right half of the EN-6340 locking tool can be recognized by the lettering "right", arrow, on the tool.
1. Prepare the right half of the EN-6340 locking tool.
1. Remove the 2 bolts (2).

2. Remove the front panel (1) from the EN-6340 locking tool - right.
Note: The spot type marking (4) on the intake camshaft adjuster does not correspond to the groove of EN-6340 locking tool - left during this process but must be
somewhat above as shown.
Install the EN-6340 locking tool - left (1) into the camshaft adjusters as shown.
Note: The spot type marking (3) on the exhaust camshaft adjuster must correspond to the groove on EN-6340 locking tool - right.
Install EN-6340 locking tool - right (2) into the camshaft adjusters as shown.
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Camshaft Position Actuator Adjuster Removal

Turn the camshaft by the hexagon until the groove on the end of the camshafts is horizontal.
Install the EN-6628-A locking tool (1).
Remove the camshaft position actuator adjuster closure bolt (1) of the intake camshaft position actuator adjuster and/or the exhaust camshaft position actuator
adjuster (3).
EN-6628-A locking tool is for the camshaft adjustment to prevent misalignment of the camshafts. The wrench is required to counterhold the camshafts during bolt torque
procedure.
Remove the intake camshaft position actuator adjuster and/or the exhaust camshaft position actuator adjuster (3).
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Camshaft Position Actuator Adjuster Replacement

Special Tools
EN-6333 Timing Belt Tensioner Locking Pin

Removal Procedure
1. Remove the air cleaner housing. Refer to Air Cleaner Assembly Replacement.
2. Remove the 2 timing belt upper front cover bolts (2).

3. Remove the timing belt upper front cover (1).
4. Remove the camshaft cover. Refer to Camshaft Cover Replacement.
5. Remove the 2 camshaft position actuator solenoid valve. Refer to Camshaft Position Actuator Solenoid Valve Replacement.
8. Set the crankshaft balancer in direction of engine rotation until the markings (1) line up with the cylinder 1 at TDC.
9. Remove the crankshaft balancer. Refer to Crankshaft Balancer Replacement.
10. Remove the EN-6625 locking device.
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Note: The right half of the EN-6340 locking tool can be recognized by the lettering "right", arrow, on the tool.
14. Prepare the right half of the EN-6340 locking tool.

2. Remove the front panel (1) from the EN-6340 locking tool - right.
Note: The spot type marking (4) on the intake camshaft adjuster does not correspond to the groove of EN-6340 locking tool - left during this process but must
Install the EN-6340 locking tool - left (1) in the camshaft adjusters as shown.
Note: The spot type marking (3) on the exhaust camshaft adjuster must correspond to the groove on EN-6340 locking tool - right.
Install EN-6340 locking tool - right (2) in the camshaft adjusters as shown.
Support the engine. Install a suitable engine lifting device. Install a suitable cable at the 3 engine lift brackets and at the engine lifting device.
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Remove the engine mount nut (3).

Remove the 5 engine mount bolts (1, 2).
Remove the engine mount (4).
Remove the 3 engine mount bracket bolts (1).

Remove the engine mount bracket (2).
Remove the center front timing belt cover from the rear timing belt cover at 2 locations.
Remove the center front timing belt cover (1).
Install the EN-6333 locking pin (3).
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Remove and DISCARD the timing belt idler pulley bolt (1).

Remove the timing belt idler pulley (2).
Note: Note the direction of the belt, if the timing belt will be reused.
Remove the timing belt (1).
Remove and DISCARD the timing belt tensioner bolt (3).
Remove the timing belt tensioner (2).
Set the crankshaft in direction of engine rotation to 60 degrees (a) before TDC. Use the EN-45059 meter and the crankshaft balancer bolt.
Note: Some engine oil will run out of the camshaft and the camshaft position actuator adjuster. That is the reason for the removal of the whole timing assembly.
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Turn the camshaft by the hexagon until the groove on the end of the camshafts is horizontal.
Install the EN-6628–A locking tool (1).

Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle.
Place a collecting basin underneath the vehicle.
Remove the camshaft position actuator adjuster closure bolt (1) of the intake camshaft position actuator adjuster and/or the exhaust camshaft position actuator
adjuster (3).
torque procedure.
Remove the intake camshaft position actuator adjuster and/or the exhaust camshaft position actuator adjuster (3).
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1. Install intake camshaft position actuator adjuster and/or the exhaust camshaft position actuator adjuster (3).
Note: Do not tighten.
2. Install a NEW intake camshaft position actuator adjuster bolt and/or a NEW exhaust camshaft position actuator adjuster bolt (2).
3. Install the EN-6340 locking tool into the camshaft position actuator adjusters.
Note: The spot type marking (4) on the intake camshaft position actuator adjuster does not correspond to the groove of EN-6340-left locking tool
during this process but must be somewhat above as shown.
1. Install the EN-6340-left locking tool (1) in the camshaft position actuator adjusters as shown.
Note: The spot type marking (3) on the exhaust camshaft position actuator adjuster must correspond to the groove on EN-6340-right locking tool.
2. Install the EN-6340-right locking tool (2) in the camshaft position actuator adjusters as shown.

Note: Use an appropriate open-end wrench in order to counterhold the camshaft hexagon. A thin cross-section wrench is required for a better fit. The
usage of EN-6628–A locking tool is for the camshaft adjustment to prevent misalignment of the camshafts. The wrench is required to counterhold the
camshafts during bolt torque procedure.
4. Tighten the camshaft position actuator adjuster bolts (2) in three passes use the EN-45059 meter:

5. Install the 2 camshaft position actuator adjuster closure plugs (1) and tighten to 30 Y (22 lb ft).
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7. Clean the timing belt tensioner thread.

8. Install the timing belt tensioner (2) and tighten the NEW timing belt tensioner bolt (1) in three passes use the EN-45059 meter:


10. Install the 3 engine mount bracket bolts (1) tighten to 62 Y (46 lb ft).
11. Install the engine mount (4).

12. Install the 2 engine mount bolts (1) and tighten to 62 Y (46 lb ft).
13. Install the 3 engine mount bolts (2) and tighten in three passes use the EN-45059 meter.

14. Remove the engine lifting device.
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15. Clean the timing belt idler pulley thread.


16. Install the crankshaft sprocket (1).
17. Set the crankshaft in the direction of engine rotation to TDC. Use the crankshaft balancer bolt.
18. Install the timing belt (1).

19. Guide the timing belt past the tensioner and place it on the crankshaft sprocket wheel.
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20. Place the timing belt on the exhaust and intake camshaft position actuator adjusters.
21. Apply tension to the timing belt tensioner (2) in the direction of the arrow, using an Allen key (1).
22. Remove the EN-6333 locking pin (3).
Note: The timing belt tensioner moves automatically to the correct position.
23. Release tension on timing belt tensioner.
24. Check position of the camshaft and camshaft position actuator adjuster.
1. Turn crankshaft 720 degrees in the direction of engine rotation by the crankshaft balancer bolt.
Note: Note marking, camshaft position actuator adjuster.
2. Insert EN-6340 locking tool into camshaft position actuator adjuster.
25. Insert the EN-6628-A locking tool (1) into the camshafts.
26. Align camshafts by hexagon until EN-6628-A locking tool can be inserted in both camshafts.
27. Check the crankshaft position.
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29. Install the lower front timing belt cover (1) and tighten the 4 bolts (2) to 6 Y (53 lb in).
30. Install the crankshaft balancer. Refer to Crankshaft Balancer Replacement.
31. Install the drive belt tensioner. Refer to Drive Belt Tensioner Replacement.
34. Install the camshaft position actuator solenoid valve. Refer to Camshaft Position Actuator Solenoid Valve Replacement.
35. Install the camshaft cover. Refer to Camshaft Cover Replacement.
36. Install the timing belt upper front cover (1).

37. Install the 2 timing belt upper front cover bolts (2) and tighten to 6 Y (53 lb in).
38. Install the air cleaner housing. Refer to Air Cleaner Assembly Replacement.
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Camshaft Position Actuator Solenoid Valve Installation

Note: Lubricate the NEW camshaft position actuator solenoid valve seals with NEW engine oil. Refer to Adhesives, Fluids, Lubricants, and Sealers.
1. Install NEW camshaft position actuator solenoid valve seals (3).
2. Install the camshaft position actuator solenoid valves (2).
3. Install the camshaft position actuator solenoid valve bolts (1) and tighten to 6 Y (53 lb in).
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Camshaft Position Actuator Solenoid Valve Removal

1. Remove the camshaft position actuator solenoid valve bolts (1).

2. Remove the camshaft position actuator solenoid valves (2).
3. Remove the camshaft position actuator solenoid valve seals (3).
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Camshaft Position Actuator Solenoid Valve Replacement

Camshaft Position Actuator Solenoid Valve Replacement
Camshaft Position Actuator Solenoid Valve Bolt (Qty: 2)

1
Tighten
6 Y (53 lb in)
2 Camshaft Position Actuator Solenoid Valve (Qty: 2)
Camshaft Position Actuator Solenoid Valve Seal (Qty: 2)

3
Tip: Coat the camshaft position actuator solenoid valve seals with NEW engine oil.
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Camshaft Removal
Note: Note removal sequence 1–4.

1. Remove the 4 camshaft bearing cap bolts.
Note: Release the bearing support by striking it gently with a plastic hammer.
2. Remove the first camshaft bearing cap (1).
3. Loosen the 8 exhaust camshaft bearing cap bolts working from outside to inside in a spiral in steps of 1/2 up to 1 turn.
4. Remove the 8 exhaust camshaft bearing cap bolts.
Note: Mark camshaft bearing caps before removal.
5. Remove the 4 exhaust camshaft bearing caps numbers 6–9 from the cylinder head.
6. Remove the exhaust camshaft (1).
7. Loosen the 8 intake camshaft bearing cap bolts working from outside to inside in a spiral in steps of 1/2 up to 1 turn.
8. Remove the 8 intake camshaft bearing cap bolts.
Note: Mark camshaft bearing caps before removal.
9. Remove the 4 intake camshaft bearing caps numbers 2–5 from the cylinder head.
10. Remove the intake camshaft (1).
11. Remove the camshaft seal rings.
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Camshaft Timing Chain Installation

Note: The marks on the timing chain are asymmetric on the timing chain.
1. Install the camshaft timing chain (1).
2. The mark on the intake camshaft gear (1) must match with the mark on the timing chain (2).
3. Install the timing chain guide (2).

4. Apply safety agent to the timing chain dampener retaining bolt (3).
5. Install 2 retaining bolts (3) from the timing chain guide (2) and tighten to 25 Y (18 lb ft).
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Camshaft Timing Chain Installation
6. The mark on the intake crankshaft gear (1) must match with the mark on the timing chain (2).
7. Install the timing chain dampener (4).

9. Install bolt (3) to the timing chain dampener (4) and tighten to 25 Y (18 lb ft).
2 of 2
Camshaft Timing Chain Removal

1. Remove the 2 retaining bolts (3) from the timing chain guide (2).

2. Remove the timing chain guide (2).
3. Remove bolt (3) from the timing chain dampener (4).
4. Remove the timing chain dampener (4).
5. Remove the camshaft timing chain (1).
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Camshaft Timing Chain Replacement

Removal Procedure
1. Remove the exhaust camshaft. Refer to Exhaust Camshaft Replacement.
2. Remove both retaining bolts (3) from the timing chain guide (2).

4. Remove 1 bolt (3) from the timing chain dampener (4).
6. Remove the camshaft timing chain (1)
Note: The marks on the timing chain are asymmetric on the timing chain.
1. Install the camshaft timing chain (1).
2. The mark on the intake camshaft gear (1) must match with the mark on the timing chain (2).
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Camshaft Timing Chain Replacement

5. Install the 2 timing chain guide retaining bolts (3) and tighten to 25 Y (18 lb ft).
6. The mark on the crankshaft gear (1) must match with the mark on the timing chain (2).

9. Install the timing chain dampener bolt (3) and tighten to 25 Y (18 lb ft).
10. Install the exhaust camshaft. Refer to Exhaust Camshaft Replacement.
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Exhaust Camshaft Installation

Special Tools
EN-50433 Adapter - Exhaust Camshaft Sprocket Fixing
1. Ensure that the crankshaft is 90° beyond TDC of combustion stroke of cylinder 1.
Caution: Use extreme care when removing the camshaft not to nick, scratch, or damage the camshaft lobes or bearing surfaces.
Note: Install the camshaft guides in order as removed.
Note: Clean the contact surfaces from camshaft , camshaft sprocket and camshaft sprocket bolt.
2. Coat the camshaft bearing surfaces with engine oil.
Note: Tighten the camshaft seat guide cap from 2. cylinder at first.
4. Install the 4 camshaft seat guide caps.
5. Install the 8 camshaft seat guide cap retaining bolts (3) and tighten to 10 Y (89 lb in).
6. Install the camshaft seat guide cap (1).
7. Install 4 camshaft seat guide cap retaining bolts (2) and tighten to 25 Y (18 lb ft).
8. The arrows on the camshaft sprockets must align as shown (1).

9. Remove the EN-50433 sprocket fixing (2) from the exhaust camshaft sprocket.
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Exhaust Camshaft Installation
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10. Rotate the engine 2 revolutions clockwise.

11. Set crankshaft 90° beyond TDC of combustion stroke of cylinder 1.
The arrow on the intake camshaft gear (1) must align with the arrow on the exhaust camshaft gear (2).
The notch in the camshaft sprocket (4) must align with the mark on the engine block (3)
2 of 2
Exhaust Camshaft Removal

Special Tools
1. Set crankshaft 90° beyond TDC of combustion stroke of cylinder 1. The arrows on the camshaft sprockets must align as shown (1).
2. Fix the exhaust camshaft sprocket with the EN-50433 sprocket fixing (2).
Note: Remove the camshaft seat guide cap from the 2. cylinder at least. Set the camshaft guides aside in order as removed.
3. Remove the 4 camshaft seat guide cap retaining bolts (2).
4. Remove the camshaft seat guide cap (1).
6. Remove the 4 camshaft seat guide caps.
1 of 1
Exhaust Camshaft Replacement

Special Tools
Removal Procedure
1. Remove the engine front cover. Refer to Engine Front Cover Replacement.
2. Remove the camshaft bearing rear cap. Refer to Camshaft Bearing Cap Removal - Rear.
3. Set crankshaft 90°beyond TDC of combustion stroke of cylinder 1. The arrows on the camshaft sprockets must match as shown (1).
4. Fix the exhaust camshaft sprocket with the EN-50433 sprocket fixing (2).
Note: Take extreme care to prevent any scratches or damage to the camshaft and the bearing surfaces. Set the camshaft guides aside in order as
removed.
Note: Remove camshaft seat guide cap from cylinder 2 at least.
5. Remove 4 camshaft seat guide cap retaining bolts (2).
6. Remove the camshaft seat guide cap (1).
7. Remove 8 camshaft seat guide cap retaining bolts (3).
8. Remove 4 camshaft seat guide caps.
1. Ensure that the crankshaft is 90°beyond TDC of combustion stroke of cylinder 1.
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Exhaust Camshaft Replacement
Note: Take extreme care to prevent any scratches or damage to the camshaft and the bearing surfaces. Install the camshaft guides in order as
removed.
Note: Clean the contact surfaces from camshaft, camshaft sprocket and camshaft sprocket bolt.
2. Coat camshaft bearing surfaces with engine oil.
Note: Tighten the camshaft seat guide cap from cylinder 2 at first.
4. Install 4 camshaft seat guide caps.

5. Install 8 camshaft seat guide cap retaining bolts (3) and tighten to 10 Y (89 lb in).
6. Install the camshaft seat guide cap (1).
7. Install 4 camshaft seat guide cap retaining bolts (2) and tighten to 25 Y (18 lb ft).
8. The arrows on the camshaft sprockets must match as shown (1).

9. Remove the EN-50433 sprocket fixing (2) from the exhaust camshaft sprocket.
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up

11. Set crankshaft 90°beyond TDC of combustion stroke of cylinder 1.
The arrow on the intake camshaft gear (1) must match with the arrow on the exhaust camshaft gear (2).
The notch in the camshaft sprocket (4) must match with mark on the engine block (3)
Install the camshaft bearing rear cap removal. Refer to Camshaft Bearing Cap Installation - Rear.
Remove the engine front cover. Refer to Engine Front Cover Replacement.
2 of 3
Hydraulic Valve Lash Adjuster Replacement

Removal Procedure

2. Remove the 16 valve rocker arms with the hydraulic valve lash adjusters (1).
Note: Unclip the valve lifter from valve rocker arm in direction as shown (arrow). Mind to the centering link on retaining spring (3).
3. Remove the 16 hydraulic valve lash adjusters (2) from the valve rocker arms (1).
Note: Clip in the valve lifter to the valve rocker arm. Mind to the centering link on the retaining spring (3).
1. Install the 16 hydraulic valve lash adjusters (2) to the valve rocker arms (1).
2. Coat the 16 hydraulic valve lash adjusters with engine oil.
1 of 2
Hydraulic Valve Lash Adjuster Replacement
Note: If the valve rocker arms are being reused, the valve rocker arms must be installed in their original position.
3. Install the 16 valve rocker arms (1) with the hydraulic valve lash adjusters.
4. Install the intake camshaft. Refer to Intake Camshaft Replacement.
2 of 2
Intake Camshaft Installation

Special Tools
EN-50432 Adapter - Flywheel Fixing
Caution: Use extreme care when installing the camshaft not to nick, scratch, or damage the camshaft lobes or bearing surfaces.
Note:
Ensure that the crankshaft is fixed 90° beyond TDC with the EN-50433 fixing tool .
Install the camshaft guides in order as removed.
Clean the contact surfaces from camshaft , camshaft sprocket and camshaft sprocket bolt. Coat the camshaft bearing surfaces with engine oil.
Note: Tighten the camshaft seat guide cap from 4. cylinder at first.
2. Install the 4 camshaft seat guide caps (2).
3. Install the 8 camshaft seat guide cap retaining bolts (1) and tighten to 10 Y (89 lb in).
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Intake Camshaft Removal

Note: Remove the camshaft seat guide cap from the 4. cylinder at least. Set the camshaft seat guide caps aside in order as removed.
2. Remove the 4 camshaft seat guide caps (2).
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Intake Camshaft Replacement

Removal Procedure
1. Remove the timing chain. Refer to Camshaft Timing Chain Replacement.
Note: Take extreme care to prevent any scratches or damage to the camshafts.
Note: Remove camshaft seat guide cap from 4. cylinder at least. Set the camshaft seat guide caps aside in order as removed.
3. Remove the 4 camshaft seat guide caps (2).
Note:
Ensure that the crankshaft is fixed 90° beyond TDC with EN-50433 fixing tool
Take extreme care to prevent any scratches or damage to the camshaft. Install the camshaft guides in order as removed.
Clean the contact surfaces from camshaft , camshaft sprocket and camshaft sprocket bolt. Coat camshaft bearing surfaces with engine oil.
Note: Tighten the camshaft seat guide cap from cylinder 4 at first.
2. Install 4 camshaft seat guide caps (2).
3. Install 8 camshaft seat guide cap retaining bolts (1). Tighten the 8 camshaft seat guide cap retaining bolts (1) to 10 Y (89 lb in).
4. Install the timing chain. Refer to Camshaft Timing Chain Replacement.
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Timing Belt Center Front Cover Installation

Install the timing belt center front cover (1) to the timing belt rear cover at 2 locations.
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Timing Belt Center Front Cover Removal

1. Remove the center front timing belt cover from the rear timing belt cover at 2 locations.
2. Remove the center front timing belt cover (1).
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Timing Belt Center Front Cover Replacement

Timing Belt Center Front Cover Replacement

1. Remove the timing belt upper front cover. Refer to Timing Belt Upper Front Cover Replacement.
2. Remove the engine mount bracket. Refer to Engine Mount Bracket Replacement.
1 Timing Belt Center Front Cover
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Timing Belt Idler Pulley Installation

Special Tools

1. Re-cut the timing belt idler pulley thread.
2. Install the timing belt idler pulley (2) and tighten the NEW timing belt idler pulley bolt (1) a first pass to 20 Y (15 lb ft).
3. Tighten the NEW timing belt idler pulley bolt a second pass to an additional 120 degrees, using the EN-45059 meter.
4. Tighten the NEW timing belt idler pulley bolt a final pass to an additional 15 degrees, using the EN-45059 meter.
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Timing Belt Idler Pulley Removal

1. Remove the timing belt idler pulley bolt (1).

2. Remove the timing belt idler pulley (2).
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Timing Belt Idler Pulley Replacement

Special Tools
Removal Procedure
1. Remove the timing belt. Refer to Timing Belt Replacement.
2. Remove and DISCARD the timing belt idler pulley bolt (1).

3. Remove the timing belt idler pulley (2).

1. Re-cut the timing belt idler pulley thread.

3. Final pass to 15 degrees.
2. Install the timing belt. Refer to Timing Belt Replacement.
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Timing Belt Lower Front Cover Installation

Install the timing belt cover (1) and tighten the 4 timing belt lower front cover bolts (2) to 6 Y (53 lb in).
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Timing Belt Lower Front Cover Removal

1. Remove the 4 timing belt lower front cover bolts (2).

2. Remove the timing belt lower front cover (1).
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Timing Belt Lower Front Cover Replacement

Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle
2. Remove the crankshaft balancer. Refer to Crankshaft Balancer Replacement


1. Install the lower timing belt cover (1).
2. Install the 4 lower timing belt cover bolts (2) and tighten to 6 Y (53 lb in).
3. Install the crankshaft balancer. Refer to Crankshaft Balancer Replacement
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Timing Belt Rear Cover Installation

1. Re-cut the 4 rear timing belt cover threads.
2. Install the timing belt rear cover (1).

Note: Service may offer bolts that are not microencapsulated. If this is the case apply thread lock agent to the bolt. If fastener is microencapsulated, install a
NEW 4 timing belt rear cover bolts. DO NOT reuse the old bolt.
3. Install the 4 NEW timing belt rear cover bolts (2) and tighten to 6 Y (53 lb in).
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Timing Belt Rear Cover Removal

1. Remove and DISCARD the 4 timing belt rear cover bolts (2).

2. Remove the timing belt rear cover (1).
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Timing Belt Tensioner Installation

Special Tools
1. Clean the timing belt tensioner thread.

2. Install the timing belt tensioner (2).
3. Install a NEW timing belt tensioner bolt (1) and tighten the bolt in 3 passes using the EN-45059 meter.

2. Second pass to an additional 120 degrees.
3. Final pass to an additional 15 degrees.
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Timing Belt Tensioner Removal

1. Remove the tensioner bolt (1).

2. Remove the timing belt tensioner (2).
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Timing Chain Dampener Replacement

EN-49073 Pin - Timing Chain Tensioner

Removal Procedure
Note: Avoid that the timing chain skips.

2. Tension the timing chain tensioner. Fix the tensioner with the EN-49073 pin (1).
3. Remove the timing chain dampener bolt (3).
1. Apply safety agent to the timing chain dampener bolt (3).

3. Install the timing chain dampener bolt (3) and tighten to 25 Y (18 lb ft).
4. Remove the EN-49073 tensioner (1).
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Timing Chain Dampener Replacement
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up

6. Set crankshaft 90°beyond TDC of combustion stroke of cylinder 1 and inspect for the following conditions:
The notch in the camshaft sprocket (4) must match with mark on the engine block (3).
Install the engine front cover. Refer to Engine Front Cover Replacement.
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Timing Chain Guide Replacement

Removal Procedure

2. Remove the 2 timing chain guide bolts (2).
1. Apply safety agent to the 2 timing chain guide bolts (2).

3. Install the 2 timing chain guide bolts (2) and tighten to 25 Y (18 lb ft).
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up

5. Set the crankshaft 90°beyond TDC of combustion stroke of cylinder 1 and inspect for the following conditions:
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Timing Chain Guide Replacement
The notch in the camshaft sprocket (4) must match with mark on the engine block (3).
Install the engine front cover. Refer to Engine Front Cover Replacement.
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Timing Chain Tensioner Installation

Special Tools
1. Tension the timing chain tensioner (1) with the EN-49073 tensioner .

2. Install the timing chain tensioner (1).
3. Install the 2 timing chain tensioner retaining bolts (2) and tighten to 10Y(89 lb in).
4. Remove the EN-49073 tensioner .
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Timing Chain Tensioner Removal

Special Tools
1. Tension the timing chain tensioner with the EN-49073 tensioner .

2. Remove the 2 timing chain tensioner retaining bolts (2).
3. Remove the timing chain tensioner (1).
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Timing Chain Tensioner Replacement

Special Tools
Removal Procedure
2. Apply tension the timing chain tensioner (1). Fix the tensioner with the EN-49073 pin .
3. Remove the 2 timing chain tensioner retaining bolts (2).
4. Remove the timing chain tensioner (1).
1. Apply tension to the timing chain tensioner and fix with the EN-49073 pin .
2. Install the timing chain tensioner (1).
3. Install 2 timing chain tensioner retaining bolts (2). Tighten the retaining bolts (2) to 10 Y (89 lb in).
4. Remove the EN-49073 pin .
5. Install the engine front cover. Refer to Engine Front Cover Replacement.
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Torque Reaction Against Timing Drive Chain Caution

Caution: A wrench must be used on the hex of the camshaft when loosening or tightening in order to prevent component damage. Failure to prevent the torque reaction
against the timing drive chain can lead to timing drive chain failure.
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Valve Guide Reaming, and Valve and Seat Grinding

Valve Cleaning Procedure
1. Use soft bristle wire brush to clean any carbon build-up from the valve head. DO NOT use a wire brush on any part of the valve stem. The valve stem is
chrome plated to provide enhanced wear characteristics. Wire brushing the stem could remove the chrome plating.
2. Thoroughly clean the valve with solvent and wipe dry.
Valve Visual Inspection Procedure
1. Inspect the valve for damage from the head to tip for the following conditions:
Pitting in the valve seat area (1)

Lack of valve margin (2)
Bending in the valve stem (3)
Pitting or excessive wear in the stem (4)
Worn valve key grooves (5)
Worn valve tip (6)
Replace the valve if any of these conditions exist.
Valve Measurement and Reconditioning Overview

Note:
Proper valve service is critical to engine performance. Therefore, all detailed measurement procedures must be followed to identify components that are out
of specification.
If the measurement procedures reveal that the valve or valve seat must be reconditioned, it is critical to perform the measurement procedures after
reconditioning.
Valve Seat Width Measurement Procedure
1. Measure the valve seat width in the cylinder head using a proper scale.
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2. Measure the seat width on the valve face (1) using a proper scale.
Note: The seat contact area must be at least 0.5 mm (0.020 in) from the outer diameter (margin) of the valve. If the contact area is too close to the
margins, the seat must be reconditioned to move the contact area away from the margin.
3. Compare your measurements with the specifications, refer to Engine Mechanical Specifications.
4. If the seat widths are acceptable, check the valve seat roundness using the Valve Seat Roundness Measurement Procedure.
5. If the seat width is not acceptable, you must grind the valve seat using the Valve and Seat Reconditioning Procedure to bring the width back into
specification. Proper valve seat width is critical to providing the correct amount of valve heat dissipation.
Valve Seat Roundness Measurement Procedure
1. Measure the valve seat roundness using a dial indicator attached to a tapered pilot installed in the guide. The pilot should have a slight bind when
installed in the guide.
Caution: The correct size pilot must be used. Do not use adjustable diameter pilots. Adjustable pilots may damage the valve guides.
2. Compare your measurements with the specifications, refer to Engine Mechanical Specifications.
3. If the valve seat exceeds the roundness specification, you must grind the valve and valve seat using the Valve and Seat Reconditioning Procedure.
4. If new valves are being used, the valve seat roundness must be within 0.05 mm (0.002 in).
Valve Margin Measurement Procedure
1. Measure the valve margin using an appropriate scale.

2. Reference the specifications in this section for minimum valve margin and compare them to your measurements.
3. If the valve margins are beyond specification, replace the valves.
4. If the valve margins are within specification and do not require refacing, test the valve for seat concentricity using the Valve-to-Seat Concentricity
Measurement Procedure.
Valve-to-Seat Concentricity Measurement Procedure
Note:
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Checking the valve-to-seat concentricity determines whether the valve and seat are sealing properly.
You must measure the valve face and the valve seat to ensure proper valve sealing.
1. Coat the valve face lightly with blue dye (3).
2. Install the valve in the cylinder head.
3. Turn the valve against the seat with enough pressure to wear off the dye.
4. Remove the valve from the cylinder head.
5. Inspect the valve face.
If the valve face is concentric, providing a proper seal, with the valve stem, a continuous mark will be made around the entire face (1).
Note: The wear mark MUST be at least 0.5 mm (0.020 in) from the outer diameter, the margin, of the valve. If the wear mark is too close to the margin,
the seat must be reconditioned to move the contact area away from the margin.
If the face is not concentric with the stem, the mark will NOT be continuous around the valve face. The valve should be refaced or replaced and the seat
must be reconditioned using the Valve and Seat Reconditioning Procedure.
Valve and Seat Reconditioning Procedure
Note:
If the valve seat width, roundness or concentricity is beyond specifications, you must grind the seats in order to ensure proper heat dissipation and
prevent the build up of carbon on the seats.
It is necessary to reface the valve if seat reconditioning is required unless a new valve is used.
1. Grind the valve seats (2) to the proper angle specification, refer to Engine Mechanical Specifications.
2. Using the proper angle specification, refer to Engine Mechanical Specifications, grind, relieve, the valve seats (1) to correctly position the valve seating
surface (2) to the valve.
3. Using the proper angle specification listed in engine mechanical specifications, refer to Engine Mechanical Specifications, grind, undercut, the valve
seats (3) to narrow the valve seat widths to the specifications, refer to Engine Mechanical Specifications.
4. If the original valve is being used, grind the valve to the specifications, refer to Engine Mechanical Specifications. Measure the valve margin again after
grinding using the Valve Margin Measurement Procedure. Replace the valve if the margin is out of specification. New valves do not require grinding.
5. When grinding the valves and seats, grind off as little material as possible. Cutting valve seat results in lowering the valve spring pressure.
6. Install the valve in the cylinder head.
If you are using refaced valves, lap the valves into the seats with a fine grinding compound. The refacing and reseating operations should leave the
refinished surfaces smooth and true so that minimal lapping is required. Excessive lapping will groove the valve face and prevent a good seat when hot.
Note: Be sure to clean any remaining lapping compound from the valve and seat with solvent and compressed air prior to final assembly.
If you are using new valves, do not lap the valves under any condition.
After obtaining the proper valve seat width in the cylinder head, you must re-measure the valve stem height using the Valve Stem Height Measurement
Procedure.
If the valve stem height is acceptable, test the seats for concentricity using the Valve-to-Seat Concentricity Measurement Procedure.
Valve Stem Height Measurement Procedure
Note: To determine the valve stem height measurement, measure from the valve spring seat to the valve spring retainer.
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1. Install the valve into the valve guide.

2. Ensure the valve is seated to the cylinder head valve seat.
3. Install the valve stem oil seal.
4. Install the valve spring retainer and valve stem locks.
5. Measure the distance (1) between the cylinder head to the bottom of the valve spring retainer. Refer to Engine Mechanical Specifications.
6. If the maximum height specification is exceeded, a new valve should be installed and the valve stem height re-measured.
Caution: DO NOT grind the valve stem tip. The tip of the valve is hardened and grinding the tip will eliminate the hardened surface causing premature
wear and possible engine damage.
Caution: DO NOT use shims in order to adjust valve stem height. The use of shims will cause the valve spring to bottom out before the camshaft lobe is
at peak lift and engine damage could result.
7. If the valve stem height still exceeds the maximum height specification, the cylinder head must be replaced.
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Valve Rocker Arm Replacement

Removal Procedure

2. Remove the 16 valve rocker arms with the hydraulic valve lash adjusters (1).
Note: Unclip the valve lifter from valve rocker arm in direction as shown (arrow). Mind to the centering link on retaining spring (3).
3. Remove the 16 valve rocker arms (1) from the hydraulic valve lash adjusters (2).
Note: Clip in the valve rocker arm to the valve lifter. Mind to the centering link on the retaining spring (3).
1. Install the 16 valve rocker arms (1) to the hydraulic valve lash adjusters (2).
2. Coat the 16 hydraulic valve lash adjusters with engine oil.
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Valve Rocker Arm Replacement
Note: If the hydraulic valve lash adjusters are beeing reused, the hydraulic valve lash adjusters must be installed in their original position.
3. Install the 16 valve rocker arms (1) with the hydraulic valve lash adjusters.
4. Install the intake camshaft. Refer to Intake Camshaft Replacement.
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Valve Spring Inspection and Measurement

Special Tool
GE-22738-B Valve Spring Tester
Inspection Procedure
1. Clean the valve springs in solvent.
Warning: Wear safety glasses in order to avoid eye damage.

2. Dry the valve springs with compressed air.
3. Inspect the valve springs for broken coils or coil ends.
Measurement Procedure
1. Measure the tension of the valve spring using the GE-22738-B tester . Refer to Engine Mechanical Specifications.
2. If low valve spring load is found, replace the valve springs. DO NOT use shims to increase spring load. The use of shims can cause the valve spring to
bottom out before the camshaft lobe is at peak lift.
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Valve Stem Oil Seal and Valve Spring Replacement

Special Tools
EN-46116 Remover / Installer Stem Seal

EN-47632 Cleaning Tool
EN-49074 Compressor - Universal Valve Spring
EN-50453 Adapter - Air Compression
For equivalent regional tools refer to Special Tools.
Removal Procedure
1. Remove the 16 valve rocker arms. Refer to Valve Rocker Arm Replacement.
Caution: Refer to EN-47632 Cleaning Tool Rotation Caution.

2. Clean the injector sealing surfaces in the cylinder head, using the EN-47632 cleaning tool (1) in following procedure:
first take the brush side to loosen the dirt.

second take the sponge side to remove the dirt.
Install the EN-50453 adapter (1) to cylinder 1.

Install the fuel injector bracket (2).
Install the fuel injector bracket bolt (3) and tighten the bolt to 20 Y (15 lb ft).
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Install the EN-49074 compressor (1) with the EN-48247 adapter (2).

Note: The following step will hold the valve seated and keep it from falling into the cylinder.
Connect the compressed air hose to EN-50453 adapter.
Subject cylinder 1 with compressed air.
Note: The EN-48247 adapter must be applied parallel to the valve retainers in order to prevent damage to the tools or the valve train components.
Press down the valve spring and the upper valve spring retainer until the valve keys are discharged from spring load. Remove the valve keys.
Remove the valve spring retainer and valve spring.
Remove the valve stem oil seals. Use the EN-46116 remover / installer (1).
1. Install the NEW valve stem oil seals. Use the EN-46116 remover / installer (1).
2. Install the valve spring retainer and valve spring.
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Note: Ensure that the cylinder is subject with compressed air.

3. Push the EN-49074 compressor (1) with the EN-48247 adapter slightly down until the valve keys are engaged in evidence.
4. Disconnect the compressed air hose from EN-50453 adapter.
5. Repeat the procedure for the cylinder 2, 3 and 4.
6. Remove the EN-49074 compressor (1) with the EN-48247 adapter (2).
7. Remove fuel injector bracket bolt (3).

8. Remove the fuel injector bracket (2).
9. Remove EN-50453 adapter (1) from cylinder 1.
10. Install the 16 valve rocker arms. Refer to Valve Rocker Arm Replacement.
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Charge Air Cooler Inlet Hose Replacement (2.0L Diesel LNP)

Removal Procedure
1. Remove the battery cover. Refer to Battery Cover Replacement.

3. Remove the 2 charge air cooler inlet hose nuts (1).

4. Remove the charge air cooler inlet hose (3) from the turbocharger and remove the gasket (2).
5. Remove the intake air duct. Refer to Intake Air Duct Replacement.
6. Disconnect the air conditioning refrigerant pressure sensor wiring harness plug from the air conditioning condenser.
7. Unclip the 2 radiator protector fenders (2) from the radiator (1).
8. Remove the 3 power steering fluid cooling pipe loop bracket hose clamp nuts (2, 4).
9. Remove the 2 power steering fluid cooling pipe loop bracket bolts (3, 6).
10. Remove the 2 power steering fluid cooling pipe loop brackets (1).
11. Remove the radiator air seal.
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12. Remove the charge air cooler inlet hose (1) from the charge air cooler (2).
13. Remove the radiator upper brackets. Refer to Radiator Upper Bracket Replacement.
14. Unclip the air conditioning condenser (2) from the charge air cooler.
15. Hang the air conditioning condenser (2) aside and secure with safety belts.
Note: Move the radiator forward to remove the charge air cooler inlet hose.
16. Remove the charge air cooler inlet hose (1) downwards from the vehicle.
Note: Move the radiator forward to install the charge air cooler inlet hose.
1. Position the charge air cooler inlet hose (1) to the vehicle.
2. Install the air conditioning condenser (2) to the charge air cooler.
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3. Install the charge air cooler inlet hose (1) to the charge air cooler (2).
4. Install the radiator upper brackets. Refer to Radiator Upper Bracket Replacement.

5. Install the 2 power steering fluid cooling pipe loop brackets (1).
6. Install the 2 power steering fluid cooling pipe loop bracket bolts (3, 6) and tighten to 9 Y (80 lb in).
7. Install the 3 power steering fluid cooling pipe loop bracket hose clamp nuts (2, 4) and tighten to 9 Y (80 lb in).
8. Install the radiator air seal.
9. Clip in the 2 radiator protector fenders (2) to the radiator (1).

10. Connect the air conditioning refrigerant pressure sensor wiring harness plug to the air conditioning condenser.
11. Install the intake air duct. Refer to Intake Air Duct Replacement.
12. Install a NEW gasket (2).

13. Install the charge air cooler inlet hose (3) to the turbocharger.
14. Install the 2 charge air cooler inlet hose nuts (1) and tighten to 22 Y (16 lb ft).
15. Connect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection.
16. Install the battery cover. Refer to Battery Cover Replacement.
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Charge Air Cooler Outlet Hose Replacement (LNP and Automatic Transmission)

Removal Procedure
2. Remove the battery tray. Refer to Battery Tray Replacement.
3. Remove the engine control module. Refer to Engine Control Module Replacement.
4. Remove the radiator surge tank. Refer to Radiator Surge Tank Replacement.
5. Unclip the engine wiring harness retaining clip from the charge air cooler outlet front hose.
6. Unclip the transmission vent hose from the charge air cooler outlet front hose.
7. Remove the charge air cooler outlet front hose bracket bolt (2).
8. Loosen the charge air cooler outlet front hose to rear hose clamp (4).
9. Detach the charge air cooler outlet front hose (1) along with the clamp (4) from the charge air cooler outlet rear hose (3).
10. Unclip the 2 wiring harness retaining clips from the charge air cooler outlet rear hose (2).
11. Place a suitable tool at the rabbet (1) and rotate the lock ring counterclockwise.
12. Detach the charge air cooler outlet rear hose (2) from the throttle body (3).
13. Remove the charge air cooler outlet rear hose (2).
14. Disconnect the exhaust temperature sensor wiring harness plug (5).

15. Unclip the heated oxygen sensor wiring harness plug (3) from the retainer clip (4) and disconnect the heated oxygen sensor wiring harness plug (3).
16. Disconnect the exhaust pressure differential sensor hose wiring harness plug (2).
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19. Unclip the 2 wiring harness clips (1) from the wiring harness bracket.
20. Remove the upper radiator brackets. Refer to Radiator Upper Bracket Replacement.
22. Remove the left radiator protector fender from the radiator.
23. Remove the charge air cooler inlet and outlet hose from the charge air cooler.
24. Remove the power steering fluid cooling pipe loop bracket bolts (2).
25. Hang the power steering fluid cooling pipe loop aside.
Note: Move the radiator forward to remove the charge air cooler outlet hose.
26. Remove the charge air cooler outlet hose (1) downwards from the vehicle.
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Note: Move the radiator forward to install the charge air cooler outlet hose.
1. Position the charge air cooler outlet hose (1) to the vehicle.

2. Install the power steering fluid cooling pipe loop.
3. Install the 2 power steering fluid cooling pipe loop bracket bolts (2) and tighten to 9 Y (80 lb in).
4. Install the charge air cooler inlet and outlet hose to the charge air cooler.
5. Install the left radiator protector fender to the radiator.
Note: Make sure that the retaining ring is locked.

8. Install the charge air cooler outlet rear hose (2) to the throttle body (3).
9. Clip in the 2 wiring harness retaining clips to the charge air cooler outlet rear hose (2).
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10. Install the charge air cooler outlet front hose (1) along with the clamp (4) to the charge air cooler outlet rear hose (3).
11. Install the charge air cooler outlet front hose bracket bolt (2) and tighten to 9 Y (80 lb in).
12. Tighten the charge air cooler outlet front hose tor rear hose clamp (4) to 4 Y (35 lb in).
13. Clip in the engine wiring harness retaining clip to the charge air cooler outlet front hose.
14. Clip in the 2 wiring harness clips (1) to the wiring harness bracket.
15. Connect the exhaust temperature sensor wiring harness plug (5).

16. Clip the heated oxygen sensor wiring harness plug (3) to the retainer clip (4) and connect the heated oxygen sensor wiring harness plug (3).
17. Connect the exhaust pressure differential sensor hose wiring harness plug (2).
18. Clip in the transmission vent hose to the charge air cooler outlet front hose.
19. Install the radiator surge tank. Refer to Radiator Surge Tank Replacement.
20. Install the engine control module. Refer to Engine Control Module Replacement.
21. Install the battery tray. Refer to Battery Tray Replacement.
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Charge Air Cooler Outlet Hose Replacement (LNP and Manual Transmission)

Removal Procedure
13. Remove the front bumper fascia. Refer to Front Bumper Fascia Removal and Installation.
14. Unclip the charge air cooler outlet hose (1) from the charge air cooler.
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2. Connect the charge air cooler outlet hose (1) to the charge air cooler.
3. Install the front bumper fascia. Refer to Front Bumper Fascia Removal and Installation.

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Charge Air Cooler Replacement (Diesel and LUJ with MT)

Removal Procedure

7. If equipped, remove the 3 power steering fluid cooling loop pipe bracket hose clamp nuts (2, 4).
8. If equipped, remove the 3 hose clamps (5).
9. If equipped, remove the 2 power steering fluid cooling loop pipe bracket bolts (3, 6).
10. If equipped, remove the 2 power steering fluid cooling loop pipe brackets (1).
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12. Remove the charge air cooler outlet hose (2) from the charge air cooler (1).
Note: Handle the cooling module with care.

13. Remove the condenser (3) from the charge air cooler (2) and secure with safety belts.
14. Remove the charge air cooler (2) in top direction from the radiator (1).

1. Install the charge air cooler (2) to the radiator (1).
2. Remove the safety belts and install the condenser (3) to the charge air cooler (2).
3. Install the charge air cooler outlet hose (2) to the charge air cooler (1).
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5. If equipped, install the 2 power steering fluid cooling loop pipe brackets (1).
6. If equipped, install the 2 power steering fluid cooling loop pipe bracket bolts (3, 6) and tighten to 9 Y (80 lb in).
7. If equipped, install the 3 hose clamps (5).
8. If equipped, install the 3 power steering fluid cooling loop pipe bracket hose clamp nuts (2, 4) and tighten to 9 Y (80 lb in).

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Coolant System Flushing

Note: Do not use a chemical flush.

Store used coolant in the proper manner, such as in a used engine coolant holding tank.
Do not pour used coolant down a drain. Ethylene glycol antifreeze is a very toxic chemical.
Do not dispose of coolant into the sewer system or ground water. This is illegal and ecologically unsound.
Various methods and equipment can be used to flush the cooling system. If special equipment is used, such as a back flusher, follow the manufactures instruction.
However, always remove the thermostat before back flushing the system.
1. Apply the park brake.

2. Drain the coolant. Refer to Cooling System Draining and Filling.
3. Fill the coolant system with clean drinkable water. Refer to Cooling System Draining and Filling.
4. Start the engine and run at 2,000 RPM until the thermostat opens.
5. Turn OFF the engine.
6. Drain the coolant system. Refer to Cooling System Draining and Filling.
7. Repeat the above procedure until the water from the coolant system is colorless.
8. Drain the coolant system. Refer to Cooling System Draining and Filling.
9. Add 3.8 liters (1.0 gal) of concentrated antifreeze since there will be some water in the system.
10. Add a mixture of 50/50 antifreeze and clean drinkable water until the level stabilizes at the weld seam on the surge tank. Refer to Cooling System Draining and
Filling.
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Cooling System Description and Operation (2.0L Diesel LNP)

Cooling System
The cooling system’s function is to maintain an efficient engine operating temperature during all engine speeds and operating conditions. The cooling system is
designed to remove approximately one-third of the heat produced by the burning of the air-fuel mixture. When the engine is cold, the coolant does not flow to the
radiator until the thermostat opens. This allows the engine to warm quickly. Refer to the following illustration for the components in the system and the basic flow
path of the coolant.
The cooling system consists of the following components:
The Water Pump (1)

The Engine Oil Cooler (2)
The Heater (3)
The Surge Tank (4)
The EGR Cooler (5)
The Water Pipe (6)
Transaxle (7)
Auxiliary Cooling Fan (8)
Intake Manifold (9)
Main Cooling Fan (10)
Thermostat (11)
Water Pump
Water pump is a component of the engine cooling system and circulated the coolant from each cooling circuit components. This water pump consists of gasket,
bearing, pulley (1), housing (2) and impeller (3) and is driven by the drive belt with the back of drive belt to loose noise to water pump pulley. Water pump apply
drain hole cup to cap to prevent coolant leakage for customers.
Thermostat
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Cooling System Description and Operation (2.0L Diesel LNP)
Thermostat controls coolant flowing and is assembled on the water pump housing. By coolant temperature, the wax-pellet (7) of the thermostat expanded and
shrunk mechanically main spring to flow the coolant. The thermostat begins to open at 80°C (176°F) and fully open at 95°C (203°F). The thermostat closes at
75°C (167°F).
Radiator
The radiator is a heat exchanger. It consists of a core and 2 tanks. The aluminum core is a tube and fin cross-flow design that extends from the inlet tank to the
outlet tank. Fins are placed around the outside of the tubes to improve heat transfer to the atmosphere. The inlet and outlet tanks are a molded, high temperature,
nylon reinforced plastic material. A high temperature rubber gasket seals the tank flange edge to the aluminum core. The tanks are clamped to the core with clinch
tabs. The tabs are part of the aluminum header at each end of the core. The radiator also has a drain cock located in the bottom of the right hand tank. The drain
cock unit includes the drain cock and drain cock seal. The radiator removes heat from the coolant passing through it. The fins on the core transfer heat from the
coolant passing through the tubes. As air passes between the fins, it absorbs heat and cools the coolant.
Surge Tank
The surge tank is a plastic tank with a threaded pressure cap. The tank is mounted at a point higher than all other coolant passages. The surge tank provides an
air space in the cooling system that allows the coolant to expand and contract. The surge tank provides a coolant fill point and a central air bleed location. During
vehicle use, the coolant heats and expands. The increased coolant volume flows into the surge tank. As the coolant circulates, any air is allowed to bubble out.
Coolant without air bubbles absorbs heat much better than coolant with bubbles.
Cooling Fan
The cooling fans are mounted behind the radiator in the engine compartment. The engine cooling fan is driven by electric power. The cooling fan draws air through
the radiator to improve the transfer of heat from the coolant to the atmosphere. As the fan blades spin, they increase the flow of air across the radiator core and
across the condenser on air condition (A/C) equipped vehicles. This helps to speed cooling when the vehicle is at idle or moving at low speeds.
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Cooling System Draining and Filling

Warning: With a pressurized cooling system, the coolant temperature in the radiator can be considerably higher than the boiling point of the solution at atmospheric
pressure. Removal of the surge tank cap, while the cooling system is hot and under high pressure, causes the solution to boil instantaneously with explosive force. This
will cause the solution to spew out over the engine, the fenders, and the person removing the cap. Serious bodily injury may result.
Note: Use only a GM released anti-freeze mixture and ensure a concentration of 50 percent water to 50 percent antifreeze. Antifreeze does not just prevent the cooling
system from freezing up, it also protects all the components that are in contact with coolant from rust/limescale deposits. As a result, antifreeze should always be added,
even in tropical countries.
In addition to the anti-freeze mixture, water quality also plays an important role. Potable tap water should normally suffice to fulfil this requirement. The quality of
regenerated sea water is not suitable.
Damage may also be caused to the engine if unauthorized anti-freeze agent is used.
If radiator, cylinder head or cylinder head seal have been replaced the old coolant must not be re-used.
Cooling System Draining
1. Open cooling system. Unscrew coolant surge tank cap.
2. For draining the cooling system, open the drain screw (1) on the radiator.
Cooling System Filling
1. Vehicles with air condition, switch air conditioning off.

2. After draining the system, close the drain screw on the radiator.
Note: Close vent screw when coolant flows out on the loosen vent screw.
3. Remove the vent screw (1) on radiator and turn in one thread again.
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Cooling System Draining and Filling
4. Top up coolant up to the bottom line of the bleed nozzle on the coolant surge tank (1).
When the coolant has stopped dropping top up the coolant until the bottom line of the down pipe hole (black arrow).
5. Start the Engine
Note: After Engine Start top up coolant immediately until the bottom line of the down pipe hole (black arrow) and close cap.
Note: After removing the heater core (located in passenger room) the following additional work has to be done:
Kick the accelerator pedal 3 times immediately – thereby the engine speed should not exceed 2500 RPM.
6. Warm up the engine.
Note: After removing the heater core (located in passenger room) let the engine run for further 2 minutes at 2.000–2.500 RPM. This ensures
complete venting of the cooling system.
7. Vent cooling system
Kick the accelerator pedal 3 times – thereby the engine speed should not exceed 2.500 RPM.
8. Switch the engine off and let the engine cool down.
9. Check coolant level and correct the coolant to welding area (1) if necessary.
10. After a test drive let the engine cool down and check the coolant level again. Adjust the coolant level to welding area (1) if necessary.
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Engine Coolant Air Bleed Hose Replacement (2.0L Diesel LNP)

Engine Coolant Air Bleed Hose Replacement
Warning: To avoid being burned, do not remove the radiator cap or surge tank cap while the engine is hot. The cooling system will release scalding
fluid and steam under pressure if radiator cap or surge tank cap is removed while the engine and radiator are still hot.
1. Remove/Install the engine sight shield. Refer to Engine Sight Shield Replacement.
Engine Coolant Air Bleed Hose Clamp (Qty: 2)

1 Procedure
Place a collecting basin underneath.
2 Engine Coolant Air Bleed Hose
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Engine Coolant Fan Replacement (2.0L Diesel LNP)

Removal Procedure
1. For vehicles with manual transmission – F40, remove the radiator. Refer to Radiator Replacement.
2. For vehicles with automatic transmission – 6T45, remove the engine coolant fan shroud. Refer to Engine Coolant Fan Shroud Replacement.
Note: For vehicles with manual transmission, the engine coolant fan shroud remains in the vehicle.
3. Unclip the 2 engine coolant fan wiring harnesses (1, 3) from the engine coolant fan shroud.
4. Unclip the 2 engine coolant fan resistor brackets (2) from the engine coolant fan shroud.
5. Remove the 6 engine coolant fan bolts (4) from the 2 engine coolant fans.
6. Remove the 2 engine coolant fans from the engine coolant fan shroud.
1. Install the 2 engine coolant fans to the engine coolant fan shroud.
2. Install the 6 engine coolant fan bolts (4) to the 2 engine coolant fans and tighten to 4 Y (35 lb in).
3. Clip the 2 engine coolant fan resistor brackets (2) into the engine coolant fan shroud.
4. Clip in the 2 engine coolant fan wiring harnesses (1, 3) to the engine coolant fan shroud.
5. For vehicles with manual transmission – F40, install the radiator. Refer to Radiator Replacement.
6. For vehicles with automatic transmission – 6T45, install the engine coolant fan shroud. Refer to Engine Coolant Fan Shroud Replacement.
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Engine Coolant Fan Resistor Mount Repair (Double Coolant Fan)

Engine Coolant Fan Resistor Mount Repair
Remove the engine cooling fan shroud. Refer to Engine Coolant Fan Shroud Replacement.
1 Engine Coolant Fan Resistor Mount
Engine Coolant Fan Resistor Mount Bolt

2
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Engine Coolant Fan Resistor Mount Repair (Single Coolant Fan)

Engine Coolant Fan Resistor Mount Repair
Remove the engine cooling fan shroud. Refer to Engine Coolant Fan Replacement.
1 Engine Coolant Fan Resistor Mount
Engine Coolant Fan Resistor Mount Bolt

Procedure
2
In case of a broken engine coolant fan resistor mount use this repair procedure.
Tighten
5 Y (44 lb in)
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Engine Coolant Fan Shroud Replacement (2.0L Diesel LNP)

Removal Procedure
2. Remove the charge air cooler. Refer to Charge Air Cooler Replacement.
3. Remove the 2 upper radiator bracket bolts (1, 3).

4. Remove the 2 upper radiator brackets (2, 4).
5. Remove the radiator outlet hose from the radiator. Refer to Radiator Outlet Hose Replacement.
6. Unclip the wiring harness clip (8) from the engine coolant fan shroud.
7. Unclip the wiring harness from the engine coolant fan shroud holders (9) and hang the wiring harness aside.
8. Disconnect the 2 engine coolant fan motor wiring harness plugs (3, 5).
9. Unclip the wiring harness clip (4, 7) from the engine coolant fan shroud.
10. Unclip the wiring harness from the engine coolant fan shroud holders (6).
11. Hang the engine coolant fan shroud wiring harness aside.
12. Remove the engine coolant fan shroud (1) in top direction from the 4 radiator clips (2, 3).
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Note: Ensure that the air conditioning condenser (3) is secured with safety belts.
13. Remove the radiator (2) from the radiator lower brackets (4) in top direction and tipping the radiator forward.
14. Remove the engine coolant fan shroud (1) in top direction from the vehicle.
15. Unclip the 2 engine coolant fan wiring harnesses (1, 3) from the engine coolant fan shroud.
16. Unclip the 2 engine coolant fan connectors (2) from the engine coolant fan shroud.
17. Remove the 6 engine coolant fan bolts (4) from the 2 engine coolant fans.
18. Remove the 2 engine coolant fans from the engine coolant fan shroud.
1. Install the 2 engine coolant fans to the engine coolant fan shroud.

2. Install the 6 engine coolant fan bolts (4) to the 2 engine coolant fans and tighten to 4 Y (35 lb in).
3. Clip the 2 engine coolant fan connectors (2) into the engine coolant fan shroud.
4. Clip in the 2 engine coolant fan wiring harnesses (1, 3) to the engine coolant fan shroud.
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5. Install the engine coolant fan shroud (1) to the vehicle.

6. Install the radiator (2) to the radiator lower brackets.
7. Install the engine coolant fan shroud (1) to the 4 radiator clips (2, 3).
8. Install and position the engine coolant fan shroud wiring harness.
9. Clip in the wiring harness to the engine coolant fan shroud holders (6).
10. Clip the wiring harness clip (4, 7) into the engine coolant fan shroud.
11. Connect the 2 engine coolant fan motor wiring harness plugs (3, 5).
12. Clip the wiring harness into the engine coolant fan shroud holders (9).
13. Clip the wiring harness clip (8) into the engine coolant fan shroud.
14. Install the radiator outlet hose to the radiator. Refer to Radiator Outlet Hose Replacement.
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15. Install the 2 upper radiator brackets (2, 4).

16. Install the 2 upper radiator bracket bolts (1, 3) and tighten to 22 Y (16 lb ft).
17. Install the charge air cooler. Refer to Charge Air Cooler Replacement.
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Engine Coolant Fan Wiring Harness Replacement (2.0L Diesel LNP)

Removal Procedure
1. Open the hood.

4. Disconnect the 2 engine control module wiring harness plugs (1) from the engine control module (2).
5. Remove the engine control module bracket (2) along with the engine control module (1) from the battery tray (3).
8. Disconnect the air conditioning refrigerant pressure sensor wiring harness plug (1).
10. Remove the engine compartment insulator. Refer to Front Compartment Insulator Replacement.
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11. Slide the CRFM module box (2) to the right and remove the CRFM module box from the bracket.
12. Disconnect the 4 wiring harness connectors (1, 3).
13. Unclip the wiring harness clip (8) from the engine coolant fan shroud.
14. Unclip the wiring harness from the engine coolant fan shroud holders (9). Hang the wiring harness aside.
16. Remove the wiring harness ground cable nut (2) and the wiring harness ground cable (1).
17. Disconnect the 2 engine coolant fan motor wiring harness plugs (3, 5).
18. Unclip the wiring harness clip (4, 7) from the engine coolant fan shroud.
19. Unclip the wiring harness from the engine coolant fan shroud holders (6).
20. Remove the engine coolant fan shroud wiring harness from the vehicle.
1. Install and position the engine coolant fan shroud wiring harness plug.
2. Clip the wiring harness to the engine coolant fan shroud holders (6).
3. Clip the wiring harness clip (4, 7) to the engine coolant fan shroud.
4. Connect the 2 engine coolant fan motor wiring harness plugs (3, 5).
5. Install the wiring harness ground cable (1) and the wiring harness ground cable nut (2) and tighten to 9 Y (80 lb in).
6. Raise the vehicle.
7. Clip the wiring harness to the engine coolant fan shroud holders (9).
8. Clip the wiring harness clip (8) to the engine coolant fan shroud.
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9. Connect the 4 wiring harness connectors (1, 3).

10. Install the CRFM module box (2) to the bracket and slide the CRFM module box to the left until it stops.
11. Install the engine compartment insulator. Refer to Front Compartment Insulator Replacement.
13. Connect the air conditioning refrigerant pressure sensor wiring harness plug (1).
16. Install the engine control module bracket (2) along with the engine control module (1) to the battery tray (3).
17. Connect the 2 engine control module wiring harness plugs (1) to the engine control module (2).
20. Close the hood.
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Engine Coolant Inlet Hose Replacement (2.0L Diesel LNP)

Removal Procedure
5. Remove the exhaust particulate filter. Refer to Exhaust Particulate Filter Replacement.
6. Remove the 2 thermostat bypass pipe bolts (1) from the thermostat bypass pipe bracket (2).
7. Loosen the water pump inlet hose clamp and the thermostat bypass hose clamp (1) from the thermostat bypass pipes.
8. Loosen the engine coolant inlet hose clamp from the thermostat bypass pipe and move the thermostat bypass pipes along with the thermostat bypass
pipe bracket (2) aside (see arrow).
9. Remove the 2 engine coolant inlet hose clamps (3) and the engine coolant inlet hose (4) from the water pump.
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Engine Coolant Inlet Hose Replacement (2.0L Diesel LNP)
1. Install the engine coolant inlet hose (4) to the water pump and position the 2 engine coolant inlet hose clamps (3).
2. Position the water pump inlet hose clamp and the thermostat bypass hose clamp (1).
3. Install the thermostat bypass pipes along with the thermostat bypass pipe bracket (2) to the 3 hoses and position the clamps (1, 3).

4. Install the 2 thermostat bypass pipe bolts (1) to the thermostat bypass pipe bracket (2) and tighten to 22 Y (16 lb ft).
5. Install the exhaust particulate filter. Refer to Exhaust Particulate Filter Replacement.
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Engine Coolant Temperature Sensor Replacement (Radiator)

Engine Coolant Temperature Sensor Replacement

1. Drain the cooling system. Refer to Cooling System Draining and Filling
2. Disconnect the electrical connection.
1 Retaining Clamp
2 Engine Coolant Temperature Sensor
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Engine Coolant Temperature Sensor Replacement (Thermostat Housing)


1 Engine Coolant Temperature Sensor Fastener
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Engine Coolant Thermostat Housing Caution

Caution: Use care when performing this procedure. Use of excessive force may damage the coolant thermostat.
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Engine Coolant Thermostat Housing Cover Replacement

Removal Procedure
2. Drain the engine cooling system. Refer to Cooling System Draining and Filling.
3. Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement.
5. Remove the 3 power steering pump retaining bolts. Hang the pump aside.
6. Remove the radiator outlet hose clamp from the thermostat housing.
7. Remove the radiator outlet hose from the thermostat housing.
8. Remove the 2 bolts (4). Remove the thermostat housing (3).
1. Inspect the seal ring (1) for damages or cracks. Install a NEW seal ring (1) if necessary.
2. Install the thermostat housing (3) and the 2 thermostat housing retaining bolts (4). Tighten the bolts (4) to 10 Y (89 lb in).
3. Install the radiator outlet hose to the thermostat housing.
4. Install the radiator outlet hose clamp to the thermostat housing.
5. Install the power steering pump to the water pump housing. Install the 3 power steering pump retaining bolts. Tighten the bolts to 22 Y (16 lb ft).
7. Install the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement.
8. Fill the engine cooling system. Refer to Cooling System Draining and Filling.
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Engine Coolant Thermostat Housing Installation

1. Install the thermostat (2) and a NEW seal ring (1).

2. Install the thermostat housing (3) and the 2 thermostat housing retaining bolts (4) and tighten to 10 Y (89 lb in).
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Engine Coolant Thermostat Housing Installation

Caution: Refer to Engine Coolant Thermostat Housing Caution.

2. Install a NEW engine coolant thermostat housing seal.
3. Install the engine coolant thermostat housing (2).

Note: Screw in the 4 bolts until the engine coolant thermostat housing is in contact with the cylinder head.
4. Install the 4 engine coolant thermostat housing bolts (3) and tighten to 2 Y (18 lb in).
Caution: Following the proper fastener tightening sequence and torque is essential. Failure to do so may fracture the thermostat housing.
5. Tighten the 4 engine coolant thermostat housing bolts to 8 Y (71 lb in) in sequence (1–2–3–4).
6. Install the engine coolant thermostat housing retainer (1).

7. Install the engine coolant thermostat housing retainer nut (4) and tighten to 6 Y (53 lb in).
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Engine Coolant Thermostat Housing Removal


1. Remove the engine coolant thermostat housing retainer nut (4).
2. Remove the engine coolant thermostat housing retainer (1).
3. Remove the 4 engine coolant thermostat housing bolts (3).
4. Remove the engine coolant thermostat housing (2).
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Engine Coolant Thermostat Housing Removal

1. Remove the 2 thermostat housing bolts (4).

2. Remove the thermostat housing (3).
3. Remove the thermostat (2).
4. Remove the thermostat seal ring (1).
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Engine Coolant Thermostat Housing Replacement (2.0L Diesel LNP)

Removal Procedure
1. Unclip the 3 wiring harness clips (2).

2. Remove the engine wiring harness bracket nut (3).
3. Remove the engine wiring harness bracket (1).
5. Place collecting basin underneath.
8. Loosen the radiator inlet hose clamp (4).

9. Remove the radiator inlet hose (3) from the engine coolant thermostat (5).
10. Remove the throttle body heater inlet hose (2) from the engine coolant thermostat (1).
11. Remove the heater inlet hose from the engine coolant thermostat housing. Refer to Heater Inlet Hose Replacement.
12. Remove the heater outlet hose from the engine coolant thermostat housing. Refer to Heater Outlet Hose Replacement.
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13. Disconnect the engine coolant temperature sensor connector (1).

14. Remove the 2 engine oil cooler pipe bolts (6).
Note: Pull the engine oil cooler pipe out of the engine oil cooler.
15. Remove the engine oil cooler pipe (5).
16. Remove the engine oil cooler pipe seals (4, 7).
17. Remove the 4 engine coolant thermostat housing bolts (3).
19. Remove the thermostat housing seal (8).
2. Install a NEW engine coolant thermostat housing seal (8).

3. Install the engine coolant thermostat housing (2).
Note: Carefully install the 4 bolts until the engine coolant thermostat housing is in contact with the cylinder head.
4. Install the 4 engine coolant thermostat housing bolts (3) and tighten to 2 Y (18 lb in).
Caution: Following the proper fastener tightening sequence and torque is essential. Failure to do so may fracture the thermostat housing.
5. Tighten the 4 engine coolant thermostat housing bolts to 8 Y (71 lb in)in sequence (1-2-3-4).
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6. Install NEW engine oil cooler pipe seals (4, 7).

Note: Push the engine oil cooler pipe into the engine oil cooler.
7. Install the engine oil cooler pipe (5).
8. Install the 2 engine oil cooler pipe bolts (6) and tighten to 8 Y (71 lb in).
9. Install the heater outlet hose to the engine coolant thermostat housing. Refer to Heater Outlet Hose Replacement.
10. Install the heater inlet hose to the engine coolant thermostat housing. Refer to Heater Inlet Hose Replacement.
11. Connect the engine coolant temperature sensor connector (1).
12. Install the throttle body heater inlet hose (2) to the engine coolant thermostat housing (1).
13. Install the radiator inlet hose (3) to the engine coolant thermostat (5).
14. Install the radiator inlet hose clamp (4).
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16. Install the engine wiring harness bracket (1).

17. Install the engine wiring harness bracket nut (3) and tighten to 6 Y (53 lb in).
18. Clip in the 3 wiring harness clips (2).
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Engine Coolant Thermostat Installation


1. Clean the engine coolant sealing surfaces.
2. Install the engine coolant seal (1).

3. Install the engine coolant thermostat assembly (2).
4. Install the 4 engine coolant thermostat bolts (3) and tighten to 8 Y (71 lb in).
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Engine Coolant Thermostat Removal


1. Remove the 4 engine coolant thermostat bolts (3).
2. Remove the engine coolant thermostat assembly (2).
3. Remove the engine coolant seal (1).
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Engine Coolant Thermostat Replacement (2.0L Diesel LNP)

Removal Procedure
6. Remove the 3 power steering pump retaining bolts. Refer to Power Steering Pump Replacement. Hang the pump aside.
7. Remove the radiator outlet hose clamp from the thermostat housing.
8. Remove the radiator outlet hose from the thermostat housing.

11. Remove the thermostat (2) along with the seal ring (1).
1. Install the thermostat (2) and a NEW seal ring (1).

2. Install the thermostat housing (3).

3. Install the 2 thermostat housing retaining bolts (4) and tighten to 10 Y (89 lb in).
4. Install the radiator outlet hose to the thermostat housing.
5. Install the radiator outlet hose clamp to the thermostat housing.
6. Install the power steering pump to the water pump housing. Refer to Power Steering Pump Replacement.
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Engine Identification

Engine Number
The engine number is stamped to the engine block (1).

Note: The engine identification number must be stamped to the cylinder block in case of engine replacement.
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Engine Oil Cooler Outlet Hose Replacement (2.0L Diesel LNP)

Removal Procedure
7. Remove the engine oil cooler outlet hose clamp (2) and the engine oil cooler outlet hose (3) from the engine oil cooler (1).
9. Remove the charge air cooler outlet rear hose from the throttle body and the charge air cooler outlet front hose from the charge air cooler outlet front
hose bracket and hang it aside. Refer to Charge Air Cooler Outlet Hose Replacement.
10. Remove the throttle body. Refer to Throttle Body Assembly Replacement.
11. Remove the engine oil cooler outlet hose clamp (2) and the engine oil cooler outlet hose (3) from the thermostat bypass pipe (1).
12. Remove the engine oil cooler outlet hose (3).
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1. Reposition the engine oil cooler outlet hose (3).

2. Install the engine oil cooler outlet hose (3) with the engine oil cooler outlet hose clamp (2) to the thermostat bypass pipe (1).
3. Install the throttle body. Refer to Throttle Body Assembly Replacement.
4. Install the charge air cooler outlet rear hose to the throttle body and the charge air cooler outlet front hose to the charge air cooler outlet front hose
bracket. Refer to Charge Air Cooler Outlet Hose Replacement.
6. Install the engine oil cooler outlet hose (3) with the engine oil cooler outlet hose clamp (2) to the engine oil cooler (1).
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Engine Oil Cooler Replacement (2.0L Diesel LNP)

Removal Procedure
4. Remove the engine oil cooler outlet hose. Refer to Engine Oil Cooler Outlet Hose Replacement.
5. Remove the exhaust gas recirculation valve cooling feed hose. Refer to Exhaust Gas Recirculation Valve Cooling Feed Hose Replacement.
6. Remove the 8 engine oil cooler retaining bolts (3, 4).

7. Remove the engine oil cooler (2) along with the 2 engine oil cooler gaskets (1).
2. Install the engine oil cooler (2) along with 2 NEW engine oil cooler gaskets (1).
3. Install the 8 engine oil cooler retaining bolts (3, 4). Tighten the bolts to 25 Y (18 lb ft).
4. Install the engine oil cooler outlet hose. Refer to Engine Oil Cooler Outlet Hose Replacement.
5. Install the exhaust gas recirculation valve cooling feed hose. Refer to Exhaust Gas Recirculation Valve Cooling Feed Hose Replacement.
8. Fill in the engine oil. Refer to Engine Oil and Oil Filter Replacement.
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Engine Water Outlet Adapter Installation

1. Install the engine water adapter housing (2) and a NEW gasket.

2. Install the 4 engine water outlet adapter bolts (1) and tighten to 10 Y (89 lb in).
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Engine Water Outlet Adapter Removal

1. Remove the 4 engine water outlet housing bolts (1).

2. Remove the engine water outlet housing (2).
Note: Replace the engine water outlet housing seal if it is porous or cracked.
3. Inspect the engine water outlet seal.
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Engine Water Outlet Adapter Replacement (2.0L Diesel LNP)

Removal Procedure
9. Remove the charge air cooler outlet front hose from the charge air cooler outlet front hose bracket. Remove the charge air cooler outlet front hose from
the charge air cooler outlet rear hose and hang it aside. Refer to Charge Air Cooler Outlet Hose Replacement.
10. Unclip the 2 engine wiring harness retaining clips from the engine wiring harness bracket.
11. Remove the 2 engine wiring harness bracket and engine water outlet adapter bolts (2) from the engine water outlet adapter.
12. Remove the engine wiring harness bracket (1) from the engine water outlet adapter.
13. Remove the radiator inlet hose (1) with the radiator inlet hose clamp (2) from the engine water outlet adapter (3).
14. Remove the heater inlet hose (4) with the heater inlet hose clamp (5) from the engine water outlet adapter (3).
15. Remove the thermostat bypass hose (7) with the thermostat bypass hose clamp (6) from the engine water outlet adapter (3).
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16. Disconnect the engine coolant temperature sensor wiring harness plug (4) from the engine coolant temperature sensor (3).
17. Remove the 2 engine water outlet adapter bolts (5).
18. Remove the engine water outlet adapter (1) and the engine water outlet adapter gasket (6) from the engine.
19. Remove the engine coolant temperature sensor (3) and the engine coolant temperature sensor seal ring (2) from the engine water outlet adapter (1).

1. Preinstall the engine coolant temperature sensor (3) with a NEW engine coolant temperature sensor seal ring (2) to the engine water outlet adapter (1)
and tighten the sensor to 13 Y (115 lb in).
2. Install the engine water outlet adapter (1) with a NEW engine water outlet adapter gasket (6) to the engine.
3. Install the 2 engine water outlet adapter bolts (5) to the engine water adapter (1) and tighten to 10 Y (89 lb in).
4. Connect the engine coolant temperature sensor wiring harness plug (4) to the engine coolant temperature sensor (3).
5. Install the thermostat bypass hose (7) with the thermostat bypass hose clamp (6) to the engine water outlet adapter (3).
6. Install the heater inlet hose (4) with the heater inlet hose clamp (5) to the engine water outlet adapter (3).
7. Install the radiator inlet hose (1) with the radiator inlet hose clamp (2) to the engine water outlet adapter (3).
8. Install the engine wiring harness bracket (1) to the engine water outlet adapter.
9. Install the 2 engine wiring harness bracket and engine water outlet adapter bolts (2) to the engine water outlet adapter and tighten to 10 Y (89 lb in).
10. Clip the 2 engine wiring harness retaining clips into the engine wiring harness bracket.
11. Install the charge air cooler outlet front hose to the charge air cooler outlet front hose bracket. Install the charge air cooler outlet front hose to the
charge air cooler outlet rear hose. Refer to Charge Air Cooler Outlet Hose Replacement.
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Exhaust Gas Recirculation Manifold Cooling Return Hose Replacement (2.0L Diesel LNP)

Removal Procedure
5. If equipped, disconnect the automatic transmission hose from the radiator surge tank mount.
6. Remove the radiator surge tank clip. Refer to Radiator Surge Tank Replacement. Hang the radiator surge tank aside.
7. Remove the charge air cooler outlet hose. Refer to Charge Air Cooler Outlet Hose Replacement.
/.
8. Remove the 2 clamps (1).

9. Remove the exhaust gas recirculation manifold cooling return hose (2).
/.
1. Install the exhaust gas recirculation manifold cooling return hose (2).

2. Install the 2 clamps (1).
3. Install the charge air cooler outlet hose. Refer to Charge Air Cooler Outlet Hose Replacement.
4. Clip the radiator surge tank into the mount. Refer to Radiator Surge Tank Replacement.
5. If equipped, connect the automatic transmission hose clip to the radiator surge tank mount.
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Exhaust Gas Recirculation Valve Cooling Feed Hose Replacement

Removal Procedure

4. Remove the exhaust gas recirculation valve cooling feed hose (4).
1. Install the exhaust gas recirculation valve feed hose (4).

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Radiator and Charge Air Cooler Bracket Repair

1. Remove the radiator. Refer to Radiator Replacement.

3. Drill hole in the charge air cooler bracket and radiator bracket (2) using a 7 mm (0.28 in)drill.
4. Install the j-clip (3) to the radiator.
5. Install the radiator. Refer to Radiator Replacement.
6. Install the charge air cooler to the radiator. Refer to Charge Air Cooler Replacement.
7. Install the repair bolt (1) with locking compound and tighten to 5 Y (45 lb in).
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Radiator Cleaning

Warning: NEVER spray water on a hot heat exchanger. The resulting steam could cause personal injury.
Caution: The heat exchanger fins are necessary for good heat transfer. Do not brush the fins. This may cause damage to the fins, reducing heat transfer.
Note: Remove bugs, leaves, dirt and other debris by blowing compressed air through the engine side of the radiator.
Some conditions may require the use of warm water and a mild detergent.
Clean the A/C condenser fins.
Clean between the A/C condenser and radiator.
Clean the radiator cooling fins.
Straighten any damaged cooling fins.
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Radiator Drain Cock Replacement

Radiator Drain Cock Replacement
Warning: With a pressurized cooling system, the coolant temperature in the radiator can be considerably higher than the boiling point of the solution at
atmospheric pressure. Removal of the surge tank cap, while the cooling system is hot and under high pressure, causes the solution to boil
instantaneously with explosive force. This will cause the solution to spew out over the engine, the fenders, and the person removing the cap. Serious
bodily injury may result.
Drain the cooling system. Refer to Cooling System Draining and Filling.
1 Radiator Drain Cock
2 Radiator Drain Cock Seal Ring
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Radiator Inlet Hose Replacement (2.0L Diesel LNP)

Radiator Inlet Hose Replacement

Radiator Inlet Hose Clamp (Qty: 2)

1 Procedure
Reposition the 2 radiator inlet hose clamps.
2 Radiator Inlet Hose
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Radiator Lower Bracket Replacement

Radiator Lower Bracket Replacement

2. Remove the charge air cooler inlet and outlet hose from the charge air cooler. Refer to Charge Air Cooler Inlet Hose Replacement and
Charge Air Cooler Outlet Hose Replacement.
Power Steering Fluid Cooling Pipe Bracket Bolt

Procedure
1
Remove bolt if power steering fluid cooling pipe is equipped.
Tighten
9 Y (80 lb in)
Radiator Lower Bracket Bolt (Qty: 2)
Procedure
2 Secure the radiator.
Tighten
22 Y (16 lb ft)
3 Radiator Lower Bracket
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Radiator Mounting Stud Repair

Repair Procedure
1. Pressure test the cooling system. Refer to Cooling System Leak Testing. If the radiator is not leaky, perform the following procedure.
3. Grind the fracture surface (1) with a proper tool.

4. Drill a hole in the center of the fractured surface, using a 6 mm (0.24 in)drill.
__
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5. Install the new radiator mounting pin (2).
Install the nut (3).

Note: The bolt should not be longer than 35 mm (1.38 in).
Install the radiator mounting pin (2) with the bolt (1).
Tighten the bolt 5 Y (44 lb in).
Install the radiator. Refer to Radiator Replacement.
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Radiator Outlet Hose Replacement (2.0L Diesel LNP)

Radiator Outlet Hose Replacement

3. Remove the air cleaner outlet front duct and the air cleaner outlet rear duct. Refer to Air Cleaner Outlet Duct Replacement.
Radiator Outlet Hose Clamp (Qty: 2)
1 Procedure
Reposition the 2 radiator inlet hose clamps.
2 Radiator Outlet Hose
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Radiator Replacement (2.0L Diesel LNP - AT)

Removal Procedure

7. Remove the radiator support bracket insulators.
8. Remove the radiator outlet hose clamp (2) and the radiator outlet hose (3) from the radiator.
9. Remove the radiator inlet hose clamp (5) and the radiator inlet hose (4) from the radiator (1).
10. Remove the safety rings and remove the upper and lower transmission fluid pipes (1, 6) with the transmission fluid pipe seal rings (7) from the radiator.
11. Remove the engine coolant fan shroud (1) in top direction from the 4 radiator clips (2, 3) and place it inside the vehicle.
Note: The engine coolant fan shroud (2) remains in the vehicle.

13. Remove the radiator (1) in top direction from the vehicle.
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Radiator Replacement (2.0L Diesel LNP - AT)
1. Install the radiator (1) to the radiator lower support brackets.
3. Install 2 NEW transmission fluid pipe seal rings (7) and clip the upper and lower transmission fluid pipes (1, 6) with the safety rings into the radiator.
4. Install the radiator inlet hose (4) with the radiator inlet hose clamp (5) to the radiator (1).
5. Install the radiator outlet hose (3) with the radiator outlet hose clamp (2) to the radiator (1).
6. Install the radiator support bracket insulators.
13. Top up and correct the transmission fluid. Refer to Transmission Fluid Drain and Fill.
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Radiator Replacement (2.0L Diesel LNP - MT)

Removal Procedure

7. Remove the radiator support bracket insulators.
8. Remove the radiator outlet hose clamp (2) and the radiator outlet hose (3) from the radiator (1).
9. Remove the radiator inlet hose clamp (5) and the radiator inlet hose (4) from the radiator (1).
10. Remove the engine coolant fan shroud (1) in top direction from the 4 radiator clips (2, 3) and place it inside the vehicle.
Note: The engine coolant fan shroud (2) remains in the vehicle.

12. Remove the radiator (1) in top direction from the vehicle.
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Radiator Replacement (2.0L Diesel LNP - MT)
1. Install the radiator (1) to the radiator lower support brackets.
3. Install the radiator inlet hose (4) with the radiator inlet hose clamp (5) to the radiator (1).
4. Install the radiator outlet hose (3) with the radiator outlet hose clamp (2) to the radiator (1).
5. Install the radiator support bracket insulators.
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Radiator Surge Tank Outlet Hose Replacement (2.0L Diesel LNP)

Radiator Surge Tank Outlet Hose Replacement
1 Radiator Surge Tank Outlet Hose Clamp (Qty: 2)
2 Radiator Surge Tank Outlet Hose
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Radiator Surge Tank Replacement

Removal Procedure
atmospheric pressure. Removal of the surge tank cap, while the cooling system is hot and under high pressure, causes the solution to boil instantaneously with
explosive force. This will cause the solution to spew out over the engine, the fenders, and the person removing the cap. Serious bodily injury may result.
Note: Use only a GM released anti-freeze mixture and ensure a concentration of 50 percent water to 50 percent antifreeze. Antifreeze does not just prevent the
cooling system from freezing up, it also protects all the components that are in contact with coolant from rust/limescale deposits. As a result, antifreeze should
always be added, even in tropical countries.
In addition to the anti-freeze mixture, water quality also plays an important role. Potable tap water should normally suffice to fulfil this requirement. The quality of
regenerated sea water is not suitable.
1. Open the cooling system by removing the radiator surge tank cap.
Note: Do NOT drain more than 1.5 liter (1.36 quarts) of coolant fluid to avoid necessity of the coolant system bleeding procedure.
3. Install a drain hose, slowly open the drain screw (1) and allow the to drain out max. 1.5 liter (1.36 quarts) coolant fluid into a clean measuring pincher.
5. Remove the engine coolant air bleed hose (6), remove the clamp.
6. Remove the radiator surge tank engine hose (5), remove the clamp.
7. Remove radiator surge tank clip (2).
8. Disconnect coolant level sensor wiring harness plug (4).
9. Remove the radiator surge tank (1), unclip from the bracket (3).
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Radiator Surge Tank Replacement
1. Install the radiator surge tank (1) and clip into the bracket (3).
2. Connect coolant level sensor wiring harness plug (4).
3. Install radiator surge tank clip (2).
4. Install the radiator surge tank engine hose (5), install the clamp.
5. Install the engine coolant air bleed hose (6), install the clamp.
6. Refill the radiator surge tank with the coolant fluid, which has been drained out before.
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Radiator Upper Bracket Replacement

Radiator Upper Bracket Replacement
Remove the front bumper fascia. Refer to Front Bumper Fascia Removal and Installation.
Radiator Support Bracket Bolt

1
Tighten
22 Y (16 lb in)
Radiator Support Bracket

2 Procedure
Pull the radiator forward until the bracket is accessible.
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Radiator Vent Valve Replacement

Radiator Vent Valve Replacement
Drain the cooling system. Refer to Cooling System Draining and Filling.
1 Radiator Vent Valve
2 Radiator Vent Valve Seal Ring
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Special Tools

Illustration Tool Number/ Description
EN-471
KM-471
Adapter
EN-46104
J-46104
Water Pump Pulley Holding Tool
(for 2.0 Diesel LNP)
EN-6327-A
KM-6327-A
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Cooling System Test Adapter
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Thermostat Bypass Hose Replacement

Removal Procedure
1. Remove the engine water outlet adapter. Refer to Engine Water Outlet Adapter Replacement.
2. Remove the thermostat bypass hose clamp (2) and the thermostat bypass hose (1) from the thermostat bypass pipe (3).
1. Install the thermostat bypass hose clamp (2) and the thermostat bypass hose (1) to the thermostat bypass pipe (3).
2. Install the engine water outlet adapter. Refer to Engine Water Outlet Adapter Replacement.
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Thermostat Bypass Pipe Installation

1. Install the thermostat bypass pipe (4).

2. Install the thermostat bypass pipe retaining bolts (2) and tighten to 10 Y (89 lb in).
3. Install the 2 thermostat bypass pipe retaining bolts (3) and tighten to 25 Y (18 lb ft).
4. Install the 4 clamps (1, 5).
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Thermostat Bypass Pipe Removal

1. Remove the 4 clamps (1, 5).

2. Remove the 3 thermostat bypass pipe retaining bolts (2, 3).
3. Remove the thermostat bypass pipe (4).
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Thermostat Bypass Pipe Replacement

Removal Procedure
1. Remove the engine water outlet adapter. Refer to Engine Water Outlet Adapter Replacement.
2. Remove the thermostat bypass hose. Refer to Thermostat Bypass Hose Replacement.
3. Remove the surge tank outlet front hose clamp (1) and the surge tank outlet front hose (2) from the surge tank outlet pipe (5).
4. Remove the heater outlet hose clip (3) and the heater outlet hose (4) from the surge tank outlet pipe (5).
5. Remove the surge tank outlet rear hose clamp (5).

6. Remove the surge tank outlet pipe bracket bolt (3) from the intake manifold (2).
7. Remove the surge tank outlet rear hose along with the surge tank outlet pipe (4) from the thermostat bypass pipe (1).
8. Remove the throttle body assembly. Refer to Throttle Body Assembly Replacement.
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11. Remove the 2 thermostat bypass pipe bolts (1) from the thermostat bypass pipe bracket (2).
12. Remove the water pump inlet hose clamp and the thermostat bypass hose clamp (1) from the thermostat bypass pipes.
13. Loosen the engine coolant inlet hose clamp from the thermostat bypass pipe and move the thermostat bypass pipes along with the thermostat bypass
pipe bracket (2) aside (see arrow).
14. Remove the exhaust gas recirculation manifold cooling return hose clamp (3) and the exhaust gas recirculation manifold cooling return hose (2) from
the thermostat bypass pipe (1).
15. Remove the thermostat bypass pipe bracket bolt (4) and remove the thermostat bypass pipe (1) in arrow direction.
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1. Position the thermostat bypass pipe (1) to the engine and install the thermostat bypass pipe bracket bolt (4). Tighten the bolt to 10 Y (89 lb in).
2. Install the exhaust gas recirculation manifold cooling return hose clamp (3) with the exhaust gas recirculation manifold cooling return hose (2) to the
thermostat bypass pipe (1).
3. Position the thermostat bypass pipes along with the thermostat bypass pipe bracket (2) to the thermostat bypass hose and the engine coolant inlet
hose (4).
4. Install the engine coolant inlet hose clamp (3) to the thermostat bypass pipe (2).
5. Install the thermostat bypass hose clamp and the water pump inlet hose clamp (1).
6. Install the 2 thermostat bypass pipe bolts (1) to the thermostat bypass pipe bracket (2) and tighten to 22 Y (16 lb ft).
8. Install the engine oil cooler outlet hose clamp (2) with the engine oil cooler outlet hose (3) to the thermostat bypass pipe (1).
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9. Install the throttle body assembly. Refer to Throttle Body Assembly Replacement.
10. Install the surge tank outlet rear hose along with the surge tank outlet pipe (4) to the thermostat bypass pipe (1) and install the surge tank outlet rear
hose clamp (5).
11. Install the surge tank outlet pipe bracket bolt (3) to the intake manifold (2) and tighten to 9 Y (80 lb in).
12. Install the heater outlet hose (4) to the surge tank outlet pipe (5) and install the heater outlet hose clip (3).
13. Install the surge tank outlet front hose clamp (1) with the surge tank outlet front hose (2) to the surge tank outlet pipe (5).
14. Install the thermostat bypass hose. Refer to Thermostat Bypass Hose Replacement.
15. Install the engine water outlet adapter. Refer to Engine Water Outlet Adapter Replacement.
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Turbocharger Coolant Feed Pipe Installation

1. Install the turbocharger coolant feed pipe (1) and NEW gaskets (2).

2. Install the 2 hollow bolts (3) to the turbocharger coolant feed pipe (1) and tighten to 32 Y (24 lb ft).
3. Install the turbocharger bracket (2).

4. Install the 2 turbocharger bracket bolts (1) to the turbocharger bracket (2) and tighten to 25 Y (18 lb ft).
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Turbocharger Coolant Feed Pipe Removal

1. Remove the 2 turbocharger bracket bolts (1) from the turbocharger and engine block.
2. Remove the turbocharger bracket (2).
3. Remove the 2 hollow bolts (3) from the turbocharger and engine block.
4. Remove the turbocharger coolant feed pipe (1).
5. Remove the 2 turbocharger coolant feed pipe gasket (2).
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Turbocharger Coolant Feed Pipe Replacement (2.0L Diesel LNP)

Removal Procedure
Warning: Refer to Exhaust Service Warning.
2. Remove the turbocharger heat shield. Refer to Turbocharger Heat Shield Replacement.
4. Remove the 2 turbocharger bracket bolts (1) from the turbocharger and the engine block.
6. Remove the 2 hollow bolts (3) from the turbocharger and the engine block.
8. Remove the 2 turbocharger coolant feed pipe gaskets (2).
1. Install the turbocharger coolant feed pipe (1) with NEW gaskets (2).

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4. Install the 2 bolts (1) to the turbocharger bracket (2) and tighten to 25 Y (18 lb ft).
6. Install the turbocharger heat shield. Refer to Turbocharger Heat Shield Replacement.
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Turbocharger Coolant Return Pipe Installation

1. Install the turbocharger coolant return rear pipe (2).

2. Install the 2 bolts (3) to the turbocharger coolant return rear pipe brackets and tighten to 10 Y (89 lb in).
3. Install the 2 clamps (1, 4) to the turbocharger coolant return rear pipe (2).
4. Install the turbocharger coolant return front pipe (2).

5. Install the hollow bolt (3) to the turbocharger coolant return front pipe (2) and a NEW gasket and tighten to 32 Y (24 lb ft).
6. Install the clamp (1) to the turbocharger coolant return front pipe (2).
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Turbocharger Coolant Return Pipe Removal

1. Remove the hollow bolt (3) from the turbocharger.

2. Remove the clamp (1) from the turbocharger coolant return front pipe (2).
3. Remove the turbocharger coolant return front pipe (2).
4. Remove the clamp (4) from the turbocharger coolant return rear pipe (2).
5. Remove the 2 bolts (3) from the camshaft cover.
6. Remove the turbocharger coolant return rear pipe (2).
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Turbocharger Coolant Return Pipe Replacement (2.0L Diesel LNP)

Removal Procedure
3. Unclip the fuel injection fuel return hose (2) from the positive crankcase ventilation valve.
4. Unclip the fuel return hose from the 2 retainer clips.
5. Remove the fuel injection fuel return hose (1) from the fuel injection pump (2) and the fuel injectors (3).
6. Remove the fuel injection fuel return hose (1).
7. Unclip and remove the vacuum hose (3) from the vacuum pump.
8. Disconnect the camshaft position sensor wiring harness plug (1).
9. Unclip the camshaft position sensor wiring harness retaining clip (2) and hang the wiring harness aside.

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2. Install the 2 turbocharger coolant return pipe bracket bolts (3) and tighten to 10 Y (89 lb in).
3. Install both clamps (1, 4) to the turbocharger coolant return rear pipe (2).
4. Install the turbocharger coolant return pipe (2).

5. Install the hollow bolt (3) to the turbocharger coolant return pipe (2) with a NEW gasket and tighten to 32 Y (24 lb ft).
6. Install the clamp (1) to the turbocharger coolant return pipe (2).
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7. Clip in the camshaft position sensor wiring harness retaining clip (2).

8. Connect the camshaft position sensor wiring harness plug (1).
9. Install the vacuum hose (3) to the vacuum pump and clip in the vacuum hose retainer.
10. Install the fuel injection fuel return hose (1) to the fuel injection pump (2) and the fuel injectors (3).
11. Clip the fuel return hose into the 2 retainer clips.
12. Clip the fuel injection fuel return hose (2) to the positive crankcase ventilation valve.
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Water Pump Inlet Hose Replacement

Removal Procedure
4. Remove the air cleaner outlet front and rear duct. Refer to Air Cleaner Outlet Duct Replacement.

8. Hang the charge air cooler inlet hose (3) aside.
9. Remove the 2 water pump inlet hose clamps (3).

10. Remove the water pump inlet hose (4) from the thermostat bypass pipe (2) and from the water pump inlet pipe (1).
1. Install the water pump inlet hose (4) to the thermostat bypass pipe (2) and to the water pump inlet pipe (1).
2. Install the 2 water pump inlet hose clamps (3).
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Water Pump Inlet Hose Replacement

3. Install the charge air cooler inlet hose (3) with a NEW gasket (2) to the turbo charger.
4. Install the 2 charge air cooler inlet hose nuts (1) and tighten to 10 Y (89 lb in).
7. Install the air cleaner outlet front and rear duct. Refer to Air Cleaner Outlet Duct Replacement.
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Water Pump Installation

1. Install the water pump (1) with a NEW gasket (2).

2. Install the water pump retaining bolts (3) and tighten to 25 Y(18 lb ft).
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Water Pump Installation

1. Clean the sealing surfaces and the 3 coolant pump threads.

2. Install NEW gasket.
3. Install the coolant pump (1).
4. Install 5 NEW bolts (2) and tighten to 8 Y (71 lb in).
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Water Pump Pulley Installation

Note: Counterhold the crankshaft balancer. The belt has to be installed for this procedure.
1. Install the water pump pulley (2) to the water pump (3).
2. Install the 3 water pump pulley bolts (1) with locking compound and tighten to 20 Y (15 lb ft).
Refer to Adhesives, Fluids, Lubricants, and Sealers.
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Water Pump Pulley Installation

Special Tools
EN-46104 Water Pump Pulley Holding Tool
1. Install the water pump pulley (1).

2. Install the 3 water pump pulley retaining bolts (2).
3. Counterhold the water pump pulley with EN-46104 holding tool and tighten the bolts (2) to 18 Y (13 lb ft).
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Water Pump Pulley Removal

Note: Counterhold the crankshaft balancer. For this procedure the drive belt has to be installed.
1. Loosen the 3 water pump pulley bolts (1).
2. Remove the 3 water pump pulley bolts (1).
3. Remove the water pump pulley (2) from the water pump (3).
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Water Pump Pulley Removal

Special Tools
EN-46104 Water Pump Pulley Holding Tool.
1. Remove 3 water pump pulley bolts (2) while counterhold water pump pulley with EN-46104 holding tool .
2. Remove the water pump pulley (1).
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Water Pump Pulley Replacement (2.0L Diesel LNP)

Special Tools
EN-46104 Water Pump Pulley Holding Tool
Removal Procedure
3. Remove the right front wheelhouse liner. Refer to Front Wheelhouse Liner Replacement.
6. Counterhold the water pump pulley with the EN-46104 holding tool and remove the 3 water pump pulley bolts (2).
7. Remove the water pump pulley (1).
1. Install the water pump pulley (1).

2. Install the water pump pulley bolts (2).
3. Counterhold the water pump pulley with the EN-46104 holding tool and tighten the bolts (2) to 18 Y (13 lb ft).
6. Install the right front wheelhouse liner. Refer to Front Wheelhouse Liner Replacement.
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Water Pump Removal

1. Remove the 5 water pump bolts (2).

2. Remove the water pump (1).
3. Remove the water pump seal.
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Water Pump Removal


3. Remove the water pump gasket (2).
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Water Pump Replacement (2.0L Diesel LNP)

Removal procedure
1. Recover the refrigerant. Refer to Refrigerant Recovery and Recharging.

4. Remove the air cleaner outlet front and rear duct. Refer to Air Cleaner Outlet Duct Replacement.
8. Remove the power steering pump. Refer to Power Steering Pump Replacement.

12. Hang the charge air cooler inlet hose (3) aside.
13. Remove the radiator outlet hose. Refer to Radiator Outlet Hose Replacement.
14. Remove the 2 thermostat housing bolts (4).

16. Remove the thermostat (2).
17. Remove the thermostat seal ring (1).
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18. Remove the water pump inlet hose clamp (1) and the water pump inlet hose (2).
19. Remove the thermostat bypass hose clamp (6) and the thermostat bypass hose (3).
20. Remove the engine coolant inlet hose clamp (5) and the engine coolant inlet hose (4).
21. Remove the water pump pulley. Refer to Water Pump Pulley Replacement.

24. Remove the water pump gasket (2).
2. Install the water pump (1) with a NEW water pump gasket (2).

3. Install the 4 water pump bolts (3) and tighten to 25 Y (18 lb ft).
4. Install the water pump pulley. Refer to Water Pump Pulley Replacement.
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5. Install the engine coolant inlet hose (4) with the engine coolant inlet hose clamp (5).
6. Install the thermostat bypass hose (3) with the thermostat bypass hose clamp (6).
7. Install the water pump inlet hose (2) with the water pump inlet hose clamp (1).
8. Install the thermostat (2) with a NEW thermostat seal ring (1).

9. Install the thermostat housing (3).
10. Install the 2 thermostat housing bolts (4) and tighten to 8 Y (71 lb in).
11. Install the charge air cooler inlet hose (3) with a NEW gasket (2) to the turbocharger.
12. Install the 2 charge air cooler inlet hose nuts (1) and tighten to 10 Y (89 lb in).
14. Install the power steering pump. Refer to Power Steering Pump Replacement.
19. Install the air cleaner outlet front and rear duct. Refer to Air Cleaner Outlet Duct Replacement.
22. Recharge the refrigerant. Refer to Refrigerant Recovery and Recharging.
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Engine Front Cover and Oil Pump Installation

1. Install the NEW engine cover gasket (1).

2. Install the engine cover with the included oil pump (4).
3. Install the 8 engine cover bolts (2, 3) and tighten to 20 Y (15 lb ft).
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Engine Front Cover and Oil Pump Removal

Note: Note the different screw lengths.

2. Remove the engine front cover with the included oil pump (4).
Note: Do not damage the sealing surfaces.
4. Clean the sealing surface.
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Removal Procedure
1. Open the hood.

7. Remove the timing belt rear cover. Refer to Timing Belt Rear Cover Replacement.
9. Remove the radiator outlet hose from the water pump. Refer to Radiator Outlet Hose Replacement.
10. Remove the engine oil cooler inlet pipe bolt (4).

11. Push the engine oil cooler inlet pipe (1) into the engine oil cooler housing (2).
12. Remove the 2 engine oil cooler outlet pipe bolts (5) from the water pump.
13. Push the engine oil cooler outlet pipe (3) into the engine oil cooler housing (2).
14. Remove the 8 engine front cover bolts (2, 3).

16. Remove the engine front cover seal (1).
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2. Install a NEW engine front cover seal (1).

4. Install the 8 engine front cover bolts (2, 3) and tighten to 20 Y (15 lb ft).
5. Push the engine oil cooler outlet pipe (3) to the water pump (6).
6. Install the engine oil cooler outlet pipe bolts (5) and tighten to 8 Y (71 lb in).
7. Push the engine oil cooler inlet pipe (1) into the water pump (6).
8. Install the engine oil cooler inlet pipe bolt (4) and tighten to 8 Y (71 lb in).
9. Install the radiator outlet hose to the water pump. Refer to Radiator Outlet Hose Replacement.
11. Install the timing belt rear cover. Refer to Timing Belt Rear Cover Replacement.
14. Install the exhaust manifold. Refer to Exhaust Manifold Replacement.
15. Connect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection.
17. Close the hood.
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Engine Oil and Oil Filter Replacement

Removal Procedure
3. Place a drain pan under the oil drain plug.
4. Remove the oil pan drain plug (1).

5. Install the oil pan drain plug (1) and tighten to 25 Y (18 lb ft)after draining the engine oil.
6. Remove the drain pan under the oil drain plug.
10. Remove the oil filter cap (1) from the oil filter housing.
11. Remove the oil filter cap seal (2).
12. Remove the oil filter (3) from the oil filter cap (1).
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Engine Oil and Oil Filter Replacement
1. Install a NEW oil filter cap seal (2).

2. Install a NEW oil filter (3) to the oil filter cap (1).
3. Install the oil filter cap (1) to the oil filter housing and tighten the oil filter cap (1) to 25 Y (18 lb ft).
5. Fill the engine with engine oil. Refer to Engine Mechanical Specifications.
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Engine Oil Cooler Installation

1. Clean the engine oil cooler to the oil filter housing sealing surfaces.
2. Install the NEW engine oil cooler gasket (2) and the engine oil cooler (1) to the engine oil cooler housing.
3. Install the 6 engine oil cooler bolts (3) and tighten to 8 Y (71 lb in).
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Engine Oil Cooler Installation


2. Install the 8 engine oil cooler retaining bolts (3, 4) and tighten to 25 Y (18 lb ft).
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Engine Oil Cooler Outlet Hose Installation

1. Install the engine oil cooler outlet hose (2).

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Engine Oil Cooler Outlet Hose Removal

1. Remove the clamps (1, 3).

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Removal Procedure
7. Remove the engine oil cooler outlet hose clamp (2) and the engine oil cooler outlet hose (3) from the engine oil cooler (1).
9. Remove the charge air cooler outlet rear hose from the throttle body and the charge air cooler outlet front hose from the charge air cooler outlet front
hose bracket and hang it aside. Refer to Charge Air Cooler Outlet Hose Replacement.
10. Remove the throttle body. Refer to Throttle Body Assembly Replacement.
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1. Reposition the engine oil cooler outlet hose (3).

2. Install the engine oil cooler outlet hose (3) with the engine oil cooler outlet hose clamp (2) to the thermostat bypass pipe (1).
3. Install the throttle body. Refer to Throttle Body Assembly Replacement.
4. Install the charge air cooler outlet rear hose to the throttle body and the charge air cooler outlet front hose to the charge air cooler outlet front hose
bracket. Refer to Charge Air Cooler Outlet Hose Replacement.
6. Install the engine oil cooler outlet hose (3) with the engine oil cooler outlet hose clamp (2) to the engine oil cooler (1).
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Engine Oil Cooler Removal

1. Remove the engine oil cooler retaining bolts (3, 4).

2. Remove the engine oil cooler (2) in conjunction with the engine oil cooler gaskets (1).
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Engine Oil Cooler Replacement (2.0L Diesel LNP)

Removal Procedure
4. Remove the engine oil cooler outlet hose. Refer to Engine Oil Cooler Outlet Hose Replacement.
6. Remove the 8 engine oil cooler retaining bolts (3, 4).

7. Remove the engine oil cooler (2) along with the 2 engine oil cooler gaskets (1).
3. Install the 8 engine oil cooler retaining bolts (3, 4). Tighten the bolts to 25 Y (18 lb ft).
4. Install the engine oil cooler outlet hose. Refer to Engine Oil Cooler Outlet Hose Replacement.
8. Fill in the engine oil. Refer to Engine Oil and Oil Filter Replacement.
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Engine Oil Level Indicator Switch Replacement

Removal Procedure
4. Disconnect the engine oil level indicator switch wiring harness plug (1) from the engine oil level indicator switch (2).
5. Remove the engine oil level indicator switch (2).

1. Install the engine oil level indicator switch (2). Tighten the oil level indicator switch to 20 Y (15 lb ft).
2. Connect the engine oil level indicator switch wiring harness plug (1) to the engine oil level indicator (2).
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Engine Oil Pressure Indicator Switch Replacement

Remove the air conditioning compressor. Refer to Air Conditioning Compressor Replacement.
Oil Pressure Switch

Procedure
1
Disconnect the oil pressure switch wiring harness plug and remove the switch.
Tighten
30 Y (22 lb ft)
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Lower Oil Pan Installation

1. Remove any old thread sealant and gasket material with a suitable tool.
2. Clean the lower oil pan and lower oil pan components with solvent.
4. Dry the lower oil pan and lower oil pan components with compressed air.
Note: The complete installation procedure of the lower oil pan should be done in 10 minutes.
Note: Do not coat sealing compound on the oil pan bolt holes and threads.
5. Apply sealing compound on sealant line (1).
6. Install the lower oil pan (1).

7. Install the 14 lower oil pan retaining bolts (2) and tighten evenly to 10 Y (89 lb in).
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Lower Oil Pan Removal

1. Remove the 14 lower oil pan retaining bolts (2).
Note: Carefully detach from engine block using suitable tool. Do not damage the sealing surfaces.
2. Remove the lower oil pan (1).
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Lower Oil Pan Replacement

Removal Procedure
4. Remove the 14 lower oil pan retaining bolts (2).

5. Remove the oil pan (1).
2. Clean the lower oil pan and lower oil pan components with solvent.
4. Dry the lower oil pan and lower oil pan components with compressed air.
Note: The complete installation procedure of the lower oil pan should be done in 10 minutes.
5. Apply sealing compound on the sealant line (1).
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Lower Oil Pan Replacement
6. Install the lower oil pan (1).

7. Install the 14 lower oil pan retaining bolts (2) and tighten evenly to 10 Y (89 lb in).
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Oil Filter Adapter and Oil Cooler Assembly Replacement

Removal Procedure
2. Remove the turbocharger oil feed pipe from the oil filter adapter. Refer to Turbocharger Oil Feed Pipe Replacement.
3. Remove the oil pressure switch. Refer to Engine Oil Pressure Switch Replacement.
4. Remove the drive belt tensioner. Refer to Drive Belt Tensioner Removal.
7. Remove the oil cooler outlet hose. Refer to Engine Oil Cooler Outlet Hose Replacement.
9. Remove the engine oil cooler. Refer to Engine Oil Cooler Replacement.
10. Remove the 4 oil filter assembly retaining bolts (3).

11. Remove the oil filter assembly (1) along with the oil filter assembly gasket (2).
1. Clean the sealant surfaces.
2. Install the oil filter assembly (1) along with the NEW oil filter assembly gasket (2).
3. Install 4 oil filter assembly retaining bolts (3) and tighten to 25 Y (18 lb ft).
4. Install the engine oil cooler. Refer to Engine Oil Cooler Replacement.
6. Install the oil cooler outlet hose. Refer to Engine Oil Cooler Outlet Hose Replacement.
8. Install the drive belt tensioner. Refer to Drive Belt Tensioner Removal.
9. Install the oil pressure switch. Refer to Engine Oil Pressure Switch Replacement.
10. Install the turbocharger oil feed pipe to the oil filter adapter. Refer to Turbocharger Oil Feed Pipe Replacement.
12. Change engine oil and oil filter. Refer to Engine Oil and Oil Filter Replacement.
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Oil Filter Adapter Installation

1. Install the oil filter assembly (1) along with a NEW oil filter assembly gasket (2).

2. Install the 4 oil filter assembly retaining bolts (3) and tighten to 25 Y (18 lb ft).
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Oil Filter Adapter Removal

1. Remove the 4 oil filter assembly retainer bolts (3).

2. Remove the oil filter assembly (1) along with the oil filter assembly gasket (2).
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Oil Flow Check Valve Replacement

Oil Flow Check Valve Replacement
Oil Flow Check Valve Bore Plug

1
Tighten
21 Y (16 lb ft)
2 Oil Flow Check Valve
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Oil Level Indicator and Tube Installation

1. Install the oil level indicator tube (3) to the lower crankcase with a NEW seal ring.

2. Install the 2 bolts (1) to the oil level indicator tube bracket (2) and tighten to 10 Y(89 lb in).
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Oil Level Indicator and Tube Removal

1. Remove 2 bolts (1) from the oil level indicator tube bracket (2).

2. Remove the oil level indicator tube (3) from the lower crankcase.
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Oil Level Indicator Tube Replacement

Removal Procedure
2. Remove the 2 bolts (1) from the oil level indicator tube bracket (2).
3. Remove the oil level indicator tube (3) from the lower crankcase.
4. Remove the oil level indicator tube seal ring.
1. Install the oil level indicator tube (3) to the lower crankcase with a NEW seal ring.
2. Install the bolts (1) to the oil level indicator tube bracket (2) and tighten to 10 Y (89 lb in).
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Oil Pan Cleaning and Inspection

1. Remove the 2 oil pan baffle bolts (1) and the oil pan baffle (2).
2. Remove the oil pump screen (3).
3. Clean the oil pan (4). Remove all the sludge and the oil deposits.
4. Remove the oil pan drain plug (5) and the oil pan drain plug seal (6).
5. Inspect the thread of the oil pan drain plug.
6. Inspect the oil pan for cracking near the pan rail and the transmission mounting points.
7. Inspect the oil pan for cracking resulting from impact or flying road debris.
8. Inspect the oil pan baffle and oil pump screen.
9. Repair or replace the oil pan as necessary.
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Oil Pan Installation


2. Apply approximately a 3.5 mm (0.138 in) thick bead of oil pan sealant to the joints (arrows). Refer to Adhesives, Fluids, Lubricants, and Sealers for the
recommended sealant.
Note: The assembly time, including torque check, must take no longer than 10 minutes.
3. Apply approximately a 3.5 mm (0.138 in) thick bead of oil pan sealant (1) to the oil pan. Refer to Adhesives, Fluids, Lubricants, and Sealers for the
recommended sealant.
4. Install the oil pan (2).

5. Install the 15 oil pan bolts (1) on the cylinder block and tighten to10 Y (89 lb in).
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Oil Pan Removal

1. Remove the 15 oil pan bolts (1) from the engine block.

2. Use a suitable tool to remove the oil pan (2) evenly all the way around.
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Oil Pan Replacement

Removal Procedure
2. Place collecting basin underneath.
3. Remove the oil drain bolt.
4. Collect the engine oil.
5. Install the NEW seal ring and the oil drain bolt, tighten to 14 Y (124 lb in).
7. Remove the oil level indicator tube. Refer to Oil Level Indicator Tube Replacement.
10. Remove the exhaust front pipe. Refer to Exhaust Front Pipe Replacement.
11. Remove the 3 oil pan bolts (3 from the transmission.
Note: Remove the oil pan evenly all the way around with a suitable tool.
12. Remove the 15 oil pan bolts (1) and remove the oil pan (2).
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Oil Pan Replacement
Note: Use a screwdriver or another suitable tool.

13. To prevent damage to the oil screen, ensure that the oil screen (2) remains in the oil pan (3). If the oil screen gets caught on the cylinder block (1), push
it into the oil pan.
14. Remove the oil pan.
2. Apply an approximately 3.5 mm (0.14 in) thick bead of oil pan sealant to the joints (arrows).
Note: The assembly time including torque check must take no longer than 10 minutes.
3. Apply an approximately 3.5 mm (0.14 in) thick bead of oil pan sealant (1) as illustrated.

4. Install the 15 oil pan bolts (1) to the oil pan (2) and tighten to 10 Y (89 lb in).
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Oil Pan Replacement
5. Install the 3 oil pan bolts (3) to the transmission and tighten to 45 Y (33 lb ft).
6. Install the exhaust front pipe. Refer to Exhaust Front Pipe Replacement.
9. Install the oil level indicator tube. Refer to Oil Level Indicator Tube Replacement.
Note: Inspect the engine oil level and correct if necessary.
10. Refill the collected engine oil.
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Oil Pressure Relief Valve Replacement

Removal Procedure
2. Remove the oil pressure relief valve closure bolt (1).

3. Remove the oil pressure relief valve assembly (2).
4. Remove the piston (3) and the spring (4).
Warning: Bodily injury may occur if the cleaning solvent is inhaled or exposed to the skin.
Warning: To avoid eye injury, use approved safety lenses, goggles, or face shield when using buffing and cleaning equipment.
5. Clean the parts.
6. Inspect the parts.
7. Clean the thread.
1. Install the piston (3) and the spring (4).

2. Install the oil pressure relief valve assembly (2).
3. Install the oil pressure relief valve closure bolt (1) and tighten to 30 Y (22 lb ft).
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Oil Pump Cleaning and Inspection

1. Remove the external rotor with the internal rotor.

2. Visually inspect the components.
3. Install the external and the internal rotors.
4. Inspect the axial clearance of the rotors in respect to the control unit housing upper edge.
Specifications
Permissible measurement is 0.02–0.058 mm (0.00079–0.00228 in).
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Upper Oil Pan Installation

Special Tools
EN-50435 Guide Pins
2. Clean the upper oil pan and upper oil pan components with solvent.
4. Dry the upper oil pan and upper oil pan components with compressed air.
5. Apply sealing compound on sealant line (1) including circular dispensing on 4 holes (2).
6. Apply spot dispensing at 2 areas (3).
7. There must be a seal line which extends 26 mm (1.023 in)from the last bolt hole (4).
8. Fill sealant compound at 2 areas (1) between front cover and bed plate if the space is empty.
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Upper Oil Pan Installation
9. To aid in upper oil pan alignment, install 2 EN-50435 guide pins (1) on the bed plate.
10. Install the upper oil pan (1).

11. Install the 14 oil pan retaining bolts (2, 3) and handtighten.
12. Remove the EN-50435 guide pins .
13. Tighten the 14 upper oil pan retaining bolts (2, 3) evenly to 25 Y (18 lb ft).
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Upper Oil Pan Removal

1. Remove the 14 upper oil pan retaining bolts (2, 3).
Note: Carefully detach from engine block using suitable tool. Do not damage the sealing surfaces.
2. Remove the upper oil pan (1).
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Upper Oil Pan Replacement

Special Tools
EN-50435 Guide Pin
Removal Procedure
1. Remove the oil level indicator.

5. Remove the lower oil pan. Refer to Lower Oil Pan Replacement.
7. Remove the front wheel drive intermediate shaft bracket. Refer to Front Wheel Drive Intermediate Shaft Bracket Replacement.
8. Disconnect the engine oil level indicator wiring harness plug (1) from the engine oil level indicator (2).
9. For manual transmission, remove the 3 oil pan to transmission bolts (1).
10. For automatic transmission, remove the 2 oil pan to transmission bolts (1).
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11. Remove 14 upper oil pan retaining bolts (2, 3).

Note: Carefully detach from engine block using suitable tool. Do not damage sealing surfaces.
12. Remove the oil pan (1).
2. Clean the upper oil pan and upper oil pan components with solvent.
Note: Ensure that the sealing surface is clear of oil, grease and old sealing material.
4. Dry the upper oil pan and upper oil pan components with compressed air.
Note: The complete installation procedure of the upper oil pan should be done in 10 minutes.
Note: DO NOT coat sealing compound on the upper oil pan bolt holes and bolt threads.
5. Apply sealing compound on the sealant line (1) including circular dispensing on 4 holes (2).
6. Apply spot dispensing at 2 areas (3).
7. There must be a seal line which extends 26 mm (1.02 in)from the last hole (4).
8. Fill sealant compound at 2 areas (1) between front cover and bed plate if the space is empty.
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9. To aid in upper oil pan alignment, install 2 EN-50435 guide pins (1) on the bed plate.
10. Install the upper oil pan (1).

11. Install the oil pan retaining bolts and handtighten.
12. Remove the EN-50435 guide pins .
13. Install 14 upper oil pan retaining bolts (2, 3) and tighten evenly to 25 Y (18 lb ft).
14. For manual transmission, install the 3 oil pan to transmission bolts (1) and tighten to 58 Y (43 lb ft).
15. For automatic transmission, install the 2 oil pan to transmission bolts (1) and tighten to 58 Y (43 lb ft).
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16. Connect the engine oil level indicator wiring harness plug (1) to the engine oil level indicator (2).
17. Install the front wheel drive intermediate shaft bracket. Refer to Front Wheel Drive Intermediate Shaft Bracket Replacement.
19. Install the lower oil pan. Refer to Lower Oil Pan Replacement.
22. Install the oil level indicator.
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Evaporative Emission Canister Replacement

Special Tools
CH–807 Plug
Removal Procedure
Warning: Do not breathe the air through the EVAP component tubes or hoses. The fuel vapors inside the EVAP components may cause personal injury.
Warning: Gasoline or gasoline vapors are highly flammable. A fire could occur if an ignition source is present. Never drain or store gasoline or diesel fuel
in an open container, due to the possibility of fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby.
Warning: Always wear safety goggles when working with fuel in order to protect the eyes from fuel splash.
Note: Do not remove the fuel tank filler hose when the fuel contents in the fuel tank is over the half filled with fuel.
2. If the fuel level is over half filled, refer to Fuel Tank Draining.
3. Remove the clamp (2).
4. Remove the fuel tank filler hose (3) from the fuel tank filler pipe (1).
5. Disconnect the fuel tank filler vent pipe (4). Refer to Plastic Collar Quick Connect Fitting Service.
6. Unclip the fuel feed pipe and the fuel vent pipe from the rear bracket clip at the underbody.
7. Place a suitable adjustable jack under the fuel tank.
8. Remove the 2 fuel tank strap bolts (3) and the fuel tank strap bolt retainers (2).
10. Demount the 2 fuel tank straps (4).
Note: Attention to other parts like pipes or hoses that are installed at the fuel tank. Lower the fuel tank only a little bit, when its not able to remove the
evaporative emission canister easily. Remove the fuel tank, if necessary.

11. Lower the fuel tank to a height where its able to remove the evaporative emission canister easily.
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12. Disconnect the fuel tank vent pipe (2).

13. Close the fuel tank vent pipe (2) with the CH-807 plug .
14. Disconnect the evaporative emission canister purge pipe (4).
15. Close the evaporative emission canister purge pipe (4) with the CH-807 plug .
16. Remove the evaporative emission canister (1) from the evaporative emission canister bracket (3).
1. Install the evaporative emission canister (1) to the evaporative emission canister bracket (3).
2. Remove the CH-807 plug from the evaporative emission canister purge pipe (4).
3. Connect the evaporative emission canister purge pipe (4).
4. Remove the CH-807 plug from the fuel tank vent pipe (2).
5. Connect the fuel tank vent pipe (2).
6. Raise the fuel tank to the original position.
7. Pre-install the 4 fuel tank strap bolts (3, 5) with the 4 fuel tank strap bolt retainers (2, 6) to the fuel tank straps (4).
8. Mount the 2 fuel tank straps (4).
9. Install the 4 fuel tank strap bolts (3, 5) and tighten to 20 Y (15 lb ft).
10. Remove the adjustable jack from the fuel tank.
11. Clip the fuel feed pipe and the fuel vent pipe into the rear bracket clip at the underbody.
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12. Connect the fuel tank filler vent pipe (4). Refer to Plastic Collar Quick Connect Fitting Service.
13. Install the fuel tank filler hose (3) to the fuel tank filler pipe (1).
14. Install the clamp (2).
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Evaporative Emission Control System Description

EVAP System Operation

The evaporative emission (EVAP) control system used is the charcoal canister storage method. This method transfers fuel vapor from the fuel tank to an activated
carbon, charcoal, storage device, or canister, to hold the vapors when the vehicle is not operating. When the engine is running, the fuel vapor is purged from the
carbon element by intake airflow and consumed in the normal combustion process.
Gasoline vapors from the fuel tank flow into the canister. These vapors are absorbed into the carbon. The canister is purged by the engine control module (ECM)
when the engine has been running for a specified amount of time. Air is drawn into the canister and mixed with the vapor. This mixture is then drawn into the
intake manifold.
The ECM supplies a ground to energize the evaporative emission (EVAP) canister purge solenoid valve. This valve is pulse width modulated (PWM) or turned ON
and OFF several times a second. The evaporative emission (EVAP) canister purge solenoid valve PWM duty cycle varies according to operating conditions
determined by engine load, fuel trim, and intake air temperature.
Poor idle, stalling, and poor driveability can be caused by the following conditions:
An inoperative evaporative emission (EVAP) canister purge solenoid valve

A damaged canister
Hoses that are split, cracked, or not connected to the proper tubes
Evaporative Emission Canister

The Evaporative Emission (EVAP) canister is an emission control device containing activated charcoal granules. The EVAP emission canister is used to store fuel
vapors from the fuel tank. Once certain conditions are met, the engine control module (ECM) activates the evaporative emission (EVAP) canister purge solenoid
valve, allowing the fuel vapors to be drawn into the engine cylinders and burned.
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Exhaust Gas Recirculation (EGR) System Description

The exhaust gas recirculation (EGR) system is used to reduce the amount of nitrogen oxide (NOx) emission levels caused by high combustion temperatures. At
temperatures above 1 371°C (2 500°F), oxygen and nitrogen combine to form oxides of nitrogen (NOx). Introducing small amounts of exhaust gas back into the
combustion chamber displaces the amount of oxygen entering the engine. With less oxygen in the air/fuel mixture and as a result combustion temperatures are
decreased, restricting the formation of NOx.
The EGR valve motor is a direct current (DC) stepper motor utilizing a worm gear that extends from the motor to push on the EGR valve stem. The worm gear is not
attached to the valve stem and can only force the valve open. A return spring is used to force the valve closed.
Exhaust Gas Recirculation (EGR) System Operation

The exhaust gas recirculation (EGR) valve is controlled by the engine control module (ECM) through the EGR motor high control and EGR motor low control
circuits. The ECM supplies voltage that is near ignition voltage to the high and low control circuits at all times. This voltage is used by the ECM as a reference
voltage during non EGR operation in order to detect circuit failures. The ECM will pulse width modulate (PWM) the low control circuit to ground and an increase in
amperage on the high control circuit can be observed with a DMM when the EGR valve is commanded open. A lower pulse width will increase the open position of
the valve. In order to close the EGR valve, the ECM will PWM the high control circuit to ground.
When the ignition is turned ON, the ECM will drive the EGR motor worm gear out with just enough force to touch the EGR valve stem. The ECM will do this 3 times
in quick succession. This action determines the minimum closed position of the valve and only happens once per ignition cycle. If the valve is prevented from
closing all of the way after the minimum closed position is learned, the scan tool EGR Position parameter will not reflect this position until the next ignition cycle.
The EGR motor worm gear is not connected to the EGR valve stem and can only push the valve open. The valve is returned to the closed position by a return
spring.
The ECM uses the EGR position sensor to determine the position of the EGR valve. The ECM sends a reference voltage through the 5 V reference circuit to the
EGR position sensor. The ECM provides a voltage return path for the sensor through the low reference circuit. A variable voltage signal, based on the EGR valve
position, is sent from the sensor to the ECM through the EGR position sensor signal circuit.
EGR Valve Control Enabling Conditions
Exhaust gas recirculation (EGR) valve control will only be enabled during idle and cruising conditions while the following conditions are met:
The intake air temperature (IAT) is more than 5.25°C (41.5°F). EGR valve control will remain enabled until the IAT is less than 0°C (32°F) and will not
enable again until the IAT is more than 5.25°C (41.5°F).
The engine coolant temperature (ECT) is between 60–96.75°C (140–206.15°F). EGR valve control will remain enabled until the ECT is less than 57°C
(134.6°F) or more than 99.75°C (211.55°F) and will not enable again until the ECT is between 60–96.75°C (140–206.15°F).
The barometric pressure is more than 74 kPa (10.73 PSI). EGR valve control will remain enabled until the barometric pressure is less than 72 kPa (10.44
PSI) and will not enable again until 74 kPa (10.73 PSI).
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Exhaust Gas Recirculation Cooler Installation

1. Install the exhaust gas recirculation (EGR) cooler (1) with a NEW gasket (6).

2. Install 5 retaining bolts (2, 4, 5) and the nut (3) and tighten to 25 Y (18 lb ft).
3. Install the vacuum hose (1). Clip the vacuum hose (1) to the brackets (3).
4. Install the vacuum hose (1) to the vacuum surge tank (2) and the exhaust gas recirculation vacuum regulator solenoid valve (4).
5. Install the vacuum control solenoid valve hose (1) to the charge air bypass regulator solenoid valve and the intake manifold runner control valve actuator.
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Exhaust Gas Recirculation Cooler Removal

1. Remove the vacuum control solenoid valve hose (1) from the charge air bypass regulator solenoid valve and the intake manifold runner control valve actuator.
2. Remove the vacuum hose (1) from the vacuum surge tank (2) and the exhaust gas recirculation vacuum regulator solenoid valve (4).
3. Remove the vacuum hose (1). Clip the vacuum hose (1) in the brackets (3).
4. Remove 5 retaining bolts (2, 4, 5) and the nut (3).

5. Remove the exhaust gas recirculation (EGR) cooler (1) and the gasket (6).
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Exhaust Gas Recirculation Manifold Cooling Return Hose Installation

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Exhaust Gas Recirculation Manifold Cooling Return Hose Removal

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Exhaust Gas Recirculation Manifold Cooling Return Hose Replacement (2.0L Diesel LNP)

Removal Procedure
5. If equipped, disconnect the automatic transmission hose from the radiator surge tank mount.
6. Remove the radiator surge tank clip. Refer to Radiator Surge Tank Replacement. Hang the radiator surge tank aside.
7. Remove the charge air cooler outlet hose. Refer to Charge Air Cooler Outlet Hose Replacement.
/.

/.

3. Install the charge air cooler outlet hose. Refer to Charge Air Cooler Outlet Hose Replacement.
4. Clip the radiator surge tank into the mount. Refer to Radiator Surge Tank Replacement.
5. If equipped, connect the automatic transmission hose clip to the radiator surge tank mount.
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Exhaust Gas Recirculation Pipe Installation

Note: Clean the sealing surfaces.

1. Install the exhaust gas recirculation pipe (2) along with NEW gaskets (1, 4).
2. Install the 4 exhaust gas recirculation retaining bolts (3) and tighten to 10 Y (89 lb in).
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Exhaust Gas Recirculation Pipe Removal

1. Remove the 4 exhaust gas recirculation retaining bolts (3).

2. Remove the exhaust gas recirculation pipe (2) along with the gaskets (1, 4).
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Exhaust Gas Recirculation Pipe Replacement

Removal Procedure
2. Remove the air inlet grille panel. Refer to Air Inlet Grille Panel Replacement.
3. Remove front compartment insulator. Refer to Front Compartment Insulator Replacement.
4. Remove the 4 exhaust gas recirculation bolts (3).


2. Install the 4 exhaust gas recirculation bolts (3) and tighten to 10 Y (89 lb in).
3. Install front compartment insulator. Refer to Front Compartment Insulator Replacement.
4. Install the air inlet grille panel. Refer to Air Inlet Grille Panel Replacement.
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Exhaust Gas Recirculation Vacuum Regulator Solenoid Valve Vacuum Hose Replacement

Removal Procedure
1. Remove the engine sight shield. Refer to Engine Sight Shield Replacement
2. Remove the exhaust gas recirculation vacuum regulator solenoid valve vacuum hose (2) from the exhaust gas recirculation vacuum regulator solenoid
valve (1).
3. Remove the exhaust gas recirculation vacuum regulator solenoid valve vacuum hose (2) from the exhaust gas recirculation bypass valve (3).
1. Install the exhaust gas recirculation vacuum regulator solenoid valve vacuum hose (2) to the exhaust gas recirculation vacuum regulator solenoid valve
(1).
2. Install the exhaust gas recirculation vacuum regulator solenoid valve vacuum hose (2) to the exhaust gas recirculation bypass valve (3).
3. Install the engine sight shield. Refer to Engine Sight Shield Replacement
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Exhaust Gas Recirculation Valve Cooler Bypass Control Solenoid Valve Replacement

Removal Procedure
2. Disconnect the exhaust gas recirculation bypass control solenoid valve wiring harness plug (2).
3. Remove the 2 exhaust gas recirculation bypass control solenoid valve hoses (3).
4. Remove the 2 exhaust gas recirculation bypass control solenoid valve bolts (1).
5. Remove the exhaust gas recirculation valve cooler bypass control solenoid valve (4).
1. Install the exhaust gas recirculation valve cooler bypass control solenoid valve (4).
2. Install the 2 exhaust gas recirculation bypass control solenoid valve bolts (1) and tighten to 6 Y (53 lb in).
3. Install the 2 exhaust gas recirculation bypass control solenoid valve hoses (3).
4. Connect the exhaust gas recirculation bypass control solenoid valve wiring harness plug (2).
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Exhaust Gas Recirculation Valve Cooler Replacement

Removal Procedure
2. Remove the dash upper extension panel opening cover. Refer to Dash Upper Extension Panel Opening Cover Replacement.
6. Remove the exhaust gas recirculation pipe. Refer to Exhaust Gas Recirculation Pipe Replacement.
8. For vehicles with MT: Disconnect the transmission shift lever and selector cable from the transmission. Refer to Manual Transmission Shift Lever and
Selector Lever Cable Replacement.
For vehicles with AT: Disconnect the range selector lever cable from the automatic transmission. Refer to Range Selector Lever Cable
Replacement.
9. Disconnect the vacuum solenoid valve wiring harness plug (8).

10. Disconnect the exhaust gas recirculation valve wiring harness plug (9).
11. Disconnect the intake actuator valve wiring harness plug (7).
12. Disconnect the fuel injection rail pressure sensor wiring harness plug (3).
13. Disconnect the 4 glow plug wiring harness plugs (5).
14. Disconnect the 4 fuel injector wiring harness plugs (1).
15. Unclip the 4 engine wiring harness clips (2, 4) from the camshaft cover.
16. Unclip the engine wiring harness conduit (6) in top direction from the 3 exhaust gas recirculation cooler brackets. Hang the engine wiring harness aside.
17. Remove the engine coolant air bleed hose. Refer to Engine Coolant Air Bleed Hose Replacement.
18. Remove the vacuum pump hose. Refer to Vacuum Pump Hose Replacement.
19. Remove the intake manifold tuning valve vacuum control solenoid valve hose. Refer to Intake Manifold Tuning Valve Vacuum Control Solenoid Valve
Hose Replacement.
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26. Place a suitable tool at the market position (arrow) and rotate the lock ring (1) counterclockwise.
29. Remove the exhaust gas recirculation manifold cooling return hose. Refer to Exhaust Gas Recirculation Manifold Cooling Return Hose Replacement.
30. Remove the exhaust gas recirculation cooling feed hose. Refer to Exhaust Gas Recirculation Valve Cooling Feed Hose Replacement.
31. Remove the turbocharger coolant return pipe from the exhaust gas recirculation cooler. Refer to Turbocharger Coolant Return Pipe Removal.
32. Remove the exhaust gas recirculation cooler nut (5) and the 5 exhaust gas recirculation cooler bolt (3, 4 and 6).
33. Remove the exhaust gas recirculation cooler (2) and the gasket (1).
1. Install the exhaust gas recirculation cooler (2) and a NEW gasket (1).

2. Install the 5 exhaust gas recirculation cooler bolt (3, 4 and 6) and the exhaust gas recirculation cooler nut (5) and tighten to 25 Y (18 lb ft).
3. Install the turbocharger coolant return pipe to the exhaust gas recirculation cooler. Refer to Turbocharger Coolant Return Pipe Removal.
4. Install the exhaust gas recirculation cooling feed hose. Refer to Exhaust Gas Recirculation Valve Cooling Feed Hose Replacement.
5. Install the exhaust gas recirculation manifold cooling return hose. Refer to Exhaust Gas Recirculation Manifold Cooling Return Hose Replacement.
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Note: Note: Ensure that the retaining ring (1) is locked.

13. Install the intake manifold tuning valve vacuum control solenoid valve hose. Refer to Intake Manifold Tuning Valve Vacuum Control Solenoid Valve
Hose Replacement.
14. Install the vacuum pump hose. Refer to Vacuum Pump Hose Replacement.
15. Install the engine coolant air bleed hose. Refer to Engine Coolant Air Bleed Hose Replacement.
16. Position the engine wiring harness to the vehicle.

17. Clip the engine wiring harness conduit (6) to the 3 exhaust gas recirculation cooler brackets.
18. Clip the 4 engine wiring harness clips (2, 4) to the camshaft cover.
19. Connect the 4 fuel injector wiring harness plugs (1).
20. Connect the fuel injection rail pressure sensor wiring harness plug (3).
21. Connect the 4 glow plug wiring harness plugs (5).
22. Connect the intake actuator valve wiring harness plug (7).
23. Connect the exhaust gas recirculation valve wiring harness plug (9).
24. Connect the vacuum solenoid valve wiring harness plug (8).
25. For vehicles with MT: Connect the transmission shift lever and selector cable from the transmission. Refer to Manual Transmission Shift Lever and
For vehicles with AT: Connect the range selector lever cable from the automatic transmission. Refer to Range Selector Lever Cable Replacement.
27. Install the exhaust gas recirculation pipe. Refer to Exhaust Gas Recirculation Pipe Replacement.
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31. Install the dash upper extension panel opening cover. Refer to Dash Upper Extension Panel Opening Cover Replacement.
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Exhaust Gas Recirculation Valve Cooling Feed Hose Installation

1. Install the exhaust gas recirculation valve cooling feed hose (4).

2. Install the 2 clamps (3) to the exhaust gas recirculation valve cooling feed hose (4).
3. Install the exhaust gas recirculation valve cooling feed hose (2).
4. Install the 2 clamps (1) to the exhaust gas recirculation valve cooling feed hose (2).
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Exhaust Gas Recirculation Valve Cooling Feed Hose Removal

1. Remove 2 clamps (1) from the exhaust gas recirculation valve cooling feed hose (2).
3. Remove 2 clamps (3) from the exhaust gas recirculation valve cooling feed hose (4).
4. Remove exhaust gas recirculation valve cooling feed hose (4).
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Exhaust Gas Recirculation Valve Cooling Feed Hose Replacement

Removal Procedure

1. Install the exhaust gas recirculation valve feed hose (4).

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Exhaust Gas Recirculation Valve Installation

1. Install the exhaust gas recirculation valve (1) along with a NEW gasket (3).

2. Install the 3 exhaust gas recirculation valve retaining bolts (2) and tighten to 25 Y (18 lb ft).
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Exhaust Gas Recirculation Valve Removal

1. Remove 3 exhaust gas recirculation valve retaining bolts (2).

2. Remove the exhaust gas recirculation valve (1) along with the gasket (3).
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Exhaust Gas Recirculation Valve Replacement

Removal Procedure
2. Disconnect exhaust gas recirculation valve wiring harness plug.
3. Remove the 3 exhaust gas recirculation valve bolts (2).

4. Remove the exhaust gas recirculation valve (1) and the gasket (3).
1. Install the exhaust gas recirculation valve (1) and a NEW gasket (3).

2. Install the 3 exhaust gas recirculation valve bolts (2) and tighten to 25 Y (18 lb ft).
3. Connect exhaust gas recirculation valve wiring harness plug.
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Fuel and Evaporative Emission Pipe Warning

Warning: In order to reduce the risk of fire and personal injury observe the following items:
Replace all nylon fuel pipes that are nicked, scratched or damaged during installation, do not attempt to repair the sections of the nylon fuel pipes
Do not hammer directly on the fuel harness body clips when installing new fuel pipes. Damage to the nylon pipes may result in a fuel leak.
Always cover nylon vapor pipes with a wet towel before using a torch near them. Also, never expose the vehicle to temperatures higher than 115°C (239°F) for
more than one hour, or more than 90°C (194°F) for any extended period.
Apply a few drops of clean engine oil to the male pipe ends before connecting fuel pipe fittings. This will ensure proper reconnection and prevent a possible fuel
leak. (During normal operation, the O-rings located in the female connector will swell and may prevent proper reconnection if not lubricated.)
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Fuel Vapors in Evaporative Emission Components Warning

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Fuel and Evaporative Emission Hose/Pipe Connection Cleaning Caution

Caution: Clean all of the following areas before performing any disconnections in order to avoid possible contamination in the system:
The fuel pipe connections

The hose connections
The areas surrounding the connections
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Positive Crankcase Ventilation Hose/Pipe/Tube Replacement

Removal Procedure
1. Remove the engine sight shield. Refer to. Engine Sight Shield Replacement.
2. Remove the 2 positive crankcase ventilation valve hose clamps (1).

3. Remove the positive crankcase ventilation valve hose (2).
1. Install the positive crankcase ventilation valve hose (2).

2. Install the 2 positive crankcase ventilation valve hose clamps (1).
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Positive Crankcase Ventilation Valve Installation

1. Install the positive crankcase ventilation valve (2) and a NEW gasket (1).

2. Install the 8 positive crankcase ventilation valve retaining bolts (3) and tighten evenly to 10 Y (89 lb in).
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Positive Crankcase Ventilation Valve Removal

1. Remove 8 positive crankcase ventilation valve retaining bolts (3).

2. Remove the positive crankcase ventilation valve (2) along with the gasket (1).
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Positive Crankcase Ventilation Valve Replacement

Removal Procedure
2. Remove the fuel injection fuel return hose. Refer to Fuel Injection Fuel Return Hose Replacement.
3. Remove the positive crankcase ventilation hose. Refer to Positive Crankcase Ventilation Hose/Pipe/Tube Replacement.
4. Remove 8 positive crankcase ventilation valve retaining bolts (3).

5. Remove the positive crankcase ventilation valve (2) and the gasket (1).
1. Install the positive crankcase ventilation valve (2) and a NEW gasket (1).

2. Install 8 positive crankcase ventilation valve retaining bolts (3). Tighten to 10 Y (89 lb in).
3. Install the positive crankcase ventilation hose. Refer to Positive Crankcase Ventilation Hose/Pipe/Tube Replacement.
4. Install the fuel injection fuel return hose. Refer to Fuel Injection Fuel Return Hose Replacement.
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Three-Way Catalytic Converter Damage Caution

Caution: In order to avoid damaging the replacement three-way catalytic converter, correct the engine misfire or mechanical fault before replacing the three-way catalytic
converter.
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Fuel Feed Pipe Replacement - Fuel Filter to Fuel Feed Pipe

Removal Procedure
3. Place a collecting basin underneath.
Warning: Refer to Gasoline/Gasoline Vapors Warning.

4. Disconnect the fuel feed pipe (3) from the fuel filter (1). Refer to Plastic Collar Quick Connect Fitting Service.
5. Disconnect the fuel feed pipe (3) from the fuel feed pipe (2). Refer to Plastic Collar Quick Connect Fitting Service.
1. Connect the fuel feed pipe (3) to the fuel feed pipe (2). Refer to Plastic Collar Quick Connect Fitting Service.
2. Connect the fuel feed pipe (3) to the fuel filter (1). Refer to Plastic Collar Quick Connect Fitting Service.
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Fuel Feed Pipe Replacement - Fuel Tank Fuel Pump to Fuel Filter Housing

Removal Procedure
1. Remove the fuel tank. Refer to Fuel Tank Replacement.
2. Disconnect the fuel feed pipe (1) from the fuel tank fuel pump module (3). Refer to Plastic Collar Quick Connect Fitting Service.
4. Unclip the fuel feed pipe from the retainer clip.
1. Position the fuel feed pipe (1) and clip in to the retainer clip.
3. Connect the fuel feed pipe (1) to the fuel tank fuel pump module (3). Refer to Plastic Collar Quick Connect Fitting Service.
4. Install the fuel tank. Refer to Fuel Tank Replacement.
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Removal Procedure
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Removal Procedure
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Fuel Filter Replacement


Fuel Filter Cap

1
Tighten
25 Y (19 lb in)
2 Fuel Filter Sealant
3 Fuel Filter
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Fuel Injection Fuel Feed Pipe Installation

Special Tools
EN-50434 Dust Cap - Fuel Rail Port
1. Remove the EN-50434 dust cap from the multiport fuel injection fuel rail (3).
2. Loosen the 2 fuel injection fuel rail retaining bolts.
3. Install the fuel feed pipes (1).
4. Tighten the 10 fuel injection fuel feed pipe nuts (2) to 27 Y(20 lb ft).
5. Tighten the 2 fuel injection fuel rail retaining bolts to 25 Y(18 lb ft).
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Fuel Injection Fuel Feed Pipe Removal

Special Tools
1. Remove the 10 fuel injection fuel feed pipe nuts from the fuel injection pump, the fuel feed rail (3), and the 4 fuel injectors (2).
2. Remove the 5 fuel feed pipes (1).
3. Close all connections with the EN-50434 dust caps .
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Fuel Injection Fuel Feed Pipe Replacement - Fuel Injection Pump to Fuel Rail

Special Tools
EN-50434 Closure Plugs
Removal Procedure
Caution: Clean all fuel pipe and hose connections and surrounding areas before disassembling to avoid possible contamination of the fuel system. Spray
the fuel pump module cam-lock ring tang with penetrating oil prior to attempting removal.
2. Remove the fuel injection fuel rail pipe (1) from the fuel injection pump (2) and from the fuel injection fuel rail (3).
3. Close the fuel feed injection fuel rail and the fuel injection pump with the EN-50434 closure plugs .
1. Remove the EN-50434 closure plugs from the fuel feed injection fuel rail and the fuel injection pump.

2. Install the fuel injection fuel rail pipe (1) to the fuel injection pump (2) and to the fuel injection fuel rail (3) and tighten to 27 Y (20 lb ft).
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Fuel Injection Fuel Feed Pipe Replacement - Fuel Rail to Fuel Injector

Special Tools
Removal Procedure
2. Disconnect the 4 fuel injectors wiring harness plugs.
3. Remove the 4 fuel injector feed pipes (1) from the 4 fuel injectors (2) and from the fuel rail (3).
4. Close the 4 fuel injectors (2) and the fuel rail (3) with the EN-50434 closure plugs .
1. Remove the EN-50434 closure plugs from the 4 fuel injectors (2) and the fuel rail (3).
2. Install the 4 fuel injector feed pipes (1) to the 4 fuel injectors (2) and to the fuel rail (3) and tighten to 27 Y (20 lb ft).
3. Connect the 4 fuel injectors wiring harness plugs.
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Special Tools
Removal Procedure
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Fuel Injection Fuel Rail Assembly Replacement

Special Tools
Removal Procedure
2. Remove the fuel injection fuel feed pipe - fuel injection pump to fuel rail. Refer to Fuel Injection Fuel Feed Pipe Replacement - Fuel Injection Pump to
Fuel Rail.
3. Remove the fuel injection fuel feed pipe - fuel rail to fuel injector. Refer to Fuel Injection Fuel Feed Pipe Replacement - Fuel Rail to Fuel Injector.
4. Close all connections with the EN-50434 plugs .
5. Remove the 2 fuel injection fuel rail retaining bolts (1).

6. Remove the fuel injection fuel rail (2).
1. Install the fuel injection fuel rail (2).

2. Install 2 fuel injection fuel rail retaining bolts and tighten to 25 Y (18 lb ft).
3. Remove the EN-50434 plugs .
4. Install the fuel injection fuel feed pipe - fuel rail to fuel injector. Refer to Fuel Injection Fuel Feed Pipe Replacement - Fuel Rail to Fuel Injector.
5. Install the fuel injection fuel feed pipe - fuel injection pump to fuel rail. Refer to Fuel Injection Fuel Feed Pipe Replacement - Fuel Injection Pump to Fuel
Rail.
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Fuel Injection Fuel Return Hose Installation

1. Install the fuel injection fuel return hose (1).

2. Install the fuel injection fuel return hose to the fuel injection pump (2) and the fuel injectors (3).
3. Clip in the fuel injection fuel return hose to the mountings at the positive crankcase ventilation valve.
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Fuel Injection Fuel Return Hose Removal

1. Unclip the fuel injection fuel return hose (1) from the mountings at the positive crankcase ventilation valve.
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Fuel Injection Fuel Return Hose Replacement

Removal Procedure
2. Unclip the fuel injection fuel return hose (2) 3 times from the mountings at the positive crankcase ventilation valve.
5. Discard the fuel injection fuel return hose (1).
Note: Do not reuse the fuel injection fuel return hose. After fuel injection fuel return hose is removed, install a NEW fuel injection fuel return hose.
1. Install a NEW fuel injection fuel return hose (1) to the fuel injection pump (2) and the fuel injectors (3).
2. Clip the fuel injection fuel return hose (2) 3 times in the mountings at the positive crankcase ventilation valve.
3. Clip in the fuel return hose to the 2 retainer clips.
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Fuel Injection Pump Installation

Special Tools
Note: Do not tilt the fuel injection pump actuator at the intake camshaft.
1. Install the fuel injection pump (1).

2. Install the 3 fuel injection pump retaining bolts (2) and tighten to 22 Y (16 lb ft).
3. Remove the EN-50434 dust cap .
4. Install the fuel feed pipe (1).

5. Install 2 fuel injection fuel feed pipe nuts to the fuel feed rail and the fuel injection pump. Tighten the fuel pipe nuts to 27 Y (20 lb ft).
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Fuel Injection Pump Removal

Special Tools
1. Remove the 2 fuel injection fuel feed pipe nuts from the fuel feed rail and the fuel injection pump.
2. Remove the fuel feed pipe (1).
4. Remove the 3 fuel injection pump retaining bolts (2).

Note: Do not tilt the fuel injection pump actuator at intake camshaft.
5. Remove the fuel injection pump (1).
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Fuel Injection Pump Replacement

Special Tools
EN-796 Remover-Quick Connector

Removal Procedure
6. Detach the charge air cooler outlet front hose (1) along with the clamp (4) from the charge air cooler outlet rear hose (3). Hang the charge air cooler
outlet front hose aside (1).
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10. Disconnect the fuel injection pump wiring harness plug (4).

12. Disconnect the fuel feed front pipe (5) and unclip from the fuel return front pipe clip. Refer to Plastic Collar Quick Connect Fitting Service.
13. Close the fuel return front pipe with the EN-6015 closure plugs .
14. Disconnect the fuel return front pipe (2), using the EN-796 remover . Refer to Plastic Collar Quick Connect Fitting Service.
15. Remove the fuel injection fuel feed pipe (1). Refer to Fuel Injection Fuel Feed Pipe Replacement - Fuel Injection Pump to Fuel Rail.
16. Close the fuel injection fuel feed pipe with the EN-807 closure plugs .
17. Remove the 3 injection pump bolts (3).

18. Remove the injection pump (2) and the gasket (1).
1. Install the injection pump (2) and a NEW gasket (1).

2. Install the 3 injection pump bolts (3) and tighten to 25 Y (18 lb ft).
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3. Remove the EN-807 closure plugs from the fuel injection fuel feed pipe (1).
4. Install the fuel injection fuel feed pipe (1). Refer to Fuel Injection Fuel Feed Pipe Replacement - Fuel Injection Pump to Fuel Rail.
5. Remove the EN-6015 closure plugs from the fuel return front pipe (2).
6. Connect the fuel return front pipe (2). Refer to Plastic Collar Quick Connect Fitting Service.
7. Connect the fuel feed front pipe (5) and clip to the fuel return front pipe clip. Refer to Plastic Collar Quick Connect Fitting Service.
9. Connect the fuel injection pump wiring harness plug (4).
15. Tighten the charge air cooler outlet front hose to the rear hose clamp (4) to 4 Y (35 lb in).
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Fuel Injector Diagnosis (Special Tool)

Diagnostic Instructions
Perform the Diagnostic System Check - Vehicle prior to using this diagnostic procedure.
Review Strategy Based Diagnosis for an overview of the diagnostic approach.
Diagnostic Procedure Instructions provides an overview of each diagnostic category.
Circuit/System Description
The control module enables the appropriate fuel injector pulse for each cylinder. The ignition voltage is supplied directly to the fuel injectors. The control module
controls each fuel injector by grounding the control circuit via a solid state device called a driver. A fuel injector coil winding resistance that is too high or too low
will affect the engine driveability. A fuel injector control circuit DTC may not set, but a misfire may be apparent. The fuel injector coil windings are affected by
temperature. The resistance of the fuel injector coil windings will increase as the temperature of the fuel injector increases.
The active fuel injector tester CH 47976 Active Fuel Injector Tester is used to test the fuel pump, fuel system leak down, and the fuel injectors. Following the user
guide, and the on screen prompts or selections, will indicate the steps required to perform each of the available tests. The tester will perform all of the tests
automatically and display the results of the test. The results can also be downloaded for storage and printing.
Reference Information
Schematic Reference
Engine Controls Schematics
Connector End View Reference
Component Connector End Views
Electrical Information Reference
Circuit Testing
Connector Repairs
Testing for Intermittent Conditions and Poor Connections
Wiring Repairs
Special Tools
CH 47976 Active Fuel Injector Tester
Component Testing
Fuel Injector Coil Static Test
Verify the resistance of each fuel injector with one of the following methods:
If the B34A Engine Coolant Temperature Sensor 1 is between 10–32°C (50–90°F), the resistance of each fuel injector should be 11–14 Ω.
If the injectors measure OK, perform the active fuel injector tester test procedure.
If not within the specified range, replace the fuel injector.
If the B34A Engine Coolant Temperature Sensor 1 is not between 10–32°C (50–90°F), measure and record the resistance of each fuel injector with a DMM.
Subtract the lowest resistance value from the highest resistance value. The difference between the two should be equal to or less than 3 Ω.
If the difference is equal to or less than 3 Ω, refer to active fuel injector tester test procedure for further diagnosis of the fuel injectors.
If the difference is more than 3 Ω, add all of the fuel injector resistance values to obtain a total resistance value. Divide the total resistance value by the
number of fuel injectors to obtain an average resistance value. Subtract the lowest individual fuel injector resistance value from the average resistance
value. Compute the difference between the highest individual fuel injector resistance value and the average resistance value. Replace the fuel injector
that displays the greatest difference above or below the average.
Active Fuel Injector Tester Static Test Procedure
Note:
DO NOT perform this test if the engine coolant temperature (ECT) is above 94°C (201°F). Irregular fuel pressure readings may result due to hot
soak fuel boiling.
Verify that adequate fuel is in the fuel tank before proceeding with this diagnostic.
1. Turn OFF all accessories.
2. Turn OFF the ignition.
3. Install the active fuel injector tester. Refer to the active fuel injector tester user guide.
4. Turn ON the active fuel injector tester and select the vehicle.
5. Turn ON the ignition and perform the injector test.
If the active fuel injector tester aborts testing due to fuel pressure or fuel leak down, refer to Fuel System Diagnosis.
View the test results.
If any injector exceeds the recommended tolerance, replace the injector(s).
Repair Instructions
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Perform the Diagnostic Repair Verification after completing the diagnostic procedure.
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Fuel Injector Flow Rate Programming

The control functions for the fuel injection system are integrated in the engine control module (ECM). Each injectors flow rate information, or injection quantity
adjustment flow rate numbers, and cylinder position are stored in the memory of the ECM. The fuel injector flow rate programming must be done when any of the
following procedures are performed:
The ECM is replaced

A fuel injector is replaced
Injector Flow Rate Programming
1. Ignition OFF.
2. Record all the injection quantity adjustment codes from the corresponding cylinder from each injector that is being replaced or from all injectors if the
ECM was replaced.
Note: Enter the 20 digit injection quantity adjustment code from the injector or injectors that is printed on the top.
3. Perform the scan tool Injector Flow Rate Programming and follow the instructions on the screen.
Repair Verification
1. Install any components or connectors that have been removed or replaced during diagnosis.
2. Perform any adjustment, programming or setup procedures that are required when a component or module is removed or replaced.
3. Ignition OFF for 60 s.
4. Ignition ON, engine OFF.
5. Clear the DTCs.
6. If the repair was related to a DTC, duplicate the Conditions for Running the DTC and use the Freeze Frame/Failure Records, if applicable, in order to
verify the DTC does not reset. If the DTC resets or another DTC is present, refer to the Diagnostic Trouble Code (DTC) List - Vehicle and perform the
appropriate diagnostic procedure.
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Fuel Injector Installation

Special Tools

EN-48559 Injector Protective Caps

Note: Use both sides of the EN-47632 cleaning tool (1), one for loosing the dirt and the other to remove the dirt.
1. Clean the sealing surfaces, using the EN-47632 cleaning tool.

2. Install the 4 camshaft cover retaining bolts. Tighten the bolts to 10 Y (89 lb in).
3. Remove the 4 EN-48559 protective caps.
4. Install the 4 fuel injectors (1).
5. Install the 4 fuel injector brackets (3).
6. Install the 4 NEW fuel injector bracket retaining bolts (2) and tighten to 14 Y + 110° (10 lb ft + 110°).
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Fuel Injector Removal

Special Tools
EN-50428 Remover - Injector

1. Remove the 4 fuel injector bracket retaining bolts (2).

2. Remove the 4 fuel injector brackets (3).
3. Remove the 4 inner camshaft cover retaining bolts to install the EN-50428 remover .
4. Remove the 4 fuel injectors (1), using the EN-50428 remover .
5. Close the 4 fuel injector nozzles with the EN-48559 protective caps .
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Fuel Injector Replacement

Special Tools
EN-34730-91 Fuel Pressure Gauge

CH-807 Closure Plugs
Removal Procedure
1. Open the hood.

2. Disconnect the negative cable from the battery. Refer to Battery Negative Cable Disconnection and Connection.
3. Remove the positive crankcase ventilation tube. Refer to Positive Crankcase Ventilation Hose/Pipe/Tube Replacement.
4. Disconnect the wiring harness from the:
1. Evaporative emission purge valve

2. Fuel injectors
6. Release the fuel pressure using the test connection with EN-34730-91 gauge .
7. Disconnect the quick-release fitting of the fuel feed pipe (1). Refer to Plastic Collar Quick Connect Fitting Service.
8. Install and close the fuel feed pipe with CH-807 plug .
9. Remove the 2 evaporative emission canister purge solenoid valve bracket bolts (2).
10. Remove the evaporative emission canister purge solenoid valve bracket (1) from the intake manifold (7).
11. Remove the 2 multiport fuel injection fuel rail bolts (3).
12. Remove the multiport fuel injection fuel rail (4) with the fuel injectors (5) from the intake manifold (7).
13. Remove the 4 fuel injector seals (6).
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14. Remove the fuel injector retainer (1).

15. Remove the fuel injectors.
1. Install the fuel injectors.

Note: Install NEW fuel injector seals, coat the multiport fuel injector seals with silicone grease.
2. Install the fuel injector retainer (1).
Note: Coat the fuel injector seals with silicone grease.

3. Install the 4 NEW fuel injector seals (6).
4. Install the multiport fuel injection fuel rail (4) and the fuel injectors (5) to the intake manifold (7).
5. Install the 2 multiport fuel injection fuel rail bolts (3) and tighten to 8 Y (71 lb in).
6. Install the evaporative emission canister purge solenoid valve bracket (1) to the intake manifold (7).
7. Install the 2 evaporative emission canister purge solenoid valve bracket bolts (2) and tighten to 8 Y (71 lb in).
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8. Remove the CH-807 plug .

9. Connect the quick-release fitting of the fuel feed pipe (1). Refer to Plastic Collar Quick Connect Fitting Service.
10. Connect the wiring harness to the:
1. Evaporative emission purge valve

2. Fuel injectors
11. Install the positive crankcase ventilation tube. Refer to Positive Crankcase Ventilation Hose/Pipe/Tube Replacement.
12. Connect the negative cable to the battery. Refer to Battery Negative Cable Disconnection and Connection.
13. Close the hood.
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Special Tools

Removal Procedure
2. Remove the 4 fuel injection fuel feed pipes - fuel rail to fuel injector. Refer to Fuel Injection Fuel Feed Pipe Replacement - Fuel Rail to Fuel Injector.
3. Remove the fuel injection fuel feed pipe - fuel pump to fuel rail. Refer to Fuel Injection Fuel Feed Pipe Replacement - Fuel Injection Pump to Fuel Rail.
4. Remove and DISCARD the 4 fuel injector bracket retaining bolts (2).

6. Remove the 4 fuel injectors (1), using the EN-50428 remover. Remove the 4 inner camshaft cover retaining bolts to use remover.
7. Close the 4 fuel injector nozzles with the EN-48559 protective caps.

Note: Use both sides of EN-47632 cleaning tool, one for loosing the dirt and the other to haul out the dirt.
1. Clean the sealing surfaces, use the EN-47632 cleaning tool.
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6. Install the 4 NEW fuel injector bracket retaining bolts (2). Tighten the bolts to 14 Y + 110° (10 lb ft + 110°).
7. Install the 4 fuel injection fuel feed pipes - fuel rail to fuel injector. Refer to Fuel Injection Fuel Feed Pipe Replacement - Fuel Rail to Fuel Injector.
8. Install the fuel injection fuel feed pipe - fuel pump to fuel rail. Refer to Fuel Injection Fuel Feed Pipe Replacement - Fuel Injection Pump to Fuel Rail.
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Fuel Pressure Relief


Warning: Remove the fuel tank cap and relieve the fuel system pressure before servicing the fuel system in order to reduce the risk of personal injury. After you relieve
the fuel system pressure, a small amount of fuel may be released when servicing the fuel lines, the fuel injection pump, or the connections. In order to reduce the risk of
personal injury, cover the fuel system components with a shop towel before disconnection. This will catch any fuel that may leak out. Place the towel in an approved
container when the disconnection is complete.
1. Disconnect the battery. Refer to Battery Negative Cable Disconnection and Connection.
2. Remove the protective cap from the test connection.

3. Relieve the fuel pressure, using the EN-34730–91 Pressure Tester (1).
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Fuel Rail Installation

1. Install the fuel rail (2).

2. Install the 2 fuel rail retaining bolts (1) and tighten to 25 Y (18 lb ft).
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Fuel Rail Removal

1. Remove the 2 fuel rail retaining bolts (1).

2. Remove the fuel rail (2).
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Fuel Return Pipe Replacement - Fuel Return Pipe to Fuel Pump

Removal Procedure
2. Disconnect the fuel return pipe (1) from the fuel tank fuel pump module (2). Refer to Plastic Collar Quick Connect Fitting Service.
3. Unclip the fuel return pipe from the retainer clip.
1. Position the fuel return pipe (1) and clip in to the retainer clip.
2. Connect the fuel return pipe (1) to the fuel tank fuel pump module (2). Refer to Plastic Collar Quick Connect Fitting Service.
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Fuel Return Pipe Replacement

Special Tools
Removal Procedure

3. Disconnect the fuel return pipe (1) from the fuel injection pump (2) and unclip from 2 retainer clips. Refer to Plastic Collar Quick Connect Fitting Service.
4. Plug the connections with EN-6015 plugs .
5. Open the upper bulkhead bracket (2).

6. Unclip the fuel return pipe (1) from the bulkhead bracket.
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9. Remove the 4 exhaust pipe front hanger bracket bolts (2).

10. Remove the drivetrain and the front suspension frame bolt (3).
11. Remove the right drivetrain and the front suspension frame support.
12. Unclip the fuel return pipe (1) from the 4 bracket clips (2).
13. Disconnect the fuel return pipe (3) from the fuel return pipe connector (1). Refer to Plastic Collar Quick Connect Fitting Service.
15. Unclip the fuel return pipe (3) from the last bracket clip (2).
16. Remove the fuel return pipe (3).
1. Install and position the fuel return pipe (3) and clip it in to the last bracket clip (2).
3. Connect the fuel return pipe (3) to the fuel return pipe connector (1).
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4. Clip in the fuel return pipe (1) to the 4 bracket clips (2).
5. Install the right drivetrain and the front suspension frame support.
6. Install the drivetrain and the front suspension frame bolt (3).
7. Install the 4 exhaust pipe front hanger bracket bolts (2). Refer to Exhaust Pipe Front Hanger Bracket Replacement.
8. Tighten the drivetrain and the front suspension frame bolt (3) to 160 Y (118 lb ft).
11. Clip in the fuel return pipe (1) to the upper bulkhead bracket (2).
12. Close the upper bulkhead bracket.

14. Connect the fuel return pipe (1) to the fuel injection pump (2) and clip it in to 2 retainer clips.
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Fuel System Cleaning

Cleaning Water From the Fuel System
1. Disconnect the negative battery. Refer to Battery Negative Cable Disconnection and Connection.
3. Inspect the fuel tank and the fuel sender for rust, fungi or bacteria. If there is rust, replace the rusted components.
4. Clean the inside of the fuel tank and the fuel sender with hot water.
Warning: Wear safety glasses when using compressed air in order to prevent eye injury.
5. Use compressed air in order to dry the fuel tank and the fuel sender.
6. Disconnect the ends of the following lines:
The fuel filter inlet line (both ends)

The fuel filter outlet line (both ends)
The fuel filter drain
The fuel return line (both ends)
Inspect each of the pipes and lines.
Clean the inside of the fuel filter housing.
Dry the fuel filter housing with compressed air.
Dry the inside of each line with low pressure air.
Install a new fuel filter. Refer to Fuel Filter Replacement.
Install the fuel tank. Refer to Fuel Tank Replacement.
Add clean diesel fuel to the primary tank until the tank is 1/4 full.
Reconnect the following lines:
The fuel filter inlet line

The fuel filter outlet line
The transfer pump pressure and suction (both ends) lines
The fuel return line (tank end)
Connect the fuel filter drain to a line that flows into a clean metal container.
Connect the batteries.
Operate the fuel system hand primer at the fuel filter until clean fuel flows from the fuel filter drain into a metal container.
Install a hose on the fuel return line , and insert other end into a 7.6 liters (2 gallons) metal container.
Crank the engine for 30 second time intervals, with 1 minute cool-down periods. Continue until 3.8 liters (1 gallon) of fuel has passed into the container.
Connect the fuel return line.
Start and run the engine.
Stop the engine.
Clean any fuel spillage from the engine.
Fill the fuel tank and add a biocide, if needed.
Cleaning Fuel From the Fuel System
1. Drain the fuel tank.

2. Fill the fuel tank to 1/4 full.
3. Unplug the crankshaft position (CKP) sensor.
4. Disconnect the fuel return line near the cylinder head.
5. Install a hose on the fuel return line, and insert the other end into a 7.6 liters (2 gallons) metal container.
6. Crank the engine for 15 second time intervals, with 1 minute cool-down periods. Continue until 3.8 liters (1 gallon) of fuel has passed into the container.
7. Reconnect the fuel return line.
8. Plug in the CKP sensor.
9. Attempt to start and run the engine for 15 minutes. If the engine does not start, turn on/off ignition ten times, that the fuel pump module convey fuel to
the fuel injection pump.
10. Stop the engine.
11. Clean any fuel spillage from the engine.
12. Clear the engine of any diagnostic trouble codes (DTCs).
Fuel Tank Cleaning

Note:
Only use oil free compressed air to blow out the fuel pipes.
Inspect the fuel tank internally and clean the fuel tank if you find a plugged fuel filter.
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2. Drain the fuel tank. Refer to Fuel Tank Draining.

4. Inspect the fuel pump strainer. Replace a contaminated strainer and inspect the fuel pump.
5. Inspect the fuel pump inlet for dirt and debris. Replace the fuel pump if you find dirt or debris in the fuel pump inlet.
6. Locate a stand or fixture suitable to support the weight of the fuel tank and water.
7. Turn the in-frame rail fuel tank over so that the modular reservoir assembly opening is facing down.
8. Install side mounted fuel tanks upright and horizontal on stand of fixture and remove the drain plug and set aside for re-installation.
Note:
When flushing the fuel tank, handle the fuel and water mixture as a hazardous material. Handle the fuel and water mixture in accordance with all
applicable local, state, and federal laws and regulations.
Do not drill any access or drain holes in the fuel tank.
9. Using a high pressure water spray-wand, spray all interior surfaces with clean/non-contaminated water. Be sure to spray all interior tank surfaces
including for and aft sections of tank behind baffles, while allowing water to drain out the modular reservoir assembly opening or drain hole. Perform
each wash cycle for a minimum of 30 seconds using a minimum of 4 liters (1 gallon) of clean/non-contaminated water.
10. Using a high pressure wand, dry all interior tank surfaces. Tank should be tipped accordingly to facilitate removal of water. Assure pressurized air does
not contain any contaminants.
11. Repeat steps 10 and 11 for a total of 3 wash/dry cycles.
12. Hand dry tank surfaces with a white towel to confirm dryness and cleanliness.
Use a non-metallic extension to push the towel beyond tank baffles.
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Note: If the fuel filter is plugged, the fuel tank should be inspected internally and cleaned if necessary.
2. Remove the fuel pump module assembly. Refer to Fuel Tank Fuel Pump Module Replacement.
3. Inspect the fuel pump module strainer. Replace the pump module assembly if the fuel strainer is contaminated.
Note: When flushing the fuel tank, handle the fuel and water mixture as a hazardous material. Handle the fuel and water in accordance with all applicable local,
state, and federal laws and regulations.
4. Flush the fuel tank with hot water.
5. Pour the water out of the fuel sender assembly opening in the fuel tank. Rock the fuel tank in order to be sure that the removal of the water from the fuel tank
is complete.
6. Allow the tank to dry completely before reassembly.
7. Disconnect the fuel feed pipe at the engine fuel rail. Refer to Fuel Feed Pipe Replacement.
Note: Only use oil-free compressed air to blow out the fuel pipes.
8. Clean the fuel pipes by applying air pressure in the opposite direction of the fuel flow.
9. Connect the fuel feed pipe to the engine fuel rail. Refer to Fuel Feed Pipe Replacement.
10. Install the fuel pump module assembly. Refer to Fuel Tank Fuel Pump Module Replacement.
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Fuel System Description

Fuel System Overview

The fuel pump module, located in the right side of the fuel tank, supplies fuel through the fuel feed pipe to the high pressure mechanical fuel injection pump. The
mechanical fuel injection pump is located on the lower left side of the engine. Fuel is drawn through the fuel filter/heater element housing, which combines a water
separator, a fuel heater element, and a filter element. The mechanical fuel injection pump output is controlled by the engine control module (ECM), and provides
fuel at the pressure needed by the fuel injectors. The fuel injectors supply fuel directly to the combustion chambers of the engine. A separate pipe returns unused
fuel through to the fuel tank. The mechanical fuel injection pump, fuel rail pressure, fuel injection timing, and injection duration are controlled by the ECM.
Fuel Tank
The fuel tank stores the fuel supply. The fuel pump is an electric pump that is attached to the primary fuel tank module assembly. The fuel pump supplies fuel to
the high pressure mechanical fuel injection pump. The fuel pump also supplies fuel to the siphon jet pump. The siphon jet pump draws fuel from the secondary
side of the fuel tank to the primary side of the fuel tank.
The fuel tank is held in place by 2 metal straps that attach to the frame. The fuel tank is molded from high density polyethylene.
Fuel Filler Cap

The fuel filler cap has a torque-limiting device that prevents the cap from being over tightened. To install , turn the cap clockwise until you hear audible clicks. This
indicates that the cap is fully seated.
Fuel Sender Assembly

The fuel tank module is located inside of the fuel tank. The fuel tank module consists of the following major components:
The fuel pump and reservoir assembly

The fuel level sensor
The fuel strainer
Fuel Level Sensor

The fuel level sensor consists of a float, a wire float arm, and a ceramic resistor card. The position of the float arm indicates the fuel level. The fuel level sensor
contains a variable resistor which changes resistance in correspondence with the amount of fuel in the fuel tank. The engine control module (ECM) sends the fuel
level information to the instrument panel cluster. This information is used for the instrument panel fuel gauge and the low fuel warning indicator, if applicable. The
ECM also monitors the fuel level input for various diagnostics.
Fuel Strainer
The fuel strainer attaches to the lower end of the fuel sender. The fuel strainer is made of woven plastic. The functions of the fuel strainer are to filter contaminants
and to wick fuel. The fuel strainer is self-cleaning and normally requires no maintenance. Fuel stoppage at this point indicates that the fuel tank contains an
abnormal amount of sediment.
Fuel Pump
The fuel pump is mounted in the primary fuel tank module reservoir. The fuel pump is an electric pump. Fuel is pumped to the mechanical fuel injection pump at a
specified flow and pressure. The control module controls the electric fuel pump operation through a fuel pump relay.
Fuel Injection Pump

The fuel injection pump is a mechanical high pressure pump. The fuel injection pump is located on the lower left side of the engine. Fuel is pumped to the fuel rails
at a specified pressure. Fuel pressure is regulated by the fuel pressure regulator which is located on the inlet side of the fuel injection pump, controlled by the
engine control module (ECM). Excess fuel from the fuel injection pump returns to the fuel tank through the fuel return pipe.
Fuel Filter
The fuel filter assembly is located at the right rear of the engine compartment. The paper filter element traps particles in the fuel that may damage the fuel injection
system.
Fuel Feed and Return Pipes

The fuel feed pipe carries fuel from the fuel tank to the fuel filter/heater element housing. The fuel return pipe carries fuel from the fuel rail assemblies back to the
fuel tank. The fuel pipes consist of 2 sections:
The rear fuel pipe assemblies are located from the top of the fuel tank to the chassis fuel pipes. The rear fuel pipes are constructed of steel with sections of
rubber hose covered with braiding.
The chassis fuel pipes are located under the vehicle and connect the rear fuel pipes to the fuel rail pipes. These pipes are constructed of steel with sections
of rubber hose covered with braiding.
Quick-Connect Fittings
Quick-connect fittings provide a simplified means of installing and connecting fuel system components. The fittings consist of a unique female connector and a
compatible male pipe end. O-rings, located inside the female connector, provide the fuel seal. Integral locking tabs inside the female connector hold the fittings
together.
Fuel Pipe O-Rings

O-rings seal the connections in the fuel system. Fuel system O-ring seals are made of special material. Service the O-ring seals with the correct service part.
Fuel Rail Assembly

The fuel rail assembly attaches to the cylinder head. The fuel rail assembly distributes pressurized fuel to the fuel injectors through the fuel lines.
The fuel rail pressure sensor gives the engine control module (ECM) an indication of fuel pressure. The ECM uses this information to regulate fuel pressure, by
commanding the fuel pressure regulator open or closed on the inlet of the fuel injection pump.
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Fuel Injectors and Return Lines

A fuel injector is a solenoid device, controlled by the ECM, that meters pressurized fuel to a single engine cylinder. Fuel pressure is released from above the fuel
injector pintle, and is returned to the fuel tank through the fuel return lines. The difference in fuel pressure above and below the pintle causes the pintle to open.
Fuel from the fuel injector tip is sprayed directly into the combustion chamber on the compression stroke of the engine.
The control functions for the fuel injection system are integrated in the engine control module (ECM).
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The fuel system is a returnless on-demand design. The fuel pressure regulator is a part of the fuel pump module, eliminating the need for a return pipe from the
engine. A returnless fuel system reduces the internal temperature of the fuel tank by not returning hot fuel from the engine to the fuel tank. Reducing the internal
temperature of the fuel tank results in lower evaporative emissions.
An electric turbine-style fuel pump is attached to the fuel pump module inside the fuel tank. The fuel pump supplies high pressure fuel through the fuel feed pipe to
the fuel injection system. The fuel pump provides fuel at a higher rate of flow than is needed by the fuel injection system. The fuel pump module contains a reverse
flow check valve. The check valve and the fuel pressure regulator maintain fuel pressure in the fuel feed pipe and the fuel rail in order to prevent long cranking
times.
Fuel Tank
The fuel tank stores the fuel supply. The fuel tank is located in the rear of the vehicle. The fuel tank is held in place by 2 metal straps that are attached to the
underbody. The fuel tank is molded from high-density polyethylene.
Fuel Filler Cap

Note: If a fuel tank filler cap requires replacement, use only a fuel tank filler cap with the same features. Failure to use the correct fuel tank filler cap can result in a
serious malfunction of the fuel and Evaporative Emission (EVAP) system.
The fuel fill pipe has a tethered fuel filler cap. A torque-limiting device prevents the cap from being overtightened. To install the cap, turn the cap clockwise until the
cap clicks audibly. This indicates that the cap is correctly torqued and fully seated. A fuel filler cap that is not fully seated may cause a malfunction in the emission
system.
Fuel Pump Module

The fuel pump module consists of the following major components:

The fuel pump
The fuel strainer
The fuel pressure regulator
The fuel filter
Fuel Level Sensor
contains a variable resistor which changes resistance in correspondence with the position of the float arm. The ECM sends the fuel level information via the serial
data circuit to the instrument panel cluster. This information is used for the instrument panel cluster fuel gauge and the low fuel warning indicator, if applicable. The
Fuel Pump
The fuel pump is mounted in the fuel pump module reservoir. The fuel pump is an electric low-pressure pump. Fuel is pumped to the fuel injection system at
specified rates of flow and pressure. The fuel pump delivers a constant flow of fuel to the engine even during low fuel conditions and aggressive vehicle
maneuvers. The ECM controls the electric fuel pump operation through a fuel pump relay. The fuel pump flex pipe acts to dampen the fuel pulses and noise
generated by the fuel pump.
Fuel Strainer
The fuel strainer is attached to the lower end of the fuel pump module. The fuel strainer is made of woven plastic. The functions of the fuel strainer are to filter
contaminants and to wick away fuel. Normally, the fuel strainer does not require maintenance. Fuel stoppage at this point indicates that the fuel tank contains an
abnormal amount of sediment or contamination.
Fuel Pressure Regulator

The fuel pressure regulator is contained in the fuel pump module near the fuel pump outlet. The fuel pressure regulator is a diaphragm relief valve. The diaphragm
has fuel pressure on one side and regulator spring pressure on the other side. Fuel pressure is controlled by a pressure balance across the regulator. The fuel
system pressure is constant.
Fuel Feed Pipes

The fuel feed pipe carries fuel from the fuel tank to the fuel injection system. The fuel pipe consists of 3 sections:
The rear fuel pump fuel feed hose runs from the top of the fuel tank to the chassis fuel pipe. The rear fuel hose is constructed of nylon.
The fuel feed intermediate pipe is located under the vehicle and connects the rear fuel pump fuel feed hose to the front fuel pump fuel feed hose. The
intermediate fuel pipe is constructed of a combination of nylon and steel pipes.
The front fuel pump fuel feed hose connects the fuel feed intermediate pipe to the fuel rail. The front fuel hose contains the fuel pulse dampener and is
constructed of a combination of nylon and steel pipes.
Nylon Fuel Pipes

Warning: Refer to Fuel and Evaporative Emission Pipe Warning.
Nylon pipes are constructed to withstand maximum fuel system pressure, exposure to fuel additives, and changes in temperature.
Heat resistant rubber hose or corrugated plastic conduit protect the sections of the pipes that are exposed to chasing, high temperature, or vibration.
Nylon fuel pipes are somewhat flexible and can be shaped around gradual turns under the vehicle. However, if nylon fuel pipes are forced into sharp bends, the
pipes may kink and restrict the flow of fuel. Also, once exposed to fuel, nylon pipes may become stiffer and are more likely to kink if bent too far. Exercise special
care when working on a vehicle with nylon fuel pipes.
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Fuel Pulse Dampener
The fuel pulse dampener is a part of the front fuel pump fuel feed hose. The fuel pulse dampener is diaphragm-operated with fuel pump pressure on one side and
with spring pressure on the other side. The function of the dampener is to dampen the fuel pump pressure pulsations.
Fuel Rail Assembly

The fuel rail assembly is attached to the cylinder head. The fuel rail assembly performs the following functions:
Positions the injectors in the intake ports of the cylinder head

Distributes fuel evenly to the injectors
Fuel Injectors
The fuel injector assembly is a solenoid device controlled by the ECM that meters pressurized fuel to a single engine cylinder. The ECM energizes the high-
impedance, 12 Ω, injector solenoid to open a ball valve, normally closed. This allows fuel to flow into the top of the injector, past the ball valve, and through a
director plate at the injector outlet. The director plate has machined holes that control the flow of fuel, generating a spray of finely atomized fuel at the injector tip.
Fuel from the injector tip is directed at the intake valve, causing the fuel to become further atomized and vaporized before entering the combustion chamber. This
fine atomization improves fuel economy and emissions. The fuel pressure regulator compensates for engine load by increasing fuel pressure as the engine
vacuum drops.
Fuel Metering Modes of Operation

The ECM monitors voltages from several sensors in order to determine how much fuel to feed to the engine. The ECM controls the amount of fuel delivered to the
engine by changing the fuel injector pulse width. The fuel is delivered under one of several modes.
Starting Mode
When the ECM detects reference pulses from the crankshaft position sensor, the ECM will enable the fuel pump. The fuel pump runs and builds up pressure in the
fuel system. The ECM then monitors the manifold absolute pressure (MAP), intake air temperature (IAT), engine coolant temperature (ECT), and accelerator pedal
position (APP) sensor signals in order to determine the required injector pulse width for starting.
Run Mode
The run mode has 2 conditions referred to as open loop and closed loop. When the engine is first started and the engine speed is above a predetermined rounds
per minute, the system begins open loop operation. The ECM ignores the signal from the heated oxygen sensor (HO2S). The engine ECM calculates the air/fuel
ratio based on inputs from the engine coolant temperature (ECT), the manifold absolute pressure (MAP), and accelerator pedal position (APP) sensor. The system
stays in open loop until meeting the following conditions:
The heated oxygen sensor (HO2S) has varying voltage output, showing that the heated oxygen sensor (HO2S) is hot enough to operate properly.
The ECT sensor is above a specified temperature.
A specific amount of time has elapsed after starting the engine.
Specific values for the above conditions exist for each different engine, and are stored in the programmable read-only memory (EEPROM), which may be erased
electrically. The system begins closed loop operation after reaching these values. In closed loop, the ECM calculates the air/fuel ratio, injector ON time, based
upon the signal from various sensors, but mainly from the heated oxygen sensor (HO2S). This allows the air/fuel ratio to stay very close to 14.7:1.
Acceleration Mode
The ECM monitors the changes in the accelerator pedal position (APP) sensor. and the manifold absolute pressure (MAP) sensor signal in order to determine
when the vehicle is being accelerated. The ECM will then increase the injector pulse width in order to provide more fuel for increased performance.
Deceleration Mode
The ECM monitors changes in accelerator pedal position (APP) sensor and manifold absolute pressure (MAP) sensor signals to determine when the vehicle is
being decelerated. The ECM will then decrease injector pulse width or even turn OFF injectors for short periods to reduce exhaust emissions, and for better
(engine braking) deceleration.
Battery Voltage Correction Mode

When the battery voltage is low, the ECM compensates for the weak spark delivered by the ignition system in the following ways:
Increasing the amount of fuel delivered

Increasing the idle engine speed
Increasing the ignition dwell time
Fuel Cutoff Mode

The ECM cuts OFF fuel from the fuel injectors when the following conditions are met in order to protect the powertrain from damage and improve driveability:
The ignition is OFF. This prevents engine run-on.

The ignition is ON but there is no ignition reference signal. This prevents flooding or backfiring.
The engine speed is too high, above red line.
During an extended, high speed, closed throttle coast down, this reduces emissions and increases engine braking.
Fuel Trim
The ECM controls the air/fuel metering system in order to provide the best possible combination of driveability, fuel economy, and emission control. The ECM
monitors the heated oxygen sensor (HO2S) signal voltage while in closed loop and regulates the fuel delivery by adjusting the pulse width of the injectors based
on this signal. The ideal fuel trim values are around 0% for both short and long term fuel trim. A positive fuel trim value indicates the ECM is adding fuel in order to
compensate for a lean condition by increasing the pulse width. A negative fuel trim value indicates that the ECM is reducing the amount of fuel in order to
compensate for a rich condition by decreasing the pulse width. A change made to the fuel delivery changes the long and short term fuel trim values. The short
term fuel trim values change rapidly in response to the heated oxygen sensor (HO2S) signal voltage. These changes fine-tune the engine fueling. The long term
fuel trim makes rough adjustments to fueling in order to recenter and restore control to short term fuel trim. A scan tool can be used to monitor the short and long
term fuel trim values. The long term fuel trim diagnostic is based on an average of several of the long term speed load learn cells. The ECM selects the cells
based on the engine speed and engine load. If the ECM detects an excessively lean or rich condition, the ECM will set a fuel trim diagnostic trouble code (DTC).
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Fuel System Priming

Note: In order for the diesel fuel system to work properly, the fuel lines must be full of fuel and contain no air. If air gets into the fuel lines, it will be necessary to prime the
fuel system to eliminate the air before operating the vehicle. Air could have entered the system in one of the following ways:
The vehicle ran out of fuel.

The filter was removed for service or replacement.
The fuel lines were removed or disconnected for servicing.
The fuel pump was removed for servicing.
The fuel filter water drain cock was opened while the engine was running.
If one or more of the above occurred, air has entered the fuel system and you will need to prime the system prior to operating the vehicle.
1. Turn the ignition key ON and wait 5 seconds.
Note:
Do not turn the ignition key to START. It could damage the injection pump.
Fuel priming can be performed using the scan tool.
2. Turn the ignition key OFF and wait 3 seconds.
3. Repeat steps 1 and 2 five more times.
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Fuel Tank Baffle Replacement

Removal Procedure
Warning: Refer to Fuel Vapors in Evaporative Emission Components Warning.
Warning: Refer to Safety Goggles and Fuel Warning.

2. Place the fuel tank onto a workbench.
3. Remove the fuel tank fuel pump module. Refer to Fuel Tank Fuel Pump Module Replacement.
4. Press the fuel tank baffle (1) completely down as shown in the picture.
5. Push the lug (2) toward the baffle and hold it.
6. Release tension from the fuel tank baffle (1) until the lug (2) engages safely.
7. Remove the baffles (1) one by one.

8. Repeat steps 5 to 8 to remove the other baffle.
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Note: Perform the steps 1–3 only when the fuel tank baffles are not transferred from the OLD to the NEW tank.
1. Tension the fuel tank baffle (1) completely by pressing it down.
3. Release tension from the fuel tank baffle (1) until the lug (2) engages safely.
4. Install the baffles (1) one by one.
5. Press the fuel tank baffle together until the lug (1) becomes unlocked.
6. Release tension slowly from the fuel tank baffle and let the baffle engage safely in the installation site.
7. Check the proper seat of the fuel tank baffle at the fuel tank installation sites (1). Use a mirror if necessary.
8. Repeat steps 1–7 to install the other baffle.
9. Install the fuel tank fuel pump module. Refer to Fuel Tank Fuel Pump Module Replacement.
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Removal Procedure

4. Press the fuel tank baffle (1) completely together as shown in the picture.
6. Release tension from the fuel tank baffle (1) and let the lug (2) engage safely.

Note: Perform the following steps 1–3 only when the fuel tank baffles are retrofitted.
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1. Tension the fuel tank baffle (1) completely together by press it down.

Note: Mount the baffles in the shown direction.

5. Press the fuel tank baffle together. The lug (1) will unlock by its own.
6. Release slowly tension from the fuel tank baffle and let the baffle engage safely in the installation site.
7. Check for proper seat of the fuel tank baffle at the fuel tank installation sites (1). Use a mirror if necessary.
8. Repeat steps 1 to 7 to install the other baffle.
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Fuel Tank Draining

Special Tools
CH-45004 Fuel Tank Drain Hose
Warning: Never drain or store fuel in an open container. Always use an approved fuel storage container in order to reduce the chance of fire or explosion.
Warning: Place a dry chemical (Class B) fire extinguisher nearby before performing any on-vehicle service procedures. Failure to follow these precautions may result in
personal injury.
1. Open the hood.

3. Remove the fuel fill cap.
5. Remove the fuel tank filler pipe from the fuel tank. Refer to Fuel Tank Filler Pipe Replacement.
6. Insert the CH-45004 drain hose into the fuel tank until the hose reaches the bottom of the fuel tank.
7. Use an hand or air operated pump device in order to drain as much fuel as possible.
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Fuel Tank Draining


Caution: The fuel tank is fitted with a fuel tank filler valve. This filler valve is located on the end of the fuel tank filler hose at the entrance of the fuel tank. To prevent
damaging to the fuel tank filler valve during fuel tank draining, a flexible but inherently stable suction hose with a diameter of no more than 10 mm (0.4 in) must be used.
Note: The fuel tank must be drained with a suitable, commercially-available fuel removal unit and suction hose - follow safety regulations and national
legislation. In the presence of fuel vapors or escaping fuel - observe safety regulations and national legislation. Store drained fuel in a suitable, sealable
container.
2. Remove the fuel tank filler cap.
3. Insert a suitable suction hose into the fuel tank filler pipe.
4. Attach a suitable suction hose to the hose used with the hand or air operated pump devise.
5. Using a hand or air operated pump drain as much fuel from the tank as possible.
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Fuel Tank Filler Door Replacement

Fuel Tank Filler Door Replacement
Fuel Tank Filler Door

Procedure
1
1. Open the fuel tank filler door.
2. Unclip the fuel tank filler door.
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Fuel Tank Filler Hose Replacement

Warning: Gasoline or gasoline vapors are highly flammable. A fire could occur if an ignition source is present. Never drain or store gasoline or diesel
fuel in an open container, due to the possibility of fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby.
1. Open the hood.

1 Fuel Tank Filler Hose Clamp (Qty: 2)
2 Fuel Tank Filler Hose
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Fuel Tank Filler Pipe Housing Replacement

Fuel Tank Filler Pipe Housing Replacement
Remove the rear wheelhouse panel liner. Refer to Rear Wheelhouse Liner Replacement.
Fuel Tank Filler Pipe Housing

Procedure
1
1. Disconnect electrical connector from fuel tank filler door lock actuator.
2. Clip out the fuel tank filler pipe housing.
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Fuel Tank Filler Pipe Replacement

2. Remove the fuel tank filler pipe housing. Refer to Fuel Tank Filler Pipe Housing Replacement.
Fuel Tank Filler Pipe Bracket Bolt

1
Tighten
9 Y (80 lb in)
2 Lower Recirculation Tube Quick Release Fitting
3 Fuel Tank Filler Pipe Clamp
Fuel Tank Filler Pipe Ground Bolt

4 Tighten
9 Y (80 lb in)
5 Fuel Tank Filler Pipe
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1. Open the hood.


1
Tighten
9 Y (80 lb in)

4 Tighten
9 Y (80 lb in)
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Fuel Tank Fuel Pump Module Replacement

Special Tools
EN-48279 Main Fuel Pump Locking Ring Remover/Installer
Removal Procedure
2. Remove the fuel feed pipe (1) from the fuel tank fuel pump module (4) and the fuel filter housing (3). Refer to Plastic Collar Quick Connect Fitting
Service.
3. Remove the fuel return pipe (2) from the fuel tank fuel pump module (4). Refer to Plastic Collar Quick Connect Fitting Service.
4. Install the EN-48253 remover/installerto the fuel pump module lock ring.
Note: Do NOT use impact tools. Significant force will be required to release the lock ring. The use of a hammer and screwdriver is not recommended.
Secure the fuel tank in order to prevent fuel tank rotation.
5. Using the EN-48253 remover/installer and a long breaker-bar, rotate the lock ring in a counterclockwise direction in order to unlock the lock ring.
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6. Remove the fuel pump module lock ring (1).

7. Remove the fuel pump module (2).
Note: Lift the fuel pump module up slightly.
8. Remove and discard the fuel pump module seal (3).
9. Remove the fuel level sensor from the fuel pump module. Refer to Fuel Level Sensor Replacement.
1. Install the fuel level sensor to the fuel pump module. Refer to Fuel Level Sensor Replacement.
2. Install a NEW fuel pump module seal (3).

3. Install the fuel pump module (2).
4. Install the fuel pump module lock ring (1).
5. Install the EN-48253 remover/installer (1) to the fuel pump module lock ring (2).
6. Using the EN-48253 remover/installer and a long breaker-bar, rotate the lock ring in a clockwise direction in order to lock the lock ring.
7. Install the fuel return pipe (2) to the fuel tank fuel pump module (4). Refer to Plastic Collar Quick Connect Fitting Service.
8. Install the fuel feed pipe (1) to the fuel tank fuel pump module (4) and the fuel filter housing (3). Refer to Plastic Collar Quick Connect Fitting Service.
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Special Tools
Removal Procedure
Service.
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Fuel Tank Fuel Pump Module Wiring Harness Replacement

Special Tools
Removal Procedure
2. Fuel tank draining. Refer to Fuel Tank Draining.
3. Remove the rear wheelhouse panel liner. Refer to Rear Wheelhouse Liner Replacement.
5. Disconnect the fuel tank fuel pump module wiring harness (1) and unclip from the body.
7. Close all connections with EN-6015 plugs .
8. Disconnect the fuel feed pipe (3) from the fuel feed pipe connector (1). Refer to Plastic Collar Quick Connect Fitting Service.
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10. Disconnect the fuel tank fill EVAP emission pipe quick connect fitting (5) from the fuel tank vent pipe (1). Refer to Plastic Collar Quick Connect Fitting
Service.
11. Close all connection with EN-6015 plugs .
12. Loosen the fuel filler pipe clamp (3).
13. Remove the fuel filler hose (4) from the fuel filler pipe (2).
15. Remove the 2 fuel tank strap bolts (2).

16. Remove the 2 fuel tank straps (1).
17. Lower the fuel tank (2) slowly and carefully to a height where the fuel pump wiring harness (1) is accessible.
Unclip the fuel tank fuel pump module wiring harness from the 2 bracket clips (3).
18. Disconnect the fuel pump wiring harness plug (1) from the fuel tank fuel pump module (2).
19. Disconnect the fuel filter wiring harness plug (3) from the fuel filter (4).
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1. Connect the fuel pump wiring harness plug (1) to the fuel tank fuel pump module (2).
2. Connect the fuel filter wiring harness plug (3) to the fuel filter (4).
3. Clip the fuel tank fuel pump module wiring harness (1) to the 2 bracket clips (3).
4. Install the 2 fuel tank straps (1).

5. Install the 2 fuel tank strap bolts (2) and tighten to 23 Y (17 lb ft).
6. Install the fuel filler hose (4) to the fuel filler pipe (2).

7. Install the fuel filler pipe clamp (3).
8. Remove the EN-6015 plugs from all connections.
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9. Connect the fuel tank fill EVAP emission pipe quick connect fitting (5) to the fuel tank vent pipe (1). Refer to Plastic Collar Quick Connect Fitting Service.
10. Remove the EN-6015 plugs plugs from all connections.

11. Connect the fuel feed pipe (3) to the fuel feed pipe connector (1). Refer to Plastic Collar Quick Connect Fitting Service.

13. Connect the fuel return pipe (3) to the fuel return pipe connector (1). Refer to Plastic Collar Quick Connect Fitting Service.
14. Clip the fuel tank fuel pump module wiring harness (1) to the body.
15. Install the rear wheelhouse panel liner. Refer to Rear Wheelhouse Liner Replacement.
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Special Tools
Removal Procedure
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Service.

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4 of 4
Fuel Tank Heat Shield Replacement (2.0L Diesel LNP)

Fuel Tank Heat Shield Replacement

Warning: Refer to Actions to Take When Working with Fuel Warning.
Remove the fuel tank. Refer to Fuel Tank Replacement.
1 Fuel Tank
2 Fuel Tank Heat Shield Retaining Clamp (Qty: 2)
3 Fuel Tank Heat Shield
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Fuel Tank Replacement

Special Tools
Removal Procedure
Service.
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12. Lower the fuel tank slowly down to a height where the fuel pump wiring harness plug (3) is accessible.
13. Disconnect the fuel pump wiring harness plug (3) from the fuel pump module (4).
14. Disconnect the 2 fuel filter wiring harness plugs (1) and (2) from the fuel filter (6).
15. Unclip the wiring harness from the clip (5) and (7).
16. Lower the fuel tank.
Disassembly Procedure
1. Remove the fuel feed pipe (1) from fuel tank fuel pump module (4) and fuel filter housing (3). Refer to Plastic Collar Quick Connect Fitting Service.
2. Remove the fuel return pipe (2) from fuel tank fuel pump module (4). Refer to Plastic Collar Quick Connect Fitting Service.
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3. Install the EN-48253 remover/installer to the fuel pump module lock ring.


8. Remove the fuel filter (2) from the fuel filter bracket (1).

9. Remove the fuel tank heat shield. Refer to Fuel Tank Heat Shield Replacement.
10. Remove the fuel tank baffle. Refer to Fuel Tank Baffle Replacement.
Assembly Procedure
1. Install the fuel tank baffle. Refer to Fuel Tank Baffle Replacement.
2. Install the fuel tank heat shield. Refer to Fuel Tank Heat Shield Replacement.
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3. Install the fuel filter (2) at the fuel filter bracket (1).

10. Install the fuel feed pipe (1) to the fuel tank fuel pump module (4) and fuel filter housing (3). Refer to Plastic Collar Quick Connect Fitting Service.
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1. Raise the fuel tank with a suitable adjustable jack to a height where the fuel pump wiring harness plug (3) is accessible.
2. Clip in the wiring harness to the clip (5) and (7).
3. Connect the fuel pump wiring harness plug (3) to the fuel pump module (4).
4. Connect the 2 fuel filter wiring harness plugs (1) and (2) to the fuel filter (6).


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Fuel Tank Vent Pipe Replacement

Special Tools
EN–6015 Closer Plug
Removal Procedure
Warning: Gasoline or gasoline vapors are highly flammable. A fire could occur if an ignition source is present. Never drain or store gasoline or diesel fuel in an
open container, due to the possibility of fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby.
1. Open the hood.

3. Remove the fuel tank vent pipe (1) from the evaporative emission canister purge solenoid valve (3).
4. Close the fuel tank vent pipe with EN-6015 closer plug .
5. Unclip the fuel tank vent pipe (1) from the brake and fuel pipe clip (2).
7. Remove the exhaust pipe front hanger and front suspension support bolts (2).
8. Remove the drivetrain and front suspension frame bolt (3).
9. Remove the drivetrain and front suspension frame support.
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10. Unclip the fuel vent pipe (3) from the rear brake and fuel pipe clip (2).
11. Disconnect the evaporative emission canister fuel vent pipe connector (1) from the fuel tank vent pipe (3). Refer to Plastic Collar Quick Connect Fitting
Service.
12. Close the fuel tank vent pipe and emission canister fuel vent pipe with EN-6015 plugs .
13. Unclip the fuel tank vent pipe (1) from the 4 other brake and fuel pipe clips (2).
Note: Do not bend the fuel tank vent pipe.
14. Remove the fuel tank vent pipe (1).

1. Install the fuel tank vent pipe (1).
2. Clip the fuel tank vent pipe (1) into the 4 brake and fuel pipe clips (2).
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3. Remove the EN-6015 closer plugs from the emission canister fuel vent pipe (1) and the fuel tank vent pipe (3).
4. Connect the fuel vent pipe (3) to the emission canister fuel vent pipe (1). Refer to Plastic Collar Quick Connect Fitting Service.
5. Install the drivetrain and front suspension frame support.

Note: Do NOT reuse old bolts.
6. Install the NEW drivetrain and front suspension frame bolt (3) and tighten to 160 Y (118 lb ft).
7. Install the NEW exhaust pipe front hanger bolts (2) - M8 and tighten to 20 Y (15 lb ft).
8. Install the NEW front suspension support bolts (2) - M10 and tighten to 60 Y (44 lb ft).
10. Remove the EN-6015 closer plug from the fuel tank vent pipe (1).
11. Install the fuel tank vent pipe (1) to the evaporative emission canister purge solenoid valve (3).
12. Clip the fuel tank vent pipe (1) into the brake and fuel pipe clip (2).
14. Close the hood.
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Relieving Fuel Pressure Warning

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Air Cleaner Assembly Replacement

Removal Procedure
1. Disconnect the mass air flow sensor wiring harness plug (1) from mass air flow sensor.
2. Unclip the mass air flow sensor wiring harness clip (2) from the air filter assembly.
3. Remove the air cleaner draining hose (1) from the air cleaner housing.
4. Remove the air cleaner assembly (1).

5. Remove the 2 air cleaner bracket insulators.
1. Install the 2 air cleaner bracket insulators.
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2. Install the air cleaner assembly (1).
3. Install the air cleaner housing draining hose (1) to the air cleaner housing.
4. Clip in the mass air flow sensor wiring harness clip (2) to the air filter assembly.
5. Connect the mass air flow sensor wiring harness plug (1) to the mass air flow sensor.
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Air Cleaner Inlet Duct Replacement

Removal Procedure
2. Remove the intake air duct bolt (2).

3. Remove the intake air duct (1).
1. Install the intake air duct (1).

2. Install the intake air duct bolt (2) and tighten to 5 Y (44 lb in).
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Air Cleaner Outlet Duct Replacement

Caution: Any time service is being performed which requires removal of the air cleaner assembly, always cover the throttle body opening. This will
prevent any foreign material from entering the engine.
Air Cleaner Outlet Duct to Air Cleaner Housing Cover Clamp

1
Tighten
3.5 Y (31 lb in)
2 Air Cleaner Outlet Duct
Air Cleaner Outlet Duct to Intake Manifold Clamp

3 Tighten
3.5 Y (31 lb in)
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Removal Procedure

4. Remove the air cleaner outlet duct (2).
5. Remove the positive crankcase ventilation valve hose from the air cleaner outlet duct. Refer to Positive Crankcase Ventilation Hose/Pipe/Tube
Replacement.
1. Install the positive crankcase ventilation valve hose to the air cleaner outlet duct. Refer to Positive Crankcase Ventilation Hose/Pipe/Tube Replacement.
2. Install the air cleaner outlet duct (2).
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Air Cleaner Replacement

Removal Procedure
3. Remove the air cleaner outlet duct (1) from the mass air flow sensor.
4. Remove the 6 air cleaner housing bolts (2).
5. Remove the air cleaner housing cover (3).
6. Remove the air cleaner element (4).
1. Install the air cleaner element (4).

2. Install the air cleaner housing cover (3).
3. Install the 6 air cleaner housing bolts (2).
4. Install the air cleaner outlet duct (1) to the mass air flow sensor.
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Air Intake System Description

The primary function of the air intake system is to provide filtered air to the engine. The system uses a filter-element mounted in a housing. The filter-housing is
remotely mounted and uses intake ducts to route the incoming air into the throttle body. The secondary function of the air intake system is to muffle air induction
noise. This is achieved by the use of resonators attached to the air intake ducts. The resonators are tuned to the specific powertrain. The intake air temperature
(IAT) sensor is used to measure the temperature of the air entering the engine.
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Intake Air Duct Replacement

Removal Procedure
2. Remove the front intake air duct bolt (2).

3. Remove the front intake air duct (3) from the rear intake air duct (1).
1. Install the front intake air duct (3) to the rear intake air duct (1).

2. Install the front intake air duct bolt (2) and tighten.
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Intake Air Pressure and Temperature Sensor Replacement

Removal Procedure
2. Disconnect the intake air pressure/temperature sensor wiring harness plug (3).

3. Remove the intake air pressure/temperature sensor bolt (2).
4. Remove the intake air pressure/temperature sensor (1) and the gasket (4).
1. Install the intake air pressure/temperature sensor (1) and a NEW gasket (4).

2. Install the intake air pressure/temperature sensor bolt (2) and tighten to 9 Y (80 lb in).
3. Connect the intake air pressure/temperature sensor wiring harness plug (3).
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Intake Air Tuning Valve Vacuum Control Solenoid Valve Replacement

Removal Procedure
2. Disconnect the 2 tuning valve vacuum control solenoid valve wiring harness plugs (5, 8).
3. Remove the 4 tuning valve vacuum control solenoid valve hoses (1, 2).
4. Remove the 2 tuning valve vacuum control solenoid valve bolts (4).
5. Remove the intake air tuning valve vacuum control solenoid valve (3).
6. Remove the 2 additional tuning valve vacuum control solenoid valve bolts (7).
7. Remove the additional intake air tuning valve vacuum control solenoid valve (6).
1. Install the additional intake air tuning valve vacuum control solenoid valve (6).
2. Install the 2 additional tuning valve vacuum control solenoid valve bolts (7) and tighten to 10 Y (89 lb in).
3. Install the intake air tuning valve vacuum control solenoid valve (3).
4. Install the 2 tuning valve vacuum control solenoid valve bolts (4) and tighten to 10 Y (89 lb in).
5. Install the 4 tuning valve vacuum control solenoid valve hoses (1, 2).
6. Connect the 2 tuning valve vacuum control solenoid valve wiring harness plugs (5, 8).
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Intake Manifold Bracket Replacement

Removal Procedure
2. Remove the 2 intake manifold bracket bolts (1) from the engine block.
3. Remove the intake manifold bracket bolt (2) from the intake manifold.
4. Remove the intake manifold bracket (1).
1. Install the intake manifold bracket (1).

2. Install the intake manifold bracket bolt (2) to the intake manifold and tighten to 25 Y (18 lb ft).
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Intake Manifold Bracket Replacement
3. Install the 2 intake manifold bracket bolts (1) to the engine block and tighten to 25 Y (18 lb ft).
4. Install the starter. Refer to Starter Replacement.
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Intake Manifold Installation

1. Install the intake manifold (2) along with a NEW intake manifold gasket (1).

2. Install the 6 retaining bolts (5) and the 2 retaining nuts (3). Tighten the bolts and the nut to 25 Y (18 lb ft).
3. Install the retaining bolt (4) to the intake manifold bracket and tighten to 25 Y (18 lb ft).
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Intake Manifold Removal

1. Remove the retaining bolt (4) from the intake manifold bracket.

2. Remove the 6 retaining bolts (5) and the 2 retaining nuts (3).
3. Remove the intake manifold along with the intake manifold gasket (1).
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Intake Manifold Replacement

Removal Procedure
1. Remove the exhaust gas recirculation valve cooler. Refer to Exhaust Gas Recirculation Valve Cooler Replacement.
2. Remove the 2 intake air tuning valve vacuum control solenoid valves. Refer to Intake Air Tuning Valve Vacuum Control Solenoid Valve Replacement.
3. Remove the charge air control vacuum hose bracket bolt (1) from intake manifold.
4. Remove the 2 charge air control vacuum hose bracket bolts (2) from engine front cover.
5. Remove the 4 throttle body assembly bolts (3).

6. Remove the throttle body assembly (2) along with the gasket (1).
8. Remove the vacuum regulator valve hose (1) from charge air bypass valve vacuum tank (4).
9. Remove the vacuum pump hose (2) from the charge air bypass valve vacuum tank (4).
10. Remove the 2 charge air bypass valve vacuum tank bracket bolts (3).
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11. Remove the intake manifold bracket bolt (5).

12. Remove the 4 lower intake manifold bolts (6).
14. Remove the 2 intake manifold nuts (3).
15. Remove the 2 upper intake manifold bolts (4).
16. Remove the intake manifold (2).
17. Remove the intake manifold gasket (1).
1. Install the intake manifold (2) along with a NEW intake manifold gasket (1).
2. Install the 2 upper intake manifold bolts (4) and the 2 intake manifold nuts (3) and tighten to 25 Y (18 lb ft).
4. Install 4 lower intake manifold bolts (6) and tighten to 25 Y (18 lb ft).
5. Install intake manifold bracket bolt (5) and tighten to 25 Y (18 lb ft).
6. Install 2 charge air bypass valve vacuum tank bracket bolts (3) and tighten to 10 Y (89 lb in).
7. Install the vacuum pump hose (2) to the charge air bypass valve vacuum tank (4).
8. Install the vacuum regulator valve hose (1) to the charge air bypass valve vacuum tank (4).
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11. Install the throttle body assembly (2) along with a NEW gasket (1).
12. Install 4 throttle body assembly bolts (3) and tighten to 10 Y (89 lb in).
13. Install the 3 charge air control vacuum hose bolts (1, 2) and tighten to 9 Y (80 lb ft).
14. Install the 2 intake air tuning valve vacuum control solenoid valves. Refer to Intake Air Tuning Valve Vacuum Control Solenoid Valve Replacement.
15. Install the exhaust gas recirculation valve cooler. Refer to Exhaust Gas Recirculation Valve Cooler Replacement.
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Special Tools
CH-807 Closure Plugs

Removal Procedure
1. Open the hood.

4. Place a drip pan underneath.
5. Release the fuel pressure, using the test connection with EN-34730-91 gauge .
8. Disconnect the oxygen wiring harness (3).

9. Remove the wiring harness bracket (1) from the intake manifold (2).
10. Remove the 2 intake manifold brace bolts (2, 3).

11. Remove the intake manifold brace (1).
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13. Remove the fuel tank vent pipe (1) from the evaporative emission canister purge solenoid valve (3). Refer to Plastic Collar Quick Connect Fitting
Service.
14. Close the fuel tank vent pipe (1) with EN-6015 closure plugs .
15. Disconnect wiring harness plug (3).

16. Disconnect the pipe (5) from the evaporative emission canister purge solenoid valve (2) to intake manifold (4). Refer to Plastic Collar Quick Connect
Fitting Service.
17. Remove the 2 evaporative emission canister bracket bolts (1).
18. Remove the evaporative emission canister purge solenoid valve (2) and the rubber mounting from the intake manifold (4).
19. Close the fuel tank vent pipe with EN-6015 closure plugs .
20. Unclip the fuel feed pipe (1) from the fuel feed pipe clip (2). Refer to Plastic Collar Quick Connect Fitting Service.
21. Release the fuel feed pipe (1) from the multiport fuel injection fuel rail (3).
22. Close the fuel feed pipe (1) and the multiport fuel injection fuel rail (3) with CH-807 closure plugs .
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23. Remove the positive crankcase ventilation tube (1) from throttle body (3) and the camshaft cover (2). Refer to Plastic Collar Quick Connect Fitting
Service.
24. Disconnect the manifold absolute pressure sensor wiring harness plug (5).
25. Remove the clamp (2) and remove the throttle body heater inlet hose (1) from the throttle body (3). Refer to Plastic Collar Quick Connect Fitting Service.
26. Disconnect the throttle body heater outlet hose (4) from the throttle body (3). Refer to Plastic Collar Quick Connect Fitting Service.
27. Remove the engine management wiring harness and the fuel injectors wiring harness.
28. Disconnect the throttle body heater inlet hose connector from the engine coolant thermostat housing (1). Refer to Plastic Collar Quick Connect Fitting
Service.
29. Remove the throttle body heater inlet hose (2).
30. Remove the throttle body assembly. Refer to Throttle Body Assembly Replacement.
31. Remove the 2 multiport fuel injection fuel rail bolts (1).

32. Remove the multiport fuel injection fuel rail (2) and the fuel injectors (4) from the intake manifold (5).
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33. Remove the 4 multiport fuel injector seals (4).
34. Remove the manifold absolute pressure sensor bolt (1).

35. Remove the manifold absolute pressure sensor (2) from the intake manifold (3).
36. Disconnect the booster vacuum pipe (2) from the intake manifold (1).
37. Remove the 7 intake manifold bolts (1).

38. Remove the intake manifold (2).
39. Remove the intake manifold gaskets (1, 3) from the intake manifold (2).
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40. Remove the rubber bracket (2) from the intake manifold (1).
Cleaning and Inspection Procedure

Clean and inspect the intake manifold. Refer to Intake Manifold Cleaning and Inspection.
2. Install the rubber bracket (2) to the intake manifold (1).
3. Install the NEW gaskets (1, 3) to the intake manifold (2).

4. Install the intake manifold (2) and the 7 intake manifold bolts (1) and tighten to 20 Y (15 lb ft).
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5. Install the manifold absolute pressure sensor (2) to the intake manifold (3).

6. Install the manifold absolute pressure sensor bolt (1) and tighten to 6 Y (53 lb in).
7. Install the 4 multiport fuel injector seals (4).

8. Install the multiport fuel injection fuel rail (2) and the fuel injectors (3) to the intake manifold (5).
9. Install the 2 multiport fuel injection fuel rail bolts (1) and tighten to 8 Y (71 lb in).
10. Connect the booster vacuum pipe (2) to the intake manifold (1).

11. Install the throttle body assembly. Refer to Throttle Body Assembly Replacement.
12. Install the throttle body heater inlet hose (2).

13. Connect the throttle body heater inlet hose (2) to the engine coolant thermostat housing (1). Refer to Plastic Collar Quick Connect Fitting Service.
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14. Connect the throttle body heater outlet hose (4) to the throttle body (3). Refer to Plastic Collar Quick Connect Fitting Service.
15. Install the throttle body heater inlet hose (1) to the throttle body (3) install the clamp (2).
16. Connect the manifold absolute pressure sensor wiring harness plug (5).
17. Install the engine management wiring harness and the fuel injectors wiring harness.
18. Install the positive crankcase ventilation tube (1) to the throttle body (3) and to the camshaft cover (2). Refer to Plastic Collar Quick Connect Fitting
Service.
19. Remove the CH-807 closure plugs from the fuel feed pipe (1) and the multiport fuel injection fuel rail (3).
20. Install the fuel feed pipe (1) to the multiport fuel injection fuel rail (3). Refer to Plastic Collar Quick Connect Fitting Service.
21. Clip the fuel feed pipe (1) into the fuel feed pipe clip (2).
22. Install the evaporative emission canister purge solenoid valve (2) and the rubber mounting to the intake manifold (4).
23. Install the 2 evaporative emission canister bracket bolts (1) and tighten to 8 Y (71 lb in).
24. Connect the pipe (5) to the evaporative emission canister purge solenoid valve (2) and to the intake manifold (4). Refer to Plastic Collar Quick Connect
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Fitting Service.
25. Connect wiring harness plug (3).
26. Remove the EN-6015 closure plug from the fuel tank vent pipe (1).
27. Install the fuel tank vent pipe (1) to the evaporative emission canister purge solenoid valve (3). Refer to Plastic Collar Quick Connect Fitting Service.
29. Install the intake manifold brace (1).

30. Install the 2 intake manifold brace bolts (2, 3) and tighten to 8 Y (71 lb in).
31. Install the wiring harness bracket (1) to the intake manifold (2).

32. Connect the oxygen wiring harness (3).
37. Close the hood.
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Intake Manifold Tuning Valve Vacuum Control Solenoid Valve Hose Replacement

Removal Procedure
2. Remove the intake manifold tuning valve vacuum control solenoid valve hose (1) from the intake air tuning valve vacuum control solenoid valve (3) and
from the intake manifold runner control valve actuator (2).
3. Remove the intake manifold tuning valve vacuum control solenoid valve hose clip (4) from the exhaust gas recirculation cooler.
4. Remove the intake manifold tuning valve vacuum control solenoid valve hose.
1. Install the intake manifold tuning valve vacuum control solenoid valve hose (1).
2. Install the intake manifold tuning valve vacuum control solenoid valve hose to the intake air tuning valve vacuum control solenoid valve (3) and to the
intake manifold runner control valve actuator (2).
3. Install the intake manifold tuning valve vacuum control solenoid valve hose clip (4) to the exhaust gas recirculation cooler.
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Passenger Compartment Air Filter Replacement

Passenger Compartment Air Filter Replacement
Unhinge the instrument panel compartment door.
Passenger Compartment Air Filter Cover

1 Procedure
Unlock the 3 retaining tabs.
2 Passenger Compartment Air Filter
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Rear Intake Air Duct Replacement

Removal Procedure
2. Separate the front intake air duct (2) from the rear intake air duct (1).
3. Push the rear intake air duct carefully out of the 2 lower bracket insulators.
4. Remove the rear intake air duct (2) from the air cleaner adapter (1) and from the brackets.
5. Remove the 3 rear intake air duct bracket insulators (3) from the rear intake air duct (2).
6. Install the 3 bracket insulator (1) to the guidance.
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Note: Ensure that the rear intake duct is properly engaged into the bracket insulator (3).
1. Install the rear intake air duct (2) to the air cleaner adapter (1) and to the brackets.
2. Push the rear intake air duct (1) carefully into the 2 lower bracket insulators and to the front intake air duct (2).
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Clutch Actuator Cylinder Front Pipe Replacement (D16, D20, and Left Hand Drive)

Removal Procedure

Note: Do NOT disconnect engine coolant hoses.
3. Position the radiator surge tank aside.
Note: Before disconnecting the clutch actuator cylinder front pipe, remove the clutch/brake fluid from the reservoir tank.
4. Remove the clutch actuator cylinder front pipe retainer (1, 4).
5. Remove the clutch actuator cylinder front pipe from the retainer (3).
6. Remove the clutch actuator cylinder front pipe (2).
1. Install the clutch actuator cylinder front pipe (2).

2. Install the clutch actuator cylinder front pipe to the retainer (3).
3. Install the clutch actuator cylinder front pipe retainer (1, 4).
4. Bleed the hydraulic clutch system. Refer to Hydraulic Clutch System Bleeding.
5. Fill the reservoir with clutch/brake fluid up to the MAX level.
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Clutch Actuator Cylinder Front Pipe Replacement (D16, D20, and Right Hand Drive)

Removal Procedure
1. Remove brake pressure modulator valve bracket. Refer to Brake Pressure Modulator Valve Bracket Replacement.
2. Place basin underneath.
3. Clip clutch actuator cylinder front pipe out of retainers at bulkhead.
4. Open retaining clip (arrow).

5. Disconnect clutch actuator cylinder front pipe (1) from clutch master cylinder.
6. Open retaining clip (1).

7. Disconnect clutch actuator cylinder front pipe (2) from clutch actuator cylinder pipe elbow.
8. Remove clutch actuator cylinder front pipe.
1. Install clutch actuator cylinder front pipe (2).

2. Connect clutch actuator cylinder front pipeto clutch actuator cylinder pipe elbow.
3. Close retaining clip (1).
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Clutch Actuator Cylinder Front Pipe Replacement (D16, D20, and Right Hand Drive)
4. Connect clutch actuator cylinder front pipe (1) to clutch master cylinder.

5. Close retaining clip (arrow).
6. Clip clutch actuator cylinder front pipe into retainers at bulkhead.
7. Install brake pressure modulator valve bracket. Refer to Brake Pressure Modulator Valve Bracket Replacement.
8. Bleed hydraulic clutch system. Refer to Hydraulic Clutch System Bleeding.
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Clutch Actuator Cylinder Front Pipe Replacement (F40 and Left Hand Drive)

Removal Procedure
1. Remove battery tray. Refer to Battery Tray Replacement.

2. Remove radiator surge tank Radiator Surge Tank Replacement and lay aside.
4. Clip clutch actuator cylinder front pipe (2) out of 2 retainers.

5. Open retaining clip (1).
6. Disconnect clutch actuator cylinder front pipe from clutch actuator cylinder pipe elbow.
7. Remove 2 brake pressure modulator valve bracket bolts (1).

Note: For removal of clutch actuator cylinder front pipe lift brake pressure modulator valve bracket carefully.
10. Remove clutch actuator cylinder front pipe.
Note: For installation of clutch actuator cylinder front pipe lift brake pressure modulator valve bracket carefully.
1. Install clutch actuator cylinder front pipe.
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Clutch Actuator Cylinder Front Pipe Replacement (F40 and Left Hand Drive)

4. Connect clutch actuator cylinder front pipe (2) to clutch actuator cylinder pipe elbow.
5. Close retaining clip (1).
6. Clip clutch actuator cylinder front pipe (1) into 2 retainers.

7. Install 2 brake pressure modulator valve bracket bolts (1) and tighten to 20 Y (15 lb ft).
8. Install radiator surge tank Radiator Surge Tank Replacement.
10. Install battery tray. Refer to Battery Tray Replacement.
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Clutch Actuator Cylinder Front Pipe Replacement (F40 and Right Hand Drive)

Removal Procedure
1. Remove brake pressure modulator valve bracket. Refer to Brake Pressure Modulator Valve Bracket Replacement.
3. Clip clutch actuator cylinder front pipe out of retainers at bulkhead.


7. Disconnect clutch actuator cylinder front pipe (1) from clutch actuator cylinder pipe elbow.
8. Remove clutch actuator cylinder front pipe (2).
1. Install clutch actuator cylinder front pipe.

2. Connect clutch actuator cylinder front pipe (1) to clutch actuator cylinder pipe elbow.
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Clutch Actuator Cylinder Front Pipe Replacement (F40 and Right Hand Drive)

6. Clip clutch actuator cylinder front pipe into retainers at bulkhead.
7. Install brake pressure modulator valve bracket. Refer to Brake Pressure Modulator Valve Bracket Replacement.
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Exhaust Front Pipe Replacement (2.0L Diesel LNP)


Warning: Refer to Protective Goggles and Glove Warning.
Caution: Do not bend the exhaust flex pipe more than 10 degrees in any direction. Bending of more than 10 degrees or twisting in a range of ±0.5 degrees will damage
the exhaust flex decoupler.
Removal Procedure
3. Support the exhaust system.

4. Remove the 3 catalytic converter to exhaust front pipe nuts (3).
5. Remove the exhaust front pipe (4) from the catalytic converter flange (1).
7. Remove the 2 exhaust front pipe to intermediate pipe nuts (1).

8. Remove and DISCARD the 2 drive frame bolts (4)
9. Remove the 2 exhaust front pipe hanger bracket bolts (5).
10. Remove the exhaust front pipe (3) and the gasket (2).
11. Remove the exhaust front pipe hanger bracket from the exhaust front pipe. Refer to Exhaust Pipe Front Hanger Bracket Replacement.
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Exhaust Front Pipe Replacement (2.0L Diesel LNP)
1. Install the exhaust front pipe hanger bracket to the exhaust front pipe. Refer to Exhaust Pipe Front Hanger Bracket Replacement.
2. Install the exhaust front pipe (3) and a NEW gasket (2).
3. Install the 2 NEW drive frame bolts M10 (4) and tighten the bolts to 60 Y +30°-45° (44 lb ft +30°-45°).
4. Install the 2 exhaust front pipe to intermediate pipe nuts (1) and tighten the nuts to 17 Y (13 lb ft).
5. Install the 2 exhaust front pipe hanger bracket bolts M8 (5) and tighten the bolts to 22 Y (17 lb ft).
6. Install the exhaust front pipe (4) to the catalytic converter flange (1) with a NEW gasket (2).
7. Install the 3 catalytic converter to exhaust front pipe nuts (3) and tighten the nuts to 22 Y (16 lb ft).
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Exhaust Heat Shield Replacement (Diesel and Gasoline)

Exhaust Heat Shield Replacement
Warning: In order to avoid being burned, do not service the exhaust system while it is still hot. Service the system when it is cool.
Warning: Always wear protective goggles and gloves when removing exhaust parts as falling rust and sharp edges from worn exhaust components
could result in serious personal injury.
Remove the exhaust front pipe. Refer to Exhaust Front Pipe Replacement.
1 Heat Shield Retainer (Qty: 7)
2 Heat Shield
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Exhaust Manifold Heat Shield Installation

1. Install the exhaust manifold heat shield (2).

2. Install the 3 exhaust manifold heat shield bolts (1) and tighten to 10 Y (89 lb in).
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Exhaust Manifold Heat Shield Installation


2. Install the 3 exhaust manifold heat shield bolts (1) and tighten to 10 Y (89 lb in).
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Exhaust Manifold Heat Shield Removal

1. Remove the 3 exhaust manifold heat shield bolts (1).

2. Remove the exhaust manifold heat shield (2).
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Exhaust Manifold Heat Shield Removal

1. Remove the 3 exhaust manifold heat shield bolts (1).

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Exhaust Manifold Heat Shield Replacement (2.0L Diesel LNP)

Removal Procedure

Caution: Do not bend the exhaust flex pipe more than 10 degrees in any direction. Bending of more than 10 degrees or twisting in a range of ±0.5
degrees will damage the exhaust flex decoupler.
1. Remove the turbocharger. Refer to Turbocharger Replacement.
2. Remove 3 exhaust manifold heat shield bolts (1).


2. Install the exhaust manifold heat shield bolts (1) and tighten the bolts to 10 Y (89 lb in).
3. Install the turbocharger. Refer to Turbocharger Replacement.
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Exhaust Manifold Heat Shield Replacement (2.0L Diesel LNP)

Removal Procedure

1. Remove the turbocharger. Refer to Turbocharger Replacement.
2. Remove 3 exhaust manifold heat shield bolts (1).


2. Install the exhaust manifold heat shield bolts (1) and tighten the bolts to 10 Y (89 lb in).
3. Install the turbocharger. Refer to Turbocharger Replacement.
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Exhaust Manifold Installation

1. Install the exhaust manifold (1) and a NEW exhaust manifold gasket (2).

2. Install the exhaust manifold bolts (3) and tighten to 20Y (15 lb ft).
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Exhaust Manifold Removal

1. Remove 10 exhaust manifold bolts (3).

2. Remove the exhaust manifold (1).
3. Remove the exhaust manifold gasket (2).
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Exhaust Manifold Replacement (2.0L Diesel LNP)

Removal Procedure
Caution: Do not bend the exhaust flex pipe more than 10 degrees in any direction. Bending of more than 10 degrees or twisting in a range of ±0.5 degrees will
damage the exhaust flex decoupler.
1. Remove the exhaust manifold heat shield. Refer to Exhaust Manifold Heat Shield Replacement.
2. Remove 10 exhaust manifold bolts (3).

3. Remove the exhaust manifold (1).
4. Remove the exhaust manifold gasket (2).
1. Install the exhaust manifold (1) and a NEW exhaust manifold gasket (2).

2. Install the 10 exhaust manifold bolts (3) and tighten to 20 Y (15 lb ft).
3. Install the exhaust manifold heat shield. Refer to Exhaust Manifold Heat Shield Replacement.
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Exhaust Particulate Filter Heat Shield Installation - Front

1. Install the exhaust particulate filter heat shield (1).

2. Install the 3 exhaust particulate filter heat shield retaining bolts (2) and the nut (3) and tighten to 9 Y (80 lb in).
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Exhaust Particulate Filter Heat Shield Installation - Rear

1. Install the rear exhaust particulate filter heat shield (1).

2. Install the 2 exhaust particulate filter heat shield bolts (3) and the nut (2) and tighten to 9 Y (80 lb in).
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Exhaust Particulate Filter Heat Shield Removal - Front

1. Remove 3 exhaust particulate filter heat shield retaining bolts (2) and 1 nut (3).
2. Remove the exhaust particulate filter heat shield (1).
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Exhaust Particulate Filter Heat Shield Removal - Rear

1. Remove 2 exhaust particulate filter heat shield bolts (3) and nut (2).

2. Remove the rear exhaust particulate filter heat shield (1).
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Exhaust Particulate Filter Heat Shield Replacement - Front

Removal Procedure
2. Disconnect the heated oxygen sensor wiring harness plug. Remove clip from DPF sensor bracket. Refer to Heated Oxygen Sensor Replacement.
3. Remove 3 bolts (2) and the nut (3).

4. Remove the exhaust particulate filter heat shield - front (1).
1. Install the exhaust particulate filter heat shield - front (1).

2. Install the 3 bolts (2) and tighten the bolts to 9 Y (80 lb in).
3. Install the nut (3) and tighten the nut to 9 Y (80 lb in).
4. Install the heated oxygen sensor wiring harness plug. Install clip to DPF sensor bracket. Refer to Heated Oxygen Sensor Replacement.
5. Connect battery negative cable. Refer to Battery Negative Cable Disconnection and Connection.
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Exhaust Particulate Filter Heat Shield Replacement - Rear

Removal Procedure
5. Remove the 2 exhaust particulate filter heat shield bolts (3) and the nut (2).
6. Remove exhaust particulate filter heat shield (1).
1. Install the exhaust particulate filter heat shield (1).

2. Install the 2 bolts (3) and tighten the bolts to 9 Y (80 lb in).
3. Install the nut (2) and tighten the nut to 9 Y (80 lb in).
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Exhaust Pipe Front Hanger Bracket Replacement (2.0L Diesel LNP)

Removal Procedure
2. Support the exhaust front pipe (1).

3. Remove the 2 exhaust front pipe hanger bracket bolts (4) and the 2 drive frame bolts (3).
4. Remove the 2 exhaust front pipe hanger insulator nuts (5).
5. Remove the exhaust front pipe hanger bracket (6) from the exhaust front pipe hanger insulators (2).
1. Install the exhaust front pipe hanger bracket (6) to the exhaust front pipe hanger insulators (2).
2. Install the 2 exhaust front pipe hanger insulator nuts (5) and tighten the nuts to 22 Y (16 lb ft).
3. Install the 2 drive frame bolts M10 (3) and tighten the bolts to 60 Y + 30° - 45° (44 lb ft) + 30° - 45°.
4. Install the 2 exhaust front pipe hanger bracket bolts M8 (4) and tighten the bolts to 22 Y (17 lb ft).
5. Remove the support from the exhaust front pipe (1).
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Exhaust Rear Muffler Heat Shield Replacement (except 2.0L LBN)

Removal Procedure
Warning: Always wear protective goggles and gloves when removing exhaust parts as falling rust and sharp edges from worn exhaust components could
result in serious personal injury.
1. Remove the Spare Wheel and Carrier. Refer to Spare Wheel and Carrier Replacement.
2. Remove the 2 exhaust rear muffler hanger insulators (3) from the exhaust rear muffler.
3. Remove the exhaust rear muffler hanger insulator bracket bolt (1) from the exhaust rear muffler hanger insulator bracket (2).
4. Place the exhaust system onto the rear axle.
5. Remove the 4 exhaust rear muffler heat shield retainers (2).

6. Remove the exhaust rear muffler heat shield (1)
1. Install the exhaust rear muffler heat shield (1)
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Exhaust Rear Muffler Heat Shield Replacement (except 2.0L LBN)
2. Install the 4 exhaust rear muffler heat shield retainers (2).

3. Install the exhaust rear muffler hanger insulator bracket bolt (1) to the exhaust rear muffler hanger insulator bracket (2) and tighten the bolt to 25 Y (18
lb ft).
4. Install the 2 exhaust rear muffler hanger insulators (3) to the exhaust rear muffler.
5. Install the Spare Wheel and Carrier. Refer to Spare Wheel and Carrier Replacement.
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Exhaust Rear Muffler Replacement (except 2.0L LBN)

Special Tools
CH–6614 Chain - Type Pipe Cutter
Removal Procedure
1. Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle
2. Review the exhaust system cutting instructions. Refer to Exhaust System Cutting.
Warning: Always wear protective goggles and gloves when removing exhaust parts as falling rust and sharp edges from worn exhaust components could
result in serious personal injury.
3. Remove the 2 exhaust rear muffler hanger insulators (3) from the exhaust rear muffler (4).
4. Remove the exhaust rear muffler hanger insulators bracket bolt (1) from the exhaust rear muffler end pipe bracket (2).
5. Remove the exhaust rear muffler end pipe bracket (2).
6. Place the exhaust system onto the rear axle.
7. Note the dent marks (1) around the exhaust pipe.
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Exhaust Rear Muffler Replacement (except 2.0L LBN)
8. Support the intermediate pipe.

9. Cut the exhaust rear muffler end pipe from the exhaust rear muffler (4) with the CH-6614 cutter(2) at the marked positions (3).
10. Remove the exhaust rear muffler end pipe.
11. Cut the exhaust rear muffler (4) at the marked position (1).
12. Remove the exhaust rear muffler (4).
1. In case of reuse of the exhaust parts, check the exhaust pipes at the separating sets for the following conditions:
roundness of the exhaust pipe, any deformation in the range of the double-clamp must be eliminated
burrs inside and outside the exhaust pipe at the cutting edge, use a file to eliminate
rust at the exhaust pipe outside, use a sandpaper to eliminate

Install the exhaust rear muffler (7) to the 2 exhaust rear muffler hanger insulators (6).
Install the exhaust pipe clamp (1) and loosely tighten.
Install the exhaust rear muffler end pipe (5).
Install the exhaust rear muffler end pipe bracket (4) to the exhaust rear muffler end pipe.
Install the exhaust rear muffler end pipe bracket bolt (3) to the exhaust rear muffler end pipe bracket (4) and tighten to 25 Y (18 lb ft).
Install the exhaust pipe clamp (2) and loosely tighten.
Position the exhaust rear muffler.
Tighten the exhaust pipe clamp (1) to 30 Y (22 lb ft).
Position the exhaust rear muffler end pipe (5).
Tighten the exhaust pipe clamp (2) 30 Y (22 lb ft).
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Exhaust System Cutting

Cutting Instructions
General Instructions
Cut the exhaust pipe with a chain type pipe cutter or a suitable tool.
Make sure that the cutting is in an angle of 90 degrees to the exhaust pipe.
How to use the Chain Type Pipe Cutter
Lay the cutter chain around the exhaust pipe.

Tighten the chain until the chain is loosely around the exhaust pipe.
Position the chain type pipe cutter onto the required cutting position at the exhaust pipe.
Note: Don't compress the exhaust pipe with the cutter.
Tighten the chain again so that the chain cutter is softly tensioned around the exhaust pipe.
Make sure that the chain cuts in a line around the exhaust pipe
Move the chain type pipe cutter back and forth around the exhaust pipe until the chain cutter could be moved easily.
Tighten the chain again so that the chain cutter is softly tensioned around the exhaust pipe.
Repeat the 2 previous steps until the pipe is completely cut.
Which cutting line to choose
Note: The pipe must be cut that the dent marks are completely removed.
1. Note the dent marks (3) around the exhaust pipe. There will be 3 marks at each cutting position.
Cut on line (1) left from the dent mark (3) to replace part (4) of the exhaust system.
Cut on line (2) right from the dent mark (3) to replace part (5) of the exhaust system.
For example shown by a exhaust rear muffler replacement
1. Cut on line (1) left from the dent mark (2) on the exhaust pipe.
2. Cut on line (4) right from the dent mark (3) on the exhaust pipe.
3. Remove the exhaust rear muffler (5).
Reuse of cut exhaust parts

Make sure that the following conditions are given.
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Exhaust System Cutting
Roundness of the exhaust pipe, any deformation in the range of the double-clamp must be eliminated.
No burrs inside and outside the exhaust pipe at the cutting edge, use a file to eliminate.
No rust at the exhaust pipe outside, use a sandpaper to eliminate.
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Exhaust System Description (2.0L Diesel LNP)

Note: Use of non-OEM parts may cause driveability concerns.

The exhaust system carries exhaust gases, treated by the catalytic converter, through a resonator, if applicable and into the exhaust muffler where exhaust noise is
lessened. In order to secure the exhaust pipe to the exhaust manifold, a flange and seal-joint coupling is utilized. The exhaust system may utilize a slip-joint coupling
design with a clamp and a U-bolt or a flange connection with a gasket. Exhaust hangers and rubber insulators help to support the weight of the exhaust pipe along with
insulating any exhaust system vibration, rattle, or noise. Exhaust hangers also space the exhaust system away from the underbody of the vehicle and allows the exhaust
system to expand as the exhaust system warms up. Exhaust heat shields are used to protect the body and other components from damage due to the heat from the
exhaust system. The exhaust system may be comprised of the following components:
Exhaust manifold
Exhaust pipes
Catalytic converters
Exhaust muffler
Exhaust resonator, if equipped
Exhaust tail pipe, if equipped
Exhaust hangers
Exhaust heat shields
Catalytic converter
The catalytic converter is an emission control device added to the engine exhaust system in order to reduce hydrocarbons (HC), carbon monoxide (CO), and
oxides of nitrogen (NOx) pollutants from the exhaust gas. The catalytic converter is comprised of a ceramic monolith substrate, supported in insulation and housed
within a sheet metal shell. The substrate may be washcoated with 3 noble metals:
Platinum (Pt)
Palladium (Pd)
Rhodium (Rh)
The catalyst in the converter is not serviceable.
Muffler
The exhaust muffler reduces the noise levels of the engine exhaust by the use of tuning tubes. The tuning tubes create channels inside the exhaust muffler that
lower the sound levels created by the combustion of the engine.
Resonator
Some exhaust systems are equipped with a resonator. The resonator, located either before or after the muffler, allows the use of mufflers with less back pressure.
Resonators are used when vehicle characteristics require specific exhaust tuning.
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Exhaust System Replacement (2.0L Diesel LNP)

Removal Procedure
1. Read the exhaust system cutting instructions. Refer to Exhaust System Cutting.
2. Remove the exhaust rear muffler. Refer to Exhaust Rear Muffler Replacement.
4. Remove all hanger insulators from the exhaust pipe and the underbody.
1. Install all hanger insulators to the exhaust pipe and the underbody.
3. Install the exhaust rear muffler. Refer to Exhaust Rear Muffler Replacement.
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Fuel Tank Heat Shield Replacement (2.0L Diesel LNP)

Fuel Tank Heat Shield Replacement

Warning: Refer to Actions to Take When Working with Fuel Warning.
Remove the fuel tank. Refer to Fuel Tank Replacement.
1 Fuel Tank
2 Fuel Tank Heat Shield Retaining Clamp (Qty: 2)
3 Fuel Tank Heat Shield
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Hot Exhaust System Warning

Warning: While engine is operating, the exhaust system will become extremely hot. To prevent burns avoid contacting a hot exhaust system.
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Turbocharger Heat Shield Installation

1. Install the turbocharger heat shield (2).

2. Install the 3 turbocharger heat shield retaining bolts (1) and tighten to 10 Y (89 lb in).
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Turbocharger Heat Shield Removal

1. Remove 3 turbocharger heat shield retaining bolts (1).

2. Remove the turbocharger heat shield (2).
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Turbocharger Heat Shield Replacement

Removal Procedure


2. Install the 3 turbocharger heat shield retaining bolts (1), tighten to 10 Y (89 lb in).
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Removal Procedure


8. Remove the 3 power steering fluid cooling pipe loop bracket hose clamp nuts (2, 4).
9. Remove the 2 power steering fluid cooling pipe loop bracket bolts (3, 6).
10. Remove the 2 power steering fluid cooling pipe loop brackets (1).
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14. Unclip the air conditioning condenser (2) from the charge air cooler.
Note: Move the radiator forward to remove the charge air cooler inlet hose.
16. Remove the charge air cooler inlet hose (1) downwards from the vehicle.
Note: Move the radiator forward to install the charge air cooler inlet hose.
1. Position the charge air cooler inlet hose (1) to the vehicle.
2. Install the air conditioning condenser (2) to the charge air cooler.
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5. Install the 2 power steering fluid cooling pipe loop brackets (1).
6. Install the 2 power steering fluid cooling pipe loop bracket bolts (3, 6) and tighten to 9 Y (80 lb in).
7. Install the 3 power steering fluid cooling pipe loop bracket hose clamp nuts (2, 4) and tighten to 9 Y (80 lb in).

12. Install a NEW gasket (2).

13. Install the charge air cooler inlet hose (3) to the turbocharger.
14. Install the 2 charge air cooler inlet hose nuts (1) and tighten to 22 Y (16 lb ft).
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Removal Procedure

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19. Unclip the 2 wiring harness clips (1) from the wiring harness bracket.
20. Remove the upper radiator brackets. Refer to Radiator Upper Bracket Replacement.
22. Remove the left radiator protector fender from the radiator.
23. Remove the charge air cooler inlet and outlet hose from the charge air cooler.
24. Remove the power steering fluid cooling pipe loop bracket bolts (2).
25. Hang the power steering fluid cooling pipe loop aside.
Note: Move the radiator forward to remove the charge air cooler outlet hose.
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Note: Move the radiator forward to install the charge air cooler outlet hose.

2. Install the power steering fluid cooling pipe loop.
3. Install the 2 power steering fluid cooling pipe loop bracket bolts (2) and tighten to 9 Y (80 lb in).
4. Install the charge air cooler inlet and outlet hose to the charge air cooler.
5. Install the left radiator protector fender to the radiator.

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14. Clip in the 2 wiring harness clips (1) to the wiring harness bracket.

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Removal Procedure
14. Unclip the charge air cooler outlet hose (1) from the charge air cooler.
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2. Connect the charge air cooler outlet hose (1) to the charge air cooler.

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Removal Procedure

7. If equipped, remove the 3 power steering fluid cooling loop pipe bracket hose clamp nuts (2, 4).
8. If equipped, remove the 3 hose clamps (5).
9. If equipped, remove the 2 power steering fluid cooling loop pipe bracket bolts (3, 6).
10. If equipped, remove the 2 power steering fluid cooling loop pipe brackets (1).
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12. Remove the charge air cooler outlet hose (2) from the charge air cooler (1).

13. Remove the condenser (3) from the charge air cooler (2) and secure with safety belts.
14. Remove the charge air cooler (2) in top direction from the radiator (1).

1. Install the charge air cooler (2) to the radiator (1).
2. Remove the safety belts and install the condenser (3) to the charge air cooler (2).
3. Install the charge air cooler outlet hose (2) to the charge air cooler (1).
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5. If equipped, install the 2 power steering fluid cooling loop pipe brackets (1).
6. If equipped, install the 2 power steering fluid cooling loop pipe bracket bolts (3, 6) and tighten to 9 Y (80 lb in).
7. If equipped, install the 3 hose clamps (5).
8. If equipped, install the 3 power steering fluid cooling loop pipe bracket hose clamp nuts (2, 4) and tighten to 9 Y (80 lb in).

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Radiator and Charge Air Cooler Bracket Repair


3. Drill hole in the charge air cooler bracket and radiator bracket (2) using a 7 mm (0.28 in)drill.
4. Install the j-clip (3) to the radiator.
5. Install the radiator. Refer to Radiator Replacement.
6. Install the charge air cooler to the radiator. Refer to Charge Air Cooler Replacement.
7. Install the repair bolt (1) with locking compound and tighten to 5 Y (45 lb in).
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Turbocharger Coolant Feed Pipe Installation

1. Install the turbocharger coolant feed pipe (1) and NEW gaskets (2).


4. Install the 2 turbocharger bracket bolts (1) to the turbocharger bracket (2) and tighten to 25 Y (18 lb ft).
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Turbocharger Coolant Feed Pipe Removal

1. Remove the 2 turbocharger bracket bolts (1) from the turbocharger and engine block.
3. Remove the 2 hollow bolts (3) from the turbocharger and engine block.
5. Remove the 2 turbocharger coolant feed pipe gasket (2).
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Removal Procedure
4. Remove the 2 turbocharger bracket bolts (1) from the turbocharger and the engine block.
6. Remove the 2 hollow bolts (3) from the turbocharger and the engine block.
8. Remove the 2 turbocharger coolant feed pipe gaskets (2).
1. Install the turbocharger coolant feed pipe (1) with NEW gaskets (2).

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Turbocharger Coolant Return Pipe Installation


2. Install the 2 bolts (3) to the turbocharger coolant return rear pipe brackets and tighten to 10 Y (89 lb in).
3. Install the 2 clamps (1, 4) to the turbocharger coolant return rear pipe (2).
4. Install the turbocharger coolant return front pipe (2).

5. Install the hollow bolt (3) to the turbocharger coolant return front pipe (2) and a NEW gasket and tighten to 32 Y (24 lb ft).
6. Install the clamp (1) to the turbocharger coolant return front pipe (2).
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Turbocharger Coolant Return Pipe Removal


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Removal Procedure
3. Unclip the fuel injection fuel return hose (2) from the positive crankcase ventilation valve.
7. Unclip and remove the vacuum hose (3) from the vacuum pump.
9. Unclip the camshaft position sensor wiring harness retaining clip (2) and hang the wiring harness aside.

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2. Install the 2 turbocharger coolant return pipe bracket bolts (3) and tighten to 10 Y (89 lb in).
3. Install both clamps (1, 4) to the turbocharger coolant return rear pipe (2).
4. Install the turbocharger coolant return pipe (2).

5. Install the hollow bolt (3) to the turbocharger coolant return pipe (2) with a NEW gasket and tighten to 32 Y (24 lb ft).
6. Install the clamp (1) to the turbocharger coolant return pipe (2).
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7. Clip in the camshaft position sensor wiring harness retaining clip (2).

9. Install the vacuum hose (3) to the vacuum pump and clip in the vacuum hose retainer.
10. Install the fuel injection fuel return hose (1) to the fuel injection pump (2) and the fuel injectors (3).
11. Clip the fuel return hose into the 2 retainer clips.
12. Clip the fuel injection fuel return hose (2) to the positive crankcase ventilation valve.
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Turbocharger Heat Shield Installation


2. Install the 3 turbocharger heat shield retaining bolts (1) and tighten to 10 Y (89 lb in).
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Turbocharger Heat Shield Removal


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Turbocharger Heat Shield Replacement

Removal Procedure


2. Install the 3 turbocharger heat shield retaining bolts (1), tighten to 10 Y (89 lb in).
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Turbocharger Installation

1. Install the turbocharger (1) and a NEW gasket (3) to the exhaust manifold.

2. Install the 4 exhaust turbocharger inlet pipe nuts (2, 4) and tighten to 30 Y (22 lb ft).
3. Install the charge air control vacuum hose (5) to the turbocharger (1).
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Turbocharger Oil Feed Pipe Installation

1. Install the turbocharger oil feed pipe (3) and 2 NEW turbocharger oil feed pipe gaskets (2).

2. Install the 2 hollow bolts (1) to the turbocharger oil feed pipe (3) and tighten to 32 Y (24 lb ft).
3. Install the turbocharger oil feed pipe bracket bolt (5) and tighten to 10 Y (89 lb in).
4. Clip the wiring harness exhaust temperature sensor plug (4) to the turbocharger oil feed pipe bracket.
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Turbocharger Oil Feed Pipe Removal

1. Unclip the wiring harness exhaust temperature sensor plug (4) from the turbocharger oil feed pipe bracket.
2. Remove the turbocharger oil feed pipe bracket bolt (5) from the engine front cover.
3. Remove the 2 hollow bolts (1) from the oil filter assembly and turbocharger.
4. Remove the turbocharger oil feed pipe (3).
5. Remove the 2 turbocharger oil feed pipe gaskets (2).
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Turbocharger Oil Feed Pipe Replacement

Removal Procedure
4. Remove the turbocharger coolant return pipe from the turbocharger. Refer to Turbocharger Coolant Return Pipe Replacement.
5. Open the retainer clamp (1).

6. Unclip the power steering fluid reservoir outlet hose (2) from the clamp (1) and the bracket (3).
7. Hang the power steering fluid reservoir outlet hose (2) aside.
8. Unclip the exhaust temperature sensor wiring harness plug (4) from the turbocharger oil feed pipe bracket.
9. Remove the turbocharger oil feed pipe bracket bolt (5) from the engine front cover.
10. Remove the 2 hollow bolts (1) from the oil filter assembly and turbocharger.
11. Remove the turbocharger oil feed pipe (3).
12. Remove the 2 turbocharger oil feed pipe gaskets (2).
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Turbocharger Oil Feed Pipe Replacement
1. Install the turbocharger oil feed pipe (3) with 2 NEW gaskets (2).

2. Install both hollow bolts (1) to the turbocharger oil feed pipe (3) and tighten to 32 Y (24 lb ft).
3. Install the turbocharger oil feed pipe bracket bolt (5) and tighten to 10 Y (89 lb in).
4. Clip in the exhaust temperature sensor wiring harness plug (4) to the turbocharger oil feed pipe bracket.
5. Install the power steering fluid reservoir outlet hose (2) to the clamp (1) and the bracket (3).
6. Close the retainer clamp (1).
7. Install the turbo charger coolant return pipe to the turbocharger. Refer to Turbocharger Coolant Return Pipe Replacement.
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Turbocharger Oil Return Pipe Installation

1. Install the turbocharger oil return pipe (2). Use 2 NEW gaskets (1, 3).

2. Install the 4 turbocharger oil return pipe bolts (4) to the turbocharger oil return pipe (2) and tighten to 10 Y (89 lb in).
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Turbocharger Oil Return Pipe Removal

1. Remove 4 turbocharger oil return pipe bolts (4) from the turbocharger and upper oil pan.
2. Remove the turbocharger oil return pipe (2).
3. Remove the 2 turbocharger oil return pipe gaskets (1, 3).
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Turbocharger Oil Return Pipe Replacement

Removal Procedure
1. Remove the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection.
3. Remove the charge air cooler inlet hose. Refer to Charge Air Cooler Inlet Hose Replacement.
4. Remove the exhaust particulate filter. Refer to Exhaust Particulate Filter Removal.
5. Remove the 2 turbocharger bracket bolts (1).

6. Remove the turbo charger bracket (2).
7. Remove the 4 turbocharger oil return pipe bolts (4).

8. Remove the turbocharger oil return pipe (2) and the 2 turbocharger oil return pipe gaskets (1, 3).
1. Install the turbocharger oil return pipe (2) and 2 NEW gaskets (1, 3).

2. Install the 4 turbocharger oil return pipe bolts (4) and tighten to 10 Y (89 lb in).
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Turbocharger Oil Return Pipe Replacement

5. Install the exhaust particulate filter. Refer to Exhaust Particulate Filter Installation.
6. Install the charge air cooler inlet hose. Refer to Charge Air Cooler Inlet Hose Replacement.
8. Install the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection.
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Turbocharger Removal

1. Remove the charge air control vacuum hose (5) from the turbocharger (1).
2. Remove the 4 exhaust turbocharger inlet pipe nuts (2, 4).
3. Remove the turbocharger (1).
4. Remove the turbocharger gasket (3).
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Turbocharger Replacement

Removal Procedure
Warning: Always wear protective goggles and gloves when removing exhaust parts as falling rust and sharp edges from worn exhaust components could result in
serious personal injury.
Caution: Do not bend the exhaust flex decoupler more than 3 degrees in any direction. Movement of more than 3 degrees will damage the exhaust flex decoupler.
1. Disconnect battery negative cable. Refer to Battery Negative Cable Disconnection and Connection
5. Remove the turbocharger coolant return pipe. Refer to Turbocharger Coolant Return Pipe Replacement.
6. Remove the turbocharger oil feed pipe. Refer to Turbocharger Oil Feed Pipe Replacement.
7. Remove the charge air cooler inlet air hose. Refer to Charge Air Cooler Inlet Hose Replacement.
9. Remove the turbo charger coolant feed pipe. Refer to Turbocharger Coolant Feed Pipe Replacement.
10. Disconnect the exhaust temperature sensor position 1 wiring harness plug. Refer to Exhaust Temperature Sensor Replacement - Position 1.
11. Remove the charge air control vacuum hose (5) from the turbocharger (1).
12. Disconnect turbocharger wastegate actuator wiring harness plug.
13. Remove the turbocharger oil return pipe. Refer to Turbocharger Oil Return Pipe Replacement.
14. Remove the 4 exhaust turbocharger inlet pipe nuts (2, 4).
15. Remove the turbocharger (1).
16. Remove the turbocharger gasket (3).
17. Remove the exhaust temperature sensor position 1 from the turbocharger. Refer to Exhaust Temperature Sensor Replacement - Position 1.
1. Install the exhaust temperature sensor position 1 to the turbo charger. Refer to Exhaust Temperature Sensor Replacement - Position 1.
2. Install the turbocharger (1) to the exhaust manifold. Use a NEW gasket (3).

3. Install the exhaust turbocharger inlet pipe nuts (2, 4) and tighten to 30 Y (22 lb ft).
4. Install the turbocharger oil return pipe. Refer to Turbocharger Oil Return Pipe Replacement.
5. Connect the turbocharger wastegate actuator wiring harness plug.
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Turbocharger Replacement
6. Install the charge air control vacuum hose (5) to the turbocharger (1).

7. Connect the exhaust temperature sensor position 1 wiring harness plug. Refer to Exhaust Temperature Sensor Replacement - Position 1.
8. Install the turbocharger coolant feed pipe. Refer to Turbocharger Coolant Feed Pipe Replacement.
10. Install the charge air cooler inlet air hose. Refer to Charge Air Cooler Inlet Hose Replacement.
11. Install the turbocharger oil feed pipe. Refer to Turbocharger Oil Feed Pipe Replacement.
12. Install the turbocharger coolant return pipe. Refer to Turbocharger Coolant Return Pipe Replacement.
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Turbocharger System Description

The turbocharger increases engine power by pumping compressed air into the combustion chambers, allowing a greater quantity of fuel to combust at the optimal air/fuel
ratio.
Turbocharger Boost Pressure Sensor

The turbocharger boost pressure sensor is mounted on the intake manifold and measures boost pressure and air temperature.
Turbocharger Vane Position Control Solenoid or Boost Pressure Actuator

The turbocharger for this system uses a turbocharger vane position control solenoid valve or a boost pressure actuator and is controlled by the engine control
module (ECM). The turbocharger vane position control solenoid valve uses an ignition voltage circuit and a control circuit. The turbocharger vanes are controlled
to vary the amount of boost pressure. The boost pressure can be controlled independent of engine speed. There are 11 controllable vanes in this turbocharger.
The vanes mount to a drive ring that can be rotated to change the vane angle. The ECM will vary the boost dependent upon the load requirements of the engine.
The turbocharger vanes are normally open when the engine is not under a load. The ECM will close the turbocharger vanes to increase engine power and to
create a high pressure, using boost pressure actuator.
The ECM will often close the turbocharger vanes to create back pressure to drive exhaust gas through the exhaust gas recirculation (EGR) valve as required. At
extreme cold temperatures, the ECM may close the turbocharger vanes at low load conditions in order to accelerate engine coolant heating. The ECM may also
close the turbocharger vanes under exhaust braking conditions.
The Charged Air Cooler

The charged air cooler is located in front of the radiator. The turbocharger supplies hot compressed air from the turbine by sucking exhaust gas to the engine to
increase power. The airflow through the radiator cools the hot compressed air from the turbocharger.
Engine Control Module (ECM)

The engine control module (ECM) controls all turbocharger control functions. The ECM monitors information from various sensor inputs that include the following:
The accelerator pedal position (APP) sensor

The engine coolant temperature (ECT) sensor
The mass air flow (MAF) sensor
The intake air temperature (IAT) sensor
The vehicle speed sensor (VSS)
The transmission gear position or range information sensors
The manifold absolute pressure (MAP) sensor
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Removal Procedure
3. Remove the air cleaner draining hose (1) from the air cleaner housing.
4. Remove the air cleaner assembly (1).

5. Remove the 2 air cleaner bracket insulators.
1. Install the 2 air cleaner bracket insulators.
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2. Install the air cleaner assembly (1).
3. Install the air cleaner housing draining hose (1) to the air cleaner housing.
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Air Cleaner Inlet Duct Replacement

Removal Procedure
2. Remove the intake air duct bolt (2).

3. Remove the intake air duct (1).
1. Install the intake air duct (1).

2. Install the intake air duct bolt (2) and tighten to 5 Y (44 lb in).
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Removal Procedure

4. Remove the air cleaner outlet duct (2).
5. Remove the positive crankcase ventilation valve hose from the air cleaner outlet duct. Refer to Positive Crankcase Ventilation Hose/Pipe/Tube
Replacement.
1. Install the positive crankcase ventilation valve hose to the air cleaner outlet duct. Refer to Positive Crankcase Ventilation Hose/Pipe/Tube Replacement.
2. Install the air cleaner outlet duct (2).
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Removal Procedure
3. Remove the air cleaner outlet duct (1) from the mass air flow sensor.
4. Remove the 6 air cleaner housing bolts (2).
5. Remove the air cleaner housing cover (3).
6. Remove the air cleaner element (4).
1. Install the air cleaner element (4).

2. Install the air cleaner housing cover (3).
3. Install the 6 air cleaner housing bolts (2).
4. Install the air cleaner outlet duct (1) to the mass air flow sensor.
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Air Intake System Description

The primary function of the air intake system is to provide filtered air to the engine. The system uses a filter-element mounted in a housing. The filter-housing is
remotely mounted and uses intake ducts to route the incoming air into the throttle body. The secondary function of the air intake system is to muffle air induction
noise. This is achieved by the use of resonators attached to the air intake ducts. The resonators are tuned to the specific powertrain. The intake air temperature
(IAT) sensor is used to measure the temperature of the air entering the engine.
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Battery Negative Cable Disconnection and Connection (without Start/Stop System)

Removal Procedure
1. Turn on the radio and record all of the customer radio station presets.
2. Ensure that all lamps and accessories are turned off.
3. Turn the ignition OFF and remove the ignition key.
4. Remove the battery cover (1).
Warning: Refer to Battery Disconnect Warning.

5. Loosen the battery negative cable nut (2).
6. Remove the battery negative cable (1) from the battery.
1. Install the battery negative cable (1) to the battery.

2. Fasten the battery negative cable nut (2) and tighten the nut to 4.5 Y (40 lb in).
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3. Install the battery cover (1).

4. Insert the ignition key and turn the ignition to the ON position.
5. Program volatile memory. Refer to Volatile Memory Programming.
6. Program all of the customer's radio station presets and set the radio clock to the current time.
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Battery Negative Cable Replacement (without Start/Stop System)

Removal Procedure
2. Remove the battery ground cable nut (1).

3. Remove the battery negative cable (2).
4. Disconnect the wiring harness current sensor plug (4).

5. Remove the current sensor (5) from the battery tray.
6. Remove battery ground cable from the battery negative cable nut (2).
7. Remove the ground cable (3).
9. Remove the current sensor (2) from the battery negative cable (1).
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1. Install the current sensor (2) to the battery negative cable (1).
2. Install the battery negative cable (1).

3. Install the ground cable (3).
4. Install the battery ground cable to the battery negative cable nut (2) and tighten to 9 Y (80 lb in).
5. Install the current sensor (5) at the battery tray.
6. Connect the wiring harness current sensor plug (4).

8. Install the battery ground cable nut (1) and tighten to 9 Y (80 lb in).
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Battery Tray Replacement (without Start/Stop System)

Removal Procedure
1. Open the hood.

2. Remove the battery. Refer to Battery Replacement.
3. Unclip all wiring harness from the battery tray.
4. Unclip the engine control module bracket from the battery tray.
5. If equipped, unclip the radiator surge tank engine hose from the battery tray.
6. Unclip the battery current sensor (1) from the battery tray.
7. Remove the 3 battery tray bolts (1).

8. Remove the battery tray (2).
1. Install the battery tray (2).

2. Install the 3 battery tray bolts (1) and tighten to 15 Y (11 lb ft).
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3. Clip in the battery current sensor (1) to the battery tray.

4. If equipped, clip in the radiator surge tank engine hose to the battery tray.
5. Install battery. Refer to Battery Replacement.
6. Clip in all wiring harness at the battery tray.
7. Clip in the engine control module bracket to the battery tray.
8. Close the hood.
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Camshaft Actuator System Overview
(1) Camshaft Actuator Vane

(2) Timing Chain Sprocket
(3) Engine Oil Pressure-For retarding the camshaft
(4) Camshaft
(5) Input Signals from Engine Sensors
(6) Engine Control Module (ECM)
(7) Camshaft Actuator Solenoid
(8) Engine Oil Pump
(9) Engine Oil Pressure Supply
(10) Engine Oil Drain
(11) Engine Oil Pressure-For advancing the camshaft
(12) Camshaft Actuator Rotor
(13) Camshaft Position Sensor Reluctor
(14) Camshaft Actuator Lock Pin
(15) Camshaft Actuator Housing
The camshaft actuator system enables the engine control module (ECM) to change camshaft timing of all 4 camshafts while the engine is operating. The camshaft
position (CMP) actuator assembly (15) varies the camshaft position in response to directional changes in oil pressure. The CMP actuator solenoid valve controls the oil
pressure that is applied to advance or retard a camshaft. Modifying camshaft timing under changing engine demand provides better balance between the following
performance concerns:
Engine power output

Fuel economy
Tailpipe emissions
The CMP actuator solenoid valve (7) is controlled by the ECM. The crankshaft position (CKP) sensor and the CMP sensors are used to monitor changes in camshaft
positions. The ECM uses the following information in order to calculate the desired camshaft positions:
Engine coolant temperature

Calculated engine oil temperature (EOT)
Mass air flow (MAF)
Throttle position (TP)
Vehicle speed
Volumetric efficiency
Operation
The CMP actuator assembly has an outer housing that is driven by an engine timing chain. Inside the assembly is a rotor with fixed vanes that is attached to the
camshaft. Oil pressure that is applied to the fixed vanes will rotate a specific camshaft in relationship to the crankshaft. The movement of the intake camshafts will
advance the intake valve timing. The movement of the exhaust camshafts will retard the exhaust valve timing. When oil pressure is applied to the return side of the
vanes, the camshafts will return to 0 crankshaft degrees, or top dead center (TDC). The CMP actuator solenoid valve directs the oil flow that controls the camshaft
movement. The ECM commands the CMP solenoid to move the solenoid plunger and spool valve until oil flows from the advance passage (11). Oil flowing thru the
CMP actuator assembly from the CMP solenoid advance passage applies pressure to the advance side of the vanes in the CMP actuator assembly. When the
camshaft position is retarded, the CMP actuator solenoid valve directs oil to flow into the CMP actuator assembly from the retard passage (3). The ECM can also
command the CMP actuator solenoid valve to stop oil flow from both passages in order to hold the current camshaft position.
The ECM operates the CMP actuator solenoid valve by pulse width modulation (PWM) of the solenoid coil. The higher the PWM duty cycle, the larger the change
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in camshaft timing. The CMP actuator assembly also contains a lock pin (14) that prevents movement between the outer housing and the rotor vane assembly.
The lock pin is released by oil pressure before any movement in the CMP actuator assembly takes place. The ECM is continuously comparing CMP sensor inputs
with CKP sensor input in order to monitor camshaft position and detect any system malfunctions. If a condition exists in either the intake or exhaust camshaft
actuator system, the opposite bank, intake or exhaust, camshaft actuator will default to 0 crankshaft degrees.
CMP Actuator System Operation
Change in Camshaft
Driving Condition Position Objective Result
Idle No Change Minimize Valve Overlap Stabilized Idle Speed
Light Engine Load Retarded Valve Timing Decrease Valve Overlap Stabled Engine Output
Better Fuel Economy with

Medium Engine Load Advanced Valve Timing Increase Valve Overlap
Lower Emissions
Low to Medium RPM with Advance Intake Valve Improved Low to Mid-range
Advanced Valve Timing
Heavy Load Closing Torque
High RPM with Heavy Load Retarded Valve Timing Retard Intake Valve Closing Improved Engine Output
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Crankshaft Position System Variation Learn

Note: The crankshaft position sensor system variation learn procedure is required when the following service procedures have been performed, regardless of whether
DTC P0315 00 is set:
Engine replacement
Engine control module (ECM) replacement
Crankshaft damper replacement
Crankshaft replacement
Any engine repairs which disturb the crankshaft to crankshaft position sensor relationship
Note: The scan tool monitors certain component signals to determine if all the conditions are met to continue with the crankshaft position sensor system variation learn
procedure. The scan tool only displays the condition that inhibits the procedure. The scan tool monitors the following components:
Crankshaft Position Sensor activity – If there is a crankshaft position sensor condition, refer to the applicable DTC that set.
Camshaft position signal activity – If there is a camshaft position sensor signal condition, refer to the applicable DTC that set.
Engine coolant temperature (ECT) – If the engine coolant temperature is not warm enough, idle the engine until the engine coolant temperature reaches the
correct temperature.
1. Install a scan tool.

2. Monitor the ECM for DTCs with a scan tool. If other DTCs are set, except DTC P0315 00, refer to Diagnostic Trouble Code (DTC) List - Vehicle for the
applicable DTC that set.
3. With a scan tool, select the Crankshaft Position System Variation Learn procedure and perform the following:
1. Observe the fuel cut-off for the applicable engine.

2. Block the drive wheels.
3. Set the parking brake.
4. Place the vehicles transmission in Park or Neutral.
5. Turn the air conditioning (A/C) OFF.
6. Cycle the ignition from OFF to ON.
7. Apply and hold the brake pedal for the duration of the procedure.
8. Start and idle the engine.
9. Accelerate to wide open throttle (WOT). The engine should not accelerate beyond the calibrated fuel cut-off RPM value noted in step 3.1. Release the
throttle immediately if the value is exceeded.
Note: While the learn procedure is in progress, release the throttle immediately when the engine starts to decelerate. The engine control is returned to
the operator and the engine responds to throttle position after the learn procedure is complete.
10. Release the throttle when fuel cut-off occurs.
Accelerate to wide open throttle (WOT). The engine should not accelerate beyond the calibrated fuel cut-off RPM value noted in step 3.1. Release the throttle
immediately if the value is exceeded.
Note: While the learn procedure is in progress, release the throttle immediately when the engine starts to decelerate. The engine control is returned to the operator and
the engine responds to throttle position after the learn procedure is complete.
The scan tool displays Learn Status: Learned this Ignition. If the scan tool indicates that DTC P0315 00 only) ran and passed, the crankshaft position sensor variation
learn procedure is complete. If the scan tool indicates DTC P0315 00 failed or did not run, refer to DTC P0315. If any other DTCs set, refer to Diagnostic Trouble Code
(DTC) List - Vehicle for the applicable DTC that set.
Turn OFF the ignition for 30 s after the learn procedure is completed successfully.
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Electronic Ignition System Description

Electronic Ignition System Operation

The electronic ignition system produces and controls the high energy secondary spark. This spark ignites the compressed air/fuel mixture at precisely the correct
time, providing optimal performance, fuel economy, and control of exhaust emissions. The engine control module (ECM) collects information from the crankshaft
position sensor and the camshaft position sensor – intake and camshaft position sensor – exhaust to determine the sequence, dwell, and timing of the spark for
each cylinder. The ECM transmits a frequency signal to the ignition coil assembly on the appropriate ignition control circuit to fire the spark plugs.
Crankshaft Position Sensor

The crankshaft position sensor circuits consist of an engine control module (ECM) supplied 5 V reference circuit, low reference circuit, and an output signal circuit.
The crankshaft position sensor is an externally magnetically biased digital output integrated circuit sensing device. The sensor provides a pulse for each magnetic
pole of the magnetic encoder wheel on the crankshaft. Each pole on the encoder wheel is spaced at 58-pole spacing, with 2 missing poles for the reference gap.
The crankshaft position sensor produces an ON/OFF DC voltage of varying frequency, with 58 output pulses per crankshaft revolution. The frequency of the
crankshaft position sensor output depends on the velocity of the crankshaft. The crankshaft position sensor sends a digital signal, which represents an image of
the crankshaft encoder wheel, to the ECM as each pole on the wheel rotates past the crankshaft position sensor. The ECM uses each crankshaft position sensor
signal pulse to determine crankshaft speed and decodes the crankshaft encoder wheel reference gap to identify crankshaft position. This information is then used
to determine the optimal ignition and injection points of the engine. The ECM also uses crankshaft position sensor output information to determine the camshaft
position sensor – intake and camshaft position sensor – exhaust relative to the crankshaft, to control camshaft phasing, and to detect cylinder misfire.
Crankshaft Encoder Wheel

The crankshaft encoder wheel is part of the crankshaft. The encoder wheel consists of 58 poles and a reference gap. Each pole on the encoder wheel is spaced
6° apart with a 12° space for the reference gap. The pulse from the reference gap is known as the sync pulse. The sync pulse is used to synchronize the coil firing
sequence with the crankshaft position, while the other poles provide cylinder location during a revolution.
Camshaft Position Sensor

The camshaft position sensor – intake and camshaft position sensor – exhaust is triggered by a notched reluctor wheel built onto the intake camshaft sprocket.
The camshaft position sensor – intake and camshaft position sensor – exhaust provides four signal pulses to every camshaft revolution. Each notch, or feature of
the reluctor wheel is of a different size which is used to identify the compression stroke of each cylinder and to enable sequential fuel injection. The camshaft
position sensor – intake and camshaft position sensor – exhaust is connected to the ECM by the following circuits:
A 5 V reference circuit

A low reference circuit
A signal circuit
Ignition Coil Assembly

The ignition coil assembly used on this engine integrates the 4 coils and the module within a single sealed component.
The ignition coil has the following circuits:
An ignition voltage circuit

A ground
4 ignition control circuits
The ECM controls the individual coils by transmitting timing pulses on the ignition control circuit of each ignition coil to enable a spark event.
The spark plugs are connected to each coil by a short boot. The boot contains a spring that conducts the spark energy from the coil to the spark plug. The spark
plug electrode is coated with platinum for long wear and higher efficiency.

The ECM controls all ignition system functions, and constantly adjusts the spark timing. The ECM monitors information from various sensor inputs that include the
following:
The crankshaft position sensor

The accelerator pedal position (APP)
The engine knock sensor
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Remove the air conditioning compressor. Refer to Air Conditioning Compressor Replacement.
Oil Pressure Switch

Procedure
1
Disconnect the oil pressure switch wiring harness plug and remove the switch.
Tighten
30 Y (22 lb ft)
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Special Tools
CH–807 Plug
Removal Procedure
Note: Do not remove the fuel tank filler hose when the fuel contents in the fuel tank is over the half filled with fuel.
2. If the fuel level is over half filled, refer to Fuel Tank Draining.
4. Remove the fuel tank filler hose (3) from the fuel tank filler pipe (1).
5. Disconnect the fuel tank filler vent pipe (4). Refer to Plastic Collar Quick Connect Fitting Service.
6. Unclip the fuel feed pipe and the fuel vent pipe from the rear bracket clip at the underbody.
10. Demount the 2 fuel tank straps (4).
Note: Attention to other parts like pipes or hoses that are installed at the fuel tank. Lower the fuel tank only a little bit, when its not able to remove the
evaporative emission canister easily. Remove the fuel tank, if necessary.

11. Lower the fuel tank to a height where its able to remove the evaporative emission canister easily.
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12. Disconnect the fuel tank vent pipe (2).

13. Close the fuel tank vent pipe (2) with the CH-807 plug .
14. Disconnect the evaporative emission canister purge pipe (4).
15. Close the evaporative emission canister purge pipe (4) with the CH-807 plug .
16. Remove the evaporative emission canister (1) from the evaporative emission canister bracket (3).
1. Install the evaporative emission canister (1) to the evaporative emission canister bracket (3).
2. Remove the CH-807 plug from the evaporative emission canister purge pipe (4).
3. Connect the evaporative emission canister purge pipe (4).
4. Remove the CH-807 plug from the fuel tank vent pipe (2).
5. Connect the fuel tank vent pipe (2).
6. Raise the fuel tank to the original position.
7. Pre-install the 4 fuel tank strap bolts (3, 5) with the 4 fuel tank strap bolt retainers (2, 6) to the fuel tank straps (4).
8. Mount the 2 fuel tank straps (4).
9. Install the 4 fuel tank strap bolts (3, 5) and tighten to 20 Y (15 lb ft).
10. Remove the adjustable jack from the fuel tank.
11. Clip the fuel feed pipe and the fuel vent pipe into the rear bracket clip at the underbody.
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12. Connect the fuel tank filler vent pipe (4). Refer to Plastic Collar Quick Connect Fitting Service.
13. Install the fuel tank filler hose (3) to the fuel tank filler pipe (1).
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EVAP System Operation

The evaporative emission (EVAP) control system used is the charcoal canister storage method. This method transfers fuel vapor from the fuel tank to an activated
carbon, charcoal, storage device, or canister, to hold the vapors when the vehicle is not operating. When the engine is running, the fuel vapor is purged from the
carbon element by intake airflow and consumed in the normal combustion process.
Gasoline vapors from the fuel tank flow into the canister. These vapors are absorbed into the carbon. The canister is purged by the engine control module (ECM)
when the engine has been running for a specified amount of time. Air is drawn into the canister and mixed with the vapor. This mixture is then drawn into the
intake manifold.
The ECM supplies a ground to energize the evaporative emission (EVAP) canister purge solenoid valve. This valve is pulse width modulated (PWM) or turned ON
and OFF several times a second. The evaporative emission (EVAP) canister purge solenoid valve PWM duty cycle varies according to operating conditions
determined by engine load, fuel trim, and intake air temperature.
Poor idle, stalling, and poor driveability can be caused by the following conditions:
An inoperative evaporative emission (EVAP) canister purge solenoid valve

A damaged canister
Hoses that are split, cracked, or not connected to the proper tubes
Evaporative Emission Canister

The Evaporative Emission (EVAP) canister is an emission control device containing activated charcoal granules. The EVAP emission canister is used to store fuel
vapors from the fuel tank. Once certain conditions are met, the engine control module (ECM) activates the evaporative emission (EVAP) canister purge solenoid
valve, allowing the fuel vapors to be drawn into the engine cylinders and burned.
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Exhaust Gas Recirculation (EGR) System Description

The exhaust gas recirculation (EGR) system is used to reduce the amount of nitrogen oxide (NOx) emission levels caused by high combustion temperatures. At
temperatures above 1 371°C (2 500°F), oxygen and nitrogen combine to form oxides of nitrogen (NOx). Introducing small amounts of exhaust gas back into the
combustion chamber displaces the amount of oxygen entering the engine. With less oxygen in the air/fuel mixture and as a result combustion temperatures are
decreased, restricting the formation of NOx.
The EGR valve motor is a direct current (DC) stepper motor utilizing a worm gear that extends from the motor to push on the EGR valve stem. The worm gear is not
attached to the valve stem and can only force the valve open. A return spring is used to force the valve closed.
Exhaust Gas Recirculation (EGR) System Operation

The exhaust gas recirculation (EGR) valve is controlled by the engine control module (ECM) through the EGR motor high control and EGR motor low control
circuits. The ECM supplies voltage that is near ignition voltage to the high and low control circuits at all times. This voltage is used by the ECM as a reference
voltage during non EGR operation in order to detect circuit failures. The ECM will pulse width modulate (PWM) the low control circuit to ground and an increase in
amperage on the high control circuit can be observed with a DMM when the EGR valve is commanded open. A lower pulse width will increase the open position of
the valve. In order to close the EGR valve, the ECM will PWM the high control circuit to ground.
When the ignition is turned ON, the ECM will drive the EGR motor worm gear out with just enough force to touch the EGR valve stem. The ECM will do this 3 times
in quick succession. This action determines the minimum closed position of the valve and only happens once per ignition cycle. If the valve is prevented from
closing all of the way after the minimum closed position is learned, the scan tool EGR Position parameter will not reflect this position until the next ignition cycle.
The EGR motor worm gear is not connected to the EGR valve stem and can only push the valve open. The valve is returned to the closed position by a return
spring.
The ECM uses the EGR position sensor to determine the position of the EGR valve. The ECM sends a reference voltage through the 5 V reference circuit to the
EGR position sensor. The ECM provides a voltage return path for the sensor through the low reference circuit. A variable voltage signal, based on the EGR valve
position, is sent from the sensor to the ECM through the EGR position sensor signal circuit.
EGR Valve Control Enabling Conditions
Exhaust gas recirculation (EGR) valve control will only be enabled during idle and cruising conditions while the following conditions are met:
The intake air temperature (IAT) is more than 5.25°C (41.5°F). EGR valve control will remain enabled until the IAT is less than 0°C (32°F) and will not
enable again until the IAT is more than 5.25°C (41.5°F).
The engine coolant temperature (ECT) is between 60–96.75°C (140–206.15°F). EGR valve control will remain enabled until the ECT is less than 57°C
(134.6°F) or more than 99.75°C (211.55°F) and will not enable again until the ECT is between 60–96.75°C (140–206.15°F).
The barometric pressure is more than 74 kPa (10.73 PSI). EGR valve control will remain enabled until the barometric pressure is less than 72 kPa (10.44
PSI) and will not enable again until 74 kPa (10.73 PSI).
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Exhaust Gas Recirculation Pipe Replacement

Removal Procedure
2. Remove the air inlet grille panel. Refer to Air Inlet Grille Panel Replacement.
3. Remove front compartment insulator. Refer to Front Compartment Insulator Replacement.
4. Remove the 4 exhaust gas recirculation bolts (3).


2. Install the 4 exhaust gas recirculation bolts (3) and tighten to 10 Y (89 lb in).
3. Install front compartment insulator. Refer to Front Compartment Insulator Replacement.
4. Install the air inlet grille panel. Refer to Air Inlet Grille Panel Replacement.
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Exhaust Gas Recirculation Vacuum Regulator Solenoid Valve Vacuum Hose Replacement

Removal Procedure
1. Remove the engine sight shield. Refer to Engine Sight Shield Replacement
2. Remove the exhaust gas recirculation vacuum regulator solenoid valve vacuum hose (2) from the exhaust gas recirculation vacuum regulator solenoid
valve (1).
3. Remove the exhaust gas recirculation vacuum regulator solenoid valve vacuum hose (2) from the exhaust gas recirculation bypass valve (3).
1. Install the exhaust gas recirculation vacuum regulator solenoid valve vacuum hose (2) to the exhaust gas recirculation vacuum regulator solenoid valve
(1).
2. Install the exhaust gas recirculation vacuum regulator solenoid valve vacuum hose (2) to the exhaust gas recirculation bypass valve (3).
3. Install the engine sight shield. Refer to Engine Sight Shield Replacement
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Exhaust Gas Recirculation Valve Cooler Bypass Control Solenoid Valve Replacement

Removal Procedure
2. Disconnect the exhaust gas recirculation bypass control solenoid valve wiring harness plug (2).
3. Remove the 2 exhaust gas recirculation bypass control solenoid valve hoses (3).
4. Remove the 2 exhaust gas recirculation bypass control solenoid valve bolts (1).
5. Remove the exhaust gas recirculation valve cooler bypass control solenoid valve (4).
1. Install the exhaust gas recirculation valve cooler bypass control solenoid valve (4).
2. Install the 2 exhaust gas recirculation bypass control solenoid valve bolts (1) and tighten to 6 Y (53 lb in).
3. Install the 2 exhaust gas recirculation bypass control solenoid valve hoses (3).
4. Connect the exhaust gas recirculation bypass control solenoid valve wiring harness plug (2).
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Removal Procedure
6. Remove the exhaust gas recirculation pipe. Refer to Exhaust Gas Recirculation Pipe Replacement.
Replacement.

16. Unclip the engine wiring harness conduit (6) in top direction from the 3 exhaust gas recirculation cooler brackets. Hang the engine wiring harness aside.
17. Remove the engine coolant air bleed hose. Refer to Engine Coolant Air Bleed Hose Replacement.
18. Remove the vacuum pump hose. Refer to Vacuum Pump Hose Replacement.
19. Remove the intake manifold tuning valve vacuum control solenoid valve hose. Refer to Intake Manifold Tuning Valve Vacuum Control Solenoid Valve
Hose Replacement.
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26. Place a suitable tool at the market position (arrow) and rotate the lock ring (1) counterclockwise.
29. Remove the exhaust gas recirculation manifold cooling return hose. Refer to Exhaust Gas Recirculation Manifold Cooling Return Hose Replacement.
30. Remove the exhaust gas recirculation cooling feed hose. Refer to Exhaust Gas Recirculation Valve Cooling Feed Hose Replacement.
31. Remove the turbocharger coolant return pipe from the exhaust gas recirculation cooler. Refer to Turbocharger Coolant Return Pipe Removal.
32. Remove the exhaust gas recirculation cooler nut (5) and the 5 exhaust gas recirculation cooler bolt (3, 4 and 6).
33. Remove the exhaust gas recirculation cooler (2) and the gasket (1).
1. Install the exhaust gas recirculation cooler (2) and a NEW gasket (1).

2. Install the 5 exhaust gas recirculation cooler bolt (3, 4 and 6) and the exhaust gas recirculation cooler nut (5) and tighten to 25 Y (18 lb ft).
3. Install the turbocharger coolant return pipe to the exhaust gas recirculation cooler. Refer to Turbocharger Coolant Return Pipe Removal.
4. Install the exhaust gas recirculation cooling feed hose. Refer to Exhaust Gas Recirculation Valve Cooling Feed Hose Replacement.
5. Install the exhaust gas recirculation manifold cooling return hose. Refer to Exhaust Gas Recirculation Manifold Cooling Return Hose Replacement.
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Note: Note: Ensure that the retaining ring (1) is locked.

13. Install the intake manifold tuning valve vacuum control solenoid valve hose. Refer to Intake Manifold Tuning Valve Vacuum Control Solenoid Valve
Hose Replacement.
14. Install the vacuum pump hose. Refer to Vacuum Pump Hose Replacement.
15. Install the engine coolant air bleed hose. Refer to Engine Coolant Air Bleed Hose Replacement.

17. Clip the engine wiring harness conduit (6) to the 3 exhaust gas recirculation cooler brackets.
25. For vehicles with MT: Connect the transmission shift lever and selector cable from the transmission. Refer to Manual Transmission Shift Lever and
For vehicles with AT: Connect the range selector lever cable from the automatic transmission. Refer to Range Selector Lever Cable Replacement.
27. Install the exhaust gas recirculation pipe. Refer to Exhaust Gas Recirculation Pipe Replacement.
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Exhaust Gas Recirculation Valve Replacement

Removal Procedure
2. Disconnect exhaust gas recirculation valve wiring harness plug.
3. Remove the 3 exhaust gas recirculation valve bolts (2).

4. Remove the exhaust gas recirculation valve (1) and the gasket (3).
1. Install the exhaust gas recirculation valve (1) and a NEW gasket (3).

2. Install the 3 exhaust gas recirculation valve bolts (2) and tighten to 25 Y (18 lb ft).
3. Connect exhaust gas recirculation valve wiring harness plug.
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Exhaust Particulate Filter Cleaning

If a vehicle has an active or inactive diesel particulate filter (DPF) related diagnostic trouble code (DTC) a scan tool can be used to initiate a controlled service
mode DPF regeneration. This function assists in locating the DPF components requiring repair. The service regeneration mode is also the only way to regenerate
the DPF when the soot mass level has increased past the maximum threshold. When the DPF soot mass level exceeds a calibrated value, the ECM will command
power reduction and normal driving regeneration is inhibited. Performing a service regeneration will remove the power reduction command. The service
regeneration mode ignores many of the abort conditions required for normal driving regeneration. The service regeneration mode is also useful to verify that
repairs to the DPF system have been successful. DPF diagnostics are active during a service regeneration. Monitoring for DPF DTCs during the service
regeneration will help determine if any issues are present. If any DTCs occur, repair the issue and rerun the service regeneration mode. During the service
regeneration procedure, the tailpipe outlet temperature will be greater than 550°C (1 022°F). Use caution around the engine compartment, and exhaust system
during the regeneration procedure.
Scan Tool Reference
Control Module References for scan tool information
Circuit/System Verification
1. Ignition OFF, verify the coolant is at the correct level.
If the coolant is low

Refer to Loss of Coolant for diagnosis of the cooling system.
If the coolant is not low

Ignition ON, observe the scan tool diagnostic trouble code (DTC) information.
Verify there are no DTCs set.
If there are any DTCs set

Refer to Diagnostic Trouble Code (DTC) List - Vehicle for further diagnosis.
If not DTCs are set

Engine idling, verify there are no engine mechanical conditions.
Observe the scan tool DPF soot mass parameter. The parameter should be less than 5 g.
Circuit/System Testing
Warning: Tailpipe outlet exhaust temperatures will be greater than 550°C (1022°F) during service regeneration. In order to prevent personal injury or property
damage from fire, or burns, perform the following:
1. Inspect and remove any debris from the exhaust system prior to service regeneration.
2. Do not connect any shop exhaust removal hoses to the vehicle tailpipe.
3. Park the vehicle outdoors with the hood open, away from walls or buildings.
4. Keep people, other vehicles, and combustible material away during service regeneration.
5. Do not leave the vehicle unattended.
Note: The service regeneration procedure can be stopped at any time in an emergency by switching off the ignition, depressing the brake pedal, or with a scan
tool. Depressing the brake pedal returns the engine to idle speed. The scan tool function allows the engine to slowly return to idle.
1. Inspect the DPF.

2. Verify there is no soot leaking from the DPF.
If soot is present
Replace the DPF
If no soot present
Select the DPF service regeneration in the scan tool output control menu.
Follow the corresponding instructions displayed on the screen of the scan tool.
After completing the DPF service regeneration, operate the engine at 1 500 RPM for 1 min in order to let the exhaust cool evenly.
Ignition OFF, allow the engine to cool down.
Verify the coolant is at the correct level.
Repair Instructions
Exhaust Particulate Filter Replacement
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Exhaust Particulate Filter Cleaning
Repair Verification
1. Ignition ON.
2. Verify there are no DTCs set.
If there are any DTCs set

Refer to Diagnostic Trouble Code (DTC) List - Vehicle for further diagnosis.
If there no DTCs are set

Engine idling.
Verify the scan tool DPF soot mass parameter is near 0 g.
If not within the specified range

Repeat this service regeneration procedure.
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Exhaust Particulate Filter System Description

Diesel Particulate Filter (DPF)

The diesel exhaust aftertreatment system consists of an under hood pre-catalyst and an underbody catalyst, which includes the main diesel oxidation catalyst and
coated diesel particulate filter. The diesel particulate filter (DPF) consists of a solid honeycomb-like body made from silicon carbide, which is full of microscopic
channels, and is coated with noble metal. The diesel exhaust after-treatment system reduces exhaust emissions such as hydrocarbons, carbon monoxide (CO)
and particulate matter. The DPF collects particulate matter from the engine exhaust to minimize discharge of soot to the atmosphere. The exhaust flows through
the channels and soot particles are deposited on the channel walls.
The soot particles accumulate in the channels of the DPF and are burned off at regular intervals, through a process called regeneration or cleaning. The DPF
cleaning process prevents the DPF from clogging. Excess soot in filter can cause a drop in engine performance and crack the filter during regeneration.
DPF Differential Pressure Sensor

A DPF differential pressure sensor is connected across the DPF and provides feedback on soot level or exhaust back pressure to the engine control module
(ECM) . The pressure pipes, which are connected to the differential pressure sensor, measure the pressure differential between the entrance and exit of the diesel
particulate filter. The pressure differential or back pressure indicates the amount of soot collected in the DPF. To protect the engine, the ECM enables a
regeneration when critical soot level is detected in the filter.
Exhaust Gas Temperature Sensor

The exhaust gas temperature sensor is a variable resistor that measures the temperature of the output of the pre-catalyst and the underbody catalyst. The engine
control module (ECM) supplies 5 V to the exhaust gas temperature signal circuit and supplies a ground to the low reference circuit.
DPF Cleaning
During the cleaning process, additional fuel is injected via multiple post injections to increase the exhaust gas temperature. During this period, the DPF
temperature is raised to approximately 600°C (1 112°F) and the deposited soot is oxidized or burned off to carbon dioxide (CO2).
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Exhaust Pressure Differential Sensor Replacement

Removal Procedure
1. Disconnect the exhaust pressure differential sensor wiring harness plug (1).

2. Loosen the 2 exhaust pressure differential sensor hose clamps (4).
3. Remove the 2 exhaust pressure differential sensor hoses (3) and the 2 exhaust pressure differential sensor hose clamps.
4. Remove the 2 exhaust pressure differential sensor bolts (2).
5. Remove the exhaust pressure differential sensor (5).
1. Install the exhaust pressure differential sensor (5).

2. Install the 2 exhaust pressure differential sensor bolts (2) and tighten to 9 Y (80 lb ft).
3. Install the 2 exhaust pressure differential sensor hoses (3) and the 2 exhaust pressure differential sensor hose clamps.
4. Fix the 2 exhaust pressure differential sensor hose clamps (4).
5. Connect the exhaust pressure differential sensor wiring harness plug (1).
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Exhaust Temperature Sensor Replacement - Position 1

Special Tools
EN-50429 Adapter Exhaust Temperature Sensor Remover/Installer
Removal Procedure
3. Remove the positive crankcase ventilation hose. Refer to Positive Crankcase Ventilation Hose/Pipe/Tube Replacement.
5. Disconnect the exhaust temperature sensor wiring harness plug position 1 from the engine wiring harness.
6. Remove the exhaust temperature sensor position 1 (2) from the turbocharger (1), using the EN-50429 adapter .

1. Install the exhaust temperature sensor position 1 (2) to the turbocharger (1), using the EN-50429 adapter . Tighten the exhaust temperature sensor
position 1 (2) to 45 Y (33 lb ft).
2. Connect the exhaust temperature sensor wiring harness plug position 1 to the engine wiring harness.
4. Install the positive crankcase ventilation hose. Refer to Positive Crankcase Ventilation Hose/Pipe/Tube Replacement.
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Special Tools
Removal Installation
1. Disconnect and unclip the exhaust temperature sensor wiring harness plug (2) from the exhaust pressure sensor bracket.
2. Remove the exhaust temperature sensor position 2 (1) with the EN-50429 adapter .

1. Install the exhaust temperature sensor position 2 (1) with the EN-50429 adapter and tighten to 45 Y (33 lb ft).
2. Connect and clip in the exhaust temperature sensor wiring harness plug (2) to the exhaust pressure sensor bracket.
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Special Tools
Removal Procedure
2. Remove the 2 charge air cooler inlet air hose nuts. Hang the charge air cooler inlet air hose aside.
3. Disconnect and unclip the exhaust temperature sensor wiring harness plug from the charge air control vacuum pipe (1).
4. Remove the exhaust temperature sensor position 3 (2), using the EN-50429 adapter .

1. Install the exhaust temperature sensor position 3 (2) and tighten to 45 Y (33 lb ft), using the EN-50429 adapter .
2. Connect and clip in the exhaust temperature sensor wiring harness to the charge air control vacuum pipe (1).
3. Install the 2 charge air cooler inlet air hose nuts and tighten to 22 Y (16 lb ft).
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Fuel Feed Pipe Replacement - Fuel Filter to Fuel Feed Pipe

Removal Procedure

5. Disconnect the fuel feed pipe (3) from the fuel feed pipe (2). Refer to Plastic Collar Quick Connect Fitting Service.
1. Connect the fuel feed pipe (3) to the fuel feed pipe (2). Refer to Plastic Collar Quick Connect Fitting Service.
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Removal Procedure
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Fuel Feed Pipe Replacement

Special Tools
EN-6015 Closer Plug

Removal Procedure
1. Open the hood.

3. Release the fuel pressure, using the test connection with EN-34730-91 gauge .
4. Unclip the fuel feed pipe (1) from the fuel feed pipe clip (2).
5. Release the fuel feed pipe (1) from the multiport fuel injection fuel rail (3).
6. Close the fuel feed pipe (1) and the multiport fuel injection fuel rail (3) with EN–6015 plugs .
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11. Unclip the fuel feed pipe (3) from the rear brake and fuel pipe clip (2).
13. Close the fuel feed pipe (3) and the fuel feed pipe connector (1) with EN-6015 plugs .
14. Unclip the fuel feed pipe (1) from the other 5 brake and fuel pipe clips (2).
Note: Do not bend the fuel feed pipe.
15. Remove the fuel feed pipe (1).
Note: Do not bend the fuel feed pipe.

1. Install the fuel feed pipe (1).
2. Clip the fuel feed pipe (1) into the 5 brake and fuel pipe clips (2).
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3. Remove the EN-6015 closer plugs from the fuel feed pipe connector (1) and the fuel feed pipe (3).
4. Connect the fuel feed pipe (3) to the fuel feed pipe connector (1). Refer to Plastic Collar Quick Connect Fitting Service
5. Clip the fuel feed pipe (3) into the rear brake and fuel pipe clip (2).


11. Remove the EN-6015 closer plugs from the fuel feed pipe (1) and the multiport fuel injection fuel rail (3).
12. Install the fuel feed pipe (1) to the multiport fuel injection fuel rail (3).
13. Clip the fuel feed pipe (1) into the fuel feed pipe clip (2).
15. Close the hood.
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Fuel Filter Cap

1
Tighten
25 Y (19 lb in)
2 Fuel Filter Sealant
3 Fuel Filter
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Fuel Injection Fuel Feed Pipe Installation

Special Tools
1. Remove the EN-50434 dust cap from the multiport fuel injection fuel rail (3).
2. Loosen the 2 fuel injection fuel rail retaining bolts.
3. Install the fuel feed pipes (1).
4. Tighten the 10 fuel injection fuel feed pipe nuts (2) to 27 Y(20 lb ft).
5. Tighten the 2 fuel injection fuel rail retaining bolts to 25 Y(18 lb ft).
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Fuel Injection Fuel Feed Pipe Removal

Special Tools
1. Remove the 10 fuel injection fuel feed pipe nuts from the fuel injection pump, the fuel feed rail (3), and the 4 fuel injectors (2).
2. Remove the 5 fuel feed pipes (1).
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Fuel Injection Fuel Feed Pipe Replacement - Fuel Injection Pump to Fuel Rail

Special Tools
Removal Procedure
2. Remove the fuel injection fuel rail pipe (1) from the fuel injection pump (2) and from the fuel injection fuel rail (3).
3. Close the fuel feed injection fuel rail and the fuel injection pump with the EN-50434 closure plugs .
1. Remove the EN-50434 closure plugs from the fuel feed injection fuel rail and the fuel injection pump.

2. Install the fuel injection fuel rail pipe (1) to the fuel injection pump (2) and to the fuel injection fuel rail (3) and tighten to 27 Y (20 lb ft).
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Special Tools
Removal Procedure
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Fuel Injection Fuel Rail Assembly Replacement

Special Tools
Removal Procedure
2. Remove the fuel injection fuel feed pipe - fuel injection pump to fuel rail. Refer to Fuel Injection Fuel Feed Pipe Replacement - Fuel Injection Pump to
Fuel Rail.
3. Remove the fuel injection fuel feed pipe - fuel rail to fuel injector. Refer to Fuel Injection Fuel Feed Pipe Replacement - Fuel Rail to Fuel Injector.
4. Close all connections with the EN-50434 plugs .
5. Remove the 2 fuel injection fuel rail retaining bolts (1).

6. Remove the fuel injection fuel rail (2).
1. Install the fuel injection fuel rail (2).

2. Install 2 fuel injection fuel rail retaining bolts and tighten to 25 Y (18 lb ft).
4. Install the fuel injection fuel feed pipe - fuel rail to fuel injector. Refer to Fuel Injection Fuel Feed Pipe Replacement - Fuel Rail to Fuel Injector.
5. Install the fuel injection fuel feed pipe - fuel injection pump to fuel rail. Refer to Fuel Injection Fuel Feed Pipe Replacement - Fuel Injection Pump to Fuel
Rail.
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Fuel Injection Fuel Return Hose Installation


2. Install the fuel injection fuel return hose to the fuel injection pump (2) and the fuel injectors (3).
3. Clip in the fuel injection fuel return hose to the mountings at the positive crankcase ventilation valve.
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Fuel Injection Fuel Return Hose Removal

1. Unclip the fuel injection fuel return hose (1) from the mountings at the positive crankcase ventilation valve.
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Fuel Injection Fuel Return Hose Replacement

Removal Procedure
2. Unclip the fuel injection fuel return hose (2) 3 times from the mountings at the positive crankcase ventilation valve.
5. Discard the fuel injection fuel return hose (1).
Note: Do not reuse the fuel injection fuel return hose. After fuel injection fuel return hose is removed, install a NEW fuel injection fuel return hose.
1. Install a NEW fuel injection fuel return hose (1) to the fuel injection pump (2) and the fuel injectors (3).
2. Clip the fuel injection fuel return hose (2) 3 times in the mountings at the positive crankcase ventilation valve.
3. Clip in the fuel return hose to the 2 retainer clips.
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Special Tools
EN-796 Remover-Quick Connector

Removal Procedure
outlet front hose aside (1).
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10. Disconnect the fuel injection pump wiring harness plug (4).

12. Disconnect the fuel feed front pipe (5) and unclip from the fuel return front pipe clip. Refer to Plastic Collar Quick Connect Fitting Service.
13. Close the fuel return front pipe with the EN-6015 closure plugs .
14. Disconnect the fuel return front pipe (2), using the EN-796 remover . Refer to Plastic Collar Quick Connect Fitting Service.
15. Remove the fuel injection fuel feed pipe (1). Refer to Fuel Injection Fuel Feed Pipe Replacement - Fuel Injection Pump to Fuel Rail.
16. Close the fuel injection fuel feed pipe with the EN-807 closure plugs .
17. Remove the 3 injection pump bolts (3).

18. Remove the injection pump (2) and the gasket (1).
1. Install the injection pump (2) and a NEW gasket (1).

2. Install the 3 injection pump bolts (3) and tighten to 25 Y (18 lb ft).
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3. Remove the EN-807 closure plugs from the fuel injection fuel feed pipe (1).
4. Install the fuel injection fuel feed pipe (1). Refer to Fuel Injection Fuel Feed Pipe Replacement - Fuel Injection Pump to Fuel Rail.
5. Remove the EN-6015 closure plugs from the fuel return front pipe (2).
6. Connect the fuel return front pipe (2). Refer to Plastic Collar Quick Connect Fitting Service.
7. Connect the fuel feed front pipe (5) and clip to the fuel return front pipe clip. Refer to Plastic Collar Quick Connect Fitting Service.
9. Connect the fuel injection pump wiring harness plug (4).
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The control module enables the appropriate fuel injector pulse for each cylinder. The ignition voltage is supplied directly to the fuel injectors. The control module
controls each fuel injector by grounding the control circuit via a solid state device called a driver. A fuel injector coil winding resistance that is too high or too low
will affect the engine driveability. A fuel injector control circuit DTC may not set, but a misfire may be apparent. The fuel injector coil windings are affected by
temperature. The resistance of the fuel injector coil windings will increase as the temperature of the fuel injector increases.
The active fuel injector tester CH 47976 Active Fuel Injector Tester is used to test the fuel pump, fuel system leak down, and the fuel injectors. Following the user
guide, and the on screen prompts or selections, will indicate the steps required to perform each of the available tests. The tester will perform all of the tests
automatically and display the results of the test. The results can also be downloaded for storage and printing.
Schematic Reference
Circuit Testing
Connector Repairs
Wiring Repairs
Special Tools
CH 47976 Active Fuel Injector Tester
Component Testing
Fuel Injector Coil Static Test
Verify the resistance of each fuel injector with one of the following methods:
If the B34A Engine Coolant Temperature Sensor 1 is between 10–32°C (50–90°F), the resistance of each fuel injector should be 11–14 Ω.
If the injectors measure OK, perform the active fuel injector tester test procedure.
If not within the specified range, replace the fuel injector.
If the B34A Engine Coolant Temperature Sensor 1 is not between 10–32°C (50–90°F), measure and record the resistance of each fuel injector with a DMM.
Subtract the lowest resistance value from the highest resistance value. The difference between the two should be equal to or less than 3 Ω.
If the difference is equal to or less than 3 Ω, refer to active fuel injector tester test procedure for further diagnosis of the fuel injectors.
If the difference is more than 3 Ω, add all of the fuel injector resistance values to obtain a total resistance value. Divide the total resistance value by the
number of fuel injectors to obtain an average resistance value. Subtract the lowest individual fuel injector resistance value from the average resistance
value. Compute the difference between the highest individual fuel injector resistance value and the average resistance value. Replace the fuel injector
that displays the greatest difference above or below the average.
Active Fuel Injector Tester Static Test Procedure
Note:
DO NOT perform this test if the engine coolant temperature (ECT) is above 94°C (201°F). Irregular fuel pressure readings may result due to hot
soak fuel boiling.
Verify that adequate fuel is in the fuel tank before proceeding with this diagnostic.
1. Turn OFF all accessories.
2. Turn OFF the ignition.
3. Install the active fuel injector tester. Refer to the active fuel injector tester user guide.
4. Turn ON the active fuel injector tester and select the vehicle.
5. Turn ON the ignition and perform the injector test.
If the active fuel injector tester aborts testing due to fuel pressure or fuel leak down, refer to Fuel System Diagnosis.
View the test results.
If any injector exceeds the recommended tolerance, replace the injector(s).
Repair Instructions
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Perform the Diagnostic Repair Verification after completing the diagnostic procedure.
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Fuel Injector Flow Rate Programming

The control functions for the fuel injection system are integrated in the engine control module (ECM). Each injectors flow rate information, or injection quantity
adjustment flow rate numbers, and cylinder position are stored in the memory of the ECM. The fuel injector flow rate programming must be done when any of the
following procedures are performed:
The ECM is replaced

A fuel injector is replaced
1. Ignition OFF.
2. Record all the injection quantity adjustment codes from the corresponding cylinder from each injector that is being replaced or from all injectors if the
ECM was replaced.
Note: Enter the 20 digit injection quantity adjustment code from the injector or injectors that is printed on the top.
3. Perform the scan tool Injector Flow Rate Programming and follow the instructions on the screen.
Repair Verification
1. Install any components or connectors that have been removed or replaced during diagnosis.
2. Perform any adjustment, programming or setup procedures that are required when a component or module is removed or replaced.
3. Ignition OFF for 60 s.
4. Ignition ON, engine OFF.
5. Clear the DTCs.
6. If the repair was related to a DTC, duplicate the Conditions for Running the DTC and use the Freeze Frame/Failure Records, if applicable, in order to
verify the DTC does not reset. If the DTC resets or another DTC is present, refer to the Diagnostic Trouble Code (DTC) List - Vehicle and perform the
appropriate diagnostic procedure.
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Special Tools

Removal Procedure
2. Remove the 4 fuel injection fuel feed pipes - fuel rail to fuel injector. Refer to Fuel Injection Fuel Feed Pipe Replacement - Fuel Rail to Fuel Injector.
3. Remove the fuel injection fuel feed pipe - fuel pump to fuel rail. Refer to Fuel Injection Fuel Feed Pipe Replacement - Fuel Injection Pump to Fuel Rail.
4. Remove and DISCARD the 4 fuel injector bracket retaining bolts (2).

6. Remove the 4 fuel injectors (1), using the EN-50428 remover. Remove the 4 inner camshaft cover retaining bolts to use remover.
7. Close the 4 fuel injector nozzles with the EN-48559 protective caps.

Note: Use both sides of EN-47632 cleaning tool, one for loosing the dirt and the other to haul out the dirt.
1. Clean the sealing surfaces, use the EN-47632 cleaning tool.
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6. Install the 4 NEW fuel injector bracket retaining bolts (2). Tighten the bolts to 14 Y + 110° (10 lb ft + 110°).
7. Install the 4 fuel injection fuel feed pipes - fuel rail to fuel injector. Refer to Fuel Injection Fuel Feed Pipe Replacement - Fuel Rail to Fuel Injector.
8. Install the fuel injection fuel feed pipe - fuel pump to fuel rail. Refer to Fuel Injection Fuel Feed Pipe Replacement - Fuel Injection Pump to Fuel Rail.
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Fuel Pressure Gauge Installation and Removal

Special Tools
EN-50457 Fuel Pressure Gauge

EN-50517 Fuel Pressure Gauge Adapter
Removal Procedure
Warning: Refer to Relieving Fuel Pressure Warning.

Disconnect the fuel feed pipe (2) from the fuel injection pump (1) and unclip from the retainer clip. Refer to Plastic Collar Quick Connect Fitting Service.
1. Connect the EN–50517 Fuel Pressure Gauge Adapter (2) to the fuel feed line port at position (4) and to the fuel feed pipe (1).
2. Connect the EN-50457 Fuel Pressure Gauge (3) to the EN-50517 Fuel Pressure Gauge Adapter (2).
3. Check the fuel leakage.
4. Remove the EN-50457 Fuel Pressure Gauge (3) from the EN-50517 Fuel Pressure Gauge Adapter (2).
5. Remove the EN-50517 Fuel Pressure Gauge Adapter (2) from the fuel feed line port (4) and from the fuel feed pipe (1).
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Fuel Pressure Gauge Installation and Removal
6. Connect the fuel feed pipe (2) to the fuel injection pump (1) and clip in to the retainer clip.
7. Prime the fuel system. Refer to Fuel System Priming.
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Fuel Pressure Relief


1. Disconnect the battery. Refer to Battery Negative Cable Disconnection and Connection.
2. Remove the protective cap from the test connection.

3. Relieve the fuel pressure, using the EN-34730–91 Pressure Tester (1).
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Fuel Return Pipe Replacement - Fuel Return Pipe to Fuel Pump

Removal Procedure
2. Disconnect the fuel return pipe (1) from the fuel tank fuel pump module (2). Refer to Plastic Collar Quick Connect Fitting Service.
3. Unclip the fuel return pipe from the retainer clip.
1. Position the fuel return pipe (1) and clip in to the retainer clip.
2. Connect the fuel return pipe (1) to the fuel tank fuel pump module (2). Refer to Plastic Collar Quick Connect Fitting Service.
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Special Tools
Removal Procedure

3. Disconnect the fuel return pipe (1) from the fuel injection pump (2) and unclip from 2 retainer clips. Refer to Plastic Collar Quick Connect Fitting Service.
5. Open the upper bulkhead bracket (2).

6. Unclip the fuel return pipe (1) from the bulkhead bracket.
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9. Remove the 4 exhaust pipe front hanger bracket bolts (2).

10. Remove the drivetrain and the front suspension frame bolt (3).
11. Remove the right drivetrain and the front suspension frame support.
12. Unclip the fuel return pipe (1) from the 4 bracket clips (2).
15. Unclip the fuel return pipe (3) from the last bracket clip (2).
16. Remove the fuel return pipe (3).
1. Install and position the fuel return pipe (3) and clip it in to the last bracket clip (2).
3. Connect the fuel return pipe (3) to the fuel return pipe connector (1).
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4. Clip in the fuel return pipe (1) to the 4 bracket clips (2).
5. Install the right drivetrain and the front suspension frame support.
6. Install the drivetrain and the front suspension frame bolt (3).
7. Install the 4 exhaust pipe front hanger bracket bolts (2). Refer to Exhaust Pipe Front Hanger Bracket Replacement.
8. Tighten the drivetrain and the front suspension frame bolt (3) to 160 Y (118 lb ft).
11. Clip in the fuel return pipe (1) to the upper bulkhead bracket (2).
12. Close the upper bulkhead bracket.

14. Connect the fuel return pipe (1) to the fuel injection pump (2) and clip it in to 2 retainer clips.
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Note: If the fuel filter is plugged, the fuel tank should be inspected internally and cleaned if necessary.
2. Remove the fuel pump module assembly. Refer to Fuel Tank Fuel Pump Module Replacement.
3. Inspect the fuel pump module strainer. Replace the pump module assembly if the fuel strainer is contaminated.
Note: When flushing the fuel tank, handle the fuel and water mixture as a hazardous material. Handle the fuel and water in accordance with all applicable local,
state, and federal laws and regulations.
4. Flush the fuel tank with hot water.
5. Pour the water out of the fuel sender assembly opening in the fuel tank. Rock the fuel tank in order to be sure that the removal of the water from the fuel tank
is complete.
6. Allow the tank to dry completely before reassembly.
7. Disconnect the fuel feed pipe at the engine fuel rail. Refer to Fuel Feed Pipe Replacement.
Note: Only use oil-free compressed air to blow out the fuel pipes.
8. Clean the fuel pipes by applying air pressure in the opposite direction of the fuel flow.
9. Connect the fuel feed pipe to the engine fuel rail. Refer to Fuel Feed Pipe Replacement.
10. Install the fuel pump module assembly. Refer to Fuel Tank Fuel Pump Module Replacement.
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The fuel system is a returnless on-demand design. The fuel pressure regulator is a part of the fuel pump module, eliminating the need for a return pipe from the
engine. A returnless fuel system reduces the internal temperature of the fuel tank by not returning hot fuel from the engine to the fuel tank. Reducing the internal
temperature of the fuel tank results in lower evaporative emissions.
An electric turbine-style fuel pump is attached to the fuel pump module inside the fuel tank. The fuel pump supplies high pressure fuel through the fuel feed pipe to
the fuel injection system. The fuel pump provides fuel at a higher rate of flow than is needed by the fuel injection system. The fuel pump module contains a reverse
flow check valve. The check valve and the fuel pressure regulator maintain fuel pressure in the fuel feed pipe and the fuel rail in order to prevent long cranking
times.
Fuel Tank
The fuel tank stores the fuel supply. The fuel tank is located in the rear of the vehicle. The fuel tank is held in place by 2 metal straps that are attached to the
underbody. The fuel tank is molded from high-density polyethylene.
Fuel Filler Cap

Note: If a fuel tank filler cap requires replacement, use only a fuel tank filler cap with the same features. Failure to use the correct fuel tank filler cap can result in a
serious malfunction of the fuel and Evaporative Emission (EVAP) system.
The fuel fill pipe has a tethered fuel filler cap. A torque-limiting device prevents the cap from being overtightened. To install the cap, turn the cap clockwise until the
cap clicks audibly. This indicates that the cap is correctly torqued and fully seated. A fuel filler cap that is not fully seated may cause a malfunction in the emission
system.
Fuel Pump Module

The fuel pump module consists of the following major components:

The fuel pump
The fuel strainer
The fuel pressure regulator
The fuel filter
Fuel Level Sensor
contains a variable resistor which changes resistance in correspondence with the position of the float arm. The ECM sends the fuel level information via the serial
data circuit to the instrument panel cluster. This information is used for the instrument panel cluster fuel gauge and the low fuel warning indicator, if applicable. The
Fuel Pump
The fuel pump is mounted in the fuel pump module reservoir. The fuel pump is an electric low-pressure pump. Fuel is pumped to the fuel injection system at
specified rates of flow and pressure. The fuel pump delivers a constant flow of fuel to the engine even during low fuel conditions and aggressive vehicle
maneuvers. The ECM controls the electric fuel pump operation through a fuel pump relay. The fuel pump flex pipe acts to dampen the fuel pulses and noise
generated by the fuel pump.
Fuel Strainer
The fuel strainer is attached to the lower end of the fuel pump module. The fuel strainer is made of woven plastic. The functions of the fuel strainer are to filter
contaminants and to wick away fuel. Normally, the fuel strainer does not require maintenance. Fuel stoppage at this point indicates that the fuel tank contains an
abnormal amount of sediment or contamination.
Fuel Pressure Regulator

The fuel pressure regulator is contained in the fuel pump module near the fuel pump outlet. The fuel pressure regulator is a diaphragm relief valve. The diaphragm
has fuel pressure on one side and regulator spring pressure on the other side. Fuel pressure is controlled by a pressure balance across the regulator. The fuel
system pressure is constant.
Fuel Feed Pipes

The fuel feed pipe carries fuel from the fuel tank to the fuel injection system. The fuel pipe consists of 3 sections:
The rear fuel pump fuel feed hose runs from the top of the fuel tank to the chassis fuel pipe. The rear fuel hose is constructed of nylon.
The fuel feed intermediate pipe is located under the vehicle and connects the rear fuel pump fuel feed hose to the front fuel pump fuel feed hose. The
intermediate fuel pipe is constructed of a combination of nylon and steel pipes.
The front fuel pump fuel feed hose connects the fuel feed intermediate pipe to the fuel rail. The front fuel hose contains the fuel pulse dampener and is
constructed of a combination of nylon and steel pipes.
Nylon Fuel Pipes

Warning: Refer to Fuel and Evaporative Emission Pipe Warning.
Nylon pipes are constructed to withstand maximum fuel system pressure, exposure to fuel additives, and changes in temperature.
Heat resistant rubber hose or corrugated plastic conduit protect the sections of the pipes that are exposed to chasing, high temperature, or vibration.
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Fuel Pulse Dampener
The fuel pulse dampener is a part of the front fuel pump fuel feed hose. The fuel pulse dampener is diaphragm-operated with fuel pump pressure on one side and
with spring pressure on the other side. The function of the dampener is to dampen the fuel pump pressure pulsations.
Fuel Rail Assembly

The fuel rail assembly is attached to the cylinder head. The fuel rail assembly performs the following functions:
Positions the injectors in the intake ports of the cylinder head

Distributes fuel evenly to the injectors
Fuel Injectors
The fuel injector assembly is a solenoid device controlled by the ECM that meters pressurized fuel to a single engine cylinder. The ECM energizes the high-
impedance, 12 Ω, injector solenoid to open a ball valve, normally closed. This allows fuel to flow into the top of the injector, past the ball valve, and through a
director plate at the injector outlet. The director plate has machined holes that control the flow of fuel, generating a spray of finely atomized fuel at the injector tip.
Fuel from the injector tip is directed at the intake valve, causing the fuel to become further atomized and vaporized before entering the combustion chamber. This
fine atomization improves fuel economy and emissions. The fuel pressure regulator compensates for engine load by increasing fuel pressure as the engine
vacuum drops.
Fuel Metering Modes of Operation

The ECM monitors voltages from several sensors in order to determine how much fuel to feed to the engine. The ECM controls the amount of fuel delivered to the
engine by changing the fuel injector pulse width. The fuel is delivered under one of several modes.
Starting Mode
When the ECM detects reference pulses from the crankshaft position sensor, the ECM will enable the fuel pump. The fuel pump runs and builds up pressure in the
fuel system. The ECM then monitors the manifold absolute pressure (MAP), intake air temperature (IAT), engine coolant temperature (ECT), and accelerator pedal
position (APP) sensor signals in order to determine the required injector pulse width for starting.
Run Mode
The run mode has 2 conditions referred to as open loop and closed loop. When the engine is first started and the engine speed is above a predetermined rounds
per minute, the system begins open loop operation. The ECM ignores the signal from the heated oxygen sensor (HO2S). The engine ECM calculates the air/fuel
ratio based on inputs from the engine coolant temperature (ECT), the manifold absolute pressure (MAP), and accelerator pedal position (APP) sensor. The system
stays in open loop until meeting the following conditions:
The heated oxygen sensor (HO2S) has varying voltage output, showing that the heated oxygen sensor (HO2S) is hot enough to operate properly.
The ECT sensor is above a specified temperature.
A specific amount of time has elapsed after starting the engine.
Specific values for the above conditions exist for each different engine, and are stored in the programmable read-only memory (EEPROM), which may be erased
electrically. The system begins closed loop operation after reaching these values. In closed loop, the ECM calculates the air/fuel ratio, injector ON time, based
upon the signal from various sensors, but mainly from the heated oxygen sensor (HO2S). This allows the air/fuel ratio to stay very close to 14.7:1.
Acceleration Mode
The ECM monitors the changes in the accelerator pedal position (APP) sensor. and the manifold absolute pressure (MAP) sensor signal in order to determine
when the vehicle is being accelerated. The ECM will then increase the injector pulse width in order to provide more fuel for increased performance.
Deceleration Mode
The ECM monitors changes in accelerator pedal position (APP) sensor and manifold absolute pressure (MAP) sensor signals to determine when the vehicle is
being decelerated. The ECM will then decrease injector pulse width or even turn OFF injectors for short periods to reduce exhaust emissions, and for better
(engine braking) deceleration.
Battery Voltage Correction Mode

When the battery voltage is low, the ECM compensates for the weak spark delivered by the ignition system in the following ways:
Increasing the amount of fuel delivered

Increasing the idle engine speed
Increasing the ignition dwell time
Fuel Cutoff Mode

The ECM cuts OFF fuel from the fuel injectors when the following conditions are met in order to protect the powertrain from damage and improve driveability:
The ignition is OFF. This prevents engine run-on.

The ignition is ON but there is no ignition reference signal. This prevents flooding or backfiring.
The engine speed is too high, above red line.
During an extended, high speed, closed throttle coast down, this reduces emissions and increases engine braking.
Fuel Trim
The ECM controls the air/fuel metering system in order to provide the best possible combination of driveability, fuel economy, and emission control. The ECM
monitors the heated oxygen sensor (HO2S) signal voltage while in closed loop and regulates the fuel delivery by adjusting the pulse width of the injectors based
on this signal. The ideal fuel trim values are around 0% for both short and long term fuel trim. A positive fuel trim value indicates the ECM is adding fuel in order to
compensate for a lean condition by increasing the pulse width. A negative fuel trim value indicates that the ECM is reducing the amount of fuel in order to
compensate for a rich condition by decreasing the pulse width. A change made to the fuel delivery changes the long and short term fuel trim values. The short
term fuel trim values change rapidly in response to the heated oxygen sensor (HO2S) signal voltage. These changes fine-tune the engine fueling. The long term
fuel trim makes rough adjustments to fueling in order to recenter and restore control to short term fuel trim. A scan tool can be used to monitor the short and long
term fuel trim values. The long term fuel trim diagnostic is based on an average of several of the long term speed load learn cells. The ECM selects the cells
based on the engine speed and engine load. If the ECM detects an excessively lean or rich condition, the ECM will set a fuel trim diagnostic trouble code (DTC).
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Fuel System Priming

Note: In order for the diesel fuel system to work properly, the fuel lines must be full of fuel and contain no air. If air gets into the fuel lines, it will be necessary to prime the
fuel system to eliminate the air before operating the vehicle. Air could have entered the system in one of the following ways:
The vehicle ran out of fuel.

The filter was removed for service or replacement.
The fuel lines were removed or disconnected for servicing.
The fuel pump was removed for servicing.
The fuel filter water drain cock was opened while the engine was running.
If one or more of the above occurred, air has entered the fuel system and you will need to prime the system prior to operating the vehicle.
1. Turn the ignition key ON and wait 5 seconds.
Note:
Do not turn the ignition key to START. It could damage the injection pump.
Fuel priming can be performed using the scan tool.
2. Turn the ignition key OFF and wait 3 seconds.
3. Repeat steps 1 and 2 five more times.
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Removal Procedure

4. Press the fuel tank baffle (1) completely together as shown in the picture.

Note: Perform the following steps 1–3 only when the fuel tank baffles are retrofitted.
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1. Tension the fuel tank baffle (1) completely together by press it down.

Note: Mount the baffles in the shown direction.

5. Press the fuel tank baffle together. The lug (1) will unlock by its own.
6. Release slowly tension from the fuel tank baffle and let the baffle engage safely in the installation site.
7. Check for proper seat of the fuel tank baffle at the fuel tank installation sites (1). Use a mirror if necessary.
8. Repeat steps 1 to 7 to install the other baffle.
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Fuel Tank Draining

Special Tools
CH-45004 Fuel Tank Drain Hose
Warning: Never drain or store fuel in an open container. Always use an approved fuel storage container in order to reduce the chance of fire or explosion.
Warning: Place a dry chemical (Class B) fire extinguisher nearby before performing any on-vehicle service procedures. Failure to follow these precautions may result in
personal injury.
1. Open the hood.

3. Remove the fuel fill cap.
5. Remove the fuel tank filler pipe from the fuel tank. Refer to Fuel Tank Filler Pipe Replacement.
6. Insert the CH-45004 drain hose into the fuel tank until the hose reaches the bottom of the fuel tank.
7. Use an hand or air operated pump device in order to drain as much fuel as possible.
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1. Open the hood.

1 Fuel Tank Filler Hose Clamp (Qty: 2)
2 Fuel Tank Filler Hose
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1
Tighten
9 Y (80 lb in)

4 Tighten
9 Y (80 lb in)
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Special Tools
Removal Procedure
Service.
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Special Tools
Removal Procedure
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Service.

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Special Tools
Removal Procedure
Service.
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12. Lower the fuel tank slowly down to a height where the fuel pump wiring harness plug (3) is accessible.
13. Disconnect the fuel pump wiring harness plug (3) from the fuel pump module (4).
14. Disconnect the 2 fuel filter wiring harness plugs (1) and (2) from the fuel filter (6).
15. Unclip the wiring harness from the clip (5) and (7).
16. Lower the fuel tank.
Disassembly Procedure
1. Remove the fuel feed pipe (1) from fuel tank fuel pump module (4) and fuel filter housing (3). Refer to Plastic Collar Quick Connect Fitting Service.
2. Remove the fuel return pipe (2) from fuel tank fuel pump module (4). Refer to Plastic Collar Quick Connect Fitting Service.
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3. Install the EN-48253 remover/installer to the fuel pump module lock ring.


8. Remove the fuel filter (2) from the fuel filter bracket (1).

9. Remove the fuel tank heat shield. Refer to Fuel Tank Heat Shield Replacement.
10. Remove the fuel tank baffle. Refer to Fuel Tank Baffle Replacement.
Assembly Procedure
1. Install the fuel tank baffle. Refer to Fuel Tank Baffle Replacement.
2. Install the fuel tank heat shield. Refer to Fuel Tank Heat Shield Replacement.
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3. Install the fuel filter (2) at the fuel filter bracket (1).

10. Install the fuel feed pipe (1) to the fuel tank fuel pump module (4) and fuel filter housing (3). Refer to Plastic Collar Quick Connect Fitting Service.
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1. Raise the fuel tank with a suitable adjustable jack to a height where the fuel pump wiring harness plug (3) is accessible.
2. Clip in the wiring harness to the clip (5) and (7).
3. Connect the fuel pump wiring harness plug (3) to the fuel pump module (4).
4. Connect the 2 fuel filter wiring harness plugs (1) and (2) to the fuel filter (6).


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Special Tools
EN–6015 Closer Plug
Removal Procedure
1. Open the hood.

3. Remove the fuel tank vent pipe (1) from the evaporative emission canister purge solenoid valve (3).
4. Close the fuel tank vent pipe with EN-6015 closer plug .
5. Unclip the fuel tank vent pipe (1) from the brake and fuel pipe clip (2).
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10. Unclip the fuel vent pipe (3) from the rear brake and fuel pipe clip (2).
11. Disconnect the evaporative emission canister fuel vent pipe connector (1) from the fuel tank vent pipe (3). Refer to Plastic Collar Quick Connect Fitting
Service.
12. Close the fuel tank vent pipe and emission canister fuel vent pipe with EN-6015 plugs .
13. Unclip the fuel tank vent pipe (1) from the 4 other brake and fuel pipe clips (2).
14. Remove the fuel tank vent pipe (1).

1. Install the fuel tank vent pipe (1).
2. Clip the fuel tank vent pipe (1) into the 4 brake and fuel pipe clips (2).
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3. Remove the EN-6015 closer plugs from the emission canister fuel vent pipe (1) and the fuel tank vent pipe (3).
4. Connect the fuel vent pipe (3) to the emission canister fuel vent pipe (1). Refer to Plastic Collar Quick Connect Fitting Service.

10. Remove the EN-6015 closer plug from the fuel tank vent pipe (1).
11. Install the fuel tank vent pipe (1) to the evaporative emission canister purge solenoid valve (3).
12. Clip the fuel tank vent pipe (1) into the brake and fuel pipe clip (2).
14. Close the hood.
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Glow Plug Controller Bracket Replacement

Removal Procedure
1. Remove the glow plug controller. Refer to Glow Plug Controller Replacement.
2. Remove the glow plug controller bracket (1) in top direction from the battery tray (2).
1. Install the glow plug controller bracket (1) to the battery tray (2).

2. Install the glow plug controller. Refer to Glow Plug Controller Replacement.
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Glow Plug Controller Replacement

Removal Procedure
1. Disconnect the 2 wiring harness plugs (3).

2. Remove the glow plug control module (1) by loosening the 2 retainer clips (2).
1. Install the glow plug control module (1). Slide the glow plug control module (1) to the 2 retainer clips (2) until they hearable engage.
2. Connect the 2 wiring harness plugs (3).
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Glow Plug Replacement

Removal Procedure
Caution: Use care when disconnecting the glow plug electrical connector. Use of excessive force may damage the electrical connector.
3. Remove the 4 glow plugs (1).

1. Install the 4 glow plugs (1) and tighten to 11 Y (97 lb in).
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Glow Plug System Description

Glow plugs are used to heat the combustion chambers of diesel engines in cold conditions to help with ignition at cold start-up. In the tip of the glow plug is a coil of a
resistive wire or a filament which heats up when electricity is connected.
Glow plugs are required because diesel engines produce the heat needed to ignite their fuel by the compression of air in the cylinder and combustion chamber. In cold
weather, and when the engine block, engine oil and cooling water are cold, the heat generated during the first revolutions of the engine is conducted away by the cold
surroundings, preventing ignition. The glow plugs are switched on prior to turning over the engine to provide heat to the combustion chamber, and remain on as the
engine is turned over to ignite the first charges of fuel. Once the engine is running, the glow plugs are no longer needed, although some engines run the glow plugs for
between 5–10 s after starting to ensure smooth and efficient running and sometimes to keep the engine within emissions regulations, since combustion efficiency is
greatly reduced when the engine is very cold. During this period, the power fed to the glow plugs is greatly reduced to prevent them burning out by overheating.
Control of the glow plugs is accomplished by a glow plug control module. The temperature and the power consumption is controlled between the engine control module
(ECM) and the controller within a wide range to suit the engine pre heating requirements. Each glow plug is energized individually. This capability yields more optimum
heat times for the glow plugs, thus pre glow times can be kept to a minimum for short wait to crank times and maximum glow plug durability. A DTC will set if there is a
glow plug system fault.
A normal functioning system operates as follows:
Turn the ignition ON with the engine OFF, and at room temperature.
The glow plugs turn ON and heat up in 2 s and then are pulse-width modulated (PWM) for another 2 s.
The glow plug wait lamp is ON for 1 s during cold start.
The glow plug wait lamp may not illuminate during a warm engine start.
If the engine is cranked during or after the above sequence, the glow plugs may cycle ON and OFF after the ignition switch is returned from the start position,
whether the engine starts or not. The engine does not have to be running to terminate the glow plug cycling.
The glow plug initial ON time will vary based on the system voltage and temperature. Lower temperatures cause longer ON times.
The ECM provides glow plug operation after starting a cold engine. This post-start operation is initiated when the ignition switch is returned to Run, from the Start
position. This function helps clean up excessive white smoke and/or poor idle quality after starting.
Glow Plugs
The glow plugs are 4.4 V heaters in each of the cylinders that turn ON, then are pulse-width modulated when the ignition switch is turned to the RUN position prior
to starting the engine. The glow plug controller remains pulsing the glow plugs a short time after starting, then are turned OFF.
A Wait to Start lamp on the instrument panel provides information on engine starting conditions. The Wait to Start lamp will not illuminate during post-start glow
plug operation.
Glow Plug/Controller
The glow plug controller is a solid state device which operates the glow plugs. The glow plug controller is connected to the following circuits:
The battery voltage circuits

The CAN communication circuit located between the ECM and the glow plug controller
The engine ground circuit
The glow plug supply voltage circuits located between the glow plug controller and the glow plugs
The glow plug diagnostic circuits are directly monitored individually by using a separate transistor to control current to each glow plug. Individual diagnosis is thus
possible for every glow plug.
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Ignition Coil Replacement

Special Tools
EN-6009 Remover and Installer Ignition Coil
Removal Procedure
1. Remove the engine wiring harness guide (1) from the cylinder head.
2. Disconnect the ignition coil plug (2).
Note: Note the arrow on the cover.
3. Remove the cover of the ignition coil in the direction of the arrow.
4. Remove the 2 ignition coil bolts.
5. Install the EN-6009 remover/installer (1).

6. Remove the ignition coil (2).
7. Remove the EN-6009 remover/installer (1).
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4. Install the 2 ignition coil bolts an tighten to 9 Y (80 lb in).
5. Install the ignition coil cover in the direction of the arrow.
6. Connect the ignition coil plug (2).

7. Install the engine wiring harness guide (1) at the cylinder head.
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Intake Air Duct Replacement

Removal Procedure
2. Remove the front intake air duct bolt (2).

3. Remove the front intake air duct (3) from the rear intake air duct (1).
1. Install the front intake air duct (3) to the rear intake air duct (1).

2. Install the front intake air duct bolt (2) and tighten.
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Intake Air Tuning Valve Vacuum Control Solenoid Valve Replacement

Removal Procedure
2. Disconnect the 2 tuning valve vacuum control solenoid valve wiring harness plugs (5, 8).
3. Remove the 4 tuning valve vacuum control solenoid valve hoses (1, 2).
4. Remove the 2 tuning valve vacuum control solenoid valve bolts (4).
5. Remove the intake air tuning valve vacuum control solenoid valve (3).
6. Remove the 2 additional tuning valve vacuum control solenoid valve bolts (7).
7. Remove the additional intake air tuning valve vacuum control solenoid valve (6).
1. Install the additional intake air tuning valve vacuum control solenoid valve (6).
2. Install the 2 additional tuning valve vacuum control solenoid valve bolts (7) and tighten to 10 Y (89 lb in).
3. Install the intake air tuning valve vacuum control solenoid valve (3).
4. Install the 2 tuning valve vacuum control solenoid valve bolts (4) and tighten to 10 Y (89 lb in).
5. Install the 4 tuning valve vacuum control solenoid valve hoses (1, 2).
6. Connect the 2 tuning valve vacuum control solenoid valve wiring harness plugs (5, 8).
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Plastic Collar Quick Connect Fitting Service

Plastic Quick Connect Fitting Type Identification

Plastic Quick Connect Fitting Type A
Quick connect fitting type A - TI loc with one latch (1).

Plastic Quick Connect Fitting Type B
Quick connect fitting type B – TI loc upper latch (1).

Quick connect fitting type B – TI loc lower latch (2).
Plastic Quick Connect Fitting Type C
Quick connect fitting type C (1).

Plastic Quick Connect Fitting Type D
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Quick connect fitting type D (1).

Plastic Quick Connect Fitting Type E
Quick connect fitting type E (1).

Plastic Quick Connect Fitting Type F
Quick connect fitting type F (1).

Plastic Quick Connect Fitting Type G
Quick connect fitting type G (1).

Plastic Quick Connect Fitting Type H
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Quick connect fitting type H (1).
General Instructions for Handling the Connectors

Before Disconnection
Warning: Wear safety glasses when using compressed air, as flying dirt particles may cause eye injury.
Note: The following instructions apply to all of these types of fittings.
Using compressed air, to blow any dirt out of the quick connect fitting.
After Disconnection
Wipe off the male pipe end using a clean shop towel.
Inspect both ends of the fitting for dirt and burrs.
Clean components as required.
Replace damaged components.
Type A - Disconnect/Connect
Disconnect
Note: Mechanical violence is not necessary for a successful disconnection/connection.

1. Push the tube (3) into the connector (1) and push down the latch (2).
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2. Push the latch (2) into the connector (1).
3. Pull the pipe (3) out of the connector (1).

4. Release the latch (2).
Connect
1. Push the pipe (3) into the connector (1).
2. When the connector is locked correctly, the latch (2) must align to the connector (1).
3. Do not rely only on the audible click to confirm a secure connection has been made.
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4. Pull on both sides of the quick connect fitting in order to make sure the connection is secure.
Type B - Disconnect/Connect
Disconnect

1. Unlock the connector by pulling the latch (1) out of the connector. Use a suitable tool if necessary.
3. Push the latch (1) into the connector.
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5. Release the latch.
Connect
2. When the connector is locked correctly, the latch (1) must align to the connector.
Note: The latch (2) can only pushed into the connector (1) when the pipe (3) is connected correctly.
3. Push the latch (2) into the connector (1) to secure the connection.
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Type C - Disconnect/Connect
Disconnect

1. Squeeze the plastic quick connect fitting release tabs with the EN-796-A release tool.
2. Pull the connection apart.

Connect
1. Push both sides of the quick connect fitting together in order to cause the retaining feature to snap into place.
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3. Once installed, pull on both sides of the quick connect fitting in order to make sure the connection is secure.
Type D - Disconnect/Connect
Disconnect

1. Release the fitting by pushing the tab toward the other side of the slot in the fitting.

Connect
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Type E – Disconnect/Connect
Disconnect

1. Squeeze where indicated by arrows on both sides of the plastic ring surrounding the quick connect fitting.

Connect
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Type F – Disconnect/Connect
Disconnect

1. Release the fitting by pressing on one side of the release tab causing it to push in slightly. If the tab does not move, try pressing the tab in from the
opposite side. The tab will only move in one direction.

Connect
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Type G – Disconnect/Connect
Disconnect

1. Push the tube (3) into the connector (1) and push down the latch (2) as the arrow shows.
2. Hold the latch (2) in this position.

4. Release the latch (2).
Connect
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2. When the connector is locked correctly, the latch (2) must go back in opposite arrow direction.
Type H – Disconnect/Connect
Disconnect

1. Push the tube (3) into the connector (1) and press the latches (2) together.
2. Hold the latch (2) in this position.
3. Push the latch (1) completely down into the connector.
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Connect
Note: The latch (1) can only pushed into the connector when the pipe is connected correctly.
2. When the connector is connected completely, push the latch (1) back into the connector.
3. The latch (2) must completely lock at the outside at the connector (1).

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Removal Procedure
2. Separate the front intake air duct (2) from the rear intake air duct (1).
3. Push the rear intake air duct carefully out of the 2 lower bracket insulators.
4. Remove the rear intake air duct (2) from the air cleaner adapter (1) and from the brackets.
5. Remove the 3 rear intake air duct bracket insulators (3) from the rear intake air duct (2).
6. Install the 3 bracket insulator (1) to the guidance.
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Note: Ensure that the rear intake duct is properly engaged into the bracket insulator (3).
1. Install the rear intake air duct (2) to the air cleaner adapter (1) and to the brackets.
2. Push the rear intake air duct (1) carefully into the 2 lower bracket insulators and to the front intake air duct (2).
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Spark Plug Inspection

Spark Plug Usage
1. Ensure that the correct spark plug is installed. An incorrect spark plug causes driveability conditions. Refer to the electronic parts catalog for the correct
spark plug.
2. Ensure that the spark plug has the correct heat range. An incorrect heat range causes the following conditions:
Spark plug fouling—Colder plug

Pre-ignition causing spark plug and/or engine damage—Hotter plug
1. Inspect the terminal post (1) for damage.
Inspect for a bent or broken terminal post (1).

Test for a loose terminal post (1) by twisting and pulling the post. The terminal post (1) should NOT move.
Inspect the insulator (2) for flashover or carbon tracking, soot. This is caused by the electrical charge traveling across the insulator (2) between the terminal post
(1) and ground. Inspect for the following conditions:
Inspect the spark plug boot for damage.

Inspect the spark plug recess area of the cylinder head for moisture, such as oil, coolant, or water. A spark plug boot that is saturated causes arcing to
ground.
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Inspect the insulator (2) for cracks. All or part of the electrical charge may arc through the crack instead of the electrodes (3, 4).
Inspect for evidence of improper arcing.
Measure the gap between the center electrode (4) and the side electrode (3) terminals. Refer to Ignition System Specifications. An excessively wide
electrode gap can prevent correct spark plug operation.
Inspect for the correct spark plug torque. Refer to Ignition System Specifications. Insufficient torque can prevent correct spark plug operation. An over
torqued spark plug, causes the insulator (2) to crack.
Inspect for signs of tracking that occurred near the insulator tip instead of the center electrode (4).
Inspect for a broken or worn side electrode (3).
Inspect for a broken, worn, or loose center electrode (4) by shaking the spark plug.
A rattling sound indicates internal damage.
A loose center electrode (4) reduces the spark intensity.
Inspect for bridged electrodes (3, 4). Deposits on the electrodes (3, 4) reduce or eliminates the gap.
Inspect for worn or missing platinum pads on the electrodes (3, 4) If equipped.
Inspect for excessive fouling.
Inspect the spark plug recess area of the cylinder head for debris. Dirty or damaged threads can cause the spark plug not to seat correctly during
installation.
Spark Plug Visual Inspection
1. Normal operation—Brown to grayish-tan with small amounts of white powdery deposits are normal combustion by-products from fuels with additives.
2. Carbon Fouled—Dry, fluffy black carbon, or soot caused by the following conditions:
Rich fuel mixtures

Leaking fuel injectors
Excessive fuel pressure
Restricted air filter element
Incorrect combustion
Reduced ignition system voltage output
Weak coils
Worn ignition wires
Incorrect spark plug gap
Excessive idling or slow speeds under light loads can keep spark plug temperatures so low that normal combustion deposits may not burn off.
Deposit Fouling—Oil, coolant, or additives that include substances such as silicone, very white coating, reduces the spark intensity. Most powdery deposits
will not effect spark intensity unless they form into a glazing over the electrode.
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Spark Plug Replacement

Remove the ignition coil. Refer to Ignition Coil Replacement.
Spark Plug Fastener

1
Tighten
25 Y (18 lb ft)
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Special Tools

Illustration Tool Number/Description
CH-44581
J-44581
Fuel Line Disconnect Tool
CH-45004
J-45004
Fuel Tank Drain Hose
DT-49407-83
Sliding Hammer
EL-43244
J-43244
Relay Puller Pliers
EN-32-025
Sliding Hammer Adapter
EN-6015
KM-6015
Closure Plugs
EN-6368
KM-6368
Set of Plugs
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Special Tools
EN-6602
KM-6602
Remover
EN-6603-KM
Fixing Wrench
EN-23738-A
J-23738-A
Mityvac
EN-24460-01
J-24460-01
Cooling System Pressure Tester
EN-46786-32
Injector Removal Tool
EN-46790-32
Puller
EN-47632-32
Cleaning Tool
EN-48248
Cylinder Compression Pressure Gauge
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Special Tools
EN-48279
Main Fuel Pump Lock Ring Remover/Installer
EN-48357
Injector Remover
EN-48390
Remover/Installer Glow Plugs (For glow plugs without pressure sensor)
EN-48558
Glow Plug Socket Remover
EN-48560
Injector Fixing Tool
GE-42220
J-42220
Universal 12 V Leak Detection Lamp
J-38641-B
Diesel Fuel Quality Tester
J-43178
Fuel Line Disconnect Tool
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Special Tools
EN-50457
Fuel Pressure Gauge
EN-50517
Fuel Pressure Gauge Adapter
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Special Tools

Illustration Tool Number / Description
CH-807
Closure Plugs
EN-6009
KM-6009
83 96 335
J-43301
Remover and Installer Ignition Coil
EN-6015
KM-6015
Closure Plugs
EN-6179
KM-6179
Heated Oxygen Sensor Remover/Installer
EN-6363
KM-6363
Spark Plug Remover/Installer
EN-23738-A
J–23738-A
DW09915-67310
Mityvac
EL-26792
J 26792
HEI Spark Tester
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Special Tools
EN-34730-91
KM-J-34730-91
Pressure Tester
Similar tools:
CH-48027
Digital Pressure Gauge
EL-35616-E
J-35616-E
KM-609
GM-Approved Terminal Test Kit includes J 35616-200 Test Light– Probe
Kit
EN-36012-A
J-36012-A
Ignition System Diagnosis Harness
EN-41413-VLV
J-41413-VLV
EVAP Service Port Vent Fitting
CH-41769
J-41769
Fuel Line Disconnect Tool Set
EL-43244
J-43244
DW540-010
Relay Puller Pliers
CH-44175
J 44175
Fuel Composition Tester
CH-45004
J-45004
Fuel Tank Drain Hose
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Special Tools
CH-48027
Digital Pressure Gauge
Similar Tools:
EN-34730-91
KM-J-34730-91
Pressure Tester
EN-48279
Main Fuel Pump Locking Ring Remover/Installer
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Turbocharger System Description

The turbocharger increases engine power by pumping compressed air into the combustion chambers, allowing a greater quantity of fuel to combust at the optimal air/fuel
ratio.
Turbocharger Boost Pressure Sensor

The turbocharger boost pressure sensor is mounted on the intake manifold and measures boost pressure and air temperature.
Turbocharger Vane Position Control Solenoid or Boost Pressure Actuator

The turbocharger for this system uses a turbocharger vane position control solenoid valve or a boost pressure actuator and is controlled by the engine control
module (ECM). The turbocharger vane position control solenoid valve uses an ignition voltage circuit and a control circuit. The turbocharger vanes are controlled
to vary the amount of boost pressure. The boost pressure can be controlled independent of engine speed. There are 11 controllable vanes in this turbocharger.
The vanes mount to a drive ring that can be rotated to change the vane angle. The ECM will vary the boost dependent upon the load requirements of the engine.
The turbocharger vanes are normally open when the engine is not under a load. The ECM will close the turbocharger vanes to increase engine power and to
create a high pressure, using boost pressure actuator.
The ECM will often close the turbocharger vanes to create back pressure to drive exhaust gas through the exhaust gas recirculation (EGR) valve as required. At
extreme cold temperatures, the ECM may close the turbocharger vanes at low load conditions in order to accelerate engine coolant heating. The ECM may also
close the turbocharger vanes under exhaust braking conditions.
The Charged Air Cooler

The charged air cooler is located in front of the radiator. The turbocharger supplies hot compressed air from the turbine by sucking exhaust gas to the engine to
increase power. The airflow through the radiator cools the hot compressed air from the turbocharger.

The engine control module (ECM) controls all turbocharger control functions. The ECM monitors information from various sensor inputs that include the following:
The accelerator pedal position (APP) sensor

The mass air flow (MAF) sensor
The vehicle speed sensor (VSS)
The transmission gear position or range information sensors
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Vacuum Modulator Replacement

2. Remove the exhaust gas recirculation bypass control solenoid valve hose (1).
3. Unclip the vacuum modulator rod (3) from the exhaust gas recirculation cooler bypass valve shaft (4).
4. Turn the vacuum modulator (2) counterclockwise until it stops.
5. Remove the vacuum modulator in top direction from the exhaust gas recirculation cooler bypass valve bracket.
1. Install the vacuum modulator (2) to the exhaust gas recirculation cooler bypass valve bracket.
2. Turn the vacuum modulator clockwise until it stops.
3. Clip the vacuum modulator rod (3) to the exhaust gas recirculation cooler bypass valve shaft (4).
4. Install the exhaust gas recirculation bypass control solenoid valve hose (1).
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Vacuum Pump Assembly Replacement

Removal Procedure
7. Detach the charge air cooler outlet front hose (1) along with the rear hose clamp (4) from the charge air cooler outlet rear hose (3). Hang the charge air
cooler outlet hose aside (1).
8. Disconnect the exhaust pressure differential wiring harness plug.
9. Disconnect the engine wiring harness from the glow plug wiring harness plug.
10. Unclip the engine wiring harness from the wiring harness bracket.
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13. Remove the vacuum pump hose (1).

14. Loosen the power brake booster vacuum pipe clamp (3) and remove the power brake booster vacuum pipe (2).
15. Remove the 3 vacuum pump assembly bolts (4).
16. Remove the vacuum pump assembly (5) and the vacuum pump assembly gasket.
1. Install the vacuum pump assembly (5) and a NEW vacuum pump assembly gasket.
2. Install the 3 vacuum pump assembly bolts (4) and tighten to 10 Y (89 lb in).
3. Install the power brake booster vacuum pipe (2) and fix the power brake booster vacuum pipe clamp (3).
4. Install the vacuum pump hose (1).
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7. Clip the engine wiring harness to the wiring harness bracket.
8. Connect the engine wiring harness to the glow plug wiring harness plug.
9. Connect the exhaust pressure differential wiring harness plug.
10. Install the charge air cooler outlet front hose (1) along with the rear hose clamp (4) to the charge air cooler outlet rear hose (3).
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Vacuum Pump Hose Replacement

Removal Procedure
2. Remove the vacuum pump hose (2) from the vacuum pump (1).

3. Remove the vacuum pump hose from the 2 vacuum pump hose clips (3).
4. Remove the wiring harness conduit (1) in top direction from the 3 exhaust gas recirculation cooler brackets. Hang the wiring harness conduit aside.
5. Remove the vacuum pump hose (3) from the exhaust gas recirculation valve cooler bypass control solenoid valve (5).
6. Remove the 3 vacuum pump hose clips (2).
7. Remove the vacuum pump hose (3) from the charge air bypass valve vacuum tank (4).
1. Install the vacuum pump hose (3) to the charge air bypass valve vacuum tank (4).
2. Install the 3 vacuum pump hose clips (2).
3. Install the vacuum pump hose (3) to the exhaust gas recirculation valve cooler bypass control solenoid valve (5).
4. Install the wiring harness conduit (1) to the 3 exhaust gas recirculation cooler brackets.
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Vacuum Pump Hose Replacement
5. Install the vacuum pump hose to the 2 vacuum pump hose clips (3).
6. Install the vacuum pump hose (2) to the vacuum pump (1).
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Accelerator Pedal Position Sensor Replacement

Accelerator Pedal Position Sensor Replacement
Accelerator Pedal Position Sensor Fastener

1
Tighten
10 Y (89 lb in)
Accelerator Pedal Position Sensor

2 Procedure
Disconnect electrical connector.
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Accelerator Pedal Position System Description

The accelerator pedal position (APP) system along with the engine control module (ECM) and other components is used to calculate and control the amount of
acceleration and deceleration by controlling the amount of fuel delivery.
The APP system includes the following components:
The APP sensor assembly

The engine control module (ECM)
Accelerator Pedal Position (APP) Sensor

The APP sensor is mounted on the accelerator pedal control assembly. The sensor is made up of 2 individual sensors within one housing. Two separate signals, low
reference, and 5 V reference circuits are used in order to interface the accelerator pedal sensor assembly with the engine control module (ECM). Each sensor has a
unique functionality to determine pedal position. The ECM uses the APP sensor to determine the amount of acceleration or deceleration desired by the person driving the
vehicle. The APP sensor 1 voltage should increase as the accelerator pedal is depressed, from below 0.7 V at 0% pedal travel to 4.5 V at 100% pedal travel. APP sensor
2 voltage should increase from above 0.3 V at 0% pedal travel to 2.2 V at 100% pedal travel.
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Brake, Accelerator, and Clutch Pedal Replacement (Left Hand Drive)

Special Tools
DT-6202–A Pliers
DT-6202–B Pliers
DT-6202–20 Adapter to DT-6202–A
DT-50894 Remover
Removal Procedure


4. Remove the radiator surge tank clip (2).
5. Remove the radiator surge tank (1). Position the radiator surge tank (1) aside.
6. Remove the BPMV bracket bolts (1).
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7. Remove the brake booster bolts (1).
Note:
Do NOT open hydraulic brake system.

Second mechanic required.
8. Pull the brake booster and the BPMV assembly forward in order to get access to the brake pedal bracket nuts (1).
9. Remove the brake pedal bracket nuts (1).
10. Remove the instrument panel lower trim pad cover. Refer to Instrument Panel Lower Trim Pad Cover Replacement.
11. Remove the steering column upper trim cover. Refer to Steering Column Upper Trim Cover Replacement.
12. Remove the steering column lower trim cover. Refer to Steering Column Lower Trim Cover Replacement.
13. Remove the intermediate steering shaft. Refer to Intermediate Steering Shaft Replacement.
14. Remove the steering column. Refer to Steering Column Replacement.
15. Disconnect the brake pedal pushrod (1) from the brake pedal with brake pedal applied a bit.
16. Replace click fit connector (1) between booster pushrod and brake pedal with new part.
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17. If equipped, disconnect the clutch master cylinder push rod from the clutch pedal (3), using either the DT-6202–A pliers (1) and the DT-6202–20
adapters in conjunction with the DT-50894 remover (2), or the DT-6202–B pliers (1) in conjunction with the DT-50894 remover (2).
18. Remove the clutch master cylinder nuts (2) from the pedal bracket, if equipped.
19. Remove the brake pedal bracket bolt (1) from the tie bar.
20. Separate wiring harness from pedal bracket.
21. Disconnect electrical connectors.
22. Carefully reposition the fuse box bracket (1) to the side to allow space for pedal assembly removal.
23. Remove brake and accelerator and clutch pedal assembly from vehicle.
24. Transfer component parts as needed.
1. Install the brake and accelerator and clutch pedal assembly to the vehicle.
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2. Carefully place the fuse box bracket (1) back in position

3. Install wiring harness to brake pedal bracket.
4. Connect electrical connectors.

5. Install brake pedal bracket bolts and tighten to 20 Y (15 lb ft).
6. Connect clutch master cylinder push rod (1) to the clutch pedal, if equipped.
7. Install the clutch master cylinder nuts (2) to the pedal bracket, if equipped and tighten to 18 Y (13 lb ft).
8. Connect the brake pedal pushrod (1) to the brake pedal.

9. Install the steering column. Refer to Steering Column Replacement.
10. Install the intermediate steering shaft. Refer to Intermediate Steering Shaft Replacement.
11. Install the steering column lower trim cover. Refer to Steering Column Lower Trim Cover Replacement.
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12. Install the steering column upper trim cover. Refer to Steering Column Upper Trim Cover Replacement.
13. Install the instrument panel lower trim pad cover. Refer to Instrument Panel Lower Trim Pad Cover Replacement.
Note:
Do NOT open hydraulic brake system.

Second mechanic required.
14. Pull the brake booster and the BPMV assembly forward in order to gain access to the brake pedal bracket nuts (1).
15. Install the pedal bracket nuts (1) and tighten to 20 Y (15 lb ft).
16. Install the brake booster bolts (1) and tighten to 19 Y (14 lb ft).
17. Install the BPMV bracket bolts (1) and tighten to 20 Y (15 lb ft).
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18. Install the radiator surge tank (1).
19. Install the radiator surge tank clip (2).
20. Install dash upper extension panel opening cover. Refer to Dash Upper Extension Panel Opening Cover Replacement.
22. Install the battery. Refer to Battery Replacement.
23. Calibrate the brake pedal position sensor. Refer to Brake Pedal Position Sensor Calibration.
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Brake, Accelerator, and Clutch Pedal Replacement

Note: The clutch pedal is part of the brake, accelerator, and clutch pedal assembly and cannot be serviced separately.
To replace the brake, accelerator and clutch pedal assembly, refer to Brake, Accelerator, and Clutch Pedal Replacement.
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Camshaft Position Sensor Replacement

Removal Procedure
2. Disconnect the camshaft position sensor wiring harness plug.

3. Remove the camshaft position sensor bolt (3) and the camshaft position sensor (2).
4. Remove the camshaft position sensor gasket (1).
1. Install the camshaft position sensor (2) with a NEW camshaft position sensor gasket (1).
2. Install the camshaft position sensor bolt (3) and tighten to 10 Y (89 lb in).
3. Connect the camshaft position sensor wiring harness plug.
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Remove the starter motor. Refer to Starter Replacement.
Crankshaft Position Sensor Fastener

Procedure
1
Remove the crankshaft position sensor bolt
Tighten
4.5 Y (40 lb in)

2 Procedure
Disconnect all electrical connectors as needed.
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Engine Control Module Description

The engine control module (ECM) interacts with many emission related components and systems, and monitors the emission related components and systems for
deterioration. OBD II diagnostics monitor the system performance and a diagnostic trouble code (DTC) sets if the system performance degrades.
The malfunction indicator lamp (MIL) operation and the DTC storage are dictated by the DTC type. A DTC is ranked as a type A or type B if the DTC is emissions-related.
Type C is a non-emissions-related DTC.
The ECM is located in the engine compartment. The ECM is the control center of the engine controls system. The ECM controls the following components:
The fuel injection system

The ignition system
The emission control systems
The on-board diagnostics
The A/C and fan systems
The throttle body motor system
The ECM constantly monitors the information from various sensors and other inputs, and controls the systems that affect the vehicle performance and the emissions. The
ECM also performs diagnostic tests on various parts of the system. The ECM can recognize operational conditions and alert the driver via the MIL. When the ECM
detects a malfunction, the ECM stores a DTC. The condition area is identified by the particular DTC that is set. This helps the technician in making repairs.
ECM Function
The engine control module (ECM) can supply 5 V or 12 V to the various sensors or switches. This is done through pull-up resistors to the regulated power supplies
within the ECM. In some cases, even an ordinary shop voltmeter will not give an accurate reading because the resistance is too low. Therefore, a DMM with at
least 10 MΩ input impedance is required in order to ensure accurate voltage readings.
The ECM controls the output circuits by controlling the ground or the power feed circuit through the transistors or a device called an output driver module.
EEPROM
The programmable read only memory (EEPROM), which can be erased electronically, is a permanent memory that is physically part of the engine control module
(ECM). The EEPROM contains program and calibration information that the ECM needs in order to control the powertrain operation.
Special equipment, as well as the correct program and calibration for the vehicle, are required in order to reprogram the ECM.
ECM Default Actions

When a malfunction occurs within the engine control system, the engine control module (ECM) maintains control of the system with default actions. Default actions
are calculated values, and/or calibrated default values, that are stored within the ECM. A certain level of engine performance is possible when a malfunction
occurs dependant on the default actions taken. The ECM default actions prevent a complete loss of engine performance.
ECM Output Controls

The scan tool can control certain solenoids, valves, motors, and relays. The output controls can be found under the special functions selection of the scan tool.
Some output controls may be disabled by the engine control module (ECM) during certain types of vehicle operation.
Data Link Connector (DLC)

The data link connector (DLC) is a 16-pin connector that provides the technician with a means of accessing serial data for aid in the diagnosis. This connector
allows the technician to use a scan tool in order to monitor the various serial data parameters, and display the DTC information. The DLC is located inside the
drivers compartment, underneath the dash.
Malfunction Indicator Lamp (MIL)
The malfunction indicator lamp (MIL) is located on the instrument panel cluster or the driver information center. The MIL is controlled by the engine control module
(ECM) and illuminates when the ECM detects a condition that affects the vehicle emissions.
ECM Service Precautions

The engine control module (ECM), by design, can withstand the normal current draws that are associated with the vehicle operations. However, care must be
taken in order to avoid overloading any of these circuits. When testing for opens or shorts, do not ground or apply voltage to any of the ECM circuits unless the
diagnostic procedure instructs you to do so. These circuits should only be tested with a DMM.
Aftermarket (Add-On) Electrical And Vacuum Equipment

Caution: Do not attach add-on vacuum operated equipment to this vehicle. The use of add-on vacuum equipment may result in damage to vehicle components or
systems.
Caution: Connect any add-on electrically operated equipment to the vehicle's electrical system at the 12 V battery (power and ground) in order to prevent damage
to the vehicle.
Aftermarket, add-on, electrical and vacuum equipment is defined as any equipment installed on a vehicle after leaving the factory that connects to the vehicles
electrical or vacuum systems. No allowances have been made in the vehicle design for this type of equipment.
Add-on electrical equipment, even when installed to these strict guidelines, may still cause the powertrain system to malfunction. This may also include equipment
not connected to the vehicle electrical system, such as portable telephones and radios. Therefore, the first step in diagnosing any powertrain condition is to make
sure all of the after-market electrical equipment is removed or disconnected from the vehicle. After this has been done and if the condition still exists, the condition
may be diagnosed in the normal manner.
Electrostatic Discharge (ESD) Damage

Note: In order to prevent possible electrostatic discharge damage to the ECM, do not touch the connector pins on the ECM.
The electronic components that are used in the control systems are often designed to carry very low voltage. The electronic components are susceptible to
damage caused by electrostatic discharge. Less than 100 V of static electricity can cause damage to some electronic components. By comparison, it takes as
much as 4000 V for a person to even feel the zap of a static discharge.
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Engine Control Module Description
There are several ways for a person to become statically charged. The most common methods of charging are by friction and by induction. An example of
charging by friction is a person sliding across a car seat.
Charging by induction occurs when a person with well insulated shoes stands near a highly charged object and momentarily touches ground. Charges of the same
polarity are drained off leaving the person highly charged with the opposite polarity. Static charges can cause damage, therefore, it is important to exercise great
care when handling and testing electronic components.
Underhood Inspection
Note: This inspection is very important and must be done carefully and thoroughly.
Perform a careful underhood inspection when performing any diagnostic procedure or diagnosing the cause of an emission test failure. This can often lead to
repairing a condition without further steps. Use the following guidelines when performing an inspection:
Inspect all of the vacuum hoses for correct routing, pinches, cuts, or disconnects.
Inspect any hoses that are difficult to see.
Inspect all of the wires in the engine compartment for the following conditions:
Burned or chased spots

Pinched wires
Contact with sharp edges
Contact with hot exhaust manifolds
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Engine Control Module Replacement

Service of the engine control module (ECM) should consist of either replacement of the ECM of programming of the electrically erasable programmable read only
memory (EEPROM). If the diagnostic procedures call for the ECM to be replaced, the replacement ECM should be checked to ensure that the correct part is being used.
If the correct part is being used, remove the faulty ECM and install the new service ECM.
Caution:
Turn the ignition OFF when installing or removing the control module connectors and disconnecting or reconnecting the power to the control module (battery cable,
powertrain control module (PCM)/engine control module (ECM)/transaxle control module (TCM) pigtail, control module fuse, jumper cables, etc.) in order to prevent
internal control module damage.
Control module damage may result when the metal case contacts battery voltage. DO NOT contact the control module metal case with battery voltage when
servicing a control module, using battery booster cables, or when charging the vehicle battery.
In order to prevent any possible electrostatic discharge damage to the control module, do no touch the connector pins or the soldered components on the circuit
board.
Remove any debris from around the control module connector surfaces before servicing the control module. Inspect the control module connector gaskets when
diagnosing or replacing the control module. Ensure that the gaskets are installed correctly. The gaskets prevent contaminant intrusion into the control module.
The replacement control module must be programmed.
Note: Before removing the engine control module (ECM), use the scan tool to capture the ECM data. This captured data will then need to be restored into the NEW
ECM. Refer to Control Module References.
Removal Procedure
1. Prepare the engine control module (ECM) for replacement. Refer to Control Module References.
Caution: In order to prevent any possible electrostatic discharge damage to the ECM, do not touch the connector pins.
3. Disconnect the 2 ECM wiring harness plugs (1) from the ECM (2).
4. Unclip the retainer clip (3) with a screwdriver.

5. Remove the ECM bracket (2) along with the ECM (1) from the battery tray.
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6. Unclip the retainer clips (3) with a screwdriver.

7. Remove the ECM (1) from the ECM bracket (2).
Note: The retainer clips (3) must engage safely.

1. Install the ECM (1) to the ECM bracket (2).
Note: The retainer clip (3) must engage safely.

2. Install the ECM bracket (2) with the ECM (1) to the battery tray.
Note: The safety locks on the ECM wiring harness plugs (1) must engage safely.
3. Connect the ECM wiring harness plugs (1) to the ECM (2).
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5. Program the engine control module, if required. Refer to K20 Engine Control Module: Programming and Setup.
6. Turn OFF the ignition for at least 5 seconds after the programming is complete.
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Engine Control Module Wiring Harness Replacement (2.0L Diesel LNP)

Removal Procedure
5. Remove the windshield washer solvent container filler tube. Refer to Windshield Washer Solvent Container Filler Tube Replacement.
6. Remove the front compartment fuse block. Refer to Front Compartment Fuse Block Replacement.
8. Remove the wiring harness ground cable nut (2) and remove the wiring harness ground cable (3).
9. Remove the wiring harness plug (1) in top direction from the front compartment fuse block housing.
10. Disconnect the wiring harness connection adapter plug (4).
11. Remove the 2 wiring harness clips from the drivetrain and front suspension frame front inner support and from the charge air cooler outlet hose.
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17. Remove the 2 charge air cooler inlet air hose bolts (7) from the 2 charge air cooler inlet air hose nuts (5). Hang the charge air cooler inlet air hose (6)
aside.
19. Disconnect the exhaust temperature sensor wiring harness plug (4) and unclip the wiring harness clip (3) from the steering pump.
20. Disconnect the turbocharger wastegate actuator wiring harness plug (8).
21. Disconnect the mass air flow sensor wiring harness plug (1) and remove the wiring harness clip from the air cleaner housing.
22. Disconnect the oil pressure sensor wiring harness plug (2).

23. Remove the wiring harness clip (3) from the charge air control vacuum hose.
24. Remove the 2 wiring harness channel bolts (1) from the wiring harness channel.
26. Disconnect the 2 wiring harness clips (4) from the oil filter assembly and from the intake manifold.
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27. Disconnect the backup lamp switch wiring harness plug from the transmission.
28. Remove the wiring harness clip (1) from the transmission.
31. Disconnect the 2 knock sensor wiring harness plugs (3, 6).

32. Disconnect the generator wiring harness plug (4).
33. Disconnect the starter wiring harness plug (7).
34. Disconnect the vacuum solenoid valve wiring harness plug (1) and the vacuum solenoid valve wiring harness plug (2).
35. Remove the 2 wiring harness clips (5) from the 2 brackets.
36. Disconnect the crankshaft position sensor wiring harness plug (3).

37. Disconnect the throttle body wiring harness plug (1).
38. Unclip the wiring harness clip (2) from the charge air cooler outlet hose.
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39. Disconnect the air conditioning wiring harness plug (1) and the engine oil level indicator wiring harness plug (2). Hang the wiring harness aside.
41. Remove the front charge air cooler outlet hose bolt (2) from the wiring harness bracket.
42. Remove the front charge air cooler outlet hose clamp (4) from the rear charge air cooler outlet hose (3). Hang the front charge air cooler hose (1) aside.
43. Unclip and disconnect the glow plug wiring harness plug (2) from the engine wiring harness bracket.
44. Disconnect the fuel pump wiring harness plug (3)
45. Disconnect the engine coolant temperature sensor wiring harness plug (5).
46. Unclip the 4 wiring harness clips (1, 4) from the wiring harness bracket.

54. Unclip the engine wiring harness channel (6) in top direction from the 3 exhaust gas recirculation cooler brackets.
55. Remove the engine wiring harness from the vehicle.
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2. Clip the engine wiring harness channel (6) to the 3 exhaust gas recirculation cooler brackets.
7. Connect the fuel injection pressure sensor wiring harness plug (3).
11. Clip the 4 wiring harness clips (1, 4) to the wiring harness bracket.
12. Connect the engine coolant temperature sensor wiring harness plug (5).
13. Connect the fuel pump wiring harness plug (3).
14. Clip and connect the glow plug wiring harness plug (2) to the engine wiring harness bracket.

15. Position the front charge air cooler outlet hose (1) along with the front charge air cooler outlet hose clamp (4) to the rear charge air cooler outlet hose
(3) and tighten the clamp to 3.5 Y (31 lb in).
16. Install the front charge air cooler outlet hose bolt (2) to the wiring harness bracket and tighten to 10 Y (89 lb in).
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18. Position the wiring harness.

19. Connect the air conditioning wiring harness plug (1) and the engine oil level indicator wiring harness plug (2).
20. Clip the wiring harness clip (2) to the charge air cooler outlet hose.
21. Connect the throttle body wiring harness plug (1).
22. Connect the crankshaft position sensor wiring harness plug (3).
23. Install the 2 wiring harness clips (5) to the 2 brackets.

24. Connect the vacuum solenoid valve wiring harness plug (1) and the vacuum solenoid valve wiring harness plug (2).
25. Connect the starter wiring harness plug (7).
26. Connect the generator wiring harness plug (4).
27. Connect the 2 knock sensor wiring harness plugs (3, 6).
30. Install the wiring harness clip (1) to the transmission.
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31. Connect the backup lamp switch wiring harness plug to the transmission.
32. Connect the 2 wiring harness clips (4) to the oil filter assembly and to the intake manifold.
34. Install the 2 wiring harness channel bolts (1) to the wiring harness channel and tighten to 10 Y (89 lb in).
35. Install the wiring harness clip (3) to the charge air control vacuum hose.
36. Connect the oil pressure sensor wiring harness plug (2).
37. Connect the mass air flow sensor wiring harness plug (1) and install the wiring harness clip to the air cleaner housing.
38. Connect the turbocharger wastegate actuator wiring harness plug (8).
39. Connect the exhaust temperature sensor wiring harness plug (4) and clip the wiring harness clip (3) to the steering pump.
41. Install the 2 charge air cooler inlet air hose bolts (7) to the 2 charge air cooler inlet air hose nuts (5) and tighten to 22 Y (16 lb ft).

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47. Install the 2 wiring harness clips to the drivetrain and front suspension frame front inner support and to the charge air cooler outlet hose.
48. Connect the wiring harness connection adapter plug (4).
49. Install the wiring harness plug (1) to the front compartment fuse block housing.
50. Install the wiring harness ground cable (3) and install the wiring harness ground cable nut (2) and tighten to 9 Y (80 lb in).
51. Install the front compartment fuse block. Refer to Front Compartment Fuse Block Replacement.
53. Install the windshield washer solvent container filler tube. Refer to Windshield Washer Solvent Container Filler Tube Replacement.
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Engine Coolant Temperature Sensor Replacement (Radiator)


1. Drain the cooling system. Refer to Cooling System Draining and Filling
1 Retaining Clamp
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Engine Coolant Temperature Sensor Replacement (Thermostat Housing)


1 Engine Coolant Temperature Sensor Fastener
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Removal Procedure
3. Loosen the charge air cooler outlet hose and hang aside. Refer to Charge Air Cooler Outlet Hose Replacement.
4. Disconnect the engine wiring harness plug from the engine coolant temperature sensor (1).
5. Remove the engine coolant temperature sensor and the engine coolant temperature sensor seal ring (2) from the engine water outlet adapter.

1. Install the engine coolant temperature sensor with a NEW engine coolant temperature sensor seal ring (2) to the engine water outlet adapter and
tighten to 13 Y (115 lb in).
2. Connect the engine wiring harness plug to the engine coolant temperature sensor (1).
3. Tighten the charge air cooler outlet hose. Refer to Charge Air Cooler Outlet Hose Replacement.
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Engine Oil Pressure Switch Replacement

Removal Procedure
3. Clip the power steering fluid reservoir outlet hose out of the 2 mounts and hang aside.
4. Remove the 2 bolts (2) from the mount brackets.

5. Remove the power steering fluid reservoir outlet hose mount bracket (1).
6. Disconnect the oil pressure switch wiring harness plug (1) from the engine oil pressure switch (2).
7. Remove the engine oil pressure switch (2).

1. Install the engine oil pressure switch (2) and tighten to 20 Y (15 lb ft).
2. Connect the oil pressure switch wiring harness plug (1) to the engine oil pressure switch (2).
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Engine Oil Pressure Switch Replacement
3. Install the power steering fluid reservoir outlet hose mount bracket (1).
4. Install the 2 retaining bolts (2) to the mount brackets and tighten to 10 Y (89 lb in).
5. Clip in the power steering fluid reservoir outlet hose into the 2 mounts.
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Heated Oxygen and Oxygen Sensor Caution

Caution: Do not remove the pigtail from either the heated oxygen sensor (HO2S) or the oxygen sensor (O2S). Removing the pigtail or the connector will affect sensor
operation.
Handle the oxygen sensor carefully. Do not drop the HO2S. Keep the in-line electrical connector and the louvered end free of grease, dirt, or other contaminants. Do not
use cleaning solvents of any type.
Do not repair the wiring, connector or terminals. Replace the oxygen sensor if the pigtail wiring, connector, or terminal is damaged.
This external clean air reference is obtained by way of the oxygen sensor signal and heater wires. Any attempt to repair the wires, connectors, or terminals could result in
the obstruction of the air reference and degraded sensor performance.
The following guidelines should be used when servicing the heated oxygen sensor:
Do not apply contact cleaner or other materials to the sensor or vehicle harness connectors. These materials may get into the sensor causing poor performance.
Do not damage the sensor pigtail and harness wires in such a way that the wires inside are exposed. This could provide a path for foreign materials to enter the
sensor and cause performance problems.
Ensure the sensor or vehicle lead wires are not bent sharply or kinked. Sharp bends or kinks could block the reference air path through the lead wire.
Do not remove or defeat the oxygen sensor ground wire, where applicable. Vehicles that utilize the ground wired sensor may rely on this ground as the only ground
contact to the sensor. Removal of the ground wire will cause poor engine performance.
Ensure that the peripheral seal remains intact on the vehicle harness connector in order to prevent damage due to water intrusion. The engine harness may be
repaired using Packard's Crimp and Splice Seals Terminal Repair Kit. Under no circumstances should repairs be soldered since this could result in the air
reference being obstructed.
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Heated Oxygen Sensor Installation

Special Tools
EN-48259 Installer - Oxygen Sensor

Install the heated oxygen sensor (1), using the EN-48259 installer and tighten to 50 Y (37 lb ft).
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Heated Oxygen Sensor Removal

Special Tools
EN-48259 Remover - Oxygen Sensor
Remove the heated oxygen sensor (1), using EN-48259 remover .
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Heated Oxygen Sensor Replacement

Special Tools
EN-48259 Remover - Oxygen Sensor
Removal Procedure
1. Disconnect the heated oxygen sensor wiring harness plug.

2. Remove the heated oxygen sensor (1), using the EN-48259 remover .

1. Install the heated oxygen sensor (1), using the EN-48259 installer and tighten to 50 Y (37 lb ft).
2. Connect the heated oxygen sensor wiring harness plug.
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Heated Oxygen Sensor Resistance Learn Reset Caution

Caution: When replacing the HO2S perform the following:
A code clear with a scan tool, regardless of whether or not a DTC is set
HO2S heater resistance learn reset with a scan tool, where available
Perform the above in order to reset the HO2S resistance learned value and avoid possible HO2S failure.
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Inside Air Temperature Sensor Replacement - Left Side Lower (Left Hand Drive)

Inside Air Temperature Sensor Replacement - Left Side Lower
Remove instrument panel lower trim pad cover. Refer to Instrument Panel Lower Trim Pad Cover Replacement.
1 Inside Air Temperature Sensor - Left Side Lower
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Inside Air Temperature Sensor Replacement - Left Side Lower (Right Hand Drive)

Inside Air Temperature Sensor Replacement - Left Side Lower

1. Remove instrument panel compartment. Refer to Instrument Panel Compartment Replacement.

2. Remove floor front air outlet duct— left side. Refer to Floor Front Air Outlet Duct Replacement - Left Side.
3. Remove radio cooling duct. Refer to Radio Cooling Duct Replacement.
Inside Air Temperature Sensor
1 Procedure
Disconnect electrical connectors.
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Inside Air Temperature Sensor Replacement - Left Side Upper (Left Hand Drive)

Inside Air Temperature Sensor Replacement - Left Side Upper
Remove instrument panel lower trim pad cover. Refer to Instrument Panel Lower Trim Pad Cover Replacement.
1 Inside Air Temperature Sensor - Left Side Upper
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Inside Air Temperature Sensor Replacement - Left Side Upper (Right Hand Drive)

Inside Air Temperature Sensor Replacement - Left Side Upper

1. Remove instrument panel compartment. Refer to Instrument Panel Compartment Replacement.

2. Remove floor front air outlet duct— left side. Refer to Floor Front Air Outlet Duct Replacement - Left Side.
3. Remove radio cooling duct. Refer to Radio Cooling Duct Replacement.
Inside Air Temperature Sensor
1 Procedure
Disconnect electrical connectors.
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Intake Air Pressure and Temperature Sensor Replacement

Removal Procedure

3. Remove the intake air pressure/temperature sensor bolt (2).
4. Remove the intake air pressure/temperature sensor (1) and the gasket (4).
1. Install the intake air pressure/temperature sensor (1) and a NEW gasket (4).

2. Install the intake air pressure/temperature sensor bolt (2) and tighten to 9 Y (80 lb in).
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Intake Air Temperature Sensor Replacement

Intake Air Temperature Sensor Replacement
Intake Air Temperature Sensor Assembly

1 Caution: Any time service is being performed which requires removal of the air cleaner assembly, always cover the throttle body
opening. This will prevent any foreign material from entering the engine.
2 Intake Air Temperature Sensor Cable Clip
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Intake Manifold Tuning Valve Vacuum Control Solenoid Valve Hose Replacement

Removal Procedure
2. Remove the intake manifold tuning valve vacuum control solenoid valve hose (1) from the intake air tuning valve vacuum control solenoid valve (3) and
from the intake manifold runner control valve actuator (2).
3. Remove the intake manifold tuning valve vacuum control solenoid valve hose clip (4) from the exhaust gas recirculation cooler.
4. Remove the intake manifold tuning valve vacuum control solenoid valve hose.
1. Install the intake manifold tuning valve vacuum control solenoid valve hose (1).
2. Install the intake manifold tuning valve vacuum control solenoid valve hose to the intake air tuning valve vacuum control solenoid valve (3) and to the
intake manifold runner control valve actuator (2).
3. Install the intake manifold tuning valve vacuum control solenoid valve hose clip (4) to the exhaust gas recirculation cooler.
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K20 Engine Control Module: Programming and Setup (LNP)

The following service procedures require either a programming or a setup event performed for a complete repair.
Before Programming The Engine Control Module

Note: DO NOT program a control module unless you are directed by a service procedure or you are directed by a General Motors LLC service bulletin.
Programming a control module at any other time will not permanently correct a customers concern.
Ensure the following conditions are met before programming a control module:
Vehicle system voltage
There is no charging system concern. All charging system concerns must be repaired before programming a control module.
Battery voltage is between 12–16 V. The battery must be charged before programming the control module if the battery voltage is low.
A battery charger is NOT connected to the vehicle battery. Incorrect system voltage or voltage fluctuations from a battery charger may cause programming
error or control module damage.
Turn OFF or disable any of the following systems that may put a load on the vehicle battery:
Twilight sentinel
Interior lights
Daytime running lamps (DRL)—Applying the parking brake, on most vehicles, disables the DRL system. Refer to the Owners Manual.
HVAC systems
Engine cooling fans, etc.
The ignition switch is in the proper position. The scan tool prompts you to turn ON the ignition, with the engine OFF. DO NOT change the position of the
ignition switch during the programming procedure, unless instructed to do so.
All of the following tool connections are secure:
The connection at the data link connector (DLC)

The voltage supply circuits
DO NOT disturb the tool harnesses while programming. If an interruption occurs during the programming procedure, programming error or control module damage
may occur.
ECM Replacement
If the engine control module (ECM) needs to be replaced, the following procedures must be performed:
1. Connect a scan tool to the vehicle and access SPS. Refer to Service Programming System (SPS).
2. Before removing the old control module, perform the SPS function Prepare Control Module for Removal.
Note: The Prepare Control Module for Removal function can only be performed when communication with the old control module is still possible.
3. Replace the ECM.
4. Perform the SPS function Engine Control Module – Programming and follow the on-screen instructions.
5. Perform the SPS function Engine Control Module – Configuration and Setup and follow the on-screen instructions. On the screen Control Module –
Configuration and Setup Function(s), select both control module Configuration/Reconfiguration and the appropriate control module Setup.
6. Perform the SPS Function Immobilizer Learn. Refer to Immobilizer System Component Programming.
7. Clear DTCs after completing the programming procedure.
8. Start and idle engine.
9. Using a scan tool, perform the Diesel Particulate Filter (DPF) Service Regeneration
10. If the SPS function Prepare Control Module for Removal could not be performed, perform the following:
Engine Oil Life Remaining—When available, use a scan tool to reset the Engine Oil Life back to the original percentage recorded before the module was replaced.
ECM Reprogramming
If the engine control module (ECM) needs to be reprogrammed, the following procedures must be performed:
1. Connect a scan tool to the vehicle and access SPS. Refer to Service Programming System (SPS).
2. Perform the SPS function Engine Control Module – Programming and follow the on-screen instructions.
3. Engine Oil Life Remaining—When available, use a scan tool to reset the Engine Oil Life back to the original percentage recorded before the module
was reprogrammed.
Setup for Component Replacement

The replacement of some components will require a setup procedure for complete repair.
If any of the following components are replaced, use a scan tool to perform the appropriate learn function.
Fuel Injector
Fuel Rail Pressure Sensor
If any of the following components are replaced, use a scan tool to perform the appropriate reset function.
Diesel Particulate Filter (DPF)
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K20 Engine Control Module: Programming and Setup (LNP)
Fuel Rail Pressure Sensor
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K20 Engine Control Module: Scan Tool Information (LNP)

Table 1: Engine Control Module Scan Tool Data

Table 2: Engine Control Module (ECM) Scan Tool Output Controls
The Engine Control Module Scan Tool Data List contains all engine related parameters that are available on the scan tool. This is a master list arranged in alphabetical
order and not all the parameters listed are in every engine platform.
Use the Engine Scan Tool Data List only after the following is determined:
The Diagnostic System Check - Vehicle

No diagnostic trouble codes (DTCs)
On-board diagnostics are functioning properly
The scan tool values from a properly running engine may be used for comparison with the engine you are diagnosing. The Engine Scan Tool Data List represents values
that may be seen on a normally running engine.
Note: A scan tool that displays faulty data should not be used. The scan tool concern should be reported to the manufacturer. Use of a faulty scan tool can result in
misdiagnosis and unnecessary parts replacement.
Only the parameters listed below are referenced in this service manual for use in diagnosis.
Engine Control Module Scan Tool Data
Parameter System State Expected Value Description
Base Operating Conditions: Engine Idling/Radiator Hose Hot/Park or Neutral/Closed Loop
This parameter displays OK if there is no 5 V

5 V Reference 1 or 2
Ignition ON OK reference circuit condition. If the circuit is shorted
Circuit Status
to ground or shorted to B+, Fault is displayed.
This parameter displays the state of the air

A/C Compressor Clutch
A/C ON Active conditioning (A/C) clutch relay control circuit as
Relay Command
commanded by the control module.
This parameter displays whether the A/C pressure

A/C Disabled – A/C
A/C ON No is out of range for normal operation as determined
Pressure Out of Range
by the control module.
The parameter indicates the reason the air

conditioning (A/C) compressor was disengaged.
A/C Disengage 1–8 Reason for A/C The scan tool displays None, A/C Pressure,
A/C ON
History Disengagement Engine Speed, Battery Voltage, Anti Stall, RPM
Unstable, WOT, Launch Performance, Coolant
Hot, APP, Air Bag Deploy, or A/C Relay DTC.
A/C OFF 0–5 V This parameter displays the voltage from the A/C
A/C High Side Pressure
high side pressure sensor signal circuit to the
Sensor
A/C ON 0–5 V control module.
700–900 kPa (101–130
A/C OFF
PSI) This parameter displays the pressure from the A/C
Sensor
900–1 300 kPa control module.
A/C ON
(130–174 PSI)

A/C Off for WOT A/C ON Inactive conditioning (A/C) clutch relay control circuit as
This parameter displays the angle of accelerator

Accelerator Pedal
pedal position in percentage if a engine
Position Sensor When
— Varies overspeed condition is detected as calculated by
Engine Overspeed
the control module using the signals from the APP
Detected
sensors.
APP 1–0.94 V This parameter displays the voltage of each APP

APP Sensor 1 or 2 — sensor signal circuit as measured by the control
APP 2–0.47 V module.

APP Sensors — 0% pedal position as calculated by the control module
using the signals from the APP sensors.
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This parameter displays the barometric pressure.

65–104 kPa (8–16 PSI) – The control module uses the barometric pressure
BARO —
Varies with altitude sensor input for fuel control to compensate for
altitude differences.
This parameter displays the turbocharger boost

pressure inside the engine as calculated by the
Boost Pressure Sensor — 82–110 kPa (12–16 PSI)
control module based on the signal from the Boost
pressure sensor.
This parameter displays the voltage of the

turbocharger boost pressure inside the engine
Boost Pressure Sensor — 0.85–1.55 V
calculated by the control module based on the
signal from the Boost pressure sensor.
Cooling Fan Relay

This parameter displays the control module
Control 1, Control 2, or Fans Commanded ON On
commanded state of the fan relay control circuits.
Control 3 Command
This parameter displays the clutch pedal learn

CPP Learn Status — Inactive status. There are 6 different possible states for the
clutch pedal learn status.
This parameter displays the position learned for

CPP Learned Apply the clutch pedal position sensor when the clutch
— Volts
Position pedal is fully applied during the associated learn
procedure.

CPP Learned Release
— Volts the clutch pedal position sensor when the clutch
Position
pedal is released.
This parameter displays the displacement of the

clutch pedal (corrected and normalized based
upon its learned released and fully applied
CPP Sensor — %
positions), where 0% corresponds to the clutch
pedal being released and 100% corresponds to
the clutch pedal being fully applied.
This parameter displays the clutch pedal position

CPP Sensor — Volts sensor analog input as a percentage of its
reference voltage.
This parameter displays the state of the cruise

Cruise Control Cancel Cruise Cancel Switch
Active Resume/Accelerate switch input to the control
Switch ON
module from the cruise control system.
The parameter displays the last 8 cruise control

Cruise Control Reason for Cruise disengages in order from 1–8, with 8 being the
Cruise Control ON
Disengage History 1–8 Disengagement most recent. There are approximately 40 possible
causes for the cruise control to disengage.
Cruise Control ON/OFF This parameter displays the state of the cruise
Cruise Control ON On
Switch ON/OFF switch input to the control module.
Cruise This parameter displays the state of the cruise

Cruise Control Resume
Resume/Accelerate Active Resume/Accelerate switch input to the control
Switch
Switch ON module from the cruise control system.

Cruise Control Set Cruise Set/Coast Switch
Active Set/Coast switch input to the control module from
Switch ON
the cruise control system.
Current Gear When

This parameter displays the selected gear if an
Engine Overspeed — Varies
engine overspeed is detected.
Detected
This parameter displays the desired turbocharger

boost pressure inside the engine as calculated by
Desired Boost Pressure — 98 kPa (14.21 PSI)
the control module based on the signal from the
Boost pressure sensor.
This parameter displays the desired EGR position

Desired EGR Position — %
as calculated by the control module.
This parameter displays the desired fuel rail

Desired Fuel Rail 23–26 MPa pressure as calculated by the control module. This
—
Pressure 3 335.92–3 771.04 PSI value is calculated based on engine speed,
engine load, and sensor inputs.
This parameter displays the desired engine idle

Desired Idle Speed — 700–800 RPM
speed as commanded by the control module.
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Desired Turbocharger vane position as calculated by the control module
— 0–100%
Vane Position based on the signal from the Boost pressure
sensor.
This parameter displays the mileage that has

Distance Since Last
— Varies elapsed since the last diesel particulate filter
DPF Regeneration
regeneration has occurred.
Distance Since Last This parameter displays the mileage since the last
— Varies
DPF Replacement diesel particulate filter replacement.
This parameter displays the distance that has

Distance Since Last Oil
— Varies elapsed since the last oil level warning has
Level Warning
occurred.

— Varies elapsed since the last oil pressure warning has
Pressure Warning
occurred.

Distance with MIL ON — Varies
elapsed since the last MIL on status has occurred.
This parameter indicates the pressure at the DPF

DPF Differential −3–15 kPa (−0.43–2.17
— and is calculated by the control module based on
Pressure Sensor PSI)
the signal from the sensor.
This parameter displays the voltage calculated by

the control module, based on the input from the
DPF Differential
— 0.40–0.60 V exhaust gas temperature sensors when the
Pressure Sensor
particulate filter is full and needs a particulate filter
regeneration.
This parameter displays the amount of calculated

DPF Soot Accumulation — 0–100%
soot in exhaust particulate filter.
This parameter displays the status of the

ECM Challenge Status — Invalid
immobilizer system as received in the control unit.
This parameter displays the temperature of the

−39 to +140°C ( −38 to engine coolant based on input to the control
ECT Sensor —
+284°F) module from the engine coolant temperature
(ECT) sensor.

ECT Sensor — 0–5 V the control module from the engine coolant
temperature (ECT) sensor.
This parameter displays the percent of the duty

EGR Command — 40–55%
cycle commanded by the control module.
EGR Cooler Bypass This parameter displays the status of the duty
— OFF
Valve Command cycle commanded by the control module.
This parameter displays the percent of the EGR

EGR Position Sensor — 0–100%
position calculated by the control module.
This parameter displays the voltage of the EGR

EGR Position Sensor — Varies
11–30%
Engine Idling
Varies This parameter displays the calculated engine
Engine Load load in percent based on inputs to the control
module from various engine sensors.
Engine speed at 2 500
25–40%
RPM
This parameter displays if the level of the engine

oil is within range as determined by the control
Engine Oil Level Switch — OK
module from information received from the engine
oil level switch.
Engine Oil Life

— Varies This parameter displays the remaining oil life.
Remaining
This parameter displays the state of the engine oil

pressure as determined by the control module.
The control module monitors the engine oil
Engine Oil Pressure
— OK pressure switch to determine if the engine oil
Switch
pressure is sufficient. The scan tool displays Low
when the engine oil pressure is below a
predetermined value.
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This parameter displays the calculated value from

Engine Overheat
— OK the ECM for a possible engine overheat situation
Possible
to occur.
This parameter displays the status if overspeed

Engine Overspeed — Not Present
detected.
Engine Overspeed This parameter displays the status if overspeed

— Varies
Counter detected.
Engine Speed When This parameter displays the speed of the engine
Engine Overspeed — Varies crankshaft rotation stored if an engine overspeed
Detected is detected.
This parameter displays the time elapsed since

the engine was started. The scan tool will display
Engine Run Time Engine Operating Varies the time in hours, minutes and seconds. The
engine run time will reset to zero when the engine
stops running.
Engine Cranking Greater than 60 RPM

This parameter displays the speed of the engine
Engine Speed crankshaft rotation from information received from
Approximately 650–950
Engine Idling the crankshaft position sensor.
RPM
Engine Speed out of This parameter displays the status of the engine
— OK
range speed.
Exhaust Gas
Temperature
1–110–140°C ( This parameter displays the temperature of the
Exhaust Gas 230–284°F) exhaust gas calculated by the control module
Temperature Sensor 1, 2 —
Exhaust Gas based on the input from the exhaust gas
or 3
Temperature temperature sensors.
2–80–120°C
(176–248°F)
Exhaust Gas
Temperature
Exhaust Gas 1–1.00–1.15 V This parameter displays the voltage calculated by
Temperature Sensor 1, 2 — the control module based on the input from the
or 3 Exhaust Gas exhaust gas temperature sensors.
Temperature
2–0.90–1.10 V
This parameter displays the voltage from the

sensor used to monitor the fuel level inside the
fuel tank. The scan tool will display a low voltage
Fuel Level Sensor — Varies reading when that the fuel level in the tank is low
or near empty. The scan tool will display a high
voltage reading when the fuel level in the tank is
high or near full.
Ignition ON, engine OFF Fuel pump on for 2 s This parameter displays the control modules
Fuel Pump Relay
commanded state of the fuel pump relay control
Command
Engine idling On circuit.
This parameter displays the control modules

Fuel Rail Pressure
— % commanded state of the fuel rail pressure
Regulator 1 Command
regulator.
Fuel Rail Pressure This parameter displays the control modules

— mA
Regulator Command commanded state of the fuel pressure regulator.
23–26 MPa This parameter displays the fuel rail pressure

Fuel Rail Pressure
— calculated by the control module using the signal
Sensor 3 335.92–3 771.04 PSI from the fuel rail pressure sensor.
This parameter displays the voltage of the fuel rail

Fuel Rail Pressure
— 0.80–1.20 V pressure calculated by the control module using
Sensor
the signal from the fuel rail pressure sensor.
This parameter displays the fuel temperature

Fuel Temperature
— 25–40°C (77–104°F) calculated by the control module based on input
Sensor
from the fuel temperature sensor.

Fuel Temperature
— 0.5–1.5 V the control module based on input from the fuel
Sensor
temperature sensor.
This parameter displays the calculated status of

Gear Engaged or Clutch
— OK the actual connection between the engine and
Pressed
transmission.
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Generator F-Terminal This parameter displays the commanded state of

— 60–70%
Signal the generator by the control module.
Generator L-Terminal This parameter indicates the generator

— %
Command commanded state by the ECM.

— On/Off
Signal Command commanded state by the ECM.

Glow Plug Command — Inactive
commanded state of the glow plug.
This parameter displays the temperature of the air

−39 to +140°C (−38 to entering the engine air duct calculated by the
IAT Sensor 1 or Sensor 2 —
+284°F) control module based on the input from the intake
air temperature sensors.
This parameter displays B+ when the control

Ignition 1 Signal — B+ module detects a voltage at the ignition 1 input
terminal.
This parameter displays the state of the ignition

Ignition Accessory
— ON accessory position input to the control module
Signal
from the ignition switch.
This parameter displays the voltage measured at

the ignition 1 circuit of the control module. Voltage
Ignition Switch Status — Active
is applied to the control module when the ignition
switch is in the ignition 1 position.
Immobilizer Password Learning Enabled indicates that learning of

Ignition ON Enabled/Disabled
Learn immobilizer code information is enabled.
Immobilizer Security This Parameter displays the status of the

Ignition ON Yes/No
Code Accepted immobilizer system.

Ignition ON Yes/No
Code Lockout immobilizer system.

Ignition ON Yes/No
Code Programmed immobilizer system.

Ignition ON Yes/No
Information Programmed immobilizer system.
Standby/Immobilized at
Startup/Immobilized No
Response/Immobilized
Negative
Immobilizer System This Parameter displays the status of the
Ignition ON Response/Immobilized
Status immobilizer system.
Incorrect
Response/Post-Release
State/Pre-Release
State/Release State
This parameter displays the state of the brake

Initial Brake Apply Signal Brake Pedal applied Active
pedal position input to the control module.
Injection Limitation This parameter displays status of the injection

— OK
Active limitation as commanded by the ECM.
This parameter displays the percent of the control

Intake Air Flow Valve
— Varies modules commanded state of the intake air flow
Motor Command
valve.
Intake Air Flow Valve This parameter displays the percent of the
— Varies
Position position of the intake air flow valve.
Intake Air Flow Valve This parameter displays the voltage of the position
— Varies
Position Sensor of the intake air flow valve.

Intake Manifold Runner
— Varies modules commanded state of the intake manifold
Control Valve Command
runner valve.

This parameter displays the position from the
Control Valve Position — %
intake manifold runner valve in percentage.
Sensor
This parameter displays the quantity calculated by

MAF Sensor — g/s the control module based on a signal from the
mass air flow (MAF) sensor.
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This parameter indicates the frequency signal

received from the MAF sensor by the control
MAF Sensor — 1 700–2 100 Hz module. The scan tool will display a high value at
high engine speeds, and a low value at low
engine speeds.
This parameter displays the air flow of the engine

MAF When Engine as calculated by the control module based on the
— Varies
Overspeed Detected signal from the Mass Air Flow Sensor if a engine
overspeed condition is detected.
Maximum Engine Speed This parameter displays the maximum speed of

When Engine — Varies the engine crankshaft rotation stored if an engine
Overspeed Detected overspeed is detected.
This parameter displays the status of the MIL

MIL Command — Off
indicator as commanded by the control module.
Odometer When Engine This parameter displays the vehicle speed stored
— Varies
Overspeed Detected if an engine overspeed condition is detected.
Park/Neutral Position This parameter displays the position of the shift

— Varies
Switch lever.
This Parameter displays the state of the System

Power Mode. This signal is based upon the state
OFF/Accessory of the system power mode received over serial
Power Mode Ignition ON
/Run/Crank Request communication from the vehicle electronics. If the
serial data signal not received, the Parameter will
display OFF.
This parameter displays the amount of fuel

remaining in the fuel tank as measured in
0–100% percentage. The control module determines the
Remaining Fuel in Tank — amount of fuel remaining in the tank by using
Varies information from the fuel level sensors. The scan
tool will display a higher value with a full fuel tank,
and a lower value with an empty fuel tank.
Manual Transmission Reverse Switch ON

Reverse Position Switch — OFF indicates that the reverse switch hard wire input to
the ECM is active.
This parameter displays the status of the amount

Soot Mass Too Large — OK
of soot in the DPF as calculated by the ECM.
The scan tool displays ON or OFF. The scan tool

Starter Relay Command — OFF displays OFF until the ignition is placed into the
CRANK position.
This parameter displays the actual battery

System Voltage — 11.0–14.5 V
voltage.
Total Engine Overspeed This parameter displays the time, how long an
— Varies
Time engine overspeed condition was detected.
This parameter displays the percent of

turbocharger vane position as calculated by the
— 0–100%
control module using the information from the
turbocharger vane position sensor.
Turbocharger Vane
Position Sensor
This parameter displays the voltage of
— Varies

Turbocharger Vane
modules commanded state of the turbocharger
Position Solenoid Valve — Varies
vane position valve based on the boost pressure
Command
sensor.
This parameter displays the speed of the vehicle

as calculated by the transmission control module
Vehicle Speed — 0 km/h (0 MPH)
(TCM) from information received from the vehicle
speed sensor (VSS).
This parameter displays the speed of the vehicle if

Vehicle Speed When a engine overspeed condition is detected as
Engine Overspeed — 0 km/h (0 MPH) calculated by the engine control module (ECM)
Detected from information received from the antilock brake
system.
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Engine Control Module (ECM) Scan Tool Output Controls
Output Control Description
This function activates the A/C compressor relay. The normal commanded state of the A/C relay is OFF.
The A/C compressor will turn ON/OFF when commanded ON/OFF. The system remains in the
A/C Compressor Clutch Relay
commanded state for approximately 5 s. The engine control module (ECM) will inhibit the operation of the
A/C relay when the ambient air temperature is low.
Clutch Pedal Position Learn This device control is used to trigger the procedure to learn the clutch pedal fully applied position.
This device control is used to setup the engine for a compression test. The fuel system is disabled. The
throttle is opened to a wide open throttle (WOT) position. The extended crank feature is not active. The
scan tool initiates the test when the following conditions are met:
Transmission in Park or Neutral.

Compression Test No transmission range switch DTCs set.
The engine speed is 0 RPM.
There are no crankshaft position sensor DTCs set.
The vehicle speed is 0 km/h (0 MPH).
There are no VSS sensor DTCs set.
This function controls the low speed cooling fan relay. When commanded ON, the cooling fan will turn ON
Cooling Fan Relay 1
at low speed for approximately 5 s.
This function controls the high speed cooling fan relay. When commanded ON, the cooling fan will turn ON
Cooling Fan Relay 2
at medium speed.
Cooling Fan Relay 3
at high speed.
Cylinder Power Balance Fuel Injector Enable; Fuel Injector ON
Note: This function is only allowed with the ignition ON, engine OFF.
DPF Reset This function resets the learned values for the diesel particulate filter in the ECM after the DPF has been
replaced.
DPF Pressure Sensor Learn This function resets the learned values for the diesel particulate filter in the ECM after the DPF pressure
sensor has been replaced.
This function resets the learned values for the diesel particulate filter in the ECM after the DPF has been
DPF Service Regeneration
replaced.
This function opens or closes the EGR cooler bypass valve. The device control will not change unless
EGR Cooler Bypass Valve
changed or cancelled by the scan tool.
This function opens or closes the exhaust gas recirculation (EGR) solenoid. The EGR solenoid increases
EGR Valve or decreases in 10% increments. The device control will not change unless changed or cancelled by the
scan tool.
Engine Oil Life Reset This function turns OFF the change oil lamp and resets the values in the ECM.
Note: This function is only allowed with the engine idling.

Engine Speed This function adjusts the engine speed in 25, 100, or 500 RPM increments between 600–1 500 RPM. The
device control will not change unless changed or cancelled by the scan tool.
This function activates the fuel heater relay ON or OFF. The Device Control will not change unless
Fuel Heater Relay
Fuel Injector Learn
This function resets the learned fuel injector values in the ECM after the ECM has been replaced.
Fuel Pump Relay This function activates the fuel transfer pump or prime pump (depending on application) ON or OFF. The
Device Control will not change unless changed or cancelled by the scan tool.
Fuel Rail Pressure Sensor or Fuel

This function allows the fuel rail pressure sensor or fuel rail to be relearned by the ECM.
Rail Learn
Generator L-Terminal This function controls the system voltage. When commanded ON, normal system voltage output is
present. When commanded OFF, system voltage output is no longer present, Ignition 1 signal continues to
drop, Generator L-Terminal goes to OFF and Generator F-Terminal continues to drop.
This function activates the Glow Plug Controller ON or OFF. The Device Control will be aborted after 12 s
Glow Plugs for the first activation, and after 5 s for every other activation. The Device Control is inhibited if the engine
is running.
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This function resets the learned fuel injector values in the ECM after the injector or ECM has been
replaced.
This function opens or closes the throttle blade. The throttle blade increases or decreases in 10%
increments. The scan tool initiates the test when the following conditions are met:
Intake Air Flow Valve Position There are no vehicle speed sensor DTCs set.
The ignition is ON, with the engine OFF.
The ECM is not commanding a throttle learn.
The system remains in the commanded state until cancelled by the scan tool.
Intake Manifold Runner Control

Intake Manifold Runner Command 0–100%
Valve

The ECM executes the Intake Manifold Runner Learn Routine when commanded from the scan tool.
Valve Learn
This function activates the malfunction indicator lamp (MIL). The MIL will remain illuminated until cancelled
by the scan tool.
This function resets the following:
Setup new Control Module This function resets the learned values for the diesel particulate filter in the ECM after the ECM has
been replaced.
This function resets the learned values for the diesel particulate filter in the ECM after one or more
fuel injectors have been replaced.

Turbocharger Vane Position
Solenoid Valve Cycles the turbocharger vane position solenoid to 95% boost and back to 0% boost. The device control is
limited to engine speeds less than 2 000 RPM.
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Knock Sensor 1 Replacement

Removal Procedure
6. Remove the knock sensor wiring harness plug (1) from the wiring harness connector (4).
7. Remove the knock sensor bolt (3).
8. Remove the knock sensor (2).
1. Install the knock sensor (2).

2. Install the knock sensor bolt (3) and tighten to 25 Y (18 lb ft).
3. Install the knock sensor wiring harness plug (1) to the wiring harness connector (4).
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Knock Sensor 2 Replacement

Removal Procedure
5. Remove the engine oil cooler. Refer to Engine Oil Cooler Replacement.
6. Disconnect the knock sensor wiring harness plug (4) from the wiring harness connector (1)
7. Remove the knock sensor bolt (2).
8. Remove the knock sensor (3).
1. Install the knock sensor (3).

2. Install the knock sensor bolt (2) and tighten to 25 Y (18 lb ft).
3. Install the knock sensor wiring harness plug (4) to the wiring harness connector (1).
4. Install the engine oil cooler. Refer to Engine Oil Cooler Replacement.
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Knock Sensor System Description

The knock sensor system enables the engine control module (ECM) to control the ignition timing for the best possible performance while protecting the engine
from potentially damaging levels of detonation. The ECM uses the knock sensor system to test for abnormal engine noise that may indicate detonation, also
known as spark knock.
Sensor Description
This knock sensor system uses one or two flat response two-wire sensors. The sensor uses piezo-electric crystal technology that produces an alternating current
voltage signal of varying amplitude and frequency based on the engine vibration or noise level. The amplitude and frequency are dependant upon the level of
knock that the knock sensor detects. The ECM receives the knock sensor signal through 2 isolated signal circuits.
If the ECM has determined that knock is present, it will retard the ignition timing to attempt to reduce the knock. The ECM is capable of controlling spark retard on
an individual cylinder basis. The ECM will always try to work back to a zero compensation level, or no spark retard. Knock sensor diagnostics are calibrated to
detect faults with the knock sensor circuitry inside the ECM, the knock sensor wiring, or the knock sensor voltage output. Some diagnostics are also calibrated to
detect constant noise from an outside influence such as a loose/damaged component or excessive mechanical engine noise.
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Mass Airflow Sensor with Intake Air Temperature Sensor Replacement

Removal Procedure
1. Disconnect the mass airflow sensor wiring harness plug (3).

2. Loosen the 2 mass airflow sensor clamps (1).
3. Remove the mass airflow sensor (5) from the air cleaner outlet front duct (4) and from the air cleaner assembly (2).
1. Install the mass airflow sensor (5) to the air cleaner assembly (2) and to the air cleaner outlet front duct (4).
2. Install the 2 mass airflow sensor clamps (1) and tighten.
3. Connect the mass airflow sensor wiring harness plug (3).
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Mass Airflow Sensor with Intake Air Temperature Sensor Replacement

Removal Procedure
1. Disconnect the mass airflow sensor wiring harness plug (3).

2. Loosen the 2 mass airflow sensor clamps (1).
3. Remove the mass airflow sensor (5) from the air cleaner outlet front duct (4) and from the air cleaner assembly (2).
1. Install the mass airflow sensor (5) to the air cleaner assembly (2) and to the air cleaner outlet front duct (4).
2. Install the 2 mass airflow sensor clamps (1) and tighten.
3. Connect the mass airflow sensor wiring harness plug (3).
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Silicon Contamination of Heated Oxygen Sensors Caution

Caution: Contamination of the oxygen sensor can result from the use of an inappropriate RTV sealant (not oxygen sensor safe) or excessive engine coolant or oil
consumption. Remove the HO2S and visually inspect the portion of the sensor exposed to the exhaust stream in order to check for contamination. If contaminated, the
portion of the sensor exposed to the exhaust stream will have a white powdery coating. Silicon contamination causes a high but false HO2S signal voltage (rich exhaust
indication). The control module will then reduce the amount of fuel delivered to the engine, causing a severe driveability problem. Eliminate the source of contamination
before replacing the oxygen sensor.
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Throttle Actuator Control (TAC) System Description

The engine control module (ECM) is the control center for the throttle actuator control (TAC) system. The ECM determines the driver intent based on input from
the accelerator pedal position sensors, then calculates the appropriate throttle response based on the throttle position sensors. The ECM achieves throttle
positioning by providing a pulse width modulated voltage to the throttle actuator motor. The throttle blade is spring loaded in both directions, and the default
position is slightly open.
Modes Of Operation
Normal Mode
During the operation of the TAC system, several modes, or functions, are considered normal. The following modes may be entered during normal operations:
Minimum pedal value — At key-up, the ECM updates the learned minimum pedal value.
Minimum throttle position values — At key-up, the ECM updates the learned minimum throttle position value. In order to learn the minimum throttle position
value, the throttle blade is moved to the closed position.
Ice break mode — If the throttle blade is not able to reach a predetermined minimum throttle position, the ice break mode is entered. During the ice break
mode, the ECM commands the maximum pulse width several times to the throttle actuator motor in the closing direction.
Battery saver mode — After a predetermined time without engine speed, the ECM commands the battery saver mode. During the battery saver mode, the
throttle body TAC module removes the voltage from the motor control circuits, which removes the current draw used to maintain the idle position and allows
the throttle to return to the spring loaded default position.
Reduced Engine Power Mode
When the ECM detects a condition with the TAC system, the ECM may enter a reduced engine power mode. Reduced engine power may cause one or more of
the following conditions:
Acceleration limiting — The ECM will continue to use the accelerator pedal for throttle control, however, the vehicle acceleration is limited.
Limited throttle mode — The ECM will continue to use the accelerator pedal for throttle control, however, the maximum throttle opening is limited.
Throttle default mode — The ECM will turn OFF the throttle actuator motor, and the throttle will return to the spring loaded default position.
Forced idle mode — The ECM will perform the following actions:
Limit engine speed to idle positioning the throttle position, or by controlling the fuel and spark if the throttle is turned OFF.
Ignore the accelerator pedal input.
Engine shutdown mode — The ECM will disable fuel and de-energize the throttle actuator.
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Throttle Body Assembly Installation


2. Install the 4 bolts (3) and tighten to 10 Y (89 lb in).
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Throttle Body Assembly Removal


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Throttle Body Assembly Replacement

Removal Procedure
Replacement.
outlet hose aside (1).
12. Place a suitable tool at the flange (arrow) of the retaining ring (1) and rotate the retaining ring counterclockwise.
1 of 3
15. Remove the 4 throttle body assembly bolts (3).


2. Install 4 throttle body assembly bolts (3) and tighten to 10 Y (89 lb in).
Note: Ensure that the retaining ring (1) is locked.

2 of 3

7. Tighten the clamp (4) to 4 Y (35 lb in).
11. For vehicles with MT: Connect the transmission shift lever and selector cable to the transmission. Refer to Manual Transmission Shift Lever and
For vehicles with AT: Connect the range selector lever cable to the automatic transmission. Refer to Range Selector Lever Cable Replacement.
3 of 3
Electronic Ignition System Description

Electronic Ignition System Operation

The electronic ignition system produces and controls the high energy secondary spark. This spark ignites the compressed air/fuel mixture at precisely the correct
time, providing optimal performance, fuel economy, and control of exhaust emissions. The engine control module (ECM) collects information from the crankshaft
position sensor and the camshaft position sensor – intake and camshaft position sensor – exhaust to determine the sequence, dwell, and timing of the spark for
each cylinder. The ECM transmits a frequency signal to the ignition coil assembly on the appropriate ignition control circuit to fire the spark plugs.

The crankshaft position sensor circuits consist of an engine control module (ECM) supplied 5 V reference circuit, low reference circuit, and an output signal circuit.
The crankshaft position sensor is an externally magnetically biased digital output integrated circuit sensing device. The sensor provides a pulse for each magnetic
pole of the magnetic encoder wheel on the crankshaft. Each pole on the encoder wheel is spaced at 58-pole spacing, with 2 missing poles for the reference gap.
The crankshaft position sensor produces an ON/OFF DC voltage of varying frequency, with 58 output pulses per crankshaft revolution. The frequency of the
crankshaft position sensor output depends on the velocity of the crankshaft. The crankshaft position sensor sends a digital signal, which represents an image of
the crankshaft encoder wheel, to the ECM as each pole on the wheel rotates past the crankshaft position sensor. The ECM uses each crankshaft position sensor
signal pulse to determine crankshaft speed and decodes the crankshaft encoder wheel reference gap to identify crankshaft position. This information is then used
to determine the optimal ignition and injection points of the engine. The ECM also uses crankshaft position sensor output information to determine the camshaft
position sensor – intake and camshaft position sensor – exhaust relative to the crankshaft, to control camshaft phasing, and to detect cylinder misfire.
Crankshaft Encoder Wheel

The crankshaft encoder wheel is part of the crankshaft. The encoder wheel consists of 58 poles and a reference gap. Each pole on the encoder wheel is spaced
6° apart with a 12° space for the reference gap. The pulse from the reference gap is known as the sync pulse. The sync pulse is used to synchronize the coil firing
sequence with the crankshaft position, while the other poles provide cylinder location during a revolution.
Camshaft Position Sensor

The camshaft position sensor – intake and camshaft position sensor – exhaust is triggered by a notched reluctor wheel built onto the intake camshaft sprocket.
The camshaft position sensor – intake and camshaft position sensor – exhaust provides four signal pulses to every camshaft revolution. Each notch, or feature of
the reluctor wheel is of a different size which is used to identify the compression stroke of each cylinder and to enable sequential fuel injection. The camshaft
position sensor – intake and camshaft position sensor – exhaust is connected to the ECM by the following circuits:
A 5 V reference circuit

A low reference circuit
A signal circuit
Ignition Coil Assembly

The ignition coil assembly used on this engine integrates the 4 coils and the module within a single sealed component.
The ignition coil has the following circuits:
An ignition voltage circuit

A ground
4 ignition control circuits
The ECM controls the individual coils by transmitting timing pulses on the ignition control circuit of each ignition coil to enable a spark event.
The spark plugs are connected to each coil by a short boot. The boot contains a spring that conducts the spark energy from the coil to the spark plug. The spark
plug electrode is coated with platinum for long wear and higher efficiency.

The ECM controls all ignition system functions, and constantly adjusts the spark timing. The ECM monitors information from various sensor inputs that include the
following:
The crankshaft position sensor

The accelerator pedal position (APP)
The engine knock sensor
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Glow Plug Controller Bracket Replacement

Removal Procedure
1. Remove the glow plug controller. Refer to Glow Plug Controller Replacement.
2. Remove the glow plug controller bracket (1) in top direction from the battery tray (2).
1. Install the glow plug controller bracket (1) to the battery tray (2).

2. Install the glow plug controller. Refer to Glow Plug Controller Replacement.
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Glow Plug Controller Replacement

Removal Procedure
1. Disconnect the 2 wiring harness plugs (3).

2. Remove the glow plug control module (1) by loosening the 2 retainer clips (2).
1. Install the glow plug control module (1). Slide the glow plug control module (1) to the 2 retainer clips (2) until they hearable engage.
2. Connect the 2 wiring harness plugs (3).
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Glow Plug Installation

Install the 4 glow plugs (1) and tighten to 11 Y (97 lb in).
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Glow Plug Removal

Remove 4 glow plugs (1)
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Removal Procedure
Caution: Use care when disconnecting the glow plug electrical connector. Use of excessive force may damage the electrical connector.
3. Remove the 4 glow plugs (1).

1. Install the 4 glow plugs (1) and tighten to 11 Y (97 lb in).
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2 of 2
Glow Plug System Description

Glow plugs are used to heat the combustion chambers of diesel engines in cold conditions to help with ignition at cold start-up. In the tip of the glow plug is a coil of a
resistive wire or a filament which heats up when electricity is connected.
Glow plugs are required because diesel engines produce the heat needed to ignite their fuel by the compression of air in the cylinder and combustion chamber. In cold
weather, and when the engine block, engine oil and cooling water are cold, the heat generated during the first revolutions of the engine is conducted away by the cold
surroundings, preventing ignition. The glow plugs are switched on prior to turning over the engine to provide heat to the combustion chamber, and remain on as the
engine is turned over to ignite the first charges of fuel. Once the engine is running, the glow plugs are no longer needed, although some engines run the glow plugs for
between 5–10 s after starting to ensure smooth and efficient running and sometimes to keep the engine within emissions regulations, since combustion efficiency is
greatly reduced when the engine is very cold. During this period, the power fed to the glow plugs is greatly reduced to prevent them burning out by overheating.
Control of the glow plugs is accomplished by a glow plug control module. The temperature and the power consumption is controlled between the engine control module
(ECM) and the controller within a wide range to suit the engine pre heating requirements. Each glow plug is energized individually. This capability yields more optimum
heat times for the glow plugs, thus pre glow times can be kept to a minimum for short wait to crank times and maximum glow plug durability. A DTC will set if there is a
glow plug system fault.
A normal functioning system operates as follows:
Turn the ignition ON with the engine OFF, and at room temperature.
The glow plugs turn ON and heat up in 2 s and then are pulse-width modulated (PWM) for another 2 s.
The glow plug wait lamp is ON for 1 s during cold start.
The glow plug wait lamp may not illuminate during a warm engine start.
If the engine is cranked during or after the above sequence, the glow plugs may cycle ON and OFF after the ignition switch is returned from the start position,
whether the engine starts or not. The engine does not have to be running to terminate the glow plug cycling.
The glow plug initial ON time will vary based on the system voltage and temperature. Lower temperatures cause longer ON times.
The ECM provides glow plug operation after starting a cold engine. This post-start operation is initiated when the ignition switch is returned to Run, from the Start
position. This function helps clean up excessive white smoke and/or poor idle quality after starting.
Glow Plugs
The glow plugs are 4.4 V heaters in each of the cylinders that turn ON, then are pulse-width modulated when the ignition switch is turned to the RUN position prior
to starting the engine. The glow plug controller remains pulsing the glow plugs a short time after starting, then are turned OFF.
A Wait to Start lamp on the instrument panel provides information on engine starting conditions. The Wait to Start lamp will not illuminate during post-start glow
plug operation.
Glow Plug/Controller
The glow plug controller is a solid state device which operates the glow plugs. The glow plug controller is connected to the following circuits:
The battery voltage circuits

The CAN communication circuit located between the ECM and the glow plug controller
The engine ground circuit
The glow plug supply voltage circuits located between the glow plug controller and the glow plugs
The glow plug diagnostic circuits are directly monitored individually by using a separate transistor to control current to each glow plug. Individual diagnosis is thus
possible for every glow plug.
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Ignition and Start Switch Housing Replacement

Ignition and Start Switch Housing Replacement

1. Remove theft deterrent module. Refer to Theft Deterrent Module Replacement.

2. Disconnect electrical connector.
Ignition Lock Cylinder Bolt

1
:
Use suitable chisel to remove and install bolt.
2 Ignition and Start Switch Housing
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Ignition and Start Switch Replacement

Ignition and Start Switch Replacement

1. Remove ignition and start switch housing. Refer to Ignition and Start Switch Housing Replacement.
2. Disconnect electrical connector.
Ignition and Start Switch Bolt (Qty: 2)

1
2 Ignition and Start Switch
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Ignition Coil Installation

Special Tools
EN-6009 Remover/Installer Ignition Module
1. Install the ignition coil module (2) with the EN-6009 remover/installer (1).

3. Install the 2 ignition coil bolts and tighten to 8 Y (71 lb in).
4. Install the cover of the DIS ignition coil against the direction of the arrow.
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Ignition Coil Removal

Special Tools
EN-6009 Remover/Installer Ignition Module

1. Remove the cover of the DIS ignition coil in the direction of the arrow.
4. Remove the ignition coil module (2) with the EN-6009 remover/installer (1).
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Special Tools
EN-6009 Remover and Installer Ignition Coil
Removal Procedure
1. Remove the engine wiring harness guide (1) from the cylinder head.
2. Disconnect the ignition coil plug (2).
3. Remove the cover of the ignition coil in the direction of the arrow.

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4. Install the 2 ignition coil bolts an tighten to 9 Y (80 lb in).
5. Install the ignition coil cover in the direction of the arrow.
6. Connect the ignition coil plug (2).

7. Install the engine wiring harness guide (1) at the cylinder head.
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Spark Plug Usage
1. Ensure that the correct spark plug is installed. An incorrect spark plug causes driveability conditions. Refer to the electronic parts catalog for the correct
spark plug.
2. Ensure that the spark plug has the correct heat range. An incorrect heat range causes the following conditions:
Spark plug fouling—Colder plug

Pre-ignition causing spark plug and/or engine damage—Hotter plug
1. Inspect the terminal post (1) for damage.
Inspect for a bent or broken terminal post (1).

Test for a loose terminal post (1) by twisting and pulling the post. The terminal post (1) should NOT move.
Inspect the insulator (2) for flashover or carbon tracking, soot. This is caused by the electrical charge traveling across the insulator (2) between the terminal post
(1) and ground. Inspect for the following conditions:
Inspect the spark plug boot for damage.

Inspect the spark plug recess area of the cylinder head for moisture, such as oil, coolant, or water. A spark plug boot that is saturated causes arcing to
ground.
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Inspect the insulator (2) for cracks. All or part of the electrical charge may arc through the crack instead of the electrodes (3, 4).
Inspect for evidence of improper arcing.
Measure the gap between the center electrode (4) and the side electrode (3) terminals. Refer to Ignition System Specifications. An excessively wide
electrode gap can prevent correct spark plug operation.
Inspect for the correct spark plug torque. Refer to Ignition System Specifications. Insufficient torque can prevent correct spark plug operation. An over
torqued spark plug, causes the insulator (2) to crack.
Inspect for signs of tracking that occurred near the insulator tip instead of the center electrode (4).
Inspect for a broken or worn side electrode (3).
Inspect for a broken, worn, or loose center electrode (4) by shaking the spark plug.
A rattling sound indicates internal damage.
A loose center electrode (4) reduces the spark intensity.
Inspect for bridged electrodes (3, 4). Deposits on the electrodes (3, 4) reduce or eliminates the gap.
Inspect for worn or missing platinum pads on the electrodes (3, 4) If equipped.
Inspect for excessive fouling.
Inspect the spark plug recess area of the cylinder head for debris. Dirty or damaged threads can cause the spark plug not to seat correctly during
installation.
Spark Plug Visual Inspection
1. Normal operation—Brown to grayish-tan with small amounts of white powdery deposits are normal combustion by-products from fuels with additives.
2. Carbon Fouled—Dry, fluffy black carbon, or soot caused by the following conditions:
Rich fuel mixtures

Leaking fuel injectors
Excessive fuel pressure
Restricted air filter element
Incorrect combustion
Reduced ignition system voltage output
Weak coils
Worn ignition wires
Incorrect spark plug gap
Excessive idling or slow speeds under light loads can keep spark plug temperatures so low that normal combustion deposits may not burn off.
Deposit Fouling—Oil, coolant, or additives that include substances such as silicone, very white coating, reduces the spark intensity. Most powdery deposits
will not effect spark intensity unless they form into a glazing over the electrode.
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Remove the ignition coil. Refer to Ignition Coil Replacement.
Spark Plug Fastener

1
Tighten
25 Y (18 lb ft)
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Battery Charging

Special Tools
EL 50313 Battery Tester
Diagnostic Aids
For best results, use an automatic taper-rate battery charger with a voltage capability of 16 V.
The charging area should be well ventilated.
Do not charge a battery that appears to be frozen. Allow the battery to warm to room temperature and test it using the EL 50313 before charging.
Battery State of Charge

Note: Using voltage to determine the batteries state of charge is only accurate after the battery has been at rest for 24 hours. This is enough time for the acid in
each cell to equalize. If the battery has been charged or discharged in the past 24 hours, the battery state of charge will only be an estimate.
The maintenance-free batteries state of charge is estimated by reading the voltage of the battery across the battery terminals. Because the voltage is affected by
current flow into or out of the battery, the engine must be stopped and all electrical loads turned OFF, including parasitic loads, when checking the voltage. The
voltage can also be affected if the battery has just been charged or discharged, so it is important to consider what has happened to the battery in the time just
before testing. Use the following procedure to determine the battery's state of charge:
1. Be sure all electrical loads are turned OFF.

2. Determine whether the battery has been used in a vehicle or charged within the past 12 hours.
If the answer is no, the terminal voltage will be stabilized and no action is necessary before reading the voltage. Skip to step 3.
If the answer is yes, terminal voltage will not be stabilized and you should wait 12 hours since the last time the battery was used.
Estimate the battery temperature by determining the average temperature to which the battery has been exposed for the past 12 hours.
Note: The table is accurate to 10 % only after the battery has been at rest for 12 hours.
Measure the battery voltage at the battery terminals. Refer to the following table to determine the state of charge according to the estimated battery
temperature:
Battery Voltage % Charge at 0°C (32°F) % Charge at 25°C (75°F)
12.75 V 100% 100%
12.7 V 100% 90%
12.6 V 90% 75%
12.45 V 75% 65%
12.2 V 65% 45%
12.0 V 40% 20%
Use the state of charge information as follows:
A battery with a state of charge that is below 65% must always be recharged before returning it to service or continuing storage.
A battery with a state of charge that is 65% or greater is generally considered to be charged enough in order to be returned to normal service or in order to
continue storage. However, if the battery is being used in slow traffic or with short drive times, or if the temperature is very hot or very cold, the battery
should be fully charged, to at least 90%, before returning it to service or continuing storage.
Charging Time Required

The time required to charge a battery will vary depending upon the following factors:
The battery charger capacity—The higher the charger amperage, the less time it will take to charge the battery.
The state of charge of the battery—A completely discharged battery requires more than twice as much charging time as a half charged battery. In a
discharged battery with a voltage below 11 V, the battery has a very high internal resistance and may only accept a very low current at first. Later, as the
charging current causes the acid content to increase in the electrolyte, the charging current will increase. Extremely discharged batteries may not activate
the reversed voltage protection in some chargers. Refer to the manufacturer's instructions for operating this circuitry.
The temperature of the battery—The colder the battery is, the more time it takes to recharge the battery. The charging current accepted by a cold battery is
very low at first. As the battery warms, the charging current will increase.
Charging Procedure
Caution: Turn OFF the ignition when connecting or disconnecting the battery cables, the battery charger or the jumper cables. Failure to do so may damage the
ECM/PCM or other electronic components.
When charging side-terminal batteries with the battery cables connected, connect the charger to the positive cable bolt and to a ground located away from the
battery. When charging side-terminal batteries with the battery cables disconnected, install the battery side terminal adapters and connect the charger to the
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Battery Charging
adapters.
Tighten
Tighten the battery side terminal adapters to 15 Y (11 lb ft).
Use the following procedure to charge the battery:
1. Turn OFF the charger.

2. Ensure that all of the battery terminal connections are clean and tight.
3. Connect the charger positive lead to the battery positive terminal on the battery or the remote jumper stud underhood.
Caution: Do not connect the negative charger lead to the housings of other vehicle electrical accessories or equipment. The action of the battery charger
may damage such equipment.
4. Connect the negative charger lead to a solid engine ground or to a ground stud in the engine compartment that is connected directly to the battery
negative terminal, but away from the battery. If the negative battery cable is disconnected and a terminal adapter is being used, connect directly to the
adapter.
5. Turn ON the charger and set to the highest setting for normal charging.
6. Inspect the battery every half hour after starting the battery charger.
Charge the battery until the taper-rate charger indicates that the battery is fully charged.
Estimate the battery temperature by feeling the side of the battery. If it feels hot to the touch or its temperature is over 45°C (125°F), discontinue charging
and allow the battery to cool before resuming charging.
After charging, test the battery. Refer to Battery Inspection/Test.
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Battery Cover Replacement

Removal Procedure
Note: Mind the 3 battery cover retainer clips (arrows). The battery cover could be damaged if the retainer clips are not fully unlocked.
Remove the battery cover (1) from the battery tray.
Note: Ensure the proper seat of the battery cover.

Install the battery cover (1) to the battery tray.
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Battery Current Sensor Replacement

Removal Procedure
2. Remove the negative cable nut (1).

3. Remove the negative cable (2).

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Battery Current Sensor Replacement
1. Install the current sensor (2) at the battery negative cable (1).

4. Install the negative cable (2).

5. Install the negative cable nut (1) and tighten to 9 Y (80 lb in).
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Battery Description and Operation

Warning: Batteries produce explosive gases, contain corrosive acid, and supply levels of electrical current high enough to cause burns. Therefore, to reduce the risk of
personal injury when working near a battery:
Always shield your eyes and avoid leaning over the battery whenever possible.
Do not expose the battery to open flames or sparks.
Do not allow the battery electrolyte to contact the eyes or the skin. Flush immediately and thoroughly any contacted areas with water and get medical help.
Follow each step of the jump starting procedure in order.
Treat both the booster and the discharged batteries carefully when using the jumper cables.
Note: Because of the materials used in the manufacture of automotive lead acid batteries, dealers and service shops that handle them are subject to various regulations
issued by OSHA, EPA, DOT, and various state or local agencies. Other regulations may also apply in other locations. Always know and follow these regulations when
handling batteries.
Batteries that are no longer wanted must be disposed of by an approved battery recycler and must never be thrown in the trash or sent to a landfill.
Batteries that are not part of the vehicle itself, not the battery under the hood, must only be transported on public streets for business purposes via approved hazardous
material transportation procedures.
Battery storage, charging and testing facilities in repair shops must meet various requirements for ventilation, safety equipment, material segregation, etc.
The maintenance free battery is standard. There are no vent plugs in the cover. The battery is completely sealed except for 2 small vent holes in the side. These vent
holes allow the small amount of gas that is produced in the battery to escape.
The battery has 3 functions as a major source of energy:
Engine cranking
Voltage stabilizer
Alternate source of energy with generator overload
Battery Low Start Vehicle Message

The body control module (BCM) monitors battery positive voltage to determine battery state of charge. If one or more of the BCM battery positive voltage terminals
measure less than approximately 11.6V compared to the BCM ground circuits, this message will display and four chimes may sound. Start the vehicle immediately.
If the vehicle is not started and the battery continues to discharge, the climate controls, heated seats, and audio systems will shut off and the vehicle may require a
jump start. These systems will function again after the vehicle is started.
Battery Ratings
A battery has 2 ratings:
Cold cranking amperage

Amperage hours
When a battery is replaced use a battery with similar ratings. See battery specification label on the original battery.
Amperage Hours
The amperage hour rating tells you how much amperage is available when discharged evenly over a 20 hour period. The amperage hour rating is cumulative, so
in order to know how many constant amperage the battery will output for 20 h, you have to divide the amperage hour rating by 20. Example: If a battery has an
amperage hour rating of 74, dividing by 20 = 3.75. Such a battery can carry a 3.75 A load for 20 hours before dropping to 10.5 V. (10.5 V is the fully discharged
level, at which point the battery needs to be recharged.) A battery with an amperage hour rating of 55 will carry a 2.75 A load for 20 hours before dropping to 10.5
V.
Cold Cranking Amperage

The cold cranking amperage is an indication of the ability of the battery to crank the engine at cold temperatures. The cold cranking amperage rating is the
minimum amperage the battery must maintain for 30 seconds at −18°C (0°F) while maintaining at least 7.2 V. See battery label for the cold cranking amperage
rating of this battery.
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Battery Disconnect Warning

Warning: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any
electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal.
Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.
For Vehicles equipped with OnStar® (UE1) with Back Up Battery:
The Back Up Battery is a redundant power supply to allow limited OnStar® functionality in the event of a main vehicle battery power disruption to the VCIM
(OnStar®module). Do not disconnect the main vehicle battery or remove the OnStar® fuse with the ignition key in any position other than OFF. Retained accessory
power should be allowed to time out or be disabled (simply opening the driver door should disable retained accessory power) before disconnecting power. Disconnecting
power to the OnStar® module in any way while the ignition is On or with retained accessory power activated may cause activation of the OnStar® Back-Up Battery
system and will discharge and permanently damage the back-up battery. Once the Back-Up Battery is activated it will stay on until it has completely discharged. The
back-up battery is not rechargeable and once activated the back-up battery must be replaced.
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Battery Inspection/Test

Diagnostic Aids
Note: For Warranty repairs —
You must use regionally required battery test equipment for warranty repairs.For accurate test results the battery must be disconnected from the vehicle and the
equipment connected directly to the battery posts. When setting up the equipment, select “Out of Vehicle” and then the correct battery type (Flooded or AGM) and
rated CCA (both from the battery label) must be entered.
Failure to obtain the correct connections during the test may result in a failed test on a good battery.
Use the Out of Vehicle test (both batteries disconnected with test equipment connected directly to the post) test for each battery when testing a vehicle with
dual batteries.
Follow these instructions in order to avoid an incorrect diagnosis because of connections:
If testing the vehicle with the battery cables still connected, wiggle the battery tester clips on the terminal. This may cut through any coating or through any
oxidation that may be present on the terminal.
If correct connections to the battery terminals in the vehicle are in doubt, perform the following steps:
1. Disconnect the negative battery cable.

2. Disconnect the positive battery cable.
3. Follow the instructions for testing a removed battery.
If the tester displays a REPLACE BATTERY or BAD CELL-REPLACE result for a battery tested in the vehicle with the battery cables connected, perform the
following steps:
1. Disconnect the negative battery cable.

2. Disconnect the positive battery cable.
Note: Always write the test code displayed by the tester on the repair order for any warranty purposes. The number is a unique code that describes the
test data for a particular battery at a particular time. The test code may occasionally repeat when you retest the same battery. More often, each test will
result in a different code. Use the test code from the second, or Out of Vehicle test.
3. Follow the instructions for testing a removed battery.
4. Replace the battery only if the second test shows a REPLACE BATTERY or BAD CELL-REPLACE result.
Use the test code from the second test for any warranty purposes.
Schematic Reference
Starting and Charging Schematics
Description and Operation
Starting System Description and Operation
Circuit Testing
Connector Repairs
Wiring Repairs
Scan Tool Reference
Control Module References for scan tool information
Special Tools
EL 50313 Battery Tester
Circuit/System Testing
Warning: Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any
electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical
terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components.
For Vehicles equipped with OnStar® (UE1) with Back Up Battery:
The Back Up Battery is a redundant power supply to allow limited OnStar® functionality in the event of a main vehicle battery power disruption to the VCIM
(OnStar®module). Do not disconnect the main vehicle battery or remove the OnStar® fuse with the ignition key in any position other than OFF. Retained
accessory power should be allowed to time out or be disabled (simply opening the driver door should disable retained accessory power) before disconnecting
power. Disconnecting power to the OnStar® module in any way while the ignition is On or with retained accessory power activated may cause activation of the
OnStar® Back-Up Battery system and will discharge and permanently damage the back-up battery. Once the Back-Up Battery is activated it will stay on until it has
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Battery Inspection/Test
completely discharged. The back-up battery is not rechargeable and once activated the back-up battery must be replaced.
1. Verify the C1 or C1B Battery case is not cracked, broken, or damaged, which may be indicated by battery acid leakage.
If there is any apparent damage

Replace the C1 or C1B Battery.
If there is no damage
Verify the cold cranking amperage and amperage hour rating of the C1 or C1B Battery. Refer to the manufacturer specifications on the battery label.
If the C1 or C1B Battery does not meet specifications

Replace the C1 or C1B Battery.
If the C1 or C1B Battery meets specifications

Verify that the battery cables are clean and tight. The battery terminal bolts should be torqued as specified in Fastener Tightening Specifications.
If the battery cables need to be cleaned or tightened

Clean as required and tighten as specified.
If the battery cables are clean and tight

Install the battery tester and follow directions supplied by the tester.
Repair Instructions
Perform the Diagnostic Repair Verification after completing the repair.
Battery Replacement
2 of 2

Removal Procedure
1. Turn on the radio and record all of the customer radio station presets.
2. Ensure that all lamps and accessories are turned off.
3. Turn the ignition OFF and remove the ignition key.
4. Remove the battery cover (1).
Warning: Refer to Battery Disconnect Warning.

5. Loosen the battery negative cable nut (2).
6. Remove the battery negative cable (1) from the battery.
1. Install the battery negative cable (1) to the battery.

2. Fasten the battery negative cable nut (2) and tighten the nut to 4.5 Y (40 lb in).
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3. Install the battery cover (1).

4. Insert the ignition key and turn the ignition to the ON position.
5. Program volatile memory. Refer to Volatile Memory Programming.
6. Program all of the customer's radio station presets and set the radio clock to the current time.
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Removal Procedure
2. Remove the battery ground cable nut (1).


6. Remove battery ground cable from the battery negative cable nut (2).
7. Remove the ground cable (3).
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1. Install the current sensor (2) to the battery negative cable (1).

3. Install the ground cable (3).
4. Install the battery ground cable to the battery negative cable nut (2) and tighten to 9 Y (80 lb in).

8. Install the battery ground cable nut (1) and tighten to 9 Y (80 lb in).
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Battery Positive and Negative Cable Replacement (2.0L Diesel LNP with Automatic Transmission)

Removal Procedure
1. Remove the transmission fluid cooler outlet and inlet pipe. Refer to Transmission Fluid Cooler Outlet Pipe Replacement and Transmission Fluid Cooler
Inlet Pipe Replacement.

4. Disconnect the transmission range selector lever cable terminal from the transmission manual shift lever pin.
5. Press the locking tabs inward in order to release the transmission range selector lever cable (1) from the cable bracket.
6. Hang the transmission range selector lever cable aside to gain access to the generator and starter cable (4).
7. Unclip the generator and starter cable retainers (2) from the rear transmission bracket.
8. Unclip the generator and starter cable conduit retainers (3).
11. Remove the positive and negative cable nut (2).

12. Remove the positive and negative cable (5) from the starter.
13. Remove the ground cable bolt (4).
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14. Remove the ground cable (3) from the engine block.

15. Unclip the positive and negative cable clip from bracket.
16. Fold the generator cap (2) aside.

17. Remove the generator positive cable retaining nut (3).
18. Remove the generator positive cable (4) from the generator.
19. Hang the positive and negative cable aside.
21. Remove the positive and negative cable from the vehicle.
1. Position the positive and negative cable to the vehicle.

3. Position the positive and negative cable.
4. Install the positive and negative cable (4) to the generator.

5. Install the positive and negative cable retaining nut (3) and tighten to 17 Y (13 lb ft).
6. Fold the generator cap (2) to the positive and negative cable terminal.
7. Clip in the positive and negative cable clip to the bracket.

8. Install the ground cable (3) to the engine block.
9. Install the ground cable bolt (4) and tighten to 22 Y (16 lb ft).
10. Install the positive and negative cable (5) to the starter.
11. Install the positive and negative cable nut (2) and tighten to 9.5 Y (84 lb in).
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14. Clip in the generator and starter cable conduit retainers (3).

15. Clip in the generator and starter cable retainers (2) to the rear transmission bracket.
16. Install the transmission range selector lever cable (1) to the cable bracket.
17. Connect the transmission range selector lever cable terminal to the transmission manual shift lever pin.

20. Install the transmission fluid cooler outlet and inlet pipe. Refer to Transmission Fluid Cooler Outlet Pipe Replacement and Transmission Fluid Cooler
Inlet Pipe Replacement.
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Battery Positive and Negative Cable Replacement (2.0L Diesel LNP with Manual Transmission)

Removal Procedure
2. Unlock the retaining tab (1) on the battery fuse box cover.

3. Use a suitable screw driver (2) to unlock the clip (4) through the window (3).
Note: Pull the battery fuse box housing. DO NOT pull the flap.
4. Open the battery fuse box cover (1).
5. Remove the battery positive to starter cable nut (2).
6. Remove the battery positive to starter cable (3) from the battery.

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10. Remove the engine control module (2) in top direction.
12. Remove the 2 positive and negative cable bracket nuts (1, 2).

15. Remove the positive and negative cable nut (2).

16. Remove the positive and negative cable (5) from the starter.
17. Remove the ground cable bolt (4).
18. Remove the ground cable (3) from the engine block.
19. Unclip the positive and negative cable clip from bracket.
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20. Fold the generator cap (2) aside.

21. Remove the generator positive cable retaining nut (3).
22. Remove the generator positive cable (4) from the generator.
23. Hang the positive and negative cable aside.
25. Remove the positive and negative cable from the vehicle.
1. Position the positive and negative cable to the vehicle.

3. Position the positive and negative cable.
4. Install the positive and negative cable (4) to the generator.

5. Install the positive and negative cable retaining nut (3) and tighten to 17 Y (13 lb ft).
6. Fold the generator cap (2) to the positive and negative cable terminal.
7. Clip in the positive and negative cable clip to the bracket.

8. Install the ground cable (3) to the engine block.
9. Install the ground cable bolt (4) and tighten to 22 Y (16 lb ft).
10. Install the positive and negative cable (5) to the starter.
11. Install the positive and negative cable nut (2) and tighten to 9,5 Y (84 lb in).
14. Install the 2 positive and negative cable bracket nuts (1, 2) and tighten to 17 Y (13 lb ft).
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17. Install the engine control module (2).

21. Install the battery positive to starter cable (3) to the battery.

22. Install and tighten the battery positive to starter cable nut (2).
23. Close the battery fuse box cover and lock the retaining tabs (1) and (4).
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Battery Positive Cable Replacement

Removal Procedure

3. Use a suitable screwdriver (2) to unlock the clip (4) through the window (3).
Note: Pull the battery fuse box housing, DO NOT pull the flap.
4. Open the battery fuse box cover.
5. Remove the battery positive cable to fuse box nut (1).

6. Remove the battery positive cable to battery nut (2).
7. Remove the battery positive cable to fuse box cable (3).
1. Install the battery positive cable to fuse box cable (3).

2. Install the battery positive cable to battery nut (2) and tighten to 4.5 Y (40 lb in).
3. Install the battery positive cable to fuse box nut (1) and tighten to 9 Y (80 lb in).
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Battery Positive Cable Replacement
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Battery Replacement (Diesel)

Special Tools
GE-49379 Battery Remover
Removal Procedure

3. Use a suitable screw driver (2) to unlock the clip (4) through the window (3).
5. Remove the positive battery cable to starter nut (2).
6. Remove the positive battery cable to starter (3) from the battery.
7. Loosen the positive battery cable nut (1) on the battery.

8. Remove the positive battery cable (2)
9. Unlock the 2 retaining tabs (3) and remove positive battery cable cover.
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10. Remove the battery hold down retainer nut (2).

11. Remove the battery hold down retainer (1) from the battery tray (3).
13. Disconnect the glow plug controller wiring harness plug (4).
14. Remove the glow plug controller bracket (2) from the battery tray.
15. Unlock the retaining tab (2) and remove the protector battery tray (1).
16. Remove the battery with the GE-49379 remover .
1. Install the battery with the GE-49379 remover .
2. Install the protector battery tray (1).
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3. Install the glow plug controller bracket (2) at the battery tray.

4. Connect the glow plug controller wiring harness plug (4).
5. Clip in the battery current sensor (3) at the battery tray.
6. Install the battery hold down retainer (1) at the battery tray (3).

7. Install the battery hold down retainer nut (2) and tighten to 9 Y (80 lb in).
8. Install the positive battery cable cover and lock the 2 retaining tabs (3).
9. Install the positive battery cable (2).
10. Tighten the positive battery cable nut (1) on the battery to 9 Y (80 lb in).
11. Install the positive battery cable to starter (3).

12. Install the positive battery cable to starter nut (2) and tighten to 9 Y (80 lb in).
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4 of 4

Removal Procedure
1. Open the hood.

3. Unclip all wiring harness from the battery tray.
4. Unclip the engine control module bracket from the battery tray.
5. If equipped, unclip the radiator surge tank engine hose from the battery tray.
7. Remove the 3 battery tray bolts (1).

8. Remove the battery tray (2).
1. Install the battery tray (2).

2. Install the 3 battery tray bolts (1) and tighten to 15 Y (11 lb ft).
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3. Clip in the battery current sensor (1) to the battery tray.

4. If equipped, clip in the radiator surge tank engine hose to the battery tray.
5. Install battery. Refer to Battery Replacement.
6. Clip in all wiring harness at the battery tray.
7. Clip in the engine control module bracket to the battery tray.
8. Close the hood.
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Charging System Description and Operation

Electrical Power Management Overview

The electrical power management system is designed to monitor and control the charging system and send diagnostic messages to alert the driver of possible
problems with the battery and generator. This electrical power management system primarily utilizes existing on-board computer capability to maximize the
effectiveness of the generator, to manage the load, improve battery state-of-charge and life, and minimize the system's impact on fuel economy. The electrical
power management system performs 3 functions:
It monitors the battery voltage and estimates the battery condition.

It takes corrective actions by boosting idle speeds, and adjusting the regulated voltage.
It performs diagnostics and driver notification.
The battery condition is estimated during ignition-off and during ignition-on. During ignition-off the state-of-charge of the battery is determined by measuring the
open-circuit voltage. The state-of-charge is a function of the acid concentration and the internal resistance of the battery, and is estimated by reading the battery
open circuit voltage when the battery has been at rest for several hours.
The state-of-charge can be used as a diagnostic tool to tell the customer or the dealer the condition of the battery. Throughout ignition-on, the algorithm
continuously estimates state-of-charge based on adjusted net amp hours, battery capacity, initial state-of-charge, and temperature.
While running, the battery degree of discharge is primarily determined by a battery current sensor, which is integrated to obtain net amp hours.
In addition, the electrical power management function is designed to perform regulated voltage control to improve battery state-of-charge, battery life, and fuel
economy. This is accomplished by using knowledge of the battery state-of-charge and temperature to set the charging voltage to an optimum battery voltage level
for recharging without detriment to battery life.
The Charging System Description and Operation is divided into 3 sections. The first section describes the charging system components and their integration into the
electrical power management. The second section describes charging system operation. The third section describes the instrument panel cluster operation of the charge
indicator, driver information center messages, and voltmeter operation.
Charging System Components

Generator
The generator is a serviceable component. If there is a diagnosed failure of the generator it must be replaced as an assembly. The engine drive belt drives the
generator. When the rotor is spun it induces an alternating current (AC) into the stator windings. The AC voltage is then sent through a series of diodes for
rectification. The rectified voltage has been converted into a direct current (DC) for use by the vehicles electrical system to maintain electrical loads and the battery
charge. The voltage regulator integral to the generator controls the output of the generator. It is not serviceable. The voltage regulator controls the amount of
current provided to the rotor. If the generator has field control circuit failure, the generator defaults to an output voltage of 13.8 V.
Body Control Module (BCM)
The body control module (BCM) is a GMLAN device. It communicates with the engine control module (ECM) and the instrument panel cluster for electrical power
management (electrical power management) operation. The BCM determines the output of the generator and sends the information to the ECM for control of the
generator turn on signal circuit. It monitors the generator field duty cycle signal circuit information sent from the ECM for control of the generator. It monitors a
battery current sensor, the battery positive voltage circuit, and estimated battery temperature to determine battery state of charge. The BCM performs idle boost.
Battery Current Sensor
The battery current sensor is a serviceable component that is connected to either the negative or positive battery cable at the battery. The battery current sensor is
a 3-wire hall effect current sensor. The battery current sensor monitors the battery current. It directly inputs to the BCM. It creates a 5-volt pulse width modulation
(PWM) signal of 128 Hz with a duty cycle of 0–100 percent. Normal duty cycle is between 5–95 percent. Between 0–5 percent and 95–100 percent are for
diagnostic purposes.
When the engine is running, the generator turn-on signal is sent to the generator from the ECM, turning on the regulator. The generator's voltage regulator controls
current to the rotor, thereby controlling the output voltage. The rotor current is proportional to the electrical pulse width supplied by the regulator. When the engine
is started, the regulator senses generator rotation by detecting AC voltage at the stator through an internal wire. Once the engine is running, the regulator varies
the field current by controlling the pulse width. This regulates the generator output voltage for proper battery charging and electrical system operation. The
generator field duty terminal is connected internally to the voltage regulator and externally to the ECM. When the voltage regulator detects a charging system
problem, it grounds this circuit to signal the ECM that a problem exists. The ECM monitors the generator field duty cycle signal circuit, and receives control
decisions based on information from the BCM.
Instrument Panel Cluster
The instrument panel cluster provides the customer notification in case a concern with the charging system. There are 2 means of notification, a charge indicator
and a driver information center message of SERVICE BATTERY CHARGING SYSTEM if equipped.
Charging System Block Diagram
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P16
Instrument
Cluster
K20
Engine
Control
Module
G13
Generator
C1
Battery
K9 B18
Body Battery
Control Current
Module Sensor
Charging System Operation

The purpose of the charging system is to maintain the battery charge and vehicle loads. There are 6 modes of operation and they include:
Battery Sulfation Mode

Charge Mode
Fuel Economy Mode
Headlamp Mode
Start Up Mode
Voltage Reduction Mode
The engine control module (ECM) controls the generator through the generator turn ON signal circuit. The ECM monitors the generator performance though the
generator field duty cycle signal circuit. The signal is a pulse width modulation (PWM) signal of 128 Hz with a duty cycle of 0–100 percent. Normal duty cycle is
between 5–95 percent. Between 0–5 percent and 95–100 percent are for diagnostic purposes. The following table shows the commanded duty cycle and output
voltage of the generator:
Commanded Duty Cycle Generator Output Voltage
10% 11 V
20% 11.56 V
30% 12.12 V
40% 12.68 V
50% 13.25 V
60% 13.81 V
70% 14.37 V
80% 14.94 V
90% 15.5 V
The generator provides a feedback signal of the generator voltage output through the generator field duty cycle signal circuit to the ECM. This information is sent
to the body control module (BCM). The signal is PWM signal of 128 Hz with a duty cycle of 0–100 percent. Normal duty cycle is between 5–99 percent. Between
0–5 percent and 100 percent are for diagnostic purposes.
Battery Sulfation Mode

The BCM will enter this mode when the interpreted generator output voltage is less than 13.2 V for 45 minutes. When this condition exists the BCM will enter
Charge Mode for 2–3 minutes. The BCM will then determine which mode to enter depending on voltage requirements.
Charge Mode
The BCM will enter Charge Mode when ever one of the following conditions are met.
The wipers are ON for more than 3 seconds.

GMLAN (Climate Control Voltage Boost Mode Request) is true, as sensed by the HVAC control head. High speed cooling fan, rear defogger and HVAC high
speed blower operation can cause the BCM to enter the Charge Mode.
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The estimated battery temperature is less than 0°C (32°F).

Battery State of Charge is less than 80 percent.
Vehicle speed is greater than 145 km/h (90 mph)
Current sensor fault exists.
System voltage was determined to be below 12.56 V
When any one of these conditions is met, the system will set targeted generator output voltage to a charging voltage between 13.9–15.5 V, depending on the
battery state of charge and estimated battery temperature.
Fuel Economy Mode
The BCM will enter Fuel Economy Mode when the estimated battery temperature is at least 0°C (32°F) but less than or equal to 80°C (176°F), the calculated
battery current is less than 15 amperes and greater than −8 amperes, and the battery state-of-charge is greater than or equal to 80 percent. Its targeted generator
output voltage is the open circuit voltage of the battery and can be between 12.5–13.1 V. The BCM will exit this mode and enter Charge Mode when any of the
conditions described above are present.
Headlamp Mode
The BCM will enter Headlamp Mode when ever the headlamps are ON (high or low beams). Voltage will be regulated between 13.9–14.5 V.
Start Up Mode
When the engine is started the BCM sets a targeted generator output voltage of 14.5 V for 30 seconds.
Voltage Reduction Mode

The BCM will enter Voltage Reduction Mode when the calculated ambient air temperature is above 0°C (32°F). The calculated battery current is less than 1
ampere and greater than −7 amperes, and the generator field duty cycle is less than 99 percent. Its targeted generator output voltage is 12.9 V. The BCM will exit
this mode once the criteria are met for Charge Mode.
Instrument Panel Cluster Operation

Charge Indicator Operation
The instrument panel cluster illuminates the charge indicator and displays a warning message in the driver information center if equipped, when the one or more of
the following occurs:
The engine control module (ECM) detects that the generator output is less than 11 V or greater than 16 V. The instrument panel cluster receives a GMLAN
message from the ECM requesting illumination.
The instrument panel cluster determines that the system voltage is less than 11 V or greater than 16 V for more than 30 seconds. The instrument panel
cluster receives a GMLAN message from the body control module (BCM) indicating there is a system voltage range concern.
The instrument panel cluster performs the displays test at the start of each ignition cycle. The indicator illuminates for approximately 3 seconds.
Display Message: BATTERY NOT CHARGING SERVICE CHARGING SYSTEM or SERVICE BATTERY CHARGING SYSTEM
The BCM and the ECM will send a serial data message to the driver information center for the BATTERY NOT CHARGING SERVICE CHARGING SYSTEM or
SERVICE BATTERY CHARGING SYSTEM message to be displayed. It is commanded ON when a charging system DTC is a current DTC. The message is
turned OFF when the conditions for clearing the DTC have been met.
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Data Link Communications Description and Operation

Note: This is an overview of different serial data buses used by GM devices to communicate with each others. Use Data Communication Schematics to find out which
serial data buses are configured for a specific vehicle.
Circuit Description
There are many components in a vehicle that rely on information from other sources, transmit information to other sources, or both. Serial data communication
networks provide a reliable, cost effective, way for various components of the vehicle to “talk” to one another and share information.
GM uses a number of different communication buses to insure the timely and efficient exchange of information between devices. When compared to each other,
some of these buses are different in nature as far as speed, signal characteristics, and behavior. An example of this is the High Speed GMLAN and Low Speed
GMLAN buses.
On the other hand, when other buses are compared to each other they have similar characteristics and simply operate in parallel. In this case they are used to
group together components which have high interaction. Examples are the High Speed GMLAN, Powertrain Expansion, and Chassis Expansion buses. This
allows them to communicate with each other on a bus with reduced message congestion insuring faster and the more timely exchange of information than if all
vehicle devices were on a single bus.
The majority of information that exists within a given network generally stays local; however some information will have to be shared on other networks. Control
modules designated as Gateway’s perform the function of transferring information between the various buses. A Gateway module is connected to at least 2 buses
and will interact with each network according to its message strategy and transmission models.
GMLAN provides the capability for a receiving device to monitor message transmissions from other devices in order to determine if messages of interest are not
being received. The primary purpose is to allow reasonable default values to be substituted for the information no longer being received. Additionally, a device may
set a Diagnostic Trouble Code to indicate that the device it is expecting information from is no longer communicating.
High Speed GMLAN Circuit Description

A High Speed GMLAN Bus is used where data needs to be exchanged at a high enough rate to minimize the delay between the occurrence of a change in sensor
value and the reception of this information by a control device using the information to adjust vehicle system performance.
The High Speed GMLAN serial data network consists of two twisted wires. One signal circuit is identified as GMLAN-High and the other signal circuit is identified
as GMLAN-Low. At each end of the data bus there is a 120 Ω termination resistor between the GMLAN-High and GMLAN-Low circuits.
Data symbols (1’s and 0’s) are transmitted sequentially at a rate of 500 Kbit/s. The data to be transmitted over the bus is represented by the voltage difference
between the GMLAN-High signal voltage and the GMLAN-Low signal voltage.
When the two wire bus is at rest the GMLAN-High and GMLAN-Low signal circuits are not being driven and this represents a logic “1”. In this state both signal
circuits are at the same voltage of 2.5 V. The differential voltage is approximately 0 V.
When a logic “0” is to be transmitted, the GMLAN-High signal circuit is driven higher to about 3.5 V and the GMLAN-Low circuit is driven lower to about 1.5 V. The
differential voltage becomes approximately 2.0 (+/- 0.5) V.
Chassis High Speed GMLAN Circuit Description

The GMLAN Chassis Expansion Bus is basically a copy of the High Speed GMLAN Bus except that its use is reserved for chassis components. This
implementation splits message congestion between two parallel buses helping to insure timely message transmission and reception. Sometimes communication is
required between the Chassis Expansion Bus and the primary High Speed GMLAN Bus. This is accomplished by using the K17 Electronic Brake Control Module
(EBCM) as the Gateway module. Since the High Speed GMLAN Chassis Expansion Bus and primary High Speed GMLAN Bus operate in the same manner, the
diagnostics for each are similar.
Object High Speed GMLAN Circuit Description

The GMLAN Object Bus is basically a copy of the High Speed GMLAN Bus except that its use is reserved for the enhanced safety system. This implementation is
used to isolate the heavy communication among the enhanced safety system devices from the other vehicle buses, reducing congestion. The K124 Active Safety
Control Module is connected to the Object Bus as well as the Primary High Speed GMLAN Bus, the Chassis Expansion Bus, and the Low Speed GMLAN Bus.
The K124 Active Safety Control Module acts as a Gateway module for all required communication between the Object Bus devices and devices on these other
vehicle buses. The GMLAN Object Bus operates in the same manner as the Chassis Expansion and Primary High Speed buses and so the diagnostics are similar.
The Object Bus is physically partitioned into a Front Object Bus and a Rear Object Bus with each partition having its own communication enable circuit to activate
the partition, but functional operation of both is identical. The Front Object Bus standard devices are the K124 Active Safety Control Module, the K109 Frontview
Camera Module, and the B233B Radar Sensor Module – Long Range. The Front Object Bus optional devices are the B233LF Radar Sensor Module – Short
Range Left Front and the B233RF Radar Sensor Module – Short Range Right Front. The Rear Object Bus is optional and when present will have the K124 Active
Safety Control Module and B233R Radar Sensor Module – Short Range Rear on the bus, and optionally the Radar Sensor Module – Short Range Right Rear. All
Object Bus components are powered by the K124 Active Safety Control Module via the communication enable circuits, except the K109 Frontview Camera Module
which is powered directly by battery.
Media Oriented Systems Transport (MOST) Circuit Description

The MOST Infotainment network is a dedicated high speed multimedia streaming data bus independent from GMLAN. The MOST bus will be configured in a
physical hardwired loop with each device within the bus sends and receives data on an assigned MOST addresses in a set order. Each device on the MOST bus
will be required to have twisted pair copper wires (2 transmit TX, 2 receive RX, and 1 electronic control line which is a 12 V wakeup signal line). The A11 Radio is
the MOST Master and will monitor the bus for vehicle configuration, Infotainment data messages and errors on the bus. The MOST initialization consists of a short
100 ms low voltage pulse on the electronic control line (or MOST control line) connected to all devices contained on the MOST ring. This wakeup message once
received by each device, will first respond with a generic device response. Once these initial responses on the MOST bus are reported successfully without error
to the A11 Radio, the second data request will record the MOST device addresses, their functionality requirements and capabilities within. The A11 Radio will learn
this information and also record the address node sequence on the MOST bus at this point. This node address list will now be stored within the A11 Radio as the
MOST bus configuration (called “Last Working MOST ID of Node 1 – 9” on scan tool data display).
When MOST receive, transmit, or control line faults are detected, transmit/receive messages will not received as expected from the wakeup request. The A11
Radio and the K74 Human Machine Interface Control Module will then perform diagnostics to isolate these MOST faults. If the MOST control line is shorted low to
0 V for excess amount of time, the A11 Radio will set a U2098 DTC and K74 Human Machine Interface Control Module will set a U0029 02 DTC. At this point the
MOST bus will be unable to communicate until the shorted MOST control line is repaired.
Once the shorted MOST control line diagnostics pass, the A11 Radio will attempt to resend the initial short pulse attempts up to 3 times on the MOST control line.
If the expected responses are not received, the A11 Radio continues into a failure mode setting a U0028 DTC and will continue on to send one 300 ms long pulse,
which will enable the furthest upstream transmitting device to become the surrogate MOST Master in this MOST fault/diagnostic mode. When the A11 Radio
receives this new MOST Master identity, the surrogate MOST master device can be identified based on scan tool data parameter “Surrogate MOST Master Node
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Data Link Communications Description and Operation
Upstream Position”. The scan tool should be used to determine the MOST bus configuration and direction by utilizing the “Last Working MOST ID of Node 1 – 9”
parameters from the A11 Radio data display. When a fault is present, it will indicate the newly enabled “Surrogate MOST Master Node Upstream Position” from the
A11 Radio. This will assist in determining where the MOST bus/control is at fault. The MOST device upstream from the surrogate MOST master device, transmit,
receive, or control lines will be the suspect areas for diagnostics at this point. These faults can be associated with any of the MOST transmit, receive, or control
line twisted copper wires or possibly an internal device fault.
The K74 Human Machine Interface Control Module will set a U0029 00 DTC when it diagnoses a MOST bus not communicating properly after one attempt. When
the DTC U0029 00 is set by the K74 Human Machine Interface Control Module without the corresponding DTC U0028 from the A11 Radio, it will be an indication of
an intermittent wiring/device condition.
CAN Graphical Interface (CGI) Circuit Description

This bus is used by the Entertainment sub-system to transfer high-rate display graphics between the A11 Radio and the P17 Info Display Module and/or
Radio/HVAC Control. The electrical characteristics of the CAN Graphical Interface (CGI) Bus are very similar to the High Speed GMLAN Bus. The message
strategy and construction of messages are different however. Sometimes communication is required between the CAN Graphical Interface Bus and the Low
Speed GMLAN Bus. This is accomplished by using the A11 Radio as the Gateway module. Since the CAN Graphical Interface Bus and primary High Speed
GMLAN Bus have similar electrical characteristics, the diagnostics for each are similar.
In the case where the P17 Info Display Module and Radio/HVAC Control are separate devices the P17 Info Display Module is responsible for passing information
between the A11 Radio and the Radio/HVAC Control. The A11 Radio interfaces only with the P17 Info Display Module and the P17 Info Display Module then
communicates with the Radio/HVAC Control through a Local Interconnect Network (LIN) interface.
A bus wake up signal will be generated by the A11 Radio or by the P17 Info Display Module when the system functionality is required. The communication function
of the CAN Graphical Interface shall be enabled or disabled based on the voltage level of the Center Stack Wake. The network will stay awake as long as the
circuit voltage is driven low, to less than 1.5 V. Communications are disabled with a high circuit voltage around 5.0 V.
The A11 Radio can execute a warm reset of the P17 Info Display Module if the P17 Info Display Module fails to respond to the A11 Radio’s request. The Center
Stack Reset is a low-asserted pull down output (less than 1.5 V) from the A11 Radio to the P17 Info Display Module and has the same electrical characteristics as
those for the Center Stack Wake signal defined above.
Mid Speed GMLAN Circuit Description

The Mid Speed GMLAN Bus is very similar to the High Speed GMLAN Bus except that it uses a slower transmission rate of 125 Kbit/s. This bus is intended for use
where the system response time demands that a large amount of data be transmitted in a relatively short amount of time, such as updating a graphics display. As
such it has usually been used for infotainment applications. Sometimes communication is required between the Low Speed GMLAN Bus and the Mid Speed
GMLAN Bus. This is accomplished by using the A11 Radio as the Gateway module. Since the Mid Speed GMLAN Bus and primary High Speed GMLAN Bus
operate in a similar manner, the diagnostics for each are similar.
Low Speed GMLAN Circuit Description

Low Speed GMLAN Bus is used in applications where a high data rate is not required which allows for the use of less complex components. It is typically used for
operator controlled functions where the response time requirements are slower than those required for dynamic vehicle control.
The Low Speed GMLAN Serial Data Network consists of a single wire, ground referenced bus with high side voltage drive. During on road vehicle operation data
symbols (1’s and 0’s) are transmitted sequentially at the normal rate of 33.3 Kbit/s. For component programming only, a special high speed data mode of 83.3
Kbit/s may be used.
Unlike the high speed dual wire networks, the single wire low speed network does not use terminating resistors at either end of the network.
The data symbols to be transmitted over the bus are represented by different voltage signals on the bus. When the Low Speed GMLAN Bus is at rest and is not
being driven, there is a low signal voltage of approximately 0.2 V. This represents a logic “1”. When a logic “0” is to be transmitted, the signal voltage is driven
higher to around 4.0 V or higher.
Local Interconnect Network (LIN) Circuit Description

The Local Interconnect Network (LIN) Bus consists of a single wire with a transmission rate of 10.417 Kbit/s. This bus is used to exchange information between a
master control module and other smart devices which provide supporting functionality. This type of configuration does not require the capacity or speed of either a
High Speed GMLAN Bus or Low Speed GMLAN Bus and is thus relatively simpler.
The data symbols (1’s and 0’s) to be transmitted are represented by different voltage levels on the communication bus. When the LIN Bus is at rest and is not
being driven, the signal is in a high voltage state of approximately Vbatt. This represents a logic “1”. When a logic “0” is to be transmitted, the signal voltage is
driven low to about ground (0.0 V).
Communication Enable Circuit Description

Devices on High Speed GMLAN Bus enable or disable communication based on the voltage level of the communication enable circuit. When the circuit voltage is
high (around 12 V), communications are enabled. When the circuit is low, communications are disabled.
Data Link Connector (DLC)
The X84 Data Link Connector (DLC) is a standardized 16-cavity connector. Connector design and location is dictated by an industry wide standard, and is required
to provide the following:
Pin 1 Low speed GMLAN communications terminal

Pin 2 Class 2 communications terminal
Pin 3 Mid speed GMLAN serial bus (+) terminal or Object high speed GMLAN serial bus (+) terminal
Pin 4 Scan tool power ground terminal
Pin 5 Common signal ground terminal
Pin 6 High speed GMLAN serial data bus (+) terminal
Pin 7 Keyword communications terminal
Pin 11 Mid speed GMLAN serial bus (-) terminal or Object high speed GMLAN serial bus (-) terminal
Pin 12 Chassis high speed GMLAN serial bus (+) terminal
Pin 13 Chassis high speed GMLAN serial bus (-) terminal
Pin 14 High speed GMLAN serial data bus (-) terminal
Pin 16 Scan tool power, battery positive voltage terminal
Serial Data Reference

The scan tool communicates over the various buses on the vehicle. When a scan tool is installed on a vehicle, the scan tool will try to communicate with every
device that could be optioned into the vehicle. If an option is not installed on the vehicle, the scan tool will display No Comm (or Not Connected) for that optional
device. In order to avert misdiagnoses of No Communication with a specific device, refer to Data Link References for a list of devices, the buses they
communicate with, and the RPO codes for a specific device.
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Electrical Power Management Description and Operation

Electrical Power Management

The electrical power management is used to monitor and control the charging system and alert the driver of possible problems within the charging system. The
electrical power management system makes the most efficient use of the generator output, improves the battery state-of-charge, extends battery life, and
manages system electrical loads.
The load shed operation is a means of reducing electrical loads during a low voltage or low battery state-of-charge condition.
The idle boost operation is a means of improving generator performance during a low voltage or low battery state-of-charge condition.
Each electrical power management function, either idle boost or load shed, is discrete. No two functions are active at the same time. Idle boost is activated in
incremental steps, idle boost 1 must be active before idle boost 2 can be active. The criteria used by the body control module (BCM) to regulate electrical power
management are outlined below:
Electrical Power Management Block Diagram
K9
Body
Control
Module
K20
Engine
Control
Module
G13
Generator
Battery Temperature Battery Voltage Amp-Hour

Function Calculation Calculation Calculation Action Taken
Less Than −15°C First level Idle boost

Idle Boost 1 Start Less Than 13 V —
(5°F) requested
Battery has a net loss First level Idle boost

Idle Boost 1 Start — —
greater than 0.6 Ah requested
First level Idle boost

Idle Boost 1 Start — Less Than 10.9 V —
requested
Greater Than −15°C Battery has a net loss First level Idle boost
Idle Boost 1 End Greater Than −12 V
(5°F) less than 0.2 Ah request cancelled
Rear Defrost, Heated

Battery has a net loss Mirrors, Heated Seats
Load Shed 1 Start — —
of 4 Ah cycled OFF for 20%
of their cycle

Mirrors, Heated Seats
Load Shed 1 Start — Less Than 10.9 V —
cycled OFF for 20%
of their cycle
Battery has a net loss

Load Shed 1 End — Greater Than 12 V Clear Load Shed 1
of less than 2 Ah
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Electrical Power Management Description and Operation

Battery has a net loss Second level Idle

greater than 1.6 Ah boost requested
Second level Idle

boost requested
Second level Idle

Idle Boost 2 End — Greater Than 12 V boost request
less than 0.8 Ah
cancelled
Battery has a net loss Third level Idle boost

of 10 Ah requested
Third level Idle boost

requested

Idle Boost 3 End — Greater Than 12 V
of less than 6.0 Ah request cancelled

cycled OFF for 50%
Battery has a net loss of their cycle. The
Load Shed 2 Start — Less Than 10 V
greater than 12 Ah BATTERY SAVER
ACTIVE message will
be displayed on the
DIC

cycled OFF for 50%
of their cycle. The
BATTERY SAVER
ACTIVE message will
be displayed on the
DIC

Load Shed 2 End — Greater Than 12.6 V Clear Load Shed 2
of less than 10.5 Ah

cycled OFF for 100%
Load Shed 3 Start — Less Than 11.9 V
greater than 20 Ah BATTERY SAVER
ACTIVE message will
be displayed on the
DIC

of less than 15 Ah
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Removal Procedure
5. Remove the windshield washer solvent container filler tube. Refer to Windshield Washer Solvent Container Filler Tube Replacement.
6. Remove the front compartment fuse block. Refer to Front Compartment Fuse Block Replacement.
8. Remove the wiring harness ground cable nut (2) and remove the wiring harness ground cable (3).
9. Remove the wiring harness plug (1) in top direction from the front compartment fuse block housing.
10. Disconnect the wiring harness connection adapter plug (4).
11. Remove the 2 wiring harness clips from the drivetrain and front suspension frame front inner support and from the charge air cooler outlet hose.
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17. Remove the 2 charge air cooler inlet air hose bolts (7) from the 2 charge air cooler inlet air hose nuts (5). Hang the charge air cooler inlet air hose (6)
aside.
19. Disconnect the exhaust temperature sensor wiring harness plug (4) and unclip the wiring harness clip (3) from the steering pump.
20. Disconnect the turbocharger wastegate actuator wiring harness plug (8).
21. Disconnect the mass air flow sensor wiring harness plug (1) and remove the wiring harness clip from the air cleaner housing.
22. Disconnect the oil pressure sensor wiring harness plug (2).

23. Remove the wiring harness clip (3) from the charge air control vacuum hose.
24. Remove the 2 wiring harness channel bolts (1) from the wiring harness channel.
26. Disconnect the 2 wiring harness clips (4) from the oil filter assembly and from the intake manifold.
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27. Disconnect the backup lamp switch wiring harness plug from the transmission.
28. Remove the wiring harness clip (1) from the transmission.
31. Disconnect the 2 knock sensor wiring harness plugs (3, 6).

32. Disconnect the generator wiring harness plug (4).
34. Disconnect the vacuum solenoid valve wiring harness plug (1) and the vacuum solenoid valve wiring harness plug (2).
35. Remove the 2 wiring harness clips (5) from the 2 brackets.
36. Disconnect the crankshaft position sensor wiring harness plug (3).

37. Disconnect the throttle body wiring harness plug (1).
38. Unclip the wiring harness clip (2) from the charge air cooler outlet hose.
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39. Disconnect the air conditioning wiring harness plug (1) and the engine oil level indicator wiring harness plug (2). Hang the wiring harness aside.
41. Remove the front charge air cooler outlet hose bolt (2) from the wiring harness bracket.
42. Remove the front charge air cooler outlet hose clamp (4) from the rear charge air cooler outlet hose (3). Hang the front charge air cooler hose (1) aside.
43. Unclip and disconnect the glow plug wiring harness plug (2) from the engine wiring harness bracket.
44. Disconnect the fuel pump wiring harness plug (3)
45. Disconnect the engine coolant temperature sensor wiring harness plug (5).
46. Unclip the 4 wiring harness clips (1, 4) from the wiring harness bracket.

54. Unclip the engine wiring harness channel (6) in top direction from the 3 exhaust gas recirculation cooler brackets.
55. Remove the engine wiring harness from the vehicle.
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2. Clip the engine wiring harness channel (6) to the 3 exhaust gas recirculation cooler brackets.
7. Connect the fuel injection pressure sensor wiring harness plug (3).
11. Clip the 4 wiring harness clips (1, 4) to the wiring harness bracket.
12. Connect the engine coolant temperature sensor wiring harness plug (5).
13. Connect the fuel pump wiring harness plug (3).
14. Clip and connect the glow plug wiring harness plug (2) to the engine wiring harness bracket.

15. Position the front charge air cooler outlet hose (1) along with the front charge air cooler outlet hose clamp (4) to the rear charge air cooler outlet hose
(3) and tighten the clamp to 3.5 Y (31 lb in).
16. Install the front charge air cooler outlet hose bolt (2) to the wiring harness bracket and tighten to 10 Y (89 lb in).
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18. Position the wiring harness.

19. Connect the air conditioning wiring harness plug (1) and the engine oil level indicator wiring harness plug (2).
20. Clip the wiring harness clip (2) to the charge air cooler outlet hose.
21. Connect the throttle body wiring harness plug (1).
22. Connect the crankshaft position sensor wiring harness plug (3).
23. Install the 2 wiring harness clips (5) to the 2 brackets.

24. Connect the vacuum solenoid valve wiring harness plug (1) and the vacuum solenoid valve wiring harness plug (2).
26. Connect the generator wiring harness plug (4).
27. Connect the 2 knock sensor wiring harness plugs (3, 6).
30. Install the wiring harness clip (1) to the transmission.
6 of 8
31. Connect the backup lamp switch wiring harness plug to the transmission.
32. Connect the 2 wiring harness clips (4) to the oil filter assembly and to the intake manifold.
34. Install the 2 wiring harness channel bolts (1) to the wiring harness channel and tighten to 10 Y (89 lb in).
35. Install the wiring harness clip (3) to the charge air control vacuum hose.
36. Connect the oil pressure sensor wiring harness plug (2).
37. Connect the mass air flow sensor wiring harness plug (1) and install the wiring harness clip to the air cleaner housing.
38. Connect the turbocharger wastegate actuator wiring harness plug (8).
39. Connect the exhaust temperature sensor wiring harness plug (4) and clip the wiring harness clip (3) to the steering pump.
41. Install the 2 charge air cooler inlet air hose bolts (7) to the 2 charge air cooler inlet air hose nuts (5) and tighten to 22 Y (16 lb ft).

7 of 8
47. Install the 2 wiring harness clips to the drivetrain and front suspension frame front inner support and to the charge air cooler outlet hose.
48. Connect the wiring harness connection adapter plug (4).
49. Install the wiring harness plug (1) to the front compartment fuse block housing.
50. Install the wiring harness ground cable (3) and install the wiring harness ground cable nut (2) and tighten to 9 Y (80 lb in).
51. Install the front compartment fuse block. Refer to Front Compartment Fuse Block Replacement.
53. Install the windshield washer solvent container filler tube. Refer to Windshield Washer Solvent Container Filler Tube Replacement.
8 of 8
Front Compartment Fuse Block Cover Replacement

Front Compartment Fuse Block Cover Replacement
Front Compartment Fuse Block Cover

1 Procedure
Squeeze 3 tabs to release cover.
1 of 1
Front Compartment Fuse Block Housing Replacement

Removal Procedure
1. Remove front compartment fuse block. Refer to Front Compartment Fuse Block Replacement.
2. Remove windshield washer solvent container filler tube.
3. Remove front compartment fuse block housing nut (1).

4. Remove front compartment fuse block housing.
Remove 3 connector from front compartment fuse block housing

Remove attaching parts.
1. Install front compartment fuse block housing.
Install attaching parts

Install 3 connector.
Install wiring harness and install nut, tighten to 22 Y (16 lb ft).
Install windshield washer solvent container filler tube.
Install front compartment fuse block. Refer to Front Compartment Fuse Block Replacement.
1 of 1
Front Compartment Fuse Block Replacement

Removal Procedure
1. Disconnect battery negative cable. Refer to Battery Negative Cable Disconnection and Connection
2. Remove the front compartment fuse block cover. Refer to Front Compartment Fuse Block Cover Replacement
3. Open the front compartment fuse block housing cover (1) and remove the 3 power steering wiring harness nut (2) .
Note: Bolts (1) are encapsulated on the end of threads so that they can not be removed from the fuse block.
4. Remove the 3 front compartment fuse block bolt (1) and the front compartment fuse block wiring harness supply (2).
5. Unlock retaining tabs and remove the front compartment fuse block (3).
1. Push down the the 3 electrical connectors (3) before installation of the front compartment fuse block (2).
2. Install front compartment fuse block wiring harness supply (1) and tighten to 12 Y (106 lb in).
1 of 2
Front Compartment Fuse Block Replacement
3. Install 3 front compartment fuse block bolt (1) and tighten to 7.2 Y (64 lb in).
4. Install the 3 power steering wiring harness nut (2) and tighten to 4.7 Y (42 lb in).
5. Close the front compartment fuse block housing cover (1)
6. Install the front compartment fuse block cover. Refer to Front Compartment Fuse Block Cover Replacement
7. Connect battery negative cable. Refer to Battery Negative Cable Disconnection and Connection
2 of 2
Fuse Block Replacement

Removal Procedure

3. Use a suitable screwdriver (2) to unlock the clip (4) through the window (3).
5. Remove the positive battery cable to starter from the battery.
6. Remove the starter generator cable (3) and starter generator cable nut (1).
7. Loosen the 2 fuse block mounting panel nut (2).
1 of 2
Fuse Block Replacement
in
Note: Due to various option content there might be 2 or 4 body wiring harness nuts installed.
8. Remove body wiring harness nuts (1) and front compartment fuse block cable nut (2).
9. Unlock retaining tabs (3) and remove fuse block (4) with integrated positive battery cable.
1. Install fuse block with integrated positive battery cable and lock the retaining tabs.
Note: Due to various option content there might be 2 or 4 body wiring harness nuts installed.
2. Install body wiring harness and body wiring harness nuts and tighten to 2.5 Y (22 lb in).
3. Install front compartment fuse block cable nut and tighten to 12 Y (106 lb in).
4. Install the starter generator cable and starter generator cable nut and tighten to 12 Y (106 lb in).
5. Install the 2 fuse block mounting panel nuts and tighten to 12 Y (106 lb in).
6. Install the positive battery cable to the battery and tighten to 4.5Y (40 lb in).
7. Close the battery fuse box cover and lock the retaining tabs (1, 4).
2 of 2

1 Generator Pulley Nut Cap
Generator Pulley
Procedure
Remove the generator pulley nut by using EN-6372 counterhold.
Note: Be aware of the left-hand thread.
2
Tighten
80 Y (59 lb ft)
Special Tools
EN-6372 Counterhold
1 of 1
Generator Replacement (2.0L Diesel LNP)

Removal Procedure
5. Remove the transmission mount:
Automatic transmission, refer to Transmission Rear Mount Replacement.

Manual transmission, refer to Transmission Rear Mount Replacement.
Unclip the engine wiring harness from the knock sensor 2 wiring harness plug brackets.
Disconnect the generator wiring harness plug (1) from the generator.

Fold the generator cap (2) aside.
Remove the generator positive cable retaining nut (3).
Remove the generator positive cable (4) from the generator.
Remove the upper generator retaining bolt (1).

Note: DO NOT pull the lower generator retaining bolt completely out of the generator mounting hole.
Remove the lower generator retaining bolt (3).
Remove the generator (2).
1 of 2
Generator Replacement (2.0L Diesel LNP)
1. Install the generator (2).

2. Install the lower generator retaining bolt (3).
3. Install the upper generator retaining bolt (1).
4. Tighten the 2 generator retaining bolts (1, 3) to 58 Y (43 lb ft).
5. Install the positive generator cable (4) to the generator.

6. Install the generator positive cable retaining nut (3) and tighten to 17 Y (13 lb ft).
7. Fold the generator cap (2) to the generator positive cable terminal.
8. Connect the generator wiring harness plug (1) to the generator.
9. Clip in the engine wiring harness to the knock sensor 2 wiring harness plug bracket.
10. Install the transmission rear mount:
Automatic transmission, refer to Transmission Rear Mount Replacement.

Manual transmission, refer to Transmission Rear Mount Replacement.
Install the drive belt tensioner. Refer to Drive Belt Tensioner Replacement.
Install the front compartment insulator. Refer to Front Compartment Insulator Replacement.
Lower the vehicle.
2 of 2
Load Shed System Description and Operation

Electrical Power Management

The electrical power management is used to monitor and control the charging system and alert the driver of possible problems within the charging system. The
electrical power management system makes the most efficient use of the generator output, improves the battery state-of-charge, extends battery life, and
manages system electrical loads.
The load shed operation is a means of reducing electrical loads during a low voltage or low battery state-of-charge condition.
The idle boost operation is a means of improving generator performance during a low voltage or low battery state-of-charge condition.
Each electrical power management function, either idle boost or load shed, is discrete. No two functions are active at the same time. Idle boost is activated in
incremental steps, idle boost 1 must be active before idle boost 2 can be active. The criteria used by the body control module (BCM) to regulate electrical power
management are outlined below:

Less Than −15°C First level Idle boost

Idle Boost 1 Start Less Than 13 V —
(5°F) requested
Battery has a net loss First level Idle boost

greater than 0.6 AH requested
First level Idle boost

requested
Greater Than −15°C Battery has a net loss First level Idle boost
Idle Boost 1 End Greater Than −12 V
(5°F) less than 0.2 AH request cancelled

Battery has a net loss Mirrors, Heated Seats
Load Shed 1 Start — —
of 4 AH cycled OFF for 20%
of their cycle

cycled OFF for 20%
of their cycle

Load Shed 1 End — Greater Than 12 V Clear Load Shed 1
of less than 2 AH
Battery has a net loss Second level Idle

greater than 1.6 AH boost requested
Second level Idle

boost requested
Second level Idle

Idle Boost 2 End — Greater Than 12 V boost request
less than 0.8 AH
cancelled

of 10.0 AH requested
Third level Idle boost

requested

Idle Boost 3 End — Greater Than 12 V
of less than 6.0 AH request cancelled

cycled OFF for 50%
greater than 12 AH BATTERY SAVER
ACTIVE message will
be displayed on the
DIC

cycled OFF for 50%
Load Shed 2 Start — Less Than 10.9 V — of their cycle. The
BATTERY SAVER
ACTIVE message will
1 of 2
Load Shed System Description and Operation

be displayed on the
DIC

of less than 10.5 AH

cycled OFF for 100%
greater than 20 AH BATTERY SAVER
ACTIVE message will
be displayed on the
DIC

of less than 15 AH
2 of 2
Relay Replacement (Attached to Wire Harness)

Removal Procedure
1. Locate the relay. Refer to the Master Electrical Component List to locate the relay in the vehicle.
2. Remove any fasteners which hold the relay in place.
3. Remove any connector position assurance (CPA) devices or secondary locks.
Note: Use care when removing a relay in a wiring harness when the relay is secured by fasteners or tape.
4. Separate the relay (1) from the wire harness connector (2).
1. Connect the relay (1) to the wire harness connector (2).

2. Install any connector position assurance (CPA) devices or secondary locks.
3. Install the relay using any fasteners or tape that originally held the relay in place.
1 of 1
Special Tools (Diagnostic Tools)

EL 38758
EL 50074
J 38758
Parasitic Draw Test Switch
EL 50313
EL 42000
EL 50076
J 42000
Battery Tester
1 of 1
Special Tools (Removal and Installation)

Illustration Tool Number/ Description
GE-49379
Battery Remover / Installer
1 of 1
Starter Replacement (2.0L Diesel LNP with AT)

Removal Procedure
4. Remove the transmission rear mount. Refer to Transmission Rear Mount Replacement.

6. Remove the positive starter cable nut (2) and the positive starter cable (5).
7. Remove the ground cable retaining bolt (4) and the ground cable (3) from the engine block.
8. Remove the 3 starter retaining bolts (1, 3).

9. Remove the starter (2).
1. Install the starter (2).

2. Install the 3 starter retaining bolts (1, 3). Tighten the bolts (1, 3) to 58 Y (43 lb ft).
1 of 2
Starter Replacement (2.0L Diesel LNP with AT)

4. Install the positive starter cable (5) and the positive starter cable nut (2). Tighten the nut to 95 Y (84 lb in).
5. Install the ground cable (3) and the ground cable retaining bolt (4) to the engine block. Tighten the bolt to 22 Y (16 lb ft).
6. Install the transmission rear mount. Refer to Transmission Rear Mount Replacement.
2 of 2
Starter Replacement (2.0L Diesel LNP with MT)

Removal Procedure
4. Remove the transmission rear mount. Refer to Transmission Rear Mount Replacement.

6. Remove the positive starter cable nut (2) and the positive starter cable (5).
7. Remove the ground cable retaining bolt (4) and the ground cable (3) from the engine block.
8. Remove the engine wiring harness bracket retaining nut (2) and remove the engine wiring harness (1).
9. Remove the 3 starter retaining bolts (1, 3).

10. Remove the starter (2).
1 of 2
Starter Replacement (2.0L Diesel LNP with MT)
1. Install the starter (2).

2. Install the 3 starter retaining bolts (1, 3) and tighten to 58 Y (43 lb ft).
3. Install the engine wiring harness (1) and the engine wiring harness bracket retaining nut (2) and tighten to 9.5 Y (84 lb in).

5. Install the positive starter cable (5) and the positive starter cable nut (2). Tighten the nut to 9,5 Y (84 lb in).
6. Install the ground cable (3) and the ground cable retaining bolt (4) to the engine block. Tighten the bolt to 22 Y (16 lb ft).
7. Install the transmission rear mount. Refer to Transmission Rear Mount Replacement.
2 of 2
Starting System Description and Operation

The starter motors are non-repairable starter motors. They have pole pieces that are arranged around the armature. Both solenoid windings are energized. The pull-in
winding circuit is completed to the ground through the starter motor. The windings work together magnetically to pull and hold in the plunger. The plunger moves the shift
lever. This action causes the starter drive assembly to rotate on the armature shaft spline as it engages with the flywheel ring gear on the engine. Moving at the same
time, the plunger also closes the solenoid switch contacts in the starter solenoid. Full battery voltage is applied directly to the starter motor and it cranks the engine.
As soon as the solenoid switch contacts close, current stops flowing thorough the pull-in winding because battery voltage is applied to both ends of the windings. The
hold-in winding remains energized. Its magnetic field is strong enough to hold the plunger, shift lever, starter drive assembly, and solenoid switch contacts in place to
continue cranking the engine. When the engine starts, pinion overrun protects the armature from excessive speed until the switch is opened.
When the ignition switch is released from the START position, the START relay opens and battery voltage is removed from the starter solenoid S terminal. Current flows
from the motor contacts through both windings to the ground at the end of the hold-in winding. However, the direction of the current flow through the pull-in winding is now
opposite the direction of the current flow when the winding was first energized.
The magnetic fields of the pull-in and hold-in windings now oppose one another. This action of the windings, along with the help of the return spring, causes the starter
drive assembly to disengage and the solenoid switch contacts to open simultaneously. As soon as the contacts open, the starter circuit is turned off.
Circuit Description (Key Start)

When the ignition switch is placed in the Start position, a discrete signal is supplied to the body control module (BCM) notifying it that the ignition is in the Start
position. The BCM then sends a message to the engine control module (ECM) notifying it that CRANK has been requested. The ECM verifies that the
transmission is in Park or Neutral. If it is, the ECM then supplies 12 volts to the control circuit of the crank relay. When this occurs, battery positive voltage is
supplied through the switch side of the crank relay to the S terminal of the starter solenoid.
Starting System Block Diagram
K20
Engine
Control
Module
C1 KR27 K9 T12
Battery Starter Body Automatic
Relay Control Transmission
Module Assembly
M64 K84 S39

Starter Keyless Ignition
Motor Entry Switch
Control
Module
(HW) Hard-Wired
(DD) Serial Data - GMLAN High Speed
(HW) Hard-Wired
(HW) Hard-Wired
(HW) Hard-Wired
(HW) Hard-Wired
(HW) Hard-Wired
(K20) K20 Engine Control Module
(C1) C1 Battery
(KR27) KR27 Starter Relay
(K9) K9 Body Control Module
(T12) T12 Automatic Transmission Assembly
(M64) M64 Starter Motor
(K84) K84 Keyless Entry Control Module
(S39) S39 Ignition Switch
1 of 3
Adhesives, Fluids, Lubricants, and Sealers

Application Type of Material GM Part Number
Bolt Connections Screw Locking Compound Refer to Electronic Parts Catalog
Camshaft and Hydraulic Valve Lifters MoS 2 Lubricating Paste Refer to Electronic Parts Catalog
Camshaft Cover Bolt Pipe Sealant Refer to Electronic Parts Catalog
DEXOS II, 0-W30, 0-W40,

Engine Oil Refer to Electronic Parts Catalog
5-W30 and 5-W40
First Camshaft Bearing Cap Surface Sealant Refer to Electronic Parts Catalog
Adhesive Sealing
First Camshaft Bearing Cap and Cylinder Head Transition Refer to Electronic Parts Catalog
Compound
Oil Pan Oil Pan Sealant Refer to Electronic Parts Catalog
Oxygen Sensor Assembly Paste Refer to Electronic Parts Catalog
Seal Rings Silicon Grease Refer to Electronic Parts Catalog
1 of 1

Application Type of Material GM Part Number
Engine Oil Viscosity 5W-30 Refer to electronic parts catalog
Engine Oil Quality Dexos2 Refer to electronic parts catalog
Bolt Connections Locking Compound Refer to electronic parts catalog
Oil Pan, Camshaft Housing, Lower

RTV Sealant Refer to electronic parts catalog
Crankcase
1 of 1
Altitude Versus Barometric Pressure

Barometric Pressure Barometric Pressure

Altitude Measured in Meters Measured in Kilopascals Measured in Pounds Per
(m) Altitude Measured in Feet (ft) (kPa) Square Inch (PSI)
Determine your altitude by contacting a local weather station or by using another reference source.
4,267 14,000 56–64 8.1–9.3
3,962 13,000 58–66 8.4–9.6
3,658 12,000 61–69 8.8–10.0
3,353 11,000 64–72 9.3–10.4
3,048 10,000 66–74 9.6–10.7
2,743 9,000 69–77 10.0–11.2
2,438 8,000 71–79 10.3–11.5
2,134 7,000 74–82 10.7–11.9
1,829 6,000 77–85 11.2–12.3
1,524 5,000 80–88 11.6–12.8
1,219 4,000 83–91 12.0–13.2
914 3,000 87–95 12.6–13.8
610 2,000 90–98 13.1–14.2
305 1,000 94–102 13.6–14.8
0 0 Sea Level 96–104 13.9–15.1
−305 −1,000 101–105 14.6–15.2
1 of 1

Barometric Pressure Measured in

Altitude Measured in Meters (m) Altitude Measured in Feet (ft) Kilopascal (kPa)
Determine your altitude by contacting a local weather station or by using another reference source.
4 267 14 000 56–64
3 962 13 000 58–66
3 658 12 000 61–69
3 353 11 000 64–72
3 048 10 000 66–74
2 743 9 000 69–77
2 438 8 000 71–79
2 134 7 000 74–82
1 829 6 000 77–85
1 524 5 000 80–88
1 219 4 000 83–91
914 3 000 87–95
610 2 000 90–98
305 1 000 94–102
0 0 Sea Level 96–104
−305 −1 000 101–105
1 of 1
Engine Cooling System Specifications (2.0L Diesel LNP)

Engine Cooling System Specifications
Specification
Application Metric English
Coolant System
7.5 liters 7.9 quarts

Cooling Filling Quantity
Centrifugal Pump
Type of Coolant Pump
220 liters / min 358.1 gal / min
Delivery Rate with 4500 RPM
Thermostat
Outlet Thermostat System

Type
82° C 179.6° F
Start to Opening
95° C 203° F
Fully Open
1 of 1
Engine Mechanical Specifications (LNP)

Engine Mechanical Specifications
Specification
General Data
LNP
RPO
4 Cylinder Inline
Engine Type
1998 ccm 121.92 cu in
Displacement
86 mm 3.3858 in
Bore Diameter
86 mm 3.3858 in
Stroke
16.3:1
Compression Ratio
120 KW / 3800 RPM
Output @ Engine Speed
360 Y /1750–2750 RPM 265.5 lb ft / 1750–2750 RPM
Torque @ Engine Speed
725 RPM
Idle Speed
5000 RPM
No-Load max. Speed
1800 bar 26106.8 PSI
Injection Pressure of Common Rail System
Engine Management
Delphi E20
ECM Type
Delphi DFP 3.2
Injection Pressure Pump Type
Delphi DFI 1,5
Injector Type
1-3-4-2
Firing Order
Metallic, Low Voltage

Glow Plug Type
4.4 Volt
Glow Plug Voltage
Drive Belt
1 of 6
Specification
Drive Belt Length 2220 mm 87.4 in

with Air Conditioning, Generator, Power Steering Pump
Oil Circulation System
5.4 L 5.7 quarts
Engine Oil Filling with Oil Filter
Engine Oil Quality (European Countries) Dexos2
5W–30
Engine Oil Viscosity
For disposal the engine oil follow safety regulations and national legislation.
Disposal of Engine Oil
0.34 L 0.36 quarts
Oil Consumption / 1000 km
Oil Pump
Rotor Pump – Located in BSM (Balanceshaft Module)

Oil Pump Type
Oil Pressure with Idle Speed and under hot running >100 kPa / 725 RPM
conditions (120° C / 248° F)
Oil Pressure with 2000 RPM under hot running >200 kPa / 2000 RPM

Coolant System
Centrifugal Pump
7.5 L 7.93 quarts
Filling
220 L / min 58.1 gal / min
Thermostat

Type
82° C 179.6° F
Start to Opening
95° C 203° F
Fully Open
Cylinder Head Gasket
0.0393–0.0433 in / 0.0082–0.0118
Cylinder Head Gasket Thickness / Piston Projection 1.00–1.10 mm / 0.21–0.30 mm
in
Dimension (Gasket without Hole)
0.0433–0.0472 in / 0.0122–0.0153
in
Dimension (Gasket with one Hole)
0.0472–0.0511 in / 0.0157–0.0192
in
Dimension (Gasket with two Holes)
2 of 6
Specification
Cylinder Head
130 mm 5.1 in
Cylinder Head Height
0.10 mm 0.0039 in
Maximum Sag of Cylinder Head
45°
Valve Seat Angle at Valve Head
10.045–10.060 mm 0.3954–0.3960 in
Valve Guide External Diameter Standard
4.4–4.6 mm 0.1732–0.1811 in
Valve Guide Internal Diameter
Balanceshaft Module Gear Backlash
0.9 mm (0.046 mm) 0.0354 in (0.0018 in)

Gauge Value Min. (Gear Backlash Specification)
1.1 mm (0.087 mm) 0.0433 in (0.0034 in)

Gauge Value Nominal (Gear Backlash Specification)
1.3 mm (0.128 mm) 0.0512 in (0.0050 in)

Gauge Value Max. (Gear Backlash Specification)
Valves
4.982–5.00 mm 0.1961–0.1968 in
Valve Stem Diameter – Intake
4.972–4.990 mm 0.1957–0.1964 in
Valve Stem Diameter – Exhaust
46.35 mm 1.82 in
Valve Spring Length – Unstressed
33.0 mm 1.30 in
Valve Spring Length – 199.5 – 220.5 N
24.2 mm 0.95 in
28.7–28.9 mm 1.1299–1.1377 in
Valve Diameter Intake
26.6–26.5 mm 1.0354–1.0433 in
Valve Diameter Exhaust
Engine Block
245.5–245.6 mm 9.6653–9.6692 in
Engine Block Height
Deck Surface Flatness (Overall/Partial) 0.1 / 0.05 / 100 mm 0.0039 / 0.0019 / 3.93 in
150 mm 5.9 in
Conrod Length
Camshaft
Camshaft Bearing Journal Diameter – 1. Bearing 29.944–29.960 mm 1.1788–1.1795 in

Journal
3 of 6
Specification
Camshaft Bearing Journal Diameter – 2.-6. Bearing 23.944–24.960 mm 0.9426–0.9826 in

Journal
0.1–0.171 mm 0.0039–0.0067 in
Camshaft Axial Clearance
Camshaft Housing
30.00–30.021 mm 1.1811–1.1819 in
Camshaft Bearing Diameter – 1. Bearing
24.00–24.021 mm 0.9448–0.9457 in
Camshaft Bearing Diameter – 2.-6. Bearing
Connecting Rod
0.024–0.042 mm 0.0009–0.0016 in
Con Rod Bearing Clearance
52.0190–52.0235 mm 2.0478–2.0481 in
Con Rod Bearing Journal Diameter – Class A
52.0145–52.0190 mm 2.0478–2.0479 in
Con Rod Bearing Journal Diameter – Class B
52.0100–52.0145 mm 2.0476–2.0478 in
Con Rod Bearing Journal Diameter – Class C
55.0045–55.0090 mm 2.1655–2.1657 in
Con Rod Big End Bore Diameter – Class A
55.0090–55.0135 mm 2.1657–2.1658 in
Con Rod Big End Bore Diameter – Class B
55.0135–55.0180 mm 2.01658–2.1660 in
Con Rod Big End Bore Diameter – Class C
1.474–1.478 mm 0.0580–0.0581 in
Con Rod Bearing Shell – Class A (violet)
1.479–1.483 mm 0.0582–0.0583 in
Con Rod Bearing Shell – Class B (yellow)
1.483–1.487 mm 0.0583–0.0585 in
Con Rod Bearing Shell – Class C (blue)
Crankshaft
0.090–0.320 mm 0.0035–0.0125 in
Axial Clearance
0.024–0.042 mm 0.0009–0.0016 in
Main Bearing Clearance
60.0190–60.0235 mm 2.3629–2.3631 in
Main Bearing Journal Diameter – Class A
60.0145–60.0190 mm 2.3627–2.3629 in
Main Bearing Journal Diameter – Class B
60.0100–60.0145 mm 2.3626–2.3627 in
Main Bearing Journal Diameter – Class C
64.0045–64.0090 mm 2.5198–2.5200 in
Bearing Bore Diameter in Cylinder Block – Class A
4 of 6
Specification
64.0090–64.0135 mm 2.5200–2.5202 in
Bearing Bore Diameter in Cylinder Block – Class B
64.0145–64.0180 mm 2.5202–2.5203 in
Bearing Bore Diameter in Cylinder Block – Class C
1.974–1.97 mm 0.0777–0.078 in
Main Bearing Shells – Class A (violet)
1.979–1.983 mm 0.0779–0.0780 in
Main Bearing Shells – Class B (yellow)
1.983–1.98 mm 0.0780–0.0782 in
Main Bearing Shells – Class C (blue)
Piston
85.925–85.935 mm 3.3828–3.3832 in
Piston Diameter (99 grade)
85.935–85.945 mm 3.3832–3.3836 in
85.945–85.955 mm 3.3836–3.384 in
32.993–32.008 mm 1.2989–1.2601 in
Piston Pin Diameter
0.006–0.017 mm 0.0002–0.0006 in
Clearance Piston Pin in Piston
0.024–0.041 mm 0.0009–0.0016 in
Clearance Piston Pin in Con Rod
± 0.007 kg
Piston Weight Difference
Piston Rings
3.45–3.75 mm 0.1358–0.1476 in
Compression Ring 1 – Thickness
3.25–3.55 mm 0.1279–0.1397 in
2.6–2.85 mm 0.1023–0.1122 in
Oil Scraper Ring – Thickness
0.13–0.175 mm 0.0051–0.0068 in
Compression Ring 1 – Axial Clearance
0.07–0.115 mm 0.0027–0.0045 in
0.03–0.07 mm 0.0011–0.0027 in
Oil Scraper Ring – Axial Clearance
0.24–0.40 mm 0.0094–0.0157 in
Compression Ring 1 – Gap
0.6–0.8 mm 0.0236–0.0315 in
0.25–0.50 mm 0.0098–0.0196 in
Oil Scraper Ring – Gap
5 of 6

Engine Mechanical Specifications
Specification
General Data
LNP
RPO
4 Cylinder Inline
Engine Type
1998 ccm 121.92 cu in
Displacement
86 mm 3.3858 in
Bore Diameter
86 mm 3.3858 in
Stroke
16.3:1
Compression Ratio
120 KW / 3800 RPM
Output @ Engine Speed
360 Y /1750–2750 RPM 265.5 lb ft / 1750–2750 RPM
Torque @ Engine Speed
725 RPM
Idle Speed
5000 RPM
No-Load max. Speed
1800 bar 26106.8 PSI
Injection Pressure of Common Rail System
Engine Management
Delphi E20
ECM Type
Delphi DFP 3.2
Injection Pressure Pump Type
Delphi DFI 1,5
Injector Type
1-3-4-2
Firing Order
Metallic, Low Voltage

Glow Plug Type
4.4 Volt
Glow Plug Voltage
Drive Belt
1 of 6
Specification
Drive Belt Length 2220 mm 87.4 in

with Air Conditioning, Generator, Power Steering Pump
Oil Circulation System
5.4 L 5.7 quarts
Engine Oil Filling with Oil Filter
Engine Oil Quality (European Countries) Dexos2
5W–30
Engine Oil Viscosity
For disposal the engine oil follow safety regulations and national legislation.
Disposal of Engine Oil
0.34 L 0.36 quarts
Oil Consumption / 1000 km
Oil Pump
Rotor Pump – Located in BSM (Balanceshaft Module)

Oil Pump Type
Oil Pressure with Idle Speed and under hot running >100 kPa / 725 RPM
Oil Pressure with 2000 RPM under hot running >200 kPa / 2000 RPM

Coolant System
Centrifugal Pump
7.5 L 7.93 quarts
Filling
220 L / min 58.1 gal / min
Thermostat

Type
82° C 179.6° F
Start to Opening
95° C 203° F
Fully Open
Cylinder Head Gasket
0.0393–0.0433 in / 0.0082–0.0118
in
Dimension (Gasket without Hole)
0.0433–0.0472 in / 0.0122–0.0153
in
Dimension (Gasket with one Hole)
0.0472–0.0511 in / 0.0157–0.0192
in
Dimension (Gasket with two Holes)
2 of 6
Specification
Cylinder Head
130 mm 5.1 in
Cylinder Head Height
0.10 mm 0.0039 in
Maximum Sag of Cylinder Head
45°
Valve Seat Angle at Valve Head
10.045–10.060 mm 0.3954–0.3960 in
Valve Guide External Diameter Standard
4.4–4.6 mm 0.1732–0.1811 in
Valve Guide Internal Diameter
Balanceshaft Module Gear Backlash
0.9 mm (0.046 mm) 0.0354 in (0.0018 in)

Gauge Value Min. (Gear Backlash Specification)
1.1 mm (0.087 mm) 0.0433 in (0.0034 in)

Gauge Value Nominal (Gear Backlash Specification)
1.3 mm (0.128 mm) 0.0512 in (0.0050 in)

Gauge Value Max. (Gear Backlash Specification)
Valves
4.982–5.00 mm 0.1961–0.1968 in
Valve Stem Diameter – Intake
4.972–4.990 mm 0.1957–0.1964 in
Valve Stem Diameter – Exhaust
46.35 mm 1.82 in
Valve Spring Length – Unstressed
33.0 mm 1.30 in
24.2 mm 0.95 in
28.7–28.9 mm 1.1299–1.1377 in
Valve Diameter Intake
26.6–26.5 mm 1.0354–1.0433 in
Valve Diameter Exhaust
Engine Block
245.5–245.6 mm 9.6653–9.6692 in
Engine Block Height
Deck Surface Flatness (Overall/Partial) 0.1 / 0.05 / 100 mm 0.0039 / 0.0019 / 3.93 in
150 mm 5.9 in
Conrod Length
Camshaft
Camshaft Bearing Journal Diameter – 1. Bearing 29.944–29.960 mm 1.1788–1.1795 in

Journal
3 of 6
Specification
Camshaft Bearing Journal Diameter – 2.-6. Bearing 23.944–24.960 mm 0.9426–0.9826 in

Journal
0.1–0.171 mm 0.0039–0.0067 in
Camshaft Axial Clearance
Camshaft Housing
30.00–30.021 mm 1.1811–1.1819 in
Camshaft Bearing Diameter – 1. Bearing
24.00–24.021 mm 0.9448–0.9457 in
Camshaft Bearing Diameter – 2.-6. Bearing
Connecting Rod
0.024–0.042 mm 0.0009–0.0016 in
Con Rod Bearing Clearance
52.0190–52.0235 mm 2.0478–2.0481 in
Con Rod Bearing Journal Diameter – Class A
52.0145–52.0190 mm 2.0478–2.0479 in
Con Rod Bearing Journal Diameter – Class B
52.0100–52.0145 mm 2.0476–2.0478 in
Con Rod Bearing Journal Diameter – Class C
55.0045–55.0090 mm 2.1655–2.1657 in
Con Rod Big End Bore Diameter – Class A
55.0090–55.0135 mm 2.1657–2.1658 in
Con Rod Big End Bore Diameter – Class B
55.0135–55.0180 mm 2.01658–2.1660 in
Con Rod Big End Bore Diameter – Class C
1.474–1.478 mm 0.0580–0.0581 in
Con Rod Bearing Shell – Class A (violet)
1.479–1.483 mm 0.0582–0.0583 in
Con Rod Bearing Shell – Class B (yellow)
1.483–1.487 mm 0.0583–0.0585 in
Con Rod Bearing Shell – Class C (blue)
Crankshaft
0.090–0.320 mm 0.0035–0.0125 in
Axial Clearance
0.024–0.042 mm 0.0009–0.0016 in
Main Bearing Clearance
60.0190–60.0235 mm 2.3629–2.3631 in
Main Bearing Journal Diameter – Class A
60.0145–60.0190 mm 2.3627–2.3629 in
Main Bearing Journal Diameter – Class B
60.0100–60.0145 mm 2.3626–2.3627 in
Main Bearing Journal Diameter – Class C
64.0045–64.0090 mm 2.5198–2.5200 in
Bearing Bore Diameter in Cylinder Block – Class A
4 of 6
Specification
64.0090–64.0135 mm 2.5200–2.5202 in
Bearing Bore Diameter in Cylinder Block – Class B
64.0145–64.0180 mm 2.5202–2.5203 in
Bearing Bore Diameter in Cylinder Block – Class C
1.974–1.97 mm 0.0777–0.078 in
Main Bearing Shells – Class A (violet)
1.979–1.983 mm 0.0779–0.0780 in
Main Bearing Shells – Class B (yellow)
1.983–1.98 mm 0.0780–0.0782 in
Main Bearing Shells – Class C (blue)
Piston
85.925–85.935 mm 3.3828–3.3832 in
85.935–85.945 mm 3.3832–3.3836 in
85.945–85.955 mm 3.3836–3.384 in
32.993–32.008 mm 1.2989–1.2601 in
Piston Pin Diameter
0.006–0.017 mm 0.0002–0.0006 in
Clearance Piston Pin in Piston
0.024–0.041 mm 0.0009–0.0016 in
Clearance Piston Pin in Con Rod
± 0.007 kg
Piston Weight Difference
Piston Rings
3.45–3.75 mm 0.1358–0.1476 in
3.25–3.55 mm 0.1279–0.1397 in
2.6–2.85 mm 0.1023–0.1122 in
Oil Scraper Ring – Thickness
0.13–0.175 mm 0.0051–0.0068 in
0.07–0.115 mm 0.0027–0.0045 in
0.03–0.07 mm 0.0011–0.0027 in
Oil Scraper Ring – Axial Clearance
0.24–0.40 mm 0.0094–0.0157 in
0.6–0.8 mm 0.0236–0.0315 in
0.25–0.50 mm 0.0098–0.0196 in
Oil Scraper Ring – Gap
5 of 6
Fastener Tightening Specifications - Engine Control

Fastener Tightening Specifications
Specification
Additional Intake Air Tuning Valve Vacuum Control Solenoid Valve Bolt 10 Y 89 lb in
Camshaft Cover Retaining Bolt 10 Y 89 lb in
Charge Air Cooler Inlet Air Hose Nut 22 Y 16 lb ft
Charge Air Cooler Outlet Front Hose Bracket Bolt 9 Y 80 lb in
Charge Air Cooler Outlet Front Hose Bracket Clamp 4 Y 35 lb in
Charge Air Control Vacuum Hose Bolt 9 Y 80 lb in
Drivetrain and Front Suspension Frame Bolt 160 Y 118 lb ft
Engine Oil Level Indicator Switch 20 Y 15 lb ft
Engine Water Outlet Adapter Bolt 10 Y 89 lb in
Exhaust Gas Recirculation Bypass Control Solenoid Valve Bolt 6 Y 53 lb in
Exhaust Gas Recirculation Cooler Bolt 25 Y 18 lb ft
Exhaust Gas Recirculation Cooler Nut 25 Y 18 lb ft
Exhaust Gas Recirculation Pipe Bolt 10 Y 89 lb in
Exhaust Gas Recirculation Valve Bolt 25 Y 18 lb ft
Exhaust Pressure Differential Sensor Bolt 9 Y 80 lb in
Exhaust Temperature Sensor Position 1 45 Y 33 lb ft
Front Intake Air Duct Bolt 5 Y 44 lb in
Fuel Injector Bracket Retaining Bolt 14 Y +110° (1) 124 lb in +110° (1)
Fuel Injection Fuel Feed Pipe Nut 27 Y 20 lb ft
Fuel Injection Fuel Rail Retaining Bolt 25 Y 18 lb ft
Fuel Injection Pump Bolt 25 Y 18 lb ft
Fuel Tank Filler Pipe Bracket Bolt 9 Y 80 lb in
Fuel Tank Filler Pipe Ground Bolt 9 Y 80 lb in
Fuel Tank Strap Bolt 23 Y 17 lb ft
Glow Plugs 11 Y 97 lb in
Heated Oxygen Sensor 50 Y 37 lb ft
Intake Air Pressure/Temperature Sensor Bolt 9 Y 80 lb in
Intake Air Tuning Valve Vacuum Control Solenoid Valve Bolt 10 Y 89 lb in
Knock Sensor 1 25 Y 18 lb ft
Knock Sensor 2 25 Y 18 lb ft
Mass Air Flow Sensor Clamps 3.5 Y 31 lb in
1 of 2
Fastener Tightening Specifications - Engine Control
Specification
Positive Crankcase Ventilation Valve Retaining Bolt 10 Y 89 lb in
Throttle Body Assembly Bolt 10 Y 89 lb in
Vacuum Pump Assembly Bolt 10 Y 89 lb in
1 = Use NEW Fastener
2 of 2
Fastener Tightening Specifications - Engine

Specification
Air Conditioning Compressor Bracket Mounting Bolt 22 Y 16 lb ft
Camshaft Cover Mounting Bolt 10 Y 89 lb ft
Camshaft Guide Retaining Bolt (M6) 10 Y 89 lb in
Camshaft Guide Retaining Bolt (M8) 25 Y 18 lb ft
Camshaft Position Sensor Bolt 10 Y 89 lb in
Charge Air Control Vacuum Hose Bracket Bolt 10 Y 89 lb in
Connecting Rod Bearing Cap Bolt 30 Y + 70° (1) 22 lb ft + 70° (1)
Crankshaft Balancer Retaining Bolt (Final) 50 Y + 90° (1) 37 lb ft + 90° (1)
Crankshaft Balancer Retaining Bolt (First) 20 Y 15 lb ft
Crankshaft Position Sensor Bolt 10 Y 89 lb in
Crankshaft Position Sensor Inner Exciter Ring Bolts 12 Y 106 lb in
Crankshaft Pulley Bolt 120 Y + 90° (1) 89 lb ft + 90° (1)
Cylinder Head Bolt 30 Y +100 Y + 90° + 90° (1) 22 lb ft + 74 lb ft + 90° + 90° (1)
Drive Belt and Pulley Cover Bolt 10 Y 89 lb in
Drive Belt Idler Pulley-Lower Bolt 58 Y 43 lb ft
Drive Belt Idler Pulley-Upper Bolt 58 Y 43 lb ft
Drive Belt Tensioner Bolt 45 Y 33 lb ft
Engine Automatic Transmission Flex Plate Bolt 60 Y + 45° (1) 44 lb ft + 45° (1)
Engine Coolant Outlet Adapter Bolt 10 Y 89 lb in
Engine Coolant Temperature Sensor 12.5 Y 111 lb in
Engine Coolant Thermostat Housing Bolt 10 Y 89 lb in
Engine Flywheel Bolt 160 Y (1) 118 lb ft (1)
Engine Front Cover Bolts (M6) 9 Y 80 lb in
Engine Front Cover Bolts (M8) 22 Y 16 lb ft
Engine Lift Front Bracket Bolt 22 Y 16 lb ft
Engine Lift Rear Bracket Bolt 22 Y 16 lb ft
Engine Mount Bolt to Body 62 Y 46 lb ft
Engine Mount Bolt to Bracket 50 Y + 60° - 75° 37 lb ft + 60° - 75°
Engine Mount Bracket Bolt 58 Y 43 lb ft
Engine Mount Nut to Body 62 Y 46 lb ft
Engine Oil Cooler Bolt 25 Y 18 lb ft
Engine Oil Pressure Switch 20 Y 15 lb ft
1 of 3
Specification
Engine Wiring Harness Upper Channel Bolt (to Camshaft

10 Y 89 lb in
Cover)
Exhaust Camshaft Cap Bolt (M6) 10 Y 89 lb in
Exhaust Camshaft Cap Bolt (M8) 25 Y 18 lb ft
Exhaust Gas Recirculation Cooler Assembly Bolt 25 Y 18 lb ft
Exhaust Gas Recirculation Cooler Assembly Nut 25 Y 18 lb ft
Exhaust Gas Recirculation Pipe Bolt 10 Y 89 lb in
Exhaust Manifold Bolt 20 Y 15 lb ft
Exhaust Manifold Heat Shield Bolt 10 Y 89 lb in
Exhaust Particulate Filter Bracket Bolt 22 Y 16 lb ft
Exhaust Particulate Filter Bracket Nut (to Engine Block) 28 Y 21 lb ft
Exhaust Particulate Filter Bracket Nut (to Exhaust Particulate

35 Y 26 lb ft
Filter)
Exhaust Particulate Filter Heat Shield - Front Bolt/Nut 9 Y 80 lb in
Exhaust Particulate Filter Heat Shield - Rear Bolt/Nut 9 Y 80 lb in
Exhaust Temperature Sensor - Position 1 45 Y 33 lb ft
Fuel Injection Bracket Bolt 14 Y + 110° (1) 124 lb in + 110° (1)
Fuel Injection Fuel Feed Pipe 27 Y 20 lb ft
Fuel Injection Pump Bolt 25 Y 18 lb ft
Fuel Rail Bolt 25 Y 18 lb ft
Generator Bolt 58 Y 43 lb ft
Glow Plug 10.5 Y 93 lb in
Intake Camshaft Cap Bolt (M6) 10 Y 89 lb in
Intake Camshaft Cap Bolt (M8) 25 Y 18 lb ft
Intake Manifold Bolt/Nut 25 Y 18 lb ft
Lower Crankcase Bolt (M12, Inner) 55 Y + 120° (1) 41 lb ft + 120° (1)
Lower Crankcase Bolt (Outer) 35 Y 26 lb ft
Lower Oil Pan Bolt 10 Y 89 lb in
Oil Filter Assembly Bolt 25 Y 18 lb ft
Oil Filter Cap 25 Y 18 lb ft
Oil Level Indicator and Tube Bracket Bolt 10 Y 89 lb in
Oil Level Indicator Switch 20 Y 15 lb ft
Oil Pan Drain Plug 25 Y 18 lb ft
Positive Crankcase Ventilation Valve Bolt 10 Y 89 lb in
Starter Bolt 58 Y 43 lb ft
Thermostat Bypass Pipe Bracket Bolt 25 Y 18 lb ft
Timing Chain Guide Bolt 25 Y 18 lb ft
2 of 3
Specification
Timing Chain Tensioner Bolt 10 Y 89 lb in
Throttle Body Bolt 10 Y 89 lb in
Turbocharger Bracket Bolt 25 Y 18 lb ft
Turbocharger Coolant Feed Pipe Bolt 32 Y 24 lb ft
Turbocharger Coolant Return Pipe Bolt 32 Y 24 lb ft
Turbocharger Heat Shield Bolt 10 Y 89 lb in
Turbocharger Nut 30 Y 22 lb ft
Turbocharger Oil Feed Pipe Bolt (M12) 32 Y 24 lb ft
Turbocharger Oil Feed Pipe Bracket Bolt (M6) 10 Y 89 lb in
Turbocharger Oil Return Pipe Bolt 10 Y 89 lb in
Upper Oil Pan Bolt 25 Y 18 lb ft
Upper Oil Pan Bolt (to Transmission) 45 Y 33 lb ft
Vacuum Pump Bolt 10 Y 89 lb in
Water Pump Bracket Bolt 25 Y 18 lb ft
Water Pump Cover Bolt/Stud 8 Y 71 lb in
Water Pump Pulley Bolt 18 Y 13 lb ft
3 of 3
Fastener Tightening Specifications (2.0L Diesel LNP)

Specification
Charge Air Cooler Inlet Hose Nut 22 Y 16 lb ft
Charge Air Cooler Outlet Front Hose Bracket Bolt 9 Y 80 lb in
Engine Coolant Temperature Sensor 13 Y 115 lb in
Engine Water Outlet Adapter Bolt 10 Y 89 lb in
Power Steering Fluid Cooling Pipe Bracket Bolt 9 Y 80 lb in
Radiator Lower Bracket Bolt 22 Y 16 lb ft
Radiator Upper Bracket Bolt 22 Y 16 lb ft
Surge Tank Outlet Pipe Bracket Bolt 9 Y 80 lb in
Thermostat Bypass Pipe Bolt 22 Y 16 lb ft
Thermostat Bypass Pipe Bracket Bolt 10 Y 89 lb in
Thermostat Housing Bolt 8 Y 71 lb in
Turbocharger Bracket Bolt 25 Y 18 lb ft
Turbocharger Coolant Feed Pipe Hollow Bolt 32 Y 24 lb ft
Turbocharger Coolant Return Pipe Bracket Bolt 10 Y 89 lb in
Turbocharger Coolant Return Pipe Hollow Bolt 32 Y 24 lb ft
Water Pump Bolt 25 Y 18 lb ft
Water Pump Pulley Bolt 18 Y 13 lb ft
1 of 1

Specification
Charge Air Cooler Inlet Air Hose Nut 22 Y 16 lb ft
Exhaust Front Pipe Nut (Front Pipe to Exhaust Particulate Filter) 22 Y 16 lb ft
Exhaust Front Pipe Hanger Bracket Bolt - M8 22 Y 16 lb ft
Exhaust Front Pipe Hanger Bracket Bolt - M10 60 Y +30° -45° (1) 44 lb ft +30° -45° (1)
Exhaust Front Pipe Hanger Insulator Nut 22 Y 16 lb ft
Exhaust Manifold Heat Shield Bolt 10 Y 89 lb in
Exhaust Manifold Mounting Bolt 20 Y 15 lb ft
Exhaust Particulate Filter Mounting Bolt 22 Y 16 lb ft
Exhaust Particulate Filter Mounting Nut 28 Y 21 lb ft
Exhaust Particulate Filter Clamp 9.5 Y 84 lb in
Exhaust Particulate Filter Heat Shield - Front Retaining Bolt/Nut 9 Y 80 lb in
Exhaust Particulate Filter Heat Shield - Rear Retaining Bolt/Nut 9 Y 80 lb in
Exhaust Pressure Differential Sensor Bolt 10 Y 89 lb in
Exhaust Temperature Sensor Pos. 1 45 Y 33 lb ft
Exhaust Rear Muffler Nut (Exhaust Rear Muffler to Exhaust Front Pipe) 22 Y 16 lb ft
Exhaust Rear Pipe Hanger Insulator Mounting Bolt 22 Y 16 lb ft
Turbocharger Bracket Retaining Bolt 25 Y 18 lb ft
Turbocharger Bracket Retaining Bolt 25 Y 18 lb ft
Turbocharger Coolant Feed Pipe Hollow Bolt 32 Y 24 lb ft
Turbocharger Coolant Return Pipe Hollow Bolt 32 Y 24 lb ft
Turbocharger Heat Shield Bolt 10 Y 89 lb in
Turbocharger Nut - Lower 30 Y 22 lb ft
Turbocharger Nut - Upper 30 Y 22 lb ft
Turbocharger Oil Feed Pipe Hollow Bolt 32 Y 24 lb ft
Turbocharger Oil Feed Pipe Mounting Bolt 10 Y 89 lb in
Turbocharger Oil Return Pipe Mounting Bolt 10 Y 89 lb in
1 of 2

Specification
Battery Ground Cable Nut 9 Y 80 lb in
Battery Ground Cable To Battery Negative Cable Nut 9 Y 80 lb in
Battery Hold Down Retainer Nut 12 Y 106 lb in
Battery Negative Cable Nut 4.5 Y 40 lb in
Battery Positive Cable Nut 4.5 Y 40 lb in
Battery Positive Cable To Fuse Box Nut 9 Y 80 lb in
Battery Positive Cable Nut To Starter Cable Nut 12 Y 106 lb in
Battery Positive Plate Nut 12 Y 106 lb in
Battery Tray Bolt 15 Y 11 lb ft
Engine Wiring Harness Channel Bolts 10 Y 89 lb in
Engine Coolant Fan Shroud Ground Cable Nut 9 Y 80 lb in
Front Compartment Fuse Block Bolts 22 Y 16 lb ft
Generator Positive Cable Nut 17 Y 13 lb ft
Positive And Negative Cable Bracket To Transmission Bolts 17 Y 13 lb ft
Starter Bolts 58 Y 43 lb ft
Starter Ground Cable To Engine Block Bolt 22 Y 16 lb ft
Starter And Generator Positive Cable Nut 9.5 Y 84 lb in
1 of 1
Ignition System Specifications

Ignition System Specifications
Specification
Ignition Type Coil-On-Plug
Firing Order 1–3–4–2
Spark Plug 25 Y 19 lb ft
Spark Plug Gap— 1.6L LDE 0.9 mm 0.035 in
Spark Plug Gap— 1.6L LXV 1.1 mm 0.043 in
Spark Plug Gap— 1.8L 2H0 0.9 mm 0.035 in
Spark Plug Gap— 1.8L LFH 0.7 mm 0.028 in
1 of 1




Circuit Status

Relay Command


A/C ON
Sensor
700–900 kPa (101–130
A/C OFF
Sensor
A/C ON
(130–174 PSI)


Accelerator Pedal
Engine Overspeed
Detected
sensors.


1 of 8

BARO —

pressure sensor.

Cooling Fan Relay

Control 3 Command


— Volts
procedure.

CPP Learned Release
Position
pedal is released.

CPP Sensor — %

reference voltage.

Switch ON

Cruise Control ON

Switch

Switch ON
Current Gear When

Detected



—

2 of 8

— 0–100%
sensor.

Distance Since Last
DPF Regeneration
— Varies

Level Warning
occurred.

Pressure Warning
occurred.



DPF Differential
Pressure Sensor
regeneration.



ECT Sensor —
(ECT) sensor.


— OFF


11–30%
Engine Idling
25–40%
RPM

oil level switch.
Engine Oil Life

Remaining

Engine Oil Pressure
Switch
3 of 8

Engine Overheat
Possible
to occur.

detected.

— Varies
Counter detected.

stops running.

RPM
— OK
range speed.
Exhaust Gas
Temperature
or 3
2–80–120°C
(176–248°F)
Exhaust Gas
Temperature
Temperature
2–0.90–1.10 V

high or near full.
Fuel Pump Relay
Command

Fuel Rail Pressure
Regulator 1 Command
regulator.

— mA

Fuel Rail Pressure

Fuel Rail Pressure
Sensor

Fuel Temperature
Sensor

Fuel Temperature
Sensor
temperature sensor.

Pressed
transmission.
4 of 8

— 60–70%

— %

— On/Off



terminal.

Ignition Accessory
Signal



Ignition ON Yes/No

Ignition ON Yes/No

Ignition ON Yes/No

Ignition ON Yes/No
Negative
Incorrect
State/Pre-Release
State/Release State


— OK

Motor Command
valve.
— Varies
— Varies

runner valve.

Sensor

5 of 8

engine speeds.

— Varies


MIL Command — Off
— Varies

— Varies
Switch lever.

display OFF.


the ECM is active.


CRANK position.

voltage.
— Varies

— 0–100%
Turbocharger Vane
Position Sensor
— Varies

Turbocharger Vane
Command
sensor.

speed sensor (VSS).

system.
6 of 8

Cooling Fan Relay 1
Cooling Fan Relay 2
at medium speed.
Cooling Fan Relay 3
at high speed.
replaced.
replaced.
scan tool.

Fuel Heater Relay
Fuel Injector Learn

Rail Learn
is running.
7 of 8
replaced.

Valve

Valve Learn
by the scan tool.
been replaced.

8 of 8




Circuit Status

Relay Command


A/C ON
Sensor
700–900 kPa (101–130
A/C OFF
Sensor
A/C ON
(130–174 PSI)


Accelerator Pedal
Engine Overspeed
Detected
sensors.


1 of 8

BARO —

pressure sensor.

Cooling Fan Relay

Control 3 Command


— Volts
procedure.

CPP Learned Release
Position
pedal is released.

CPP Sensor — %

reference voltage.

Switch ON

Cruise Control ON

Switch

Switch ON
Current Gear When

Detected



—

2 of 8

— 0–100%
sensor.

Distance Since Last
DPF Regeneration
— Varies

Level Warning
occurred.

Pressure Warning
occurred.



DPF Differential
Pressure Sensor
regeneration.



ECT Sensor —
(ECT) sensor.


— OFF


11–30%
Engine Idling
25–40%
RPM

oil level switch.
Engine Oil Life

Remaining

Engine Oil Pressure
Switch
3 of 8

Engine Overheat
Possible
to occur.

detected.

— Varies
Counter detected.

stops running.

RPM
— OK
range speed.
Exhaust Gas
Temperature
or 3
2–80–120°C
(176–248°F)
Exhaust Gas
Temperature
Temperature
2–0.90–1.10 V

high or near full.
Fuel Pump Relay
Command

Fuel Rail Pressure
Regulator 1 Command
regulator.

— mA

Fuel Rail Pressure

Fuel Rail Pressure
Sensor

Fuel Temperature
Sensor

Fuel Temperature
Sensor
temperature sensor.

Pressed
transmission.
4 of 8

— 60–70%

— %

— On/Off



terminal.

Ignition Accessory
Signal



Ignition ON Yes/No

Ignition ON Yes/No

Ignition ON Yes/No

Ignition ON Yes/No
Negative
Incorrect
State/Pre-Release
State/Release State


— OK

Motor Command
valve.
— Varies
— Varies

runner valve.

Sensor

5 of 8

engine speeds.

— Varies


MIL Command — Off
— Varies

— Varies
Switch lever.

display OFF.


the ECM is active.


CRANK position.

voltage.
— Varies

— 0–100%
Turbocharger Vane
Position Sensor
— Varies

Turbocharger Vane
Command
sensor.

speed sensor (VSS).

system.
6 of 8

Cooling Fan Relay 1
Cooling Fan Relay 2
at medium speed.
Cooling Fan Relay 3
at high speed.
replaced.
replaced.
scan tool.

Fuel Heater Relay
Fuel Injector Learn

Rail Learn
is running.
7 of 8
replaced.

Valve

Valve Learn
by the scan tool.
been replaced.

8 of 8
Battery Usage

Battery Usage
Application Specification
Cold Cranking Amperage (CCA) 525 A
AMP Hours 60 A/H
1 of 1

Specification
Battery Ground Cable Nut 9 Y 80 lb in
Battery Ground Cable To Battery Negative Cable Nut 9 Y 80 lb in
Battery Hold Down Retainer Nut 12 Y 106 lb in
Battery Negative Cable Nut 4.5 Y 40 lb in
Battery Positive Cable Nut 4.5 Y 40 lb in
Battery Positive Cable To Fuse Box Nut 9 Y 80 lb in
Battery Positive Cable Nut To Starter Cable Nut 12 Y 106 lb in
Battery Positive Plate Nut 12 Y 106 lb in
Battery Tray Bolt 15 Y 11 lb ft
Engine Wiring Harness Channel Bolts 10 Y 89 lb in
Engine Coolant Fan Shroud Ground Cable Nut 9 Y 80 lb in
Front Compartment Fuse Block Bolts 22 Y 16 lb ft
Generator Positive Cable Nut 17 Y 13 lb ft
Positive And Negative Cable Bracket To Transmission Bolts 17 Y 13 lb ft
Starter Bolts 58 Y 43 lb ft
Starter Ground Cable To Engine Block Bolt 22 Y 16 lb ft
Starter And Generator Positive Cable Nut 9.5 Y 84 lb in
1 of 1
Generator Usage

Generator Usage
Application Specification
1.6L (LXV)
Generator Model TG13 (Valeo)
Rated Output 125 A
Load Test Output 87 A
2.0L (diesel)
Generator Model TG13 (Valeo)
Rated Output 125 A
Load Test Output 87 A
1 of 1
Symptoms - Engine Controls

Symptoms Description
Symptoms cover conditions that are not covered by DTCs. Certain conditions can cause multiple symptoms. These conditions are listed together under Symptoms
Testing. Conditions that may only cause specific symptoms are listed separately under additional symptoms testing. Perform the symptoms testing before using
the additional symptoms testing.
Symptoms Definition
Backfire
Fuel ignites in the intake manifold or in the exhaust system, making a loud popping noise.
Cuts Out, Misses
A steady pulsation or jerking that follows engine speed, which is usually more pronounced as the engine load increases. This condition is not normally felt
above 1 500 RPM or 48 km/h (30 MPH). The exhaust has a steady spitting sound at idle or at low speed.
Detonation/Spark Knock
A mild to severe ping which usually gets worse while under acceleration. The engine makes sharp metallic knocks that change with throttle opening.
Dieseling, Run On
Fuel ignites in the intake manifold or in the exhaust system, making a loud popping noise.
Hard Start
Engine cranks OK, but does not start for a long time. The vehicle does eventually run, or may start but immediately stalls.
Hesitation, Sag, Stumble
Momentary lack of response as the accelerator is pushed down. This condition can occur at any vehicle speed. This condition is usually more pronounced
when first trying to make the vehicle move, as from a stop. This condition may cause the engine to stall in severe conditions.
Lack of Power, Sluggishness, or Sponginess
The engine delivers less than expected power. Little or no increase in speed when the accelerator pedal is pushed down part way.
Poor Fuel Economy
Fuel economy, as measured by an actual road test, is noticeably lower than expected. Also, the fuel economy is noticeably lower than it was on this vehicle
at one time, as previously shown by an actual road test.
Poor Fuel Fill Quality
Difficulty when refueling the vehicle.
Rough, Unstable, or Incorrect Idle and Stalling
The engine runs unevenly at idle. If severe, the engine or the vehicle may shake. Engine idle may vary in speed. Either condition may be severe enough to
stall the engine.
Surges/Chuggles
Engine power variation under steady throttle or cruise. Feels like the vehicle speeds up and slows down with no change in the accelerator pedal position.
Symptoms Verification
The engine control module (ECM) and the malfunction indicator lamp (MIL) are operating correctly.
There are no DTCs stored.
The scan tool data is within the normal operating range.
Bulletins are not available for the current symptom.
The ECM grounds are clean, tight, and in the correct locations.
The vehicle tires are correctly inflated and meet original equipment specifications.
The air filter element is not restricted.
Symptoms Testing
1. Test for the following conditions:
For the correct installation of the Mass Air Flow (MAF)/Intake Air Temperature (IAT) Sensor.
The fuel system for the following:
Correct fuel pressure. Refer to Fuel System Diagnosis.

Fuel injectors that are leaking or improper operation. Refer to Fuel Injector Diagnosis.
Contaminated or a poor fuel quality condition. Refer to Alcohol/Contaminants-in-Fuel Diagnosis.
The ignition system for the following:
Spark plugs for incorrect heat range or an abnormal condition. Refer to Spark Plug Replacement.
1 of 3
For diagnosis of coolant or oil fouled spark plugs.

Wet down the secondary ignition system with water from a spray bottle. Wetting down the secondary ignition system may help locate damaged or
deteriorated components. Look/listen for arcing or misfiring as the water is applied.
Weak spark using the EL 26792 HEI Spark Tester . For equivalent regional tools, refer to Special Tools. Refer to Electronic Ignition System Diagnosis.
The operation of the transmission torque converter clutch (TCC). The scan tool should indicate an engine speed drop when the TCC is commanded ON.
The operation of the A/C compressor
Items that can cause an engine to run lean or rich. Refer to DTC P0172 or P2096 or DTC P0171 or P2097.
The crankshaft position sensor for the correct resistance. The crankshaft position sensor resistance may be out of range after a hot soak. The resistance
should be between 700–1 200 Ω.
The engine for the following mechanical failures. Refer to Symptoms - Engine Mechanical.
Excessive oil in the combustion chamber or leaking valve seals

Incorrect cylinder compression
Sticking or leaking valves
Worn camshaft lobes
Incorrect valve timing
Broken valve springs
Excessive carbon buildup in the combustion chambers. clean the chambers with top engine cleaner. Follow the instructions on the can.
Incorrect engine parts
Vacuum hoses for splits or kinks. Verify that the routing and connections are as shown on the vehicle emission control information label.
Knock sensor system for excessive spark retard activity. Refer to Knock Sensor Replacement and DTC P0335 or P0336.
Fuel octane switch setting. Verify the fuel octane switch is set to the proper fuel octane rating for the fuel being used in the vehicle.
Turbocharger system for proper operation, if equipped
Turbocharger charge air cooler system has no leaks, if equipped
The exhaust system components for the following:
Physical damage or possible internal failure

The 3-way catalytic converters for a restriction
For more information, refer to Symptoms - Engine Exhaust.
Electromagnetic interference on the reference circuit can cause a misfire condition. You can usually detect electromagnetic interference with a scan tool by
monitoring the engine speed parameter. A sudden increase in the engine speed parameter with little change in actual engine speed indicates that
electromagnetic interference is present. Inspect the high voltage components near the ignition control circuit if a condition exists.
Inspect the positive crankcase ventilation system and all connections for leaks or restrictions.
Evaporative Emission (EVAP) Canister Purge Solenoid Valve that is stuck open
The engine cooling system for the following conditions:
The thermostat is the correct heat range. Refer to Thermostat Diagnosis.

The engine coolant thermostat heater is working proper. Refer to DTC P0597-P0599.
Proper engine coolant level. Refer to Cooling System Draining and Filling.
If the above conditions do not address the symptom, refer to the additional symptoms tests.
Additional Symptoms Tests

Detonation/Spark Knock
Test the engine for an overheating condition. Refer to Symptoms - Engine Cooling.
Poor Fuel Economy
Inspect for foreign material accumulation in the throttle bore, and for carbon deposits on the throttle plate and shaft. Also inspect for throttle body tampering.
Rough, Unstable, or Incorrect Idle and Stalling
Inspect the engine mounts Engine Mount Replacement.
Surges/Chuggles
Test the heated oxygen sensors (HO2S). The HO2S should respond quickly to a change in throttle position. If the HO2S do not respond to different throttle
positions, inspect for contamination from fuel, silicon, or the incorrect use of room temperature vulcanizing sealant. The sensors may have a white powdery
coating and result in a high, but false, signal voltage, which gives a rich exhaust indication. The ECM reduces the amount of fuel delivered to the engine,
causing a driveability condition.
Hard Start
Test the engine coolant temperature (ECT) sensor. Compare the ECT sensor value to the intake air temperature (IAT) sensor value on a cold engine. The
ECT and IAT sensor values should be within approximately 3°C (5°F). If the ECT sensor is out of range with the IAT sensor, test the resistance of the ECT
sensor. Refer to Temperature Versus Resistance for resistance specifications. Replace the ECT sensor if the resistance is not within specification. If the
sensor is within the specification, test the ECT circuits for a high resistance.
Test the fuel pump relay operation. The fuel pump should turn ON for 2 s when the ignition is turned ON.
Hesitation, Sag, Stumble
Test the fuel pressure. Refer to Fuel System Diagnosis.

Test the manifold absolute pressure (MAP) sensor. Refer to DTC P0106.
Test the generator. Refer to Symptoms - Engine Electrical. Repair the charging system if the generator output voltage is less than 9 V or more than 16 V.
Poor Fuel Economy
Heavy loads being carried or towed

Acceleration rate too much or too often
Inspect for foreign material accumulation in the throttle bore, and for carbon deposits on the throttle plate and shaft. Also inspect for throttle body tampering.
Poor Fuel Fill Quality

Difficult to Fill
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Restricted vent lines

High fuel temperature
A condition with the internal components of the fuel tank assembly
For more information, refer to the following:

Fuel Odor
Saturated EVAP canister. Refer to Evaporative Emission Control System Description.

A condition with the internal components of the fuel tank assembly. Refer to Fuel System Description.
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Temperature Versus Resistance (ECT and IAT Sensor)

Engine Coolant Temperature (ECT) and Intake Air Temperature (IAT) Sensor
°C °F Ω
Temperature vs. Resistance Values (Approximate)
130 266 85
120 248 110
110 230 142
100 212 186
90 194 246
80 176 329
70 158 446
60 140 612
50 122 851
45 113 1 009
40 104 1 200
35 95 1 432
30 86 1 715
25 77 2 063
20 68 2 511
15 59 3 075
10 50 3 791
5 41 4 707
0 32 5 887
−5 23 7 419
−10 14 9 426
−15 5 12 078
−20 −4 15 614
−30 −22 26 854
−40 −40 48 153
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Temperature Versus Resistance (ECT)

Temperature Versus Resistance
°C °F OHMS
Temperature vs Resistance Values (Approximate)
140 284 50
126 258 75
116 240 100
108 226 120
99 210 160
92 197 200
84 183 250
78 172 300
69 156 400
63 145 500
58 136 600
51 123 750
47 116 900
39 102 1200
33 91 1500
29 84 1800
24 75 2250
19 66 2800
15 59 3500
9 48 4500
5 41 5500
1 33 7000
−6 +22 9500
−9 +16 12000
−14 +7 16000
−19 −2 21500
−24 −11 28500
−24 −11 31000
−27 −16 33000
−27 −16 35000
−28 −18 39000
−30 −22 49000
−33 −27 60000
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Temperature Versus Resistance (ECT)
°C °F OHMS
−37 −34 70000
−40 −40 93000
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Temperature Versus Resistance (Exhaust Temperature Sensor)

Temperature Versus Resistance
°C °F Ω
Temperature vs. Resistance Values (Approximate)
1 000 1 832 849
900 1 652 795
800 1 472 738
700 1292 679
600 1 112 618
500 932 554
450 842 521
400 752 488
350 662 454
300 572 420
250 482 385
200 392 349
150 302 313
100 212 276
50 122 239
25 77 220
0 32 201
−20 −4 185
−40 −40 170
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2.0L VCDi LNP DIESEL ENGINE MANUAL PDF

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What steps are involved in installing the 2-6 clutch piston?

What steps are involved in installing the 2-6 clutch piston?

What are the steps to measure the crankshaft axial play?

What are the steps to measure the crankshaft axial play?

2-6 Clutch Piston Installation (6T40/45/50)

2011 Chevrolet Orlando

2-6 Clutch Piston Installation

Callout Component Name

2–6 Clutch Piston Assembly

2 2–6 Clutch Spring

2–6 Clutch Spring Retainer

DT-47797 Spring Installer

For equivalent regional tools, refer to Special Tools.

EBSCO Publishing Green Initiatives

2011 Chevrolet Orlando

Clean the lower crankcase (bed plate) sealing surface.

Axial Play Measurement

EBSCO Publishing Green Initiatives

2011 Chevrolet Orlando

EBSCO Publishing Green Initiatives

2011 Chevrolet Orlando

Note: Inspect the installation position.

Oil bearing clips.

Note: Inspect the installation position.

Caution: Refer to Fastener Caution.

Caution: Refer to Torque-to-Yield Fastener Caution.

First pass to 50 Y (37 lb ft)

Note: Inspect the installation position.

First pass to 35 Y (26 lb ft)

Turn the crankshaft through 180°.

First pass to 35 Y (26 lb ft)

EBSCO Publishing Green Initiatives

2011 Chevrolet Orlando

EBSCO Publishing Green Initiatives

2011 Chevrolet Orlando

1. Identify all the connecting rod bearing caps (1).

2. Remove the 4 bolts.

5. Remove the 4 bolts.

8. Remove the crankshaft bearing caps (1).

EBSCO Publishing Green Initiatives

2011 Chevrolet Orlando

Warning: Refer to Safety Glasses and Compressed Air Warning.

Note: The EN-50431 adapter must be horizontal to the balancer.

EBSCO Publishing Green Initiatives

2011 Chevrolet Orlando

EN-652 Flywheel Holder

For equivalent regional tools, refer to Special Tools.

1. First pass to 95 Y (70 lb ft).

EBSCO Publishing Green Initiatives

2011 Chevrolet Orlando

EN-50430 Pin - Balance Shaft Module Locking

For equivalent regional tools, refer to Special Tools.

1. Set the piston of cylinder #1 to TDC of combustion stroke.

3. Install the balance shaft module (1) to the lower crankcase.

EBSCO Publishing Green Initiatives

2011 Chevrolet Orlando

2. Remove and DISCARD the crankshaft balancer bolt (4).

EBSCO Publishing Green Initiatives

2011 Chevrolet Orlando