Contents: Dismantling ⇩ Assembly ⇩
Before disconnecting the battery, make sure that all requirements and conditions contained in the section on disconnecting the battery are met.
GENERAL INFORMATION, Precautions when working with electrical equipment.
Dismantling
1. Disconnect the negative battery terminal.
2. Remove the air intake hose.
ENGINE MANAGEMENT SYSTEM: V8 engine, REPAIR WORK, Hose connecting the air flow sensor to the throttle body.
3. Remove the left ignition coil cover.
ENGINE MANAGEMENT SYSTEM: V8 engine, REPAIR WORK, Left-hand ignition coil cover.
4. Remove the right ignition coil cover.
ENGINE MANAGEMENT SYSTEM: V8 engine, REPAIR WORK, Right bank ignition coil cover.
5. Disconnect the connectors from the ignition coils.
6. Disconnect the connectors from the throttle body, thermostat heater, camshaft position (CMP) sensor, and coolant temperature (ECT) sensor.
7. Cut off 2 plastic ties and release the engine harness.
8. Disconnect the connectors from the variable valve timing (VCC) solenoids.
9. Release the VCC solenoid valve connector from the clamp.
10. Disconnect the connector from the fuel vapor canister purge solenoid valve.
11. Disconnect the connector from the generator.
12. Release the generator harness from the 4 clamps.
13. Disconnect the connector from the knock sensor (KS) and camshaft position sensor (CMP).
14. Unscrew the 2 bolts securing the fuel injector wiring harness to the fuel rail.
15. Release the vacuum receiver and mounting bracket from the left fuel injector wiring harness mounting stud.
16. Remove the fuel pipe and bracket from the left fuel injector wiring harness mounting stud.
17. Release the alternator harness from the two clamps on the upper engine casing brackets.
18. Disconnect the connectors from the left row injectors.
19. Disconnect the engine harness from the clamps and move it away from the valve cover.
20. Unscrew the 2 nuts securing the engine harness to the intake manifold.
21. Disconnect the electrical connector from the SAI solenoid valve. (afterburning systems).
22. Remove SAI valve (afterburning systems) from the right stud of the injector harness.
23. Remove the washer from the fuel injector wiring harness stud.
24. Disconnect the connector from the right knock sensor (KS).
25. Disconnect the connectors from the right-hand row injectors.
26. Route the fuel injector wiring harness to its location.
27. Remove the air intake receiver.
HEATING AND VENTILATION, REPAIR WORKS, Air intake box.
28. Release residual pressure in the fuel supply system.
V8 ENGINE FUEL SUPPLY SYSTEM, ADJUSTMENTS AND MAINTENANCE, Relief of residual pressure.
29. Disconnect the fuel supply hose from the fuel rail.
CAUTION: Always plug the fittings and holes to protect the system from dirt.
30. Loosen the clamp and disconnect the crankcase ventilation hose from the valve cover.
31. Loosen the clamp and disconnect the vacuum hose from the canister purge solenoid valve. Disconnect the SAI vacuum tube. (afterburning systems).
32. Remove the 4 bolts securing the upper engine casing brackets from the intake manifold.
33. Loosen the bolt securing the fuel rail to the intake manifold and remove the rail with injectors.
Assembly
1. Wipe the injectors and recesses in the intake manifold.
2. Insert the injectors with the rail into the intake manifold and screw in the bolt.
3. Install 2 new brackets on the manifold and tighten the 5 bolts. Tightening torque 10 Nm.
4. Install the solenoid valve and connect the vacuum tube.
5. Connect the vacuum pipe of the brake booster.
6. Connect the brake system vacuum hose and secure it with a clamp.
7. Connect the crankcase ventilation hose to the valve cover and tighten the clamp.
8. Wipe the fuel hose connectors.
9. Connect the fuel supply hose to the fuel rail.
10. Install the air intake receiver in place.
HEATING AND VENTILATION, REPAIR WORKS, Air intake box.
11. Route the fuel injector wiring harness to its location.
12. Connect the connectors to the right row injectors.
13. Connect the connector to the knock sensor (KS).
14. Install the washer onto the fuel injector harness mounting stud.
15. Install SAI valve (afterburning systems) on the right stud of the injector harness.
16. Screw on the 2 nuts securing the fuel injector harness to the intake manifold and tighten them.
17. Connect the connector to the solenoid valve of the afterburning system (SAI).
18. Install the engine harness onto the bracket and secure it with clamps.
19. Connect the connectors to the left row injectors.
20. Connect the alternator harness to the two clamps on the upper engine cover.
21. Install the fuel hose with the bracket onto the left row injector harness mounting stud.
22. Attach the vacuum receiver with the bracket to the left-hand injector harness mounting stud.
23. Screw on the 2 nuts securing the fuel injector harness to the intake manifold and tighten them.
24. Connect the connector to the knock sensor (KS).
25. Connect the connector to the camshaft position (CMP) sensor.
26. Secure the generator wiring harness with 4 fasteners.
27. Connect the generator connector.
28. Connect the connector to the fuel vapor canister purge valve.
29. Secure the VCC harness connector to the clamp.
30. Connect the connectors to the camshaft position control solenoid valves (VCC).
31. Install new plastic ties and secure the harness.
32. Connect the connector to the camshaft position (CMP) sensor.
33. Connect the connector to the throttle body.
34. Connect the connector to the coolant temperature (ECT) sensor.
35. Place the connectors on the ignition coils.
36. Install the left ignition coil cover.
ENGINE MANAGEMENT SYSTEM: V8 engine, REPAIR WORK, Right bank ignition coil cover.
37. Install the right ignition coil cover.
ENGINE MANAGEMENT SYSTEM: V8 engine, REPAIR WORK, Left-hand ignition coil cover.
38. Reinstall the air intake hose.
ENGINE MANAGEMENT SYSTEM: V8 engine, REPAIR WORK, Hose connecting the air flow sensor to the throttle body.
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