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Engine Controls/fuel - 2.0l - Repair Instructions Buick Regal V

Testing & Diagnostics 41 illustrations ~3877 words

Description

The engine control module (ECM) learns the airflow through the throttle body to ensure the correct idle. The learned airflow values are stored within the ECM. These values are learned to adjust for production variation and will continuously learn during the life of the vehicle to compensate for reduced airflow due to throttle body coking. Anytime the throttle body airflow rate changes, for example due to cleaning or replacing, the values must be relearned.

An engine that had a heavily coked throttle body that has been cleaned or replaced may take several drive cycles to learn out the coking. To accelerate the process, the scan tool has the ability to reset all learned values back to zero. A new ECM will also have values set to zero.

The idle may be unstable or a DTC may set if the learned values do not match the actual airflow.

Conditions for Running the Idle Learn Procedure

Reset Procedure

  1. DTCs P0068, P0101, P0102, P0103, P0106, P0107, P0108, P0116, P0117, P0118, P0119, P0121, P0122, P0123, P0128, P0171, P0172, P0201-P0204, P0222, P0223, P0300-P0304, P0351-P0354, P0496, P0506, P0507, P0601-P0604, P0606, P062B, P062F, P0630, P0641, P0651, P0697, P06A3, P1101, P1516, P16F3, P2101, P2119, P2122, P2123, P2127, P2128, P2135, P2138, P2176, or P2610 are not set.
  2. Ignition ON, engine OFF.
  3. The vehicle speed sensor (VSS) is 0 km/h (0 mph).

Learn Procedure

  1. DTCs P0068, P0101, P0102, P0103, P0106, P0107, P0108, P0116, P0117, P0118, P0119, P0121, P0122, P0123, P0128, P0171, P0172, P0201-P0204, P0222, P0223, P0300-P0304, P0351-P0354, P0496, P0506, P0507, P0601-P0604, P0606, P062B, P062F, P0630, P0641, P0651, P0697, P06A3, P1101, P1516, P16F3, P2101, P2119, P2122, P2123, P2127, P2128, P2135, P2138, P2176, or P2610 are not set.
  2. The engine speed is between 450-4, 000 RPM.
  3. The engine vacuum is greater than 5 kPa.
  4. The mass air flow (MAF) is greater than 2 g/s.
  5. The ignition 1 voltage is greater than 10 V.

Reset/Learn Procedure

Reset Procedure - Performed after the throttle body is cleaned or replaced

  1. Ignition ON, engine OFF, perform the Idle Learn Reset in Module Setup with a scan tool.
  2. Engine idling, monitor the Throttle Body Idle Airflow Compensation parameter. The Throttle Body Idle Airflow Compensation value should equal 0 % and the engine should be idling at a normal idle speed.
  3. Clear the DTCs and return to the diagnostic that referred you here.

Learn Procedure - Performed after the ECM is programmed or replaced

  1. Engine idling for 3 minutes.
  2. Monitor the Desired Idle Speed and the actual Engine Speed with a scan tool.
  3. The ECM will start to learn the new idle cells and Desired Idle Speed should start to decrease.
  4. Ignition OFF for 60 s.
  5. Engine idling for 3 minutes.
  6. After the 3 minute run time the engine speed should return to normal. NOTE: During the drive cycle monitor the DTC information with a scan tool to verify DTC P0506 and P0507 do not set. If DTC P0506 and P0507 set, clear the DTCs so the ECM can continue to learn. If the engine idle speed has not been learned the vehicle will need to be driven at speeds above 70 km/h (44 mph) with several decelerations and extended idles.
  7. After the drive cycle, the engine speed should return to normal. If the engine idle speed has not been learned, turn OFF the ignition for 60 s and repeat step 6.
  8. Once the engine speed has returned to normal, clear DTCs and return to the diagnostic that referred you here.

Crankshaft Position System Variation Learn

Note. The Crankshaft Position Variation Learn procedure is also required when the following service procedures have been performed, regardless of whether DTC P0315 is set: An engine replacement An engine control module (ECM) replacement A crankshaft balancer replacement A crankshaft replacement A crankshaft position sensor replacement Any engine repairs which disturb the crankshaft to crankshaft position sensor relationship.

Note. The ECM monitors certain component signals to determine if all the conditions are met to continue with the Crankshaft Position Variation Learn procedure.

  1. Ignition ON, observe the DTC information with a scan tool. Verify no other DTCs are set, except DTCs P0300-P0304, or P0315. If DTCs are set, except DTCs P0300-P0304, or P0315, refer to «Diagnostic Trouble Code (DTC) List - Vehicle»(/buick/regal/v-2009-2013/remont/oem-general-information/#vehicle-diagnostic-information-diagnostic-information-and-procedures__diagnostic-trouble-code-dtc-list) for further diagnosis.
  2. Select the Crankshaft Position Variation Learn Procedure with a scan tool and perform the following: NOTE: Close the hood. NOTE: The engine must be at operating temperature. Block drive wheels. Set parking brake. DO NOT apply brake pedal. Turn the air conditioning (A/C) OFF. When directed, apply and hold brake pedal for the duration of the procedure. Ignition ON, engine running at operating temperature. The vehicle must remain in Park or Neutral. 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. Accelerate to wide open throttle (WOT) and release when the fuel cut-off occurs.
  3. The scan tool displays Learn In Progress.
  4. The scan tool displays Learn Successful.
  5. Verify DTC P0315 ran and passed This Ignition Cycle. If DTC P0315 failed or did not run This Ignition Cycle, or another DTC is present, refer to «Diagnostic Trouble Code (DTC) List - Vehicle»(/buick/regal/v-2009-2013/remont/oem-general-information/#vehicle-diagnostic-information-diagnostic-information-and-procedures__diagnostic-trouble-code-dtc-list) for the applicable DTC that set.
  6. Once the Crankshaft Position Variation Learn procedure has successfully completed, and in order to store the crankshaft position variation values in the ECM, turn OFF the ignition and verify all vehicle systems are OFF. This may take up to 2 minutes.

Scheme 77

Scheme 77: Engine Control Module Replacement
Scheme 77: Engine Control Module Replacement
CalloutComponent Name
Preliminary Procedure Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
1Engine Control Module Retainer (Qty: 3) Procedure Disconnect the electrical connector. Pull up the engine control module from the battery box. Open with caution both retainers at the sides and pull the engine control module outside the bracket.
2Engine Control Module 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. Procedure Refer to Control Module References for programming and set up of the engine control module. 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 .
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 .

Engine Control Module Replacement

Scheme 78

Scheme 78: Engine Coolant Temperature Sensor Replacement
Scheme 78: Engine Coolant Temperature Sensor Replacement
CalloutComponent Name
Preliminary Procedures Remove the intake manifold cover. Refer to Intake Manifold Cover Replacement . Drain the cooling system. Refer to Cooling System Draining and Filling (Static Fill) , Cooling System Draining and Filling (GE 47716) .
1Engine Coolant Temperature Sensor CAUTION: Refer to Fastener Caution . Procedure Use a new gasket. Disconnect the electrical connector. Tighten 20 N.m (15 lb ft)
CAUTION
Refer to Fastener Caution .

Engine Coolant Temperature Sensor Replacement

Scheme 79

Scheme 79: Mass Airflow Sensor with Intake Air Temperature Sensor Replacement
Scheme 79: Mass Airflow Sensor with Intake Air Temperature Sensor Replacement
CalloutComponent Name
1Mass Airflow Sensor Screws (Qty: 2) CAUTION: Refer to Fastener Caution .
2Mass Airflow Sensor Procedure Disconnect the electrical sensor.
CAUTION
Refer to Fastener Caution .

Mass Airflow Sensor with Intake Air Temperature Sensor Replacement

Scheme 80

Scheme 80: Manifold Absolute Pressure Sensor Replacement
Scheme 80: Manifold Absolute Pressure Sensor Replacement
CalloutComponent Name
Preliminary Procedure Remove the intake manifold cover. Refer to Intake Manifold Cover Replacement .
1Manifold Absolute Pressure Sensor Fastener (Qty: 2) CAUTION: Refer to Fastener Caution . Procedure Disconnect the electrical connector. Tighten 4 N.m (36 lb in)
2Manifold Absolute Pressure Sensor
CAUTION
Refer to Fastener Caution .

Manifold Absolute Pressure Sensor Replacement

Scheme 81

Scheme 81: Heated Oxygen Sensor Replacement - Sensor 1
Scheme 81: Heated Oxygen Sensor Replacement - Sensor 1
CalloutComponent Name
Preliminary Procedure Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
1Heated Oxygen Sensor 1 Fastener CAUTION: Refer to Fastener Caution . Procedure Disconnect the electrical connector. Release the retainer. Remove the heated oxygen sensor 1 with CH-6179 remover/installer and GE-611 wrench. Tighten 42 N.m (31 lb ft) Special Tools CH-6179 Oxygen Sensor Wrench Remover/Installer GE-611 Torque Wrench 3/8" For equivalent regional tools, refer to Special Tools (Diagnostic Tools) .
CAUTION
Refer to Fastener Caution .

Heated Oxygen Sensor Replacement - Sensor 1

Scheme 82

Scheme 82: Heated Oxygen Sensor Replacement - Sensor 2
Scheme 82: Heated Oxygen Sensor Replacement - Sensor 2
CalloutComponent Name
Preliminary Procedure Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
1Heated Oxygen Sensor 2 Fastener Procedure Disconnect the electrical connector. Release the retainer. Remove the heated oxygen sensor 2 with CH-6179 remover/installer and GE-611 wrench. Tighten 42 N.m (31 lb ft) Special Tools CH-6179 Oxygen Sensor Wrench Remover/Installer GE-611 Torque Wrench 3/8" For equivalent regional tools, refer to Special Tools (Diagnostic Tools) .

Heated Oxygen Sensor Replacement - Sensor 2

Scheme 83

Scheme 83: Accelerator Pedal Position Sensor Replacement
Scheme 83: Accelerator Pedal Position Sensor Replacement
CalloutComponent Name
1Accelerator Pedal Position Sensor Fastener CAUTION: Refer to Fastener Caution . Tighten 10 N.m (89 lb in)
2Accelerator Pedal Position Sensor
CAUTION
Refer to Fastener Caution .

Accelerator Pedal Position Sensor Replacement

Scheme 84

Scheme 84: Throttle Inlet Absolute Pressure Sensor Replacement
Scheme 84: Throttle Inlet Absolute Pressure Sensor Replacement
CalloutComponent Name
1Throttle Inlet Absolute Pressure Sensor Fastener CAUTION: Refer to Fastener Caution . Tighten 4 N.m (35 lb in)
2Throttle Inlet Absolute Pressure Sensor Procedure Disconnect the electrical connector.
CAUTION
Refer to Fastener Caution .

Throttle Inlet Absolute Pressure Sensor Replacement

Scheme 85

Scheme 85: Throttle Body Assembly Replacement
Scheme 85: Throttle Body Assembly Replacement
CalloutComponent Name
Preliminary Procedures Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection . Release the charge air cooler outlet pipe. Refer to Charge Air Cooler Outlet Pipe Replacement .
1Throttle Body Assembly Fastener (Qty: 4) CAUTION: Refer to Fastener Caution . Tighten 10 N.m (89 lb in)
2Throttle Body Procedure Disconnect the electrical connector.
CAUTION
Refer to Fastener Caution .

Throttle Body Assembly Replacement

Throttle Body Cleaning

WARNINGTurn OFF the ignition before inserting fingers into the throttle bore. Unexpected movement of the throttle blade could cause personal injury.
CAUTIONDo not insert any tools into the throttle body bore in order to avoid damage to the throttle valve plate.
CAUTIONDo not use any solvent that contains Methyl Ethyl Ketone (MEK). This solvent may damage fuel system components.
  1. Remove the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(/buick/regal/v-2009-2013/remont/testing-diagnostics/#engine-controlsfuel-24l-repair-instructions) .
  2. Inspect the throttle body bore and the throttle valve plate for deposits. You must open the throttle valve in order to inspect all of the surfaces.
  3. Clean the throttle body bore and the throttle valve plate using a clean shop towel with Top Engine Cleaner P/N 1052626 (Canadian P/N 993026), ACDelco® P/N X66, or an equivalent product.
  4. Install the air cleaner outlet duct. Refer to «Air Cleaner Outlet Duct Replacement»(/buick/regal/v-2009-2013/remont/testing-diagnostics/#engine-controlsfuel-24l-repair-instructions) .
  5. Perform the throttle/idle learn procedure. Refer to «Throttle/Idle Learn»(/buick/regal/v-2009-2013/remont/testing-diagnostics/#engine-controlsfuel-24l-repair-instructions) .

Fuel Pressure Relief

WARNINGRemove 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. If the fuel system requires repair, prevent fuel spillage by removing the fuel pump fuse. Refer to «Electrical Center Identification Views»(/buick/regal/v-2009-2013/remont/electrical-component-locations/#wiring-systems-and-power-management-component-locator-electrical-center-identification-views) .
  2. Loosen the fuel fill cap in order to relieve the fuel tank vapor pressure.
  3. Remove the engine cover, if required.
  4. Remove the fuel rail service port cap.
  5. Wrap a shop towel around the fuel rail service port and using a small flat-bladed tool, depress (open) the fuel rail test port valve.
  6. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container.
  7. Install the fuel rail service port cap.
  8. Install the engine cover, if required.
  9. Tighten the fuel fill cap.

Special Tools

CH-48027-100 Digital Pressure Gauge

For equivalent regional tools, refer to Special Tools (Diagnostic Tools) .

Installation Procedure

WARNINGRemove 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. Relieve the fuel system pressure. Refer to «Fuel Pressure Relief»(/buick/regal/v-2009-2013/remont/testing-diagnostics/#engine-controlsfuel-24l-repair-instructions__fuel-pressure-relief) .
  2. Connect the CH-48027-1 (1) to the CH-48027-2 (2).
  3. Remove the shop towel from around the fuel pump feed pipe service port, and place in an approved gasoline container.
  4. Perform any tests and/or diagnostics as needed. For the proper usage of the «CH-48027-100»(/buick/regal/v-2009-2013/remont/oem-general-information/#general-information-special-tools) , refer to the manufacture's directions.

Removal Procedure

  1. Relieve the fuel system pressure, if required. Perform the following steps: Wrap a shop towel around the fuel pump feed pipe service port. Place the hose on the CH-48027-2 (2) into an approved gasoline container. Open the valve on the CH-48027-2 (2) in order to bleed any fuel from the fuel rail. Close the valve on the CH-48027-2 (2). Remove the hose on the CH-48027-2 (2) from the approved gasoline container. Remove the shop towel from around the fuel rail service port, and place in an approved gasoline container.
  2. Disconnect the CH-48027-1 (1) from the CH-48027-2 (2).
  3. Disconnect the CH-48027-2 (2) from the CH-48027-3 (3).
  4. Disconnect the CH-48027-3 (3) from the fuel Pump feed pipe service port.
  5. Install the service port cap.
  6. Install the engine cover, if required.
  7. Tighten the fuel fill cap.

Special Tool

EN 41769 Fuel Line Disconnect Tool Set

  1. Relieve the fuel system pressure before servicing any fuel system connection. Refer to the «Fuel Pressure Relief»(/buick/regal/v-2009-2013/remont/testing-diagnostics/#engine-controlsfuel-24l-repair-instructions__fuel-pressure-relief) .
  2. Remove the retainer from the quick-connect fitting.
  3. Blow dirt out of the fitting using compressed air.
  4. Choose the correct tool from the EN 41769 set for the size of the fitting. Insert the tool into the female connector, then push inward in order to release the locking tabs.
  5. Pull the connection apart.
  6. Use a clean shop towel in order to wipe off the male pipe end.
  7. Inspect both ends of the fitting for dirt and burrs. Clean or replace the components as required.
  1. Apply a few drops of clean engine oil to the male pipe end.
  2. Push both sides of the fitting together in order to snap the retaining tabs into place.
  3. Once installed, pull on both sides of the fitting in order to make sure the connection is secure.
  4. Install the retainer to the quick-connect fitting.
  1. Relieve the fuel system pressure before servicing any fuel system connection. Refer to the «Fuel Pressure Relief»(/buick/regal/v-2009-2013/remont/testing-diagnostics/#engine-controlsfuel-20l-repair-instructions__fuel-pressure-relief) .
  2. Using compressed air, blow any dirt out of the quick-connect fitting.
  3. This step applies to Bartholomew style connectors ONLY. Squeeze the plastic quick-connect fitting release tabs.
  4. This step applies to Q Release style connectors ONLY. Release the fitting by Pushing the tab toward the other side of the slot in the fitting.
  5. This step applies to Squeeze to Release style connectors ONLY. Squeeze where indicated by arrows on both sides of the plastic ring surrounding the quick-connect fitting.
  6. This step applies to Squeeze to Release style connectors ONLY. Push in the male side slightly in order to slide the retainer away from the retainers, squeeze where indicated by arrows on both sides of the plastic ring surrounding the quick-connect fitting.
  7. This step applies to Sliding Retainer style connectors ONLY. Release the fitting by pressing on one side of the release tab causing it to push in slightly. If the tab doesn't move try pressing the tab in from the opposite side. The tab will only move in one direction.
  8. This step applies to the Global Connector style only. Push the connector toward the tube in order to release the pressure. Press and hold down the release mechanism, and pull the connector straight out.
  9. This step applies to the TI Loc style only. Push the connector toward the tube in order to release the pressure. Release the redundant latch (1) with two fingers or a flat bladed tool. Then press and hold down the bottom release mechanism (2) and pull the connector straight out.
  10. This step applies to the Safe Lock style only. Push the connector toward the tube in order to release the pressure. Release the second latch (1) with two fingers. Then press and hold down the bottom release mechanism (2) and pull the connector straight out.
  11. Using a clean shop towel, wipe off the male pipe end.
  12. Inspect both ends of the fitting for dirt and burrs.
  13. Clean or replace components as necessary.
  1. Apply a few drops of clean engine oil to the male pipe end.
  2. Push both sides of the quick-connect fitting together in order to cause the retaining feature to snap into place.
  3. Pull on both sides of the quick-connect fitting to make sure the connection is secure.
  4. Insert the tube in the connector until the retainer snaps in place.
  5. Push down on the redundant latch (1) until it is fully engaged and snapped into position.
  6. Insert the tube in the connector until the retainer snaps in place.
  7. Push down on the second latch (1) in order to secure the connection.
  8. Inspect for leaks using the following procedure: Turn the ignition ON, with the engine OFF for 2 seconds. Turn the ignition OFF, for 10 seconds. Turn the ignition ON, with the engine OFF for 2 seconds. Turn the ignition OFF. Inspect for leaks.

Fuel Tank Draining (Non E-85)

Special Tool

CH 45004 Fuel Tank Drain Hose

WARNINGNever 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.
WARNINGPlace 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. Remove the fuel fill cap.
  2. Insert the CH 45004 hose into the fuel tank until the bottom is reached.
  3. Use a hand or air operated pump device in order to drain as much fuel through the fuel fill pipe as possible.

Scheme 86

Scheme 86: Fuel Tank Protector Replacement
Scheme 86: Fuel Tank Protector Replacement
CalloutComponent Name
Preliminary Procedure Remove the left fuel tank strap. Refer to Fuel Tank Replacement .
1Fuel Tank Protector Retainer (Qty: 3)
2Fuel Tank Protector

Fuel Tank Protector Replacement

  1. Relieve the system fuel pressure. Refer to «Fuel Pressure Relief»(/buick/regal/v-2009-2013/remont/testing-diagnostics/#engine-controlsfuel-20l-repair-instructions__fuel-pressure-relief) .
  2. Drain the fuel tank. Refer to «Fuel Tank Draining (Non E-85)»(/buick/regal/v-2009-2013/remont/testing-diagnostics/#engine-controlsfuel-20l-repair-instructions__fuel-tank-draining-non-e-85) .
  3. Disconnect the evaporative emission and fuel pipes (1). Refer to «Plastic Collar Quick Connect Fitting Service»(/buick/regal/v-2009-2013/remont/testing-diagnostics/#engine-controlsfuel-20l-repair-instructions) .
  4. Disconnect the fuel pressure sensor electrical connector (2).
  5. Loosen the hose clamps (1) and remove the filler tube (2).
  6. Disconnect the fuel tank harness electrical connector (1).
  7. Support the fuel tank with a suitable jack.
  8. Remove the fuel tank strap bolts (1).
  9. Swing the fuel tank straps (1) out of the way.
  10. Remove the fuel tank (1).
  11. Remove the following components if replacing just the fuel tank. Fuel tank fuel pump module. Refer to «Fuel Tank Fuel Pump Module Replacement (NU6)»(/buick/regal/v-2009-2013/remont/testing-diagnostics/#engine-controlsfuel-20l-repair-instructions) , «Fuel Tank Fuel Pump Module Replacement (NT7)»(/buick/regal/v-2009-2013/remont/testing-diagnostics/#engine-controlsfuel-20l-repair-instructions) . Evaporative emission carbon canister. Refer to «Evaporative Emission Canister Replacement»(/buick/regal/v-2009-2013/remont/testing-diagnostics/#engine-controlsfuel-20l-repair-instructions) . Transfer components as necessary.
  1. Install the following components if fuel tank replacement was necessary: Fuel tank fuel pump module. Refer to «Fuel Tank Fuel Pump Module Replacement (NU6)»(/buick/regal/v-2009-2013/remont/testing-diagnostics/#engine-controlsfuel-20l-repair-instructions) , «Fuel Tank Fuel Pump Module Replacement (NT7)»(/buick/regal/v-2009-2013/remont/testing-diagnostics/#engine-controlsfuel-20l-repair-instructions) . Evaporative emission carbon canister. Refer to «Evaporative Emission Canister Replacement»(/buick/regal/v-2009-2013/remont/testing-diagnostics/#engine-controlsfuel-20l-repair-instructions) .
  2. Use a suitable jack and install the fuel tank (1).
  3. Reposition the fuel tank straps (1).
  4. Install the fuel tank strap bolts (1) and tighten to 27 N.m (20 lb ft).
  5. Connect the fuel tank harness electrical connector (1).
  6. Install the filler tube (2) and tighten the hose clamps (1) to 4Y(35 lb in).
  7. Connect the evaporative emission line (3). Refer to «Plastic Collar Quick Connect Fitting Service»(/buick/regal/v-2009-2013/remont/testing-diagnostics/#engine-controlsfuel-20l-repair-instructions) .
  8. Connect the evaporative emission and fuel pipes (1). Refer to «Plastic Collar Quick Connect Fitting Service»(/buick/regal/v-2009-2013/remont/testing-diagnostics/#engine-controlsfuel-20l-repair-instructions) .
  9. Connect the fuel pressure sensor electrical connector (2).
  10. Refill the fuel tank.
  11. Inspect for fuel leaks.

Scheme 87

Scheme 87: Fuel Tank Pressure Sensor Replacement
Scheme 87: Fuel Tank Pressure Sensor Replacement
CalloutComponent Name
1Fuel Tank Pressure Sensor Procedure Disconnect the electrical connector.

Fuel Tank Pressure Sensor Replacement

J 45722 Fuel Sender Lock Ring Wrench

For equivalent regional tools, refer to Special Tools (Diagnostic Tools) .

  1. Remove the fuel tank. Refer to «Fuel Tank Replacement»(/buick/regal/v-2009-2013/remont/testing-diagnostics/#engine-controlsfuel-20l-repair-instructions) .
  2. Disconnect the fuel pump electrical connector (1) and the quick connects (2). Refer to «Plastic Collar Quick Connect Fitting Service»(/buick/regal/v-2009-2013/remont/testing-diagnostics/#engine-controlsfuel-20l-repair-instructions) .
  3. Use the J 45722 wrench by turning counter clockwise and remove the lock ring (1).
  4. Remove the fuel tank module (1) and the O-ring (2).
  1. Install a NEW seal (2) and the fuel tank module (1).
  2. Use the J 45722 wrench by turning clockwise and install the lock ring (1).
  3. Connect the fuel pump electrical connector (1) and the quick connects (2). Refer to «Plastic Collar Quick Connect Fitting Service»(/buick/regal/v-2009-2013/remont/testing-diagnostics/#engine-controlsfuel-20l-repair-instructions) .
  4. Install the fuel tank. Refer to «Fuel Tank Replacement»(/buick/regal/v-2009-2013/remont/testing-diagnostics/#engine-controlsfuel-20l-repair-instructions) .

J 45722 Fuel Sender Lock Ring Wrench

For equivalent regional tools, refer to Special Tools (Diagnostic Tools) .

  1. Remove the fuel tank. Refer to «Fuel Tank Replacement»(/buick/regal/v-2009-2013/remont/testing-diagnostics/#engine-controlsfuel-20l-repair-instructions) .
  2. Disconnect the fuel pump electrical connector (1) and the quick connects (2). Refer to «Plastic Collar Quick Connect Fitting Service»(/buick/regal/v-2009-2013/remont/testing-diagnostics/#engine-controlsfuel-20l-repair-instructions) .
  3. Use the J 45722 wrench by turning counter clockwise and remove the lock ring (1).
  4. Remove the fuel tank module (1) and the O-ring (2).
  1. Install a NEW seal (2) and the fuel tank module (1).
  2. Use the J 45722 wrench by turning clockwise and install the lock ring (1).
  3. Connect the fuel pump electrical connector (1) and the quick connects (2). Refer to «Plastic Collar Quick Connect Fitting Service»(/buick/regal/v-2009-2013/remont/testing-diagnostics/#engine-controlsfuel-20l-repair-instructions) .
  4. Install the fuel tank. Refer to «Fuel Tank Replacement»(/buick/regal/v-2009-2013/remont/testing-diagnostics/#engine-controlsfuel-20l-repair-instructions) .

Scheme 88

Scheme 88: Fuel Pressure Sensor Replacement - Fuel Feed Pipe
Scheme 88: Fuel Pressure Sensor Replacement - Fuel Feed Pipe
CalloutComponent Name
Preliminary Procedures Relieve the fuel system pressure. Refer to Fuel Pressure Relief . Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
1Fuel Pressure Sensor CAUTION: Refer to Fastener Caution . Procedure Disconnect the electrical connector. Use a NEW O-ring whenever the sensor is removed. Tighten 9Y (80 lb in)
CAUTION
Refer to Fastener Caution .

Fuel Pressure Sensor Replacement - Fuel Feed Pipe

Fuel System Cleaning

  1. Remove the fuel tank. Refer to «Fuel Tank Replacement»(/buick/regal/v-2009-2013/remont/testing-diagnostics/#engine-controlsfuel-24l-repair-instructions) .
  2. Remove the fuel pump module. Refer to «Fuel Tank Fuel Pump Module Replacement (NT7)»(/buick/regal/v-2009-2013/remont/testing-diagnostics/#engine-controlsfuel-24l-repair-instructions) , «Fuel Tank Fuel Pump Module Replacement (NU6)»(/buick/regal/v-2009-2013/remont/testing-diagnostics/#engine-controlsfuel-24l-repair-instructions) .
  3. Inspect the fuel pump module strainer. Replace the pump module assembly if the fuel strainer is contaminated.
  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 «Metal Collar Quick Connect Fitting Service»(/buick/regal/v-2009-2013/remont/testing-diagnostics/#engine-controlsfuel-24l-repair-instructions) .
  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 «Metal Collar Quick Connect Fitting Service»(/buick/regal/v-2009-2013/remont/testing-diagnostics/#engine-controlsfuel-24l-repair-instructions) .
  10. Install the fuel pump module. Refer to «Fuel Tank Fuel Pump Module Replacement (NT7)»(/buick/regal/v-2009-2013/remont/testing-diagnostics/#engine-controlsfuel-24l-repair-instructions) , «Fuel Tank Fuel Pump Module Replacement (NU6)»(/buick/regal/v-2009-2013/remont/testing-diagnostics/#engine-controlsfuel-24l-repair-instructions) .
  11. Install the fuel tank. Refer to «Fuel Tank Replacement»(/buick/regal/v-2009-2013/remont/testing-diagnostics/#engine-controlsfuel-24l-repair-instructions) .

Scheme 89

Scheme 89: Fuel Feed Pipe Replacement (LTD)
Scheme 89: Fuel Feed Pipe Replacement (LTD)
CalloutComponent Name
1Fuel Feed Pipe Retainer (Qty: 8) Refer to Plastic Collar Quick Connect Fitting Service .
2Fuel Feed Pipe

Fuel Feed Pipe Replacement (LTD)

  1. EN-796-A Remover
  2. GE-611 Torque Wrench
  3. GE-6600-207 Installer

For equivalent regional tools, refer to Special Tools (Diagnostic Tools) .

  1. Relieve the fuel pressure. Refer to «Fuel Pressure Relief»(/buick/regal/v-2009-2013/remont/testing-diagnostics/#engine-controlsfuel-20l-repair-instructions__fuel-pressure-relief) .
  2. Remove intake manifold cover. Refer to «Intake Manifold Cover Replacement»(/buick/regal/v-2009-2013/remont/mechanical/#engine-mechanical-20l-repair-instructions-on-vehicle) .
  3. Remove the fastener (1) from the fuel pump module (2) with EN-796-A remover.
  4. Remove the fuel feed pipe plastic (3) with EN-796-A remover from the fuel feed pipe metal (4).
  5. Remove the 2 fasteners (1) and get out the fuel feed pipe metal (2).
  1. Install the 2 fasteners (1) to the intake manifold but do not tighten yet.
  2. Install the fastener (2) to the fuel pump module and tighten to 30 N.m (22 lb ft)with GE-6600-207 installer and GE-611 wrench.
  3. Tighten the 2 fasteners (1) to 7 N.m (62 lb in).
  4. Install the fuel feed pipe plastic to the fuel feed pipe metal.

Scheme 90

Scheme 90: Fuel Feed Intermediate Pipe Replacement
Scheme 90: Fuel Feed Intermediate Pipe Replacement
CalloutComponent Name
Preliminary Procedures Relieve the fuel pressure. Refer to Fuel Pressure Relief . Remove the intake manifold cover. Refer to Intake Manifold Cover Replacement .
1Fuel Feed Intermediate Pipe Fastener (Qty: 2) CAUTION: Refer to Fastener Caution . Tighten 30 N.m (22 lb ft)
2Fuel Feed Intermediate Pipe
CAUTION
Refer to Fastener Caution .

Fuel Feed Intermediate Pipe Replacement

Scheme 91

Scheme 91: Fuel Injection Fuel Rail Fuel Pressure Sensor Replacement
Scheme 91: Fuel Injection Fuel Rail Fuel Pressure Sensor Replacement
CalloutComponent Name
Preliminary Procedures Remove the intake manifold cover. Refer to Intake Manifold Cover Replacement . Remove the radiator inlet hose. Refer to Radiator Inlet Hose Replacement (LUK) , Radiator Inlet Hose Replacement (LHU) , Radiator Inlet Hose Replacement (LEA) .
1Fuel Injection Fuel Rail Fuel Pressure Sensor CAUTION: Refer to Fastener Caution . Procedure Disconnect the electrical connector. Tighten 33 N.m (25 lb ft)
CAUTION
Refer to Fastener Caution .

Fuel Injection Fuel Rail Fuel Pressure Sensor Replacement

Scheme 92

Scheme 92: Fuel Pump Replacement
Scheme 92: Fuel Pump Replacement
CalloutComponent Name
WARNING: Relieve the fuel system pressure before servicing fuel system components in order to reduce the risk of fire and personal injury. After relieving the system pressure, a small amount of fuel may be released when servicing the fuel lines or connections. In order to reduce the chance of personal injury, cover the regulator and the fuel line fittings with a shop towel before disconnecting. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete. Preliminary Procedures Remove the intake manifold cover. Refer to Intake Manifold Cover Replacement . Remove the fuel feed intermediate pipe. Refer to Fuel Feed Intermediate Pipe Replacement . Release the fuel feed pipe - metal. Refer to Fuel Feed Pipe Replacement (LDK) , Fuel Feed Pipe Replacement (LTD) .
1Fuel Pump Module Fastener (Qty: 2) CAUTION: Refer to Fastener Caution . Tighten 15 N.m (11 lb ft)
2Fuel Pump Module Procedure Haul the fuel pump insulator of the fuel pump module. Disconnect the electrical connector.
WARNING
Relieve the fuel system pressure before servicing fuel system components in order to reduce the risk of fire and personal injury. After relieving the system pressure, a small amount of fuel may be released when servicing the fuel lines or connections. In order to reduce the chance of personal injury, cover the regulator and the fuel line fittings with a shop towel before disconnecting. This will catch any fuel that may leak out. Place the towel in an approved container when the disconnection is complete.
CAUTION
Refer to Fastener Caution .

Fuel Pump Replacement

Scheme 93

Scheme 93: Direct Fuel Injector Replacement
Scheme 93: Direct Fuel Injector Replacement
CalloutComponent Name
Preliminary Procedure Remove the fuel injection fuel rail assembly. Refer to Fuel Injection Fuel Rail Assembly Replacement .
1Direct Fuel Injector Procedure Disconnect the electrical connector.
2Direct Fuel Injector Procedure Remove the injector with EN-37281-A injector remover and DT-2619-01 slide hammer. Special Tools EN-37281-A Injector Remover DT-2619-01 Slide Hammer For equivalent regional tools, refer to Special Tools (Diagnostic Tools) .

Direct Fuel Injector Replacement

Scheme 94

Scheme 94: Evaporative Emission Canister Purge Solenoid Valve Replacement
Scheme 94: Evaporative Emission Canister Purge Solenoid Valve Replacement
CalloutComponent Name
Preliminary Procedure Remove the intake manifold cover. Refer to Intake Manifold Cover Replacement .
1Evaporative Emission Canister Purge Solenoid Valve Fastener CAUTION: Refer to Fastener Caution . Procedure Disconnect the electrical connector Tighten 4 N.m (36 lb in)
2Evaporative Emission Canister Purge Solenoid Valve
CAUTION
Refer to Fastener Caution .

Evaporative Emission Canister Purge Solenoid Valve Replacement

Scheme 95

Scheme 95: Evaporative Emission Canister Vent Solenoid Valve Replacement
Scheme 95: Evaporative Emission Canister Vent Solenoid Valve Replacement
CalloutComponent Name
Preliminary Procedure Remove the canister. Refer to Evaporative Emission Canister Replacement .
1Evaporative Emission Canister Vent Solenoid Valve

Evaporative Emission Canister Vent Solenoid Valve Replacement

Scheme 96

Scheme 96: Evaporative Emission Canister Replacement
Scheme 96: Evaporative Emission Canister Replacement
CalloutComponent Name
Preliminary Procedure Remove the fuel tank. Refer to Fuel Tank Replacement . Disconnect the evaporative pipes at the canister. Refer to Plastic Collar Quick Connect Fitting Service .
1Evaporative Emission Canister Procedure Disconnect the canister purge solenoid harness connector. Release the retaining tab and pull upwards to remove.

Evaporative Emission Canister Replacement

Scheme 97

Scheme 97: Ignition Coil Replacement
Scheme 97: Ignition Coil Replacement
CalloutComponent Name
Preliminary Procedure Remove the intake manifold cover. Refer to Intake Manifold Cover Replacement .
1Ignition Coil Fastener CAUTION: Refer to Fastener Caution Procedure Disconnect the electrical connector. Tighten 10 N.m (89 lb in)
2Ignition Coil
CAUTION
Refer to Fastener Caution

Ignition Coil Replacement

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.
  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

Spark Plug Inspection

  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.
  2. 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.
  3. Inspect the insulator (2) for cracks. All or part of the electrical charge may arc through the crack instead of the electrodes (3, 4).
  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»(/buick/regal/v-2009-2013/remont/testing-diagnostics/#engine-controlsfuel-20l-specifications__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»(/buick/regal/v-2009-2013/remont/testing-diagnostics/#engine-controlsfuel-20l-specifications__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. 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
  3. Excessive idling or slow speeds under light loads can keep spark plug temperatures so low that normal combustion deposits may not burn off.
  4. 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.

Scheme 98

Scheme 98: Spark Plug Replacement
Scheme 98: Spark Plug Replacement
CalloutComponent Name
Preliminary Procedure Remove the ignition coil. Refer to Ignition Coil Replacement .
1Spark Plug CAUTION: Refer to Fastener Caution . Tighten 20 N.m (15 lb ft)
CAUTION
Refer to Fastener Caution .

Spark Plug Replacement

Scheme 99

Scheme 99: Crankshaft Position Sensor Replacement
Scheme 99: Crankshaft Position Sensor Replacement
CalloutComponent Name
Preliminary Procedures Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection . Remove the starter motor. Refer to Starter Replacement (LDK Or LHU) , Starter Replacement (LEA) .
1Crankshaft Position Sensor Fastener CAUTION: Refer to Fastener Caution . Procedure Disconnect the electrical connector. Tighten 10 N.m (89 lb in)
2Crankshaft Position Sensor
CAUTION
Refer to Fastener Caution .

Crankshaft Position Sensor Replacement

Scheme 100

Scheme 100: Camshaft Position Sensor Replacement - Intake
Scheme 100: Camshaft Position Sensor Replacement - Intake
CalloutComponent Name
Preliminary Procedure Disconnect the battery negative cable. Refer to Battery Negative Cable Disconnection and Connection .
1Camshaft Position Sensor Fastener CAUTION: Refer to Fastener Caution . Procedure Disconnect the electrical connector. Tighten 10 N.m (89 lb in)
2Camshaft Position Sensor
CAUTION
Refer to Fastener Caution .

Camshaft Position Sensor Replacement - Intake

Scheme 101

Scheme 101: Camshaft Position Sensor Replacement - Exhaust
Scheme 101: Camshaft Position Sensor Replacement - Exhaust
CalloutComponent Name
Preliminary Procedure Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
1Camshaft Position Sensor Fastener CAUTION: Refer to Fastener Caution . Procedure Disconnect the electrical connector. Tighten 10 N.m (89 lb in)
2Camshaft Position Sensor
CAUTION
Refer to Fastener Caution .

Camshaft Position Sensor Replacement - Exhaust

Scheme 102

Scheme 102: Camshaft Position Actuator Solenoid Valve Replacement (Exhaust)
Scheme 102: Camshaft Position Actuator Solenoid Valve Replacement (Exhaust)
CalloutComponent Name
Preliminary Procedures Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection . Remove the intake manifold cover. Refer to Intake Manifold Cover Replacement .
1Camshaft Position Actuator Solenoid Valve Fastener CAUTION: Refer to Fastener Caution . Procedure Disconnect the electrical connector. Tighten 10 N.m (89 lb in)
2Camshaft Position Actuator Solenoid Valve
CAUTION
Refer to Fastener Caution .

Camshaft Position Actuator Solenoid Valve Replacement (Exhaust)

Scheme 103

Scheme 103: Camshaft Position Actuator Solenoid Valve Replacement (Intake)
Scheme 103: Camshaft Position Actuator Solenoid Valve Replacement (Intake)
CalloutComponent Name
Preliminary Procedures Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection . Remove the intake manifold cover. Refer to Intake Manifold Cover Replacement .
1Camshaft Position Actuator Solenoid Valve Fastener CAUTION: Refer to Fastener Caution . Procedure Disconnect the electrical connector. Tighten 10 N.m (89 lb in)
2Camshaft Position Actuator Solenoid Valve
CAUTION
Refer to Fastener Caution .

Camshaft Position Actuator Solenoid Valve Replacement (Intake)

Scheme 104

Scheme 104: Knock Sensor Replacement (Right Side)
Scheme 104: Knock Sensor Replacement (Right Side)
CalloutComponent Name
Preliminary Procedures Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection . Remove the oil level indicator and tube.
1Knock Sensor Fastener CAUTION: Refer to Fastener Caution . Procedure Disconnect the electrical connector. Tighten 25 N.m (18 lb ft)
2Knock Sensor
CAUTION
Refer to Fastener Caution .

Knock Sensor Replacement (Right Side)

Scheme 105

Scheme 105: Knock Sensor Replacement (Left Side)
Scheme 105: Knock Sensor Replacement (Left Side)
CalloutComponent Name
Preliminary Procedure Disconnect the negative battery cable. Refer to Battery Negative Cable Disconnection and Connection .
1Knock Sensor Fastener CAUTION: Refer to Fastener Caution . Tighten 25Y (18 lb in)
2Knock Sensor Procedure Disconnect the electrial connector.
CAUTION
Refer to Fastener Caution .

Knock Sensor Replacement (Left Side)

Scheme 106

Scheme 106: Intake Air Pressure and Temperature Sensor Replacement
Scheme 106: Intake Air Pressure and Temperature Sensor Replacement
CalloutComponent Name
1Intake Air Pressure and Temperature Sensor Fastener (Qty: 2) CAUTION: Refer to Fastener Caution . Procedure Disconnect the electrical connector. Tighten 7 N.m (62 lb in)
2Intake Air Pressure and Temperature Sensor
CAUTION
Refer to Fastener Caution .

Intake Air Pressure and Temperature Sensor Replacement

Scheme 107

Scheme 107: Charge Air Bypass Valve Replacement
Scheme 107: Charge Air Bypass Valve Replacement
CalloutComponent Name
Preliminary Procedure Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement .
1Charge Air Bypass Fastener (Qty: 3) CAUTION: Refer to Fastener Caution . Procedure Disconnect the vacuum hose. Tighten 10 N.m (89 lb in)
2Charge Air Bypass Valve
3Charge Air Bypass Valve Diaphragm Spring
4Charge Air Bypass Valve
CAUTION
Refer to Fastener Caution .

Charge Air Bypass Valve Replacement

Scheme 108

Scheme 108: Charge Air Bypass Valve Vacuum Tank Replacement
Scheme 108: Charge Air Bypass Valve Vacuum Tank Replacement
CalloutComponent Name
Preliminary Procedure Remove the intake manifold cover. Refer to Intake Manifold Cover Replacement .
1Vacuum Pipe (Qty: 2) Procedure Release the vacuum hose from charger air bypass valve vacuum tank.
2Charge Air Bypass Valve Vacuum Tank Fastener (Qty: 2) CAUTION: Refer to Fastener Caution . Tighten 10 N.m (89 lb in)
3Charge Air Bypass Valve Vacuum Tank
CAUTION
Refer to Fastener Caution .

Charge Air Bypass Valve Vacuum Tank Replacement

Scheme 109

Scheme 109: Turbocharger Control Solenoid Valve Replacement
Scheme 109: Turbocharger Control Solenoid Valve Replacement
CalloutComponent Name
Preliminary Procedure Remove the intake manifold cover. Refer to Intake Manifold Cover Replacement .
1Turbocharger Control Solenoid Valve Replacement Clamp (Qty: 3) Procedure Remove the vacuum hose. Disconnect the electrical connector.

Turbocharger Control Solenoid Valve Replacement

Scheme 110

Scheme 110: Turbocharger Wastegate Regulator Solenoid Valve Replacement
Scheme 110: Turbocharger Wastegate Regulator Solenoid Valve Replacement
CalloutComponent Name
Preliminary Procedure Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement .
1Turbocharger Wastegate Regulator Solenoid Valve Fastener CAUTION: Refer to Fastener Caution . Procedure Disconnect the vacuum hoses. Tighten 10 N.m (89 lb in)
2Turbocharger Wastegate Regulator Solenoid Valve
CAUTION
Refer to Fastener Caution .

Turbocharger Wastegate Regulator Solenoid Valve Replacement

Turbocharger Wastegate Actuator Replacement

CalloutComponent Name
Preliminary Procedure Remove the air cleaner outlet duct. Refer to Air Cleaner Outlet Duct Replacement .
1Wastegate Actuator Bolt CAUTION: Refer to Fastener Caution . Procedure Disconnect the vacuum hose. Tighten 10 N.m (89 lb in)
2Turbocharger Wastegate Actuator
CAUTION
Refer to Fastener Caution .

Turbocharger Wastegate Actuator Replacement

Scheme 111

Scheme 111: Air Cleaner Element Replacement
Scheme 111: Air Cleaner Element Replacement
CalloutComponent Name
1Air Cleaner Assembly Screws (Qty: 5) CAUTION: Refer to Fastener Caution . Tighten 4 N.m (35 lb in)
2Air Cleaner Element
CAUTION
Refer to Fastener Caution .

Air Cleaner Element Replacement

Scheme 112

Scheme 112: Air Cleaner Assembly Replacement
Scheme 112: Air Cleaner Assembly Replacement
CalloutComponent Name
Preliminary Procedure Disconnect the outlet duct from the air cleaner assembly. Refer to Air Cleaner Outlet Duct Replacement .
1Air Cleaner Assembly Procedure Lift upwards to dislodge the rubber grommet. Transfer parts as necessary.

Air Cleaner Assembly Replacement

Scheme 113

Scheme 113: Air Cleaner Outlet Duct Replacement
Scheme 113: Air Cleaner Outlet Duct Replacement
CalloutComponent Name
Preliminary Procedure Disconnect the PCV connector. Refer to Plastic Collar Quick Connect Fitting Service .
1Air Cleaner Outlet Duct Clamp CAUTION: Refer to Fastener Caution . Tighten 4 N.m (35 lb in)
2Air Cleaner Outlet Duct
CAUTION
Refer to Fastener Caution .

Air Cleaner Outlet Duct Replacement

Scheme 114

Scheme 114: Charge Air Cooler Inlet Air Tube Replacement
Scheme 114: Charge Air Cooler Inlet Air Tube Replacement
CalloutComponent Name
1Charge Air Cooler Inlet Air Tube Fastener (Qty: 2) CAUTION: Refer to Fastener Caution . Tighten 22 N.m (16 lb ft)
2Charge Air Cooler Inlet Air Tube Fastener Tighten 10 N.m(89 lb in)
3Charge Air Cooler Inlet Air Tube Retaining Clip
4Charge Air Cooler Inlet Air Tube
CAUTION
Refer to Fastener Caution .

Charge Air Cooler Inlet Air Tube Replacement

Scheme 115

Scheme 115: Charge Air Cooler Inlet Pipe Replacement
Scheme 115: Charge Air Cooler Inlet Pipe Replacement
CalloutComponent Name
1Charge Air Cooler Inlet Pipe Retaining Clip
2Charge Air Cooler Inlet Pipe Clamp CAUTION: Refer to Fastener Caution . Tighten 2.7 N.m (24 lb in)
3Charge Air Cooler Inlet Pipe
CAUTION
Refer to Fastener Caution .

Charge Air Cooler Inlet Pipe Replacement

Scheme 116

Scheme 116: Charge Air Cooler Outlet Pipe Replacement
Scheme 116: Charge Air Cooler Outlet Pipe Replacement
CalloutComponent Name
Preliminary Procedure Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle
1Charge Air Cooler Outlet Pipe Bracket Nut CAUTION: Refer to Fastener Caution . Tighten 2.7 N.m (24 lb in)
2Charge Air Cooler Outlet Pipe Upper Clamp Procedure Rotate the upper clamp enough to disengage the charge air cooler hose from the throttle body.
3Charge Air Cooler Outlet Pipe Lower Clamp
4Charge Air Cooler Outlet Pipe Procedure Disconnect the intake air pressure and temperature sensor harness connector. Disconnect the vacuum hose from the charge air cooler outlet pipe. Transfer parts as necessary.
CAUTION
Refer to Fastener Caution .

Charge Air Cooler Outlet Pipe Replacement

Scheme 117

Scheme 117: Charge Air Cooler Replacement
Scheme 117: Charge Air Cooler Replacement
CalloutComponent Name
Preliminary Procedures Reposition the air conditioning condenser without discharging the A/C system. Refer to Air Conditioning Condenser Replacement Unclip and reposition the power steering cooler pipe without disconnecting the power steering hoses. Refer to Power Steering Fluid Cooling Pipe Replacement (L4) Disconnect the charge air cooler outlet pipe from the charge air cooler. Refer to Charge Air Cooler Outlet Pipe Replacement Disconnect the charge air cooler inlet pipe from the charge air cooler. Refer to Charge Air Cooler Inlet Pipe Replacement Reposition power steering lines off condenser if necessary.
1Charge Air Cooler Assembly Procedure Unclip the charge air cooler from the radiator and remove the charge air cooler from below

Charge Air Cooler Replacement

See also:
• Diagnostic Trouble Code (DTC) List - Vehicle
• Battery Negative Cable Disconnection and Connection
• Control Module References
• Intake Manifold Cover Replacement
• Cooling System Draining and Filling (Static Fill)
• Fastener Caution
• Special Tools (Diagnostic Tools)
• Air Cleaner Outlet Duct Replacement
• Gasoline/Gasoline Vapors Warning
• Electrical Center Identification Views
• CH-48027-100
• Special Tools (Diagnostic Tools)
• Fuel Pressure Relief
• Safety Glasses and Compressed Air Warning
• Relieving Fuel Pressure Warning
• Fuel Pipe Fitting Warning
• Safety Glasses Warning
• Lifting and Jacking the Vehicle
• Intake Manifold Cover Replacement
• Ignition System Specifications
• Air Conditioning Condenser Replacement
• Power Steering Fluid Cooling Pipe Replacement (L4)
• Charge Air Cooler Outlet Pipe Replacement
• Fuel Pressure Relief
• Fuel Tank Draining (Non E-85)

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