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Engine Controls/fuel - 2.4L - Repair Instructions: Removal & Installation GMC Terrain I

Testing & Diagnostics 16 illustrations ~3210 words

Fuel Pressure Gauge Installation and Removal

Special Tools

CH 48027 Digital Pressure Gauge

For equivalent regional tools, refer to Special Tools

Installation Procedure

WARNINGRefer to Gasoline/Gasoline Vapors Warning .
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»(ref-491199-S29945600062012073000000) .
  2. Connect the CH 48027 gauge (1) to the CH 48027 adapter (2).
  3. Remove the shop towel from around the fuel rail 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 gauge (1), 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 rail service port. Place the hose on the CH 48027 adapter (2) into an approved gasoline container. Open the valve on the CH 48027 adapter (2) in order to bleed any fuel from the fuel rail. Close the valve on the CH 48027 adapter (2). Remove the hose on the CH 48027 adapter (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 gauge (1) from the CH 48027 gauge (2).
  3. Disconnect the CH 48027 adapter (2) from the CH 48027 adapter (3).
  4. Disconnect the CH 48027 adapter (3) from the fuel rail service port.
  5. Install the fuel rail service port cap.
  6. Install the engine cover, if required.
  7. Tighten the fuel fill cap.
  1. Relieve the fuel system pressure before servicing any fuel system connection. Refer to «Fuel Pressure Relief»(ref-491198-S23860166962012073000000) .
  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-37088-A 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.
WARNINGRefer to Gasoline/Gasoline Vapors Warning .
  1. Relieve the fuel system pressure. Refer to «Fuel Pressure Relief»(ref-491198-S23860166962012073000000) .
  2. Using compressed air, blow any dirt out of the quick connect fitting.
  3. This step applies to the Bartholomew style connectors ONLY. Squeeze the plastic quick connect fitting release tabs.
  4. This step applies to the Q release type connectors ONLY. Release the fitting by pushing the tab toward the other side of the slot in the fitting.
  5. This step applies to the 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 also applies to the Squeeze to release style connectors ONLY. Squeeze where indicated by the arrows on both sides of the plastic ring surrounding the quick connect fitting.
  7. This step applies to the 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 does not move, try pressing the tab in from the opposite side. the tab will only move in one direction.
  8. This step applies to the Push down TI style connectors ONLY. Release the fitting by pressing on the tabs indicated by the arrow.
  9. Pull the connection apart.
  10. Wipe off the male pipe end using a clean shop towel.
  11. Inspect both ends of the fitting for dirt and burrs.
  12. Clean or replace the components as required.
  1. Apply a few drops of clean engine oil to the male connection end.
  2. Push both sides of the quick connect fitting together in order to cause the retaining feature to snap into place.
  3. Once installed, pull on both sides of the quick connect fitting in order to make sure the connection is secure.
  1. Ensure that the fuel level in the tank is less than 1/4 full. If necessary, drain the fuel tank to at least this level. Refer to «Fuel Tank Draining»(ref-491198-S39519890782012073000000) .
  2. Relieve the fuel system pressure. Refer to «Fuel Pressure Relief»(ref-491198-S23860166962012073000000) .
  3. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection»(ref-491171-S06136050852012073000000) .
  4. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-491131-S06536846302012073000000) .
  5. Remove the exhaust system. Refer to «Exhaust Muffler Replacement»(ref-491179-S25464646772012073000000) .
  6. Remove the propeller shaft. Refer to «Propeller Shaft Replacement»(ref-491180-S38513472952012073000000) .
  7. Place a suitable container under the fuel line connection in order to catch any dripping fuel.
  8. Remove the evaporative emission canister. Refer to «Evaporative Emission Canister Replacement»(ref-491198-S09558168372012073000000) .
  9. Disconnect the chassis fuel supply line (2) from the fuel tank.
  10. Disconnect the fuel filler tube, EVAP vent hose, and fresh air hose from the fuel tank.
  11. Disconnect the fuel tank electrical connector and remove the electrical connector retainer from the rear frame.
  12. Using a suitable adjustable jack, support the fuel tank.
  13. Remove the fuel tank strap nuts and lower the fuel tank straps.
  14. Lower the front of the fuel tank (with shield), and pull the tank forward to clear the rear drive module.
  15. If replacing the fuel tank, remove the fuel tank module assemblies. Refer to «Fuel Tank Fuel Pump Module Replacement»(ref-491198-S41527592242012073000000) , and «Fuel Tank Fuel Pump Module Replacement - Secondary (With Out)»(ref-491198-S02698973362012073000000) .
  16. If replacing the fuel tank, remove the heat shield, hoses and wiring harness and transfer to the new tank.
  1. If previously removed, install the fuel tank module assemblies. Refer to «Fuel Tank Fuel Pump Module Replacement»(ref-491198-S41527592242012073000000) , and «Fuel Tank Fuel Pump Module Replacement - Secondary (With Out)»(ref-491198-S02698973362012073000000) .
  2. Using a suitable adjustable jack, install the fuel tank heat shield and fuel tank assembly to the vehicle.
  3. Install the fuel tank straps and the fuel tank strap-to-body nuts and tighten to 20 N.m (15 lb ft).
  4. Connect the fuel tank electrical connector and install the electrical connector retainer to the rear frame.
  5. Connect the EVAP vent, and fresh air hoses to the fuel tank.
  6. Connect the fuel filler tube to the fuel tank. Tighten the fuel filler tube clamp to 5 N.m (44 lb in).
  7. Connect the chassis fuel supply line (2) to the fuel tank.
  8. Install the evaporative emission canister. Refer to «Evaporative Emission Canister Replacement»(ref-491198-S09558168372012073000000) .
  9. Install the propeller shaft. Refer to «Propeller Shaft Replacement»(ref-491180-S38513472952012073000000) .
  10. Install the exhaust system. Refer to «Exhaust Muffler Replacement»(ref-491179-S25464646772012073000000) .
  11. Lower the vehicle.
  12. Fill the fuel tank with gasoline.
  13. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection»(ref-491171-S06136050852012073000000) .
  14. Prime the fuel system: Cycle the ignition ON for 5 seconds and then OFF for 10 seconds. Repeat the previous step twice. Crank the engine until it starts. The maximum starter motor cranking time is 20 seconds. If the engine does not start, repeat steps 14.1-14.3.
  1. Ensure that the fuel level in the tank is less than 1/4 full. If necessary, drain the fuel tank to at least this level. Refer to «Fuel Tank Draining»(ref-491198-S39519890782012073000000) .
  2. Relieve the fuel system pressure. Refer to «Fuel Pressure Relief»(ref-491198-S23860166962012073000000) .
  3. Disconnect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection»(ref-491171-S06136050852012073000000) .
  4. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-491131-S06536846302012073000000) .
  5. Remove the exhaust system. Refer to «Exhaust Muffler Replacement»(ref-491179-S25464646772012073000000) .
  6. Disconnect the canister vent valve electrical connectors.
  7. Disconnect the vent hose from the canister filter.
  8. Disconnect the fuel tank vent pipe from the evaporative emission canister.
  9. Disconnect the chassis fuel supply line (2) from the fuel tank.
  10. Disconnect the fuel filler tube, EVAP vent hose, and fresh air hose from the fuel tank.
  11. Disconnect the fuel tank electrical connector and remove the electrical connector retainer from the rear frame.
  12. Support the fuel tank using a suitable jack.
  13. Remove the fuel tank strap nuts, and lower the fuel tank straps.
  14. Lower the fuel tank from the underbody of the vehicle.
  15. If replacing the fuel tank, remove the fuel tank module assemblies. Refer to «Fuel Tank Fuel Pump Module Replacement»(ref-491198-S41527592242012073000000) , and «Fuel Tank Fuel Pump Module Replacement - Secondary (With Out)»(ref-491198-S02698973362012073000000) .
  16. If replacing the fuel tank, remove the heat shield, hoses and wiring harness, and transfer to the new tank.
  1. If previously removed, install the fuel tank module assemblies. Refer to «Fuel Tank Fuel Pump Module Replacement»(ref-491198-S41527592242012073000000) , and «Fuel Tank Fuel Pump Module Replacement - Secondary (With Out)»(ref-491198-S02698973362012073000000) .
  2. Using an adjustable jack, slowly raise and reposition the fuel tank (3) in order to install the tank to the vehicle.
  3. Install the fuel tank straps and the fuel tank strap-to-body nuts and tighten to 20 N.m (15 lb ft).
  4. Connect the fuel tank electrical connector and install the electrical connector retainer to the rear frame.
  5. Connect the EVAP vent, and fresh air hoses to the fuel tank.
  6. Connect the fuel filler tube to the fuel tank. Tighten the fuel filler tube clamp to 5 N.m (44 lb in).
  7. Connect the chassis fuel supply line (2) to the fuel tank.
  8. Connect the fuel tank vent pipe to the evaporative emission canister.
  9. Connect the vent hose to the canister filter.
  10. Connect the canister vent valve electrical connector.
  11. Install the exhaust system. Refer to «Exhaust Muffler Replacement»(ref-491179-S25464646772012073000000) .
  12. Lower the vehicle.
  13. Fill the fuel tank with gasoline.
  14. Connect the negative battery cable. Refer to «Battery Negative Cable Disconnection and Connection»(ref-491171-S06136050852012073000000) .
  15. Prime the fuel system: Cycle the ignition ON for 5 seconds and then OFF for 10 seconds. Repeat the previous step twice. Crank the engine until it starts. The maximum starter motor cranking time is 20 seconds. If the engine does not start, repeat steps 15.1-15.3.

Fuel Tank Fuel Pump Module Replacement

Special Tools

J-45722 Fuel Tank Sender Wrench

For equivalent regional tools, refer to Special Tools .

  1. Remove the fuel tank. Refer to «Fuel Tank Replacement (AWD)»(ref-491198-S08323556402012073000000) , «Fuel Tank Replacement (FWD)»(ref-491198-S42031062462012073000000) .
  2. Disconnect the crossover tube from the secondary fuel pump module. Refer to «Fuel Tank Fuel Pump Module Replacement - Secondary (With Out)»(ref-491198-S02698973362012073000000) .
  3. Disconnect the electrical connectors (1).
  4. Disconnect the fuel and evaporative emission lines (2). Refer to «Plastic Collar Quick Connect Fitting Service»(ref-491198-S03222845352012073000000) .
  5. Using the J-45722 wrench, remove the cam lock ring (1) by turning counterclockwise.
  6. Remove the primary fuel tank module (1) and the O-ring (2).
  7. If replacing the fuel pump module only, remove the primary fuel level sensor. Refer to «Primary Fuel Level Sensor Replacement»(ref-491198-S40976729902012073000000) .
  1. If replacing the fuel pump module only, install the primary fuel level sensor. Refer to «Primary Fuel Level Sensor Replacement»(ref-491198-S40976729902012073000000) .
  2. Install a NEW O-ring (2) and the primary fuel tank module (1).
  3. Using the J-45722 wrench, install the cam lock ring (1) by turning clockwise.
  4. Connect the electrical connectors (1).
  5. Connect the fuel and evaporative emission lines (2). Refer to «Plastic Collar Quick Connect Fitting Service»(ref-491198-S03222845352012073000000) .
  6. Connect the crossover tube to the secondary fuel pump module. Refer to «Fuel Tank Fuel Pump Module Replacement - Secondary (With Out)»(ref-491198-S02698973362012073000000) .
  7. Install the fuel tank. Refer to «Fuel Tank Replacement (AWD)»(ref-491198-S08323556402012073000000) , «Fuel Tank Replacement (FWD)»(ref-491198-S42031062462012073000000) .

Fuel Tank Fuel Pump Module Replacement - Secondary (With Out)

Special Tools

CH-48482 Fuel Tank Sender Wrench

For equivalent region tools, refer to Special Tools .

  1. Remove the fuel tank. Refer to «Fuel Tank Replacement (FWD)»(ref-491199-S32546615472012073000000) , «Fuel Tank Replacement (AWD)»(ref-491199-S25100409322012073000000) .
  2. Disconnect the electrical connector (1).
  3. Disconnect the evaporative emission line (2). Refer to «Plastic Collar Quick Connect Fitting Service»(ref-491199-S09034919432012073000000) .
  4. Using the CH-48482 wrench, remove the cam lock ring (1) by turning counterclockwise.
  5. Partially raise the secondary fuel pump module and disconnect the crossover tube (1) by squeezing the plastic retaining tabs (2).
  6. Remove the secondary fuel tank module (1) and the O-ring (2).
  1. Partially install the secondary fuel pump module and connect the crossover tube (1) by sliding into position.
  2. Install a NEW O-ring (2) and the secondary fuel tank module (1).
  3. Using the CH-48482 wrench, install the cam lock ring (1) by turning clockwise.
  4. Connect the electrical connector (1).
  5. Connect the evaporative emission line (2). Refer to «Plastic Collar Quick Connect Fitting Service»(ref-491199-S09034919432012073000000) .
  6. Install the fuel tank. Refer to «Fuel Tank Replacement (FWD)»(ref-491199-S32546615472012073000000) , «Fuel Tank Replacement (AWD)»(ref-491199-S25100409322012073000000) .

Scheme 16

Scheme 16: Fuel Pump Flow Control Module Replacement
Scheme 16: Fuel Pump Flow Control Module Replacement
CalloutComponent Name
1Fuel Pump Flow Control Module Fastener CAUTION: Refer to Fastener Caution Tighten 8 N.m(71 lb in)
2Fuel Pump Flow Control Module Procedure Open the spare tire compartment lid. Disconnect the electrical connector. If replacing, reprogram the module. Refer to Control Module References
CAUTION
Refer to Fastener Caution

Fuel Pump Flow Control Module Replacement

Scheme 17

Scheme 17: Fuel Tank Pressure Sensor Replacement (NU6)
Scheme 17: Fuel Tank Pressure Sensor Replacement (NU6)
CalloutComponent Name
Preliminary Procedure Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
1Fuel Tank Pressure Sensor Procedure Use a flat bladed tool to remove the sensor. Disconnect the electrical connector.

Fuel Tank Pressure Sensor Replacement (NU6)

Scheme 18

Scheme 18: Fuel Tank Pressure Sensor Replacement (Without NU6)
Scheme 18: Fuel Tank Pressure Sensor Replacement (Without NU6)
CalloutComponent Name
Preliminary Procedures Lower the fuel tank. Refer to Fuel Tank Replacement (FWD) , Fuel Tank Replacement (AWD) . Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
1Fuel Tank Pressure Sensor Procedure Use a flat bladed tool to remove the sensor. Disconnect the electrical connector.

Fuel Tank Pressure Sensor Replacement (Without NU6)

Scheme 19

Scheme 19: Primary Fuel Level Sensor Replacement
Scheme 19: Primary Fuel Level Sensor Replacement
CalloutComponent Name
Preliminary Procedure Remove the fuel pump module. Refer to Fuel Tank Fuel Pump Module Replacement .
1Fuel Level Sensor Procedure Release the retaining tabs. Disconnect the electrical connector.

Primary Fuel Level Sensor Replacement

Scheme 20

Scheme 20: Fuel Tank Filler Pipe Replacement
Scheme 20: Fuel Tank Filler Pipe Replacement
CalloutComponent Name
Preliminary Procedure Remove the rear wheel house liner. Refer to Rear Wheelhouse Panel Liner Replacement (Terrain) , Rear Wheelhouse Panel Liner Replacement (Equinox) . Disconnect the evaporative emission lines. Refer to Plastic Collar Quick Connect Fitting Service .
1Filler Pipe Fastener (Qty: 3) CAUTION: Refer to Fastener Caution . Tighten 10 N.m (89 lb in)
2Fuel Tank Filler Pipe Clamp Tighten 4 N.m (35 lb in)
3Fuel Tank Filler Pipe
CAUTION
Refer to Fastener Caution .

Fuel Tank Filler Pipe Replacement

Scheme 21

Scheme 21: Fuel Pump Cover Replacement
Scheme 21: Fuel Pump Cover Replacement
CalloutComponent Name
1Fuel Pump Cover Fastener (Qty: 3) CAUTION: Refer to Fastener Caution . Tighten 10 N.m(89 lb in)
2Fuel Pump Cover
3Fuel Pump Insulator
CAUTION
Refer to Fastener Caution .

Fuel Pump Cover Replacement

Scheme 22

Scheme 22: Fuel Feed Pipe Replacement (With Direct Injection)
Scheme 22: Fuel Feed Pipe Replacement (With Direct Injection)
CalloutComponent Name
Preliminary Procedures Remove the intake manifold cover. Refer to Intake Manifold Cover Replacement . Disconnect the fuel lines. Refer to Metal Collar Quick Connect Fitting Service .
1Fuel Feed Pipe Fastener CAUTION: Refer to Fastener Caution . Tighten 10 N.m (89 lb in)
2Fuel Feed Pipe
CAUTION
Refer to Fastener Caution .

Fuel Feed Pipe Replacement (With Direct Injection)

Scheme 23

Scheme 23: Fuel Feed Hose Replacement
Scheme 23: Fuel Feed Hose Replacement
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 . Remove the fuel tank. Refer to Fuel Tank Replacement (AWD) , Fuel Tank Replacement (FWD) Disconnect the quick connectors. Refer to Plastic Collar Quick Connect Fitting Service .
1Fuel Feed Hose Procedure Disengage the hose from the plastic retainers.

Fuel Feed Hose Replacement

  1. Relieve the fuel system pressure. Refer to «Fuel Pressure Relief»(ref-491198-S23860166962012073000000) .
  2. Raise and suitably support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-491131-S06536846302012073000000) .
  3. Disconnect the body wiring harness electrical connector (1) from the fuel pressure sensor (2).
  4. Wrap a shop towel around the fuel pressure sensor fitting in order to absorb any fuel that may leak out.
  5. Remove the fuel pressure sensor (1) from the fuel line.
  6. Remove and discard the fuel pressure sensor O-ring seal (2).
  1. Lubricate a NEW fuel pressure sensor O-ring seal with clean engine oil.
  2. Install the NEW fuel pressure sensor O-ring seal (2) onto the fuel line fitting.
  3. Install the fuel pressure sensor (1) to the fuel line. Tighten the sensor to 15 N.m (11 lb ft).
  4. Connect the body wiring harness electrical connector (1) to the fuel pressure sensor (2).
  5. Lower the vehicle.
  6. Use the following procedure in order to inspect for leaks: 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. Inspect for fuel leaks.

Scheme 24

Scheme 24: Fuel Line Replacement - Chassis
Scheme 24: Fuel Line Replacement - Chassis
CalloutComponent Name
Preliminary Procedures Relieve the fuel system pressure. Refer to Fuel Pressure Relief . Remove the intake manifold cover. Refer to Intake Manifold Cover Replacement . Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle . Disconnect the quick connectors. Refer to Metal Collar Quick Connect Fitting Service , and Plastic Collar Quick Connect Fitting Service .
1Fuel Feed Line Procedure Disengage the line from the plastic retainers.

Fuel Line Replacement - Chassis

Scheme 25

Scheme 25: Fuel Feed Intermediate Pipe Replacement
Scheme 25: Fuel Feed Intermediate Pipe Replacement
CalloutComponent Name
Preliminary Procedures Relieve the system pressure. Refer to Fuel Pressure Relief . Remove the fuel pump cover. Refer to Fuel Pump Cover Replacement .
1Fuel Feed Intermediate Pipe CAUTION: Refer to Fastener Caution . Procedure DISCARD the pipe when removed, and install a NEW pipe. Lubricate the pipes with silicon free engine oil. Refer to Adhesives, Fluids, Lubricants, and Sealers . Pressurize the fuel system and inspect for leaks. Tighten 30 N.m (22 lb ft)
CAUTION
Refer to Fastener Caution .

Fuel Feed Intermediate Pipe Replacement

Fuel Pump Replacement

Special Tools

EN-48896 High Pressure Fuel Pump Installation Alignment Gauge

  1. Relieve the low and high side fuel system pressure. Refer to «Fuel Pressure Relief»(ref-491198-S23860166962012073000000) .
  2. Disconnect the engine wiring harness electrical connector from the high pressure fuel pump.
  3. Remove the low pressure feed pipe. Refer to «Fuel Feed Pipe Replacement (With Direct Injection)»(ref-491198-S41159083162012073000000) .
  4. Remove the high pressure pipe. Refer to «Fuel Feed Intermediate Pipe Replacement»(ref-491198-S38076030822012073000000) . Discard this pipe.
  5. Remove and discard the high pressure fuel pump bolts (1).
  6. Remove the high pressure fuel pump (2).
  7. Remove and discard the high pressure fuel pump O-ring (3).
  8. Remove and discard the high pressure fuel pump gasket (4).
  9. Remove the high pressure fuel pump roller lifter (5).
  1. Use the EN-48896 alignment gauge to ensure that the camshaft lobe is in the base circle position. At base circle the tool will be flush with the head.
  2. Lubricate the high pressure fuel pump cylinder head bore and roller lifter with camshaft prelube GM P/N 12345501 (Canadian P/N 992704) or equivalent.
  3. Install the high pressure fuel pump roller lifter (5).
  4. Install a NEW high pressure fuel pump O-ring (3).
  5. Position the NEW high pressure fuel pump gasket (4) and bolts (1) to the fuel pump.
  6. Install the high pressure fuel pump (2). Force will be required while hand tightening the bolts.
  7. Tighten the high pressure fuel pump retaining bolts to 15 N.m (11 lb ft).
  8. Ensure the high pressure fuel pump and fuel rail fittings are clean prior to assembly.
  9. Install a NEW high pressure fuel pipe. Refer to «Fuel Feed Intermediate Pipe Replacement»(ref-491198-S38076030822012073000000) .
  10. Install the fuel feed pipe to the high pressure fuel pump. Refer to «Fuel Feed Pipe Replacement (With Direct Injection)»(ref-491198-S41159083162012073000000) .
  11. Connect the high pressure fuel pump wiring harness.
  12. Install the fuel tank cap.
  13. Inspect for leaks using the following procedure: Turn ON the ignition, with the engine OFF for 2 seconds. Turn OFF the ignition, for 10 seconds. Turn ON the ignition, with the engine OFF. Inspect for fuel leaks.
  14. Install the pressure relief cap to the fuel feed pipe.
  15. Install the high pressure fuel pump cover. Refer to «Fuel Pump Cover Replacement»(ref-491198-S23695830292012073000000) .

Scheme 26

Scheme 26: Fuel Injection Fuel Rail Assembly Replacement
Scheme 26: Fuel Injection Fuel Rail Assembly Replacement
CalloutComponent Name
Preliminary Procedures Relieve the fuel system pressure. Refer to Fuel Pressure Relief . Remove the intake manifold. Refer to Intake Manifold Replacement .
1Fuel Injection Fuel Rail Fastener (Qty: 4) CAUTION: Refer to Fastener Caution . Tighten 25Y (18 lb ft)
2Fuel Injection Fuel Rail Procedure Disconnect the electrical connector. It is necessary to rebuild the fuel injectors. Refer to Direct Fuel Injector Replacement .
CAUTION
Refer to Fastener Caution .

Fuel Injection Fuel Rail Assembly Replacement

Scheme 27

Scheme 27: Fuel Injection Fuel Rail Fuel Pressure Sensor Replacement
Scheme 27: Fuel Injection Fuel Rail Fuel Pressure Sensor Replacement
CalloutComponent Name
Preliminary Procedures Relieve the fuel system pressure. Refer to Fuel Pressure Relief . Remove the intake manifold. Refer to Intake Manifold Replacement .
1Fuel Pressure Sensor CAUTION: Refer to Fastener Caution . Procedure Disconnect the electrical connector. Tighten 32 N.m (24 lb ft)
CAUTION
Refer to Fastener Caution .

Fuel Injection Fuel Rail Fuel Pressure Sensor Replacement

Fuel Injector and Fuel Rail Replacement

CalloutComponent Name
Preliminary Procedures Relieve the fuel system pressure. Refer to Fuel Pressure Relief . Remove the intake manifold. Refer to Intake Manifold Replacement . Remove the fuel feed intermediate pipe. Refer to Fuel Feed Intermediate Pipe Replacement .
1Fuel Injection Fuel Rail Fastener (Qty: 4) CAUTION: Refer to Fastener Caution . Tighten 25 N.m (18 lb ft)
2Fuel Injection Fuel Rail Procedure Disconnect the electrical connector. Remove the fuel rail and injectors as an assembly. Refer to Fuel Rail and Injectors Removal . It is necessary to rebuild the fuel injectors. Refer to Fuel Rail and Injectors Cleaning and Inspection (LAF, LEA, or LUK) . Install the fuel rail and injectors as an assembly. Refer to Fuel Rail and Injectors Installation .
CAUTION
Refer to Fastener Caution .

Fuel Injector and Fuel Rail Replacement

  1. Relieve the high side fuel system pressure. Refer to «Fuel Pressure Relief»(ref-491198-S23860166962012073000000) .
  2. Remove the fuel injection fuel rail assembly. Refer to «Fuel Injector and Fuel Rail Replacement»(ref-491198-S41456442932012073000000) .
  3. Remove and discard the fuel injector retainers (1).
  4. Clean and inspect the fuel rail and injectors. Refer to «Fuel Rail and Injectors Cleaning and Inspection (LAF, LEA, or LUK)»(ref-491134-S30773862702012073000000) .
  1. Install NEW fuel injector retainers (1).
  2. Install the fuel injection fuel rail assembly. Refer to «Fuel Injector and Fuel Rail Replacement»(ref-491198-S41456442932012073000000) .

Scheme 28

Scheme 28: Evaporative Emission Canister Purge Solenoid Valve Replacement
Scheme 28: Evaporative Emission Canister Purge Solenoid Valve Replacement
CalloutComponent Name
Preliminary Procedures Remove the intake manifold cover. Refer to Intake Manifold Cover Replacement . Disconnect the evaporative emission pipes. Refer to Plastic Collar Quick Connect Fitting Service .
1Evaporative Emission Canister Purge Solenoid Fastener CAUTION: Refer to Fastener Caution . Tighten 25 N.m(18 lb ft)
2Evaporative Emission Canister Purge Solenoid Procedure Disconnect the electrical connector.
CAUTION
Refer to Fastener Caution .

Evaporative Emission Canister Purge Solenoid Valve Replacement

Scheme 29

Scheme 29: Evaporative Emission Canister Purge Tube Replacement
Scheme 29: Evaporative Emission Canister Purge Tube Replacement
CalloutComponent Name
Preliminary Procedure Remove the intake manifold cover. Refer to Intake Manifold Cover Replacement . Disconnect the plastic quick connectors. Refer to Plastic Collar Quick Connect Fitting Service .
1Evaporative Emission Canister Purge Tube

Evaporative Emission Canister Purge Tube Replacement

  1. Remove the evaporative emission (EVAP) canister. Refer to «Evaporative Emission Canister Replacement»(ref-491199-S05278807032012073000000) .
  2. Rotate the EVAP canister vent valve counterclockwise to release from the locked position.
  3. Remove the vent valve from the EVAP canister.
  1. Insert the EVAP canister vent solenoid valve into the EVAP canister, with the valve aligned to the released position.
  2. Rotate vent valve clockwise to secure into the locked position.
  3. Install the EVAP canister. Refer to «Evaporative Emission Canister Replacement»(ref-491199-S05278807032012073000000) .

Scheme 30

Scheme 30: Evaporative Emission Line Replacement - Canister to Tank
Scheme 30: Evaporative Emission Line Replacement - Canister to Tank
CalloutComponent Name
Preliminary Procedure Remove the fuel tank. Refer to Fuel Tank Replacement (AWD) , Fuel Tank Replacement (FWD) . Disconnect the plastic quick connects. Refer to Plastic Collar Quick Connect Fitting Service .
1Evaporative Emission Line Canister to Tank Procedure Disconnect the electrical connector.

Evaporative Emission Line Replacement - Canister to Tank

Scheme 31

Scheme 31: Evaporative Emission Line Replacement - Engine to Chassis
Scheme 31: Evaporative Emission Line Replacement - Engine to Chassis
CalloutComponent Name
Preliminary Procedure Disconnect the evaporative emission lines. Refer to Plastic Collar Quick Connect Fitting Service . Raise and support the vehicle. Refer to Lifting and Jacking the Vehicle .
1Evaporative Emission Line Engine-Chassis Procedure Remove the line from the plastic retainers.

Evaporative Emission Line Replacement - Engine to Chassis

  1. Raise and support the vehicle. Refer to «Lifting and Jacking the Vehicle»(ref-491131-S06536846302012073000000) .
  2. Disconnect the EVAP canister fresh air hose/pipe from the fuel tank fresh air hose/pipe (2). Refer to «Plastic Collar Quick Connect Fitting Service»(ref-491199-S09034919432012073000000) .
  3. Disconnect the EVAP canister vent hose/pipe from the EVAP canister. Refer to «Plastic Collar Quick Connect Fitting Service»(ref-491199-S09034919432012073000000) .
  4. Disconnect the EVAP canister purge hose/pipe (1) from the EVAP canister.
  5. Remove the EVAP canister-to-underbody nuts (3).
  6. Lower the EVAP canister.
  7. Disconnect the EVAP vent solenoid electrical connector (1).
  8. Remove the EVAP canister (4) from the vehicle.
  1. Connect the EVAP vent solenoid electrical connector (1).
  2. Install the EVAP canister (4) to the underbody of the vehicle.
  3. Install the EVAP canister-to-underbody nuts (3). Tighten Tighten the nuts to 9 N.m (80 lb in).
  4. Connect the EVAP canister purge hose/pipe (1) to the EVAP canister.
  5. Connect the EVAP canister vent hose/pipe (3) to the EVAP canister. Refer to «Plastic Collar Quick Connect Fitting Service»(ref-491199-S09034919432012073000000) .
  6. Connect the EVAP canister fresh air hose/pipe to the fuel tank fresh air hose/pipe (2). Refer to «Plastic Collar Quick Connect Fitting Service»(ref-491199-S09034919432012073000000) .
  7. Lower the vehicle.
  1. Remove the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(ref-491134-S37063866352012073000000) .
  2. Disconnect the engine wiring harness electrical connectors (1) from the ignition coil(s) (2).
  3. Remove the ignition coil bolt(s).
  4. Remove the ignition coil(s).
  1. Install the ignition coil(s).
  2. Install the ignition coil bolt(s) and tighten to 10 N.m (89 lb in).
  3. Connect the engine wiring harness electrical connector(s) (1) to the ignition coil(s) (2).
  4. Install the intake manifold cover. Refer to «Intake Manifold Cover Replacement»(ref-491134-S37063866352012073000000) .
CAUTIONThis engine has aluminum cylinder heads. Do not remove the spark plugs from a hot engine, allow it to cool first. Removing the spark plugs from a hot engine may cause spark plug thread damage or cylinder head damage.
  1. Remove the ignition coil(s). Refer to «Ignition Coil Replacement»(ref-491198-S15190790812012073000000) .
  2. Remove the spark plugs using a 5/8 inch spark plug socket.
  1. Install the spark plugs. Specification The spark plug gap is 1.0 mm (0.040 in). Tighten Tighten the plugs to 20 N.m (15 lb ft).
  2. Install the ignition coil(s). Refer to «Ignition Coil Replacement»(ref-491198-S15190790812012073000000) .

Air Cleaner Outlet Resonator Replacement

CalloutComponent Name
Preliminary Procedure Disconnect the PCV valve from the resonator. Refer to Positive Crankcase Ventilation Hose/Pipe/Tube Replacement .
1Resonator Clamps (Qty: 2) CAUTION: Refer to Fastener Caution . Tighten 5 N.m (44 lb in)
2Air Cleaner Outlet Resonator
CAUTION
Refer to Fastener Caution .

Air Cleaner Outlet Resonator Replacement

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