SECONDARY AIR INJECTION CHECK VALVE & PIPE - REAR (2000 9-5 V6 LEV)
Remove engine cover. Disconnect both HO2S connectors from mount on rear SAI valve. Unbolt SAI pipe from cylinder head and exhaust manifold. Disconnect SAI valve hose by squeezing clip and pulling hose back. Remove pipe and valve. Remove two 10-mm valve mounting bolts. To install, replace check valve gasket and reverse removal procedure.
Trionic T-5 Engine Management Systems
Disconnect CAB valve electrical connector. Lift up rear hood seal and carefully pull mounting plate outward to unhook it from edge of firewall. Mark vacuum hoses and remove CAB valve and mounting plate. Drill out rivets holding CAB valve to plate. To install, reverse removal procedure. Rivet new CAB valve to mounting plate. Spray electrical connector with Kontakt 61.
Trionic T-7 Engine Management Systems
Remove engine harness cover from CAB valve. Unplug upper electrical connector. Unplug 2-pin connector from bottom of CAB valve. Unscrew both CAB valve retaining nuts and loosen windshield cover weather strip. Gently pull out mounting plate and unhook it from firewall. Lift valve up and unplug lower multiconnector. Take note of vacuum hose location and remove them. Lift out CAB valve holder and drill out 2 rivets. To install, spray 2-pin connector terminals with Kontakt 61 and reverse removal procedure.
FUEL TANK PRESSURE (FTP) SENSOR
| WARNING | Replacing FTP sensor involves partial disassembly of fuel system. Work only in a well-ventilated area and use vapor extraction equipment if available. Keep a BE-rated fire extinguisher handy in case of fire. Wear protective gloves and goggles. DO NOT smoke anywhere near open fuel system. |
HO2S SENSORS
Note. When installing HO2S sensors, ensure that wiring harnesses are resecured and not twisted to prevent damage to them. Handle HO2S sensors gently, as they are sensitive to impact and must be handled with caution.
VEHICLE SPEED SENSOR
Trionic T-5 and T-7 Engine Management Systems receive vehicle speed signal from anti-lock brake system. See appropriate ANTI-LOCK article in BRAKES. Also see BODY COMPUTER SYSTEMS article in ACCESSORIES & EQUIPMENT.
FUEL SYSTEM
| WARNING | Always relieve fuel pressure before disconnecting any fuel injection-related component. DO NOT allow fuel to contact engine or electrical components. |
FUEL SYSTEM PRESSURE RELEASE
To relieve fuel pressure, start engine and allow to idle. Remove fuse No. 32 on 9-3 Series or fuse No. 19 on 9-5 Series from driver's fuse block, located on end of instrument panel. Run engine until it stalls. Turn ignition off. Reinstall fuse.
FUEL INJECTORS
| WARNING | Replacing fuel injectors involves partial disassembly of fuel system. Work only in a well-ventilated area and use vapor extraction equipment if available. Keep a BE-rated fire extinguisher handy in case of fire. Wear protective gloves and goggles. DO NOT smoke anywhere near open fuel system. |
FUEL FILTER
| WARNING | Replacing fuel filter involves partial disassembly of fuel system. Work only in a well-ventilated area and use vapor extraction equipment if available. Keep a BE-rated fire extinguisher handy in case of fire. Wear protective gloves and goggles. DO NOT smoke anywhere near open fuel system. |
Release fuel pressure. See FUEL SYSTEM PRESSURE RELEASE . Locate fuel filter at right front side of fuel tank. Remove fuel filter splash guard. Remove both banjo bolts at inlet and outlet fuel lines on filter. Remove fuel filter clamp bolt and filter. To install, reverse removal procedure. Tighten banjo bolts to specification. See TORQUE SPECIFICATIONS .
FUEL PUMP
| WARNING | Replacing fuel pump involves partial disassembly of fuel system. Work only in a well-ventilated area and use vapor extraction equipment if available. Keep a BE-rated fire extinguisher handy in case of fire. Wear protective gloves and goggles. DO NOT smoke anywhere near open fuel system. |
FUEL TANK
| WARNING | Removing fuel tank involves partial disassembly of fuel system. Work only in a well-ventilated area and use vapor extraction equipment if available. Keep a BE-rated fire extinguisher handy in case of fire. Wear protective gloves and goggles. DO NOT smoke anywhere near open fuel system. |
THROTTLE/PEDAL POSITION SENSORS
Trionic T-7 Engine Management System uses 2 throttle position sensors and 2 pedal position sensors. They are an integral part of throttle body and are not replaced separately. See THROTTLE BODY .
V6 ENGINE
- Remove upper engine cover. Remove turbo pressure hose, bypass pipe and valve. Plug charge air cooler outlet. Remove exhaust manifold heat shield. Remove crankcase breather pipe between turbo intake pipe and cylinder head along with hose from oil trap. Move pipe to the side. Disconnect turbo intake pipe and move it to the side. Disconnect turbo outlet hose to charge air cooler.
- Remove radiator fan. Pinch off inlet and return coolant hoses. Remove turbo coolant pipe, dipstick tube and front pipe from turbo. Disconnect HO2S connector. Raise and support vehicle. Release cable tie securing HO2S harness. Note how harness is laid out for reinstallation reference. Unbolt front exhaust system from rear exhaust. Unbolt and remove front exhaust pipe from rear exhaust manifold and turbo.
- Remove turbo oil return pipe and turbo mounting bracket. Lower vehicle. Remove front exhaust manifold mounting nuts. Remove manifold and turbo assembly. To reinstall, reverse removal procedure. Replace exhaust manifold gasket. Make sure turbocharger mating surfaces are clean. Coat turbo mounting studs lightly with MolyCote 1000. Spray electrical connectors with Kontakt 61. Tighten all mounting bolts and hoses to specification. See «TORQUE SPECIFICATIONS»(ref-2997-S09909195702000041700000) . Check and top off engine oil and coolant.
Note. Fill turbo oil inlet with oil before assembling. Spin turbo impeller by hand for a long period to ensure proper lubrication of turbo shaft on startup.