Engine Electrical Devices: Removal & Installation Suzuki XL7 I

Installation Procedure

Note. A special anti-seize compound is used in the HO2S threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an exhaust component and if for any reason the sensor is to reinstalled, the threads must have anti-seize compound applied before the reinstallation.

Scheme 3

Scheme 4

1. If reinstalling the old sensor, coat the threads with anti-seize compound GM P/N 12377953, or equivalent. CAUTION: Refer to «FASTENER NOTICE»(ref-268407-S42682275612007102300000) .
2. Install the HO2S (1) to the exhaust manifold. Tightening torque Tighten the sensor to 42 N.m (31 lb ft) .
3. Connect the engine wiring harness electrical connector (3) to the HO2S electrical connector (2).
4. Install the HO2S electrical connector retainer to the camshaft cover.
5. Install the fuel injector sight shield, if necessary. Refer to «INSTALLATION PROCEDURE»(ref-268436-S18519466112007102300000) .

Scheme 5

Scheme 6

1. Raise and support the vehicle. Refer to «LIFTING AND JACKING THE VEHICLE»(ref-268408-S26898100292007102300000) .
2. Disconnect the heated oxygen sensor (HO2S) electrical connector (2) from the engine wiring harness electrical connector.
3. Remove the HO2S (2) from the catalytic converter.

Note. A special anti-seize compound is used in the HO2S threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an exhaust component and if for any reason the sensor is to reinstalled, the threads must have anti-seize compound applied before the reinstallation.

Scheme 7

Scheme 8

1. If reinstalling the old sensor, coat the threads with anti-seize compound GM P/N 12377953, or equivalent. CAUTION: Refer to «FASTENER NOTICE»(ref-268407-S42682275612007102300000) .
2. Install the HO2S (2) to the catalytic converter. Tightening torque Tighten the sensor to 42 N.m (31 lb ft) .
3. Connect the HO2S electrical connector (2) to the engine wiring harness electrical connector.
4. Lower the vehicle.

Scheme 9

Scheme 10

1. Remove the fuel injector sight shield, if necessary. Refer to «REMOVAL PROCEDURE»(ref-268436-S19439002942007102300000) .
2. Disconnect the engine wiring harness electrical connector (3) from the heated oxygen sensor (HO2S) electrical connector (4).
3. Remove the HO2S electrical connector retainer (5) from the retainer clip.
4. Remove the HO2S (1) from the exhaust manifold.

Note. A special anti-seize compound is used in the HO2S threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an exhaust component and if for any reason the sensor is to reinstalled, the threads must have anti-seize compound applied before the reinstallation.

Scheme 11

Scheme 12

1. If reinstalling the old sensor, coat the threads with anti-seize compound GM P/N 12377953, or equivalent. CAUTION: Refer to «FASTENER NOTICE»(ref-268407-S42682275612007102300000) .
2. Install the HO2S (1) to the exhaust manifold. Tightening torque Tighten the sensor to 42 N.m (31 lb ft) .
3. Connect the engine wiring harness electrical connector (3) to the HO2S electrical connector (4).
4. Install the HO2S electrical connector retainer (5) to the retainer clip.
5. Install the fuel injector sight shield, if necessary. Refer to «INSTALLATION PROCEDURE»(ref-268436-S18519466112007102300000) .

Scheme 13

Scheme 14

1. Raise and support the vehicle. Refer to «LIFTING AND JACKING THE VEHICLE»(ref-268408-S26898100292007102300000) .
2. Disconnect the heated oxygen sensor (HO2S) electrical connector (2) from the engine wiring harness electrical connector.
3. Remove the HO2S (2) from the catalytic converter.

Note. A special anti-seize compound is used in the HO2S threads. The compound consists of liquid graphite and glass beads. The graphite tends to burn away, but the glass beads remain, making the sensor easier to remove. New, or service replacement sensors already have the compound applied to the threads. If the sensor is removed from an exhaust component and if for any reason the sensor is to reinstalled, the threads must have anti-seize compound applied before the reinstallation.

Scheme 15

Scheme 16

1. If reinstalling the old sensor, coat the threads with anti-seize compound GM P/N 12377953, or equivalent. CAUTION: Refer to «FASTENER NOTICE»(ref-268407-S42682275612007102300000) .
2. Install the HO2S (2) to the catalytic converter. Tightening torque Tighten the sensor to 42 N.m (31 lb ft) .
3. Connect the HO2S electrical connector (2) to the engine wiring harness electrical connector.
4. Lower the vehicle.

Engine Control Module Replacement

Note. It is necessary to record the remaining engine oil life. If the replacement module is not programed with the remaining engine oil life, the engine oil life will default to 100 percent. If the replacement module is not programmed with the remaining engine oil life, the engine oil will need to be changed at 5 000 km (3,000 mi) from the last engine oil change. It is necessary to record the remaining automatic transmission fluid life. If the replacement module is not programed with the remaining automatic transmission fluid life, the automatic transmission fluid life will default to 100 percent. If the replacement module is not programmed with the remaining automatic transmission fluid life, the automatic transmission fluid will need to be changed at 83 000 km (50,000 mi) from the last automatic transmission fluid change.

Scheme 17

Scheme 18

Scheme 19

1. Turn the ignition OFF.
2. Using a scan tool, retrieve the percentage of remaining engine oil and the remaining automatic transmission fluid life. Record the remaining engine oil and the remaining automatic transmission fluid life.
3. Disconnect the negative battery cable. Refer to «BATTERY NEGATIVE CABLE DISCONNECTION AND CONNECTION»(ref-268417-S08892916432007102300000) .
4. Disconnect the engine wiring harness electrical connector (2) from the ECM. CAUTION: In order to prevent any possible electrostatic discharge damage to the ECM, do not touch the connector pins.
5. Grasp the ECM retainer and slide the retainer rearward until the retainer disengages from the 4 clips on the battery cover.
6. Disengage the clips (1) on the ECM retainer from the ECM, and slide the ECM out of the retainer.

Scheme 20

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Scheme 22

1. Slide the ECM into the retainer until the clips (1) engage the ECM.
2. Grasp the ECM retainer and slide the retainer forward until the retainer locks against the 4 clips on the battery cover.
3. Connect the engine wiring harness electrical connector (2) to the ECM.
4. Connect the negative battery cable. Refer to «BATTERY NEGATIVE CABLE DISCONNECTION AND CONNECTION»(ref-268417-S08892916432007102300000) .
5. If a NEW ECM was installed, reprogram the ECM. Refer to «ENGINE CONTROL MODULE PROGRAMMING AND SETUP»(ref-268445-S06553288922007102300000) .

ECM Replacement

If the engine control module (ECM) is replaced, the following procedures must be performed

1. ECM Reprogramming - Refer to «SERVICE PROGRAMMING SYSTEM (SPS)»(ref-268408-S26236429192007102300000) .
2. Idle Learn Procedure - Refer to «IDLE LEARN»(ref-268429-S33079892862007102300000) in Engine Controls - 3.6L (LY7).
3. Theft Deterrent - Refer to «THEFT DETERRENT CONTROL MODULE PROGRAMMING AND SETUP»(ref-268423-S30920106272007102300000) . The ECM will learn the incoming fuel continue password immediately upon receipt of a password message. Once a password message is received, and a password is learned, a learn procedure must be performed to change this password again. An ECM which has been previously installed in another vehicle will have learned the other vehicle's fuel continue password, and will require a learn procedure after programming to learn the current vehicle's password.
4. Engine Oil Life Remaining - When available, use a scan tool to reset the Engine Oil Life Remaining back to the original percentage recorded before the module was replaced.
5. Transmission Fluid Life Remaining - When available, use the scan tool to reset the Transmission Fluid Life Remaining back to the original percentage recorded before the module was replaced.

Setup for Component Replacement

The replacement of some components will require a setup procedure for complete repair.

If any of the following components are replaced, an Idle Learn Procedure must be performed. Refer to IDLE LEARN in Engine Controls - 3.6L (LY7).

1. Throttle body assembly
2. ECM