download
WARNING: The evaporative emissions system contains fuel vapor and condensed fuel vapor. Although not present in large quantities, it still presents the danger of explosion or fire. Disconnect the battery ground cable from the battery to minimize the possibility of an electrical spark occurring, possibly causing a fire or explosion if fuel vapor or liquid fuel are present in the area. Failure to follow these instructions can result in personal injury. WARNING: Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel related component. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in personal injury. 1. With the vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Section 100-00. 2. Disconnect the battery ground cable. For additional information, refer to Section 414-00. 3. Remove the parts in the order indicated in the following illustrations and tables. To remove individual parts, only carry out the listed steps: Items 2, 5 and 13: Quick Connect Fitting Removal Note 1. CAUTION: Fuel injection equipment is manufactured to very precise tolerances and fine clearances. It is therefore essential that absolute cleanliness is observed when working with these components. Always install blanking plugs to any open orifices or tubes. CAUTION: When reusing liquid or vapor tube connectors, make sure to use compressed air to remove any foreign material from the connector retaining clip area before separating from the tube. Disconnect the quick release fitting.

download
1. NOTE: When the battery has been disconnected or reconnected, volatile memory information will be lost. The affected systems will have to be programmed by the technician or customer. These systems include: radio station presets, clock settings, seat memory, mirror memory, window memory and customer input keyless, window memory and customer input keyless entry codes. Disconnect the battery ground cable. For additional information, refer to Section 14-01. 2. Drain the cooling system. For additional information, refer to section 03-03. 3. Remove the engine cover (covering the throttle body). 4. Disconnect the crankcase ventilation tube and the idle air control valve inlet tube from the air cleaner outlet tube. Remove the air cleaner outlet tube. 5. WARNING: THE FUEL SUPPLY LINES ON VEHICLES EQUIPPED WITH FUEL INJECTED ENGINES REMAIN PRESSURIZED FOR LONG PERIODS AFTER ENGINE SHUT DOWN. THE FUEL SYSTEM PRESSURE MUST BE RELIEVED PRIOR TO FUEL SYSTEM SERVICE, TO PREVENT POSSIBLE INJURY. Connect the Multiport Fuel Injection (MFI) Fuel Pressure Gauge (T80L-9974-B) to the fuel pressure relief valve on the fuel supply manifold. Open the manual valve on the gauge to relieve the fuel system pressure. Once the pressure is relieved, close the valve and remove the gauge. 6. Remove the locking clip from the pressure and return fuel line spring lock couplings. Using the spring lock coupling disconnect tools (D87L-9280-A for 3/8-inch line, D87L-9280-B for 1/2-inch line) on the couplings. Push the tool into the cage opening to release the female fitting from the garter spring. Remove the tool and pull the male coupling and fitting apart. Install protective caps over the lines and the fuel rail. 7. Disconnect the upper radiator hose from the water outlet connection and position it out of the way. 8. Disconnect the accelerator cable and the speed control actuator cable from the throttle body and the locator. Remove the screws retaining the cables to the accelerator cable bracket and position the cables out of the way. 9. Disconnect the wiring connectors from the throttle position sensor (TP), idle air control valve (IAC) and the engine coolant temperature sensor (ECT). Disconnect the wiring connectors from the LH fuel injectors and the two wiring locators from the fuel rail. Position the harness out of the way. 10. CAUTION: Do not pull directly on the ignition wires, the wires could separate from the connectors inside the boots. Disconnect the ignition wires from the LH spark plugs and position them out of the way. Refer to Section 03-07. 11. Remove the bolts retaining the spark plug wiring harness bracket to the intake manifold and the generator. Disconnect the ignition wires from the locators and remove the bracket. 12. Remove the serpentine drive belt from the generator pulley. Refer to Section 03-05. 13. Remove the generator retaining bolts and position it out of the way. 14. Remove the PCV valve and tube. 15. Disconnect the wiring connectors from the water temperature indicator sender unit and the EGR vacuum regulator solenoid. Disconnect the RH fuel injector connectors and harness locators from the fuel rail. Position the harness out of the way. 16. CAUTION: Do not pull directly on the ignition wires, the wires could separate from the connectors inside the boots. Disconnect the ignition wires from the RH spark plugs and position them out of the way. For additional information, refer to Section 03-07. 17. Disconnect the vacuum line from the fuel vapor storage canister purge valve. Disconnect the heater hose from the rear of the intake manifold. 18. Disconnect the main vacuum hose from the rear of the intake manifold. Disconnect the hose from the fuel vapor storage canister purge valve. 19. Disconnect the EGR tube nut from the EGR valve. 20. Disconnect the vacuum hose from the EGR valve. Remove the EGR valve and gasket. 21. Remvoe the water outlet connection housing. 22. Remove the intake manifold. Remove and discard the intake manifold gaskets.

download
1. Verify the customer concern by operating the system. 2. Visually inspect for obvious signs of mechanical or electrical damage. Visual Inspection Chart Mechanical Fuel vapor hoses EVAP canister Vapor management valve (VMV) 3. If an obvious cause for an observed or reported concern is found, correct the cause (if possible) before proceeding to the next step. 4. If the NGS tester does not power up, refer to the New Generation STAR tester manual. 5. Carry out the DATA LINK DIAGNOSTIC TEST. If the NGS tester responds with: CKT914, CKT915 or CKT70-ALL ECUS NO RESP/NOT EQUIP, REFER to Section 418-00. NO RESP/NOT EQUIP for Powertrain Control Module (PCM), REFER to Powertrain Control/Emissions Diagnosis (PC/ED) manual. System passed, retrieve and record the continuous diagnostic trouble codes (DTCs). 6. If the DTCs retrieved are related to the concern, go to the Diagnostic Trouble Code (DTC) Index. 7. If no DTCs related to the concern are retrieved, proceed to the Symptom Chart to continue diagnostics. Electrical Loose or corroded connector(s) Symptom Chart Symptom Chart Hissing sound when removing the fuel cap Excessive fuel odor Condition Possible Sources Circuit(s). Vapor Management Valve (VMV). EVAP canister purge Valve. Blocked fuel vapor hose. Circuit(s). Vapor Management Valve (VMV). EVAP canister purge Valve. EVAP canister. Fuel vapor hose. Action Go To Pinpoint Test A. Go To Pinpoint Test B.

download
1. Disconnect the battery ground cable. For additional information, refer to Section 414-01. 2. Remove the air cleaner outlet tube. For additional information, refer to Section 303-12. 3. Remove the air cleaner housing. 1. Disconnect the mass air flow (MAF) sensor electrical connector. 2. Remove the bolt. 3. Remove the housing. 4. CAUTION: To disconnect the Norma fitting, squeeze the tabs and pull straight out or damage to the fitting can occur. Disconnect the crankcase ventilation tube. 5. Disconnect the fuel hose. For additional information, refer to Section 310-00. 6. Disconnect the evaporative emission canister purge valve hose. 7. Remove the vapor management valve (VMV) cover. 8. Remove the VMV. 1. Disconnect the vacuum hose. 2. Disconnect the purge hose. 3. Disconnect the electrical connector and the push pin. 4. Remove the nuts and the valve. 9. Remove the exhaust gas recirculation (EGR) vacuum regulator solenoid. 1. Disconnect the electrical connector. 2. Remove the screws and the EGR vacuum regulator solenoid. 10. Remove the bracket. 1. Remove the hose. 2. Remove the bracket. 11. Position the engine wiring harness up. 12. Remove the ignition coil cover. Inspect the gasket and install a new gasket as necessary.

download
1. Disconnect the battery ground cable. For additional information, refer to Section 414-01. 2. Remove the air cleaner outlet tube. For additional information, refer to Section 303-12. 3. Remove the air cleaner housing. 1. Disconnect the mass air flow (MAF) sensor electrical connector. 2. Remove the bolt. 3. Remove the housing. 4. CAUTION: To disconnect the normal fitting, squeeze the tabs and pull straight out or damage to the fitting may occur. Disconnect the crankcase ventilation tube. 5. Disconnect the fuel line. For additional information, refer to Section 310-00. 6. Disconnect the evaporative emission canister purge valve hose. 7. Remove the vapor management valve (VMV) cover. 8. Position the VMV aside. 1. Disconnect the vacuum hose. 2. Disconnect the purge line. 3. Remove the nuts and position the valve aside. 9. Position the engine vacuum regulator (EVR) solenoid aside. 10. Remove the bracket. 1. Remove the hose. 2. Remove the bracket. 11. Position the engine wiring harness up. 12. Remove the ignition coil cover. Inspect the gasket and install a new gasket as necessary. 13. Disconnect the ignition coil electrical connectors. 14. Remove the four LH ignition coils. 15. Disconnect the four wiring harness retainers. 16. Remove the fuel line bracket bolt from the LH shock tower. 17. Remove the bolts and position the power steering pump reservoir aside. 18. Remove the nut and the oil level indicator tube.