Auto Repair Manual Free Download and ReviewsFree download ebook pdf files automotive manual

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Removal 1. Disconnect the battery ground cables. 2. WARNING: RED-STRIPED WIRE HARNESS CARRIES 115V DC. SEVERE ELECTRICAL SHOCK MAY BE RECEIVED. DO NOT PIERCE. CAUTION: Do not attempt to service the fuel injector. The fuel injector is serviced as an assembly. If the fuel injector is disassembled for any reason, the calibration of the fuel injector will be inaccurate. There are two different fuel injectors used in the 7.3L DI turbo diesel engine: a 49-state injector and the California injector (rate shaped injector). These two injectors must not be interchanged because the Powertrain Control Modules are calibrated to the specific injector. Before replacing any injectors, refer to the Vehicle Emission Control Information (VECI) decal for proper injector selection. Failure to do so can cause poor engine performance, high emissions levels or damage to engine. Remove the engine cover. 3. Remove the two (2) nuts retaining the air cleaner-outlet tube support bracket to the left valve cover. Remove the engine harness bracket from the air cleaner- outlet tube support bracket and position aside. 4. Remove and discard the crankcase ventilation hose clamp and disconnect the hose. Loosen the clamps at the turbocharger and air cleaner and disconnect the intake duct and outlet tube. 5. Remove the bolt and nut retaining the air cleaner assembly, disconnect the air intake sensor and remove the air cleaner assembly. 6. CAUTION: Do not pierce engine electrical wires or damage to the harness can occur. Remove the engine harness tie strap from the left engine-lifting bracket. 7. Remove the two (2) crankcase breather filter retaining screws and remove the crankcase breather filter from the left valve cover. 8. Remove the left valve cover. 9. Disconnect the electrical connectors from the left valve cover gasket. Remove the valve cover gasket. 10. Disconnect the electrical connectors from the left fuel injectors and the glow plugs. 11. Drain the oil from the left cylinder head by removing the internal oil rail drain plugs. 12. Remove the left oil deflectors. 13. WARNING: DO NOT ROTATE THE CRANKSHAFT WITH THE FUEL INJECTOR REMOVED. OIL AND FUEL WILL ENTER THE COMBUSTION CHAMBER WHICH COULD CAUSE ENGINE DAMAGE OR PERSONAL INJURY. NOTE: The shoulder bolt on the inboard side of the fuel injector does not require removal. Remove the left outboard fuel injector-retaining bolts.

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1) Getting started a) b) c) d) Make sure vehicle is parked on a level surface. Set parking brake. Disconnect negative battery terminal. If engine has run within the past two hours let it cool down. 2) Removing the stock air inlet system Push in and remove. Clip a) Push in clip on the center circle to remove. Remove both clips. Remove inlet duct to air box. b) Locate the 4 clips on each corner of the air box. Remove c) Unfasten the 4 clips that hold down the top to the air box. Remove top. 3 Loosen only. Remove d) Remove the filter element. Remove the bolts holding down the bottom portion of the air box. e) Loosen the hose clamp connected to the bottom portion of the air box. NOTE: Do not loosen the worm gear type hose clamp located on the charge pipe. Loosen and remove. Unplug. f) Disconnect the MAF sensor harness from the bottom portion of the air box. Carefully remove the bottom portion of the air box. The honeycombs in the MAF sensor are sensitive, take note not to damage during removal. g) Carefully remove the 4 bolts holding the MAF sensor to the bottom portion of the air box. Check the MAF sensor gasket for tears or cracks. Replace as necessary. h) Loosen the hose clamp connecting the blow off valve to the turbo inlet hose. Disconnect the blow off valve from the inlet hose. Remove hose clamp from the inlet hose. Loosen and remove. 4 Disconnect. Loosen hose clamp i) Loosen the hose clamp on the turbo inlet hose at the turbo. This double ring clamp is similar to the clamp in step f. j) Disconnect the crankcase breather tube at the turbo inlet hose. Remove k) Disconnect vacuum line from the boost solenoid to the turbo inlet hose. The vacuum line is located underneath the turbo inlet hose. Remove the turbo inlet hose.

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Installation Instructions Part Number 200-630 2008-09 Buick Enclave 2008-09 Chevrolet Equinox Sp. 2008-09 Chevrolet Malibu 2008-09 Chevrolet Traverse 2008-09 GMC Acadia 2008-09 Pontiac G6 GXP 2008-09 Pontiac G8 2008-09 Pontiac Torrent GXP 2008-09 Saturn Outlook 2008-09 Saturn Vue XR 2008-09 Suzuki LX7 3.6L V-6 2. Disconnect the breather hose elbow from the intake tube. Loosen the two hose clamps that secure the intake tube to the throttlebody, and the mass air flow sensor. Remove the air intake tube. 1. Disconnect the negative battery cable! Remove the oil fill cap and set it aside. Lift straight up on the engine beauty cover and set it aside. Reinstall the oil fill cap after the beauty cover has been re- moved to prevent any foreign material from entering the crank- case. 3. Remove the four bolts that secure the throttlebody to the in- take manifold. 5. Install the provided bolts and washers thru the throttlebody and Poweraid Spacer and tighten to the manufacturer’s specifi- cations. 4. Install the Poweraid Spacer between the throttlebody and the intake manifold with the first supplied gasket next to the intake manifold, and the second supplied gasket next to the throttle- body as shown. Make sure the “flow” arrow printed on the spacer is pointing towards the intake manifold. 6. Reinstall the intake tube, tighten the two hose clamps, and reconnect the crankcase breather tube. Reinstall the beauty cover, and oil cap in the reverse order that they were removed. Re-connect the negative battery cable!

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AC compressor clutch relay AC master switch AC refrigerant triple pressure switch Accelerator pedal position (APP) sensor Battery – Battery + Brake pedal position (BPP) switch Camshaft position (CMP) sensor Clutch pedal position (CPP) switch Crankcase breather heater Crankshaft position (CKP) sensor Data link connector (DLC) Engine control (EC) relay Engine control module (ECM) Engine coolant blower motor relay Engine coolant heater Engine coolant heater relay Engine coolant ‘hot’ warning lamp Engine coolant temperature (ECT) sensor Engine malfunction indicator lamp (MIL) Exhaust gas recirculation (EGR) solenoid Exhaust gas recirculation (EGR) valve position sensor Fuel lift pump Fuel lift pump relay Fuel pressure control solenoid Fuel pressure sensor Fuel temperature sensor Fuse Fuse box/relay plate Glow plug Glow plug control module Glow plug warning lamp Ignition switch – ignition ON Inertia fuel shut-off (IFS) switch Injector Instrument panel Renault Scenic