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

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WARNING: WHEN DRAINING FUEL FROM THE FUEL TANK, KEEP SPARKS, SMOKING MATERIALS, AND OPEN FLAMES AWAY FROM THE VEHICLE. WARNING: THE FUEL SYSTEM CONTAINS PRESSURIZED FUEL AFTER THE VEHICLE IS SHUT DOWN AND WILL MAINTAIN THE PRESSURE FOR A LONG PERIOD OF TIME. 1. Relieve the fuel pressure; refer to Section 310-00. 2. Disconnect the battery ground cable (14301); refer to Section 414-01. 3. Raise and support the vehicle; refer to Section 100-02. 4. Disconnect the fuel tank filler pipe hose (9047) from the fuel tank (9002). 5. Drain the fuel from the fuel tank (9002); refer to Section 310-00. 6. Disconnect the fuel tank vent tube (9A228) from fuel tank filler pipe (9034). 7. Disconnect the fuel pump electrical connector. 8. If equipped, remove fuel tank skid plate. 1. Remove the five fuel tank skid plate bolts. 2. Lower the fuel tank skid plate. 9. Position a suitable jack under the fuel tank (9002). 10. Remove the front fuel tank support strap (9092). 1. Remove the two bolts. 2. Remove the front fuel tank support strap (9092). 11. Remove the rear fuel tank support strap (9092). 1. Remove the three bolts. 2. Remove the rear fuel tank support strap. 12. Partially lower the fuel tank and disconnect the two EVAP emissions hoses. 13. Remove the two safety clips from the fuel lines. 14. Disconnect the fuel lines from the fuel pump (9350). 1. Install and push the (A) fuel line disconnect tool into the (B) female fitting. 2. Separate the male and female fitting. 15. Remove the fuel tank. 16. Remove the fuel pump. 1. Remove the fuel pump locking retaining ring (9C385). 2. Remove the fuel pump and discard the O-ring. Installation 1. Install the fuel pump (9350). 1. Install a new O-ring and fuel pump (9350). 2. Install the fuel pump locking retainer ring (9C385). 2. With a suitable jack, position the fuel tank (9002). 3. Connect the fuel lines. 4. Connect the safety clips. 5. Connect the EVAP emissions hoses.

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All vehicles 1. Disconnect the battery ground cable. For additional information, refer to Section 414-01. 2. Partially drain the cooling system. For additional information, refer toSection 303-03. 3. Remove the power steering fluid reservoir bracket. 1. Remove the bolts. 2. Position the power steering fluid reservoir bracket out of the way. 4. Remove the accelerator control splash shield. 1. Remove the bolts. 2. Remove the accelerator control splash shield. 5. Disconnect the fuel pressure regulator vacuum hose. CAUTION: After disconnecting, plug the fuel lines to prevent leakage. 6. Disconnect the fuel lines. For additional information, refer to Section 310-00. 7. Disconnect the eight fuel injector electrical connectors. 8. Disconnect the eight ignition coil electrical connectors. 9. Remove the brake booster bracket and tube. 1. Remove the nut. 2. Release and move the two hose clamps. 3. Remove the brake booster tube. 10. Remove the positive crankcase ventilation (PCV) hose. For vehicles equipped with 4.6L engine 11. Disconnect the differential pressure feedback exhaust gas recirculation (EGR) connector, then disconnect the upper and lower EGR valve tube fitting.

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WARNING: Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel-related components. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in personal injury. WARNING: Fuel in the fuel system remains under high pressure even when the engine is not running. Before working on or disconnecting any of the fuel lines or fuel system components, the fuel system pressure must be relieved. Failure to follow these instructions may result in personal injury. 1. Disconnect the battery ground cable (14301). For additional information, refer to Section 414-01. 2. Relieve the fuel pressure. For additional information, refer to Section 310-00A (Gasoline) or Section 310-00B (Natural Gas). 3. Disconnect the fuel lines. For additional information, refer to Section 310-00A (Gasoline) or Section 310-00B (Natural Gas). 4. Remove the throttle body (9E926). For additional information, refer to Throttle Body in this section. 5. On gasoline engines, remove the EGR valve to exhaust manifold tube (9D477). For additional information, refer to Section 303-08. 6. Remove the drive belt (8620). For additional information, refer to Section 303-05. Vehicles equipped with natural gas engines 7. Disconnect the fuel temperature sensor connector. 8. Disconnect the fuel pressure sensor connector. All vehicles 9. Disconnect the main fuel shut-off solenoid connector. 10. Disconnect the generator cable, electrical connector, and harness pin-type retainer. 11. Remove the bolts and the generator mounting bracket (10153). 12. Remove the bolts. 13. Unclip the accelerator cable (9A758) and the speed control actuator cable (9A825) from the two crash brackets and position out of the way. 14. Separate the LH heated oxygen sensor and the transmission electrical connector from the bracket at the rear of the cylinder head. 15. Separate the fuel charging wiring pin-type retainer from the crash bracket. 16. Remove the wiring bracket. Disconnect the wiring connectors. Separate the transmission harness from the stud. Remove the nut and the bolt and remove the bracket.

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1. Once the engine has been allowed to cool, disconnect the negative battery cable, relieve fuel system pressure and drain engine coolant, referring to the appropriate vehicle service manual for the procedure on doing so. 2. First the factory manifold must be removed using the following steps, for specific details and instructions refer to the factory service manual. 3. Remove the turbo intercooler (top mount only) and air intake duct. 4. Disconnect all the wiring harness connections, noting where each goes. 5. Remove the bolts holding accessories and brackets to the manifold. 6. Disconnect all vacuum lines from the manifold, noting where each goes. 7. Remove the tumbler valve bolts connecting them to the heads, keeping the intake bolted to the top of the tumbler valve. In some cases it may be easier to remove the tumbler valves from the intake manifold. 8. Disconnect the fuel lines from the fuel rail assembly located on the driver side by the firewall, placing clean shop towels around the fuel lines to catch any gasoline that may be spilled during their removal 9. Carefully lift off the intake manifold, tumbler valve, OE fuel rail assembly. 10. Remove the three bolts holding the OE fuel lines to the bottom of the intake manifold. 11. Remove the four bolts holding the OE fuel rails to the tumbler valves. 12. Remove the OE fuel rail assembly from the intake manifold assembly, being careful not to damage the fuel injector pipe insulator between the bottom of the OE fuel rail and the tumbler valve. Fuel Injector Pipe Insulator 13. Remove each of the injector spring clips.

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1) Remove air duct, battery cover, battery, lower battery tray and silver wiring harness bracket that is mounted with two bolts to
the battery tray. 2) Remove bypass valve along with both tubes connected to it. 3) Remove air intake box and tube. 4) At this point you can now install the air filter fan shield using the supplied M8 bolts. If you are using an OEM or Aftermarket intercooler pipe that still utilizes the mount on the battery tray remove the bolt and install the fan shield with the spacer in between the shield and intercooler pipe tab, tighten it down with the supplied longer M8 bolt. If you are using an Aftermarket intercooler pipe that doesn’t have the mount you will need to use the supplied longer spacer to space the fan shield away from the battery correctly. Refer to picture below. 5) Remove the backing from the battery tray and stick it into place. Then you can set the battery on it and install the battery cables at the angles shown. 6) You can now lay the battery into position and tie it down using the supplied tie down. This can be done using the OEM hook locations. You may have to remove some of the wire tie downs to allow the cables to move with the battery. 7) Install the turbo to intake custom silicone coupler onto the turbo, leave the clamps loose at this time. This coupler is to be routed underneath the fuel lines and engine harness. Be sure to completely seat the coupler onto the turbo. Install the intake pipe and filter leaving the clamps loose for further adjustment. 9) Now at this time get the tube that connected the bypass valve to the intercooler piping and cut 1 in. off of one end as shown below*. The end that you cut goes to on the bypass valve, the other end to the intake.