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

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General Precautions (Cont’d) After disconnecting vacuum or air hoses, attach a tag to indicate the proper connection. • Use only the fluids and the lubricants specified in MA sec- tion and HA section or their equivalents • Use approved bonding agent, sealants or their equivalents when required • Use tools and recommended special tools where specified for safe and efficient service repairs. • When repairing the fuel, oil, water, vacuum or exhaust systems, check all affected lines for leaks. • Dispose of drained oil or the solvent used for cleaning parts in an appropriate manner. • Precautions for Multiport Fuel Injection System or ECCS Engine Sefore connecting or disconnecting multiport fuel injection system or ECM (ECCS control module) harness connector, be sure to turn the ignition switch to the “OFF” position and disconnect the negative battery terminal Otherwise, there may be damage to ECM. • Before disconnecting pressurized fuel line from fuel pump to injectors, be sure to release fuel pressure to eliminate danger • Be careful not to jar components such as ECM and mass air flow sensor • Precautions for Three Way Catalyst If a large amount of unburned fuel flows into the converter, the converter temperature wfll be excessively high. To prevent this, follow the procedure below: 1. Use unleaded gasoline only. Leaded gasoline will seri- ously damage the three way catalyst. 2. When checking for ignition spark or measuring engine compression, make tests quickly and onfy when neces- sary. 3. Do not run engine when the fuel tank level is low, other- wise the engine may misfire causing damage lo Ihe con- verter. Do not place the vehicle on flammable material. Keep flamma- ble material off the exhaust pipe and the three way catalyst Precautions for Turbocharger The turbocharger turbine revolves at extremely high speeds and becomes very hot. Therefore, it is essential to maintain a clean supply of oil flowing through the turbocharger and to follow all required maintenance instructions and operating procedures. For proper operation of Ihe system, follow the procedure below. 1 Always use the recommended oil. Follow the instructions for proper time to change the oil and proper oil level 2. Avoid accelerating engine to a high rpm immediately after starting. 3. If engine had been operating at high rpm for an extended period of time, let it idle for a few minutes prior [o shutting it off. Engine Oils Prolonged and repealed contact with used engine oil may cause skin cancer. Try to avoid direct skin contact with used oil. If skin contact is made, wash thoroughly with soap or hand cleaner as soon as possible HEALTH PROTECTION PRECAUTIONS • Avoid prolonged and repeated contact with oils, particu- larly used engine oils, • Wear protective clothing, including impervious gloves where practicable. • Do not put oily rags in pockets • Avoid contaminating clothes, particularly underpants, with oil. • Heavily sailed clothing and oil-impregnated footwear should not be worn. Overalls must be cleaned regularly • First Aid treatment shouid be obtained immediately for open cuts and wounds • Use barrier creams, applying them before each work period, to help the removal of oil from the skin • Wash with soap and water to ensure all oil is removed (skin cleansers and nail brushes will help). Preparations containing lanolin replace the natural skin oils which have been removed • Do not use gasoline, kerosine, diesel fuel, gas oil, Ihinners or solvents for cleaning skin • If skin disorders develop, obtain medical advice without delay • Where practicable, degrease components prior to han- dling • Where there is a risk of eye contact, eye protection should be worn, for example, chemical goggles or face shields; in addition an eye wash facility should be provided. i-v ENVIRONMENTAL PROTECTION PRECAUTIONS Burning used engine oil in small space heaters or boilers can . be recommended only for units of approved design The heat- ing system must meet the requirements of HM Inspectorate ol Pollution for small burners of less than 0,4 MW. If in doubt check with Ihe appropriate local authority and/or manufacturer of the approved appliance. Dispose of used oil and used oil fillers through authorized . waste disposal contractors to licensed waste disposal sites, or to the waste oil reclamation trade. If in doubt, contact the local authority for advice on disposal facilities, :•• It is illegal to pour used oil on to the ground, down sewers or drains, or into water courses The regulations concerning the pollution of the environment witl vary from country to country.

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Caution: Refer to Gasoline/Gasoline Vapors Caution in the Preface section. Important: There are several types of Plastic Collar Fuel and Evaporative Emission Quick Connect Fittings used on this vehicle. • Bartholomew (1) • Q Release (2) • Squeeze to Release (3) • Sliding Retainer (4) • Push Down TI (5) The following instructions apply to all of these types of Plastic Collar Quick Connect Fittings except where indicated. 1. Relieve the fuel system pressure before servicing any fuel system connection. Refer to the Fuel Pressure Relief . Caution: Refer to Safety Glasses Caution in the Preface section. Notice: Refer to Fuel and Evaporative Emission Hose/Pipe Connection Cleaning Notice in the Preface section. 2. Using compressed air, blow any dirt out of the quick-connect fitting. 3. This step applies to Bartholomew style connectors ONLY. Squeeze the plastic quick connect fitting release tabs. 4. This step applies to Q Release style connectors ONLY. Release the fitting by Pushing the tab toward the other side of the slot in the fitting. 5. This step applies to Squeeze to Release style connectors ONLY. Squeeze where indicated by arrows on both sides of the plastic ring surrounding the quick connect fitting. 6. This step applies to Sliding Retainer style connectors ONLY. Release the fitting by pressing on one side of the release tab causing it to push in slightly. If the tab does not move, try pressing the tab in from the opposite side. The tab will only move in one direction. 7. This step applies to the Push Down TI style connectors ONLY. Release the fitting by pressing on the tab indicated by arrow. Caution: Refer to Relieving Fuel Pressure Caution in the Preface section.

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1. With vehicle in NEUTRAL, position it on a hoist. For additional information, refer to Section 100-00. 2. Release the fuel pressure. For additional information, refer to Section 310-00. 3. Disconnect the battery ground cable. For additional information, refer to Section 414-00. 4. If removing the fuel tank or fuel pump module, use the special tool and siphon the fuel through the fuel filler hose into a suitable container. 5. Remove the parts in the order indicated in the following illustrations and tables. To remove individual parts, only carry out the listed steps: 6. To install, reverse the removal procedure. 7. Turn the ignition key to the ON position to pressurize the fuel system. 8. Visually inspect the fuel system for leaks. Item 3: Fuel Filler Pipe Pin-Type Retainer Removal Note 1. Remove the LH rear wheel well inner splash shield. Item 7: Fuel Filler Pipe Removal Note 1. CAUTION: Some fuel will remain in the fuel filler pipe after draining the fuel tank. Carefully drain the filler pipe into an appropriate container. Separate the fuel vapor fresh air hose from the fuel filler pipe mounting bracket. Items 9, 10 and 18: Fuel Supply and Vapor Tube Quick Connect Fittings Removal Note 1. 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 the tube. NOTE: If the fuel tube or retainer clip is broken or damaged, install a new clip using a suitable fuel line disconnect tool to separate the retainer clip legs. Once the retainer clip legs have been separated, lift the clip out of the connector housing, lifting from the stamped side of the connector body. Disconnect the fuel tube quick release coupling. Push the connector towards the tube to release pressure. Press the fuel tube quick release coupling button and pull the fuel tube to disconnect.

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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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1. Remove the upper intake manifold. For additional information, refer to Upper Intake Manifold in this section. 2. Disconnect the fuel line spring lock couplings. For additional information, refer to Section 310-00. 3. Disconnect the fuel pressure sensor. 1. Disconnect the fuel pressure sensor electrical connector. 2. Disconnect the fuel pressure vacuum line. 4. Disconnect the fuel injector electrical connectors and position the wiring harness to one side. 5. CAUTION: Do not loosen or bend the intake manifold runner control (IMRC) cable bracket. The bracket alignment is critical and damage to the IMRC actuator may occur. Disconnect the IMRC actuator cable from the stud and bracket. 6. NOTE: Remove the bolts in the indicated sequence. Remove the lower intake manifold and discard the gaskets. Installation 1. NOTE: Use new lower intake manifold gaskets. NOTE: Tighten the bolts in the indicated sequence. Install the lower intake manifold. Install the gaskets with the locating holes facing downwards. Position the gaskets in the position holes.