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

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cooler Hose replacement Procedure 1) Place vehicle on lift. 2) Remove the engine under cover. Hose clamp location 3) Squeeze the hose clamps and reposition to remove the hose. Confirm the direction and angle of the original hose clamps before removal. It is important to reinstall clamps in their original position. 4) Place a drain pan under the hose to collect any CVTF which may leak out. caution: if the cVtF has spilled onto the exhaust pipe or body frame, wipe it off with a rag to avoid dripping fluid. 5) Remove the inlet cooler hose. Note: Be extremely careful not to damage the pipe. 6) Make sure the cooler hose pipe ends are clean prior to installing a new hose. 7) Install a new hose reusing the original hose clamps. Note: Do not permit the end of the hose to extend past the raised lip section of the pipe. Be sure to place the hose clamps in their original position. If the original hose clamps are damaged or deformed, replace as necessary. note: Neither replenishment of transmission fluid nor inspection of fluid level will be neces- sary during replacement of the hose unless the original hose was found to be leaking fluid. Approx. 50cc through 70cc of fluid may be lost during hose replacement. The amount of fluid remaining will still keep the necessary level with sufficient reserve margin. check and add cVtF cAution: • CVTF level changes along with CVTF temperature. When inspecting CVTF level, observe the specified CVTF temperature. • Always use specified CVTF or equivalent. Using other fluid except for specified or equivalent will cause malfunction.

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WARNINGS AND NOTES 1. Make sure ignition is turned off (dash off). For extra protection, you may disconnect the battery (in the trunk). 2. Make sure all hose clamps are positioned after the bead on the intercooler piping. Failure to do so will result in boost leaks or hoses popping off. SILICONE HOSE C L A M P C L A M P BEAD IN INTERCOOLER PIPE 3. Do not over tighten hose clamps. If you notice distortion of the clamp or tearing of the silicone hose, you’ve gone too tight! 4. After you’ve taken your car for a test drive, check all hose clamps again to make sure they are tight and correctly positioned.INSTALLATION INSTRUCTIONS INSTRUCTIONS 1. REMOVE RADITOR SHROUD AND AIR INLET – Remove air inlet scoop by unscrewing Phillips head body clips and gently pulling scoop from airbox. – Remove radiator shroud by removing plastic clips with flathead screwdriver. Use care not to break the clips. Once the tab is popped out ½ way, you can remove the both pieces at once by hand. Once all plastic clips are removed, pull the radiator shroud up toward you until it pops out of place. Make sure all clips are removed before pulling too hard. 2. REMOVE 12MM BOLTS SECURING UICP TO RADIATOR SUPPORT 3. LOOSEN HOSE CLAMPS AND REMOVE INTERCOOLER PIPE NOTE: ACCESSING LOWER HOSE CLAMP THROUGH GRILL W/ 10MM SOCKET 4. REMOVE FACTORY INTERCOOLER PIPE BUSHINGS AND INSTALL TO HARMAN INTERCOOLER PIPE 5. INSTALL HARMAN MOTIVE INTERCOOLER PIPE 2.5” Straight Hose 6. REINSTALL RADIATOR SHROUD AND AIR INLET SCOOP START THE CAR AND LISTEN FOR ANY LEAKS. TAKE THE CAR ON A TEST DRIVE THEN RECHECK ALL HOSE CLAMPS.

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FUEL SYSTEM PRESSURE RELEASE NOTE: 1. Loosen fuel tank filler cap to relieve tank pressure. Remove fuel pump relay from underhood fuse/relay box. Start and operate engine until it stalls. Crank engine an additional 30 seconds. 2. Loosen hose clamp of fuel line on side of pressure regulator, coming from fuel line inlet distributor pipe. Cover fuel hose with a shop towel, and slowly pull hose from pressure regulator to relieve fuel pressure. When fuel stops leaking, reinstall hose and clamp. FUEL PRESSURE & FUEL PUMP RELAY TEST NOTE: Fuel Pressure 1. Relieve fuel pressure. See FUEL SYSTEM PRESSURE RELEASE . Attach Fuel Pressure Gauge Set (J-34730-1 ) and Adapter (J-35957-1 ) to Schrader fitting on fuel rail. Disconnect pressure regulator vacuum hose. Turn ignition on. Allow fuel pump to run for about 2 seconds. 2. Fuel system pressure should be about 41-46 psi (2.8-3.2 kg/cm2 ). See FUEL PUMP PERFORMANCE . Start engine and check for leaks. Connect pressure regulator vacuum hose. If engine will not start, the fuel pump relay can be by-passed. Also see appropriate CHART A-3 – ENGINE CRANKS BUT WILL NOT RUN under TROUBLE SHOOTING CHARTS. With engine idling, fuel pressure should be 25-30 psi (1.8-2.1 kg/cm2 ). NOTE: Fuel pump relay is located in engine compartment fuse/relay box. Begin basic fuel system diagnosis with testing fuel pressure. To test the fuel pump relay circuit, proceed to CHART A-5 – FUEL PUMP RELAY CIRCUIT under TROUBLE SHOOTING CHARTS. Fuel Pump Relay 1. ECM supplies power to relay as long as ECM receives ignition reference signals or starter crank signal. To run fuel pump without starting engine, remove relay and jumper terminals No. 2 and 4. See Fig. 5 and Fig. 6 . 2. To test relay, use jumper wires to ground terminal No. 4 of relay and apply battery voltage to terminal No. 2 of relay. Using ohmmeter, check for continuity between relay terminals No. 1 and 3. If continuity is not present, replace relay.

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Fuel Injector: Service and Repair NOTE: Before removing nozzle assemblies, clean exterior of each nozzle assembly and the surrounding area with solvent to prevent entry of dirt into engine when nozzle assemblies are removed. Also, clean fuel inlet and fuel leak-off piping connections. Blow dry with compressed air. Remove and cap line sensor on number 1 cylinder to permit removal of fuel leak-off tee. REMOVAL 1. Disconnect nozzle fuel inlet (high pressure) and fuel leak-off tees from each nozzle assembly and position out of the way. Cover open ends of fuel inlet lines and nozzles to prevent entry of dirt with fuel system protective cap set. 2. Remove fuel leak-off lines as an assembly. a. Remove pump to fuel return tube hose at fuel return elbow cap elbow at pump. disconnect hose (from leak-off tee of fuel filter) at leak-off tee. b. Loosen two fuel return tube retaining clamps, one at intake manifold and one at engine lifting eye. Remove fuel return hose clamp at CDR valve bracket. c. With clamps removed, remove return lines and tees as an assembly by lifting tees off nozzles. 3. Remove injection nozzles by turning counterclockwise. Pull nozzle assembly with copper washer from engine. Be careful not to strike nozzle tip against any hard surface during removal. Cover nozzle assembly fuel inlet opening and nozzle tip with plastic cap to prevent entry of dirt. NOTE: Remove copper injector nozzle gasket from nozzle bore with O-Ring tool T71P-19703-C or equivalent if not attached to the nozzle tip. 4. Place nozzle assemblies in a fabricated holder as they are removed from the heads. The holds should be marked with numbers corresponding to the cylinder numbering of the engine. Use of this holder permits nozzle installation into original location in the cylinder heads. INSTALLATION 1. Thoroughly clean nozzle bore in cylinder head before reinserting nozzle assembly with nozzle seat cleaner. Pay particular attention to seating surface, in order that no small particles of metal or carbon will cause assembly to be cocked or permit blow-by of combustion gases. Blow out particles with compressed air. 2. Remove protective cap and install a new copper gasket nozzle assembly, with a small dab of polyethylene grease. NOTE: Anti-seize compound should be used on nozzle threads to aid installation and future removal. 3. Install nozzle assembly into cylinder head nozzle bore. CAUTION: Be careful that nozzle tip does not strike against recess wall. 4. Tighten nozzle assembly to 47 Nm (35 ft lb). 5. Remove protective caps from nozzle assemblies and fuel lines. 6. Install leak-off tees and lines as an assembly by lowering onto nozzles. Connect clip and hose to fuel return elbow at pump. Install line to retaining clamps. NOTE: Install two new O-ring seals for each fuel return tee. 7. Connect high pressure fuel line(s) and tighten to 30 Nm (22 ft lb) using fuel line nut wrench. 8. Start engine. 9. If necessary, purge high-pressure fuel lines of air by loosening connector one-half to one turn and cranking engine until bubble-free fuel flows from connection.

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1. Remove the fuel tank. 2. Disconnect the evaporative emission (EVAP) line (3) from the canister.3. Reposition the EVAP canister hose clamp. 4. Remove the EVAP canister hose. 5. Disconnect the canister EVAP line from the fuel sender. 6. Squeeze the small retainer in front of the canister in order to disengage the canister. 7. Remove the EVAP canister. Installation Procedure Notice: Do not attempt to straighten kinked nylon pipes. Replace any kinked nylon pipes in order to prevent damage to the vehicle. Do not attempt to repair sections of nylon pipes. Replace damaged nylon pipes. Replace the vapor pipes with original equipment or parts that meet GM specifications. Replace the vapor hoses with original equipment or parts meeting GM specifications. Use only reinforced fuel-resistant hose identified with the word Fluoroelastomers or GM 6163M on the hose. 1. Install the EVAP canister. 2. Squeeze the small retainer in front of the canister in order to engage the canister. 3. Connect the canister EVAP line to the fuel sender. 4. Install the EVAP canister hose. 5. Position the EVAP canister hose clamp. 6. Connect the EVAP line (3) to the canister. 7. Install the fuel tank.