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

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1. Remove the auxiliary battery. For additional information, refer to Section 414-01. 2. Remove the air cleaner assembly. For additional information, refer to Section 303-12. 3. Remove the cooling fan-blade, clutch and shroud, 6.0L diesel engine. For additional information, refer to Section 303-03. 4. Remove the coolant reservoir. For additional information, refer to Section 303-03. 5. Remove the upper radiator hose. 6. NOTE: Engine side shown, charge air cooler (CAC) side similar. Remove the turbocharger-to-charge air cooler pipe. 7. NOTE: Engine side shown, charge air cooler side similar. Remove the charge air cooler-to-engine pipe. Vehicles with dual generators 8. Remove the accessory drive belt. 9. Remove the bolt and the accessory drive belt tensioner. 10. Remove the accessory drive belt. 11. Remove the bolts, bracket and accessory drive belt idler pulley. 12. Remove the bolts and the accessory drive belt tensioner. 13. Disconnect the wire retainer, generator electrical connector and B+ wire. 14. Remove the bolts and the generator with mounting bracket. Vehicles with single generator 15. Remove the accessory drive belt. All vehicles 16. Position the boot back and disconnect the generator B+ wire and electrical connector. 17. Remove the three bolts and the generator. 18. Remove the turbocharger and the turbocharger pedestal. For additional information, refer to Section 303-04F. 19. Remove the bolts and position the heater hose tube aside. ? Remove and discard the O-ring. 20. Disconnect the manifold absolute pressure (MAP) sensor hose. 21. Disconnect the engine coolant vent hose. 22. Remove the fuel injector control module. For additional information, refer to Section 303-14C. 23. Disconnect the wiring retainer, injector pressure regulator and injector control pressure (ICP) sensor electrical connector. 24. Disconnect the exhaust gas recirculation (EGR) valve electrical connector. 25. Disconnect the oil pressure sensor electrical connector. 26. Disconnect the oil temperature sensor electrical connector.

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Fuel Charging and Controls The fuel charging and controls system consists of: fuel pressure regulator (9C968) fuel injection supply manifold (9F792) fuel injectors (9F593) fuel shut off valve solenoid (9D278) fuel pressure relief valve (9H321) injection pressure sensor engine fuel temperature sensor fuel charging wiring harness Component Location Fuel Pressure Regulator The fuel pressure regulator is located on the inside of the LH frame rail just forward of the transmission support crossmember. It is part of an assembly that includes the coalescer/filter. The fuel pressure regulator reduces the line pressure from tank pressure 20685 kPa (3000 psi) to line pressure 655 kPa (95 psi). Heating/Defrosting—Natural Gas Vehicle Fuel pressure regulator heating is provided by two 3/8-inch taps from the existing heater supply and return hoses on the RH rear of the engine. Two high-temperature 3/8-inch ID heater hoses (packaged with the front low-pressure fuel line) are used to connect the fuel pressure regulator to the tap points on the engine heater hoses. Refer to the Line — Low Pressure Fuel procedure in Section 310-01B for fuel pressure regulator heater hose replacement. Fuel Pressure Regulator Heater Hoses Fuel Injection Supply Manifold The fuel injection supply manifold delivers high-pressure fuel from the vehicle fuel supply line to the fuel injectors. The fuel injection supply manifold consists of the following: a tubular fuel rail eight fuel injector connectors a fuel pressure relief valve a fuel shut off valve solenoid mounting attachments which locate the fuel injection supply manifold and provide fuel injector retention. a fuel inlet connection which has a push-connect fitting an injection pressure sensor an engine fuel temperature sensor Fuel Injection Supply Manifold Fuel Injectors The natural gas fuel injectors are electro-mechanical devices that meter fuel delivered to the engine. The natural gas fuel injectors are mounted in the lower intake manifold (9424) and are positioned so that their tips direct fuel just ahead of the engine intake valves (6507). The natural gas fuel injector bodies consist of a solenoid and a needle and valve assembly. Natural gas fuel injectors can be identified by an aqua cap on the injector body. Fuel Shutoff Valve Solenoid The fuel shut off valve solenoid seals the upstream fuel pressure from entering the fuel injection supply manifold when the engine is not running. The fuel shut off valve solenoid is open only when it is activated by the solenoid valve (fuel pump) relay. Fuel Pressure Relief Valve The fuel pressure relief valve is located on the fuel injection supply manifold, and is used to relieve fuel system pressure from the fuel delivery system. Injection Pressure Sensor The injection pressure sensor is located on the fuel injection supply manifold, and is used to provide a signal to the powertrain control module (PCM) (12A650) that is proportional to pressure in the fuel injection supply manifold. Engine Fuel Temperature Sensor The engine fuel temperature sensor is located on the fuel injection supply manifold, and is used to provide a signal to the powertrain control module that indicates the temperature of the fuel in the fuel injection supply manifold. Fuel Charging Wiring The fuel charging wiring is a single harness that includes electrical connectors for the fuel injectors, ignition coils and various sensors, valves and senders that monitor all engine functions. Fuel Charging Wiring

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Removal NOTICE: Electronic modules are sensitive to static electrical charges. If exposed to these charges, damage to the module may result. NOTE: Prior to the replacement of the module, it is necessary to upload the module configuration information to a scan tool. This information must be downloaded into the new Smart Junction Box (SJB) after installation. For additional information, refer to Section 418-01 to carry out Programmable Module Installation (PMI). NOTE: For the SJB to accept the PMI procedure, the following conditions must be met: The headlamp switch must be in the OFF position (must not be in the AUTOLAMP position, if equipped) The key must be in the ON position The driver door must be open The doors must be unlocked electronically by pressing the door lock control switch to the UNLOCK position momentarily Failure to follow this procedure will result in the PMI procedure to fail. NOTE: The Tire Pressure Monitoring System (TPMS) functionality is integral to the SJB. NOTE: A new SJB is delivered in a “manufacturing mode” with 7 pre-set DTCs. A successful configuration of the SJB, then a successful TPMS sensor training, then a successful self-test including the clearing of all DTCs is required in order to clear the 7 pre-set manufacturing mode DTCs. The 7 manufacturing mode DTCs are: B106D (Tire Pressure Monitor System [TPMS] Initiators Not Configured) This DTC is present when the SJB is not configured, even on applications that are not equipped with initiators. B2477 (Module Configuration Failure) B2868 (Left Front Tire Pressure Sensor Fault) B2869 (Right Front Tire Pressure Sensor Fault) B2870 (Right Rear Tire Pressure Sensor Fault) B2871 (Left Rear Tire Pressure Sensor Fault) C2780 (ECU in Manufacturer Sub-State) 1. NOTE: This step is only necessary if the SJB is being replaced. Upload the module configuration information from the SJB into the scan tool. For additional information, refer to Section 418-01. 2. Turn the key to the OFF position. 3. Remove the RH cowl panel side trim. 4. Disconnect the 7 electrical connectors. 5. Remove the 2 bolts and the SJB. Installation 1. Position the SJB and install the 2 bolts. Tighten the bolts to 2 Nm (18 lb-in). 2. Connect the 7 SJB electrical connectors. 3. NOTE: If the SJB is not being replaced, this is the last step that is necessary.

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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.

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1. Disconnect the battery ground cable (14301). For additional information, refer to Section 414-01. 2. WARNING: Fuel supply lines will remain pressurized for long periods of time after engine shut down. This pressure must be relieved before disconnecting any fuel lines or fuel system components. Relieve the fuel system pressure. For additional information, refer to Section 310-00. 3. Remove the engine air cleaner outlet tube. For additional information, refer to Section 303-03. 4. Remove the timing belt. For additional information, refer to Timing Drive Components—Timing Belt in this section. 5. Remove the vacuum hoses at the: positive crankcase ventilation (PCV) valve (6A666). throttle body (9E926). intake manifold (9424). fuel pressure sensor. 6. Disconnect the fuel charging wiring (9D930) electrical connectors at main engine connector. 7. Disconnect the crankshaft position (CKP) sensor electrical connector. 8. Disconnect the fuel line. For additional information, refer to Section 303-04. 9. Remove the power steering pump (3A674) and bracket as an assembly. For additional information, refer to Section 211-02. 10. Remove the generator (GEN). For additional information, refer to Section 414-02. 11. Remove the oil level indicator tube (6754). For additional information, refer to Oil Level Indicator and Tube in this section. 12. Disconnect the heater hoses. For additional information, refer to Section 412-02. 13. Lower the vehicle. 14. Disconnect the upper radiator hose (8260) from the thermostat housing water hose connection. For additional information, refer to Section 303-03. 15. Remove the camshafts (6250). For additional information, refer to Camshaft in this section. 16. Remove the ignition coil (12029) and bracket. For additional information, refer to Section 303-07. 17. Remove the water thermostat housing. For additional information, refer to Section 303-03. 18. Disconnect the knock sensor electrical connector.