Fuel Junction Block Replacement
FUEL JUNCTION BLOCK REPLACEMENTREMOVAL PROCEDURE
1. Move the hood to the service position, by moving the hood hinge bolts (1) to the service position (2).
2. Disconnect the negative battery cable.
3. Loosen the outlet duct clamp at the upper intake manifold cover.
4. Remove the upper intake manifold cover from the outlet duct.
5. Remove the upper intake manifold cover.
6. Drain the cooling system.
7. Remove the drive belt.
8. Reposition the air conditioning (A/C) compressor using the following procedure:
8.1. Disconnect the A/C compressor clutch electrical connector.
8.2. Disconnect the A/C cut out switch electrical connector.
8.3. Remove the A/C compressor mounting bolts.
8.4. Reposition the A/C compressor with the hoses attached to the right side of the engine compartment.
9. Disconnect the left front injector harness electrical connector (1).
10. Disconnect the oil pressure sending unit electrical connector.
11. Disconnect the turbocharger coolant hose and clamp from the turbocharger bypass valve.
12. Disconnect the water outlet tube using the following procedure:
12.1. Remove the bolts attaching the water outlet tube to the left rocker arm cover.
12.2. Remove the bolt attaching the water outlet tube to the thermostat housing.
12.3. Remove the water outlet tube.
12.4. Remove and discard the O-ring seal.
13. Reposition the positive crankcase ventilation (PCV) hose clamp.
14. Remove the PCV hose from the upper valve rocker arm cover.
15. Loosen the charged air cooler inlet duct to turbocharger clamp (1).
IMPORTANT: Do not use a screwdriver or other tool to pry the hose loose. The hose can be torn or damaged. Loosen the hose by twisting.
16. Remove the charged air cooler inlet duct from the turbocharger.
17. Remove the banjo bolt (1) from the fuel junction block.
18. Disconnect the fuel pipes (3) from the fuel junction block.
19. Disconnect the fuel pipe junction block from the fuel rail (1).
20. Remove the fuel junction block nuts.
21. Remove the fuel junction block.
INSTALLATION PROCEDURE
NOTE: Refer to Fastener Notice in Service Precautions.
1. Install the fuel junction block and nuts.
Tighten
Tighten the nuts to 25 N.m (18 lb ft).
2. Install the fuel pipe junction block to the fuel rail (1).
Tighten
Tighten the bolt to 15 N.m (11 lb ft).
3. Connect the fuel pipes (3) to the junction block.
Tighten
Tighten the fittings to 44 N.m (32 lb ft).
4. Connect the fuel pipe junction block to the fuel rail (1).
Tighten
Tighten the fitting to 44 N.m (32 lb ft).
5. Install the charged air cooler inlet duct to the turbocharger.
6. Align the mark on the duct (2) with the mark on the turbocharger.
7. Position the clamp (1) as shown for proper clearance.
Tighten
Tighten the clamp to 6 N.m (53 lb in).
8. Install the PCV hose to the upper valve rocker arm cover.
9. Reposition the PCV hose clamp.
10. Install the water outlet tube using the following procedure:
10.1. Install a new O-ring seal on the water outlet tube.
10.2. Lightly lubricate the O-ring seal with coolant.
10.3. Install the water outlet tube.
10.4. Install the bolt attaching the water outlet tube to the thermostat housing.
Tighten
Tighten the bolt to 21 N.m (16 lb ft).
10.5. Install the bolts attaching the water outlet tube to the rocker arm cover.
Tighten
Tighten the bolts to 21 N.m (16 lb ft).
11. Install the turbocharger coolant hose and clamp to the turbocharger bypass valve.
12. Connect the oil pressure sending unit electrical connector.
13. Connect the left front injector harness electrical connector (1).
14. Install the A/C compressor using the following procedure:
14.1. Install the A/C compressor bolts.
Tighten
Tighten the bolts to 50 N.m (37 lb ft).
14.2. Connect the A/C cut out switch electrical connector.
14.3. Connect the A/C compressor clutch electrical connector.
15. Install the drive belt.
16. Fill the cooling system.
17. Install the upper intake manifold cover.
18. Install the upper intake manifold cover to the outlet duct.
19. Tighten the outlet duct clamp at the upper intake manifold cover.
Tighten
Tighten the clamp to 6 N.m (53 lb in).
20. Connect the negative battery cable.
21. Position the hood in the normal operating position by moving the hood hinge bolts from the service position (2) to the normal operating position (1).
Tighten
Tighten the bolts to 25 N.m (18 lb ft).
22. Purge air from the fuel system.