Fuel Injector Wiring Harness: Service and Repair

REMOVAL

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.

1. Disconnect the battery ground cable.
2. Partially drain the engine cooling system.
3. Remove the air cleaner outlet pipe.







4. Disconnect the Exhaust Gas Recirculation (EGR) valve vacuum hose and the evaporative emission canister purge valve hose and position them aside.







5. Disconnect the evaporative emission canister purge valve vacuum hose.







6. Remove the crankcase ventilation tube.
7. Disconnect the fuel hose spring lock couplings.

CAUTION: After disconnecting, plug the fuel tubes to prevent leakage.







8. Remove the nut and disconnect the brake booster vacuum tube and bracket.







9. Remove the exhaust manifold to EGR valve tube.
^ Disconnect the exhaust manifold to EGR valve tube upper fitting.
^ Disconnect the differential pressure feedback EGR system electrical connector.
^ Disconnect the exhaust manifold to EGR valve tube lower fitting.







10. Disconnect the following electrical connectors:
^ Idle Air Control (IAC) valve
^ Throttle Position (TP) sensor
^ EGR vacuum regulator solenoid







11. Disconnect the intake manifold tuning valve electrical connector.

NOTE: The generator is removed for clarity.







12. Disconnect the heater hose and position aside.







13. Disconnect and remove the Positive Crankcase Ventilation (PCV) hose.







14. Disconnect the LH radio frequency interference capacitor and Cylinder Head Temperature (CHT) sensor electrical connectors.







15. Disconnect the Camshaft Position (CMP) sensor electrical connector.







16. Disconnect the RH radio frequency interference capacitor electrical connector.







17. Disconnect the eight ignition coil electrical connectors.







18. Disconnect the eight fuel injector electrical connectors.







19. Disconnect the climate control vacuum connector.







20. Disconnect the 42-pin and 16-pin electrical connectors.

NOTE: Battery removed for clarity.

21. Remove the fuel charging wiring harness bracket from the heater outlet tube mounting studs.







22. Disconnect the attachments to the heater outlet tube.
1 Disconnect the heater outlet hose.
2 Disconnect the heated PCV outlet hose and remove the PCV valve and hose harness.
3 Release the wiring harness routing clip retainer.
4 Disconnect the knock sensor electrical connector.







23. Remove the outboard heater outlet tube stud.
24. Raise and support the vehicle.







25. Disconnect the A/C compressor clutch electrical connector.

NOTE: The A/C compressor clutch electrical connector can be reached through the wheel well.







26. Disconnect the Crankshaft Position (CKP) sensor electrical connector.







27. Disconnect the two Heated Oxygen Sensor (HO2S) electrical connectors.

NOTE: The transmission is removed for clarity.







28. Disconnect the oil pressure switch electrical connector.

NOTE: The oil pressure switch wire may be secured to the oil filter adapter with a wire tie.

29. Lower the vehicle.
30. Remove the fuel charging wiring harness.

INSTALLATION
1. Roughly position the fuel charging wiring harness.
2. Raise and support the vehicle.







3. Connect the oil pressure switch electrical connector.







4. Connect the two HO2S electrical connectors.

NOTE: The transmission is removed for clarity.







5. Connect the CKP sensor electrical connector.







6. Connect the A/C compressor clutch electrical connector.

NOTE: The A/C compressor clutch electrical connector can be reached through the wheel well.

7. Lower the vehicle.







8. Install the outboard heater outlet tube stud.
^ Tighten the stud to 25 Nm (18 Lb-ft).







9. Connect the attachments to the heater outlet tube.
1 Connect the heater outlet hose.
2 Connect the heated PCV outlet hose.
3 Install the wiring harness routing clip retainer.
4 Connect the knock sensor electrical connector.

10. Install the fuel charging wiring harness bracket on the heater outlet tube mounting studs.
^ Tighten the nuts to 10 Nm (89 Lb-in).







11. Connect the 42-pin and 16-pin electrical connectors.

NOTE: Battery removed for clarity.







12. Connect the climate control vacuum connector.







13. Connect the eight fuel injector electrical connectors.







14. Connect the eight ignition coil electrical connectors.







15. Connect the RH radio frequency interference capacitor electrical connector.







16. Connect the CMP sensor electrical connector.







17. Connect the LH radio frequency interference capacitor and CHT sensor electrical connectors.







18. Install the PCV hose.







19. Connect the heater hose.







20. Connect the intake manifold tuning valve electrical connector.

NOTE: The generator is removed for clarity.







21. Connect the following electrical connectors:
^ IAC valve
^ TP sensor
^ EGR vacuum regulator solenoid







22. Install the exhaust manifold to EGR valve tube.







23. Connect the differential pressure feedback EGR system electrical connector.







24. Connect the brake booster vacuum tube and bracket and install the nut.
25. Connect the fuel hose spring lock couplings.







26. Install the crankcase ventilation tube.







27. Connect the evaporative emission canister purge valve vacuum hose.







28. Connect the evaporative emission canister purge valve hose and the EGR valve vacuum hose.
29. Install the air cleaner outlet pipe.
30. Connect the battery ground cable.
31. Fill and bleed the engine cooling system.