Engine Controls - PremAir(R) Sensor R & I Instructions
Date: July 2011Order No.: S-B-07.04/87
Supersedes:
Group: 07
SUBJECT: All Passenger and Light Truck Models Equipped with Engine M272 and PremAir Sensor B11/15
PremAir Sensor Removal and Installation Instructions
The below provided premair sensor removal and installation instruction is to be performed in the event the PZEV coated radiator requires replacement or a sensor fault has been determined in conjunction with S-B-07.04/88.
Note:
Read through the entire work instruction before proceeding. Any damage caused to a radiator in the process of removing and or installing the premair sensor will result in a claim debit.
Note:
Review WIS documents when performing repairs (AR07.04-P-5004GZH refers to PremAir sensor - follow this bulletin to perform PremAir sensor removal and installation). Refer to SDS guided tests and other publications for additional information.
PremAir Sensor Repair Instructions - Removal/Installation
1. Remove the radiator from the vehicle as outlined in WIS, and place it on a flat level surface.
2. Place a suitable plastic door panel tool (flat wedge) between the B11/15 PremAir sensor and the radiator (Figure 1).
3. Insert an instrument cluster hook (or a similar type tool) under one of the locking tabs.
4. Simultaneously pull up on the locking tab and gently pry up on the sensor with the wedge just enough to where the locking tab is no longer locked in place.
5. While holding slight pressure on the door panel tool unlatch the adjacent locking tab with the instrument cluster hook.
6. Firmly take hold of the sensor and detach it from the radiator.
Note:
Do not use the door panel tool to pry the sensor away from the radiator, or use a tool other than a small hook such as the instrument cluster tool otherwise irreparable damage could occur to the radiator (as shown in Figure 2).
7. Carefully clean the mounting plate on the radiator to accommodate the new PremAir sensor (Figure 3 & 4). If the original sensor tip broke off during disassembly (see figure 2), and the existing radiator is to be used, then it is essential to shave off the remainder of the sensor tip flush with the mounting plate.
Note:
Refrain from removing any metal from the mounting plate as this could prevent the PremAir sensor from locking firmly into place.
8. Start by filling in one of the mounting holes with Loctite 4204 P/N A009 989 09 71 (or Sikaflex 260 sealing adhesive P/N A 003 989 95 20 10 - check availability).
9. Then apply a thin film of adhesive across the entire mounting bracket surface.
10. Install the PremAir sensor/tip and allow the adhesive to cure for 12 hours before installing the radiator into the vehicle. The PremAir sensor must be securely locked onto the radiator (Figure 5).
Note:
When either installing a new sensor on a replacement radiator or on an existing radiator, it is essential to perform the bonding process with the radiator placed on a flat level surface.
In the event one of the mounting holes is occupied, then it is necessary to install the premair sensor in the adjacent hole by turning it 180 degrees. In this case insure that the sensor harness is not pinched and or under tension after installing the radiator. In the event both mounting holes are occupied from prior repairs, then the radiator must be replaced. DO NOT drill out the old sensor tip.
Note:
Always refer to EPC for latest parts information.
Parts Information