Attachment III - Technical Information
OVERVIEWDealers are to replace the fuel jumper line between the body mounted fuel line and the rear of the engine that may have been damaged during the manufacturing process. Also, dealers are to inspect the Positive Crankcase Ventilation (PCV) hose connection to the air induction system and reconnect if necessary.
NOTICE:
Affected vehicles are not to be driven on roads until this repair has been performed.
Vehicles can be driven at low speeds within dealership property into the service bay.
The HVAC (blower motor) should be turned off and windows down. If you notice any fuel odor, warning lights, overheat, or loss-of-power, the vehicle should not be driven.
SERVICE PROCEDURE
Fuel Jumper Line Removal
WARNING:
Before beginning this service procedure, review the Safety Warnings contained in Workshop Manual (WSM), Section 100-00.
NOTICE:
Do not loosen any fittings or plugs on the fuel injection pump.
1. Remove the two retainers and the lower passenger side Instrument Panel (IP) insulator. See Figure 1.
2. Remove the Body Control Module (BCM) Fuse # 56, (Fuel Pump Module fuse). See Figure 2.
3. Start the engine and allow it to idle until the engine stalls.
4. Crank the engine for approximately five seconds to make sure that the fuel rail pressure is released.
5. Turn the ignition switch to the OFF position.
6. Disconnect the battery ground cable. Refer to WSM, Section 414-01.
7. Remove the engine appearance cover.
NOTICE:
When working with liquid or vapor tube connectors, make sure to use compressed air to remove any foreign material from the connector retaining clip area before separating from the tube or damage to the tube or connector retaining clip can occur. Apply clean engine oil to the end of the tube before inserting the tube into the connector.
NOTICE:
Fuel injection equipment is manufactured to very precise tolerances and fine clearances. It is essential that absolute cleanliness is observed when working with these components or component damage can occur. Always install plugs to any open orifices or tubes.
NOTICE:
Do not use any tools to disconnect the quick connect coupling on the air intake tube center section. The use of tools may cause a deformity in the clip components which may cause leaks.
NOTICE:
Whenever turbocharger air intake system components are removed, always cover open ports to protect from debris. It is important that no foreign material enter the system. The turbocharger compressor vanes are susceptible to damage from even small particles. All components should be inspected and cleaned, if necessary, prior to installation or reassembly.
8. Disconnect the EVAP line quick connect coupling from the air intake tube center section. See Figure 3.
^ Set the clip aside for reinstallation to prevent it from falling into the engine compartment.
9. Loosen the 2 clamps and remove the air intake tube center section. See Figure 3.
10. Remove the two bolts and position the master cylinder reservoir aside. See Figure 4.
^ To install, tighten to 2.5 Nm (22 lb-in).
NOTE:
Use a shop towel to absorb any residual fuel that is released when disconnecting the fuel lines.
11. Remove and discard the fuel jumper line. See Figure 5.
a. Using Special tool 310-S039 or equivalent disconnect the fuel line quick connect couplings.
b. Remove the fuel jumper line.
NOTE:
Perform the "PCV Hose Inspection" procedure before installing a new fuel jumper line.
PCV Hose Inspection
1. Inspect the PCV hose fresh air connector for correct installation/seating into the rear of the fresh air intake tube. See Figure 6.
2. Push lightly on the hose toward the rear of the vehicle at the fresh air intake tube connection. See Figure 6.
Inspection Results:
- If the hose is loose or disconnected, attempt to reconnect the hose and listen for an audible click to verify it is securely connected. Push lightly toward the rear of the vehicle to ensure a secure connection has been made. If the hose does not securely attach to the fresh air intake tube, call the Special Service Support Center.
- If the hose is seated properly, pull forward on the hose toward the front of the vehicle at the fresh air intake tube connection to ensure it is firmly attached.
3. Check the constant tension clamp on the PCV hose to cam cover connection and ensure that it is properly installed. Verify the PCV hose is fully seated and aligned with the mark on the cam cover. See Figure 7.
4. Verify that the PCV hose pin type retainer is pressed firmly in the side of the coil bracket. See Figure 8.
Fuel Jumper Line Installation
NOTE:
The fuel pulse damper should be positioned closest to the engine connection side. See Figure 9.
NOTICE:
When connecting the new fuel jumper line, do not force it in at an angle or damage to the fuel line 0-rings may occur. Minimal effort is required to connect the fuel line. If excessive effort is observed, re-align and try again.
1. To install the new fuel jumper line, reverse the removal procedure.
^ Be sure that the fuel pulse damper is positioned closest to the engine connection side of the system before attachment. Confirm the tag on the new fuel jumper line is oriented toward the engine as indicated on the tag. See Figure 9.
^ Connect the engine side of the fuel jumper line first.
^ Position the air cleaner outlet pipe back to allow clearance during installation of the new fuel line.
^ After installation is complete, carry out a Key ON Engine OFF (KOEO) visual inspection for fuel leaks.