Page 985 of 3229
Publi s hed: 11-May-2011
Fuel Charging and Controls - I6 3.2L Petrol - Throttle Body
Removal and Inst all ati on
Removal
1. W ARNING: Make sure t o s upport the vehicle wit h axles tands .
Rais e and s upport t he vehi cl e.
1.
Remove t he engi ne undershi eld.
Refer t o: Engi ne Unders hi eld (501-02 Front End Body Panel s ,Removal and Ins tall ati on).
2.
3.
4.
Releas e t he air cleaner out let pipe.5.
Page 986 of 3229
Remove t he thrott le body.
6.
Remove and dis card t he gas ket .
7.
Installation
Clean t he component mat ing faces .
1.
Inst all a new gas ket.
2. 3. CAUTION: Make s ure that the mati ng faces are
clean and free of foreign materi al.
Inst all t he thrott le body and t ighten the s crews i n t he
s equence s hown.
T orque: 8 Nm 3.
Inst all t he engi ne undershi eld.
Refer t o: Engi ne Unders hi eld (501-02 Front End Body Panel s ,
Removal and Ins tall ati on).
4.
Inst all t he front unders hiel d.
5.
Inst all t he front towing eye cover.
6.
Page 987 of 3229
Publi s hed: 11-May-2011
Fuel Charging and Controls - I6 3.2L Petrol - Fuel Injector
Removal and Inst all ati on
Removal
• NOTE: The process to remove a fuel injector i s s hown the t he Fuel Rai l procedure.
Remove t he fuel inject or.
Refer t o: Fuel Rail (303-04A Fuel Chargi ng and Cont rol s - I6 3.2LPetrol, Removal and Ins tall ati on).
1.
Installation
Inst all t he fuel inject or.
Refer t o: Fuel Rail (303-04A Fuel Chargi ng and Cont rol s - I6 3.2LPetrol, Removal and Ins tall ati on).
1.
Page 988 of 3229
Publi s hed: 11-May-2011
Fuel Charging and Controls - I6 3.2L Petrol - Fuel Rail
Removal and Inst all ati on
Removal
W ARNING: W ait for a mi nimum of 1 mi nut e after t he engi ne has st opped before carrying out any repair t o t he fuelinject ion s ys tem.
Remove t he cover and dis connect the bat tery ground cabl e.
Refer t o: Specificati ons (414-00 Bat tery and Charging Sys tem -General Informat ion, Specificati ons).
1.
Remove t he engi ne cover.
Refer t o: Engi ne Cover - I6 3.2L Pet rol (501-05 Int eri or Trim andOrnament ati on, Removal and Ins tal lat ion).
2.
3. W ARNINGS:
Avoid fl ames , s parks or li ght ed s ubst ances .
Be prepared t o collect es caping fuel.
Releas e t he fuel pres s ure.
3.
4.
5. CAUTIONS:
Ext reme cl eanli ness must be exerci sed whenhandl ing t hese components .
Make s ure that all openings are sealed.
5.
Page 989 of 3229
6. NOTE: Do not remove t he fuel i nject ors , i f the rail isbeing removed for acces s .6.
7. CAUTION: A new O-ring seal is to be ins tall ed.7.
8. CAUTION: Cap t he fuel inject or nozzle toprevent damage before st ori ng verti cal ly.
• NOTE: Do not di sas s emble furt her i f the component isremoved for acces s onl y.
• NOTE: If the fuel injectors are not bei ng removedfrom the fuel rail only the l ower O -ring s eals wi ll needt o be renewed.
Remove and dis card t he fuel i nject or O-ring seals .
8.
9.
Page 990 of 3229
10.
Installation 1. CAUTION: A new O-ring seal is to be ins tall ed.
Inst all t he fuel rai l Schraeder val ve.
T orque: 6 Nm 1.
2. CAUTION: A new O-ring seal is to be ins tall ed.
Inst all t he fuel rai l press ure s ens or.
T orque: 6 Nm 2.
3. NOTE: Ins t al l new O-ri ng seal s.
Lubricat e and ins tal l the new O-rings .
3.
If removed, ins tall t he inject ors .
4.
5. CAUTION: A new O-ring seal is to be ins tall ed.
Inst all t he fuel li ne to fuel rai l seal ass embl y.
5.
Inst all t he fuel inject or cl amp plat e.
T orque: 6 Nm 6.
Inst all t he fuel rai l.
T orque: 10 Nm 7.
Connect and s ecure t he electrical connect ors .
8.
Inst all t he engi ne cover.
Refer t o: Engi ne Cover - I6 3.2L Pet rol (501-05 Int eri or Trim and
Ornament ati on, Removal and Ins tal lat ion).
9.
Connect t he batt ery ground cable and ins tall t he cover.
Refer t o: Specificati ons (414-00 Bat tery and Charging Sys tem -
General Informat ion, Specificati ons).
10.
Page 991 of 3229
Publi s hed: 11-May-2011
Fuel Charging and Controls - I6 3.2L Petrol - Fuel Pump Driver Module
(FPDM)
Removal and Inst all ati on
Removal
• NOTE: Removal s t eps in t his procedure may cont ain i nst all ati on det ail s.
Remove t he LH rear quart er trim panel .
Refer t o: C-Pil lar Tri m Panel (501-05 Int erior Trim and
Ornament ati on, Removal and Ins tal lat ion).
1. T orque:
10 Nm 2.
Installation To i nst all , revers e t he removal procedure.
1.
Page 992 of 3229
Publi s hed: 11-May-2011
Fuel Charging and Controls - TD4 2.2L Diesel -
General SpecificationItemSpecification
Maximum cont inuous fl ow160 l /hr
Maximum engine cons umpt ion40 l /hrMaximum ret urn fl ow90 l /hr
Maximum pres s ure on return l ine0.7 bar (10.2 lb/in²)
Mi ni mum pres sure at engi ne0.5 bar (7.3 lb/in²)Mi ni mum pres sure at fi lt er0.3 bar (4.4 lb/in²)
Recommended fuelEN590
Fuel Pressures
Componentbarlb/in²
Fuel pump (vacuum pressure):Cranking0.1331.9
Full load0.2673.9
Hi gh pres sure fuel i nject ion pump160023206
Torque SpecificationsDescriptionNmlb-ft
EGR pi pe107
Fuel i njector clamp ret ai ning bolt s5 + 110°4 + 110°Fuel rail ret aini ng bol ts1813
Fuel pump to fuel rail hi gh-pres s ure fuel l ine retaini ng bolt107
Fuel pump to fuel rail high-pressure fuel line unions:Stage 12216
Stage 22518
Fuel i njecti on pump s ecuring bolt s2216Fuel pump bracket107
High pressure fuel supply line unions:
Stage 12216Stage 22518
Throt tl e body s crews97