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9.5
GENERAL
2.
3.
4.
Using a needle nose pliers, carefully pull idle cable barrel from upper hole in throttle wheel. Pull throttle cable
barrel from lower hole. Using slots, release idle and
throttle cables from guides in throttle cable bracket.
5.
INDUCTION MODULE
6.
REMOVAL
7.
8.
Remove throttle position sensor and intake air temperature sensor connectors.
1.
Induction Module
Fuel Supply Line
Fuel Rail/Fuel Supply Tube
Fuel Injectors
Intake Air Temperature Sensor
Throttle Position Sensor
Manifold Absolute Pressure Sensor
Idle Air Control
1.
2.
3.
4.
5.
Front
9
7
8
f1939x9x
Rear
9-31
HOME
13. Remove seals from flange adapters. Discard seals.
Remove flange adapters from outlet ports of induction
module.
f1965x8x
14. If it should become necessary to split the induction module, that is, separate the throttle body from the intake
manifold, proceed as follows:
a.
Remove top and bottom T20 TORX screws to separate intake manifold and throttle body flanges.
b.
Wheel Pin
INSTALLATION
End Fitting
1.
If induction module was split, assemble the intake manifold and throttle body as follows:
a.
b.
2.
Slide fuel supply line onto tube at top of induction module. A slight tug will verify that the line is locked in place.
3.
4.
Place a new seal in each flange adapter with the beveled side in against the counterbore.
5.
6.
1WARNING
7.
A small amount of gasoline will drain from the fuel supply line when disconnected from the supply tube. Thoroughly wipe up any spilled fuel immediately. Dispose of
rags in a suitable manner. Gasoline is extremely flammable and highly explosive. Inadequate safety precautions
could result in death or serious injury.
8.
f1922x9x
9-32
HOME
f1966x9x
Breather Bolts
T27 TORX
Screws
Backplate
18. Install fuel tank. See Section 9.4 FUEL TANK (FUEL
INJECTED),
INSTALLATION
(AFTER
PARTIAL
REMOVAL), FLHT/C/U/I, FLTRI, or FLHR/C/I.
19. Install backplate and air cleaner. See Section 4.5 AIR
CLEANER, INSTALLATION.
f2079x9x
9.
b.
Backplate: Install two breather bolts to fasten backplate to front and rear cylinder heads. Install three
T27 TORX screws to secure backplate to face of
induction module. See upper frame of Figure 9-29.
Alignment bracket: Fitting pins on inboard side
into holes in face of induction module, install two
breather bolts to fasten bracket to front and rear cylinder heads. See lower frame of Figure 9-29.
REMOVAL
1.
1WARNING
A small amount of gasoline will drain from the fuel supply line when disconnected from the fuel tank. Thoroughly wipe up any spilled fuel immediately. Dispose of
rags in a suitable manner. Gasoline is extremely flammable and highly explosive. Inadequate safety precautions
could result in death or serious injury.
NOTE
Check valve in the fuel tank fitting impedes any further fuel
seepage once external fuel line has drained.
9-33
HOME
REMOVAL
f1922x9x
2.
3.
4.
1.
2.
3.
4.
Gently pull fuel supply tube from fuel rail. Remove sealing washer from end of fuel supply tube. Remove O-ring
from fuel rail bore. Discard sealing washer and O-ring.
Fuel Supply
Tube Clamp
1WARNING
A small amount of gasoline will drain from the fuel supply line when disconnected from the supply tube at the
top of the induction module. Thoroughly wipe up any
spilled fuel immediately. Dispose of rags in a suitable
manner. Gasoline is extremely flammable and highly
explosive. Inadequate safety precautions could result in
death or serious injury.
5.
Fuel Injector
Clip
7909
INSTALLATION
1.
Slide fuel supply line onto tube at top of induction module. A slight tug will verify that the line is locked in place.
See Figure 9-30.
2.
3.
9-34
Fuel Rail
7910
HOME
3.
Push fuel rail over fuel injectors until fuel rail flange contacts boss on induction module.
4.
Slide fuel injector clip onto fuel rail until clip fully
engages groove in each fuel injector. Full engagement
occurs when the tabs on both sides of the clip are flush
with the left side edge of the fuel rail. See Figure 9-33.
5.
Using a T20 TORX drive head, install two screws to fasten fuel rail to induction module. Alternately tighten
screws to 18 in-lbs (2.0 Nm). See Figure 9-32.
6.
Note the collar on each end of the fuel supply tube. Slide
a new sealing washer down the shorter neck until it contacts the collar. Slide a new o-ring down the tube until it
contacts the sealing washer. See Figure 9-34. Push tube
into fuel rail bore until collar is flush with casting.
7.
Align hole in fuel supply tube clamp with hole in fuel rail.
Using a T20 TORX drive head, install screw and tighten
to 18 in-lbs (2.0 Nm). See Figure 9-31. Rotate fuel supply tube so that it angles downward.
8.
8323
Tab
f1935x9x
O-Ring
Sealing
Washer
FUEL INJECTORS
REMOVAL
1.
2.
3.
5.
Slide fuel injector clip toward left side of induction module (intake manifold side) to release from fuel rail.
4.
Slide fuel injector clip toward left side of induction module (intake manifold side) to release from fuel rail.
6.
5.
7.
8.
Pull fuel injectors from fuel rail. To overcome the resistance of the top O-ring, gently rock each fuel injector
while pulling.
9.
O-Ring
Electrical
Connector
INSTALLATION
1.
Apply a thin coat of clean engine oil to new injector Orings. Install O-rings on fuel injectors. See Figure 9-35.
2.
f1934x9x
9-35
HOME
6.
7.
Pull fuel injectors from fuel rail. To overcome the resistance of the top O-ring, gently rock each fuel injector
while pulling.
8.
7910
INSTALLATION
1.
Apply a thin coat of clean engine oil to new injector Orings. Install O-rings on fuel injectors. See Figure 9-35.
2.
3.
Push fuel rail over fuel injectors until fuel rail flange contacts boss on induction module.
4.
Intake Air
Temperature
Sensor
Slide fuel injector clip onto onto fuel rail until clip fully
engages groove in each fuel injector. Full engagement
occurs when the tabs on both sides of the clip are flush
with the left side edge of the fuel rail.
5.
Using a T20 TORX drive head, install two screws to fasten fuel rail to induction module. Alternately tighten
screws to 18 in-lbs (2.0 Nm). See Figure 9-32.
6.
Align hole in fuel supply tube clamp with hole in fuel rail.
Using a T20 TORX drive head, install screw and tighten
to 18 in-lbs (2.0 Nm). See Figure 9-31. Rotate fuel supply tube so that it angles downward.
7.
Throttle
Position
Sensor
f1936x9x
Thermistor
Gasket
1WARNING
To protect against shock and accidental start-up of vehicle, disconnect the negative battery cable before proceeding. Inadequate safety precautions could result in
death or serious injury.
2.
3.
4.
9-36
5.
6.
INSTALLATION
1.
2.
Insert sensor into induction module with electrical connector facing toward the left side of the vehicle. See Figure 9-36.
3.
4.
5.
HOME
6.
7.
Throttle Cable
Bracket
1WARNING
To protect against shock and accidental start-up of vehicle, disconnect the negative battery cable before proceeding. Inadequate safety precautions could result in
death or serious injury.
2.
3.
4.
5.
T20 TORX
Screws
8315
f1701x9x
Electrical
Connector
INSTALLATION
Rubber
Seal
Pressure Port
1.
With electrical connector facing down, fit pocket of throttle position sensor over throttle shaft.
2.
3.
4.
REMOVAL
5.
6.
7.
The screw securing the throttle cable bracket and idle air
control flange to the induction module has a loctite
patch that may make it very difficult to remove. Since a
heat gun may be needed to break down the loctite,
remove induction module from vehicle, so that heat is
not applied close to fuel tank. Gasoline is extremely
flammable and highly explosive. Inadequate safety precautions could result in death or serious injury.
8.
MANIFOLD ABSOLUTE
PRESSURE SENSOR
1WARNING
1.
9-37
HOME
CAUTION
Idle Air
Control
The idle air control screw has a loctite patch that may
make it very difficult to remove. If necessary, use a heat
gun to break down the loctite. Apply heat evenly around
screw head in a circular motion. Do not direct heat at idle
air control and other components or damage can occur.
2.
3.
4.
If replacing sensor, remove and save rubber seal if condition is good. Replace the seal if cut, torn or shows
signs of deterioration.
7910
INSTALLATION
1.
2.
3.
4.
5.
6.
7.
8.
f1938x9x
O-Ring
Figure 9-41. Idle Air Control
CAUTION
1WARNING
The screws securing the idle air control flange to the
induction module have a loctite patch that may make
them very difficult to remove. Since a heat gun may be
needed to break down the loctite, remove induction
module from vehicle, so that heat is not applied close to
fuel tank. Gasoline is extremely flammable and highly
explosive. Inadequate safety precautions could result in
death or serious injury.
1.
9-38
The idle air control screws have a loctite patch that may
make them very difficult to remove. If necessary, use a
heat gun to break down the loctite. Apply heat evenly
around screw head in a circular motion. Do not direct
heat at idle air control and other components or damage
can occur.
2.
3.
4.
5.
Remove O-ring from body of idle air control. Discard Oring. See Figure 9-41.
HOME
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
21.
22.
23.
24.
25.
2
13
14
10
2 11
15
16
10
12
9
2
17
4
2
18
19
20
22
1
23
25
f1933x9x
19
21
24
Figure 9-42. Induction Module Assembly
INSTALLATION
1.
2.
3.
4.
5.
6.
7.
8.
9.
9-39
HOME
NOTES
9-40