intake air temperature sensor (iat) 4 davidson... · intake air temperature sensor home 2009 dyna...

4.8INTAKE AIR TEMPERATURE SENSOR (IAT)

GENERALRefer to the ELECTRICAL DIAGNOSTIC MANUAL forinformation on the function and testing of the intake air temper-ature sensor (IAT sensor).

REMOVAL

To prevent accidental vehicle start-up, which could causedeath or serious injury, disconnect negative (-) batterycable before proceeding. (00048a)

1. Disconnect negative battery cable.

2. Remove air cleaner backplate. See 4.5 AIR CLEANERASSEMBLY.

3. See Figure 4-11. Unplug IAT sensor connector [89].

4. Remove fastener to detach IAT sensor. Discard fastener.

INSTALLATION1. See Figure 4-12. Inspect O-ring (1) in groove of intake air

temperature sensor for cuts, tears or signs of deterioration.Install new O-ring if necessary.

2. See Figure 4-11. Insert sensor into induction module withelectrical connector facing toward the left side of themotorcycle.

3. See Figure 4-12. Install fastener (2) and tighten to 15-20in-lbs (1.7-2.3 Nm).

4. Connect IAT sensor connector [89].

5. Install air cleaner assembly. See 4.5 AIR CLEANERASSEMBLY.

6. Connect negative battery cable.

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Figure 4-11. Intake Air Temperature Sensor Location

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1. O-ring2. Fastener

Figure 4-12. Intake Air Temperature Sensor

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2009 Dyna Service: Fuel System 4-13

4.9ENGINE TEMPERATURE SENSOR (ET)

GENERAL

Stop the engine when refueling or servicing the fuelsystem. Do not smoke or allow open flame or sparks neargasoline. Gasoline is extremely flammable and highlyexplosive, which could result in death or serious injury.(00002a)

Refer to the ELECTRICAL DIAGNOSTIC MANUAL forinformation on the function and testing of the engine temper-ature sensor (ET sensor).

REMOVAL

To prevent spray of fuel, purge system of high-pressurefuel before supply line is disconnected. Gasoline isextremely flammable and highly explosive, which couldresult in death or serious injury. (00275a)

1. Purge the fuel supply line of high pressure gasoline.

a. See Figure 4-13. Remove the fuel pump fuse fromthe fuse block.

b. Start the engine and allow the vehicle to run.

c. When the engine stalls, operate the starter for 3seconds to remove any remaining fuel from the fuellines.

Gasoline can drain from quick-connect fitting whenremoving fuel line. Gasoline is extremely flammable andhighly explosive, which could result in death or seriousinjury. Wipe up spilled fuel immediately and dispose ofrags in a suitable manner. (00267a)

2. See Figure 4-14. Pull up on chrome sleeve of quick-con-nect fitting (1) and pull down on fuel supply line (2) to dis-connect.

To prevent accidental vehicle start-up, which could causedeath or serious injury, disconnect negative (-) batterycable before proceeding. (00048a)

3. Disconnect negative battery cable.

4. See Figure 4-15. Pull back boot to reveal ET sensor atback of front cylinder.

5. Unplug ET sensor connector [90] by pulling external latchoutward and using rocking motion to remove.

6. See Figure 4-16. Loosen ET sensor using socket. Whensensor starts to turn easily, finish removing by hand.

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Figure 4-13. Fuel Pump Fuse

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1. Quick connect fitting2. Fuel supply line

Figure 4-14. Fuel Supply Line Fitting

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Figure 4-15. Engine Temperature Sensor

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4-14 2009 Dyna Service: Fuel System

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Figure 4-16. Engine Temperature Sensor Removal

INSTALLATION1. Hand start new ET sensor into cylinder head bore 2-3

turns.

2. Tighten sensor to 10-15 ft-lbs (13.6-20.3 Nm).

3. Connect ET sensor connector [90].

4. Pull boot over connector.

5. See Figure 4-14. Install fuel line fitting.

6. See Figure 4-13. Install fuel pump fuse.

7. Connect negative battery cable.

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4.10INDUCTION MODULE

REMOVAL


1. Gain access to the induction module by removing fuel tankhardware and fuel line. Carefully pivot tank upward andprop in position. See 4.6 FUEL TANK.

2. Remove air cleaner backplate. See 4.5 AIR CLEANERASSEMBLY.

3. See Figure 4-17. Pull purge hose from fitting (5) at top ofinduction module (California models only).

4. See Figure 4-18. Pull idle cable barrel (1) from upper holein throttle wheel. Pull throttle cable barrel (2) from lowerhole. Using slots, release idle and throttle cables fromguides in throttle cable bracket.

5. See Figure 4-17. Remove idle air control connector (3)[87] and manifold absolute pressure sensor connector (7)[80].

6. Remove front fuel injector connector (1) [84] and rear fuelinjector connector (8) [85].

7. Remove throttle position sensor connector (4) [88] andintake air temperature sensor connector (6) [89].

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7.1. MAP sensor [80]Front fuel injector [84]2. 8.Throttle cable bracket Rear fuel injector [85]

9.3. Rear mounting flangeIAC connector [87]4. 10.TP sensor [88] Fuel supply tube

11.5. Front mounting flangePurge hose fitting (used on California models only)6. IAT sensor [89]

Figure 4-17. Induction Module

8. On left side of vehicle, loosen two hex screws holding frontand rear mounting flanges (9, 11) to cylinder head.

9. On right side of vehicle, remove two Allen screws holdingfront and rear mounting flanges to cylinder head. Removeinduction module from vehicle.

Gasoline can drain from the fuel line when disconnectedfrom induction module. Gasoline is extremely flammableand highly explosive, which could result in death or ser-ious injury. Wipe up spilled fuel immediately and disposeof rags in a suitable manner. (00269a)

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10. See Figure 4-20. If fuel supply line (2) is being replaced,squeeze ends of tab (1) and pull tab away from fuel supplyline to release from fuel supply tube (3).

11. Remove seals from flange adapters. Discard seals.Remove flange adapters from outlet ports of inductionmodule.

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1. Idle cable barrel2. Throttle cable barrel3. Throttle wheel4. Throttle cable bracket

Figure 4-18.Throttle/Idle Cables

INSTALLATION1. See Figure 4-17. Place a new seal in each mounting

flange (9, 11) with the beveled side in against the counter-bore.

NOTEWhen induction module is positioned on manifold mountingscrews, be sure the flanges are installed correctly on themanifold. Be sure the rubber seals are in place.

2. Place intake manifold seal, flanges, and induction modulein position. Install the manifold mounting screws fingertight.

3. See Figure 4-20. Slide fuel supply line (2) onto fuel supplytube (3). Push in on tab until it locks the fuel supply line(2) on fuel supply tube (3). Tug on fuel supply line (2) toverify it is locked into place.

4. See Figure 4-18. Install sleeve on throttle cable housinginto cable guide at top of throttle cable bracket (4). Drawingthrottle cable downward, fit barrel end (2) into lower holein throttle wheel (3). Install sleeve and spring on idle cable

housing into cable guide at bottom of throttle cable bracketinserting barrel end (1) into upper hole in throttle wheel.

5. See Figure 4-17. On California models, attach purge hoseto fitting (5) on throttle body.

6. Connect front (1) and rear (8) fuel injector connectors, IAC(3) connector, MAP sensor (7) connector, TP sensor (4)connector and IAT (6) sensor connector.

7. Install air cleaner back plate. See 4.5 AIR CLEANERASSEMBLY.

8. Tighten manifold mounting screws to 96-144 in-lbs (10.8-16.3 Nm).

9. Turn the Ignition/Light Key Switch to ON and then backto OFF to reset idle air control to park position.

10. Install air cleaner filter and cover.

11. Secure fuel tank. See 4.6 FUEL TANK.

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Figure 4-19. EVAP Hose Connection

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1. Tab2. Fuel supply line3. Fuel supply tube

Figure 4-20. Fuel Supply Line

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4.11IDLE AIR CONTROL (IAC)

GENERAL


Refer to the ELECTRICAL DIAGNOSTIC MANUAL forinformation on the function and testing of the idle air control(IAC).

REMOVAL1. Remove induction module. See 4.10 INDUCTION

MODULE.

2. See Figure 4-21. Remove two fasteners (2) to releasethrottle cable bracket (1) from induction module. Discardfasteners.

3. See Figure 4-22. Pull IAC (1) and O-ring (2) from throttlebody.

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1. Throttle cable bracket2. Fasteners3. Idle air control (IAC)

Figure 4-21. Idle Air Control Location

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1. Idle air control (IAC)2. O-ring

Figure 4-22. Idle Air Control

INSTALLATION1. See Figure 4-22. Apply clean engine oil to IAC O-ring (2).

Install O-ring in counterbore of induction module.

2. With the electrical connector facing the rear left side ofthe induction module, install idle air control into bore.

3. Place idle air control and o-ring into throttle body. Be sureo-ring is properly seated in throttle body groove.

4. See Figure 4-23. Insert index pin (2) at bottom of throttlecable bracket (1) into hole in boss at top of inductionmodule.

5. See Figure 4-21. Install new throttle cable bracketfasteners (2). Tighten to 20-35 in-lbs (2.3-4.0 Nm).

6. Install induction module. See 4.10 INDUCTION MODULE.

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1. Throttle cable bracket2. Index pin

Figure 4-23.Throttle Cable Bracket

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4.12MANIFOLD ABSOLUTE PRESSURE SENSOR(MAP)

GENERALRefer to the electrical diagnostic manual for information on thefunction and testing of the temperature/manifold absolutepressure (TMAP) sensor.

REMOVAL1. Remove induction module. See 4.10 INDUCTION

MODULE.

2. See Figure 4-24. Remove two fasteners (2) to releasethrottle cable bracket (1) from induction module. Discardfasteners.

3. Using appropriate tool, gently push up on MAP sensorand attached seal to remove from intake manifold.

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1. Throttle cable bracket2. Fasteners3. Manifold Absolute Pressure Sensor (MAP)

Figure 4-24.Throttle Cable Bracket Location

INSTALLATIONNOTE

See Figure 4-25. If the original sensor is re-installed, the seal(1) must be inspected. Seals not in good condition could causevacuum leaks. Install new seal if necessary.

1. Push MAP sensor and seal into intake manifold.

2. With the electrical connector facing toward the rear of theinduction module (side opposite throttle wheel), insert MAPsensor into hole in induction module.

3. See Figure 4-26. Insert index pin (2) at bottom of throttlecable bracket into hole in boss at top of induction module.

4. See Figure 4-24. Install new throttle cable bracketfasteners (2). Tighten to 20-35 in-lbs (2.3-4.0 Nm).

5. Install induction module. See 4.10 INDUCTION MODULE.

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1. Seal2. MAP sensor

Figure 4-25. MAP Sensor

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1. Throttle cable bracket2. Index pin

Figure 4-26.Throttle Cable Bracket

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intake air temperature sensor (iat) 4 davidson... · intake air temperature sensor home 2009 dyna...

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