HOME
INDUCTION MODULE ASSEMBLY
9.5
GENERAL
2.
Remove air cleaner and backplate. See Section 4.5 AIR
CLEANER, REMOVAL.
See Figure 9-26. The Induction Module Assembly consists of
the following components:
3.
Pull purge tube from fitting at top of induction module
(California models only). See Figure 9-26.
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.
On cruise control equipped models, remove E-clip from
sleeve at end of cruise cable housing. Using slot,
remove cable housing from cable guide in throttle cable
bracket. Push the plastic end fitting on the cruise cable
to the outboard side to release from wheel pin. See Figure 9-27.
INDUCTION MODULE
6.
Remove idle air control and manifold absolute pressure
sensor connectors. Pull external latch(es) outward and
use rocking motion to separate pin and socket halves.
REMOVAL
7.
Depress wire form to remove electrical connectors from
front and rear fuel injectors.
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
Partially remove fuel tank. See Section 9.4 FUEL TANK
(FUEL INJECTED), PARTIAL REMOVAL, either FLHT/
C/U/I, FLTRI or FLHR/C/I.
1.
2.
3.
4.
5.
Fuel Injector (Front)
Throttle Cable Bracket
Idle Air Control
Throttle Position Sensor
Purge Tube Fitting
(California Models Only)
6. Intake Air Temperature Sensor
7. Manifold Absolute Pressure
Sensor
8. Fuel Injector (Rear)
10
9. Fuel Rail
10. Fuel Supply Tube
Front
9
7
8
f1939x9x
Rear
Figure 9-26. Induction Module Assembly
2003 Touring: Fuel Injection
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.
Remove O-ring from counterbore of throttle body
flange. Discard O-ring.
Wheel Pin
INSTALLATION
End Fitting
1.
If induction module was split, assemble the intake manifold and throttle body as follows:
a.
Apply a thin coat of clean engine oil to new O-ring.
Install O-ring in counterbore of throttle body flange.
Mate intake manifold and throttle body flanges.
b.
Apply Loctite Wicking Threadlocker 290 (green) to
threads of two T20 TORX screws. Install screws and
alternately tighten to 27-33 in-lbs (3.1-3.7 Nm).
Allow approximately 3-6 hours to elapse for compound to cure.
Figure 9-27. Remove End Fitting From Wheel Pin
Button
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.
Orientate the induction module as shown in Figure 9-26.
With the counterbore facing outward, slide cylinder head
flange adapters onto outlet ports of induction module.
The flange adapters are not interchangeable. Look next
to the slotted bolt hole for a stamp that indicates F(ront)
and R(ear) cylinder.
4.
Place a new seal in each flange adapter with the beveled side in against the counterbore.
5.
Standing on right side of engine, slide induction module
toward installed position so that open-ended slots on
flange adapters begin to engage allen head socket
screws loosely installed on left side. Use caution around
horn bracket to prevent damage to fuel line.
6.
1WARNING
Install sleeve on throttle cable housing into shorter cable
guide at top of throttle cable bracket. Drawing throttle
cable downward, fit barrel end into lower hole in throttle
wheel. Install sleeve and spring on idle cable housing
into longer cable guide at bottom of throttle cable bracket
inserting barrel end into upper hole in throttle wheel.
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.
On cruise control equipped models, slide groove in
cruise cable end fitting over cap of wheel pin. Push on
end fitting until it snaps in place. Using slot, slip cruise
cable housing into cable guide in throttle cable bracket.
Install new E-clip on sleeve at end of cruise cable housing.
8.
Align fixed holes in flange adapters with those in cylinder
heads and start allen head socket screws. For best
results, use a long 1/4 inch ball allen head socket with
end driver 4 inches long.
f1922x9x
Figure 9-28. Remove Fuel Supply Line From Supply Tube
9.
Remove right side allen head socket screws from front
and rear cylinder head flange adapters. For best results,
use a long 1/4 inch ball allen head socket with end driver
4 inches long.
10. Moving to opposite side of vehicle, just loosen left side
allen head socket screws from flange adapters. Slots in
flanges make removal of left side screws unnecessary.
To better access bolts, loosen acorn nut and swing horn
assembly out of the way.
11. Slide induction module out from right side of vehicle.
Use caution around horn bracket to prevent damage to
fuel line.
12. Depress button on inboard side of fuel supply line and
remove from supply tube. See Figure 9-28.
9-32
2003 Touring: Fuel Injection
HOME
f1966x9x
11. Remove breather bolts and T27 TORX screws to remove
backplate, if installed.
Breather Bolts
12. Tighten allen head socket screws in fixed holes of flange
adapters to 96-144 in-lbs (10.9-16.3 Nm).
13. Remove breather bolts to remove alignment bracket, if
installed.
14. Install electrical connectors on fuel injectors.
15. Install manifold absolute pressure sensor and idle air
control connectors.
16. Install intake air temperature sensor and throttle position
sensor connectors.
17. Connect purge tube to fitting at top of induction module
(California models only). See Figure 9-26.
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
20. Check throttle and idle control cable adjustment. Check
cruise cable adjustment.
FUEL SUPPLY LINE
1WARNING
Bracket
Figure 9-29. Install Backplate or Bracket
9.
Use the air cleaner backplate or INDUCTION SYSTEM
ALIGNMENT BRACKET (P&A Part No. 40054-01) to
properly locate induction module. Proceed as follows:
a.
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.
10. Tighten allen head socket screw in fixed holes of flange
adapters until snug. Moving to left side of engine, tighten
screws in slotted holes to 96-144 in-lbs (10.9-16.3 Nm).
If moved, swing horn assembly back into position and
tighten acorn nut.
The gasoline in the fuel supply line downstream of the
fuel pump is under high pressure (58 psi). To avoid an
uncontrolled discharge or spray of gasoline, always
purge the system of high pressure gas before the fuel
supply line is disconnected. Inadequate safety precautions could result in death or serious injury.
REMOVAL
1.
Partially remove fuel tank. See Section 9.4 FUEL TANK
(FUEL INJECTED), PARTIAL REMOVAL, FLHT/C/U/I,
FLTRI, or FLHR/C/I.
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.
2003 Touring: Fuel Injection
9-33
HOME
FUEL RAIL/FUEL SUPPLY TUBE
Button
REMOVAL
f1922x9x
Figure 9-30. Remove Fuel Supply Line From Supply Tube
2.
Pull up on chrome sleeve of quick-connect fitting on left
side of fuel tank and pull down on fuel supply line to disconnect. See Figure 9-27.
3.
Raise fuel tank approximately 2 inches. Move the fuel
tank crossover hose to the rear of the ignition coil, so
that the tank can be raised an additional 2-3 inches.
Move fuel tank straight back slightly and rest on frame
backbone.
4.
Obtain several 1 x 2 inch wooden blocks. Raise the front
and rear of the fuel tank off the frame backbone by placing blocks in the recess centered at the bottom of the
tank.
1.
See INDUCTION MODULE, REMOVAL, in this section.
2.
Depress button on inboard side of fuel supply line and
remove from fuel supply tube. See Figure 9-30.
3.
Using a T20 TORX drive head, remove screw to release
fuel supply tube clamp. See Figure 9-31.
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
Figure 9-31. Remove Fuel Supply Tube Clamp
and Fuel Injector Clip
T20 TORX
Screws
Depress button on inboard side of fuel supply line and
remove from supply tube. See Figure 9-30.
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.
Pull up on chrome sleeve of quick-connect fitting on left
side of tank and insert neck of fuel supply line fitting.
While pushing up on bottom of fuel supply line fitting,
pull down on chrome sleeve until it clicks into the
locked position. Tug on fuel supply line to be sure that it
will not come free.
3.
Install fuel tank. See Section 9.4 FUEL TANK (FUEL
INJECTED),
INSTALLATION
(AFTER
PARTIAL
REMOVAL), FLHT/C/U/I, FLTRI, or FLHR/C/I.
9-34
2003 Touring: Fuel Injection
Fuel Rail
7910
Figure 9-32. Remove Fuel Rail
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.
See INDUCTION MODULE, INSTALLATION, in this section.
8323
Tab
Figure 9-33. Install Fuel Injector Clip
f1935x9x
O-Ring
Sealing
Washer
FUEL INJECTORS
REMOVAL
Figure 9-34. Install Fuel Supply Tube
1.
See INDUCTION MODULE, REMOVAL, in this section.
2.
Depress button on inboard side of fuel supply line and
remove from fuel supply tube. See Figure 9-30.
3.
Using a T20 TORX drive head, remove screw to release
fuel supply tube clamp. See Figure 9-31.
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.
Using a T20 TORX drive head, remove two screws to
release fuel rail from induction module. See Figure 9-32.
5.
Using a T20 TORX drive head, remove two screws to
release fuel rail from induction module. See Figure 9-32.
7.
Pull fuel rail with attached fuel injectors from induction
module. To overcome the resistance of the bottom Oring on both fuel injectors, gently rock assembly back
and forth while pulling.
8.
Pull fuel injectors from fuel rail. To overcome the resistance of the top O-ring, gently rock each fuel injector
while pulling.
9.
Remove O-rings from fuel injectors. Discard O-rings.
See Figure 9-35.
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.
With the electrical connector topside, push fuel injectors
into induction module bores. Rotate fuel injectors, so
that the electrical connectors are on the outboard side.
f1934x9x
Figure 9-35. Fuel Injector
2003 Touring: Fuel Injection
9-35
HOME
6.
Pull fuel rail with attached fuel injectors from induction
module. To overcome the resistance of the bottom Oring on both fuel injectors, gently rock assembly back
and forth while pulling.
7.
Pull fuel injectors from fuel rail. To overcome the resistance of the top O-ring, gently rock each fuel injector
while pulling.
8.
Remove O-rings from fuel injectors. Discard O-rings.
See Figure 9-35.
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.
With the electrical connector topside, push fuel injectors
into induction module bores. Rotate fuel injectors, so
that the electrical connectors are on the outboard side.
3.
Push fuel rail over fuel injectors until fuel rail flange contacts boss on induction module.
4.
Intake Air
Temperature
Sensor
Figure 9-36. Induction Module (Rear View)
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.
See INDUCTION MODULE, INSTALLATION, in this section.
Throttle
Position
Sensor
f1936x9x
Thermistor
Gasket
Figure 9-37. Intake Air Temperature Sensor
INTAKE AIR TEMPERATURE
SENSOR
REMOVAL
1.
Remove seat. See Section 2.22 SEAT, REMOVAL.
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.
Unthread bolt and remove battery negative cable (black)
from battery negative (-) terminal.
3.
Remove air cleaner and backplate. See Section 4.5 AIR
CLEANER, REMOVAL.
4.
Disconnect the intake air temperature sensor connector.
See Figure 9-36. Pull external latches outward and use
a rocking motion to separate pin and socket halves.
9-36
2003 Touring: Fuel Injection
5.
Using a T10 TORX drive head, remove two screws to
release intake air temperature sensor from induction
module. See Figure 9-36.
6.
Remove and discard gasket.
INSTALLATION
1.
Place new gasket on flange of intake air temperature
sensor.
2.
Insert sensor into induction module with electrical connector facing toward the left side of the vehicle. See Figure 9-36.
3.
Using a T10 TORX drive head, install two screws to
secure intake air temperature sensor to induction module. Alternately tighten screws to 12 in-lbs (1.4 Nm).
See Figure 9-36.
4.
Install the intake air temperature sensor connector.
5.
Install backplate and air cleaner. See Section 4.5 AIR
CLEANER, INSTALLATION.
HOME
6.
7.
Insert bolt through battery negative cable (black) into
threaded hole of battery negative (-) terminal. Tighten
bolt to 60-96 in-lbs (6.8-10.9 Nm).
Throttle Cable
Bracket
Install seat. See Section 2.22 SEAT, INSTALLATION.
THROTTLE POSITION SENSOR
REMOVAL
1.
Remove seat. See Section 2.22 SEAT, REMOVAL.
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.
Unthread bolt and remove battery negative cable (black)
from battery negative (-) terminal.
3.
Remove air cleaner and backplate. See Section 4.5 AIR
CLEANER, REMOVAL.
4.
Disconnect the throttle position sensor connector. See
Figure 9-36. Pull external latch outward and use a rocking motion to separate pin and socket halves.
5.
Using a T20 TORX drive head, remove two screws to
release sensor from induction module. See Figure 9-36.
T20 TORX
Screws
8315
Figure 9-38. Remove Screws to Release Bracket
f1701x9x
Electrical
Connector
INSTALLATION
Rubber
Seal
Pressure Port
1.
With electrical connector facing down, fit pocket of throttle position sensor over throttle shaft.
2.
Align holes in flange of throttle position sensor with
holes in induction module. It may be necessary to turn
the sensor slightly to align holes.
3.
Using a T20 TORX drive head, install two screws to
secure throttle position sensor to induction module.
Alternately tighten screws to 18 in-lbs (2.0 Nm). See
Figure 9-36.
4.
Using the throttle lever mechanism, open and close the
throttle plates to check for proper operation. Be sure that
the mechanism operates smoothly without binding or
sticking.
REMOVAL
5.
Install the throttle position sensor connector.
6.
Install backplate and air cleaner. See Section 4.5 AIR
CLEANER, INSTALLATION.
7.
Insert bolt through battery negative cable (black) into
threaded hole of battery negative (-) terminal. Tighten
bolt to 60-96 in-lbs (6.8-10.9 Nm).
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.
Install seat. See Section 2.22 SEAT, INSTALLATION.
Figure 9-39. Manifold Absolute Pressure Sensor
MANIFOLD ABSOLUTE
PRESSURE SENSOR
1WARNING
1.
See INDUCTION MODULE, REMOVAL, in this section.
2003 Touring: Fuel Injection
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.
Using a T20 TORX drive head, remove two screws to
release throttle cable bracket from induction module.
See Figure 9-38. Discard flange screw of idle air control.
3.
Pull pressure port (enveloped in rubber seal) from hole
in induction module.
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.
Install rubber seal on pressure port, if removed.
2.
With the electrical connector facing toward the rear of
the induction module (side opposite throttle cable
bracket), insert pressure port into hole in induction module. See Figure 9-39.
3.
Align hole in throttle cable bracket with hole at side of
induction module. Start screw into induction module.
See Figure 9-38.
4.
Align hole at top of throttle cable bracket with thru hole in
flange of idle air control. Start new screw with loctite
patch into induction module.
5.
Using a T20 TORX drive head, tighten screw at side of
throttle cable bracket to 18 in-lbs (2.0 Nm).
6.
Tighten flange screw of idle air control to 25 in-lbs (2.8
Nm).
7.
Move free end of throttle return spring into slot in throttle
cable bracket.
8.
See INDUCTION MODULE, INSTALLATION, in this section.
Figure 9-40. Induction Module (Rear View)
f1938x9x
O-Ring
Figure 9-41. Idle Air Control
CAUTION
IDLE AIR CONTROL
REMOVAL
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
See INDUCTION MODULE, REMOVAL, in this section.
2003 Touring: Fuel Injection
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.
Using a T20 TORX drive head, remove two screws to
release throttle cable bracket from induction module.
See Figure 9-38. Discard flange screw of idle air control.
3.
Remove remaining screw to release flange of idle air
control from top of induction module. Discard screw.
4.
Pull idle air control from bore of induction module.
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.
Throttle Position Sensor
T20 TORX Screw- 14mm (6)
T10 TORX Screw (2)
Intake Air Temperature Sensor
Gasket
O-Ring
Idle Air Control
T20 TORX Screw (2)
Throttle Cable Bracket
Fuel Injector
Fuel Rail
Fuel Injector Clip
Fuel Supply Tube Clamp
Fuel Supply Tube
Sealing Washer
O-Ring
Manifold Absolute
Pressure Sensor
18. Rubber Seal
19. Socket Head Screw (4)
20. Flange Adapter (2)
21.
22.
23.
24.
25.
Adapter Seal (2)
Intake Manifold
O-Ring
Throttle Body
T20 TORX Screw- 17mm (2)
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.
Apply a thin coat of clean engine oil to new O-ring.
Install O-ring on counterbore of induction module flange.
2.
With the electrical connector facing the left side of the
induction module (intake manifold side), install idle air
control into bore.
3.
4.
Align hole in throttle cable bracket with hole at side of
induction module. Start screw into induction module.
See Figure 9-38.
Align hole at top of throttle cable bracket with thru hole in
flange of idle air control. Start new screw with loctite
patch into induction module.
5.
Install remaining screw into flange of idle air control.
Again, use new screw with loctite patch.
6.
Using a T20 TORX drive head, tighten screw at side of
throttle cable bracket to 18 in-lbs (2.0 Nm).
7.
Alternately tighten flange screws of idle air control to 25
in-lbs (2.8 Nm).
8.
Move free end of throttle return spring into slot in throttle
cable bracket.
9.
See INDUCTION MODULE, INSTALLATION, in this section.
2003 Touring: Fuel Injection
9-39
HOME
NOTES
9-40
2003 Touring: Fuel Injection
