Ä |
|
FUEL SYSTEMS 14 - 161 |
|
(5) Connect negative cable to battery.
(1)Perform fuel system pressure release procedure before servicing or starting repairs. Refer to Fuel System Pressure Release Procedure in this section.
(2)Disconnect negative cable from battery.
(3)Remove air cleaner and hose assembly (Fig. 1).
(4)Remove throttle cable (Fig. 6). Remove wiring harness from throttle cable bracket and intake manifold water tube.
Fig. 6 Throttle Cable Attachment
(5)Disconnect automatic idles speed (AIS) motor and throttle position sensor (TPS) electrical connectors (Fig. 7). Refer to Automatic Idle Speed motor and Throttle Position Sensor in this section.
(6)Remove vacuum hose harness from throttle body (Fig. 7).
(7)Remove PCV and brake booster vacuum hoses from air intake plenum.
(8)Remove EGR tube to intake manifold flange bolts (Fig. 8).
(9)Remove vacuum harness connectors from intake plenum (Fig. 8).
(10)Remove cylinder head to intake plenum strut (Fig. 8).
(11)Disconnect electrical connectors from the MAP sensor and heated oxygen sensor electrical connection. Remove the engine mounted ground strap (Fig. 9).
WARNING: WRAP A SHOP TOWEL AROUND HOSES TO CATCH ANY GASOLINE SPILLAGE.
Fig. 7 Electrical and Vacuum Connection to Throttle Body
Fig. 8 EGR Tube
(12)Remove the fuel hose quick connect fittings from the chassis tubes. Refer to Fuel Hoses,
Clamps and Quick Connect Fittings in the Fuel Delivery Section of this Group. Place a shop towel under the connections to absorb any fuel spilled. fittings.
(13)Remove direct ignition system (DIS) coils and alternator bracket to intake manifold bolt (Fig. 10).
14 - 162 FUEL SYSTEMS |
|
Ä |
|
Fig. 9 MAP Sensor Electrical Connector
Fig. 10 Ignition Coils
(14)Remove intake mounting manifold bolts and rotate manifold back over rear valve cover (Fig. 11).
(15)Cover intake manifold with suitable cover when servicing (Fig. 12).
(16)Remove vacuum harness connector from Fuel Pressure Regulator.
(17)Remove fuel tube retainer bracket screw and fuel rail attaching bolts (Fig. 12). Spread the retainer bracket to allow fuel tube removal clearance.
(18)Remove fuel rail injector wiring clip from the alternator bracket (Fig. 13).
(19)Disconnect cam sensor, coolant temperature sensor, and engine temperature sensors (Fig. 13).
(20)Remove fuel rail. Be careful not to damage the injector O-rings upon removal from their ports (Fig. 14).
Fig. 11 Intake Manifold Bolts
Fig. 12 Fuel Rail Attaching Bolts
(1)Ensure injector holes are clean. Replace O-rings if damaged.
(2)Lubricate injector O-rings with a drop of clean engine oil to ease installation.
(3)Put the tip of each injector into their ports. Push the assembly into place until the injectors are seated in the ports (Fig. 14).
(4)Install the fuel rail mounting bolts. Tighten bolts to 22 NIm (200 in. lbs.) torque (Fig. 12).
(5)Install fuel tube retaining bracket screw. Tighten screw to 4 NIm (35 in. lbs.) torque.
(6)Connect electrical connectors to cam sensor, coolant temperature sensor and engine temperature sensors (Fig. 13).
(7)Install fuel injector harness wiring clips on the alternator bracket and intake manifold water tube (Fig. 13).
(8)Connect vacuum line to fuel pressure regulator.
(9)Remove covering on lower intake manifold and clean surface.
Ä |
|
FUEL SYSTEMS 14 - 163 |
|
Fig. 13 Fuel Injector Wiring Clip
Fig. 14 Fuel Rail Removal
(10)Place intake manifold gasket on lower manifold. Put upper manifold into place and install bolts finger tight.
(11)Install the alternator bracket to intake manifold bolt and the cylinder head to intake manifold strut bolts. (Do not tighten.)
(12)Following the tightening sequence in Figure 11, tighten intake manifold bolts to 28 NIm (250 in. lbs.) torque.
(13)Tighten alternator bracket to intake manifold bolt to 54 NIm (40 ft. lbs.) torque (Fig. 13).
(14)Tighten the cylinder head to intake manifold strut bolts to 54 NIm (40 ft. lbs.) torque (Fig. 8).
(15)Connect ground strap, MAP and heated oxygen sensor electrical connectors.
(16)Connect vacuum harness to intake plenum. Connect PCV system hoses.
(17)Using a new gasket, connect the EGR tube to
the intake manifold plenum. Tighten screws to 22 NIm (200 in. lbs.) torque.
(18)Clip wiring harness into the hole in the throttle cable bracket.
(19)Connect electrical connectors to the throttle position sensor (TPS) and Automatic Idle Speed (AIS) motor.
(20)Connect vacuum harness to throttle body.
(21)Install the direct ignition system (DIS) coils. Tighten fasteners to 12 NIm (105 in. lbs.) torque.
(22)Install fuel hose quick connectors fittings to chassis tubes. Refer to Fuel Hoses, Clamps and
Quick Connect Fittings in the Fuel Delivery Section of this Group. Push the fittings onto the chassis tubes until they click into place. Pull on the fittings to ensure complete insertion. Fuel supply fitting is 5/16 inch and fuel return fitting is 1/4 inch.
(23)Install throttle cable.
(24)Install air cleaner and hose assembly.
(25)Connect negative cable to battery.
CAUTION: When using the ASD Fuel System Test, the Auto Shutdown (ASD) Relay remains energized for either 7 minutes, until the test is stopped, or until the ignition switch is turned to the Off position.
(26) With the ignition key in ON position, access the DRB II ASD Fuel System Test to pressurize the fuel system. Check for leaks.
(1)Perform fuel system pressure release procedure before attempting any repairs. Refer to Fuel Pressure Regulator Procedure in this section.
(2)Remove fuel pressure regulator vacuum connector. (Fig. 15).
(3)Remove regulator retainer screw (Fig. 15).
(4)Remove the fuel pressure regulator retainer (Fig. 15).
WARNING: PLACE A SHOP TOWEL UNDER FUEL PRESSURE REGULATOR TO ABSORB ANY FUEL SPILLAGE.
(5) Remove fuel pressure regulator and O-rings (Fig. 16).
14 - 164 FUEL SYSTEMS |
|
Ä |
|
Fig. 15 Fuel Pressure Regulator
Fig. 16 Fuel Pressure Regulator
Removal/Installation
(1)Ensure fuel pressure regulator has two plastic spacers (Fig. 16). Place O-rings in the fuel pressure regulator cavity (Fig. 17). Do not install O-rings on the fuel pressure regulator.
(2)Insert fuel pressure regulator into the fuel rail.
(3)Install fuel pressure regulator retainer (Fig. 15).
(4)Install retainer screw. Tighten to 7 NIm (60 in. lbs.) torque.
(5)Connect vacuum line to the fuel pressure regu-
lator.
CAUTION: When using the ASD Fuel System Test, the Auto Shutdown (ASD) Relay remains energized for either 7 minutes, until the test is stopped, or until the ignition switch is turned to the Off position.
(6) With the ignition key in ON position, access the DRB II ASD Fuel System Test to pressurize the fuel system. Check for leaks.
Fig. 17 Fuel Pressure Regulator O-Rings
The fuel rail must be removed first. Refer to Fuel Injector Rail Assembly Removal in this section.
(1)Disconnect injector wiring connector from injec-
tor.
(2)Position fuel rail assembly so that the fuel injectors are easily accessible (Fig. 18).
Fig. 18 Fuel Injector and RailÐTypical
(3)Rotate injector and pull injector out of fuel rail. The clip will stay on the injector.
(4)Check injector O-ring for damage. If O-ring is damaged, it must be replaced. If injector is reused, a protective cap must be installed on the injector tip to prevent damage. Replace the injector clip if it is damaged.
(5)Repeat for remaining injectors.