GM FUEL PRESSURE SENSOR BY-PASS INSTALLATION INSTRUCTIONS P11X AF

Transcription

1 GM UEL PRESSURE SENSOR BY-PASS PX4-924-A Revision: - Dated 0/3/3 Replaces: E - Dated 5/3/3

2 NUMBER 0 E K C D G A B J H U L M N P R T Q S 0) THE OLLOWING IS A LIST O COMPONENTS CONTAINED WITHIN THE A B C D E G H J K L M N P Q R S T U GM UEL PRESSURE SENSOR BY-PASS KIT (PX4-205-AD) UEL PRESSURE SENSOR ADAPTOR /8" NPT X /4" HOSE BARB /4" NPT X /4" HOSE BARB /4" NPT X /4" HOSE BARB W/.0 ORIICE SOLENOID ASSEMBLY SEL TAP SCREW LAT WASHER /4" UEL HOSE CLAMP USE HOLDER W/5 AMP USE /4" UEL HOSE - L-5' WIRE ASSY - UEL PRESSURE SENSOR BY-PASS 8 GA. BLACK WIRE (L=0') /4" SPLIT CORRUGATE (L=4') -/2" x 3/4" COPPER PIPE WITH /8" NPT HOLE #6 HOSE CLAMP 90 STREET ELBOW /4" SHRINK TUBE /2" CABLE CLAMP RING TERMINAL PART NUMBER QTY DESCRIPTION TOOLS A UEL PRESSURE SENSOR ADAPTOR B /8" NPT X /4" HOSE BARB C /4" NPT X /4 HOSE BARB D /4" NPT X /4 HOSE BARB (W/.0 ORIICE) E SOLENOID ASSEMBLY SEL TAP SCREW G LAT WASHER H /4" UEL HOSE CLAMP J USE HOLDER W/5 AMP USE K 3000 /4" UEL HOSE - L=5" L WIRE ASSY - UEL PRESS. SENSOR BY-PASS M GA. BLACK WIRE W/ICU TERMINAL (L=0') N /4" SPLIT CORRUGATE (L=4') P /2" x 3/4" COPPER PIPE WITH /8" NPT HOLE Q #6 HOSE CLAMP R STREET ELBOW GM UEL PRESSURE SENSOR BY-PASS S /4" SHRINK TUBE (L=3") T /2" CABLE CLAMP U RING TERMINAL PX4-924-A O

3 NUMBER 20 20) LOCATE THE UEL PRESSURE SENSOR ATTACHED TO THE UEL LINE ON THE INBOARD SIDE O THE RAME BELOW THE DRIVER SIDE DOOR 30) DISCONNECT THE OEM WIRE HARNESS CONNECTION ROM THE SENSOR 30 40) CAREULLY REMOVE THE UEL PRESSURE SENSOR ROM THE GASOLINE UEL TUBE 50 50) OBTAIN THE UEL PRESSURE SENSOR ADAPTOR (A); APPLY APPROVED LUBRICANT ONTO O-RING 60) INSTALL AND GENTLY TIGHTEN ADAPTOR ONTO THE GASOLINE UEL TUBE AS SHOWN 60 DESCRIPTION TOOLS A UEL PRESSURE SENSOR ADAPTOR GM UEL PRESSURE SENSOR BY-PASS PX4-924-A 2 O

4 NUMBER 70) REINSTALL AND GENTLY TIGHTEN THE UEL PRESSURE SENSOR ONTO THE ADAPTOR 70 80) REINSTALL THE WIRE HARNESS CONNECTOR ONTO THE UEL PRESSURE SENSOR 90) OBTAIN () /4" NPT X /4" HOSE BARB WITH.0/ORIICE (D) (VERIY CORRECT HOSE BARB WITH.0 ORIICE) 80 OR APPLICATIONS WHERE AN OBSTRUCTION WILL NOT ALLOW ACCESS TO THE HOSE BARB ONCE INSTALLED INTO THE ADAPTOR, USE THE SUPPLIED 90 STREET ELBOW APPLY APPROVED THREAD SEALER TO ELBOW THREADS BEORE INSTALLING INTO ADAPTOR 00) APPLY APPROVED THREAD SEALER TO HOSE BARB THREADS 90 INSTALL AND ULLY TIGHTEN HOSE BARB INTO ADAPTOR AS SHOWN 00 R D DESCRIPTION TOOLS A UEL PRESSURE SENSOR ADAPTOR 7/6" OPEN END WRENCH D /4" NPT X /4 HOSE BARB (W/.0 ORIICE) THREAD SEALER R STREET ELBOW O-RING LUBRICANT GM UEL PRESSURE SENSOR BY-PASS PX4-924-A 3 O

5 NUMBER 0) OBTAIN THE OLLOWING: () SOLENOID ASSY (E), (2) /4" NPT x /4" HOSE BARB (C ) APPLY APPROVED THREAD SEALER TO HOSE BARB THREADS INSTALL AND ULLY TIGHTEN HOSE BARBS INTO SOLENOID PORTS AS SHOWN 0 20) OBTAIN (2) SEL TAP SCREWS () AND (2) LAT WASHERS (G) 20 DETERMINE MOUNTING LOCATION ON THE VEHICLE RAME CLOSE TO THE GASOLINE UEL PRESSURE SENSOR MOUNT THE SOLENOID ONTO THE RAME WITH THE SOLENOID POSITIONED 'UP' USING THE (2) SEL TAP SCREWS W/WASHERS 30) OBTAIN /4" UEL HOSE (K) AND (2) /4" UEL HOSE CLAMPS (H) 30 INSTALL () UEL HOSE CLAMP ONTO END O UEL HOSE; ULLY INSERT HOSE ONTO THE HOSE BARB ON THE INLET SIDE O THE SOLENOID; POSITION CLAMP OVER BARB; ULLY TIGHTEN CLAMP TO SECURE HOSE DESCRIPTION TOOLS C /4" NPT X /4" HOSE BARB 9/6" OPEN END WRENCH E SOLENOID ASSY THREAD SEALER SEL TAP SCREW G LAT WASHER H /4" UEL HOSE CLAMP K 3000 /4" UEL HOSE - L=5" GM UEL PRESSURE SENSOR BY-PASS PX4-924-A 4 O

6 NUMBER 40 40) CAREULLY ROUTE THE HOSE TO THE HOSE BARB ON THE UEL PRESSURE SENSOR ADAPTOR, INSURING THE HOSE ROUTING DOES NOT CREATE SHARP BENDS OR KINKS IN THE HOSE CUT HOSE TO REQUIRED LENGTH WITH APPROPRIATE HOSE CUTTER 50) INSTALL () UEL HOSE CLAMP ONTO END O UEL HOSE; ULLY INSERT HOSE ONTO UEL PRESSURE SENSOR ADAPTOR HOSE BARB AND POSITION CLAMP OVER BARB; ULLY TIGHTEN CLAMP TO SECURE HOSE 50 60) OBTAIN REMAINING HOSE ROM PIOUS STEP 20 AND (2) /4" UEL HOSE CLAMPS (H) 70) INSTALL () UEL HOSE CLAMP ONTO END O UEL HOSE; ULLY INSERT HOSE ONTO REMAINING SOLENOID HOSE BARB AND POSITION CLAMP OVER BARB; ULLY TIGHTEN CLAMP TO SECURE HOSE 70 DESCRIPTION TOOLS H /4" UEL HOSE CLAMP 7mm NUT DRIVER HOSE CUTTER GM UEL PRESSURE SENSOR BY-PASS PX4-924-A 5 O

7 NUMBER 80) LOCATE METAL PORTION O GASOLINE UEL ILLER TUBE DRILL AND TAP TO /8" NPT THE GASOLINE TANK UEL ILLER TUBE 80 90) OBTAIN () /8" NPT x /4" HOSE BARB (B); APPLY APPROVED THREAD SEALER TO HOSE BARB THREADS INSTALL AND TIGHTEN HOSE BARB INTO UEL ILLER TUBE 95) OR VEHICLES EQUIPPED WITH AN ALL RUBBER GASOLINE UEL ILLER TUBE, OBTAIN THE -/2" x 3/4" COPPER PIPE (P) AND (2) #6 HOSE CLAMP (Q) APPLY JB WELD TO THE THREADS ON THE /8" NPT x /4" HOSE BARB (B); INSTALL HOSE BARB INTO THREADED HOLE IN THE COPPER PIPE AND ULLY TIGHTEN AS SHOWN CUT THE GASOLINE UEL ILLER HOSE IN HAL AT THE DESIRED LOCATION; INSTALL A #6 HOSE CLAMP (Q ) ONTO EACH END O THE CUT HOSE; INSTALL EACH END O THE CUT ILLER HOSE ONTO THE COPPER PIPE; POSITION CLAMPS OVER THE COPPER PIPE AND ULLY TIGHTEN 200) CAREULLY ROUTE HOSE TO THE HOSE BARB ON THE GASOLINE UEL ILLER TUBE, INSURING THE HOSE ROUTING DOES NOT CREATE SHARP BENDS OR KINKS IN THE HOSE CUT HOSE TO THE REQUIRED LENGTH 200 DESCRIPTION TOOLS B /8" NPT X /4" HOSE BARB DRILL P /2" x 3/4" COPPER PIPE WITH /8" NPT HOLE /8" NPT TAP Q #6 HOSE CLAMP THREAD SEALER JB WELD GM UEL PRESSURE SENSOR BY-PASS PX4-924-A 6 of

8 NUMBER 20) INSTALL () UEL HOSE CLAMP ONTO END O UEL HOSE; ULLY INSERT HOSE ONTO HOSE BARB AND POSITION HOSE CLAMP OVER BARB: ULLY TIGHTEN CLAMP TO SECURE HOSE 20 25) SECURE UEL HOSE TO VEHICLE WHERE NEEDED USING THE PROVIDED /2" CABLE CLAMP (U) AND SEL TAP SCREW () L 220) OBTAIN THE WIRE ASSY - UEL PRESS. SENSOR BY-PASS (L) AND THE 8 GA. BLACK WIRE (0') (M) 220 M 230) USING WIRE STRIPPERS, REMOVE APPROXIMATELY /2" O INSULATION ROM THE END O THE LONG RED WIRE (L=0') AND BLACK WIRE ) SOLDER THE RED WIRE TO ONE O THE SOLENOID LEADS AND THE BLACK WIRE TO THE REMAINING SOLENOID LEAD; SEAL BOTH SOLDER CONNECTIONS WITH ELECTRICAL TAPE DESCRIPTION TOOLS L SEL TAP SCREW 8GA. RED WIRE W/TERMINAL (L=0') SOLDER IRON WIRE CUTTER / STRIPPER N GA. BLACK WIRE (L=0') ELECTRICAL TAPE U /2" CABLE CLAMP GM UEL PRESSURE SENSOR BY-PASS PX4-924-A 7 of

9 NUMBER ) CAREULLY ROUTE THE WIRE ASSY AND BLACK WIRE ROM THE SOLENOID TOWARD THE RONT O THE VEHICLE AND INTO THE ENGINE COMPARTMENT 260) ROM INSIDE THE ENGINE COMPARTMENT, LOCATE THE 3-PIN CONNECTOR WIRE LEAD ATTACHED TO THE ICOM ENGINE WIRE HARNESS ASSY WITH THE ORANGE, GREEN AND YELLOW WIRES; ALIGN AND SEAT THE WIRE ASSY (RED WIRES) INTO THE CONNECTOR WIRE LEAD ON THE ICOM ENGINE WIRE HARNESS (PUSH/PULL CONNECTORS TO VERIY ULLY LOCKED) ) ROUTE THE SHORT RED WIRE ON THE WIRE ASSY TOWARD THE POSITIVE CABLE ON THE BATTERY AS SHOWN DESCRIPTION TOOLS U RING TERMINAL WIRE CUTTER / STRIPPER WIRE CRIMPER GM UEL PRESSURE SENSOR BY-PASS PX4-924-A 8 of

10 NUMBER ) OBTAIN THE RING TERMINAL (U) U ) CAREULLY REMOVE APPROXIMATELY /2" O WIRE INSULATION ROM THE END O THE SHORT RED WIRE; INSTALL THE RING TERMINAL ONTO THE END O THE WIRE AS SHOWN 300 J 300) OBTAIN THE USE HOLDER W/5 AMP USE (J) ) USING WIRE CUTTERS, CUT THE SHORT RED WIRE IN HAL APPROXIMATELY 6-8 INCHES DOWN ROM THE RING TERMINAL 320) INSTALL USE HOLDER ONTO THE CUT WIRES PER ICOM USE HOLDER INSTALLATION INSTRUCTION PX-9208-AA DESCRIPTION TOOLS J USE HOLDER W/5 AMP USE WIRE CUTTER / STRIPPER SOLDER ELECTRICAL TAPE GM UEL PRESSURE SENSOR BY-PASS PX4-924-A 9 of

11 NUMBER 330) LOCATE AND GRASP THE BLACK SOLENOID WIRE LEAD CAREULLY REMOVE APPROXIMATELY /2" O WIRE INSULATION ROM THE END O THE BLACK WIRE 340) LOCATE THE BROWN WIRE ON THE MAIN WIRE HARNESS GOING TO PIN #24 IN THE OLLOWER MODULE CONNECTOR 350) CAREULLY REMOVE APPROXIMATELY /2" O WIRE INSULATION ROM THE BROWN WIRE (DO NOT CUT WIRE) 360) ATTACH THE BLACK WIRE (M) ONTO THE STRIPPED BROWN WIRE COMING ROM PIN #24; SOLDER CONNECTION TOGETHER AND SEAL WITH ELECTRICAL TAPE UEL BY-PASS SOLENOID H DESCRIPTION TOOLS WIRE CUTTER / STRIPPER SOLDER IRON ROSIN CORE SOLDER ELECTRICAL TAPE GM UEL PRESSURE SENSOR BY-PASS PX4-924-A 0 of

12 NUMBER 370) ATTACH THE RING TERMINAL ON THE SHORT RED WIRE WITH THE USE HOLDER ONTO THE POSITIVE SIDE O THE BATTERY AS SHOWN ) OBTAIN THE /4" CORRUGATE (P) P 390) INSTALL THE /4" SPLIT CORRUGATE ONTO THE RED AND BLACK WIRES BETWEEN THE UEL BY-PASS SOLENOID AND THE ICU/OLLOWER MODULES; CUT THE CORRUGATE TO THE REQUIRED LENGTH ) SECURE CORRUGATE & UEL HOSE TO VEHICLE WHERE NEEDED USING THE PROVIDED /2" CABLE CLAMP (T) AND SEL TAP SCREW () 400 DESCRIPTION TOOLS SEL TAP SCREW WIRE CUTTER / STRIPPER T /2" CABLE CLAMP GM UEL PRESSURE SENSOR BY-PASS PX4-924-A of

13 Title: GM UEL PRESSURE SENSOR BY- PASS INSTALLATION Document I.D.: PX4-924 Page Rev ISIONS NUMBER ISION LEVEL DESCRIPTION O CHANGE DATE APPROVED BY A INITIAL RELEASE 9/24/202 M. STEPPEY UPDATED PHOTOS AND OLLOWER MODULE WIRING B 2/5/202 M. STEPPEY INSTRUCTIONS 400 C THE INSTRUCTION TO SOLDER THE RED WIRE TO PIN # 32 IS INCORRECT AND WAS CHANGED TO THE BLACK WIRE AND PIN #24 2/2/202 M. STEPPEY 250, 260 ADD PART NUMBER TO OLLOWER MODULE D DESCRIPTION OR BETTER CLARIICATION 5/0/203 M. STEPPEY 95 25, 400 E ADD ADDITIONAL COMPONENTS REQUIRED OR VEHICLES EQUIPPED WITH AN ALL RUBBER GASOLINE UEL ILLER TUBE ADD /2" CABLE CLAMPS TO SECURE UEL HOSE AND WIRING I NEEDED 5/3/203 M. STEPPEY 220 ADD WIRE ASSY WITH 3-PIN CONNECTOR CHANGE CONNECTION O SOLENOID POWER LEADS TO ICOM ENGINE WIRE HARNESS ASSY 0/3/203 M. STEPPEY Author: Marc Steppey Approval: Date: 0/3/203 Title: Technical Manager Title: Initials