FUEL SYSTEM. Table of Contents. Section 3B Direct Fuel Injection

Transcription

1 FUEL SYSTEM Section 3B Direct Fuel Injection Tle of Contents DIRECT FUEL INJECTION Specifictions B-2 Specil Tools B-3 Air Hndler B-6 Air Hndler Components B-8 Vpor Seprtor Components B-10 Air Hoses B-12 Wter Hoses B-14 Fuel Hoses B-16 Fuel Rils B-18 Air Compressor Components B-20 DFI Opertion B-22 Air Induction Through Crnkcse B-22 Air Compressor System B-22 Fuel B-22 Oil B-23 Electricl B-23 Opertion B-23 Testing Electric Fuel Pump Pressure Output 3B-24 Low Pressure Electric Fuel Pump B-24 High Pressure Electric Fuel Pump B-25 Fuel Mngement Assemly Removl B-26 Reed Block Disssemly/Assemly B-29 Air Temperture Sensor Removl B-29 Air Temperture Sensor Instlltion B-30 Throttle Plte Assemly Removl B-30 Throttle Plte Assemly Instlltion B-30 Vpor Seprtor Disssemly B-30 Vpor Seprtor Ressemly B-32 Air Plenum Instlltion B-33 Low Pressure Electric Fuel Pump Instlltion B-33 Vpor Seprtor Instlltion B-36 Fuel Ril Removl B-38 Fuel Pressure Regultor B-43 Air Pressure Regultor B-46 Trcker Vlve B-48 Fuel Ril Clening B-50 Direct Injector Removl B-51 Direct Injector Lek Test B-53 Fuel Ril nd Direct Injector Instlltion. 3B-54 Air Compressor B-55 Compressor Removl B-56 Air Compressor Disssemly/Ressemly B-58 Air Compressor Flow Digrm B-59 Air Compressor Pressure Test B-60 3 B JANUARY 2001 Pge 3B-1

2 Specifictions DIRECT INJECTION AIR COMPRESSOR Injectors Quntity Injectors re Crnk Angle Driven y ECM #2 Cylinder #4 Cylinder #6 Cylinder #1 Cylinder #3 Cylinder #5 Cylinder Fuel Line Injectors Air Pressure High Pressure Electric Fuel Pump Amperge Drw Low Pressure Electric Fuel Pump Amperge Drw Low Pressure Electric Fuel Pump Output Fuel Injector Ohm Resistnce Direct Injector Ohm Resistnce Fuel/Air Differentil Type Compressor Output Cylinder Block Displcement Cylinder Bore Dimeter (Stndrd) Tper/Out-of-Round/ Wer Mximum Bore Type Stroke Length Piston Type Piston Dimeter 6 RED/WHT + RED/BLU Leds YEL/WHT + RED/BLU Leds PPL/WHT + RED/BLU Leds BRN/WHT + RED/BLU Leds ORG/WHT + RED/BLU Leds BLU/WHT + RED/BLU Leds 89 ± 2 psi (613.5 ± 13.8 kp) 79 ± 2 psi (544.0 ± 13.8 kp) 5 9 Amperes 1 2 Amperes 6 9 psi ( kp) 1.8 ± 0.1 Ω 1.3 ± 0.3 Ω 10 psi (68.5 kp) Reciprocting Piston (1 to 1 rtio with engine Idle 80 W.O.T. 110 psi 7.07 cu. in. (116 cc) in. (65.0 mm) in. (0.025 mm) Cst Iron in. (34.9 mm) Aluminum ±.0004 in. (64.97 ± mm) Dimension A t Right Angle (90 ) to Piston Pin in. Pge 3B JANUARY 2001

3 AIR COMPRESSOR Piston Ring End Gp Top Ring Middle Ring Bottom Ring Reeds Stnd Open in. ( mm) in. ( mm) in. ( mm) in. (0.25 mm) DIRECT FUEL INJECTION Specil Tools 1. Duel Fuel/Air Pressure Guge 160 psi A1/A2/A Schrder Vlve ( ) 2. Adptors to convert pressure guge A1/A2 to n A3 NOTE: 2 Adptors A2 re required to convert pressure guge set. c d -1/2 to 1/4 Adpter (if required) -Femle Quick Disconnect c -Mle Quick Disconnect d-screw on Schrder 3. Screw (5mm x 25mm) (2 ech) Flt Wsher (2 ech) JANUARY 2001 Pge 3B-3

4 5. Sel/Teflon Ring Instlltion Tool Sel/Teflon Ring Sizing Tool DMT 2000 Digitl Tchometer Multi-meter P/N T1 8. Clmp Tool Kit A Clmp Tool T Pge 3B JANUARY 2001

5 9. Gercse Lekge Tester (FT-8950) DIRECT FUEL INJECTION JANUARY 2001 Pge 3B-5

6 Air Hndler Pge 3B JANUARY 2001

7 Air Hndler TORQUE REF. NO. QTY. DESCRIPTION l-in l-ft Nm. 1 1 COVER ASSEMBLY 2 2 GROMMET (0.310 x 0.620) 3 GROMMET (0.270 x 0.570) 4 1 AIR FILTER 5 1 COVER 6 1 DECAL (Mercury Optimx 200 M2 Jet Drive) 7 2 SCREW (M5 x 16) SENSOR-Crnk Position 9 1 PIN (Specil) 10 1 GROMMET-Throttle Body SCREW ( x 1.500) CLAMP 13 2 J CLIP 14 1 SLEEVE 15 1 PUMP ASSEMBLY-Fuel 16 1 ELBOW 17 1 CABLE TIE (14.00 Inch) 18 1 DECAL -EPA Lel Info 19 1 PUMP ASSEMBLY-Fuel 20 1 SCREW (M6 x 35) BRACKET 22 3 SCREW (M6 x 16) BRACKET KIT 24 1 GROMMET SCREW (M6 x 10) CABLE ASSEMBLY 27 1 O RING 28 1 FITTING 29 4 CLAMP 30 1 HOSE-Molded (Fuel Pump to Vpor Seprtor) 31 1 VAPOR SEPARATOR ASSEMBLY JANUARY 2001 Pge 3B-7

8 Air Hndler Components Pge 3B JANUARY 2001

9 Air Hndler Components TORQUE REF. NO. QTY. DESCRIPTION l-in l-ft Nm. 1 AIR HANDLER 1 1 ADAPTOR PLATE KIT 2 1 GASKET 3 1 GASKET 4 6 REED BLOCK 5 12 SCREW (1/4-20 x.88) OIL PUMP 7 6 BUSHING 8 6 GROMMET 9 3 SCREW (M8 x 35) WASHER 11 1 AIR PLENUM KIT 12 1 TEMPERATURE SENSOR 13 3 O RING 14 2 SCREW (M4 x 16) Drive Tight 15 1 THROTTLE BODY KIT 16 1 O RING 17 4 SCREW SCREW MAP SENSOR 20 1 BRACKET 21 1 SCREW (M6 x 16) JANUARY 2001 Pge 3B-9

10 Vpor Seprtor Components Pge 3B JANUARY 2001

11 Vpor Seprtor Components TORQUE REF. NO. QTY. DESCRIPTION l-in l-ft Nm. 1 VAPOR SEPARATOR ASSY 1 1 COVER KIT 2 1 FITTING - Stright ELBOW SEAL 5 1 FITTING KIT-Pump Outlet O RING 7 7 SCREW GASKET 9 1 FLOAT KIT 10 1 FLOAT PIN 11 1 NEEDLE VALVE 12 1 SCREW FUEL PUMP KIT 14 1 SLEEVE 15 1 BOWL KIT 16 1 FITTING KIT 17 1 O RING 18 1 SEAL 19 1 PLUG KIT 20 2 ELBOW 21 1 FUEL FILTER ASSEMBLY See Note 22 1 PROBE-Wter Sensing NOTE: Tighten filter until finger tight, then tighten dditionl 1/2 to 3/4 turn JANUARY 2001 Pge 3B-11

12 Air Hoses Pge 3B JANUARY 2001

13 Air Hoses TORQUE REF. NO. QTY. DESCRIPTION l-in l-ft Nm 1 2 CLAMP 2 1 HOSE (AIR SUPPLY) 3 1 SLEEVE 4 1 HOSE (AIR BALANCE) 5 1 HOSE (AIR BYPASS) 6 2 STA-STRAP 7 1 CLAMP CONNECTOR 9 1 FITTING (90-3/4 Inch) JANUARY 2001 Pge 3B-13

14 Wter Hoses Pge 3B JANUARY 2001

15 Wter Hoses TORQUE REF. NO. QTY. DESCRIPTION l-in l-ft Nm 1 1 ELBOW 2 2 CLAMP HOSE ASSEMBLY (32.00 Inches) 4 1 FITTING-Striner O RING 6 2 STA-STRAP (8.00 Inch) 7 1 HOSE-Air Bypss (4.500 Inches) 8 1 FITTING-Stright 9 1 SCREW ( x 0.500) J-CLIP 11 1 FITTING 12 1 TUBING (26.00 Inches) 13 1 FITTING 14 1 WATER PRESSURE SENSOR 15 1 CLIP 16 2 CLAMP FITTING 18 1 FITTING 19 1 HOSE (21.00 Inches) 20 1 CONNECTOR ( ) 21 2 CLAMP HOSE (19.00 Inches) 23 3 CLAMP FITTING 25 3 TUBING (5.250 Inches) 26 3 STA-STRAP (8.00 Inch) 27 2 FITTING 28 1 HOSE (To Thru Hull Fitting) 29 1 NUT ( ) 30 1 FITTING-Cool Wter Vent JANUARY 2001 Pge 3B-15

16 Fuel Hoses Pge 3B JANUARY 2001

17 Fuel Hoses TORQUE REF. NO. QTY. DESCRIPTION l-in. l-ft. Nm 1 5 CLAMP 2 HOSE (8.50 Inches) 3 1 HOSE ASSEMBLY-Fuel Return 4 1 HOSE ASSEMBLY 5 1 HOSE (8.50 Inches) 6 1 HOSE (7.50 Inches) 7 1 SLEEVE (27.00 Inches) 8 1 CLAMP JANUARY 2001 Pge 3B-17

18 Fuel Rils Stroke Outord Oil ( A12) 110 Pge 3B JANUARY 2001

19 Fuel Rils TORQUE REF. NO. QTY. DESCRIPTION l-in l-ft Nm 1 1 RAIL AND HOSE ASSEMBLY (Port) 2 1 RAIL AND HOSE ASSEMBLY (Strord) 3 1 PLUG (AIR) 4 1 O-RING KIT 5 2 CAP-Air Injector 6 2 VALVE ASSEMBLY-Fuel 7 27 SCREW (M5 x 8) CLAMP 9 2 CLAMP 10 1 O-RING KIT 11 2 CLAMP 12 1 VALVE ASSEMBLY-Air 13 1 CLAMP AIR REGULATOR (Port) 15 1 O-RING 16 1 O-RING 17 1 O-RING 18 4 CLAMP 19 8 SCREW (M5 x 16) COVER SPRING 22 1 O-RING 23 1 DIAPHRAGM ASSEMBLY 24 1 FITTING 25 4 CLIP 26 6 FUEL INJECTOR 27 2 SPACER STUD (M10 x 91) 29 1 SCREW ( x 0.500) J CLIP 31 2 NUT (M10) SEAL KIT 33 6 AIR INJECTOR KIT 34 6 WASHER ASSEMBLY JANUARY 2001 Pge 3B-19

20 Air Compressor Components Dielectric Grese ( ) Loctite PST Pipe Selnt ( ) Cycle Outord Oil ( A24) 25 Liquid Neoprene ( ) Pge 3B JANUARY 2001

21 Air Compressor Components TORQUE REF. NO. QTY. DESCRIPTION l-in l-ft Nm 1 1 AIR COMPRESSOR 2 1 PULLEY 3 5 SCREW (M6 x 12) DECAL 5 1 DECAL 6 1 END CAP ASSEMBLY 7 1 RING-Retining 8 1 O-RING (2.862 x 0.103) 9 1 O-RING (2.739 x 0.070) 10 4 SCREW (6 x 20) BODY-Compressor 12 1 FITTING 13 2 VALVE-Check 14 1 ELBOW (90 ) 15 1 CONNECTING ROD ASSEMBLY 16 1 BEARING 17 2 BEARING 18 1 PISTON ASSEMBLY 19 2 RING-Lock 20 1 PIN-Wrist 21 1 RING-Oil 22 1 RING-Oil Scrper 23 1 RING-Top 24 1 REED PLATE ASSEMBLY 25 2 O-RING (3.489 x 0.070) 26 1 O-RING (2.739 x 0.070) 27 1 SEAL 28 1 FITTING 29 1 GROMMET 30 1 FITTING-Stright HEAD ASSEMBLY-Compressor 32 1 PLUG-Pipe ( ) 33 1 O-RING 34 1 FITTING RETAINER 36 1 SCREW (M8 x 12) SENSOR-Temperture 38 4 SCREW (M8 x 35) PLUG 40 2 SCREW (M10 x 25) STUD ( x 4.190) 42 2 WASHER 43 1 NUT ( ) O-RING KIT JANUARY 2001 Pge 3B-21

22 DFI Opertion Air Induction Through Crnkcse Air Compressor System Fuel Comustion ir enters the ilge through ir intkes of the ot. The ir intkes on the ot deck hve hoses tht route the ir to ottom of ilge. This limits the exposure of slt ir to the components inside the ilge. Once inside the ilge, the ir enters the plenum through the throttle shutter which is locted in the plenum ssemly. The ir then continues through the reed vlves nd into the crnkcse. The throttle shutter is ctuted y the throttle shft. Mounted on seprte shft is throttle position sensor (TPS). This sensor tells the engine control unit (ECM) the position of the throttle. If the TPS should fil, the wrning horn will sound. Engine speed will e reduced y nd the ECM will reference the MAP sensor for fuel clirtion. Air from inside the ilge is drwn into the compressor through the flywheel cover. This cover cts like muffler to quiet compressor noise nd contins filter to prevent the ingestion of deris into the compressor. The compressor is driven y elt from pulley mounted on the flywheel nd is utomticlly self djusted using single idler pulley. This ir compressor is single cylinder unit contining connecting rod, piston, rings, erings, reed vlves, nd crnkshft. The compressor is wter cooled to lower the temperture of the ir chrge nd is luricted y oil from the engine oil pump ssemly. As the compressor piston moves downwrd inside the cylinder, ir is pulled through the filter, reed vlves nd into the cylinder. After the compressor piston chnges direction, the intke reeds close nd the exhust reeds open llowing compressed ir into the hose leding to the ir/fuel rils. The ir/fuel rils contin two pssges; one for fuel, the second is the ir pssge. The ir pssge is common etween ll the cylinders included in the ril. A hose connects the strord ril ir pssge to the ir compressor. Another hose connects the strord ir ril pssge to the port ir ril pssge. An ir pressure regultor will limit the mount of pressure developed inside the ir pssges to pproximtely 10 psi elow the pressure of the fuel inside the fuel pssges (i.e. 80 psi ir vs 90 psi fuel). Air exiting the pressure regultor is returned to the dptor plte nd exits thru the pump. Fuel for the engine is stored in typicl fuel tnk. A fuel lift pump drws fuel through the fuel line to fuel pump ssemly tht pushes the fuel thru wter seprting fuel filter. This filter removes ny contmintes nd wter efore the fuel reches the vpor seprtor. Fuel vpors re vented through hose to the fuel tnk. The electric fuel pump is different thn the fuel pump tht is utilized on the stndrd EFI engine (non DFI), nd is cple of developing fuel pressures in excess of 90 psi. Fuel inside the ril must remin pressurized t exctly 10 psi over the ir ril pressure or the ECM (mp) clirtions will e incorrect. Fuel from the vpor seprtor is supplied to the ottom of the strord fuel ril. A fuel line connects the ottom of the first ril to the opposite fuel ril. Fuel is stored inside the ril until n injector opens. A fuel pressure regultor controls pressure in the fuel rils, nd llows excess fuel to return into the vpor seprtor. The fuel regultor not only regultes fuel pressure ut lso regultes it t pproximtely 10 p.s.i. higher thn whtever the ir ril pressure is. The fuel regultor diphrgm is held closed with spring tht re- Pge 3B JANUARY 2001

23 Oil Electricl Opertion DIRECT FUEL INJECTION quires 10 p.s.i. to force the diphrgm off the diphrgm set. The ck side of the diphrgm is exposed to ir ril pressure. As the ir ril pressure increses, the fuel pressure needed to open the regultor will eqully increse. Exmple: If there is 50 p.s.i. of ir pressure on the ir ril side of the diphrgm, 60 p.s.i. of fuel pressure will e required to open the regultor. The port fuel ril is wter cooled. To equlize the pulses developed y the pumps (oth ir nd fuel) trcker diphrgm is instlled in the strord ril. The trcker diphrgm is positioned etween the fuel nd ir pssges. The trcker diphrgm is ruer diphrgm which expnds nd retrcts depending upon which side of the diphrgm senses the pressure increse (pulse). Oil in this engine is not mixed with the fuel efore entering the comustion chmer. Oil is stored inside stndrd remote oil reservoir. Crnkcse pressure will force oil from the remote oil tnk into the oil reservoir on the side of the powerhed. Oil will flow from the oil reservoir into the oil pump. The oil pump is solenoid design. It is ctivted y the ECM nd includes 7 pistons with corresponding dischrge ports. The oil pump is mounted directly onto the powerhed. Ech cylinder is luricted y one of the dischrge ports. The oil is dischrged into the crnkcse. The seventh pssge connects to the hose tht leds to the ir compressor for luriction. Excess oil from the compressor is returned to the min erings. The ECM will chnge the dischrge rte of the oil pump, depending upon engine demnd. The ECM will lso pulse the pump on initil strt up to fill the oil pssges eliminting the need to leed the oil system. The ECM provides dditionl oil for rek in, s determined y its internl clock. The oil rtio vries with engine rpm nd lod. The electricl system consists of the ECM, crnk position sensor (flywheel speed & crnkshft position), throttle position sensor (TPS), MAP sensor, engine temperture sensor(s), ignition coils nd injectors (fuel & direct). The engine requires ttery to strt (i.e. the ignition nd injection will not occur if the ttery is ded). The system will run off of the lterntor. The opertion of the system hppens in milliseconds (ms); exct timing is criticl for engine performnce. As the crnkshft rottes, ir is drwn into the crnkcse through the throttle shutter, into the plenum nd through the reed vlves. As the piston ners ottom ded center, ir from the crnkcse is forced through the trnsfer system into the cylinder. As the crnkshft continues to rotte the exhust nd intke ports close. With these ports closed, fuel cn e injected into the cylinder. The ECM will receive signl from the throttle position sensor (TPS), engine temperture sensor (TS) nd the crnk position sensor (flywheel speed nd position sensor). With this informtion the ECM refers to the fuel clirtion (mps) to determine when to ctivte (open nd close) the injectors nd fire the ignition coils. With the piston in the correct position, the ECM opens the fuel injector, 90 psi fuel is dischrged into mchined cvity inside the ir chmer of the ir/fuel ril. This mixes the fuel with the ir chrge. Next the direct injector will open, dischrging the ir/fuel mixture into the comustion chmer. The direct injector directs the mixture t the owl locted in top of the piston. The piston s owl directs the ir/fuel mixture into the center of the comustion chmer. This ir fuel mixture is then ignited y the sprk plug. Compressor Notes: To id in strting when the ir ril pressure is low nd efore the compressor hs time to uild pressure, some direct injectors re held open y the ECM. This llows the compression from inside the cylinders to pressurize the ir ril fster (1 or 2 strokes, or 60 of crnkshft rottion) JANUARY 2001 Pge 3B-23

24 Idle Notes: Idle qulity is controlled y fuel volume nd fuel timing. The throttle shutter will e open t idle speed. The TPS signls the ECM to chnge the fuel nd sprk without movement of the throttle shutters. The throttle cm is mnufctured to llow the TPS sensor shft to move efore opening the throttle shutter. Testing Electric Fuel Pump Pressure Output Low Pressure Electric Fuel Pump IMPORTANT: After completing fuel pressure tests, reconnect nd secure fuel outlet hose to fuel pump with full circle stinless clmps in Clmp Tool Kit A1. 1. Remove outlet fuel hose from low pressure pump. Instll short piece of hose (otin loclly) onto pump outlet fitting. Instll Schrder Vlve t-fitting ( ) etween outlet fuel hose (removed from pump) nd new fuel hose (instlled on pump). Secure hose connections with st-strps. Due to the low pressure output of this pump, it is recommended tht the ir guge of the Dul Fuel/Air Pressure Guge ( A1/A2/A3) e connected to the Schrder Vlve. Guge should indicte 6 9 psi ( kp). c d Outlet Fuel Hose -Low Pressure Electric Fuel Pump c -Fuel Hose (otin loclly) d-schrder Vlve ( ) Pge 3B JANUARY 2001

25 High Pressure Electric Fuel Pump DIRECT FUEL INJECTION 1. Instll Pressure Guge Assemly A1/A2/A3 to port fuel ril pressure test vlve. NOTE: If low ir or low fuel pressure is indicted, swp hoses etween ir nd fuel test ports. If low reding moves, guge ccurcy should e checked. NOTE: After 15 seconds of crnking engine with strter motor, fuel pressure guge should indicte 89 ± 2 psi (613.5 ± 13.8 kp). -Fuel Pressure Guge (Should Indicte 89 ± 2 psi (613.5 ± 13.8 kp) -Fuel Pressure Test Vlve JANUARY 2001 Pge 3B-25

26 Fuel Mngement Assemly Removl CAUTION Fuel system must e led off prior to removl of fuel system components. NOTE: Use Fuel/Air Pressure Guge or A1/A2/A3 to de-pressurize ir hose first nd then fuel hose. 1. De-pressurize fuel system. c -Port Fuel Ril -Fuel Pressure Port c -Air Pressure Port Plce suitle continer underneth vpor seprtor drin plug nd remove plug. 3. Disconnect wter seprtor sensor led. 4. Disconnect electric fuel pump hrness connectors. c c Drin Plug -Sensor Led c -Hrness Connectors Pge 3B JANUARY 2001

27 NOTE: Upper fuel hose is excess fuel return from fuel rils; lower fuel hose is fuel inlet from electric circulting pump eside fuel/wter seprtor. 5. Remove the fuel inlet hose from the fuel lift pump. 6. Remove vpor seprtor vent hose. 7. Remove the fuel outlet hose nd fuel return hose from fuel rils. 8. Remove vpor seprtor ground led. 9. Remove 3 mounting olts nd remove seprtor. c d e g f -Fuel Inlet Hose to Fuel Lift Pump -Vpor Seprtor Vent Hose c -Fuel Outlet Hose f d-fuel Return Hose e -Fuel Inlet Hose f -Mounting Bolts (3) g-ground Led JANUARY 2001 Pge 3B-27

28 10. Disconnect throttle cm link rod nd the Throttle Position Sensor link rod. 11. Disconnect MAP Sensor from ir mngement ssemly. d Throttle Link Rod -Throttle Position Sensor Link Rod c -MAP Sensor d-temperture Sensor c Disconnect oil hoses from oil pump. 13. Remove nd plug oil inlet hose to oil pump. 14. Remove 12 olts securing ir mngement ssemly to crnkcse nd remove ssemly. c d Oil Outlet Hoses -Oil Inlet Hose c -Air Mngement d-bolts (12 ech) Pge 3B JANUARY 2001

29 Reed Block Disssemly/Assemly DIRECT FUEL INJECTION 1. Remove 2 screws securing ir plenum to reed plte ssemly. Drive screws tight on ressemly. 2. Remove 12 screws securing reed locks to reed plte ssemly. Torque screws to 90 l. in. (10 Nm) on ressemly. -Screws (2 ech) (M4x16) -Screws (12 ech) (1/4x20x0.88) Air Temperture Sensor Removl Disconnect sensor hrness nd unscrew sensor. -Air Temperture Sensor JANUARY 2001 Pge 3B-29

30 Air Temperture Sensor Instlltion Screw sensor into ir plenum. Reconnect sensor hrness. Throttle Plte Assemly Removl NOTE: The throttle plte ssemly is clirted nd preset for proper running chrcteristics nd emissions t the fctory. Other thn complete ssemly removl from the ir plenum, no further disssemly should e mde. Remove 4 olts securing throttle plte ssemly to ir plenum nd remove ssemly. -Bolts -Throttle Plte Assemly Throttle Plte Assemly Instlltion Secure throttle plte ssemly to ir plenum with 4 olts. Torque olts to 100 l. in. (11.5 Nm). Vpor Seprtor Disssemly 1. Remove 7 screws securing seprtor cover nd remove cover. 2. Inspect sel in fuel pump chmer of seprtor tnk for cuts nd risions. Replce sel if necessry. If sel is servicele, pply 2-4-C w/teflon Mrine Luricnt ( A12) to sel lips. -Screws (7 ech) -Sel Pge 3B JANUARY 2001

31 3. Fuel pump my e removed from cover y wiggling slightly while pulling outwrd. IMPORTANT: DO NOT twist pump during removl s wire hrness my e dmged. 4. Disconnect hrness from pump to seprte pump from cover. Inspect filter screen for deris. Screen my e pried out of pump nd clened s required. 5. Inspect sel ove fuel pump for cuts or risions. Replce sel if necessry. Apply 2-4-C w/teflon to sel lips. d c Filter Screen -Hrness Connector c -Pump d-sel (Sel shoulder fces OUT) Loosen screw securing flot ssemly nd remove flot. Inspect flot for deteriortion or fuel retention. Replce flot s required. 7. Remove phenolic seling plte nd inspect imedded neoprene sel on oth sides of plte for cuts or risions. Replce plte/sel ssemly s required. c d Screw -Flot c -Plte d-sel JANUARY 2001 Pge 3B-31

32 Vpor Seprtor Ressemly 1. Reinstll phenolic seling plte onto vpor seprtor cover. 2. Secure flot, needle nd pivot pin ssemly to seprtor cover with screw. Torque screw to 10 l. in. (1.0 Nm) 3. Apply 2-4-C w/teflon to lips of sel in seprtor cover. 4. Connect electricl hrness to fuel pump. Inspect fuel pump filter screen for deris. Remove screen nd clen s required. 5. Set fuel pump nd hrness into seprtor cover eing creful not to pinch hrness. c d f e -Seling Plte -Flot c -Needle d-pivot Pin e -Screw [Torque to 10 l. in. (1.0 N m) g ci f -Sel (Sel shoulder fces OUT) g-hrness h-filter i -Fuel Pump h 6. Apply 2-4-C w/teflon to lips of sel in seprtor tnk. 7. Instll seprtor cover with pump onto seprtor tnk. 8. Secure cover to tnk with 7 screws. Torque screws to 30 l. in. (3.5 Nm) Sel -Screws [Torque to 30 l. in. (3.5 Nm)] Pge 3B JANUARY 2001

33 Air Plenum Instlltion DIRECT FUEL INJECTION Secure plenum to crnkcse with 12 olts. Torque olts to 175 l. in. (20 Nm). in sequence shown Air Plenum -Bolts [Torque to 175 l. in. (20 Nm)] Low Pressure Electric Fuel Pump Instlltion NOTE: If pump does not hve sleeve or grommet, refer to Service Bulletin Set electric fuel pump w/sleeve ginst grommet in pump rcket. Secure pump to rcket with st-strp. d c -Low Pressure Electric Fuel Pump -Sleeve c -Grommet d-brcket JANUARY 2001 Pge 3B-33

34 2. Secure rcket ssemly to vpor seprtor with 3 screws. Torque screws to 145 l. in. (16 Nm). Screw (d) is used to secure electric fuel lift pump with clmp to rcket. c d d -Screws Torque to 145 l. in. (16 Nm) -St-strp securing pump to rcket c -Ground led ttch to ir plenum d-screw Secures fuel lift pump Torque to 145 l. in. (16 Nm) IMPORTANT: Only use tool T (or Snp-On equivlent YA3080) to crimp full circle clmps. Using different tool could result in crimp tht is too loose, or too tight. Do not use screw type metl hose clmp s it my dmge hose. 3. Connect fuel hose from ottom of low pressure fuel pump to 90 elow in ottom of vpor seprtor. Secure hose with 18.3 mm full circle clmp ( ) using crimping tool T Secure Fuel Hose with 18.3 mm Full Circle Clmp ( ) Pge 3B JANUARY 2001

35 4. Connect fuel hose from top of low pressure fuel pump to 90 elow on ck side of vpor seprtor. Secure hose with 18.3 mm full circle clmp ( ) using crimping tool T. (Bck view of vpor seprtor shown elow) -Secure Fuel Hose with 18.3 mm Full Circle Clmp ( ) JANUARY 2001 Pge 3B-35

36 Vpor Seprtor Instlltion 1. Secure vpor seprtor to ir plenum with 3 olts. Torque olts to 140 l. in. (16.0 Nm). 2. Connect fuel inlet hose to fuel lift pump. 3. Connect vent hose to vpor seprtor. 4. Connect fuel outlet hose nd fuel return hose to vpor seprtor. 5. Connect wter seprtor sensor led to wter seprtor. 6. Connect electric fuel pump hrnesses. d e h g c g -Mounting Bolts [Torque to 140 l. in. (16.0 Nm) -Fuel Inlet Hose c -Vent Hose d-fuel Outlet Hose e -Fuel Return Hose f f -Wter Seprtor Sensor Led g-electricl Hrnesses h-fuel Outlet from Low Pressure Pump Pge 3B JANUARY 2001

37 7. If fuel hoses were removed, secure hoses with proper full circle clmp using tool T (or Snp-On equivlent YA3080) to crimp clmps. Use stinless screw clmp on vpor seprtor vent hose nd inlet fuel hose to fuel lift pump Full Circle Clmp -Stinless Screw Clmp JANUARY 2001 Pge 3B-37

38 Fuel Ril Removl NOTE: To provide improved ccess to the fuel rils, it is recommended tht the expnsion chmer e removed s follows: 1. Remove coolnt hose etween ir compressor nd expnsion chmer. 2. Remove 6 nuts securing expnsion chmer nd ly chmer off to one side. -Coolnt Hose -Nuts (6) CAUTION Fuel system must e led off prior to removl of fuel system components NOTE: Use Fuel/Air Pressure Guge or A1/A2 to de-pressurize ir hose first nd then fuel hose. 1. De-pressurize fuel system. 2. Remove fuel injector hrness from ech injector y compressing spring clip with flt tip screw driver while pulling on connector. f c e Port Fuel Ril -Air Pressure Port c -Fuel Pressure Port d d-fuel Injector e -Hrness Connector (hidden) f -Spring Clip NOTE: Alwys remove fuel/ir hose nd fitting together y removing fitting retiner rther thn cutting clmps. Pge 3B JANUARY 2001

39 3. Remove fuel, wter nd ir hoses from fuel ril. DIRECT FUEL INJECTION d c f e Port Top Fuel Ril Connections -Wter Inlet Hose to Compressor -Retiner c -Allen Screws (remove) Strord Top Fuel Ril Connections d-air Hose e -Retiner f -Allen Screws (remove) c d f g e Port Bottom Fuel Ril Connections -Wter Inlet Hose to Fuel Ril -Air Hose c -Allen Screws (remove) d-fuel Hose Strord Bottom Fuel Ril Connections e -Air Hose f -Allen Screws g-fuel Hose NOTE: It is recommended tht direct injectors remin in the cylinder hed (if they re not to e replced) while removing the fuel ril. The direct injectors hve teflon sel which my expnd if the injector is removed from the hed. This expnsion my cuse reinstlltion difficulty or require the replcement of the sel. 4. Remove 2 nuts securing fuel ril JANUARY 2001 Pge 3B-39

40 5. As fuel ril is removed, use flt tip screw driver to hold direct injectors in cylinder hed. -Fuel Ril Direct Injectors The strord fuel ril contins 3 fuel injectors nd trcker vlve. The port fuel ril contins 3 fuel injectors, 1 fuel regultor, nd 1 ir regultor. NOTE: Ech fuel/ir inlet or outlet hose dptor hs 2 o-ring sels. These o-rings should e inspected for cuts or risions nd replced s required when fuel ril is disssemled for clening. e d f c i g h j Fuel Injector -Fuel Regultor c -Air Regultor d-trcker Vlve e -Fuel Inlet f -Excess Fuel Return to VST g-wter Inlet for Cooling Fuel Ril h-excess Air to Adptor Plte i -90 psi (616 kp) Fuel j -80 psi (547.8 kp) Air Pge 3B JANUARY 2001

41 FUEL INJECTOR REMOVAL DIRECT FUEL INJECTION NOTE: A leking fuel injector will crete fuel in the ir side of the ir/fuel ril. Using the dul pressure guges, dischrge the ir side nd wtch for fuel vpors. If vpors exist, pull the ril ck for visiility nd re-pressurize the system without rotting the engine (key on ). Inspect ech injector for signs of fuel droplets. Multiple sttic tests will induce fuel into the ir side s nturl occurrence. The engine will run up (flir) on initil restrt. 1. Remove 2 screws securing injector. NOTE: Use cotter pin extrctor tool in pry holes to remove injectors. 2. Gently pry up on injector to loosen o-ring dhesion nd remove injector Screws -Pry Holes Inspect fuel injector orifices for foreign deris; o-rings for cuts or risions nd plstic components for het dmge. Replce components s required JANUARY 2001 Pge 3B-41

42 4. An ohm test of the fuel injector my e mde y connecting test leds to injector terminls. Ohm reding should e 1.8 ± 0.1 ohm. OHMS VOLTS 0 0 DC AMPS DCV ACV 0 c DVA X Fuel Injector -Fuel Nozzle c -O-Rings FUEL INJECTOR INSTALLATION NOTE: Apply nti-seize grese (otin loclly) or 2-4-C w/teflon to fuel injector ttching screw threds. 1. Insert fuel injector into fuel ril with connector pins fcing (inwrds) towrds center of engine. NOTE: Turn injector ck-nd-forth slightly to set injector o-rings in fuel ril while securing injector with retiner nd 2 screws. Torque screws to 70 l. in. (8.0 Nm). c Injector -Retiner c -Screws [Torque to 70 l. in. (8.0 Nm)] Pge 3B JANUARY 2001

43 Fuel Pressure Regultor The fuel regultor is locted on the port fuel ril. DIRECT FUEL INJECTION The fuel pump is cple of delivering more fuel thn the engine cn consume. Excess fuel flows through the fuel pressure regultor, interconnecting pssges/hoses nd ck to the vpor seprtor tnk. This constnt flow of fuel mens tht the fuel system is lwys supplied with cool fuel, therey preventing the formtion of fuel vpor ules nd minimizing the chnces of vpor lock. The fuel pressure regultor is clirted to rise the fuel pressure to 10 psi ove the ir pressure. The fuel regultor is mounted on the port fuel ril, ner the top. This regultor relies on oth ir nd spring pressure to control the fuel pressure. Inside the regultor ssemly is 10 l. spring, this spring holds the diphrgm ginst the diphrgm set. The contct etween the diphrgm nd diphrgm set closes the pssge etween the incoming fuel (from the electric fuel pump) nd the fuel return pssge. When the engine is not running (no ir pressure on the spring side of the diphrgm) the fuel pressure required to move the diphrgm is 10 psi. When the engine is running, ir pressure from the ir compressor (80 psi) is routed through the ir pssges, to the spring side of the fuel pressure regultor diphrgm. The ir pressure (80 psi) nd spring pressure (10 psi) comine to regulte system fuel pressure to 90 psi - or 10 psi higher thn the ir pressure in the DFI system fuel/ir rils JANUARY 2001 Pge 3B-43

44 Regultor Closed Regultor Open Top Cover 2 -Expnsion Plug 3 -O-ring 4 -Spring Retiner 5 -Spring 6 -O-ring 7 -Diphrgm Set 8 -Air Ril 9 -Air Pssge (from Air Compressor) 10 - Fuel Return Pssge (to Vpor Seprtor) 11 - Fuel Inlet Pssge (from Electric Fuel Pump) 12 - Diphrgm Assemly 13 - Clirtion Screw (Do Not Turn) Pge 3B JANUARY 2001

45 FUEL REGULATOR REMOVAL DIRECT FUEL INJECTION 1. Remove 4 screws securing regultor nd remove regultor. 2. Inspect regultor diphrgm for cuts or ters. 3. Inspect regultor housing o-ring for cuts nd risions. If prts re dmged, port ril ssemly must e replced. c e d f -Screws -Fuel Regultor FUEL REGULATOR INSTALLATION c -Diphrgm d-spring e -Cup f -O-Ring NOTE: Apply light cot of 2-4-C w/teflon to diphrgm surfce nd o-ring to id in the retention of diphrgm nd o-ring on fuel ril during ressemly. 1. Position diphrgm on fuel ril. 2. Position o-ring on fuel ril. 3. Position spring nd cup onto diphrgm. NOTE: Apply nti-seize grese (otin loclly) or 2-4-C w/teflon to regultor ttching screw threds. 4. Plce cover over spring/cup/diphrgm ssemly nd secure with 4 screws. Torque screws to 70 l. in. (8.0 Nm). c e e d Diphrgm -O-Ring c -Spring d-cup e -Screws [Torque to 70 l. in. (8.0 Nm)] JANUARY 2001 Pge 3B-45

46 Air Pressure Regultor The ir pressure regultor is locted on the port fuel ril. The ir pressure regultor is designed to limit the ir pressure inside the rils to pproximtely 80 psi. The ir regultor uses spring (pressure) to control the ir pressure. This spring (80 psi) holds the diphrgm ginst the diphrgm set. The contct re locks (closes) the ir inlet pssge from the excess ir, return pssge. As the ir pressure rises (elow the diphrgm), it must rech pressure equl to or greter thn the spring pressure holding the diphrgm closed. Once this pressure is chieved, the spring compresses, llowing the diphrgm to move. The diphrgm moves wy from the diphrgm set, llowing ir to exit through the diphrgm set, into the excess ir pssge leding to the exhust dptor plte. Pge 3B JANUARY 2001

47 AIR REGULATOR REMOVAL DIRECT FUEL INJECTION 1. Remove 2 screws securing regultor nd remove regultor. 2. Inspect regultor o-rings for cuts nd rsions. Replce s required. NOTE: Air regultor is not servicele. If regultor doesn t mintin pproximtely 80 psi replce it. c d Screws -Air Regultor c -O-Rings d-retiner AIR REGULATOR INSTALLATION 1. Position ir regultor, retiner nd screws onto fuel ril s shown elow. NOTE: Apply nti-seize grese (otin loclly) or 2-4-C w/teflon to regultor ttching screw threds. Torque screws to 70 l. in. (8.0 Nm). NOTE: Apply light cot of outord oil to regultor o-rings to ese instlltion. c -Screws -Retiner c -Air Regultor JANUARY 2001 Pge 3B-47

48 Trcker Vlve The trcker vlve is locted on the strord fuel/ir ril ssemly The DFI system must mintin constnt 10 psi pressure difference etween the fuel pressure nd ir pressure in the rils, t ll times. The trcker is designed to mintin the 10 psi differentil when the ir or fuel pressure suddenly rises (i.e. pulses generted y the compressor s piston or y the fuel injectors opening nd closing). The trcker contins spring on the ir side of the diphrgm. This spring positions the diphrgm ginst the diphrgm s set (when the engine is not running). After the engine strts, nd the fuel nd ir pressure rech norml operting rnge, the fuel pressure will compress the spring nd the diphrgm will move slightly wy from the set (to neutrl position). At this point the pressure on oth sides of the trcker diphrgm is equl (10 psi spring pressure + 80 psi ir pressure = 90 psi fuel pressure). Any ir or fuel pressure spikes on one side of the diphrgm will trnsfer this pressure rise to the other system (ir or fuel) on the other side of the diphrgm. Both systems will hve momentry increse in pressure so tht the 10 psi difference etween ir nd fuel system pressures cn e mintined. NOTE: To prevent excessive wer in the set, the trcker is clirted to llow the diphrgm to e slightly wy from the set during norml opertion. Pge 3B JANUARY 2001

49 Engine Off (No Pressure) Engine t Operting Pressures Top Cover 2 -Spring Retiner (not shown) 3 -Spring 4 -O-ring 5 -Diphrgm (t rest) Set 6 -Air Ril 7 -Air Pssge (from Air Compressor) 8 -Fuel Inlet Pssge (from Electric Fuel Pump) 9 -Diphrgm Assemly JANUARY 2001 Pge 3B-49

50 TRACKER VALVE REMOVAL 1. Remove 4 screws securing trcker vlve nd remove trcker ssemly. 2. Inspect trcker diphrgm for cuts nd ters. 3. Inspect trcker cover o-ring for cuts nd risions. Replce components s required. c d Screws -Diphrgm c -Spring d-o-ring TRACKER VALVE INSTALLATION NOTE: Apply light cot of 2-4-C w/teflon to trcker diphrgm nd cover o-ring to id in their retention on fuel ril while reinstlling trcker vlve to fuel ril. NOTE: Apply nti-seize grese (otin loclly) or 2-4-C w/teflon to trcker vlve ttching screw threds. 1. Position diphrgm, spring nd o-ring onto fuel ril. 2. Plce cover over diphrgm/spring/o-ring ssemly nd secure with 4 screws. Torque screws to 70 l. in. (8.0 Nm). e c d e Diphrgm -Spring c -O-Ring d-cover e -Screws [Torque to 70 l. in. (8.0 Nm)] Fuel Ril Clening After ll fuel injectors, ir regultor, trcker vlve, fuel regultor, inlet hoses nd outlet hoses hve een removed, the fuel rils my e flushed out with suitle prts clening solvent. Use compressed ir to remove ny remining solvent. Pge 3B JANUARY 2001

51 Direct Injector Removl DIRECT FUEL INJECTION NOTE: If direct injector should fil due to roken pintle, inspect the end of the fuel injector djcent to the roken direct injector. If the fuel injector tip hs lck uild up on it, replce it. Inspect for nd clen out ny dirt or deris in the ir pssge of the fuel ril djcent to the roken direct injector. 1. Remove hrness connectors from direct injectors. 2. Remove direct injector from cylinder hed Direct Injector (3 ech -Hrness Connector cylinder hed) 3. Inspect injector teflon seling ring (white) for signs of comustion lowy (teflon ring will e streked rownish lck). If lowy is present, replce teflon seling ring. If lowy is not present, seling ring my e reused. 4. Inspect o-rings for cuts or risions. Replce components s required. 5. If teflon sel requires replcement, use teflon ring instlltion tool to slide new sel onto injector. Following instlltion of teflon ring, the teflon ring sizing tool ( ) cn e used to compress the teflon sel to id in the instlltion of the injector into the cylinder hed. c d e e f Teflon Seling Ring -O-Ring c -Teflon Sel d-sel Instlltion Tool ( ) e -O-Ring f -Teflon Ring Sizing Tool ( ) JANUARY 2001 Pge 3B-51

52 6. An ohm test of the direct injector my e mde y connecting test leds to injector terminls. Ohm reding should e 1.3 ± 0.3 ohm. 7. An ohm test to determine if direct injector windings re shorted to ground cn e mde y connecting one ohm led to either injector pin while touching the other ohm led to the injector metl cse. There should e no continuity. If there is continuity, the internl windings re shorted nd the injector must e replced. OHMS VOLTS 0 2 DC AMPS OHMS VOLTS 0 2 DC AMPS DCV ACV DCV ACV DVA X1 DVA X Direct Injector Ohm Test (1.3 ± 0.3 ohm) -Direct Injector Short to Ground Ohm Test (no continuity) 8. Cron uildup on tip of direct injector my e removed y use of rss wire hnd rush. -Direct Injector -Tip Pge 3B JANUARY 2001

53 Direct Injector Lek Test 1. Attch Gercse Lekge Tool (FT-8950) to dischrge side of injector. DIRECT FUEL INJECTION -Gercse Lekge Tool (FT-8950) -Direct Injector Pump up lekge tool to indicte psi ( kp) 3. Direct injector should not lek down more thn 1/2 psi (3.5 kp) in 1 minute. 4. If injector does not meet the ove specifictions, replce injector. NOTE: If cylinder hed is going to e replced, remove cup wshers from ech direct injector port y prying out with flt tip screwdriver. Reinstll wshers with retiners into new cylinder hed. Wshers provide tension etween direct injectors, cylinder hed nd fuel rils. -Cup Wsher -Retiner JANUARY 2001 Pge 3B-53

54 Fuel Ril nd Direct Injector Instlltion NOTE: Refer to Powerhed Section 4A for complete instlltion instructions. 1. Use Teflon Ring Sizing Tool ( ) to compress new teflon seling rings prior to instlltion of injector into cylinder hed. 2. Crefully slide fuel ril over mounting studs nd onto direct injectors. IMPORTANT: If fuel or ir hoses hve een replced, they MUST e secured with proper full circle clmps using tool T (or Snp-On equivlent YA3080) to crimp clmps. 3. Secure ech fuel ril. Torque nuts to 35 l. ft. (47 Nm). 4. Reinstll fuel injector hrness connectors. -Nuts [Torque to 35 l.ft. (47 Nm)] -Fuel Injector Hrness Connectors (6) (3 ech fuel ril) Pge 3B JANUARY 2001

55 Air Compressor DIRECT FUEL INJECTION Air Compressor The ir compressor is single cylinder wter cooled compressor, nd is luricted y the outord oil pump. Air Compressor Specifictions Type Compressor Output Reciprocting Piston (1 to 1 rtio with engine Idle 80 W.O.T. 110 psi Cylinder Block Displcement 7.07 cu. in. (116 cc) Cylinder Bore Dimeter (Stndrd) Tper/Out-of-Round/Wer Mximum Bore Type in. (65.0 mm) in. (0.025 mm) Cst Iron Stroke Length in. (34.9 mm) Piston Piston Type Aluminum Piston Dimeter ±.0004 in. (64.97 ± mm) Dimension A t Right Angle (90 ) to Piston Pin in. Piston Ring End Gp Top Ring Middle Ring Bottom Ring in. ( mm) in. ( mm) in. ( mm) Reeds Reed Stnd Open in. (0.25 mm) JANUARY 2001 Pge 3B-55

56 Compressor Removl 1. Disconnect ttery cles from ttery terminls. 2. Remove flywheel cover. 3. Use 3/8 inch (9.5 mm) drive on elt tensioner rm to relieve elt tension. Remove elt. -Belt Tensioner -3/8 in. (9.5 mm) drive Pge 3B JANUARY 2001

57 CAUTION DIRECT FUEL INJECTION If engine hs een recently run, ir pressure outlet hose fittings my e extremely hot. Allow components to cool off efore eginning disssemly. NOTE: Remove 2 screws securing retiner plte to remove ir pressure outlet hose. Inspect o-rings on ir pressure hose fitting for cuts or risions. Replce o-rings s required. 4. Remove ir pressure outlet hose. 5. Disconnect compressor wter inlet hose nd remove 2 screws. c d Air Pressure Outlet Hose -Retiner Screws c -Compressor Wter Inlet Hose d-compressor Screws 6. Disconnect ir compressor oil inlet hose. 7. Disconnect ir compressor wter outlet hose to expnsion chmer outlets. 8. Disconnect excess oil return hoses (2). c -Air Compressor Oil Inlet Hose -Air Compressor Wter Outlet Hose to Expnsion Chmer Outlets c -Excess Oil Return Hoses (2) Remove 2 olts nd 1 nut securing ir compressor to engine nd remove compressor JANUARY 2001 Pge 3B-57

58 Air Compressor Disssemly/Ressemly NOTE: If cylinder ore is scored, ir compressor must e replced s n ssemly. Items to inspect or replce fter compressor filure re: Air/fuel ril inlet fitting (for deris restricting ir flow) Oil return (from compressor) check vlve (for deris) To inspect for deris inside plenum, remove throttle plte from top of plenum, wipe inside of plenum with white pper towel. NOTE: The piston nd rings re not sold seprtely. They must e replced s n ssemly. The connecting rod nd erings re not sold seprtely. They must e replced s n ssemly. c d Ç f 9 g e 6 Dielectric Grese ( ) 9 h k 9 Loctite PST Pipe Selnt ( ) 14 2 Cycle Outord Oil ( A24) 6 i j NOTE: End cp ering nd sel re not sold seprtely. End cp must e replced s n ssemly. NOTE: Piston Instlltion use metl hose clmp for piston ring compressor. Stgger piston ring openings. -Bolt [Torque to 100 l. in. (11.5 Nm)] -Bolt (4 ech) [Torque to 100 l. in. (11.5 Nm)] c -End Cp Assemly (Inspect ering for roughness) d-o-rings (Inspect for cuts or risions) e -O-Rings (Inspect for cuts or risions) f -Reed Plte (Inspect for roken or chipped reeds/stops) Mximum Reed Stnd-Open in. (0.254 mm) g-o-rings (Inspect for cuts or risions) h-cylinder Hed i -Bolt [Torque to 20 l. ft. (27 Nm)] j -Temperture Sensor k -Bolt [Torque to 20 l. ft. (27 Nm)] Pge 3B JANUARY 2001

59 Air Compressor Flow Digrm e DIRECT FUEL INJECTION ÎÎ ÎÎ z c f d g r j i h s t u v k r y w l m n q x p -Air Inlet -Air Filter c -Compressor Oil Inlet d-oil to Upper Min Bering e -Compressor Air Inlet f -Compressor Wter Inlet g-fuel System Pressure Test Vlve h-#2 Fuel Injector i -Port Fuel Ril j -Excess Fuel Return to VST k -#4 Fuel Injector l -Air Pressure Test Vlve m-excess Air Return to Exhust Adptor Plte n-#6 Fuel Injector o-wter Inlet to Fuel Ril o p p-high Pressure Fuel [89 ± 2 psi (613.5 ± 13.8 kp)] q-air [79 ± 2 psi (544.0 ± 13.8 kp)] r -Air Regultor [79 ± 2 psi (544.0 ± 13.8 kp)] s -Fuel Regultor [89 ± 2 psi (613.5 ± 13.8 kp)] t -Wter Outlet to Expnsion Chmer Outlets u-#1 Fuel Injector v -Strord Fuel Ril w-#3 Fuel Injector x -#5 Fuel Injector y -Trcker Vlve z -Low Pressure (Air) - High Pressure (Air) - Oil to Lower Crnkshft Bering JANUARY 2001 Pge 3B-59

60 Air Compressor Pressure Test Instll Pressure Guge Assemly A1/A2 to fuel ril pressure test vlves. The fuel pressure nd ir pressure test vlves re locted on the strord ril. NOTE: After 15 seconds of crnking engine with strter motor, ir pressure guge should indicte 79 ± 2 psi (544.0 ± 13.8 kp) nd fuel pressure guge should indicte 89 ± 2 psi (613.5 ± 13.8 kp). c d Air Pressure Guge (Should Indicte 79 ± 2 psi (544.0 ± 13.8 kp) -Fuel Pressure Guge (Should Indicte 89 ± 2 psi (613.5 ± 13.8 kp) c -Fuel Pressure Test Vlve d-air Pressure Test Vlve Pge 3B JANUARY 2001

61 FUEL PRESSURE AND AIR PRESSURE TROUBLESHOOTING CHART DIRECT FUEL INJECTION PROBLEM CORRECTIVE ACTION Fuel Pressure nd Air Pressure re Both Low 1. Inspect ir compressor ir intke (ir filter in flywheel cover) for lockge. 2. Remove ir compressor cylinder hed nd inspect for scuffing of cylinder wll. Inspect for roken reeds nd/or reed stops. 3. Trcker Vlve Remove nd inspect diphrgm for cuts or ters nd set dmge on diphrgm nd ril. 4. Air Regultor Remove nd inspect diphrgm for cuts or ters on diphrgm nd ril. Fuel Pressure Low or Fuel Pressure Drops while Running (Air Pressure Remins Norml) 1. Ech time key is turned to the RUN position, oth electric pumps should operte for 2 seconds. If it they do not run, check 20 mpere fuse nd wire connections. 2. If pumps run ut hve no fuel output, check vpor seprtor (remove drin plug) for fuel. 3. If no fuel present in vpor seprtor, check fuel/ wter seprtor for deris. Check crnkcse mounted fuel pump for output. 4. Check high pressure pump mperge drw. Norml drw is 6 9 mperes; if drw is elow 2 mperes, check fuel pump filter (se of pump) for deris. If filter is clen, replce pump. If mperge is ove 9 mperes, pump is defective replce pump. Check low pressure output 8 12 psi. Check low pressure electric fuel pump mperge drw. Norml drw is 1 2 mperes; if drw is elow 1 mpere, check for lockge etween pump inlet fitting nd vpor seprtor tnk. If mpere drw is ove 2 mperes, replce pump. 5. Fuel Regultor Remove nd inspect diphrgm for cuts or ters. Fuel Pressure High nd Air Pressure is Norml 1. Stuck check vlve in fuel return hose. 2. Deris locking fuel regultor hole. 3. Fulty pressure guge Fuel nd Air Pressure Higher thn Norml 1. Deris locking ir regultor pssge. 2. Air dump hose (ril to driveshft housing) locked/plugged JANUARY 2001 Pge 3B-61