FUEL SYSTEM. Table of Contents. Section 3B Direct Fuel Injection. Specifications... 3B-2 Special Tools... 3B-3

Transcription

1 FUEL SYSTEM Setion 3B Diret Fuel Injetion Tle of Contents DIRECT FUEL INJECTION Speifitions B-2 Speil Tools B-3 Notes: B-5 Air Hndler B-6 Air Hndler Components B-8 Vpor Seprtor Components B-10 Air Hoses B-12 Fuel System B-14 Fuel Rils B-16 Air Compressor Components B-18 DFI Opertion B-20 Air Indution Through Crnkse B-20 Air Compressor System B-20 Fuel B-20 Oil B-21 Eletril B-21 Opertion B-21 Testing Eletri Fuel Pump Pressure Output 3B-22 Low Pressure Eletri Fuel Pump B-22 High Pressure Eletri Fuel Pump B-23 Fuel Mngement Assemly Removl B-24 Reed Blok Assemly Removl B-27 Reed Blok Assemly Instlltion B-27 Air Temperture Sensor Removl B-28 Air Temperture Sensor Instlltion B-28 Throttle Plte Assemly Removl B-28 Throttle Plte Assemly Instlltion B-28 Vpor Seprtor Disssemly B-29 Vpor Seprtor Ressemly B-31 Air Plenum Instlltion B-32 Low Pressure Eletri Fuel Pump Instlltion B-32 Vpor Seprtor Instlltion B-34 Fuel Ril Removl B-36 Fuel Pressure Regultor B-40 Air Pressure Regultor B-43 Air Regultor Trouleshooting B-43 Trker Vlve B-47 Fuel Ril Clening B-50 Diret Injetor Removl B-50 Diret Injetor Lek Test B-51 Fuel Ril nd Diret Injetor Instlltion. 3B-52 Air Compressor B-53 Air Compressor Disssemly/Ressemly 3B-56 Air Compressor End Cp/Crnkshft Removl nd Ressemly B-57 Air Compressor Flow Digrm B-60 Air Compressor Pressure Test B-61 3 B R1 DECEMBER 2000 Pge 3B-1

2 Speifitions Fuel Pressure Air Pressure Fuel/Air Differentil High Pressure Eletri Fuel Pump Amperge Drw Low Pressure Eletri Fuel Pump Amperge Drw Low Pressure Eletri Fuel Pump Output Fuel System Speifitions 89 ± 2 psi (613.5 ± 13.8 kp) 79 ± 2 psi (544.0 ± 13.8 kp) 10 psi (68.5 kp) 6-9 Amps 1-2 Amps 6-10 psi (41.37 kp kp) Fuel Injetor Ohm Resistne 1.8 ± 0.1Ω Diret Injetor Ohm Resistne 1.3 ± 0.3Ω Air Compressor Speifitions Air Compressor Type Compressor Output Reiproting Piston (1 to 1 rtio with engine Idle 80 W.O.T. 110 psi Cylinder Blok Displement 7.07 u. in. (116 ) 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) Pge 3B R1 DECEMBER 2000

3 Speil Tools DIRECT FUEL INJECTION 1. Duel Fuel/Air Pressure Guge 160 psi A1/A2/A Shrder Vlve Tee ( ) 2. Adptors to onvert pressure guge A1/A2 to n A23 *NOTE: 2 Adptors A2 re required to onvert pressure guge set. d -1/2 in. to 1/4 in. Adpter (if required) -Femle Quik Disonnet -Mle Quik Disonnet d-srew on Shrder 3. Srew (5 mm x 25 mm) (2 eh) Flt Wsher (2 eh) Sel/Teflon Ring Instlltion Tool Sel/Teflon Ring Sizing Tool R1 DECEMBER 2000 Pge 3B-3

4 7. DMT 2000 Digitl Thometer Multi-meter P/N A1 8. Clmp Tool Kit A2 -Clmp Tool T Gerse Lekge Tester (FT-8950) Pge 3B R1 DECEMBER 2000

5 Notes: DIRECT FUEL INJECTION R1 DECEMBER 2000 Pge 3B-5

6 Air Hndler Pge 3B R1 DECEMBER 2000

7 Air Hndler TORQUE REF. NO. QTY. DESCRIPTION l-in l-ft Nm. 1 1 COVER 2 1 GROMMET 3 1 GROMMET 4 2 GROMMET 5 1 AIR FILTER 6 1 COVER 7 4 SCREW (M5 x 13) 8 1 AIR HANDLER ASSEMBLY 9 1 DECAL-Cution-Strt in Ger 10 1 BRACKET 11 4 SCREW (M6 x 16) FUEL PUMP 13 1 GROMMET 14 1 ELBOW 15 4 CLAMP 16 1 HOSE 17 1 INSULATING SLEEVE 18 1 FITTING 19 1 O RING 20 1 HOSE 21 1 DECAL-EPA Lel Informtion (SEE NOTE) 22 1 SCREW (M6 x 45) AIR ATTENUATOR 24 1 CLIP 25 1 SCREW (10-16 x 3/4 IN.) 26 1 CABLE 27 1 SCREW (M6 x 8) 28 1 CABLE TIE (14 IN.) NOTE: THE EPA LABEL HAS IMPORTANT INFORMATION ON EPA EMISSION REGULATIONS. REPLACE ANY MISSING OR UNREADABLE EPA LABEL R1 DECEMBER 2000 Pge 3B-7

8 Air Hndler Components Pge 3B R1 DECEMBER 2000

9 Air Hndler Components TORQUE REF. NO. QTY. DESCRIPTION l-in l-ft Nm. 1 AIR HANDLER 1 1 ADAPTOR PLATE 2 1 GASKET 3 6 REED BLOCK 4 12 SCREW (M6 x 1) BUSHING 6 6 GROMMET 7 3 SCREW (M8 x 35) WASHER 9 1 AIR PLENUM KIT 10 1 SCREW 11 1 GASKET 12 1 SENSOR MAP 13 1 BRACKET 14 1 TEMPERATURE SENSOR 15 1 O RING 16 1 THROTTLE BODY KIT 17 4 SCREW O RING 19 3 SCREW OIL PUMP 21 1 ROLLER 22 1 THROTTLE ROLLER 23 1 SCREW (M5 x 16) Drive Tight 24 1 WASHER 25 1 STAR WASHER 26 1 RETAINING RING 27 1 CAM ASSEMBLY 28 1 BUSHING 29 1 SCREW (M8 X 40) THREADED BALL 31 1 SWIVEL BUSHING 32 1 CLAMP SCREW (M6 x 40) FITTING R1 DECEMBER 2000 Pge 3B-9

10 Vpor Seprtor Components Pge 3B R1 DECEMBER 2000

11 Vpor Seprtor Components TORQUE REF. NO. QTY. DESCRIPTION l. in. l. ft. N m 1 1 COVER KIT 2 1 ELBOW 3 1 SEAL 4 1 FITTING KIT-Pump Outlet 5 1 O RING 6 7 SCREW GASKET 8 1 FLOAT KIT 9 1 FLOAT PIN 10 1 NEEDLE VALVE 11 1 SCREW FUEL PUMP KIT 13 1 SLEEVE 14 1 BOWL KIT 15 1 SEAL 16 1 PLUG KIT 17 2 ELBOW 18 1 FUEL FILTER ASSEMBLY 19 1 PROBE R1 DECEMBER 2000 Pge 3B-11

12 Air Hoses TO CRANKCASE Pge 3B R1 DECEMBER 2000

13 Air Hoses TORQUE REF. NO. QTY. DESCRIPTION l-in l-ft Nm 1 1 ELBOW 2 3 STA STRAP 3 1 HOSE-Pulse Line 4 2 CLAMP 5 1 HOSE 6 1 HOSE 7 1 HOSE R1 DECEMBER 2000 Pge 3B-13

14 Fuel System Pge 3B R1 DECEMBER 2000

15 Fuel System TORQUE REF. NO. QTY. DESCRIPTION l-in l-ft Nm 1 4 CLAMP 2 1 CHECK VALVE 3 1 T CLAMP 4 1 SCREW (M5 x 35) 5 5 STA STRAP 6 1 CONNECTOR 7 1 HOSE/SLEEVE 8 1 HOSE 9 1 HOSE-Fuel Supply 10 1 HOSE-Fuel Bypss 11 1 HOSE-Fuel Blne 12 1 HOSE (18 IN.) 13 1 ELBOW 14 1 HOSE 15 1 HOSE 16 1 TUBING 17 2 SLEEVE (14 IN.) 18 1 SLEEVE (8 IN.) 19 1 CAP R1 DECEMBER 2000 Pge 3B-15

16 Fuel Rils A stroke Outord Oil ( A12) A To Vpor Seprtor 32 Pge 3B R1 DECEMBER 2000

17 Fuel Rils TORQUE REF. NO. QTY. DESCRIPTION l-in l-ft Nm. 1 FUEL RAIL ASSEMBLY 1 6 INJECTOR 2 6 CUPPED WASHER 3 1 FUEL RAIL (PORT) 4 1 FUEL RAIL (STARBOARD) 5 4 CLAMP 6 4 CLAMP 7 2 CLAMP 8 2 CLAMP 9 1 O-RING KIT 10 1 AIR PLUG 11 1 FITTING 12 1 AIR VALVE KIT 13 1 FUEL VALVE KIT 14 2 CAP 15 6 FUEL INJECTOR 16 1 O-RING KIT 17 1 O-RING KIT 18 1 DIAPHRAGM 19 1 SPRING 20 1 O-RING 21 1 COVER 22 4 SCREW (M5 X 16) O-RING (16 PER KIT) SCREW (M5 X 8) AIR REGULATOR (MODEL 2001) 26 1 CLAMP 27 1 O-RING KIT 28 4 STUD (M10 x 91) 29 4 NUT (M10) CLIP CONDUIT 31 1 AIR HOSE (80 PSI) 32 1 FUEL HOSE (90 PSI) 33 1 WATER INLET HOSE 34 1 FITTING 35 1 FUEL RETURN HOSE TO VAPOR SEPARATOR R1 DECEMBER 2000 Pge 3B-17

18 Air Compressor Components Ç Ç Ç Dieletri Grese ( ) 14 9 Lotite PST Pipe Selnt ( ) Cyle Outord Oil ( A24) Pge 3B R1 DECEMBER 2000

19 Air Compressor Components TORQUE REF. NO. QTY. DESCRIPTION l-in l-ft Nm. 1 1 AIR COMPRESSOR 2 1 END CAP 3 1 SNAP RING 4 4 SCREW (M6 x 20) Note* 5 1 O RING 6 1 O RING 7 1 CONNECTING ROD 8 1 PISTON ASSEMBLY 9 2 LOCK RING 10 1 REED PLATE ASSEMBLY 11 2 O RING 12 1 O RING 13 1 SEAL 14 1 COMPRESSOR HEAD 15 1 FITTING-Stright 16 4 SCREW (M8 x 35) ELBOW 18 1 ELBOW 19 2 ELBOW (CHECK VALVE) 20 1 CONNECTOR 21 1 FITTING 22 1 O RING 23 1 TEMPERATURE SENSOR 24 1 RETAINER 25 1 SCREW (M6 x 12) SCREW (M6 x 12) PULLEY 28 4 SCREW (M8 x 50) PLUG *NOTE: Model Yer 2000 (GOLD olored pulley) Torque for pulley srews is 190 l. in. (21.5 Nm) *NOTE: Model Yer 2001 (BLACK olored pulley) Torque for pulley srews is 170 l. in. (19 Nm) R1 DECEMBER 2000 Pge 3B-19

20 DFI Opertion Air Indution Through Crnkse Air Compressor System Fuel Comustion ir enters the owl through holes loted in the top ft end of the owl. The owl liner direts this ir to the ottom of the powerhed. This limits the exposure of slt ir to the omponents inside the engine owl. One inside the owl the ir enters the plenum through the throttle shutter whih is loted in the plenum ssemly. The ir then ontinues through the reed vlves nd into the rnkse. The throttle shutter is tuted y the throttle shft. Mounted on seprte shft is throttle position sensor (TPS). This sensor tells the engine ontrol unit (ECM) the position of the throttle. If the TPS should fil, the dsh mounted CHECK ENGINE light will flsh nd the wrning horn will sound. Engine speed will e redued. Air from inside the engine owl is drwn into the ompressor through the flywheel over. This over ts like muffler to quiet ompressor noise nd ontins filter to prevent the ingestion of deris into the ompressor. The ompressor is driven y elt from pulley mounted on the flywheel nd is utomtilly self djusted using single idler pulley. This ir ompressor is single ylinder unit ontining onneting rod, piston, rings, erings, reed vlves, nd rnkshft. The ompressor is wter ooled to lower the temperture of the ir hrge nd is lurited y oil from the engine oil pump ssemly. As the ompressor piston moves downwrd inside the ylinder, ir is pulled through the filter, reed vlves nd into the ylinder. After the ompressor piston hnges diretion, the intke reeds lose nd the exhust reeds open llowing ompressed ir into the hose leding to the ir/fuel rils. The ir/fuel rils ontin two pssges; one for fuel, the seond is the ir pssge. The ir pssge is ommon etween ll the ylinders inluded in the ril. A hose onnets the strord ril ir pssge to the ir ompressor. Another hose onnets 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 into the ir plenum. Fuel for the engine is stored in typil fuel tnk. A primer ul is instlled into the fuel line to llow priming of the fuel system. A rnkse mounted pulse driven diphrgm fuel pump drws fuel through the fuel line, primer ul, fuel pump ssemly nd then pushes the fuel thru wter seprting fuel filter. This filter removes ny ontmintes nd wter efore the fuel rehes the vpor seprtor. Fuel vpors re vented through hose into the ir ompressor inlet in the front of the flywheel over. The eletri fuel pump is different thn the fuel pump tht is utilized on the stndrd EFI engine (non DFI), nd is ple of developing fuel pressures in exess of 90 psi. Fuel inside the ril must remin pressurized t extly 10 psi over the ir ril pressure or the ECM (mp) lirtions will e inorret. Fuel from the vpor seprtor is supplied to the top of the port fuel ril. A fuel line onnets the ottom of the first ril to the opposite fuel ril. Fuel is stored inside the ril until n injetor opens. A fuel pressure regultor ontrols pressure in the fuel rils, nd llows exess 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 losed with spring tht requires 10 Pge 3B R1 DECEMBER 2000

21 Oil Eletril Opertion DIRECT FUEL INJECTION p.s.i. to fore the diphrgm off the diphrgm set. The k side of the diphrgm is exposed to ir ril pressure. As the ir ril pressure inreses, the fuel pressure needed to open the regultor will eqully inrese. 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 ooled. To equlize the pulses developed y the pumps (oth ir nd fuel) trker diphrgm is instlled in the strord ril. The trker diphrgm is positioned etween the fuel nd ir pssges. The trker diphrgm is ruer diphrgm whih expnds nd retrts depending upon whih side of the diphrgm senses the pressure inrese (pulse). Oil in this engine is not mixed with the fuel efore entering the omustion hmer. Oil is stored inside stndrd remote oil reservoir. Crnkse pressure will fore 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 tivted y the ECM nd inludes 7 pistons with orresponding dishrge ports. The oil pump is mounted diretly onto the powerhed. Eh ylinder is lurited y one of the dishrge ports. The oil is dishrged into the rnkse. The seventh pssge onnets to the hose tht leds to the ir ompressor for lurition. Exess oil from the ompressor returns into the plenum nd is ingested through the rnkse. The ECM will hnge the dishrge 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 lok. The oil rtio vries with engine rpm nd lod. The eletril system onsists of the ECM, rnk position sensor (flywheel speed & rnkshft position), throttle position sensor (TPS), MAP sensor, engine temperture sensor, ignition oils nd injetors (fuel & diret). The engine requires ttery to strt (i.e. the ignition nd injetion will not our if the ttery is ded). The system will run off of the lterntor. The opertion of the system hppens in milliseonds (ms); ext timing is ritil for engine performne. As the rnkshft rottes, ir is drwn into the rnkse through the throttle shutter, into the plenum nd through the reed vlves. As the piston ners ottomded-enter, ir from the rnkse is fored through the trnsfer system into the ylinder. As the rnkshft ontinues to rotte the exhust nd intke ports lose. With these ports losed, fuel n e injeted into the ylinder. The ECM will reeive signl from the throttle position sensor (TPS), engine temperture sensor (TS) nd the rnk position sensor (flywheel speed nd position sensor). With this informtion the ECM refers to the fuel lirtion (mps) to determine when to tivte (open nd lose) the injetors nd fire the ignition oils. With the piston in the orret position, the ECM opens the fuel injetor, 90 psi fuel is dishrged into mhined vity inside the ir hmer of the ir/fuel ril. This mixes the fuel with the ir hrge. Next the diret injetor will open, dishrging the ir/fuel mixture into the omustion hmer. The diret injetor direts the mixture t the owl loted in top of the piston. The piston s owl direts the ir/fuel mixture into the enter of the omustion hmer. 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 ompressor hs time to uild pressure, some diret injetors re held open y the ECM. This llows the ompression from inside the ylinders to pressurize the ir ril fster (1 or 2 strokes, or 60 0 of rnkshft rottion) R1 DECEMBER 2000 Pge 3B-21

22 Idle Notes: Idle qulity is ontrolled y fuel volume nd fuel timing. The throttle shutter will e open t idle speed. The shift ut-out swith will interrupt the fuel to 3 of the ylinders to ssist in shifting. The TPS signls the ECM to hnge the fuel nd sprk without movement of the throttle shutters. The throttle m is mnuftured to llow the TPS sensor shft to move efore opening the throttle shutter. Testing Eletri Fuel Pump Pressure Output Low Pressure Eletri Fuel Pump IMPORTANT: After ompleting fuel pressure tests, reonnet nd seure fuel outlet hose to fuel pump with full irle stinless lmps in Clmp Tool Kit A1. 1. Remove outlet fuel hose from low pressure pump. Instll short piee of hose (otin lolly) onto pump outlet fitting. Instll Shrder Vlve t-fitting ( ) etween outlet fuel hose (removed from pump) nd new fuel hose (instlled on pump). Seure hose onnetions with st-strps. Due to the low pressure output of this pump, it is reommended tht the ir guge of the Dul Fuel/Air Pressure Guge ( A1/A2/A3) e onneted to the Shrder Vlve. Guge should indite 6-9 psi ( kp). d Outlet Fuel Hose -Low Pressure Eletri Fuel Pump -Fuel Hose (otin lolly) d-shrder Vlve ( ) Pge 3B R1 DECEMBER 2000

23 High Pressure Eletri Fuel Pump DIRECT FUEL INJECTION 1. Instll Pressure Guge Assemly A1/A2/A3 to strord fuel ril pressure test vlve. *NOTE: After 15 seonds of rnking engine with strter motor, fuel pressure guge should indite 89 ± 2 psi (613.5 ± 13.8 kp). -Fuel Pressure Guge [Should Indite 89 ± 2 psi (613.5 ± 13.8 kp)] -Fuel Pressure Test Vlve R1 DECEMBER 2000 Pge 3B-23

24 Fuel Mngement Assemly Removl CAUTION Fuel system must e led off prior to removl of fuel system omponents. WARNING Drin fuel from vpor seprtor tnk (VST) into suitle ontiner. Even though VST hs een drined, fuel my still remin in fuel rils nd hoses. Norml preutionry proedures should e dhered to while working with the fuel system. Avoid sprks, smoking nd open flme while in the presene of liquid fuel or fuel vpors. *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. d Port Fuel Ril -Fuel Pressure Port -Air Pressure Port d-strord Fuel Ril 2. Remove vpor seprtor vent hose. 3. Remove olt seuring ir mngement ssemly ttenutor. -Vent Hose Bolt Pge 3B R1 DECEMBER 2000

25 4. Ple suitle ontiner underneth vpor seprtor drin plug nd remove plug. 5. Disonnet wter seprtor sensor led. 6. Disonnet eletri fuel pump hrness onnetors. -Drin Plug Sensor Led -Hrness Connetors *NOTE: Lower fuel hose is exess fuel return from fuel rils; upper fuel hose is fuel inlet from eletri pump eside fuel/wter seprtor. 7. Remove the fuel inlet hose from the pulse fuel pump. 8. Remove the fuel outlet hose nd fuel return hose from fuel rils. 9. Remove 3 mounting olts nd remove seprtor. d d Fuel Inlet Hose from Pulse Pump -Fuel Outlet Hose Fuel Return Hose d-mounting Bolts R1 DECEMBER 2000 Pge 3B-25

26 10. Disonnet throttle m link rod nd the Throttle Position Sensor link rod. 11. Disonnet MAP Sensor nd ir temperture sensor from ir mngement ssemly. d -Throttle Link Rod -Throttle Position Sensor Link Rod -MAP Sensor d-air Temperture Sensor Connetor Disonnet oil hoses from oil pump. 13. Remove nd plug oil inlet hose to oil pump. 14. Remove 12 olts seuring ir plenum ssemly to rnkse nd remove ssemly. d -Oil Hoses -Oil Inlet Hose -Air Plenum d-bolts (12 eh) Pge 3B R1 DECEMBER 2000

27 Reed Blok Assemly Removl DIRECT FUEL INJECTION 1. Remove 11 srews seuring ir plenum to rnkse over. -Srews (11 eh) (1/4x20x0.88) Reed Blok Assemly Instlltion 1. Seure oil pump to ir plenum with 3 olts. Torque olts to 140 l. in. (16 Nm). 2. Seure ir plenum/reed lok ssemly to rnkse over with 12 srews. Torque srews in pproprite torque sequene to 100 l.in. (11.5 Nm) Oil Pump -This srew must e removed to seure ir silener nd then reinstlled R1 DECEMBER 2000 Pge 3B-27

28 Air Temperture Sensor Removl Disonnet sensor hrness nd unsrew sensor. -Air Temperture Sensor Hrness Connetor -Air Temperture Sensor Air Temperture Sensor Instlltion Srew sensor into ir plenum. Reonnet sensor hrness. Throttle Plte Assemly Removl *NOTE: The throttle plte ssemly is lirted nd preset for proper running hrteristis nd emissions t the ftory. Other thn omplete ssemly removl from the ir plenum, no further disssemly should e mde. Remove 4 olts seuring throttle plte ssemly to ir plenum nd remove ssemly. -Bolts -Throttle Plte Assemly Throttle Plte Assemly Instlltion Seure throttle plte ssemly to ir plenum with 4 olts. Torque olts to 100 l. in. (11.5 Nm). Pge 3B R1 DECEMBER 2000

29 Vpor Seprtor Disssemly DIRECT FUEL INJECTION 1. Remove 7 srews seuring seprtor over nd remove over. 2. Inspet sel in fuel pump hmer of seprtor tnk for uts nd risions. Reple sel if neessry. If sel is serviele, pply 2-4-C w/teflon Mrine Lurint ( A12) to sel lips. -Srews (7 eh) -Sel Fuel pump my e removed from over y wiggling slightly while pulling outwrd. IMPORTANT: DO NOT twist pump during removl s wire hrness my e dmged. 4. Disonnet hrness from pump to seprte pump from over. Inspet filter sreen for deris. Sreen my e pried out of pump nd lened s required. 5. Inspet sel ove fuel pump for uts or risions. Reple sel if neessry. Apply 2-4-C w/teflon to sel lips. d Filter Sreen -Hrness Connetor -Pump d-sel (Sel shoulder fes OUT) R1 DECEMBER 2000 Pge 3B-29

30 6. Loosen srew seuring flot ssemly nd remove flot. Inspet flot for deteriortion or fuel retention. Reple flot s required. 7. Remove phenoli seling plte nd inspet imedded neoprene sel on oth sides of plte for uts or risions. Reple plte/sel ssemly s required. d Srew -Flot -Plte d-sel Pge 3B R1 DECEMBER 2000

31 Vpor Seprtor Ressemly DIRECT FUEL INJECTION 1. Reinstll phenoli seling plte onto vpor seprtor over. 2. Seure flot, needle nd pivot pin ssemly to seprtor over with srew. Torque srew to 10 l. in. (1.0 Nm). 3. Apply 2-4-C w/teflon to lips of sel in seprtor over. 4. Connet eletril hrness to fuel pump. Inspet fuel pump filter sreen for deris. Remove sreen nd len s required. 5. Set fuel pump nd hrness into seprtor over eing reful not to pinh hrness. d f e -Seling Plte -Flot -Needle d-pivot Pin e -Srew [Torque to 10 l. in. (1.0 N m) g i f -Sel (Sel shoulder fes 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 over with pump onto seprtor tnk. 8. Seure over to tnk with 7 srews. Torque srews to 30 l. in. (3.5 Nm). -Sel -Srews [Torque to 30 l. in. (3.5 Nm)] R1 DECEMBER 2000 Pge 3B-31

32 Air Plenum Instlltion Seure plenum to rnkse with 12 olts. Torque olts to 100 l. in. (11.5 Nm). in sequene shown Air Plenum -Bolts [Torque to 100 l. in. (11.5 Nm)] Low Pressure Eletri Fuel Pump Instlltion *NOTE: If pump does not hve sleeve or grommet, refer to Servie Bulletin Set eletri fuel pump w/sleeve ginst grommet in pump rket. Seure pump to rket with st-strp. d -Low Pressure Eletri Fuel Pump -Sleeve -Grommet d-brket Pge 3B R1 DECEMBER 2000

33 2. Seure rket ssemly to vpor seprtor with 4 srews. Torque srews to 100 l. in. (11.5 Nm). -Srews Torque to 100 l. in. (11.5 Nm) -St-strp seuring pump to rket -Ground led tth to ir plenum IMPORTANT: Only use tool T (or Snp-On equivlent YA3080) to rimp full irle lmps. Using different tool ould result in rimp tht is too loose, or too tight. Do not use srew type metl hose lmp s it my dmge hose. 3. Connet fuel hose from ottom of low pressure fuel pump to 90 elow in ottom of vpor seprtor. Seure hose with 16.2 mm full irle lmp ( ) using rimping tool T. -Seure Fuel Hose with 16.2 mm Full Cirle Clmp ( ) R1 DECEMBER 2000 Pge 3B-33

34 4. Connet fuel hose from top of low pressure fuel pump to 90 elow on k side of vpor seprtor. Seure hose with 15.3 mm full irle lmp ( ) using rimping tool T. Vpor Seprtor Instlltion Seure Fuel Hose with 15.3 mm Full Cirle Clmp ( ) 1. Seure vpor seprtor to ir plenum with 3 olts. Torque olts to 140 l. in. (16.0 Nm). 2. Connet fuel inlet hose from pulse pump. 3. Connet fuel outlet hose nd fuel return hose to vpor seprtor. e d f -Mounting Bolts [Torque to 140 l. in. (16.0 Nm)] -Fuel Inlet Hose -Fuel Outlet Hose d-fuel Return Hose e -Low Pressure Eletri Fuel Pump (6-9 psi) f -Inlet Fuel Hose to Low Pressure Pump Pge 3B R1 DECEMBER 2000

35 4. Connet wter seprtor sensor led to wter seprtor. 5. Connet eletri fuel pump hrnesses. 6. Connet vent hose from ir plenum to vpor seprtor. DIRECT FUEL INJECTION d e f -Sensor Led -Eletri Fuel Pump Hrness Connetors -Vpor Seprtor Vent Hose Fitting d-high Pressure (90 psi) Fuel Outlet Hose e -Fuel Inlet Hose from Low Pressure Pump (6-9 psi) f -Exess Fuel Return Hose from Fuel Rils R1 DECEMBER 2000 Pge 3B-35

36 Fuel Ril Removl CAUTION Fuel system must e led off prior to removl of fuel system omponents. *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 injetor hrness from eh injetor y ompressing spring lip with flt tip srew driver while pulling on onnetor. e d Fuel Pressure Port -Air Pressure Port -Fuel Injetor d-hrness Connetor e -Spring Clip *NOTE: Alwys remove fuel/ir hose nd fitting together y removing fitting retiner rther utting lmps. 3. Remove fuel, wter nd ir hoses from fuel ril. d f e Port Top Fuel Ril Connetions -Wter Inlet Hose to Compressor -Retiner -Allen Srews (remove) Strord Top Fuel Ril Connetions d-air Hose e -Retiner f -Allen Srews Pge 3B R1 DECEMBER 2000

37 f g e d Port Bottom Fuel Ril Connetions -Wter Inlet Hose to Fuel Ril -Air Hose -Allen Srews (remove) d-fuel Hose Strord Bottom Fuel Ril Connetions e -Air Hose f -Allen Srews g-fuel Hose *NOTE: It is reommended tht diret injetors remin in the ylinder hed (if they re not to e repled) while removing the fuel ril. The diret injetors hve teflon sel whih my expnd if the injetor is removed from the hed. This expnsion my use reinstlltion diffiulty or require the replement of the sel. 4. Remove 2 nuts seuring fuel ril. 5. As fuel ril is removed, use flt tip srew driver to hold diret injetors in ylinder hed. -Fuel Ril -Diret Injetors The strord fuel ril ontins 3 fuel injetors nd trker vlve. The port fuel ril ontins 3 fuel injetors, 1 fuel fuel regultor, nd 1 ir regultor R1 DECEMBER 2000 Pge 3B-37

38 *NOTE: Eh fuel/ir inlet or outlet hose dptor hs 2 o-ring sels. These o-rings should e inspeted for uts or risions nd repled s required when fuel ril is disssemled for lening. e d j i g h k -Fuel Injetor -Fuel Regultor -Air Regultor d-trker Vlve e -Coolnt Inlet to Air Compressor f f -Exess Fuel Return to VST g-40 psi Chek Vlve h-wter Inlet for Cooling Fuel Ril i -Exess Air to Air Plenum j -90 psi (616 kp) Fuel k -80 psi (547.8 kp) Air FUEL INJECTOR REMOVAL 1. Remove 2 srews seuring injetor. *NOTE: Use otter pin extrtor tool in pry holes to remove injetors. 2. Gently pry up on injetor to loosen o-ring dhesion nd remove injetor Srews -Pry Holes Pge 3B R1 DECEMBER 2000

39 3. Inspet fuel injetor orifies for foreign deris; o-rings for uts or risions nd plsti omponents for het dmge. Reple omponents s required. 4. An ohm test of the fuel injetor my e mde y onneting test leds to injetor terminls. Ohm reding should e 1.8 ± 0.1 ohm Fuel Injetor -Fuel Nozzle -O-Rings FUEL INJECTOR INSTALLATION *NOTE: Apply nti-seize grese (otin lolly) or 2-4-C w/teflon to fuel injetor tthing srew threds. 1. Insert fuel injetor into fuel ril with onnetor pins fing (inwrds) towrds enter of engine. *NOTE: Turn injetor k-nd-forth slightly to set injetor o-rings in fuel ril while seuring injetor with retiner nd 2 srews. Torque srews to 70 l. in. (8.0 Nm). -Injetor -Retiner -Srews [Torque to 70 l. in. (8.0 Nm)] R1 DECEMBER 2000 Pge 3B-39

40 Fuel Pressure Regultor The fuel regultor is loted on the port fuel ril The fuel pump is ple of delivering more fuel thn the engine n onsume. Exess fuel flows through the fuel pressure regultor, interonneting pssges/hoses, fuel ooler, nd k to the vpor seprtor tnk. This onstnt flow of fuel mens tht the fuel system is lwys supplied with ool fuel, therey preventing the formtion of fuel vpor ules nd minimizing the hnes of vpor lok. The fuel pressure regultor is lirted to rise the fuel pressure to 10 psi ove the ir pressure. The fuel regultor is mounted on the port fuel ril, ner the ottom. This regultor relies on oth ir nd spring pressure to ontrol the fuel pressure. Inside the regultor ssemly is 10 l. spring, this spring holds the diphrgm ginst the diphrgm set. The ontt etween the diphrgm nd diphrgm set loses the pssge etween the inoming fuel (from the eletri 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 ompressor (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) omine to regulte system fuel pressure to 90 psi - or 10 psi higher thn the ir pressure in the DFI system fuel/ir rils. Pge 3B R1 DECEMBER 2000

41 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 Eletri Fuel Pump) 12 - Diphrgm Assemly 13 - Clirtion Srew (Do Not Turn) R1 DECEMBER 2000 Pge 3B-41

42 FUEL REGULATOR REMOVAL 1. Remove 4 srews seuring regultor nd remove regultor. 2. Inspet regultor diphrgm for uts or ters. 3. Inspet regultor housing o-ring for uts nd risions. Reple omponents s required. e d f FUEL REGULATOR INSTALLATION Srews d-spring -Fuel Regultor e -Cup -Diphrgm f -O-Ring *NOTE: Apply light ot of 2-4-C w/teflon to diphrgm surfe 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 up onto diphrgm. *NOTE: Apply nti-seize grese (otin lolly) or 2-4-C w/teflon to regultor tthing srew threds. 4. Ple over over spring/up/diphrgm ssemly nd seure with 4 srews. Torque srews to 70 l. in. (8.0 Nm). e e d -Diphrgm -O-Ring -Spring d-cup e -Srews [Torque to 70 l. in. (8.0 Nm)] Pge 3B R1 DECEMBER 2000

43 Air Pressure Regultor The ir pressure regultor is loted on the port fuel ril. DIRECT FUEL INJECTION 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 ontrol the ir pressure. This spring (80 psi) holds the diphrgm ginst the diphrgm set. The ontt re loks (loses) the ir inlet pssge from the exess ir, return pssge. As the ir pressure rises (elow the diphrgm), it must reh pressure equl to or greter thn the spring pressure holding the diphrgm losed. One this pressure is hieved, the spring ompresses, llowing the diphrgm to move. The diphrgm moves wy from the diphrgm set, llowing ir to exit through the diphrgm set, into the exess ir pssge leding to the ir plenum. Air Regultor Trouleshooting Air pressure should e mesured t the ir shrder vlve loted ner the middle of the port fuel ril ssemly. Is ir pressure within 78 to 82 psi rnge t neutrl idle psoition? Less thn 78 psi? No Greter thn 82 psi? Yes Air regultor is OK Remove ir regultor nd lmp. Inspet ir regultor o-ring. Air regultor o-ring OK nd ir pressure is less thn 78 psi? Remove ir ypss hose from exhust dptor nd mesure ir pressure t neutrl idle ondition. Air pressure norml 78 to 82 psi? Air pressure greter thn 82 psi? Air exiting ir ypss? Plugged ypss iruit in dptor plte. Filed ir regultor. Yes? No? Filed ir regultor. Ostrution t ompressor inlet or outlet or filed ompressor R1 DECEMBER 2000 Pge 3B-43

44 Regultor Closed Regultor Open ÇÇÇ ÇÇ Top Cover 2 -Expnsion Plug 3 -Spring Retiner 4 -Vent 5 -Spring 6 -Diphrgm Set 7 -Air Ril 8 -Air Pssge (from Air Compressor) 9 -Exess Air Pssge (to Exhust Adptor) 10 - Fuel Inlet Pssge (from Eletri Fuel Pump) 11 - Diphrgm Assemly 12 - Clirtion Srew (Do Not Turn) Pge 3B R1 DECEMBER 2000

45 MODEL YEAR 2000 AIR REGULATOR REMOVAL 1. Remove 4 srews seuring regultor nd remove regultor. 2. Inspet regultor diphrgm for uts or ters. Reple s required. DIRECT FUEL INJECTION d e -Srews -Air Regultor -Diphrgm MODEL YEAR 2000 AIR REGULATOR INSTALLATION d-spring e -Cup *NOTE: Apply light ot of 2-4-C w/teflon to diphrgm surfe to id in the retention of diphrgm on fuel ril during ressemly. 1. Position diphrgm, spring nd up onto fuel ril with fuel ril in horizontl position. *NOTE: Apply nti-seize grese (otin lolly) or 2-4-C w/teflon to regultor tthing srew threds. *NOTE: Due to the stiffness of the regultor spring, it is reommended tht 2 longer srews (5mm x 25mm long) ( ) nd 2 flt wshers ( ) e instlled through over first to egin ompression. This will llow 2 shorter srews (5mm x 15mm long) to e instlled. Remove 2 long srews w/flt wshers nd instll remining 2 short srews (5mm x 15mm). Torque srews to 70 l. in. (8.0 Nm). d e f e f -Cup -Spring -Diphrgm d-cover e -Srews (5mm x 25mm) ( ) f -Flt Wshers ( ) R1 DECEMBER 2000 Pge 3B-45

46 MODEL YEAR 2001 AIR REGULATOR REMOVAL 1. Remove 2 srews seuring regultor nd remove regultor. 2. Inspet regultor o-rings for uts nd rsions. Reple s required. *NOTE: Air regultor is not serviele. If regultor doesn t mintin pproximtely 80 psi reple it d Srews -Air Regultor -O-Rings d-retiner MODEL YEAR 2001 AIR REGULATOR INSTALLATION 1. Position ir regultor, retiner nd srews onto fuel ril s shown elow. *NOTE: Apply nti-seize grese (otin lolly) or 2-4-C w/teflon to regultor tthing srew threds. Torque srews to 70 l. in. (8.0 Nm). *NOTE: Apply light ot of outord oil to regultor o-rings to ese instlltion. -Srews -Retiner -Air Regultor Pge 3B R1 DECEMBER 2000

47 Trker Vlve The trker vlve is loted on the strord fuel/ir ril ssemly. DIRECT FUEL INJECTION The DFI system must mintin onstnt 10 psi pressure differene etween the fuel pressure nd ir pressure in the rils, t ll times. The trker is designed to mintin the 10 psi differentil when the ir or fuel pressure suddenly rises (i.e. pulses generted y the ompressor s piston or y the fuel injetors opening nd losing). The trker ontins 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 reh norml operting rnge, the fuel pressure will ompress 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 trker 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 inrese in pressure so tht the 10 psi differene etween ir nd fuel system pressures n e mintined. *NOTE: To prevent exessive wer in the set, the trker is lirted to llow the diphrgm to e slightly wy from the set during norml opertion R1 DECEMBER 2000 Pge 3B-47

48 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 Eletri Fuel Pump) 9 -Diphrgm Assemly Pge 3B R1 DECEMBER 2000

49 TRACKER VALVE REMOVAL DIRECT FUEL INJECTION 1. Remove 4 srews seuring trker vlve nd remove trker ssemly. 2. Inspet trker diphrgm for uts nd ters. 3. Inspet trker over o-ring for uts nd risions. Reple omponents s required. d -Srews -Diphrgm -Spring d-o-ring TRACKER VALVE INSTALLATION *NOTE: Apply light ot of 2-4-C w/teflon to trker diphrgm nd over o-ring to id in their retention on fuel ril while reinstlling trker vlve to fuel ril. *NOTE: Apply nti-seize grese (otin lolly) or 2-4-C w/teflon to trker vlve tthing srew threds. 1. Position diphrgm, spring nd o-ring onto fuel ril. 2. Ple over over diphrgm/spring/o-ring ssemly nd seure with 4 srews. Torque srews to 70 l. in. (8.0 Nm). e Diphrgm -Spring -O-Ring d-cover e -Srews [Torque to 70 l. in. (8.0 Nm)] d e R1 DECEMBER 2000 Pge 3B-49

50 Fuel Ril Clening Diret Injetor Removl After ll fuel injetors, ir regultor, trker vlve, fuel regultor, inlet hoses nd outlet hoses hve een removed, the fuel rils my e flushed out with suitle prts lening solvent. Use ompressed ir to remove ny remining solvent. 1. Remove hrness onnetors from diret injetors. 2. Remove diret injetor from ylinder hed -Diret Injetor (3 eh ylinder hed) -Hrness Connetor Inspet injetor teflon seling ring (white) for signs of omustion lowy (teflon ring will e streked rownish lk). If lowy is present, reple teflon seling ring. If lowy is not present, seling ring my e reused. 4. Inspet o-rings nd teflon ring for uts or risions. Reple omponents s required. 5. If teflon sel requires replement, use teflon ring instlltion tool to slide new sel onto injetor. Following instlltion of teflon ring, the teflon ring sizing tool ( ) n e used to ompress the teflon sel to id in the instlltion of the injetor into the ylinder hed. d e e Teflon Seling Ring -O-Ring -Teflon Sel f d-sel Instlltion Tool ( ) e -O-Ring f -Teflon Ring Sizing Tool ( ) Pge 3B R1 DECEMBER 2000

51 6. An ohm test of the diret injetor my e mde y onneting test leds to injetor terminls. Ohm reding should e 1.3 ± 0.3 ohm. 7. An ohm test to determine if diret injetor windings re shorted to ground n e mde y onneting one ohm led to either injetor pin while touhing the other ohm led to the injetor metl se. There should e no ontinuity. If there is ontinuity, the internl windings re shorted nd the injetor must e repled. OHMS VOLTS 0 2 DC AMPS OHMS VOLTS 0 2 DC AMPS DCV ACV DCV ACV DVA X1 DVA X Diret Injetor Ohm Test (1.3 ± 0.3 ohm) -Diret Injetor Short to Ground Ohm Test (no ontinuity) Diret Injetor Lek Test 1. Atth Gerse Lekge Tool (FT-8950) to dishrge side of injetor. -Gerse Lekge Tool (FT-8950) -Diret Injetor Pump up lekge tool to indite psi ( kp). 3. Diret injetor should not lek down more thn 1/2 psi (3.5 kp) in 1 minute. 4. If injetor does not meet the ove speifitions, reple injetor R1 DECEMBER 2000 Pge 3B-51

52 *NOTE: If ylinder hed is going to e repled, remove up wshers from eh diret injetor port y prying out with flt tip srewdriver. Reinstll wshers with retiners into new ylinder hed. Wshers provide tension etween diret injetors, ylinder hed nd fuel rils. -Cup Wsher -Retiner Fuel Ril nd Diret Injetor Instlltion 1. Use Teflon Ring Sizing Tool ( ) to ompress new teflon seling rings prior to instlltion of injetor into ylinder hed. 2. Crefully slide fuel ril over mounting studs nd onto diret injetors. IMPORTANT: ALL fuel nd ir hoses tthed to the fuel rils MUST e seured with stinless steel hose lmps. 3. Seure eh fuel ril with 2 nuts. Torque nuts to 33 l. ft. (44 Nm). 4. Reinstll diret injetor hrness onnetors. -Nuts [Torque to 33 l.ft. (44 Nm)] -Diret Injetor Hrness Connetors (6) (3 eh fuel ril) Pge 3B R1 DECEMBER 2000

53 Air Compressor Air Compressor DIRECT FUEL INJECTION Air ompressor is single ylinder, wter ooled nd lurited y the outord oil pump. Air Compressor Speifitions Type Compressor Output Reiproting Piston (1 to 1 rtio with engine Idle 80 W.O.T. 110 psi Cylinder Blok Displement 7.07 u. in. (116 ) 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 Dimension A t Right Angle (90 ) to Piston Pin in ±.0004 in. (64.97 ± mm) Piston Ring End Gp Top Ring Middle Ring Bottom Ring in. ( mm) in. ( mm) in. ( mm) Reeds Reed Stnd Open in. (0.25 mm) R1 DECEMBER 2000 Pge 3B-53

54 COMPRESSOR REMOVAL 1. Disonnet ttery les from ttery terminls. 2. Remove top owling. IMPORTANT: Prior to removing flywheel over, remove vent hose from fitting on flywheel over. 3. Remove flywheel over. 4. Use 3/8 inh (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 R1 DECEMBER 2000

55 CAUTION DIRECT FUEL INJECTION If engine hs een reently run, ir pressure outlet hose fittings my e extremely hot. Allow omponents to ool off efore eginning disssemly. *NOTE: Remove 2 srews seuring retiner plte to remove ir pressure outlet hose. Inspet o-rings on ir pressure hose fitting for uts or risions. Reple o-rings s required. 5. Remove ir pressure outlet hose. 6. Disonnet ompressor wter inlet hose. -Air Pressure Outlet Hose -Compressor Wter Inlet Hose -Compressor Temperture Sensor 7. Disonnet ir ompressor oil inlet hose. 8. Disonnet wter outlet hose (tell-tle). 9. Disonnet exess oil return hoses d d -Air Compressor Oil Inlet Hose -Wter Outlet Hose (tell-tle) -Wter Inlet Hose d-exess Oil Return Hoses Remove 4 olts seuring ir ompressor to outord nd remove ompressor R1 DECEMBER 2000 Pge 3B-55

56 Air Compressor Disssemly/Ressemly IMPORTANT: If n internl filure of the ir ompressor hs ourred, i.e. roken reed, suffed piston, ering filure, et. ll ir hoses, fuel rils nd injetors should e disssemled nd inspeted for metl deris. Filure to remove ll metl deris will result in poor performne nd/or powerhed filure. *NOTE: If ylinder ore is sored, ir ompressor must e repled s n ssemly. *NOTE: The piston nd rings re not sold seprtely. They must e repled s n ssemly. The onneting rod nd erings re not sold seprtely. They must e repled s n ssemly. d e Ç g f 6 Dieletri Grese ( ) 9 Lotite PST Pipe Selnt ( ) 14 2 Cyle Outord Oil ( A24) h i 6 j k l *NOTE: End p ering nd sel re not sold seprtely. End p must e repled s n ssemly *NOTE: Piston Instlltion use metl hose lmp for piston ring ompressor. Stgger piston ring openings. -Bolt (GOLD Pulley) Torque to 190 l. in. (21.5 Nm) (BLACK Pulley) Torque to 170 l. in. (19 Nm) -Bolt (4 eh) (Torque to 20 l. ft. [27 Nm]) -Bolt (4 eh) (Torque to 100 l. in. [11.5 Nm]) d-end Cp Assemly (Inspet ering for roughness) e -O-Rings (Inspet for uts or risions) f -O-Rings (Inspet for uts or risions) g-reed Plte (Inspet for roken or hipped reeds/stops) Mximum Reed Stnd-Open in. (0.254 mm) h-o-rings (Inspet for uts or risions) i -Cylinder Hed j -Bolt (Torque to 20 l. ft. [27 Nm]) k -Temperture Sensor l -Bolt (Torque to 20 l. ft. [27 Nm]) Pge 3B R1 DECEMBER 2000

57 Air Compressor End Cp/Crnkshft Removl nd Ressemly DISASSEMBLY DIRECT FUEL INJECTION 1. Remove flywheel over. 2. Use 3/8-inh (9.5 mm) drive on elt tensioner rm to relieve elt tension, nd remove elt. 3. Remove the 5 olts tht retin the pulley to the pulley flnge Pulley retining olts (5) -Tensioner -3/8 (9.5 mm) squre drive R1 DECEMBER 2000 Pge 3B-57

58 4. Remove the 4 olts tht retin the end p to the ompressor ody. -End p retining olts (4) While rotting the pulley flnge lterntely lokwise nd ounterlokwise out 1/8 to 1/4 turn, pull outwrd on the pulley flnge. Continue rotting until the end p ssemly hs een removed from the ompressor ody. Pge 3B R1 DECEMBER 2000

59 REASSEMBLY DIRECT FUEL INJECTION 1. Lurite end p O-ring nd O-ring ontt re in ompressor ody with two yle oil. 2. Slide the new end p ssemly into the ompressor ody, keeping the onneting rod journl lined up with the open end of the onneting rod, until the rnkshft just enters the open end of the onneting rod. -Conneting rod open end -Crnkshft onneting rod Journl 3. While rotting the pulley flnge lokwise nd ounterlokwise, push the end p into the ompressor. Continue rotting the flnge until the end p is ll the wy down ginst the ompressor ody. 4. To onfirm tht the onneting rod journl hs properly engged with the onneting rod, rotte the flnge until you feel resistne from the piston trying to ompress ir in the ylinder. 5. Apply Lotite 271 (P/N ) to the threds of the end p retining olts nd torque to 100 l. in. (11.5 Nm). 6. Apply Lotite 271 (P/N ) to the pulley retining olts. Torque to 190 l. in. (21.5 Nm) for GOLD pulley. Torque to 170 l. in. (19 Nm) for BLACK pulley. 7. Instll ompressor/lterntor elt. 8. Run engine to onfirm tht ompressor is funtioning orretly R1 DECEMBER 2000 Pge 3B-59

60 Air Compressor Flow Digrm ÎÎ ÎÎ d k e q r p f s o g t n h i v u l m j d -Air Inlet -Air Filter -Compressor Air Inlet d-air [79 ± 2 psi (544.0 ± 13.8 kp)] e -Fuel System Pressure Test Vlve f -#1 Fuel Injetor g-trker Vlve h-#3 Fuel Injetor i -Strord Fuel Ril j -#5 Fuel Injetor k -High Pressure Fuel [89 ± 2 psi (613.5 ± 13.8 kp)] l -#6 Fuel Injetor w k m-fuel Regultor [89 ± 2 psi (613.5 ± 13.8 kp)] n-#4 Fuel Injetor o-air Regultor [79 ± 2 psi (544.0 ± 13.8 kp)] p-#2 Fuel Injetor q-compressor Wter Inlet r -Port Fuel Ril s -Air Pressure Test Vlve t -Exess Air Return to Air Plenum u-exess Fuel Return to VST v -40 psi Chek Vlve w-wter Inlet to Fuel Ril Pge 3B R1 DECEMBER 2000

61 Air Compressor Pressure Test DIRECT FUEL INJECTION Instll Pressure Guge Assemly A1/A2/A3 to fuel ril pressure test vlves. Strord ril hs fuel pressure test vlve. Port fuel ril hs ir pressure test vlve. *NOTE: After 15 seonds of rnking engine with strter motor, ir pressure guge should indite 79 ± 2 psi (544.0 ± 13.8 kp) nd fuel pressure guge should indite 89 ± 2 psi (613.5 ± 13.8 kp). d -Air Pressure Guge (Should Indite 79 ± 2 psi (544.0 ± 13.8 kp) -Fuel Pressure Guge (Should Indite 89 ± 2 psi (613.5 ± 13.8 kp) -Fuel Pressure Test Vlve d-air Pressure Test Vlve R1 DECEMBER 2000 Pge 3B-61

62 FUEL PRESSURE AND AIR PRESSURE TROUBLESHOOTING CHART PROBLEM CORRECTIVE ACTION Fuel Pressure nd Air Pressure re Both Low 1. Inspet ir ompressor ir intke (ir filter in flywheel over) for lokge. 2. Remove ir ompressor ylinder hed nd inspet for suffing of ylinder wll. Inspet for roken reeds nd/or reed stops. 3. Trker Vlve Remove nd inspet diphrgm for uts or ters nd set dmge on diphrgm nd ril. 4. Air Regultor Remove nd inspet diphrgm for uts or ters on diphrgm nd ril. Fuel Pressure Low or Fuel Pressure Drops while Running (Air Pressure Remins Norml) 1. Eh time key is turned to the RUN position, oth eletri pumps should operte for 2 seonds. If it they do not run, hek 20 mpere fuse nd wire onnetions. 2. If pumps run ut hve no fuel output, hek vpor seprtor (remove drin plug) for fuel. 3. If no fuel present in vpor seprtor, hek fuel/ wter seprtor for deris. Chek rnkse mounted fuel pump for output. 4. Chek high pressure pump mperge drw. Norml drw is 6-9 mperes; if drw is elow 2 mperes, hek fuel pump filter (se of pump) for deris. If filter is len, reple pump. If mperge is ove 9 mperes, pump is defetive reple pump. Chek low pressure output 6-9 psi. Chek low pressure eletri fuel pump mperge drw. Norml drw is 1-2 mperes; if drw is elow 1 mpere, hek for lokge etween pump inlet fitting nd vpor seprtor tnk. If mpere drw is ove 2 mperes, reple pump. 5. Fuel Regultor Remove nd inspet diphrgm for uts or ters. Fuel Pressure High nd Air Pressure is Norml 1. Stuk hek vlve in fuel return hose. 2. Deris loking fuel regultor hole. 3. Fulty pressure guge Fuel nd Air Pressure Higher thn Norml 1. Deris loking ir regultor pssge. 2. Air dump hose (ril to ir plenum) loked/ plugged. Pge 3B R1 DECEMBER 2000