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

Transcription

1 Tle of Contents FUEL SYSTEM Section 3B - Fuel Injection FUEL INJECTION Specifictions B-2 Specil Tools B-3 Notes: B-5 Fuel Mngement System B-6 Vpor Seprtor Components B-10 Electronic Fuel Injection (EFl) System B-14 Introduction B-14 Using the Test Procedures B-14 EFI System Tests B-14 Sfety Precutions B-14 Fuel Injection System Function B-15 Preliminry Checks B-15 Ignition Sprk Check B-15 Electronic Fuel Injection Set Up B-16 Fresh Qulity Fuel B-16 Low Bttery Voltge B-16 Fuel Flow Digrm B-17 Fuel Flow Component Description B-18 Pulse Fuel Pump B-18 Wter Seprting Filter B-18 Vpor Seprtor B-18 Finl Filter B-18 Electric Fuel Pump (Inside Vpor Seprtor) B-18 Fuel Injectors B-18 Fuel Pressure Regultor B-18 Fuel Lift Pump B-19 EFI Electricl Components B-19 EFI Fuel Mngement (Low Pressure Fuel Route) B-21 EFI Fuel Mngement (High Pressure Fuel Route) B-22 Fuel Ril Electricl/Fuel Determintion B-23 EFI System Test Procedures B-24 Fuel Guge Connection/Pressure Test.. 3B-24 Vpor Seprtor Fuel Delivery Test B-25 Pulse Fuel Pump Delivery Test B-26 Wter Seprting Filter Inspection B-27 Vpor Seprtor Flot Test B-28 Electric Fuel Pump Inlet Filter Check nd De-Pressurizing EFI System Procedures 3B-29 Pressure Regultor Test B-31 Electric Fuel Pump Voltge/Pressure Test 3B-32 Injector Electricl Hrness Test B-33 Injector Lod Test B-34 Fuel Ril Assemly Lekge Test B-34 Air Temperture Sensor nd Hed Temperture Sensor Test B-35 Detontion Control System Test B-36 Throttle Position Sensor Test B-37 MAP Sensor Test B-38 Prolem Dignosis B-39 Engine Hed Temperture Sensor Removl 3B-42 Engine Hed Temperture Sensor Instlltion B-42 EFI System Clening nd Inspection B-43 Clening B-43 Inspection B-43 Fuel Mngement Assemly Removl B-44 Fuel Ril Removl B-48 Fuel Ril Instlltion B-50 Reed Block Assemly Removl B-52 Reed Block Assemly Instlltion B-52 Air Temperture Sensor Removl B-53 Air Temperture Sensor Instlltion B-53 Mnifold Asolute Pressure (MAP) Sensor Removl B-53 Mnifold Asolute Pressure (MAP) Sensor Instlltion B-53 Throttle Plte Assemly Removl B-54 Throttle Plte Assemly Instlltion B-54 Vpor Seprtor Disssemly B-54 Vpor Seprtor Ressemly B-55 Air Plenum Instlltion B-57 Vpor Seprtor (VST) Instlltion B-58 Wter Seprting Filter Assemly Removl B-59 Wter Seprting Filter Assemly Instlltion B-59 Throttle Position Sensor Removl B-60 Throttle Position Sensor Instlltion B-60 Oil Reservoir Removl B-61 Oil Reservoir Instlltion B-61 Fuel Pressure Regultor Removl B-62 Fuel Pressure Regultor Disssemly.. 3B-63 Fuel Pressure Regultor Ressemly... 3B-63 3 B DECEMBER 2001 Pge 3B-1

2 Specifictions FUEL INJECTION Idle RPM Wide Open Throttle (WOT) RPM Flot Adjustment (Vpor Seprtor) Flot Level Injectors All Models (Quntity) Injectors re Crnk Angle Driven y ECM #1 Cylinder #2 Cylinder #3 Cylinder #4 Cylinder #5 Cylinder #6 Cylinder Line Injectors Injector Resistnce Electric Fuel Pump Resistnce Electric Fuel Pump Amperge Drw 1050 ± Fctory 6 RED + BRN Leds RED + WHT Leds RED + ORG Leds RED + YEL Leds RED + LT. BLUE Leds RED + PUR Leds 41 psi 45 psi (283 kp 310 kp) 12.3 ohms ± 0.5 ohms 0.7 ± 0.3 ohms 4 mperes ± 0.5 mperes Pge 3B DECEMBER 2001

3 Specil Tools FUEL INJECTION 1. Fuel Pressure Guge A3() or Fuel Pressure Guge A1() Digitl Dignostic Terminl (DDT) T Softwre Crtridge A2 4. DDT Reference Mnul DECEMBER 2001 Pge 3B-3

4 5. Adptor Hrness A5 (use with DDT) 6. Remote Strter Switch A1 7. DMT 2000 Digitl Tchometer Multi-meter P/N A1 8. Inductive Timing Light Sprk Gp Tester T 10. Strp Wrench A Pge 3B DECEMBER 2001

5 11. Tmper Proof Torx Screw Set FUEL INJECTION 12. Sprk Plug Led Extensions A Notes: DECEMBER 2001 Pge 3B-5

6 Fuel Mngement System Pge 3B DECEMBER 2001

7 Fuel Mngement System TORQUE REF. NO. QTY. DESCRIPTION l-in l-ft Nm. 1 1 AIR PLENUM 2 1 SENSOR MAP 3 1 BRACKET 4 1 SCREW (M6 x 16) O-RING 6 1 THROTTLE BODY ASSEMBLY 7 1 LEVER Throttle 8 4 SCREW (M6 x 40) SENSOR ASSEMBLY Temperture O RING 11 1 GASKET Plenum 12 2 CLAMP 13 4 SCREW(#10 24) SCREW (M6 x 25) WASHER 16 2 BRACKET Fuel Ril 17 4 GROMMET 18 4 BUSHING 19 1 FUEL RAIL 20 4 SCREW (#8 32 x 0.380) PLATE Fuel Ril 22 2 O RING 23 1 TUBE Fuel 24 2 O RING 25 7 RETAINER Injector 26 7 SCREW (#8 32 x 0.380) HARNESS ASSEMBLY Injectors 28 6 FUEL INJECTORS (With O Rings) SCREW ( x 0.880) PLATE Adptor 31 1 GASKET Inlet 32 6 REED BLOCK ASSEMBLY 33 1 RETAINER Fitting 34 1 SCREW (#10 24 x 0.375) O RING 36 1 FITTING Elow (90 Degree) 37 1 CLAMP (18.3) 38 1 HOSE Fuel Supply 39 1 PUMP ASSEMBLY Oil 40 1 FITTING Elow (90 Degree) CABLE TIE (4 in.) (10.2 cm.) 42 1 HOSE (34 in.) (86.4 cm.) 43 3 BUSHING 44 3 GROMMET DECEMBER 2001 Pge 3B-7

8 Fuel Mngement System Pge 3B DECEMBER 2001

9 Fuel Mngement System TORQUE REF. NO. QTY. DESCRIPTION l-in l-ft Nm WASHER 46 3 SCREW (M8 x 30) CABLE TIE (8 in.(20.3 cm.) 48 1 TUBING (24 in.) (60.9 cm.) 49 1 HOSE (28 in.) (71 cm.) 50 1 CONDUIT (7 in.) (17.8 cm.) 51 1 BEARING 52 1 CAM Throttle 53 1 BUSHING 54 1 BALL Threded 55 1 Screw (M8 x 40) BUSHING SCREW ( x 1.50) DECEMBER 2001 Pge 3B-9

10 Vpor Seprtor Components Pge 3B DECEMBER 2001

11 Vpor Seprtor Components TORQUE REF. NO. QTY. DESCRIPTION l. in. l. ft. N m 1 VAPOR SEPARATOR ASSEMBLY 1 1 COVER KIT 2 1 GASKET 3 1 SEAL 4 1 BALL (0.125 Dimeter) 5 1 VALVE (Dignostic) CAP Vlve 7 1 FITTING (Elow) (Pressed in) 8 1 FILTER 9 1 FITTING KIT (Stright) O RING 11 1 O RING 12 1 WIRE ASSEMBLY 13 1 FITTING (Elow) FITTING (Elow) PLUG ( ) 16 1 CONNECTOR CAP Fitting 18 2 CAP Fitting 19 1 REGULATOR KIT 20 1 O RING KIT 21 1 WASHER (Ruer) 22 1 WIRE ASSEMBLY (Ground) 23 SCREW (M5 x 0.8) (2 Ech) (Regultor) SCREW (M5 x 0.8) (1 Ech) (Ground Wire) 24 3 SCREW (M6 x 16) BRACKET Fuel Pump Mount 26 1 CAP Fitting 27 7 SCREW AND WASHER (#8 32 x 0.750) SCREW BAFFLE Fuel 30 1 PUMP KIT Fuel 31 1 SEAL 32 1 FLOAT KIT 33 1 SHAFT Flot 34 1 VALVE/SEAT KIT Inlet 35 1 SCREW FILTER KIT Fuel 3/4 Turn fter Gsket Contct 37 1 PROBE Wter Sensing BODY 39 1 SEAL 40 1 PLUG KIT ( ) O RING DECEMBER 2001 Pge 3B-11

12 Vpor Seprtor Components Pge 3B DECEMBER 2001

13 Vpor Seprtor Components TORQUE REF. NO. QTY. DESCRIPTION l. in. l. ft. N m 42 3 BUSHING 43 3 GROMMET 44 3 WASHER 45 3 SCREW (M8 x 35) SCREW (M6 x 10) (Ground Wire) CLAMP (18.3) 48 1 CLIP Plug Mount 49 1 DECAL (Wrning) 50 1 DECAL Ignition Protection DECEMBER 2001 Pge 3B-13

14 Electronic Fuel Injection (EFl) System Introduction The trouleshooting informtion provided here consists of preliminry checks (checks to e followed efore proceeding with EFI tests), digrms (fuel flow nd electricl wiring), component description (from digrms), flow chrts (low pressure fuel delivery, high pressure fuel delivery, fuel delivery vs. electricl delivery), prolem dignosis, nd series of test nd check procedures tht will help isolte prolems ssocited with the fuel injection system. Ech test/check (listed) cn e completed without mjor fuel system disssemly. Using the Test Procedures EFI System Tests Sfety Precutions Red the entire test efore eginning to perform outlined procedures. Study the RESULTS mteril prior to testing. This will help in determining tht ech test is providing desired results. EFI Electricl System nd ECM Check Fuel Guge Connection/Pressure Test Vpor Seprtor Fuel Delivery Test Vpor Seprtor Flot Test Wter Seprting Filter Flow Test Pulse Fuel Pump Delivery Test Finl Filter Check Fuel Pressure Regultor Test Electric Fuel Pump Test Injector Electricl Test Injector Fuel Delivery Test Injector Operting Test Induction Mnifold Lek Check Sensor Tests CAUTION Alwys use pproved sfety glsses or goggles when working on pressurized fuel systems. DANGER Motor fuels re extremely flmmle. Do not show open sprks or flmes when working ner fuel systems. WARNING To void potentil fire hzrds, use extreme cution when connecting nd disconnecting fuel line connections nd test dptors. Do not llow fuel to spill on hot engine prts or on live electricl connections. Pge 3B DECEMBER 2001

15 Wipe up fuel spills immeditely. CAUTION CAUTION FUEL INJECTION Depressurize fuel system prior to opening line connections or removing fuel system components. DANGER Perform the tests in this section in well ventilted re to void eing overcome y fuel vpors or poisonous exhust gses. Fuel Injection System Function Preliminry Checks Ignition Sprk Check Fuel is delivered directly to the engine y wy of fuel injectors. These injectors re provided with constnt supply of fuel (41 to 45 psi; 283 to 310 kp) delivered to the fuel ril. The injectors re opened nd closed electroniclly y the Electronic Control Module (ECM). The ECM receives input signls from vrious sensors in the EFI system which in turn trnsmits controlling outputs (open/close) to the injectors. The length of time the injectors sty open is considered pulse width. The pulse width will widen (richer) or nrrow (lener) depending on signls ECM receives from sensors, to llow efficient opertion t ll speeds nd conditions. IMPORTANT: The following preliminry steps MUST BE FOLLOWED efore ttempting EFI prolem dignosis. Purpose: This test determines if the ignition system is delivering usle sprk to the sprk plugs. By performing this test, the prole cuse cn e isolted to either the ignition system or fuel system. 1. Disconnect ll sprk plug wires from sprk plugs. 2. Connect sprk gp tester Quicksilver ( T) to good ground on engine. Connect Sprk Plug Extensions ( A1) etween tester nd sprk plug leds. 3. Connect Remote Strter Switch Quicksilver ( A1) to strter solenoid.. Connect RED led from switch to lrge positive (+) terminl with RED nded cle ttched [(+) cle from ttery].. Connect BLACK led from switch to smll terminl with YELLOW/RED led ttched. 4. Turn ignition key switch to the ON position. OFF ON START 5. Look t sprk gp tester viewing port for presence of good qulity sprk. A stedy, lue sprk should e present t ech sprk plug wire. If good sprk is present, prolem my not e ignition relted. If good sprk is not present, prolem my e ignition relted. Trouleshoot ignition system. Refer to pproprite ignition section in this service mnul DECEMBER 2001 Pge 3B-15

16 Electronic Fuel Injection Set Up Fresh Qulity Fuel IMPORTANT: Follow EFI Synchronizing/Adjustment section 2C efore ttempting tests on EFI system. EFI set up procedures must e followed efore tests on system re performed (refer to Section 2C). Improper set up cn result in poor engine performnce (i.e. uncontrollle idle speeds, len sneezing, low power during ccelertion or engine will simply not run.) Filure to properly set up the EFI system cn led to misdirections in solving simple prolems in the EFI system. Low Bttery Voltge Using remote fuel tnk contining mjor rnd of premium unleded gsoline, test run the outord to eliminte ny prolems relted to restricted fuel supply (clogged lines, mlfunctioning nti-siphon vlve, etc.) nd/or mrginl gsoline. Low ttery voltge cn cuse EFI system to deliver fuel in n inconsistent mnner. Inspect ttery connections nd chrging system, refer to Section 2B. The EFI system requires sustntil mount of voltge to function properly. Operting engine t low RPM for n extended period of time while operting numerous electricl ccessories cn cuse low voltge. Pge 3B DECEMBER 2001

17 Fuel Flow Digrm FUEL INJECTION c q p o n m d l e j k r i h f g Fuel Ril -Reed Block Plte Assemly c-fuel Injectors (6) d-pulse Fuel Pump e-fuel/wter Seprtor f-wter Sensor g-from Fuel Tnk h-vpor Seprtor i-electric Fuel Pump Filter j-electric Fuel Pump k-vpor Seprtor Flot l-needle nd Set m-vpor Seprtor to Flywheel Cover Vent Hose n-finl Filter o-fuel Ril Pressure Port p-fuel Pressure Regultor q-fuel Pressure Regultor Vent Hose r-fuel Lift Pump DECEMBER 2001 Pge 3B-17

18 Fuel Flow Component Description Pulse Fuel Pump (d) Wter Seprting Filter (e) Vpor Seprtor (h) Finl Filter (n) Opertes through lternting crnkcse pressure to deliver fuel through the wter seprting filter to the vpor seprtor. Fuel Idle: 2 3 psi ( kp) [Minimum 1 psi (6.9 kp)]. Fuel Wide-Open-Throttle: 6 8 psi ( ) [Minimum: 4 psi (27.6 kp)]. Protects the fuel injectors from wter nd deris. The filter contins sensor proe which monitors wter level in the filter. If wter is ove the sensor proe, the wrning horn will egin series of eeps. Fuel reservoir which continuously lends nd circultes fresh fuel nd oil.. Fuel Inlet Fresh fuel delivered from the wter seprtor y the crnkcse mounted pulse fuel pump. The mount of fuel llowed to enter the vpor seprtor is controlled y needle/set nd flot ssemly mounted in the cover of the vpor seprtor.. Oil Inlet Oil delivered y ECM controlled oil pump. c. Fuel Pressure Regultor Inlet Unused fuel/oil mixture eing recirculted from the pump ck into the vpor seprtor. Locted ove the electric fuel pump in the rss fuel fitting. The filter collects deris nd prevents them from flowing into the fuel ril nd injectors. Electric Fuel Pump (Inside Vpor Seprtor) (j) Fuel Injectors (c) Runs continuously while providing fuel in excess of engine demnds. The excess fuel is circulted through the fuel ril to the fuel pressure regultor nd ck to the vpor seprtor. Norml fuel pressure is psi (283 to 310 kp). Locted on the fuel ril. The injector vlve ody consists of solenoid ctuted needle nd set ssemly. The injector receives signls from the EFI Electronic Control Module. These signls determine how long the needle is lifted from the set (pulse width) llowing mesured fuel flow. The pulse width will widen (richer) or nrrow (lener) depending on vrious signls received from sensors connected to the EFI ECM. The ECM receives signl from the crnk position sensor to fire ech injector ccordingly. A 12 wire hrness connects the fuel injectors to the ECM. The RED wire is t 12 volts nd connects to ll injectors. The BLUE, YELLOW, WHITE, BROWN, PURPLE nd ORANGE wires ech go to individul injectors nd re normlly t 12 volts for zero differentil. To fire the injectors this voltge is rought down to ner ground creting potentil cross the injectors. Fuel Pressure Regultor (p) Locted on top of the vpor seprtor nd is continuously regulting fuel pressure produced y the electric fuel pump. The electric pump is cple of producing 90 psi (621 kp) of fuel pressure. The pressure regultor limits fuel pressure t the injectors to 41 to 45 psi (283 to 310 kp). Pge 3B DECEMBER 2001

19 Fuel Lift Pump (r) FUEL INJECTION Electric pump tht lifts fuel from the ot fuel tnk to the engine pulse fuel pump. This electric pump is protected y 3 mpere fuse. EFI Electricl Components ELECTRONIC CONTROL MODULE (ECM) The ECM is continully monitoring vrious engine conditions (engine temperture, engine detontion control, engine throttle opening nd climte conditions (induction ir temperture, rometric pressure nd ltitude level) needed to clculte fuel delivery (pulse width length) of injectors. The pulse width is constntly djusted (rich/len conditions) to compenste for operting conditions, such s crnking, cold strting, climte conditions, ltitude, ccelertion nd decelertion, llowing the outord to operte efficiently t ll engine speeds. 12 Volt Bttery - The 12 volt ttery provides power to the ECM through the min power rely. IMPORTANT: When disssemling EFI System DISCONNECT BATTERY CABLES. In the strt position, injector pulse widths re incresed s engine hed temperture is reduced to provide dequte fuel for quick strt up. Fuel Injectors - A 12 wire hrness connects the fuel injectors to the ECM. The red wire is t 12 volts nd connects to ll injectors. The BLUE, YELLOW, WHITE, BROWN, PUR- PLE nd ORANGE wires ech go to individul injectors nd re normlly t 12 volts for zero differentil. To fire the injectors this voltge is rought down to ner ground creting potentil cross the injectors. Electric Fuel Pump - The ECM contins fuel pump driver circuit tht provides power to the electric fuel pump. The fuel pump does not hve its negtive terminl ( ) BLACK/RED wire grounded to the pump housing. The fuel pump positive terminl (+) RED wire nd the negtive terminl ( ) re t 12 volts with the ignition switch in the off position for zero differentil. When the pump is on, the negtive terminl is rought down to ner ground (i.e. 1.5 volts). SENSOR INTERACTION WITH THE ECM IMPORTANT: DO NOT run engine for extended periods of time with sensors disconnected or ypssed (shorted). Serious engine dmge my result. AIR TEMPERATURE SENSOR The ir temperture sensor trnsmits mnifold solute ir temperture, through full RPM rnge, to the ECM. As ir temperture increses sensor resistnce decreses cusing the ECM to decrese fuel flow (lener mixture). Disconnecting the ir temperture sensor or temperture sensor filure will cuse the ECM to revert to defult temperture source of 32 F (0 C). MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR The mp sensor is non-servicele sensor mounted on top of the ir plenum. The MAP sensor is used to sense chnges in mnifold solute pressure. The MAP sensor is functioning through the full RPM rnge nd is continully signling induction mnifold pressure redings to the ECM. The ECM in turn determines fuel flow s signls re received. The MAP sensor s opertion cn e monitored using the DDT. With the engine running, s the throttle is incresed or decresed, the MAP sensor s DDT disply should chnge. If no chnge occurs, MAP sensor is not functioning properly DECEMBER 2001 Pge 3B-19

20 ENGINE HEAD TEMPERATURE SENSOR (PORT AND STARBOARD CYLINDER HEAD) The Engine Hed Temperture Sensors provide the ECM signls relted to engine temperture to determine level of fuel enrichment during engine wrm up. The ECM is receiving informtion t ll engine tempertures. Disconnecting the temperture sensors or temperture sensor filure will cuse the ECM to revert to defult temperture source of 32 F (0 C). The temperture sensors cn e monitored with the DDT. THROTTLE POSITION SENSOR (TPS) The TPS trnsmits throttle ngle informtion to the ECM which vries the injector pulse width ccordingly. Should the sensor fil, the dsh mounted CHECK ENGINE light will illuminte nd the wrning horn will sound. RPM will e reduced y the ECM. The TPS is not djustle. TPS settings cn e monitored with the Digitl Dignostic Terminl. Voltge chnge should e smooth from idle to wide open throttle. If voltge chnge is errtic, the TPS is defective. IGNITION SYSTEM Throttle Position W.O.T vdc vdc WATER SENSING SYSTEM The system consists of wter seprting fuel filter (port side powerhed) nd sensing proe (ottom of filter). WATER SENSING SYSTEM FUNCTION 1. The filter seprtes the ccumulted wter from the fuel. 2. A voltge is lwys present t sensing proe. When wter reches top of proe it completes the circuit to ground. 3. The completed circuit ctivtes the wrning horn which intermittntly sounds. The system cn e tested y disconnecting the TAN wire from sensor proe nd holding to good engine ground connection for 10 seconds. Pge 3B DECEMBER 2001

21 EFI Fuel Mngement (Low Pressure Fuel Route) FUEL INJECTION Instll fuel pressure guge on to VST pressure port. Plce ignition switch in OFF position 30 seconds efore testing. Plce ignition switch in ON position nd note pressure within 30 seconds (41 to 45 psi; 283 to 310 kp). Pump does not run No or low fuel pressure Fuel pressure ove 45 psi (310 kp) Follow High Pressure Fuel Route Flow Chrt. Perform Vpor Seprtor Fuel Delivery Test. Follow High Pressure Fuel Route Flow Chrt. Results No or little fuel flow from vpor seprtor. Results Fuel flows freely from vpor seprtor. Inspect flot system of vpor seprtor. Follow High Pressure Fuel Route Flow Chrt. Check fuel/wter seprtor. Perform Wter Seprting Filter Flow Test. Results Low or no fuel flow from wter seprting inlet hose. Reconnect hose. Results Fuel flows freely from wter seprting filter inlet hose. Reconnect hose. Perform Pulse Fuel Pump Delivery Test. Replce wter seprting filter. Results Fuel flows freely from pulse pump inlet hose. Results No fuel flow to pulse fuel pump. See pulse pump removl nd inspection section 3A. Locte ll frgments of filed pump efore ressemly. Check for restrictions, holes or loose connections from fuel supply DECEMBER 2001 Pge 3B-21

22 EFI Fuel Mngement (High Pressure Fuel Route) Perform low pressure checks efore performing checks on high pressure route. Instll fuel pressure guge (P/N A3) or (P/N A1) on to mnifold pressure port. Plce ignition switch in OFF position 30 seconds efore testing. Plce ignition switch in ON position nd note pressure (41 to 45 psi; 283 to 310 kp). Fuel pressure ove 45 psi (310 kp) No or low fuel pressure Pump does not run Clogged or fulty fuel pressure regultor remove nd replce. Results Perform Finl Filter Check Perform Electric Fuel Pump Voltge Test. Results Finl filter OK. Finl filter clogged. Perform pump inlet filter check Inlet filter clogged. Clen or replce finl filter. Inlet filter OK. Clen or replce finl filter. Perform Fuel Pressure Regultor Test. Results Results Stedy strem of fuel [pressure still elow 41 psi (283 kp). Low or no fuel flow. Replce fuel regultor. Perform Electric Fuel Pump Voltge Test. Results Results Voltge from ECM driver circuit OK. Low or inconsistent voltge from ECM driver circuit. Replce fuel pump. Replce ECM. Pge 3B DECEMBER 2001

23 Fuel Ril Electricl/Fuel Determintion FUEL INJECTION Perform ll preliminry checks pge 3B-11. Adequte fuel pressure (41 to 45 psi; 283 to 310 kp) follow Low/High Fuel Route Flow Chrts. Run engine t or ove 2000 rpm nd with DDT, perform cylinder lod test. Results No RPM chnge on cylinder(s), indicting prolem in cylinder(s). Results RPM decreses (on ech cylinder). Perform Fuel Injector lod test. Fuel delivery OK. Results Results Fuel Injector hs udile click. Fuel Injector does not hve udile click. Injector is functioning properly Perform Ignition Coil lod test. Defective injector or roken circuit to injector. Perform Induction Mnifold Disssemly nd inspection. Results Results Wek or no ignition sprk Ignition sprk OK Replce defective coil, sprk plug or wiring Perform compression check on prolem cylinder. Results Results Low or no compression on cylinder. Compression OK. Inspect cylinder ore. Refer to Section 4 for disssemly. NOTE: Injector filters must e inspected prior to ressemly. Check: 1) Dmged reeds 2) End cp sels 3) Crnkcse split line lek 4) Crnkshft seling rings DECEMBER 2001 Pge 3B-23

24 EFI System Test Procedures NOTE: A clogged finl filter locted in fitting ove fuel pump will cuse low fuel pressure redings t the fuel pressure port. Remove fuel fitting nd inspect finl filter. Clen nd/or replce finl filter s necessry. -Finl Filter Fuel Guge Connection/Pressure Test IMPORTANT: When checking fuel pressure while engine is running, fuel pressure my fluctute. Fuel pressure fluctution [i.e. 41 to 45 psi (283 to 310 kp)] is common, s the regulted pressure is differentil etween fuel ril nd mnifold vcuum. Purpose: Checking fuel mnifold pressure ensures tht fuel under usle pressure is ville to the fuel injectors. This test isoltes the prole cuse s either fuel delivery or EFI electricl system filure. IMPORTANT: Fuel pressure should e monitored through full RPM rnge to determine fuel supply prolems t high engine speeds. 1. Connect fuel pressure guge to VST pressure port. c Pressure Port -Fuel Pressure Guge ( A1) c-direct fuel into suitle continer Pge 3B DECEMBER 2001

25 2. Turn ignition key switch to ON position. FUEL INJECTION OFF ON START 3. Operte electric fuel pump (ignition key on). NOTE: Fuel pump will only operte for pproximtely 2-4 seconds. By turning the key switch to OFF nd then ck to ON the pump will operte for 2-4 seconds more. 4. Tke reding on fuel pressure guge. Results: If pressure reding is 41 to 45 psi (283 to 310 kp), the electric fuel pump is providing fuel with enough pressure to e used y the injectors. Pump mlfunction is not the cuse of EFI troule. If fuel pressure is well elow 41 psi (283 kp), fuel delivery to electric fuel pump, fuel pump filure or other relted prolem exists. Inspect finl filter for deris. If fuel pressure is ove 45 psi (310 kp) go to fuel pressure regultor test. Vpor Seprtor Fuel Delivery Test Purpose: Verifying there is dequte fuel flow to the electric fuel pump (through full RPM rnge) will determine components in low pressure fuel system re functioning correctly. 1. Remove vpor seprtor drin plug nd plce clen continer under drin. 2. Prime fuel line primer ul. Results: Fuel should flow when plug is removed nd continue to flow s fuel lift pump is ctivted. If fuel flow is not present, inspect fuel lift pump, wter seprtor filter or VST flot nd needle vlve. If fuel flow is present, go to High Pressure Flow Chrt DECEMBER 2001 Pge 3B-25

26 Pulse Fuel Pump Delivery Test Purpose: This test will indicte pulse fuel pump is cple of supplying dequte fuel. 1. Plce emergency stop switch in OFF position to prevent engine from strting. 2. Remove fuel inlet hose from fuel/wter seprtor Inlet Fuel Hose to Fuel/Wter Seprtor 3. Turn ignition key switch to START nd operte strter motor for 10 to 20 seconds. Results: Fuel should flow freely from hose. Refer to Fuel/Wter Seprtor Inspection nd/or Vpor Seprtor Flot Test. If fuel does not flow from hose: 4. Remove inlet hose to pulse fuel pump nd put end into clen continer. 5. Key on nd off severl times to ctivte fuel lift pump. -Inlet Fuel Hose Pge 3B DECEMBER 2001

27 Results: If low or no fuel flow is present, inspect fuel hose for restrictions. Inspect nti-siphon vlve nd ot fuel tnk for proper fuel delivery. If fuel flow is present, remove, disssemle nd inspect pulse fuel pump. All frgments of filed pump must e locted efore ressemly. -Pulse Fuel Pump -Attching Screws Wter Seprting Filter Inspection Remove fuel/wter seprtor filter. Inspect filter for deris. Replce filter s required. 1. Plce emergency stop switch in OFF position to prevent engine from strting. 2. Remove vpor seprtor drin plug nd plce clen continer under drin. 3. Crnk engine over with strter. Results: If fuel flow is present, fuel is eing delivered to electric fuel pump. If fuel is not present, refer to Vpor Seprtor Flot Test DECEMBER 2001 Pge 3B-27

28 Vpor Seprtor Flot Test NOTE: If squeezing the primer ul in the Vpor Seprtor Fuel Delivery Test previous provides dequte fuel to the vpor seprtor, the vpor seprtor flot, needle nd set is functioning properly nd the following test does not need to e performed. Purpose: This test will indicte if flot is stuck in the up (closed) position. NOTE: If flot is stuck down, vpor seprtor will over flow cusing rich condition. 1. Plce emergency stop switch in OFF position to prevent engine from strting. 2. Turn ignition key switch to START position nd operte strter motor for 15 to 20 seconds. OFF ON START 3. Remove vpor seprtor drin plug nd plce clen continer under drin Results: If fuel flow is low or not present, remove, disssemle nd inspect flot ssemly. See vpor seprtor disssemly Pge 3B DECEMBER 2001

29 Electric Fuel Pump Inlet Filter Check nd De-Pressurizing EFI System Procedures FUEL INJECTION Purpose: Checking the inlet filter for ostructions, dmge etc. elimintes this component s possile source of restriction in the system. 1. De-pressurize EFI fuel system y wrpping clen cloth round pressure port vlve nd inserting tip of screwdriver into vlve, depressing vlve core. Let fuel drin from vlve. -Pressure Port -Drin Plug Remove drin plug from vpor seprtor nd llow fuel to drin into suitle continer DECEMBER 2001 Pge 3B-29

30 3. Remove 3 olts securing vpor seprtor ssemly to mnifold. -Bolts Tilt vpor seprtor ssemly out from mnifold nd remove 9 screws securing cover. 5. Remove vpor seprtor tnk from cover. 6. Pull downwrd to remove filter from fuel pump. -Inlet Filter Inspect filter for deris or dmge. Results: If filter is clogged with deris, clen filter with solvent nd compressed ir or replce filter. Ressemle vpor seprtor to mnifold nd recheck fuel pressure. If pressure is still elow 41 psi (283 kp), perform fuel Pressure Regultor Test. Pge 3B DECEMBER 2001

31 Pressure Regultor Test FUEL INJECTION NOTE: Low fuel pressure cn e cused y indequte fuel supply, defective electric fuel pump or fuel pressure regultor. Verify dequte fuel is eing supplied to the vpor seprtor. If fuel supply is proper, inspect finl filter inside outlet fuel fitting on vpor seprtor for deris. If filter is clen, perform mperge drw test on electric fuel pump. If mperge drw is within specifictions, replce fuel pressure regultor. Purpose: This test will determine if wek, plugged or open pressure regultor is cusing indequte fuel pressure in the system. 1. Connect pressure guge A1 to EFI test port A1 -Test Port Turn ignition key switch to ON position nd check fuel pressure reding on guge. If pressure reding is elow 41 psi (283 kp) replce regultor. OFF ON START DECEMBER 2001 Pge 3B-31

32 Electric Fuel Pump Voltge/Pressure Test NOTE: The Digitl Dignostic Terminl (DDT) cn implement lod test for the electric fuel pump. If the electric fuel pump does not pper to run, it is recommended tht the DDT lod test e performed first efore performing the following voltge test. Purpose: If insufficient electricl power is ville t the pump, no or low fuel pressure will e developed. 1. Disconnect electric fuel pump hrness connector. 2. Set volt meter to red ttery voltge nd connect lck test led to BLACK wire in the fuel pump connector, positive test led to positive wire (RED/BLUE) of fuel pump connector (engine hrness end) Fuel Pump Hrness Connector Positive test led to RED/BLUE wire nd Negtive test led to BLACK wire (engine hrness end) -3 Ampere Fuse for Fuel Lift Pump 3. Turn key to RUN position. Bttery voltge will e pplied to the RED/BLUE led for out 2 seconds. Results: If ttery voltge is not present, inspect ttery, ttery connections nd hrness for corrosion, dmge or loose connections. If correct ttery voltge is present, replce electric pump. NOTE: If electric fuel pump runs ut fuel pressure is low, perform mperge drw test on electric pump. Amperge drw should e 4 mperes ± 0.5 mperes. If mperge drw is high, replce pump. Pge 3B DECEMBER 2001

33 Injector Electricl Hrness Test FUEL INJECTION An injector lod test cn e performed using the Digitl Dignostic Terminl (DDT). An udile click will e herd ech time n injector is ctivted. If n injector does not respond to the lod test, n ohm test cn e mde on the hrness nd the injector(s). -Injector Hrness #1 Cylinder RED + BRN Leds #2 Cylinder RED + WHT Leds #3 Cylinder RED + ORG Leds #4 Cylinder RED + YEL Leds #5 Cylinder RED + LT. BLUE Leds #6 Cylinder RED + PUR Leds Injector Resistnce 12.3 ohms ± 0.5 ohms DECEMBER 2001 Pge 3B-33

34 Injector Lod Test An injector lod test cn e performed using the Digitl Dignostic Terminl (DDT). An udile click will e herd ech time n injector is ctivted. This test will verify tht ech injector is operting mechniclly, not tht ech injector is llowing the proper mount of fuel to enter ech cylinder. Refer to DDT Reference Mnul for test procedures. Fuel Ril Assemly Lekge Test Purpose: This test will determine if the supply tue or injector o-rings re leking or if n injector is stuck open. 1. Remove 4 screws securing throttle plte ssemly to ir plenum nd remove ssemly Screws -Throttle Plte Assemly 2. Put ignition key switch in ON position. Electric fuel pump should run for pproximtely 2 seconds. OFF ON START 3. While pump is running, oserve fuel ril. Results: If lekge is oserved, refer to Fuel Ril Removl. Replce o-rings nd/or injectors s required. Pge 3B DECEMBER 2001

35 Air Temperture Sensor nd Hed Temperture Sensor Test FUEL INJECTION Purpose: This test elimintes possiilities of improper fuel delivery relted to ir/hed temperture sensors. NOTE: Air/Hed Temperture Sensor functioning cn e monitored using the Digitl Dignostic Terminl (DDT). The Air Temperture sensor should indicte mient ir temperture. The Hed Temperture sensor should indicte cylinder hed wter temperture. The ECM will revert to defult temperture of 32 F (0 C) if it should lose either ir or hed temperture sensor signl. The sensors cn lso e tested using DMT2000 Digitl Multimeter A Air Temperture Sensor -Hed Temperture Sensor Disconnect temperture sensor hrness nd check continuity with digitl or nlog ohmmeter test leds etween oth connector pins. With engine t temperture (F ) indicted, ohm redings should e s indicted ±10%. There should e no continuity etween ech connector pin nd ground. 1. Disconnect nd remove temperture sensors from engine. 2. Connect DMT ( A1) to leds of sensor. 3. Plce sensor in ice wter while monitoring meter reding. Use chrt (elow) for reference. Results: Resistnce does not chnge inversely with temperture chnge. Replce defective temperture sensor. Resistnce chnges inversely with temperture chnge. Temperture sensor OK. Temperture Sensor Specifictions Fhrenheit Centigrde OHMS DECEMBER 2001 Pge 3B-35

36 Detontion Control System Test Temperture Sensor Specifictions Fhrenheit Centigrde OHMS Port Knock Sensor -Strord Knock Sensor Purpose: Determines whether the detontion sensor nd circuit locted in the ECM is functioning. 1. Plce outord in wter, connect Digitl Dignostic Terminl (DDT) to engine. NOTE: If either knock sensor is not functioning, #4 LED indictor light on DDT will e illuminted. 2. Strt engine, llow to wrm up. Using SPECIAL FUNCTIONS portion of DDT, ccess KNOCK OUTPUT LOAD TEST. Results: As throttle is dvnced nd engine is under lod (in ger), numericl vlue on DDT disply should increse. As throttle is retrded, numericl vlue should decrese indicting knock sensor/circuit is functioning. If numericl vlue does not chnge s throttle setting nd lod on engine vries, knock sensor or knock circuit in ECM is defective. Pge 3B DECEMBER 2001

37 Throttle Position Sensor Test FUEL INJECTION Throttle Position Sensor Purpose: Determines whether Throttle Position Sensor is functioning properly through the use of the Digitl Dignostic Terminl (DDT). The Throttle Position Sensor is not djustle. 1. Plce outord in wter, connect Digitl Dignostic Terminl (DDT) to engine. NOTE: If throttle position sensor is not functioning, #4 LED indictor light on DDT will e illuminted. 2. Strt engine, llow to wrm up. Using DATA MONITOR portion of DDT, ccess TPI VOLTS. Results: As throttle is dvnced, numericl vlue on DDT disply should increse. As throttle is retrded, numericl vlue should decrese. HEAT TEST With engine t idle, het the TPS (with hot ir gun) elow the electricl connection until wrm to the touch. Wtch for ny one or comintion of the following symptoms: RPM chnge Check engine light illumintion Momentry wrning horn signl TPS voltge vlue chnge (1/2 volt) on DDT NOTE: Excessive het will dmge TPS DECEMBER 2001 Pge 3B-37

38 PRESSURE TEST IMPORTANT: When testing TPS voltge, do not move the drive mechnism (rotor/ wiper). 1. Connect DDT nd rotte the key to the ON position. 2. Set DDT to red TPS voltge; expnd the screen to show Now/Min/Mx. NOTE: Test ccurcy is improved when TPS is t its lowest voltge reding; this my e idle or WOT depending on model yer. 3. Cler the minimum/mximum vlues on the DDT press the 0 utton. 4. Wtch the DDT redings while pressing elow the electricl connection point on the TPS cover. MAP Sensor Test -Press on cover elow electricl connection 5. Voltge reding should chnge: Less thn couple of digits (i.e v to 1.92 v) NOTE: Version 5.0 crtridge gives 3 deciml point (millivolts) ccurcy if elow 1 volt. Less thn 10 millivolts (i.e v to v) Replce ny TPS tht fils either test MAP Sensor Purpose: Determines whether the Mnifold Asolute Pressure (MAP) Sensor is functioning properly through the use of the Digitl Dignostic Terminl (DDT). 1. Plce outord in wter, connect Digitl Dignostic Terminl (DDT) to engine. NOTE: If MAP sensor is not functioning, #4 LED indictor light on DDT will e illuminted. 2. Strt engine, llow to wrm up. Using DATA MONITOR portion of DDT, ccess MAP PSI. Results: As throttle is dvnced, numericl vlue on DDT disply should increse. As throttle is retrded, numericl vlue should decrese indicting MAP sensor is functioning. If numericl vlue does not chnge s throttle setting vries, MAP sensor is defective. The ECM would revert to defult of pproximtely 14.7 PSI (ner se level) should it not receive signl from the MAP sensor. Pge 3B DECEMBER 2001

39 Prolem Dignosis FUEL INJECTION Condition Possile Source Action Engine Down On Power Or RPM Filed Ignition Coil Refer to Section 2 Electricl nd Ignition Tests. Poor Accelertion Idles Ok, Top Speed Ok Low Compression Broken Reed Fuel Delivery Prolem Fuel Ril Lek Vpor Seprtor Flooding Over, Engine Running Rich. Cylinder Hed Temperture Sensor Circuit Filed. Improper EFI Set Up. Wter Covering Idle Relief Exhust Ports. T.P.S. Filure. MAP Sensor Filure R.F.I. Prolem* Refer to Section 4 Power Hed. Inspect Reeds. Follow Low/High Pressure Fuel Route Flow Chrts nd Fuel Ril Electricl/Fuel Determintion Flow Chrt. Perform Fuel Ril Lek Test. Check for fuel coming out of vpor seprtor vent hose. Check cylinder hed temperture sensor. Refer to Section 2 Electricl nd Ignition for proper EFI set up procedures. Bots with extended trnsoms or low engine mount cn cuse engine to lod up on ccelertion. Refer to pge 3B-33. Refer to pge 3B-34. Instll BPZ8HS-10 Sprk Plugs DECEMBER 2001 Pge 3B-39

40 Condition Possile Source Action Poor Accelertion Idles Ok, Timing Not Advncing. Check Timing Advnce with DDT. Top Speed Ok (Continued) Engine Surges Between 4000 And 5000 RPM Intermittnt Ignition Coil Filure. Refer to Section 2A Electricl nd Ignition for tests. Engine Idles Ok But Stumles At Off Idle Speeds Finl Filter Clogging. T.P.S. Injector Connector Prolem. Vpor Seprtor Flooding Over. Injector Filter Clogged. Improper EFI Setup. Filed Ignition Coil. Filed Or Disconnected EFI Sensors. Fuel Delivery Prolem. Mnifold Fuel Lek. R.F.I.* Prolem. Perform Finl Filter Check. Check TPS Opertion with DDT Perform DDT Lod Test nd Ohms Test. Check for fuel coming out of vpor seprtor vent hose. Must e determined y elimintion; mechnicl, electricl nd lod tests Refer to Section 2C Electricl nd Ignition for proper EFI set up procedures. Refer to Section 2A Electricl nd Ignition Tests. Perform EFI sensor tests. Follow Low/High Pressure Fuel Route Flow Chrts nd Fuel Ril Electricl/Fuel Determintion Flow Chrt. Perform Induction Mnifold Lek Check. Instll BPZ8HS-10 Sprk Plugs. Engine Idles Rough (My Len Sneeze) Accelertion Ok; Full Throttle Ok Induction Mnifold Air Lek. MAP Sensor Filure. Improper EFI Setup. MAP Sensor Filure. Check mnifold cover gsket, mnifold to reed lock housing gsket nd reed lock housing to crnkcse gsket. Refer to pge 3B-34. Refer to Section 2C Electricl nd Ignition for proper EFI set up procedures. Refer to pge 3B-34. Pge 3B DECEMBER 2001

41 Condition Possile Source Action Ignition Coil Filure. Engine Idles Rough (My Len Sneeze) Accelertion OK; Full Throttle Ok. (continued) Engine Runs ut Slowly Drops RPM then Dies. Broken Reed. Restrictions in Fuel System etween Tnk nd Engine. FUEL INJECTION Refer to Section 2A Electricl nd Ignition Tests. Inspect Reed Assemly Instll remote gs tnk with fresh, high qulity fuel. Engine Stops for No Apprent Reson or Does Not Strt. Clogged Finl Filter. Pulse Fuel Pump Filure. Electric Fuel Pump Delivery Filure. Lift Pump Filure Bttery Underchrged. EFI Hrness Connections. Ignition System Filure. Pulse Fuel Pump Filure. Electric Fuel Pump Filure. ECM Filure. Perform Finl Filter Check. Follow Low Pressure Fuel Route Flow Chrt. Follow High Pressure Fuel Route Flow Chrt. Inspect 3 mp fuse, fuel filter nd pump output. Check ttery connections, under chrged ttery or worn out ttery. Check EFI hrness connector for improper connection. Refer to Section 2A Electricl nd Ignition Tests. Follow Low Pressure Fuel Route Flow Chrt. Follow High Pressure Fuel Route Flow Chrt. The DDT ( T2) will monitor informtion coming from sensors or switches to the ECM nd will indicte if the sensor or switch is defective. For more thorough nlysis of the ECM, refer to EFI Tester Mnul A2. Engine Stops for No Apprent Reson, ut will Restrt. Lift Pump Filure Inspect 3 mp fuse, fuel filter nd pump output. Restriction in Fuel System Check fuel pressure on fuel ril t the RPM tht filure occurs. *R.F.I. Rdio Frequency Interference. High voltge cn lter signls ECM receives from sensors cusing improper fuel delivery. Route ll sensor wires wy from high voltge leds (i.e. sprk plug leds) DECEMBER 2001 Pge 3B-41

42 Engine Hed Temperture Sensor Removl DIGITAL TEMPERATURE SENSOR 1. Disconnect wire hrness for PORT nd STARBOARD sensors -Port Digitl Temperture Sensor Strord Digitl Temperture Sensor Engine Hed Temperture Sensor Instlltion DIGITAL TEMPERATURE SENSOR 1. Instll sensors into cylinder heds. Torque sensors to 14 l. in. (1.6 Nm). 2. Reconnect sensor hrness connectors. Pge 3B DECEMBER 2001

43 EFI System Clening nd Inspection FUEL INJECTION Clening Inspection 1. Clen ll non-electricl metl prts using good grde solvent. 2. Use soft ristle rush for removing lrge ccumultions of dirt or grese nd oil. 3. Vrnish type coting of induction mnifold prts my e removed using cruretor clener. 4. Wiring hrnesses cn e wiped down with slightly solvent dmpened rg. 5. Clen ll fuel pssges in induction mnifold. 6. Dry ll components using clen lint free cloths tht re free of rsives such s metl shvings or dirt. 7. Compressed ir my e used to dry prts if the ir used is free of moisture nd unluricted. 1. Look t entire system for signs of n ovious prolem such s poor condition of wire insultion, leking fitting, crcked or loose hoses nd lines. 2. Look for fuel or oil leks wherever these fluids re used (i.e. fuel filter cp, fuel pump, vpor seprtor cp, etc.). 3. Check for signs of tmpering or use such s modifictions to wiring or hose routing. 4. Look t min connector etween engine hrness nd ECM ox for missing, corroded or ent contct pins nd socket. Check for dislodged grommet in ECM where hrness enters ox. 5. Look t ll sensors (throttle position, ir temperture nd wter temperture) connectors nd hrnesses for d connections or poor insultion conditions such s frying, stripping, crcks or signs of rsion wer. 6. Look for loose, missing or dmged mounting hrdwre such s stripped threds on screws. 7. Look t sensors for signs of wer or dmge such s crcks, chips, etc. 8. Look t filter housing for crcks, holes or other dmge. Check for secure mounting. 9. Look t vpor seprtor for leks, crcks, pitting or other dmge. 10. Check ll ruer mounting grommets for swelling ters, crcks or other conditions tht would render prts unservicele. 11. Check vpor seprtor flot for signs of fuel entry in the flot. Look t needle for wer of point. 12. Look t injectors for signs of plugging or looseness in fit with induction mnifold. 13. Look t throttle linkge for ends, kinking or inding. Check spring for kinks. 14. Inspect ll ruer sels nd gskets for swelling, crcks or slices tht would cuse improper seling DECEMBER 2001 Pge 3B-43

44 Fuel Mngement Assemly Removl CAUTION Fuel system must e led off prior to removl of fuel system components. NOTE: Use Fuel/Air Pressure Guge A1 to de-pressurize fuel system. 1. De-pressurize fuel system A Fuel Pressure Port -Fuel Pressure Guge A1 2. Plce suitle continer underneth vpor seprtor drin plug nd remove plug. -Drin Plug Pge 3B DECEMBER 2001

45 3. Disconnect the following hoses nd connectors: FUEL INJECTION c d g h f e -Fuel Hose from Pulse Pump to Fuel/Wter Seprtor -Fuel Hose from Fuel Lift Pump to Pulse Pump c-fuel Lift Pump Hrness Connector d-fuel Hose from Fuel Tnk to Fuel Lift Pump e-vst Vent Hose f-vst Output Fuel Hose g-fuel Pressure Regultor Vent Hose h-vst Oil Input Hose i-vst Electric Fuel Pump Hrness Connector i DECEMBER 2001 Pge 3B-45

46 4. Remove ground led etween VST nd ir plenum. 5. Disconnect throttle cm link rod nd the Throttle Position Sensor link rod. c Throttle Cm Link Rod - TPS Link Rod c- VST Ground Led 6. Remove 3 olts securing VST to ir plenum nd remove VST VST Attching Bolts Pge 3B DECEMBER 2001

47 7. Disconnect the following hoses nd connectors: FUEL INJECTION d c e g -Air Temperture Sensor -MAP Sensor c-fuel Regultor Hose d-engine Hrness 8. Disconnect oil pump electricl hrness. f e-oil Inlet Hose (plug to prevent lekge) f-oil Output Hose g-fuel Injector Hrness Connector -Electricl Hrness DECEMBER 2001 Pge 3B-47

48 9. Remove 12 olts securing ir mngement ssemly to crnkcse nd remove ssemly. -Bolts (12 ech) Fuel Ril Removl The fuel ril/injector/reed lock ssemly is ttched to the crnkcse ssemly plte y 4 screws. -Fuel Ril/Injector Assemly -Screws (4) Pge 3B DECEMBER 2001

49 1. Remove 4 screws to securing fuel ril/injector ssemly to reed lock ssemly Screws 2. Lift fuel ril ssemly from reed lock ssemly. 3. Inspect o-rings for cuts nd rsions. Replce if necessry. d c e -Fuel Injectors (6) -Fuel Ril Fuel Inlet Pipe c-o-rings d-fuel Ril e-reed Block Assemly DECEMBER 2001 Pge 3B-49

50 4. Individul fuel injectors nd fuel inlet pipe cn e removed from fuel ril y removing ttching screws. Use Tmper Proof Torx Screw Set to remove screws. -Fuel Injector Attching Screws -Fuel Inlet Pipe Attching Screw Fuel Ril Instlltion NOTE: Inspect ll o-rings for cuts nd rsions. Applying light oil to ll o-rings nd o-ring contct surfces on reed lock ssemly plte will ese instlltion of fuel ril ssemly. 1. Secure fuel injectors to fuel ril with tmper proof screws. Torque screws to 27 l. in. [3.0 Nm]. 2. Secure fuel inlet pipe to fuel ril with tmper proof screw. Torque screw to 65 l. in. [7.0 Nm] Fuel Injector Attching Screws [Torque to 27 l. in. (3.0 Nm)] -Fuel Inlet Pipe Attching Screw [Torque to 65 l. in. (7.0 Nm)] Pge 3B DECEMBER 2001

51 3. Apply light oil to ll o-rings nd o-ring contct surfces on reed lock ssemly plte to ese instlltion of fuel ril ssemly. d c e f f f f -Fuel Injectors (6) -Fuel Ril Fuel Inlet Pipe c-o-rings d-fuel Ril e-reed Block Assemly f-o-ring Contct Surfce Secure fuel ril ssemly to reed lock ssemly plte with 4 screws. Torque screws to 65 l. in. [7.0 Nm] Screws [Torque to 65 l. in. (7.0 Nm)] DECEMBER 2001 Pge 3B-51

52 Reed Block Assemly Removl 1. Remove 12 screws securing ir plenum to reed plte ssemly. 2. Remove 12 screws securing reed locks to reed plte ssemly. g f e d c -Screws (2 ech per reed lock) (M4x16) -Air Plenum c-screws (12 ech) (1/4x20x0.88) d-gsket e-adptor Plte f-gsket g-reed Block (6 ech) Reed Block Assemly Instlltion NOTE: The gsket etween the ir plenum nd the dptor plte hs seling ed which fces towrd the ir plenum during ssemly. Gskets my e reused if they do not show signs of ters, rsions or oil sturtion. Replce gskets if necessry. 1. Secure reed lock ssemly to dptor plte with 2 screws. Torque screws to 105 l. in. (11.8 Nm). 2. Secure ir plenum nd dptor plte/reed lock ssemly to cylinder lock crnkcse with 12 screws. Torque screws to 15 l. ft. (20 Nm). Pge 3B DECEMBER 2001

53 Air Temperture Sensor Removl Disconnect sensor hrness nd unscrew sensor. FUEL INJECTION -Temperture Sensor Hrness Air Temperture Sensor Instlltion Air Temperture Sensor 1. Crefully thred sensor into ir plenum. Torque sensor to 14 l. in. (1.6 Nm). 2. Reconnect sensor hrness. Mnifold Asolute Pressure (MAP) Sensor Removl 1. Disconnect MAP sensor hrness connector. 2. Remove sensor retining screw. c -MAP Hrness Connector -Retining Screw c-map Sensor Mnifold Asolute Pressure (MAP) Sensor Instlltion 1. Secure MAP sensor with screw. Torque screw to 80 l. in. (9.0 Nm). 2. Reconnect sensor hrness DECEMBER 2001 Pge 3B-53