FUEL SYSTEMS 3 C FUEL INJECTION SN 0G AND BELOW

Transcription

1 FUEL SYSTEMS 3 C FUEL INJECTION SN 0G AND BELOW

2 Tle of Contents Pge Speifitions C-1 Speil Tools C-1 Eletroni Control Moule (ECM) Assemly. 3C-2 Fuel Mngement System C-4 Fuel Pump n Fuel Filter C-8 Outor Powerhe View C-10 Eletroni Fuel Injetion (EFl) System C-10 Introution C-10 Using the Test Proeures C-10 EFI System Tests C-11 Sfety Preutions C-11 Fuel Injetion System Funtion C-11 Preliminry Steps C-12 Ignition Sprk Chek C-12 Eletroni Fuel Injetion Set Up C-12 Fresh Qulity Fuel C-13 Low Bttery Voltge C-13 Fuel Flow Digrm C-14 Fuel Flow Components C-15 EFI Eletril Digrm C-16 EFI Eletril Components C-17 EFI Fuel Mngement (Low Pressure Fuel Route) C-19 EFI Fuel Mngement (High Pressure Fuel Route) C-20 Fuel Ril Eletril/Fuel Determintion C-21 EFI System Test Proeures C-22 Fuel Guge Connetion/Pressure Test.. 3C-22 Vpor Seprtor Fuel Delivery Test C-23 Vpor Seprtor Flot Test C-23 Wter Seprting Filter Flow Test C-24 Pulse Fuel Pump Delivery Test C-25 Finl Filter Chek n De-pressurizing EFI System Proeures C-26 Pressure Regultor Test C-27 Eletri Fuel Pump Test C-28 Voltge Test Chrt C-30 Injetor Eletril Hrness Test C-31 Injetor Fuel Delivery Test C-31 Injetor Opertion Test C-32 Inution Mnifol Lek Chek C-33 Air Temperture Sensor Test C-34 Engine He Temperture Sensor Test.. 3C-35 Detontion Control System Test (200 Moels Only) C-35 Detontion Sensor Chek C-36 Detontion Control Moule Chek C-36 Throttle Position Sensor Test C-37 Mp Sensor Test C-37 Prolem Dignosis C-37 Pge Engine He Temperture Sensor Removl 3C-40 EFI Inution Mnifol Removl C-40 Wter Seprting Filter Assemly Removl C-41 Throttle Position Sensor/Temperture Sensor/ Fuel Injetor Hrness Disonnetions. 3C-41 Oil Reservoir Removl C-42 Finl Filter Assemly Removl C-42 Eletri Fuel Pump Removl C-43 Vpor Seprtor Removl C-43 Vpor Seprtor Disssemly C-44 Pressure Regultor Removl n Disssemly C-44 Vpor Seprtor Flot Removl C-44 Vpor Seprtor Component Ressemly 3C-46 Vpor Seprtor Flot Instlltion C-46 Mnifol Removl C-47 EFI Inution Mnifol Disssemly C-48 Air Temperture Sensor Removl C-48 Throttle Position Sensor Removl C-49 Fuel Ril Removl C-49 Fuel Ril Disssemly C-50 Fuel Injetor Removl n Disssemly. 3C-51 Injetor Hrness Removl C-52 Throttle Linkge Remove C-52 EFI System Clening n Inspetion C-53 Clening C-53 Inspetion C-53 Inution Mnifol Assemly C-54 Injetor Hrness Instlltion C-54 Fuel Injetor Assemly n Instlltion.. 3C-55 Fuel Ril Assemly C-55 Fuel Ril Instlltion C-56 Throttle Position Sensor Instlltion C-57 Air Temperture Sensor Instlltion C-57 EFI Inution Mnifol Instlltion C-58 Vpor Seprtor Instlltion C-60 Eletri Fuel Pump Instlltion C-60 Finl Filter Assemly Instlltion C-61 Oil Reservoir Instlltion C-62 Throttle Position Sensor n Temperture Sensor Fuel Injetor Hrness Connetions C-62 Wter Seprting Filter Assemly Instlltion C-63 ECM Instlltion C-63 Engine He Temperture Sensor Instlltion C-64 3C-0 - FUEL SYSTEMS R3 JUNE 2002

3 Speifitions Eletroni Fuel Injetion Ile RPM All Moels 650 ± 50 Wie Open Throttle RPM Moel 150XRI/175XRI Moel 200XRI Pro Mx/Super Mgnum 150/200/ Flot Ajustment (Vpor Seprtor) Flot Level Ftory Fuel Injetors All Moels (Quntity) Inner Swith Box Controls: #1 Primry Ciruit #3 Primry Ciruit #5 Primry Ciruit 6 #3 n #4 Injetors #5 n #6 Injetors #1 n #2 Injetors Line Injetors ECM Amperge Drw with Ignition Swith in the ON or RUN Position 36 psi 39 psi (248kP 269kP) 60 to 90 Millimperes Speil Tools Eletroni Fuel Injetion Tester A2 Fuel Pressure Guge R3 JUNE 2002 FUEL SYSTEMS - 3C-1

4 Eletroni Control Moule (ECM) ASSEMBLY Dieletri Grese ( ) 25 Liqui Neoprene ( ) 3C-2 - FUEL SYSTEMS R3 JUNE 2002

5 Eletroni Control Moule (ECM) Assemly TORQUE REF. NO. QTY. DESCRIPTION l. in. l. ft. N m 1 1 ECM ASSEMBLY 2 2 SPACER 3 1 CLIP 4 2 MOUNT owl mounting rket 5 4 WASHER 6 4 NUT CABLE ASSEMBLY 8 1 GROMMET 9 1 BUSHING 10 1 SCREW LOCKWASHER 12 1 WASHER 13 1 WATER SENSOR MODULE ASSEMBLY 14 1 WIRE ASSEMBLY (BLACK) 15 2 SCREW WASHER 17 1 WIRING HARNESS ECM n injetors 18 1 COUPLER RING 19 1 CABLE (150/175) 20 1 CAVITY PLUG STA-STRAP R3 JUNE 2002 FUEL SYSTEMS - 3C-3

6 Fuel Mngement System C-4 - FUEL SYSTEMS R3 JUNE 2002

7 Fuel Mngement System TORQUE REF. NO. QTY. DESCRIPTION l. in. l. ft. N m FUEL MANAGEMENT ASSEMBLY 1 1 THROTTLE BODY 2 1 COVER 3 1 RETAINING KIT 4 1 ROLLER m 5 6 FUEL INJECTOR 6 1 FILTER injetor 7 1 HARNESS KIT 8 1 FUEL FILTER KIT (DESIGN 1) 9 1 FUEL FILTER KIT (DESIGN 2) 10 1 FUEL FILTER KIT (DESIGN 3) 11 1 FUEL FILTER 12 1 SCREW filter over 13 1 LOCKWASHER over srew 14 1 HOSE (1/2 O.D.) 15 1 HOSE (1/8 O.D.) 16 1 HOSE (3/32 O.D.) 17 1 REGULATOR pressure 18 1 ELBOW KIT 19 1 GASKET pressure regultor 20 1 PLATE pressure regultor 21 AR SCREW COVER KIT 23 6 SCREW over to seprtor 24 6 LOCKWASHER over srew 25 1 SEAL vpor seprtor 26 1 O-RING n SEAL KIT 27 1 FLOAT VALVE KIT 28 1 FLOAT KIT 29 1 BODY KIT 30 1 CHECK VALVE 31 3 SCREW seprtor CHECK VALVE 33 1 SHUT-OFF VALVE 34 1 SEAL injetor mnifol 35 3 GROMMET 36 3 SPACER 37 3 WASHER (LARGE) 38 3 WASHER (SMALL) 39 2 CLAMP hose 40 1 TUBING (1-3/4 ) 41 2 STA-STRAP 42 1 BLANKET fuel pump 43 1 COVER fuel pump 44 4 SCREW LOCKWASHER SCREW WASHER 48 1 FUEL PUMP 49 1 HOSE 50 1 FUEL FILTER R3 JUNE 2002 FUEL SYSTEMS - 3C-5

8 Fuel Mngement System C-6 - FUEL SYSTEMS R3 JUNE 2002

9 Fuel Mngement System TORQUE REF. NO. QTY. DESCRIPTION l. in. l. ft. N m 1 1 LINK LEVER KIT 2 1 STOP SCREW KIT 3 1 FUEL RAIL 4 1 FUEL PIPE JOINT KIT SCREW KIT Fuel Ril LINK (DESIGN 1) 7 1 LINK (DESIGN 2) 8 1 SCHRADER VALVE KIT R3 JUNE 2002 FUEL SYSTEMS - 3C-7

10 Fuel Pump n Fuel Filter C-8 - FUEL SYSTEMS R3 JUNE 2002

11 Fuel Pump n Fuel Filter TORQUE REF. NO. QTY. DESCRIPTION l. in. l. ft. N m 1 1 FUEL PUMP ASSEMBLY 2 1 DIAPHRAGM KIT 3 2 CHECK VALVE ruer 4 1 GASKET oost 5 2 DIAPHRAGM 6 1 GASKET pulse 7 1 SPRING 8 1 CAP 9 2 CHECK VALVE 10 2 RETAINER 11 1 SPRING 12 1 CAP 13 1 GASKET se 14 1 BASE fuel pump 15 1 PLATE fuel pump 16 1 ELBOW 17 2 SCREW fuel pump SCREW fuel pump to rnkse HOSE pulse 20 1 ELBOW 21 1 TUBING 22 AR STA-STRAP fuel tuing 23 1 FUEL CONNECTOR 24 1 SCREW SEAL 26 2 TUBING 27 1 BASE fuel filter 28 2 SCREW fuel filter se DESIGN BRACKET 30 1 SCREW FITTING se 32 1 FUEL FILTER ASSEMBLY 33 1 PROBE wter sensing 34 1 FUEL FILTER BASE DESIGN SCREW (1/4-20 x 1-1/8 ) R3 JUNE 2002 FUEL SYSTEMS - 3C-9

12 Outor Powerhe View Engine port view of EFI omponents. g Engine stror view of EFI omponents. e h e f - Eletri Fuel Pump - Fuel Pressure Regultor - Vpor Seprtor - Engine He Temperture Sensor e - Lue Alert Moule f - Ile Stilizer Moule g - Detontion Control Moule (200) h - Detontion Sensor (200) Engine front view of EFI omponents Eletroni Control Moule (ECM) - ECM Hrness - Engine Hrness - Throttle Position Sensor Hrness e - Wter Seprting Filter Eletroni Fuel Injetion (EFl) System Introution The trouleshooting informtion provie here onsists of preliminry heks (heks to e followe efore proeeing with EFI tests), igrms (fuel flow n eletril wiring), omponent esription (from igrms), flow hrts (low pressure fuel elivery, high pressure fuel elivery, fuel elivery vs. eletril elivery), prolem ignosis, n series of test n hek proeures tht will help isolte prolems ssoite with the fuel injetion system. Eh test/hek (liste) n e omplete without mjor fuel system isssemly. Using the Test Proeures e - Eletroni Control Moule (ECM) - Finl Filter - Eletri Fuel Pump - ECU hrness e - Wter Sensing Moule Eh test proeure is ivie into three prts. The first prt PURPOSE tells wht this test will omplish. PROCEDURE provies etile steps for performing the test. RESULTS isusses the results otine y the test n how to orret the prolem or where to go next in the trouleshooting proeure if more informtion is neee. Re the entire test efore eginning to perform outline proeures. Stuy the RESULTS mteril prior to testing. This will help in etermining tht eh test is proviing esire results. 3C-10 - FUEL SYSTEMS R3 JUNE 2002

13 EFI System Tests EFI Eletril System n ECM Chek Fuel Guge Connetion/Pressure Test Vpor Seprtor Fuel Delivery Test Vpor Seprtor Flot Test Wter Seprting Filter Flow Test Pulse Fuel Pump Delivery Test Finl Filter Chek Fuel Pressure Regultor Test Eletri Fuel Pump Test Injetor Eletril Test Injetor Fuel Delivery Test Injetor Operting Test (Mnifol Cover Remove) Inution Mnifol Lek Chek (Mnifol Cover Remove) Sensor Tests Sfety Preutions CAUTION Alwys use pprove sfety glsses or goggles when working on pressurize fuel systems. DANGER Outor motor fuels re extremely flmmle. Do not show open sprks or flmes when working ner fuel systems. WARNING To voi potentil fire hzrs, use extreme ution when onneting n isonneting fuel line onnetions n test ptors. Do not llow fuel to spill on hot engine prts or on live eletril onnetions. CAUTION Wipe up fuel spills immeitely. CAUTION Depressurize fuel system prior to opening line onnetions or removing fuel system omponents. DANGER Perform the tests in this setion in well ventilte re to voi eing overome y fuel vpors or poisonous exhust gses. WARNING Disle the ignition system y grouning merury swith prior to performing ny tests tht require removl of the inution mnifol over. Fuel Injetion System Funtion Fuel is elivere iretly to the engine y wy of fuel injetors. These injetors re provie with onstnt supply of fuel (36 to 39 psi; 248 to 269 kp) elivere to the fuel ril. The injetors re opene n lose eletronilly y the Eletroni Control Moule (ECM). The ECM reeives input signls from vrious sensors in the EFI system whih in turn trnsmits ontrolling outputs (open/lose) to the injetors. The length of time the injetors sty open is onsiere pulse with. The pulse with will wien (riher) or nrrow (lener) epening on signls ECM reeives from sensors, to llow effiient opertion t ll spees n onitions. IMPORTANT: The following preliminry steps MUST BE FOLLOWED efore ttempting EFI prolem ignosis R3 JUNE 2002 FUEL SYSTEMS - 3C-11

14 Preliminry Steps Ignition Sprk Chek Purpose: This test etermines if the ignition system is elivering usle sprk to the sprk plugs. By performing this test, the prole use n e isolte to either the ignition system or fuel system. Proeure: STEP 1: Disonnet ll sprk plug wires from sprk plugs. STEP 2: Connet sprk gp tester Quiksilver ( A1) to No. 1 sprk plug wire n to goo groun on engine. STEP 3: Connet Remote Strter Swith Quiksilver (P/N A1).. Connet re le from swith to lrge positive (+) terminl with re ne le tthe [(+) le from ttery].. Connet YELLOW le from swith to smll terminl with yellow/re le tthe. STEP 4: Turn ignition key swith to the ON position. Results: IMPORTANT: The presene of goo sprk will not neessrily inite onition of timing. Ignition timing my e off fr enough to prevent the engine from strting, ut still llow goo sprk to e present in the sprk gp tester. A stey, lue sprk shoul e present t eh sprk plug wire. If goo sprk is present, prolem my not e ignition relte. If goo sprk is not present, prolem my e ignition relte. Troule shoot ignition system or mke sure engine timing is set orretly. Refer to pproprite ignition setion in this servie mnul. Ignition system filure (swith ox, sttor, trigger, et.) n use fuel elivery prolems. Injetors re triggere in pirs y one, three, five primry iruits (inner swith ox). No. 1 Primry Triggers No. 3 & 4 Injetors No. 3 Primry Triggers No. 5 & 6 Injetors No. 5 Primry Triggers No. 1 & 2 Injetors Filure in one or more of these primry iruits will use no sprk n no fuel to respetive yliners (ove). Chek sprk n sprk plugs on ll yliners efore ttempting EFI tests. Eletroni Fuel Injetion Set Up IMPORTANT: Follow EFI Timing/Synhronizing/ Ajustment setion 2C efore ttempting tests on EFI system. OFF ON START STEP 5: Turn over engine using remote strter swith. STEP 6: Look t sprk gp tester viewing port for presene of goo qulity sprk. Complete steps 1 through 6 on eh sprk plug. EFI set up proeures must e followe efore tests on system re performe (refer to Setion 2C). Improper set up n result in poor engine performne (i.e. unontrollle ile spees, len sneezing, low power uring elertion or engine will simply not run.) Filure to properly set up the EFI system n le to misiretions in solving simple prolems in the EFI system. 3C-12 - FUEL SYSTEMS R3 JUNE 2002

15 Fresh Qulity Fuel Low Bttery Voltge Using remote fuel tnk ontining mjor rn of premium unlee gsoline, test run the outor to eliminte ny prolems relte to restrite fuel supply (logge lines, mlfuntioning nti-siphon vlve, et.) n/or mrginl gsoline. Low ttery voltge n use EFI system to eliver fuel in n inonsistent mnner. Inspet ttery onnetions n hrging system, refer to Setion 2B. The EFI system requires sustntil mount of voltge to funtion properly. Operting engine t low RPM for n extene perio of time n use low voltge R3 JUNE 2002 FUEL SYSTEMS - 3C-13

16 Fuel Flow Digrm u t s v r f g e q w p m h l x o n i k j - To Upper Mnifol Fitting - Blee Shut Off Vlve - Blee Line Filter - Blee System Ciruit of Engine e - To Upper Mnifol Lower Fitting f - Blee Line Inlet g - Fresh Fuel Inlet h - Neele/Flot Devie i. - Oil Supply Inlet j. - Wter Seprting Filter k - Pulse Fuel Pump l. - Fuel Chek Vlve; Vpor Seprtor m - Vpor Seprtor n - Fuel Filter o - Eletri Fuel Pump p - Fuel Ril q - Finl Filter r - High Pressure Fuel ( IN Line) s - Fuel Pressure Regultor t - FueL Ril Pressure Port u - High Pressure Fuel ( OUT Line) v - #1 n #2 Injetors (Triggere y #5 Primry Ciruit) w - #3 n #4 Injetors (Triggere y #1 Primry Ciruit) x - #5 n #6 Injetors (Triggere y #3 Primry Ciruit) 3C-14 - FUEL SYSTEMS R3 JUNE 2002

17 Fuel Flow Components (from Fuel Flow Digrm) A esription of eh omponent (on igrms) will i in the ignosis of EFI prolems. PULSE FUEL PUMP (K) The pulse fuel pump, mounte on the rnkse, elivers fuel through the wter seprting filter to the vpor seprtor. Typil fuel pressure (t 5000 RPM) is 6 to 8 psi. WATER SEPARATING FILTER (J) The Wter Seprting Filter protets fuel system omponents from wter n eris. The filter ontins sensor proe whih monitors wter level in the filter. If wter is ove sensor proe, re light on wter sensing moule will illuminte triggering series of eeps from the wrning horn. VAPOR SEPARATOR (M) The vpor seprtor n e onsiere fuel reservoir whih ontinuously lens n irultes fresh fuel, oil, n unuse fuel/oil from the fuel ril. * Fuel Inlet - fresh fuel elivere to system. * Oil Inlet - oil elivere from oil reservoir. * Crnkse lee Inlet - reirulte fuel (unurne) elivere from lee lines t low RPM. * Fuel pressure regultor Inlet - fuel eing reirulte through the fuel ril loop. The fresh fuel elivere to the vpor seprtor is ontrolle y neele/flot evie (h) lote in the vpor seprtor. BLEED SYSTEM (F, C,B) Unlike rurete engines, the unurne exess fuel from rnkse is omine together through the lee system to the vpor seprtor. The lee system flow is lose off to the vpor seprtor uring off ile spees y the lee shut off vlve. The lee shut off vlve is tivte y throttle linkge on the mnifol. At ile spees the flow n e lose to 1000 s of gsoline per hour. Also, smll filter (30 miron) is instlle in the lee line to keep ontminnts from entering the vpor seprtor. If the filter eomes logge the engine will e prone to lo up t ile spees n hesitte upon elertion. ELECTRIC FUEL PUMP (O) The eletri fuel pump is ontinully proviing fuel in exess of engine emns. The exess fuel irultes through the fuel ril k to the vpor seprtor. With the key in run position (engine off), the ECM signls the pump to run for pproximtely 30 seons then shut off. With the key in run position (engine running), the ECM etermines pump spee (2 spees) epening on RPM. During low spee opertion pump is t low spee. FINAL FILTER (Q) The finl filter is lote ove the eletri fuel pump. The filter ollets eris flowing from the eletri fuel pump to the fuel ril n n withstn lokge up to 50% n still llow equte fuel flow. FUEL INJECTOR (V,W,X) The fuel injetors re lote insie the inution mnifol on the fuel ril. The injetor vlve oy onsists of solenoi tute neele n set ssemly. The injetor reeives signls from the Eletroni Control Moule. These signls etermine how long the neele is lifte from set (pulse with) llowing mesure fuel flow. The pulse with will wien (riher) or nrrow (lener) epening on vrious signls reeive from sensors onnete to the ECM. The ECM reeives signls from primry ignition iruit one, three n five to fire eh pir of injetors oringly. FUEL PRESSURE REGULATOR (S) The fuel pressure regultor is lote on top of the vpor seprtor n is ontinuously regulting fuel pressure from the eletri fuel pump. The eletri fuel pump is ple of prouing 90 psi (621 kp) of fuel pressure. The pressure regultor regultes fuel to injetors own to usle 36 to 39 psi (248 to 269 kp). INDUCTION MANIFOLD The inution mnifol is ommon plenum hmer for urte pressure mesurement. It ontins four throttle shutters on two throttle shfts. The shutter opening (ile ir opening) n e juste uring EFI set-up proeure. The mnifol ontins the fuel ril, injetors, throttle position sensor n ir temperture sensor. A fuel ril pressure port (q) is lote on the finl filter housing R3 JUNE 2002 FUEL SYSTEMS - 3C-15

18 EFI Eletril Digrm Detontion Sensor* 2 - Detontion Moule* 3 - Engine He Temperture Sensor 4 - To Temperture Guge 5 - Air Temperture Sensor 6 - Strter Solenoi 7-12 Volt Supply from Regultor 8 - Eletri Fuel Pump 9 - Eletroni Control Moule 10- Mnifol Asolute Pressure Sensor Throttle Position Sensor 12- Fuel Injetors 13- Injetor Wiring Hrness 14- To Outer Swith Box 15- Inner Swith Box 16- #5 Ignition Coil 17- #3 Ignition Coil 18- #2 Ignition Coil 19- #1 Ignition Coil *200 Moels Only BLK = Blk BLU = Blue BRN = Brown GRY = Gry GRN = Green ORN = Ornge PNK = Pink PUR = Purple RED = Re TAN = Tn WHT = White YEL = Yellow LIT = Light DRK = Drk 3C-16 - FUEL SYSTEMS R3 JUNE 2002

19 EFI Eletril Components (from Eletril Component Digrm) ELECTRONIC CONTROL MODULE (ECM) The ECM is ontinully monitoring vrious engine onitions (engine temperture, engine etontion ontrol, engine throttle opening) n limte onitions (inution ir temperture, rometri pressure n ltitue level) neee to lulte fuel elivery (pulse with length) of injetors. The pulse with is onstntly juste (rih/len onitions) to ompenste for operting onitions, suh s rnking, ol strting, limte onitions, ltitue, elertion n eelertion, llowing the outor to operte effiiently t ll engine spees. SENSOR INTERACTION WITH THE ECM IMPORTANT: DO NOT run engine for extene perios of time with sensors isonnete or ypsse (shorte). Serious engine mge my result. AIR TEMPERATURE SENSOR The ir temperture sensor trnsmits mnifol solute ir temperture, through full RPM rnge, to the ECM. As ir temperture inreses sensor resistne ereses using the ECM to erese fuel flow (lener mixture). Disonneting the ir temp sensor (open iruit) will inrese fuel flow (rihen mixture) y 10%. Bypssing ir temp sensor (short in iruit) will use fuel flow to erese 10%. The ir temperture sensor iruit n e teste using the EFI tester. The ir temperture sensor n e teste following ir temperture sensor test on pge 3C-34. MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR The MAP sensor is non-serviele sensor mounte in the ECM ox. The MAP sensor is use to sense hnges in mnifol solute pressure n is onnete to the intke mnifol y the wy of vuum hose. The MAP sensor is funtioning through the full RPM rnge n is ontinully signling inution mnifol pressure reings to the ECM. The ECM in turn etermines fuel flow s signls re reeive. Drwing vuum on the MAP sensor hose will rete len fuel onition ltering engine opertion. If no hnge ours when rwing vuum, MAP sensor is not funtioning properly. MAP sensor n e teste with the EFI tester. ENGINE HEAD TEMPERATURE SENSOR The Engine He Temperture Sensor provies the ECM signls relte to engine temperture to etermine level of fuel enrihment uring engine wrm up. The ECM is reeiving informtion t ll engine tempertures ut stops fuel enrihment t n engine temperture of 90 F (32 C). An open iruit on the temperture sensor will inrese fuel flow up to 40% ut will not e ffete t wie open throttle. If no hnge ours when sensor is isonnete, sensor my not e funtioning properly. The engine he temperture sensor n e teste following Engine He Temperture Sensor Test on pge 3C-35. NOTE: If sensor oes not mke len ontt with yliner he rih onition my exist. THROTTLE POSITION SENSOR (TPS) The TPS trnsmits informtion to the ECM uring low spee n mi rnge opertion, relte to throttle ngle uner vrious lo onitions. TPS justment is ritil step in engine set up (Setion 2C). Disonneting the TPS will inrese fuel flow 40% t ile ut oes not effet WOT. NOTE: The higher the resistne the riher the fuel flow. Refer to TPS Ajustment (Setion 2C). DETONATION CONTROL SYSTEM (200 MODEL) The Detontion Control System onsists of etontion ontrol sensor lote on the port sie yliner he n etontion ontrol moule mounte on the engine. The etontion ontrol moule hs seven wires: WHITE/BLUE - Connets to knok sensor, trnsmits knok signl to ontrol moule. GREEN - Connets to #2 primry wire. The primry voltge signls the ontroller to monitor omustion noise uring winow of time (See Detontion System Funtion following). WHITE/BLACK - Two of these wires onnet to the swith oxes is iruit terminls. A thir wire is splie in one is iruit (inner swithox) n onnets to the ile stilizer moule. (See omplete Engine Wiring Digrm - refer to Setion 2D). GRAY/WHITE - Connets to the ECM; signls ECM to enrih fuel mixture when knoking ours. PURPLE -12 Volt power supply R3 JUNE 2002 FUEL SYSTEMS - 3C-17

20 DETONATION CONTROL SYSTEM FUNCTION 1. Comustion noise (or virtion) exites the piezoeletri iruit lote insie the etontion sensor, whih trnsmits voltge to the ontrol moule. 2. When yliner numer two ignition primry fires, it signls the ontroller to look t one milliseon winow of sensor output, whih it retins s referene level of omustion kgroun noise. 3. When kgroun noise rehes mesurle vlue, usully etween 2500 n 3500 RPM (it is epenent on lo), the ignition timing is vne 6 egrees eyon wht the mehnil timing is set t. Timing vne is omplishe y lowering the is voltge. 4. The ontroller ontinues to monitor sensor output. If the output exees pre-etermine threshol level over the kgroun noise (whih is initive knok is ourring) ignition timing is retre y up to 8 egrees n fuel flow is enrihe y up to 15% until the sensor output is reue elow the threshol level. The etontion ontrol system tully ts s n ignition vne moule, when knok ours it tkes wy the vne. Ignition timing will not vne if:. Knok sensor fils.. Blue/White wire eomes isonnete.. Blk wire hs poor groun onnetion.. Purple power wire eomes isonnete. NOTE: Disonnete Gry/White wire will not ffet ignition timing n will not llow fuel enrihment. Other omponents ssoite with the ECM. 12 Volt Bttery -The 12 volt ttery provies power to the ECM even with the ignition swith in the OFF position. IMPORTANT: When isssemling EFI System DISCONNECT BATTERY CABLES. Strter Solenoi - Provies 12 volt signl when key is in the strt position. In the strt position, injetor pulse withs re triple when engine he temperture is elow 90 F (32.2 C) to provie equte fuel for quik strt up. When key is returne to the run position or engine he temperture is ove 90 F (32.2 C), pulse withs return to norml vlue. Fuel Injetors - A four wire hrness onnets the fuel injetors to the ECM. The re wire is t 12 volts n onnets to ll injetors. The lue, yellow n white wires eh go to pir of injetors n re normlly t 12 volts for zero ifferentil. To fire the injetors this voltge is rought own to ner groun reting potentil ross the injetors. Eletri Fuel Pump - The ECM ontins fuel pump river iruit tht provies power to the eletri fuel pump (2 spees). The fuel pump oes not hve its negtive terminl (-) RED/PURPLE wire groune to the pump housing. The fuel pump positive terminl (+) RED wire n the negtive terminl (-) re t 12 volts with the ignition swith in the off position for zero ifferentil. When the pump is on, the negtive terminl is rought own to ner groun (i.e. 1.5 volts t high spee). WATER SENSING SYSTEM The system onsists of wter seprting fuel filter (stror sie powerhe), sensing proe (ottom of filter) n wter sensing moule (elow ECM ox). The wter sensing moule hs four wires: PURPLE - Connets to 12 volt power supply. LIGHT BLUE - Connets to lue lert, whih souns the wrning horn when tivte. TAN - Connets to sensing proe. BLACK - Connets to groun. WATER SENSING SYSTEM FUNCTION 1. The filter seprtes the umulte wter from the fuel. 2. A voltge is lwys present t sensing proe. When wter rehes top of proe it ompletes the iruit to groun. 3. The omplete iruit tivtes the wrning. The wrning hs 5-10 seon ely, then the moule s re light illumintes n wrning horn intermittently souns. The system n e teste y isonneting the TAN wire from sensor proe n holing to goo engine groun onnetion for 10 seons. 3C-18 - FUEL SYSTEMS R3 JUNE 2002

21 EFI Fuel Mngement (Low Pressure Fuel Route) Perform ll preliminry heks Instll fuel pressure guge (P/N A2) on to mnifol pressure port. Ple ignition swith in OFF position 30 seons efore testing. Ple ignition swith in ON position n note pressure within 30 seons (36 to 39 psi; 248 to 269 kp). Pump oes not run No or low fuel pressure Fuel pressure ove 39 psi (269 kp) Follow High Pressure Fuel Route Flow Chrt. Perform Vpor Seprtor Fuel Delivery Test (pge 3C-23). Follow High Pressure Fuel Route Flow Chrt. Results Results No or little fuel flow from vpor seprtor. Reonnet hose. Chek in-line Filter Perform Vpor Seprtor Flot Test (pge 3C-23). Fuel flows freely from vpor seprtor. Reonnet hose. Follow High Pressure Fuel Route Flow Chrt. Results Results Fuel flows from fresh fuel inlet hose. Little or no flow from fresh fuel inlet hose. Reonnet hose. Inspet flot system of vpor seprtor. Perform Wter Seprting Filter Flow Test (pge 3C-24). Results Results Low or no fuel flow from wter seprting inlet hose. Reonnet hose. Fuel flows freely from wter seprting filter inlet hose. Reonnet hose. Perform Pulse Fuel Pump Delivery Test (pge 3C-25). Reple wter seprting filter. Results Results Fuel flows freely from pulse pump inlet hose. No fuel flow to pulse fuel pump. See pulse pump removl n inspetion Setion 3A. Lote ll frgments of file pump efore ressemly. Chek for restritions, holes or loose onnetions from fuel supply R3 JUNE 2002 FUEL SYSTEMS - 3C-19

22 EFI Fuel Mngement (High Pressure Fuel Route) Perform low pressure heks (3C-19) efore performing heks on high pressure route. Instll fuel pressure guge (P/N A2) on to mnifol pressure port. Ple ignition swith in OFF position 30 seons efore testing. Ple ignition swith in ON position n note pressure within 30 seons (36 to 39 psi; 248 to 269 kp). Fuel pressure ove 39 psi (269 kp) No or low fuel pressure Pump oes not run Clogge or fulty fuel pressure regultor remove n reple. Perform Finl Filter Chek (pge 3C-26). Perform Eletri Fuel Pump Proeure B Test (pge 3C-28). Results Results Finl filter OK. Finl filter logge. Perform Fuel Pressure Regultor Test (pge 3C-27). Clen or reple finl filter. Results Results Stey strem of fuel (pressure still elow 36 psi). Low or no fuel flow. Reple fuel regultor. Perform Eletri Fuel Pump Test (pge 3C-28). Results Results Voltge from ECM river iruit OK. Low or inonsistent voltge from ECM river iruit. Reple fuel pump. Reple ECM. 3C-20 - FUEL SYSTEMS R3 JUNE 2002

23 Fuel Ril Eletril/Fuel Determintion Perform ll preliminry heks pge 3C-12. Aequte fuel pressure (36 to 39 psi; 248 to 269 kp) follow Low/High Fuel Route Flow Chrts. Ple outor in wter or on flush tthment (P/N 44357A2) run engine spee etween 2000 n 2500 RPM. With engine running ( RPM) remove sprk plug les one t time using insulte pliers. Results Results No RPM hnge on yliner(s), initing prolem in yliner(s). RPM ereses (on eh yliner). Perform Injetor Eletril Hrness Test (3C-31). Fuel elivery OK. Results Results Broken iruit to injetor. Injetor iruit tests OK. Perform inution mnifol isssemly n inspetion (3C-47). Perform Injetor Fuel Delivery Test (pge 3C-31). Results Results RPM inrese ours. No RPM hnge. Perform inution mnifol isssemly. Inspet injetor n filter. Results Perform ompression hek on prolem yliner see setion 1. Results Low or no ompression on yliner. Compression OK. Inspet yliner ore. Refer to setion 4 for isssemly. NOTE: Injetor filters must e inspete prior to ressemly. Chek 1) Dmge rees 2) En p sels 3) Crnkse split line lek 4) Crnkshft seling rings R3 JUNE 2002 FUEL SYSTEMS - 3C-21

24 EFI System Test Proeures Fuel Guge Connetion/Pressure Test IMPORTANT: When heking fuel pressure while engine is running, fuel pressure my flutute. Fuel pressure flutution (i.e. 36 to 39 psi 213 to 290 kp ) is ommon, s the regulte pressure is ifferentil etween fuel ril n mnifol vuum. Purpose: Cheking fuel mnifol pressure ensures tht fuel uner usle pressure is ville to the fuel injetors. This test isoltes the prole use s either fuel elivery or EFI eletril system filure. IMPORTANT: Fuel pressure shoul e monitore through full RPM rnge to etermine fuel supply prolems t high engine spees. Proeure: STEP 1: Connet fuel pressure guge to inution mnifol pressure port. STEP 2: Prime engine using fuel primer ul. STEP 3: Turn ignition key swith to On position. OFF ON START STEP 4: Operte eletri fuel pump for pproximtely 10 seons. NOTE: Fuel pump will only operte for pproximtely 30 seons. By turning the key swith to OFF n then k to ON the pump will operte for 30 seons more. STEP 5: Tke reing on fuel pressure guge. Results: If pressure reing is 36 to 39 psi (248 to 269 kp), the eletri fuel pump is proviing fuel with enough pressure to e use y the injetors. Pump mlfuntion is not the use of EFI troule. If fuel pressure is well elow 36 psi (248 kp), fuel elivery to eletri fuel pump, fuel pump filure or other relte prolem exists. Follow low/high fuel pressure flow hrts. If fuel pressure is ove 39 psi (269 kp) go to fuel pressure regultor test C-22 - FUEL SYSTEMS R3 JUNE 2002

25 Vpor Seprtor Fuel Delivery Test Purpose: Verifying there is equte fuel flow to the eletri fuel pump (through full RPM rnge) will etermine omponents in low pressure fuel system re funtioning orretly. Proeure: STEP 1: Remove hose from intke port of eletri fuel pump n put isonnete en of hose in len ontiner. STEP 4: Look for fuel flow from hose. IN-LINE FILTER Results: If low or no fuel flow is present following inspetion of in-line filter, perform Vpor Seprtor Flot Test Results: If fuel flow is present, fuel is eing elivere to eletri fuel pump. Go to high pressure flow hrt. If fuel flow is not present, proee to step 2. STEP 2: Ple emergeny stop swith in OFF position to prevent engine from strting. If ot is not equippe with emergeny stop swith, onnet jumper le from the BLACK/YELLOW terminl on the swith ox to engine groun. STEP 3: Turn ignition key swith to START n operte strter motor for 10 to 20 seons. Vpor Seprtor Flot Test Purpose: This test will inite if flot is stuk in the up position. NOTE: If flot is stuk own vpor seprtor will over flow using rih onition. Proeure: If flot is suspete of stiking in the up position: STEP 1: Remove fuel inlet hose from vpor seprtor n put en of hose in len ontiner. STEP 2: Remove ll sprk plugs from engine to prevent engine from strting R3 JUNE 2002 FUEL SYSTEMS - 3C-23

26 STEP 3: Turn ignition key swith to START position n operte strter motor for 15 to 20 seons. OFF ON START Wter Seprting Filter Flow Test Purpose: This test will inite if wter seprting filter is logge. Proeure: STEP 1: Remove fuel inlet hose to wter seprting filter. Put en of hose in len ontiner. STEP 4: Look for fuel flow from hose. Results: If fuel flow is present t hose, remove, isssemle n inspet flot ssemly. See vpor seprtor isssemly. If fuel flow is low or not present, perform Wter Seprting Filter Flow Test STEP 2: Ple emergeny stop swith in OFF position to prevent engine from strting. If ot is not equippe with emergeny stop swith, onnet jumper le from the BLACK/YELLOW terminl on the swith ox to engine groun. STEP 3: Turn ignition key swith to START n operte strter motor for 10 to 20 seons. OFF ON START 3C-24 - FUEL SYSTEMS R3 JUNE 2002

27 STEP 4: Look for fuel flow from hose. Pulse Fuel Pump Delivery Test Purpose: This test will inite pulse fuel pump is ple of supplying the low pressure fuel route with equte fuel supply. Proeure: STEP 1: Remove inlet hose to pulse fuel pump n put en into len ontiner Results: Fuel flows from wter seprting inlet hose. Remove n reple logge filter. Low or no fuel flow from wter seprting inlet hose. Perform pulse fuel pump elivery test STEP 2: Squeeze primer ul severl times. STEP 3: Look for fuel flow from hose R3 JUNE 2002 FUEL SYSTEMS - 3C-25

28 Results: Fuel flows freely from pulse pump inlet hose. Remove, isssemle, n inspet pulse fuel pump (Setion 3A). IMPORTANT: All frgments of file pump must e lote efore re-ssemly. No or low fuel flow from pulse pump inlet hose. Chek for restritions, holes, or loose onnetions from fuel supply. STEP 2: Remove filter p. g h NOTE: Inspet nti-siphon vlve on tnk. Finl Filter Chek n De-pressurizing EFI System Proeures Purpose: Cheking the finl filter for ostrutions, mge et. elimintes this omponent s possile soure of restrition in the system. Proeure: STEP 1: De-pressurize EFI fuel system y wrpping len loth roun pressure port vlve n inserting tip of srewriver into vlve, epressing vlve ore. Let fuel rin from vlve. - Filter Housing - Lrge O-ring - Filter Element - Smll O-ring e - Filter Cp f - Lokwsher g - Srew h - Cp e f STEP 3: Look t filter for plugging, mge or other signs of unusul onition. Results: Filter is logge with eris. Clen with ruretor lener n ompresse ir or reple. Rehek fuel pressure. Filter is O.K. Pressure still elow 36 psi (248 kp). Perform fuel pressure regultor test Pressure Port my e lote t this lotion on some moels. NOTE: Pressure port vlve my e lote on mnifol fitting on some moels. 3C-26 - FUEL SYSTEMS R3 JUNE 2002

29 Pressure Regultor Test Purpose: This test will etermine if wek, plugge or open pressure regultor is using inequte fuel pressure in the system. NOTE: Inution mnifol over shown remove for illustrtive purposes only. Proeure: STEP 1: Connet pressure guge to EFI test port. STEP 3: Remove fuel pressure regultor, ut o not isonnet ny hoses from regultor. STEP 4: Put ishrge en of regultor in len ontiner. STEP 5: Turn ignition key swith to ON position. OFF ON START STEP 6: Chek for fuel flow out of regultor STEP 2: Turn ignition key swith to ON position n hek fuel pressure reing on guge. If pressure reing is elow 36 psi (248 kp) go to step 3 following. OFF ON START Results: If stey strem of fuel exits regultor into ontiner n pressure is elow 36 psi (248 kp) reple pressure regultor. If low or no fuel exits regultor into ontiner n pressure is elow 36 psi (248 kp) perform eletri fuel pump pressure test. If low or no fuel flow exits regultor into ontiner n pressure is ove 39 psi (269 kp) reple regultor R3 JUNE 2002 FUEL SYSTEMS - 3C-27

30 Eletri Fuel Pump Test Purpose: This test will etermine if eletri fuel pump is ple of prouing equte fuel pressure neee for norml engine opertion, 36 to 39 psi (248 to 269 kp). Proeure A: STEP 1: Connet pressure guge to pressure port. CAUTION Do not lose-off fuel hose ompletely in step 4, or mge oul result to hose or pump. STEP 4: Prtilly lose off fuel hose to pressure regultor STEP 2: Put ignition key swith in ON position. ON OFF START STEP 5: Look t pressure guge for inrese in pressure. Results: Fuel pressure inreses s hose is prtilly lose off. Eletri fuel pump OK, perform Inution Mnifol Lek Chek (pge 3C-33). Fuel pressure oes not inrese when hose is prtilly lose off. This my inite efetive eletri fuel pump. Before repling, perform Proeure B following. STEP 3: Tke fuel pressure reing, within 30 seons C-28 - FUEL SYSTEMS R3 JUNE 2002

31 Proeure B: Negtive Test Terminl CAUTION When heking voltge t pump, DO NOT pry oot overs off terminls with metl ojet, s eh terminl is t 12 volts when engine is off. Serious mge to eletri fuel pump n/or ECM ox n result. Purpose: If insuffiient eletril power is ville t the pump, no or low fuel pressure will e evelope. Proeure: STEP 1: Set volt meter to re ttery voltge n onnet lk test le to groun, positive test le to positive (+) post of fuel pump. NOTE: Positive test le n e piere through oot over for testing. Refer to voltge test hrt (pge 3C-30) for voltge reings. Positive Test Terminl STEP 2: Set volt meter to re ttery voltge n onnet lk test le to groun, positive test le to negtive (-) post of fuel pump R3 JUNE 2002 FUEL SYSTEMS - 3C-29

32 STEP 3: Perform voltge tests ll (1-6) engine moes elow. VOLTAGE TEST CHART Engine Moe BLACK Meter Le to Engine Groun; RED Meter Le to: Approximte Voltge Reing If Approximte Voltge is not otine, this inites: 1. All moels (+) terminl of fuel pump volts If reing is elow 12 volts, the ttery is, ishrge or hs onnetion(s). 2. Ignition key in OFF position. 3. Ignition key in ON position n engine NOT running. ( ) terminl of fuel pump. Sme reing shoul e otine s reing in hek No. 1 (ove) ( ) terminl of fuel pump. 2 volts or less (voltge shoul rise to volts fter pproximtely 30 seons. If reing is lower thn in hek 1, the ECM is. B ECM or fuel pump*. 4. Engine eing rnke. ( ) terminl of fuel pump. 2 volts or less. B ECM or fuel pump. 5. Engine running elow pproximtely 2000 RPM. 6. Engine running ove pproximtely 2000 RPM. *Chek for proper eletril opertion of eletri fuel pump. (Step 4) STEP 4: Disonnet RED/PURPLE wire to negtive terminl on eletri fuel pump. Connet groun jumper wire from negtive pump terminl to goo engine groun. ( ) terminl of fuel pump. 2 volts or less (for pproximtely 30 seons n then swith to pproximtely 5 volts. B ECM or fuel pump. ( ) terminl of fuel pump. 2 volts or less. B ECM or fuel pump. Results: Pump oes not operte. Reple eletri fuel pump. Pump opertes. But, pressure reing oes not hnge when performing eletri fuel pump pressure test. Reple eletri fuel pump. Pump opertes. Chek RED/PURPLE ( ) le n hrness for goo ontinuity. NOTE: RED/PURPLE le is onnete to pin 2 of EFI hrness. 3C-30 - FUEL SYSTEMS R3 JUNE 2002

33 Injetor Eletril Hrness Test Purpose: This test will etermine if eletril or fuel elivery prolem exists uring the fuel elivery proess y heking for open iruits in injetor hrness. Proeure: STEP 1: With outor in wter, strt n llow to wrm up. Rise engine spee to RPM. Remove sprk plug les one t time n note RPM hnge. Determine non-working (no RPM hnge) yliner. Stop engine. STEP 2: Disonnet injetor hrness (4 pin onnetor). IMPORTANT: Use igitl ohmmeter when testing injetor hrness. STEP 3: Connet igitl ohmmeter (il set t 200 sle) les. Positive le from ohmmeter onnets to positive prong 2 (re wire) of hrness onnetor. Connet negtive le from ohmmeter to the remining wires of hrness onnetor s follows: WHITE Le = Injetors, Cyliners 1 n 2 DARK BLUE Le = Injetors, Cyliners 3 n 4 YELLOW = Injetors, Cyliners 5 n 6 Results: If reings re 1.1 ±.2 oth injetor iruits re omplete. Perform Injetor Fuel Delivery Test. If reings re 2.2 ±.2 one injetor oes not hve omplete iruit. Perform inution mnifol isssemly n inspetion following. Injetor Fuel Delivery Test CAUTION CAUTION: Swith oxes must e groune to engine lok if remove for fuel elivery test to prevent possile mge to ignition system. Purpose: This test will etermine if injetor is elivering fuel when signl is reeive. Proeure: STEP 1: Ple outor in wter, strt engine n llow to wrm up. Rise engine spee to RPM. Remove sprk plug les one t time n note RPM hnge. Determine non-working yliner (no RPM hnge). STEP 2: Using squirt ottle of fuel n hose, injet smll mount of fuel into yliner lee fitting () on non-working yliner. NOTE: Swith ox pnel n lue lert ontrol ox my hve to e shifte to the sie to llow lee fitting onnetion. Groun oxes to motor s require (1) YELLOW (2) RED (3) DARK BLUE (4) WHITE R3 JUNE 2002 FUEL SYSTEMS - 3C-31

34 Results: If RPM inrese ours while injeting fuel into isle yliner, logge injetor filter or efetive injetor my e the prolem. Perform Inution Mnifol Disssemly (pge 3C-38) for inspetion. NOTE: Injetor fuel elivery n e teste with mnifol over remove. See Injetor Opertion Test (mnifol over remove) elow. RPM oes not hnge when injeting fuel into lee fittings oul inite lk of ompression, mge rees, en p sels, rnkse split line sel, or rnkshft seling rings. Remining tests on EFI omponents my require some EFI isssemly. See EFI System Disssemly following. Injetor Opertion Test (Mnifol Cover Remove) Purpose: This test etermines if the injetors re tully injeting fuel into the engine t norml rte. WARNING Do not strt engine with inution mnifol over remove. Disle ignition system prior to oing this test. Proeure A: STEP 1: Remove inution mnifol over using proeures outline uner lnution Mnifol Removl. STEP 3: Connet jumper wire etween the ECM metl se n goo engine groun. STEP 4: Disonnet ll sprk plug wires from sprk plugs n sel les with eletril tpe to prevent sprking. STEP 5: Put ignition key swith in START position. OFF ON START STEP 6: Look t injetor spry pttern using n explosive proof flshlight. Results A: If fuel spry is not present in ll injetors or spry pttern is extremely wek, hek wiring hrness to injetor onnetors, or injetor filters for plugging. If spry ptterns re ville in most of the injetors, ut not ll, perform Proeure B. STEP 2: Re-tth inution mnifol to engine using 1/4-20 x 2-3/4 srews. 3C-32 - FUEL SYSTEMS R3 JUNE 2002

35 Proeure B: STEP 1: Connet EFI tester. Steps outline in eletril system n ECM hek. STEP 2: Connet remote strter Quiksilver ( A1) to negtive terminl of eletri fuel pump n goo engine groun. Depress remote strt swith, pump will operte s long s swith is epresse. WARNING Do not operte pump for more thn 20 seons ontinuously. Inution Mnifol Lek Chek (Mnifol Cover Remove) Purpose: Lk of goo fuel pressure my e use y n internl lek in the fuel inution mnifol n not use y wek pump. This test elimintes the possiility of inution mnifol leks s prole use. WARNING Do not strt engine with inution mnifol over remove. Disle ignition system prior to performing this test. WARNING Opertion of EFI system with over remove n llow fuel to spry omponents. Be extremely reful when operting the fuel system in this onition. Proeure: STEP 1: Remove inution mnifol over using proeures outline uner Inution Mnifol Removl. STEP 3: Perform fuel injetor test proeures (outline) while epressing remote strter swith. STEP 2: Retth mnifol oy without over to engine using twelve 1/4-20 x 2-3/4 srews in ple of srews normlly use. Results B: If fuel spry is present using EFI tester, ut not present while rnking, perform swith ox DVA tests Setion 2A (1, 3, 5 swith ox filure). If fuel spry pttern is equl on ll injetors system is funtioning normlly R3 JUNE 2002 FUEL SYSTEMS - 3C-33

36 STEP 3: Connet jumper wire etween the metl se of ECM n goo engine groun. WARNING If serious lek is present in the inution mnifol, fuel my spry out of sel. Hve len up rgs ville to remove exess fuel from omponents. STEP 4: Ple emergeny stop swith in OFF position to prevent engine from strting. If ot is not equippe with emergeny stop swith, onnet jumper le from the BLACK/YELLOW terminl on the swith ox to engine groun. STEP 5: Connet remote strter Quiksilver ( A1) to negtive terminl of eletri fuel pump n goo engine groun. Depress remote strt swith, pump will operte s long s swith is epresse. WARNING Do not operte pump for more thn 20 seons ontinuously. STEP 6: Look for lek points on inution mnifol while epressing remote strter swith. Results: If no leks re present, reple over n gsket using norml length srews. If fuel lek is present etween seling surfes, reuil system using new O-rings. Air Temperture Sensor Test Purpose: This test elimintes possiilities of improper fuel elivery relte to ir temperture sensor. Proeure: STEP 1: Disonnet n remove Air Temperture Sensor from inution mnifol. STEP 2: Connet igitl meter set t 20K sle (from EFI Tester P/N A2) to les of sensor. STEP 3: Ple sensor in ie wter while monitoring meter reing. Use grph (following pge) for referene. 3C-34 - FUEL SYSTEMS R3 JUNE 2002

37 NOTE: Temperture/resistne reing my iffer slightly from grph urve. NOTE: Temperture/resistne reing my iffer slightly from grph urve. AIR TEMP. SENSOR RESISTANCE (K OHMS) SENSOR RESISTANCE VS. AIR TEMPERATURE Results: Resistne oes not hnge inversely with temperture hnge. Reple efetive Air Temperture Sensor. Resistne hnges inversely with temperture hnge. Air Temperture Sensor OK. Engine He Temperture Sensor Test Purpose: This test elimintes possiilities of improper fuel elivery relte to the wter temperture sensor. Proeure: STEP1: Disonnet n remove Engine He Temperture Sensor (pge 3C-40). STEP 2: Connet Digitl Meter set t 2K Sle (from EFI Tester P/N A2) to ullet les of sensor. STEP 3: Ple sensor in ie wter while monitoring meter reing. Use grph (elow) for referene. Results: Resistne oes not hnge inversely with temperture hnge. Reple efetive Engine He Temperture Sensor. Resistne hnges inversely with temperture hnge. Engine He Temperture Sensor OK. Detontion Control System Test (200 Moels Only) Purpose: This test elimintes possiilities of improper fuel elivery ue to filure in etontion ontrol. Proeure: STEP 1: Ple outor in wter, instll timing light to numer one yliner. STEP 2: Strt engine, llow to wrm up. Avne throttle (etween RPM in ger). NOTE: Timing vnement. Results: Timing vnes from 19 to 25 BTDC system funtioning properly. Timing vne from 19 to 25 ut retrs while mintining stey throttle position. System funtioning properly etontion my e ourring. See Detontion Sensor/Moule Cheks (following). Timing vnement oes not our (19 to 25 BTDC). System funtioning properly etontion my e ourring. See Detontion Sensor/Moule Cheks (following) R3 JUNE 2002 FUEL SYSTEMS - 3C-35

38 Detontion Sensor Chek IMPORTANT: When testing etontion ontrol system keep ll test les wy from high tension les (i.e. sprk plug le, eletril wiring et.) to voi flse reings. Purpose: This hek will etermine if sensor is orretly signling ontrol moule. Proeure: STEP 1: Connet Digitl Volt Meter (from EFI Tester P/N A2) to etontion sensor s shown. Re V-Ω test le to sensor terminl, lk om test le to sensor housing (groun). Detontion Control Moule Chek Purpose: This hek will etermine if ontrol moule is orretly signling ECM when signls re reeive from sensor. Proeure: STEP 1: Insert proe () (i.e. pper lip) to gry/white wire onnetor (). Connet igitl volt meter (from EFI tester A2) positive lip () to proe n groun lip to engine groun () s shown Proe - Connetor - Positive Clip - Groun Clip STEP 2: Turn meter il to 200 MV volts, AC position n power swith in on position. Ple outor in wter. STEP 3: Strt n operte engine t ile spee. STEP 4: Chek meter reing. A typil reing of.075 to.120 volts AC shoul e present. NOTE: As RPM inreses volt reings will inrese. Results: If voltge reing is not within.075 to.120 volts AC reple etontion sensor. Torque sensor to 144 I. in. (16.2 N m). If voltge reing is within.075 to.120 volts AC perform hek on etontion ontrol moule. IMPORTANT: Hnle etontion sensor with re when testing or repling. Rough hnling oul use unetetle internl mge using flse reings to e trnsmitte to etontion moule. STEP 2: Turn meter il to 20 volts DC position n power swith in ON position. Ple outor in wter. STEP 3: Strt n operte engine t ile. STEP 4: Chek meter reing. A reing etween 0.30 to 0.70 volts DC shoul e ttine. STEP 5: Inrese engine spee (with engine in ger) etween RPM. Chek meter reing. A typil reing shoul e.01 volts DC. Results: If meter reing is.30 to.70 volt DC t ile n.01 volts DC t RPM, etontion ontrol unit is funtioning properly (no etontion ourring). If voltge reing oes not fll within rnge (.30 to.70 volts DC) t ile, ontrol moule my e. If voltge reing is ove.01 volts DC n etween 1.0 to 6.6 volts DC t 3000 to 4000 RPM etontion is ourring. A onstnt voltge of 6.6 volts DC woul inite etontion ontrol moule. 3C-36 - FUEL SYSTEMS R3 JUNE 2002