ELECTRONIC FUEL INJECTION
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- Godwin Wilkerson
- 5 years ago
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1 Tl o Contnts ELECTRONIC FUEL INJECTION Stion 3C - Srvi Prours Spiitions C-2 Spil Tools C-2 Intk Silnr C-4 Intk C-6 Ful Injtion Nozzl C-8 Ful Injtion Pump C-10 Ful Pump C-12 Intk Silnr Assmly C-14 Rmovl C-14 Instlltion C-15 Intk Assmly C-16 Rmovl C-16 Instlltion C-19 Throttl Boy C-22 Rmovl C-22 Instlltion C-24 Throttl Control Lvr n Link C-25 Rmovl C-25 Instlltion C-26 Hih Prssur Ful Lin C-27 Rlsin Ful Prssur in th Hih-Prssur Ful Lin C-27 Rmovl C-28 Instlltion C-29 Ful Coolr C-30 Rmovl/Instlltion C-30 Ful Hoss C-31 Rmovl/Instlltion C-31 Ful Injtors C-32 Rmovl/Instlltion C-32 Ful Ril C-33 Disssmly/Assmly C-33 Vpor Sprtor C-34 Rmovl C-34 Instlltion C-34 Disssmly C-35 Assmly C-37 Prssur Rultor C-39 Rmovl/Instlltion C-39 Il Sp Control Assmly C-40 Rmovl/Instlltion C-40 Disssmly/Assmly C-41 Intk Mniol C-42 Disssmly/Assmly C-42 Throttl Position Snsor C-43 Rmovl/Instlltion C-43 Low Prssur Ful Lin/Ful Pump C-44 Rmovl C-44 Instlltion C-45 Disssmly/Assmly C-46 Ful Filtr C-47 Disssmly/Assmly C-47 Ful Pump C-48 Disssmly C-48 Assmly C-50 3 C R1 NOVEMBER 2001 P 3C-1
2 Spiitions FUEL SYSTEM FUEL INJECTION Ful Pump Typ Ful Pump: Dishr 3000 rpm) Prssur (Mximum) Plunr Strok Ful Tnk Cpity Ful Injtion Systm Il rpm (In Nutrl) Wrm Il rpm (In Forwr Gr) Wrm Ful Ril Extrnl (Plunr/Diphrm) 17 ph (65 L/h) 7 psi (49 kp) in. ( mm) Assory Bth (1 & 4) - (2 & 3) 750 ± 50 rpm 700 ± 50 rpm 43.5 psi (300 kp) Spil Tools 1. Ful Prssur Gu A7 or Ful Prssur Gu A A A3 2. Tmpr proo srw torx it st p/n P 3C R1 NOVEMBER 2001
3 Nots: R1 NOVEMBER 2001 P 3C-3
4 INTAKE SILENCER P 3C R1 NOVEMBER 2001
5 INTAKE SILENCER TORQUE REF. NO. QTY. DESCRIPTION l. in. l.t. Nm 1 1 INTAKE SILENCER 2 1 INTAKE AIR TEMPERATURE SENSOR 3 4 O-RING 4 6 BOLT (M6 X 16 MM) BOLT (M8 X 20 MM) BRACKET 7 2 BRACKET 8 8 BOLT (M6 X 20 MM) INDUCTION SILENCER 10 1 MOUNTING BRACKET 11 1 SCREW (M6 X 20 MM) PIN 13 1 GASKET 14 1 BREATHER PIPE 15 2 CLAMP 16 2 BOLT (M6 X 12 MM) CLIP 18 1 CLAMP 19 2 BOLT (M6 X 105 MM) BOLT (M8 X 40 MM) SCREEN R1 NOVEMBER 2001 P 3C-5
6 INTAKE P 3C R1 NOVEMBER 2001
7 INTAKE TORQUE REF. NO. QTY. DESCRIPTION l. in. l.t. Nm 1 1 MANIFOLD 2 4 O-RING 3 4 DOWEL PIN 4 3 BOLT 5 1 THROTTLE BODY 6 1 SPRING 7 2 SCREW 8 6 BOLT (M8 X 70 MM) WASHER 10 1 THROTTLE BODY 11 1 SCREW 12 2 SPRING 13 1 SCREW 14 2 SCREW 15 1 LINK JOINT 16 1 LINK JOINT 17 1 NUT 18 1 THROTTLE POSITION SENSOR 19 1 O-RING 20 2 SCREW (M5 X 15 MM) WASHER 22 1 BRACKET 23 3 SCREW (TAMPERPROOF) HOSE 1 CONTROL VALVE ASSEMBLY 25 1 BODY 26 1 CONTROL VALVE 27 1 O-RING 28 3 SCREW (M4 X 12 MM) WASHER 30 1 FILTER 31 1 MAP SENSOR 32 2 SCREW (M5 X 6 MM) BOLT (M6 X 24 MM) BOLT (M6 X 60 MM) WIRE HARNESS R1 NOVEMBER 2001 P 3C-7
8 FUEL INJECTION NOZZLE P 3C R1 NOVEMBER 2001
9 FUEL INJECTION NOZZLE TORQUE REF. NO. QTY. DESCRIPTION l. in. l.t. Nm 1 1 PRESSURE REGULATOR 2 2 SCREW (M6 X 12 MM) LOCKWASHER 4 4 CLIP 5 1 HOSE 6 2 SCREW (M5 X 16 MM) CLIP 8 4 BOLT 9 4 GASKET 10 3 COLLAR 11 1 COOLER 12 2 BOLT (M6 X 30 MM) WASHER 14 2 CLAMP 15 1 HOSE 16 1 HOSE 17 1 CLAMP 18 1 FUEL RAIL 19 4 INJECTOR UNIT 20 1 O-RING 21 1 CAP 22 1 BOLT (M6 X 25 MM) BOLT (M8 X 45 MM) WASHER 25 2 COLLAR 26 1 NIPPLE 27 1 O-RING R1 NOVEMBER 2001 P 3C-9
10 FUEL INJECTION PUMP A = To ittin in xhust plt A P 3C R1 NOVEMBER 2001
11 FUEL INJECTION PUMP TORQUE REF. NO. QTY. DESCRIPTION l. in. l.t. Nm 1 VAPOR SEPARATOR 1 1 COVER 2 1 VALVE SEAT 3 1 O-RING 4 1 BODY 5 1 FLOAT 6 1 FLOAT PIN 7 1 NEEDLE VALVE 8 1 PLATE 9 1 SCREW (M3 X 8 MM) 10 7 SCREW (M4 X 16 MM) GASKET 12 1 DAMPER 13 1 FUEL PUMP 14 1 FILTER 15 1 COVER 16 1 DRAIN SCREW 17 1 GASKET 18 1 HOSE KIT 19 2 CLIP 20 5 CLIP 21 1 HOSE 22 2 HOSE 23 5 TEE 24 1 HOSE 25 1 HOSE 26 1 HOSE 27 6 HOSE 28 1 HOSE 29 1 HOSE 30 1 HOSE 31 6 COLLAR 32 3 DAMPER R1 NOVEMBER 2001 P 3C-11
12 FUEL PUMP P 3C R1 NOVEMBER 2001
13 FUEL PUMP TORQUE REF. NO. QTY. DESCRIPTION l. in. l.t. Nm 1 1 FUEL PUMP 2 1 BODY 3 1 SPRING 4 1 PLUNGER 5 1 SPRING 6 1 DIAPHRAGM 7 1 PIN 8 1 BODY 9 1 DIAPHRAGM 10 1 BODY 11 3 SCREW 12 3 NUT 13 1 O-RING 14 2 CLAMP 15 2 BOLT (M6 X 30 MM) HOSE 17 1 BRACKET 18 1 BOLT (M6 X 16 MM) NUT FILTER ASSEMBLY 21 1 CUP 22 1 O-RING 23 1 FLOAT 24 1 ELEMENT 25 2 CLAMP 26 1 BRACKET 27 2 BOLT (M7 X 48 MM) DOWEL PIN 29 2 WASHER 30 1 FUEL CHANGE LEVER 31 1 SHAFT 32 2 PIN 33 1 HOSE (55 IN.) 34 1 STA-STRAP 35 1 CONNECTOR 36 1 CAP 37 1 CONDUIT R1 NOVEMBER 2001 P 3C-13
14 Intk Silnr Assmly Rmovl 1. Rmov ss pnl rom port si ottom owl. -Ass Pnl 2. Disonnt th ir tmprtur snsor onntor. 3. Rmov th ollowin rthr hoss: ylinr h to intk silnr, il ir ontrol ssmly to intk silnr. 4. Rmov mountin srws rom intk silnr n mountin srw rom inution silnr. 5. Rmov intk silnr. j i h -Air Tmprtur Snsor -Mountin Srw (6) M6 x 20 -Mountin Srw (2) M6 x 105 -Cylinr H Brthr Hos -Vpor Sprtor Vnt Hos -Il Air Control Assmly Brthr Hos -Intk Silnr h-inution Silnr i -Inution Silnr Mountin Srw(1) M6x20 j -O-rin (4) P 3C R1 NOVEMBER 2001
15 Instlltion 1. Connt il ir ontrol ssmly rthr hos to intk silnr. 2. Instll intk/inution silnr mountin srws n tihtn to spii torqu. 3. Connt vpor sprtor vnt hos to ptor plt ittin. 4. Connt ylinr h rthr hos to intk silnr n sur th hos ns with plsti st-strp. 5. Plu-in th ir tmprtur snsor onntor. j i h -Air Tmprtur Snsor -Mountin Srw (6) M6 x 20 -Mountin Srw (2) M6 x 105 -Cylinr H Brthr Hos -Vpor Sprtor Vnt Hos -Il Air Control Assmly Brthr Hos -Intk Silnr h-inution Silnr i -Inution Silnr Mountin Srw(1) M6x20 j -O-rin (4) Intk Silnr Mountin Srw Torqu 70 l-t. (8 Nm) R1 NOVEMBER 2001 P 3C-15
16 Intk Assmly Rmovl 1. Rmov th intk silnr ssmly. Rr to Intk Silnr Assmly Rmovl. 2. Rmov lowr owl. Rr to Mi - Stion smnt o this mnul. 3. Disonnt throttl n shit ls. Rr to Atthmnts/Control Link stion o this mnul. 4. Disonnt th vpor sprtor vnt hos rom th ptor plt ittin Vpor Sprtor Vnt Hos P 3C R1 NOVEMBER 2001
17 5. Disonnt th ollowin wir onntors: throttl position snsor, il ir ontrol hrnss, MAP snsor n hih prssur ul pump. 6. Disonnt th uppr n lowr wtr hoss rom th ul oolr. Rtin th mtl hos lmps or rssmly. 7. Disonnt th ul pump hos (ul pump to vpor sprtor). h i -Throttl Position Snsor Conntor -Il Air Control Conntor -MAP Snsor Conntor -Hih Prssur Ful Pump Conntor -Ful Coolr Uppr Wtr Hos -Ful Coolr Lowr Wtr Hos -Mtl Hos Clmp (2) (Rtin) h-st-strp (Disr) i -Ful Pump Hos (ul pump to vpor sprtor) R1 NOVEMBER 2001 P 3C-17
18 8. Disonnt th shit position swith n ul injtor onntors. Cut th st-strps rom th injtor hrnss. Pl th injtor hrnss out o th wy (on th top o th nin) Shit Position Swith -Ful Injtor Conntor (4) -St-strp (2) (Disr) 9. Rmov th intk ssmly mountin srws n th rkt mountin srws. -Intk Assmly Mountin Srws (5) -Brkt Mountin Srws (4) P 3C R1 NOVEMBER 2001
19 Instlltion 1. Instll th intk ssmly n tihtn mountin srws to spii torqu. 2. Instll th rkt mountin srws n tihtn to spii torqu Intk Assmly Mountin Srws (5) M8 x 40 -Brkt Mountin Srws (4) M6 x 20 Intk Assmly Mountin Srw Torqu 13 l-t. (18 Nm) Brkt Mountin Srw Torqu 70 l-in (8 Nm) 3. Instll vpor sprtor vnt hos onto ptor plt ittin Vpor Sprtor Vnt Hos R1 NOVEMBER 2001 P 3C-19
20 4. Rout th ul injtor hrnss s shown n sur with st-strps in lotions shown. 5. Plu in th ul injtor onntors n th shit position swith onntor. -Shit Position Swith Conntor -Ful Injtor Conntor (4) -St-strp (2) (Nw) P 3C R1 NOVEMBER 2001
21 6. Plu in th ollowin onntors: il ir ontrol, throttl position snsor, MAP snsor, hih prssur ul pump. 7. Connt th ul oolr wtr hoss (uppr n lowr) n sur with mtl hos lmp (rtin rom isssmly). 8. Connt th ul pump hos n sur with st-strp. 9. Instll throttl n shit ls. Rr to Atthmnts/Control Link stion o this mnul. 10. Instll lowr owl. Rr to Mi - Stion smnt o this mnul. 11. Instll intk silnr ssmly. Rr to Intk Silnr Assmly Instlltion. h i -Throttl Position Snsor Conntor -Il Air Control Conntor -MAP Snsor Conntor -Hih Prssur Ful Pump Conntor -Ful Coolr Uppr Wtr Hos -Ful Coolr Lowr Wtr Hos -Mtl Hos Clmp (2) (Rtin) h-st-strp (Nw) i -Ful Pump Hos (ul pump to vpor sprtor) R1 NOVEMBER 2001 P 3C-21
22 Throttl Boy Rmovl 1. Rmov th intk silnr ssmly. Rr to Intk Silnr Assmly Rmovl. 2. Disonnt th throttl link ro rom th throttl ontrol lvr y rully pryin th plsti n o o th ll joint. 3. Rmov rkt mountin srws Brkt Mountin Srws (4) M6 x 25 -Throttl Link Ro -Throttl Control Lvr P 3C R1 NOVEMBER 2001
23 4. Rmov throttl oy mountin srws. 5. Disonnt ir lins (throttl oy to il ir ontrol). Rtin mtl hos lmps or rssmly. 6. Rmov th rkt mountin srws n rmov th rkts rom h throttl oy (i rquir). NOTE: Whn rmovin th throttl oy ssmlis rul not to los th owl pins n o-rins. NOTE: Whn sprtin th uppr n lowr throttl oy ssmlis rul not to los th sprin. -Brkt Mountin Srw (4) M6 x 25 -Air Lins (2) (throttl oy to il ir ontrol) -Throttl Boy Mountin Srw (6) M8 x 70 -Sprin -Lotin Pin (4) -O-rin (4) -Mtl Hos Clmp (2) (Rtin) R1 NOVEMBER 2001 P 3C-23
24 Instlltion 1. Assml throttl oy to intk mniol. Tihtn srws to spii torqu. 2. Assml mountin rkts to throttl oy. Tihtn srws to spii torqu. 3. Instll sprin twn uppr n lowr throttl oy s shown. 4. Connt ir lins n sur with mtl hos lmps. 5. Instll intk silnr ssmly. Rr to Intk Silnr Assmly Instlltion. -Brkt Mountin Srw (4) M6 x 25 -Air Lins (2) (throttl oy to il ir ontrol) -Throttl Boy Mountin Srw (6) M8 x 70 -Sprin -Lotin Pin (4) -O-rin (4) -Mtl Hos Clmp (2) (Rtin) Throttl Boy Mountin Srw Torqu 13 l-t.. (18 Nm) Brkt Srw Torqu 70 l-in (8 Nm) P 3C R1 NOVEMBER 2001
25 Throttl Control Lvr n Link Rmovl 1. Rmov intk silnr ssmly. Rr to Intk Silnr Assmly Rmovl. 2. Rmov throttl ontrol lvr mountin srw. 3. Rmov rminin omponnts s shown. 4. Rmov lrtor m nut. 5. Rmov rminin omponnts s shown. h i LT C with Tlon Mountin Srw (1) M6 x 30 -Collr(2) -Wv Wshr(2) -Wshr(3) -Throttl Control Lvr -Sprin -Alrtor Cm Nut h-alrtor Cm i -Stu Bolt R1 NOVEMBER 2001 P 3C-25
26 Instlltion 1. Instll sprin so t loks into noth s shown. h i LT j C with Tlon Mountin Srw (1) M6 x 30 -Collr(2) -Wv Wshr(2) -Wshr(3) -Throttl Control Lvr -Sprin -Nut h-alrtor Cm i -Stu Bolt j -Sprin T 2. Rssml omponnts s shown ov. Tihtn lrtor m nut n mountin srw to spii torqu. Alrtor Cm Nut Torqu 70 l-in (8 Nm) Throttl Control Lvr Mountin Srw Torqu 70 l-in (8 Nm) P 3C R1 NOVEMBER 2001
27 Hih Prssur Ful Lin WARNING Alwys rls th ul prssur in th hih-prssur ul lin or srviin th lin or th vpor sprtor. I th ul prssur is not rls, prssuriz ul my spry out. Rlsin Ful Prssur in th Hih-Prssur Ful Lin 1. Instll th ul prssur u onto th prssur hk vlv. 2. Pl th rin hos into ontinr. 3. Opn th vlv n rls th prssur A7 -Ful Prssur Gu -Vlv -Drin Hos R1 NOVEMBER 2001 P 3C-27
28 Rmovl 1. Rmov intk ssmly. Rr to Intk Assmly Rmovl. 2. Rmov th vpor sprtor mountin srws. 3. Disonnt hoss s n. 4. Rmov ul ril mountin srws. 5. Rmov ul oolr mountin srws. l j k i h m -Vpor Sprtor Mountin Srw (3) M6 x 30 -Vpor Sprtor -Prssur Rultor Hos (to intk mniol ittins n il ir ontrol iltr) -Prssur Rultor -Ful Ril Mountin Srw (2) M8 x 45 -Ful Ril Mountin Srw (1) M6 x 25 -Ful Ril h-ful Coolr Mountin Srw (2) M6 x 25 i -Ful Coolr j -Flt Wshr(3) k -Collr(3) l -Plsti Collr (3) m-plsti Collr (2) (stpp) P 3C R1 NOVEMBER 2001
29 Instlltion 1. Assml vpor sprtor to intk mniol. Tihtn srws to spii torqu. 2. Assml ul oolr n ul ril to intk mniol. Tihtn srws to spii torqu. 3. Atth hoss s shown. 4. Assml intk mniol ssmly to nin. Rr to Intk Assmly Instlltion. l j k i h m -Vpor Sprtor Mountin Srw (3) M6 x 30 -Vpor Sprtor -Prssur Rultor Hos (to intk mniol ittins n il ir ontrol iltr) -Prssur Rultor -Ful Ril Mountin Srw (2) M8 x 45 -Ful Ril Mountin Srw (1) M6 x 25 -Ful Ril h-ful Coolr Mountin Srw (2) M6 x 25 i -Ful Coolr j -Flt Wshr(3) k -Collr(3) l -Plsti Collr (3) m-plsti Collr (2) (stpp) Vpor Sprtor Mountin Srw Torqu 70 l-in (8 Nm) Ful Ril Mountin Srw Torqu (M8 x 45) 13 l-t. (18 Nm) Ful Ril/Ful Coolr Mountin Srw Torqu (M6 x 25) 70 l-in (8 Nm) R1 NOVEMBER 2001 P 3C-29
30 Ful Coolr Rmovl/Instlltion REMOVAL 1. Cut st-strps n rmov ul oolr mountin srws. NOTE: Whn rmovin th mountin srws, rul not to los th sprs twn ul oolr s n intk mniol. 2. Disonnt th ul oolr wtr n ul hoss. Rtin mtl hos lmps. INSTALLATION 1. Connt ul oolr wtr n ul hoss n sur with mtl hos lmps (rtin rom isssmly). 2. Instll ul oolr mountin srws n sprs. Tihtn srws to spii torqu. 3. Atth st-strps s shown Ful Coolr -St-Strp (2) -Mountin Srw (2)(M6 x 30) -Spr (2) -Wtr Hos -Ful Hos -Mtl Hos Clmp (4) (Rtin) Ful Coolr Mountin Srw Torqu 70 l-in (8 Nm) P 3C R1 NOVEMBER 2001
31 Ful Hoss Rmovl/Instlltion REMOVAL 1. Rmov intk ssmly. Rr to Intk Assmly Rmovl. 2. Rmov hoss s shown low. Rtin mtl hos lmps. INSTALLATION 1. Ronnt hoss s shown low. 2. Sur ul hoss with mtl hos lmps (rtin rom isssmly). 3. Instll intk ssmly. Rr to Intk Assmly Instlltion. -Mtl Hos Clmp (6) (Rtin) -Ful Hos (Vpor Sprtor to Ful Ril) -Ful Hos (Prssur Rultor to Ful Coolr) -Ful Hos (Ful Coolr to Vpor Sprtor) R1 NOVEMBER 2001 P 3C-31
32 Ful Injtors Rmovl/Instlltion REMOVAL 1. Rmov ul ril rom intk mniol. Rr to Hih Prssur Ful Lin Rmovl. 2. Rmov th ul injtors rom th ul ril (twist whil pullin out). INSTALLATION 1. Lurit th o-rin. 2. Instll th ul injtor into th ul ril. 3. Instll th ul ril ssmly to th intk mniol. Rr to Hih Prssur Ful Lin Instlltion. -Ful Injtor -Ful Ril -Intk Mniol -O-rin -Rur Dmpr -Rur Sl P 3C R1 NOVEMBER 2001
33 Ful Ril Disssmly/Assmly DISASSEMBLY 1. Rmov ul ril rom intk mniol. Rr to Hih Prssur Ful Lin Rmovl. 2. Rmov ul injtors rom ul ril. Rr to Ful Injtor Rmovl. 3. Rmov ul hoss. Rr to Ful Hos Rmovl. 4. Rmov prssur rultor. Rr to Prssur Rultor Rmovl. 5. Rmov ul ril joint srws. Rmov ul ril joint. ASSEMBLY 1. Lurit o-rin n instll onto ul ril joint. 2. Instll ul ril joint onto ul ril n tihtn srws to spii torqu. 3. Instll prssur rultor. Rr to Prssur Rultor Instlltion. 4. Instll ul hoss. Rr to Ful Hos Instlltion. 5. Instll ul injtors onto ul ril. Rr to Ful Injtor Instlltion. 6. Instll ul ril onto intk mniol. Rr to Hih Prssur Ful Lin Instlltion. -Cp -Ful Ril -O-rin -Ful Ril Joint -Ful Ril Joint Srw (2) M5 x 10 Ful Ril Joint Srw Torqu 43 l-in (5 Nm) R1 NOVEMBER 2001 P 3C-33
34 Vpor Sprtor Rmovl 1. Rmov th intk mniol ssmly. Rr to Intk Assmly Rmovl. 2. Rmov th ollowin ul lins: vpor sprtor to ul oolr (rus mtl hos lmps), vpor sprtor to ul ril (isr th mtl hos lmps rom this hos) Ful Hos (vpor sprtor to ul oolr) -Ful Hos (vpor sprtor to ul ril) 3. Rmov th vpor sprtor mountin srws. Rmov th vpor sprtor. Instlltion -Vpor Sprtor Mountin Srw (3) M6 x 30 -Vpor Sprtor 1. Assml th vpor sprtor to th intk mniol s shown in th illustrtion ov. Tihtn mountin srws to spii torqu. 2. Connt th ollowin ul lins: vpor sprtor to ul oolr (sur with mtl hos lmps rtin rom isssmly), vpor sprtor to ul ril (instll nw mtl hos lmps on this hos). 3. Instll th intk mniol ssmly. Rr to Intk Assmly Instlltion. Vpor Sprtor Mountin Srw Torqu 70 l-in (8 Nm) P 3C R1 NOVEMBER 2001
35 Disssmly 1. Rmov top ovr srws. Rmov top ovr ssmly. 2. Rmov hih prssur ul pump iltr n holr. Inspt iltr or ris n ln i nssry. -Top Covr Srw (7) M4 x 16 -Top Covr Assmly -Hih Prssur Ful Pump Filtr -Holr -O-rin -Flot Chmr 3. Rmov lot pin y prssin on th roun n, NOT THE SQUARE END. Driv th pin out in th irtion shown. -Flot Pin -Squr En -Roun En R1 NOVEMBER 2001 P 3C-35
36 4. Rmov nl vlv, srw n rtinr. CAUTION Whn rmovin th ollr o not r th I.D. with plirs or similr tool. Doin this my us m to th or n rsult in th nl vlv stikin or not stin proprly. 5. Rmov th ollr i rquir. 6. Disonnt th hih prssur ul pump onntor. 7. Rmov th hih prssur ul pump (my hv to twist whil pullin out). h -Nl Vlv -Srw (1) M3 x 8 -Rtinr -Collr -O-rin -Hih Prssur Ful Pump Conntor -Rur Grommt h-hih Prssur Ful Pump P 3C R1 NOVEMBER 2001
37 Assmly 1. Lurit o-rin on ollr n instll ollr (i rmov). Twist ollr whil pushin in. 2. Instll rtinr n tihtn srw. 3. Instll nl vlv in ollr. 4. Instll lot n lot pin (roun n o pin shoul instll irst). Flot pin n shoul lush with sur. 5. Plu in hih prssur ul pump onntor. 6. Instll th rur rommt into th top ovr ssmly. Instll th hih prssur ul pump r n into th rur rommt (pply lurint i nssry). j k i h -Nl Vlv -Srw (1) M3 x 8 -Rtinr -Collr -O-rin -Hih Prssur Ful Pump Conntor -Rur Grommt h-hih Prssur Ful Pump i -Flot Pin j -Squr En k -Roun En R1 NOVEMBER 2001 P 3C-37
38 7. Instll hih prssur ul pump iltr n holr. 8. Instll top ovr ssmly into lot hmr. Ts on hih prssur ul pump iltr n to lin with noths t ottom o lot hmr. 9. Instll n tihtn srws. -Top Covr Srw (7) M4 x 16 -Top Covr Assmly -Hih Prssur Ful Pump -Hih Prssur Ful Pump Filtr -Holr -O-rin -Flot Chmr P 3C R1 NOVEMBER 2001
39 Prssur Rultor Rmovl/Instlltion REMOVAL 1. Rmov mtl hos lmps (rtin) n hoss. 2. Rmov srws n pull prssur rultor rom injtor ril (twist whil pullin). INSTALLATION 1. Lurit o-rin n instll prssur rultor. 2. Tihtn srws to spii torqu. 3. Instll hoss. Instll hos lmp on hos (prssur rultor to ul oolr). -Mtl Hos Clmp (Rtin) -Hos (prssur rultor to ul oolr) -Hos (intk mniol to prssur rultor) -Srw (2) M6 x 15 -Prssur Rultor -O-rin Prssur Rultor Srw Torqu 70 l-in (8 Nm) R1 NOVEMBER 2001 P 3C-39
40 Il Sp Control Assmly Rmovl/Instlltion REMOVAL 1. Rmov intk ssmly. Rr to Intk Assmly Rmovl. 2. Disonnt vuum hos rom iltr. 3. Rmov il ir ontrol mountin srws. 4. Rmov il ir ontrol ssmly. 5. Rmov mtl hos lmps (rtin) n hoss s n. INSTALLATION 1. Instll il ir ontrol ssmly. Tihtn srws to spii torqu. 2. Connt vuum hos to iltr. 3. Connt ir hoss n sur with mtl hos lmps (rtin rom isssmly). i j h Filtr -Vuum Hos (il ir ontrol to intk mniol) -Il Air Control Mountin Srw (2) M8 x 60 -Il Air Control Mountin Srw (1) M8 x 24 -Il Air Control Assmly -Hos (il ir ontrol ssmly to throttl oy #2) -Hos (il ir ontrol ssmly to throttl oy #1) h-mtl Hos Clmp (4) (Rtin) i -Throttl Boy #1 j -Throttl Boy #2 Il Air Control Assmly Mountin Srw Torqu 156 l-in (18 Nm) P 3C R1 NOVEMBER 2001
41 Disssmly/Assmly DISASSEMBLY 1. Rmov prssur snsor srws n prssur snsor (twist whil pullin). 2. Rmov il ir ontrol srws. Rmov ir sp ontrol rom il ir ontrol oy. 3. Rmov iltr. ASSEMBLY 1. Instll iltr. 2. Instll il ir ontrol to il ir ontrol oy. 3. Instll th mniol solut prssur (MAP) snsor n tihtn srws to spii torqu. -MAP Snsor Srws (2) M5 x 15 -MAP Snsor -O-rin -Srw (3) M4 x 15 -Il Air Control -O-rin -Il Air Control Boy h-filtr (24mm Hx) h Mniol Asolut Prssur Snsor Mountin Srw Torqu 43 l-in (5 Nm) Il Air Control Mountin Srw Torqu 18 l-in (2 Nm) R1 NOVEMBER 2001 P 3C-41
42 Intk Mniol Disssmly/Assmly DISASSEMBLY 1. Rmov intk ssmly. Rr to Intk Assmly Rmovl. 2. Rmov throttl oy, hih prssur ul lin, vpor sprtor, ul ril n il ir ontrol ssmly. Rr to pproprit smnt in this stion or rmovl instrutions. 3. Rmov omponnts s s shown in illustrtion. ASSEMBLY 1. Instll omponnts s shown in illustrtion. 2. Instll throttl oy, hih prssur ul lin, vpor sprtor, ul ril n il sp ontrol ssmly. Rr to pproprit smnt in this stion or instlltion instrutions. -Hos (prssur rultor to intk mniol to il sp ontrol ssmly) -Rur Sl (4) (Ful Injtor) -Intk Mniol -Collr (6) (Vpor Sprtor Mount) -Grommt (3) (Vpor Sprtor Mount) P 3C R1 NOVEMBER 2001
43 Throttl Position Snsor Rmovl/Instlltion REMOVAL 1. Disonnt throttl position snsor onntor. 2. Rmov th tmpr proo srws or th rkt (ovrin th throttl position snsor) n throttl position snsor usin spil tool p/n INSTALLATION 1. Instll throttl position snsor n torqu tmpr proo srws usin spil tool Instll th rkt n torqu tmpr proo srws usin spil tool Connt throttl position snsor onntor. Rr to stion 2C Timin, Synhronizin n Ajustin or justmnt o th throttl position snsor. i h Throttl Position Snsor -Wshr (2) -Wshr (2) -Tmpr Proo Srw (2) M4 x 12 (T20) Throttl Position Snsor Tmpr Proo Srw Torqu 18 l-in (2 Nm) Brkt Tmpr Proo Srw Torqu 40 l-in (5 Nm) -Brkt -Lok Wshr (3) -Spool (3) h-wshr (3) (Cupp) i -Tmpr Proo Srw (3) M5 x 12 (T25) R1 NOVEMBER 2001 P 3C-43
44 Low Prssur Ful Lin/Ful Pump Rmovl 1. Rmov rommt rtinin plt. 2. Cut st-strp n rmov ul hos rom rommt. -Grommt Rtinin Plt -Srw (2) M6 x 28 -Ful Hos Opnin -Rur Grommt -St-Strp (Disr) 3. Rmov sprk plu ovr. 4. Disonnt ul hos rom ul pump n ul iltr. 5. Rmov ul pump. Rmov ul iltr mountin rkt ssmly. i h j k -Sprk Plu Covr -Srw (5) M6 x 16 -St-Strp (4) (Disr) -Ful Hos (ul pump to vpor sprtor) -Ful Filtr Mountin Brkt Assmly -Srw (1) M6 x 16 -Ful Pump h-srw (2) M6 x 30 i -O-rin j -Low Prssur Ful Lin k -Conuit P 3C R1 NOVEMBER 2001
45 Instlltion 1. Instll ul pump n ul iltr. Tihtn mountin srws to spii torqu. 2. Connt ul hoss s shown. Sur with st-strps. 3. Instll sprk plu ovr. Tihtn srws to spii torqu. h i j k -Sprk Plu Covr -Srw (5) M6 x 16 -St-Strp (4) (Nw) -Ful Hos (ul pump to vpor sprtor) -Ful Filtr Mountin Brkt Assmly -Srw (1) M6 x 16 -Ful Pump h-srw (2) M6 x 30 i -O-rin j -Low Prssur Ful Lin k -Conuit 4. Rout th ul lin throuh th opnin in th rur rommt n instll st-strp. 5. Instll rommt rtinin plt. Tihtn srws to spii torqu. -Grommt Rtinin Plt -Srw (2) M6 x 28 M6 Mountin Srw Torqu 70 l-in (8 Nm) -Ful Hos Opnin -Rur Grommt -St-Strp (Nw) R1 NOVEMBER 2001 P 3C-45
46 Disssmly/Assmly DISASSEMBLY 1. Rmov ul hoss rom ul iltr ssmly n ul pump s shown. Disr ststrps. ASSEMBLY 2. Connt ul hoss to ul iltr n ul pump s shown. Sur with nw st-strps. -Ful Filtr Assmly -Ful Hos (ul supply to ul iltr) -Ful Pump -Ful Hos (ul iltr to ul pump) -St-Strps (3) -Conuit P 3C R1 NOVEMBER 2001
47 Ful Filtr Disssmly/Assmly DISASSEMBLY 1. Rmov ul iltr rkt. 2. Unsrw ul iltr up n rmov lot, ul iltr lmnt, n o-rins. ASSEMBLY 1. Instll ul iltr lmnt onto ul iltr p. 2. Instll lot into ul iltr up. Lin up noths in lot with ris on th insi o th ul iltr up. 3. Hn tihtn ul iltr up. h -Nut -Ful Filtr Mountin Brkt -Ful Filtr Cp -O-rin -O-Rin -Ful Filtr Elmnt -Flot h-ful Filtr Cup R1 NOVEMBER 2001 P 3C-47
48 Ful Pump Disssmly 1. Rmov ul pump ssmly rom nin. 2. Rmov ul pump ovr. 3. Rmov ul pump oy rom ul pump s ssmly. 4. Disssml s shown. LT Ful Pump Boy -Ful Pump Bs Assmly -Ful Pump Covr -Gskt -Srw (3) M6 x Insrt srwrivr in th plunr slot n rott until th pin lins up with th roov Plunr -Groov -Ful Pump Bs Assmly P 3C R1 NOVEMBER 2001
49 CAUTION Plunr is sprin lo. Pl th ul pump ssmly on nh top (so plunr is in own) or pullin th pin ompltly out. Filur to o this oul rsult in injury u to ojts lyin throuh th ir. 6. Insrt srwrivr in k si o slot n push pin out. Gr pin with nl nos n pull ompltly out Pin -Plunr 7. Disssml omponnts s shown. -Diphrm -Sprin -Ful Pump Bs -Sprin -Plunr -Pin -Nut R1 NOVEMBER 2001 P 3C-49
50 Assmly 1. Instll omponnts s shown. -Diphrm -Sprin -Ful Pump Bs -Sprin -Plunr -Pin 2. Push own on th plunr until th roov lins up with th hol in th n o th iphrm sht. Insrt pin Pin -Plunr -Hol in Diphrm Sht 3. Rott plunr k to oriinl position (pin shoul 90 rom roov) Plunr -Groov -Ful Pump Bs Assmly P 3C R1 NOVEMBER 2001
51 4. Alinmnt mrks on ul pump oy, s ssmly n ovr shoul s shown low. Assml ul pump oy, ovr, n nw skt to ul pump s. Apply Lotit 242 (otin lolly) n tihtn srws to spii torqu Lotit 242 Thr Lokr -Ful Pump Boy -Ful Pump Bs Assmly -Ful Pump Covr -Gskt (NEW) -Srw (3) M6 x 35 -Nut (3) M6 Mountin Srw Torqu 70 l-in (8 Nm) R1 NOVEMBER 2001 P 3C-51
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