Файл: 92FWD_14.pdf

Fig. 9 Fuel Injector Ports

(5)Install the injector assemblies into their holes and install the attaching bolts. Draw the fuel rail assembly evenly into the intake manifold, making sure each injector enters its own hole. The oil separator bracket must be on top of the fuel rail bracket (Fig. 8).

(6)Once all injectors are evenly seated, tighten the fuel rail attaching bolts to 23 NIm (200 in. lbs.) torque.

(7)Connect the fuel injector wiring harness to the main harness.

(8)Lubricate the ends of the chassis tubes with clean 30 weight engine oil.

(9)Connect fuel hose quick connect fittings to the chassis fuel tubes. Pull on the fittings to ensure complete connection.

Refer to Quick Connect Fittings in the Fuel Delivery Section of this group.

(10)Connect the vacuum hose to the fuel pressure regulator.

(11)Connect negative cable to battery.

CAUTION: When using the ASD Fuel System Test, the Auto Shutdown (ASD) Relay remains energized for either 7 minutes, until the test is stopped, or until the ignition switch is turned to the Off position.

(12) With the DRB II use the ASD Fuel System Test to pressurize the fuel system to check for leaks.

FUEL INJECTORS

Remove the fuel rail to service the injectors. Refer to Fuel Injector Rail Assembly in this section.

REMOVAL

(1)Disconnect injector electrical connector from injector. (Fig. 10).

(2)Position fuel rail assembly so that the fuel injectors are easily accessible (Fig. 11).

Fig. 10 Fuel Rail and Injector Assembly

Fig. 11 Servicing Fuel Injectors

(3)Remove injector lock ring off the fuel rail and injector. Pull injector straight out of fuel rail receiver cup (Fig. 11).

(4)Check injector O-ring for damage. If O-ring is damaged, it must be replaced. If injector is reused, a protective cap must be installed on the injector tip to prevent damage.

(5)Repeat for remaining injectors.

INSTALLATION

(1)Before installing an injector, the rubber O-ring must be lubricated with a drop of clean engine oil to aid in installation.

(2)Being careful not to damage the O-ring, install injector top end into fuel rail receiver cup.

(3)Install injector lock ring by sliding open end into slot of the injector and onto the receiver cup ridge into the side slots of ring (Fig. 11).

(4)Repeat steps for remaining injectors.

(5)Install injector wiring harness to injectors. Place harness into retaining clips.

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FUEL PRESSURE REGULATOR

WARNING: THE 2.5L TURBO I FUEL SYSTEM IS UNDER A CONSTANT PRESSURE OF APPROXIMATELY 380 KPA (55 PSI). PERFORM FUEL PRESSURE RELEASE PROCEDURE BEFORE SERVICING THE FUEL PRESSURE REGULATOR.

REMOVAL

(1)Perform fuel system pressure release procedure.

(2)Disconnect negative cable from battery.

(3)Disconnect vacuum hose from fuel pressure regulator (Fig. 12).

Fig. 12 Servicing Fuel Pressure Regulator

Place a shop towel under fuel pressure regulator to absorb any fuel spillage.

(4)Loosen fuel hose clamp and remove fuel return

hose.

(5)Remove fuel pressure regulator mounting nuts. Remove fuel pressure regulator from rail (Fig. 12). Check O-Ring for damage. If O-Ring is damaged it must be replaced.

INSTALLATION

(1)Lubricate O-ring with a drop of clean engine oil. Install O-ring into the receiver cup on fuel rail.

(2)Install fuel pressure regulator mounting nuts. Tighten nuts to 7 NIm (65 in. lbs.) torque.

(3)Connect fuel return hose to pressure regulator. Tighten hose clamp to 1 NIm (10 in. lbs.) torque (Fig. 12).

(4)Install vacuum hose on fuel pressure regulator.

(5)Connect negative cable to battery.

CAUTION: When using the ASD Fuel System Test, the Auto Shutdown (ASD) Relay remains energized for either 7 minutes, until the test is stopped, or until the ignition switch is turned to the Off position.

(6) With the DRB II use the ASD Fuel System Test to pressurize system and check for leaks.

FUEL SYSTEMS 14 - 103

MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR SERVICE

(1)Remove vacuum hose from MAP sensor (Fig. 13)

(2)Remove MAP sensor mounting screws (Fig. 13).

(3)Remove electrical connector. Remove sensor.

(4)Reverse the above procedure for installation.

Fig. 13 Manifold Absolute Pressure Sensor

WASTEGATE AND CANISTER PURGE SOLENOID SERVICE

(1)Remove vacuum hoses from sensors (Fig. 14).

(2)Disconnect electrical connector from solenoids (Fig. 14).

(3)Remove solenoid pack mounting nut. Remove solenoid pack.

(4)Depress tab on top of solenoid to be replaced and slide the solenoid downward out of mounting bracket.

(5)Reverse above procedure to install.

Fig. 14 Solenoid Mounting

ENGINE CONTROLLER SERVICE

(1)Remove air cleaner duct from engine controller.

(2)Remove battery.

Fig. 15 Engine Controller

HEATED OXYGEN SENSOR (O2 SENSOR)

The oxygen sensor is installed in the exhaust manifold (Fig. 16).

CAUTION: Do not pull on the oxygen sensor wires when disconnecting the electrical connector.

WARNING: THE EXHAUST MANIFOLD MAY BE EXTREMELY HOT. USE CARE WHEN SERVICING THE OXYGEN SENSOR.

(1)Disconnect oxygen sensor electrical connector.

(2)Remove sensor using Tool C-4907 (Fig. 17).

Fig. 16 Oxygen Sensor

Fig. 17 Oxygen Sensor Socket

When the sensor is removed, the exhaust manifold threads must be cleaned with an 18 mm X 1.5 + 6E tap. If using original sensor, coat the threads with Loctite 771-64 anti-seize compound or equivalent. New sensors are packaged with compound on the threads and do not require additional compound. Tighten the sensor to 27 NIm (20 ft. lbs.) torque.

sure (air density) are the primary inputs that determine injector pulse width.

SYSTEM DIAGNOSIS

The engine controller tests many of its own input and output circuits. If a fault is found in a major system, the information is stored in memory. Technicians can display fault information through the instrument panel Check Engine lamp or by connecting the Diagnostic Readout Box II (DRB II). For fault code information, refer to On Board Diagnostics in 3.0 Multi-Point Fuel InjectionÐGeneral Diagnosis section of this group.

CCD BUS

Various controllers and modules exchange information through a communications port called the CCD Bus. The engine controller transmits the check engine lamp On/Off signal, engine RPM and vehicle load data on the CCD Bus.

ENGINE CONTROLLER

The engine controller is a digital computer containing a microprocessor (Fig. 2). The controller receives input signals from various switches and sensors that are referred to as Engine Controller Inputs. Based on these inputs, the controller adjusts various engine and vehicle operations through devices referred to as Engine Controller Outputs.