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1998 Ford F-150/250 Fuel Charging and Controls DESCRIPTION AND OPERATION

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Filed Under (Ford) by admin on 25-03-2011

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Fuel Charging and Controls The fuel charging and controls system consists of: fuel pressure regulator (9C968) fuel injection supply manifold (9F792) fuel injectors (9F593) fuel shut off valve solenoid (9D278) fuel pressure relief valve (9H321) injection pressure sensor engine fuel temperature sensor fuel charging wiring harness Component Location Fuel Pressure Regulator The fuel pressure regulator is located on the inside of the LH frame rail just forward of the transmission support crossmember. It is part of an assembly that includes the coalescer/filter. The fuel pressure regulator reduces the line pressure from tank pressure 20685 kPa (3000 psi) to line pressure 655 kPa (95 psi). Heating/Defrosting—Natural Gas Vehicle Fuel pressure regulator heating is provided by two 3/8-inch taps from the existing heater supply and return hoses on the RH rear of the engine. Two high-temperature 3/8-inch ID heater hoses (packaged with the front low-pressure fuel line) are used to connect the fuel pressure regulator to the tap points on the engine heater hoses. Refer to the Line — Low Pressure Fuel procedure in Section 310-01B for fuel pressure regulator heater hose replacement. Fuel Pressure Regulator Heater Hoses Fuel Injection Supply Manifold The fuel injection supply manifold delivers high-pressure fuel from the vehicle fuel supply line to the fuel injectors. The fuel injection supply manifold consists of the following: a tubular fuel rail eight fuel injector connectors a fuel pressure relief valve a fuel shut off valve solenoid mounting attachments which locate the fuel injection supply manifold and provide fuel injector retention. a fuel inlet connection which has a push-connect fitting an injection pressure sensor an engine fuel temperature sensor Fuel Injection Supply Manifold Fuel Injectors The natural gas fuel injectors are electro-mechanical devices that meter fuel delivered to the engine. The natural gas fuel injectors are mounted in the lower intake manifold (9424) and are positioned so that their tips direct fuel just ahead of the engine intake valves (6507). The natural gas fuel injector bodies consist of a solenoid and a needle and valve assembly. Natural gas fuel injectors can be identified by an aqua cap on the injector body. Fuel Shutoff Valve Solenoid The fuel shut off valve solenoid seals the upstream fuel pressure from entering the fuel injection supply manifold when the engine is not running. The fuel shut off valve solenoid is open only when it is activated by the solenoid valve (fuel pump) relay. Fuel Pressure Relief Valve The fuel pressure relief valve is located on the fuel injection supply manifold, and is used to relieve fuel system pressure from the fuel delivery system. Injection Pressure Sensor The injection pressure sensor is located on the fuel injection supply manifold, and is used to provide a signal to the powertrain control module (PCM) (12A650) that is proportional to pressure in the fuel injection supply manifold. Engine Fuel Temperature Sensor The engine fuel temperature sensor is located on the fuel injection supply manifold, and is used to provide a signal to the powertrain control module that indicates the temperature of the fuel in the fuel injection supply manifold. Fuel Charging Wiring The fuel charging wiring is a single harness that includes electrical connectors for the fuel injectors, ignition coils and various sensors, valves and senders that monitor all engine functions. Fuel Charging Wiring

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1997 Isuzu Rodeo S FUEL PUMP PRESSURE TEST

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Filed Under (Isuzu) by admin on 23-12-2010

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NOTE: 1. Release fuel pressure. See FUEL SYSTEM PRESSURE RELEASE . Install a fuel pressure gauge between fuel pressure regulator and fuel distributor pipe. See Fig. 1 . Bleed air from fuel line going to pressure gauge. 2. Unplug fuel pressure regulator Vacuum Switching Valve (VSV) connector on right side fender skirt. This is a 4-wire connector with Black and Blue wires in harness. PCM controls VSV to cut vacuum to fuel pressure regulator during hot engine starts. 3. Start engine and measure fuel pressure at idle. Disconnect fuel pressure regulator vacuum hose. Note fuel pressure at idle with vacuum hose disconnected (no vacuum). Fuel pressure should be 42 psi (3.0 kg/cm2 ). See FUEL PUMP PERFORMANCE . 4. If fuel pump pressure is low, check for fuel leaks, restrictions in intake side of fuel pump, leaking injectors, faulty pressure regulator or faulty fuel pump. If fuel pressure is high, check for restrictions in return line to tank or faulty pressure regulator. If pressure does not change when pressure regulator is disconnected, replace pressure regulator. 5. Reconnect pressure regulator vacuum hose and check fuel pressure (with vacuum). Fuel pressure should be 35 psi (2.4 kg/cm2 ). Apply battery voltage to VSV connector Blue wire terminal, and ground Black wire terminal (with vacuum). See Fig. 2 . Fuel pressure gauge should read about 42 psi (3.0 kg/cm2 ). If fuel pressure is not within specification, check for defective VSV. 6. Disconnect and plug vacuum hose from fuel pressure regulator. Stop engine and ensure fuel pressure remains greater than 35 psi (2.4 kg/cm2 ) for 4 minutes after engine stops. 7. If pressure drops, check for leaking injectors, faulty pressure regulator or bad check valve in fuel pump. If engine does not start, by-pass fuel pump relay to check for fuel pressure. Remove fuel pump relay from underhood fuse/relay box. Connect a fused jumper wire between terminals No. 1 and 3 of fuel pump relay connector in fuse block. See Fig. 3 and Fig. 4 . 8. If fuel pump does not operate, check for battery voltage to terminal No. 3. If battery voltage is present, check for open in fuel pump circuit. If fuel pump operates with jumper wire installed, check fuel pump relay and relay energizing circuit. Repair as necessary. Begin basic fuel system diagnosis with testing fuel pressure.

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1995 Ford Mustang Camshaft Position (CMP) Sensor Removal Installation

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Filed Under (Ford) by admin on 08-02-2011

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1. Disconnect battery ground cable (14301) . 2. Disconnect fuel charging wiring (9D930) from distributor stator (12A112) (camshaft position sensor). 3. Remove stator camshaft position sensor retaining screws and distributor stator (camshaft position sensor) from camshaft position sensor housing. 4. If removing camshaft position sensor housing from the engine front cover (6019) , proceed with Removal Step 5. If camshaft position sensor housing is not being removed, proceed to Installation Step 6. 5. CAUTION: Before proceeding with this procedure, set cylinder No. 1 to 26 degrees After Top Dead Center (ATDC) of the compression stroke. Then note the position of the stator (camshaft position sensor) electrical connector. The installation procedure requires that the connector be located in the same position. Remove retaining bolt and hold-down clamp (12270) . 6. NOTE: The oil pump intermediate shaft (6A618) should be removed with the camshaft position sensor housing. Remove camshaft position sensor housing from engine front cover . Installation 1. CAUTION: If the replacement distributor stator (camshaft position sensor) does not contain a plastic locator cover tool, a special service tool such as Syncro Positioning Tool T89P-12200-A must be obtained prior to installation of the replacement distributor stator (camshaft position sensor). Failure to follow this procedure will result in improper stator (camshaft position sensor) alignment. This will result in the fuel system being out of time with the engine, possibly causing engine damage. If the plastic locator cover tool is not attached to the replacement distributor stator (camshaft position sensor), attach Syncro Positioning Tool T89P-12200-A as follows: a. Engage camshaft position sensor housing vane into the radial slot of the tool. b. Rotate tool on camshaft position sensor housing until tool boss engages notch in camshaft position sensor housing. The cover tool should be square and in contact with entire top surface of camshaft position sensor housing. 2. Transfer oil pump intermediate shaft from old camshaft position sensor housing to replacement camshaft position sensor housing. 3. CAUTION: If stator (camshaft position sensor) electrical connector is not positioned properly (for example, contacting the A/C compressor bracket), DO NOT reposition the connector by rotating the camshaft position sensor housing. This will result in the fuel system being out of time with the engine, possibly causing engine damage. Remove the camshaft position sensor housing and repeat installation procedure, beginning with Step 1. Install camshaft position sensor housing so that drive gear engagement occurs when arrow on locator tool is pointed approximately 30 degrees counterclockwise from the front face of the cylinder block (6010) . This step will locate stator (camshaft position sensor) electrical connector in the pre-removal position. 4. Install hold-down clamp and retaining bolt and tighten bolt to 20-30 Nm (15-22 lb-ft). 5. Remove Syncro Positioning Tool T89P-12200-A. 6. CAUTION: If stator (camshaft position sensor) electrical connector is not positioned properly (for example, contacting the A/C compressor bracket), DO NOT reposition the connector by rotating the camshaft position sensor housing. This will result in the fuel system being out of time with the engine, possibly causing engine damage. Remove the camshaft position sensor housing and repeat installation procedure, beginning with Step 1. Install distributor stator (camshaft position sensor) and retaining screws. Tighten screws to 2.5-3.5 Nm (22-31 lb-in). 7. Connect fuel charging wiring connector to distributor stator (camshaft position sensor). 8. Connect battery ground cable .

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1998 Ford Windstar Camshaft Position (CMP) Sensor REMOVAL AND INSTALLATION

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Filed Under (Ford) by admin on 17-02-2011

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CAUTION: Prior to removal of the camshaft position sensor (CMP sensor) (12126) , set cylinder No.1 to zero degrees top dead center (TDC) of compression stroke. Then note the position of the camshaft position sensor electrical connector. The installation procedure requires the connector be located in the same position. Removal 1. Disconnect battery ground cable (14301). Refer to Section 14-01. 2. Disconnect fuel charging wiring connector from camshaft position sensor. 3. Remove camshaft position sensor retaining screws and camshaft position sensor from camshaft position sensor housing. 4. If removing camshaft position sensor housing from the cylinder block (6010), proceed with Removal Step 5. If not removing camshaft position sensor housing, proceed to Step 6 of the installation procedures. 5. Remove hold-down clamp (12270) (bolt and washer assembly). 6. NOTE: Remove the oil pump intermediate shaft (6A618) with the camshaft position sensor housing. Remove camshaft position sensor housing from cylinder block. Installation 1. CAUTION: If the replacement camshaft position sensor housing does not contain a plastic locator cover tool, a special service tool must be obtained prior to installation of the replacement camshaft position sensor. Failure to follow this procedure will result in improper camshaft position sensor alignment. This will result in the ignition fuel system being out of time with the engine, possibly causing engine damage. NOTE: For 3.0L engines, use Syncro Positioning Tool 303-589. For 3.8L engines, use Syncro Positioning Tool 303-562 (T96T-12200-A). If the plastic locator cover tool is not attached to the replacement camshaft position sensor housing, attach syncro positioning tool as follows: a. Engage camshaft position sensor housing vane into the radial slot of the tool. b. Rotate tool on camshaft position sensor housing until tool boss engages notch in camshaft position sensor housing. 2. Transfer oil pump intermediate shaft from old camshaft position sensor housing to replacement camshaft position sensor housing. 3. Install camshaft position sensor housing so drive gear engagement occurs when arrow on syncro positioning tool is pointed approximately as shown in the illustrations. This step will locate camshaft position sensor electrical connector in the pre-removal position. 4. Install hold-down clamp (washer and bolt assembly) and tighten bolt to 20-30 Nm (15-22 lb-ft). 5. Remove syncro positioning tool. 6. CAUTION: If camshaft position sensor electrical connector is not positioned properly, DO NOT reposition the connector by rotating the camshaft position sensor housing. This will result in the fuel system being out of time with the engine, possibly causing engine damage. Remove the camshaft position sensor housing and repeat installation procedure, beginning with Step 1. Install camshaft position sensor and retaining screws. On 3.0L engine, tighten screws to 2.5-3.5 Nm (23-30 lb-in). On 3.8L engine, tighten screws to 4.5-7 Nm (40-61 lb-in). 7. Connect fuel charging wiring connector to camshaft position sensor. 8. Connect battery ground cable. Refer to Section 14-01. Camshaft Position Sensor—3.0L Engine

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2006 Dodge RAM 1500 P2122-ACCELERATOR PEDAL POSITION SENSOR

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Filed Under (Dodge) by admin on 04-05-2011

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brake pedal is pressed or has failed. Acceleration rate and Engine output are limited. One trip fault and the code will set within 5 seconds . ETC light is flashing. POSSIBLE CAUSES (F855) 5-volt supply circuit open (F855) 5-volt supply circuit shorted to ground (K23) APP sensor no.1 signal circuit open (K23) APP sensor no.1 signal circuit shorted to ground (K23) APP sensor no.1 signal circuit shorted to the (K167) APP sensor no.1 return circuit (K23) APP sensor no.1 signal circuit shorted to the (K400) APP sensor no.2 return circuit APP sensor PCM Always perform the Pre-Diagnostic Troubleshooting procedure before proceeding. DIAGNOSTIC TEST 1. APP SENSOR BELOW 0.25 OF A VOLT Ignition on, engine not running. With a scan tool, read the APP Sensor No.1 voltage. Q: Is the voltage below 0.25 of a volt? YES: Go To 2 NO: Go To 11 2. (F855) 5-VOLT SUPPLY CIRCUIT WHEN MONITORED: With the ignition on and no other APPS No.1 DTCs present. SET CONDITION: When the APP Sensor No.1 voltage is too low. Engine will additionally idle if the Turn the ignition off. Disconnect the APP Sensor harness connector. Ignition on, engine not running. Measure the voltage on the (F855) 5-volt Supply circuit in the APP Sensor harness connector. Q: Is the voltage between 4.5 and 5.2 volts? YES: Go To 3 NO: Go To 8 3. ACCELERATOR PEDAL POSITION SENSOR

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