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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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Installation All engines 1. NOTE: Lubricate the new O-ring seals with clean engine oil to aid installation. Install new O-ring seals, as required. 2. Install the fuel injectors into the fuel injection supply manifold. 3. Position the fuel injection supply manifold and install the four bolts. 4. Connect the evaporative emission canister purge valve hose and the EGR valve vacuum hose. 4.6L engines 5. Install the exhaust manifold to EGR valve tube. 6. Connect the differential pressure feedback EGR system electrical connector. 5.4L engines 7. Install the exhaust manifold to EGR valve tube and connect the differential pressure feedback EGR system hoses. All engines 8. NOTE: 4.6L shown, 5.4L similar. Install the positive crankcase ventilation (PCV) hose. 9. Install the crankcase ventilation tube. 4.6L engines 10. Connect the brake booster vacuum tube and bracket and install the nut. 5.4L engines 11. Install the brake booster vacuum tube and bracket. 12. Connect the water heater inlet tube hose. 1. Connect the water heater inlet tube hose. 2. Compress and install the hose clamp. All engines 13. Connect the eight fuel injector electrical connectors. 14. Connect the eight ignition coil electrical connectors. 15. Connect the fuel tubes. For additional information, refer toSection 310-00A. 16. Connect the fuel pressure regulator valve vacuum hose.

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1. Disconnect the battery ground cable. For additional information, refer to Section 414-01. 2. Drain the engine cooling system. For additional information, refer to Section 303-03. 3. Remove the air cleaner outlet tube. For additional information, refer to Section 303-12. 4. Disconnect the fuel line. For additional information, refer to Section 310-00A or Section 310-00B. 5. Remove the wiper arm and pivot shaft. For additional information, refer to Section 501-16. 6. Remove the drive belt. For additional information, refer to Section 303-05. 7. Raise the vehicle on a hoist. For additional information, refer to Section 100-02. 8. Disconnect the electrical connector at the crankshaft position (CKP) sensor. Disconnect the pin-type retainer from the A/C compressor bracket. 9. Disconnect the electrical connector from the A/C compressor. 10. Remove the oil bypass filter. 11. Disconnect the oil pressure sensor electrical connector and the power steering pressure (PSP) switch electrical connector. 12. Disconnect the exhaust gas recirculation (EGR) tube from the exhaust manifold. 13. Lower the vehicle. 14. Disconnect the two differential pressure feedback EGR hoses. 15. Disconnect the RH heated oxygen sensor electrical connector. 16. Disconnect the fuel charging wiring electrical connectors from the eight ignition coils. 17. Disconnect the fuel charging wiring electrical connectors from the eight fuel injectors. 18. Disconnect the accelerator cable and the speed control actuator cable. 19. Remove the cables from the EGR tube heat shield and position out of the way. 20. Remove the bolts and the EGR tube heat shield.

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Circuit Description The control module enables the appropriate fuel injector on the intake stroke for each cylinder. An ignition 1 voltage is supplied directly to the fuel injectors. The control module controls each fuel injector by grounding the control circuit via a solid state device called a driver. Diagnostic Aids • Monitoring the fuel injector circuit status with a scan tool, while moving the fuel injector harness, may help to isolate an intermittent condition. • Performing the Fuel Injector Coil Test may help isolate an intermittent condition. Refer to Fuel Injector Solenoid Coil Test . • For an intermittent condition, refer to Intermittent Conditions . Test Description The numbers below refer to the step numbers on the diagnostic table. 4. This step tests for a short to ground on the ignition 1 voltage supply circuit of the fuel injector. 5. This step tests for an open ignition 1 voltage supply circuit between the injector fuse and a fuel injector electrical connector.

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Customer Concern: Tests/Procedures: Potential Causes: Tech Tips: Has a misfire on start up only. Sets cylinder #1 misfire code P0301 and cylinder #4 misfire code P0304. Sets pending misfire code P1399 as well. The problem only lasts a few seconds. Suspecting headgasket since the coolant level is low and smells anti-freeze when the engine is started. 1. Check for evidence of anti-freeze on the spark plugs or in the cylinders. Pressure test the cooling system and check for anti-freeze going into the cylinders. 2. If not anti-freeze, check fuel pressure and see if it holds in case a fuel injector is leaking down. 3. If pulling the cylinder head to replace the headgasket, have the cylinder head sent out and checked for cracks. Cylinder Head Cylinder Head Gasket Fuel Injectors Cylinder head was cracked. Other causes of a misfire like spark plug wires and incorrect valve adjustment are common but those wouldn’t likely be a misfire for just a few seconds on cold start up.