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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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Following instructions apply to left cylinder head. Removing Remove ribbed belt => page 13-6. Remove toothed belt => page 13-10. Remove noise insulation panel (arrows). Unbolt left and right-side front exhaust pipes from exhaust manifolds. Unbolt exhaust system from transmission bracket. Place clean VW1306 receptacle or drain pan under engine. Remove filler cap from coolant expansion tank. WARNING! The cooling system is pressurized when the engine is warm. When opening the expansion tank, wear gloves and other appropriate protection, cover the cap with a cloth and open carefully to relieve system pressure slowly. Unscrew drain plug (arrow) on left-side of radiator. Install drain hose to connection if necessary. Remove coolant drain plug on engine (arrow) using 3247 hex ball socket, and drain coolant. Remove intake air duct between mass air flow sensor and intake air elbow. Disconnect harness connectors for intake manifold tuning valve -3- and intake air temperature sensor -4-. Move wiring clear. Disconnect vacuum lines (arrows). Disconnect hose between Evaporative Emission (EVAP) canister purge regulator valve and throttle assembly at throttle assembly. Unbolt retaining plate for intake manifold tuning valve (bolts -2-). Disconnect connector on throttle assembly and disconnect vacuum hose on fuel pressure regulator. Disconnect harness connectors from camshaft adjustment valve and fuel injectors (arrows). Disconnect harness connectors from Engine Coolant Temperature (ECT) sensor and Camshaft Position (CMP) sensor (arrows). Cut open tie wraps on cylinder head cover, unclip wiring retainer on fuel rail and disconnect cylinder block breather from left and right-side cylinder head covers. Move hoses and wiring clear to rear. Remove 4 bolts for fuel rail on intake manifold. Unclip fuel supply and return lines from retainer. Move fuel rail together with fuel injectors clear toward side. Note: Cover the fuel injectors with a clean cloth. Disconnect spark plug wires (left-side). Unbolt bracket for ignition coils (4 bolts) and move clear to right together with ignition coils.

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WARNING: Begin fuel system trouble shooting and diagnosis with fuel system pressure test. Relieve fuel system pressure before disconnecting any components or installing fuel pressure gauge. TBI 1. Turn ignition off for 10 seconds. Turn ignition on, and listen at fuel tank for fuel pump operation. Pump should run 2 seconds (20 seconds on models with fuel module). If fuel pump runs, go to next step. If fuel pump does not run, go to step 7). 2. If fuel pump runs, turn ignition off. Verify fuel tank has fuel. Relieve fuel pressure. See FUEL SYSTEM PRESSURE RELIEF . Remove air cleaner, and plug air cleaner vacuum ports (if equipped). Disconnect fuel line between throttle body and fuel filter. Install Fuel Pressure Gauge (J-29658A) and Adapter (J- 2968A-85) between steel fuel line and flexible hose, ahead of in-line fuel filter. 3. Turn ignition on, and note reading on pressure gauge. If fuel pressure is 9-13 psi (.63-.91 kg/cm2 ), no problems exist. If pressure is less than 9 psi (.63 kg/cm2 ), go to step 5). If pressure is greater than 13 psi (.91 kg/cm2 ), turn ignition off, and bleed fuel pressure. Disconnect fuel return line downstream of pressure gauge. Insert return line into a gasoline container. 4. Turn ignition on. If pressure is now 9-13 psi (.63-.91 kg/cm2 ), correct restriction in fuel return line between disconnected point and fuel tank. If fuel pressure is greater than 13 psi (.91 kg/cm2 ), check for restricted return line (including fuel filter) downstream of pressure gauge. If no restrictions are present, replace fuel pressure regulator (TBI 700) or fuel meter cover/pressure regulator (TBI 220). 5. Check for restricted line between in-tank fuel pump and pressure regulator. If fuel line is okay, disconnect injector connector. Turn ignition on. Gradually pinch fuel pressure gauge outlet hose. Note pressure. CAUTION: DO NOT pinch off fuel return line completely. DO NOT allow fuel pressure build-up to exceed specification, as damage to fuel pressure regulator may occur. 6. If pressure is greater than 13 psi (.91 kg/cm2 ), replace fuel pressure regulator (TBI 700) or fuel meter cover/pressure regulator (TBI 220). If pressure is less than 9 psi (.63 kg/cm2 ), check for faulty fuel pump or incorrect part. Check fuel pump coupling hose and pump inlet filter in fuel tank. On models with dual fuel tanks, check for faulty fuel tank selector valve and meter switch.

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Removal WARNING: Do not smoke or carry lighted tobacco or open flame of any type when working on or near any fuel-related components. Highly flammable mixtures are always present and may be ignited. Failure to follow these instructions may result in personal injury. WARNING: Fuel in the fuel system remains under high pressure even when the engine is not running. Before working on or disconnecting any of the fuel lines or fuel system components, the fuel system pressure must be relieved. Failure to follow these instructions may result in personal injury. All engines 1. Disconnect the battery ground cable (14301). For additional information, refer toSection 414-01. 2. Relieve the fuel pressure. For additional information, refer toSection 310-00A. 3. Partially drain the cooling system. For additional information, refer toSection 303-03A or Section 303-03B. 4. Remove the power steering reservoir bracket. 1. Remove the bolts. 2. Position the power steering reservoir bracket out of the way. 5. Remove the accelerator control splash shield. 1. Remove the bolts. 2. Remove the accelerator control splash shield. 6. Disconnect the fuel pressure regulator valve vacuum hose. 7. CAUTION: After disconnecting, plug the fuel lines to prevent leakage. Disconnect the fuel lines. For additional information, refer toSection 310-00A. 8. Disconnect the eight ignition coil electrical connectors. 9. Disconnect the eight fuel injector electrical connectors. 4.6L engines 10. Remove the nut and disconnect the brake booster vacuum hose and bracket 5.4L engines 11. Remove the brake booster bracket and tube. 1. Remove the nut. 2. Release and move the two hose clamps. 3. Remove the brake booster tube. All engines 12. Remove the positive crankcase ventilation (PCV) hose. 5.4L engines 13. Disconnect the water heater inlet tube hose. 1. Release and move the hose clamp. 2. Disconnect the water heater inlet tube hose and position aside.

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All vehicles 1. Disconnect the battery ground cable. For additional information, refer to Section 414-01. 2. Partially drain the cooling system. For additional information, refer toSection 303-03. 3. Remove the power steering fluid reservoir bracket. 1. Remove the bolts. 2. Position the power steering fluid reservoir bracket out of the way. 4. Remove the accelerator control splash shield. 1. Remove the bolts. 2. Remove the accelerator control splash shield. 5. Disconnect the fuel pressure regulator vacuum hose. CAUTION: After disconnecting, plug the fuel lines to prevent leakage. 6. Disconnect the fuel lines. For additional information, refer to Section 310-00. 7. Disconnect the eight fuel injector electrical connectors. 8. Disconnect the eight ignition coil electrical connectors. 9. Remove the brake booster bracket and tube. 1. Remove the nut. 2. Release and move the two hose clamps. 3. Remove the brake booster tube. 10. Remove the positive crankcase ventilation (PCV) hose. For vehicles equipped with 4.6L engine 11. Disconnect the differential pressure feedback exhaust gas recirculation (EGR) connector, then disconnect the upper and lower EGR valve tube fitting.