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Use this test in conjunction with the Fuel Pump Pressure Test and Fuel Pump Capacity Test. Check Valve Operation: The electric fuel pump outlet contains a one-way check valve to prevent fuel flow back into the tank and to maintain fuel supply line pressure (engine warm) when pump is not operational. It is also used to keep the fuel supply line full of gasoline when pump is not operational. After the vehicle has cooled down, fuel pressure may drop to 0 psi (cold fluid contracts), but liquid gasoline will remain in fuel supply line between the check valve and fuel injectors. Fuel pressure that has dropped to 0 psi on a cooled down vehicle (engine OFF) is a normal condition. When the electric fuel pump is activated, fuel pressure should immediately (1 – 2 seconds) rise to specification. Abnormally long periods of cranking to restart a hot engine that has been shut down for a short period of time may be caused by: Fuel pressure bleeding past a fuel injector(s). Fuel pressure bleeding past the check valve in the fuel pump module. 1. Disconnect the fuel inlet line at fuel rail. Refer to Fuel Tubes/Lines/Hoses and Clamps for procedures. On some engines, air cleaner housing removal may be necessary before fuel line disconnection. 2. Obtain correct Fuel Line Pressure Test Adapter Tool Hose. Tool number 6539 is used for 5/16″ fuel lines and tool number 6631 is used for 3/8″ fuel lines. Fig.7 Connecting Adapter Tool (Typical) 3. Connect correct Fuel Line Pressure Test Adapter Tool Hose between disconnected fuel line and fuel rail (Fig. 7). 4. Connect the 0 – 414 kPa (0 – 60 psi) fuel pressure test gauge (from Gauge Set 5069) to the test port on the appropriate Adaptor Tool. The DRB III Scan Tool along with the PEP module, the 500 psi pressure transducer, and the transducer-to-test port adapter may also be used in place of the fuel pressure gauge. The fittings on both tools must be in good condition and free from any small leaks before performing the proceeding test. 5. Start engine and bring to normal operating temperature. 6. Observe test gauge. Normal operating pressure should be 339 kpa ±34 kPa (49.2 psi ±5 psi) . 7. Shut engine OFF. 8. Pressure should not fall below 30 psi for five minutes . 9. If pressure falls below 30 psi , it must be determined if a fuel injector, the check valve within the fuel pump module, or a fuel tube/line is leaking. 10. Again, start engine and bring to normal operating temperature. 11. Shut engine OFF. 12. Testing for fuel injector or fuel rail leakage: Clamp OFF the rubber hose portion of Adaptor Tool between the fuel rail and the test port “T” on Adapter Tool. If pressure now holds at or above 30 psi , a fuel injector or the fuel rail is leaking.

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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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1. NOTE: When the battery has been disconnected or reconnected, volatile memory information will be lost. The affected systems will have to be programmed by the technician or customer. These systems include: radio station presets, clock settings, seat memory, mirror memory, window memory and customer input keyless, window memory and customer input keyless entry codes. Disconnect the battery ground cable. For additional information, refer to Section 14-01. 2. Drain the cooling system. For additional information, refer to section 03-03. 3. Remove the engine cover (covering the throttle body). 4. Disconnect the crankcase ventilation tube and the idle air control valve inlet tube from the air cleaner outlet tube. Remove the air cleaner outlet tube. 5. WARNING: THE FUEL SUPPLY LINES ON VEHICLES EQUIPPED WITH FUEL INJECTED ENGINES REMAIN PRESSURIZED FOR LONG PERIODS AFTER ENGINE SHUT DOWN. THE FUEL SYSTEM PRESSURE MUST BE RELIEVED PRIOR TO FUEL SYSTEM SERVICE, TO PREVENT POSSIBLE INJURY. Connect the Multiport Fuel Injection (MFI) Fuel Pressure Gauge (T80L-9974-B) to the fuel pressure relief valve on the fuel supply manifold. Open the manual valve on the gauge to relieve the fuel system pressure. Once the pressure is relieved, close the valve and remove the gauge. 6. Remove the locking clip from the pressure and return fuel line spring lock couplings. Using the spring lock coupling disconnect tools (D87L-9280-A for 3/8-inch line, D87L-9280-B for 1/2-inch line) on the couplings. Push the tool into the cage opening to release the female fitting from the garter spring. Remove the tool and pull the male coupling and fitting apart. Install protective caps over the lines and the fuel rail. 7. Disconnect the upper radiator hose from the water outlet connection and position it out of the way. 8. Disconnect the accelerator cable and the speed control actuator cable from the throttle body and the locator. Remove the screws retaining the cables to the accelerator cable bracket and position the cables out of the way. 9. Disconnect the wiring connectors from the throttle position sensor (TP), idle air control valve (IAC) and the engine coolant temperature sensor (ECT). Disconnect the wiring connectors from the LH fuel injectors and the two wiring locators from the fuel rail. Position the harness out of the way. 10. CAUTION: Do not pull directly on the ignition wires, the wires could separate from the connectors inside the boots. Disconnect the ignition wires from the LH spark plugs and position them out of the way. Refer to Section 03-07. 11. Remove the bolts retaining the spark plug wiring harness bracket to the intake manifold and the generator. Disconnect the ignition wires from the locators and remove the bracket. 12. Remove the serpentine drive belt from the generator pulley. Refer to Section 03-05. 13. Remove the generator retaining bolts and position it out of the way. 14. Remove the PCV valve and tube. 15. Disconnect the wiring connectors from the water temperature indicator sender unit and the EGR vacuum regulator solenoid. Disconnect the RH fuel injector connectors and harness locators from the fuel rail. Position the harness out of the way. 16. CAUTION: Do not pull directly on the ignition wires, the wires could separate from the connectors inside the boots. Disconnect the ignition wires from the RH spark plugs and position them out of the way. For additional information, refer to Section 03-07. 17. Disconnect the vacuum line from the fuel vapor storage canister purge valve. Disconnect the heater hose from the rear of the intake manifold. 18. Disconnect the main vacuum hose from the rear of the intake manifold. Disconnect the hose from the fuel vapor storage canister purge valve. 19. Disconnect the EGR tube nut from the EGR valve. 20. Disconnect the vacuum hose from the EGR valve. Remove the EGR valve and gasket. 21. Remvoe the water outlet connection housing. 22. Remove the intake manifold. Remove and discard the intake manifold gaskets.

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Installation All engines 1. NOTICE: If the engine is repaired or replaced because of upper engine failure, typically including valve or piston damage, check the intake manifold for metal debris. If metal debris is found, install a new intake manifold. Failure to follow these instructions can result in engine damage. NOTE: 2.0L engine shown, 2.3L is similar. Inspect and install new intake manifold gaskets if necessary. 2. Install the EGR tube. 3. Position the intake manifold and connect the PCV hose. 4. Connect the KS electrical connector. 2.3L engines 5. NOTE: Be sure to install the bolts in the previously marked locations. NOTE: To ease installation of the intake manifold, lower center mounting bolt, use a 6-inch long, 5/16-inch diameter hose. Install the intake manifold and the seven mounting bolts. 6. NOTE: Lubricate the O-ring with clean engine oil. Install the oil level indicator tube and bolts. 7. Connect the swirl valve electrical connectors and pin-type retainers. 2.0L engines 8. NOTE: Be sure to install the bolts in the previously marked locations. Install the intake manifold and the seven mounting bolts. 9. NOTE: Lubricate the O-ring with clean engine oil. Install the oil level indicator tube and bolt. 10. Connect the swirl control valve electrical connector. 11. If equipped, connect the AIR vacuum supply hose. All engines 12. Install the lower intake bolt. 13. Connect the MAP sensor electrical connector. 14. Connect the IMRC actuator electrical connector. 15. Attach the wiring harness pin-type retainer. 16. Connect the fuel rail pressure and temperature sensor vacuum hose. 17. Connect the power brake booster vacuum tube. Push the vacuum tube into the quick release fitting. 18. Connect the evaporative emissions hose. 19. Connect the IAC valve electrical connector and wiring harness pin-type retainer.