Auto Repair Manual Free Download and ReviewsFree download ebook pdf files automotive manual

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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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cooler Hose replacement Procedure 1) Place vehicle on lift. 2) Remove the engine under cover. Hose clamp location 3) Squeeze the hose clamps and reposition to remove the hose. Confirm the direction and angle of the original hose clamps before removal. It is important to reinstall clamps in their original position. 4) Place a drain pan under the hose to collect any CVTF which may leak out. caution: if the cVtF has spilled onto the exhaust pipe or body frame, wipe it off with a rag to avoid dripping fluid. 5) Remove the inlet cooler hose. Note: Be extremely careful not to damage the pipe. 6) Make sure the cooler hose pipe ends are clean prior to installing a new hose. 7) Install a new hose reusing the original hose clamps. Note: Do not permit the end of the hose to extend past the raised lip section of the pipe. Be sure to place the hose clamps in their original position. If the original hose clamps are damaged or deformed, replace as necessary. note: Neither replenishment of transmission fluid nor inspection of fluid level will be neces- sary during replacement of the hose unless the original hose was found to be leaking fluid. Approx. 50cc through 70cc of fluid may be lost during hose replacement. The amount of fluid remaining will still keep the necessary level with sufficient reserve margin. check and add cVtF cAution: • CVTF level changes along with CVTF temperature. When inspecting CVTF level, observe the specified CVTF temperature. • Always use specified CVTF or equivalent. Using other fluid except for specified or equivalent will cause malfunction.

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1. Disconnect the brake booster vacuum check valve (1) from the brake booster. 2. If the vacuum check valve (1) needs to be separated from the vacuum hose (3), release and reposition the clamp (2) on the vacuum hose (3) and remove the check valve (1) from the hose (3). 3. If replacing the vacuum check valve (1), remove the grommet (4) from the brake booster and discard the grommet. 4. If removing the vacuum hose (2), take note of the vacuum hose routing then disconnect from the engine intake manifold connection (3) by releasing tension on the vacuum hose clamp (1) and sliding the vacuum hose (2) off the intake manifold connection (3). Installation Procedure Important: A small amount of denatured alcohol can be used as an assembly aid when installing the vacuum check valve and/or grommet. Do NOT use soap. 1. If the vacuum hose (2) was removed, install the vacuum hose into position on the vehicle as noted prior to removal, then connect the vacuum hose (2) to the engine intake manifold connection (3) and secure with the vacuum hose clamp (1). 2. If the vacuum check valve (1) is being replaced, install a NEW grommet (4) to the brake booster. 3. If the vacuum check valve (1) was separated from the vacuum hose (3), install the check valve (1) to the vacuum hose (3). Install and secure the clamp (2) into position on the hose (3). 4. Connect the brake booster vacuum check valve (1) to the brake booster.

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Remove the negative battery cable. Remove the intake manifold sight shield-four nuts. Relieve the fuel system pressure. Refer to Fuel Pressure Relief Procedure in Powertrain Management. Remove the air intake duct from the throttle body. Remove the transaxle vent hose and transaxle shift cable at the bracket. Remove the TP sensor and IAC valve connectors. Remove the accelerator cable and cruise control cable at the throttle body. Remove the front bank spark plug wires and lay them aside. Remove the throttle body coolant hoses at the throttle body and the surge tank pipe. Refer to Throttle Body Coolant Hose Replacement in Cooling System. 10. Remove the EGR pipe and the crankcase ventilation pipe at the throttle body spacer. 11. Remove the brake booster vacuum hose at the intake manifold vacuum fitting. 12. Remove the fuel rail ground wire at the rear cylinder head. 13. Remove the quick-connect fittings at the fuel rail. 13.1. Grasp both sides of the fitting. 13.2. Twist the female connector 1/4 turn in each direction to loosen any dirt within fitting. 1. 2. 3. 4. 5. 6. 7. 8. 9. Caution: Safety glasses must be worn when using compressed air, as flying dirt particles may cause eye injury. Blow the dirt out of the fitting using compressed air. Choose the correct tool from the J 37088-A for the size of the fitting. Insert the tool into the female connector, then push/pull inward to release the locking tabs. 13.5. Pull the connection apart. – Using a clean shop towel, wipe off the male pipe end. – Inspect both ends of the fitting for dirt and burrs. – Clean or replace the components or assemblies as required 14. Disconnect the fuel rail bracket at the EGR valve. 15. Disconnect the PCV hose at the intake manifold. 16. Disconnect the injector harness main connector. 13.3. 13.4.