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

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1. Remove the timing belt. For additional information, refer to Section 303-01A Engine / 303-01B Engine. 2. Detach the air conditioning (A/C) compressor and secure it to one side. 3. Remove the A/C compressor retaining bracket. 4. Remove the components in the order indicated in the following illustration(s) and table(s). Item Part Number 1 – Generator electrical connector retaining nut 2 – Battery positive cable 3 – Generator electrical connector 4 Special tool (303 193) 21-104 See Removal Detail See Installation Detail Generator retaining bolts Generator Generator bracket retaining nut Generator bracket retaining bolts Generator retaining bracket Description 10 – Fuel injection pump support bracket retaining bolts 11 – High-pressure fuel injection pipe to fuel injector unions See Removal Detail See Installation Detail 12 – High-pressure fuel injection pipe to fuel injection pump unions 13 – High-pressure fuel injection pipes See Removal Detail See Installation Detail 14 – High-pressure fuel injection pipe to fuel injector unions See Installation Detail 15 – High-pressure fuel injection pipe to fuel injection pump unions 16 – High-pressure fuel injection pipes See Removal Detail See Installation Detail 17 – Fuel injection pump supply line See Removal Detail 18 – Fuel injection pump return line See Removal Detail See Installation Detail 19 – Fuel injection pump electrical connector 20 – Fuel injection pump support bracket retaining bolts 21 – Fuel injection pump support bracket

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FUEL PUMP Removal & Installation (Diamante, Eclipse, Galant & Montero) 1) Fuel pump assembly is located inside fuel tank. Release fuel pressure. See FUEL SYSTEM PRESSURE RELEASE. Remove access panel under seat, in trunk or in rear cargo area. Disconnect electrical connectors and fuel hoses at fuel tank. 2) Remove fuel filler hose from fuel tank. Remove fuel pump assembly. To install, reverse removal procedure. Tighten nuts to specification. See TORQUE SPECIFICATIONS. Removal & Installation (Mirage, Montero Sport & 3000GT) 1) Fuel pump assembly is located inside fuel tank. Release fuel pressure. See FUEL SYSTEM PRESSURE RELEASE. Raise vehicle on hoist. Drain fuel into suitable container. Disconnect electrical connectors and breather/fuel hoses at fuel tank. 2) Remove fuel filler hose from fuel tank. Support fuel tank with transmission jack. Remove nuts securing fuel tank. Remove fuel tank from vehicle. Remove fuel pump assembly. To install, reverse removal procedure. Tighten nuts to specification. See TORQUE SPECIFICATIONS. FUEL RAILS & INJECTORS WARNING: Use a rag to cover fuel hose connection before disconnecting high pressure fuel hose at fuel rail. Some residual fuel pressure may still be in system. CAUTION: DO NOT drop injectors while removing or installing fuel rail. Removal (Diamante, Montero Sport 2.4L & 3000GT)

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FUEL SYSTEM PRESSURE RELEASE NOTE: 1. Loosen fuel tank filler cap to relieve tank pressure. Remove fuel pump relay from underhood fuse/relay box. Start and operate engine until it stalls. Crank engine an additional 30 seconds. 2. Loosen hose clamp of fuel line on side of pressure regulator, coming from fuel line inlet distributor pipe. Cover fuel hose with a shop towel, and slowly pull hose from pressure regulator to relieve fuel pressure. When fuel stops leaking, reinstall hose and clamp. FUEL PRESSURE & FUEL PUMP RELAY TEST NOTE: Fuel Pressure 1. Relieve fuel pressure. See FUEL SYSTEM PRESSURE RELEASE . Attach Fuel Pressure Gauge Set (J-34730-1 ) and Adapter (J-35957-1 ) to Schrader fitting on fuel rail. Disconnect pressure regulator vacuum hose. Turn ignition on. Allow fuel pump to run for about 2 seconds. 2. Fuel system pressure should be about 41-46 psi (2.8-3.2 kg/cm2 ). See FUEL PUMP PERFORMANCE . Start engine and check for leaks. Connect pressure regulator vacuum hose. If engine will not start, the fuel pump relay can be by-passed. Also see appropriate CHART A-3 – ENGINE CRANKS BUT WILL NOT RUN under TROUBLE SHOOTING CHARTS. With engine idling, fuel pressure should be 25-30 psi (1.8-2.1 kg/cm2 ). NOTE: Fuel pump relay is located in engine compartment fuse/relay box. Begin basic fuel system diagnosis with testing fuel pressure. To test the fuel pump relay circuit, proceed to CHART A-5 – FUEL PUMP RELAY CIRCUIT under TROUBLE SHOOTING CHARTS. Fuel Pump Relay 1. ECM supplies power to relay as long as ECM receives ignition reference signals or starter crank signal. To run fuel pump without starting engine, remove relay and jumper terminals No. 2 and 4. See Fig. 5 and Fig. 6 . 2. To test relay, use jumper wires to ground terminal No. 4 of relay and apply battery voltage to terminal No. 2 of relay. Using ohmmeter, check for continuity between relay terminals No. 1 and 3. If continuity is not present, replace relay.

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TEST HB: NATURAL GAS FUEL DELIVERY SYSTEM NOTE: After each service or repair procedure has been completed, reconnect all components. Clear DTCs and repeat QUICK TEST procedures to ensure all EEC- V systems are working properly and DTCs are no longer present. Diagnostic Aids Perform this test when directed by QUICK TEST or if directed by other test procedures. This test is used to diagnose: Fuel Pressure Fuel Supply Lines Fuel Filter Fuel Injector(s) Fuel Pressure Regulator Fuel Injection Supply Manifold (Fuel Rail) Fuel Rail Solenoid Shutoff Valve(s) NOTE: Fuel rail solenoid shutoff valve is also referred to as low pressure solenoid shutoff valve. Fuel tank solenoid shutoff valve is also referred to as fuel tank solenoid valve.

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FUEL SYSTEM DESCRIPTION Fuel is drawn by the supply pump through a pre-filter screen in the tank and to the engine through the fuel supply lines. There is no lift pump in the fuel tanks or on the frame. The fuel passes through the base plate of the fuel injector control module (FICM) to cool the module. From the FICM the fuel flows to the fuel filter/heater element housing, which combines a water separator, a prime pump, a fuel heater element and a filter element. The fuel is then delivered to the high-pressure pump. An integrated hand pump is used to prime the fuel system after changing the fuel filter or servicing the fuel system. The fuel injection pump at the front of the engine valley includes the fuel supply pump and the high-pressure pump. If the fuel system is not suppling enough fuel, a driveability concern may occur. If air is being drawn into the fuel injection system, a Cranks But Will Not Run or Hart Start symptom could exist. HIGH PRESSURE SYSTEM The much larger section of the pump assembly is the high-pressure fuel injection pump. The pump is engine-driven by the camshaft gear. From the high-pressure pump, the pressurized flows to the left common fuel rail. A balance pipe from the center of the left rail then feeds the right common fuel rail. Each common fuel rail supplies one bank of 4 fuel injectors. The fuel rail pressure sensor is mounted in the middle of the right common fuel rail. RETURN SYSTEM The fuel return system routes fuel from the fuel injectors and the fuel injection pump. The fuel rail pressure relief valve is located in the rear of the left common rail. The return fuel travels to the fuel cooler and then to the fuel tank. This fuel is used to cool and lubricate the injection pump and the injectors. DIAGNOSTIC AIDS The following conditions may cause an air leak into the fuel supply system: Deformed or cut O-rings at the fuel supply line connections Improperly seated fuel supply line fittings Porous or weathered rubber fuel supply lines