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Coolant loss through the water pump bearing seal is commonly caused by a faulty cooling system pressure cap. With certain designs of the plastic pressure cap, if the cooling system overheats distortion of the pressure relief valve in the cap can cause the valve to stick and result in excessive pressure in the cooling system. It is recommended that the coolant pressure cap is always checked for correct operation, prior to the fitment of a new water pump. Thermostat Testing In order to confirm if the thermostat is operating as required, the correct testing procedure should be adopted. Equipment required : 1) A container of undiluted anti-freeze mixture, to allow the temperature of the liquid to be raised above boiling point. (DO NOT use plain water). 2) A suitable heating element to raise the temperature of the liquid. 3) An accurately calibrated thermometer, with a range suitable for the thermostat to be tested. Testing Lower the thermostat into the container of anti-freeze, along with the thermometer, and heat the liquid slowly to the temperature marked on the thermostat, e.g 88 degrees, whilst agitating the thermostat. Let the temperature remain stable for one minute, then check for initial opening of the thermostat valve, Note: The valve will only just crack open at this temperature. Increase the temperature of the liquid to at least 14 degrees above the initial opening temperature, e.g.102 degrees, again allow one minute, then check the valve is fully opened. Allow the liquid to cool to below the initial opening temperature, then check that the valve is fully closed. Opening and fully open temperatures should be within plus or minus 2 degrees of those stated A build up of sediment coating on the thermostat can adversely effect the performance of the thermostat.

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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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1. Rotate crankshaft (6303) to zero degrees top dead center (TDC) on the compression stroke. 2. Disconnect battery ground cable (14301). 3. Drain engine cooling system. Refer to Section 03-03. 4. Remove air cleaner outlet tube (9B659) to throttle body (9E926) . Refer to Section 03-12. 5. Mark and remove vacuum lines to upper intake manifold (9424). 6. Disconnect EGR backpressure transducer hose from EGR valve to exhaust manifold tube (9D477) , loosen lower EGR valve to exhaust manifold tube nut and rotate EGR valve to exhaust manifold tube away from EGR valve (EGR valve) (9D475) . 7. Disconnect the throttle position sensor (TP sensor) (9B989), idle air control valve (IAC valve) (9F715) , EGR backpressure transducer and EGR vacuum regulator solenoid electrical connectors. 8. WARNING: COVER FUEL PRESSURE RELIEF VALVE (9H321) WITH SHOP CLOTH TO PREVENT ACCIDENTAL FUEL SPRAY INTO EYES. Relieve pressure at the fuel pressure relief valve . Refer to Section 03-04A. 9. Remove fuel tube safety clips. 10. CAUTION: Cover fuel tube ends with clean shop cloths to prevent dirt from entering opening. Disconnect fuel tubes (9291). Refer to Section 10-01. 11. Remove upper intake manifold as described. Discard old intake manifold upper gasket (9H486) . 12. Disconnect engine control sensor wiring retainers from rocker arm cover stud bolts and each fuel injector, and position the engine control sensor wiring (12A581) out of the way. 13. NOTE: Fuel injectors and fuel injection supply manifold (9F792) may be removed with lower intake manifold as an assembly. Remove fuel injection supply manifold and fuel injector. 14. Remove ignition wires from spark plugs (12405) . Refer to Section 03-07A. Remove wire harness retainers from valve cover retaining stud bolts. 15. Remove ignition coil (12029) and bracket from LH front cylinder head (6049) and set aside. Refer to Section 03-07A. 16. Disconnect upper radiator hose (8260) and heater water hoses (18472) . 17. Remove camshaft position sensor (CMP sensor) (6B288) and housing. Refer to Section 03-14. 18. Disconnect engine control sensor wiring from engine coolant temperature sensor (ECT sensor) (12A648) and the water temperature indicator sender unit (10884) . 19. If LH (front) cylinder head is being removed, perform the following: Disconnect generator electrical connectors. Remove drive belt (8620). Refer to Section 03-05. Remove drive belt tensioner (6B209). Refer to Section 03-05. Remove generator brace and generator (GEN) (10346). Remove power steering support bracket and power steering pump (3A674) as an assembly and set aside in a position to prevent fluid from leaking out. Remove oil level indicator tube retaining nut from exhaust manifold stud bolt. Rotate or remove oil level indicator tube (6754) from exhaust manifold (9430) . 20. If RH (rear) cylinder head is being removed, perform the following:

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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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1. 2. 3. 4. Disconnect negative cable from battery. Remove timing belt. Remove timing belt rear cover. Remove oil pan. 5. Remove crankshaft sprocket using Special Tools 6793 and C-4685-C2 (Fig. 104). 6. Remove crankshaft key (Fig. 105). 7. Remove oil pick-up tube. 8. Remove oil pump (Fig. 106) and front crankshaft seal. DISASSEMBLY 1. To remove the relief valve, proceed as follows: a. Remove the threaded plug and gasket from the oil pump (Fig. 107). b. Remove spring and relief valve (Fig. 107). 2. Remove oil pump cover fasteners, and lift off cover (Fig. 108). 3. Remove pump rotors (Fig. 108). 4. Wash all parts in a suitable solvent and inspect carefully for damage or wear. CLEANING Clean all parts thoroughly. INSPECTION 1. Inspect the mating surface of the oil pump. Surface should be smooth (Fig. 109). Replace pump cover if scratched or grooved. 2. Lay a straightedge across the pump cover surface (Fig. 110). If a 0.025 mm (0.001 inch) feeler gauge can be inserted between cover and straight edge, cover should be replaced. 3. Measure thickness and diameter of outer rotor. If outer rotor thickness measures 9.40 mm (0.370 inch) or less (Fig. 111), or if the diameter is 79.95 mm (3.148 inch) or less, replace outer rotor. 4. If inner rotor measures 9.40 mm (0.370 inch) or less replace inner rotor (Fig. 112) . ASSEMBLY 1. Assemble pump, using new parts as required. Install the inner rotor with chamfer facing the cast iron oil pump cover. 2. Prime oil pump before installation by filling rotor cavity with engine oil. 3. Install cover and tighten fasteners to 12 Nm (105 inch lbs.) (Fig. 108). CAUTION: Oil pump pressure relief valve must be installed as shown in