SERVICE PROCEDURES

ELECTRONIC FUEL INJECTION

Section 3C - Service Procedures
Table of Contents
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-1 Throttle Position Sensor (TPS)
Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-2 Removal/Installation . . . . . . . . . . . . . . . . . . . . 3C-31
Intake Manifold . . . . . . . . . . . . . . . . . . . . . . . . .
Vapor Separator Components . . . . . . . . . . . . .
3C-4
3C-6
ECM Removal/Installation . . . . . . . . . . . . . . . .
Crank Position Sensor (CPS)
3C-32
3
Vapor Separator Components . . . . . . . . . . . . . 3C-8 Removal/Installation . . . . . . . . . . . . . . . . . . . . 3C-33 C
Fuel Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-10 Engine Coolant Temperature (ECT)
Fuel Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-12 Sensor Removal/Installation . . . . . . . . . . . . . . 3C-34
Torque Sequence . . . . . . . . . . . . . . . . . . . . . . . 3C-14 Low Pressure Fuel Line/Fuel Pump . . . . . . . . 3C-35
Intake Manifold Assembly . . . . . . . . . . . . . . . . 3C-15 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-35
Releasing Fuel Pressure in the Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-36
High-Pressure Fuel Line . . . . . . . . . . . . . . 3C-15 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . 3C-37
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-16 Cleaning/Inspection/Repair . . . . . . . . . . . . 3C-38
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-19 Check Valve Inspection/Replacement . . . 3C-38
Throttle Body Removal/Installation . . . . . . . . 3C-23 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-39
Idle Air Control (IAC) Removal/Installation . . 3C-24 Fuel Filter Disassembly/Assembly . . . . . . . . . 3C-41
Fuel Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-25 Vapor Separator (VST) . . . . . . . . . . . . . . . . . . . 3C-42
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-25 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-42
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-26 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-43
Manifold Absolute Pressure (MAP) Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . 3C-44
Sensor Removal/Installation . . . . . . . . . . . . . . 3C-27 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-46
Fuel Distribution Manifold . . . . . . . . . . . . . . . . 3C-28 Pressure Regulator Removal/Installation . . . 3C-48
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-28 High Pressure Fuel Line
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 3C-29 Removal/Installation . . . . . . . . . . . . . . . . . . . . 3C-49
Manifold Air Temperature (MAT)
Sensor Removal/Installation . . . . . . . . . . . . . . 3C-30

Specifications
Fuel Pump Type Mechanical Water Cooled
(Plunger/Diaphragm)
FUEL
Fuel Pump:
SYSTEM
Pressure 3-6 psi
Fuel Tank Capacity Accessory
Fuel Injector System Batch (1 & 4) - (2 & 3)
Idle rpm (Out Of Gear) 725 ± 25 rpm
Idle rpm (In Forward Gear) 725 ± 25 rpm
FUEL INJECTION
Wide Open Throttle rpm (WOT)
Range 5500–6000
Fuel Pump Pressure - Electric 42-44 psi (290-303 kPa)

90-883065 APRIL 2001 Page 3C-1

SERVICE PROCEDURES

Special Tools
1. DMT 2000 Digital Tachometer Multi-meter P/N 91-854009A1.

2. Digital Diagnostic Terminal P/N 91-823686A2

3. DDT Cartridge 91-822608-2

4. Fuel Injector Cap Tool 91-883877A1

58816

Page 3C-2 90-883065 APRIL 2001

 SERVICE PROCEDURES

5. Clamp Tool Kit 91-803146A2

57316

a - Clamp Tool 91-803146T

6. Fuel Pressure Gauge 91-16850A7 or Fuel Pressure Gauge 91-852087A3.

91-16850A7

90-883065 APRIL 2001 Page 3C-3

SERVICE PROCEDURES

INTAKE MANIFOLD

26

24
66 26
27
22
1 28
2 18

17
26

19 16 21
20

14
15

5
13
66

25 12 23

3 4

6
7

11
8

10
66 Loctite 242 (92-809821)

Page 3C-4 90-883065 APRIL 2001

 SERVICE PROCEDURES

INTAKE MANIFOLD
TORQUE
REF.
REF
NO. QTY. DESCRIPTION lb-in lb-ft Nm.
1 1 INTAKE MANIFOLD
2 4 GASKET
3 1 SCREW 31 3.5
4 1 BRACKET
5 1 NUT 75 8.5
6 1 IDLE AIR CONTROL (IAC)
7 1 FUEL DISTRIBUTION MANIFOLD
8 4 INJECTOR
9 2 SCREW 31 3.5
10 4 SCREW 31 3.5
11 4 CLIP
12 1 HOSE
13 1 THROTTLE BODY
14 1 GASKET
15 2 SCREW 31 3.5
16 1 THROTTLE POSITION SENSOR (TPS)
17 2 SCREW 18 2
18 1 MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR
19 1 MANIFOLD AIR TEMPERATURE (MAT) SENSOR 12.5 1.4
20 1 O RING
21 1 SOUND ATTENUATOR
22 8 SCREW (M6 X 25) 75 8.5
1 RESTRICTOR (50)
23
1 RESTRICTOR (40)
24 1 BREATHER HOSE
25 1 SCREW (M6 X 30) 75 8.5
26 3 STA-STRAP
27 1 SCREW (10-16 X .625) Drive Tight
28 1 RETAINER

90-883065 APRIL 2001 Page 3C-5

SERVICE PROCEDURES

VAPOR SEPARATOR COMPONENTS

66 11

12 9

13 2
3 2
4 1
9 14 22
15
6 11
11
8
7
17 21
20 16
5 24
9 10 23
19

9
26
12
66 12
25 18

33

27

29
41
40 28
43
33 44 66
46
34
9
32 45
38
39

30
35
9
37
36 31

9 Loctite PST Pipe Sealant (92-809822) 42

66 Loctite 242 (92-809821)

Page 3C-6 90-883065 APRIL 2001

 SERVICE PROCEDURES

VAPOR SEPARATOR COMPONENTS

TORQUE
REF.
REF
NO. QTY. DESCRIPTION lb-in lb-ft Nm.
1 1 COVER KIT
2 2 FITTING
3 1 ELECTRICAL PASS-THRU KIT 45-55 5.1-6.2
4 1 O RING
5 1 RETAINER
6 1 FITTING 45-55 5.1-6.2
7 1 FITTING 45-55 5.1-6.2
8 1 DIAGNOSTIC VALVE 40-50 4.5-5.7
9 1 CAP
10 1 DRAIN TUBE
11 5 SCREW 35-40 4-4.5
12 6 SCREW 20-24 2.3-2.7
13 1 REGULATOR
14 1 O RING
15 1 O RING
16 1 SEAL KIT 30-35 3.4-4
17 1 GASKET
18 1 FLOAT KIT
19 1 FLOAT SHAFT
20 1 INLET NEEDLE KIT
21 1 VENT HOSE
22 1 STA STRAP
23 1 FUEL BAFFLE
24 1 HARNESS
25 1 PUMP KIT
26 1 SLEEVE
27 1 GROMMET
28 1 FUEL BOWL KIT
29 1 GASKET
30 1 DRAIN SCREW 30-35 3.4-4
31 1 FITTING Press to Shoulder
32 1 FUEL COOLER BODY KIT
33 4 CLAMP
34 2 FITTING 45-55 5.1-6.2
35 5 PLUG
36 2 ELBOW FITTING Install 5 to 7 Turns
37 1 ELBOW FITTING 45-55 5.1-6.2
10.8- 14.7-
38 1 SCREW
12.5 17
39 1 GASKET
40 1 HOSE (1-5/8)
41 1 HOSE (4-1/2)
42 1 DRAIN HOSE

90-883065 APRIL 2001 Page 3C-7

SERVICE PROCEDURES

VAPOR SEPARATOR COMPONENTS

66 11

12 9

13 2
3 2
4 1
9 14 22
15
6 11
11
8
7
17 21
20 16
5 24
9 10 23
19

9
26
12
66 12
25 18

33

27

29
41
40 28
43
33 44 66
46
34
9
32 45
38
39

30
35
9
37
36 31

9 Loctite PST Pipe Sealant (92-809822) 42

66 Loctite 242 (92-809821)

Page 3C-8 90-883065 APRIL 2001

 SERVICE PROCEDURES

VAPOR SEPARATOR COMPONENTS

TORQUE
REF.
REF
NO. QTY. DESCRIPTION lb-in lb-ft Nm.
43 3 BUSHING
44 3 GROMMET
45 3 SCREW (M6 X 25) 45 5.1
46 3 WASHER

90-883065 APRIL 2001 Page 3C-9

SERVICE PROCEDURES

FUEL PUMP
21
20 22

23 19
13 A
B
24 13
18
15 10
25
11

13
14
13
8

13

17
13 9
13
1 2
16 13

12

C
A = TO VAPOR SEPARATOR COVER
B = TO VST COOLER
C = TO TELL TALE

3
3

4
3

5
3 3
66
1
3
6
7

3
66 Loctite 242 (92-809821)

Page 3C-10 90-883065 APRIL 2001

 SERVICE PROCEDURES

FUEL PUMP
TORQUE
REF.
REF
NO. QTY. DESCRIPTION lb-in lb-ft Nm.
1 1 FUEL PUMP
2 4 SCREW
3 1 DIAPHRAGM/O-RING KIT
4 1 SPRING
5 4 NUT
6 1 SPRING
7 1 CAP
8 1 COWL DEFLECTOR
9 2 SCREW (M6 X 30) 75 8.5
10 1 TUBING (34 IN.)
11 1 TUBING (19 IN.)
12 1 TUBING (6 IN.)
13 AR STA STRAP
14 1 TUBING (8 IN.)
15 1 FUEL FILTER
16 1 TUBING (38 IN.)
17 1 FUEL CONNECTOR
18 1 BUSHING
19 1 GROMMET
20 1 WASHER
21 1 NUT (M6) 45 5.1
22 1 BRACKET
23 2 SCREW (M6 X 13) 75 8.5
24 1 CONDUIT (13 IN.)
25 1 CONDUIT (26 IN.)

90-883065 APRIL 2001 Page 3C-11

SERVICE PROCEDURES

FUEL LINES

Page 3C-12 90-883065 APRIL 2001

 SERVICE PROCEDURES

FUEL LINES
TORQUE
REF.
REF
NO. QTY. DESCRIPTION lb-in lb-ft Nm.
1 1 CONDUIT (24 IN.)
2 1 FUEL LINE
3 1 FUEL FILTER
4 1 PROTECTIVE SLEEVE
5 1 FUEL LINE

90-883065 APRIL 2001 Page 3C-13

SERVICE PROCEDURES

Torque Sequence

INTAKE MANIFOLD FLANGE

3
4

1
2

5
6

Page 3C-14 90-883065 APRIL 2001

 SERVICE PROCEDURES

Intake Manifold Assembly

WARNING
Always release the fuel pressure in the high-pressure fuel line before servicing the
line or the vapor separator. If the fuel pressure is not released, pressurized fuel
may spray out.

Releasing Fuel Pressure in the High-Pressure Fuel Line

1. Install the fuel pressure gauge onto the pressure check valve.
2. Place the drain hose into a container.
3. Push the relief button and release the pressure.

b
91-16850A7

58821
a - Fuel Pressure Gauge
b - Pressure Relief Button
c - Drain Hose

90-883065 APRIL 2001 Page 3C-15

SERVICE PROCEDURES

Removal
4. Push in on the fuel injector harness connector retaining clip and unplug the harness
from each fuel injector. It is not necessary to remove the retaining clip from the connec-
tor.
5. Unplug the Idle Air Control (IAC) connector.
6. AFTER RELIEVING PRESSURE disconnect the high pressure fuel line from the fuel
distribution manifold by depressing the locking tab and pulling back on the fuel line.
7. Remove the flywheel cover.

f
g

e
b

d
c
58860

a - Fuel Injector (4)

b - Harness Connector Retaining Clip
c - Idle Air Control (IAC) Connector
d - Throttle Air Bypass Hose
e - High Pressure Fuel Line
f - Locking Tab
g - Flywheel Cover

Page 3C-16 90-883065 APRIL 2001

 SERVICE PROCEDURES

8. Remove intake assembly mounting screws and remove intake assembly.

58817

a - Intake Assembly Mounting Screw (6) M6 x 25

b - Intake Assembly Mounting Screw (1) M6 x 30
c - Intake Assembly Mounting Screw (2) M6 x 40
9. Disconnect throttle link rod from the throttle body ball socket.

a - Throttle Link Rod

b - Throttle Body Ball Socket

90-883065 APRIL 2001 Page 3C-17

SERVICE PROCEDURES

10. Disconnect ECM harness connectors.

11. Remove the ECM mounting screws and washers. Remove the ECM from the mounting
plate.
b
e

a c

b
b d 58811

a - ECM Harness Connectors d - J-Clip

b - ECM Mounting Screw (3) M6 x 25 e - Washers (3)
c - ECM
12. Disconnect the following sensors: Manifold Absolute Pressure (MAP), Manifold Air
Temperature (MAT), and Throttle Position Sensor (TPS).
13. Cut sta-strap and remove crankcase breather hose from sound attenuator. Remove
intake assembly from engine.

d
a
f
e

a - Manifold Absolute Pressure (MAP) Sensor

b - MAP Sensor Retaining Clip
c - Screw (10-16 x .625)
d - Manifold Air Temperature (MAT) Sensor Connector
e - Throttle Position Sensor (TPS) Connector
f - Crankcase Breather Hose
g - Sound Attenuator

Page 3C-18 90-883065 APRIL 2001

 SERVICE PROCEDURES

Installation
1. Install intake manifold assembly to engine. Make sure O-rings are in place. Tighten
screws (in sequence shown) to specified torque.

3
b
4
66

1
2
66 a

5
6

7
58817
66 Loctite 242 (92-809821)

a - Intake Assembly Mounting Screw (6) M6 x 25

b - Intake Assembly Mounting Screw M6 x 30
c - Intake Assembly Mounting Screw M6 x 40
Intake Assembly Mounting Screw Torque
75 lb-in (8.5 Nm)

2. Connect throttle link rod to the throttle body ball socket.

IMPORTANT: Check for proper throttle link rod adjustment as outlined in section 7A.

a - Throttle Link Rod

b - Throttle Body Ball Socket

90-883065 APRIL 2001 Page 3C-19

SERVICE PROCEDURES

3. Connect the following sensors: Manifold Absolute Pressure (MAP), Manifold Air Tem-
perature (MAT) Sensor, and Throttle Position Sensor (TPS).
4. Install MAP sensor retaining clip and tighten screw to specified torque.
5. Install crankcase breather hose into sound attenuator. Secure with sta-strap.

d
a
f
e

g
a - Manifold Absolute Pressure (MAP) Sensor
b - MAP Sensor Retaining Clip
c - Screw (10-16 x .625)
d - Manifold Air Temperature (MAT) Sensor
e - Throttle Position Sensor (TPS)
f - Crankcase Breather Hose
g - Sound Attenuator

Page 3C-20 90-883065 APRIL 2001

 SERVICE PROCEDURES

6. Connect the fuel line to the fuel distribution manifold. Push on until locked into place.
7. Route injector harness as shown and plug-in the fuel injector and IAC connectors.
8. Install flywheel cover. Tighten screws to specified torque.

f
g

c d

58860

a - Fuel Injector (4)

b - Fuel Injector Connector (4)
c - Idle Air Control (IAC) Connector
d - Throttle Air Bypass Hose
e - Fuel Line
f - Locking Tab
g - Flywheel Cover
Flywheel Cover Screw Torque
75 lb-in (8.5 Nm)

90-883065 APRIL 2001 Page 3C-21

SERVICE PROCEDURES

9. Install ECM to mounting plate. Tighten mounting screws to specified torque.

10. Plug in ECM harness connectors.
b
e

a c

b
b d 58811

a - ECM Harness Connectors

b - ECM Mounting Screw (3) M6 x 25
c - ECM
d - J-Clip
e - Washers (3)
ECM Mounting Screw Torque
45 lb-in (5.1 Nm)

Page 3C-22 90-883065 APRIL 2001

 SERVICE PROCEDURES

Throttle Body Removal/Installation

REMOVAL
1. Remove the intake manifold assembly. Refer to Intake Manifold Assembly Removal.
2. Remove throttle body mounting screws and remove throttle body assembly from the
intake assembly.
INSTALLATION
1. Lubricate O-ring and install throttle body to intake assembly. Tighten screws to specified
torque.
2. Install the intake assembly. Refer to Intake Assembly Installation.

b
a

a - Throttle Body Mounting Screws (2) 25mm long

b - Throttle Body Assembly
c - Seal
d - Intake Assembly
Throttle Body Mounting Screw Torque
31 lb-in (3.5 Nm)

90-883065 APRIL 2001 Page 3C-23

SERVICE PROCEDURES

Idle Air Control (IAC) Removal/Installation

REMOVAL
1. Disconnect the IAC harness connector.
2. Remove IAC mounting screw.
3. Disconnect the throttle air bypass hose and remove the IAC valve.
INSTALLATION
1. Install IAC and secure with mounting screw.
2. Connect IAC harness connector and bypass hose.

b c
a d
a - IAC Mounting Screw
b - IAC Harness Connector
c - Throttle Air Bypass Hose
d - Idle Air Control (IAC) Valve
IAC Mounting Screw Torque
31 lb-in (3.5 Nm)

Page 3C-24 90-883065 APRIL 2001

 SERVICE PROCEDURES

Fuel Injectors
WARNING
Always release the fuel pressure in the high-pressure fuel line before servicing the
line or the vapor separator. If the fuel pressure is not released, pressurized fuel
may spray out.
Removal
1. Remove fuel injector cap retaining clips and screws.
2. Push in on the harness connector retaining clip and unplug the harness from each fuel
injector.
3. Using service tool 91-883877A1, pry injector cap from the injector.
4. Remove fuel injectors from intake manifold.

b
d

91-883877A1
a - Fuel Injector (4)
b - Fuel Injector Cap (4)
c - Fuel Injector Cap Retaining Clip (4)
d - Screw (4)
e - Harness Connector Retaining Clip (4)

90-883065 APRIL 2001 Page 3C-25

SERVICE PROCEDURES

Installation
1. Install fuel injector cap by pushing it on the fuel injector until it bottoms out.
2. Lubricate O-rings and install fuel injectors into intake manifold.
3. Install fuel injector cap retaining screws and tighten to specified torque. Install fuel in-
jector cap retaining clips so that the locking teeth line up with the locking rib on the fuel
injector (as shown).
4. Connect the harness connectors to each fuel injector. Push the connector on until the
retaining clip locks in place.

f
g h

58823

b d

a - Fuel Injector (4)

b - Fuel Injector Cap (4)
c - Fuel Injector Cap Retaining Clip (4)
d - Fuel Injector Cap Retaining Screw (4)
e - Fuel Injector Harness Retaining Clip (4)
f - Fuel Injector Harness Connector (4)
g - Locking Teeth
h - Locking Rib
Fuel Injector Cap Retaining Screw Torque
31 lb-in (3.5 Nm)

Page 3C-26 90-883065 APRIL 2001

 SERVICE PROCEDURES

Manifold Absolute Pressure (MAP) Sensor

Removal/Installation
REMOVAL
1. Remove the intake assembly. Refer to Intake Assembly Removal.
2. Remove the MAP sensor retaining screw and bracket. Remove the MAP from the intake
by pulling and twisting simultaneously (pulls out hard).
INSTALLATION
1. Lubricate seal and push MAP into intake assembly.
2. Install retaining clip and screw. Tighten screw securely.
3. Install intake assembly. Refer to Intake Assembly Installation.

a - MAP Sensor
b - Retaining Clip
c - Screw

90-883065 APRIL 2001 Page 3C-27

SERVICE PROCEDURES

Fuel Distribution Manifold

WARNING
Always release the fuel pressure in the high-pressure fuel line before servicing the
line or the vapor separator. If the fuel pressure is not released, pressurized fuel
may spray out.
Removal
1. Remove fuel injector cap retaining screws.
2. Remove the fuel injector cap retaining clips.
3. Using service tool 91-883877A1, pry the fuel injector cap off of each fuel injector.
4. Remove fuel distribution manifold mounting screws.
5. AFTER RELIEVING FUEL PRESSURE disconnect the high pressure fuel line by de-
pressing the locking tab and pulling back. Remove fuel distribution manifold.

f e
d

91-883877A1

a - Fuel Injector Cap Retaining Screw (4)

b - Fuel Injector Cap (4)
c - Fuel Injector Cap Retaining Clip (4)
d - Fuel Distribution Manifold Mounting Screw (2)
e - Fuel Distribution Manifold
f - High Pressure Fuel Line Locking Tab

Page 3C-28 90-883065 APRIL 2001

 SERVICE PROCEDURES

Installation
1. Install fuel distribution manifold and tighten mounting screws to specified torque.
2. Push fuel injector cap onto the fuel injector until the cap bottoms out on the injector.
3. Install fuel injector cap retaining screws and tighten securely. Install fuel injector cap
retaining clips so that the locking teeth line up with the locking rib on the fuel injector
(as shown).
4. Connect high pressure fuel line. Push on until locking tab snaps in place.
f
g e

91-883877A1

a - Fuel Injector Cap Retaining Screw (4)

b - Fuel Injector Cap (4)
c - Fuel Injector (4)
d - Fuel Injector Cap Retaining Clip (4)
e - Fuel Distribution Manifold Mounting Screw (2)
f - Fuel Distribution Manifold
g - High Pressure Fuel Line
Mounting Screw Torque
31 lb-in (3.5 Nm)

90-883065 APRIL 2001 Page 3C-29

SERVICE PROCEDURES

Manifold Air Temperature (MAT) Sensor

Removal/Installation
REMOVAL
1. Remove the intake manifold assembly. Refer to Intake Manifold Assembly Remov-
al.
2. Disconnect manifold air temperature (MAT) sensor connector.
3. Unscrew MAT sensor from the intake manifold assembly. Inspect o-ring and replace
if necessary.
INSTALLATION

CAUTION
Overtightening the manifold air temperature (MAT) sensor can lead to failing the
plastic threads. Be sure to tighten to the specified torque.
1. Lubricate O-ring and screw in air temperature sensor. Tighten to specified torque.
2. Connect MAT sensor connector.
3. Install the intake manifold assembly. Refer to Intake Manifold Assembly Installa-
tion.

b
c

a - Manifold Air Temperature (MAT) Sensor

b - MAT Sensor Connector
c - O-ring
Air Temperature Sensor Torque
12.5 lb-in. (1.4 Nm)

Page 3C-30 90-883065 APRIL 2001

 SERVICE PROCEDURES

Throttle Position Sensor (TPS) Removal/Installation

REMOVAL
1. Remove the intake manifold assembly. Refer to Intake Manifold Assembly Remov-
al.
2. Disconnect throttle position sensor (TPS) connector.
3. Remove mounting screws and remove throttle position sensor.
INSTALLATION
1. Install throttle position sensor. Tighten screws to specified torque.
2. Connect throttle position sensor connector.
3. Install the intake manifold assembly. Refer to Intake Manifold Assembly Installa-
tion.

b
a

a - Throttle Position Sensor (TPS)

b - TPS Connector
c - TPS Mounting Screws(2) 15 mm long
Throttle Position Sensor Mounting Screw Torque
18 lb-in (2 Nm)

90-883065 APRIL 2001 Page 3C-31

SERVICE PROCEDURES

ECM Removal/Installation
Removal
1. Remove ECM harness connectors.
2. Remove the ECM mounting screws and washers. Remove the ECM from the mounting
plate.
Installation
1. Install ECM onto mounting bracket (position the j-clip as shown). Install screws and
washers. Tighten screws to specified torque.
2. Connect ECM harness connectors.
b
e

a c

b
b d 58811

a - ECM Harness Connectors

b - ECM Mounting Screw (3) M6 x 25
c - ECM
d - J-clip
e - Washers (3)

ECM Mounting Screw Torque

45 lb. in. (5.1 N·m)

Page 3C-32 90-883065 APRIL 2001

 SERVICE PROCEDURES

Crank Position Sensor Removal/Installation

1. Disconnect sensor from wiring harness.
2. Remove sensor mounting screws.
3. Reverse steps for installation. Tighten screws to specified torque.

58228

a - Crank Position Sensor

b - Harness Connector
c - Screw (2) M5x16

Crank Position Sensor Mounting Screw Torque

45 lb. in. (5.1 N·m)

90-883065 APRIL 2001 Page 3C-33

SERVICE PROCEDURES

Engine Coolant Temperature (ECT) Sensor

Removal/Installation
1. Disconnect sensor from wiring harness.
2. Remove sensor from exhaust cover.
3. Reverse steps for installation. Tighten to specified torque.

CAUTION
Over-tightening the coolant temperature sensor can lead to failing the plastic
threads. Be sure to tighten to the specified torque.

b c

58225

a - Harness Connector
b - Temperature Sensor
c - Exhaust Cover

Temperature Sensor Mounting Torque

15 lb. in. (1.7 N·m)

Page 3C-34 90-883065 APRIL 2001

 SERVICE PROCEDURES

Low Pressure Fuel Line/Fuel Pump

Removal
1. Cut sta-straps and remove fuel pump inlet/outlet hoses, and fuel cooler water inlet/out-
let hoses.
2. Remove fuel pump mounting bolts and cowl deflector.
3. Separate fuel pump from cylinder head cover.

e
c
a

g f

d
58814

a - Inlet Fuel Hose (from filter)

b - Outlet Fuel Hose (to VST)
c - Fuel Cooler Water Inlet Hose (from VST fuel cooler)
d - Fuel Cooler Water Outlet Hose (to tell-tale outlet)
e - Mounting Screw (2) M6 x 30
f - Cowl Deflector
g - Fuel Pump

90-883065 APRIL 2001 Page 3C-35

SERVICE PROCEDURES

Installation
1. Secure fuel pump and cowl deflector to cylinder head cover with screws. Tighten to
specified torque.
2. Connect fuel lines to pump and secure with new sta-straps.

c
h

a b

66
e
a
e
c d
b

g f

58814
66 Loctite 242 (92-809821)

a - Inlet Fuel Hose (from fuel filter)

b - Outlet Fuel Hose (to VST)
c - Fuel Cooler Water Inlet Hose (from VST fuel cooler)
d - Fuel Cooler Water Outlet Hose (to tell-tale outlet)
e - Mounting Screw (2) M6 x 30
f - Cowl Deflector
g - Fuel Pump
h - Conduit (13 in.)
i - Conduit (21 in.)
j - Sta-strap

Fuel Pump Mounting Screw Torque

75 lb. in. (8.5 N·m)

Page 3C-36 90-883065 APRIL 2001

 SERVICE PROCEDURES

Disassembly
IMPORTANT: Before separating fuel pump components mark each component with
an awl or marker. This will ensure the components are oriented correctly during
reassembly.
1. Remove screws to separate pump cover, cover seal, diaphragm and valve body from
pump base.

a
h
b
c
d
e

f
g

28378
a - Screws (4) e - Valve Body
b - Pump Cover f - Pump Base
c - Cover Seal g - Nuts (4)
d - Diaphragm h - I.D. Marks (Create These)

2. Rotate plunger to line up slots.

a b

53615
a - Slots Offset
b - Slots Aligned

3. Compress pump assembly to free spring load on pin.

4. Tilt assembly to allow pin to slide out.

53617

a - Pin

90-883065 APRIL 2001 Page 3C-37

SERVICE PROCEDURES

Cleaning/Inspection/Repair
1. Inspect springs for damage, replace if necessary.

2. Inspect cover seal and diaphragm, replace if damaged.

b a

a - Cover Seal
b - Diaphragm

Check Valve Inspection/Replacement

1. Inspect the check valves for damage, replace if necessary.
REMOVAL
2. If replacement is needed remove old check valves by grabbing the seal and pulling.

a
58831
a - Check Valve/Seal Assembly (2)

Page 3C-38 90-883065 APRIL 2001

 SERVICE PROCEDURES

INSTALLATION
1. Fabricate an installation tool to the dimensions specified.
2. Lubricate the end of the seal and push the assembly into the valve body.
NOTE: Drill into the handle using a 5/64 in. (2mm) drill bit. Insert the peg into the drilled
hole until 0.312 in. (8mm) remains exposed.

c .312 in. ±0.010 in. 58832

(7.7 - 8.2mm)

5/64 in. dia.

(2mm)
b 0.375 in. dia.
(9.5mm)

a
58831
a - Check Valve/Seal Assembly (2)
b - Installation Tool (make yourself)
c - Valve Body
Assembly
1. Assemble springs, diaphragm, and plunger onto pump base.

a - Diaphragm
b - Diaphragm Spring
c - Pump Body
d - Spring
e - Plunger

90-883065 APRIL 2001 Page 3C-39

SERVICE PROCEDURES

2. Line up slots and compress assembly.

3. Insert pin into hole.

c
b

a - Pump Body
b - Slots
c - Pin
4. Rotate plunger 90° to offset slots.

a b

53615
a - Slots Aligned
b - Slots Offset
5. Assemble valve body, diaphragm, seal, and cover to pump base. Be sure to line up
I.D. marks that were made before disassembly. Apply Loctite 242 to screws and se-
cure with nuts.
NOTE: Seal installs in one direction only.

a
h

b
c
d
e

f
g

66
66 Loctite 242 (92-809821)
28378
a - Screws (4) e - Valve Body
b - Pump Cover f - Pump Base
c - Cover Seal g - Nuts (4)
d - Diaphragm h - I.D. Marks

Page 3C-40 90-883065 APRIL 2001

 SERVICE PROCEDURES

6. Inspect O-ring and replace if necessary. Install onto fuel pump assembly.

53620

a - O-ring

Fuel Filter Disassembly/Assembly

DISASSEMBLY
1. Unscrew fuel filter cup and remove fuel filter element and o-rings.
2. Inspect o-rings and replace if necessary.
3. Clean fuel filter cup and replace fuel filter element if needed.
ASSEMBLY
1. Lubricate o-rings and install fuel filter element.
2. Install fuel filter cup and hand tighten.

a b

a - Fuel Filter Assembly d - O-ring

b - Fuel Filter Cap e - Fuel Filter Cup
c - Fuel Filter Element

90-883065 APRIL 2001 Page 3C-41

SERVICE PROCEDURES

Vapor Separator (VST)

WARNING
Always release the fuel pressure in the high-pressure fuel line before servicing the
line or the vapor separator. If the fuel pressure is not released, pressurized fuel
may spray out.
Removal
1. Release fuel pressure. Refer to Releasing Fuel Pressure in the High Pressure Fuel
Line.
2. Remove the lower cowl. Drain the fuel from the VST into a suitable container.
3. Disconnect fuel lines, water lines and high pressure fuel pump harness connector.
4. Remove vapor separator (VST) mounting screws and remove VST from engine.

c
h

g
d
e a

b
f

58812

a - VST Drain Valve

b - VST Drain Hose
c - Fuel Hose (Mechanical Fuel Pump to VST)
d - High Pressure Fuel Hose (Fuel Cooler to Fuel Distribution Manifold)
e - Water Hose (VST Fuel Cooler to Mechanical Fuel Pump Fuel Cooler)
f - Water Hose (Exhaust Cover to Fuel Cooler)
g - VST Vent Hose
h - High Pressure Fuel Pump Harness Connector
i - Vapor Separator Mounting Screws (3) M6 x 25

Page 3C-42 90-883065 APRIL 2001

 SERVICE PROCEDURES

Installation
1. Tighten drain valve and install VST to engine. Tighten mounting screws to specified
torque.
2. Connect fuel and water hoses as shown below. Secure with sta-straps.
3. Plug in high pressure fuel pump harness connector.

c
h

i
66

g
d
e a

b
f

66 Loctite 242 (92-809821) 58812

a - VST Drain Valve

b - VST Drain Hose
c - Fuel Hose (Mechanical Fuel Pump to VST)
d - High Pressure Fuel Hose (Fuel Cooler to Fuel Distribution Manifold)
e - Water Hose (VST Fuel Cooler to Mechanical Fuel Pump Fuel Cooler)
f - Water Hose (Exhaust Cover to Fuel Cooler)
g - VST Vent Hose
h - High Pressure Fuel Pump Harness Connector
i - Vapor Separator Mounting Screws (3) M6 x 25

Vapor Separator Mounting Screw Torque

45 lb. in. (5 N·m)

90-883065 APRIL 2001 Page 3C-43

SERVICE PROCEDURES

Disassembly
1. Remove fuel cooler mounting screw.
2. If removal of fuel cooler is required (because of damaged/plugged hoses or fuel cooler
replacement), cut metal hose clamps and remove fuel hoses from VST cover. Remove
fuel cooler.
3. Remove VST cover screws and remove cover assembly.

c
d

e
c

a - Fuel Cooler Mounting Screw (1) M6 x 25

b - Fuel Cooler
c - Metal Hose Clamp
d - VST Cover Screws (5)
e - VST Cover Assembly

Page 3C-44 90-883065 APRIL 2001

 SERVICE PROCEDURES

4. Disconnect high pressure fuel pump connectors and remove high pressure fuel pump.
5. Inspect and clean high pressure fuel pump screen.

a - Connectors
b - High Pressure Fuel Pump
c - Screen
6. Loosen float pin retaining screw and remove float assembly.
7. Remove baffle plate (if desired).
8. Remove and inspect seat.
9. Inspect and clean VST float chamber.

g a

e
c

d
f

b
i
h
a - Float Pin Retaining Screw
b - Float
c - Float Shaft
d - Clip
e - Needle
f - Baffle Plate
g - VST Float Chamber
h - Seat
i - Gasket

90-883065 APRIL 2001 Page 3C-45

SERVICE PROCEDURES

Assembly
1. Apply Loctite 242 to screws and install baffle plate (if removed). Tighten screws to spe-
cified torque.
2. Install seat (with new gasket) and tighten.
3. Install float assembly as shown. Install float pin and tighten retaining screw to specified
torque.

a
66

f
e
c
d

b
h
g
66 Loctite 242 (92-809821)
a - Float Pin Retaining Screw e - Needle
b - Float f - Baffle Plate Screw (3)
c - Float Shaft g - Seat
d - Clip h - Gasket

Screw Torque
22 lb. in. (2.5 N·m)

4. Connect the high pressure fuel pump connectors. Push the nozzle into the rubber
grommet (lubricate with light oil if necessary). Make sure the alignment pin is positioned
properly and lines up with hole in the high pressure fuel pump.

a
c

a - Connectors
b - High Pressure Fuel Pump
c - Alignment Pin

Page 3C-46 90-883065 APRIL 2001

 SERVICE PROCEDURES

5. Install grommet to the bottom of the high pressure fuel pump.

6. Lightly clamp the VST float chamber in a vise. Position the VST cover assembly so the
high pressure fuel pump is horizontal. This will prevent the grommet from falling off.
7. Install VST cover assembly and new gasket, into float chamber. Push the cover and
float chamber together, this will compress the grommet and allow the screws to be
threaded in.
8. Install VST cover screws and tighten to specified torque.

g
e
g
d

h
a
i

91-803146T

a - Grommet
b - Gasket
c - VST Float Chamber
d - High Pressure Fuel Pump
e - VST Cover Assembly
f - VST Cover Screws (5)
g - Metal Hose Clamp (4)
h - Fuel Cooler Mounting Screw(1) M4 x 20
i - Fuel Cooler

Screw Torque
32 lb. in. (3.5 N·m)

90-883065 APRIL 2001 Page 3C-47

SERVICE PROCEDURES

Pressure Regulator Removal/Installation

WARNING
Always release the fuel pressure in the high-pressure fuel line before servicing the
line or the vapor separator. If the fuel pressure is not released, pressurized fuel
may spray out.
NOTE: The pressure regulator vent is an open fitting that does not require a hose to be
attached.

Removal

1. Release fuel pressure. Refer to Releasing Fuel Pressure in the High Pressure Fuel
Line.

2. Remove fuel pressure regulator mounting screws and remove regulator from VST cover.

3. Inspect o-rings. Replace if necessary. Inspect and clean screen.

Installation
1. Lubricate o-rings with light lubricant and reassemble the pressure regulator to the VST
cover (twist while pushing in).
2. Apply Loctite 242 to mounting screws and tighten to specified torque.

a
d
b
66
c

66 Loctite 242 (92-809821)

a - Mounting Screw (2)

b - Fuel Pressure Regulator
c - O-rings
d - Vent (no hose)

Pressure Regulator Mounting Screw Torque

22 lb. in. (2.5 N·m)

Page 3C-48 90-883065 APRIL 2001

 SERVICE PROCEDURES

High Pressure Fuel Line Removal/Installation

WARNING
Always release the fuel pressure in the high-pressure fuel line before servicing the
line or the vapor separator. If the fuel pressure is not released, pressurized fuel
may spray out.
REMOVAL
1. Disconnect the fuel line from the fuel distribution manifold by depressing the locking
tab.
2. Disconnect the fuel line from the fuel cooler by depressing the locking tab.
3. Remove the high pressure fuel line assembly.
4. Inspect filter for cracks/debris. Replace if necessary.
INSTALLATION
1. Connect fuel lines as shown.

f
a

a - Locking Tab
b - Fuel Filter
c - Fuel Line (to VST fuel cooler)
d - Fuel Line (to fuel distribution manifold)
e - Protective Sleeve
f - Conduit
g - Conduit

90-883065 APRIL 2001 Page 3C-49