BASIC FUEL SYSTEM DIAGNOSIS 5-2

FUEL LINES AND FllllNGS 5-2

FUELLINEFITTINGS 5-2
REMOVAL&INSTALLATION 5-2
MULTI-POINT FUEL INJECTION
SYSTEM (MPI) 5-3
GENERALINFORMATION5-3
FUELSYSTEMSERVICE
PRECAUTIONS 5-3
RELIEVINGFUELSYSTEM
PRESSURE 5-3
THROTTLEBODY 5-3
REMOVAL& INSTALLATION 5-3
FUELRAILAND INJECTORS(S) 5-4
REMOVAL&INSTALLATION 5-4
TESTING 5-8
FUELPRESSUREREGULATOR5-9
REMOVAL& INSTALLATION 5-9
PRESSURERELIEFVALVE5-9
REMOVAL&INSTALLATION 5-9
FUEL TANK 5-10
TANKASSEMBLY 5-10
REMOVAL&INSTALLATION 5-10
 I

5-2, FUELSYSTEM

Whenthereis a problem startingor drivinga vehi- “istherefuel? will oftenleadto solvingmostbasic thismanual. If theignitionsystemchecksout(there
cle,twoof themostimportant checksinvolvetheig- problems. Forignitionsystemdiagnosis andtesting, is spark),thenyoumustdetermine if thefuelsystem
nitionandthefuelsystems. Thequestions mostme- pleasereferto theinformation onengineelectrical is operatingproperly(istherefuel?).
chanicsattemptto answerfirst,“is therespark?”and components andignitionsystems foundearlierin

REMOVAL&INSTALLATION
# See Figures 1 thru 7
Thefuellinesusedonall modelscoveredbythis
manualarequitestraightforward.Typicallythefit-
tingsareeitherrubberhosesconnecting to steellines
withclamps,or steellinesconnecting to steellines
usingretainingboltsorflarefittings.Severalfittings
areuniquesuchasthebanjo-boltfittingonthefuel
feedlinefromthefuelfilter.
Fig. 1 This photo of the fuel pump lines is
an example of the type of fittings found on
Observeall applicablesafety precautions most models.The return line utilizes a rub- Fig. 2 This fitting on the fuel pressurereg-
whenworking aroundfuel. Wheneverservic- ber hose and a hose clamp, while the feed ulator utilizes a rubber hose and a hose
ing ___
the_fuel
. system,always.. work
_ in a well line utilizes a flare fitting clamp. Removethe hose clamp . . .
ventitateuarea. Do not allow fuel spray or
vaporsto come in contactwith a sparkor
ooen flame. Keena drv chemicalfire extin-
guishernear the’work &ea. Always keepfuel
in a containerspecifically designedfor fuel
storage;also, always pmperlyseal fuel con-
tainers to avoid the possibility of fire or ex-
plosion.

93153p45

Fig. 4 The fuel feed line-to-fuel rail fitting

ren disconnectthe hose from is held by retaining bolts. Unfasten the
1the pressure regulator bolts . . .

Fig. 5 . . . then remove the fuel feed line

from the fuel injector rail
I 93155pzl

1Fig. 6 The fitting on the too of the fueg;?lzI I Fig. 7 On the banjo-bolt type fitting, it is
ter utilizes a banjo-bolt type fitting. Re- crucial that the copper washers are re-
move the bolt from the filter feed line on I I placed every time the fitting is removed
the top of the filter
 FUELSYSTEM513

TheMulti-Point Injection (MPI)systemiselectroni-
rallycontrolledbytheEngine ControlModule(ECM),
basedondatafromvarioussensors. TheECMcontrols
thefuelflow,idlespeedandignitiontiming.
Fuelissuppliedtotheinjectors byanelectricin-
tankfuelpumpandisdistributed totherespective in-
jectorsviathemainfuelpipe.Thefuelpressure ap-
pliedtotheinjectorisconstant andhigherthanthe
pressure intheintakemanifold. Thepressure iscon-
trolledbythefuelpressure regulator.Theexcess fuel
is returnedtothefueltankthroughthefuelreturnpipe.
Whenanelectriccurrentflowsintheinjector,the
injectorvalveis fullyopenedto supplyfuel.Sincethe
fuelpressure is constant,theamountofthefuelin-
jettedfromtheinjectorintothemanifoldis increased
or decreased in proportion tothetimetheelectric
currentflows.BasedonECUsignals,theinjectorsin-
jectfuelto thecylindermanifoldportsin firingorder.
Theflowrateof theair drawnthroughtheair
cleaneris measured bytheairflowsensor.Theair
enterstheair intakeplenumor manifoldthroughthe
throttlebody.Intheintakemanifold, theair is mixed
withthefuelfromtheinjectorsandis drawnintothe
cylinder,Theairflowrateis controlled according to
thedegreeof thethrottlevalveandtheservomotor
openings. Thesystemis monitored througha num-
berof sensorswhichfeedinformation onenginecon-
ditionsandrequirements to theECM.TheECMcal-
culatestheinjectiontimeandrateaccording tothe
signalsfromthesensors,
l AlwaysreplacewornfuelfittingO-ringswith
new.Donotsubstitute fuelhoseor equivalent,
where I
fuelpipeis installed.
Fuel injectionsystemsremain underpres-
sure after the enginehas beenturnedOFF.
Properlyrelieve fuel pressurebefore discon-
neetingany fuel lines. Failure to do so may
result in fire or personalinjury.
Fig, 8 Detachthe connectorfor the throttle
1. TurntheignitiontotheOFFposition.
2. Loosenthefuelfillercapto releasefueltank position (TP) sensor
pressure.
I
Observeall applicablesafety precautions
whenworkingaroundfuel. Wheneverservic-
ing the fuel system,always work in a well
ventilatedarea. Do not allow fuel sprayor va-
porsto comein contactwith a sparkor open
flame. Keepa dry chemicalfire extinguisher
nearthe work area. Alwayskeepfuel in a con-
tainer specifically designedfor fuel storage;
also, always properlyseal fuel containersto
avoidthe possibility of fire or explosion.
3. FortheMirage,Diamante, and1994-00 93153ps5

Galant,remove therearseatcushion,thenremove Fig, 9 Remove the accelerator cable end

theservicecoveranddetachthefuelpumpharness from the throttle lever
connector.
Safetyis themostimportant factorwhenperform- 4. Forthe1990-93FWDGalant,detachthefuel
ingnotonlyfuelsystemmaintenance butanytypeof pumpharness connectorlocatedintheareaof the
maintenance. Failureto conductmaintenance andre- fueltank.It maybenecessary to raisethevehicleto
pairsin a safemanner mayresultin seriouspersonal accesstheconnector.
injuryor death.Maintenance andtestingof thevehi- 5. Forthe1990-93AWDGalant,remove thecar-
cle’sfuelsystemcomponents canbeaccomplished petfromthetrunk,locatethefueltankwiringatthe
safelyandeffectively byadhering to thefollowing pumpaccesscover,thendetachthewiring.
rulesandguidelines. 6. Startthevehicleandallowit to rununtilit
l Toavoidthepossibilityof fireandpersonalin- stallsfromlackof fuel.TurnthekeytotheOFFposi-
jury,alwaysdisconnect thenegative batterycableun- tion.
lesstherepairor testprocedure requires thatbattery 7. Disconnect thenegative batterycable,thenat-
voltagebeapplied. tachthefuelpumpconnector. Installtheaccess .
l Alwaysrelievethefuelsystempressure priorto cover,cushionor carpetasnecessary.
disconnecting anyfuelsystemcomponent (injector, 8. Wrapshoptowelsaroundthefittingthatis be-
fuelrail,pressure regulator,etc.),fittingorfuelline ingdisconnected to absorbresidualfuelinthelines.
connection. Exerciseextreme cautionwhenever re- 9. Placeshoptowelsintopropersafetycontainer. Fig. IO Removethe hose shown here from
lievingfuelsystempressure to avoidexposingskin,
faceandeyesto fuelspray.Pleasebeadvisedthat
fuelunderpressure maypenetrate theskinorany
partof thebodythatit contacts.
l Alwaysplacea shoptowelor clotharoundthe REMOVAL&INSTALLATION
fittingor connection priorto loosening to absorbany
excessfueldueto spillage.Ensure thatall fuel p See Figures 8 thru 18
spillage(shouldit occur)is quicklyremoved from
enginesurfaces. Ensure thatall fuelsoakedclothsor 1. Properlyrelievethefuelsystempressure as
towelsaredeposited intoa suitablewastecontainer. outlinedearlierinthissection.
l Alwayskeepa drychemical (ClassB)fireex- 2. Draintheenginecoolingsystemintoa suit-
tinguisher neartheworkarea. ablecontainer.
l Donotallowfuelsprayorfuelvaporstocome 3. Matchmark thejocationoftheadjusterbolt
intocontactwitha sparkor openflame. ontheaccelerator cablemounting flange.Thiswill
l Alwaysusea backupwrenchwhenloosening’ assurethatthecableis installedin itsoriginalloca-
andtightening fuellineconnection fittings.Thiswill tion.Remove thethrottlecableadjustingboltand
preventunnecessary stressandtorsiontofuelline disconnectthecablefromtheleveronthethrottle
piping.Alwaysfollowthepropertorquespecifica- body.Positioncableaside.
tions.
5-4 FUELSYSTEM
15-Z Nm 15-22 Nm
11-16 lt.lbs. 11-16 ft.lbr.

93155422

Fig. 12 Explodedview of the throttle body

and related components-l .5L engine

1. Connectnn for accelerator cable

2. Connection for breather hose

3 Connection for au intake hose
4 Connectton for au hose C
5. Connectton for vacuum hose
6 Connectton for IAC motor connector and
closed throttle posItIon swtch connector ’
7 ConnectIon for TPS connector
8 Connectton for water hose
9 Connectnon for water by-pass hose
10 Ground plate mounting screw
11. Throttle body stay and ground plate
12 Au flttlng
13 Gasket
14 Throttle body
15 Gasket
89575422

:ig. 14 Explodedview of the throttle body and related components-l.61 and 2.OLDOHCen-
line

93155g24

Yg. 15 Explodedview of the throttle body and related components- :ig. 16 Explodedview of the throttle body and related components-
1.OLSOHCengine, DOHCsimilar 1.5Lengine

4. Removethe connectionfor the breatherhose
andthe air intakehosefrom the throttlebody and po-
sition aside.
5. Tagand disconnectthe necessaryvacuum
hoses.
6. Labeland detachthe electricalconnectorsat
the throttlebody,as necessary.
7. Disconnectthe waterand waterby-pass
hosesat the baseof the throttlebody.
8. If equipped,unfastenthe groundplate
mountingscrews,then removethe throttlebodystay
and QrOUndplatefrom the engine.
9. Removethe air fitting and gasket.
10. Unfastenthe throttlebody mountingbolts,
then removethe throttlebodyfrom the engine.Re-
moveand discardthe gasket.
To install:
11. Cleanall old gasketmaterialfrom the both
throttlebody mountingsurfaces.Install newgasket
1 onto the intakemanifoldplenummountingsurface.
*Poor idling quality and poor performance
may be experiencedif the gasketis installed
incorrectly.
12. Installthe throttlebodyto the intakemanifold
plenumand tightenthe mountingbolts.
13. Installthe air fitting, if equipped,makingsure
newgasketiS in place.
14. If equipped,installthe throttlebody stayand
QrOUnd plate.Securewith retainerstightenedto
11-16 ft. Ibs. (15-22 Nm).
15. Installthe groundplatemountingscrew.
16. Connectthe waterhosesto the throttlebody.
Installnewhoseclamps if required.
17. Attachthe electricaland vacuumconnectors
to the throttle body,as taggedduring removal.
18 Connectthe acceleratorcableto the throttle
bodyand installthe adjustingbolt in original posi-
tion. Checkadjustmentof cable.
19 Installthe air intakeand breatherhoses.
20. If removed,installthe batteryand connectthe
positivecable.
 FUELSYSTEM5-5,
21. Connectthe negativebatterycable.Refillthe
cooling system.

REMOVAL& INSTALLATION

1.5L, 1.8L, And 2.OLSOHCEngines

ti See Figures 17, 18, and 19
1. Relievethe fuel systempressureas described
in this section.
2. Disconnectthe PCV hosefrom the valve
cover.Also disconnectthe breatherhoseat the oppo-
site end of the valve cover.
1Hilt4naunfu(norc e Fu(l
3. Removethe bolts holdingthe high pressure :E%!,,.,.- 1: IEE
fuel line to the fuel rail and disconnectthe line. Be : Efgz tz!z? :: %%I
13m
;P&.xmeaw
preparedto containfuel spillage;plug the line to
keepout dirt and debris.
Fig. 17 Explodedview of the fuel injectors and related components-l .5L engine

Observeall applicablesafety precautions

when working aroundfuel. Wheneverservic-
ing the fuel system,always work in a well
ventilated area. 00 not allow fuel spray or
vaporsto comein contactwith a spark or
openflame. Keepa dry chemicalfire extin-
guishernear the work area. Always keepfuel
in a containerspecifically designedfor fuel
storage;also, always properly seal fuel con-
tainers to avoid the possibility of fire or ex-
plosion.
4. Removethe vacuumhosefrom the fuel pres-
sure regulator.
5. Disconnectthe fuel returnhosefrom the
pressureregulator.
6. Labeland detachthe electricalconnectors
from eachinjector.
7. Removethe bolt(s) holdingthe fuel rail to the
manifold.Carefullylift the rail up and removeit with
the injectorsattached.Takegreatcarenot to drop an
injector Placethe rail and Injectorsin a safelocation
on the workbench;protectthe tips of the injectors
from dirt and/or Impact.
8. Removeand discardthe injectorrnsulators
from the intakemanifold.The insulatorsare not I
reusable.
9. Removethe injectorsfrom the fuel rail by
pullinggentlyin a straightoutwardmotion. Make .xs.
certainthe grommetand O-ring comeoff with the in- 1 Connection for breather hose
jector. 2
3
Connection
Connection
for PCV hose
for high tm?ss”re fuel hose
To install: 4
5
0-ring
Connection for vacuum hose
10. Installa newinsulatorin eachinjectorport in 6 Connecr~on for fuel return hose
7 Fuel pressure regulator
the manifold. 8 0-ring
11. Removethe old grommetand O-ringfrom 9
10
Connection
Fuel ml
for control harness

eachinjector Installa newgrommetand O-ring;coat 11

12
Insulator
insulator
the O-ring lightly with clean,thin oil. 13 lnlector
14 O-ring
12. If the fuel pressureregulatorwas removed, 15 Grommet
replacethe O-ring with a newone and coat it lightly 89575026

with clean,thin oil Insertthe regulatorstraightinto
the rail, then checkthat it can be rotatedfreely. If It
doesnot rotatesmoothly,removeit and inspectthe
O-ringfor deformationor jamming.Whenproperly
installed,align the mountingholesand tightenthe
retainingbolts to 7 ft. Ibs. (9 Nm).This procedure
must befollowedevenif the fuel rail was not re-
moved.
13. Installthe injectorinto the fuel rail, constantly
turningthe injectorleft and right during installation.
Fig. 19 Explodedview of the fuel injectors and related components-2.01 SOHCengine
Whenfully installed,the injectorshouldstill turn 15. Installthe fuel rail retainingbolts and tighten
freely in the rail. If it does not, removethe injector * themto 9 ft. Ibs. (12 Nm).
and inspectthe O-ring for deformationor damage. 16. Connectthe wiring harnessesto the appro-
14. Installthe deliverypipe and injectorsto the priateinjector.
engine.Makecertainthat eachinjectorfits correctly 17. Connectthe fuel returnhoseto the pressure
into its port and thatthe rubberinsulatorsfor the fuel regulator,then connectthe vacuumhose.
rail mountsare in position. 18. Replacethe O-ring on the high pressurefuel
line, coatthe O-ring lightlywith clean,thin oil and
 5-6 FUELSYSTEM
installthelinetothefuelrail.Tightenthemounting
bolts,
19. AttachthePCVhoseandthebreather hoseif
thevweredisconnected.
20. Connect thenegative batterycable.Pressur-
izethefuelsystemandinspectall connections for I
leaks.
1.6L and 2.01 DOHCEngines
b See Figure 20
1. Relieve
thefuelsystempressure asdescribed
inthissection.
2. Disconnect
thenegativebatterycable.
3. Wraptheconnectionwitha shoptoweland
disconnect
thehighpressurefuellineatthefuelrail.

Observeall applicablesafety precautions

when working aroundfuel. Wheneverservic-
ing the fuel system,always work in a well
ventilated area. Do not allow fuel spray or
vapors to comein contactwith a spark or
openflame. Keepa dry chemicalfire extin-
guishernear the work area. Always keepfuel
in a containerspecifically designedfor fuel
storage;also, always properly seal fuel con- 1 x Connection for PCV hose 10. Connection for control harness
* tainers to avoid the possibility of fire or ex- 2. Connection for high pressure fuel hose 11 Fuel rail
plosion. 3. O-ring 12. Insulator
4. Connection for vacuum hose 13. Insulator
4. Disconnect thefuelreturnhoseandremove 5. Connection for fuel return hose 14. Injector
&2 I=,1c.1nrncc*.ra regu,ator 15. O-ring
theO-ring. 16. Grommet
5. Disconnect thevacuumhosefromthefuel 8. Accelerator ca lble clamD.
pressureregulator. 9. Center cover
6. Disconnect thePCVhose.On2.OLengine, 89575g27
remove thecentercover. Explodedview of the fuel injectors and related components-1.6L and 2.QLDOHC
7. Labelanddetachtheelectricalconnectors
fromeachiniector.
8. Remove theinjectorrailretainingbolts,Make
suretherubbermounting bushings donotgetlost.
9. Lifttherailassembly upandawayfromthe
engine.
10. Remove theinjectorsfromtherailbypulling
gently.Discardthelowerinsulator.Checktheresis-
tancethroughtheinjector.Thespecification for 2.OL
turbocharged engineis2-3 ohmsat70°F(20°C).
Thespecificationfortheothersis 13-15ohmsat
70°F (20°C).
To install:
11. Installa newgrommet andO-ringto thein-
jector.CoattheO-ringwithlightoil.
12. installtheinjectorto thefuelrail.
13. Replace theseatsin theintakemanifold.In- Fig. 21 Remove the fuel feed line-to-fuel Fig. 22 . . . then remove the fuel feed line
stallthefuelrailandinjectors to themanifold. Make rail retaining fitting bolts . . . from the fuel injector rail
suretherubberbushings arein placebeforetighten-
ingthemounting bolts.
14. Tightentheretainingboltsto 72inchlbs.(11
Nm).
15. Attachtheconnectors to theinjectorsandin-
stallthecentercover.Connect thePCVhose.
16. Connect thefuelpressure regulatorvacuum
hose.
17. Connect thefuelreturnhose.
18. Replace theO-ring,lightlylubricateit and
connectthehighpressure fuelline.
19. Connect thenegative batterycableandcheck
theentiresystemfor properoperation andleaks.
2.4L Engine
b See Figures 21 thru 30
 FUELSYSTEM5-7

Fig, 25 Removethe vacuumhose from the Fig. 25 Detach the connectorsfrom all of Fig. 27 Removethe two fuel rail retaining
pressure regulator the fuel injectors bolts . . .

93155ps

1H; :A ..;lt;;aft~rgi,i~;yl the ;F: 1 / Fig. 29 Removethe fuel injectors from

93155p15
the 1 Fig. 30 Always replace the O-rings on the
tall by gently rocking them loose injectors before reinstalling them

1. Relievethefuelsystempressure asdescribed ontheworkbench; protectthetipsof theinjectors 18. Connect thefuelreturnhoseto thepressure

in thissection. fromdirtand/orimpact. regulator,thenconnectthevacuumhose.
2. Labelanddisconnect thesparkplugwires. ’ 9. Remove anddiscardtheinjectorinsulators 19. Replace theO-ringonthehighpressure fuel
Positionthewiresaside. fromtheintakemanifold. Theinsulators arenot line,coattheO-ringlightlywithclean,thinoil and
3. Disconnect thePCVhosefromthevalve reusable. installthelineto thefuelrail.Tiahtenthemountina
cover, 10. Remove theinjectorsfromthefuelrailby boltsto 4 ft. Ibs.(6 Nm). -
4. Remove theboltsholdingthehighpressure pullinggentlyinastraightoutwarc I motion.Makecer- 20. Connect thePCVhoseandsparkplugwires.
fuellineto thefuelrail,thendisconnecttheline.Be tainthegrommet andO-ringcomeoffwiththeinjector. 21. Connect thenegativebatterycable.Pressurize
prepared to containfuelspillage;plugthelineto To install: thefuelsystem andinspectallconnections for leaks.
keepoutdirtanddebris. 11. Installa newinsulatorin eachinjectorportin
themanifold. 3.OLand 3.5L Engines
12. Remove theoldgrommet andD-ringfrom
eachinjector.Installa newgrommet andO-ring;coat # See Figures31 and 32
Observeall applicablesafety precautions theO-ringlightlywithclean,thinoil. > - ,. .* , ,
when working aroundfuel. Wheneverservic- 1. nenevemerueIsystempressure.
13. Ifthefuelpressure regulator
wasremoved, re- 2. Disconnect
thenegative
batterycable.
ing the fuel system,always work in a well placetheO-ringwitha newoneandcoatit lightlywith
ventilated area. Do not allow fuel spray or clean,thinoil.Inserttheregulator straightintotherail, I I
vaporsto comein contactwith a spark or thencheckthatit canberotatedfreely.If it doesnotro-
openflame. Keepa dry chemicalfire extin- tatesmoothly, removeit andinspect theO-ringfor de- WorkMUSTNOTbe starteduntil at least 90
guishernear the work area. Always keepfuel formation orjamming. Whenproperlyinstalled, align secondsafter the ignition switch is turnedto
in a containerspecifically designedfor fuel themounting holesandtightentheretaining boltsto 7 the LOCKposition andthe negativebattery
storage;also, always properly seal fuel con- ft. Ibs.(9Nm).Thisprocedure mustbefollowedevenif cable is disconnectedfrom the battery. This
tainers to avoid the possfbility of fire or ex- thefuelrailwasnotremoved. will allow time for the air bagsystembackup
plosion. 14. Installtheinjectorintothefuelrail,constantly power supplyto deplete its stored energy,
turningtheinjectorleftandrightduringinstallation. preventingaccidentalair bag deployment
5. Remove thevacuumhosefromthefuelpres- Whenfully installed, theinjectorshouldstillturn which could result in unnecessaryair bag
sureregulator. freelyintherail.If it doesnot,remove theinjector systemrepairs and/orpersonalinjury.
6. Disconnect thefuelreturnhosefromthe andinspecttheO-ringfor deformation or damage.
pressure regulator. 15. Installthedeliverypipeandinjectorsto the 3. Drainthecoolingsystem.
7. Labelanddetachtheelectricalconnectors engine.Makecertainthateachinjectorfitscorrectly 4. Disconnect all components fromtheair in-
fromeachinjector. intoitsportandthattherubberinsulators forthefuel takeplenumandremove theplenumfromtheintake
8. Remove thebolt(s)holdingthefuelrailtothe railmountsarein position. manifold.Referto Section3.
manifold. Carefullylift therailupandremoveit with 16. Installthefuelrailretainingboltsandtighten 5. Wraptheconnection witha shoptoweland
theinjectorsattached. Takegreatcarenotto dropan themto 9 ff. Ibs.(12Nm). disconnectthehighpressure fuellineatthefuelrail.
injector.Placetherailandinjectorsina safelocation 17. Connect thewiringharnesses totheappro-
priateinjector.
5-8 FUELSYSTEM
9 ,npimr w1m.m
1: i”“L,
1: 82”w
Fig.31 Explodedview of the fuel injectors and related components-
s.OLengines
Observeall applicable safety precautions
whenworking aroundfuel. Wheneverservic-
ing the fuel system,always work in a well
ventilated area. Do not allow fuel spray or
vaporsto comein contactwith a spark or
openflame. Keepa dry chemicalfire extin-
guishernear the work area. Always keepfuel
in a containerspecifically designedfor fuel
storage;also, always properly seal fuel con-
tainers to avoid the possibility of fire or ex-
plosion.
6. Disconnectthe fuel returnhoseand remove
the O-ring.
7. Disconnectthe vacuumhosefrom the fuel
pressureregulator.
8. Detachthe electricalconnectorsfrom each
injector.
9. Removethe fuel pipe connectmgthe fuel
rails. Removethe injectorrail retainingbolts. Make
surethe rubbermountingbushingsdo not get lost.
10. Lift the rail assembliesup and awayfrom the
engine.
11. Removethe injectorsfrom the rail by pulling
gently.Discardthe lowerinsulator.
To install:
*Some of the vehicles may have a clip that
securesthe injector to the fuel rail. Besure
to removeor install the injector clip where
necessary.
12. Installa newgrommetand O-ring to the in-
jector. Coatthe O-ring with light oil.
13. Installthe injectorto the fuel rail.
14. Replacethe seatsin the intakemanifold.In-
stall the fuel rails and injectorsto the manifold.Make
surethe rubberbushingsare in placebeforetighten-
ing the mountingbolts.
15. Tightenthe retainingbolts to 7-9 ft. Ibs.
(W-13 Nm) Installthe fuel pipe with newgasket.
16. Attachthe electricalconnectorsto the injec-
tors
93155gx
Fig. 32 Explodedview of the fuel injectors and related components-
3.5L engine
17. Connectthe fuel returnhose.
18. Replacethe O-ring, lightly lubricateit and
connectthe high pressurefuel line.
19. Usmgnewgaskets,installthe intakeplenum
and all relateditems.Referto Section3.
20. Fill the cooling system.
21. Connectthe negativebatterycableand check
the entiresystemfor properoperationand leaks.
The easiestwayto testthe operationof the fuel in-
jectors is to listen for a clicking soundcomingfrom
the injectorswhile the engineISrunning.This is ac-
complishedusinga mechanic’sstethoscope,or a
long screwdriver.Placethe end of the stethoscopeor
the screwdriver(tip end, not handle)ontothe bodyof
the injector.Placethe ear piecesof the stethoscope
in your ears,or if usinga screwdriver,placeyour ear
on top of the handle.An audiblechckingnoise
should be heard;this is the solenoidoperating.If the
injectormakesthis noise,the injectordriver circuit
and computerare operatingas designed.Continue
testingall the injectorsthis way.
Be extremelycareful while working on an op-
erating engine, makesure you have no dan-
gling jewelry, extremely loose clothes,
powertool cords or other itemsthat might
get caughtin a movingpart of the ermine.
All Injectors Clicking
If all the injectors are clicking, but you have de-
termined that the fuel system is the cause of your
driveability problem, continue diagnostics. Make
sure that you have checkedfuel pump pressureas
outlined earlier in this section. An easy way to de-
termine a weak or unproductive cylinder is a cylin-
der drop test. This is accomplished by removing
one spark plug wire at a time, and seeing which
cylinder causesthe least difference in the idle.
The one that causesthe least change is the weak
cylinder.
If the injectorswereall clicking andthe ignition
systemis functioningproperly,removethe injectorof
the suspectcylinderand benchtest it. This is accom-
plishedby checkingfor a spraypatternfrom the in-
jector itself Installa fuel supply line to the injector
(or rail if the injectoris left attachedto the rail) and
momentarilyapply12 volts DC anda groundto the
injectoritself;a visible fuel sprayshouldappear.If no
sprayis achieved,replacethe injectorand checkthe
runningconditionof the engine.
Oneor More InjectorsAre Not Clicking
6 See Figures33, 34, 35, and 36
If oneor more injectorsarefoundto be not operat-
ing, testingthe injectordriver circuit and computer
can be accomplishedusing a “noid” light. First, with
the enginenot runningand the ignition key in the
OFFposition, removethe connectorfrom the injector
you planto test,then plug the “noid” light tool into
the injectorconnector.Startthe engineand the
“noid” light shouldflash,signalingthatthe injector
driver circuit is working.If the “noid” light flashes,
but the injectordoes not click whenpluggedin, test
the injectors resistance.Resistanceshould be be-
tween:
l All non-turboengines:13-16 ohmsat 68°F
(20°C)
l Turbochargedengines:2-3 ohmsat 68 “F
(20°C)
If the “noid” light does not flash, the injectordri-
ver circuit is faulty. Disconnectthe negativebattery
cable. Unplugthe “noid” light from the injectorcon-
nectorand also unplugthe PCM. Checkthe harness
betweenthe appropriatepins on the harnessside of
the PCM connectorand the injectorconnector.Re-
sistanceshould be less than 5.0 ohms; if not, repair
the circuit. If resistanceIS within specifications,the
injector driver inside the PCM is faulty and replace-
ment of the PCM will be necessary.
 \ FUELSYSTEM5-9

REMOVAL&INSTALLATION
p See Figures 37, 38, 39, 49, and 41
1. Properlyrelievethefuelsystempressure as
outlinedearlierinthissection.
2. Remove thevacuumhosefromthefuelpres-
sureregulator.
3. Disconnect thefuelreturnhosefromthe
pressureregulator.

Fig. 33 Unplugthe fuel injector connector Observeall applicablesafety precautions

whenworking aroundfuel. Wheneverservic-
, ing the fuel system, always work in a well
ventilated area. Do not apow fuel spray or
vaporsto come in contactwith a spark or
openflame. Keepa dry chemicalfire extin-
guishernear the work area. Always keepfuel
in a containerspecifically designedfor fuel
storage;also, always properly seal fuel con-
tainers to avoid the possibility of fire or ex-
plosion.
4. Remove thefuelregulatorretainerboltsor re-
movetheretaining
snapring,
thenremove thefuel
rrwkdnr
,“~“*I.“. frnm
..-.. * the
. ..” fl~el
._“. rail
.-...

91055pu2
Fig. 35 Plugthe correct “noid” light directly
into the iniector harnessconnector
I I
I
I To install:
5. Replace theO-ringonfuelpressure regulator
Fig. 36 If the correct “noid” light flashes witha newoneandcoatit lightlywithclean,thinoil.
while the engineis running,the injector dri-
. .. Insert
chl 6. .. the*regulator
* . . straight
, . intotherail,then
ver circuit inside the PCMis working xk matn canoerorarearreery.
I ,
r, If it doesnot rotate smoothly,removeit
and inspectthe O-ringfor deformationor
damage.
7. Whenproperlyinstalled, alignthemounting
holes.If equipped, installandtightentheretaining
boltsto 8 ft. Ibs.(11Nm).If equipped, installthereg-
ulatorretaining snapring.
8. Connect thefuelreturnhosetothepressure
regulator.
9. Installthevacuumhosetothefuelpressure
regulator.
10. Connect thenegative batterycableandpres-
surizethefuelsystem.Inspect for leaks.

1Fig
ret;rnline
37 Remove
~ . . the hose clamp on theg315sp10
fuel 1 1~~~.~~~s~~~~~u~s,“p”“““’ the hose? 1

Fig. 40 Removethe regulator-to-fuel rail re-

Fig. 39 Removethe vacuumhose from the taining bolts, then removethe pressurereg-
pressure regulator ulator from the fuel rail
1. 5-10
_ FUELSYSTEM
REMOVAL&INSTALLATION
p See Figures42 and 43
1. Raiseand safelysupportthe vehiclesecurely
on jackstands.
2. Removethe hosesand removethe pressurere-
lief valve.
3. The installationis the reverseof removal.
c, Always install the pressurerelief valve
with the arrow pointingtoward the EVAPcan-
ister side, not the fuel tank
REMOVAL&INSTALLATION
p See Figures44 thru 58
1. Properlyrelievethe fuel systempressureus-
ing properprocedures.
2. Disconnectthe negativebatterycable.
3. Raisethe vehicleand supportsafelv.
4. Drainthe fuel from the fuel tank into an ap-
provedcontainer.
Observeall applicablesafety precautions
when working aroundfuel. Wheneverservic-
ing the fuel system,always work in a well
ventilated area. Do not allow fuel spray or
vapors to comein contactwith a spark or
openflame. Keepa dry chemicalfire extin-
guishernear the work area. Always keepfuel
in a containerspecifically designedfor fuel
storage;also, always properly seal fuel con-
tainers to avoid the possibility of fire or ex-
plosion.
Tg. 44 Fuel tank and related componentsexploded view-1990-92
mirage
Fuel tank pressure
- relef vdive \
Fig 42 Pressurerelief valve location-llia
1mame shown, others similar g3155g”
5. On Diamantemodels:
a. Removethe left rearwheelwell liner.
b Disconnectthe centerexhaustsystemfrom
the main muffler.Disconnectthe rear exhaust
hangers,lower the exhaustand secureaside.
c. On modelsequippedwith 4-wheelsteering,
removethe mountingbolts and lower the rear
steeringgear.
6. Disconnectthe returnhose,high pressure
hoseand vapor hosesfrom the fuel pump.
7. Detachthe electricalconnectorsat the
pump/sendingunit.
8. Disconnectthe filler and vent hoses. s a. If equippedwith 4-wheel steering,install
9. Placea suitablejack underthe centerof the
fuel tankand applya slight upwardpressure.Remove
the fuel tank strap retainingnuts.
10. Lowerthe tank slightly and detachany re-
mainingelectricalor hoseconnectorsat the fuel tank.
11. Removethe fuel tank from the vehicle.
To install:
12. If replacingthe tank,transferany necessary
componentsto the newtank includingany heat
shields,hoses,valves,and the fuel pump.
13. Installthe fuel tank onto the jack. Rarsethe
tank in position underthe vehicle.Leaveenough
:ig. 45 Fuel tank and related componentsexploded view-1993-96
vlirage
I Evaporatwe emlsslon
I
canister side
Tank side
+k
93155gt7
Fig. 43 Always install the pressure relief
valve with the arrow pointing toward the
EVAPcanister side, not the fuel tank
clearanceto attachthe electricaland hoseconnec-
tions to the top of the fuel pump.
14. Attachall connectronsto the top of the tank.
15. Raisethe tank completelyand positionthe re-
tainerstrapsaroundthe fuel tank.Install newfuel
tank self-lockingnutsand tightenthe nuts.
16. Connectthe returnhoseand high pressure
hoses.
17. Installthe vapor hoseandthe filler hose.In-
stall the filler hose retainerscrewsto the fender,if re-
moved.
18. On Diamantemodels:
the power cylinder unit and tightenthe mounting
bolts to 31 ft. Ibs. (43 Nm).
b. Connectthe exhaustpipe and securethe
rear hangers.
c. Install the left rear wheelwell liner, if re-
moved.
19. Lowerthe vehicleand pour the drainedfuel
into the gastank.
20. Connectthe negativebatterycable.Checkthe
fuel pumpfor properpressureand inspectthe entire
systemfor leaks.
93155(12E

Fig. 46 Fuel tank and related components exploded view-1997-98
Mirage
Vapor hose
Filler
hose
Fig. 48 Connection of the vapor and filler hoses-1990-93
REMOVAL&INSTALLATION
Fuel injection systems remain under pres-
sure after the engine has been turned OFF.
Properly relieve fuel pressure before discon-
necting any fuel lines. Failure to do so may
result in fire or personal iniury.
*Cover all fuel hose connections with a
shop towel, prior to disconnecting, to prevent
splash of fuel that could be caused by resid-
ual pressure remaining in the fuel line.
93155gZi
Fig. 47 Fuel tank and related components exploded view-1999-00
FWD Galanl Qt. 49 Fuel tank and related components-1990-93
1990-92 Mirage
p See Figure 44
1. Properlyrelievethe fuel systempressureus-
ing properprocedures.Disconnectthe negativebat-
tery cable
2. Raisethe vehicleand supportsafely.
3. Dramthe fuel from the fuel tank Intoan ap-
provedcontainer.
Observe all applicable safety precautions
when working around fuel. Whenever servic-
ing the fuel system, always work in a well
ventilated area. Do not allow fuel spray or
vapors to come in contact with a spark or
open flame. Keep a dry chemical fire extin-
FUELSYSTEM5-11
<up to 1996 moclab>
FWD Galant
guisher near the work area. Always keep fuel
in a container specifically designed for fuel
storage; also, always properly seal fuel con-
tainers to avoid the possibility of fire or ex-
plosion.
4. Lowerthe tank slightly and detachany re-
mainingelectricalor hoseconnectorsat the fuel tank.
5. Removethe fuel tankfrom the vehicleas de-
scribedIn this section.
6 Removethe five nutssecuringthe fuel pump
to the fuel tank and removethe pumpassembly.
To install:
7. Installfuel pump into fuel tank,with new
packinggasket,andtightenmountingnuts.
8. Installthe fuel tank into the vehrcle.Referto
the procedurein this section.
 5-12 FUELSYSTEM

Fig. 50 Fuel tank and related components-1990-93 AWDGalant

:ig. 52 Fuel tank and related components-1994-96 Galantwith Cal-

fornia emissions

9. Lowerthe vehicleand pour the drainedfuel
into the gastank.
10. Connectthe negativebatterycable.
11. Checkthe fuel pumpfor properpressureand J
inspectthe entiresystemfor leaks,
1990-93 Galant
FRONT WHEEL DRIVE (FWD)
e See Figures59, 60, and 61
1. Relievethe fuel systempressureusing proper
procedure.
2. Disconnectnegativebatterycable.
3. Raiseand safelysupportthe vehicle.
4. Drainthe fuel from the fuel tank Into an ap-
provedgasolinecontainer.
Observeall applicablesafety precautions
whenworking aroundfuel. Wheneverservic-
ing the fuel system,always work in a well
ventilated area. Do not allow fuel spray or
vaporsto comein contactwith a sparkor
openflame. Keepa dry chemicalfire extin-
guishernear the work area. Always keepfuel
in a containerspecifically designedfor fuel
storage;also, always properly seal fuel con-
tainers to avoid the possibility of fire or ex-
plosion.
5. Removethe electricalconnectorsat the fuel
pump.Makesurethereis enoughslack in the electri-
 FUELSYSTiM 5-13

1.BODY HARNESS CONNECTION 1; ;;JL RETURN HOSE

2 HOSE CONNECTION
3 PURGE HOSE 15 FUEL PUMP MODULE
4 VAPOR HOSE 16 FILLER NECK
5 VENT HOSE 17 FUEL CAP
6 FllLER HOSE IS REINFORCEMENT
7 PIPE ASSEMBLY 19 PACKING
8.BAND ASSEMBLY 20 VAPOR HOSE
9 FUEL TANK ASSEMBLY 21 SEPARATOR ASSEMBLY
10.DIFFERENTIAL PRESSURE 22 VAPOR HOSE
SENSOR 23 FUEL CHECK VALVE ASSEMBLY
11 FUEL HARNESS 24 FUEL FILLER NECK ASSEMBLY
12 HIGH-PRESSURE FUEL HOSE

Fig. 54 Fuel tank and related components-1999-00 Galant :ia. 55 Fuel tank and related components-1992-96 Diamante

7923PG79

:ig. 57 Proper method of supporting real

rxhaustsystem-Diamante 3.01 engine

1 PatkIng brake cable COnneCtlo” 11 “.qm hose

2 Fuel tank 12 Fuel fllk, neck
3 “apot hose 13 Fuel filler assembly
4 Pressure hose 14 Fuel p,pe
5 Vapor hose COnneCflOn
6 Fuel pump am gauge assembly
7 Vapor hose
8 Valve assembly
9 Fuel mer cap
10 FllkY hose
93155g15

:ig. 56 Fuel tank and related components-1997-00 Diamante

cal harnessof the fuel gaugeunit to allowfor the fuel
tankto be loweredslightly. If not, labeland discon-
nectthe electricalharnessat the fuel gaugeunit.
6. Detachthe high pressurefuel line connector
at the pump.
7. Loosenself-lockinqnutson tank suooort
strapsto the end of the stud bolts.
8 Removethe right side lateralrod attaching
bolt and drsconnectthe arm from the right body cou-
pling. Lowerthe lateralrod and suspendfrom the
axle beamusingwire.
9. Removethe six retainingbolts and gasket
from the baseof the tank.
10. Removethe fuel pumpassembly.
To install:
*If the packingmaterial is damagedor de-
formed, replace it with new packing.
11. Align the 3 projectionson packingwith the
holes on the fuel pumpand the nippleson the pump
facingthe samedirectionas beforeremoval.
12. Installthe holdrngbolt throughthe bottomof
the tank. Makesurethe gasketon the bolt is replaced
and is not pinchedduring installation.Torqueto 10
ft. Ibs.(14 Nm).

5-14 FUELSYSTEM
93155(10:
‘ig. 59 loosen self-locking nuts on tank
mpporf straps to the end of the stud bolts
-1990-93 FWDGalant
93i55Qo$
:ig. 60 Removethe six retaining bolts and
lasket from the base of the tank-1990-93
:WD Galant
cl@=
m
Q 0
a 2. Disconnectthe negativebatterycable.
a-
u seatstopperoutwardand lifting the lower cushion
a al2 0 upward.
0 4. Removethe accesscover.
Q a a
Posmdmng projectton
93155910
Fig. 61 Align the 3 projections on packing
with the holes on the fuel pumpandthe nip-
ples on the pumpfacing the same direction
as before removal-1990-93 FWDGalant
13. Installthe right side lateralrod and attaching
bolt into the right body coupling.Tightenloosely
only, at this time.
14. Tightenthe self-lockingnuts on the tank sup-
port strapsuntil the tank is fully seated.Torquethe
nutsto 22 ft. Ibs. (31 Nm).
15. Installthe high pressurefuel hoseconnector
and tightento 29 ft. Ibs.(40 Nm).
16. Installthe electricalconnectorsonto the fuel
pumpand gaugeunit assemblies.
17. Lowerthe vehicleso the suspensionsupports
the weightof the vehicle.Tightenthe lateralrod at-
tachingbolt to 58-72 ft Ibs. (So-100 Nm).
18. Refillthe fuel tankwith fuel drainedduring
this procedure.
19. Connectthe negativebatterycableand check
the entiresystemfor properoperationand leaks.
ALL WHEEL DRIVE (A WO)
# See Figures62, 63, and 64
1. Relievethe fuel systempressureusing proper
procedure.
2. Disconnectnegativebatterycable.
3. Thefuel pump is locatedin the fuel tank. Re-
movethe accesscover locatedin the rearfloor pan
4 Parballydrainthe fuel tank into an approved
gasolinecontainer.
Observeall applicablesafety precautions
whenworkina aroundfuel. Wheneverservic-
ing the fuel system,always work in a well
ventilated area. Do not allow fuel spray or
vaporsto comein contactwith a spark or
openflame. Keepa dry chemicalfire extin-
guishernear the work area. Always keepfuel
in a containerspecifically designedfor fuel
r
-ig. 62 The fuel pumpis located in the fuel
ank. Removethe access cover located m
he rear floor pan -1990-93 AWDGalant
93155go7
Fig. 63 Removethe six pumpretaining bolts
and remove the fuel pump and gauge as-
sembly from the tank-1990-93 AWD
1Galant
93155goa
Fig. 64 Install 3M ATD Part No. 8625 or
equivalent,to the rear floor pan and install
iheaccesscover into place-1990-93 AWD
Ealant
.
storage;also, always properly seal fuel con-
tainers to avoid the possibility of fire or ex-
plosion.
5 Removethe electricalconnectorfrom the fuel
pump.
6. Removethe overfill limiter (two-wayvalve),
as required.
7. Removethe high pressurefuel hoseconnec-
tor.
8. Removethe six pump retamingbolts and re-
move the fuel pumpand gaugeassemblyfrom the
tank. Notepositioningof pumpprior to removalfrom
tank.
To install:
*If the packingmaterial is damagedor de-
formed, replace it with new packing.
9. Align the 3 projectionson the packingwith
the holes on the fuel pumpand the nippleson the
pumpfacmgthe samedirectionas beforeremoval.
Installthe retainersand tlghtento 2 ft. Ibs. (3 Nm).
10. Installthe high pressurehoseconnectionand
tightento 29 ft. Ibs. (40 Nm).
11. Installthe overfill limiter (two-wayvalve) and
the electricalconnectorto the fuel pump.
12. Fill the fuel tankwith the gasolineremoved
duringthis procedure.
13. Reconnectthe negativebatterycableand
checkthe entiresystemfor leaks.
14. Install3M ATD PartNo. 8625 or equivalent,
to the rearfloor panand install the accesscover into
place.
Diamante,1993-00 Mirage, and 1994-98
Galant
# See Figures 65 thru 72
1. Properlyrelievethe fuel systempressure.
3. Removethe rearseatcushion,by pullingthe
5. Disconnectthe fuel pumpwiring.
6. Disconnectthe returnhoseand the high
pressurefuel hose.
7. Removethe pumpmountingnutsand remove
the pumpassembly.
Observeall applicablesafety precautions
whenworking aroundfuel. Wheneverservic-
ing the fuel system,always work in a well
ventilated area. Do not allow fuel spray or
vaporsto comein contactwith a spark or
openflame. Keepa dry chemicalfire extin-
guishernear the work area. Always keepfuel
in a containerspecifically designedfor fuel
storage;also, always properly seal fuel con-
tainers to avoid the possibility of fire or ex-
plosion.
To install:
rlf the packingmaterial is damagedor de-
formed, replace it with new packing.
8. Installthe packingto the fuel tank.
9. Installthefuel pumpassemblyto thetankand
tightenthe retainingnutsto 22 inch Ibs.(2 5 Nm).
 FUELSYSTEM5-15
*Tilt the float to the left of the vehicle, when
installing the pumpassembly..
10. Connect thehighpressure hose,returnhose
andthefueltankwiring.
11. Connect thenegative batterycable.
12. Checkthefuelpumpfor properpressure and
\ inspecttheentiresystemfor leaks.
13. Applysealanttotheaccesscoverandinstall
thecover.
14. Installtherearseatcushion.
1999-M Galant
b See Figures65 thru 75 ’
1. Properlyrelievethefuelsystempressure.
2. Disconnectthenegative batterycable.
3. Remove therearseatcushion,bypullingthe
seatstopperoutwardandliftingthelowercushion
upward.
4. Remove theaccesscover.

Fig. 73 Using special tool MB991480or

1equivalerIt, removethe fuel pumpretaining

--
93155~03
. _.
. . . then lift the cover from tne floor-
II Fig. 71 The fuel pump, just like the send-
ing unit (shown
._. . here), is held by six re-
tammgnuts; removetne
out of the fuel tank
-. m and lift the pump
Fig. 74 Install the packing to the fuel tank
-1999-00 Galant

J I A/ -p,486
I

, 72 Ins$ll 3M ATD Part No. 6625 ori /’Fig. 75 lnstaII the fuel pump assembly toi
Fig, 68 On Mirage models there is a plug equivalent to the rear floor pan and install the tank and align the mating markson the
rather than an access cover the accesscover or plug into place pumpand the floorpan -1999110 Galant

5-16 FUELSYSTEM
6. Disconnectthe returnhoseandthe high
pressurefuel hose.
7. Usingspecialtool MB991480 or equivalent,
removethe fuel pumpretainingcapand removethe
pumpassembly.
Observeall applicablesafety precautions
whenworking aroundfuel. Wheneverservic-
ing the fuel system,always work in a well
ventilated area. Do not allow fuel spray or
vaporsto comein contactwith a spark or
openflame. Keepa dry chemicalfire extin-
guishernear the work area. Always keepfuel
in a containerspecifically designedfor fuel
storage;also, always properly seal fuel con-
tainers to avoid the possibility of fire or ex-
plosion.
To install:
*If the packingmaterial is damagedor de-
formed, replace it with new packing.
8. Installthe packingto the fuel tank.
9. Installthe fuel pumpassemblyto the tank
and align the matingmarkson the pumpand the
floorpan.
10. Tightenthe fuel pumpretainingcap using
tool MB991480or equrvalent.
11. Connectthe high pressurehose,returnhose
and the fuel tankwirmg.
12. Connectthe negativebatterycable.
13. Checkthe fuel pumpfor properpressureand
inspectthe entiresystemfor leaks.
14. Apply sealantto the accesscoverand install
the cover.
15. Installthe rearseatcushion.
TESTING
1. Relievefuel systempressure.
2. Disconnectthe batterynegativecable.
3. Disconnectthe fuel hrghpressurehoseat the
deliverypipe side.
Observeall applicablesafety precautions
when working aroundfuel. Wheneverservic-
ing the fuel system,always work in a well
ventilated area. Do not allow fuel spray or
vaporsto comein contactwith a sparkor
openflame. Keepa dry chemicalfire extin-
guishernear the work area. Always keepfuel
in a containerspecifically designedfor fuel
storage;also, always properly seal fuel con-
tainers to avoid the possibility of fire or ex-
alosion.
4. Connecta fuel pressuregaugeto tools
MD998709 and MD998742 or exactequivalent,with
appropriateadapters,sealsand/or gasketsto prevent
leaksduringthe test. Installthe gaugeand adapter
betweenthe deliverypipe and high pressurehose.In-
stall carefullyto preventleaks.
5. Connectthe negativebatterycable.
6. Apply batteryvoltageto the terminalfor fuel
pumpactivation(locatedin the enginecompartment)
to run the fuel pump,andcheckfor leaks.
7. Startthe engineand run at curb idle speed.
8. Measurethe fuel pressureand compareto
the specificationslisted in the chart in Section1.
9. Locateand disconnectthe vacuumhoserun-
ning to the fuel pressureregulator.Plugthe end of
the hoseand recordthe fuel pressureagain.Thefuel
pressureshould haveincreasedapproximatelyIO
psi.
.
10. Reconnectthe vacuumhosethe fuel pressure
regulator.Afterthe fuel pressurestabilizes,racethe
engine2-3 times and checkthatthe fuel pressure
does not fall whenthe engineis runningat idle.
il. Checkto be surethereis fuel pressurein the
returnhoseby gentlypressingthe fuel returnhose
with fingerswhile racingthe engine.Therewill be no
fuel pressurein the returnhosewhenthe volumeof
fuel flow is low.
12. If fuel pressureis too low,checkfor a
cloggedfuel filter, a defectivefuel pressureregulator
or a defectivefuel pump,any of which will requirere-
placement.
13. If fuel pressureis too high, the fuel pressure
regulatoris defectiveand will haveto be replacedor
the fuel returnis bentor clogged.If the fuel pressure
readmgdoesnot changewhenthe vacuumhoseis
disconnected,the hoseis cloggedor the valve is
stuck in the fuel pressureregulatorand it will haveto
be replaced.
14. Stop the engineand checkfor changesin the
fuel pressuregauge.It should not drop. If the gauge
readingdoesdrop, watchthe rateof drop. If fuel
pressuredrops slowly, the likely causeis a leaking
injectorwhich will requirereplacement.If the fuel
pressuredrops immediatelyafterthe engineis
stopped,the checkvalve in the fuel pumpisn’t clos-
ing andthe fuel pumpwill haveto be replaced.
15. Relievefuel systempressure.
16. Disconnectthe high pressurehoseand re-
movethe fuel pressuregaugefrom the deliverypipe.
17. Installa newO-ring in the groove of the high
pressurehose.Connectthe hoseto the deliverypipe
and tightenthe screws.After Installation,applybat-
teryvoltageto the terminalfor fuel pumpactivationto
run the fuel pump.Checkfor leaks.