Service Procedures
Fuel System
Section 3C - Service Procedures
Table of Contents
Fuel System Specifications................................................3C-2
Throttle Body..................................................................... 3C-2
Throttle Body Removal............................................... 3C-2
Throttle Body Installation............................................ 3C-3
Fuel Rail.............................................................................3C-5
Fuel Rail Removal and Disassembly..........................3C-5
90-8M0060785 DECEMBER 2011
3
Fuel Rail Assembly and Installation............................3C-6
Fuel Supply Module (FSM)................................................ 3C-8
FSM Removal.............................................................3C-8
FSM Disassembly.....................................................3C-10
FSM Assembly......................................................... 3C-13
C
FSM Installation........................................................3C-20
Page 3C-1
Service Procedures

Fuel System Specifications

Fuel System Specifications
Automotive unleaded with a minimum pump posted octane rating of 87 (90
Type of fuel
RON)
Approximate fuel pressure at idle 280–310 kPa (40.6–45.0 psi)
Approximate fuel pressure engine not running 340–370 kPa (49.3–53.7 psi)
Fuel filtration
Fuel inlet 20 microns
High pressure 20 microns

Lubricants, Sealants, Adhesives

Tube Ref No. Description Where Used Part No.
O-rings
Seal grommet
95 2-4-C with PTFE 92-802859A 1
Fuel pressure regulator O-rings
O-rings and seal grommets

Special Tools
Clamp Tool 91‑803146T
Used to clamp high‑pressure (Oetiker®) hose clamps. Part of Clamp Tool Kit
39648 (91‑803146A4).

Throttle Body
Throttle Body Removal
1. Remove the flywheel cover.
2. Remove the vent hose assembly from the throttle body.
3. Disconnect the throttle link from the throttle body lever.
4. Disconnect the engine harness connector from the throttle position sensor.

a a - Vent hose assembly

b - Throttle link
c - Throttle position sensor engine harness
c connector

48115

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 Service Procedures
5. Remove four screws securing the throttle body to the intake manifold. Remove the throttle body from the manifold.

48116

6. Remove the two screws securing the throttle position indicator to the throttle body. Remove the throttle position indicator.

a - Throttle position indicator

b - Screws (2)
a

b 48117

Throttle Body Installation

1. Install the throttle position indicator onto the throttle body throttle shaft.
2. Rotate the throttle position indicator clockwise to align the screw holes.

48118

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Service Procedures
3. Install the screws and tighten to the specified torque.

a - Throttle position indicator

b - Screws (2)
a

b 48117

Description Nm lb‑in. lb‑ft

Throttle position indicator screws (2) 2.3 20.3

4. Replace the throttle body seal on the intake manifold.

48119

5. Install the throttle body and secure with four M6 x 20 screws. Tighten the screws to the specified torque.

48116

Description Nm lb‑in. lb‑ft

Screws (M6 x 20) (4) 8 70.8

6. Connect the engine harness connector to the throttle position sensor.

7. Connect the throttle link to the throttle body lever.

Page 3C-4 90-8M0060785 DECEMBER 2011

 Service Procedures
8. Install the vent hose assembly onto the throttle body.

a a - Vent hose assembly

b - Throttle link
c - Throttle position sensor engine harness
c connector

48115
9. Install the flywheel cover.

Fuel Rail
Fuel Rail Removal and Disassembly
Fuel Rail Removal

! WARNING
Performing service or maintenance without first disconnecting the battery can cause product damage, personal injury, or
death due to fire, explosion, electrical shock, or unexpected motor starting. Always disconnect the battery cables from the
battery before maintaining, servicing, installing, or removing motor components.

! CAUTION
Failure to release pressure from the fuel system will result in fuel spraying out, which can cause a fire or explosion. Allow the
engine to cool completely and release all fuel pressure before servicing any part of the fuel system. Always protect eyes and
skin from pressurized fuel and vapors.

1. Disconnect the battery cables from the batteries.

2. Connect a fuel pressure gauge to the fuel rail test port and release the fuel pressure into an appropriate container.
3. Remove the metal hose clamp and remove the high‑pressure fuel hose from the fuel rail. Capture the fuel that will drain
from the fuel rail and high‑pressure fuel hose into an appropriate container.

a a - Fuel rail
b - Metal hose clamp

48183
4. Disconnect the engine harness connectors from the fuel injectors.
5. Remove the screws securing the fuel rail to the intake manifold.

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Service Procedures

6. Pull the fuel rail assembly off of the intake manifold.

a - Engine harness connectors

b - Screws securing the fuel rail
c - Fuel rail test port
a b

48185

Fuel Rail Disassembly

1. Push the fuel injector retainer off of the fuel injector and fuel rail.
2. Pull the fuel injector off the fuel rail.

a - Fuel injector retainer

48186

Fuel Rail Assembly and Installation

Fuel Rail Assembly
IMPORTANT: The fuel injector filter is not serviceable, but can be cleaned with a mild solvent and compressed air.
1. Before installing the fuel injectors, flush the fuel rail with a mild solvent. Use compressed air to remove any possible debris
from inside the fuel rail.

Page 3C-6 90-8M0060785 DECEMBER 2011

 Service Procedures

2. Replace the fuel injector O‑rings.

a - O‑rings
b - Filter

a 48187

3. Push the filter end of the fuel injector into the fuel rail. Verify the fuel injector retainer groove is above the fuel rail injector
port.

48188

4. Align the fuel injector retainer with the fuel rail and the fuel injector retainer groove.
5. Push the fuel injector retainer onto the fuel rail and fuel injector.

a - Fuel injector retainer

48191

Fuel Rail Installation

1. Push the fuel rail assembly onto the intake manifold and secure with four M6 x 20 screws. Tighten the screws to the
specified torque.

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Service Procedures

2. Connect the engine harness connectors onto the fuel injectors.

a - Engine harness connectors

b - Screws securing the fuel rail

a b

48192

Description Nm lb‑in. lb‑ft

Screws (M6 x 20) 8 70.8

3. Install a 15.7 mm metal hose clamp onto the high‑pressure fuel hose.
4. Install the high‑pressure fuel hose onto the fuel rail.
5. Secure the hose with the metal hose clamp using the hose clamp tool.

a a - Fuel rail
b - Metal hose clamp

48183

Clamp Tool 91‑803146T

6. Connect the battery cables to the batteries.

Fuel Supply Module (FSM)

FSM Removal
1. Release the fuel pressure on the fuel rail. Refer to Fuel Rail Removal.

! CAUTION
Failure to release pressure from the fuel system will result in fuel spraying out, which can cause a fire or explosion. Allow the
engine to cool completely and release all fuel pressure before servicing any part of the fuel system. Always protect eyes and
skin from pressurized fuel and vapors.

Page 3C-8 90-8M0060785 DECEMBER 2011

 Service Procedures
IMPORTANT: The FSM does not have a drain port incorporated into the upper or lower housing. If the FSM requires
disassembly, the extraction of fuel in the FSM can be accomplished with the following method.
Disconnect the fuel supply hose on the FSM. Attach a fuel pressure gauge to the fuel rail test port. Drain the fuel with the
pressure gauge into an appropriate container by turning the key switch "ON" several times while holding the purge valve
open, or use the CDS G3 Diagnostic Interface tool to energize the fuel pumps.
2. Disconnect all batteries from the engine.
3. Remove the remote control harness, fuel line, throttle, and shift cables.
4. Remove the lower cowls. Refer to Section 4A ‑ Lower Cowl.
5. Remove the screw securing the muffler to the adapter plate.
6. Cut the cable tie securing the hose to the muffler. Remove the muffler from the hose.

b a - Screw
b - Cable tie

a
48054
7. Cut the cable tie securing the fuel pump harness connector to the MAT sensor harness.
8. Disconnect the fuel pump harness connector from the engine harness.
9. Remove the 15.7 mm metal hose clamp securing the high‑pressure fuel line to the fuel rail. Remove the high‑pressure fuel
line from the fuel rail.
10. Remove the manifold pressure reference line from the FSM.
11. Cut the cable tie securing the FSM cooling water supply hose and remove the hose.

a - Metal hose clamp securing the high‑pressure fuel

a b line
b - MAT sensor harness
c - Cable tie securing the fuel pump harness connector
d - Manifold pressure reference line
e - Cable tie securing hose (hidden)
c

d
49244
12. Remove the screw and washer securing the FSM to the driveshaft housing.
13. Cut the cable tie securing the water hose and remove the hose.
14. Push the lock in and remove the fuel hose from the FSM.
NOTE: Fuel will drain from this hose when it is disconnected. Use an appropriate container to capture the fuel.

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Service Procedures
15. Pull the FSM out of the grommet to remove.

a- Grommet
a b- Screw and washer
c- Cable tie
d- Fuel hose

c 49248

FSM Disassembly
NOTE: The FSM cannot be completely drained of fuel prior to disassembly. Use appropriate containers to capture fuel during
the disassembly process. Wipe up fuel spills immediately and dispose of in an appropriate container.
1. Place the FSM in an appropriate container to capture any fuel that will spill.
2. Remove the metal hose clamp securing the high‑pressure hose to the FSM upper housing and remove the hose.

49257

3. Remove the four screws securing the upper housing to the lower housing.

a - Screws (4)

49136
4. Grasp the lower housing and the upper housing and push the upper housing slightly to partially separate the upper housing
from the lower housing.

Page 3C-10 90-8M0060785 DECEMBER 2011

 Service Procedures
5. Insert two pry tools between the upper and lower housing and carefully separate the housing.
NOTE: Use caution when separating the housing. The lower housing may be completely filled with fuel.

49141

6. Carefully lift the upper housing to access the power wire connections.
7. Disconnect the upper housing power wires from the fuel pump connectors and remove the O‑ring.

a - Power wires
b - O‑ring
a

49144

NOTE: Some of the internal components may be adhering to the upper housing when separated. Remove the fuel pumps
with an appropriate tool. Use caution not to twist the fuel pumps when removing them. Use a vice grip tool to clamp onto
the manifold webbing and pull the manifold out of the upper housing.

a - Manifold webbing

49318

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Service Procedures
8. Remove the manifold from the tubes and fuel pumps.

a- Manifold
b- Lift fuel pump
c- Tubes (4)
a d- High‑pressure fuel pump

b
d

c 49147

9. Remove the tubes and fuel pumps from the lower housing.
IMPORTANT: If the fuel pumps are difficult to remove, use an appropriate tool to extract them. Use caution not to twist the
fuel pumps when removing.

a - Fuel tube (2)

b - Water tube (2)
a

b
49150
10. Remove the seal grommets from the manifold.

a - High‑pressure fuel pump seal grommet

b - Fuel lift pump seal grommet
a

b
49155

Page 3C-12 90-8M0060785 DECEMBER 2011

 Service Procedures
11. Remove three O‑rings and a spacer from the manifold.

a - O‑rings
b b - Spacer on fuel pressure regulator
a

49156
12. Carefully spread the retainers and remove the fuel pressure regulator.
IMPORTANT: Use extreme care not to spread the retainers excessively. Spreading the retainers excessively will cause the
retainer to break off the manifold.
13. Remove the O‑ring and spacer from the fuel pressure regulator.

a - O‑ring
b - Spacer
a
b

49158

14. Inspect the inside of the upper and lower housings for seal grommets and remove them.

49162

15. Remove the fuel pump wire harness seal grommet from the upper housing by pushing on the seal grommet from the
outside of the upper housing with a blunt tool.

FSM Assembly
1. Install the O‑rings onto the water tubes and fuel tubes.

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Service Procedures
2. Lubricate the O‑rings on the tubes with 2‑4‑C with PTFE.

a
a - O‑rings
b - Water tube
c - Fuel tube

c
49167
3. Install the fuel tubes into the lower housing.

49168

Tube Ref No. Description Where Used Part No.

95 2-4-C with PTFE O-rings 92-802859A 1
4. Install the water tubes.

b a - Water tube
a b - Fuel tube

49199

Page 3C-14 90-8M0060785 DECEMBER 2011

 Service Procedures
5. Install the seal grommet halfway onto the high‑pressure fuel pump outlet.

49206

6. Lubricate the seal grommet with 2‑4‑C with PTFE and install the high‑pressure fuel pump into the lower housing so the
wires are between the webbing and the water tube.

49213
49211

Wires between webbing Close up view without tube installed

Tube Ref No. Description Where Used Part No.

95 2-4-C with PTFE Seal grommet 92-802859A 1
7. Install the seal grommet onto the fuel lift pump and lubricate with 2‑4‑C with PTFE.

49214

Tube Ref No. Description Where Used Part No.

95 2-4-C with PTFE Seal grommet 92-802859A 1
8. Install the fuel lift pump into the lower housing so the outlet port of the pump faces towards the center of the FSM.
9. Install the seal grommet halfway onto the outlet port of the fuel lift pump.
10. Install the seal grommet onto the high‑pressure fuel pump.

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Service Procedures
11. Lubricate both seal grommets with 2‑4‑C with PTFE.

a - Fuel lift pump seal grommet

a b - High‑pressure fuel pump seal grommet

49217

Tube Ref No. Description Where Used Part No.

95 2-4-C with PTFE Seal grommet 92-802859A 1
12. Install two O‑rings onto the manifold.
13. Verify the hole in the manifold is open and that no debris partially blocks the hole.
IMPORTANT: Use only appropriate solvents and compressed air to remove debris which may be blocking the hole. Do not
use wire or any ridged material that may damage the hole.

a a - Hole in manifold
b - O‑rings

49165
14. Carefully install the manifold while aligning the fuel pumps and tubes. Verify the manifold is seated on the fuel pumps.
Ensure the fuel pump wires are not binding between the water tube and the fuel pump.

a - Manifold seated on fuel pump

b - Wires are not binding

a
b 49223

15. Verify the spacer is installed onto the fuel pressure regulator.

Page 3C-16 90-8M0060785 DECEMBER 2011

 Service Procedures
16. Verify the fuel pressure regulator filter is clear of debris.
NOTE: The fuel pressure regulator filter is not a serviceable part, but can be cleared of debris with a mild solvent and
low‑pressure compressed air.
17. Install the O‑rings onto the fuel pressure regulator and lubricate them with 2‑4‑C with PTFE.

b a - Spacer
c b - Filter
c - O‑rings
a

49164

Tube Ref No. Description Where Used Part No.

95 2-4-C with PTFE Fuel pressure regulator O-rings 92-802859A 1
18. Install the fuel pressure regulator onto the manifold.
19. Install the spacer and O‑ring onto the fuel pressure regulator.

a a - O‑ring
b b - Spacer

49225

20. Install the seal grommet halfway onto the manifold.

21. Insert the red wire harness connector onto the fuel lift pump positive terminal.

a - Red wire
b - Seal grommet
b

49226

22. Install the O‑ring onto the upper housing.

23. Install new O‑rings onto the fuel pump wire harness seal grommet. Verify the blue O‑ring is installed on the upper groove of
the seal grommet. Lubricate the O‑rings with 2‑4‑C with PTFE.

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Service Procedures
24. Pull on the wire harness to seat the seal grommet into the upper housing. A gentle push on the seal grommet on the inside
of the housing with a blunt tool will ensure it is properly seated.

a a - Upper housing O‑ring

b - Blue O‑ring
b c - Second O‑ring on seal grommet
c

49231

Tube Ref No. Description Where Used Part No.

95 2-4-C with PTFE O-rings 92-802859A 1
25. Connect the red wire from the upper housing to the positive terminal on the fuel lift pump.
26. Connect the black wire from the upper housing to the negative terminal on the fuel lift pump.
27. Connect the high‑pressure fuel pump black wire to the terminal on the fuel lift pump.
28. Lubricate all the visible O‑rings and seal grommets with 2‑4‑C with PTFE.

a - Black wires
b - Red wires

a b
49234

Tube Ref No. Description Where Used Part No.

95 2-4-C with PTFE O-rings and seal grommets 92-802859A 1

Page 3C-18 90-8M0060785 DECEMBER 2011

 Service Procedures
29. Verify the wires will not become pinched and install the upper housing.

49237

30. Carefully push the upper housing into the lower housing until there is no gap between the upper and lower housing.
IMPORTANT: If the gap between the upper and lower housing cannot be closed, the wires may be pinched or a seal
grommet is not properly aligned.
31. Install the screws and tighten the screws to the specified torque.

a - No gap
b - Screw (4)

a
49240

Description Nm lb‑in. lb‑ft

Screw 10 88.5

32. Install a 15.7 mm metal hose clamp onto the high‑pressure hose and install the hose onto the FSM upper housing. Use the
hose clamp tool to secure the hose to the FSM.

49257

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Service Procedures

Clamp Tool 91‑803146T

FSM Installation
1. Install the FSM into the grommet on the adapter plate.
2. Secure the FSM to the driveshaft housing with the M6 x 25 flange head screw and washer. Tighten the screw to the
specified torque.
3. Push the fuel hose onto the FSM far enough to lock it in place.
4. Install the exhaust cooling hose to the fitting and secure with a cable tie.

a- Grommet
a b- Screw and washer
c- Cable tie
d- Fuel hose

c 49248

Description Nm lb‑in. lb‑ft

Screw (M6 x 25) 8 70.8
5. Install the FSM cooling water supply hose onto the FSM and secure with a cable tie.
6. Install a 15.7 mm metal hose clamp onto the high‑pressure fuel line. Install the high‑pressure fuel line to the fuel rail. Use
the clamp tool to secure the hose to the rail.
7. Connect the fuel pump harness connector to the engine harness connector and secure the fuel pump harness connector to
the MAT sensor harness.
8. Connect the manifold pressure reference line to the FSM.

a - Metal hose clamp securing the high‑pressure fuel

a b line
b - MAT sensor harness
c - Cable tie securing the fuel pump harness connector
d - Manifold pressure reference line
e - Cable tie securing hose (hidden)
c

d
49244

Clamp Tool 91‑803146T

9. Install the muffler and secure it to the adapter plate with a M6 x 12 screw. Tighten the screw to the specified torque.

Page 3C-20 90-8M0060785 DECEMBER 2011

 Service Procedures
10. Secure the hose to the muffler with a cable tie.

b a - Screw
b - Cable tie

a
48054

Description Nm lb‑in. lb‑ft

Screw (M6 x 12) 6 53.1
11. Connect the battery cables.
12. Install the lower cowls. Refer to Section 4A ‑ Lower Cowl.
13. Purge the fuel supply module. Refer to Section 3B ‑ Fuel Supply Module Priming Procedure.

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Service Procedures

Notes:

Page 3C-22 90-8M0060785 DECEMBER 2011