Fuel Charging System

The fuel charging system consists of the fuel injection supply manifold, fuel injectors, fuel pressure regulator, upper intake manifold and lower intake manifold (IMRC). Prior to service or removal of the fuel charging system, perform the following steps:

Pre-Service Procedures
1. Disconnect battery ground cable.
2. Remove fuel tank filler caps and release fuel tank pressure.

Fuel Pressure Relief

Fuel Pressure Gauge:

SPECIAL SERVICE TOOL(S) REQUIRED

Description Tool Number
Fuel Pressure Gauge 310-012 (T80L-9974-B)

WARNING: FUEL SUPPLY TUBES WILL REMAIN PRESSURIZED FOR LONG PERIODS OF TIME AFTER ENGINE SHUTDOWN. THIS PRESSURE MUST BE RELIEVED BEFORE SERVICING OF THE FUEL SYSTEM IS BEGUN. A VALVE IS PROVIDED ON THE FUEL INJECTION SUPPLY MANIFOLD FOR THIS PURPOSE.

1. Remove engine Air Cleaner (ACL).
2. Connect Fuel Pressure Gauge 310-012 (T80L-9974-B) to the fuel pressure relief valve cap on the fuel injection supply manifold.
3. Open the manual valve or Fuel Pressure Gauge 310-012 (T80L-9974-B) to relieve fuel system pressure.

Post-Service Procedures
After the service is complete and the fuel charging system is installed to engine, perform the following steps:
1. Install fuel tank filler cap on fuel tank.
2. Connect battery ground cable.
3. Install Fuel Pressure Gauge 310-012 (T80L-9974-B).
4. Turn ignition switch ON/OFF several times without starting engine to pressurize the fuel system.

WARNING: THE FUEL SYSTEM IS NORMALLY PRESSURIZED TO 276 KPA (40 PSI). USE CARE WHEN SERVICING THE FUEL SYSTEM OR PERSONAL INJURY MAY OCCUR.

NOTE: Make sure the fuel system maintains pressure. If a loss of pressure is noted, the fuel injector O-rings may be damaged or incorrectly installed, allowing excess fuel to leak into the cylinders. In this case, disassemble the system and repair the problem before starting the engine.

5. Add engine coolant if required.
6. Turn ignition switch ON/OFF several times without starting engine to pressurize system. Check for fuel leaks.
7. Start engine and warm to operating temperature. Check for coolant look it coolant was removed.

NOTE: Check all connections at fuel injection supply manifold and push connect fittings.

8. Perform PCM on-board diagnostic.