Idle Air Control (IAC) Removal and Installation Section 3C ... · 2 1 Harness assembly retainer clip 3 3 Grommet 4 3 Bushing 5 1 Cover 6 8 Screw 5 44.2 7 1 Fuel pressure regulator

Servicing Procedures

90-899185 SEPTEMBER 2006 Page 3C-1

3C

Fuel SystemSection 3C - Servicing Procedures

Table of Contents

Fuel System Specifications..............................3C-2Fuel System Module Components...................3C-4Integrated Air Fuel Module..............................3C-6Integrated Air Fuel Module Components.........3C-8Fuel System Module Mount Components......3C-10Fuel System Module Hoses...........................3C-12Throttle Position Sensor (TPS) Removal andInstallation......................................................3C-14

TPS Removal.........................................3C-14TPS Installation......................................3C-14

Idle Air Control (IAC) Removal and Installation.......................................................................3C-15

IAC Removal..........................................3C-15IAC Installation.......................................3C-15

Vent Canister Purge Valve (VCPV) Removal andInstallation......................................................3C-16

Vent Canister Purge Valve (VCPV) Removal................................................................3C-16Vent Canister Purge Valve (VCPV) Installation................................................................3C-19

Vent Canister Switch (VCS) Removal andInstallation......................................................3C-20

Vent Canister Switch (VCS) Removal . . .3C-20Vent Canister Switch (VCS) Installation................................................................3C-21

Fuel Rail.........................................................3C-22Fuel Rail Removal..................................3C-22Fuel Rail Disassembly and Reassembly................................................................3C-25Fuel Rail Installation...............................3C-27

Intake Manifold..............................................3C-28Intake Manifold Removal........................3C-28Intake Manifold Disassembly..................3C-34Intake Manifold Reassembly..................3C-37Intake Manifold Installation.....................3C-40

Fuel System Module (FSM)...........................3C-44Fuel System Module Removal................3C-44Fuel System Module Disassembly andInspection...............................................3C-48Fuel System Module Assembly..............3C-51Fuel System Module Installation.............3C-55


Page 3C-2 90-899185 SEPTEMBER 2006

Fuel System SpecificationsFuel System Specifications

Type of fuel Automotive unleaded with a minimum pump posted octane rating of 87(90 RON)

High pressure fuel pump

Engine not running 350 ± 32 kPa (50.7 ± 4.6 psi)

Engine running Pressure dependent on manifold vacuum pressure

Fuel filtration (inlet/high pressure) 20 microns

Fuel lift pump vacuum (maximum) 10.16 kPa (3.00 Hg)

Idle air control duty cycle @ idle 25 ‑ 33

MAP sensor @ idle 38 ‑ 43 kPa (11.2 ‑ 12.7 Hg)

MAP sensor @ WOT 95 ‑ 100 kPa (28 ‑ 29.5 Hg)

Lubricant, Sealant, AdhesivesTube Ref No. Description Where Used Part No.

66 Loctite 242 Threadlocker FSM mounting screws 92-809821

110 4-Stroke 10W-30 Outboard OilIAC O-rings

Fuel rail fuel inlet O-ringsFuel injector O-rings

92-802833A1

Special Tools

Fuel Pressure Gauge Kit 91‑881833A03

rms32

Tests the fuel pump pressure; can be used to relieve fuelpressure.

Dual Fuel/Air Pressure Gauge Kit 91‑881834A 1

5822

Tests fuel and air pressure; the dual gauges allow the viewingof both pressures simultaneously.



Digital Pressure Meter 91‑892651A01

5786

Connects to the fuel system/manifold and can be used inconjunction with Computer Diagnostic System (CDS).

Hose Clamp Tool Kit 91‑803146A2

5819

Aids in the installation of high pressure (Oetiker ®) hoseclamps.

DMT 2004 Digital Multimeter 91‑892647A01

A C O M m A V H z

mV

V

H z TEMPm A

A

IG

IPOFF

H z

TEMP

4516

Measures RPM on spark ignition (SI) engines, ohms, amperes,AC and DC voltages; records maximums and minimumssimultaneously, and accurately reads in high RFI environments.



Fuel System Module Components

1

2

34

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

43

1920

22149



Fuel System Module Components

Ref. No. Qty. Description

Torque

Nm lb. in. lb. ft.

1 1 Harness assembly

2 1 Harness assembly retainer clip

3 3 Grommet

4 3 Bushing

5 1 Cover

6 8 Screw 5 44.2

7 1 Fuel pressure regulator

8 2 Clamp (6.25 mm)

9 1 Hose

10 1 Float switch

11 1 High pressure fuel pump

12 1 Isolator

13 1 Seal

14 1 Seal

15 1 Fuel lift pump

16 1 Isolator

17 1 Seal

18 1 Housing assembly

19 1 Plug 5.7 50.4

20 1 O‑ring



Integrated Air Fuel Module

15876

12

2

3 3

4

5

67

8

9

10

11

11 12

13

36



Integrated Air Fuel Module


Torque

Nm lb. in. lb. ft.

1 1 Integrated air fuel module assembly

2 2 Screw (M6 x 50) 10 88.5

3 2 Washer

4 5 Screw (M6 x 30) 10 88.5

5 1 Vent canister bracket

6 1 Vent canister assembly

7 1 Grommet

8 1 Purge vent assembly

9 1 Air filter

10 1 Restrictor plate (75/80 EU)

11 4 Clip

12 1 Screw (M6 x 20) 8 70.8

13 1 Cable tie



Integrated Air Fuel Module Components

21434

1

2

3

4

5

6

67

8

9

9

1011

11

1112

13

14

15

16 17

18

18



Integrated Air Fuel Module Components


Torque

Nm lb. in. lb. ft.

1 1 Integrated air fuel module assembly

2 4 Fuel injector

3 1 Fuel rail

4 2 Screw (M6 x 20) 10 88.5

5 1 Manifold Air Temperature (MAT) sensor

6 3 Screw (M4 x 16) 1.7 15

7 1 Retaining bracket

8 1 Manifold Absolute Pressure (MAP) sensor

9 5 Screw (M6 x 20) 8 70.8

10 1 Idle Air Control (IAC) valve

11 4 Clamp (24.1 mm)

12 1 Hose

13 1 IAC manifold housing

14 1 Hose

15 1 Throttle body assembly

16 1 Throttle Position Sensor (TPI)

17 2 Screw (M5 x 17) 3.2 28.3

18 4 Seal



Fuel System Module Mount Components

14787

1

2

34

5

6

78

10

9

1112



Fuel System Module Mount Components


Torque

Nm lb. in. lb. ft.

1 1 Fuel System Module

2 1 Fuel System Module mounting bracket

3 3 Screw (M8 x 35) 24 17.7

4 3 Washer

5 3 Screw (M8 x 35) 24 17.7

6 2 Clip and cable tie

7 1 Throttle bracket assembly

8 3 Screw (M8 x 20) 24 17.7

9 1 Clip

10 1 Cable assembly

11 1 Washer

12 1 Cotter pin



Fuel System Module Hoses

78

45

5

6

15044

1

2

3

10

9

99

11

1213

1415

16

16

1817

19



Fuel System Module Hoses


Torque

Nm lb. in. lb. ft.

1 1 Strainer 12 106.2

2 1 Cylinder block strainer to fuel system module hose

3 1 Fuel system module outlet hose

4 1 Fuel system module to high pressure fuel filter hose

5 2 Filter (inlet/high pressure)

6 1 High pressure fuel filter to fuel rail hose

7 1 Hose 20.3 cm (8 in.)

8 1 Fuel system module to vent canister hose

9 3 Clamp (15.7 mm)

10 1 Cable tie

11 1 Grommet

12 1 Clip

13 1 Fuel filter to fuel system module hose

14 1 Fuel inlet hose

15 1 Cap

16 3 Clamp

17 1 Tube

18 2 Cable tie

19 1 Clamp (16.2 mm)



Throttle Position Sensor (TPS) Removal and InstallationTPS Removal

! CAUTIONDisconnect the battery leads before removing, repairing or installing any electrical or fueldelivery component.

1. Disconnect the battery cables from the battery.2. Disconnect the engine harness connector from the TPS.3. Remove the two screws securing the TPS to the throttle body. Remove the TPS from

the throttle body.

21767

a

b

a - Engine harness connectorb - TPS mounting screws (2)

TPS Installation1. Install the TPS onto the throttle body.2. Rotate the TPS to align the screw holes on the TPS with the screw holes in the throttle

body.

21768

3. Secure the TPS to the throttle body with two screws. Tighten the screws to the specifiedtorque.



4. Connect the engine harness connector to the TPS.

21767

a

b

a - Engine harness connectorb - TPS mounting screws (2)

Description Nm lb. in. lb. ft.

TPS mounting screws (2) 3.2 28.3

Idle Air Control (IAC) Removal and Installation! CAUTION

Disconnect the battery leads before removing, repairing or installing any electrical or fueldelivery component.

IAC Removal1. Disconnect the battery cables from the battery.2. Remove the engine harness connector from the IAC.3. Remove the two bolts securing the IAC to the intake manifold bypass.4. Carefully remove the IAC from the intake manifold bypass.

a

b

21738

a - Bolts (2) b - Engine harness connector

IAC Installation1. Ensure the O‑rings on the IAC are not damaged. Replace the O‑rings if they are

damaged.



2. Lubricate the IAC O‑rings with 4‑Stroke 10W‑30 Outboard Oil.

a21739

Tube Ref No. Description Where Used Part No.

110 4-Stroke 10W-30 Outboard Oil IAC O-rings 92-802833A1

3. Install the IAC by pushing it into the intake manifold bypass.4. Secure the IAC to the intake manifold bypass with two bolts. Tighten the bolts to the

specified torque.5. Connect the engine harness to the IAC.

a

b

21738

a - Bolts (2) b - Engine harness connector


IAC bolt (2) 8 70.8

Vent Canister Purge Valve (VCPV) Removal and InstallationVent Canister Purge Valve (VCPV) Removal




! CAUTIONPressurized fuel system! Release all pressure before servicing any part of the fuelsystem. This system can build pressure if the engine has not run for an extended periodof time. If the fuel system is not relieved of pressure, fuel and vapors may be expelled ata significant velocity. Always protect your eyes and skin from pressurized fuel and vaporswhen servicing the fuel system.

1. Disconnect the battery cables from the battery.2. Remove the cap from the fuel vapor purge relief valve.

a

20813

a - Fuel vapor purge relief valve

3. Place a rag or towel around the valve, and release the fuel pressure by pushing thecore of the valve end in.

! CAUTIONFuel vapor vent system is under pressure. Cover valve assembly with a rag or towel toprevent fuel or fuel vapor spray. Relieve pressure slowly.

13282



4. Remove the vent line from the air filter.

a

b

21742

a - Vent canister purge valve b - Vent line at the air filter

5. Disconnect the engine harness from the VCPV.6. Cut the cable tie securing the vent line to the vent float switch.7. Remove the vent line from the retaining clip.8. Carefully remove the vent line from the intake manifold.

ab

21743

c

a - Engine harness connectorb - Cable tie securing vent line

c - Retaining clip



Vent Canister Purge Valve (VCPV) Installation1. Carefully install the vent line onto the intake manifold.

a

b

c

21745

a - Vent lineb - Manifold absolute pressure sensor

c - Intake manifold

2. Install the vent line to the vent canister float switch. Secure the vent line to the ventcanister float switch with a cable tie.

3. Secure the vent line to the retaining clip.4. Connect the engine harness to the VCPV.

a

b

c

21746

a - Cable tie securing the vent line to the vent canister float switchb - Retaining clipc - VCPV engine harness connector

5. Insert the vent line into the air filter.

a

b

21742

a - Vent canister purge valve b - Vent line at the air filter



Vent Canister Switch (VCS) Removal and InstallationVent Canister Switch (VCS) Removal




a

20813




13282

4. Cut the cable tie securing the vent line to the VCS.5. Remove the vent line from the VCS.



6. Cut the cable tie securing the VCS harness connectors to the engine wire harness.Disconnect the engine harness from the VCS harness connector.

a

b

c

21748

de

a - Cable tie securing the vent line to the VCSb - Cable tie securing the VCS harness connectorc - Vent lined - Fuel system module (FSM) vent linee - Rubber grommet

7. Push in the vent line lock release with a screwdriver to remove the FSM vent line fromthe vent canister switch.

8. Remove the FSM vent line from the VCS.

a

21749

a - Vent line lock release

9. Remove the VCS from the rubber grommet.

Vent Canister Switch (VCS) Installation1. Install the vent line to the VCS. Secure the vent line to the VCS with a cable tie.



2. Guide the VCS harness connector through the rubber grommet. Connect the VCSharness connector to the engine harness.

a

b

b

c

21752

a - Rubber grommetb - Vent canister wire harness

c - Cable tie securing the vent line tothe VCS

3. Install the VCS into the rubber grommet.4. Install the FSM vent line to the VCS.5. Secure the VCS harness connector to the engine harness with a cable tie.6. Secure the vent line with the retaining clip.

a

b

21753

c

d

a - Cable tie securing the VCSharness connector

b - Retaining clip

c - FSM vent lined - Rubber grommet

Fuel RailFuel Rail Removal






a

20813




13282



4. Connect a fuel pressure gauge to the high pressure Schrader valve. Relieve the fuelpressure into an appropriate container.

a

22364

a - Schrader valve




5. Cut the four cable ties securing the engine harness connectors to the fuel rails.6. Remove the fuel injector harness from the fuel injector.7. Cut the cable tie securing the engine harness to the MAT sensor.

bac

22443

a - Cable ties securing the engine harness to the fuel rail (4)b - Cable tie securing the engine harness to the MAT sensorc - Fuel injector connectors

8. Disconnect the fuel hose from the high pressure fuel filter.



9. Remove the fuel hose from the retaining clip.

a

b

22442

a - Fuel hose connection b - Retaining clip

10. Remove the two screws securing the fuel rail to the intake manifold.11. Pull the fuel rail off the intake manifold.

a

22444

a - Screws securing the fuel rail to the intake manifold (2)

Fuel Rail Disassembly and ReassemblyFUEL RAIL DISASSEMBLY

1. Pull the fuel injectors off the fuel rail.2. Remove the two screws securing the fuel rail inlet to the fuel rail. Remove the fuel inlet

from the fuel rail.NOTE: It is not necessary to remove the fuel hose from the fuel rail inlet unless the fuelhose is damaged or the fuel rail inlet is damaged.

a

22446

a - Fuel rail inlet screws



FUEL RAIL REASSEMBLY1. Ensure the O‑ring on the fuel rail inlet is not damaged.

a

b22447

a - Fuel rail inlet O‑ring b - Clamp (16.2 diameter)

2. Lubricate the fuel rail inlet O‑ring with 4‑Stroke 10W‑30 Outboard Oil.3. Install the fuel rail inlet onto the fuel rail and secure with two screws. Tighten the screws

to the specified torque.

a

22446

a - Fuel rail inlet screws (2)


110 4-Stroke 10W-30 Outboard Oil Fuel rail fuel inlet O-rings 92-802833A1


Fuel rail inlet screws (2) 1.7 15

4. Inspect the fuel injector filter for debris.NOTE: The fuel injector filter is a non‑serviceable component but can be cleared of debris.Replace the fuel injector if the fuel injector filter cannot be cleared of debris.5. Replace the O‑rings on the fuel injector.

a

b

22782

a - O‑ring (2) b - Fuel injector filter



6. Lubricate the O‑rings with 4‑Stroke 10W‑30 Outboard Oil.7. Install the fuel injectors into the fuel rail.

22784


110 4-Stroke 10W-30 Outboard Oil Fuel injector O-rings 92-802833A1

Fuel Rail Installation1. Install the fuel rail onto the intake manifold.2. Secure the fuel rail to the intake manifold with two screws. Tighten the screws to the

specified torque.

a

22444

a - Screws securing the fuel rail to the intake manifold (2)


Screws securing the fuel rail to the intake manifold (2) 10 88.5

3. Connect the fuel inlet line to the fuel filter.



4. Secure the fuel inlet line to the intake manifold with the retaining clip.

a

b

22442

a - Fuel hose connection b - Retaining clip

5. Connect the engine harness to the MAT sensor.6. Secure the engine harness to the MAT sensor with a cable tie.7. Connect the engine harness connectors to the fuel injectors.8. Secure the engine harness to the fuel rail with four cable ties.

bac

22443

a - Cable ties securing the engine harness to the fuel rail (4)b - Cable tie securing the engine harness to the MAT sensorc - Fuel injector connectors

Intake ManifoldIntake Manifold Removal





1. Disconnect the battery leads from the battery.2. Remove the cap from the fuel vapor purge relief valve.

a

20813




13282




a

22364

a - Schrader valve




5. Disconnect the fuel line from the engine.6. Use a fuel pressure gauge to relieve the fuel system pressure into an appropriate

container.7. Remove the remote control throttle and shift cables from the engine.8. Disconnect the fuel filter at the aft connection. Remove the fuel hose from the intake

manifold retaining clip.

a

b

22108

a - Intake manifold retaining clip b - Fuel filter aft connection

9. Loosen the throttle cable adjustment nuts.10. Remove the cotter pin and plastic washer securing the throttle cable to the throttle lever

assembly.



11. Remove the throttle cable from the throttle bracket assembly.

a c

b

22109

a - Throttle cable adjustment nutsb - Cotter pin

c - Plastic washer

12. Disconnect the engine harness from the TPS.13. Remove the vent hose from the air filter.14. Remove the air filter.15. Disconnect the engine harness from the IAC.

a

b

c

d

22110

a - Vent hoseb - Air filter

c - IAC engine harness connectord - TPS engine harness connector



16. Remove the fuel pressure regulator reference hose from the FSM.

a

22119

a - Fuel pressure regulator reference hose

17. Disconnect the engine harness from the MAP sensor.18. Disconnect the engine harness from the purge valve.19. Cut the cable tie securing the vent canister float switch connector to the engine harness.

Disconnect the engine harness from the vent canister float switch.20. Carefully remove the engine harness from the top of the intake manifold.

ab

d

c

22111

a - MAP engine harness connectorb - Purge valve engine harness connectorc - Vent canister float switch connectord - Cable tie securing the vent canister float switch connector to the engine

harness

21. Cut the cable tie securing the engine harness to the MAT sensor. Disconnect the engineharness connector from the MAT sensor.

22. Cut the four cable ties securing the engine harness to the fuel rail.



23. Disconnect the engine harness from the four fuel injectors.

a b c

22112

a - Cable ties securing fuel injector harness to the fuel rail (4)b - Cable tie securing the engine harness to the MAT sensorc - Fuel injector engine harness connectors

24. Remove the five screws securing the intake manifold to the cylinder head.25. Remove the two screws securing the intake manifold to the cylinder block.26. Allow the intake manifold to rest on the cowl.

ab

22114

a - Screws securing the intake manifold to the cylinder block (2)b - Screws securing the intake manifold to the cylinder head (5)

27. Remove the vent canister hose from the retaining clip on the intake manifold.



28. Disconnect the vent canister hose from the vent canister float switch.

ab

22115

a - Vent canister hose disconnect b - Vent canister hose retaining clip

Intake Manifold Disassembly1. Remove the four manifold seals.2. Remove the bolt securing the vent canister float switch mounting bracket to the intake

manifold.3. Remove the vent hose from the retaining clip on the intake manifold.

a

b

22118

c

a - Manifold seals (4)b - Bolt securing the vent canister float switch mounting bracketc - Vent hose retaining clip

4. Remove the vent hose from the intake manifold vent hose support.

ab

22120

a - Vent hose b - Intake manifold vent hose support



5. Remove the MAP sensor retainer screw. Remove the MAP sensor from the intakemanifold.

a b

22121

a - MAP sensor retainer screwb - MAP sensor

6. Remove the fuel pressure regulator reference hose from the intake manifold.7. Cut the hose clamp securing the IAC manifold hose to the intake manifold.

a

b

22122

c

a - Hose clamp securing the IAC manifoldb - IAC manifoldc - Fuel pressure regulator reference hose

8. Remove the three screws securing the throttle body to the intake manifold. Removethe throttle body from the intake manifold.

a

22124

a - Throttle body screws (3)

9. Remove the fuel hose from the fuel hose retaining clip.10. Remove the two screws securing the MAT sensor to the intake manifold. Remove the

MAT sensor form the intake manifold.



11. Remove the two screws securing the fuel rail to the intake manifold. Remove the fuelrail and fuel injectors from the intake manifold.

ab c

22128

a - Fuel hose retaining clipb - MAT sensor screws (2)c - Screws securing the fuel rail (2)

12. Remove the two outward facing and the two inward facing retaining clips from the intakemanifold.

a

b

22131

a - Outward facing retaining clips (2) b - Inward facing retaining clips (2)



Intake Manifold Reassembly1. Install the two outward facing and the two inward facing retaining clips onto the intake

manifold.

a

b

22131

a - Retaining clips facing out (2) b - Retaining clips facing in (2)

2. Install the fuel rail onto the intake manifold and secure with two screws. Tighten thescrews to the specified torque.

3. Secure the fuel hose to the retaining clip on the intake manifold.4. Install the MAT sensor onto the intake manifold and secure with two screws. Tighten

the screws to the specified torque

ab c

22128

a - Fuel hose retaining clipb - MAT sensor screws (2)

c - Fuel rail screws (2)


MAT sensor screws (2) 1.7 15

Fuel rail screws (2) 10 88.5



5. Install a new throttle body seal onto the throttle body.

a

23622

a - Throttle body seal

6. Install the throttle body onto the intake manifold and secure with three screws. Tightenthe screws to the specified torque.

a

22124

a - Throttle body screws (3)


Throttle body screws (3) 8 70.8

7. Install a 24.1 diameter hose clamp onto the IAC manifold hose.8. Install the IAC manifold hose onto the intake manifold. Crimp the hose clamp with the

hose clamp tool to secure the IAC manifold hose to the intake manifold.




9. Install the fuel pressure regulator reference hose to the intake manifold.

a

b

22122

c

a - 24.1 diameter hose clamp securing the IAC manifold hoseb - IAC manifoldc - Fuel pressure regulator reference hose

10. Install the MAP sensor onto the intake manifold and secure with a retainer and screw.Tighten the screw to the specified torque.

a b

22121

a - MAP sensor retainer screwb - MAP sensor


MAP sensor retainer screw 1.7 15

11. Install the vent hose onto the intake manifold.

ab

22120

a - Vent hose b - Intake manifold vent hose support

12. Install the four manifold seals.13. Secure the vent canister float switch mounting bracket to the intake manifold with a

screw. Tighten the screw to the specified torque.



14. Secure the vent hose with the retaining clip on the intake manifold.

a

b

22118

c

a - Manifold seals (4)b - Vent canister float switch mounting bracket screwc - Vent hose retaining clip


Vent canister float switch mounting bracket screw 8 70.8

Intake Manifold Installation1. Connect the vent canister hose to the vent canister float switch.2. Secure the vent canister hose to the intake manifold with the retaining clip.

ab

22115

a - Vent canister hose disconnect b - Vent canister hose retaining clip

3. Secure the intake manifold to the cylinder block with two screws. Do not tighten thescrews.

4. Secure the intake manifold to the cylinder head with five screws.



5. Tighten the seven intake manifold screws in the sequence shown to the specifiedtorque.

1

2

3

4

5

6

7

22145


Intake manifold screws (7) 10 88.5

6. Connect the four fuel injector engine harness connectors to the fuel injectors.7. Connect the engine harness connector to the MAT sensor. Secure the MAT sensor

harness to the MAT sensor with a cable tie.8. Secure the engine harness to the fuel rail with four cable ties.

a b c

22112

a - Cable ties securing fuel injector harness to the fuel rail (4)b - Cable tie securing the engine harness to the MATc - Fuel injector engine harness connectors

9. Connect the engine harness connector to the MAP sensor.10. Connect the engine harness connector to the purge valve.



11. Connect the engine harness connector to the vent canister float switch. Secure the ventcanister float switch connector to the engine harness with a cable tie.

ab

d

c

22111

a - MAP engine harness connectorb - Purge valve engine harness connectorc - Vent canister float switch engine harness connectord - Cable tie securing the vent canister float switch engine harness connector to

the engine harness

12. Install the fuel pressure regulator reference hose to the fuel pressure regulatorreference hose port on the FSM.

a

22119

a - Fuel pressure regulator reference hose

13. Connect the IAC engine harness connector to the IAC.14. Install the air filter onto the throttle body.15. Connect the vent hose to the air filter.



16. Connect the TPS engine harness connector the the TPS.

a

b

c

d

22110

a - Vent hoseb - Air filter

c - IAC engine harness connectord - TPS engine harness connector

17. Install the throttle body cable end onto the throttle arm. Secure the throttle body cableto the throttle arm with a washer and cotter pin. Bend the cotter pin ends to retain thethrottle body cable end and the washer to the throttle arm.

18. Adjust the throttle cable. Refer to Section 2C - Timing, Synchronizing, andAdjusting.

a c

b

22109

a - Throttle cable adjustment nutsb - Cotter pin

c - Plastic washer



19. Connect the fuel filter to the fuel line and secure the fuel line with the retaining clip.

a

b

22108

a - Intake manifold retaining clip b - Fuel filter aft connection

20. Connect the remote control throttle and shift cables to the engine. Refer to Section1D - Electrical, Fuel Hose, and Control Cables.

21. Connect the battery leads to the battery.22. Turn the key switch to the "ON" position to prime the fuel system and inspect for fuel

leaks.

Fuel System Module (FSM)Fuel System Module Removal



1. Disconnect the battery cable from the battery.2. Remove the lower cowls. Refer to Section 4A - Cylinder Block/Crankcase.



3. Remove the cap from the fuel vapor purge relief valve.

a

20813




13282


a

22364

a - Schrader valve

6. Disconnect the trim position sensor wire and the FSM harness connection from theengine harness.

7. Remove the breather hose from the air filter.



8. Disconnect the alternator sense connector from the alternator.9. Disconnect the TPS and the shift switch from the engine harness.

a

b

c

d

e

f

22366

a - Trim position sensor connectorb - Alternator sense connectorc - Breather hose

d - TPS connectore - FSM connectorf - Shift switch connector

10. Remove the hose clamp securing the water inlet hose to the FSM. Remove the waterinlet hose from the FSM.

11. Remove the hose clamp securing the water outlet hose to the FSM. Remove the wateroutlet hose from the FSM.

a

b

22375

a - Water inlet hose b - Water outlet hose

12. Disconnect the vent canister line (blue tab) from the FSM.



13. Remove the fuel pressure regulator reference line from the FSM.

a

b

22376

a - Vent canister line (blue tab)b - Fuel pressure regulator reference line

14. Remove the upper left and lower screw securing the FSM to the FSM mounting bracket.15. Remove the FSM from the upper right mounting grommet.NOTE: It is not necessary to remove the upper right screw securing the mounting grommetto the FSM mounting bracket.

c

b

a

22377

a - Lower screw securing the FSMb - Upper left screw securing the FSMc - Upper right mounting grommet

16. Remove the low pressure (vacuum) fuel lift line from the FSM.



17. Remove the high pressure fuel line from the FSM

a

b

22380

a - Low pressure (vacuum) fuel lift line b - High pressure fuel line

Fuel System Module Disassembly and InspectionFSM DISASSEMBLY

1. Remove the grommets from the FSM.2. Remove the drain screw and allow the FSM to drain into an appropriate container.

ab

22381

a - Drain screw b - Grommets (2)

3. Remove the screws securing the FSM cover to the FSM housing. Remove the FSMcover.

22382

4. Cut the cable tie securing the fuel pump.



5. Disconnect the fuel lift pump, high pressure fuel pump, and float switch from the FSMwire harness.

a

b

c

d

22383

a - Cable tie securing high pressurefuel pump

b - Fuel pressure regulator

c - Fuel lift pumpd - Float switch

6. Remove the FSM cover gasket.7. Remove the clip securing the FSM wire harness to the FSM cover. Remove the FSM

wire harness from the FSM cover.

a b

c

22384

a - FSM wire harness clipb - Fuel lift pump

c - FSM cover gasket

8. Push on the tabs to remove the float switch.9. Pull on the high pressure fuel pump to remove the pump from the FSM cover.10. Pull the fuel lift pump to remove the pump from the FSM cover.11. Remove the manifold reference hose from the fuel pressure regulator.



12. Pull the fuel pressure regulator off the FSM cover.

ab

cd

e

22385

a - High pressure fuel pumpb - Manifold reference hosec - Fuel pressure regulator

d - Float switch tabe - Fuel lift pump

FSM INSPECTION1. Visually check the float switch to ensure fuel has not leaked into the float.2. Connect a DMT 2004 Multi‑meter to the float switch wires.3. With the float switch in a normal operating position with the wires facing up there should

be continuity. Replace the float switch if no continuity is found.

a

b

22386

a - Ohm meter leadsb - Float switch in a normal operating position (continuity)

4. Invert the float switch with the wires facing down there should be no continuity. Replacethe float switch if there is continuity.

a

b

22387

a - Meter leadsb - Float switch inverted (no continuity)

DMT 2004 Digital Multimeter 91‑892647A01

5. Remove the grommets on the high pressure fuel pump.6. Remove the grommets and screen on the fuel lift pump.



7. Inspect the screen for debris. Clean as needed.8. Visually inspect the fuel pressure regulator. Replace the fuel pressure regulator if debris

is found on the fuel pressure regulator screen.

Fuel System Module Assembly1. Insert the small grommet into the FSM cover.

4208

2. Install the high pressure fuel pump.3. Ensure the filter on the high pressure fuel pump is clear of debris.

a

4207

b

c

da - Grommet in FSM coverb - High pressure fuel pump

c - Isolatord - Filter

4. Install the fuel pressure regulator onto the FSM cover. Secure the manifold referencehose to the fuel pressure regulator with a 6.5 diameter hose clamp. Crimp the manifoldreference hose to the fuel pressure regulator with the hose clamp tool.

NOTE: The fuel pressure regulator O‑rings cannot be purchased separately.

a

b

c

d 4209

a - Fuel pressure regulatorb - Fuel pressure regulator hose

clamp (6.5 diameter)

c - Manifold reference hosed - High pressure fuel pump


5. Insert the lift pump grommet into the FSM cover.



6. Insert the fuel lift pump into the grommet. Ensure the fuel lift pump is fully seated intothe grommet.

a

b

4210

a - Fuel lift pump grommet b - Fuel lift pump

7. Guide the float switch wires into the slot on the FSM cover.8. Align the float switch tabs with the FSM retaining holes.9. Push the float switch completely into the FSM cover.

ab

cd

e

22385

a - High pressure fuel pumpb - Fuel pressure regulator manifold reference linec - Fuel pressure regulatord - Float switch tabe - Fuel lift pump

10. Ensure the O‑ring on the FSM harness grommet is not damaged.11. Guide the FSM harness connectors through the FSM cover.



12. Push the FSM harness grommet into the FSM cover until it bottoms out.

a

b

c

22388

a - FSM harness grommetb - O‑ring

c - Grommet recess for retaining ring

13. Install the FSM harness grommet retaining ring.14. Connect the high pressure fuel pump harness.15. Connect the fuel lift pump orange wire to the terminal identified with a positive (+) sign.

Connect the fuel lift pump brown wire to the terminal identified with a negative (‑) sign.16. Connect the float switch harness.17. Install the FSM cover gasket

a b

c

22384

a - FSM harness grommet retaining ringb - Fuel lift pumpc - FSM cover gasket



18. Secure fuel pump with a cable tie.

a

b

c

d

22383

a - Cable tie securing high pressurefuel pump

b - Fuel pressure regulator

c - Lift pumpd - Float switch

19. Inspect the fuel cooling coil inside the FSM housing for damage.NOTE: If damage to the fuel cooling coil is severe enough to cause water flow restriction,or if the coil is suspected of leaking water into the FSM, the fuel system module housingmust be replaced.

a

b c

d

4213

a - FSM housingb - Fuel cooler

c - Fuel cooler water inletd - Fuel cooler water outlet

20. Install the FSM cover onto the FSM housing.



21. Secure the FSM cover to the FSM housing. Tighten the FSM cover screws evenly andto the specified torque.

22382


FSM cover screws (8) 5 44.2

22. Install an O‑ring onto the FSM drain screw.23. Install the FSM drain screw into the FSM. Tighten the screw to the specified torque.24. Install the grommets onto the FSM.

ab

22381

a - FSM drain screw b - Grommets (2)


FSM drain screw 5.7 50.4

Fuel System Module Installation1. Ensure the rubber grommet and bushing is installed on the upper and lower FSM

mounts.2. Connect the low pressure (vacuum) fuel lift line to the FSM.



3. Connect the high pressure fuel line to the FSM.

a

b

22380

a - Low pressure (vacuum) fuel lift line b - High pressure fuel line

4. Install the FSM onto the upper right mounting grommet.5. Apply Loctite 242 Threadlocker to the two FSM mounting screws.6. Secure the FSM to the FSM mounting bracket with the two screws. Tighten the screws

to the specified torque.

c

b

a

22377

a - Lower screw securing the FSMb - Upper left screw securing the FSM

c - Upper right mounting grommet


66 Loctite 242 Threadlocker FSM mounting screws 92-809821


FSM mounting screws (2) 24 17.6

7. Connect the vent canister line (blue tab) to the FSM.



8. Connect the fuel pressure regulator reference line to the FSM.

a

b

22376

a - Vent canister line (blue tab)b - Fuel pressure regulator reference line

9. Install a 15.7 mm diameter hose clamp onto the water inlet hose. Install the water inlethose to the FSM. Crimp the hose clamp with the hose clamp tool to secure the waterinlet hose to the FSM.

10. Install a 15.7 mm diameter hose clamp onto the water outlet hose. Install the wateroutlet hose to the FSM. Crimp the hose clamp with the hose clamp tool to secure thewater outlet hose to the FSM.

a

b

22375

a - Water inlet hose b - Water outlet hose


11. Connect the TPS and the shift switch to the engine harness.12. Connect the alternator sense connector to the alternator.13. Install the breather hose onto the air filter.



14. Connect the trim position sensor wire and the FSM harness connection to the engineharness.

a

b

c

d

e

f

22366

a - Trim position sensor connectorb - Alternator sense connectorc - Breather hose

d - TPS connectore - FSM connectorf - Shift switch connector

Documents

Idle Air Control (IAC) Removal and Installation Section 3C ... · 2 1 Harness assembly retainer clip 3 3 Grommet 4 3 Bushing 5 1 Cover 6 8 Screw 5 44.2 7 1 Fuel pressure regulator