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FUEL PRESSURE REGULATOR

WARNING: THE 2.5L TURBO I FUEL SYSTEM IS UNDER A CONSTANT PRESSURE OF APPROXIMATELY 380 KPA (55 PSI). PERFORM FUEL PRESSURE RELEASE PROCEDURE BEFORE SERVICING THE FUEL PRESSURE REGULATOR.

REMOVAL

(1)Perform fuel system pressure release procedure.

(2)Disconnect negative cable from battery.

(3)Disconnect vacuum hose from fuel pressure regulator (Fig. 12).

Fig. 12 Servicing Fuel Pressure Regulator

Place a shop towel under fuel pressure regulator to absorb any fuel spillage.

(4)Loosen fuel hose clamp and remove fuel return

hose.

(5)Remove fuel pressure regulator mounting nuts. Remove fuel pressure regulator from rail (Fig. 12). Check O-Ring for damage. If O-Ring is damaged it must be replaced.

INSTALLATION

(1)Lubricate O-ring with a drop of clean engine oil. Install O-ring into the receiver cup on fuel rail.

(2)Install fuel pressure regulator mounting nuts. Tighten nuts to 7 NIm (65 in. lbs.) torque.

(3)Connect fuel return hose to pressure regulator. Tighten hose clamp to 1 NIm (10 in. lbs.) torque (Fig. 12).

(4)Install vacuum hose on fuel pressure regulator.

(5)Connect negative cable to battery.

CAUTION: When using the ASD Fuel System Test, the Auto Shutdown (ASD) Relay remains energized for either 7 minutes, until the test is stopped, or until the ignition switch is turned to the Off position.

(6) With the DRB II use the ASD Fuel System Test to pressurize system and check for leaks.

FUEL SYSTEMS 14 - 103

MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR SERVICE

(1)Remove vacuum hose from MAP sensor (Fig. 13)

(2)Remove MAP sensor mounting screws (Fig. 13).

(3)Remove electrical connector. Remove sensor.

(4)Reverse the above procedure for installation.

Fig. 13 Manifold Absolute Pressure Sensor

WASTEGATE AND CANISTER PURGE SOLENOID SERVICE

(1)Remove vacuum hoses from sensors (Fig. 14).

(2)Disconnect electrical connector from solenoids (Fig. 14).

(3)Remove solenoid pack mounting nut. Remove solenoid pack.

(4)Depress tab on top of solenoid to be replaced and slide the solenoid downward out of mounting bracket.

(5)Reverse above procedure to install.

Fig. 14 Solenoid Mounting

ENGINE CONTROLLER SERVICE

(1)Remove air cleaner duct from engine controller.

(2)Remove battery.

Fig. 15 Engine Controller

HEATED OXYGEN SENSOR (O2 SENSOR)

The oxygen sensor is installed in the exhaust manifold (Fig. 16).

CAUTION: Do not pull on the oxygen sensor wires when disconnecting the electrical connector.

WARNING: THE EXHAUST MANIFOLD MAY BE EXTREMELY HOT. USE CARE WHEN SERVICING THE OXYGEN SENSOR.

(1)Disconnect oxygen sensor electrical connector.

(2)Remove sensor using Tool C-4907 (Fig. 17).

Fig. 16 Oxygen Sensor

Fig. 17 Oxygen Sensor Socket

When the sensor is removed, the exhaust manifold threads must be cleaned with an 18 mm X 1.5 + 6E tap. If using original sensor, coat the threads with Loctite 771-64 anti-seize compound or equivalent. New sensors are packaged with compound on the threads and do not require additional compound. Tighten the sensor to 27 NIm (20 ft. lbs.) torque.