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FUELSYSTEM 2GROUP 2

FUELSYSTEMCONTENTSDiagnosis. .. 22-FuelGaugeDiagnosis 22-Fuel njectornspect ion. . . . . . . . . 22-1Check pe ra t i on . . . . . . , . . . 22 -Fuel eakageest . . . . . . 22-1fniectorResistance. . . . . . .. 22-1Volumees t . . . . . . . 22 -FuelLineHandling. .. 22-PrimingheFuelSystem 22-FuelPump nspection. 22-HoldPressure . . . . . 22-1Fue l umpMax imumressure . . . . . . . . 22 -FuelPumpOperation 22-FuefPump elaynspect ion . . . . 22-1Check perat ion. . . 22-1Cont inui tynspect ion . . . . . . . . 22-GeneralDiagnosis. . . . . . 22-Pressureegulatornspect ion . . . . . . . . . . 22-Fue l ine ressure . . . . . . . . . 22 -HofdPressure . . . . . 22-Releasing uelSystemPressure 22-SystemChecks 22-FuelLinePressurenspection 22-Fuel Pressure old nspection 22-GeneralDescription. . . . . 22-Air Fuel nductionystem 22-Electronicue lPumpAssembly. . . . . 22-FuelFilters 22-FuelPipesand Hoses. 22-Fuel PressureRegulator alve .. 22-FuelSender ssembly. . . 22-FuelTank. .. 22-FuelTankPressure ensor.. .. 22-On-Vehicfeervice.. .. . 22-1A i rC leanerl emen t . . . . . . . . . 22 -AirCleanerssemblyndBracket. . . . . . . . 22-A i rF u n n e l . . . . . . . . . 2 2 -

Air ntakeHose.. . .. 22-3A i r n ta ke uc t . . . . . . . 22 -CheckandCutValve 22-2Dynamic hamber .... 22-3Fresh irDuct. . . . . . . . 22-FuelDistr ibutor. . . . . . . 22-FuelFilter .. 22-2Fuel njectors . . . . . . . . 22-Fuel Lines 22-2FuefPump. 22-1FuelPump ssembly. . . . . . . . . 22-FuelPump ssemblyi l ter . . . . . 22-1

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22-2 FUELSYSTEM

FuelTankSenderAssemblyFuelTankPrssureSensor .ldleAir ControlValve. . .InjectornsulatorsIn le t ipe ssembly . . . . . . .MassAir FlowSensor.PCVValve ndVentilationose. . .PressureRegulatorQuick onnector.Resonance hamberVaporSeparalor ssembly.ThrottleBodyThrottlePositionSensor.SpeciticationsFastener ightening pecifications.General pecifications. . .GENERAL ESCRIPTION

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The uelsystem or the Sportage onsists f thetollowing omponents:. Electronicuel pumpassembly. Fuel ilters 2). Fuelpipes lines) ndhoses. Fuelsenderassembly. Fuel ank. Fuel ail. Fuelpressureegulator. Fuel njectors 4). Fuelpump elay. Pulsation amperAIR FUEL NDUCTIONYSTEMTheair fuel nduction ystem arries,ilters,measures,and controlshe Jlowof air nto he hrottle odv.Fuelis metered nd mixedwith heair n the ntakemanifold. ir volume nto he engine s regulated y theacceleratorable-controlledhrottleDlatesmountednthe hrottle ody.Fuel s deliveredo thesolenoid peratedniectorsthrough he uel rail.Fuelpressurescontrolled y avariable ressureegulatorwhichvariesuelpressuredepending n the absolutemanitold ressure ctingonthe regulator t the time.An electrical ulseactivates solenoid ithin he fuelinjector ody.The duraiion f the pulses determinedby the ECM.The ECMvaries hepulsedurationbasedupon heamount f airpassinghroughhe massairflowsensor nd heenginespeedwhich s determinedby he crankshaft ensor.A throttle osition ensorattachedo the hrottleplateshaftsignalshe ECMof the hrottle osition nd herateof the hrottlemovement. hese ignals nfluencethe njector ulseduration.

The ECM-controlleddleair controlvalvesupplieselitraair to maintaindlespeed.E)draair s suDoliedoincreasedlespeedwhen heenginescold.dlespeed s increased hen he air conditioningcompressors engaged r whenmechanicaloadaffects dlespeed.Crankcase asesarevented o the intakemanifold ythe positive rankcaseentilation VCvalve.ThePCVvalve s operated y ntakemanifold acuum. t dlethe PCVvalveopens lightly nd allowssomecrankcase ases nto he combustion hamber. s rpmincrease,he PCVvalveopening ncreases llowinglarger olumeof gasesnto he ntakemanifold.ELECTRONICUELPUMPASSEMBLYThe electronicuelpumpassembly uppliesiltered,pressurizeduel o each uel njector hroughhe uelrail.The Juelpumpassemblys mountedn the ueltank o reducepumpoperating oise. t is mountedwithand connectedo the uelsendingassembly.othassemblies re removedromand nstallednto hefuel ank as a single nit.The uelpump s an electric umpcontrolledy heengine ontrolmoduleECM)hrough he uelpumprelay.When he ECMcommandshe fuelpump elayto operate, he motor otates n imDeller ithinhepumpassembly. hiscausesuel within he uel ankto be drawn nto he uel nletport.Fuel s pumped utto thethrottlebodyand uel railand niectors nderpressurehrough he uel eedpipeandhose.The uelpressures retained hen he uel pump s notrunningby meansof a control alve ocatedwithin hepump.Excess uel s returnedo the uel ank bv means f afuel retumpipeandhose.FUELFILTERSA steel n-line uel ilter sused n the fuel eedpipeaheadof the fuel niector.he ilterhousingsconstructedo withstandemperaturehanges ndexposure.t hasa paper ilterelementwhich raps

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FUELSYSTEM 22particleshatcoulddamagehe fuel niection ystem.Ascreen ilter n the uelpumpassemblyiltersoutparticlesn the uel ankJurther rotectinghe system.FUELPIPES NDHOSESFuel eed and retumpipes lines)and ubescarryueltrom he fuel ank o the uel railand back o the ueltank.Thesepipesand ubesare attachedo theunderbody f the vehicle ndmustbe inspectedorkinksor dentswhichmay estrict uel low.Fuelvaporpipesandhoses arry uel vapors rom hefuel ank o the evaporativemissions anisterocatedin the enginecompartment.he uelvaporsare storedin the canisterwhen heengine s not running.Whenthe engine s running t normal peratingemperature,and he acceleratoredals depressed,he enginecontrolmodule ECM)willcommandhe evaoorativeemissionolenoidurge alve o openandallowhestored uelvaporso bepurgednto he ntakemanifold ndbe absorbednto hecombustionorocess.FUELSENDER SSEMBLYThe uelsending ystem onsists f a float, loatarm,and a variable esistor. uel evel s measured y heposition f the float n the uel ank,and s indicated ya gauge n the nstrumentanelclusterassembly.When he uel evel hanges,he loatpositionchanges. he change nfloatpositionncreases rdecreaseshe resistancef the variable esistor. hechange n resistanceauses he position f the uelgauge eadouto change.

FUEL ANKThe uel ank s used o store uel or hevehicle.t ha 15.8gallon 60 ite0 uelcapacity. he ank s formfromsteeland s locateddirectly n frontof the rearwheels n backof andbelow he rearseat.The uel ank s held n placewith ivebolts. he ankprotectedy a gravelshield o which t is mounted.shapeot the ankallows ora conslant upplyof fuearound he uelpumpscreen ilterdunng ow uelconditions ndduringaggressive ehiclemaneuverThe uel nletporton the tank s equipped ithan nlvalve.The uel ank nletvalveoreventsuel romspewingnto he uel illerneckduring bnormalehdriving onditions.To maintain roperuel systempressure,t isimperativehat he fuel illercap be unctioningropand hat t "Clicks"whenscrewednto he illerneckothe gas ank.The uel ank,alongwith ts pipesandhoses, houldcheckedor roaddamagewhichcould esultn leakaAlso nspecthe uel {illercap or a correct ealandindicationsf physical amage.FUELPRESSUREEGULATORVALVEThe pressureegulatoregulateshe niection ressuso that t is maintainedt a pressure reaterhan290 kpa(40.5 si) han he pressuren the ntakemanifold.The pressureegulator onsislot a diaphragm, spranda fuel return ipe.Thecalibrated pringpressure gainsthe diaphragandcloseolf returnpipe.The system ressureeflectshe amount l fuelpressureequiredo open he return ipe.The uel ank s filled hrough he uel iller nletportcovered y a protective ontrol-openedanelon therightsideol thevehicle.FUELTANKPRESSUREENSORThe uel ankpressure ensor ocated t the uel ankan integral artof the monitoringystem. he uel anpressure ensor heckspurgevalveoperation nd edetectionn the evaporative missionsystembymonitoringressure nd vacuum evelsnthe uel anduringandbetween urgeoperatingycles.

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22-4 FUELSYSTEM

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1 CheckandCutValve2 VaporSeparator3 Return ine4 FeedLine5 FuelFiller HighPressure ide)6 Fuel njector4)7 FuelPressure egulatorI FuelPumpAssemblyI Pulsation amper10 FuelTank

11 Fil ler id'12 Filler Lid Opener13 Fil ler nletNeck14 FuelPump15 Fuel Pump Filter (Screen)16 FuelSenderAssembly17 FuelTank PressureSensor18 RolloverValve19 Check Valve20 CanisterCloseValve

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FUELSYSTEM 2

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MassAi rFlow MAF) ensorAi rCleanerResonancehamberThrottleBody lncludes hrottlePosition ensor)PlenumldleAi rControl alve

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22.6 FUELSVSTEM

GENERAL IAGNOSISProblem PossibleCause Aclion

Engineclanks but willnot slan Fuelpressure roblem ReplaceuelpressureegulatorReplaceeakingnjeclorReplacenjectorO-ringHald o start(colden9ine) ldleair control alvenotworkingDetectivehrotlleposilionensorFuelpressureoo owCoolantempsensor pen ircuit r out ot rangeReplaceReplacehrottle odyReplaceegulatorRepair amessBeplace ensorRough dle (coldengine) Throttle alves mproperlydjustedFuel njectorlowThrottle lalestuckopen

Throttle ,osilionswitchsluckopenldleair control alve noperativeAir niakeductdisconnectedetweenMAFand h.ottle odyLeakingnjectorLeakingnjectorO-ring eals

Adjust hrottleBeplacenjectorClean ndadjusthrottle lateAdjust hrottle ableReplaceReplaceReconnectir ductBeplaceReplaceSlalling or hesitalion(hot or cold engine) Throttle osition ensorailedEGFI alvemalfunction Replace P sensorReplace

Hardslart (hotengine) Inconectuel pressure Check ressu.eegulaloruelpumpStallson quickstopsordeceleration Mais air lowsensor pen ircuit ut ol range ReplaceMAFsensorCheck lectricalircuii seeETM)Pool pertormance/lossot power CloggednjectorsAir iherclogged Check njeclor lowrateReplace

DIAGNOSIS

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FUELSYSTEM 2FUELGAUGEDIAGNOSIS

Ploblem PossibleCause ActionFuelgaugeshowsemptyat all levelsol lill Loose r dirtywiring onneclionsr short ogroundwiringLeakingenderloatMissing enderloat

Short ircuitnsender ssemblySender ssemblyrm movementbslructed

Checkwiring, onnecto.s ndsenderssemblRepair, leanor tighten s needed.BeplaceenderInstallloat.Make ure loat s securednsendarm.Test or conect resistance aluesand eplaceasneeded.Inspectuel ankand senderorcause. eplacfaulty omponent.

Fuelgaugewill notread ull when ank sfullWrong endernstalledSender rmmovementbstructedfloat odbent)LeakingloatSender rgauge alibrationFuel anknot illing o rated apacity

Check artnumber.t nconecl,nstall orrect aInspectuel ankand sender orcause. eplactaulty omponent.lnstall ewsenderTest or conect resisianceva[re and eplacecomponents needed.Checkuel ank ill vent or kinks robstructioCorrect s required nd ill ank overilyprocapacity.Fuelgaugeshows ullai all levelsol fill Loose r dirtywiring onnectionsr opencircuitnwiringOpen ircuitnsending nit

Sender rmmovementbslructed

Checkwiring, onnectionsndsenderermtnaFRepair r clean t required.Testor correct esistance aluesand replacetrequrred.Inspectuel ankand senderorcause.Gentlybend loat armaway rom obstructionrreplaceomponent.Inaccude indicationscontinuebut all fuelsyslem componentsare runningproperly

Fuel ank damage Fuelsendermounting angle mayhavechangedthe senderunit may bs damaged.

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22.8 FUELSYSTEM

RELEASINGUELSYSTEMPRESSUREA mnuHcTHEFUELSYSTEM EMAINS NDERPRESSURE HEN HEENGINES NOTRUNNING, ELEASE UELSYSTEM RESSUREBEFOREDISCONNECTINGNY FUELLINETOREDUCE HECHANCE F PERSONALNJURYOR FIREDAMAGE OVEHICLE OMPONENTS,1. Start heengine.2. Disconnecthe uelpumpconnectorocated ehindlhe vehicle earseat, loor evet.3. Let he engine tall, hen urn off the gnition witch.4. Connecthe uelpumpconnector.

FuelPumpAssemblyFuelPumpAssemblyElectrical onneclor

FUELLINEHANDLINGA wanrurlcFUEL S EXPLOSIVE.HENWORKING NFUELSYSTEM ARTS. AKESURETOSUPPLYADEOUATE ENTILATIONOTHEWORKAREA.DONOTSMOKE, NDKEEPSPARKSANDOPENFLAMESAWAY.1. Whendisconnectinguelhoses, sea shop owelto absorb uel,protecting quipment ndpersonnel.2. Stop uel eakage y nstallingose lamps herethe uel ilter nd hemain uelhose onnecto heluelpressure auge.

Priminghe FuelSystemAfter uelpressure asbeen eleasedor repairs rinspection,he systemmustbe primed o avoid oomuchcrankingo restartheengine.Followhe stepsbelow.

12

1 . Connecthe data inkconnectorerminals UELPUMP ndB+witha umperwire.Turn he gnitionwitch n or no ongerhan1Osecondso pressurizehe systemand checkorfuel eaks.Ohe umperwiregetshot f it is left n torlongerhan10seconds.)Tum he gnition witchoff and ake he umperwireoff he data inkconnector.

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SYSTEM HECKSFuelPressureHold nspectionDisconnecthe negative atteryerminal.WARNINGTHEFUELSYSTEM EMAINS NDERPRESSURE HEN HEENGINESNOTRUNNING. ELEASE UELSYSTEM RESSUREBEFORE ISCONNECTINGNYFUEL INETOREDUCE HECHANCEOF PERSONALNJURYOR FIREDAMAGE OVEHICLE OMPONENTS.Releaseue lsystem ressure. efero"ReleasingFuelSystemPressure"n thissection.Install fuelpressure auge o the pressure ortlocated n he frontof the fuelrail.

3.

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FUELSYSTEM 24. Connecthe negative atteryerminal.5. Connecthe data inkconnectorerminals UELPUMP ndB+witha umper ire.6. Turn he gnition witch n or 10secondso run hefuelpump.7. Turn he gnition witchotf and emove he umperwtre.8. Check uelpressure fter5 minutes.

Fuelpressure:More han21psi 150kPa)9. lf notas noted, o he ollowingnspections:. Fuelpumpholdpressure.. Pressure egulator oldpressure.. Injectoruel eakage.

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FuelLinePressurenspection1. Disconnecthe negative attery able.2. Releaseuel systempressure. efer o "ReleasingFuelSystemPressure"n thissection.3. lnstalla fuelpressure augeo the pressureportlocated n the frontof the uelrail.4. Connecthe negative attery able.

5. Connecthedata ink onnectorerminalsUEPUMP ndB+witha jumperwire.6. Turn he gnition witch n for 10 seconds.7. Checkuel ineoressure.

Fuel ine pressure:42 psi (292.5kPa)8. Turn he gnition witchoff and removehe umpwire.9. lf notas noted, o he ollowingnspections:. Fuelpumpmaximumressure.. Fuel inecloggingnd estriction.. Fuel ilterclogging nd restriction.. Pressureegulator oldpressure.

FUELPUMP NSPECTIONA uRl,tl1cTHEFUELSYSTEM EMA'NSUNDERPRESSURE HEN HEENGINESNOTRUNNING. ELEASE UELSYSTEM RESSBEFORE ISCONNECTINGNYFUEL INETREDUCE HECHANCE F PERSONALNJUOR FIREDAMAGE O VEHICLE OMPONEFuelPumpOperation1 Connecthe data inkconnectorerminals UELPUMP ndB+witha iumoerwire.

2. Removehe uel illercap.3. Turn he gnitionwitchON.4. Determinef he uelpump s runningy istenfor the soundof it at the uel iller nlet.5. Installhe ue l iller ap .6. lf nosoundwas heard,measurehevoltagebetweenhe uelpumpconnectorwire Gff) tochassis round.

Voltage: bout12V7. lf the voltages normal,eplace he uelpump.8. lf you do not measure 2V, epair he relatedwi9. Disconnecthe umper ire.

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22.10 FUELSYSTEM,,rI2 FuelPumpAssemblyFuelPumpAssemblyElectrical onneclor l

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HoldPressureDo his nspectionf thepumpoperationnspectionsnotas soecified.1 Disconnecthe negative attery erminal.2. Release uelsystem ressure.Refer o "ReleasingFuelSystemPressure"nthis section.3. Connect fuelpressure auge o the uel ilterandplug he outletof thegaugeas shown. lnstallclampsas shown.)

Connect he negative atery erminal.WARNINGTHEFUELSYSTEM EMA]NS NDERPRESSURE HEN HEENGINES NOTRUNNING. ELEASE UELSYSTEM RESSUREBEFOREDISCONNECTINGNY FUELLINETOREDUCE HECHANCE F PERSONALNJURYORFIREDAMAGE OVEHICLE OMPONENTS.Connect he data inkconnectorerminals UELPUMP nd B+witha jumperwire.

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6. Turn he gnition witchon for 10secondso run heluelpump.7. Tumthe gnition witcholf and removehe umperwtre.8. Observe he uelpressure fter5 minutes.

Fuel pressure:More han 50 psi (340kPa)9. lf not as noted, eplacehe fuelpump.FuelPumpMaximum ressure1. Disconneclhe negative atteryerminal.2. Release uel system ressure.Refer o "ReleasingFuelSystemPressure"n this section.3. Connect fuelpressure auge o the uel ilterandplug he oulletof thegaugeas shown. lnstallclampsas shown.)4. Connect he negative attery erminal.5. Connect hedata inkconnectorerminals UELPUMP ndB+witha jumperwire.6. Tum the gnilion witchon o run he uelpump.7. Measure he uelpumpmaximum ressure.

pump maximumpressure:above50psi340 kPa)8. Turn he gnition witchoff and removehe umperwtre.9. lf this pressures not measured. eDlacehe uelpump.FUELPUMPRELAYNSPECTIONCheckOperationA wlRtttttCTHE FUELSYSTEM EMAINS NDERPRESSURE HEN HEENGINESNOTBUNNING. ELEASE UELSYSTEM RESSUREEEFOREDISCONNECTINGNY FUEL INETOREDUCE HECHANCE F PERSONALNJURY

OR FIREDAMAGE O VEHICLECOMPONENTS.

Fuel(

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FUEL SYSTEM 22-Listenor the uelpump elayclicking s he gnitionswitch s turnedON.Continuity nspectionCheckcontinuity etween elay erminals.B+: Batterypositivevoltage

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PRESSUREEGULATORINSPECTIONFuelLinePressure1. Disconnecthe negative atteryerminal.2. Release uelsystempressure. efero "ReleasingFuelSystemPressure"n thissection.3. Connect luelpressure augeo thepressure ortlocated nthe rontof the fuel rail.4. Connecthe negative attery erminal.5. Start he engineand run t at idle.6. Inspect he uel inepressuremeasurement.

Fuel ine prcssure:34 psi (235kPa)7. Disconnecthe vacuumhose rom he Dressureregulator nd measurehe fuel inepressure.

Fuel ine pressure:42 psi (292.5 Pa)Hold PressureDothis nspectionf the uel inepressurenspectionsnotas noted.1. Disconnecthe negative atteryerminal.

Terminal2-4 Terminal$(1 or 3)ApplyB+ YesB+ notapplied No

A WARNINGTHEFUELSYSTEM EMAINS NDERPRESSURE HEN HEENGINESNOTRUNNING.ELEASE UELSYSTEM RESSUBEFOREDISCONNECTINGNY FUELLINETOREDUCE HECHANCE F PERSONALNJUROR FIREDAMAGE O THEVEHICLE.Releaseuel system ressure.Refer o"ReleasFuelSystemPressure"n this section.Connect fuelpressure auge o thepressure olocated nthe rontof the uel rail.Connecthe negative atteryerminal.

7.

Connecthe data inkconnectorerminals UELPUMP ndB+witha umperwire.Tum he gnitionwitch n or 10secondso runthe uelpump.Tum he gnition witchoff and removehe umpewire.Pinch he uel returnhoseat the regulator ithpliers.Observehe fueloressureor 5 minutes.Fuelpressure:More han 21 psi (147kPa)10. f not as noted, eplacehe pressureegulator.Refer o the pressureegulatoreplacementleplocatedn this manual.

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22-12 FUELSYSTEMFUEL NJECTORNSPECTIONCheckOperation1. Warm p heengine nd et t idle.2. Listen or the soundof each niectorunning yusinga soundscopeor a screwdriver.A mnHrncFUEL S EXPLOSIVE. HENWORKING NFUELSYSTEMPARTS,MAKESURETO SUPPLYADEOUATE ENTILATIONO THEWORKAREA.DONOTSMOKE. NDKEEPSPARKSANDOPENFLAMESAWAY.

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't CautionMake surc the fuel injectorc are firmly seatedonthe tuel rail to prevent movement ancl possibledamage,3. lf no sound s heard,measurenjectoresisiance.4. lf the nieclors OK,checkwiring o the nieciorandthe voltages f the ECM erminals 6, 17,34 and35.5. lf removal f the iniector ystem s needed, efer o"On-VehicleService"nthis section or the sieos.FuelLeakage est'I. Takeout he niectorsogetherwith he fuel rail.2. Secure he niectorso the uel railwithwire.

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Connect he data inkconnectorerminals UELPUMP ndB+witha umperwire.Tum he gnition witch n.l'ilt the injectors bout60 degreesandverifyhatno fuel eaks rom he niectornozzles.lf fuel eaks, eplace he eaking njector. efero"On-VehicleService"n this section.Turn he gnition witch OFF and removehejumperwrre.

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Volume est1. Takeout he njectorsogetherwith he uel ail.2. Secure he njectorso the distributor ipewithwrre.3. Connect n injectorester o the battery nd heiniector.4. Inspect he njector olumewith a graduatedcontainer.

Iniector olume:130cm' (130cc, 7.95)/min

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FUELSYSTEM 25. lf not as noted, eplace he njectors. efero 'On-VehicleService' n this section.

* Notice. Alwaysusenew injectorO-ringswhen replacinginjectors.. Applya small amountof cleanengine oil to eachof the O+ings before nstalling.

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InjectorResistance1 Disconnecthe niector arness.2. Measureesistance f the njector.

Resistance:12 -16f)@68'F(20'C)3. lf not noted, eplace he njector. efer o "on-VehicleService"n this seclion or steos.

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ON-VEHICLE ERVICEFUEL ANKRemovalA unnrrueFUEL S EXPLOSIVE. N EMPTYFUELTANKCAN STILLCONTAIN XPLOSIVE ASES.SUPPLYADEQUATE ENTILATIONO THEWORKABEA.DONOTSMOKE NDKEEPSPARKSANDOPENFLAMESAWAY. URGEFUMES ROM HETANKAS SOON SPOSSIBLE.

1. Disconnecthe negativeerminalromthebafter2. Ooen he rearaccess oor of thevehicle.3. Releasehe catch or he rearseatand ilt t outolhe way.4. Pullback he souare f carDetn theareabehindthe iltedseatwhich overs he uelpumpassemaccesspanelon he vehicle loor.5. Disconnecthe wo halvesof the ueloumoassemblv lectrical onnector.

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6. Removehescrew oldingheground ire ug ogrouno.7. Remove he our screws ttachingheaccess oand remove he access over,movingt out of theway.8. Remove wo uel hoseclamps rom he wo uelhoseassembliesonnectedo the uelpumpassembly.9. Disconnecthe wo uel hoseassembliesrom hefuelpumpassembly.10. Disconnectuel ankpressure ensor lectricalconneclor.11 Workinghroughhe accessport, emovehe hrefuelhoseclampsromwhere he hree uel hoseare connectedo the uel ank.

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22-14 FUELSYSTEM

xtat 61t-22.ta-s12.Disconnecthe hree uel hoses rom henozzleson he uel ank.13.Loosenhe nlet oseassemblyoint lamp.14. Raise he vehicleona hydraulicift o the normalundercarriageervicingevel.15. Usinga liftingdevice,aise he iftingdevice o thebottomof the fuel ank n the vehicle.Center heliftingdeviceon the uel anldshield ssembly.16. Removeive 15 mmbolts rom he fuel anldshieldassembly.17.Carefully ull he uel anldshield ssemblv wavfrom he chassis f the vehicleand allowheassemblyo reston the iftingdevice.18. Lower he liftingdevice nd place he uel anUshieldassembly n a workbencharea.'t CautionCover the open ports on the fuel tenk withplastic caps or otlEr aveilable coversto avoidluel vapor contaminating the work area.19.Separatehe fuel ank rom he shieldby removingtwo attaching olts.Lift he uel tank away rom heshield ndstore heshield.

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InstallationA wlnNrlcFUEL15EXPLOSIVE.N EMPTYFUELTANKCAN STILLCONTAIN XPLOSIVE ASES.SUPPLY DEQUATE ENTILATIONO THEWORKAREA.OO NOTSMOKEAND KEEPSPARKSANDOPENFLAMESAWAY. URGEFUMESFROMTHETANKAS SOONASPOSSIBLE.

4.

Raisehe vehicle n a hydraulicift o the normalundercarriageervicingevel.Attach he shield o the uel tankusino woattaching olts.Ensure nyprotective apsare removedrom hefuel ankoorts.Placehe uel ank ona liftingdeviceeodcarefullyraise he uel ankassembly nder heraisedvehicleuntil heassemblys positionedt thepointot installation.Install ive l5 mm bolts o fasten he ueltanldshieldssemblyntoplaceon thevehiclechassis.

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Lower he vehicle o groundeve..Install he nlethoseassemblyointclamp.Connecthree uelhoses o the nozzles n he fueltank.Throughheaccessport,connect hree uelhoseclamps o where he hree uel hosesareconnectedo the uel ank.Connectwohoses o the uelpumpassembly.Installwo uelhoseclamps o thepointwhere hefuelhosesare connectedo the nletportson thefuel ank.Push heendsot the main uelhose, uel returnhoseandevaporative oseonto he uel ank ittinoat east1.0 nch 25mm).Push he uet i er hosejonto he tuel ankpipesand illerpipesat east1.4 nch 35mm).

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FUELSYSTEM 22

xar ql-zt.r012.Connectuel ankpressure ensor lectricalconnector.13. nserthegroundingineand he uelpumpassembly lectrical onnector iringhrough heaccesshole n the accesspanel.14. Attach he our screws o attach heaccesscover othe opof the accessareaover he uelpumpassemblymountedn the fuel ank.15. Attach hegroundwire ug o chassis roundusingthe attachino crew.

16.Connecthe two halvesof the uelpumpassemblyelectrical onnector.17.Positionhe wiring ntoplaceusing n adhesivestripandplace he squareof carpeting ackovertFeaccess reaon the vehicle looring.'t8. Releasehecatch or he rearseatand bring t backto the normalposition.19.Close he rearaccessdoorof thevehicle.20. Connecthe negativeerminalo thebattery.

1 FuelPumpAssemblyFuelPumpAssemblyElectricalConnector

FUEL PUMPASSEMBLYRemovalA wenlrHcFUEL S EXPLOSIVE. HENWORKING NFUELSYSTEMPARTS,MAKESURETO SUPPADEOUATE ENTILANONO THEWORKAREA. DO NOTSMOKEAND KEEPSPARKSAND OPENFLAMESAWAY.1 .

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7.

8.

Disconnecihe negativeerminal rom he batterOpen he rearaccess oorof the vehicle.Releasehe catch or he backseatand ilt t out othe way.Pullback hesquare fcarpetn heareabehindthe tiltedseatwhichcovers he tuelpumpassemaccessoanelon vehicle loor.Disconnecthe wo halves f the fuelpumpassembly lectricalonnector.Remove he screwholdinghe groundwire ug ogrouno.Remove he fourscrews ttachinghe.accessovand remove heaccess over,movingt outof theway.Remove he wo uelhoseclamps rom he wo uhoseassembliesonnectedo fuelpumpassemb

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22-16 FUELSYSTEM* NoticeDo not use any excessive orce on the fuelpumpassembly.Thepafts are delicate,suchas the fuelscreen which mightbe damagedby incorrectrcmoval from the fuel tank.9. Disconnecthe wo uel hoses rom he ueloumoassembly.10. Bemoveeight etaining crewsaroundhe opsurfaceof the fuelpumpassembly.11 While wisting ery arefullynd iltinghe uelpumpassembly,ul lgraduallyntil t comes utofthe op of the uel ankassembly.'12.When he uelpump ssemblyscompletelyakenout of the accessarea,wrap t in a shop owelcarefully ntil t reaches he maintenancerea.13.Sealofi the oDen uel ankDortwitha coverorplug.

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lnstallationA unrurncFUEL S EXPLOSIVE. HENWORKING NFUELSYSTEMPARTS,MAKESURETOSUPPLYADEOUATE ENTILATION OTHEWORKAFEA,DONOTSMOKE NDKEEPSPARKSANDOPENFLAMESAWAY.* NoticeDo not force fuel/pumpassemblyparts.The uel/screen s delicateand can be damagedbyimproper nstallation o the fuel tank1 Remove nycap or protectiveover rom heporton he oo of the uel ank.

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Holdinghe uelpump ssembly,uidet nto heaccessportonthe op o{ he uel tankas aras itwillgo at thatpoint.While wisting erycarefully, nd ilting he uelpumpassembly,ush raduallyntil heassemblyseats n the fuel ankcorrectly.Install ight etainingcrewsaround he opof theinstalleduelpumpassembly.

K4163-22-?!15Connect he wo uel hoses o the fueloumoassembly.Install he wo uelhoseclamps o the wo uelassembliesonnectedo the fuelpumpassembly.Inseriheground ire n he uelpump ssemblyconnector ssemblyhroughhe access ole n theaccess over.lnstall he our retainingcrewsattachingheaccess over o the looring f the vehicle.Attach he groundwire ug o the looring f thevehiclewith heatlaching crew.Connecthe hvohalvesof the fuelpumpassemblyelectricalonnector.

6.7.

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FUELSYSTEM22

12 FuelPumpAssemblyFuelPumpAssemblyEleclrical onneclor x|Are22-rls

11 Place headhesiveape over he oosewiringandput he squareof carpeting ackover he areaofthe accessdoorbehind he rearseat.12. Releasehe catch or the rearseatand ilt t backinto he normalposition.13.Close he rearaccessdoorof the vehicle.14.Connecthe negativeerminalo the battery.

FUELPUMP SSEMBLYILTEBRemovalA wlnNrt'toFUEL S EXPLOSIVE. HENWORKING NFUELSYSTEMPARTS,MAKESURETOSUPPLY DEOUATE ENTILATIONO THEWORKAREA.DO NOTSMOKE NDKEEPSPARKSANDOPENFLAMESAWAY.

1. Disconnecthe negativeerminalrom hebattery.2. Open he rearaccessdoorof the vehicle.3. Releasehecatch or the backseatand ilt t out ofthe way.4. Pullback he squareol carpet n he areabehindthe iltedseatwhichcovers he uelpumpassemblyaccessoanelon the vehicle loor.5. Disconnecthe two halvesof the uelpumpassembly lectrical onnector.6. Removehe screwholding hegroundwire ug oground.7. Removehe our screwsattachinghe access overandremovehe access over,movingt out ol thewav.

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Removehe two fuel hoseclamps rom he wo uhoseassemblies onnectedo the uelpumpassembly.NoticeDo not force fuelpumpassemblypafts. The uelscreen s delicateand can be damagedbyimproper emoval rom the fuel tank.Disconnecthe two uelhoses rom he ueloumassembly.Disconnectuel ankpressure ensor lectricalconnector.Remove ight etaining crews roundhe opsurface t the fuelpumpassembly.While wisting ery carefully nd iltinghe uelpumpassembly, ullgradually n theassemblyuntil t comesout of the oo of the fuel ank.

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When he tuelpumpassemblys completelyakeout of the accessarea,wrap t in a shop owelcarefully ntil t reacheshe maintenancerea.'I3.

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22-18 FUELSYSTEM

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Sealoff the open uel ankportwitha coverorptug.Removehe circularetainingli pat heendof hefuelpump o allow he fuel ilter screen)oseparaterom he uelpumpassembly.

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FUELSYSTEM 225. Installeight etainingcrewsaround he opsudaceof the fuelpumpassembly.6. Connecthe wo uel hoses o the uelDumpassemory.7. Install he wo uelhoseclamos o the wo uelhosesconnectedo lhe fuelpumpassembly.8. Connect uel ankDressure ensor lectricalconneclor.9. Insertheground ire n he uelpumpassemblyconnector ssemblyhrough heaccesshole n theaccesscover.10. Install he our retainingcrewsattachingheaccess over o the looring f the vehicle.1l. Attachheground ire ug o he looring t hevehicle ith heattachingcrew.12 .Connecthe wohalves f he ue lpump ssemblyelectrical onnector.'13.Place he adhesiveapeover he oosewiringandput the squareof carpeting ackover he areaofthe accessdoorbehindhe rearseat.14. Releasehecatch or the rearseatand ilt t out ofthe way.15. Close he rearaccess oorof hevehicle.16.Connect he negativeerminal o thebattery.

12 FuelPumpAssemblyFuelPumpAssemblyElectricalonnector1

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FUELPUMPRemovalA unHrHcFUEL S EXPLOSIVE.HENWORKING NFUELSYSTEM ARTS.MAKESURE OSUPPLYADEQUATE ENTILATIONO THEWORKAREA.DONOTSMOKE NDKEEPSPARKSANDOPENFLAMESAWAY.1. Disconnecthe negativeerminalrom he battery.2. Open he rearaccess oorof the vehicle.3. Releasehe catch or the backseatand ilt t out ofthe way.

6.7.

Pullback he squareof carpetntheareabehinthe iltedseatwhichcovers he fuelpumpassemaccesspanelon the vehicleloor.Disconnecthe two halvesof the uelpumpassembly lectrical onnector.Removehe screwholdinghegroundwire ug ogrouno.Removehe ourscrewsattachingheaccess oand remove he access over,movingt ouiof th

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8. Removehe wo uelhoseclamosrom he two uhoses onnectedo the fuelpumpassembly.9. Disconnecthe hvo uelhoses rom he uel oumassembly.* NoticeDo notuse any excessive orceon the fuelpumpassembly.Thepads are delicate,suchas the fuescreen whichmightbe damagedby incorrectremoval romthe fuel tank.10. Remove ight etaining crews roundhe topsurface f the uelpumpassembly.11. Disconnectuel ankoressureensor leclricalconnector.12. While wisting erycarefully nd ilting he tuelpump ssembly,ul lgraduallyn he uelpumpassembly ntil t comesout of the opof the fuellankassembly

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22-20 FUELSYSTEM13. When he tuelpumpassemblys completelyakenout of the accessarea,wrap t in a shop owelcarefully ntil t reacheshe maintenancerea.14.Sealotf theopen uel ankportwitha coverorptug.15.Remove ourretaining crewswhichhold he fuelpumpplastic etaining racket o the uel pumpassemblyrame.16. Takeoff the retaining lamp rom he uel hoseanddisconnecthe fuelhose rom he uelpump.17. Takeofl the uelpump etaining lasticmountingbracket s necessary.18.Removeuel ankpressure ensor

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InstallationA wanHrl'tcFUEL S EXPLOSIVE. HENWORKING NFUELSYSTEMPARTS,MAKESURETOSUPPLY DEOUATE ENTILATIONO THEWORKAREA.DO NOTSMOKE NDKEEPSPARKSANDOPENFLAMESAWAY.1. Installhe plasticuelpumpmounting racketontothe uelpumpand nstall he ourmountino crewswhichhold he uelpump o theassembly-trame.2. Conneclhe uelhose o the uelpumpand nstallthe retaining lamp o securehe hose o the fuelpump.3. Remove nycap or protective over rom he oorton he topof the uel ank.

12

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Holdinghe fuelpumpassembty, uide t into heaccessporton the opof the fuel ank as aras itwillgo at thatpoint.

BN7A2200g\t< NoticeDo not force fuelpumpassemblypafts. The uetscreen s delicateandcan be damagedbyimproper nstallationo the fuel tanKWhile wisting erycarefully nd tilting he uelpumpassembly,ushgradually n theassemblvuntil t is in positionn the uel ankassemblv.

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FUELSYSTEM 26. Installeightscrewsaround he opsurface f thefuelpumpassembly.7. Connecthe wo uel hoses o the uelpumpassembly.8. Install he wo uel hoseclamps o the wo uelhosesconnectedo the uelpumpassembly.9. Install uel ankoressure ensor.10. Connectuel ankpressure ensorelectrical

connector.1l . Insertheground ireand he uelpump lectricalconnectorwires hrough heaccesshole n theaccessdoorandmount t over he accesshole.12. Install ourscrewso secure he accessdoor o thevehicle looring.13 . nstallheground ire ug o the loorwith heattaching crew.'14.Connect he wohalvesof the uelpumpassemblyelectrical onnector.15.Attachadhesiveape o any oosewiringandcoverthe areaof the nstalled ccessdoorwith hesquareof carpeting.'16.Releasehe catch or he rearseatandout t to thenormal osition.'17.Close he rearaccess oorof he vehicle.18. Connect he negativeerminalo thebattery

FuelPurnp ssemblyFuelPump ssemblyEleclrical onnector

FUELTANKSENDERRemovalA wlnHrHcFUEL S EXPLOSIVE.HENWORKING NFUELSYSTEMPARTS,MAKESURETOSUPPLYADEOUATE ENTILATIONOTHEWORKAREA.DONOTSMOKE. NDKEEPSPARKSANDOPENFLAMESAWAY.

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1. Disconnecthe negativeerminalrom he batte2. Open he rearaccessdoorof thevehicle.3. Releasehe catch or the backseatand ilt t otheway.4. Pullback hesquareof carpei n theareabehithe iltedseatwhichcovers he uelpumpasseaccessoanelon the vehicle loor.5. Disconnecthe wo halvesof the uelpump

assembly lectrical onnector.6. Removehe screwholdinghe groundwire ug ground.7. Removehe fourscrewsattachingheaccessand removehe access over,movingt outof tway.

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8. Removehe wo uel hoseclampsrom he twohoses onnectedo the tuelpumpassembly.9. Disconnecthe wo uel hoses rom he uel pumassemoty.* NoticeDo not force fuelpumpassemblyparts-The fuescreen s delicateand can be damaged yimproper emoval rom the fuel tank.10. Disconnectuel ankpressure ensor lectricaconnector.11. Remove ight etaining crews roundhe opsurface f the uelpumpassembly.12. While wisting ery carefully nd iltinghe fuelpump ssembly,ullgraduallyn he uelpumassembly ntil t comesout of the opof the fuetankassemblv.

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22-22 FUELSYSTEM

\ aN7A2i!@13 .When he uelpump ssemblys completelyakenoutof the access rea,wrap t in a shop owelcarefully ntil t reacheshe maintenancerea.14.Sealoft theopen uel ankportwitha coverorplug.15. Remove etaining ardwarehat holds he uel tank

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FuelPumpAssemblyFuelTankSender ssemblyFuelTankPressure ensor1

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InstallationA mRHlHcFUEL S EXPLOSIVE.HENWOFKING NFUELSYSTEMPARTS,MAKESURETOSUPPLY DEOUATE ENTILATIONO THEWORKAREA.DONOT SMOKEANDKEEPSPARKSANDOPENFLAMESAWAY,1. Installhe retaining ardwarehat holds he fuelsenderassemblyo the fuelpumpassembly.

2. Remove nycapor protective over rom he porton the toDol the uel ank.

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Holdinghe assembleduelpump/fuel enderassembly, uide t into heaccessporton the op ofthe uel ankas ar as t willgo .

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* NoticeDo not force fuelpumpassemblyparts.The uelscreen s delicate,and canbe damagedbyimpropernstallation o the fuel tanK.While wisting erycarefully nd ilting he uelpump ssembly,ushgraduallyn theassemblyuntil t goes n positionn the uel ankassembly.Install ightscrewsaround he op surface f thefuelpumpassembly.Connecthe two uelhosesassemblieso the uelpumpassembly.Installhe two tuel hoseclamps o the two uelhoses onnectedo the uelpumpassembly.Connectuel ankpressureensorelectricalconnector.

7.