Circuit Opening Relay
Fuel Pump Check Connector
Air Flow Meter
Fuel Pump Switch
Air Flow Meter
;rA Fuel Pump
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1. CHECK FUEL PUMP OPERATION
(a) Turn on the ignition switch. NOTE: Do not start the engine.
(b) Short both terminals of the fuel pump check connector.
(c) Check that there is a pressure in the hose to the cold start injector.
NOTE: At this time, you will hear fuel return noise from the pressure regulator.
(d) Remove service wire and install the rubber cap to the check terminal.
(e) Turn off the ignition switch.
If there is no pressure, check the following parts.
• Circuit opening relay
• Wiring connections
2. CHECK FUEL PRESSURE
(a) Check the battery voltage above 12 volts.
(b) Disconnect the battery ground cable.
(c) Disconnect the wiring connector from the cold start injector.
(d) Put a suitable container or shop towel under rear end of the delivery pipe.
(e) Slowly loosen the union bolt of the cold start injector hose and remove the bolt and two gaskets from the delivery pipe.
(f) Drain the fuel in the delivery pipe.
(g) Install a gasket, SST, another gasket and union bolt to the delivery pipe as shown in the figure.
(h) Wipe off any splattered gasoline.
(i) Reconnect the battery cable.
(j) Short both terminals of the fuel pump check connector.
(k) Turn on the ignition switch.
(I) Measure the fuel pressure.
If high pressure, replace the pressure regulator. If low pressure, check the following parts.
• Fuel hoses and connection
• Pressure regulator
(m) Remove the service wire from the service connector, (n) Start the engine.
(o) Disconnect the vacuum sensing hose from the pressure regulator and pinch it off.
(p) Measure the fuel pressure at idling.
(q) Reconnect the vacuum sensing hose to the pressure regulator.
(r) Measure the fuel pressure at idling.
If not pressure, check the vacuum sensing hose and pressure regulator.
(s) Stop the engine. Check that the fuel pressure remains above 1.5 kg/cm2 (21 psi, 147 kPa) for 5 minutes after the engine is turned off. If not within specification, check the fuel pump, pressure regulator and/or injectors.
(t) After checking fuel pressure, disconnect the battery ground cable and carefully remove the SST to prevent gasoline from splashing.
(u) Using new gaskets, reconnect the cold start injector hose to the delivery pipe.
(v) Connect the wiring connector to the cold start injector.
(w) Check for fuel leakage.
REMOVAL OF FUEL PUMP
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Pump Filter i 10*31
1. DRAIN FUEL FROM FUEL TANK
WARNING: Avoid smoking and open flame when working on the fuel pump.
2. REMOVE FUEL TANK
3. REMOVE FUEL PUMP BRACKET FROM FUEL TANK
(a) Remove the bolts.
(b) Pull out the fuel pump bracket.
4. REMOVE FUEL PUMP FROM FUEL PUMP BRACKET
(a) Remove the two nuts and disconnect the wires from the fuel pump.
(b) Pull off the bracket from the lower side of the fuel pump.
(c) Remove the fuel pump from the fuel hose.
5. REMOVE FUEL PUMP FILTER FROM FUEL PUMP
(a) Remove the rubber cushion.
(b) Remove the clip and pull out the filter.
INSTALLATION OF FUEL PUMP
1. INSTALL FUEL PUMP FILTER TO FUEL PUMP
2. INSTALL FUEL PUMP TO FUEL PUMP BRACKET
(a) Insert the outlet port of the fuel pump into the fuel hose.
(b) Install the rubber cushion to the lower side of the fuel pump.
(c) Push the lower side of the fuel pumpr together with the rubber cushion, into the fuel pump bracket.
3. INSTALL FUEL PUMP BRACKET
(a) Place the bracket with a new gasket on the fuel tank.
(b) Install and tighten the screws.
4. INSTALL FUEL TANK
When installing the fuel tank, refer to FI-58 for the installation position of the protector and hose and the tightening torque.
After installation, check for leaks.
Cold Start Injector
Wiring Terminal Switch
Cold Start Start Injector Injector Time Switch
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REMOVAL OF COLD START INJECTOR
1. DRAIN COOLANT
2. REMOVE AIR INTAKE CONNECTOR
3. DISCONNECT FOLLOWING HOSES:
(a) No. 1 water by-pass hose from the ISC valve body.
(b) No. 2 water by-pass hose from the throttle body.
(c) Air valve hose from ISC valve body.
(d) PCV hose from the throttle body.
(e) Brake booster vacuum hose from the air intake chamber.
(f) Actuator vacuum hose from the air intake chamber.
(g) Label and disconnect emission control hoses from the throttle body and air intake chamber that allow removal of vacuum pipe subassembly.
4. DISCONNECT ACCELERATOR LINKAGE AND CABLE FROM THROTTLE BODY
5. DISCONNECT FOLLOWING WIRES:
(a) Cold start injector wire
(b) Throttle position sensor wire
(c) Two ISC valve connectors
(d) VSV wire connector
6. REMOVE AIR INTAKE CHAMBER STAY
7. REMOVE VACUUM PIPE SUBASSEMBLY
8. LOOSEN EGR PIPE CONNECTING NUT
9. DISCONNECT COLD START FUEL HOSE FROM DELIVERY PIPE
10. REMOVE AIR INTAKE CHAMBER
11. REMOVE COLD START INJECTOR FROM AIR INTAKE CHAMBER
INSPECTION OF COLD START INJECTOR
1. MEASURE RESISTANCE OF COLD START INJECTOR
Using an ohmmeter, check the resistance of the injector. Resistance: 3 — 5 fi
2. CHECK INJECTION OF COLD START INJECTOR
(a) Install the gasket, SST (two unions), another gaskets and two union bolts to the delivery pipe and injector.
(b) Connect the SST (hose) from the unions. SST 09268-41045
(c) Connect the SST (wire) to the injector. SST 09842-30050
NOTE: Position the injector as far away from the battery as possible.
(d) Put a container under the injector.
(e) Turn on the ignition switch. NOTE: Do not start the engine.
(f) Short both terminals of the fuel pump check connector with a service wire.
(g) Connect the test probes of the SST to the battery and check that the fuel spray is as shown.
NOTE: Perform this check within the shortest possible time.
(h) Disconnect the test probes from the battery and check that fuel does not leak from the injector.
Fuel drop: Less than one drop of fuel per minute
(i) After checking, restore the following to the previous state.
• Fuel pump check connector
• Ignition switch
• Cold start injector
• Injector wiring
INSTALLATION OF COLD START INJECTOR
1. INSTALL COLD START INJECTOR
Place the new gasket and install the cold start injector and two bolts.
2. INSTALL AIR INTAKE CHAMBER
3. CONNECT COLD START FUEL HOSE TO DELIVERY PIPE
4. TIGHTEN EGR PIPE CONNECTING NUT
5. INSTALL VACUUM PIPE SUBASSEMBLY
6. INSTALL AIR INTAKE CHAMBER STAY
7. CONNECT FOLLOWING WIRES:
(a) VSV wire connector
(b) Two ISV valve connectors
(c) Throttle position sensor wire
(d) Cold start injector wire
8. CONNECT ACCELERATOR LINKAGE AND CABLE FROM THROTTLE BODY
9. CONNECT FOLLOWING HOSES:
(a) Connect the emission control hoses to the throttle body and air intake chamber etc.
(b) Actuator vacuum hose to the air intake chamber
(c) Brake booster vacuum hose to the air intake chamber
(d) PCV hose to the throttle body
(e) Air valve hose to the ISC valve body
(f) No. 1 water by-pass hose to the ISC valve body
(g) No. 2 water by-pass hose to the throttle body
10. INSTALL AIR INTAKE CONNECTOR
11. FILL WITH COOLANT
Pressure Regulator t
CHECK FUEL PRESSURE (See page FI-45)
REMOVAL OF PRESSURE REGULATOR
1. DISCONNECT VACUUM SENSING HOSE
2. DISCONNECT FUEL HOSE
(a) Put a suitable container or shop towel under the pressure regulator.
(bl Disconnect the fuel hose from the pressure regulator.
3. DISCONNECT NO. 2 FUEL PIPE FROM PRESSURE REGULATOR
4. REMOVE PRESSURE REGULATOR
Remove the lock nut, and remove the pressure regulator.
INSTALLATION OF PRESSURE REGULATOR
1. INSTALL PRESSURE REGULATOR
Install the pressure regulator and lock nut.
Torque the lock nut.
2. CONNECT NO. 2 FUEL PIPE
Install a new gasket, pipe, another gasket and union bolt to the pressure regulator. Torque the union bolt.
3. CONNECT FUEL HOSE
4. CONNECT VACUUM SENSING HOSE
1. CHECK INJECTOR OPERATION
Check operating sound from the each injector.
(a) With the engine running or cranking, use a sound scope to check that there is normal operating noise in proportion to engine rpm.
(b) If you have no sound scope, you can check the injector transmission operation with your finger.
If no sound or an unusual sound is heard, check the wiring connector, injector, resistor or injection signal from computer.
2. MEASURE RESISTANCE OF INJECTOR
(a) Disconnect the wiring connector from the injector.
(b) Using an ohmmeter, check the continuity of both terminals.
REMOVAL OF INJECTOR
1. REMOVE AIR INTAKE CHAMBER
(See steps 1 to 10 on pages FI-49 to 50)
2. REMOVE DISTRIBUTOR
3. REMOVE N0.1 FUEL PIPE
4. DISCONNECT AND REMOVE WIRING HARNESS
5. REMOVE DELIVERY PIPE WITH INJECTORS
(a) Remove the four bolts, and then remove the delivery pipe with injectors.
• When removing the delivery pipe, be careful not to drop the injectors.
• Do not remove the injector cover.
(b) Remove the six insulators from the intake manifold.
INSPECTION OF INJECTOR
1. TEST INJECTION OF INJECTORS
CAUTION: Keep clear of sparks during the test.
(a) Connect the SST to the fuel filter outlet. SST 09268-41045
(b) Connect the SST to the pressure regulator and the injector.
(c) Hold the injector and hose with SST. SST 09842-30020
(d) Put the injector into the graduated cylinder. NOTE: Install a suitable vinyl tube onto the injector to prevent gasoline from splashing out.
(e) Connect the ground cable to the battery.
(f) Turn the ignition switch ON. NOTE: Do not start the engine.
<g) Using a service wire, short both terminals of the fuel pump check connector.
NOTE: The fuel pump will operate.
Fuel Pump x Check Connector
SST Fuel Filter
SST Fuel Filter
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(h) Connect the SST to the battery for 15 seconds and measure the injection volume with a graduated cylinder.
Test each injector two or three times. If not within specified volume, clean or replace.
Volume: 40 - 50 cc/15 sec. I2.4 - 3.1 cu In.) Difference between each Injector: Less than
NOTE: If not within specified volume, clean or replace the injector.
INSTALL OF INJECTORS
1. INSTALL INJECTORS INTO DELIVERY PIPE
(a) Install the grommet and a new O-ring to the injector.
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