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SUZUKI SV 1000 RADIATOR (COOLING SYSTEM) SERVICE MANUAL

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Filed Under (Suzuki) by admin on 26-02-2011

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FI SYSTEM MALFUNCTION CODE AND DEFECTIVE CONDITION MALFUNCTION CODE DETECTED ITEM DETECTED FAILURE CONDITION CHECK FOR COO NO FAULT C11 Camshaft position sen- sor The signal does not reach ECM for more than 3 sec . after receiving the starter signal . The camshaft position sensor wiring and mechanical parts (Camshaft position sensor, intake cam pin, wiring/coupler con- nection) C12 Crankshaft position sensor The signal does not reach ECM for more than 2 sec . after receiving the starter signal . The crankshaft position sensor wiring and mechanical parts (Crankshaft position sensor, wiring/coupler connection) C13 Intake air pressure sensor The sensor should produce following voltage . (0.50 V < sensor voltage < 4 .85 V) Without the above range, C13 is indicated. Intake air pressure sensor, wiring/coupler connection C14 Throttle position sen- sor The sensor should produce following voltage . (0.20 V < sensor voltage < 4 .80 V) Without the above range, C14 is indicated. Throttle position sensor, wiring/coupler connection C15 Engine coolant temperature sensor The sensor voltage should be the following. (0.15 V <_ sensor voltage < 4 .5 V) Without the above range, C15 is indicated. Engine coolant temperature sensor, wiring/coupler connection C21 Intake air temperature sensor The sensor voltage should be the following. (0.15 V < sensor voltage < 4 .5 V) Without the above range, C21 is indicated. Intake air temperature sensor, wiring/coupler connection C22 Atmospheric pressure sensor The sensor voltage should be the following. (0.50 V < sensor voltage < 4 .5 V) Without the above range, C22 is indicated. Atm. pressure sensor, wiring/coupler connection C23 Tip over sensor The sensor voltage should be the following for more than 2 sec . after ignition switch turns ON . (0 .20 V < sensor voltage < 4 .80 V) Without the above value, C23 is indicated. Tip over sensor, wiring/coupler connection C24 or C25 Ignition signalCrankshaft position sensor signal is produced and ECM determines the ignition signal but signal from ignition coil is interrupted continuous by 4 times or more. In this case, the code C24 or C25 is indicated. Ignition coil, wiring/coupler connection, power supply from the battery SERVICING INFORMATION 8 .3 C28 Secondary throttle valve actuator No operating voltage is supplied from the ECM, C28 is indicated. STVA can not operate. STVA lead wire/coupler, STVA C29 Secondary throttle valve position sensor The sensor should produce following voltage . (0.10 V < sensor voltage < 4 .90 V) Without the above range, C29 is indicated . Secondary throttle position sensor, wiring/coupler connection C31 Gear position signalGear position signal voltage should be higher than the following for more than 2 seconds. (Gear position switch voltage >_ 0 .6 V) Without the above value, C31 is indicated. Gear position sensor, wiring/coupler connection, gearshift cam, etc. C32 or C33 Fuel injector Crankshaft position sensor signal is produced and ECM determines the injection signal but fuel injection signal is interrupted continuous by 4 times or more. In this case, the code C32 or C33 is indicated. Injector, wiring/coupler connection, power supply to the injector C41 Fuel pump relay No voltage is applied to fuel pump although fuel pump relay is turned ON, or voltage is applied to fuel pump although fuel pump relay is turned OFF . Fuel pump relay, connecting lead, power source to fuel pump relay C42 Ignition switchIgnition switch signal is not input in the ECM . Ignition switch, lead wire/coupler C44 Heated oxygen sensor (HO2S) [For E-02, 19] During 02 feedback control, 02 sensor voltage is higher or lower than the specification . No signal is detected during engine operation or no electrical power is supplied from the battery . HO2S lead wire/coupler connection Battery voltage supply to the HO2S C49 PAIR control solenoid valve (PAIR valve) When no operating voltage is supplied from the ECM, C49 is indicated. PAIR valve can not operate. PAIR valve lead wire/coupler

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Harley-Davidson Softail, Touring, Dyna, Sportster and V-Rod, SELF LEARNING MODULE INSTALLATION MANUAL

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Filed Under (Harley Davidson) by admin on 17-04-2012

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STEP 1 – BATTERY CONNECTION Locate the battery and disconnect the negative battery cable. Mount the module in the open area in front of the battery with 2-tie straps or velcro straps, directing the harness from the module towards the 6 o’clock position. STEP 2 – THROTTLE POSITION SENSOR (TPS): Remove the air cleaner assembly and unplug the TPS sensor connector at the TPS sensor. The harness includes (2) TPS connectors which should be routed under the gas tank into the factory wire loom to the TPS sensor. The TPS sensor is located on the left side of the throttle body. Plug the (2) TPS connectors from the module in between the TPS sensor and to the factory TPS connector. STEP 3 – O2 SENSOR: Systems equipped with factory O2 sensors Rear: Unplug the Rear O2 sensor connector from the factory harness, which is located at the Rear exhaust pipe. Route the module’s harness which includes (2) O2 sensor connectors and connect one connector to the Rear O2 sensor and connect the other connector to the main factory O2 sensor connector. Front: Unplug the Front O2 sensor connector from the factory harness, which is located at the Front exhaust pipe. Route the module’s harness which includes (2) O2 sensor connectors, and connect one connector to the Front O2 sensor and connect the other connector to the main factory O2 sensor connector. Systems not equipped with factory O2 sensors NOTE: Many aftermarket exhaust systems are now equipped with plugged O2 sensor bungs which can be removed to accept an aftermarket O2 sensor. Typically these bungs already have a thread size of 18 mm x 1.5 mm. Exhaust systems not equipped with O2 sensor bungs need to have the supplied 18 mm x 1.5 mm thread size bung welded to the exhaust pipe in order to install an O2 sensor. The O2 sensor bung should be installed 3 to 6 inches away from the rear cylinder exhaust port and in front of the exhaust torque tube pipe area. The module prefers to receive information from the O2 sensor from an area that is NOT contaminated from atmospheric air. This air may enter through the tail pipe of an unrestricted or un-baffled exhaust pipe. The bung should not be installed in the “5 to 7 o’clock” area. If mounted in this area the O2 sensor can be damaged. The moisture from the gases exiting from the rear cylinder exhaust port will harm the ceramic shell element of the O2 sensor.

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YAMAHA YZF-R1P/ YZF-R1PC SERVICE MANUAL

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Filed Under (Yamaha) by admin on 25-11-2010

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1Fuel pump 2Pressure regulator 3Fuel injector 4Throttle body 5Intake temperature sensor 6Throttle position sensor 7Intake air pressure sensor 8ECU 9Atmospheric pressure sensor 0Coolant temperature sensor ACylinder identification sensor BCrankshaft position sensor ÈFuel system ÉAir system ÊControl system Illustration is for reference only. 1 – 4 GEN INFO FEATURES Fuel control block The fuel control block consists of the following main components: An engine trouble warning light is provided on meter panel. Component Function Control block ECU Total FI system control Throttle body Air volume control Pressure regulator Fuel pressure detection Sensor block Intake air pressure sensor Intake air pressure detection Atmospheric pressure sensor Atmospheric pressure detection Coolant temperature sensor Coolant temperature detection Intake temperature sensor Intake temperature detection Throttle position sensor Throttle angle detection Cylinder identification sensor Reference position detection Crankshaft position sensor Crankshaft position detection and engine RPM detection Speed sensor Speed detection Actuator block Injector Fuel injection Fuel pump Fuel feed Air Induction system, air cut valve Induction of secondary air A. Power supply circuit The power supply circuit obtains power from the battery (12 V) to supply the power (5 V) that is required for operating the ECU. B. Input interface circuits The input interface circuits convert the signals output by all the sensors into digital signals, which can be processed by the CPU, and input them into the CPU. C. CPU (Central Processing Unit) The CPU determines the condition of the sensors in accordance with the level of the signal that is output by the respective sensor. Then, the signals are temporarily stored on the RAM in the CPU. Based on those stored signals and the basic processing program on the ROM, the CPU calculates the fuel injection duration, injection timing, and ignition timing, and then sends control commands to the respective output interface circuits. D. Output interface circuits The output interface circuits convert the control signals output by the CPU into actuating signals for the respective actuators in order to actuate them. They also output commands to the indicator and relay output circuits as needed.

Harley-Davidson S&S Super E and G Series Shorty Carburetors Installation and Jetting Instructions

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Filed Under (Harley Davidson) by admin on 24-10-2010

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throttle linkage with no cable modification. S&S Super E and G carb kits for 1936 to 1989 Big Twins contain a throttle cable guide (11-2339) designed for butterfly type throttle cables, and kits for 1990 and later Big Twins contain a taller throttle cable guide (11-2338) designed for CV type throttle cables. See Picture 2. The two throttle cable guides are interchangeable on the carburetor body, and can be changed very easily to update older carburetors or to accommodate custom throttle cables which are not stock for a particular year chassis. 1981 to Present Sportster Models Stock Sportster models from 1981 to 1987 have two cable throttle system designed for butterfly type carburetors. Sportsters from 1988 to present have a two cable throttle system designed for use with the stock constant velocity (CV) type carburetor. Since the taller #11-2338 cable guide bracket can not be used on a Sportster chassis due to insufficient frame clearance, throttle cables on Sportsters originally equipped with a CV type carburetor must be changed to butterfly style cables. S&S can supply the correct style throttle cables. See S&S Throttle Cable Application Chart. Picture 2 S&S THROTTLE CABLE APPLICATION CHART Length Total Housing Length Vinyl Housing Part Number Open Side Part Number Close Side Fitment 36″ 32″ #19-0430 #19-0431 For Buell with 7/8″ handlebars 36″ 32″ #19-0432 #19-0433 To ’95 ’81-’85 FX and FL; All ’81-’85 XL (Also pre-’81 w/2-cable throttle housing replaced.) For Buell with 1″ diameter handlebar 36″ 32″ #19-0436 #19-0437 ’96-Up 883-1200 XL 39″ 35″ #19-0434 #19-0435 To ’95 Softail (FXSTC, FXST, FLSTC, FLSTF) ’86-’94 FXR, ’93-’95 Dyna 39″ 35″ #19-0438 #19-0439 ’96-Up Softail (FXSTS, FXSTC, FLSTC, FLSTF) ’96-Up Dyna 42″ 38″ #19-0446 #19-0447 To ’95 custom application 42″ 38″ #19-0440 #19-0441 ’96-Up custom application 48″ 44″ #19-0462 #19-0463 To ’95 All FLT Models 48″ 44″ #19-0464 #19-0465 ’96-Up All FLT Models ” 1996 to Present Buells 1996 and 1997 Buells require special S&S butterfly style throttle cables for Buells, which are compatible with the stock 1996-1997 throttle assembly. 1998 and later carburated Buells require installation of stock 1996 – 97 throttle grip and the special S&S Buell style throttle cables when installing Super E or G carburetors. S&S Throttle Kits S&S throttle kits fit 1″ handlebars and can be used on most chassis. (An adapter sleeve is available for use with earlier, 7 ⁄ 8 ” OEM handlebars originally equipped with internal throttle cable.) Barrel fittings on S&S cables readily “plug in” to S&S Super E, G, and stock H-D 1981-’90 butterfly type carb throttle linkage. Kits include one opening and one closing side cable, left and right grips, and handlebar clamps. Kits with 36″, 39″, 42″, or 48″ length cables are available. Length specified refers to overall cable length. Vinyl covered outer housing is 4″ shorter than overall length

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HARLEY DAVIDSON MULTI-FIT BRAIDED THROTTLE/ IDLE CABLE KITS REMOVAL AND INSTALLATION INSTRUCTIONS

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Filed Under (Harley Davidson) by admin on 01-02-2011

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REMOVAL To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a) 1. Disconnect battery cables, negative (-) cable first or remove the main fuse following the instructions in the service manual. NOTE When performing cable disassembly procedures, make careful notes as to the existing cable routing. Pay special attention to existing cable strap locations before removing so new straps can be placed into the same locations. Do not remove or install the master cylinder assembly without first positioning a 5/32-inch (4 mm) thick insert between the brake lever and lever bracket. Removing or installing the master cylinder assembly without the insert in place may result in damage to the rubber boot and plunger on the front stoplight switch. (00324a) 2. See Figure 1. Place the cardboard insert between the brake lever and lever bracket. 3. See Figure 2. Loosen cable adjuster jam nuts. Turn cable adjusters in until they are as short as possible. This will provide enough slack for easy removal. 4. Remove the right upper and lower switch housing screws INSTALLATION Throttle and Idle Cable Installation 1. See Figure 3. Apply graphite lightly to the throttle grip inside the switch housing and on the throttle end of the handlebar. NOTE The throttle control cable has a larger diameter retaining ring crimped to the cable end than does the idle control cable. For assembly, apply a drop of light oil on the retaining rings of the crimped inserts. 2. See Figure 7. Push the throttle cable housing and retaining ring into the larger hole of the switch housing, located in front of the tension adjuster screw. 3. Push the idle cable housing and retaining ring into the smaller hole of the switch housing, located behind the tension adjuster screw. 4. Push the throttle and idle control cable housings into the lower switch housing until each snaps into place. NOTE For models not equipped with factory-installed cruise control, if the friction shoe has fallen out or become dislodged, install the shoe with the concave side facing up and position it so the pin hole is over the point of the adjuster screw. 5. Push the throttle control grip over the end of the right handlebar until it bottoms against the closed end. Rotate the grip until the ferrule notches are at the top. To prevent binding, pull the grip back about 0.12 inch (3.2 mm). 6. See Figure 3. Position the lower switch housing beneath the throttle control grip. Install two brass ferrules (Item 3, Figure 11) from this kit onto cables, seating the ferrules in their respective notches on the throttle control grip. The cables must be captured in the grooves molded into the grip. 7. Position the upper switch housing over the handlebar and lower switch housing. Route the wire harness conduit through the depression at the bottom of the handlebar. 8. Tighten the upper and lower switch housing screws finger- tight. 9. Position the brake lever/master cylinder assembly inboard of the switch housing assembly, engaging the tab on the lower switch housing in the groove at the top of the brake lever bracket. 10. Align the holes in the handlebar clamp with those in the master cylinder housing and tighten the lower screw and flat washer finger-tight. Position for rider comfort. Beginning with the top screw, tighten the screws to 60-80 in-lbs (6.8-9.0 Nm)

WEGO II Wide-Band Exhaust Gas Oxygen Sensor Interface Installation Instructions

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Filed Under (Tips and Review) by admin on 27-10-2010

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1. Turn off the ignition switch before proceeding. 2. Select a convenient mounting location for the Bosch sensor. In general, the sensor should be mounted as close to the exhaust valve or exhaust manifold as practical. When choosing a mounting location, allow several inches clearance for the sensor wire harness. The wire harness must exit straight out from the sensor. Do not loop the harness back onto the sensor body. The sensor responds to oxygen pressure. Excessive backpressure will cause a reading error. For turbocharged applications, you must mount the sensor downstream of the turbo. 3. For temporary use during dyno tuning, you can mount the Bosch wide-band sensor in place of one of the original equipment rear oxygen sensors (after the catalytic converter). You can also use a sniffer in the tailpipe. For permanent mounting, an 18 x 1.5 mm weld nut must be welded onto the exhaust pipe. After welding, run an 18 x 1.5 mm tap through the threads. Failure to clean the threads may result in sensor damage. Note that most automotive muffler shops are familiar with oxygen sensor weld nut installation on custom pipes. Do not install the sensor until after the free air calibration procedure described in the following section. Always use an anti-seize lubricant such as Permatex 133A on the sensor threads. 4. Install the WEGO II unit. The WEGO II unit should be mounted where the LCD display will be visible during testing. You can secure the WEGO II unit with Velcro tape strips. 5. Connect the Bosch sensor to the 6 pin mating connector on the WEGO II wire harness. 6. Refer to Figure 1. Connect the black WEGO II wire to frame ground using the supplied ring terminal. Try to use an existing wire harness ground location. Do not extend the WEGO II ground wire or ground the WEGO II to the battery minus terminal or to the engine. 7. Connect the red WEGO II wire to switched +12 volt power. You can usually find switched +12V power at an accessory fuse on the fuse block. You can use the supplied fuse tap and 3/16″ female crimp terminal for this purpose

2001-2002 GL1800 A ABS Speed Sensor Wire Clamp Location INSPECTION/ REPAIR PROCEDURES

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Filed Under (Honda) by admin on 29-01-2011

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1. If the VIN is within the preceeding range, inspect the front ABS speed sensor wire clamp according to the following illustrations. 2001-2002 GL1800A ABS Speed Sensor Wire Clamp Location INCORRECT Installation CORRECT Installation Service Bulletin American Honda Motor Co., Inc. 2001-2002 GL1800 ABS Speed Sensor Wire Clamp Location 0112 GL1800 #9*GL1800 #9*0112*2001-2002 GL1800 ABS Speed Sensor Wire Clamp Location*GL1800, ABS Speed Sensor Wire Clamp Location*Motorcycle*1800 2 of 2 ©2001 American Honda Motor Co., Inc. – All Rights Reserved GL1800 #9 DECEMBER 2001 IDENTIFICATION There is no identification mark associated with this Service Bulletin. PARTS INFORMATION There is no parts information associated with this Service Bulletin. WARRANTY INFORMATION The normal warranty claim submission requirements apply. Submit one warranty claim per VIN with the following information only: Inspected and REPAIRED Template: GL#9 Hours: 0.2 hours Parts: None If the clamp is installed correctly on top of the speed sensor, no further action is necessary. 3. If the clamp is installed incorrectly under the speed sensor, remove and reinstall the clamp and speed sensor correctly. Torque the bolts,. Torque: 12 N • m (1.2 kgf • m, 9 lbf • ft) If the speed sensor wire clamp for the front ABS speed sensor is installed incorrectly, the ABS speed sensor air gap may be out of specification. This does not affect ABS speed sensor operation, but the clamp should be installed correctly. Inspect and repair all affected units using the Inspection/Repair procedures listed below. Inspect all unsold units and customer units brought in for service. AFFECTED UNITS 2001-2002 GL1800A units as follows: MODEL 2001 GL1800A All units 2002 GL1800A 1HFSC474*2A100001 – 1HFSC474*2A101643 * = denotes check digit Any unit in the above VIN range may be affected and should be inspected according to the procedures in this Service Bulletin. All units outside of the above VIN range do not require inspection. CUSTOMER NOTIFICATION There is no customer notification associated with this Service Bulletin.

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WEGO IV Wide-Band Exhaust Gas Oxygen Sensor System Installation Instructions

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Filed Under (Harley Davidson) by admin on 21-04-2012

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1. Turn off the ignition switch before proceeding. 2. Select a convenient mounting location for the Bosch sensor. In general, the sensor should be mounted as close to the exhaust valve or exhaust manifold as practical. When choosing a mounting location, allow several inches clearance for the sensor wire harness. The wire harness must exit straight out from the sensor. Do not loop the harness back onto the sensor body. The sensor responds to oxygen pressure. Excessive backpressure will cause a reading error. For turbocharged applications, you must mount the sensor downstream of the turbo. 3. For temporary use during dyno tuning, you can mount the Bosch wide-band sensor in place of one of the original equipment rear oxygen sensors (after the catalytic converter). You can also use a sniffer in the tailpipe. For permanent mounting, an 18 x 1.5 mm weld nut must be welded onto the exhaust pipe. After welding, run an 18 x 1.5 mm tap through the threads. Failure to clean the threads may result in sensor damage. Note that most automotive muffler shops are familiar with oxygen sensor weld nut installation on custom pipes. Do not install the sensor until after the free air calibration procedure described in the following section. Always use an anti-seize lubricant such as Permatex 133A on the sensor threads. 4. Install the WEGO IV unit where the display will be visible during testing. The unit is not sealed and must be mounted in a dry location away from sources of heat. We recommend underdash mounting or use in a dyno lab environment. The unit is not intended for underhood mounting. The unit can be secured by means of Velcro tape strips. Use nylon tie wraps to secure the wire harness near the unit. 5. Working with clamping terminal blocks . All connections to the WEGO IV terminal block must be clearly identified either by means of distinct wire colors (such as shown in Figure 1) or wire labels. If you use different wire colors, mark up Figure 1 for future reference. All connections can be made with 18-20 AWG wire. Wire should be stripped back

2006-up Harley-Davidson Single Bore Induction System Installation Instructions

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Filed Under (Harley Davidson) by admin on 10-11-2010

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Remove the stock fuel induction system, including the manifold and disconnecting all wire connections. It is up to the technician as to whether the gas tank should be removed or just raised up in the rear. Picture 1 2- You will need to disassemble the stock induction system to remove the pre-listed parts for re-use. 3- Verify the new manifold size is appropriate for your motorcycle by sliding it in place. Picture 2 Picture 3 4 5- Slide the MAP sensor in place, being sure not to pinch the orange rubber seal—some clean engine oil may make this easier. Install the cable guide and verify it is aligned with the throttle cable actuator. Once alignment is satisfactory, apply Loctite® 222 to the 10-24 x 1/4″ screws and tighten to 18-22 in-lbs. 4- Install the new O-ring into the throttle body. A light film of clean engine oil can be used to help hold the O-ring in place. Align the manifold to the throttle body, use purple 222 Loctite® on the 10-24 x 1″ socket-head assembly screws (with flat washers) and tighten them to 35-40 in-lbs. 6- Using the new S&S® supplied gasket, slide the S&S supplied intake air temperature (IAT) sensor in place. Use Loctite 222 on the T10 Torx button head M3 x .5 x 10mm screws and tighten to 6-8 in-lbs. Picture 4 Picture 5 Picture 6 5 7- For the stock throttle position sensor attach the “C” shaped spacer to the end of the throttle shaft, put a 4mm flat washer on each T20 Torx button head M4 x .7 x 12mm screw, apply some Loctite® 222 and torque screws to 18-23 in-lbs. 8- Install the new O-ring on the IAC motor. Lubricate the OD of the O-ring with a light film of clean engine oil. Put a 4mm flat washer on each T20 Torx button head M4 x .7 x 12mm screw, coat the threads with Loctite 222. Install the IAC motor and tighten the screws to 18-23 in-lbs. 9- Partially install the fuel injectors in the fuel rail. Be sure to orient the black O-rings to the rail and align the clocking tabs with their holes. It may be helpful to lubricate the O-rings with clean engine oil. See Picture 9. NOTE : These are special O-rings that seal pressurized gasoline. If you see one with damage or an abrasion—replace it immediately. Picture 7 Picture 8 Picture 9 6 10- Connect the Injectors to the manifold with a light squeezing action. Lubricate the O-rings with clean engine oil. Once in place, use Loctite® 222 on the threads of two 8-32 x 5/8″ slotted panhead screws and tighten to 15-20 in-lbs. 11- Install the backing washer and O-ring on the fuel supply tube. Lubricate the O-ring with clean engine oil. When the tube is in place, position the Y-shaped clip on the fuel rail and tighten the Loctite 222 coated T20 Torx button head M4 x 7 x 12mm screw to 18-23 in-lbs – Gently push the injectors downward toward the manifold to increase clearance for connecting the wire connectors. Cut the existing injector connectors from the motorcycle harness. Slide the sleeveing onto the injector harness. Slide heat shrink tubing on to each wire of the injector harness wires. Crimp the butt splices to the motorcycle harness. Move the heat shrinks over the splices and shrink with a heat gun. Slide the sleeve into place. Picture 10 Picture 11a Picture 11b Picture 12 Picture 12a 7 13- Put the stock manifold flanges on the manifold. YOU MUST USE THE S&S® RUBBER GASKETS ON THEM. Be sure to orient the tapered end towards the manifold and the flat end to the heads. 14- Hold the manifold up in its basic mounting position and connect all of the wiring harness connectors at this time. Install the manifold using the stock mounting flange bolts (from the primary side of the motorcycle) coated with Loctite® 242 and the new S&S cam side screws (1/4″ socket head, 5/16-18 x 3/4″). If a screw longer than 3/4″ is used, damage to the heads will result. Lightly snug all four manifold mounting bolts but DO NOT TIGHTEN AT THIS TIME. Connect the throttle cables and cruise control bracket (if applicable) at this time. NOTE: The Harley-Davidson® service manual for your model motorcycle will be helpful during this step. 15- Install the breather system now. On 4.00-inch bore or smaller engines the breather uses banjo fittings with hollow bolts and connects across the heads to the intake with a T-hose. This hose will need to be trimmed and have spring clamps attached as shown in photo. Torque the hollow bolts to 10-12 ft-lbs. On 41/8-inch bore or larger engines, install the sharp bent hose on the rear head and install the check valve with the white end towards the head. Mount the other hose on the black end of the check valve and connect it to the throttle body using spring clamps to secure the connections. Picture 13 Picture 14 Picture 15 8 16- Once the breathers are secure, install the fuel line per the factory service manual you are working with. Connect the battery and verify the fuel pump turns on to pressurize the system and there are no gas leaks, but DO NOT START THE ENGINE. At this time, PC software may also be used to verify sensor readings and adjust the throttle position sensor voltage if necessary. 17- Install two 242 Loctite® coated pipe plugs (included in kit) in the air cleaner backplate as shown in Picture 16. Torque to 35-45 in-lbs. Also, two pan screws coated with Loctite® 222 must be installed in the backplate in place of the enrichment device. See Picture 16a. Torque them to 12-18 in-lbs. Failure to install these screws could allow dirt and debris into the intake system. 18- Use a new gasket on the backplate and put it in place noting the number of shims required. Once you select the appropriate shims (included) mount the backing plate to the engine but DO NOT INSTALL THE SCREWS YET

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TERMS AND DEFINITIONS OF FUEL INJECTION MANAGEMENT SYSTEMS

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Filed Under (Tips and Review) by admin on 19-11-2010

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Throttle Body Assembly (TBA) — The throttle body assembly (also called air valve), controls the airflow to the engine through one, two or four butterfly valves and provides valve position feedback via the throttle position sensor. Rotating the throttle lever to open or close the passage into the intake manifold controls the airflow to the engine. The accelerator pedal controls the throttle lever position. Other functions of the throttle body are idle bypass air control via the idle air control valve, coolant heat for avoiding icing conditions, vacuum signals for the ancillaries and the sensors. FUEL INJECTOR — There are basically three approaches in delivering the fuel to the engine: • Above the throttle plate as in throttle body injection • In the intake port toward the intake valves as in multi-port injection or central multi-port injection. • Directly into the combustion chamber as in gasoline direct injection systems (GDI). The fuel injector is continuously supplied with pressurized fuel from the electric fuel pump. The pressure across the metering orifice of the injector is maintained constant by the fuel pressure regulator. The fuel injector is an electromagnetic valve that when driven by the ECU delivers a metered quantity of fuel into the intake manifold (or combustion chamber in the GDI system). The ECU controls the fuel flow by pulse width modulation. The time the injector is driven into an open condition is determined by the following sensor inputs: • Engine RPM • Throttle position (TPS) • Manifold absolute pressure or mass air flow • Engine coolant temperature • Oxygen sensor feedback voltage • Intake air charge temperature • Battery voltage CENTRAL POINT INJECTION SYSTEM (CPI) — Electronic fuel Injection system consisting on a single fuel injector mounted in the throttle body. DIGITAL FUEL INJECTION (DEFI OR DFI) — Electronic fuel injection system controlled by digital microprocessors as opposed to earlier systems that were of analog design. The analog input signals to the microprocessor are converted from analog to digital before being processed.

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