Section 03-04A: Fuel Charging and Controls, 4.9L Engine
1996 Vehicles Equipped with 4.9L SFI Engines Workshop Manual
REMOVAL AND INSTALLATION

Fuel Charging System

 
 

Pre-Service Procedures

 WARNING: FUEL SUPPLY TUBES WILL REMAIN PRESSURIZED FOR LONG PERIODS OF TIME AFTER ENGINE SHUTDOWN. THIS PRESSURE MUST BE RELIEVED BEFORE SERVICING OF THE FUEL SYSTEM IS BEGUN. A VALVE IS PROVIDED ON THE FUEL INJECTION SUPPLY MANIFOLD FOR THIS PURPOSE.

The fuel charging assembly consists of the throttle body (9E926), and the upper and lower intake manifolds (9424). Prior to service or removal of the fuel charging assembly, the following steps must be taken:

  1. NOTE: When the battery (10655) has been disconnected and reconnected, some abnormal drive symptoms may occur while the powertrain control module (PCM) (12A650) relearns its adaptive strategy. The vehicle may need to be driven 16 km (10 miles) or more to relearn the strategy.

    Disconnect battery ground cable (14301) and secure it out of the way.

  1. Remove air cleaner outlet tube (9B659) from air cleaner to throttle body.

  1. Remove fuel tank filler cap (9030) to relieve tank pressure.

  1. Relieve pressure from fuel system at fuel pressure relief valve (9H321) (Schrader) on the fuel injection supply manifold (9D280) as described in the following procedure.

 

Fuel Pressure Relief

 WARNING: FUEL SUPPLY TUBES WILL REMAIN PRESSURIZED FOR LONG PERIODS OF TIME AFTER ENGINE SHUTDOWN. THIS PRESSURE MUST BE RELIEVED BEFORE SERVICING OF THE FUEL SYSTEM IS BEGUN. A VALVE IS PROVIDED ON THE FUEL INJECTION SUPPLY MANIFOLD FOR THIS PURPOSE.

SPECIAL SERVICE TOOL(S) REQUIRED
DescriptionTool Number
Multiport Fuel Injection (MFI) Fuel Pressure Gauge (EFI/CFI)T80L-9974-B

  1. Remove the protective cap from the fuel pressure relief valve.

  1. Connect Multiport Fuel Injection (MFI) Fuel Pressure Gauge (EFI/CFI Fuel Pressure Gauge) T80L-9974-B to the fuel pressure relief valve on the fuel injection supply manifold.

  1. Place end of the adapter hose in a suitable container.

  1. Open the manual valve on the Multiport Fuel Injection (MFI) Fuel Pressure Gauge (EFI/CFI Fuel Pressure Gauge) T80L-9974-B to relieve fuel system pressure.

  1. Close the manual valve and disconnect the tool from the fuel injection supply manifold. Remove container.

  1. Install the protective cap on the fuel injection supply manifold.

 

Post-Service Procedures

After the service is complete and the fuel charging assembly is installed onto engine (6007), the following steps must be taken:

  1. Install air cleaner outlet tube to throttle body.

  1. Install the fuel tank filler cap.

  1. NOTE: When the battery has been disconnected and reconnected, some abnormal drive symptoms may occur while the powertrain control module relearns its adaptive strategy. The vehicle may need to be driven 16km (10 miles) or more to relearn the strategy.

    Connect battery ground cable.

  1.  WARNING: THE FUEL SYSTEM IS NORMALLY PRESSURIZED TO 385 KPA (56 PSI).

    NOTE: Check all connections at fuel injection supply manifolds, push-connect fittings, fuel injectors (9F593), etc.

    Turn ignition switch (11572) on and off several times without starting engine to pressurize the fuel system. Check for fuel leaks at fuel pressure regulator (9C968), fuel injectors and fuel connect fittings.

  1. Start engine and warm to operating temperature.

  1. Perform EEC Self Test to check system's function. Refer to Powertrain Control/Emissions Diagnosis Manual ODBII. Recheck for fuel leaks.