CHAPTER 4

SERVICING OF
DIFFERENT ENGINE
SYSTEMS
Fuel Supply
System
Service
 Fuel Supply Systems Scanning

 Scan for diagnostic trouble codes

before starting repairs
 Vehicles equipped with OBD II systems
may monitor fuel tank pressure, fuel line
pressure, fuel level, and other
conditions
 Data stream operating values may be
available for the circuit, which can
speed troubleshooting
 Fuel Tank Service
 Typical fuel tank problems include,

fuel leakage,

Physical damage, and

contamination
 Vibration or rusting can cause a
fuel tank to develop pinhole leaks
 Fuel Tank Removal
 Empty the tank using the drain plug
or by pumping the fuel out of the
tank using an approved method
 Special pumping systems with catch

tanks are available

 use extreme care because of the
obvious fire hazard
 do not use an incandescent trouble
light, which could drop and break,
lighting a fire
 Fuel Tank Removal

 A vehicle’s electric fuel pump may be used

to empty the tank
 disconnect the fuel hose at the main fuel
line and route it into an approved gas can.
 turn the ignition key on and allow the fuel
pump to force fuel from the tank to the
can.
Fuel Tank Removal

Draining the tank

 Fuel Tank Removal

 After draining, remove the tank from the

vehicle
 Disconnect the filler neck, fuel lines, wires,
and other components
 Remove the straps or bolts holding the tank
to the body
 Slowly lower the tank without dropping or
hitting it
 Fuel Tank Installation

 When installing a tank, replace the

rubber insulators
 Check that all fuel lines are properly
secured
 Replace the fuel in the tank
 Check for leaks
 Sending Unit Service

 When a fuel gauge does not work properly,

use a gauge tester before condemning the
sending unit
 If the gauge does not function with the
tester installed, either the gauge or the
circuit is faulty
 If the gauge functions with the tester
installed, replace the sending unit
 Sending Unit Service

Gauge tester
connected to
the harness
Sending Unit Service

Using a cam tool to remove the

cam lock ring
 Sending Unit Service

A long drift punch and light hammer

blows will rotate the lock ring
 Sending Unit Service

With the sending

unit removed,
measure its
resistance
 Fuel Line and Hose Service
 Faulty fuel lines and hoses are
common sources of fuel leaks
 Fuel hoses can become hard and

brittle from exposure to engine

heat and the environment
 Engine oil softens and swells
hoses
 Metal lines should be replaced

when smashed, kinked, rusted, or

leaking
Fuel Line and Hose Service

Inspect fuel lines, hoses, and fittings

for leakage and damage
Fuel Line and Hose Service

To disconnect this fitting, press down

on the locking tab while pulling apart
Fuel Line and Hose Service

To reconnect this fitting, simply push

the two halves of the fitting together
 Fuel Line and Hose Service

When installing fuel hoses, make sure

they are pushed completely over raised
areas on the fuel line
Fuel Line and Hose Service Rules

 Remember these rules when working with

fuel lines and hoses:
 Place a shop rag around the fuel line fitting
during removal
 Only use double-wall steel tubing
 Make smooth bends in tubing
 Form double-lap flares on the ends of the
fuel line
Fuel Line and Hose Service Rules

Basic steps for making a new fuel line

 Fuel Line and Hose Service Rules

 Reinstall all fuel line hold-down clamps

and brackets
 Route all lines in their original location
 Use a recommended tool to release clip-
type fittings
 If a plastic line or fitting is damaged,
replace it
Fuel Line and Hose Service Rules

 Avoid bending or rerouting stiff, used

plastic lines
 Cover plastic fuel lines with a wet
towel when welding, cutting, or
grinding nearby
 Use approved synthetic rubber fuel
hose in a fuel system
 Fuel Line and Hose Service Rules

 Make sure a fuel hose fully covers its

fitting or line before installing the
clamps
 When servicing press-fit line fittings,
you may need to replace the O-ring
seal to prevent fuel leakage
 Double-check all fittings for leaks
 Fuel Filter Service
 Involves periodic replacement or cleaning of
system filters
 Clogged fuel filter
 can restrict flow to the injectors, diesel injection
system, or carburetor

 Clogged in-tank strainer

 when clogged, the strainer can collapse and stop
fuel flow
 the strainer will open again after the engine stalls
 Fuel Pump Service

 Fuel pump problems include:

 low fuel pressure
 high fuel pressure
 fuel pump noise
 fuel leakage
 Fuel Pump Service

 Low fuel pump pressure

 caused by worn components, high
resistance in the electric pump circuit,
or leaking check valves

 High fuel pump pressure

 caused by an faulty pressure relief
valve or fuel pressure regulator
 Fuel Pump Service
 Fuel pump noise
 caused by bearing and part wear on
electric pumps
 caused by faulty rocker arm spring or
rocker arm wear on a mechanical pump
 Fuel pump leaks
 caused by diaphragm or gasket leaks on a
mechanical pump
 inline electric fuel pumps often leak from
inlet and outlet hoses
 leakage may contaminate the engine oil or
leak externally
 Fuel Pump Tests

 There are three common fuel pump

tests available:
 fuel pump pressure test
 fuel pump volume test
 fuel pump vacuum test
 Fuel Pump Tests

 Several other problems can produce symptoms

similar to those caused by a faulty fuel pump:
 restricted fuel filters
 damaged fuel lines or hoses
 air leak in the vacuum side of the pump
 injection or carburetor problems
 ignition problems
 engine mechanical problems (low compression)
 Fuel Pump Pressure Test

 Connect a pressure gauge to the output line of

the fuel pump
 fuel injected engines often have a service
fitting on the fuel rail
 To test a mechanical pump, start the engine and
allow it to idle
 To test an electric pump, you may need to
activate the pump motor or start the engine
 Fuel Pump Pressure Test

 Compare gauge readings to specifications

 If fuel pressure is not within specs, check
the pressure regulator, pump volume, fuel
lines, and filters before replacing the pump
 Isolate the fuel pressure regulator from the
pump by restricting the return line
 If pressure rises sufficiently, the problem
may be in the regulator
 Fuel Pump Pressure Test

 General fuel pressure specifications:

 Gasoline injection fuel pressure
 15–40 psi (100–280 kPa)
 Diesel supply pump pressure
 6–10 psi (40–70 kPa)
 Carbureted engine fuel pressure
 4–6 psi (30–40 kPa)
 Fuel Pump Volume Test

Route the output

line from the fuel
pump into a
graduated
container
 Fuel Pump Volume Test

 With the pump running, allow fuel to

pour into the container for the
prescribed amount of time
 Close off the valve
 Compare the volume to specifications
 General volume specification:
minimum of 0.47 liters in 30 seconds
 Fuel Pump Vacuum Test

Connect a vacuum gauge to the

inlet side of the pump
 Fuel Pump Vacuum Test

 Activate the pump

 With the pump running, compare the vacuum
reading to specifications
 General vacuum specifications:
7–10 in. Hg.

 If the pump failed the pressure or volume

tests but passed this test, the fuel supply
lines or filters may be at fault
Electric Fuel Pump Circuit Tests

 Many electric fuel pump problems

are caused by electrical circuit
problems
 Broken wires, faulty relays, shorts,
blown fuses, computer
malfunctions, and other problems
can affect electric pump operation
Electric Fuel Pump Circuit
 Supply Voltage Test

If a pump fails its performance tests,

measure the supply voltage to the motor
 Supply Voltage Test

If supply voltage is low, use a service

manual schematic to find problem areas
 Testing the Fuel Pump Relay

Energize the relay and check continuity

 Inertia Switch

 Used to open the fuel pump circuit after a

severe impact or collision
 Safety device that can prevent a serious fire by
shutting off the pump in a collision
 Usually located in the trunk or near the electric
fuel pump
 After a collision, a button on the switch must be
pressed to reset the switch and enable the
pump
Fuel Pump Removal and Replacement

 To remove a mechanical pump,

disconnect the fuel lines and unbolt
the pump
 Use a new gasket when installing a
pump
 Torque the fasteners to
specifications
Fuel Pump Removal and Replacement
Fuel Pump Removal and Replacement

To remove an in-line electric pump,

disconnect the fuel fittings and wires
Fuel Pump Removal and Replacement

 To remove an in-tank electric pump, the

fuel tank must often be removed from
the vehicle
 Some vehicles are equipped with a fuel
pump access door in the trunk or under
the rear seat
 the access door allows pump removal and
replacement without tank removal
 Fuel Pump Rebuilding

 Older mechanical fuel pumps are

held together with screws and can
be overhauled if parts are available
 Most mechanical and electric
pumps are replaced, rather than
rebuilt
 Air Filter Service

 An air filter removes dirt and dust

from the air entering the engine
intake manifold
 Air filter service involves replacing
or cleaning the filter element
 Paper elements are usually
replaced with a new unit
 Air Filter Service

When replacing
a filter element,
wipe out the
filter housing
Air Filter Assembly
Carburetor Diagnosis,
Service, and Repair
 Contents

 Carburetor problem diagnosis

 Carburetor removal
 Carburetor body sections

 Carburetor rebuild

 Carburetor installation

 Computer-controlled carburetor
service
Carburetor Problem Diagnosis

 Visually inspect carburetor

 Check for leaking fuel, sticking choke,
bending linkage, and missing or
disconnected vacuum hoses
 Check the rest of the engine
compartment for disconnected wires
and vacuum leaks
 Carburetor Inspection

External
check may
find the
source
of the
problem
 Exhaust Gas Analyzer

 Measures chemical content of exhaust

 Used to determine air-fuel mixture

 Measures amount of:

 carbon monoxide (CO)

 hydrocarbons (HC)

 carbon dioxide (CO2)

 oxygen (O2)

 nitrogen oxides (NOX)

 Float System Problems

 Symptoms:
 flooding
 rich mixture
 lean mixture
 fuel starvation
 stalling
 engine miss
 Float System Problems

May affect
operation at
all speeds
since it feeds
all carburetor
circuits
 Cond’t

High Float Level Low Float Level

 Symptoms:  Symptoms:

 rich mixture lean mixture

 high fuel high speed miss

consumption stalling when
 black exhaust cornering
smoke
 Idle System Problems
 Symptoms:
 rich mixture
 lean mixture
 rough idle
 stalling
 incorrect idle speed

 If turning mixture screws does not

change idle speed, idle circuit is not
working properly
 Idle System Problems

Appear at
very low
engine
speeds
 Idle System Inspection
 Tiny bits of dirt can upset the idle
circuit
 Clogged idle passage
 restricts fuel flow to the idle
port
 lean mixture and poor idle
quality
 Clogged idle air bleed
 obstructs air for atomizing fuel
 rich mixture
Acceleration System Problems

 Symptoms:
 hesitation
 stalling

 backfiring
 Acceleration System Problems

Possible
causes of
hesitation
on
accelerati
on
 Pump Inspection

 If accelerator pump does not squirt

a strong stream of fuel into the air
horn as the throttle is opened,
mixture will be too lean.
 Stream should start as soon as the
throttle is moved.
 High-Speed System Problems

 Symptoms:

 lean air-fuel mixture (engine

miss at cruise)
 rich air-fuel mixture (poor fuel
economy)
 surge
 High-Speed System Problems

A very
simple
and
dependa
ble
system
High-Speed System Inspection

 Very reliable circuit

 Faulty mixture control

solenoid or computer-control
circuit may cause high-speed
system problems
Full-Power System Problems

 Symptoms:

poor economy
limited engine power when
passing another car
 Bad Power Valve

 Diaphragm may stretch or rupture

 Ruptured valve allows fuel to leak into

vacuum passage
 Symptoms:

 very rich mixture

 rough idle

 poor economy
Metering Rod Adjustment

 Too far into jet:

causes a lean mixture

 Too far out of jet:

causes a rich mixture

 Choke System Problems

 Symptoms:

 poor performance when cold or

right after startup
 black smoky exhaust

 stalling

 improper idle speed

 Choke should close only when cold
 Choke System Problems

Appear
when the
engine is
started
cold
 Choke Problems

 Sticks open

 the engine may not start when cold

 Sticks closed

 causes super-rich mixture or black

smoke
 the engine runs rough
 Choke Adjustment
 Rich setting
 choke too far closed
 causes poor performance when
engine reaches operating temperature
 Lean setting
 choke too far open
 the engine is hard to start in cold
weather
 the engine stalls under acceleration
when cold
 Fast Idle Cam

 Improper adjustment may cause

stalling after startup or engine racing
for extended periods during warm-up
 Problems can stem from choke
problems or improper linkage
adjustment
 Carburetor Removal

Use safe
procedures
to avoid fuel
spills
Label
vacuum
hoses and
wires
Carburetor Body Sections

 Upper body
 fits on top of main body
 lid for the fuel bowl
 Main body
 largest section
 forms the air horn and fuel
bowl
 Throttle body
 lower section
 contains the throttle valves
Carburetor Components
 Disassemble and Clean

 Disassemble the carburetor

 Remove all plastic and rubber parts

 Soak the metal parts in decarbonizing
cleaner
 Rinse all parts

 Dry with compressed air, forcing air

through all passages
 Visual Inspection
 Check for:
 wear in the throttle body and throttle
shaft
 bending choke and linkage
 damaged carburetor body sections

 float leakage or weight

 mating surface condition
 damaged springs, fasteners, mixture
screws, etc.
 Reassemble

 Replace parts as necessary,

using the proper overhaul kit
 Use the number tag on the
carburetor
 During assembly, perform
specified adjustments
Check Float Drop Setting
Distance float can move down in bowl
Rough Idle Mixture Adjustment

Adjust idle mixture screws

Choke Linkage Adjustment

 Set almost fully closed when

engine is cold
 See service manual procedure

 Adjustment may require tang

bending or housing rotation
 Accelerator Pump Adjustment

 Adjust so that fuel squirts into the

air horn as soon as the throttle is
moved off idle
 Adjustments are done by bending
linkage rods or arms and changing
rods in their holes
 Carburetor Installation

 Install using a new base gasket

 Fit the carburetor on the manifold
 Install the fasteners
 Install all lines, hoses, and wires
 Hand operate the throttle and choke
valves to make sure they are not
bending
 Verify fuel connection before startup
to avoid fire
 After startup, perform final
adjustments
 Fast Idle Speed Adjustment

Install tachometer

Warm engine to operating temperature

Set emergency brake and block wheels

Set fast idle screw on specified step of

fast idle cam

Adjust speed to specification

 Fast Idle Speed Adjustment

Turn fast idle screw, use a tach to

measure engine rpm
 Hot Idle Speed Adjustment

Turn solenoid
adjusting
screw to
specified idle speed
Curb Idle Speed Adjustment

 Disconnect wires from idle speed

solenoid
 Adjust idle speed screws to
specified idle speed
Curb Idle Speed Adjustment

The screw moves the throttle when

turned
 Idle Mixture Adjustment

 Manual adjustment requiring a setting

between lean miss and rich miss
 Propane enrichment adjustment
provides a leaner, cleaner setting
 Exhaust gas analyzer may be used to
achieve specified emission limits
Carburetor Parts
 Computer-Controlled Carburetor Service

 May have self-diagnostics

 Dwell meter measures computer’s

signal to the mixture-control
solenoid
 Hand pump may be used to check
for air or fuel leakage through the
mixture-control solenoid
 E ND
THE