M/L, G Van and P Truck

1. Loosen the fuel tank filler cap to relieve fuel tank vapor pressure.

2. Remove the engine cover.





3. Remove ignition wires 1 3, 5, and 7 from the distributor cap.

4. Remove the vacuum brake booster hose and connector from the intake manifold.

5. Remove the fuel pipe bolt (4) at the rear of the intake manifold.

6. Relieve the fuel system pressure at the service fitting on the fuel pipe. Use a shop towel to contain any fuel that may exit the service fitting.





7. Disconnect the fuel pipes (3) at the rear of intake manifold (1).





8. Remove the nuts (1) and clamp (2) from the fuel pipe.

9. Remove the fuel pipes from the metering body. Be careful not to disturb the 0-rings, washer, and spacer in the metering body.

10. Remove the electrical connector from metering body.





11. Install J 44466-12 (2) and J 44466-13 (1) to the fuel metering body and tighten. Make sure that the fuel pipe 0-rings, washer, and spacers are present and in their proper position.





12. Install J 44466-01 (1) to the vehicle fuel lines.





13. Obtain the J 41413, close the valve (2) on the tank, and remove the regulator assembly.

14. Install the J 44466-10 (5) to the J 41413 tank (3). The J 44466-10 regulator is preset to 150 psi. The minimum pressure required on the gauge (6) is 150 psi. If 150 psi is not obtained, the tank must be refilled prior to performing this procedure.

15. Connect the J 44466-10 hose to the J 44466-12.

16. Install J 39021 Injector/Coil Balance Tester, the J 39021-210 Injector Tester Adapter Box, and J 39021-301 V6 Fuel Injector Test Adapter or J 39021-302 V8 Fuel Injector Test Adapter to metering body electrical connector.





17. Adjust the amperage selector switch on J 39021 to 0.5 amps.

18. Open the valve (2) on the tank (3).

19. Open the valve (4) on the J 44466-10 to pressurize the fuel system.

20. Close the valve (4) on the J 44466-10.

21. Energize one injector using the J 39021. Observe a pressure drop on the gauge (6) and verify the injector/poppet valve operation. An injector/poppet that is "stuck" and not operational will have no pressure drop on the gauge. If an injector remains "stuck", repeat the procedure multiple times (as required) until the injector is operational.

22. Repeat steps 19, 20, and 21, for each individual injector to verify that all injector/poppet valve assemblies are "unstuck" and functional.

23. Shut off the pressure valve (2) on the tank (3) of the J 41413.

24. Bleed off pressure at J 44466-10.

25. Disconnect and remove the J 44466-10 hose from the J 44466-12 and the J 41413.

26. Remove the J 39021-301 or J 39021-210, J 39021-210, and J 39021 from the metering body.

27. Install the vehicle electrical connector to the metering body.

28. Install ignition wires 1, 3, 5, and 7 to the distributor cap.

29. Install the vacuum brake booster hose and connector to the intake manifold.





30. Obtain J 35800-A (2). Make sure the valve (3) at the bottom of the canister is closed.

31. Remove the canister top and add 24 ml (0.8 fl. oz.) Top Engine Cleaner, P/N 1050002 (Canada P/N 992872), to the canister.

32. Fill the remainder of the canister with regular unleaded gasoline and install the canister top.

33. Suspend the J 35800-A in a convenient location.

34. Connect the hose from the J 35800-A to the service port on the J 44466-12.

35. Open the valve (3) at the bottom of J 35800-A.

36. Connect a "shop air" source to the fitting at the top of J 35800-A and adjust the regulator (1) to 75 psi.

37. Start the vehicle. It may be necessary to re-adjust the J 35800-A pressure regulator to maintain 75 psi.

38. Let the vehicle run at idle until the canister is empty and the vehicle stalls.

39. Remove the shop air supply from J 35800-A.

40. Depressurize the J 35800-A.

41. Disconnect the J 35800-A hose from the J 44466-12.

42. Remove the vacuum brake booster hose and connector from the intake manifold.

43. Remove ignition wires 1, 3, 5, and 7 from the distributor cap.

44. Bleed the residual pressure from J 44466-12.





45. Remove the J 44466-13 (1) and J 44466-12 (2) from the metering body.





46. Remove the J 44466-01 (1) from the vehicle fuel lines.





47. Install the fuel pipe (3) to the metering body. Make sure the all of the 0-rings (6 and 8), washers (7), and spacers (5) are present and in their proper position.

48. Install the clamp (2) and nuts (1).

Tighten

Tighten the nuts to 3 N.m (27 lb in).





49. Inspect the 0-rings at the fuel pipe-to-vehicle lines (1). Replace as necessary.

Tighten

Tighten the fuel line nuts to 30 N.m (22 lb ft).

50. Apply threadlock, P/N 12345382, or equivalent to the threads of the fuel pipe bolt. Install the bolt.

Tighten

Tighten the fuel pipe bolt to 6 N.m (53 lb in).

51. Install ignition wires 1, 3, 5, and 7 to the distributor cap.

52. Install the vacuum brake booster hose and connector to the intake manifold.

53. Add one (1) ounce of Port Fuel Injector Cleaner, P/N 12345104 (Canada P/N 10953467), to the vehicle fuel tank for each gallon of gasoline estimated to be in the tank. Instruct the customer to add the remainder of the bottle of Port Fuel Injector Cleaner to the vehicle fuel tank at the next fill-up. Further recommend that Port Fuel Injector Cleaner be added to the fuel tank every 3000 miles (4800 km) particularly if the vehicle is not started and driven every day. Inform the customer that the Port Fuel Injector Cleaner is not to be used at every fill up but may be reapplied every 3000 miles (4800 km).

54. Tighten the fuel tank filler cap.

55. Start the engine and check for fuel leaks.

56. Use the Tech 2(R) Scan Tool to check for any stored Powertrain DTC codes. Clear codes as required.

57. Disconnect the Tech 2(R) Scan tool.

58. Install the engine cover.

59. Advise customer to change brands of fuel.