Cleaning Procedure

This procedure should be performed before any attempt to convert the fuel system to MFI.

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

2. Remove the Positive Crankcase Ventilation (PCV) clean air tube from the air inlet tube and set aside.

3. Remove the bonnet and inlet tube from the throttle body.

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

5. Remove the electrical connector from the CSFI fuel metering body.





6. Remove ignition wires 1, 3, 5 from the distributor cap (see figure 1).

7. Remove the fuel line bolt (4) at the rear of the intake manifold (see figure 1).

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





9. Remove the nuts (1) and clamp (2) from the fuel pipe (see figure 2).

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





11. Install the J44466-12 (2) and the J44466-13 (1) to the metering body and tighten. Make sure that the fuel pipe 0-rings, washer, and spacers are present and in their proper position (see figure 3).





12. Install the J44466-11 (4), clamp (2), and J44466-13 (1) to the fuel pipe and tighten (see figure 4).





13. Obtain the J41413, close the valve (2) on the tank, and remove the regulator assembly (see figure 5).

14. Install the J44466-10 (5) to the J41413 tank (3). The J44466-10 regulator is preset to 150 psi (see figure 5).





15. Connect the J44466-10 hose (1) to the J44466-12 (3) (see figure 6).

16. Install the J39021 Injector/Coil Balance Tester, the J39021-210 Injector Tester Adapter Box, and J39021-301 V6 Fuel Injector Test Adapter (1) or J 9021-302 V8 Fuel Injector Test Adapter to the metering body electrical connector (see figure 6).

17. Adjust the amperage selector switch on J39021 to 0.5 amps (see figure 6).





18. Open the valve (2) on the tank (3) (see figure 7).

19. Open the valve (4) on the J44466-10 to pressurize the fuel system. The minimum pressure required on the gauge (6) is 150 psi. If 150 psi. is not obtained, the tank (3) must be refilled prior to performing this procedure (see figure 7).

20. Close the valve (4) on the J44466-10 (see figure 7).

21. Energize one injector using the J39021. 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 (see figure 7).

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

23. Shutoff pressure valve (2) on the tank (3) of the J41413 (see figure 7).

24. Bleed off the pressure at the J44466-10.

25. Disconnect and remove the J44466-10 (5) from the J44466-12, and the J41413 (see figure 7).

26. Remove the J39021-301 or J39021-302, J39021-210, and J39021 from the metering body.

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

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

29. Install ignition wires 1, 3, 5 to the distributor cap.

30. Install the air inlet bonnet to the throttle body, tighten the wing nut.

31. Install the PCV fresh air tube to the air inlet tube.





32. Obtain J35800-A (2). Make sure the valve at the bottom of the canister (3) is closed (see figure 8).

33. Remove the canister top and add 24 ml (0.8 fl. oz.) Top Engine Cleaner, P/N 2-90531-808-0 to the canister.

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

35. Suspend J35800-A from a convenient underhood location.

36. Connect the hose from J35800-A to the service port on the J44466-12.

37. Open the valve (3) at the bottom of J35800-A (see figure 8).

38. Connect a "shop air" source to the fitting at the top of J35800-A and adjust the regulator (1) to 75 psi.

39. Start the vehicle. It may be necessary to re-adjust the J35800-A pressure regulator to maintain 75 psi.

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

41. Remove the shop air supply from J35800-A.

42. Depressurize the J35800-A.

43. Disconnect the J35800-A hose from the J44466-12.

44. Remove the PCV clean air tube from the air inlet tube and set aside.

45. Remove the bonnet from the throttle body, and set aside.

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

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

48. Bleed the residual pressure from the J44466-12.





49. Remove J44466-13 (1) and J44466-12 (2) from the metering body (see figure 9).





50. Remove J44466-13 (1), clamp (2), and J44466-11 (4), from the fuel pipe (3) (see figure 10).





51. Install the fuel pipe (3) to the metering body. Make sure that all of the 0-rings (6 and 8), washers (7), and spacers (5) are present and in their proper position (see figure 11).

52. Install the clamp (2) and nuts (1). Tighten the nuts to 3 N.m (27 lb in) (see figure 11).

53. Apply threadlock, P/N 8-12345-382-0, or equivalent to the threads of the fuel pipe bolt (4). Install the bolt. Tighten the fuel pipe bolt to 6 N.m (53 lb in) (see figure 11).

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

55. Install the bonnet and air inlet tube to the throttle body.

56. Install the PCV fresh air tube to the inlet duct.

57. Install ignition wires 1, 3, 5 to the distributor cap.

58. Add one (1) ounce of Port Fuel Injector Cleaner, P/N 8-12345-104-0 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 added every 3000 miles (4800 km).

59. Tighten the fuel tank filler cap.

60. Start the vehicle and check for fuel leaks.

61. Using the Tech 2 scan tool, check for any stored Powertrain DTC codes. Clear codes as required.

62. Disconnect the Tech 2 Scan tool.

63. Advise the customer to change fuel brand.