Hisun HS200UTV, Service Manual

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ENGINE MANAGEMENT SYSTEM
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 Place the bolts on module cover and tighten the bolts gradually in star pattern sequence to
apply equal compression on gasket. It is shown in figure as below. Bolt Tightening Torque:
3~4 Nm.
Fuel module is installed with special bolts (step bolts). Use designated bolts only. Follow
the tightening torque and tightening sequence instruction.Over torque and
miss-sequence can cause unequal compression of gasket and leakage.
 Install the fuel tank to vehicle.
 Connect for fuel hoses with suitable hose clamps.
 Connect fuel module coupler.
 Follow “Fuel Leakage Check Procedure’ to check any leakage before the engine is started
。
Mounting Bolts – Star Tightening Pattern
5. Pressure Regulator Assembly Replacement:
 Remove the regulator retainer from module.
 Apply gradual pull force on retainer to avoid any personal injury due to spring action of
retainer.
 Take out the pressure regulator assembly from module.
 Do not hit/ damage on the regulator dome and crimping portion.
 Lubricate the O-rings in new pressure regulator assembly with recommended lubrication
oils as mentioned in Table no: 3. Lubrication oil is applied only for ease of regulator
assembly.
 Make sure that 2 O-rings (one is bigger diameter the other is smaller diameter) are
assembled in pressure regulator.
 Place the pressure regulator on module at regulator pod. Push the regulator gently in the
pod.
 Do not hit/ damage on the regulator dome and crimping portion. This will disturb the
pressure setting.
 Assemble the retainer on the regulator pod
 Replace the gasket, module with new gasket provided in the kit.
6. Fuel Pressure Relief Procedure:
NOTE
This work must not be done when engine
is hot. If done so, it may cause adverse effect to
catalyst (if equipped)
ENGINE MANAGEMENT SYSTEM
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After making sure that engine is cold, relieve fuel pressure as follows.
 Place vehicle gear in ‘Neutral’.
 Disconnect fuel module electrical coupler from vehicle harness.
 Start engine and run till it stops due to lack of fuel. Repeat ignition key ON and OFF for 2 ~ 3
times of about 3 seconds each time to relieve fuel pressure in lines. Fuel Connections are
now safe for servicing.
 Upon the completion of servicing, Connect Fuel Module Connector to Vehicle Harness.
7. Fuel Leakage Check Procedure:
After performing any service on fuel system, check to make sure that there are no fuel leakages
as below.
 Fill about 3 ~ 5 liters of fuel in tank.
 Turn Ignition key to ON position for 3 seconds (to operate fuel pump) and then turn to OFF
position. Repeat this for 3 ~ 4 times to apply fuel pressure in fuel lines.
 In this state, check to see that there are no fuel leakage from any part of fuel system (Fuel
Tank, Hoses, Hose Joints, etc)
8. Handling – DOs and DONTs:
FUEL MODULE HANDLING
ACTION REASON
DO NOT:
Drop Fuel Module on Floor Could cause internal damage to Fuel
Pump.
DO NOT :
Run Fuel Pump Dry (without fuel
at pump inlet/ strainer) ensure atleast 3
litres of gasoline is present in the fuel tank
Caused internal damage to Fuel Pump
DO NOT :
Damage the strainer during
servicing, insertion of fuel module in fuel
tank
Contamination enters fuel pump thru
damaged strainer damages the Fuel
Pump
DO NOT
:
Disassemble Fuel Pump and
regulator internal parts out side Delphi
premises.
DO NOT: Do any adjustments on pressure
regulator and pump except for
replacement.
Warranty void.
DO NOT :
Use module harness for hold/
carry fuel module.
DO NOT: Pull Wiring Harness in vertical
direction to module cover
Wiring Harness Breakage/ Fuel Pump
Power disconnection
DO NOT : Use damaged/ distorted hose
clamps.
Can cause fuel seepage/ leakage.