Service Manual
Table Of Contents
- 2008 RANGER RZR SERVICE MANUAL
- GENERAL INFORMATION
- MAINTENANCE
- PERIODIC MAINTENANCE CHART
- COMPONENT INSPECTION / SERVICE LOCATIONS
- LUBRICANTS / SERVICE PRODUCTS
- MAINTENANCE REFERENCES
- GENERAL VEHICLE INSPECTION AND MAINTENANCE
- FUEL SYSTEM AND AIR INTAKE
- ENGINE
- TRANSMISSION AND GEARCASES
- COOLING SYSTEM
- FINAL DRIVE / WHEEL AND TIRE
- ELECTRICAL AND IGNITION SYSTEM
- STEERING AND SUSPENSION
- BRAKE SYSTEM
- ENGINE
- ENGINE SPECIFICATIONS
- ENGINE COOLING SYSTEM
- GENERAL ENGINE SERVICE
- ENGINE DISASSEMBLY AND INSPECTION
- Cylinder Head Assembly Exploded View
- Rocker Arms
- Push Rods
- Cylinder Head Removal
- Cylinder Head Inspection
- Cylinder Head Warp
- Valve Seal / Spring Service (On Engine)
- Cylinder Head Disassembly
- Valve Inspection
- Combustion Chamber
- Valve Seat Reconditioning
- Cylinder Head Reassembly
- Valve Sealing Test
- Cylinder Removal
- Valve Lifter Removal / Inspection
- Piston Removal
- Cylinder Inspection
- Cylinder Hone Selection and Honing Procedure
- Honing To Deglaze
- Cleaning the Cylinder After Honing
- Piston-to-Cylinder Clearance
- Piston / Rod Inspection
- Piston Ring Installed Gap
- Starter Drive Bendix Removal / Inspection
- Flywheel / Stator Removal / Inspection
- Engine Crankcase Disassembly / Inspection
- Camshaft Inspection
- ENGINE REASSEMBLY
- ENGINE INSTALLATION
- TROUBLESHOOTING
- ELECTRONIC FUEL INJECTION
- GENERAL INFORMATION
- FUEL TANK
- ELECTRONIC FUEL INJECTION
- ELECTRONIC CONTROL UNIT (ECU)
- TEMPERATURE AND BAROMETRIC AIR PRESSURE SENSOR (T-BAP)
- CRANKSHAFT POSITION SENSOR (CPS)
- FUEL INJECTORS
- FUEL PUMP
- FUEL PRESSURE REGULATOR
- THROTTLE POSITION SENSOR (TPS)
- ENGINE COOLANT TEMPERATURE SENSOR (ECT)
- IGNITION COIL
- GENERAL TROUBLESHOOTING
- EFI SYSTEM BREAKOUT DIAGRAMS
- Diagnostic Connector Circuit
- Malfunction Indicator Lamp (MIL) Circuit
- Fuel Injector (PTO) Circuit
- Fuel Injector (MAG) Circuit
- Engine Coolant Temperature Sensor (ECT) Circuit
- Engine Overheat Lamp Driver Circuit
- Crankshaft Position Sensor (CPS) Circuit
- Air Temperature and Barometric Air Pressure Sensor (T-BAP) Circuit
- Throttle Position Sensor (TPS) Circuit
- Fuel Pump Circuit
- BODY / STEERING / SUSPENSION
- CLUTCHING
- FINAL DRIVE
- TRANSMISSION
- BRAKES
- GENERAL SPECIFICATIONS
- TORQUE SPECIFICATIONS
- SPECIAL TOOLS
- BRAKE SYSTEM SERVICE NOTES
- BRAKE NOISE TROUBLESHOOTING
- HYDRAULIC BRAKE SYSTEM OPERATION
- BRAKE SYSTEM EXPLODED VIEW
- MASTER CYLINDER
- BRAKE PEDAL LEVER
- BRAKE BLEEDING / FLUID CHANGE
- FRONT BRAKE PADS
- FRONT CALIPER SERVICE
- FRONT BRAKE DISC
- REAR BRAKE PAD
- REAR CALIPER SERVICE
- REAR BRAKE DISC
- TROUBLESHOOTING
- ELECTRICAL
- General Information
- Switches / Controls
- Instrument Cluster
- Instrument Cluster Troubleshooting Tests
- All Wheel Drive Coil
- Gear Position Indicator Switch
- Speed Sensor
- Head Lights
- Tail / Brake / Work Lights
- Cooling System Schematic
- EFI Diagnostics
- Fuel Sender
- Relays
- Fuse Box Layout
- Fuses / Circuit Breaker
- Charging System
- Battery Service
- Conventional Battery
- Low Maintenance Battery
- Starting System
- Starting System Testing Flow Chart
- Electrical BreakOut Diagrams
- INDEX
- WIRE DIAGRAMS
4.23
ELECTRONIC FUEL INJECTION
4
Fuel Tank / Fuel Pump Replacement
IMPORTANT: Syphon as much fuel from the tank as
possible before attempting to remove it from the
vehicle.
NOTE: The fuel pump assembly may be a
serviceable item on some vehicles. See the
“Electronic Parts Catalog” for fuel pump availability.
It may be possible that the fuel tank assembly must
be replaced.
If replacing only the fuel pump assembly, refer to
“Fuel Pump Removal / Installation” within this
section. If replacing the fuel tank, follow the
procedure below.
1. Remove the driver and passenger seats along with the rear
service panel.
2. Disconnect the negative battery cable from the battery
located under the driver’s seat.
3. Bleed off fuel pressure at the test valve using the Fuel
Pressure Gauge Kit (PU-43506-A).
4. While holding a shop towel over the fuel line connector,
disconnect the quick connect fuel line from the fuel pump.
NOTE: A small amount of fuel may come out of the
fuel line or tank. Properly drain fuel into a suitable
container.
5. Disconnect the fuel pump electrical harness.
6. Remove the fuel tank vent hose.
7. Remove the (2) push rivets from the rear of the center
console.
WARNING
Always wear safety goggles when working with
high pressure or flammable fluids. Failure to do so
could result in serious injury or complications.
Disconnect Here