Chrysler Cirrus, Dodge Stratus, Plymouth Breeze Haynes. Manual - part 17

 

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Chrysler Cirrus, Dodge Stratus, Plymouth Breeze Haynes. Manual - part 17

 

 

3-6

Chapter Cooling, heating and air

conditioning

system

7.21 Install a new 0-ring on the water

inlet pipe (arrow)

pipe (see illustration). Wet the 0-ring with
water to facilitate assembly.

22 Install a new gasket on the water pump
and install the inlet opening over the water

pipe. Press the water pipe into the pump
housing.

23 Install the water pump mounting bolts
and tighten the bolts to the torque listed in
this Chapter's specifications.
24 Install the timing belt (see Chapter 2B).
25

The remainder of installation is the

reverse of removal.
26

Refill the cooling system (see Chapter 1)

and operate the engine to check for leaks.

8

Coolant temperature sending
unit - check and replacement

Warning: Wait until the engine is completely
cool before beginning this procedure.

Check

1

The coolant temperature indicator sys-

tem is composed of a light or temperature
gauge mounted in the dash and a coolant
temperature sending unit mounted on the
engine (see illustration 4.3). On the models
covered by this manual, there is only one
coolant temperature sensor, which functions
as indicator to both the PCM and the instru-
ment panel.
2

If an overheating indication occurs,

check the coolant level in the system and

then make sure the wiring between the light

or gauge and the sending unit is secure and
all fuses are intact.

3

When the ignition switch is turned on

and the starter motor is turning, the indicator
li ght (if equipped) should be on (overheated

engine indication).
4

If the light is not on, the bulb may be

burned out, the ignition switch may be faulty

or the circuit may be open.
5

As soon as the engine starts, the light

should go out and remain out unless the
engine overheats. Failure of the light to go

out may be due to a grounded wire between

the light and the sending unit, a defective

sending unit or a faulty ignition switch. See
Chapter 6 for a diagnostic check of the
coolant temperature switch. Check the cool-
ant to make sure it's the proper type. Note:

Plain water may have too low a boiling point
to activate the sending unit.

Replacement

Warning: Wait until the engine is completely
cool before beginning this procedure.
6

Disconnect the electrical connector

from the sensor.
7

Wrap the threads of the new sensor with

Teflon tape to prevent leaks.
8

Unscrew the sensor. Be prepared for

some coolant spillage (read the Warning in
Section 2).
9

Install the sensor and tighten it securely.

10

Connect the electrical connector.

11

Check the coolant level after the

replacement unit has been installed and top
up the system, if necessary (see Chapter 1).
Check now for proper operation of the gauge
and sending unit. Observe the system for
leaks after operation.

9

Blower motor and circuit - check
and replacement

Warning: These models are equipped with
airbags, always disable the airbag system
before working in the vicinity of the impact
sensors, steering column or instrument panel

to avoid the possibility of accidental deploy-

ment of the airbag, which could cause per-
sonal injury (see Chapter 12).

Check

Refer to illustrations 9.3 and 9.7

1

Check the fuse and all connections in

the circuit for looseness and corrosion. Make
sure the battery is fully charged.
2

Remove the lower right dash insulator

panel (below the glove box) for access to the

blower motor. Note: When reinstalling this
panel, 
be sure the left end fits properly into its
recess in the ducting.
3

Using suitable probes, backprobe the

blower motor electrical connector at the
resistor and connect the positive probe of the
voltmeter to the dark blue wire and the nega-
tive probe to the black wire (see illustration).
4

With the transmission in Park, the park-

ing brake securely set, turn the ignition
switch On. It isn't necessary to start the vehi-
cle.
5

Move the blower switch through each of

its positions and note the voltage readings.
Changes in voltage indicate that the motor
speeds will also vary as the switch is moved
to the different positions.
6

If there is voltage present, but the

blower motor does not operate, the blower
motor is probably faulty. Disconnect the
blower motor connector and hook one side to
a chassis ground and the other to a fused

source of battery voltage. If the blower does-
n't operate, it is faulty.
7

If voltage was not present at the blower

motor at all speeds, and the motor itself
tested OK, the problem is in the blower motor
resistor, the blower switch in the control
panel assembly or the related wiring. To
check the resistor, remove the two screws
and remove the resistor from the heater
housing. Using an ohmmeter, check for con-

tinuity across each of the resistor terminals

(see illustration). If an open circuit is indi-
cated, replace the resistor assembly. To test

the blower switch, refer to Section 11,

remove the control panel assembly and
check for continuity through the switch in

each position. Refer to the wiring diagrams at
the end of Chapter 12 to determine the cor-

rect terminals for testing.

Replacement

Refer to illustration 9.11
8

Disconnect the battery negative cable

from the ground stud on the left shock tower
(see Chapter 5, Section 1).
9

Detach the panel underneath the right

9.3 Using suitable probes, backprobe the

blower harness plug (twisted pair of wires)

at the blower motor resistor block -

connect a voltmeter to the dark blue wire

(+) and black wire (-), voltage should vary

as the blower switch is moved through

each position

9.7 To test the blower resistor, check for

continuity at each of the

resistor terminals

Chapter 3 Cooling, heating and air conditioning system

3-7

9.11 Remove the screws retaining the blower motor to the

heater housing (arrow)

10.6 Remove the heater core cover

10.2 Disconnect the heater hoses at the firewall

10.7 Withdraw the heater core from the housing

3

end of the dash. It has four fasteners, all of
them facing up - two screws in front (side
toward the passenger seat) and two sheet

metal nuts on the backside (toward the
firewall).

10

Disconnect the wiring connector at the

blower motor resistor.
11

Remove the screws retaining the blower

motor to the heater housing (see illustra-

tion).

12

Lower the blower motor from the

housing

.

13

The fan is balanced with the blower

motor, and is available only as an assembly.

f the fan is damaged, both fan and blower

motor must be replaced.
14 Installation is the reverse of removal.

10 Heater core - replacement

Refer to illustrations 10.2, 10.6 and 10.7

Warning: These models are equipped with
airbags, always disable the airbag system
before working in the vicinity of the impact
sensors, steering column or instrument panel

•o avoid the possibility of accidental

deploy-ment of the airbag, which could cause

personal injury (see Chapter 12).

Drain the cooling system (see Chapter 1)

and disconnect the negative battery cable

'from the ground stud on the left shock tower

see Chapter 5, Section 1).

2

Disconnect the heater hoses at the fire -

wall (see illustration). Note: On V6 models, it
may be 
necessary to remove the upper intake
manifold to 
access the heater hoses (see
Chapter 2B).
3

Refer to Chapter 11 and remove the

radio/air conditioning control panel bezel, the
instrument panel bezel and end covers and
the knee bolster.
4

Remove the center console from the

vehicle (see Chapter 11).
5

Remove two screws at the lower right

side support beam, the bolt for the instru-
ment panel support at the A-pillar and
remove the right side instrument panel sup-
port strut.
6

Remove the heater core cover screws

and the cover (see illustration).

7

Withdraw the heater core from the hous-

ing (see illustration).

8

If the heater core has been leaking,

clean the coolant from the heater/air condi-
tioning housing. Note: If a significant amount
of coolant has leaked into the housing, it is
recommended that the complete heater/air
conditioning housing be removed from the
vehicle,

disassembled

and thoroughly

cleaned (see Section 16).
9

Installation is the reverse of removal. Be

sure to refill the cooling system (see Chap-
ter 1).

11 Heater/air conditioner control

assembly - removal, check and
installation

Warning: These models are equipped with
airbags, always disable the airbag system
before working in the vicinity of the impact
sensors, steering column or instrument panel
to avoid the possibility of accidental deploy-
ment of 
the airbag, which could cause per-

sonal injury (see Chapter 12).

Removal

Refer to illustrations 11.2, 11.3 and 11.7
1

Disconnect the negative battery cable

from the ground stud on the left shock tower
(see Chapter 5, Section 1).
2

Remove the trim bezel from the instru-

ment panel (see illustration).

TRIM

BEZEL

11.2 Remove the radio/control

module bezel

3-8

Chapter

3

Cooling, heating and

air

conditioning

system

3

Remove the three cluster hood screws

from the trim bezel opening (see illustra-
tion).
4

Pry up the cluster hood bezel a few

inches to expose the cubby bin screws.
5

Disconnect the wiring and remove the

cubby bin.
6

Remove the control module screws (see

illustration 11.3).
7

Lower the control module into the cubby

bin opening (see illustration) and disconnect
the wiring harness from the rear of the control
module.
8

Release the cable clips from the top of

the control module. Retain the clips for fur-
ther use. Disconnect the temperature control
and the recirculation control cables.
9

Remove the control module.

Check

Refer to illustration 11.11

10

Remove the control module (see Steps

above).

11

Using an ohmmeter, measure the resis-

tance between terminals 5 and 8 of the con-
trol module 8-way connector (see illustra-
tion). 
Turn the control module to each posi-
tion and check the resistance as follows:

a) PANEL = 828 to 856 ohms
b) BI-LEVEL = 1280 to 1300 ohms
c) FLOOR = 2300 to 2358 
ohms
d) MIX 5200 to 5300 ohms
e) DEFROST = 99 to 100 K-ohms

12 If any resistance is not correct, replace
the control module.

13 If the resistance's are correct, check for

blown fuses, damaged wiring, bad connec-
tions, defective Body Control Module (BCM) or
bulkhead connector. Refer to the wiring dia

-

grams at the end of Chapter 12, if necessary.

14

Further testing of the system can be

accomplished with the use of a special scan
tool; see a dealer or other qualified repair
shop.

c) Pull the cable housing away from the

cable end to remove all freeplay and clip
the 
cable housing to the control module.

d) Verify the knob travels through its full

range.

12 Air conditioning and heating

system - check and maintenance

Warning: The air conditioning system is
under high pressure. Do not loosen any hose
fittings or remove any components until after
the system 
has been discharged by a dealer
service department or air conditioning service
station. Always 
wear eye protection when dis-
connecting air conditioning system fittings.

1

The following maintenance checks

should be performed on a regular basis to
ensure the air conditioner continues to oper-
ate at peak efficiency.

a) Check the compressor drivebelt. If it's

worn or deteriorated, replace it (see
Chapter 1).

b) Check the drivebelt tension and, if nec-

essary, adjust it (see Chapter 1).

c) Check the system hoses. Look for

cracks, bubbles, hard spots and deterio-
ration. Inspect the 
hoses and all fittings
for oil bubbles and 
seepage. If there's
any evidence of wear, damage or 
leaks,
replace the hose(s).
Inspect the condenser fins for leaves,
bugs and other debris. 
Use a "fin comb"
or compressed air to clean the con-
denser.
Make 
sure the system has the correct
refrigerant 
charge.

f) Check the evaporator housing drain

tube for blockage.

2

It's a good idea to operate the system

for about 10 minutes at least once a month,
particularly during the winter. Long term non-
use can cause hardening, and subsequent
failure, of the seals.
3

Because of the complexity of the air con-

ditioning system and the special equipment
necessary to service it, in-depth troubleshoot-
ing and repairs are not included in this manual
(refer to the Haynes Automotive Heating and

Air Conditioning Repair Manual). However.

simple checks and component replacement
procedures are provided in this Chapter.
4

The most common cause of poor cool-

ing is simply a low system refrigerant charge.
If a noticeable drop in cool air output occurs.

the following quick check will help you deter-

mine if the refrigerant level is low.

Checking the refrigerant
charge

5

Warm the engine up to normal operating

temperature.
6

Place the air conditioning temperature

selector at the coldest setting and the blower
at the highest setting. Open the doors (to
make sure the air conditioning system does
not cycle off as soon as it cools the passen-
ger compartment).
7

With the compressor engaged - the

clutch will make an audible click and the cen-
ter of the clutch will rotate - note the temper-
ature of the compressor inlet and discharge
li nes. If the compressor discharge line feels
warm and the compressor inlet pipe feels
cool, the system is properly charged.
8

Place a thermometer in the dashboard

Installation

d)

15

Installation is the reverse of removal. If

necessary, adjust the cables as follows:

a) Attach the cable to the control module

lever.

e)

b) Rotate the knob fully counterclockwise.

Chapter 3 Cooling, heating and air conditioning system

3-9

12.12 Cans of R-134A refrigerant are

available in auto parts stores that can be

added to your system with a simple

recharging kit

vent nearest the evaporator and operate the
system until the indicated temperature is
around 40 to 45 degrees F. If the ambient

(outside) air temperature is very high, say 110

degrees F, the duct air temperature may be
as high as 60 degrees F, but generally the air
conditioning is 30-50 degrees F cooler than
the ambient air. Note: Humidity of the ambi-
ent air also affects the cooling capacity of the
system. Higher ambient humidity lowers the
effectiveness of the air conditioning system.

Adding refrigerant

Refer to illustration 12.12
9

Buy an automotive charging kit at an

auto parts store. A charging kit includes a 14-
ounce can of refrigerant, a tap valve and a
short section of hose that can be attached

between the tap valve and the system low

side service valve. Because one can of refrig-
erant may not be sufficient to bring the sys-
tem charge up to the proper level, it's a good

idea to buy an additional can. Make sure that

one of the cans contains red refrigerant dye.

If the system is leaking, the red dye will leak
out with the refrigerant and help you pinpoint

the location of the leak. Caution: There are

two types of refrigerant used in automotive

systems; R-12 - which has been widely used
on earlier models and the more environmen-

tally-friendly R-134a used in all models cov-

ered by this manual. These two refrigerants

(and their appropriate refrigerant oils) are not

compatible and must never be mixed or com-
ponents will be damaged. Use only R-134a
refrigerant in the models 
covered by this
manual.

10

Hook up the charging kit by following

the manufacturer's instructions. Warning:
DO NOT hook the charging kit hose to the
system high side! The fittings on the charging
kit are designed to fit only on the low side of

the system.
11

Back off the valve handle on the charg-

ing kit and screw the kit onto the refrigerant
can, making sure first that the 0-ring or rub-
ber seal inside the threaded portion of the kit
is in place. Warning: Wear protective eye-
wear when dealing with pressurized refriger-

ant cans.

12

Remove the dust cap from the low-side

charging connection and attach the quick-
connect fitting on the kit hose (see illustra-
tion).

13

Warm up the engine and turn on the air

conditioner. Keep the charging kit hose away
from the fan and other moving parts. Note:

The charging process requires the compres-

sor to be running.

14

Turn the valve handle on the kit until the

stem pierces the can, then back the handle
out to release the refrigerant. You should be
able to hear the rush of gas. Add refrigerant to
the low side of the system until both the

receiver-drier surface and the evaporator inlet
pipe feel about the same temperature. Allow

stabilization time between each addition.

15 If you have an accurate thermometer,

you can place it in the center air conditioning
duct inside the vehicle and keep track of the

"conditioned" air temperature. A charged

system that is working properly should cool

down to approximately 40 degrees F. If the
ambient (outside) air temperature is very high,
say 110 degrees F, the duct air temperature
may be as high as 60 degrees F, but gener-
ally the air conditioning is 30 to 40 degrees F
cooler than the ambient air.
16

When the can is empty, turn the valve

handle to the closed position and release the
connection from the low-side port. Replace
the dust cap. Warning: Never add more than
two cans of refrigerant to the system.
17

Remove the charging kit from the can

and store the kit for future use with the pierc-
ing valve in the UP position, to prevent inad-
vertently piercing the can on the next use.

13 Air conditioning compressor -

removal and installation

Warning: The air conditioning system is

under high pressure. DO NOT disassemble

any part of the system (hoses, compressor,
line fittings, etc.) until after the system has
been evacuated and the refrigerant recovered
by a dealer service department or air condi-

tioning service station.
Note: The filter-drier/receiver-drier (see Sec-
tion 14) should be replaced whenever the
compressor is replaced.

Removal

Refer to illustrations 13.3, 13.5 and 13.6

1

Have the system discharged (see the

Warning at the beginning of this Section).

2

Disconnect the negative battery cable

from the ground stud on the left shock tower

(see Chapter 5, Section 1).
3

Unplug the electrical connector from the

compressor clutch (see illustration).
4

Remove the drivebelt (see Chapter 1).

5

Disconnect the refrigerant lines from the

compressor (see illustration). Plug the open

fittings to prevent entry of dirt and moisture.

6

Unbolt the compressor from the mount-

ing bracket (see illustration) and lift it out of

the vehicle.

3

13.3 Unplug the electrical connector

(arrow) from the compressor clutch

13.5 Remove the retaining bolts, detach

and plug the refrigerant lines at

the compressor

13.6 To detach the compressor from its

mounting bracket, remove these

bolts (arrows)

3-10

Chapter 3 Cooling, heating and air conditioning system

14.4 Using a back-up wrench to prevent

damage to the fittings, disconnect the

refrigerant lines (arrows) from the

receiver-drier

Installation

7

If a new compressor is being installed,

pour out the oil from the old compressor into
a graduated container and add that amount
of new refrigerant oil to the new compressor.
Also follow any directions included with the
new compressor.
8

The clutch may have to be transferred

from the original to the new compressor.
9

Installation is the reverse of removal.

Replace all 0-rings with new ones specifi-
cally made for use with R-134a refrigerant
and lubricate them with R-134a-compatible
refrigerant oil.
10

Have the system evacuated, recharged

and leak tested by the shop that discharged
it.

14 Air conditioning receiver-drier -

removal and installation

Warning: The air conditioning system is

under high pressure. DO NOT disassemble

any part of the system (hose, compressor,
line fittings, etc.) until after the system has
been evacuated and the refrigerant recovered
by a dealer service department or air condi-

tioning service station.
Caution: Replacement filter-drier/receiver-

drier units are so effective at absorbing mois-
ture that they can quickly saturate upon expo-
sure to the atmosphere. When installing a
new unit, have all tools and supplies ready for
quick reassembly to avoid having the system
open any longer than necessary.

Removal

Refer to illustration 14.4

1

The receiver-drier acts as a reservoir for

the system refrigerant. It's located on the
right side of the engine compartment, next to
the radiator and condenser.
2

Have the system discharged (see the

Warning at the beginning of this Section).
3

Disconnect the negative battery cable

from the ground stud on the left shock tower

15.4 Remove the upper radiator

support crossmember

(see Chapter 5, Section 1).

4

Disconnect the refrigerant lines from the

receiver-drier (see illustration). Use a back-
up wrench to prevent twisting the tubing

where it joins the condenser.
5

Plug the open fittings to prevent entry of

dirt and moisture.
6

Remove the bracket bolt at the base of

the receiver/drier. Spread the aluminum
clamp and remove the receiver/drier.

Installation

7

Installation is the reverse of removal. If a

new receiver-drier is being installed add one
ounce of refrigerant oil to it before installa-
tion.
8

Take the vehicle back to the shop that

discharged it. Have the system evacuated,
recharged and leak tested.

15 Air conditioning condenser -

removal and installation

Warning: The air conditioning system is
under high 
pressure. Do not loosen any hose
fittings or remove any components until after
the system has been discharged by a dealer

service department or air conditioning service
station. Always 
wear eye protection when dis-

connecting air conditioning system compo-

nents.

Note: The receiver-drier should be replaced
whenever the condenser is replaced 
(see
section 14).

Removal

Refer to illustrations 15.4 and 15.5

1

Have the system discharged (see the

Warning at the beginning of this Section).
2

Disconnect the negative battery cable

from the ground stud on the left shock tower

(see Chapter 5, Section 1).

3

Remove the radiator grille (see Chap-

ter 11).
4

Remove the upper radiator support

crossmember (see illustration).
5

Using the appropriate quick-connect

15.5 Using the appropriate quick-connect

coupling tool, disconnect the air

conditioner condenser lines (A) from the

condenser and remove the

mounting bolts (B)

coupling tools (available at auto parts stores),
disconnect and cap the air conditioning lines
at the condenser (see illustration).
6

Remove the radiator fan module mounts.

7

Remove the condenser line support

bracket.

8

Remove the condenser mounting bolts

(see illustration 15.5).
9

Remove the condenser from the vehicle.

Installation

10 Installation is the reverse of removal. If a

new condenser is being installed add one
ounce of refrigerant oil to it before installa-
tion.

11

Take the vehicle back to the shop that

discharged it. Have the system evacuated,
recharged and leak tested.

16 Air conditioning evaporator and

expansion valve - removal and
installation

Warning 1: These models are equipped with
airbags, always disable the airbag system
before working in the vicinity 
of the impact
sensors, steering column or instrument panel
to avoid the possibility of accidental deploy-
ment of the airbag, which could 
cause per-

sonal injury (see Chapter 12).

Warning 2: The air conditioning system is
under high pressure. Do not loosen any hose
fittings or remove any components until 
after
the system has been discharged by a dealer

service department or air conditioning service
station. Always wear eye protection when dis-

connecting air conditioning system compo-

nents.

Note: Evaporator removal on these models is

a difficult undertaking for the home mechanic.
It can be done, but it requires discharging the
air conditioning system, disconnecting the
passenger airbag system and a great many

wiring connectors under the dash and remov-

ing the complete instrument panel assembly.

Chapter 3 Cooling, heating and air conditioning system

3-11

16.3 Disconnect and cap the refrigerant

li nes from the expansion valve

16.15 Remove the evaporator probe from

the evaporator core

16.17 Remove the clips retaining the two

housing sections

16.18a Pull the two sections apart .. .

EVAPORATOR

HOUSING

HEATER

DISTRIBUTION

HOUSING

16.18b . . . and separate the heater housing from the

evaporator housing

3

The air conditioning evaporator is contained
in a two-piece housing which must be
removed from under the dash and separated
into two halves.

Expansion valve

Note: The expansion valve can be replaced
without removing the evaporator from the
vehicle or removed 
along with the evaporator.

Removal

Refer to illustration 16.3

1

Have the system discharged (see the

Warning at the beginning of this Section).
2

Disconnect the negative battery cable

from the ground stud on the left shock tower
(see Chapter 5, Section 1).
3

Remove the security clips from expan-

sion valve refrigerant line quick-connect fit-
tings. Using the appropriate quick-connect
coupling tools (available at auto parts stores),
disconnect and cap the air conditioning lines
at the expansion valve (see illustration).
4

Remove the retaining bolts and separate

the expansion valve from the evaporator.

Installation

5

Installation is the reverse of removal.

Install new 0-ring seals on the expansion

valve and lubricate them with R-134a-com-
patible refrigerant oil prior to installation.
6

Take the vehicle back to the shop that

discharged it. Have the system evacuated,
recharged and leak tested.

Evaporator

Removal

Refer to illustrations 16.15, 16.17, 16.18a,

16.18b and 16.20

7

Have the system discharged (see the

Warning at the beginning of this Section).
8

Disconnect the negative battery cable

from the ground stud on the left shock tower
(see Chapter 5, Section 1).
9

Drain the cooling system. Disconnect

the heater hoses from the heater core at the
firewall (see Section 10). Cap the heater core
fittings to prevent spilling coolant on the inte-
rior when the housing is removed.

10

Disconnect and cap the refrigerant lines

from the expansion valve (see above).

11

Refer to Chapter 11 and remove the

complete instrument, panel assembly.
12

Remove the center air distribution ducts

from the heater/air conditioning housing.

13

Disconnect any wiring harness connec-

tors attached to the housing.

14

Remove the bolts securing the heat-

er/air conditioning housing to the bulkhead
and carefully remove the housing from the

vehicle.

15

Using a screwdriver, pry the locking tab

off the evaporator probe. Twist the evapora-

tor probe access cover 1/4-turn clockwise

and remove the cover. Carefully withdraw the
evaporator probe from the evaporator core
(see illustration).
16

Remove the recirculating door inlet

cover.
17

Remove the clips retaining the housing

sections together (see illustration).
18

Separate the evaporator housing from

the heater/distribution housing (see illustra-
tions).

19

Remove the seal around the evaporator

3-12

Chapter 3 Cooling, heating and air conditioning system

tube inlet.
20

Remove the evaporator housing upper

cover (see illustration).
21

Withdraw the evaporator core from the

housing.

Installation

Note: When installing a new evaporator,

always use a new gasket on the expansion

valve (see illustration) and reinstall the tem-

perature sensor from the old core into the

new core before installation.
22 Installation is the reverse of removal. If a
new evaporator is being installed, add one
ounce of new, R-134a-compatible refrigerant
oil into it prior to installation.
23

Take the vehicle back to the shop that

discharged it. Have the system evacuated,
recharged and leak tested.

EVAPORATOR

HOUSING

COVER

16.20 Remove the

evaporator housing

upper cover

Chapter 4
Fuel and exhaust systems

Contents

Section

Accelerator cable - replacement ..........................................................10

Air cleaner assembly - removal and installation ................................... 9
Air filter - replacement ...................................................... See Chapter 1

CHECK ENGINE light........................................................See Chapter 6
Exhaust system servicing - general information.................................. 18
Fuel filter - removal and installation ..................................................... 15
Fuel injection system - general check ................................................. 12
Fuel injection system - general information ......................................... 11
Fuel level sending unit - check and replacement ..................................8
Fuel pressure regulator and fuel inlet strainer - replacement .............. 14

Fuel pressure relief procedure ............................................................... 2
Fuel pump module - removal and installation........................................7
Fuel pump/fuel pressure regulator - check............................................3
Fuel rail and injectors - check, removal and installation ......................16
Fuel tank - removal and installation ....................................................... 5
Fuel tank cleaning and repair - general information .............................. 6
General information ................................................................................1
Idle Air Control (IAC) motor - check and replacement .........................17
Quick-connect fittings and fuel lines - disassembly, assembly

and replacement...............................................................................4

Throttle body - check, removal and installation ...................................13

4

Specifications

General

Fuel pressure................................................................................................... 47 to 51 psi
Fuel injector resistance (approximate)............................................................. 12 to 15 ohms @ 68-degrees F
Fuel level sending unit resistance (approximate)

Full position.................................................................................................50 ohms (minimum)
Empty position............................................................................................ 1040 to 1060 ohms

Torque specifications

Ft-lbs (unless otherwise indicated)

Fuel rail mounting bolts

Four-cylinder engines.................................................................................200 in-lbs
V6 engine.................................................................................................... 106 in-lbs

Fuel tank drain plug ......................................................................................... 32 in-lbs
Fuel tank strap bolts........................................................................................ 44
Idle Air Control motor-to-throttle body screws ................................................25 in-lbs
Throttle body mounting bolts

Four-cylinder engines.................................................................................200 in-lbs
V6 engine....................................................................................................250 in-lbs

1

General information

The vehicles covered by this manual are

equipped with a sequential Multi-Port Fuel
Injection (MPFI) system. This system uses
ti med impulses to sequentially inject the fuel
directly into the intake ports of each cylinder.
The injectors are controlled by the Powertrain
Control Module (PCM). The PCM monitors
various engine parameters and delivers the
exact amount of fuel, in the correct

sequence, to the intake ports. It also controls
the engine idle speed via the idle air control
motor which is mounted to the throttle body.

All models are equipped with an electric

fuel pump which is located inside the fuel

tank. It is necessary to remove the fuel tank
to gain access to the fuel pump. The fuel level

sending unit is an integral component of the

fuel pump and it must be removed from the
fuel tank in the same manner. These vehicles
are equipped with a "returnless" fuel system.

In this system the fuel pressure regulator is

part of the fuel pump/fuel level sending unit
and also located inside the fuel tank. Regu-
lated fuel is sent to the fuel rail and excess
fuel is bled off directly into the fuel tank.

The exhaust system consists of the

exhaust manifold(s), a catalytic converter, an
exhaust pipe and a muffler. Each of these
components is replaceable. For further infor-
mation regarding the catalytic converter, refer
to Chapter 6.

 

 

 

 

 

 

 

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