service CHEVROLET DYNASTY 1993 Service Manual

for diagnostic and service procedures on the air control
valve and temperature sensor located in the air
cleaner.
INTAKE AND EXHAUST MANIFOLDS SERVICEÐTBI
ENGINE
Intake and exhaust manifolds use a one piece gasket.
Service procedures requiring removal and installation
( of either ) must include both manifolds.
FUEL SYSTEM PRESSURE RELEASE PROCE- DURE
The Fuel System is under a constant pressure
of at least 265 kPa (39 psi). Before servicing the
fuel pump, fuel lines, fuel filter, throttle body or
fuel injector, the fuel system pressure must be
released. (a) Loosen fuel filler cap to release fuel tank pres-
sure. (b) Disconnect injector wiring harness from engine
harness. (c) Connect a jumper wire to ground terminal
Number 1 of the injector harness (Fig. 2) to engine
ground. (d) Connect a jumper wire to the positive terminal
Number 2 of the injector harness (Fig. 2) and touch
the battery positive post for no longer than 5 seconds.
This releases system pressure. (e) Remove jumper wires.
(f) Continue fuel system service.
REMOVAL
(1) Perform fuel system pressure release procedure
before attempting any repairs. (2) Disconnect negative battery cable. Drain cool-
ing system. Refer to Cooling System, Group 7 for pro-
cedure. (3) Remove air cleaner and disconnect all vacuum
lines, electrical wiring and fuel lines from throttle
body. (4) Remove throttle linkage.
(5) Loosen power steering pump and remove belt.
(6) Remove power brake vacuum hose from intake
manifold. (7) Disconnect EGR tube from intake manifold and
remove water hoses from water crossover. (8) Raise vehicle and remove exhaust pipe from
manifold. (9) Remove power steering pump assembly and set
aside. (10) Remove intake manifold retaining screws
(Fig. 3). (11) Lower vehicle and remove intake manifold.
(12) Remove exhaust manifold retaining nuts (Fig.
3). (13) Remove exhaust manifold.
Fig. 2 Injector Harness Connector
Fig. 3 Intake and Exhaust Manifold Attaching PointsÐ2.2/2.5L Engines
Fig. 1 Air HeaterÐTBI Engine
11 - 6 EXHAUST SYSTEM AND INTAKE MANIFOLD Ä

CLEANING AND INSPECTION
(1) Discard gaskets and clean all gasket surfaces
on both manifolds and on cylinder head. (2) Test gasket surfaces of manifolds for flatness
with a straight edge. Surfaces must be flat within
0.15mm per 300mm (.006 in. per foot) of manifold
length. (3) Inspect manifolds for cracks and distortion.
INSTALLATION
(1) Install a new intake and exhaust manifold gas-
ket. Coat steel gasket lightly with Gasket Sealer on
manifold side. Do notcoat composition gasket with
(any) sealer. (2) Set exhaust manifold in place. Tighten retain-
ing nuts starting at center and progressing outward
in both directions to 23 N Im (200 in. lbs.) torque. Re-
peat this procedure until all nuts are at specified
torque. (3) Set intake manifold in place.
(4) Raise vehicle and tighten retaining screws
starting at center and progressing outward in both
directions to 23 N Im (200 in. lbs.) torque (Fig. 3). Re-
peat this procedure until all screws are at specified
torque. (5) Reverse removal procedures 1-9 for installation.
(6) With the DRBII Scan Tool use ASD Fuel Sys-
tem Test to pressurize system to check for leaks.
CAUTION: When using the ASD Fuel System Test,
the Auto Shutdown (ASD) relay will remain ener-
gized for 7 minutes or until the ignition switch is
turned to the OFF position, or Stop All Test is se-
lected.
INTAKE AND EXHAUST MANIFOLDSÐFLEXIBLE
FUEL ENGINE
INTAKE MANIFOLD
The manifold is die-cast aluminum with upper ple-
num and 4 tubes lower runners. These attach to the
cylinder head, with each runner leading directly to a
cylinder. The manifold is also machined for fuel rail attach-
ment and injector installation. The throttle body is
installed on the upper plenum of the manifold.
EXHAUST MANIFOLD
All high strength iron casting that intermesh with
the intake manifold. For standard engines a four
branch design collects and directs exhaust gases to
the conical (articulated joint connection) outlet.
INTAKE/EXHAUST MANIFOLDS
SERVICEÐFLEXIBLE FUEL ENGINES
Intake and exhaust manifolds use a one piece gas-
ket. Service procedures requiring removal and instal-
lation of either must include both manifolds.
SERVICE PRECAUTIONS
Methanol is more toxic than gasoline. Always re-
lease fuel system pressure before servicing fuel sys-
tem components and wear methanol resistant gloves
and eye protection. Avoid breathing methanol vapors or ingesting
methanol. Headaches, dizziness and even uncon-
sciousness could result from breathing these vapors.
Serious injury, blindness and even death could result
from ingesting methanol. Methanol vapors are extremely flammable and can
travel along the ground. Service vehicles in well ven-
tilated areas and avoid ignition sources. Never
smoke while servicing the vehicle. Do not allow methanol to contact skin. Prolonged
contact with methanol can cause dry skin or an al-
lergic skin reaction. Also, prolonged contact could re-
sult in absorption through the skin.
FUEL SYSTEM PRESSURE RELEASE PROCEDURE
WARNING: RELEASE FUEL SYSTEM PRESSURE
BEFORE SERVICING FUEL SYSTEM COMPONENTS.
WEAR METHANOL RESISTANT GLOVES AND EYE
PROTECTION WHILE SERVICING THE FUEL SYS-
TEM.
(a) Disconnect negative cable from battery.
(b) Remove fuel filler cap.
(c) Remove the protective cap from the fuel pres-
sure test port on the fuel rail (Fig. 4).
(d) Place the open end of fuel pressure release
hose, tool number C-4799-1, into an approved gas-
oline container. Connect the other end of hose
C-4799-1 to the fuel pressure test port (Fig. 5).
Fuel pressure will bleed off through the hose into
the gasoline container. Fuel gauge C-4799-A con-
tains hose C-4799-1.
Fig. 4 Fuel Pressure Test Port
Ä EXHAUST SYSTEM AND INTAKE MANIFOLD 11 - 7

EXHAUST MANIFOLD
REMOVAL (1) Disconnect exhaust pipe from manifold articu-
late joint. (2) Disconnect the heated oxygen sensor electrical
connection. (3) Remove 8 exhaust manifold retaining nuts and
remove exhaust manifold (Fig. 9).
CLEANING AND INSPECTION
(1) Discard gasket and clean all gasket surfaces of
manifolds and cylinder head. (2) Test gasket surfaces for flatness with straight
edge. Surface must be flat within 0.15 mm per 300
mm (.006 in. per foot) of manifold length. (3) Inspect manifolds for cracks or distortion.
EXHAUST MANIFOLD
INSTALLATION
(1) Install new two-sided grafoil or equivalent in-
take/exhaust manifold gasket. DO NOT APPLY
SEALER. (2) Set exhaust manifold in place. Install and
tighten retaining nuts, starting at center and pro-
gressing outward in both directions to 23 N Im (200
in. lbs.) torque. Repeat this procedure until all nuts
are at specified torque.
INTAKE MANIFOLD
INSTALLATION
(1) Position intake manifold, install, and tighten 8
retaining screws starting at center and progressing
outward in both directions to 23 N Im (200 in. lbs.)
torque. Repeat this procedure until all screws are at
specified torque (Fig. 9). (2) Install PCV vacuum harness and vacuum vapor
harness (Fig. 8). (3) Connect vacuum hose from fuel pressure regu-
lator. (4) Connect fuel injector wiring connector (Fig. 8).
(5) Close fuel tube clip around fuel tubes and in-
stall fastener. (6) Lubricate the ends of the chassis fuel tubes
with 30 wt oil. Connect fuel supply and return hoses
to chassis fuel tube assembly. pull back on the quick
connect fitting to ensure complete insertion. (Refer to
Fuel Hoses, Clamps and Quick Connect Fittings in
Group 14 Fuel Systems). (7) Connect automatic idle speed (AIS) motor and
throttle position sensor (TPS) wiring connectors (Fig.
7). (8) Connect accelerator and speed control cables.
Install brake booster vacuum supply hoses. (9) Reconnect negative battery cable.
(10) Install air cleaner hose to throttle body assem-
bly (Fig. 6). (11) With the DRBII Scan Tool use ASD Fuel Sys-
tem Test to pressurize system to check for leaks.
CAUTION: When using the ASD Fuel System Test,
the Auto Shutdown (ASD) relay will remain ener-
gized for 7 minutes or until the ignition switch is
turned to the OFF position, or Stop All Test is se-
lected.
INTAKE/EXHAUST MANIFOLDS AND
TURBOCHARGER SERVICEÐTURBO III ENGINE
INTAKE MANIFOLD
REMOVAL
(1) Perform fuel system pressure release procedure
before attempting any repairs. (2) Disconnect negative battery cable. Drain cool-
ing system. Refer to Cooling System, Group 7. (3) Remove fresh air duct from air filter housing.
Remove inlet hose from the intercooler (Fig. 1). (4) Remove radiator hose to cylinder head (Fig. 2).
(5) Remove DIS Ignition Coils from intake mani-
fold (Fig. 3). (6) Remove accelerator and speed control cables
(Fig. 4).
Fig. 9 Intake and Exhaust Manifolds Attaching Points
Ä EXHAUST SYSTEM AND INTAKE MANIFOLD 11 - 9

(13) Disconnect articulated exhaust pipe joint from
turbocharger housing. (14) Remove turbocharger coolant inlet line assem-
bly from engine (Fig. 11). (15) Lift turbocharger off manifold mounting studs
and lower assembly down and out of vehicle.
EXHAUST MANIFOLD
REMOVAL
Remove 9 exhaust manifold retaining fasteners and
remove exhaust manifold (Fig. 14).
CLEANING AND INSPECTION
(1) Discard gasket and clean all gasket surfaces of
manifolds and cylinder head. (2) Test manifold gasket surfaces for flatness with
straight edge. Surface must be flat within 0.15 mm
per 300 mm (.006 in. per foot) of manifold length. (3) Inspect manifolds for cracks or distortion. Re-
place manifold if necessary.
EXHAUST MANIFOLD
INSTALLATION
(1) Install new manifold gasket. DO NOT APPLY
SEALER . (2) Set exhaust manifold in place. Tighten retain-
ing nuts and bolt, starting at center and progressing
outward in both directions to 23 N Im (200 in. lbs.)
torque. Repeat this procedure until all fasteners are
at specified torque (Fig. 14).
TURBOCHARGER
INSTALLATION
(1) Position turbocharger on exhaust manifold. Ap-
ply antiseize compound to threads and install the
lower (passenger side) retaining nut (Fig. 12).
Tighten nut to 54 N Im (40 ft. lbs.) torque.
(2) Apply thread sealant to lower (inlet) coolant
line fitting and install fitting into turbocharger hous-
ing (Fig. 11). (3) Install lower coolant line assembly to engine
(Fig. 11). (4) Install oil drain back tube and fitting (with
new gasket) to turbocharger housing (Fig. 13). (5) Install turbocharger to block support bracket
and install screws finger tight (Fig. 13). Tighten
block screw FIRST to 54 N Im (40 ft. lbs.) torque,
then tighten screw to turbocharger housing to 27
N Im (20 ft. lbs.) torque.
(6) Reposition exhaust pipe. Tighten articulated
joint shoulder bolts to 28 N Im (250 in. lbs.) torque.
(7) See Suspension, Group 2, and install right
driveshaft and wheel and tire assembly. Install air
deflector on crossmember. (8) From Above: Install three turbocharger to
manifold retaining nuts. Tighten to 54 N Im (40 ft.
lbs.) torque (Fig. 12). (9) Reconnect Heated Oxygen sensor electrical con-
nection and vacuum lines. (10) Attach oil feed line to turbocharger bearing
housing. Tighten fitting to 14 N Im (125 in. lbs.)
torque (Fig. 12). (11) Install coolant line and tighten fittings to 41
N Im (30 ft. lbs.) torque (Fig. 11).
(12) Install air cleaner support (Fig. 1).
(13) Align front engine mount in crossmember
bracket. Install through bolt and tighten to 54 N Im
(40 ft. lbs.) torque. (14) Install air cleaner assembly (Fig. 1).
(15) Fill cooling system. Refer to Cooling System,
Group 7 for procedure.
INTAKE/EXHAUST MANIFOLD SERVICEÐ3.0L
ENGINE
The intake system has a large air intake plenum of
aluminum alloy and a cross type intake manifold
(Fig. 2).
Fig. 13 Oil Return Tube and Support Bracket
Fig. 14 Exhaust ManifoldÐTurbo III Engine
Ä EXHAUST SYSTEM AND INTAKE MANIFOLD 11 - 13

(e) Remove jumper wires.
(f) Continue fuel system service.
(4) Remove throttle cable and transaxle kickdown
linkage (Fig. 4). (5) Remove automatic idle speed (AIS) motor and
throttle position sensor (TPS) wiring connectors from
throttle body (Fig. 5). (6) Remove vacuum hose harness from throttle body
(Fig. 5). (7) Remove PCV and Brake booster hoses from Air
Intake Plenum. (8) Remove ignition coil from intake plenum (Fig. 6).
(9) Remove wiring connectors from coolant tempera-
ture sensor (Fig. 7). (10) Remove vacuum connections from air intake
plenum vacuum connector. (11) Remove fuel hoses from fuel rail (Fig. 7).
WARNING: WRAP SHOP TOWELS AROUND HOSES
TO CATCH ANY GASOLINE SPILLAGE. (12) Remove (8) Fasteners from Air Intake Plenum
to Intake Manifold (Fig. 8). (13) Remove air intake plenum (Fig. 9).
(14) Cover intake manifold with suitable cover when
servicing. (15) Remove vacuum hoses from fuel rail and fuel
pressure regulator (Fig. 10). (16) Disconnect Fuel Injector wiring harness from
engine wiring harness (Fig. 11). (17) Remove fuel pressure regulator attaching bolts
and remove regulator from rail (Fig. 12). Be careful
not to damage the rubber injector O-rings upon
removal from the ports. (18) Remove fuel rail attaching bolts and lift fuel rail
assembly from intake manifold. (19) Separate radiator hose from thermostat hous-
ing and heater hose from heater pipe. (20) Remove (8) nut and washer assemblies and
remove intake manifold (Fig. 2).
INSPECTION
Check for:
² Damage and cracks of each section (Fig. 13).
² Clogged water passages in end cross overs.
² Check for distortion of the cylinder head mounting
surface using a straightedge and thickness gauge (Fig.
14). Refer to (Fig. 15) for Specifications.
INSTALLATION
(1) Position new intake manifold gaskets on cylinder
head and install intake (cross) manifold. (2) Install (8) nuts and washers and tighten in
several steps in order shown in (Fig. 16) to 20 N Im
(174 in. lbs.). (3) Make sure the injector holes are clean and all
plugs have been removed. (4) Lube injector O-ring with a drop of clean en-
gine oil to ease installation. (5) Put the tip of each injector into their ports.
Push the assembly into place until the injectors are
seated in the ports. (6) Install the (3) fuel rail attaching bolts and
torque to 13 N Im (115 in. lbs.).
(7) Install fuel pressure regulator onto fuel rail. In-
stall attaching bolts to intake manifold. Torque reg-
ulator nuts and bracket bolts to 10 N Im (95 in. lbs.)
(Fig. 12). (8) Install fuel supply and return tube hold-down
bolt and the vacuum crossover tube hold-down bolt
and torque to 10 N Im (95 in. lbs.).
(9) Connect fuel injector wiring harness to engine
wiring harness (Fig. 11). (10) Connect vacuum harness to fuel pressure reg-
ulator and fuel rail assembly (Fig. 10). (11) Remove covering from lower intake manifold
and clean surface. (12) Place intake manifold gaskets with beaded
sealant side up on lower manifold. Put air intake in
Fig. 3 Throttle Body Assembly 3.0L
Fig. 4 Throttle Cable Attachment
Ä EXHAUST SYSTEM AND INTAKE MANIFOLD 11 - 15

(2) Attach exhaust pipe to exhaust manifold and
tighten shoulder bolt to 28 N Im (250 in. lbs.)
(3) Attach crossover pipe to exhaust manifold and
tighten bolt to 69 N Im (51 ft. lbs.)
(4) Connect heated oxygen sensor lead (Fig. 18).
(5) Install front exhaust manifold and attach ex-
haust crossover. (6) Install front manifold heat shield and tighten
attaching screws to 15 N Im (130 in. lbs.) (Fig. 2).
INTAKE/EXHAUST MANIFOLD SERVICEÐ3.3/3.8L
ENGINES
INTAKE MANIFOLD
REMOVAL
(1) Perform fuel system pressure release procedure,
Before attempting any repairs. (2) Disconnect negative battery cable. Drain cool-
ing system. Refer to Cooling System, Group 7.
FUEL SYSTEM PRESSURE RELEASE PROCE- DURE
The MPI fuel system is under a constant pressure
of about 330 kPa (48 psi). Before servicing the fuel
pump, fuel lines, fuel filter, throttle body or fuel
injector, the fuel system pressure must be released.
(a) Loosen fuel filler cap to release fuel tank pres-
sure. (b) Disconnect injector wiring harness from engine
harness.
(c) Connect a jumper wire to ground terminal Num-
ber 1 of the injector harness (Fig. 1) to engine ground.
(d) Connect a jumper wire to the positive terminal
Number 2 of the injector harness (Fig. 1) and touch
the battery positive post for no longer than 5 seconds.
This releases system pressure. (e) Remove jumper wires.
(f) Continue fuel system service.
(3) Remove air cleaner to throttle body hose assem-
bly (Fig. 2).
Fig. 20 Check Exhaust Manifold Mounting Surface
Fig. 21 Identify Exhaust Manifold Gaskets
Fig. 1 Injector Harness Connectors
Fig. 2 Throttle Body AssemblyÐ3.3/3.8L Engines
Ä EXHAUST SYSTEM AND INTAKE MANIFOLD 11 - 19

(4) Remove throttle cable (Fig. 3). Remove wiring
harness from throttle cable bracket.
(5) Remove automatic idle speed (AIS) motor and
throttle position sensor (TPS) wiring connectors from
throttle body (Fig. 4). (e) Remove jumper wires.
(f) Continue fuel system service.
(6) Remove vacuum hose harness from throttle
body (Fig. 4). (7) Remove PCV and brake booster hoses from air
intake plenum (Fig. 5). (8) Remove EGR tube flange from intake plenum
(Fig. 5). (9) Disconnect Charge Temperature Sensor electri-
cal connector. Remove vacuum harness connectors
from Intake Plenum (Fig. 5).
(10) Remove cylinder head to intake plenum strut
(Fig. 5). (11) Disconnect MAP Sensor and heated Oxygen
Sensor electrical connection. Remove the engine
mounted ground strap (Fig. 6).
Fig. 3 Throttle Cable Attachment
Fig. 4 Electrical and Vacuum Connection to Throttle Body
Fig. 5 Electrical and Vacuum Connections To IntakeManifold
Fig. 6 MAP Sensor Electrical Connector
11 - 20 EXHAUST SYSTEM AND INTAKE MANIFOLD Ä

FUEL SYSTEMS
CONTENTS
page page
2.2L TURBO III MULTI-PORT FUEL INJECTIONÐ GENERAL DIAGNOSIS ................. 95
2.2L TURBO III MULTI-PORT FUEL INJECTIONÐ ON-BOARD DIAGNOSTICS ............. 100
2.2L TURBO III MULTI-PORT FUEL INJECTIONÐ SERVICE PROCEDURES ............... 107
2.2L TURBO III MULTI-PORT FUEL INJECTIONÐ SYSTEM OPERATION .................. 83
2.2L/2.5L SINGLE POINT FUEL INJECTIONÐ GENERAL DIAGNOSIS .................. 35
2.2L/2.5L SINGLE POINT FUEL INJECTIONÐ ON-BOARD DIAGNOSTICS .............. 41
2.2L/2.5L SINGLE POINT FUEL INJECTIONÐ SERVICE PROCEDURES ................ 48
2.2L/2.5L SINGLE POINT FUEL INJECTIONÐ SYSTEM OPERATION .................. 24
2.5L FLEXIBLE FUEL MULTI-PORT FUEL INJECTIONÐGENERAL DIAGNOSIS ....... 66
2.5L FLEXIBLE FUEL MULTI-PORT FUEL INJECTIONÐON-BOARD DIAGNOSTICS . . . 70
2.5L FLEXIBLE FUEL MULTI-PORT FUEL INJECTIONÐSERVICE PROCEDURES ..... 77
2.5L FLEXIBLE FUEL MULTI-PORT FUEL INJECTIONÐSYSTEM OPERATION ....... 55 3.0L MULTI-PORT FUEL INJECTIONÐ
GENERAL DIAGNOSIS ................. 125
3.0L MULTI-PORT FUEL INJECTIONÐ ON-BOARD DIAGNOSTICS ............. 130
3.0L MULTI-PORT FUEL INJECTIONÐ SERVICE PROCEDURES ............... 138
3.0L MULTI-PORT FUEL INJECTIONÐ SYSTEM OPERATION ................. 113
3.3L AND 3.8L MULTI-PORT FUEL INJECTIONÐ GENERAL DIAGNOSIS ................. 157
3.3L AND 3.8L MULTI-PORT FUEL INJECTIONÐ ON-BOARD DIAGNOSTICS ............. 162
3.3L AND 3.8L MULTI-PORT FUEL INJECTIONÐ SERVICE PROCEDURES ............... 169
3.3L AND 3.8L MULTI-PORT FUEL INJECTIONÐ SYSTEM OPERATION ................. 145
ACCELERATOR PEDAL AND THROTTLE CABLE .............................. 21
FUEL DELIVERY SYSTEM ................. 3
FUEL TANKS .......................... 14
GENERAL INFORMATION .................. 1
SPECIFICATIONS ...................... 178
GENERAL INFORMATION
Throughout this group, references are made to a
particular vehicle by letter designation. A chart
showing the breakdown of these designations is in-
cluded in the Introduction Section at the front of this
service manual. The Fuel System consists of the fuel tank, fuel
pump, fuel filter, throttle body, fuel injectors, fuel
tubes and vacuum tubes. The Fuel Delivery System consists of the fuel
pump, fuel filter, fuel lines and fuel hoses. The Fuel Tank Assembly consists of the fuel tank,
filler tube, a fuel gauge sending unit assembly and a
pressure-vacuum filler cap. Also, the Evaporation Control System is part of the
fuel system. The evaporation control system is de-
signed to reduce the emission of fuel vapor into the
atmosphere. The description and function of the Evaporation
Control System is found in Group 25 of this manual.FUEL REQUIREMENTS
Your vehicle was designed to meet all emission
regulations and provide excellent fuel economy when
using high quality unleaded gasoline.
VEHICLES WITHOUT TURBOCHARGED ENGINES
Use unleaded gasoline having a minimum octane
rating of 87.
VEHICLES WITH TURBOCHARGED ENGINESÐEXCEPT 16 VALVE 2.2L ENGINES
These vehicles will operate satisfactorily on both
regular unleaded gasoline having a minimum octane
rating or 87, and premium unleaded gasoline having
a minimum octane rating of 91. The use of premium
unleaded gasoline will improve performance.
VEHICLES WITH 2.2L 16 VALVE ENGINES
The use of premium unleaded gasoline having a
minimum octane of 91 is recommended. If premium
unleaded is not available, then unleaded gasoline
Ä FUEL SYSTEMS 14 - 1

with a minimum octane of 87 may be used. However,
the use of lower octane gasoline will result in re-
duced performance.
FLEXIBLE FUEL AA-BODY VEHICLES
These vehicles will operate on either unleaded gas-
oline with a minimum posted octane of 87 or M85
fuel. M85 fuel is a mixture of 85 percent methanol
and 15 percent unleaded gasoline. The vehicle also
will operate on mixture of M85 and unleaded gaso-
line with a minimum posted octane of 87. Do not
use 100 percent methanol in these vehicles.
THE FOLLOWING IS APPLICABLE TO ALL VEHICLES
Light spark knock at low engine speeds is not
harmful to your engine. However, continued heavy
spark knock at high speeds can cause damage and
should be reported to your dealer immediately. En-
gine damage resulting from operating with a heavy
spark knock may not be covered by the new vehicle
warranty. In addition to using unleaded gasoline with the
proper octane rating, gasolines that contain deter-
gents, corrosion and stability additives are recom-
mended. Using gasolines that have these additives
will help improve fuel economy, reduce emissions,
and maintain vehicle performance. Generally, pre-
mium unleaded gasolines contain more additive than
regular unleaded. Poor quality gasoline can cause problems such as
hard starting, stalling, and stumble. If you experi-
ence these problems, try another brand of gasoline
before considering service for the vehicle.
GASOLINE/OXYGENATE BLENDS
Some fuel suppliers blend gasoline with materials
that contain oxygen such as alcohol, MTBE (Methyl
Tertiary Butyl Ether) and ETBE (Ethyl Tertiary Bu-
tyl Ether). The type and amount of oxygenate used
in the blend is important. The following are generally used in gasoline
blends: Ethanol - (Ethyl or Grain Alcohol) properly blended, is used as a mixture of 10 percent ethanol
and 90 percent gasoline. Gasoline blended with eth-
anol may be used in your vehicle. Methanol - (Methyl or Wood Alcohol) is used in a
variety of concentrations when blended with un-
leaded gasoline. You may find fuels containing 3 per-
cent or more methanol along with other alcohols
called cosolvents. Do not use gasolines containing Methanol.
Use of methanol/gasoline blends may result in
starting and driveability problems and damage criti-
cal fuel system components. Problems that are the result of using methanol/gas-
oline blends are not the responsibility of Chrysler
Motors and may not be covered by the new vehicle
warranty. MTBE/ETBE - Gasoline and MTBE (Methyl Ter-
tiary Butyl Ether) blends are a mixture of unleaded
gasoline blended and up to 15 percent MTBE. Gaso-
line and ETBE (Ethyl Tertiary Butly Ether) are
blends of gasoline and up to 17 percent ETBE. Gas-
oline blended with MTBE or ETBE may be used in
your vehicle. Clean Air Gasoline
Many gasolines are now being blended that con-
tribute to cleaner air, especially in those areas of the
country where pollution levels are high. These new
blends provide a cleaner burning fuel and some are
referred to as reformulated gasoline. In areas of the country where carbon monoxide lev-
els are high, gasolines are being treated with oxy-
genated materials such as ETBE, MTBE and
ethanol. The use of gasoline blended with these ma-
terials also contributes to cleaner air. Chrysler Corporation supports these efforts toward
cleaner air and recommends that you use these gas-
olines as they become available. Materials Added to Fuel
Indiscriminate use of fuel system cleaning agents
should be avoided. Many of these materials intended
for gum and varnish removal may contain active sol-
vents of similar ingredients that can be harmful to
fuel system gasket and diaphragm materials.
14 - 2 FUEL SYSTEMS Ä

FUEL DELIVERY SYSTEM INDEX
page page
Chassis Fuel Tubes ...................... 11
Flexible Fuel Components ................... 3
Fuel FilterÐAll Vehicles .................... 9
Fuel Hoses, Clamps, and Quick Connect Fittings . 10
Fuel Pump Assembly ...................... 5
Fuel Pump Module Installation ............... 9
Fuel Pump Module Removal ................. 8
Fuel Pump Pressure TestÐ2.2L/2.5L TBI and 3.0L MPI Engines ........................... 7
Fuel Pump Pressure TestÐAll Except 2.2L/2.5L TBI and 3.0L MPI ....................... 6
Fuel Pump Strainer Service .................. 9 Fuel System Pressure
...................... 6
Fuel System Pressure Release ProcedureÐ 2.2L/2.5L TBI ........................... 4
Fuel System Pressure Release ProcedureÐ3.0L . . 5
Fuel System Pressure Release ProcedureÐExcept 2.2L/2.5L TBI and 3.0L ................... 4
General Information ........................ 3
Identifying Flexible Fuel Components .......... 3
Mechanical Malfunctions .................... 8
Methanol Concentration SensorÐFlexible Fuel AA-Body .............................. 4
Service Precautions for Flexible Fuel Vehicles .... 3
GENERAL INFORMATION
Beginning this model year, Chrysler began produc-
ing AA-Body vehicles designed to operate on a mix-
ture of gasoline and methanol. These automobiles are
referred to as Flexible Fuel vehicles. Flexible fuel vehicles can operate on a mixture of
up to 85 percent methanol, 15 percent unleaded gas-
oline. These vehicles also operate on mixtures con-
taining a lower percentage of methanol or just pure
unleaded gasoline. In many cases, the procedures for servicing flexible
fuel components is identical to gasoline only compo-
nents. Refer to the particular Service Procedure in
this section. If the service procedure for flexible fuel
component differs from a gasoline only component,
the title of each service procedure identifies the ap-
plication.
SERVICE PRECAUTIONS FOR FLEXIBLE FUEL
VEHICLES
Methanol is more toxic than gasoline. Always re-
lease fuel system pressure before servicing fuel sys-
tem components and wear methanol resistant gloves
and eye protection. Avoid breathing methanol vapors or ingesting
methanol. Headaches, dizziness and even uncon-
sciousness could result from breathing these vapors.
Serious injury, blindness and even death could result
from ingesting methanol. Methanol vapors are extremely flammable and can
travel along the ground. Service vehicles in well ven-
tilated areas and avoid ignition sources. Never
smoke while servicing the vehicle. Do not allow methanol to contact skin. Prolonged
contact with methanol can cause dry skin or an al-
lergic skin reaction. Also, prolonged contact could re-
sult in absorption through the skin.
IDENTIFYING FLEXIBLE FUEL COMPONENTS
Flexible Fuel vehicles have unique methanol com-
patible fuel system components. Chrysler identifies
methanol compatible components that could be phys-
ically interchanged with gasoline only parts by color-
ing them green or applying a green label or tag to
them. Even though they may appear physically iden-
tical, components for gasoline only vehicles must not
be used on flexible fuel vehicles.
FLEXIBLE FUEL COMPONENTS
Flexible fuel AA-body vehicles uses many unique
fuel system components. The unique parts are green
in appearance or have a green tag or label attached
to them. While components used on gasoline only ve-
hicles may look similar or identical, they cannot be
used on flexible fuel vehicles. When servicing a com-
ponent, always use an original equipment or equiva-
lent flexible fuel replacement. The fuel system of flexible fuel AA-body vehicles
have the following unique components.
² Fuel pump module
² Fuel level sensor
² Fuel gauge (gauge cluster).
² Fuel tank
² Fuel pressure regulator (including O-rings)
² Fuel rail
² Fuel injectors (including O-rings)
² Fuel tubes
² Fuel filter
² EVAP canister
² Fuel filler cap
² Fuel filler tube
² Pressure relief/Rollover valve
² All fuel system and emission system hoses and
tubes
Ä FUEL SYSTEMS 14 - 3