lock CHEVROLET DYNASTY 1993 Service Manual

ENGINE LUBRICATION SYSTEM
The lubrication system is a full flow filtration pres-
sure feed type. Oil from the oil pan is pumped by a
internal gear type oil pump directly coupled to the
crankshaft. Its pressure is regulated by a relief valve
located in the Chain Case Cover. The oil is pumped
through an oil filter and feeds a main oil galley.This
oil gallery feeds oil under pressure to the main and
rod bearings, camshaft bearings. Passages in the cyl-
inder block feed oil to the hydraulic lifters and
rocker shaft brackets which feeds the rocker arm piv-
ots (Fig. 1).
OIL PAN SERVICE
REMOVAL
(1) Disconnect negative battery cable, remove en-
gine oil dipstick. (2) Raise vehicle. Drain engine oil.
(3) Remove oil pan screws and remove oil pan.
CLEANING AND INSPECTION
(1) Clean oil pan in solvent and wipe dry with a
clean cloth. Clean all gasket material from mounting
surfaces of pan and block. (2) Inspect oil drain plug and plug hole for stripped
or damaged threads and repair as necessary. Install
a new drain plug gasket. Tighten to 27 N Im (20 ft.
lb.). (3) Inspect oil pan mounting flange for bends or
distortion. Straighten flange if necessary. (4) Clean oil screen and pipe in clean solvent. In-
spect condition of screen.
INSTALLATION
(1) Install oil pick-up tube into Chain Case Cover
tighten screw to 28 N Im (250 in. lbs.) (Fig. 2).
(2) Apply a 1/8 inch bead of Mopar Silicone Rubber
Adhesive Sealant or equivalent, at the parting line of
the chain case cover and the rear seal retainer (Fig. 3). (3) Use a new pan gasket (Fig. 4).
(4) Install pan and tighten screws to 23 N Im (200 in.
lb.).
(5) Lower vehicle and install oil dipstick.
(6) Connect negative battery cable.
(7) Fill crankcase with oil to proper level.
Fig. 1 Engine Oiling System
Fig. 2 Oil Pump Pick-up Tube Service
9 - 122 3.3/3.8L ENGINE Ä

CHECKING ENGINE OIL PRESSURE
Check oil pressure using gauge at oil pressure
switch location. Oil pressure should be 34.47 kPa ( 5
psi.) at idle or 205 to 551 kPa (30 to 80 psi.) at 3000
RPM. (1) Remove pressure sending unit and install oil
pressure gauge (Fig. 13).
CAUTION: If oil pressure is 0 at idle, Do Not Run
engine at 3000 RPM .
(2) Warm engine at high idle until thermostat
opens.
OIL FILTER
CAUTION: When servicing the oil filter (Fig. 16)
avoid deforming the filter can by installing the re-
move/install tool band strap against the can-to-base
lockseam. The lockseam joining the can to the base
is reinforced by the base plate.
(1) Using Tool C-4065, unscrew filter from base
and discard (Fig. 14). (2) Wipe base clean, then inspect gasket contact
surface. (3) Lubricate gasket of new filter with clean en-
gine oil. (4) Install and tighten filter to 20 N
Im (15 ft. lbs.)
torque after gasket contacts base. Use filter wrench
if necessary. (5) Start engine and check for leaks.
Fig. 12 Measuring Clearance Over RotorsFig. 13 Checking Oil Pump Pressure
Fig. 14 Oil Filter
Ä 3.3/3.8L ENGINE 9 - 125

(3) Inspect quick connect fittings for damage, re-
place if necessary Refer to Fuel System, Group 14 for
procedure. Lube tube with clean 30w engine oil, Con-
nect fuel supply and return hoses to chassis tube as-
sembly. Check connection by pulling on connector to
insure it locked into position (Fig. 9). (4) Connect Fuel Injector (Fig. 8), and Charge
Temperature Sensor wiring connectors (Fig. 7).
INTAKE MANIFOLD
(5) Connect Automatic Idle Speed (AIS) and Throt-
tle Position Sensor (TPS) wiring connectors (Fig. 6). (6) Connect vacuum hoses to throttle body (Fig. 5).
(7) Install intercooler to throttle body hose and
clamp. Torque clamp to 3 N Im (30 in. lbs.) (Fig. 5). (8) Connect accelerator and speed control cables
(Fig. 4). (9) Install DIS ignition coil pack. Tighten fasteners
to 12 N Im (105 in. lbs.) torque (Fig. 3).
(10) Install upper radiator hose and spring clamps
(Fig. 2). Fill cooling system, Refer to Cooling System,
Group 7. (11) Install fresh air duct to air filter housing. In-
stall inlet hose assembly to Intercooler. Tighten
clamp to 3 N Im (30 in. lbs.) torque (Fig. 1).
(12) Connect negative battery cable.
(13) With the DRBII Scan Tool use ASD Fuel Sys-
tem Test to pressurize system to check for leaks.
Fig. 5 Intercooler to Throttle Body Hose
Fig. 6 Automatic Idle Speed (AIS) Motor and
Throttle Position Sensor (TPS) Wiring Connectors
Fig. 7 Intake Manifold Electrical and Vacuum Hose Connections
Fig. 8 Camshaft Sensor and Fuel Injectors WiringConnectors
Ä EXHAUST SYSTEM AND INTAKE MANIFOLD 11 - 11

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.
TURBOCHARGER
REMOVAL
The turbocharger is removed from below the vehi-
cle. Cylinder head removal for component accessibil-
ity is not required. (1) Disconnect negative battery cable. Remove Air
Cleaner assembly (Fig. 1). (2) From Above: Remove front engine mount
through bolt and rotate engine (Top) forward away
from cowl. Refer to Engine Removal in Engine,
Group 9. (3) Remove Air Cleaner Support (Fig. 1).
(4) Disconnect Heated Oxygen sensor lead wire
and vacuum lines. (5) Separate coolant return line from water box
and turbocharger housing (Fig. 11). Remove return
line from turbocharger.
(6) Separate oil feed line from turbocharger hous-
ing (Fig. 12). (7) Remove three (two upper and one lower driver's
side) nuts retaining turbocharger to manifold (Fig.
12). (8) From Below: Remove right front wheel and
tire assembly. (9) See Suspension, Group 2, and remove right
driveshaft assembly. Air deflector may need to be removed from cross-
member. (10) Separate oil drain back tube fitting from tur-
bocharger housing and remove fitting and hose (Fig.
13). (11) Remove turbocharger to block support bracket
(Fig. 13). (12) Remove one remaining turbocharger to mani-
fold retaining nut (Fig. 12).
Fig. 11 Coolant Tube Routing
Fig. 12 Turbocharger Attaching Nuts
Fig. 9 Fuel Supply and Return Hose Connections
Fig. 10 Intake Manifold Attaching Bolts.
11 - 12 EXHAUST SYSTEM AND INTAKE MANIFOLD Ä

(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

² Clogged water passages in end cross overs and
clogged gas passages.
INTAKE MANIFOLD
INSTALLATION
(1) Clean all surfaces of cylinder block and cylin-
der heads. (2) Place a drop (about 1/4 in. diameter) of Mopar
Silicone Rubber Adhesive Sealant or equivalent, onto
each of the fourmanifold to cylinder head gasket
corners (Fig. 15).
WARNING: INTAKE MANIFOLD GASKET IS MADE
OF VERY THIN METAL AND MAY CAUSE PER-
SONAL INJURY, HANDLE WITH CARE.
(3) Carefully install the intake manifold gasket
(Fig. 14). Tighten end seal retainer screws to 12 N Im
(105 in. lbs.) torque. (4) Install intake manifold and (8) bolts and
tighten to 1 N Im (10 in. lbs.) torque. Then retighten
bolts to 22 N Im (200 in. lbs.) torque in sequence
shown in (Fig. 13). Then retighten again to 22 N Im
(200 in. lbs.)torque. After intake manifold is in place,
inspect to make sure seals are in place. (5) Make sure the injector holes are clean and all
plugs have been removed. (6) Lube injector O-ring with a drop of clean en-
gine oil to ease installation.
Fig. 11 Fuel Injector Wiring Clip
Fig. 12 Fuel Rail Removal
Fig. 13 Intake Manifold Removal and Installation
Fig. 14 Intake Manifold Gasket
11 - 22 EXHAUST SYSTEM AND INTAKE MANIFOLD Ä

CAUTION: When using the ASD Fuel System Test,
the Auto Shutdown (ASD) Relay remains energized
for either 7 minutes, until the test is stopped, or un-
til the ignition switch is turned to the Off position.
(4) Place the ignition key in the ON position. Us-
ing the DRBII scan tool, access ASD Fuel System
Test. The ASD Fuel System Test will activate the
fuel pump and pressurize the system. If the gauge reads the pressure shown in the Fuel
System Pressure chart, further testing is not re-
quired. If pressure is not correct, record the pressure
and remove gauge. If pressure is below specifications, proceed to Fuel
System Pressure Below Specifications . If pressure
is above specifications, proceed to Fuel System
Pressure Above Specifications .
Fuel System Pressure Below Specifications
If the fuel pressure reading in step (4) was below
specifications, test the system according to the fol-
lowing procedure.
WARNING: RELEASE FUEL SYSTEM PRESSURE
BEFORE DISCONNECTING A FUEL SYSTEM HOSE
OR COMPONENT.
(a) Perform Fuel Pressure Release procedure.
(b) Install Fuel Pressure Gauge C-4799 and Fuel
Pressure Adapter 6433 in the fuel supply line (Fig.
7) between the fuel tank and fuel filter. (c) Using the DRBII scan tool, with the ignition
key in the ON position, repeat the ASD Fuel Sys-
tem Test.
² If pressure is at least 5 psi higher than reading
recorded in step (4), replace fuel filter. ² If no change is observed, gently the squeeze re-
turn hose. If fuel pressure increases, replace pressure
regulator. If the gauge reading does not change while
squeezing the return hose, the problem is either a
plugged inlet strainer or defective fuel pump. Fuel System Pressure Above Specifications If the fuel pressure reading in step (4) was above
specifications test the system according to the follow-
ing procedure.
WARNING: FUEL SYSTEM PRESSURE MUST BE
RELEASED BEFORE A FUEL SYSTEM HOSE OR
COMPONENT IS DISCONNECTED.
(a) Perform Fuel Pressure Release procedure.
(b) Install Fuel Pressure Gauge C-4799 and Fuel
Pressure Adapter 6433 in the fuel supply line be-
tween the fuel tank and fuel filter (Fig. 7). (c) Remove the fuel return line hose from the
fuel pump at fuel tank. Connect Fuel Pressure Test
Adapter 6541 to the return line (Fig. 8). Place the
other end of adapter 6541 into an approved gaso-
line container or a container approved for gasoline/
methanol mixtures (minimum 2 gallon size). All
return fuel will flow into container. (d) Using the DRBII scan tool, with the ignition
key in the ON position, repeat the ASD Fuel Sys-
tem Test.
² If pressure is now correct, replace fuel pump as-
sembly. ²
If pressure is still above specifications, remove fuel
return hose from chassis fuel tubes (at engine). Attach
Fuel Pressure Test Connect Adapter 6541 to the fuel re-
turn hose and place other end of hose in clean approved
gasoline container or a container approved for metha-
nol/gasoline mixtures (Fig. 9). Repeat test. If pressure is
now correct, check for restricted fuel return line. If no
change is observed, replace fuel pressure regulator.
MECHANICAL MALFUNCTIONS
Mechanical malfunctions are more difficult to diag-
nose with this system. The powertrain control mod-
ule (PCM) compensates for some mechanical
malfunctions. If engine performance problems are en-
countered, and no fault codes are displayed, the prob-
lem may be mechanical rather than electronic.
FUEL PUMP MODULE REMOVAL
WARNING: RELEASE FUEL SYSTEM PRESSURE
BEFORE SERVICING FUEL SYSTEM COMPONENTS.
WHEN SERVICING FLEXIBLE FUEL VEHICLES,
WEAR METHANOL RESISTANT GLOVES AND EYE
PROTECTION AND AVOID BREATHING FUMES. DO
NOT ALLOW METHANOL/GASOLINE MIXTURES TO
CONTACT SKIN. SERVICE VEHICLES IN WELL VEN-
TILATED AREAS AND AVOID IGNITION SOURCES.
NEVER SMOKE WHILE SERVICING THE VEHICLE.
Remove the fuel tank to service the fuel pump. Re-
fer to Fuel Tank Section for fuel tank removal. (1) Using a hammer and a brass drift punch care-
fully tap lock ring counter clockwise to release pump
(Fig. 11).
Fig. 10 Fuel Pressure Gauge and Adapter
14 - 8 FUEL SYSTEMS Ä

(2) Remove fuel pump and O-ring seal from tank.
Discard old seal.
FUEL PUMP MODULE INSTALLATION
WARNING: FUEL PUMP MODULES DESIGNED FOR
GASOLINE ONLY VEHICLES CANNOT BE USED ON
FLEXIBLE FUEL AA-BODY VEHICLES. WHEN SER-
VICING THE FUEL SYSTEM OF A FLEXIBLE FUEL
VEHICLE, ONLY USE ORIGINAL EQUIPMENT OR
EQUIVALENT REPLACEMENT COMPONENTS.
(1) Wipe seal area of tank clean and place a new
O-ring seal in position on pump. (2) Position fuel pump in tank with locking ring.
(3) Using a hammer and brass drift, drive ring
around in clockwise direction to lock pump in place.
CAUTION: Over tightening the pump lock ring
may result in a leak.
(4) Install tank. Refer to the Fuel Tank Section in
this Group.
FUEL PUMP STRAINER SERVICE
WARNING: RELEASE FUEL SYSTEM PRESSURE
BEFORE SERVICING FUEL SYSTEM COMPONENTS.
WHEN SERVICING FLEXIBLE FUEL VEHICLES,
WEAR METHANOL RESISTANT GLOVES AND EYE
PROTECTION AND AVOID BREATHING FUMES. DO
NOT ALLOW METHANOL/GASOLINE MIXTURES TO
CONTACT SKIN. SERVICE VEHICLES IN WELL VEN-
TILATED AREAS AND AVOID IGNITION SOURCES.
NEVER SMOKE WHILE SERVICING THE VEHICLE.
REMOVAL
(1) Remove fuel pump module. Refer to Fuel Pump
Module in this section. (2) Bend locking tabs on fuel pump reservoir as-
sembly to clear locking tangs on the fuel pump
strainer (Fig. 12). (3) Pull strainer off.
(4) Remove strainer O-ring from the fuel pump
reservoir body. (5) Remove any contaminants by washing the in-
side of the fuel tank.
INSTALLATION
WARNING: FUEL STRAINERS (AND O-RINGS) DE-
SIGNED FOR GASOLINE ONLY VEHICLES CANNOT
BE USED ON FLEXIBLE FUEL AA-BODY VEHICLES.
WHEN SERVICING THE FUEL SYSTEM OF A FLEX-
IBLE FUEL VEHICLE, ONLY USE ORIGINAL EQUIP-
MENT OR EQUIVALENT REPLACEMENT
COMPONENTS.
(1) Lubricate the strainer O-ring with Mopar Sili-
cone Spray Lube. (2) Insert strainer O-ring into outlet of strainer so
that it sits evenly on the step inside the outlet. (3) Push strainer onto the inlet of the fuel pump
reservoir body. Make sure the locking tabs on the
reservoir body lock over the locking tangs on the
strainer. (4) Install fuel pump module. Refer to Fuel Pump
Module in this section.
FUEL FILTERÐALL VEHICLES
WARNING: RELEASE FUEL SYSTEM PRESSURE
BEFORE SERVICING FUEL SYSTEM COMPONENTS.
WHEN SERVICING FLEXIBLE FUEL VEHICLES,
WEAR METHANOL RESISTANT GLOVES AND EYE
PROTECTION AND AVOID BREATHING FUMES. DO
NOT ALLOW METHANOL/GASOLINE MIXTURES TO
CONTACT SKIN. SERVICE VEHICLES IN WELL VEN-
TILATED AREAS AND AVOID IGNITION SOURCES.
NEVER SMOKE WHILE SERVICING THE VEHICLE.
Fig. 11 Fuel Pump Service
Fig. 12 Fuel Strainer Service
Ä FUEL SYSTEMS 14 - 9

REMOVAL
(1) Perform the Fuel System Pressure Release pro-
cedure. (2) ) Remove the fuel filter retaining screw (Fig.
13). Remove fuel filter from mounting plate.
(3) Wrap a shop towel around hoses to absorb fuel.
Remove quick-connect fittings at filter and fuel supply
tube. Refer to Quick-Connect Fittings in this section.
INSTALLATION
WARNING: FUEL FILTERS DESIGNED FOR GASO-
LINE ONLY VEHICLES CANNOT BE USED ON
FLEXIBLE FUEL AA-BODY VEHICLES. WHEN SER-
VICING THE FUEL SYSTEM OF A FLEXIBLE FUEL
VEHICLE, ONLY USE ORIGINAL EQUIPMENT OR
EQUIVALENT REPLACEMENT COMPONENTS.
(1) Connect quick-connect fuel fittings to the filter
and fuel supply line. Refer to Quick-Connect Fittings
in this section. (2) Position filter assembly on mounting plate and
tighten mounting screw to 8 N Im (75 in. lbs.) torque.
CAUTION: When using the ASD Fuel System Test,
the Auto Shutdown (ASD) Relay remains energized
for either 7 minutes, until the test is stopped, or un-
til the ignition switch is turned to the Off position.
(3) Place the ignition key in the ON position. Us-
ing the DRBII scan tool, access ASD Fuel System
Test. The ASD Fuel System Test will activate the
fuel pump and pressurize the system. Inspect for
leaks.
FUEL HOSES, CLAMPS, AND QUICK CONNECT
FITTINGS
HOSES AND CLAMPS
WARNING: RELEASE FUEL SYSTEM PRESSURE
BEFORE SERVICING FUEL SYSTEM COMPONENTS. WHEN SERVICING FLEXIBLE FUEL VEHICLES,
WEAR METHANOL RESISTANT GLOVES AND EYE
PROTECTION AND AVOID BREATHING FUMES. DO
NOT ALLOW METHANOL/GASOLINE MIXTURES TO
CONTACT SKIN. SERVICE VEHICLES IN WELL VEN-
TILATED AREAS AND AVOID IGNITION SOURCES.
NEVER SMOKE WHILE SERVICING THE VEHICLE.
WARNING: FUEL SYSTEM HOSES AND TUBES DE-
SIGNED FOR GASOLINE ONLY VEHICLES CANNOT
BE USED ON FLEXIBLE FUEL VEHICLES. WHEN
SERVICING THE FUEL SYSTEM OF A FLEXIBLE
FUEL VEHICLE, ONLY USE ORIGINAL EQUIPMENT
OR EQUIVALENT REPLACEMENT COMPONENTS.
Inspect all hose connections (clamps and quick con-
nect fittings) for completeness and make sure they
are not leaking. Hoses that are cracked, scuffed,
swelled, rub against other vehicle components or
show any sign of wear, should be replaced.
When installing hoses, route them away from compo-
nents they could rub against. Avoid contact with clamps
or other components that cause abrasions or scuffing.
Ensure rubber hoses are properly routed and avoid heat
sources. The clamps have rolled edge to prevent the clamp
from cutting into the hose. Only use clamps that are
original equipment or equivalent. Other types of clamps
may cut into the hoses and cause high pressure fuel
leaks. Tighten hose clamps to 1 N Im (10 in. lbs.) torque.
QUICK CONNECT FITTINGS
Most fuel lines have quick connect fittings. The fit-
tings speed up the installation and removal of fuel
lines (Fig. 14). Quick connect fittings consist of a metal casing, a
black plastic release ring, a metal locking retainer,
and internal O-rings.
METAL QUICK CONNECT FITTINGS
The fuel filter and fuel rail use steel quick-connect
fittings. The fitting contains non-serviceable sealed
O-rings. The fittings contain a plastic disconnect tool.
The quick-connect fitting consists of the O-rings, cas-
ing, disconnect tool and a retainer (Fig. 14). When the
Fig. 13 Fuel Filter
Fig. 14 Metal Quick-Connect Fittings
14 - 10 FUEL SYSTEMS Ä

fuel tube enters the fitting, the retainer locks the shoul-
der of the nipple in place and the O-rings seal the tube.
CAUTION: Quick-connect fittings are not serviced
separately. Do not attempt to repair damaged quick-
connect fittings or fuel tubes. Replace the complete
fuel tube/quick-connect fitting assembly.
When installing fuel tubes, route them in the holders
along the frame rail, fuel tank and the rear of the en-
gine.
REMOVAL
WARNING: RELEASE FUEL SYSTEM PRESSURE
BEFORE SERVICING FUEL SYSTEM COMPONENTS.
WHEN SERVICING FLEXIBLE FUEL VEHICLES,
WEAR METHANOL RESISTANT GLOVES AND EYE
PROTECTION AND AVOID BREATHING FUMES. DO
NOT ALLOW METHANOL/GASOLINE MIXTURES TO
CONTACT SKIN. SERVICE VEHICLES IN WELL VEN-
TILATED AREAS AND AVOID IGNITION SOURCES.
NEVER SMOKE WHILE SERVICING THE VEHICLE.
(1) Disconnect negative cable from the battery.
(2) Perform the Fuel Pressure Release Procedure.
Refer to the Fuel Pressure Release Procedure in this
section. (3) Remove any loose dirt from quick connect fit-
tings.
WARNING: WRAP SHOP TOWELS AROUND HOSES
TO CATCH ANY FUEL SPILLAGE.
(4) Push the quick connect fitting toward the fuel
tube while depressing the built-in release tool. Then
slightly twist the fitting and pull it off the fuel tube
(Fig. 14). (5) Cover the fitting to prevent contamination.
TUBE/FITTING SERVICE
WARNING: RELEASE FUEL SYSTEM PRESSURE
BEFORE SERVICING FUEL SYSTEM COMPONENTS.
WHEN SERVICING FLEXIBLE FUEL VEHICLES,
WEAR METHANOL RESISTANT GLOVES AND EYE
PROTECTION AND AVOID BREATHING FUMES. DO
NOT ALLOW METHANOL/GASOLINE MIXTURES TO
CONTACT SKIN. SERVICE VEHICLES IN WELL VEN-
TILATED AREAS AND AVOID IGNITION SOURCES.
NEVER SMOKE WHILE SERVICING THE VEHICLE.
If a quick connect fitting needs service, the follow-
ing procedure must be followed: (1) Disconnect the battery negative battery cable.
(2) Perform the Fuel System Pressure Release Pro-
cedure.
WARNING: WRAP SHOP TOWELS AROUND HOSES
TO CATCH ANY FUEL SPILLAGE. (3) Remove the quick connect fitting from the fuel
tube by pushing in on the plastic ring located on the
end of the fitting. Gently pull the fitting from the
fuel tube. (4) Cut off the crimp ferrules at each end of the
hose, taking care not to damage the quick connect
fitting or the fuel tube. (5) Discard the ferrules and hose.
WARNING: FUEL SYSTEM HOSES AND TUBES DE-
SIGNED FOR GASOLINE ONLY VEHICLES CANNOT
BE USED ON FLEXIBLE FUEL VEHICLES. WHEN
SERVICING THE FUEL SYSTEM OF A FLEXIBLE
FUEL VEHICLE, ONLY USE ORIGINAL EQUIPMENT
OR EQUIVALENT REPLACEMENT COMPONENTS.
(6) Replace the hose using original equipment or
equivalent hose. (7) Attach the replacement hose to the quick con-
nect fitting and fuel tube using the correct hose
clamps (Fig. 15). Original equipment hose clamps
have a special rolled edge construction to prevent the
edge of the clamp cutting into the hose. Only original
equipment clamps or equivalent may be used in this
system. Other types of clamps may cut into the hoses
and cause high pressure fuel leaks. (8) Tighten hose clamps to 1 N Im (10 in. lbs.)
torque.
CAUTION: When using the ASD Fuel System Test,
the Auto Shutdown (ASD) Relay remains energized
for either 7 minutes, until the test is stopped, or un-
til the ignition switch is turned to the Off position.
(9) Use the DRBII scan tool ASD Fuel System Test
to pressurize the fuel system. Check for leaks.
CHASSIS FUEL TUBES
Figures 16 and 17 show fuel system component lo-
cations and chassis fuel tube routings.
Fig. 15 Quick Connect Fuel Fittings
Ä FUEL SYSTEMS 14 - 11