fuel cap release CHEVROLET PLYMOUTH ACCLAIM 1993 User Guide

FUEL TANKS INDEX
page page
Flexible Fuel Vehicles ..................... 14
Fuel Pump Module ....................... 18
Fuel Reservoir ........................... 18
Fuel System Pressure Release ProcedureÐ 2.2L/2.5L TBI .......................... 15
Fuel System Pressure Release ProcedureÐ3.0L . 15
Fuel System Pressure Release ProcedureÐ Except 2.2L/2.5L TBI and 3.0L ............. 15 Fuel Tank
.............................. 16
Fuel Tank Level Sensor ................... 18
Fuel Tank Pressure Relief and Roll-Over Valve . . 20
General Information ....................... 14
Identifying Flexible Fuel Components .......... 14
Methanol Concentration Sensor .............. 18
Pressure Vacuum Fuel Filler Tube Cap ........ 14
Service Precautions for Flexible Fuel Vehicles . . . 14
GENERAL INFORMATION
The fuel tanks of Chrysler Corporation built vehi-
cles are equipped with fuel and vapor controls that
allow the vehicle to pass a full 360É rollover. The fuel delivery system used on front wheel drive
vehicles contains a fuel tank pressure relief/rollover
valve. The valve mounts on the top of the fuel tank.
The valve functions as a pressure relief valve while
the vehicle is upright. The valve also contains a
check valve that prevents fuel from escaping the fuel
tank if the vehicle turns over. The fuel filler cap also acts as a pressure/vacuum
valve. When pressure inside the fuel tank gets too
high or too low, the fuel filler cap opens to relieve
the difference in air pressure. An evaporation control system restricts fuel evapo-
ration into the atmosphere and reduces unburned hy-
drocarbons. Vapors from the fuel tank are collected
in a charcoal filled canister. The vapors are held in
the canister until the engine is operating. When the
engine operates, vapors are drawn through the in-
take manifold into the combustion chambers.
FLEXIBLE FUEL VEHICLES
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.
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 AA-body vehicles
must not be used on flexible fuel vehicles.
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.
PRESSURE VACUUM FUEL FILLER TUBE CAP
WARNING: REMOVE FUEL FILLER TUBE CAP TO
RELIEVE TANK PRESSURE BEFORE REMOVING
OR REPAIRING FUEL SYSTEM COMPONENTS.
The loss of any fuel or vapor out of the filler tube
neck is prevented by the use of a safety filler cap.
The cap releases only under significant pressure 10.9
to 13.45 kPa (1.58 to 1.95 psi). The vacuum release
for all gas caps is between .97 and 2.0 kPa (.14 and
.29 psi). The cap must be replaced by a similar unit
in order for the system to remain effective.
14 - 14 FUEL SYSTEMS Ä

WARNING: FUEL FILLER TUBE CAPS DESIGNED
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.
FUEL SYSTEM PRESSURE RELEASE
PROCEDUREÐEXCEPT 2.2L/2.5L TBI AND 3.0L
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 battery.
(2) Remove fuel filler cap.
(3) Remove the protective cap from the fuel pres-
sure test port on the fuel rail (Fig. 1).
(4) Place the open end of fuel pressure release
hose, tool number C-4799-1, into an approved gaso- line container or a container approved for methanol/
gasoline mixtures. Connect the other end of hose
C-4799-1 to the fuel pressure test port (Fig. 2). Fuel
pressure will bleed off through the hose into the gas-
oline container. Fuel gauge C-4799-A contains hose
C-4799-1.
FUEL SYSTEM PRESSURE RELEASE
PROCEDUREÐ2.2L/2.5L TBI
CAUTION: Before servicing the fuel pump, fuel
lines, fuel filter, throttle body, or fuel injector, re-
lease fuel system pressure.
(1) Loosen fuel filler cap to release fuel tank pres-
sure. (2) Disconnect injector wiring harness connector at
edge of throttle body (Fig. 3). (3) Connect a jumper wire between terminal Num-
ber 1 of the injector harness and engine ground. (4) Connect a jumper wire to the positive terminal
Number 2 of the injector harness and touch the bat-
tery positive post for no longer than 5 seconds .
This releases system pressure. (5) Remove jumper wires.
(6) Continue fuel system service.
FUEL SYSTEM PRESSURE RELEASE
PROCEDUREÐ3.0L
(1) Disconnect the fuel rail electrical harness from
the engine harness. Refer to Group 8W, Wiring Dia-
grams. (2) Connect one end of a jumper wire to the A142
circuit terminal of the fuel rail harness connector. (3) Connect the other end of the jumper wire to a
12 volt power source. (4) Connect one end of a jumper wire to a good
ground source. (5) Momentarily ground one of the injectors by
connecting the other end of the jumper wire to an in-
FUEL TANK CAPACITIES
Fig. 1 Fuel Pressure Test PortÐTypical
Fig. 2 Releasing Fuel PressureÐEngines With Test Ports On Fuel Rail
Ä FUEL SYSTEMS 14 - 15

jector terminal in the harness connector. Repeat pro-
cedure for 2 to 3 injectors.
FUEL TANK
DRAINING FUEL TANK
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) Remove fuel filler cap.
(2) Perform the Fuel System Pressure Release pro-
cedure. (3) Remove ground cable from battery.
(4) Raise vehicle on hoist.
(5) Remove rubber cap from drain tube. The tube
is located on rear of fuel tank. Connect either a por-
table holding tank or a siphon hose to the drain tube
(Fig. 4). (6) Drain fuel tank into holding tank or a properly
labeled Gasoline safety container.
FUEL TANK 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) Perform fuel system pressure release.
(2) Drain fuel tank. Refer to Draining Fuel Tank
in this section. (3) Remove fuel filler tube to quarter panel screws
(Fig. 5). (4) Raise vehicle on hoist. Some models will re-
quire removal of the right rear wheel to access the
fuel filler tube.
WARNING: WRAP SHOP TOWELS AROUND HOSES
TO CATCH ANY GASOLINE SPILLAGE.
(5) Disconnect fuel pump and gauge sending unit
electrical connectors. (6) Disconnect the fuel supply and return hoses
from fuel pump. Refer to Quick Connect Hoses in the
Fuel Delivery section of this group. (7) Support tank with transmission jack. Loosen
tank mounting straps and lower tank slightly. Re-
move hose from pressure relief/rollover valve. (8) Carefully work fuel filler tube from tank.
(9) Remove tank mounting straps and lower tank.
(10) If removing tank from an flexible fuel AA-
body vehicle, inspect the heat shield. Replace as nec-
essary.
Fig. 3 Injector Harness ConnectorÐ2.2L/2.5L TBIFig. 4 Drain Tube Connection Location
14 - 16 FUEL SYSTEMS Ä

INSTALLATION
WARNING: FUEL TANKS 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) Position fuel tank on transmission jack. Con-
nect vapor separator/rollover valve hose and position
insulator pad on fuel tank. Position vapor vent so
that it is not pinched between tank and floor pan
during installation. (2) Raise tank and fuel filler tube carefully into
position. Use a light coating of power steering fluid
to ease fuel filler tube installation. Ensure filler tube
grommet is not damaged. Verify that the tube is in-
stalled correctly. (3) Tighten fuel tank strap nuts to 23 N Im (250 in.
lbs.) torque. Remove transmission jack. Ensure
straps are not twisted or bent. (4) Lubricate the metal tubes on the fuel pump
with clean 30 weight engine oil. Install the quick
connect fuel fittings. Refer to Quick Connect Fittings
in the Fuel Delivery section of this Group. (5) Attach electrical connector to fuel pump mod-
ule and level sensor unit. (6) Lower the vehicle.
(7) Attach filler tube to filler neck opening in
quarter panel. Tighten quarter panel screws to 2
N Im (17 in. lbs.) torque.
(8) Fill fuel tank, install filler cap, and connect
battery cable.
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.
FUEL PUMP MODULE
Refer to the Fuel Delivery section of this group.
METHANOL CONCENTRATION SENSOR
Refer to the Fuel Delivery section of this group.
FUEL RESERVOIR
The fuel reservoir is internal to the fuel pump as-
sembly (Fig. 6). The purpose is to provide fuel at the
fuel pump intake during all driving conditions, espe-
cially when low fuel levels are present.
FUEL TANK LEVEL SENSOR
DIAGNOSIS
This procedure test the resistance of the level sen-
sor itself. It does not test the level sensor circuit. Re-
fer to Group 8W, Wiring Diagrams for circuit
identification and Group 8E, Instrument Panel and
Gauges for fuel gauge information. The level sensor is a variable resistor. Its resis-
tance changes with the amount of fuel in the tank.
The float arm attached to the sensor moves as the
fuel level changes. To test the level sensor, connect
an ohmmeter across the sensor signal and sensor
ground terminals of the fuel level sensor connector
(Fig. 7 or Fig. 8). Move the float lever to the full stop
and empty stop positions shown in the resistance
chart (Fig. 7 or Fig. 8). Record the resistance at each
point. Replace the level sensor if the resistance is not
within specifications. The low fuel warning light specifications determine
if the level sensor portion of the warning light circuit
functions properly. It does not test the complete
warning light circuit. Refer to Group 8W, Wiring Diagrams for circuit
identification and Group 8E, Instrument Panel and
Gauges for fuel gauge information.
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.
Fig. 6 Fuel Reservoir
14 - 18 FUEL SYSTEMS Ä

2.2L/2.5L SINGLE POINT FUEL INJECTIONÐSERVICE PROCEDURES INDEX
page page
Canister Purge Solenoid ................... 53
Electric Exhaust Gas Recirculation Transducer (EET) Service ............................... 53
Fuel Fitting ............................. 50
Fuel Injector ............................ 51
Fuel Lines and Hoses ..................... 48
Fuel Pressure Regulator ................... 51 Fuel System Pressure Release Procedure
...... 48
Heated Oxygen Sensor (O
2Sensor) .......... 54
Idle Air Control Motor ..................... 53
Manifold Absolute Pressure Sensor ........... 53
PCM Service ............................ 54
Throttle Body ............................ 48
Throttle Position Sensor ................... 52
FUEL LINES AND HOSES
Perform the Fuel System Pressure Relief Procedure
before servicing the fuel system. The procedure must
be done to bleed fuel pressure from the system before
removing clamps or hoses. Use care when removing fuel hoses to prevent dam-
age to hose or hose nipple. Always use new hose
clamps, of the correct type, during reassembly. Tighten
hose clamps to 1 N Im (10 in. lbs.) torque. Do not use
aviation style clamps on this system or hose
damage may result.
FUEL SYSTEM PRESSURE RELEASE PROCEDURE
CAUTION: Before servicing the fuel pump, fuel lines,
fuel filter, throttle body, or fuel injector, release fuel
system pressure.
(1) Loosen fuel filler cap to release fuel tank pres-
sure. (2) Disconnect injector wiring harness connector at
edge of throttle body (Fig. 1). (3) Connect a jumper wire between terminal Num-
ber 1 of the injector harness and engine ground. (4) Connect a jumper wire to the positive terminal
Number 2 of the injector harness and touch the battery
positive post for no longer than 5 seconds . This
releases system pressure. (5) Remove jumper wires.
(6) Continue fuel system service.
THROTTLE BODY
CAUTION: The fuel system is under a constant pres-
sure of 270 kPa (39 psi). When servicing the fuel
portion of the throttle body, release fuel pressure
before disconnecting any tubes. Refer to the fuel
pressure release procedure.
Always reassemble throttle body components with
new O-rings and seals where applicable. Never use
silicone lubricants on O-rings or seals, damage may
result. Use care when removing fuel tubes to prevent
damage to quick connect fittings or tube ends. Refer to Fuel Hoses, Clamps, and Quick Connect Fittings
in the Fuel Delivery Section of this Group.
REMOVAL
(1) Remove air cleaner (Fig. 2).
(2) Perform fuel system pressure release procedure.
(3) Disconnect negative battery cable.
(4) Disconnect vacuum hoses and electrical connec-
tors (Fig. 3).
Fig. 1 Injector Harness Connector
Fig. 2 Throttle Body and Air Cleaner Assembly
14 - 48 FUEL SYSTEMS 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. (6) With the ignition key in ON position, access
the DRBII scan tool ASD Fuel System Test to pres-
surize the fuel system. Check for leaks. (7) Reinstall air cleaner assembly.
FUEL PRESSURE REGULATOR
The fuel pressure regulator is mounted on top of
the throttle body (Fig. 6).
REMOVAL
(1) Remove air cleaner assembly.
(2) Perform Fuel System Pressure Release proce-
dure. (3) Disconnect battery negative cable.
(4) Remove pressure regulator mounting screws
(Fig. 6).
WARNING: PLACE A SHOP TOWEL AROUND FUEL
INLET CHAMBER TO CONTAIN ANY FUEL REMAIN-
ING IN THE SYSTEM.
(5) Pull pressure regulator from the throttle body.
(6) Carefully remove O-ring from pressure regula-
tor and remove gasket.
INSTALLATION
(1) Place new gasket on pressure regulator. Care-
fully install new O-ring. (2) Position pressure regulator on throttle body.
Press regulator into place and install mounting
screws. Tighten screws to 5 N Im (40 in. lbs.) torque.
(3) Connect negative cable to battery.
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) With the ignition key in ON position, access
the DRBII scan tool ASD Fuel System Test to pres-
surize the fuel system. Check for leaks. (5) Reinstall air cleaner assembly.
FUEL INJECTOR
The fuel injector is installed in the top of the throt-
tle body. The injector is covered by a cap.
REMOVAL
(1) Remove air cleaner assembly.
(2) Perform Fuel System Pressure Release proce-
dure. (3) Disconnect negative cable from battery.
(4) Remove injector cap holddown screw (Torx-
head). (5) With two small screwdrivers, lift the top off the
injector using the slots provided (Fig. 7).
(6) Using a small screwdriver placed in the hole in
the front of the electrical connector, gently pry the
injector from the pod (Fig. 8).
Fig. 6 Servicing Fuel Pressure Regulator
Fig. 7 Removing Injector Cap
Fig. 8 Removing Fuel Injector
Ä FUEL SYSTEMS 14 - 51

2.5L FLEXIBLE FUEL MULTI-PORT FUEL INJECTIONÐSERVICE PROCEDURES INDEX
page page
Fuel Injector ............................. 80
Fuel Injector Rail Assembly ................. 79
Fuel Pressure Regulator .................... 81
Fuel System Pressure Release Procedure ...... 78
General Information ....................... 77
Heated Oxygen Sensor (O
2Sensor) ........... 82
Identifying Flexible Fuel Components .......... 77
Idle Air Control Motor ...................... 78 Manifold Absolute Pressure (MAP) Sensor
Service ............................... 82
Methanol Concentration Sensor .............. 82
PCM Service ............................ 82
Service Precautions for Flexible Fuel Vehicles .... 77
Throttle Body ............................ 77
Throttle Body Removal ..................... 79
Throttle Position Sensor (TPS) ............... 78
GENERAL INFORMATION
In this model year Chrysler began producing AA-
Body vehicles designed to operate on a mixture of
gasoline and methanol. These automobiles are referred
to as Flexible Fuel vehicles. Fuel system components
designed for use in flexible fuel vehicles are referred to
as Methanol Compatible. Flexible fuel vehicles can operate on a mixture of up
to 85 percent methanol, 15 percent unleaded gasoline.
These vehicles also operate on mixtures containing a
lower percentage of methanol or just pure unleaded
gasoline.
SERVICE PRECAUTIONS FOR FLEXIBLE FUEL
VEHICLES
Methanol is more toxic than gasoline. Always release
fuel system pressure before servicing fuel system com-
ponents and wear methanol resistant gloves and eye
protection. Avoid breathing methanol vapors or ingesting
methanol. Headaches, dizziness and even unconscious-
ness 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 allergic
skin reaction. Also, prolonged contact could result in
absorption through the skin.
IDENTIFYING FLEXIBLE FUEL COMPONENTS
Flexible Fuel vehicles have unique methanol compat-
ible fuel system components. Chrysler identifies methanol
compatible components that could be physically inter-
changed with gasoline only parts by coloring them green
or applying a green label or tag to them. Even though
they may appear physically identical, components
for gasoline only AA-body vehicles must not be used
on flexible fuel vehicles.
FLEXIBLE FUEL COMPONENTS
The fuel system of flexible fuel AA-body vehicles have
the following unique methanol compatible components.
² Duty cycle EVAP purge solenoid
² EVAP canister
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 Fuel filler cap
² Fuel filler tube
² Methanol concentration sensor
² Pressure relief/rollover valve
² PCV Valve
² All fuel system and emission system hoses and tubes
THROTTLE BODY
WARNING: THROTTLE BODIES DESIGNED FOR
GASOLINE ONLY VEHICLES CANNOT BE USED ON
FLEXIBLE FUEL AA-BODY VEHICLES. WHEN RE-
PLACING THE THROTTLE BODY OF A FLEXIBLE
FUEL VEHICLE, ONLY USE AN ORIGINAL EQUIP-
MENT REPLACEMENT.
When servicing throttle body components, always
reassemble components with new O-rings and seals
where applicable. Never use lubricants on O-rings or
seals, damage may result. If assembly of component is
difficult, use water to aid assembly. Use care when
removing hoses to prevent damage to hose or hose
nipple.
Ä FUEL SYSTEMS 14 - 77

FUEL SYSTEM PRESSURE RELEASE PROCEDURE
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 battery.
(2) Remove fuel filler cap.
(3) Remove the protective cap from the fuel pres-
sure test port on the fuel rail (Fig. 2).
(4) Place the open end of fuel pressure release
hose, tool number C-4799-1, into a container ap-
proved for methanol/gasoline mixtures. Connect the
other end of hose C-4799-1 to the fuel pressure test
port (Fig. 3). Fuel pressure will bleed off through the
hose into the gasoline container. Fuel gauge
C-4799-A contains hose C-4799-1.
THROTTLE POSITION SENSOR (TPS)
REMOVAL
(1) Disconnect the negative cable from the battery.
(2) Disconnect harness connector from throttle po-
sition sensor (Fig. 4). (3) Remove throttle position sensor mounting
screws. (4) Lift throttle position sensor off throttle shaft.
INSTALLATION
(1) Install throttle position sensor on throttle shaft.
Install mounting screws. Tighten screws to 2 N Im (17
in. lbs.) torque. (2) Attach harness connector to sensor.
(3) Connect negative cable to negative post of the
battery.
IDLE AIR CONTROL MOTOR
REMOVAL
(1) Disconnect negative cable from battery.
(2) Disconnect harness connector from idle air con-
trol motor (Fig. 5).
Fig. 1 Throttle Body
Fig. 2 Fuel Pressure Test Port
Fig. 3 Releasing Fuel Pressure
Fig. 4 Servicing Throttle Position Sensor
14 - 78 FUEL SYSTEMS Ä

(3) Ensure the injector holes are clean and all plugs
have been removed. (4) Lubricate the injector O-rings with a drop of
clean engine oil to ease installation. (5) Install the injector assembly into their holes.
Install mounting screws. Fuel rail assembly must be
drawn into the intake manifold evenly making sure
each injector enters its own hole. Once all injectors are
seated, tighten bolts to 23 N Im (200 in. lbs) torque.
(6) Connect vacuum hose to fuel pressure regulator.
(7) Close fuel tube clip around fuel tubes and install
fastener. (8) Lubricate the ends of the chassis fuel tubes with
a light coating of clean 30 weight engine oil. Connect
fuel supply and return hoses to chassis fuel tube
assembly. Pull back on the quick connect fittings to
ensure complete insertion. Refer to Quick Connect
Fittings in the Fuel Delivery section of this group. (9) Connect vacuum hose intake manifold nipple.
(10) Connect negative cable to battery.
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 until the
ignition switch is turned to the Off position.
(11) With the DRBII scan tool, use the ASD Fuel
System Test to pressurize system and check for leaks.
FUEL INJECTOR
The fuel rail must be removed to service the injec-
tors. Refer to Fuel Injector Rail Assembly in this
section.
REMOVAL
WARNING: RELEASE FUEL SYSTEM PRESSURE BE-
FORE 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 electrical connector from injector
(Fig. 8).
(2) Position fuel rail assembly so that the fuel injec-
tors are easily accessible (Fig. 9). (3) Remove injector lock ring from fuel rail and
injector. Pull injector straight out of fuel rail receiver
cup. (4) Check injector O-ring for damage. Replace dam-
aged O-rings. If injector is reused, install a protective
cap on the injector tip to prevent damage. (5) Repeat steps for remaining injectors.
INSTALLATION
WARNING: FUEL INJECTORS AND INJECTOR
O-RINGS DESIGNED FOR GASOLINE ONLY VE-
HICLES CANNOT BE USED ON FLEXIBLE FUEL AA-
BODY VEHICLES. WHEN SERVICING THE FUEL SYS-
TEM OF A FLEXIBLE FUEL VEHICLE, ONLY USE
ORIGINAL EQUIPMENT OR EQUIVALENT REPLACE-
MENT COMPONENTS.
Fig. 7 Fuel Injector Ports
Fig. 8 Servicing Fuel Injectors
14 - 80 FUEL SYSTEMS Ä

2.2L TURBO III MULTI-PORT FUEL INJECTIONÐSERVICE PROCEDURES INDEX
page page
Fuel Injector Rail Assembly ................ 109
Fuel Injectors .......................... 110
Fuel Pressure Regulator .................. 111
Fuel System Pressure Release Procedure ..... 107
Heated Oxygen Sensor (O
2Sensor) ......... 112
Idle Air Control Motor .................... 108
Manifold Absolute Pressure (MAP) Sensor Service .............................. 111 PCM Service
........................... 111
Throttle Body ........................... 107
Throttle Body Removal ................... 108
Throttle Position Sensor (TPS) ............. 107
Wastegate and Canister Purge Solenoid Service . 111
THROTTLE BODY
When servicing throttle body components, always
reassemble components with new O-rings and seals
where applicable (Fig. 1). Never use lubricants on
O-rings or seals, damage may result. If assembly of
component is difficult, use water to aid assembly.
Use care when removing hoses to prevent damage to
hose or hose nipple.
FUEL SYSTEM PRESSURE RELEASE PROCEDURE
CAUTION: The fuel system is under a constant
pressure of approximately 380 kPa (55 psi). Before
servicing the fuel pump, fuel lines, fuel filter, throt-
tle body, or fuel injectors, the fuel system pressure
must be released.
(1) Disconnect negative cable from battery.
(2) Remove fuel filler cap. (3) Remove the protective cap from the fuel pres-
sure test port on the fuel rail (Fig. 2). (4) Place the open end of fuel pressure release
hose, tool number C-4799-1, into an approved gaso-
line container. Connect the other end of hose
C-4799-1 to the fuel pressure test port. Fuel pressure
will bleed off through the hose into the gasoline con-
tainer. Fuel gauge C-4799-A contains hose C-4799-1. (5) Continue fuel system service.THROTTLE POSITION SENSOR (TPS)
REMOVAL
(1) Disconnect the negative cable from the battery.
(2) Disconnect harness connector from throttle po-
sition sensor (Fig. 3). (3) Remove throttle position sensor mounting
screws. (4) Lift throttle position sensor off throttle shaft.
Fig. 1 Throttle Body
Ä FUEL SYSTEMS 14 - 107