fuel pump CHRYSLER CARAVAN 2003 Owner's Manual
[x] Cancel search | Manufacturer: CHRYSLER, Model Year: 2003, Model line: CARAVAN, Model: CHRYSLER CARAVAN 2003Pages: 2177, PDF Size: 59.81 MB
Page 1059 of 2177
INTEGRATED POWER MODULE C7 - 20 WAY
CAV CIRCUIT FUNCTION
1 C16 20DB/GY FUSED REAR WINDOW DEFOGGER RELAY OUTPUT
2 T751 20YL (GAS) FUSED IGNITION SWITCH OUTPUT (START)
2 T141 20YL/OR (DIESEL) FUSED IGNITION SWITCH OUTPUT (START)
3 D25 20WT/VT PCI BUS
4 L13 20WT/YL (EXPORT) HEADLAMP ADJUST SIGNAL
5 K32 18DB/YL (GAS) BRAKE TRANSMISSION SHIFT INTERLOCK SOLENOID
CONTROL
6- -
7 W7 20BR/GY FRONT WIPER PARK SWITCH SENSE
8 B20 20DG/OR BRAKE FLUID LEVEL SWITCH SENSE
9 F201 18PK/OR ORC RUN-START DRIVER
10 F214 18PK/LG (SIACM) SIACM RUN-START DRIVER
11 A106 20LB/RD FUSED B(+)
12 - -
13 F2 18PK/YL (GAS) FCM OUTPUT (UNLOCK-RUN-START)
14 - -
15 A114 16GY/RD FUSED B(+) (I.O.D.)
16 D123 20WT/BR FLASH PROGRAM ENABLE
17 L50 18WT/TN BRAKE LAMP SWITCH OUTPUT
18 X13 16DG/GY (PREMIUM 8 SPEAKER) NAME BRAND SPEAKER RELAY OUTPUT
19 X3 20DG/VT HORN SWITCH SENSE
20 F100 18PK/VT ORC RUN ONLY DRIVER
INTEGRATED POWER MODULE C8 - ORANGE 10 WAY
CAV CIRCUIT FUNCTION
1 W3 14BR/WT FRONT WIPER HIGH/LOW RELAY LOW SPEED
OUTPUT
2 N1 18DB/OR (GAS) FUEL PUMP RELAY OUTPUT
2 N1 16DB/OR (DIESEL) FUEL HEATER RELAY OUTPUT
3 A108 20LG/RD FUSED B(+)
4 A103 18GY/RD FUSED B(+)
5 L77 20WT/BR FUSED PARK LAMP RELAY OUTPUT (LEFT)
6 W4 14BR/OR FRONT WIPER HIGH/LOW RELAY HIGH SPEED
OUTPUT
7 C51 12LB/BR (3 ZONE ATC/MTC) FUSED REAR BLOWER MOTOR RELAY OUTPUT
8- -
9 L78 18WT/OR FUSED PARK LAMP RELAY OUTPUT (RIGHT)
10 L60 18WT/TN RIGHT FRONT TURN SIGNAL DRIVER
8W - 80 - 78 8W-80 CONNECTOR PIN-OUTSRS
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POWERTRAIN CONTROL MODULE C2 (SBEC) - GRAY/GRAY 40 WAY
CAV CIRCUIT FUNCTION
41 V37 18VT SPEED CONTROL SWITCH SIGNAL
42 C18 18LB/BR A/C PRESSURE SENSOR SIGNAL
43 K900 18DB/DG SENSOR GROUND
44 F888 18BR/PK 8 VOLT SUPPLY
45 - -
46 A109 18OR/RD FUSED B(+)
47 - -
48 - -
49 K39 18VT/DG IDLE AIR CONTROL NO. 1 DRIVER
50 Z131 18BK/DG GROUND
51 K141 18DB/YL OXYGEN SENSOR 1/2 SIGNAL
52 - -
53 - -
54 - -
55 - -
56 V36 18VT/YL SPEED CONTROL VACUUM SOLENOID CONTROL
57 K60 18VT/LG IDLE AIR CONTROL NO. 2 DRIVER
58 - -
59 D25 18WT/VT PCI BUS
60 - -
61 F855 18PK/YL (EXPORT) 5 VOLT SUPPLY
61 F855 20PK/YL (EXCEPT EXPORT) 5 VOLT SUPPLY
62 B29 18DG/WT SECONDARY BRAKE SWITCH SIGNAL
63 T10 18DG/LG TORQUE MANAGEMENT REQUEST SENSE
64 C13 18LB/OR A/C COMPRESSOR CLUTCH RELAY CONTROL
65 D21 18WT/BR (EXPORT) SCI TRANSMIT (PCM)
65 D21 20WT/BR (EXCEPT EXPORT) SCI TRANSMIT (PCM)
66 N7 18DB/OR VEHICLE SPEED SENSOR SIGNAL
67 K51 18BR/WT AUTOMATIC SHUT DOWN RELAY CONTROL
68 K52 18DB/WT EVAPORATIVE EMISSION SOLENOID CONTROL
69 - -
70 K70 18DB/BR EVAPORATIVE EMISSION SOLENOID SENSE
71 - -
72 K107 20VT/WT (EXCEPT EXPORT) LEAK DETECTION PUMP SWITCH SENSE
73 K173 18BR/VT RADIATOR FAN RELAY CONTROL
74 K31 18BR FUEL PUMP RELAY CONTROL
75 D20 20WT/LG SCI RECEIVE (PCM)
76 T41 18YL/DB PARK/NEUTRAL POSITION SWITCH SENSE (TRS T41)
77 K106 20VT/LB (EXCEPT EXPORT) LEAK DETECTION PUMP SOLENOID CONTROL
78 - -
79 - -
80 V35 18VT/OR SPEED CONTROL VENT SOLENOID CONTROL
8W - 80 - 108 8W-80 CONNECTOR PIN-OUTSRS
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POWERTRAIN CONTROL MODULE C3 (NGC) - BLACK 38 WAY
CAV CIRCUIT FUNCTION
1- -
2- -
3 K51 18BR/WT AUTOMATIC SHUT DOWN RELAY CONTROL
4- -
5 V35 18VT/OR S/C VENT CONTROL
6 K173 18BR/VT RAD FAN RELAY CONTROL
7 V32 18VT/YL S/C SUPPLY
8- -
9 K299 18BR/WT O2 1/2 HEATER CONTROL
10 - -
11 C13 18LB/OR A/C CLUTCH RELAY CONTROL
12 V36 18VT/YL S/C VACUUM CONTROL
13 - -
14 - -
15 - -
16 - -
17 - -
18 - -
19 K342 16BR/WT AUTOMATIC SHUT DOWN RELAY OUTPUT
20 K52 18DB/WT EVAP PURGE CONTROL
21 T141 18YL (MTX) FUSED IGNITION SWITCH OUTPUT (START)
22 - -
23 B29 18DG/WT BRAKE SWITCH SIGNAL
24 - -
25 - -
26 - -
27 - -
28 K342 16BR/WT AUTOMATIC SHUT DOWN RELAY OUTPUT
29 K70 18DB/BR EVAP PURGE SIGNAL
30 - -
31 C18 18LB/BR A/C PRESSURE SIGNAL
32 K91 18DB/YL BATTERY TEMP SIGNAL
33 - -
34 V37 18VT S/C SWITCH SIGNAL
35 K107 20VT/WT NVLD SWITCH SIGNAL
36 - -
37 K31 18BR FUEL PUMP RELAY CONTROL
38 T752 18DG/OR STARTER RELAY CONTROL
RS8W-80 CONNECTOR PIN-OUTS8W - 80 - 109
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Page 1118 of 2177
CONNECTOR NAME/NUMBER COLOR LOCATION FIG.
C317 BK Right Sliding Door 31
C318 (Trailer Tow) BK Left Quarter N/S
C319 Left Side Liftgate N/S
C320 DKGY Driver Power Seat on Seat Harness N/S
C321 DKGY Under Passenger Seat N/S
C322 BK On Seat Harness to Body 31
C324 BK Left Sliding Door N/S
C325 BK Right Sliding Door 31
C326 YL At Driver Side Airbag N/S
C327 YL At Passenger Side Airbag N/S
C328 Front of Left Quarter 46
C329 (Diesel) BK Near Fuel Tank 33
C330 (Diesel) LTGY Left Rear Engine Compartment N/S
C331 (Diesel) BK Left Rear Engine Compartment N/S
Cabin Heater RHD) At Heater N/S
Cabin Heater Assist C1 (Diesel) BK Top of Engine 15, 16
Cabin Heater Assist C2 (Diesel) BK Top of Engine 15, 16
Camshaft Position Sensor (Gas) BK Rear of Cylinder Head
Right Side of Engine11
Camshaft Position Sensor
(Diesel)BK Rear of Cylinder Head 15, 16
CD Changer Behind CD Changer N/S
Center Dome Lamp GY At Lamp N/S
Center High Mounted Stop Lamp BK At Lamp 48
Clockspring - C1 WT Steering Column 19, 20, 21, 22, 30
Clockspring - C2 YL Steering Column 19, 20, 21, 22, 30
Clockspring - C3 BK Steering Column N/S
Clockspring - C4 BK Steering Column N/S
Clockspring - C5 YL Steering Column N/S
Clutch Pedal Interlock Switch
(Diesel)RD At Switch/Driver Side 41
Clutch Pedal Upstop Switch
(Diesel)BK At Switch/Driver Side 41
Controller Anti-Lock Brake BK Right Side of Engine Compartment 11, 16, 17, 18
Crank Case Ventilation Heater
(Diesel)BK Top of Cylinder Head 15
Crankshaft Position Sensor
(Diesel)BK Rear of Engine 16
Crankshaft Position Sensor (Gas) BK Rear of Engine 13, 17
Data Link Connector WT Lower Instrument Panel Near
Steering Column40, 41
Dosing Pump BK Top of Engine N/S
Driver Airbag Squib1 BN Steering Column N/S
Driver Airbag Squib2 BK Steering Column N/S
RS8W-91 CONNECTOR/GROUND/SPLICE LOCATION8W-91-3
CONNECTOR/GROUND/SPLICE LOCATION (Continued)
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CONNECTOR NAME/NUMBER COLOR LOCATION FIG.
Engine Coolant Temperature
Sensor (Diesel)BL On Cylinder Block 15
Engine Oil Pressure Sensor
(Diesel)BK Rear of Engine 16
Engine Oil Pressure Switch (Gas) LTGN On Cylinder Block 12
EVAP/Purge Solenoid BK Right Motor Mount 10, 17
Evaporator Temperature Sensor BK Right Side of HVAC N/S
Floor Console Lamp BK At Lamp N/S
Floor Console Power Outlet RD At Front Console N/S
Front Blower Module C1 (ATC) BK On HVAC N/S
Front Blower Module C2 (ATC) BK On HVAC N/S
Front Cigar Lighter RD/NAT Rear of Lighter 19, 22, 24
Front Intrusion Sensor BK At Sensor N/S
Front Reading Lamps/Switch BK At Switch N/S
Front Washer Pump Motor BK Right Fender Well 3
Fuel Heater (Diesel) BK Left Rear Engine Compartment N/S
Fuel Injector No.1 BK At Fuel Injector N/S
Fuel Injector No.1 (Diesel) BK At Fuel Injector 15
Fuel Injector No.2 BK At Fuel Injector N/S
Fuel Injector No.2 (Diesel) BK At Fuel Injector 15
Fuel Injector No.3 BK At Fuel Injector N/S
Fuel Injector No.3 (Diesel) BK At Fuel Injector 15
Fuel Injector No.4 BK At Fuel Injector N/S
Fuel Injector No.4 (Diesel) BK At Fuel Injector 15
Fuel Injector No.5 BK At Fuel Injector N/S
Fuel Injector No.6 BK At Fuel Injector N/S
Fuel Pressure Sensor (Diesel) BK Top Left of Engine 15
Fuel Pressure Solenoid (Diesel) Right Front Engine 15
Fuel Pump Module LTGY Side of Fuel Tank 33
Generator BK Rear of Generator 11, 15, 17, 18
Glow Plug Relay (Diesel) BK Near Battery N/S
Headlamp Switch BK Rear of Switch 19, 20, 29
Headlamp Washer Pump Motor At Motor 3
High Note Horn BK Left Frame Rail 5
High Pressure Fuel Pump
(Diesel)Rear of Pump 15
Hood Ajar Switch BK Left Fender 6
Idle Air Control Motor (2.4L) BK On Throttle Body 10, 11
Idle Air Control Motor (3.3/3.8L) BK On Throttle Body 17
Ignition Coil 2.4L BK Top of Valve Cover 10, 11
Ignition Coil 3.3L, 3.8L DKGY Top of Engine 18
Ignition Switch BK Rear of Switch at Steering Column 19, 20, 21, 22, 30
Inlet Air Temperature Sensor BK Top Left of Engine 9, 10, 11
RS8W-91 CONNECTOR/GROUND/SPLICE LOCATION8W-91-5
CONNECTOR/GROUND/SPLICE LOCATION (Continued)
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Page 1183 of 2177
DIAGNOSIS AND TESTING - ENGINE DIAGNOSIS - PERFORMANCE
CONDITION POSSIBLE CAUSE CORRECTION
ENGINE WILL NOT START 1. Weak battery. 1. Test battery. Charge or replace
as necessary. (Refer to 8 -
ELECTRICAL/BATTERY SYSTEM -
DIAGNOSIS AND TESTING)
2. Corroded or loose battery
connections.2. Clean and tighten battery
connections. Apply a coat of light
mineral grease to terminals.
3. Faulty starter. 3. Test starting system. (Refer to 8 -
ELECTRICAL/STARTING -
DIAGNOSIS AND TESTING)
4. Faulty coil(s) or control unit. 4. Test and replace as needed.
(Refer to Appropriate Diagnostic
Information)
5. Incorrect spark plug gap. 5. Set gap. (Refer to 8 -
ELECTRICAL/IGNITION CONTROL
- SPECIFICATIONS)
6. Contamination in fuel system. 6. Clean system and replace fuel
filter.
7. Faulty fuel pump. 7. Test fuel pump and replace as
needed. (Refer to Appropriate
Diagnostic Information)
8. Incorrect engine timing. 8. Check for a skipped timing
belt/chain.
ENGINE STALLS OR IDLES
ROUGH1. Idle speed too low. 1. Test minimum air flow. (Refer to
Appropriate Diagnostic Information)
2. Incorrect fuel mixture. 2. (Refer to Appropriate Diagnostic
Information)
3. Intake manifold leakage. 3. Inspect intake manifold, manifold
gasket, and vacuum hoses.
4. Faulty ignition coil(s). 4. Test and replace as necessary.
(Refer to Appropriate Diagnostic
Information)
9 - 4 ENGINE 2.4LRS
ENGINE 2.4L (Continued)
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Page 1184 of 2177
CONDITION POSSIBLE CAUSE CORRECTION
ENGINE LOSS OF POWER 1. Dirty or incorrectly gapped plugs. 1. Clean plugs and set gap.
2. Contamination in fuel system. 2. Clean system and replace fuel
filter.
3. Faulty fuel pump. 3. Test and replace as necessary.
(Refer to Appropriate Diagnostic
Information)
4. Incorrect valve timing. 4. Correct valve timing.
5. Leaking cylinder head gasket. 5. Replace cylinder head gasket.
6. Low compression. 6. Test compression of each
cylinder.
7. Burned, warped, or pitted valves. 7. Replace valves.
8. Plugged or restricted exhaust
system.8. Perform exhaust restriction test.
(Refer to 11 - EXHAUST SYSTEM -
DIAGNOSIS AND TESTING) Install
new parts, as necessary.
9. Faulty ignition coil(s). 9. Test and replace as necessary.
(Refer to Appropriate Diagnostic
Information)
ENGINE MISSES ON
ACCELERATION1. Dirty or incorrectly gapped spark
plugs.1. Clean spark plugs and set gap.
2. Contamination in Fuel System. 2. Clean fuel system and replace
fuel filter.
3. Burned, warped, or pitted valves. 3. Replace valves.
4. Faulty ignition coil(s). 4. Test and replace as necessary.
(Refer to Appropriate Diagnostic
Information)
ENGINE MISSES AT HIGH SPEED 1. Dirty or incorrect spark plug gap. 1. Clean spark plugs and set gap.
2. Faulty ignition coil(s). 2. Test and replace as necessary.
(Refer to Appropriate Diagnostic
Information)
3. Dirty fuel injector(s). 3. Test and replace as necessary.
(Refer to Appropriate Diagnostic
Information)
4. Contamination in fuel system. 4. Clean system and replace fuel
filter.
RSENGINE 2.4L9-5
ENGINE 2.4L (Continued)
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Page 1195 of 2177
INSTALLATION - ENGINE ASSEMBLY
(1) Position engine and transmission assembly
under vehicle and slowly lower the vehicle over the
engine and transmission.
(2) Align engine and transmission mounts to
attaching points. Install mounting bolts at the right
(Fig. 9) and left mounts (Fig. 10).
(3) Remove safety straps.
(4) Slowly raise vehicle enough to remove the
engine dolly and cradle Special Tools 6135 and 6710.
(5) Install rear mount bracket and rear mount
through bolt. (Refer to 9 - ENGINE/ENGINE
MOUNTING/REAR MOUNT - INSTALLATION)
(6) Install the flex plate to torque converter bolts.
(7) Install structural collar. (Refer to 9 - ENGINE/
ENGINE BLOCK/STRUCTURAL COVER - INSTAL-
LATION)
(8) Install front mount bracket and front mount
through bolt. (Refer to 9 - ENGINE/ENGINE
MOUNTING/FRONT MOUNT - INSTALLATION)
(9) Connect exhaust system to manifold (Fig. 7).
(10) Install crossmember cradle plate (Fig. 6).
(11) Install new oil filter.
(12) Install power steering pump and bracket.
(13) Connect power steering supply line to pump
and remove pinch-off pliers.(14) Connect A/C compressor hoses to compressor.
(15) Install accessory drive belts. (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION)
(16) Install axle shafts. (Refer to 3 - DIFFEREN-
TIAL & DRIVELINE/HALF SHAFT - INSTALLA-
TION)
(17) Install accessory drive belt splash shield.
(18) Install front wheels and tires.
(19) Remove plugs from transmission cooler hoses
and install transaxle oil cooler line service splice kit.
Refer to instructions included with kit.
(20) Connect the transaxle shift linkage and elec-
trical connectors.
(21) Connect heater hoses (Fig. 5).
(22) Install ground straps.
(23) Connect all engine and throttle body electrical
connections.
(24) Connect all vacuum lines.
(25) Connect the throttle cables.
(26) Connect the fuel line. (Refer to 14 - FUEL
SYSTEM/FUEL DELIVERY/QUICK CONNECT FIT-
TING - STANDARD PROCEDURE)
(27) Connect radiator lower and upper hoses.
(28) Install radiator fans. (Refer to 7 - COOLING/
ENGINE/RADIATOR FAN - INSTALLATION)
(29) Fill cooling system. (Refer to 7 - COOLING -
STANDARD PROCEDURE)
(30) Connect battery cables.
(31) Install air cleaner and inlet hose.
(32) Fill engine crankcase with proper oil to cor-
rect level.
Fig. 9 RIGHT MOUNT TO RAIL AND ENGINE
1 - BOLT - MOUNT TO RAIL 68 N´m (50 ft. lbs.)
2 - BOLT - MOUNT TO ENGINE 54 N´m (40 ft. lbs.)
3 - BOLT - MOUNT TO RAIL (HORIZONTAL) 68 N´m (50 ft. lbs.)
4 - RIGHT ENGINE MOUNT
5 - RIGHT FRAME RAIL
Fig. 10 LEFT MOUNT TO FRAME BRACKET
1 - FRAME BRACKET
2 - FRAME RAIL - LEFT
3 - BOLT
4 - TRANSAXLE MOUNT
9 - 16 ENGINE 2.4LRS
ENGINE 2.4L (Continued)
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Page 1204 of 2177
²Excessive steam (white smoke) emitting from
exhaust
²Coolant foaming
CYLINDER-TO-CYLINDER LEAKAGE TEST
To determine if an engine cylinder head gasket is
leaking between adjacent cylinders, follow the proce-
dures in Cylinder Compression Pressure Test (Refer
to 9 - ENGINE - DIAGNOSIS AND TESTING). An
engine cylinder head gasket leaking between adja-
cent cylinders will result in approximately a 50±70%
reduction in compression pressure.
CYLINDER-TO-WATER JACKET LEAKAGE TEST
WARNING: USE EXTREME CAUTION WHEN THE
ENGINE IS OPERATING WITH COOLANT PRES-
SURE CAP REMOVED.
VISUAL TEST METHOD
With the engine cool, remove the coolant pressure
cap. Start the engine and allow it to warm up until
thermostat opens.
If a large combustion/compression pressure leak
exists, bubbles will be visible in the coolant.COOLING SYSTEM TESTER METHOD
WARNING: WITH COOLING SYSTEM TESTER IN
PLACE, PRESSURE WILL BUILD UP FAST. EXCES-
SIVE PRESSURE BUILT UP, BY CONTINUOUS
ENGINE OPERATION, MUST BE RELEASED TO A
SAFE PRESSURE POINT. NEVER PERMIT PRES-
SURE TO EXCEED 138 kPa (20 psi).
Install Cooling System Tester 7700 or equivalent to
pressure cap neck. Start the engine and observe the
tester's pressure gauge. If gauge pulsates with every
power stroke of a cylinder a combustion pressure
leak is evident.
CHEMICAL TEST METHOD
Combustion leaks into the cooling system can also
be checked by using Bloc-Chek Kit C-3685-A or
equivalent. Perform test following the procedures
supplied with the tool kit.
REMOVAL - CYLINDER HEAD
(1) Perform fuel system pressure release procedure
before attempting any repairs.(Refer to 14 -
FUEL SYSTEM/FUEL DELIVERY - SPECIFICA-
TIONS)
(2) Disconnect battery negative cable.
(3) Drain cooling system. (Refer to 7 - COOLING -
STANDARD PROCEDURE)
(4) Remove air filter housing and inlet tube.
(5) Remove upper intake manifold. (Refer to 9 -
ENGINE/MANIFOLDS/INTAKE MANIFOLD -
REMOVAL)
(6) Remove heater tube support bracket from cyl-
inder head.
(7) Disconnect radiator upper and heater supply
hoses from intake manifold water outlet connections.
(8) Remove accessory drive belts. (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
REMOVAL)
(9) Raise vehicle and remove exhaust pipe from
manifold.
(10) Remove power steering pump reservoir and
line support bracket from lower intake manifold and
set aside. Do not disconnect lines.
(11) Remove ignition coil and wires from engine.
(12) Disconnect cam sensor and fuel injector wir-
ing connectors.
(13) Remove timing belt and camshaft sprockets.
(Refer to 9 - ENGINE/VALVE TIMING/TIMING
BELT/CHAIN AND SPROCKETS - REMOVAL)
(14) Remove timing belt idler pulley and rear tim-
ing belt cover. (Refer to 9 - ENGINE/VALVE TIM-
ING/TIMING BELT / CHAIN COVER(S) -
REMOVAL)Fig. 13 Cylinder Head and Camshafts
1 - CAMSHAFT BEARING CAPS
2 - PLUG
3 - CAMSHAFT
4 - CYLINDER HEAD
5 - CAMSHAFT OIL SEAL
RSENGINE 2.4L9-25
CYLINDER HEAD (Continued)
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Page 1206 of 2177
(2) Position cylinder head gasket on engine block
(Fig. 18).
(3) Install cylinder head on engine block.
(4) Tighten the cylinder head bolts in the sequence
shown in (Fig. 19). Using the 4 step torque turn
method, tighten according to the following values:
²First All to 34 N´m (25 ft. lbs.)
²Second All to 68 N´m (50 ft. lbs.)
²Third All to 68 N´m (50 ft. lbs.)
CAUTION: Do not use a torque wrench for the fol-
lowing step.
²Fourth Turn an additional 1/4 Turn,
(5) Install rocker arms. (Refer to 9 - ENGINE/
CYLINDER HEAD/ROCKER ARMS - INSTALLA-
TION)
(6) Install camshafts. (Refer to 9 - ENGINE/CYL-
INDER HEAD/CAMSHAFT(S) - INSTALLATION).
(7) Install cylinder head cover. (Refer to 9 -
ENGINE/CYLINDER HEAD/CYLINDER HEAD
COVER(S) - INSTALLATION)(8) Install timing belt rear cover and timing belt
idler pulley. (Refer to 9 - ENGINE/VALVE TIMING/
TIMING BELT / CHAIN COVER(S) - INSTALLA-
TION)
(9) Install timing belt and camshaft sprockets.
(Refer to 9 - ENGINE/VALVE TIMING/TIMING
BELT/CHAIN AND SPROCKETS - INSTALLATION)
(10) Connect cam sensor and fuel injectors wiring
connectors.
(11) Install ignition coil and wires. Connect igni-
tion coil wiring connector.
(12) Install power steering pump reservoir and
line support bracket to cylinder head.
(13) Raise vehicle and install the exhaust pipe to
the manifold.
(14) Install accessory drive belts. (Refer to 7 -
COOLING/ACCESSORY DRIVE/DRIVE BELTS -
INSTALLATION)
(15) Install heater tube support bracket to cylinder
head.
(16) Connect radiator upper and heater hoses to
intake manifold water outlet connections.
(17) Install upper intake manifold. (Refer to 9 -
ENGINE/MANIFOLDS/INTAKE MANIFOLD -
INSTALLATION)
(18) Using new gaskets, install EGR tube and
tighten fasteners to 11 N´m (95 in. lbs.).
(19) Install air inlet tube and housing.
(20) Connect all vacuum lines, electrical wiring,
ground straps and fuel line.
(21) Fill cooling system. (Refer to 7 - COOLING -
STANDARD PROCEDURE)
(22) Connect battery negative cable.
CAMSHAFT OIL SEAL(S)
REMOVAL
(1) Remove timing belt (Refer to 9 - ENGINE/
VALVE TIMING/TIMING BELT AND SPROCKETS -
REMOVAL).
Fig. 17 Checking Bolts for Stretching (Necking)
1 - STRETCHED BOLT
2 - THREADS ARE NOT STRAIGHT ON LINE
3 - THREADS ARE STRAIGHT ON LINE
4 - UNSTRETCHED BOLT
Fig. 18 Cylinder Head Gasket Positioning
1 - PART NUMBER FACES UP
2 - NO. 1 CYLINDER
Fig. 19 Cylinder Head Tightening Sequence
RSENGINE 2.4L9-27
CYLINDER HEAD (Continued)
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