relay CHRYSLER VOYAGER 1996 Service Manual

DIAGNOSIS AND TESTING
ENGINE DIAGNOSISÐPERFORMANCE
CONDITION POSSIBLE CAUSES CORRECTION
ENGINE WILL NOT
CRANK OR CRANKS
SLOWLY1. Starting motor operating, but not cranking the
engine.1. Remove the starter motor. Check for broken
flywheel teeth or a broken starter motor spring.
2. Crankshaft rotation restricted. 2. Rotate the engine to check for rotational
resistance.
3. Starting circuit connections loose or corroded. 3. Clean and tighten connections.
4. Neutral safety or starter relay inoperative. 4. Check starter relay supply voltage and proper
operation of neutral safety switch (if equipped).
Replace defective parts.
5. Battery charge low. 5. Check Battery voltage. Replace battery if a
charge cannot be held.
6. No voltage to starter solenoid. 6. Check voltage to solenoid. If necessary, replace
the solenoid.
7. Solenoid or starter motor inoperative. 7. Replace starter motor.
ENGINE CRANKS, BUT
WILL NOT START, NO
SMOKE1. No fuel in supply tank. 1. Fill fuel supply.
2. Electrical fuel shutdown solenoid not operating. 2. Check for loose wires and verify that the fuel
shutdown solenoid is functioning. Check for fault
codes in the ECU.
3. Fuel injection system defective: Cranking speed
sensor. Loose connection between ECU and
harness. No power supply to the ECU. Loose
connection between injection pump and harness.3. Check for fault codes at ECU. Refer to Group 14,
Fuel System for repairs procedures.
4. Air intake or exhaust plugged. 4. Remove the obstruction.
5. Fuel filter plugged. 5. Drain fuel/water separator and replace fuel filter.
6. Excessive fuel inlet restriction. 6. Check for restriction. Correct cause.
7. Injection pump not getting fuel or fuel is aerated. 7. Check fuel flow/bleed fuel system.
8. One or more injectors worn or not operating
properly.8. Check/replace bad or improperly operating
injectors.
9. Camshaft out of time. 9. Check/correct timing chain sprocket alignment.
ENGINE HARD TO
START, OR WILL NOT
START, SMOKE FROM
EXHAUST1. Incorrect starting procedure. 1. The fuel shutoff solenoid control must be in the
run position. Ensure the proper procedure is being
used.
2. Cranking speed to slow. 2. Check the battery, starter motor and look for
loose or corroded wiring connections.
3. Cylinder head heater plugs defective. 3. Verify system is working. Verify connection
between heater plug relay and ECU. Repair/replace
inoperative parts.
4. Insufficient intake air 4. Inspect or replace air filter and check for
obstruction in air supply.
5. Air in fuel system or the fuel supply is
inadequate.5. Check the fuel flow through the filter and bleed
system. Locate and eliminate the air source.
6. Contaminated fuel. 6. Verify by operating the engine with clean fuel
from a temporary tank. Check for the presence of
gasoline. Drain and flush fuel supply tank. Replace
fuel/water separator filter.
7. Fuel screen plugged. 7. Check fuel screen.
8. One or more injectors worn or not operating
properly.8. Check/replace improperly operating injectors.
9. Injector pump out of time. 9. Check pump timing. Refer to Group 14, Fuel
System for procedure.
10. Engine compression low. 10. Check compression to identify the problem.
11. Fuel injection system defective. 11. Vacuum modulator defective causing EGR to
open in cold condition. Check for fault codes in the
ECU.
NS/GSENGINE 9 - 43

(2) Tighten intake manifold fasteners in the fol-
lowing sequence (Fig. 16). Torque to 23 N´m (200 in.
lbs.). Repeat this procedure until all bolts are at
specified torque.
(3) Install intake manifold center support bracket
bolts (Y bracket):
²Fastener to block 54 N´m (40 ft. lbs.)
²Fastener to intake 28 N´m (250 in. lbs.)
(4) Install fuel hose quick connector fitting to
chassis tubes.Refer to Fuel Hoses, Clamps and
Quick Connect Fittings in Group 14, Fuel Deliv-
ery.Push the fitting onto the chassis tube until it
clicks into place. Pull on the fitting to ensure com-
plete insertion.
(5) Reverse removal procedures 2 through 12 for
installation.
CAUTION: When using the ASD Fuel System Test,
the ASD relay and fuel pump relay remain energized
for 7 minutes or until the test is stopped, or until
the ignition switch is turned to the Off position.
(6) With the ignition key in ON position, access
the DRB scan tool ASD Fuel System Test to pressur-
ize the fuel system. Check for leaks.
EXHAUST MANIFOLDÐ2.4L ENGINE
REMOVAL
(1) Raise vehicle and disconnect exhaust pipe from
the exhaust manifold at the flex-joint.
(2) Disconnect Oxygen Sensor lead wire at the rear
exhaust manifold (Fig. 17).
(3) Remove the bolts attaching the manifold to the
cylinder head. Remove manifold (Fig. 17).
(4) Inspect and clean manifold. Refer to Cleaning
and Inspection outlined in this section for proce-
dures.
INSTALLATION
(1) Install exhaust manifold with a new gasket
and tighten attaching nuts in the order shown in
(Fig. 17) to 20 N´m (175 in. lbs.).
(2) Attach exhaust pipe to exhaust manifold and
tighten bolt to 28 N´m (250 in. lbs.).
(3) Connect heated oxygen sensor lead (Fig. 17).
INTAKE MANIFOLDÐ3.0L ENGINE
REMOVAL
(1) Perform fuel system pressure release proce-
dure(before attempting any repairs).Refer to
Group 14 Fuel System for procedure.
(2) Disconnect negative battery cable. Drain cool-
ing system. See Cooling System, Group 7.
(3) Remove air inlet resonator to throttle body
hose.
(4) Remove throttle cable and transaxle kickdown
linkage (Fig. 18).
(5) Remove automatic idle speed (AIS) motor and
throttle position sensor (TPS) wiring connectors from
throttle body (Fig. 19).
(6) Remove vacuum hose harness from throttle
body.
(7) Remove PCV and Brake booster hoses from
Air Intake Plenum.
(8) Remove Ignition Coil from Intake Plenum
(Fig. 20).
(9) Remove wiring connectors from coolant temper-
ature sensor (Fig. 21).
(10) Remove vacuum connections from Air Intake
Plenum vacuum connector.
(11) Remove fuel hose from fuel rail (Fig. 21).
WARNING: WRAP SHOP TOWELS AROUND HOSES
TO CATCH ANY GASOLINE SPILLAGE.
Fig. 17 Exhaust Manifold Attaching PointsÐ2.4L
Engine
Fig. 18 Throttle Cable Attachment
11 - 8 EXHAUST SYSTEM AND INTAKE MANIFOLDNS
REMOVAL AND INSTALLATION (Continued)

(10) Connect fuel line to fuel rail (Fig. 21). Torque
hose clamps to 1 N´m (10 in. lbs.).
(11) Connect vacuum harness to air intake ple-
num.
(12) Connect and coolant temperature sensor elec-
trical connector to sensor (Fig. 21).
(13) Connect PCV and brake booster supply hose
to intake plenum.
(14) Connect automatic idle speed (AIS) motor
and throttle position sensor (TPS) electrical connec-
tors (Fig. 19).
(15) Connect vacuum vapor harness to throttle
body (Fig. 19).
(16) Install throttle cable and transaxle kickdown
linkage (Fig. 18).
(17) Install air inlet resonator hose assembly to
throttle body.
(18) Install radiator to thermostat housing hose
and heater hose to heater pipe nipple.
(19) Fill cooling system. Refer to Filling the Cool-
ing System outlined in Group 7 Cooling System for
procedure.
(20) Connect negative battery cable.
(21) With the DRB 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
selected.
EXHAUST MANIFOLDÐ3.0L ENGINE
REMOVAL
(1) Raise vehicle and disconnect exhaust pipe
from rear (cowl side) exhaust manifold at the flex-
joint.(2) Disconnect Oxygen Sensor lead wire at the
rear exhaust manifold (Fig. 28).
(3) Remove bolts attaching cross-over pipe to
manifold (Fig. 30).
(4) Remove rear heat shield (Fig. 29).
(5) Remove nuts attaching rear manifold to cylin-
der head and remove manifold.
(6) Lower vehicle and remove screws attaching
front heat shield to front manifold (Fig. 31).
(7) Remove bolts fastening crossover pipe to front
exhaust manifold and nuts fastening manifold to cyl-
inder head. Remove assemblies.
(8) Inspect and clean manifolds. Refer to Cleaning
and Inspection outlined in this section for proce-
dures.
INSTALLATION
Install the gaskets with the numbers 1-3-5
embossed on the top on the rear bank and those with
numbers 2-4-6 on the front (Radiator side) bank (Fig.
32).
(1) Install rear exhaust manifold and tighten
attaching nuts to 20 N´m (175 in. lbs.).
Fig. 27 Intake Plenum Tightening Sequence
Fig. 28 Disconnect Up Stream Heated Oxygen
Sensor Connection
Fig. 29 Rear Exhaust Manifold Heat Shield
NSEXHAUST SYSTEM AND INTAKE MANIFOLD 11 - 11
REMOVAL AND INSTALLATION (Continued)

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
selected.
EXHAUST MANIFOLDSÐ3.3/3.8L ENGINE
REMOVAL
(1) Disconnect battery negative cable.
(2) Remove accessory drive belt. Refer to Accessory
Drive section located in Group 7 Cooling System for
procedure.
(3) Remove generator.
(4) Raise vehicle and disconnect exhaust pipe
from rear (cowl side) exhaust manifold at flex-joint.
(5) Disconnect down stream oxygen sensor connec-
tor.
(6) Lower exhaust system to gain access to rear
manifold.
(7) Separate EGR tube from rear manifold and
disconnect Heated Oxygen Sensor lead wire (Fig. 45).
(8) Remove heat shield from rear engine mount.
(9) Remove Generator/Power Steering Support
Strut (Fig. 45).
(10) Remove bolts attaching crossover pipe to
manifold (Fig. 45).
(11) Disconnect up stream oxygen sensor connec-
tor.
(12) Remove bolts attaching rear manifold to cyl-
inder head and remove manifold.
(13) Lower vehicle and remove screws attaching
front heat shield to front manifold (Fig. 46).
(14) Remove bolts fastening crossover pipe to
front exhaust manifold and nuts fastening manifold
to cylinder head. Remove assemblies (Fig. 47).
(15) Inspect and clean manifold. Refer to Cleaning
and Inspection outlined in this section for proce-
dures.
INSTALLATION
(1) Install rear exhaust manifold and tighten
attaching bolts to 23 N´m (200 in. lbs.).
(2) Install generator.
NOTE: Inspect crossover pipe fasteners for dam-
age from heat and corrosion. Replace if necessary.
(3) Using new gasket attach crossover pipe to
exhaust manifold and tighten bolts to 54 N´m (40 ft.
lbs.) and connect oxygen sensor lead (Fig. 45).
(4) Install EGR Tube and Generator/Power Steer-
ing Strut (Fig. 45).
(5) Using new gaskets install front exhaust mani-
fold and tighten attaching bolts to 23 N´m (200 in.
lbs.).(6) Attach exhaust crossover with a new gasket
and tighten fasteners to 54 N´m (40 ft. lbs.) (Fig. 47).
(7) Connect up stream oxygen sensor connector.
(8) Install exhaust system.
Fig. 45 EGR Tube, Heated Oxygen Sensor and
Generator/Power Steering Strut
Fig. 46 Heat ShieldÐFront
Fig. 47 Crossover Pipe
11 - 16 EXHAUST SYSTEM AND INTAKE MANIFOLDNS
REMOVAL AND INSTALLATION (Continued)

check valve, in the pump outlet, maintains pump
pressure during engine off conditions. The fuel pump
relay provides voltage to the fuel pump.
The fuel pump has a maximum deadheaded pres-
sure output of approximately 635 kPa (95 psi). The
regulator adjusts fuel system pressure to approxi-
mately 338 kPa (49 psi).
FUEL PUMP ELECTRICAL CONTROL
Voltage to operate the electric pump is supplied
through the fuel pump relay. For an electrical opera-
tional description of the fuel pump refer to fuel Pump
RelayÐPCM Output.
ELECTRICAL PUMP REPLACEMENT
The electric fuel pump is not serviceable. If the
fuel pump or electrical wiring harness needs replace-
ment, the complete fuel pump module must be
replaced. Perform the Fuel System Pressure Release
procedure before servicing the fuel pump.
FUEL LEVEL SENSOR
The level sensor is attached to the side of the fuel
pump module. The level sensor consists of a float, an
arm, and a variable resistor. As the fuel level
increases, the float and arm move up. This decreases
the sending unit resistance, causing the fuel gauge
on the instrument panel to read full.
FUEL PRESSURE REGULATOR
The fuel system uses a nonadjustable pressure reg-
ulator that maintains fuel system pressure at
approximately 338 kPa (49 psi), 3.3l uses approxi-
mately 379 kPa (55 psi). The fuel pressure regulator
contains a diaphragm, calibrated spring and a fuel
return valve. The spring pushes down on the dia-
phragm and closes off the fuel return port. System
fuel pressure reflects the amount of fuel pressure
required to open the return port.
The pressure regulator is a mechanical device that
is NOT controlled by the PCM or engine vacuum.
FUEL INJECTORS
The fuel injectors are 12 ohm electrical solenoids
(Fig. 2). The injector contains a pintle that closes off
an orifice at the nozzle end. When electric current is
supplied to the injector, the armature and needle
move a short distance against a spring, allowing fuel
to flow out the orifice. Because the fuel is under high
pressure, a fine spray is developed in the shape of a
hollow cone. The spraying action atomizes the fuel,
adding it to the air entering the combustion chamber.
The injectors are positioned in the intake manifold.
Fuel injectors are not interchangeable between
engines.The injectors are positioned in the intake manifold
with the nozzle ends directly above the intake valve
port (Fig. 3).
FUEL TANK
The fuel tanks of all Chrysler Motors built vehicles
are equipped with fuel and vapor controls that allow
the vehicle to pass a full 360É rollover without fuel
leakage.
Front Wheel Drive fuel delivery systems contain a
fuel tank rollover valve. The valve is mounted on top
of the fuel tank. The valve functions as a tank pres-
sure control valve while the vehicle is upright, but
contains a check valve that prevents fuel from escap-
ing from the fuel tank when the vehicle is turned
over.
The fuel filler cap acts as a pressure/vacuum relief
valve. When air pressure inside the fuel tank gets too
high or too low, the fuel filler cap opens to relieve the
difference in pressure.
An evaporation control system restricts fuel evapo-
ration into the atmosphere and reduces unburned
Fig. 2 Fuel Injector
Fig. 3 Fuel Injector LocationÐTypical
NSFUEL SYSTEM 14 - 5
DESCRIPTION AND OPERATION (Continued)

(1) Remove cap from fuel pressure test port on fuel
rail.
(2) Connect Fuel Pressure Gauge C-4799B to test
port (Fig. 7).
CAUTION: When using the ASD Fuel System Test,
the ASD relay and fuel pump relay remain energized
for 7 minutes or until the test is stopped, or until
the ignition switch is turned to the Off position.
(3) Place the ignition key in the ON position.
Using the DRB scan tool, access ASD Fuel System
Test. The ASD Fuel System Test will activate the fuel
pump and pressurize the system.²If the gauge reading equals 338 kPa (49 psi)
3.3L uses approximately 379 kPa (55 psi) further
testing is not required. If pressure is not correct,
record the pressure.
²If pressure is above specifications, check for a
kinked or restricted fuel return tube (from filter to
pump module). If the fuel return tube is not pinched
or restricted, replace the fuel pressure regulator.
²If fuel pressure is below specifications, refer to
the diagnosis chart for Fuel Pressure Below Specifi-
cations.
(4)Replace Pressure test port cap when fin-
ished doing pressure test.
Fig. 6 Fuel Pressure Test PortÐ3.3/3.8LFig. 7 Checking Fuel Pressure at Fuel Rail
NSFUEL SYSTEM 14 - 7
DIAGNOSIS AND TESTING (Continued)

SERVICE PROCEDURES
FUEL SYSTEM PRESSURE RELEASE
PROCEDUREÐ2.4/3.3/3.8L
WARNING: RELEASE FUEL SYSTEM PRESSURE
BEFORE SERVICING FUEL SYSTEM COMPONENTS.
SERVICE VEHICLES IN WELL VENTILATED AREAS
AND AVOID IGNITION SOURCES. NEVER SMOKE
WHILE SERVICING THE VEHICLE.
(1) Disconnect negative cable from battery.
(2) Remove fuel filler cap.
(3) Remove protective cap from fuel pressure test
port on fuel rail (Fig. 9) or (Fig. 10).
(4) Place open end of fuel pressure release hose,
tool number C-4799-1, into an approved gasoline con-
tainer. Connect other end of hose C-4799-1 to fuel
pressure test port (Fig. 11). Fuel pressure will bleed
off through the hose into the gasoline container. Fuel
gauge C-4799-B contains hose C-4799-1.
(5)Replace Pressure test port cap when fin-
ished doing pressure test.
FUEL SYSTEM PRESSURE RELEASE
PROCEDUREÐ3.0L ENGINE
(1) Remove the Fuel Pump relay from the Power
Distribution Center (PDC). For location of the relay,
refer to the label on the underside of the PDC cover.
(2) Start and run engine it stalls.
(3) Attemp restarting engine until it will no longer
run.(4) Turn ignition key to OFF position.
CAUTION: Steps 1, 2, 3 and 4 must be performed to
relieve high pressure fuel from within the fuel rail.
Do not attempt to use the following steps to relieve
this pressure as excessive fuel will be forced into a
cylinder chamber.
(5) Unplug connector from any injector.
(6) Attach one end of a jumper wire with alligator
clips (18 gauge or smaller) to either injector terminal.
(7) Connect the other end of the jumper wire to
the positive side of the battery.
(8) Connect one end of a second jumper wire to the
remaining injector terminal.
CAUTION: Supplying power to an injector for more
than 4 seconds will permantely damage the injector.
Do not leave the injector connected to power for
more than 4 seconds.
Fig. 9 Fuel Pressure Test PortÐ2.4L
Fig. 10 Fuel Pressure Test PortÐ3.3/3.8L
Fig. 11 Releasing Fuel Pressure
NSFUEL SYSTEM 14 - 11

(9) Momentarily touch the other end of this
jumper wire to the negative terminal of the battery
for no more than 4 seconds.
(10) Place a rag or towel below the fuel line at the
quick connect to the rail.
(11) Disconnect the quick connect fitting to the
rail. Refer to Quick-Connect Fittings in this section.
(12) Return the fuel pump relay to the PDC.
(13) One or more Diagnostic Trouble Codes (DTC's)
may have been stored in the PCM memory due to the
fuel pump relay removal. The DRB scan tool must be
used to erase a DTC. Refer to group 25, On-Board
Diagnostics.
HOSES AND CLAMPS
Inspect all hose connections (clamps and quick con-
nect fittings) for completeness and leaks. Replace
cracked, scuffed, or swelled hoses. Replace hoses that
rub against other vehicle components or show sign of
wear.
Fuel injected vehicles use specially constructed
hoses. When replacing hoses, only use hoses marked
EFM/EFI.
When installing hoses, ensure that they are routed
away from contact with other vehicle components
that could rub against them and cause failure. Avoid
contact with clamps or other components that cause
abrasions or scuffing. Ensure that rubber hoses are
properly routed and avoid heat sources.
The hose clamps have rolled edges 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´m (10 in. lbs.) torque.
QUICK-CONNECT FITTINGS
REMOVAL
When disconnecting a quick-connect fitting, the
retainer will remain on the fuel tube nipple.
WARNING: RELEASE FUEL SYSTEM PRESSURE
BEFORE DISCONNECTING A QUICK-CONNECT FIT-
TINGS. REFER TO THE FUEL PRESSURE RELEASE
PROCEDURE.
(1) Disconnect negative cable from battery.
(2) Perform Fuel Pressure Release Procedure.
Refer to the Fuel Pressure Release Procedure in this
section.
(3) Squeeze retainer tabs together and pull fuel
tube/quick-connect fitting assembly off of fuel tube
nipple. The retainer will remain on fuel tube.
INSTALLATION
CAUTION: Never install a quick-connect fitting
without the retainer being either on the fuel tube or
already in the quick-connect fitting. In either case,
ensure the retainer locks securely into the quick-
connect fitting by firmly pulling on fuel tube and fit-
ting to ensure it is secured.
(1) Using a clean lint free cloth, clean the fuel tube
nipple and retainer.
(2) Prior to connecting the fitting to the fuel tube,
coat the fuel tube nipple with clean 30 weight engine
oil.
(3) Push the quick-connect fitting over the fuel
tube until theretainer seats and a click is heard.
(4) The plastic quick-connect fitting has windows
in the sides of the casing. When the fitting com-
pletely attaches to the fuel tube, the retainer locking
ears and the fuel tube shoulder are visible in the
windows. If they are not visible, the retainer was not
properly installed (Fig. 12).Do not rely upon the
audible click to confirm a secure connection.
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 posi-
tion.
(5) Use the DRB scan tool ASD Fuel System Test
to pressurize the fuel system. Check for leaks.
REMOVAL AND INSTALLATION
FUEL FILTER
The fuel filter mounts to the top of the fuel tank.
The inlet and outlet tubes are permanently attached
to the filter (Fig. 13).
Fig. 12 Plastic Quick-Connect Fitting/Fuel Tube
Connection
14 - 12 FUEL SYSTEMNS
SERVICE PROCEDURES (Continued)

INSTALLATION
(1) Position fuel tank on transmission jack. Con-
nect pressure relief/rollover valve hose. Connect fuel
filler tube vent hose and replace clamp.
(2) Raise tank into position and carefully work
filler tube into tank. A light coating of clean engine
oil on the tube end may be used to aid assembly.
(3) Feed filler vent line thru frame rail. Careful
not to cross lines.
(4) Tighten strap bolts to 54 N´m (40 ft. lbs.)
torque. Remove transmission jack.
(5) Tighten filler hose clamp to 3.3 N´m (30 in.
lbs.).
CAUTION: Ensure straps are not twisted or bent
before or after tightening strap nuts.
(6) Connect fuel pump/module electrical connector.
Place retainer in locked position.
(7) Lubricate the fuel supply line with clean 30
weight engine oil, install the quick connect fuel fit-
ting. Refer to Tube/Fitting Assembly in the Fuel
Delivery section of this Group.
(8) Attach filler line to filler tube. Pull on connec-
tor to make sure of connection.
(9) Fill fuel tank, replace cap, and connect battery
negative cable.
CAUTION: When using the ASD Fuel System Test,
the ASD relay and fuel pump relay remain energized
for 7 minutes or until the test is stopped, or until
the ignition switch is turned to the Off position.
(10) Use the DRB scan tool ASD Fuel System Test
to pressurize the fuel system. Check for leaks.
FUEL INJECTOR RAILÐ2.4L
REMOVAL
(1) Perform fuel system pressure release procedure
before servicing or starting repairs.Refer to
Fuel System Pressure Release Procedure in this sec-
tion.
(2) Disconnect negative cable from battery.
(3) Remove air cleaner inlet hose from throttle
body.
(4) Remove throttle cable and speed control cable
(if equipped) from throttle lever.
(5) Remove throttle cables from bracket by com-
pressing retaining tabs.
(6) Remove connector from throttle position sensor.
(7) Remove connector from idle air control motor.
(8) Remove vacuum lines from intake plenum fit-
tings (Fig. 31) and (Fig. 32).(9) Remove connector from intake air temperature
sensor (Fig. 32).
(10) Remove connector from MAP sensor (Fig. 33).
(11) Remove fuel hose quick connect fitting from
the chassis tube (Fig. 34).Refer to Fuel Hoses,
Clamps and Quick Connect Fittings in this Sec-
tion.Place a shop towel under the connections to
absorb any fuel spilled from the fitting.
Fig. 31 Vacuum Fitting on Rear of Intake Manifold
Fig. 32 Electrical and Vacuum Connections
14 - 18 FUEL SYSTEMNS
REMOVAL AND INSTALLATION (Continued)

WARNING: WRAP A SHOP TOWEL AROUND
HOSES TO CATCH ANY GASOLINE SPILLAGE.
(12) Remove bolt holding bottom of intake support
bracket.
(13) Remove intake manifold screws (Fig. 35).
(14) Remove fuel rail attaching bolts.
(15) Remove fuel rail. Be careful not to damage
the injector O-rings upon removal from their ports.
INSTALLATION
(1) Ensure injector holes are clean. Replace
O-rings if damaged.
(2) Lubricate injector O-rings with a drop of clean
engine oil to ease installation.(3) Put the tip of each injector into their ports.
Push the assembly into place until the injectors are
seated in the ports.
(4) Install the fuel rail mounting bolts. Tighten
bolts to 22 N´m (200 in. lbs.) torque (Fig. 35).
(5) Install a new intake manifold gasket.
(6) Position intake manifold.
(7) Tighten retaining bolts starting at center and
progressing outward in both directions to 23 N´m
(200 in. lbs.) (Fig. 35). Repeat this procedure until all
bolts are at specified torque.
(8) Install fuel hose quick connector fitting to chas-
sis tubes.Refer to Fuel Hoses, Clamps and
Quick Connect Fittings in this Section.Push the
fitting onto the chassis tube until it clicks into place.
Pull on the fitting to ensure complete insertion.
(9) Reverse removal procedures Step 2 thru Step
12 for installation.
CAUTION: When using the ASD Fuel System Test,
the ASD relay and fuel pump relay remain energized
for 7 minutes or until the test is stopped, or until
the ignition switch is turned to the Off position.
(10) With the ignition key in ON position, access
the DRB scan tool ASD Fuel System Test to pressur-
ize the fuel system. Check for leaks.
FUEL INJECTOR RAILÐ3.0L
WARNING: THE 3.0L MPI FUEL SYSTEM IS UNDER
A CONSTANT PRESSURE OF APPROXIMATELY 330
KPA (48 PSI). PERFORM FUEL PRESSURE
RELEASE PROCEDURE BEFORE SERVICING THE
FUEL RAIL OR FUEL INJECTORS.
REMOVAL
(1) Perform the Fuel Pressure Release Procedure.
(2) Disconnect negative cable from battery.
Fig. 33 Map SensorÐ2.4L
Fig. 34 Fuel Line Quick Disconnect
Fig. 35 Intake Manifold Attaching Points
NSFUEL SYSTEM 14 - 19
REMOVAL AND INSTALLATION (Continued)