warning DODGE NEON 1999 Service Repair Manual
[x] Cancel search | Manufacturer: DODGE, Model Year: 1999, Model line: NEON, Model: DODGE NEON 1999Pages: 1200, PDF Size: 35.29 MB
Page 822 of 1200

WARNING: WRAP SHOP TOWELS AROUND HOSE
TO CATCH ANY GASOLINE SPILLAGE.
(8) Remove fuel rail assembly attaching screws
and remove fuel rail assembly from engine. Cover
injector holes with suitable covering.
CAUTION: Do not set fuel injectors on their tips,
damage may occur to the injectors
(9) Remove clean air duct and upper air filter
housing (Fig. 15).
(10) Remove accelerator, kickdown and speed con-
trol cables from throttle lever and bracket. Refer to
Group 14, Fuel System Throttle Body Removal for
procedures.
(11) Disconnect Idle Air Control (IAC) motor and
Throttle Position Sensor (TPS) wiring connectors
(Fig. 16).
(12) Disconnect vacuum hoses from throttle body
(Fig. 16).(13) Disconnect Manifold Absolute Pressure/Intake
Air Temperature Sensor (TMAP), electrical connector
(Fig. 17). Disconnect vapor and brake booster hoses.
(14) Disconnect knock sensor electrical connector
(Fig. 18) and disconnect wiring harness from tab
located on the intake manifold.
(15) Disconnect wiring at starter.
(16) Remove transmission to throttle body support
bracket fasteners at the throttle body and loosen the
fasteners at the transmission end.
(17) Remove throttle body.
(18) Remove EGR tube bolts at the valve and at
the intake manifold (Fig. 19). Remove tube from
engine.
(19) Remove the intake manifold to inlet water
tube support fastener (Fig. 20).
(20) Remove 10 intake manifold screws and wash-
ers. Discard the fasteners. Remove intake manifold.
Fig. 14 Releasing Fuel Pressure
Fig. 15 Clean Air Duct to Throttle Body Assembly
Fig. 16 Idle Air Control (IAC) Motor and Throttle
Position Sensor (TPS) Wiring Connectors and
Vacuum Hose Connection
Fig. 17 Intake Manifold Electrical and Vacuum Hose
Connections
PLEXHAUST SYSTEM AND INTAKE MANIFOLD 11 - 7
REMOVAL AND INSTALLATION (Continued)
Page 824 of 1200

INTAKE MANIFOLDÐDOHC ENGINE
REMOVAL
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) Loosen wing nut on intake and remove fresh
air inlet duct (Fig. 23).
(4) Remove the protective cap from the fuel pres-
sure test port on the fuel rail (Fig. 21).
(5) Place the open end of fuel pressure release
hose, Special Tool C-4799-1, into an approved gaso-
line container. Connect the other end of hose to the
fuel pressure test port (Fig. 22). Fuel pressure will
bleed off through the hose into the gasoline con-
tainer. Fuel gauge C-4799-A contains hose C-4799-1.
(6) Disconnect the fuel supply line quick-connect at
the fuel tube assembly.
(7) Remove clean air inlet duct.WARNING: WRAP SHOP TOWELS AROUND HOSE
TO CATCH ANY GASOLINE SPILLAGE.
(8) Disconnect the coolant temperature sensor
(Fig. 24).
(9) Disconnect heater hose from intake manifold.
(10) Disconnect heater tube from bottom of intake
manifold.
(11) Disconnect upper radiator hose and coolant
recovery hose.
(12) Remove fuel rail assembly attaching screws
and remove fuel rail assembly from engine. Cover
injector holes with suitable covering.
CAUTION: Do not set fuel injectors on their tips,
damage may occur to the injectors
Fig. 21 Fuel Pressure Test PortÐTypical
Fig. 22 Releasing Fuel PressureÐTypical
Fig. 23 Fresh Air Inlet Duct
Fig. 24 Engine Coolant Temperature Sensor
PLEXHAUST SYSTEM AND INTAKE MANIFOLD 11 - 9
REMOVAL AND INSTALLATION (Continued)
Page 832 of 1200

FRAMES
INDEX
page page
REMOVAL AND INSTALLATION
FRONT SUSPENSION CROSSMEMBER....... 3
SPECIFICATIONS
STRUCTURAL DIMENSIONS................ 4TORQUE SPECIFICATIONS................ 10
REMOVAL AND INSTALLATION
FRONT SUSPENSION CROSSMEMBER
WARNING: IF SUSPENSION CROSSMEMBER IS
REPLACED DUE TO COLLISION DAMAGE, INSPECT
THE STEERING COLUMN TO STEERING GEAR
COUPLING FOR DAMAGE. REFER TO GROUP 19,
STEERING FOR INSTRUCTIONS.
Before removing front suspension crossmem-
ber, index mark location of crossmember on
frame to aid installation.
The front suspension crossmember must be prop-
erly installed to achieve design camber, caster set-
tings and wheel stagger. The crossmember can be
installed out of position on the frame rails due to its
design. Bolts and cage nuts hold the rear of the
crossmember to the frame torque boxes. Bolts and
J-nuts hold the front of the crossmember to the
frame rails. No designed in locating device is used to
position the crossmember in the vehicle. Before
removing the crossmember mark the frame torque
box around the rear mounting location to aid instal-
lation. A crossmember that is removed during service
must be installed in the same position from which it
was removed. To verify that crossmember is in the
proper position, refer to the dimensions provided.
Front end dimensions are gauged from the principal
locating point (PLP) holes located under the frame
torque boxes rearward of the front wheels. After
removal and installation of the crossmember is per-
formed, verify that front suspension alignment is
within specifications. If camber, caster settings and
wheel stagger is not within specifications, loosen and
reposition crossmember to bring suspension within
specifications. Refer to Group 2, Front Suspension
and Driveshaft for additional information.
REMOVAL
(1) Hoist and support vehicle on safety stands.
(2) Using a suitable marking device, mark the out-
line of the suspension crossmember on the frame
torque box around the rear mounting location.(3) Remove front wheels from vehicle.
(4) Remove pinch bolts holding front ball joints to
spindles.
(5) Separate ball joints from spindles.
(6) Position a suitable lifting device under the
crossmember.
(7) Remove bolts holding suspension crossmember
to frame rails above lower control arms (Fig. 1).
(8) Remove bolts holding crossmember to frame
torque boxes and allow front of crossmember to
swing down.
(9) Remove bolts holding steering gear to cross-
member.
(10) Separate steering gear from crossmember.
(11) Tie steering gear to a suitable structure above
to support gear after crossmember is removed.
(12) Separate front suspension crossmember from
vehicle.
INSTALLATION
If a new crossmember is to be installed, transfer
stabilizer bar and lower control arms from original
crossmember. Refer to Group 2, Suspension and
Driveshaft for proper procedures.
(1) Place front suspension crossmember in position
on vehicle.
(2) Remove tie device supporting steering gear.
Fig. 1 Front Suspension Crossmember
PLFRAME AND BUMPERS 13 - 3
Page 846 of 1200

FUEL INJECTORS
The fuel injectors are 12 ohm electrical solenoids
(Fig. 4). 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. 5).
PRESSURE-VACUUM FILLER CAP
The loss of any fuel or vapor out of the filler neck
is prevented by the use of a safety filler cap. The cap
will release pressure only under significant pressure
of 10.9 to 13.45 kPa (1.58 to 1.95 psi). The vacuum
release for all gas caps is between 0.97 and 2.0 kPa
(0.14 and 0.29 psi). The cap must be replaced by a
similar unit if replacement is necessary.WARNING: REMOVE FILLER CAP TO RELIEVE
TANK PRESSURE BEFORE REMOVING OR REPAIR-
ING FUEL SYSTEM COMPONENTS.
QUICK-CONNECT FITTINGS
Different types of quick-connect fittings are used to
attach various fuel system components. These are: a
single-tab type, a two-tab type or a plastic retainer
ring type. Some are equipped with safety latch clips.
Refer to the Removal/Installation section for more
information.
CAUTION: The interior components (o-rings, spac-
ers) of quick-connect fitting are not serviced sepa-
rately. Do not attempt to repair damaged fittings or
fuel lines/tubes. If repair is necessary, replace the
complete fuel tube assembly.
Fuel tubes connect fuel system components with
plastic quick-connect fuel fittings. The fitting con-
tains non-serviceable O-ring seals (Fig. 6).
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.
The quick-connect fitting consists of the O-rings,
retainer and casing (Fig. 6). When the fuel tube
enters the fitting, the retainer locks the shoulder of
the nipple in place and the O-rings seal the tube.
ROLLOVER VALVES
All PL vehicles have two rollover valves. One in
the fuel filler tube and the other on the top of the
fuel tank. The valves prevent fuel flow through the
fuel tank vent valve hoses should the vehicle rollover.
Fig. 3 Fuel RailÐTypical
Fig. 4 Fuel Injector
Fig. 5 Fuel Injector LocationÐTypical
PLFUEL SYSTEM 14 - 5
DESCRIPTION AND OPERATION (Continued)
Page 851 of 1200

SERVICE PROCEDURES
FUEL SYSTEM PRESSURE RELEASE PROCEDURE
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 the protective cap from the fuel pres-
sure test port on the fuel rail (Fig. 11).
(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 (Fig. 12). Fuel
pressure will bleed off through the hose into the gas-
oline container. Fuel gauge C-4799-A contains hose
C-4799-1.
(5) Replace Pressure test port cap when finished
doing pressure test.
DRAINING FUEL TANK
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) Remove fuel filler cap.
(2) Perform the Fuel System Pressure Release pro-
cedure.
(3) Disconnect negative cable from battery.
(4) Raise vehicle on hoist.(5) Remove quick connect cap from drain port. The
drain port is located on rear top of fuel tank. Push a
siphon hose into the drain port (Fig. 13).
(6) Drain fuel tank into holding tank or a properly
labeledGasolinesafety container.
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.
Fig. 11 Fuel Pressure Test PortÐTypical
Fig. 12 Releasing Fuel Pressure
Fig. 13 Drain Port Location
14 - 10 FUEL SYSTEMPL
Page 852 of 1200

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. 14).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
AUTOMATIC SHUTDOWN RELAY
The relay is located in the Power Distribution Cen-
ter (PDC) (Fig. 15). The PDC is located next to the
battery in the engine compartment. For the location
of the relay within the PDC, refer to the PDC cover
for location. Check electrical terminals for corrosion
and repair as necessary.
FUEL PUMP RELAY
The fuel pump relay is located in the PDC. The
inside top of the PDC cover has a label showing relay
and fuse location.
FUEL PUMP MODULE
REMOVAL
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) Drain the fuel. Refer to Draining Fuel Tank in
the Fuel Tank section of this group.
Fig. 14 Plastic Quick-Connect Fitting/Fuel Tube
Connection
Fig. 15 Power Distribution Center (PDC)
PLFUEL SYSTEM 14 - 11
SERVICE PROCEDURES (Continued)
Page 853 of 1200

WARNING: THE FUEL RESERVOIR OF THE FUEL
PUMP MODULE DOES NOT EMPTY OUT WHEN THE
TANK IS DRAINED. THE FUEL IN THE RESERVOIR
WILL SPILL OUT WHEN THE MODULE IS
REMOVED.
(2) Disconnect fuel line from fuel pump module by
depressing quick connect retainers with thumb and
fore finger.
(3) Slide fuel pump module electrical connecter
lock to unlock.
(4) Disconnect the electrical connection from the
fuel pump module, by pushing down on connector
retainer and pulling connector off of module.
(5) Use a transmission jack to support the fuel
tank. remove bolts from fuel tank straps.
(6) Lower tank slightly.
(7) Use Special Tool 6856 to remove fuel pump
module locknut (Fig. 17).
(8) Remove fuel pump and O-ring seal from tank.
Discard old seal.
INSTALLATION
(1) Wipe seal area of tank clean and place a new
seal in position in the tank opening.
(2) Position fuel pump in the tank. Make sure the
aligment tab on the underside of the fuel pump mod-
ule flange sits in the notch on the fuel tank.
(3)
Position the locknut over the fuel pump module.
(4) Tighten the locknut using Special Tool 6856 to
55 N´m (40.5 ft. lbs.) (Fig. 17).
CAUTION: Over tightening the pump lock ring may
result in a leak.
(5) Fill fuel tank. Check for leaks.
FUEL FILTER / PRESSURE REGULATOR
REMOVAL
WARNING: THE FUEL SYSTEM IS UNDER A CON-
STANT PRESSURE, EVEN WITH ENGINE OFF. BEFORE
SERVICING THE FUEL FILTER/FUEL PRESSURE REG-
ULATOR, THE FUEL SYSTEM PRESSURE MUST BE
RELEASED.
(1) Refer to Fuel System Pressure Release in the
Fuel Delivery System section of this group.
The fuel filter/fuel pressure regulator is located on
the top of fuel pump module. Fuel pump module
removal is not necessary.
(2) Raise vehicle on hoist.
(3) Disconnect fuel supply line at the Filter/Regu-
lator nipple (refer to Quick Connect Fittings in this
section).
(4) Depress locking spring tab on side of Fuel/Reg-
ulator (Fig. 18) and rotate 90É counter-clockwise and
pull out.
NOTE: Make sure that the upper and lower O-rings
are on the Filter/Regulator assembly.
INSTALLATION
Lightly lubricate the O-rings with engine oil.
(1) Insert Filter/Regulator into the opening in the
fuel pump module, align the two hold down tabs with
the flange.
(2) While applying downward pressure, rotate the
Filter/Regulator clockwise until the the spring tab
engages the locating slot (Fig. 19).
(3) Connect the fuel line to the Filter/Regulator.
(4) Lower vehicle from hoist.
Fig. 16 Fuel Pump Module Removal
Fig. 17 Fuel Tank Locknut
14 - 12 FUEL SYSTEMPL
REMOVAL AND INSTALLATION (Continued)
Page 856 of 1200

(5) Remove fuel rail mounting screws.
(6) Lift rail off of intake manifold. Cover the fuel
injector openings in the intake manifold.
(7) Remove fuel injector retainer (Fig. 28).
(8) Pull injector out of fuel rail. Replace fuel injec-
tor O-rings (Fig. 29).
INSTALLATION
(1) Apply a light coating of clean engine oil to the
upper O-ring.(2) Install injector in cup on fuel rail.
(3) Install retaining clip.
(4) Apply a light coating of clean engine oil to the
O-ring on the nozzle end of each injector.
(5) Insert fuel injector nozzles into openings in
intake manifold. Seat the injectors in place. Tighten
fuel rail mounting screws to 22.5 N´m63 N´m
(200630 in. lbs.).
(6) Attach electrical connectors to fuel injectors.
(7) Connect fuel supply tube to fuel rail. Refer to
Quick Connect Fittings in the Fuel Delivery Section
of this Group.
FUEL TANK
REMOVAL
(1) Perform fuel system pressure release.
(2) Drain fuel tank. Refer to Draining Fuel Tank
in this section (Fig. 30).
(3) Raise vehicle on hoist.
WARNING: WRAP SHOP TOWELS AROUND
HOSES TO CATCH ANY GASOLINE SPILLAGE.
(4) Disconnect fuel pump module electrical connec-
tor (Fig. 31).
(5) Disconnect the fuel tube from Fuel Filter/Reg-
ulator. Refer to Quick Connect Fittings in the Fuel
Delivery section of this group.
(6) Support tank with transmission jack. Loosen
tank mounting straps and lower tank slightly.
(7) Disconnect fuel filler tube and filler vent tube
from filler hose at fuel tank (Fig. 32).
(8) Disconnect fuel filler vapor relief tube from tee
connecting it to the tank vapor relief tube and EVAP
canister tube.
(9) Disconnect vapor line from Evap canister tube.
(10) Remove tank mounting straps and lower tank.Fig. 27 Fuel Rail and Injectors
Fig. 28 Fuel Injector Retainer
Fig. 29 Fuel Injector O-Rings
Fig. 30 Fuel Tank
PLFUEL SYSTEM 14 - 15
REMOVAL AND INSTALLATION (Continued)
Page 887 of 1200

(25) Inspect the connection at the battery temper-
ature sensor (Fig. 76).
ASD AND FUEL PUMP RELAYS
The following description of operation and
tests apply only to the Automatic Shutdown
(ASD) and fuel pump relays. The terminals on the
bottom of each relay are numbered (Fig. 77) or (Fig.
78).
OPERATION
²Terminal number 30 is connected to battery volt-
age. For both the ASD and fuel pump relays, termi-
nal 30 is connected to battery voltage at all times.
²The PCM grounds the coil side of the relay
through terminal number 85.²Terminal number 86 supplies voltage to the coil
side of the relay.
²When the PCM de-energizes the ASD and fuel
pump relays, terminal number 87A connects to termi-
nal 30. This is the Off position. In the off position,
voltage is not supplied to the rest of the circuit. Ter-
minal 87A is the center terminal on the relay.
²When the PCM energizes the ASD and fuel
pump relays, terminal 87 connects to terminal 30.
This is the On position. Terminal 87 supplies voltage
to the rest of the circuit.
TESTING
The following procedure applies to the ASD and
fuel pump relays.
(1) Remove relay from connector before testing.
(2) With the relay removed from the vehicle, use
an ohmmeter to check the resistance between termi-
nals 85 and 86. The resistance should be between 75
65 ohms.
(3) Connect the ohmmeter between terminals 30
and 87A. The ohmmeter should show continuity
between terminals 30 and 87A.
(4) Connect the ohmmeter between terminals 87
and 30. The ohmmeter should not show continuity at
this time.
(5) Connect one end of a jumper wire (16 gauge or
smaller) to relay terminal 85. Connect the other end
of the jumper wire to the ground side of a 12 volt
power source.
(6) Connect one end of another jumper wire (16
gauge or smaller) to the power side of the 12 volt
power source.Do not attach the other end of the
jumper wire to the relay at this time.
WARNING: DO NOT ALLOW OHMMETER TO CON-
TACT TERMINALS 85 OR 86 DURING THIS TEST.
Fig. 76 Battery Temp. Sensor Connectors
Fig. 77 ASD and Fuel Pump Relay Terminals
Fig. 78 ASD and Fuel Pump Relay Terminals
14 - 46 FUEL SYSTEMPL
DIAGNOSIS AND TESTING (Continued)
Page 890 of 1200

(6) Connect the DRB scan tool to the data link
connector inside the passenger compartment.
(7) Run engine in Park or Neutral until the cooling
fan has cycled on and off at least once (180ÉF).
(8) Using the DRB scan tool, access Minimum Air-
flow Idle Speed.
(9) The following will then occur:
²Idle air control motor will fully close
²Idle spark advance will become fixed
²PCM will go open loop enriched
²DRB scan tool displays engine RPM
(10) If idle RPM is within the range shown in the
Idle Specification chart, throttle body minimum air-
flow is set correctly.
IDLE SPECIFICATION Ð2.0L ENGINEOdometer Reading Idle RPM
Below 1000 Miles.................550±1300 RPM
Above 1000 Miles.................600±1300 Miles
(11) If idle RPM is above specifications, use the
DRB scan tool to check idle air control motor opera-
tion. If idle air control motor is OK, replace throttle
body. If idle air flow is below specification, shut off
the engine and clean the throttle body as follows:
WARNING: CLEAN THROTTLE BODY IN A WELL
VENTILATED AREA. WEAR RUBBER OR BUTYL
GLOVES, DO NOT LET MOPAR PARTS CLEANER
COME IN CONTACT WITH EYES OR SKIN. AVOID
INGESTING THE CLEANER. WASH THOROUGHLY
AFTER USING CLEANER.
(a) Remove the throttle body from engine.
(b) While holding the throttle open, spray the
entire throttle body bore and the manifold side of
the throttle plate with Mopar Parts Cleaner.Only
use Mopar Parts Cleaner to clean the throttle
body.
(c) Using a soft scuff pad, clean the top and bot-
tom of throttle body bore and the edges and mani-
fold side of the throttle blade.The edges of the
throttle blade and portions of the throttle
bore that are closest to the throttle blade
when closed, must be free of deposits.
(d) Use compressed air to dry the throttle body.
(e) Inspect throttle body for foreign material.
(f) Install throttle body on manifold.
(g) Repeat steps 1 through 14. If the minimum
air flow is still not within specifications, the prob-
lem is not caused by the throttle body.
(12) Shut off engine.
(13) Remove Air Metering Orifice 6457. Install
purge hose.
(14) Remove cap from PCV valve. Connect hose to
PCV valve.
(15) Remove DRB scan tool.
VEHICLE SPEED SENSOR
To perform a complete test of the sensor and its
circuitry, refer to the DRB scan tool and appropriate
Powertrain Diagnostics Procedures Manual.
Fig. 84 Purge Hose
Fig. 85 Orifice 6457 Attached to Purge Nipple
PLFUEL SYSTEM 14 - 49
DIAGNOSIS AND TESTING (Continued)