stop start DODGE NEON 1999 Service User Guide

8W-10 POWER DISTRIBUTION
Component Page
A/C Compressor Clutch.............8W-10-14, 15
A/C Compressor Clutch Relay........8W-10-14, 15
Automatic Shut Down Relay............8W-10-16
Battery...........................8W-10-5, 6
Capacitor..........................8W-10-16
Circuit Breaker.......................8W-10-8
Clutch Pedal Position Switch.......8W-10-9, 10, 11
Controller Anti-Lock Brake.......8W-10-12, 14, 15
Data Link Connector..................8W-10-16
Diode No. 1......................8W-10-14, 15
Diode No. 2.........................8W-10-13
Dome Lamp........................8W-10-13
Downstream Heated Oxygen Sensor......8W-10-16
Engine Starter Motor..................8W-10-7
Engine Starter Motor Relay......8W-10-7, 9, 10, 11
Fog Lamp Relay.....................8W-10-17
Fuel Injector No. 1...................8W-10-16
Fuel Injector No. 2...................8W-10-16
Fuel Injector No. 3...................8W-10-16
Fuel Injector No. 4...................8W-10-16
Fuel Pump Module...................8W-10-16
Fuel Pump Relay....................8W-10-16
Fuse 1 (FB)..........................8W-10-8
Fuse 2 (FB)..........................8W-10-8
Fuse 2 (PDC).....................8W-10-5, 6, 7
Fuse 3 (FB)..........................8W-10-8
Fuse 3 (PDC).....................8W-10-5, 6, 8
Fuse 4 (FB)..........................8W-10-8
Fuse 5 (FB)..........................8W-10-8
Fuse 5 (PDC)....................8W-10-5, 6, 12
Fuse 6 (FB)..........................8W-10-8
Fuse 7 (FB)..........................8W-10-8
Fuse 8 (FB)..........................8W-10-8
Fuse 8 (PDC)....................8W-10-5, 6, 12
Fuse 9 (FB).......................8W-10-9, 10
Fuse 10 (FB)...................8W-10-9, 10, 11
Fuse 10 (PDC)...................8W-10-5, 6, 12
Fuse 11 (FB)...................8W-10-9, 10, 11
Fuse 11 (PDC)....................8W-10-5, 6, 7
Fuse 12 (FB)........................8W-10-11
Fuse 13 (PDC)...................8W-10-5, 6, 13
Fuse 14 (FB)...................8W-10-9, 10, 11
Fuse 15 (FB)...................8W-10-9, 10, 11
Fuse 16 (FB)...................8W-10-9, 10, 11Component Page
Fuse 16 (PDC).....................8W-10-6, 17
Fuse 18 (PDC)................8W-10-5, 6, 14, 15
Fuse 20 (PDC)................8W-10-5, 6, 14, 15
Fuse 21 (PDC)...................8W-10-5, 6, 16
Fuse 23 (PDC)................8W-10-5, 6, 14, 15
Fuse 25 (PDC)................8W-10-5, 6, 14, 15
Fuse Block...................8W-10-8, 9, 10, 11
G101...............................8W-10-9
G204...............................8W-10-7
Generator..........................8W-10-16
Glove Box Lamp And Switch............8W-10-13
Headlamp Switch.....................8W-10-8
High Speed Warning Module...........8W-10-13
Horn..............................8W-10-14
Horn No. 1.........................8W-10-15
Horn No. 2.........................8W-10-15
Horn Relay......................8W-10-14, 15
Ignition Coil Pack....................8W-10-16
Ignition Switch.............8W-10-7, 8, 9, 10, 11
Immobilizer......................8W-10-10, 11
Instrument Cluster.................8W-10-7, 13
Left Fog Lamp......................8W-10-17
Left Visor/Vanity Lamps...............8W-10-13
Map/Reading Lamps..................8W-10-13
Noise Supressor.....................8W-10-16
Power Distribution
Center.....8W-10-5, 6, 7, 8, 12, 13, 14, 15, 16, 17
Power Mirror Switch..................8W-10-13
Powertrain Control Module...........8W-10-9, 16
Radiator Fan Motor..................8W-10-12
Radio..............................8W-10-13
Rear Fog Lamp Switch................8W-10-17
Rear Window Defogger Switch..........8W-10-12
Right Fog Lamp.....................8W-10-17
Right Visor/Vanity Lamps..............8W-10-13
Solid State Fan Relay.................8W-10-12
Stop Lamp Switch.................8W-10-14, 15
Time Delay Relay....................8W-10-13
Time Out Relay......................8W-10-13
Trunk Lamp........................8W-10-13
Turn Signal/Hazard Switch..........8W-10-14, 15
Underhood Lamp....................8W-10-13
Upstream Heated Oxygen Sensor........8W-10-16
PL8W - 10 POWER DISTRIBUTION 8W - 10 - 1

BATTERY
1
22FUSE
40A
A2
12
PK/BK
40A
FUSE
3
3
4
A3
12
RD/WT
CENTER DISTRIBUTION
POWER7
88FUSE
30A 30A
FUSE
5
5
6
A16
14
GYA4
14
BK/RD
A0 8RD
12
1111FUSE
30A 20A
FUSE
18
18
1714
1313FUSE
10A 40A
FUSE
10
10
9
A20
12
RD/DGM1
18
PKA1
14
RD
19
2020FUSE
10A
L9
18
BK/WT
26
2525FUSE
15A 20A
FUSE
21
21
22
15A
FUSE
23
23
24
F32
18
PK/DB
IGNITION
SWITCH
TO TO
S213 SOLID
STATE
FAN
RELAY
TO
REAR
WINDOW
DEFOGGER
SWITCH
TO
TO
BRAKE ANTI-LOCK CONTROLLER
TO
S203A/C
COMPRESSOR
CLUTCH
RELAY
TO
IGNITION
SWITCH
TOTURN
SIGNAL/
HAZARD
SWITCH
TO
STOP
LAMP/
VEHICLE
SPEED
CONTROL
SWITCH
TOFUEL
PUMP/
ASD
RELAYS
(IN PDC)
TO
HORN
RELAY
(IN PDC)
TO
PK18 M1
UNDER
HOOD
LAMP
TO
(IN PDC)(IN PDC)
TO
RELAY MOTOR STARTERENGINE
S105
TO
RD/WT16 A14
(8W-20-2)
(8W-10-7) (8W-10-8) (8W-10-12)(8W-10-12)
(8W-10-7) (8W-10-14)(8W-10-13) (8W-10-12)(8W-10-14)
(8W-10-14) (8W-10-16) (8W-10-14)
PL8W-10 POWER DISTRIBUTION
EXCEPT BUILT-UP-EXPORT8W - 10 - 5
8194J988W-1

BATTERY
1
22FUSE
40A
A2
12
PK/BK
40A
FUSE
3
3
4
A3
12
RD/WT
CENTER DISTRIBUTION
POWER7
88FUSE
30A 30A
FUSE
5
5
6
A16
14
GYA4
14
BK/RD
A0 8RD
12
1111FUSE
30A
10A
FUSE
18
18
17
14
1313FUSE
10A 40A
FUSE
10
10
9
A20
12
RD/DGM1
18
PK
A1
14
RD
19
2020FUSE
10A
L9
18
BK/WT
26
2525FUSE
15A 20A
FUSE
21
21
22
15A
FUSE
23
23
24
F32
18
PK/DB
IGNITION
SWITCH
TO TO
S213 SOLID
STATE
FAN
RELAY
TO
REAR
WINDOW
DEFOGGER
SWITCH
TO
TO
BRAKE ANTI-LOCK CONTROLLER
TO
S203
A/C
COMPRESSOR
CLUTCH
RELAY
TO
IGNITION
SWITCH
TO
TURN
SIGNAL/
HAZARD
SWITCH
TO
STOP
LAMP
SWITCH
TO
FUEL
PUMP/
ASD
RELAYS
(IN PDC)
TO
HORN
RELAY
(IN PDC)
TO
15
1616FUSE
20A
TO
(IN PDC)RELAYLAMPFOG
73
PK18 M1
TO
LAMP UNDERHOOD
F61
18
WT/OR
REAR
FOG
LAMP
SWITCH
TO
A14
16
RD/WT
TO
S105
(IN PDC)(IN PDC)
TO
RELAY MOTOR STARTERENGINE
70
(8W-20-2)
(8W-10-7) (8W-10-8) (8W-10-12)(8W-10-12)
(8W-10-7)
(8W-10-15)(8W-10-13) (8W-10-12)
(8W-10-15)(8W-10-15) (8W-10-16) (8W-10-15)(8W-10-17)
8W - 10 - 6 8W-10 POWER DISTRIBUTION
BUILT-UP-EXPORTPL
J988W-18195

8W-15 GROUND DISTRIBUTION
Component Page
A/C Compressor Clutch...............8W-15-5, 6
A/C Compressor Clutch Relay..........8W-15-5, 6
A/C Heater Control....................8W-15-9
ABS Warning Lamp Relay............8W-15-7, 8
Airbag Control Module...............8W-15-7, 8
Ash Receiver Lamp................8W-15-10, 11
Battery...........................8W-15-7, 8
Brake Warning Lamp Switch..........8W-15-2, 3
Center High Mounted Stop Lamp.....8W-15-12, 14
Cigar Lighter Relay...................8W-15-11
Cigar Lighter/Power Outlet..........8W-15-10, 11
Clockspring..........................8W-15-7
Combination Flasher.................8W-15-7, 8
Controller Anti-Lock Brake............8W-15-2, 3
Data Link Connector..................8W-15-4
Daytime Running Lamp Module..........8W-15-7
Diode No. 1........................8W-15-5, 6
Downstream Heated Oxygen Sensor.....8W-15-2, 3
Driver Door Lock Switch................8W-15-9
Driver Power Window Switch............8W-15-9
Engine Starter Motor Relay...........8W-15-2, 3
Fog Lamp Relay......................8W-15-3
Fog Lamp Switch....................8W-15-10
Front Fog Lamp Switch...............8W-15-11
Fuel Pump Module................8W-15-12, 13
G101.............................8W-15-2, 3
G102...............................8W-15-4
G103.............................8W-15-5, 6
G104.............................8W-15-7, 8
G105.............................8W-15-7, 8
G110.............................8W-15-7, 8
G111...............................8W-15-8
G201.............................8W-15-7, 8
G202.............................8W-15-7, 8
G203...............................8W-15-9
G204...........................8W-15-10, 11
G301...........................8W-15-12, 13
G302...........................8W-15-12, 14
G303...........................8W-15-12, 13
Glove Box Lamp And Switch.........8W-15-10, 11
Halo Lamp......................8W-15-10, 11
Headlamp Leveling Switch.............8W-15-11
Headlamp Switch.................8W-15-10, 11
High Speed Warning Module............8W-15-8
Horn...............................8W-15-2
Horn No. 1..........................8W-15-6
Horn No. 2..........................8W-15-3
Horn Switches.......................8W-15-7
Ignition Switch...................8W-15-10, 11Component Page
Immobilizer..........................8W-15-8
Instrument Cluster................8W-15-10, 11
Intermittent Wipe/Wash Switch........8W-15-7, 8
Left Back-Up Lamp................8W-15-12, 14
Left Fog Lamp.....................8W-15-5, 6
Left Headlamp.....................8W-15-2, 3
Left Headlamp Leveling Motor...........8W-15-3
Left License Lamp...................8W-15-14
Left Park/Turn Signal Lamp...........8W-15-2, 3
Left Rear Fog Lamp..................8W-15-14
Left Repeater Lamp...................8W-15-3
Left Tail/Stop Lamp..................8W-15-14
Left Tail/Stop/Turn Signal Lamp.........8W-15-12
Left Turn Signal Lamp................8W-15-14
License Lamp.......................8W-15-12
Map/Reading Lamps...............8W-15-10, 11
Power Folding Mirror Relay.............8W-15-9
Power Mirror Switch...................8W-15-9
Power Steering Pressure Switch..........8W-15-4
Power Sunroof Motor..................8W-15-9
Powertrain Control Module..............8W-15-4
PRNDL Lamp....................8W-15-10, 11
Radiator Fan Motor.................8W-15-2, 3
Radio.............................8W-15-7, 8
Rear Fog Lamp Switch................8W-15-11
Rear Window Defogger.............8W-15-12, 13
Rear Window Defogger Switch.........8W-15-7, 8
Remote Keyless Entry Module...........8W-15-7
Right Back-Up Lamp...............8W-15-12, 13
Right Fog Lamp....................8W-15-5, 6
Right Headlamp....................8W-15-5, 6
Right Headlamp Leveling Motor..........8W-15-6
Right License Lamp..................8W-15-14
Right Park/Turn Signal Lamp..........8W-15-5, 6
Right Rear Fog Lamp.................8W-15-13
Right Repeater Lamp..................8W-15-6
Right Tail/Stop Lamp.................8W-15-13
Right Tail/Stop/Turn Signal Lamp.......8W-15-12
Right Turn Signal Lamp...............8W-15-13
Seat Belt Switch..................8W-15-12, 14
Solid State Fan Relay................8W-15-2, 3
Stop Lamp Switch.....................8W-15-4
Sunroof Vent Switch...................8W-15-9
Underhood Lamp...................8W-15-2, 3
Upstream Heated Oxygen Sensor.......8W-15-2, 3
Vehicle Speed Control Servo.............8W-15-2
Vehicle Speed Control Switch............8W-15-7
Windshield Washer Pump Motor........8W-15-2, 3
PL8W - 15 GROUND DISTRIBUTION 8W - 15 - 1

8W-30 FUEL/IGNITION SYSTEMS
Component Page
A/C Compressor Clutch Relay...........8W-30-12
A/C High Pressure Switch..............8W-30-12
Airbag Control Module.................8W-30-4
Automatic Shut Down Relay...........8W-30-2, 3
Battery Temperature Sensor...........8W-30-3, 7
Camshaft Position Sensor............8W-30-7, 16
Center High Mounted Stop Lamp........8W-30-15
Clockspring.........................8W-30-14
Controller Anti-Lock Brake...........8W-30-4, 15
Crankshaft Position Sensor...........8W-30-7, 16
Data Link Connector.................8W-30-2, 4
Downstream Heated Oxygen Sensor.......8W-30-3
Duty Cycle Evap/Purge Solenoid.......8W-30-9, 10
EGR Transducer Solenoid............8W-30-9, 10
Engine Coolant Temperature Sensor.......8W-30-7
Engine Starter Motor Relay............8W-30-13
Fuel Injector No. 1....................8W-30-5
Fuel Injector No. 2....................8W-30-5
Fuel Injector No. 3....................8W-30-5
Fuel Injector No. 4....................8W-30-5
Fuel Pump Module...................8W-30-11
Fuel Pump Relay.....................8W-30-11
Fuse 10 (FB)...................8W-30-9, 10, 11
Fuse 21 (PDC).................8W-30-2, 3, 4, 11
Fuse 25 (PDC).......................8W-30-15
Fuse Block.....................8W-30-9, 10, 11
G101............................8W-30-3, 14
G102.......................8W-30-2, 4, 14, 15Component Page
G202..............................8W-30-14
G303..............................8W-30-11
Generator..........................8W-30-12
Iat/Map Sensor.......................8W-30-6
Idle Air Control Motor.................8W-30-8
Ignition Coil Pack.....................8W-30-5
Immobilizer.....................8W-30-3, 8, 16
Immobilizer Engine Sensor.............8W-30-16
Instrument Cluster............8W-30-7, 8, 11, 12
Knock Sensor........................8W-30-6
Noise Supressor......................8W-30-5
Park/Neutral Position Switch...........8W-30-13
Power Distribution Center.....8W-30-2, 3, 4, 11, 15
Power Steering Pressure Switch..........8W-30-4
Powertrain Control
Module..........8W-30-2, 3, 4, 5, 6, 7, 8, 9, 10,
11, 12, 13, 14, 15, 16
Solid State Fan Relay.................8W-30-12
Stop Lamp Switch.................8W-30-14, 15
Throttle Position Sensor................8W-30-6
Torque Converter Clutch Solenoid......8W-30-9, 10
Turn Signal/Hazard Switch.............8W-30-15
Upstream Heated Oxygen Sensor.........8W-30-3
Vapor Canister Leak Detector............8W-30-9
Vehicle Speed Control Servo.........8W-30-14, 15
Vehicle Speed Control Switch...........8W-30-14
Vehicle Speed Sensor................8W-30-8, 16
PL8W - 30 FUEL/IGNITION SYSTEMS 8W - 30 - 1

CAV CIRCUIT FUNCTION
1 B1 18YL/DB RIGHT REAR WHEEL SPEED SENSOR (-)
2
3B3 18LG/DB
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
CONTROLLER
ANTI-LOCK
BRAKE
BLACK
23 17 1
7
8
924
25 1610
STOP LAMP SWITCH OUTPUT B4 18LG
18WT/TN 18VT
18RD/DB18RD
L50 B9
B8 B7
- -
Z1 12BK GROUND
FUSED B(+) A17 12RD/BK
B58 18GY/LB ABS MAIN RELAY CONTROLLEFT REAR WHEEL SPEED SENSOR (-)
RIGHT FRONT WHEEL SPEED SENSOR (+)
LEFT FRONT WHEEL SPEED SENSOR (-)
LEFT REAR WHEEL SPEED SENSOR (+)
LEFT FRONT WHEEL SPEED SENSOR (+)
B2 18YL
B6 18WT/DB
D2 18WT/BK CCD BUS (-)
D1 18VT/BR CCD BUS (+)
F12 18DG/WT FUSED IGNITION SWITCH OUTPUT (ST-RUN)
Z1 12BK GROUNDRIGHT REAR WHEEL SPEED SENSOR (+)
RIGHT FRONT WHEEL SPEED SENSOR (-)
FUSED B(+) A20 12RD/DG--
--
--
--
--
--
--
(MTX) POSITION SWITCHCLUTCH PEDAL
1 2
BLACK
IGNITION SWITCH (START) 14YL A41
2
SIGNAL SWITCH POSITION PEDAL CLUTCH 14YL/RD T141 1
FUNCTION CIRCUIT CAV
PL8W-80 CONNECTOR PIN-OUTS 8W - 80 - 15
PL008015J988W-1

(1) Position the vehicle on a level surface and turn
engine off.
(2) Hoist and support vehicle on safety stands.
Refer to Hoisting and Jacking Recommendations.(3) Remove oil fill cap.
(4) Place a suitable drain pan under crankcase
drain.
(5) Remove drain plug from crankcase and allow
oil to drain into pan. Inspect drain plug threads for
stretching or other damage. Replace drain plug and
gasket if damaged.
(6) Install drain plug in crankcase.
(7) Lower vehicle and fill crankcase with specified
type and amount of engine oil described in this sec-
tion.
(8) Install oil fill cap.
(9) Start engine and inspect for leaks.
(10) Stop engine and inspect oil level.
Fig. 7 Engine Oil Container Standard Notations
9 - 6 ENGINEPL
GENERAL INFORMATION (Continued)

cause of low compression unless some malfunc-
tion is present.
(11) Clean or replace spark plugs as necessary
and adjust gap as specified in Group 8, Electrical.
Tighten to specifications.
(12) Test resistance of spark plug cables. Refer to
Group 8, Electrical Ignition System Secondary Cir-
cuit Inspection.
(13) Test coil output voltage, primary and second-
ary resistance. Replace parts as necessary. Refer to
Group 8, Electrical Ignition System.
(14) Check fuel pump pressure at idle and differ-
ent RPM ranges. Refer to Group 14, Fuel System for
Specifications.
(15) The air filter elements should be replaced as
specified in Group 0, Lubrication and Maintenance,.
(16) Inspect crankcase ventilation system as out
lined in Group 0, Lubrication and Maintenance. For
emission controls see Group 25, Emission Controls
for service procedures.
(17) Inspect and adjust accessory belt drives refer-
ring to Group 7, Cooling System, Accessory Drive
Belts for proper adjustments.
(18) Road test vehicle as a final test.
CYLINDER COMBUSTION PRESSURE LEAKAGE
TEST
The combustion pressure leakage test provides an
accurate means for determining engine condition.
Combustion pressure leakage testing will detect:
²Exhaust and intake valve leaks (improper seat-
ing).
²Leaks between adjacent cylinders or into water
jacket.
²Any causes for combustion/compression pressure
loss.
WARNING: DO NOT REMOVE THE RADIATOR CAP
WITH THE SYSTEM HOT AND UNDER PRESSURE
BECAUSE SERIOUS BURNS FROM COOLANT CAN
OCCUR.
Check the coolant level and fill as required. DO
NOT install the radiator cap.
Start and operate the engine until it attains nor-
mal operating temperature, then turn the engine
OFF.
Clean spark plug recesses with compressed air.
Remove the spark plugs.
Remove the oil filler cap.
Remove the air cleaner.
Calibrate the tester according to the manufactur-
er's instructions. The shop air source for testing
should maintain 483 kPa (70 psi) minimum, 1 379
kPa (200 psi) maximum and 552 kPa (80 psi) recom-
mended.Perform the test procedures on each cylinder
according to the tester manufacturer's instructions.
While testing, listen for pressurized air escaping
through the throttle body, tailpipe and oil filler cap
opening. Check for bubbles in the radiator coolant.
All gauge pressure indications should be equal,
with no more than 25% leakage.
FOR EXAMPLE:At 552 kPa (80 psi) input pres-
sure, a minimum of 414 kPa (60 psi) should be main-
tained in the cylinder.
LASH ADJUSTER (TAPPET) NOISE DIAGNOSIS
A tappet-like noise may be produced from several
items. Check the following items.
(1) Engine oil level too high or too low. This may
cause aerated oil to enter the adjusters and cause
them to be spongy.
(2) Insufficient running time after rebuilding cylin-
der head. Low speed running up to 1 hour may be
required.
(3) During this time, turn engine off and let set for
a few minutes before restarting. Repeat this several
times after engine has reached normal operating
temperature.
(4) Low oil pressure.
(5) The oil restrictor pressed into the vertical oil
passage to the cylinder head is plugged with debris.
(6) Air ingested into oil due to broken or cracked
oil pump pick up.
(7) Worn valve guides.
(8) Rocker arm ears contacting valve spring
retainer.
(9) Rocker arm loose, adjuster stuck or at maxi-
mum extension and still leaves lash in the system.
(10) Faulty lash adjuster.
a. Check lash adjusters for sponginess while
installed in cylinder head. Depress part of rocker
arm over adjuster. Normal adjusters should feel very
firm. Spongy adjusters can be bottomed out easily.
b. Remove suspected rocker arms (sohc) or lash
adjuster (dohc) and replace.
INSPECTION (ENGINE OIL LEAKS IN GENERAL)
Begin with a through visual inspection of the
engine, particularly at the area of the suspected leak.
If an oil leak source is not readily identifiable, the
following steps should be followed:
(1) Do not clean or degrease the engine at this
time because some solvents may cause rubber to
swell, temporarily stopping the leak.
(2) Add an oil soluble dye (use as recommended by
manufacturer). Start the engine and let idle for
approximately 15 minutes. Check the oil dipstick to
make sure the dye is thoroughly mixed as indicated
with a bright yellow color under a black light.
9 - 8 ENGINEPL
DIAGNOSIS AND TESTING (Continued)

INSTALLATION
Before installing manifold. Clean all mating sur-
faces. Replace all seals, with new seals. All intakemanifold fasteners and washers are to be discarded
andNEWfasteners and washers are to be used.
(1) Install intake manifold onto cylinder head and
tighten fasteners to 12 N´m (105 in. lbs.) in sequence
shown in (Fig. 20).
(2) Install intake manifold to water inlet support.
Tighten fastener (Fig. 20) to 12 N´m (105 in. lbs.).
(3) Remove covering from fuel injector holes and
insure the holes are clean. Install fuel rail assembly
to intake manifold. Tighten screws to 23 N´m (200 in.
lbs.).
(4) Connect PCV and brake booster hoses.
(5) Inspect quick connect fittings for damage,
replace if necessary Refer to Group 14, Fuel System
for procedure. Apply a light amount of clean engine
oil to fuel inlet tube. Connect fuel supply hose to fuel
rail assembly. Check connection by pulling on connec-
tor to insure it locked into position.
(6) Install throttle body. Tighten fastener to 22
N´m (200 in. lbs.). Install transmission to throttle
body support bracket and tighten to 11.9 N´m (105
in. lbs.) at the throttle body first. Next tighten the
bracket at the transmission.
(7) Connect Manifold Absolute Pressure/Intake Air
Temperature Sensor (TMAP) wiring connector.
(8) Connect knock sensor connector, and wiring at
starter. Connect wiring harness to intake manifold
tab.
(9) Connect Idle Air Control (IAC) motor and
Throttle Position Sensor (TPS) wiring connectors.
(10) Connect vacuum hoses to throttle body.
(11) Install accelerator, kickdown and speed con-
trol cables to their bracket and connect them to the
throttle lever. Refer to Group 14, Fuel System Throt-
tle Body Installation for procedure.
(12) Loose assemble the EGR tube onto valve and
intake manifold finger tight. Tighten tube fasteners
at the EGR valve first to 11 N´m (95 in. lbs.) then,
tighten the intake manifold side fasteners to 11 N´m
(95 in. lbs.).
(13) Install clean air duct to air filter housing.
Tighten clamp to 3 N´m (30 in. lbs.).
(14) Connect negative cable to battery.
(15) Install fresh air duct to air cleaner and
tighten wing nut.
(16) With the DRB scan tool use ASD Fuel System
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.
Fig. 18 Knock Sensor
Fig. 19 EGR Tube Assembly
Fig. 20 Intake Manifold Tightening Sequence
11 - 8 EXHAUST SYSTEM AND INTAKE MANIFOLDPL
REMOVAL AND INSTALLATION (Continued)

INSTALLATION
Before installing manifolds. Clean all mating sur-
faces. Replace all gaskets, with new.
(1) Assemble lower manifold to upper (if sepa-
rated) and tighten bolts in sequence shown in (Fig.
29) to 28 N´m (250 in. lbs.).
(2) Install intake manifold onto cylinder head and
tighten fasteners to 28 N´m (250 in. lbs.) in sequence
shown in (Fig. 30).
(3) Remove covering from fuel injector holes and
insure the holes are clean. Install fuel rail assembly
to intake manifold. Tighten screws to 23 N´m (200 in.
lbs.).
(4) Connect PCV and brake booster hoses.
(5) Inspect quick connect fittings for damage,
replace if necessary Refer to Group 14, Fuel System
for procedure. Apply a light amount of clean engine
oil to fuel inlet tube. Connect fuel supply hose to fuel
rail assembly. Check connection by pulling on connec-
tor to insure it locked into position.
(6) Connect heater tube and hose to intake mani-
fold.
(7) Connect upper radiator hose and coolant recov-
ery hose.
(8) Connect coolant temperature sensor wiring con-
nector.
(9) Install throttle body. Tighten fastener to 22
N´m (200 in. lbs.).
(10) Connect Manifold Absolute Pressure/Intake
Air Temperature Sensor (TMAP) wiring connector.(11) Connect knock sensor connector and starter
wires. Connect wiring harness to heater tube tab.
(12) Connect Idle Air Control (IAC) motor and
Throttle Position Sensor (TPS) wiring connectors.
(13) Connect vacuum hoses to throttle body.
(14) Install accelerator, kickdown and speed con-
trol cables to their bracket and connect them to the
throttle lever. Refer to Group 14, Fuel System Throt-
tle Body Installation for procedure.
(15) Loose assemble the EGR tube onto valve and
intake manifold finger tight. Tighten tube fasteners
at the EGR valve first to 11 N´m (95 in. lbs.) then,
tighten the intake manifold side fasteners to 11 N´m
(95 in. lbs.).
(16) Install fresh air duct to air filter housing.
Tighten clamp to 3 N´m (25 in. lbs.).
(17) Connect negative cable to battery.
(18) With the DRB scan tool use ASD Fuel System
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 MANIFOLD
REMOVAL
(1) Remove air cleaner assembly and bracket.
(2) Remove exhaust manifold heat shield (Fig. 31).
(3) Disconnect upstream heated oxygen sensor con-
nector.
Fig. 29 Lower Intake Manifold to Upper Tightening
Sequence
Fig. 30 Intake Manifold To Cylinder Head Tightening
Sequence
Fig. 31 Exhaust Manifold Heat Shield
PLEXHAUST SYSTEM AND INTAKE MANIFOLD 11 - 11
REMOVAL AND INSTALLATION (Continued)