coolant DODGE NEON 1999 Service Service Manual

1
K4
20
BK/LBK4
20
BK/LBK4
18
BK/LB
10C161
K4
20
BK/LB
POWERTRAIN
CONTROL
MODULE
43C1
1
SENSOR POSITION
THROTTLE
BK/LB20 K4
K4
20
BK/LB
CAMSHAFT
POSITION
SENSOR
2A
BK/LB18 K4
K4
20
BK/LB
2
SENSOR KNOCK
K4
20
BK/LB
11
BK/RD20 K4
S110
S120
S118
3
BK/LB20 K4
K4
20
BK/LB
3 2
SENSOR POSITION
CRANKSHAFT
BK/LB20 K4
K4
18
BK/LB
VEHICLE
SPEED
SENSOR
2
UPSTREAM
HEATED
OXYGEN
SENSOR
K4
18
BK/LBSENSOR MAP
IAT/
* 3
* DOHC 5
BK/LB20 K4
BUILT-UP-EXPORT) (EXCEPT
SENSOR
TEMPERATURE
BATTERY
(2.0L) SENSOR
OXYGEN
HEATED
DOWNSTREAM (SOHC) (1.8L/2.0L)
SENSOR
TEMPERATURE
COOLANT
ENGINE ENGINE
COOLANT
TEMPERATURE
SENSOR
(2.0L)
(DOHC)
2C170
(BUILT-UP-EXPORT) IMMOBILIZER
(8W-30-6)
(8W-30-3) (8W-30-8) (8W-30-7)(8W-30-6)
(8W-30-7) (8W-30-6)(8W-30-3)
(8W-30-7)
(8W-30-3) (8W-30-7) (8W-30-7)(8W-61-8)
PL8W-70 SPLICE INFORMATION 8W - 70 - 3
8356J988W-1

8W-80 CONNECTOR PIN-OUTS
Component Page
A/C Compressor Clutch.................8W-80-4
A/C Cycling Switch....................8W-80-4
A/C Heater Blower Motor...............8W-80-4
A/C Heater Control....................8W-80-4
A/C High Pressure Switch..............8W-80-4
A/C Low Pressure Switch...............8W-80-5
Airbag Control Module.................8W-80-5
Ash Receiver Lamp....................8W-80-6
Back-Up Lamp Switch.................8W-80-6
Battery Temperature Sensor.............8W-80-6
Blower Motor Resistor Block.............8W-80-6
Brake Warning Lamp Switch............8W-80-6
C101...............................8W-80-7
C102...............................8W-80-7
C103...............................8W-80-7
C104...............................8W-80-8
C105...............................8W-80-8
C108...............................8W-80-8
C160...............................8W-80-8
C161...............................8W-80-8
C170...............................8W-80-9
C205...............................8W-80-9
C206..............................8W-80-10
C225..............................8W-80-10
C230..............................8W-80-10
C231..............................8W-80-11
C241..............................8W-80-12
C242..............................8W-80-12
C301..............................8W-80-12
C303..............................8W-80-12
C309..............................8W-80-12
C340..............................8W-80-13
C341..............................8W-80-13
Camshaft Position Sensor..............8W-80-14
Center High Mounted Stop Lamp........8W-80-14
Cigar Lighter/Power Outlet.............8W-80-14
Clockspring.........................8W-80-14
Clutch Pedal Position Switch...........8W-80-15
Controller Anti-Lock Brake.............8W-80-15
Crankshaft Position Sensor.............8W-80-16
Data Link Connector..................8W-80-1
Daytime Running Lamp Module.........8W-80-16Component Page
Dome Lamp........................8W-80-17
Downstream Heated Oxygen Sensor......8W-80-17
Driver Door Lock Motor...............8W-80-17
Driver Door Lock Switch...............8W-80-17
Driver Power Window Motor............8W-80-17
Driver Power Window Switch...........8W-80-18
Driver Side Airbag...................8W-80-18
Duty Cycle Evap/Purge Solenoid.........8W-80-18
EGR Transducer Solenoid..............8W-80-19
Engine Coolant Temperature Sensor......8W-80-18
Engine Oil Pressure Switch............8W-80-19
Fog Lamp Switch....................8W-80-19
Front Fog Lamp Switch...............8W-80-19
Fuel Injector No. 1...................8W-80-19
Fuel Injector No. 2...................8W-80-19
Fuel Injector No. 3...................8W-80-20
Fuel Injector No. 4...................8W-80-20
Fuel Pump Module...................8W-80-20
Generator..........................8W-80-20
Glove Box Lamp And Switch............8W-80-20
Halo Lamp.........................8W-80-21
Headlamp Dimmer And Optical
Horn Switch......................8W-80-21
Headlamp Leveling Switch.............8W-80-21
Headlamp Switch....................8W-80-21
Heater Blower Motor.................8W-80-21
High Speed Warning Module...........8W-80-22
Horn..............................8W-80-22
Horn No. 1.........................8W-80-22
Horn No. 2.........................8W-80-22
IAT/Map Sensor.....................8W-80-25
Idle Air Control Motor.................8W-80-22
Ignition Coil Pack....................8W-80-22
Ignition Switch......................8W-80-23
Immobilizer.........................8W-80-23
Immobilizer Engine Sensor.............8W-80-23
Instrument Cluster-C1................8W-80-24
Instrument Cluster-C2................8W-80-24
Intermittent Wipe/Wash Switch.........8W-80-25
Key-In Switch.......................8W-80-25
Knock Sensor.......................8W-80-25
PL8W - 80 CONNECTOR PIN-OUTS 8W - 80 - 1

CAV CIRCUIT FUNCTION
1 K52 20PK/BK DUTY CYCLE EVAP/PURGE SOLENOID CONTROL
2 F12 20DG/WT FUSED IGNITION SWITCH OUTPUT (ST-RUN)
CAV CIRCUIT FUNCTION
1 K4 20BK/LB * SENSOR GROUND
1 K4 20BK/RD ** SENSOR GROUND
2 K2 20TN/DB * ENGINE COOLANT TEMPERATURE SENSOR SIGNAL
2 K2 20TN/BK ** ENGINE COOLANT TEMPERATURE SENSOR SIGNAL
3 G20 20VT/YL ENGINE COOLANT TEMPERATURE GAUGE SIGNAL
BLACK
2 1
3
* 1.8L/2.0L SOHC
** 2.0L DOHC
1
BLACK
2
6 4 25 3 1
NATURAL
UP FRONT LEFT 14LB Q11 6DOWN FRONT LEFT 14WT Q21 5
(ST-RUN) OUTPUT SWITCH IGNITION FUSED 14TN F21 4
GROUND 14BK/VT Z8 3
UP FRONT RIGHT SWITCH MASTER 14BR/WT Q16 2
DOWN FRONT RIGHT SWITCH MASTER 14VT/WT Q26 1
FUNCTION CIRCUIT CAV
CAV CIRCUIT FUNCTION
1 Q21 14WT RIGHT FRONT DOWN
2 Q11 14WT RIGHT FRONT UP
3 Z8 14BK/VT GROUND
4 F21 14TN FUSED IGNITION SWITCH OUTPUT (ST-RUN)
5 Q26 14VT/WT LEFT FRONT DOWN
6 Q16 14BR/WT LEFT FRONT UP
NATURAL1 3 5
24 6
DRIVER
POWER WINDOW
SWITCH (RHD) SWITCH (LHD) POWER WINDOWDRIVER
DUTY CYCLE
EVAP/PURGE
SOLENOID
ENGINE COOLANT
TEMPERATURE (ECT)
SENSOR
1 2
AIRBAG DRIVER SIDE
YELLOW
1 LINE SQUIB AIRBAG DRIVER 18BK/LB R43 22 LINE SQUIB AIRBAG DRIVER 18DG/LB R45 1
FUNCTION CIRCUIT CAV
8W - 80 - 18 8W-80 CONNECTOR PIN-OUTSPL
J988W-1PL008018

CAV CIRCUIT FUNCTION
1- -
2 K19 18BK/GY IGNITION COIL NO. 1, 3 DRIVER
3 K17 18DB/TN IGNITION COIL NO. 2, 4 DRIVER
4 K20 18DG GENERATOR FIELD DRIVER
5 V32 20YL/RD SPEED CONTROL FEED
6 A142 18DG/OR AUTOMATIC SHUT DOWN RELAY OUTPUT
7 K13 18YL/WT FUEL INJECTOR NO. 3 DRIVER
8 G3 20BK/PK CHECK ENGINE LAMP DRIVER
9- -
10 Z12 18BK/TN GROUND
11 - -
12 - -
13 K11 18WT/DB FUEL INJECTOR NO. 1 DRIVER
14 - -
15 - -
16 K14 18LB/BR
17 K12 18TN
18 K173 20LG
19 - -
20F12 18DB/WT FUSED IGNITION SWITCH OUTPUT (ST-RUN)
21 - -
22 - -
23 G4 20DB FUEL LEVEL SENSOR SIGNAL
24 K42 20BK/LG** KNOCK SENSOR SIGNAL
24 K42 20DB/LG** KNOCK SENSOR SIGNAL
31 40
21 30
11 20
110
BLACK
CONTROL SOLENOID RECIRCULATION GAS EXHAUST 20GY/YL K35 40- - 39
SENSE SWITCH A/C 18BR/OR C20 38
SIGNAL SENSOR POSITION THROTTLE 20OR/DB K22 35
- - 34
SIGNAL SENSOR POSITION CAMSHAFT 20TN/YL K44 33
SIGNAL SENSOR POSITION CRANKSHAFT 20GY/BK K24 32
- - 31
SIGNAL SENSOR OXYGEN HEATED UPSTREAM 20BK/DG K41 30
- - 29
- - 28
- - 27
SIGNAL SENSOR TEMPERATURE COOLANT ENGINE 20TN/BK** K2 26
SIGNAL SENSOR TEMPERATURE COOLANT ENGINE 20TN/DB* K2 26
- - 25
POWERTRAIN
CONTROL
MODULE - C2
20DB/WT F12 (ST-RUN)OUTPUT SWITCH IGNITION FUSED
24K42 20DB/LG KNOCK SENSOR SIGNAL
* 1.8L/2.0L SOHC
** 2.0L DOHC
1.8L
2.0L 36 K1 20DG/RD MANIFOLD ABSOLUTE PRESSURE SENSOR SIGNAL
37 K21 20BK/RD INTAKE AIR TEMPERATURE SENSOR SIGNAL
FUEL INJECTOR NO. 4 DRIVER
FUEL INJECTOR NO. 2 DRIVER
SOLID STATE RELAY CONTROL
8W - 80 - 34 8W-80 CONNECTOR PIN-OUTSPL
J988W-1PL008034

Connector
Name/NumberColor Location Fig.
Daytime Running
Lamp ModuleBK Rear of Radio 15
Dome Lamp BK LT C-Pillar 20
Downstream
Heated Oxygen
SensorBK RT Rear of
EngineN/S
Driver Side
AirbagYL Rear of
Clockspring12
Duty Cycle
Evap/Purge
SolenoidGY RT Strut Tower 5
Engine Coolant
Temp SensorBK LT Side of
Cylinder Head8
EGR Solenoid GY LT Rear of
Cylinder Head8
Engine Starter
MotorLeft Front of
Engine9
Fog Lamp
SwitchBK Rear of Switch 16
Fuel Injector #1 BK At Injector 9
Fuel Injector #2 BK At Injector 9
Fuel Injector #3 BK At injector 9
Fuel Injector #4 BK At Injector 9
Fuel Pump
ModuleLT/GY At Module 23
Fuse Block Left Side of
Instrument
Panel17
G101 Top LT of
Radiator Closure
Panel6
G102 Top LT of
Radiator Closure
Panel6
G103 RT Radiator
Closure Panel5
G104 Front Lower of
EngineN/S
G105 Front of Battery 6
G110 Right Radiator
Closure Panel5
G201 RT Side of I.P.
Center Stack15
G202 RT Side of I.P.
Center Stack15
G203 LT Side of I.P.
Center Stack15
Connector
Name/NumberColor Location Fig.
G204 LT Side of I.P.
Center Stack15
G301 RT Rear Quarter
Panel24
G302 LT Rear Quarter
Panel24
G303 LT Rear Quarter
Panel24
Generator BK Rear of
Generator8
Glove Box Lamp
and SwitchBK Rear of Switch 16
Headlamp
Dimmer/Optical
Horn SwitchBK Rear of Switch 12
Headlamp
SwitchBK Bottom of
Switch14
Heater Blower
MotorBK RT Side of
HVAC HousingN/S
Horn BK LT Inner Fender 7
Horn #2 (BUX) BK Right Inner
FenderN/S
Headlamp
Leveling SwitchBK Left Side of I.P. N/S
Immobilizer Behind Center
StackN/S
Immobilizer
Engine SensorLeft Kick Panel N/S
Idle Air Control
MotorBK On Throttle
Body9
Ignition Coil
PackBK Top of Valve
Cover8
Ignition Switch GY Rear of Switch 12
Halo Lamp BK At Lamp N/S
Instrument
Cluster C1BK LT Side of
Cluster17
Instrument
Cluster C2BK RT Side of
Cluster15
Intake Air
Temp/MAP
SensorBK RT Side of
Intake9
Key-In Switch GN Rear of Switch 12
Knock Sensor GY Front of Engine 9
Left Back-Up
LampGY At Lamp 24
8W - 90 - 2 8W - 90 CONNECTOR/GROUND LOCATIONSPL
DESCRIPTION AND OPERATION (Continued)

Connector
Name/NumberColor Location Fig.
Engine Coolant
Temp SensorBK Left Side of
Engine7
Engine Oil
Pressure SwitchGN Rear Of Engine 7
Engine Starter
MotorLeft Front of
Engine7
EGR
Transducer
SolenoidGY Left Rear of
Engine7
Fog Lamp
SwitchGN Rear of Switch 14
Fuel Injector #1 BK At Injector 8
Fuel Injector #2 BK At Injector 8
Fuel Injector #3 BK At injector 8
Fuel Injector #4 BK At Injector 8
Fuel Pump
ModuleLT/GY Right Rear
Frame Rail19
Fuse Block Right Side of
I.P.N/S
G101 Top Left of
Radiator
Closure Panel5
G102 Top Left of
Radiator
Closure Panel5
G103 Right Radiator
Closure Panel4
G104 Front Lower of
EngineN/S
G105 Front of Battery 5
G201 Left Side of I.P.
Center Stack13
G202 Left Side of I.P.
Center Stack13
G203 Right Side of
I.P. Center
Stack13
G204 Right Side of
I.P. Center
Stack13
G301 Right Rear
Quarter Panel20
G302 Left Rear
Quarter Panel20
G303 Left Rear
Quarter Panel20Connector
Name/NumberColor Location Fig.
Generator GY Rear of
Generator7
Glove Box
Lamp and
SwitchBK Rear of Switch 13
Headlamp
Dimmer and
Optical Horn
SwitchBK Rear of Switch 12
Headlamp
Leveling SwitchBK Rear of Switch 14
Headlamp
SwitchBK Rear of Switch 14
Horn #1 BK LT Inner Fender 6
Horn #2 BK Right Inner
FenderN/S
Idle Air Control
MotorBK On Throttle
Body8
Ignition Coil
PackBK Top of Valve
Cover7
Ignition Switch GY Rear of Switch 10
Immobilizer
Engine SensorBK Left Fender
Side ShieldN/S
Immobilizer BK Behind Center
StackN/S
Instrument
Cluster C1BK Rear of Cluster 14
Instrument
Cluster C2BK Rear of Cluster 14
Intake Air
Temp/MAP
SensorBK Left Side of
Intake8
Halo Lamp BK At Lamp N/S
Key-In Switch GN Rear of Switch 10
Knock Sensor GY Front of Engine 8
Left Back-Up
LampGY At Lamp 20
Passenger Door
Lock SwitchWT At Switch 12
Passenger Door
Lock SwitchBK At Motor 12
Left Door
SpeakerBK At Speaker 18
Left Door
Window Lift
MotorBK At Motor 18
Left Fog Lamp BK At Lamp 4
8W - 90 - 24 8W - 90 CONNECTOR/GROUND LOCATIONSPL
DESCRIPTION AND OPERATION (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)

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)

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)

FUEL INJECTION SYSTEM
INDEX
page page
GENERAL INFORMATION
INTRODUCTION......................... 21
MODES OF OPERATION.................. 21
DESCRIPTION AND OPERATION
AIR CONDITIONING CLUTCH RELAYÐ
PCM OUTPUT......................... 31
AIR CONDITIONING PRESSURE
TRANSDUCERÐPCM INPUT............. 25
AUTOMATIC SHUTDOWN (ASD) SENSEÐ
PCM INPUT........................... 25
AUTOMATIC SHUTDOWN RELAYÐ
PCM OUTPUT......................... 32
BATTERY TEMPERATURE SENSORÐ
PCM INPUT........................... 25
BATTERY VOLTAGEÐPCM INPUT........... 25
BRAKE SWITCHÐPCM INPUT.............. 25
CAMSHAFT POSITION SENSORÐPCM INPUT . 25
CHARGING SYSTEM INDICATOR LAMPÐ
PCM OUTPUT......................... 32
CRANKSHAFT POSITION SENSORÐ
PCM INPUT........................... 26
DATA LINK CONNECTOR.................. 33
DUTY CYCLE EVAP PURGE SOLENOIDÐ
PCM OUTPUT......................... 32
ELECTRIC EGR TRANSDUCERÐ
PCM OUTPUT......................... 32
ENGINE COOLANT TEMPERATURE SENSORÐ
PCM INPUT........................... 26
FUEL INJECTORSÐPCM OUTPUT.......... 34
FUEL LEVEL SENSORÐPCM INPUT......... 27
FUEL PUMP RELAYÐPCM OUTPUT......... 32
GENERATOR FIELDÐPCM OUTPUT......... 33
HEATED OXYGEN SENSOR (O2S SENSOR)Ð
PCM INPUT........................... 27
IDLE AIR CONTROL MOTORÐPCM OUTPUT . . 33
IGNITION CIRCUIT SENSEÐPCM INPUT..... 28
IGNITION COILÐPCM OUTPUT............. 34
INTAKE AIR TEMPERATURE SENSORÐ
PCM INPUT........................... 28
KNOCK SENSORÐPCM INPUT............. 29
MALFUNCTION INDICATOR (CHECK ENGINE)
LAMPÐPCM OUTPUT.................. 34
MANIFOLD ABSOLUTE PRESSURE (MAP)
SENSORÐPCM INPUT.................. 29
PARK/NEUTRAL POSITION SWITCHÐ
PCM INPUT........................... 30
POWER DISTRIBUTION CENTER........... 23
POWER STEERING PRESSURE SWITCHÐ
PCM INPUT........................... 30
POWERTRAIN CONTROL MODULE.......... 24SCI RECEIVEÐPCM INPUT................ 30
SCI RECEIVEÐPCM OUTPUT.............. 35
SENSOR RETURNÐPCM INPUT............ 30
SOLID STATE FAN RELAYÐPCM OUTPUT.... 35
SPEED CONTROL SERVOSÐPCM OUTPUT . . . 30
SPEED CONTROLÐPCM INPUT............ 35
SYSTEM DIAGNOSIS..................... 23
TACHOMETERÐPCM OUTPUT............. 35
THROTTLE POSITION SENSORÐPCM INPUT . 30
TORQUE CONVERTOR CLUTCH SOLENOIDÐ
PCM OUTPUT......................... 35
VEHICLE SPEED SENSORÐPCM INPUT..... 30
DIAGNOSIS AND TESTING
ASD AND FUEL PUMP RELAYS............. 46
CAMSHAFT AND CRANKSHAFT POSITION
SENSOR............................. 47
ENGINE COOLANT TEMPERATURE SENSOR . . 47
HEATED OXYGEN SENSOR............... 47
IDLE AIR CONTROL (IAC) MOTOR TEST...... 47
KNOCK SENSOR........................ 47
MANIFOLD ABSOLUTE PRESSURE (MAP)
SENSOR............................. 48
THROTTLE BODY MINIMUM AIR FLOW....... 48
THROTTLE POSITION SENSOR............ 48
VEHICLE SPEED SENSOR................ 49
VISUAL INSPECTIONÐDOHC.............. 40
VISUAL INSPECTIONÐSOHC.............. 35
REMOVAL AND INSTALLATION
AIR CLEANER ELEMENT.................. 55
CAMSHAFT POSITION SENSOR............ 54
CRANKSHAFT POSITION SENSOR.......... 54
DOWNSTREAM HEATED OXYGEN SENSOR . . . 55
DUTY CYCLE EVAP PURGE SOLENOID VALVE . 53
ENGINE COOLANT TEMPERATURE SENSOR . . 56
IDLE AIR CONTROL MOTOR............... 52
KNOCK SENSOR........................ 57
MAP/IAT SENSORÐDOHC................. 53
MAP/IAT SENSORÐSOHC................. 53
POWERTRAIN CONTROL MODULE (PCM).... 54
THROTTLE BODYÐAUTOMATIC
TRANSMISSION....................... 50
THROTTLE BODYÐMANUAL TRANSMISSION . 50
THROTTLE POSITION SENSOR (TPS)....... 52
UPSTREAM HEATED OXYGEN SENSOR...... 54
VEHICLE SPEED SENSOR................ 56
SPECIFICATIONS
TORQUE.............................. 57
VECI LABEL............................ 57
SPECIAL TOOLS
FUEL................................. 57
14 - 20 FUEL SYSTEMPL