Файл: 92FWD_14.pdf

THROTTLE BODY

When servicing throttle body components, always reassemble components with new O-rings and seals where applicable. (Fig. 1) Never use lubricants on O-rings or seals, damage may result. If assembly of component is difficult, use water to aid assembly. Use care when removing hoses to prevent damage to hose or hose nipple.

FUEL SYSTEM PRESSURE RELEASE PROCEDURE

CAUTION: Before servicing the fuel pump, fuel lines, fuel filter, throttle body, or fuel injectors, the fuel system pressure must be released.

(1)Loosen fuel filler cap to release fuel tank pres-

sure.

(2)Disconnect injector wiring harness connector (Fig. 2).

(3)Connect a jumper wire between terminal Number 1 of the injector harness and engine ground.

(4) Connect a jumper wire to the positive terminal Number 2 of the injector harness and touch the battery positive post for no longer than 5 seconds.

Fig. 2 Injector Harness Connector

Fig. 3 Servicing Throttle Position Sensor

INSTALLATION

(1)Install throttle position sensor on throttle shaft. Install mounting screws. Tighten screws to 2 NIm (17 in. lbs.) torque.

(2)Attach harness connector to sensor.

(3)Connect negative cable to negative post of the battery.

AUTOMATIC IDLE SPEED (AIS) MOTOR

REMOVAL

(1)Disconnect negative cable from battery.

(2)Disconnect harness connector from AIS (Fig. 4).

(3)Remove AIS motor mounting screws.

(4)Remove the AIS motor from throttle body (make certain that the O-ring is on the AIS motor).

INSTALLATION

(1)New AIS motors have a new O-ring installed on them. If pintle measures more than 1 inch (25 mm) it must be retracted. Use the AIS MOTOR OPEN/CLOSE mode of the DRBII (battery must be reconnected for this operation).

(2)Carefully place AIS motor into throttle body.

(3)Install 2 mounting screws. Tighten screws to 2 NIm (17 in. lbs.) torque.

(4)Connect harness connector to AIS motor.

Fig. 4 Servicing Automatic Idle Speed (AIS) Motor

(5) Connect negative cable to battery.

THROTTLE BODY REMOVAL

(1)Disconnect negative cable from battery.

(2)Remove clamp from air hose. Remove hose (Fig.

5).

(3)Remove accelerator cable.

(4)Disconnect automatic idle speed (AIS) motor and throttle position sensor (TPS) electrical connectors.

(5)Disconnect vacuum hoses from throttle body.

(6)Remove throttle body to intake manifold attaching nuts (2).

(7)Remove throttle body and gasket.

(8)Reverse the above procedures for installation.

Fig. 5 Air Cleaner and Throttle Body Assembly

FUEL INJECTOR RAIL ASSEMBLY

WARNING: THE 2.5L TURBO I FUEL SYSTEM IS UNDER A CONSTANT PRESSURE OF APPROXIMATELY 380 KPA (55 PSI). PERFORM FUEL PRESSURE RELEASE PROCEDURE BEFORE SERVICING THE FUEL RAIL OR FUEL INJECTORS.

14 - 72 FUEL SYSTEMS

REMOVAL

(1)Perform fuel system pressure release procedure.

(2)Disconnect negative cable from battery.

(3)Disconnect the fuel injector harness connector from the main harness (Fig. 6).

Fig. 6 Injector Harness Connections

(4)Remove the quick connect fittings from the chassis fuel tubes. Refer to Fuel Hoses, Clamps, and Quick Connect Fittings in the Fuel Delivery section of this group.

(5)Remove vacuum and vapor hose connections (Fig. 7).

(6)Disconnect vacuum hose from the pressure regulator (Fig. 7).

Fig. 7 Electrical, Fuel, and Vacuum Connections

(7)Remove screw from the fuel tube clamp (Fig. 8).

(8)Remove fuel rail mounting screws (Fig. 8).

Ä

Fig. 8 Fuel Rail Attaching Screws

(9)Pull up on the injector rail. The injectors will pull straight out of the ports. Do not damage the injector O-rings.

(10)Remove fuel rail assembly from vehicle. Do not remove fuel injectors until fuel rail assembly has been completely removed from vehicle.

(11)Plug or cover intake manifold injector ports to prevent dirt from entering the openings (Fig. 9).

Fig. 9 Fuel Injector Ports

INSTALLATION

(1)Ensure injectors are seated into the receiver cup, with lock ring in place.

(2)Attach harness connectors to injectors. Fasten the harness into wiring clips.

(3)Ensure the injector holes are clean and all plugs have been removed.

(4)Lubricate the injector O-rings with a drop of clean engine oil to ease installation.

(5)Install the injector assembly into their holes. Install mounting screws. Fuel rail assembly must be drawn into the intake manifold evenly making sure

each injector enters its own hole. Once all injectors are seated, tighten bolts to 22.5 NIm (200 in. lbs) torque (Fig. 8).

Ä

(6)Connect electrical connector to detonation (knock) sensor (Fig. 8).

(7)Connect vacuum hose to fuel pressure regulator. Replace clamp.

(8)Close fuel tube clip around fuel tubes and install fastener.

(9)Lubricate the ends of the chassis fuel tubes with clean 30 weight engine oil. Connect fuel supply and return hoses to chassis fuel tube assembly. Pull back on the quick connect fittings to ensure complete insertion. Refer to Fuel Hoses, Clamps, and Quick Connect Fittings in the Fuel Delivery section of this group.

(10)Install vacuum, vapor hose onto intake manifold nipple. Replace clamp (Fig. 7).

(11)Connect negative cable to battery.

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 position.

(12) With the DRB II use the ASD Fuel System Test to pressurize system and check for leaks.

FUEL INJECTOR

The fuel rail must be removed to service the injectors. Refer to Fuel Injector Rail Assembly in this section.

REMOVAL

(1) Disconnect electrical connector from injector (Fig. 10).

FUEL SYSTEMS 14 - 73

(2) Position fuel rail assembly so that the fuel injectors are easily accessible (Fig. 11).

Fig. 11 Fuel Rail and Injector Assembly

(3)Remove injector lock ring from fuel rail and injector. Pull injector straight out of fuel rail receiver cup.

(4)Check injector O-ring for damage. Replace damaged O-rings. If injector is reused, install a protective cap on the injector tip to prevent damage.

(5)Repeat steps for remaining injectors.

INSTALLATION

(1)Before installing an injector, the rubber O-ring must be lubricated with a drop of clean engine oil to aid in installation.

(2)Being careful not to damage the O-ring, install injector top end into fuel rail receiver cup.

(3)Install injector lock ring by sliding open end into slot of the injector and onto the receiver cup ridge into the side slots of ring (Fig. 10).

(4)Repeat steps for remaining injectors.

(5)Install injector wiring harness to injectors and fasten into wiring clips (Fig. 12).

FUEL PRESSURE REGULATOR

WARNING: THE 2.5L TURBO I FUEL SYSTEM IS UNDER A CONSTANT PRESSURE OF APPROXIMATELY 380 KPA (55 PSI). PERFORM FUEL PRESSURE RELEASE PROCEDURE BEFORE SERVICING THE FUEL PRESSURE REGULATOR.