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: The fuel system is under a constant pressure of approximately 380 kPa (55 psi). 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).

Fig. 2 Injector Harness Connector

(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.

This releases system pressure.

(5)Remove jumper wires.

(6)Continue fuel system service.

THROTTLE POSITION SENSOR (TPS)

REMOVAL

(1)Disconnect the negative cable from the battery.

(2)Disconnect harness connector from throttle position sensor (Fig. 3).

(3)Remove throttle position sensor mounting screws.

(4)Lift throttle position sensor off throttle shaft.

Fig. 3 Throttle Position Sensor

INSTALLATION

(1)Install throttle position sensor on throttle shaft. Install mounting screws. Tighten screws to 2 Nzm (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 by using the AIS MOTOR OPEN/CLOSE mode of the DRBII (battery must be reconnected for this operation).

(2)Carefully place AIS motor into throttle body.

Fig. 4 Servicing Automatic Idle Speed (AIS) Motor

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

(4)Connect harness connector to 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 (Fig. 6).

(5)Disconnect vacuum hoses from throttle body.

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

(7)Remove throttle body and gasket.

Fig. 5 Air Cleaner Assembly

Fig. 6 Throttle Body Assembly

INSTALLATION

(1)Install throttle body with new gasket.

(2)Install throttle body attaching nuts. Tighten nuts to 25 NIm (225 in. lbs.) torque.

(3)Connect vacuum hoses to the throttle body.

(4)Attach harness connectors to the throttle position sensor (TPS) and the automatic idle speed (AIS) motor.

(5)Install throttle and speed control cables (if applicable).

(6)Install throttle body intake air hose. Tighten clamp to 4 NIm (30 in. lbs.) torque.

(7)Connect negative cable to battery.

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.

REMOVAL

(1)Perform fuel system pressure release procedure.

(2)Disconnect negative battery cable.

CAUTION: Place a shop towel should under the fuel hoses to catch any fuel spillage.

(3)Remove quick connect fittings from the chassis fuel tubes (Fig. 7). Refer to Quick Connect Fittings in the Fuel Delivery Section of this manual.

(4)Disconnect the vacuum hose from the fuel pressure regulator (Fig. 8).

Fig. 7 Quick Connect Fittings

(5)Disconnect the fuel injector wiring harness from the main harness.

(6)Place oil separator bracket out of the way and remove the fuel rail support bracket screws.

Fig. 8 Fuel Rail Fasteners

(7)Remove the fuel rail and injector assembly by pulling rail so that the injectors come straight out of their ports. Do not damage the rubber injector O-rings after removing the fuel rail.

Do not remove fuel injectors until fuel rail assembly has been completely removed from the vehicle.

(8)Cover or plug the injector ports with while servicing the injectors (Fig. 9).

INSTALLATION

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

(2)Ensure the injector wiring connectors are fully inserted into the fuel injectors.

(3)Make sure the injector holes are clean and all plugs have been removed (Fig. 9).

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