Файл: 92FWD_8D.pdf

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If idle RPM is not within specification replace throttle body.

(13)Shut off engine.

(14)Remove Special Tool number 6457 from intake manifold PCV nipple. Reinstall the PCV valve hose.

(15)Remove DRBII.

(16)Reinstall air cleaner assembly. Reinstall heated air door vacuum hose.

(17)Disconnect timing check device and tachom-

eter.

THROTTLE BODY MINIMUM AIR FLOW CHECK PROCEDUREÐTURBO I ENGINES

(1)Warm engine in Park or neutral until the cooling fan has cycled on and off at least once.

(2)Hook-up timing check device and Tachometer.

(3)Disconnect the coolant temperature sensor and set basic timing to 12° BTDC 6 2° BTDC.

(4)Shut off engine. Connect harness connector to coolant temperature sensor.

(5)Disconnect the PCV valve hose from the nipple on the intake manifold.

(6)Attach Air Metering Fitting #6457 (0.125 in. orifice) to the intake manifold PCV nipple (Fig. 7).

(7)Disconnect 3/16 inch manifold vacuum purge line from the top of the throttle body. Cap the 3/16 inch throttle body nipple.

(8)Connect Diagnostic Readout Box II (DRB II).

(9)Restart engine. Allow engine to idle for at least one minute.

(10)Using the DRB II, access Min. Airflow Idle Spd. The following will then occur:

²AIS motor will fully close.

²Idle spark advance will become fixed.

²Engine RPM will be displayed on Diagnostic Readout Box II (DRB II).

(11)Check idle RPM with tachometer, if idle RPM is within the below specification then the throttle body minimum airflow is set correctly.

IDLE SPECIFICATIONS

If the idle RPM is not within specification, replace the throttle body.

(12) Shut off engine.

IGNITION SYSTEMS 8D - 17

(13)Remove Air Metering Fitting #6457 from the intake manifold PCV nipple. Reinstall the PCV valve hose.

(14)Remove DRB II.

(15)Disconnect timing check device and tachom-

eter.

(16)Reconnect purge line to throttle body.

THROTTLE BODY MINIMUM AIR FLOW CHECK PROCEDUREÐ3.0L ENGINE

(1)Warm engine in Park or Neutral until the cooling fan has cycled on and off at least once.

(2)Ensure that all accessories are off.

(3)Hook-up the timing check device and tachom-

eter.

(4)Disconnect the coolant temperature sensor and set basic timing to 12° BTDC 6 2° BTDC.

(5)Shut off engine. Reconnect coolant temperature sensor wire.

(6)Disconnect the PCV valve hose from the PCV valve (Fig. 8).

(7)Plug the PCV valve nipple.

Fig. 8 PCV ValveÐ3.0L Engine

(8)Disconnect the idle purge hose from the engine vacuum harness tee (Fig. 9).

(9)Install Air Metering Fitting #6457 (0.125 inch orifice) in the intake manifold mounted idle purge hose (Fig. 7).

(10)Connect Diagnostic Readout Box II (DRB II).

(11)Restart the engine, allow engine to idle for at least one minute.

(12)Using the DRBII, access Min. Airflow Idle

Speed.

(13)The following will then occur:

²AIS motor will fully close.

²Idle spark advance will become fixed.

²Engine RPM will be displayed on Diagnostic Readout Box II (DRB II)

(14)Check idle RPM with tachometer, if idle RPM is within the below specification then the throttle body min. air flow is set correctly.

Fig. 9 Idle Purge HoseÐ3.0L

IDLE SPECIFICATIONS

(15) If idle RPM is not within specifications, shut off the engine and clean the throttle body as follows:

(a) Remove the throttle body from engine.

WARNING: CLEAN THROTTLE BODY IN A WELL VENTILATED AREA. WEAR RUBBER OF BUTYL GLOVES, DO NOT LET MOPAR PARTS CLEANER COME IN CONTACT WITH EYES OR SKIN. AVOID INGESTING THE CLEANER. WASH THOROUGHLY AFTER USING CLEANER.

(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 bottom of throttle body bore and the edges and manifold 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 is 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 problem is not caused by the throttle body.

(16)Shut off engine.

(17)Remove Air Metering Fitting #6457 from the intake manifold idle purge hose. Reconnect the hose to the engine vacuum harness tee.

(18)Remove the plug from the PCV valve. Reconnect the PCV valve hose to the PCV valve.

(19)Disconnect the DRB II.

IGNITION TIMING PROCEDUREÐ2.2L TBI, 2.5L TBI, TURBO I, AND 3.0L ENGINES

WARNING: APPLY PARKING BRAKE AND/OR BLOCK WHEELS BEFORE PERFORMING SETTING IGNITION TIMING OR PERFORMING ANY TEST ON AN OPERATING ENGINE.

Proper ignition timing is required to obtain optimum engine performance. The distributor must be correctly indexed to provide correct initial ignition timing.

(1)Set the gearshift selector in park or neutral and apply the parking brake. All lights and accessories must be off.

(2)If using a magnetic timing light, insert the pickup probe into the open receptacle next to the timing scale window. If a magnetic timing unit is not available, use a conventional timing light connected to the number one cylinder spark plug cable.

Do not puncture cables, boots or nipples with test probes. Always use proper adapters. Puncturing the spark plug cables with a probe will damage the cables. The probe can separate the conductor and cause high resistance. In addition breaking the rubber insulation may permit secondary current to arc to ground.

(3)Turn selector switch to the appropriate cylinder position.

(4)Start engine and run until operating temperature is obtained.

(5)With the engine at normal operating temperature, connect the DRB II to the diagnostic connector. Access the State Display screen. Refer to the appropriate Powertrain Diagnostics Procedures Manual. If not using the DRB II tester, disconnect the coolant temperature sensor electrical connector.

The electric radiator fan will operate and the Check Engine light will turn on after disconnecting the coolant sensor or starting the DRB II procedure.

(6)Aim Timing Light at timing scale (Fig. 10 or Fig. 11) or read magnetic timing unit. If flash occurs when timing mark is before specified degree mark, timing is advanced. To adjust, turn distributor housing in direction of rotor rotation.

If flash occurs when timing mark is after specified degree mark, timing is retarded. To adjust, turn dis-

Fig. 10 Timing ScaleÐ2.2L TBI, 2.5L TBI and Turbo I

Engines

Fig. 11 Timing ScaleÐ3.0L Engine

tributor housing against direction of rotor rotation. Refer to Vehicle Emission Control Information label for correct timing specification. If timing is within 6 2° of value specified on the label, proceed to step (8). If outside specified tolerance, proceed to next step.

(7)Loosen distributor hold-down arm screw enough to rotate the distributor housing (Fig. 12 or Fig. 13). Turn distributor housing to adjust timing. Tighten the hold-down arm screw and recheck timing.

(8)Turn the engine off. Remove timing light or magnetic timing unit and tachometer. If the coolant temperature sensor was disconnected, connect the sensor and erase fault codes using the Erase

Fault Code Mode on the DRBII.

DISTRIBUTORÐ2.2L TBI, 2.5L TBI and TURBO I

ENGINES

REMOVAL

(1) Disconnect distributor pick-up connector from wiring harness connector (Fig. 14).

Fig. 12 Distributor HolddownÐ2.5L Engine

Fig. 13 Distributor HolddownÐ3.0L Engine

Fig. 14 Distributor Pickup ConnectorÐ2.5L Engine

(2)Remove splash shield retaining screws (Fig. 15).

(3)Remove splash shield (Fig. 15).

Fig. 15 Splash ShieldÐ2.5L Engine

(4) Loosen distributor cap retaining screws (Fig.

16).

Fig. 16 Distributor Cap Retaining ScrewsÐ2.5L En-

gine

(5)Lift cap off of distributor (Fig. 17).

(6)Rotate engine crankshaft until the distributor rotor is pointing toward the cylinder block. Use this as reference when reinstalling distributor.

(7)Remove distributor hold-down screw.

(8)Carefully lift the distributor from the engine.

INSTALLATION

(1)Position distributor in engine. Make certain that the O-ring is properly seated on distributor. If O-ring is cracked or nicked, replace it with new one.

(2)Carefully engage distributor drive with auxiliary shaft drive. When distributor is installed properly, rotor will be pointing toward cylinder block. If engine has been cranked while distributor is

Fig. 17 Distributor CapÐ2.5L Engine

removed, establish proper relationship between the distributor shaft and Number 1 piston position as follows:

(a)Rotate the crankshaft until number one piston is at top of compression stroke. Pointer on clutch housing should be in line with the O(TDC) mark on flywheel.

(b)Rotate rotor to a position just ahead of the number one distributor cap terminal.

(c)Lower the distributor into the opening, engaging distributor drive with drive on auxiliary shaft. With distributor fully seated on engine, rotor should be under the cap number 1 tower.

(3)Install the distributor cap. Ensure all high tension wires snap firmly in the cap towers.

(4)Install hold-down arm screw and finger tighten.

(5)Install splash shield.

(6)Connect distributor pick-up connector lead wire at wiring harness connector.

(7)Set ignition timing to specification. Refer to Ignition Timing.

DISTRIBUTOR PICK-UPÐ2.2L TBI, 2.5L TBI AND TURBO I ENGINES

REMOVAL

(1)Remove splash shield and cap. Refer to Distributor Removal.

(2)Remove rotor from shaft (Fig. 18).

(3)Remove Hall effect pick-up assembly (Fig.

19).

INSTALLATION

(1) Place pick-up assembly into distributor housing (Fig. 19).

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Fig. 18 Ignition RotorÐ2.2L TBI, 2.5L TBI and Turbo

I Engines

Fig. 19 Hall Effect Pickup AssemblyÐ2.2L TBI, 2.5L

TBI and Turbo I Engines

The distributor pick-up wires may be damaged if not properly reinstalled.

(2)Install rotor (Fig. 18).

(3)Install cap and splash shield. Refer to Distributor Installation.

IGNITION SYSTEMS 8D - 21

DISTRIBUTOR SERVICEÐ3.0L ENGINE

REMOVAL

(1) Disconnect distributor connector from wiring harness connector (Fig. 20).

Fig. 20 Distributor Electrical ConnectorÐ3.0L En-

gine

(2)Loosen distributor cap retaining screws.

(3)Lift cap of off distributor (Fig. 21).

(4)Rotate engine crankshaft until the distributor rotor points the intake manifold plenum. Scribe a mark on the plenum in line with the rotor. The scribe line indicates where to position the rotor when reinstalling the distributor.

Fig. 21 Distributor CapÐ3.0L Engine

(5)Remove distributor hold down nut (Fig. 22).

(6)Carefully lift the distributor from the engine.

INSTALLATION

(1)Position distributor in engine. Make certain that the O-ring is properly seated on distributor. If O-ring is cracked or nicked replace with new one.

(2)Carefully engage distributor drive with gear on camshaft. When the distributor is installed properly,

Fig. 22 Distributor Hold-DownÐ3.0L Engine

the rotor will be in line with previously scribe line on air intake plenum. If engine was cranked while distributor was removed, establish proper relationship between the distributor shaft and Number 1 piston position as follows:

(a)Rotate the crankshaft until number one piston is at top of compression stroke.

(b)Rotate rotor to number one rotor terminal (Fig. 23).

(c)Lower the distributor into the opening, engaging distributor drive with drive on camshaft. With distributor fully seated on engine, rotor should be under the number 1 terminal (Fig. 23).

Fig. 23 Distributor Cap Terminal Routing, View from Top of CapÐ3.0L Engine

(3)Install distributor cap. Ensure sure all high tension wires are firmly in the cap towers.

(4)Install hold-down nut and finger tighten.

(5)Connect distributor electrical connector to wiring harness connector (Fig. 20).

(6)Set ignition timing to specification. Refer to Ignition Timing in this section.

DISASSEMBLY

(1)Remove distributor cap mounting screws (Fig.

21).

(2)Remove distributor cap and inspect for flashover, cracked carbon button, cracked cap, or burned terminals. If any of these conditions exist, replace cap.

(3)Remove rotor screw (Fig. 24). Inspect rotor for cracks or burned electrode. If any of these conditions exist, replace rotor.

Fig. 24 Rotor Screw

(4) Remove protective cover from distributor housing (Fig. 25).

Fig. 25 Protective Cover

(5)Remove lead wire clamp screw and remove lead wire (Fig. 26).

(6)Remove disk assembly screw (Fig. 27).

(7)Remove disk spacers and disk (Fig. 28). Disk and spacers are keyed. Check disk for warpage, cracks or damaged slots (Fig. 29).