Epl 14 PDF

PL FUEL SYSTEM 14 - 1
FUEL SYSTEM
CONTENTS
page page
FUEL DELIVERY SYSTEM . . . . . . . . . . . . . . . . . . . 3 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . 1

FUEL INJECTION SYSTEM . . . . . . . . . . . . . . . . . 20
GENERAL INFORMATION
INDEX
page page
GENERAL INFORMATION INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . 1

FUEL REQUIREMENTS . . . . . . . . . . . . . . . . . . . . 1 PCM REPLACEMENT . . . . . . . . . . . . . . . . . . . . . 1
GASOLINE/OXYGENATE BLENDS . . . . . . . . . . . . 1
GENERAL INFORMATION dealer immediately. Engine damage as a result of

heavy knock operation may not be covered by the
INTRODUCTION new vehicle warranty.
Throughout this group, references may be made to In addition to using unleaded gasoline with the
a particular vehicle by letter or number designation. proper octane rating, those that contain detergents,
A chart showing the breakdown of these designations corrosion and stability additives are recommended.
is included in the Introduction Section at the front of Using gasolines that have these additives will help
this service manual. improve fuel economy, reduce emissions, and main-
The Evaporation Control System, is also considered tain vehicle performance.
part of the fuel system. The system reduces the emis- Poor quality gasoline can cause problems such as
sion of fuel vapor into the atmosphere. hard starting, stalling, and stumble. If you experi-
The description and function of the Evaporation ence these problems, try another brand of gasoline
Control System is found in Group 25 of this manual. before considering service for the vehicle.
PCM REPLACEMENT GASOLINE/OXYGENATE BLENDS

USE THE DRB SCAN TOOL TO REPROGRAM Some fuel suppliers blend unleaded gasoline with
THE NEW PCM WITH THE VEHICLES ORIGI- materials that contain oxygen such as alcohol, MTBE
NAL IDENTIFICATION NUMBER (VIN) AND (Methyl Tertiary Butyl Ether) and ETBE (Ethyl Ter-
THE VEHICLES ORIGINAL MILEAGE. IF THIS tiary Butyl Ether). Oxygenates are required in some
STEP IS NOT DONE A DIAGNOSTIC TROUBLE areas of the country during winter months to reduce
CODE (DTC) MAY BE SET. carbon monoxide emissions. The type and amount of
oxygenate used in the blend is important.
FUEL REQUIREMENTS The following are generally used in gasoline
Your vehicle was designed to meet all emission reg- blends:
ulations and provide excellent fuel economy when Ethanol - (Ethyl or Grain Alcohol) properly
using high quality unleaded gasoline. blended, is used as a mixture of 10 percent ethanol
Use unleaded gasolines having a minimum posted and 90 percent gasoline. Gasoline blended with etha-
octane of 87. nol may be used in your vehicle.
If your vehicle develops occasional light spark MTBE/ETBE - Gasoline and MTBE (Methyl Ter-
knock (ping) at low engine speeds this is not harm- tiary Butyl Ether) blends are a mixture of unleaded
ful. However; continued heavy knock at high speeds gasoline and up to 15 percent MTBE. Gasoline and
can cause damage and should be reported to your ETBE (Ethyl Tertiary Butyl Ether) are blends of gas-
14 - 2 FUEL SYSTEM PL
GENERAL INFORMATION (Continued)
oline and up to 17 percent ETBE. Gasoline blended Gasoline. Reformulated gasolines are specially
with MTBE or ETBE may be used in your vehicle. blended to reduce vehicle emissions and improve air
Methanol - Methanol (Methyl or Wood Alcohol) is quality.
used in a variety of concentrations blended with Chrysler Corporation strongly supports the use of
unleaded gasoline. You may encounter fuels contain- reformulated gasolines whenever available. Although
ing 3 percent or more methanol along with other your vehicle was designed to provide optimum perfor-
alcohols called cosolvents. mance and lowest emissions operating on high qual-
DO NOT USE GASOLINES CONTAINING ity unleaded gasoline, it will perform equally well
METHANOL. and produce even lower emissions when operating on
Use of methanol/gasoline blends may result in reformulated gasoline.
starting and driveability problems and damage criti- Materials Added to Fuel
cal fuel system components. Indiscriminate use of fuel system cleaning agents
Problems that are the result of using methanol/ should be avoided. Many of these materials intended
gasoline blends are not the responsibility of Chrysler for gum and varnish removal may contain active sol-
Corporation and may not be covered by the vehicle vents of similar ingredients that can be harmful to
warranty. fuel system gasket and diaphragm materials.
Reformulated Gasoline
Many areas of the country are requiring the use of
cleaner-burning fuel referred to as Reformulated
FUEL DELIVERY SYSTEM
INDEX
page page
DESCRIPTION AND OPERATION HOSES AND CLAMPS . . . . . . . . . . . . . . . . . . . . 10

ELECTRIC FUEL PUMP . . . . . . . . . . . . . . . . . . . . 4 QUICK-CONNECT FITTINGS . . . . . . . . . . . . . . . 11
FUEL DELIVERY SYSTEM . . . . . . . . . . . . . . . . . . 3 REMOVAL AND INSTALLATION
FUEL FILTER/FUEL PRESSURE REGULATOR . . . 4 ACCELERATOR PEDAL . . . . . . . . . . . . . . . . . . . 17
FUEL GAUGE SENDING UNIT . . . . . . . . . . . . . . . 4 AUTOMATIC SHUTDOWN RELAY . . . . . . . . . . . 11
FUEL INJECTORS . . . . . . . . . . . . . . . . . . . . . . . . 5 FUEL FILLER NECK . . . . . . . . . . . . . . . . . . . . . . 16
FUEL PUMP MODULE . . . . . . . . . . . . . . . . . . . . . 3 FUEL FILLER TUBE ROLLOVER VALVE . . . . . . . 16
FUEL RAIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 FUEL FILTER / PRESSURE REGULATOR . . . . . 12
FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 FUEL INJECTORS . . . . . . . . . . . . . . . . . . . . . . . 14
PRESSURE-VACUUM FILLER CAP . . . . . . . . . . . 5 FUEL LEVEL SENSOR . . . . . . . . . . . . . . . . . . . . 13
QUICK-CONNECT FITTINGS . . . . . . . . . . . . . . . . 5 FUEL PUMP INLET STRAINER . . . . . . . . . . . . . 13
ROLLOVER VALVES . . . . . . . . . . . . . . . . . . . . . . 5 FUEL PUMP MODULE . . . . . . . . . . . . . . . . . . . . 11
DIAGNOSIS AND TESTING FUEL PUMP RELAY . . . . . . . . . . . . . . . . . . . . . . 11
FUEL INJECTORS . . . . . . . . . . . . . . . . . . . . . . . . 8 FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
FUEL LEVEL SENSOR . . . . . . . . . . . . . . . . . . . . . 6 THROTTLE CABLE—AUTOMATIC
FUEL PUMP PRESSURE TEST . . . . . . . . . . . . . . 6 TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . 18
SERVICE PROCEDURES THROTTLE CABLE—MANUAL TRANSMISSION . 17
DRAINING FUEL TANK . . . . . . . . . . . . . . . . . . . . 10 SPECIFICATIONS
FUEL SYSTEM PRESSURE RELEASE FUEL TANK CAPACITY . . . . . . . . . . . . . . . . . . . 19
PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . 10 TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
DESCRIPTION AND OPERATION • Electric fuel pump

• Fuel pump reservoir
FUEL DELIVERY SYSTEM • Inlet strainer
The fuel delivery system consists of: the electric • Fuel filter/pressure regulator
fuel pump, fuel filter/fuel pressure regulator, fuel • Fuel gauge sending unit
tubes/lines/hoses, fuel rail, fuel injectors, fuel tank, • Fuel supply line connection
accelerator pedal and throttle cable. The inlet strainer, fuel pressure regulator and fuel
A fuel return system is used on all models (all level sensor are the only serviceable items. If the fuel
engines). Fuel is returned through the fuel pump pump requires service, replace the fuel pump module.
module and back into the fuel tank through the fuel
filter/fuel pressure regulator. A separate fuel return
line from the engine to the tank is no longer used
with any engine.
The fuel tank assembly consists of: the fuel tank,
filler tube, fuel gauge sending unit/electric fuel pump
module, a pressure relief/rollover valve and a pres-
sure-vacuum filler cap.
Also to be considered part of the fuel system is the
evaporation control system. This is designed to
reduce the emission of fuel vapors into the atmo-
sphere. The description and function of the Evapora-
tive Control System is found in Group 25, Emission
Control Systems.
FUEL PUMP MODULE

The fuel pump module is installed in the top of the Fig. 1 Fuel Pump Module
fuel tank (Fig. 1). The fuel pump module contains the
following:
DESCRIPTION AND OPERATION (Continued)
ELECTRIC FUEL PUMP through the pressure regulator. A separate fuel
The electric fuel pump is located in and is part of return line is not used with any gas powered engine.
the fuel pump module. It is a positive displacement,
gerotor type, immersible pump with a permanent
magnet electric motor. The fuel pump module is sus-
pended in fuel in the fuel tank. The pump draws fuel
through a strainer and pushes it through the motor
to the outlet. The pump contains a check valve. The
valve, in the pump outlet, maintains pump pressure
during engine off conditions. The fuel pump relay
provides voltage to the fuel pump.
The fuel pump has a maximum deadheaded pres-
sure output of approximately 880 kPa (130 psi). The
regulator adjusts fuel system pressure to approxi-
mately 338 kPa (49 psi).
FUEL GAUGE SENDING UNIT

The fuel gauge sending unit (fuel level sensor) is
attached to the side of the fuel pump module. The
sending unit consists of a float, an arm, and a vari-
able resistor (track). The resistor track is used to
send electrical signals to the Powertrain Control
Module (PCM) for fuel gauge operation and for OBD
II emission requirements.
For fuel gauge operation: As fuel level Fig. 2 Side View—Filter/Regulator
increases, the float and arm move up. This decreases
the sending unit resistance, causing the fuel gauge to FUEL TANK
read full. As fuel level decreases, the float and arm All models pass a full 360 degree rollover test
move down. This increases the sending unit resis- without fuel leakage. To accomplish this, fuel and
tance causing the fuel gauge to read empty. vapor flow controls are required for all fuel tank con-
After this fuel level signal is sent to the PCM, the nections.
PCM will transmit the data across the CCD bus cir- All models are equipped with either one or two
cuits to the instrument panel. Here it is translated rollover valves mounted into the top of the fuel tank
into the appropriate fuel gauge level reading. (or pump module). Refer to Group 25, Emission Con-
trol System for rollover valve information.
FUEL FILTER/FUEL PRESSURE REGULATOR An evaporation control system is connected to the
A combination fuel filter and fuel pressure regula- rollover valve(s) to reduce emissions of fuel vapors
tor is used on all gas powered engines. It is located into the atmosphere. When fuel evaporates from the
on the top of the fuel pump module. A separate frame fuel tank, vapors pass through vent hoses or tubes to
mounted fuel filter is not used. a charcoal canister where they are temporarily held.
Fuel Pressure Regulator Operation: The pres- When the engine is running, the vapors are drawn
sure regulator is a mechanical device that is cali- into the intake manifold. Certain models are also
brated to maintain fuel system operating pressure of equipped with a self-diagnosing system using a Leak
approximately 338 kPa (49 psi) at the fuel injectors. Detection Pump (LDP). Refer to Group 25, Emission
It contains a diaphragm, calibrated springs and a Control System for additional information.
fuel return valve. The internal fuel filter (Fig. 2) is
also part of the assembly. FUEL RAIL
Fuel is supplied to the filter/regulator by the elec- The fuel rail supplies the necessary fuel to each
tric fuel pump through an opening tube at the bot- individual fuel injector and is mounted to the intake
tom of filter/regulator. manifold (Fig. 3). The fuel pressure regulator is no
The fuel pump module contains a check valve to longer mounted to the fuel rail on any engine. It is
maintain some fuel pressure when the engine is not now located on the fuel tank mounted fuel pump
operating. This will help to start the engine. module. Refer to Fuel Filter/Fuel Pressure Regulator
If fuel pressure at the pressure regulator exceeds in the Fuel Delivery System section of this group for
approximately 49 psi, an internal diaphragm closes information. The fuel rail is not repairable.
and excess fuel pressure is routed back into the tank
Fig. 3 Fuel Rail—Typical

FUEL INJECTORS
The fuel injectors are 12 ohm electrical solenoids
(Fig. 4). The injector contains a pintle that closes off
an orifice at the nozzle end. When electric current is Fig. 5 Fuel Injector Location—Typical
supplied to the injector, the armature and needle
move a short distance against a spring, allowing fuel WARNING: REMOVE FILLER CAP TO RELIEVE
to flow out the orifice. Because the fuel is under high TANK PRESSURE BEFORE REMOVING OR REPAIR-
pressure, a fine spray is developed in the shape of a ING FUEL SYSTEM COMPONENTS.
hollow cone. The spraying action atomizes the fuel,
adding it to the air entering the combustion chamber.
The injectors are positioned in the intake manifold. QUICK-CONNECT FITTINGS
Fuel injectors are not interchangeable between Different types of quick-connect fittings are used to
engines. attach various fuel system components. These are: a
single-tab type, a two-tab type or a plastic retainer
ring type. Some are equipped with safety latch clips.
Refer to the Removal/Installation section for more
information.
CAUTION: The interior components (o-rings, spac-

ers) of quick-connect fitting are not serviced sepa-
rately. Do not attempt to repair damaged fittings or
fuel lines/tubes. If repair is necessary, replace the
complete fuel tube assembly.
Fuel tubes connect fuel system components with

plastic quick-connect fuel fittings. The fitting con-
tains non-serviceable O-ring seals (Fig. 6).
CAUTION: Quick-connect fittings are not serviced

Fig. 4 Fuel Injector separately. Do not attempt to repair damaged quick-
connect fittings or fuel tubes. Replace the complete
The injectors are positioned in the intake manifold fuel tube/quick-connect fitting assembly.
with the nozzle ends directly above the intake valve
port (Fig. 5). The quick-connect fitting consists of the O-rings,
retainer and casing (Fig. 6). When the fuel tube
PRESSURE-VACUUM FILLER CAP enters the fitting, the retainer locks the shoulder of
The loss of any fuel or vapor out of the filler neck the nipple in place and the O-rings seal the tube.
is prevented by the use of a safety filler cap. The cap
will release pressure only under significant pressure ROLLOVER VALVES
of 10.9 to 13.45 kPa (1.58 to 1.95 psi). The vacuum All PL vehicles have two rollover valves. One in
release for all gas caps is between 0.97 and 2.0 kPa the fuel filler tube and the other on the top of the
(0.14 and 0.29 psi). The cap must be replaced by a fuel tank. The valves prevent fuel flow through the
similar unit if replacement is necessary. fuel tank vent valve hoses should the vehicle rollover.
Fig. 8 Checking Fuel Pressure at Intake Manifold—

Typical
CAUTION: When using the ASD Fuel System Test,
the ASD relay and fuel pump relay remain energized
for 7 minutes or until the test is stopped, or until
Fig. 6 Plastic Quick-Connect Fittings the ignition switch is turned to the Off position.
DIAGNOSIS AND TESTING
(3) Place the ignition key in the ON position.
Using the DRB scan tool, access ASD Fuel System
FUEL PUMP PRESSURE TEST
Test. The ASD Fuel System Test will activate the fuel
The fuel system operates at approximately 338 kPa
pump and pressurize the system.
(49 psi). Check fuel system pressure at the test port
• If the gauge reading equals 338 kPa (49 PSI)
on the fuel rail (Fig. 7).
further testing is not required. If pressure is not cor-
(1) Remove cap from fuel pressure test port on fuel
rect, record the pressure.
rail.
• If fuel pressure is below specifications, refer to
(2) Connect Fuel Pressure Gauge C-4799B to test
the Fuel Pressure Diagnosis Chart (Fig. 9).
port (Fig. 8).
• If fuel pressure is above specifications (54 psi or
higher) check for a kinked or restricted fuel supply
line. If the supply line is not kinked or restricted,
replace the Fuel Filter/Pressure Regulator.
(4) Replace Pressure test port cap when finished
doing pressure test.
FUEL LEVEL SENSOR

This procedure tests the resistance of the level sen-
sor itself. It does not test the level sensor circuit.
Refer to Group 8W - Wiring Diagrams for circuit
identification.
The level sensor is a variable resistor. Its resis-
tance changes with the amount of fuel in the tank.
The float arm attached to the sensor moves as the
fuel level changes. To test the level sensor, connect
an ohmmeter across the sensor signal and sensor
Fig. 7 Fuel Pressure Test Port—Typical ground terminals of the fuel pump module connector
(Fig. 10). Move the float lever to the positions shown
in the resistance chart (Fig. 10). Record the resis-
tance at each point. Replace the level sensor if the
resistance is not within specifications.
DIAGNOSIS AND TESTING (Continued)
Fig. 9 Fuel Pressure Diagnosis Chart

FUEL INJECTORS
For fuel injector diagnosis, refer to the Fuel Injec-
tor Diagnosis charts. For poor fuel economy diagnosis
or engine miss, also refer to Transmission Driveplate
in this section.
Fig. 10 Level Sensor Diagnosis

FUEL INJECTOR DIAGNOSIS

SERVICE PROCEDURES
FUEL SYSTEM PRESSURE RELEASE PROCEDURE
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) Remove the protective cap from the fuel pres-
sure test port on the fuel rail (Fig. 11).
Fig. 12 Releasing Fuel Pressure

(5) Remove quick connect cap from drain port. The
drain port is located on rear top of fuel tank. Push a
siphon hose into the drain port (Fig. 13).
(6) Drain fuel tank into holding tank or a properly
labeled Gasoline safety container.
Fig. 11 Fuel Pressure Test Port—Typical

(4) Place the open end of fuel pressure release
hose, tool number C-4799-1, into an approved gaso-
line container. Connect the other end of hose
C-4799-1 to the fuel pressure test port (Fig. 12). Fuel
pressure will bleed off through the hose into the gas-
oline container. Fuel gauge C-4799-A contains hose
C-4799-1.
(5) Replace Pressure test port cap when finished
doing pressure test. Fig. 13 Drain Port Location
HOSES AND CLAMPS
DRAINING FUEL TANK Inspect all hose connections (clamps and quick con-
nect fittings) for completeness and leaks. Replace
cracked, scuffed, or swelled hoses. Replace hoses that
BEFORE SERVICING FUEL SYSTEM COMPONENTS.
rub against other vehicle components or show sign of
SERVICE VEHICLES IN WELL VENTILATED AREAS
wear.
AND AVOID IGNITION SOURCES. NEVER SMOKE
Fuel injected vehicles use specially constructed
WHILE SERVICING THE VEHICLE.
hoses. When replacing hoses, only use hoses marked
(1) Remove fuel filler cap. EFM/EFI.
(2) Perform the Fuel System Pressure Release pro- When installing hoses, ensure that they are routed
cedure. away from contact with other vehicle components
(3) Disconnect negative cable from battery. that could rub against them and cause failure. Avoid
(4) Raise vehicle on hoist. contact with clamps or other components that cause
abrasions or scuffing. Ensure that rubber hoses are
properly routed and avoid heat sources.
SERVICE PROCEDURES (Continued)
The hose clamps have rolled edges to prevent the
clamp from cutting into the hose. Only use clamps
that are original equipment or equivalent. Other
types of clamps may cut into the hoses and cause
high pressure fuel leaks. Tighten hose clamps to 1
N·m (10 in. lbs.) torque.
QUICK-CONNECT FITTINGS
REMOVAL
When disconnecting a quick-connect fitting, the
retainer will remain on the fuel tube nipple. Fig. 14 Plastic Quick-Connect Fitting/Fuel Tube
Connection
BEFORE DISCONNECTING A QUICK-CONNECT FIT-
REMOVAL AND INSTALLATION
TINGS. REFER TO THE FUEL PRESSURE RELEASE
PROCEDURE.
AUTOMATIC SHUTDOWN RELAY
The relay is located in the Power Distribution Cen-
(1) Disconnect negative cable from battery. ter (PDC) (Fig. 15). The PDC is located next to the
(2) Perform Fuel Pressure Release Procedure. battery in the engine compartment. For the location
Refer to the Fuel Pressure Release Procedure in this of the relay within the PDC, refer to the PDC cover
section. for location. Check electrical terminals for corrosion
(3) Squeeze retainer tabs together and pull fuel and repair as necessary.
tube/quick-connect fitting assembly off of fuel tube
nipple. The retainer will remain on fuel tube.
INSTALLATION
CAUTION: Never install a quick-connect fitting

without the retainer being either on the fuel tube or
already in the quick-connect fitting. In either case,
ensure the retainer locks securely into the quick-
connect fitting by firmly pulling on fuel tube and fit-
ting to ensure it is secured.
(1) Using a clean lint free cloth, clean the fuel tube
nipple and retainer.
(2) Prior to connecting the fitting to the fuel tube,
coat the fuel tube nipple with clean 30 weight engine
oil. Fig. 15 Power Distribution Center (PDC)
(3) Push the quick-connect fitting over the fuel
FUEL PUMP RELAY
tube until the retainer seats and a click is heard.
The fuel pump relay is located in the PDC. The
(4) The plastic quick-connect fitting has windows
inside top of the PDC cover has a label showing relay
in the sides of the casing. When the fitting com-
and fuse location.
pletely attaches to the fuel tube, the retainer locking
ears and the fuel tube shoulder are visible in the
FUEL PUMP MODULE
windows. If they are not visible, the retainer was not
properly installed (Fig. 14). Do not rely upon the REMOVAL
audible click to confirm a secure connection.
CAUTION: When using the ASD Fuel System Test, BEFORE SERVICING FUEL SYSTEM COMPONENTS.
the Auto Shutdown (ASD) Relay remains energized SERVICE VEHICLES IN WELL VENTILATED AREAS
for either 7 minutes, until the test is stopped, or AND AVOID IGNITION SOURCES. NEVER SMOKE
until the ignition switch is turned to the Off posi- WHILE SERVICING THE VEHICLE.
tion.
(1) Drain the fuel. Refer to Draining Fuel Tank in
(5) Use the DRB scan tool ASD Fuel System Test the Fuel Tank section of this group.
to pressurize the fuel system. Check for leaks.
REMOVAL AND INSTALLATION (Continued)
WARNING: THE FUEL RESERVOIR OF THE FUEL
PUMP MODULE DOES NOT EMPTY OUT WHEN THE
TANK IS DRAINED. THE FUEL IN THE RESERVOIR
WILL SPILL OUT WHEN THE MODULE IS
REMOVED.
(2) Disconnect fuel line from fuel pump module by

depressing quick connect retainers with thumb and
fore finger.
(3) Slide fuel pump module electrical connecter
lock to unlock.
(4) Disconnect the electrical connection from the
fuel pump module, by pushing down on connector
retainer and pulling connector off of module.
(5) Use a transmission jack to support the fuel
tank. remove bolts from fuel tank straps.
(6) Lower tank slightly. Fig. 17 Fuel Tank Locknut
(7) Use Special Tool 6856 to remove fuel pump
module locknut (Fig. 17). FUEL FILTER / PRESSURE REGULATOR
(8) Remove fuel pump and O-ring seal from tank.
REMOVAL
Discard old seal.
WARNING: THE FUEL SYSTEM IS UNDER A CON-
STANT PRESSURE, EVEN WITH ENGINE OFF. BEFORE
SERVICING THE FUEL FILTER/FUEL PRESSURE REG-
ULATOR, THE FUEL SYSTEM PRESSURE MUST BE
RELEASED.
(1) Refer to Fuel System Pressure Release in the

Fuel Delivery System section of this group.
The fuel filter/fuel pressure regulator is located on
the top of fuel pump module. Fuel pump module
removal is not necessary.
(2) Raise vehicle on hoist.
(3) Disconnect fuel supply line at the Filter/Regu-
lator nipple (refer to Quick Connect Fittings in this
section).
(4) Depress locking spring tab on side of Fuel/Reg-
Fig. 16 Fuel Pump Module Removal ulator (Fig. 18) and rotate 90° counter-clockwise and
pull out.
INSTALLATION
(1) Wipe seal area of tank clean and place a new NOTE: Make sure that the upper and lower O-rings
seal in position in the tank opening. are on the Filter/Regulator assembly.
(2) Position fuel pump in the tank. Make sure the
aligment tab on the underside of the fuel pump mod-
ule flange sits in the notch on the fuel tank. INSTALLATION
(3) Position the locknut over the fuel pump module. Lightly lubricate the O-rings with engine oil.
(4) Tighten the locknut using Special Tool 6856 to (1) Insert Filter/Regulator into the opening in the
55 N·m (40.5 ft. lbs.) (Fig. 17). fuel pump module, align the two hold down tabs with
the flange.
CAUTION: Over tightening the pump lock ring may (2) While applying downward pressure, rotate the
result in a leak. Filter/Regulator clockwise until the the spring tab
engages the locating slot (Fig. 19).
(5) Fill fuel tank. Check for leaks. (3) Connect the fuel line to the Filter/Regulator.
(4) Lower vehicle from hoist.
Fig. 20 Inlet Strainer Removal

Fig. 18 Locking Spring Tab
(4) Install fuel pump module. Refer to Fuel Pump
Module Installation in this section.
FUEL LEVEL SENSOR

REMOVAL
Remove fuel pump module. Refer to Fuel Pump
Module in this section.
(1) Depress retaining tab and remove the fuel
pump/level sensor connector from the bottom of the
fuel pump module electrical connector (Fig. 21).
Fig. 19 Spring Tab In Locating Slot

FUEL PUMP INLET STRAINER
REMOVAL
(1) Remove fuel pump module. Refer to Fuel Pump
Module Removal in this section.
(2) Using a thin straight blade screwdriver, pry
back the locking tabs on fuel pump reservoir and
remove the strainer (Fig. 20).
(3) Remove strainer O-ring from the fuel pump
reservoir body. Fig. 21 Fuel Pump/Level Sensor Electrical
(4) Remove any contaminants in the fuel tank by Connector
washing the inside of the fuel tank.
(2) Pull off blue locking wedge (Fig. 22).
INSTALLATION (3) Using a small screwdriver lift locking finger
(1) Lubricate the strainer O-ring with clean engine away from terminal and push terminal out of connec-
oil. tor (Fig. 23).
(2) Insert strainer O-ring into outlet of strainer so (4) Push level sensor signal and ground terminals
that it sits evenly on the step inside the outlet. out of the connector (Fig. 24).
(3) Push strainer onto the inlet of the fuel pump (5) Insert a screwdriver between the fuel pump
reservoir body. Make sure the locking tabs on the res- module and the top of the level sensor housing (Fig.
ervoir body lock over the locking tangs on the strainer. 25). Push level sensor down slightly.
Fig. 22 Wire Terminal Locking Wedge

Fig. 25 Loosening Level Sensor
Fig. 23 Wire Terminal Locking Finger
Fig. 26 Level Sensor Removal/Installation

(4) Install level sensor wires in connector. Push
the wires up through the connector and then pull
them down until they lock in place. Ensure signal
and ground wires are installed in the correct posi-
tion.
(5) Install locking wedge on connector.
(6) Push connector up into bottom of fuel pump
Fig. 24 Removing Wires From Connector
module electrical connector.
(6) Slide level sensor wires through opening fuel (7) Install fuel pump module. Refer to Fuel Pump
pump module (Fig. 26). Module in this section.
(7) Slide level sensor out of installation channel in
module. FUEL INJECTORS
INSTALLATION REMOVAL
(1) Insert level sensor wires into bottom of opening (1) Disconnect negative cable from battery.
in module. (2) Release fuel system pressure. Refer to Fuel
(2) Wrap wires into groove in back of level sensor System Pressure Release procedure in this section.
(Fig. 25). (3) Disconnect fuel supply tube from rail. Refer to
(3) While feeding wires into guide grooves, slide Quick-Connect Fittings in the Fuel Delivery section
level sensor up into channel until it snaps into place of this group.
(Fig. 26). Ensure tab at bottom of sensor locks in (4) Disconnect electrical connectors from fuel injec-
place. tors (Fig. 27).
(2) Install injector in cup on fuel rail.
(3) Install retaining clip.
(4) Apply a light coating of clean engine oil to the
O-ring on the nozzle end of each injector.
(5) Insert fuel injector nozzles into openings in
intake manifold. Seat the injectors in place. Tighten
fuel rail mounting screws to 22.5 N·m 6 3 N·m
(200630 in. lbs.).
(6) Attach electrical connectors to fuel injectors.
(7) Connect fuel supply tube to fuel rail. Refer to
Quick Connect Fittings in the Fuel Delivery Section
of this Group.
FUEL TANK
REMOVAL
Fig. 27 Fuel Rail and Injectors
(1) Perform fuel system pressure release.
(5) Remove fuel rail mounting screws.
(6) Lift rail off of intake manifold. Cover the fuel
injector openings in the intake manifold.
(7) Remove fuel injector retainer (Fig. 28).
Fig. 30 Fuel Tank

Fig. 28 Fuel Injector Retainer
(2) Drain fuel tank. Refer to Draining Fuel Tank
(8) Pull injector out of fuel rail. Replace fuel injec-
in this section (Fig. 30).
tor O-rings (Fig. 29).
(3) Raise vehicle on hoist.
WARNING: WRAP SHOP TOWELS AROUND

HOSES TO CATCH ANY GASOLINE SPILLAGE.
(4) Disconnect fuel pump module electrical connec-

tor (Fig. 31).
(5) Disconnect the fuel tube from Fuel Filter/Reg-
ulator. Refer to Quick Connect Fittings in the Fuel
Delivery section of this group.
(6) Support tank with transmission jack. Loosen
tank mounting straps and lower tank slightly.
(7) Disconnect fuel filler tube and filler vent tube
from filler hose at fuel tank (Fig. 32).
(8) Disconnect fuel filler vapor relief tube from tee
connecting it to the tank vapor relief tube and EVAP
canister tube.
Fig. 29 Fuel Injector O-Rings
(9) Disconnect vapor line from Evap canister tube.
INSTALLATION (10) Remove tank mounting straps and lower tank.
(1) Apply a light coating of clean engine oil to the
upper O-ring.
(9) Use the DRB scan tool ASD Fuel System Test
to pressurize the fuel system. Check for leaks.
FUEL FILLER NECK

REMOVAL
(1) Loosen fuel filler tube cap.
(2) Remove fuel filler neck screws (Fig. 33).
Fig. 31 Fuel Pump Module Electrical Connector
Fig. 33 Fuel Filler Neck

(3) Disconnect fuel fill vapor tube.
(4) Disconnect fuel filler tube from fuel tank.
Remove filler neck.
INSTALLATION
(1) Reverse for installation.
Fig. 32 Fuel Filler Tube and Vent Tubes FUEL FILLER TUBE ROLLOVER VALVE
INSTALLATION
(1) Position fuel tank on transmission jack. REMOVAL
(2) Raise tank into position. Connect fuel filler The rollover valve is mounted in the fuel filler tube
tube tank inlet nipple. (Fig. 34).
(3) Tighten fuel tank strap nuts to 22.5 N·m (200
in. lbs.) torque. Remove transmission jack. Ensure
straps are not twisted or bent.
(4) Attach fuel tubes to pump module and chassis
fuel tube. Refer to Quick Connect Fittings in the Fuel
Delivery section of this Group.
(5) Connect fuel vapor tube to tee, then to Evap
canister tube.
(6) Attach electrical connector to fuel pump module.
(7) Lower vehicle.
(8) Fill fuel tank, install filler cap, and connect
battery cable.
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 Fig. 34 Fuel Filler Tube Rollover Valve
ignition switch is turned to the Off position.
(1) To release fuel tank pressure, remove the fuel
filler tube cap.
(2) Disconnect vapor tube from rollover valve.
(3) Using a straight screwdriver, pry the valve out
of the grommet in the fuel filler tube.
INSTALLATION
(1) Apply a light coating of power steering fluid to
the grommet.
(2) Install valve in grommet.
(3) Attach vapor tube to valve.
(4) Install fuel filler tube cap.
ACCELERATOR PEDAL
CAUTION: When servicing the accelerator pedal,
throttle cable or speed control cable, do not dam-
age or kink the core wire inside the cable sheath-
ing.
Fig. 36 Accelerator Pedal and Throttle Cable—Rear
View
REMOVAL (2) From inside the vehicle, hold up the pedal and
(1) Working from the engine compartment, remove install the throttle cable and cable retainer in the
the throttle control shield. upper end of the pedal shaft.
(2) Hold the throttle body throttle lever in the (3) From the engine compartment, hold the throt-
wide open position. Remove the throttle cable from tle body lever in the wide open position and install
the throttle body cam. the throttle cable. Install the throttle control shield.
(3) From inside the vehicle, hold up the pedal and
remove the cable retainer and throttle cable from the THROTTLE CABLE—MANUAL TRANSMISSION
upper end of the pedal shaft (Fig. 35) and (Fig. 36).
REMOVAL
(1) Remove throttle control shield (Fig. 37).
Fig. 35 Accelerator Pedal and Throttle Cable—Front

View
(4) Working from the engine compartment, remove
nuts from accelerator pedal attaching studs (Fig. 35).
Remove assembly from vehicle.
INSTALLATION
(1) Position accelerator pedal assembly on dash
panel. Install retaining nuts. Tighten retaining nuts Fig. 37 Throttle Control Shield
to 12 N·m (105 in. lbs.) torque. (2) Working from the engine compartment, remove
the throttle cable from the throttle body lever (Fig.
38) and (Fig. 39).
(5) From the engine compartment, rotate the
throttle lever forward to the wide open position and
install cable clasp (Fig. 39).
(6) Install throttle control shield (Fig. 37). Tighten
screw to 5.6 N·m (50 in. lbs.).
THROTTLE CABLE—AUTOMATIC TRANSMISSION

REMOVAL
(1) Remove throttle control shield (Fig. 37).
(2) Working from the engine compartment, remove
throttle cable from throttle body cam (Fig. 40) and
(Fig. 41).
Fig. 38 Throttle Cable Attachment to Throttle Body
Fig. 40 Throttle Body Cables Attachment to Throttle

Body
Fig. 39 Disconnecting Throttle Cable

(3) Compress the retaining tabs on the cable and
slide cable out of bracket.
(4) From inside the vehicle, hold the accelerator
pedal up and remove the cable retainer and cable
from upper end of pedal shaft (Fig. 35) and (Fig. 36).
(5) Remove retainer clip from throttle cable and
grommet at the dash panel.
(6) From the engine compartment, pull the throttle
cable out of the dash panel grommet. The grommet
should remain in the dash panel.
INSTALLATION
(1) From the engine compartment, push the hous-
ing end fitting into the dash panel grommet. Fig. 41 Disconnecting Throttle Cable
(2) Install cable housing (throttle body end) into (3) Compress the retaining tabs on the cable and
the cable mounting bracket on the engine. slide cable out of bracket.
(3) From inside the vehicle, hold up pedal and feed (4) From inside the vehicle, hold the throttle pedal
throttle cable core wire through hole in upper end of up and remove the cable retainer and cable from
the pedal shaft. Install cable retainer. upper end of pedal shaft (Fig. 35) and (Fig. 36).
(4) Install cable retainer clip. (5) Remove retainer clip from throttle cable and
grommet at the dash panel.
(6) From the engine compartment, pull the throttle SPECIFICATIONS
cable out of the dash panel grommet. The grommet
should remain in the dash panel. TORQUE
INSTALLATION DESCRIPTION TORQUE
(1) From the engine compartment, push the hous- Accelerator Pedal to Dash Nuts . . . . . . . . . . .12 N·m
ing end fitting into the dash panel grommet. (105 in. lbs.)
(2) Install cable housing (throttle body end) into Fuel Pump Module Locknut . . . . .55 N·m (40 ft. lbs.)
the cable mounting bracket on the engine.
Fuel Tank Strap Bolts . . . . . . .22.5 N·m (200 in. lbs.)
(3) From inside the vehicle, hold up pedal and feed
Fuel Rail Bolts . . . . . . . . . . . . . .23 N·m (195 in. lbs.)
throttle cable core wire through hole in upper end of
Ignition Coil Mounting Bolts . . . .11 N·m (95 in. lbs.)
the pedal shaft. Install cable retainer (Fig. 36).
Intake Manifold Bolts. . . . . . . . . .11 N·m (95 in. lbs.)
(4) Install cable retainer clip.
(5) From the engine compartment, rotate the Throttle Control Shield . . . . . . . .5.6 N·m (50 in. lbs.)
throttle lever forward to the wide open position and FUEL TANK CAPACITY
install cable clasp (Fig. 41).
(6) Install throttle control shield (Fig. 37). Tighten Vehicle Liters U.S. Gallons
to 5.6 N·m (50 in. lbs.). PL 47 12.5
Nominal refill capacities are shown. A variation may be
observed from vehicle to vehicle due to manufacturing
tolerance and refill procedure.
FUEL INJECTION SYSTEM
INDEX
page page
GENERAL INFORMATION SCI RECEIVE—PCM INPUT . . . . . . . . . . . . . . . . 30

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . 21 SCI RECEIVE—PCM OUTPUT . . . . . . . . . . . . . . 35
MODES OF OPERATION . . . . . . . . . . . . . . . . . . 21 SENSOR RETURN—PCM INPUT . . . . . . . . . . . . 30
DESCRIPTION AND OPERATION SOLID STATE FAN RELAY—PCM OUTPUT . . . . 35
AIR CONDITIONING CLUTCH RELAY— SPEED CONTROL SERVOS—PCM OUTPUT . . . 30
PCM OUTPUT . . . . . . . . . . . . . . . . . . . . . . . . . 31 SPEED CONTROL—PCM INPUT . . . . . . . . . . . . 35
AIR CONDITIONING PRESSURE SYSTEM DIAGNOSIS . . . . . . . . . . . . . . . . . . . . . 23
TRANSDUCER—PCM INPUT . . . . . . . . . . . . . 25 TACHOMETER—PCM OUTPUT . . . . . . . . . . . . . 35
AUTOMATIC SHUTDOWN (ASD) SENSE— THROTTLE POSITION SENSOR—PCM INPUT . 30
PCM INPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 TORQUE CONVERTOR CLUTCH SOLENOID—
AUTOMATIC SHUTDOWN RELAY— PCM OUTPUT . . . . . . . . . . . . . . . . . . . . . . . . . 35
PCM OUTPUT . . . . . . . . . . . . . . . . . . . . . . . . . 32 VEHICLE SPEED SENSOR—PCM INPUT . . . . . 30
BATTERY TEMPERATURE SENSOR— DIAGNOSIS AND TESTING
PCM INPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 ASD AND FUEL PUMP RELAYS . . . . . . . . . . . . . 46
BATTERY VOLTAGE—PCM INPUT . . . . . . . . . . . 25 CAMSHAFT AND CRANKSHAFT POSITION
BRAKE SWITCH—PCM INPUT . . . . . . . . . . . . . . 25
SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
CAMSHAFT POSITION SENSOR—PCM INPUT . 25 ENGINE COOLANT TEMPERATURE SENSOR . . 47
CHARGING SYSTEM INDICATOR LAMP— HEATED OXYGEN SENSOR . . . . . . . . . . . . . . . 47
PCM OUTPUT . . . . . . . . . . . . . . . . . . . . . . . . . 32 IDLE AIR CONTROL (IAC) MOTOR TEST . . . . . . 47
CRANKSHAFT POSITION SENSOR— KNOCK SENSOR . . . . . . . . . . . . . . . . . . . . . . . . 47
PCM INPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 MANIFOLD ABSOLUTE PRESSURE (MAP)
DATA LINK CONNECTOR . . . . . . . . . . . . . . . . . . 33 SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
DUTY CYCLE EVAP PURGE SOLENOID— THROTTLE BODY MINIMUM AIR FLOW . . . . . . . 48
PCM OUTPUT . . . . . . . . . . . . . . . . . . . . . . . . . 32 THROTTLE POSITION SENSOR . . . . . . . . . . . . 48
ELECTRIC EGR TRANSDUCER— VEHICLE SPEED SENSOR . . . . . . . . . . . . . . . . 49
PCM OUTPUT . . . . . . . . . . . . . . . . . . . . . . . . . 32 VISUAL INSPECTION—DOHC . . . . . . . . . . . . . . 40
ENGINE COOLANT TEMPERATURE SENSOR— VISUAL INSPECTION—SOHC . . . . . . . . . . . . . . 35
PCM INPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 REMOVAL AND INSTALLATION
FUEL INJECTORS—PCM OUTPUT . . . . . . . . . . 34 AIR CLEANER ELEMENT . . . . . . . . . . . . . . . . . . 55
FUEL LEVEL SENSOR—PCM INPUT . . . . . . . . . 27 CAMSHAFT POSITION SENSOR . . . . . . . . . . . . 54
FUEL PUMP RELAY—PCM OUTPUT . . . . . . . . . 32 CRANKSHAFT POSITION SENSOR . . . . . . . . . . 54
GENERATOR FIELD—PCM OUTPUT . . . . . . . . . 33 DOWNSTREAM HEATED OXYGEN SENSOR . . . 55
HEATED OXYGEN SENSOR (O2S SENSOR)— DUTY CYCLE EVAP PURGE SOLENOID VALVE . 53
PCM INPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 ENGINE COOLANT TEMPERATURE SENSOR . . 56
IDLE AIR CONTROL MOTOR—PCM OUTPUT . . 33 IDLE AIR CONTROL MOTOR . . . . . . . . . . . . . . . 52
IGNITION CIRCUIT SENSE—PCM INPUT . . . . . 28 KNOCK SENSOR . . . . . . . . . . . . . . . . . . . . . . . . 57
IGNITION COIL—PCM OUTPUT . . . . . . . . . . . . . 34 MAP/IAT SENSOR—DOHC . . . . . . . . . . . . . . . . . 53
INTAKE AIR TEMPERATURE SENSOR— MAP/IAT SENSOR—SOHC . . . . . . . . . . . . . . . . . 53
PCM INPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 POWERTRAIN CONTROL MODULE (PCM) . . . . 54
KNOCK SENSOR—PCM INPUT . . . . . . . . . . . . . 29 THROTTLE BODY—AUTOMATIC
MALFUNCTION INDICATOR (CHECK ENGINE) TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . 50
LAMP—PCM OUTPUT . . . . . . . . . . . . . . . . . . 34 THROTTLE BODY—MANUAL TRANSMISSION . 50
MANIFOLD ABSOLUTE PRESSURE (MAP) THROTTLE POSITION SENSOR (TPS) . . . . . . . 52
SENSOR—PCM INPUT . . . . . . . . . . . . . . . . . . 29 UPSTREAM HEATED OXYGEN SENSOR . . . . . . 54
PARK/NEUTRAL POSITION SWITCH— VEHICLE SPEED SENSOR . . . . . . . . . . . . . . . . 56
PCM INPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 SPECIFICATIONS
POWER DISTRIBUTION CENTER . . . . . . . . . . . 23 TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
POWER STEERING PRESSURE SWITCH— VECI LABEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
PCM INPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 SPECIAL TOOLS
POWERTRAIN CONTROL MODULE . . . . . . . . . . 24 FUEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
GENERAL INFORMATION During CLOSED LOOP modes the PCM monitors

the inputs from the upstream and downstream
INTRODUCTION heated oxygen sensors. The upstream heated oxygen
All engines used in this section have a sequential sensor input tells the PCM if the calculated injector
Multi-Port Electronic Fuel Injection system. The MPI pulse width resulted in the ideal air-fuel ratio of 14.7
system is computer regulated and provides precise to one. By monitoring the exhaust oxygen content
air/fuel ratios for all driving conditions. The Power- through the upstream heated oxygen sensor, the
train Control Module (PCM) operates the fuel injec- PCM can fine tune injector pulse width. Fine tuning
tion system. injector pulse width allows the PCM to achieve opti-
The PCM regulates: mum fuel economy combined with low emissions.
• Ignition timing For the PCM to enter CLOSED LOOP operation,
• Air/fuel ratio the following must occur:
• Emission control devices (1) Engine coolant temperature must be over 35°F.
• Cooling fan • If the coolant is over 35° the PCM will wait 44
• Charging system seconds.
• Idle speed • If the coolant is over 50°F the PCM will wait 38
• Vehicle speed control seconds.
Various sensors provide the inputs necessary for • If the coolant is over 167°F the PCM will wait
the PCM to correctly operate these systems. In addi- 11 seconds.
tion to the sensors, various switches also provide (2) For other temperatures the PCM will interpo-
inputs to the PCM. late the correct waiting time.
All inputs to the PCM are converted into signals. (3) O2 sensor must read either greater than .745
The PCM can adapt its programming to meet chang- volts or less than .1 volt.
ing operating conditions. (4) The multi-port fuel injection systems has the
Fuel is injected into the intake port above the following modes of operation:
intake valve in precise metered amounts through • Ignition switch ON (Zero RPM)
electrically operated injectors. The PCM fires the • Engine start-up
injectors in a specific sequence. Under most operat- • Engine warm-up
ing conditions, the PCM maintains an air fuel ratio • Cruise
of 14.7 parts air to 1 part fuel by constantly adjust- • Idle
ing injector pulse width. Injector pulse width is the • Acceleration
length of time the injector is open. • Deceleration
The PCM adjusts injector pulse width by opening • Wide Open Throttle
and closing the ground path to the injector. Engine • Ignition switch OFF
RPM (speed) and manifold absolute pressure (air (5) The engine start-up (crank), engine warm-up,
density) are the primary inputs that determine injec- deceleration with fuel shutoff and wide open throttle
tor pulse width. modes are OPEN LOOP modes. Under most operat-
ing conditions, the acceleration, deceleration (with
MODES OF OPERATION A/C on), idle and cruise modes, with the engine at
As input signals to the PCM change, the PCM operating temperature are CLOSED LOOP modes.
adjusts its response to output devices. For example,
the PCM must calculate a different injector pulse IGNITION SWITCH ON (ZERO RPM) MODE
width and ignition timing for idle than it does for When the ignition switch activates the fuel injec-
Wide Open Throttle (WOT). There are several differ- tion system, the following actions occur:
ent modes of operation that determine how the PCM • The PCM monitors the engine coolant tempera-
responds to the various input signals. ture sensor and throttle position sensor input. The
There are two different areas of operation, OPEN PCM determines basic fuel injector pulse width from
LOOP and CLOSED LOOP. this input.
During OPEN LOOP modes the PCM receives • The PCM determines atmospheric air pressure
input signals and responds according to preset PCM from the MAP sensor input to modify injector pulse
programming. Inputs from the upstream and down- width.
stream heated oxygen sensors are not monitored dur- When the key is in the ON position and the engine
ing OPEN LOOP modes, except for heated oxygen is not running (zero rpm), the Auto Shutdown (ASD)
sensor diagnostics (they are checked for shorted con- and fuel pump relays de-energize after approximately
ditions at all times). 1 second. Therefore, battery voltage is not supplied to
the fuel pump, ignition coil, fuel injectors and heated
oxygen sensors.
ENGINE START-UP MODE • Power steering pressure switch
This is an OPEN LOOP mode. If the vehicle is in • Vehicle speed
park or neutral (automatic transaxles) or the clutch • Speed control
pedal is depressed (manual transaxles) the ignition • Both O2 sensors
switch energizes the starter relay. The following • All diagnostics
actions occur when the starter motor is engaged. The PCM adjusts injector pulse width and controls
• If the PCM receives the camshaft position sensor injector synchronization by turning the individual
and crankshaft position sensor signals, it energizes ground paths to the injectors On and Off.
the Auto Shutdown (ASD) and fuel pump relays. If The PCM adjusts ignition timing and engine idle
the PCM does not receive both signals within approx- speed. Engine idle speed is adjusted through the idle
imately one second, it will not energize the ASD air control motor.
relay and fuel pump relay. The ASD and fuel pump
relays supply battery voltage to the fuel pump, fuel CRUISE OR IDLE MODE
injectors, ignition coil and heated oxygen sensors. When the engine is at operating temperature this
• The PCM energizes all four injectors (on the 69° is a CLOSED LOOP mode. During cruising or idle
degree falling edge) for a calculated pulse width until the following inputs are received by the PCM:
it determines crankshaft position from the camshaft • Intake air temperature
position sensor and crankshaft position sensor sig- • Engine coolant temperature
nals. The PCM determines crankshaft position within • Manifold absolute pressure
1 engine revolution. • Crankshaft position (engine speed)
• After determining crankshaft position, the PCM • Camshaft position
begins energizing the injectors in sequence. It adjusts • Knock sensor
injector pulse width and controls injector synchroni- • Throttle position
zation by turning the individual ground paths to the • Exhaust gas oxygen content
injectors On and Off. • A/C control positions
• When the engine idles within 664 RPM of its • Power steering pressure switch
target RPM, the PCM compares current MAP sensor • Battery voltage
value with the atmospheric pressure value received • Vehicle speed
during the Ignition Switch On (zero RPM) mode. If The PCM adjusts injector pulse width and controls
the PCM does not detect a minimum difference injector synchronization by turning the individual
between the two values, it sets a MAP diagnostic ground paths to the injectors On and Off.
trouble code into memory. The PCM adjusts engine idle speed and ignition
Once the ASD and fuel pump relays have been timing. The PCM adjusts the air/fuel ratio according
energized, the PCM determines injector pulse width to the oxygen content in the exhaust gas (measured
based on the following: by the upstream and downstream heated oxygen sen-
• Battery voltage sor).
• Engine coolant temperature The PCM monitors for engine misfire. During
• Engine RPM active misfire and depending on the severity, the
• Intake air temperature (IAT) PCM either continuously illuminates or flashes the
• Throttle position malfunction indicator lamp (Check Engine light on
• The number of engine revolutions since cranking instrument panel). Also, the PCM stores an engine
was initiated misfire DTC in memory.
During Start-up the PCM maintains ignition tim- The PCM performs several diagnostic routines.
ing at 9° BTDC. They include:
• Oxygen sensor monitor
ENGINE WARM-UP MODE • Downstream heated oxygen sensor diagnostics
This is an OPEN LOOP mode. The following inputs during open loop operation (except for shorted)
are received by the PCM: • Fuel system monitor
• Engine coolant temperature • EGR monitor
• Manifold Absolute Pressure (MAP) • Purge system monitor
• Intake air temperature (IAT) • All inputs monitored for proper voltage range.
• Crankshaft position (engine speed) • All monitored components (refer to Group 25 for
• Camshaft position On-Board Diagnostics).
• Knock sensor The PCM compares the upstream and downstream
• Throttle position heated oxygen sensor inputs to measure catalytic
• A/C switch convertor efficiency. If the catalyst efficiency drops
• Battery voltage
below the minimum acceptable percentage, the PCM • Throttle position
stores a diagnostic trouble code in memory. When the PCM senses a wide-open-throttle condi-
During certain idle conditions, the PCM may enter tion through the Throttle Position Sensor (TPS) it de-
a variable idle speed strategy. During variable idle energizes the A/C compressor clutch relay. This
speed strategy the PCM adjusts engine speed based disables the air conditioning system.
on the following inputs. The PCM does not monitor the heated oxygen sen-
• A/C sense sor inputs during wide-open-throttle operation except
• Battery voltage for downstream heated oxygen sensor and both
• Battery temperature shorted diagnostics. The PCM adjusts injector pulse
• Engine coolant temperature width to supply a predetermined amount of addi-
• Engine run time tional fuel.
• Power steering pressure switch
• Vehicle mileage IGNITION SWITCH OFF MODE
When the operator turns the ignition switch to the
ACCELERATION MODE OFF position, the following occurs:
This is a CLOSED LOOP mode. The PCM recog- • All outputs are turned off, unless 02 Heater
nizes an abrupt increase in Throttle Position sensor Monitor test is being run. Refer to Group 25,
output voltage or MAP sensor output voltage as a On-Board Diagnostics.
demand for increased engine output and vehicle • No inputs are monitored except for the heated
acceleration. The PCM increases injector pulse width oxygen sensors. The PCM monitors the heating ele-
in response to increased fuel demand. ments in the oxygen sensors and then shuts down.
DECELERATION MODE
This is a CLOSED LOOP mode. During decelera- DESCRIPTION AND OPERATION
tion the following inputs are received by the PCM:
• A/C pressure transducer SYSTEM DIAGNOSIS
• A/C sense The PCM can test many of its own input and out-
• Battery voltage put circuits. If the PCM senses a fault in a major
• Intake air temperature system, the PCM stores a Diagnostic Trouble Code
• Engine coolant temperature (DTC) in memory.
• Crankshaft position (engine speed) For DTC information, refer to Group 25, Emission
• Exhaust gas oxygen content (upstream heated Control Systems. See On-Board Diagnostics.
oxygen sensor)
• Knock sensor POWER DISTRIBUTION CENTER
• Manifold absolute pressure The power distribution center (PDC) is located next
• Power steering pressure switch to the battery (Fig. 1). The PDC contains the starter
• Throttle position relay, radiator fan relay, A/C compressor clutch relay,
• IAC motor control changes in respones to MAP auto shutdown relay, fuel pump relay and several
sensor feedback fuses.
The PCM may receive a closed throttle input from
the Throttle Position Sensor (TPS) when it senses an
abrupt decrease in manifold pressure. This indicates
a hard deceleration. In response, the PCM may
momentarily turn off the injectors. This helps
improve fuel economy, emissions and engine braking.
If decel fuel shutoff is detected, downstream oxy-
gen sensor diagnostics is performed.
WIDE-OPEN-THROTTLE MODE
This is an OPEN LOOP mode. During wide-open-
throttle operation, the following inputs are received
by the PCM:
• Intake air temperature
• Engine coolant temperature
• Engine speed
• Knock sensor Fig. 1 Power Distribution Center (PDC)
• Manifold absolute pressure
POWERTRAIN CONTROL MODULE • Generator Field
The Powertrain Control Module (PCM) is a digital • Idle Air Control Motor
computer containing a microprocessor (Fig. 2). The • Ignition Coils
PCM receives input signals from various switches • Malfunction Indicator (Check Engine) Lamp
and sensors that are referred to as PCM Inputs. • Radiator Fan Relay
Based on these inputs, the PCM adjusts various • Speed Control Solenoids
engine and vehicle operations through devices that • Tachometer
are referred to as PCM Outputs. • Torque Convertor Clutch Solenoid
Based on inputs it receives, the PCM adjusts fuel
injector pulse width, idle speed, ignition spark
advance, ignition coil dwell and EVAP canister purge
operation. The PCM regulates the cooling fan, air
conditioning and speed control systems. The PCM
changes generator charge rate by adjusting the gen-
erator field. The PCM also performs diagnostics.
The PCM adjusts injector pulse width (air-fuel
ratio) based on the following inputs.
• Battery voltage
• Coolant temperature
• Intake air temperature
• Exhaust gas content (oxygen sensor)
• Engine speed (crankshaft position sensor)
• Manifold absolute pressure
• Throttle position
The PCM adjusts ignition timing based on the fol-
Fig. 2 Powertrain Control Module (PCM)
lowing inputs.
PCM Inputs: • Coolant temperature
• Air Conditioning Controls • Intake air temperature
• Battery Voltage • Engine speed (crankshaft position sensor)
• Battery Temperature Sensor • Knock sensor
• Brake Switch • Manifold absolute pressure
• Camshaft Position Sensor • Throttle position
• Crankshaft Position Sensor • Transmission gear selection (park/neutral
• Engine Coolant Temperature Sensor switch)
• Fuel Level Sensor The PCM also adjusts engine idle speed through
• Ignition Switch the idle air control motor based on the following
• Intake Air Temperature Sensor inputs.
• Knock Sensor • Air conditioning sense
• Manifold Absolute Pressure (MAP) Sensor • Battery voltage
• Oxygen Sensors • Battery temperature
• Power Steering Pressure Switch • Brake switch
• SCI Receive • Coolant temperature
• Speed Control Switches • Engine speed (crankshaft position sensor)
• Throttle Position Sensor • Engine run time
• Transmission Park/Neutral Switch (automatic • Manifold absolute pressure
transmission) • Power steering pressure switch
• Vehicle Speed Sensor • Throttle position
PCM Outputs: • Transmission gear selection (park/neutral
• Air Conditioning WOT Relay switch)
• Auto Shutdown (ASD) Relay • Vehicle distance (speed)
• Charging Indicator Lamp The Auto Shutdown (ASD) and fuel pump relays
• Data Link Connector are mounted externally, but turned on and off by the
• Duty Cycle EVAP Canister Purge Solenoid PCM.
• EGR Solenoid The crankshaft position sensor signal is sent to the
• Fuel Injectors PCM. If the PCM does not receive the signal within
• Fuel Pump Relay approximately one second of engine cranking, it deac-
tivates the ASD relay and fuel pump relay. When CAMSHAFT POSITION SENSOR—PCM INPUT
these relays deactivate, power is shut off from the The PCM determines fuel injection synchronization
fuel injectors, ignition coils, heating element in the and cylinder identification from inputs provided by
oxygen sensors and the fuel pump. the camshaft position sensor (Fig. 3) or (Fig. 4) and
The PCM contains a voltage converter that crankshaft position sensor. From the two inputs, the
changes battery voltage to a regulated 9 volts direct PCM determines crankshaft position.
current to power the camshaft position sensor, crank-
shaft position sensor and vehicle speed sensor. The
PCM also provides a 5 volt direct current supply for
the manifold absolute pressure sensor and throttle
position sensor.
AIR CONDITIONING PRESSURE TRANSDUCER—

PCM INPUT
The Powertrain Control Module (PCM) monitors
the A/C compressor discharge (high side) pressure
through the air conditioning pressure transducer.
The transducer supplies an input to the PCM. The
PCM engages the A/C compressor clutch if pressure
is sufficient for A/C system operation.
AUTOMATIC SHUTDOWN (ASD) SENSE—PCM

INPUT Fig. 3 Camshaft Position Sensor—SOHC
The ASD sense circuit informs the PCM when the
ASD relay energizes. A 12 volt signal at this input
indicates to the PCM that the ASD has been acti-
vated. This input is used only to sense that the ASD
relay is energized.
When energized, the ASD relay supplies battery
voltage to the fuel injectors, ignition coils and the
heating element in each oxygen sensor. If the PCM
does not receive 12 volts from this input after
grounding the ASD relay, it sets a Diagnostic Trouble
Code (DTC).
BATTERY VOLTAGE—PCM INPUT

The PCM monitors the battery voltage input to
determine fuel injector pulse width and generator
field control.
If battery voltage is low the PCM will increase
injector pulse width (period of time that the injector Fig. 4 Camshaft Position Sensor—DOHC
is energized). The camshaft position sensor attaches to the rear
of the cylinder head. A target magnet attaches to the
BATTERY TEMPERATURE SENSOR—PCM INPUT rear of the camshaft and indexes to the correct posi-
The PCM uses the temperature of the battery area tion. The target magnet has four different poles
to control the charge rate. The signal is used to reg- arranged in an asymmetrical pattern (Fig. 5). As the
ulate the system voltage. The system voltage is target magnet rotates, the camshaft position sensor
higher at cold temperatures and is gradually reduced senses the change in polarity (Fig. 6). The sensor out-
as temperature is increased. put switch switches from high (5.0 volts) to low (0.5
volts) as the target magnet rotates. When the north
BRAKE SWITCH—PCM INPUT pole of the target magnet passes under the sensor,
When the brake switch is activated, the PCM the output switches high. The sensor output switches
receives an input indicating that the brakes are low when the south pole of the target magnet passes
being applied. The brake switch is mounted on the underneath.
brake pedal support bracket. The sensor also acts as a thrust plate to control
camshaft endplay.
voltage switches from low (metal) to high (notch)
then back to low.
If available, an oscilloscope can display the square
wave patterns of each voltage pulses. From the width
of the output voltage pulses, the PCM calculates
engine speed. The width of the pulses represent the
amount of time the output voltage stays high before
switching back to low. The period of time the sensor
output voltage stays high before switching back to
low is referred to as pulse width. The faster the
engine is operating, the smaller the pulse width on
the oscilloscope.
By counting the pulses and referencing the pulse
from the 60 degree signature notch, the PCM calcu-
lates crankshaft angle (position). In each group of
timing reference notches, the first notch represents
69 degrees before top dead center (BTDC). The sec-
ond notch represents 49 degrees BTDC. The third
notch represents 29 degrees. The last notch in each
set represents 9 degrees before top dead center
(TDC).
The timing reference notches are machined at 20°
Fig. 5 Target Magnet—Typical increments. From the voltage pulse width the PCM
tells the difference between the timing reference
notches and the 60 degree signature notch. The 60
degree signature notch produces a longer pulse width
than the smaller timing reference notches. If the
camshaft position sensor input switches from high to
low when the 60 degree signature notch passes under
the crankshaft position sensor, the PCM knows cylin-
der number one is the next cylinder at TDC.
The crankshaft position sensor mounts to the
engine block behind the alternator, just above the oil
filter (Fig. 8).
ENGINE COOLANT TEMPERATURE SENSOR—PCM

INPUT
The combination coolant temperature sensor has
two elements. One element supplies coolant temper-
Fig. 6 Target Magnet Polarity ature signal to the PCM. The other element supplies
coolant temperature signal to the instrument panel
CRANKSHAFT POSITION SENSOR—PCM INPUT gauge cluster. The PCM determines engine coolant
The PCM determines what cylinder to fire from the temperature from the coolant temperature sensor.
crankshaft position sensor input and the camshaft As coolant temperature varies the coolant temper-
position sensor input. The second crankshaft counter- ature sensors resistance changes resulting in a differ-
weight has two sets of four timing reference notches ent input voltage to the PCM and the instrument
including a 60 degree signature notch (Fig. 7). From panel gauge cluster.
the crankshaft position sensor input the PCM deter- When the engine is cold, the PCM will provide
mines engine speed and crankshaft angle (position). slightly richer air- fuel mixtures and higher idle
The notches generate pulses from high to low in speeds until normal operating temperatures are
the crankshaft position sensor output voltage. When reached.
a metal portion of the counterweight aligns with the
crankshaft position sensor, the sensor output voltage SOHC
goes low (less than 0.5 volts). When a notch aligns The coolant sensor threads into the rear of the cyl-
with the sensor, voltage goes high (5.0 volts). As a inder head, next to the camshaft position sensor (Fig.
group of notches pass under the sensor, the output 9). New sensors have sealant applied to the threads.
Fig. 7 Timing Reference Notches

DOHC
The coolant sensor threads into the intake mani-
fold next to the thermostat housing (Fig. 10). New
sensors have sealant applied to the threads.
Fig. 8 Crankshaft Position Sensor
Fig. 10 Engine Coolant Temperature Sensor—DOHC

FUEL LEVEL SENSOR—PCM INPUT
The fuel level sensor (fuel gauge sending unit)
sends a signal to the PCM to indicate fuel level. The
purpose of this feature is to prevent a false setting of
misfire and fuel system monitor trouble codes if the
fuel level is less than approximately 15 percent of its
rated capacity. It is also used to send a signal for fuel
gauge operation via the CCD bus circuits.
HEATED OXYGEN SENSOR (O2S SENSOR)—PCM

INPUT
Fig. 9 Engine Coolant Temperature Sensor—SOHC As vehicles accumulate mileage, the catalytic con-
vertor deteriorates. The deterioration results in a
less efficient catalyst. To monitor catalytic convertor
deterioration, the fuel injection system uses two The heating element in the sensor provides heat to
heated oxygen sensors. One sensor upstream of the the sensor ceramic element. Heating the sensor
catalytic convertor, one downstream of the convertor. allows the system to enter into closed loop operation
The PCM compares the reading from the sensors to sooner. Also, it allows the system to remain in closed
calculate the catalytic convertor oxygen storage loop operation during periods of extended idle.
capacity and converter efficiency. Also, the PCM uses In Closed Loop, the PCM adjusts injector pulse
the upstream heated oxygen sensor input when width based on the upstream heated oxygen sensor
adjusting injector pulse width. input along with other inputs. In Open Loop, the
When the catalytic converter efficiency drops below PCM adjusts injector pulse width based on prepro-
emission standards, the PCM stores a diagnostic grammed (fixed) values and inputs from other sen-
trouble code and illuminates the malfunction indica- sors.
tor lamp (MIL). The upstream oxygen sensor threads into the out-
The O2S sensors produce voltages from 0 to 1 volt, let flange of the exhaust manifold (Fig. 11).
depending upon the oxygen content of the exhaust
gas in the exhaust manifold. When a large amount of
oxygen is present (caused by a lean air/fuel mixture),
the sensors produces a low voltage. When there is a
lesser amount present (rich air/fuel mixture) it pro-
duces a higher voltage. By monitoring the oxygen
content and converting it to electrical voltage, the
sensors act as a rich- lean switch.
The oxygen sensors are equipped with a heating
element that keeps the sensors at proper operating
temperature during all operating modes. Maintaining
correct sensor temperature at all times allows the
system to enter into closed loop operation sooner.
Also, it allows the system to remain in closed loop
operation during periods of extended idle.
In Closed Loop operation the PCM monitors the
O2S sensor input (along with other inputs) and Fig. 11 Upstream Heated Oxygen Sensor
adjusts the injector pulse width accordingly. During
Open Loop operation the PCM ignores the O2 sensor DOWNSTREAM OXYGEN SENSOR
input. The PCM adjusts injector pulse width based The downstream heated oxygen sensor threads into
on preprogrammed (fixed) values and inputs from the outlet pipe at the rear of the catalytic convertor
other sensors. (Fig. 12). The downstream heated oxygen sensor
The Automatic Shutdown (ASD) relay supplies bat- input is used to detect catalytic convertor deteriora-
tery voltage to both the upstream and downstream tion. As the convertor deteriorates, the input from
heated oxygen sensors. The oxygen sensors are the downstream sensor begins to match the upstream
equipped with a heating element. The heating ele- sensor input except for a slight time delay. By com-
ments reduce the time required for the sensors to paring the downstream heated oxygen sensor input
reach operating temperature. to the input from the upstream sensor, the PCM cal-
culates catalytic convertor efficiency.
UPSTREAM OXYGEN SENSOR
The input from the upstream heated oxygen sensor IGNITION CIRCUIT SENSE—PCM INPUT
tells the PCM the oxygen content of the exhaust gas. The ignition circuit sense input tells the Power-
Based on this input, the PCM fine tunes the air-fuel train Control Module (PCM) the ignition switch has
ratio by adjusting injector pulse width. energized the ignition circuit. Refer to the wiring dia-
The sensor input switches from 0 to 1 volt, depend- grams for circuit information.
ing upon the oxygen content of the exhaust gas in
the exhaust manifold. When a large amount of oxy- INTAKE AIR TEMPERATURE SENSOR—PCM INPUT
gen is present (caused by a lean air-fuel mixture), the The Intake Air Temperature (IAT) sensor measures
sensor produces voltage as low as 0.1 volt. When the temperature of the intake air as it enters the
there is a lesser amount of oxygen present (rich air- engine. The sensor supplies one of the inputs the
fuel mixture) the sensor produces a voltage as high PCM uses to determine injector pulse width and
as 1.0 volt. By monitoring the oxygen content and spark advance.
converting it to electrical voltage, the sensor acts as
a rich-lean switch.
Fig. 12 Downstream Heated Oxygen Sensor Fig. 14 MAP/Intake Air Temperature Sensor—DOHC
As Intake Air temperature varies the Intake Air
Temperature sensors resistance changes resulting in
a different input voltage to the PCM.
The IAT sensor and Manifold Absolute Pressure
(MAP) switch are a combined into a single sensor
that attachs to the intake manifold (Fig. 13) or (Fig.
14).
Fig. 15 Knock Sensor

MANIFOLD ABSOLUTE PRESSURE (MAP)
SENSOR—PCM INPUT
The PCM supplies 5 volts direct current to the
MAP sensor. The MAP sensor converts intake mani-
fold pressure into voltage. The PCM monitors the
MAP sensor output voltage. As vacuum increases,
Fig. 13 / MAP/Intake Air Temperature Sensor—SOHC
MAP sensor voltage decreases proportionately. Also,
KNOCK SENSOR—PCM INPUT as vacuum decreases, MAP sensor voltage increases
The knock sensor threads into the side of the cyl- proportionately.
inder block in front of the starter (Fig. 15). When the At key on, before the engine is started, the PCM
knock sensor detects a knock in one of the cylinders, determines atmospheric air pressure from the MAP
it sends an input signal to the PCM. In response, the sensor voltage. While the engine operates, the PCM
PCM retards ignition timing for all cylinders by a determines intake manifold pressure from the MAP
scheduled amount. sensor voltage. Based on MAP sensor voltage and
Knock sensors contain a piezoelectric material inputs from other sensors, the PCM adjusts spark
which sends an input voltage (signal) to the PCM. As advance and the air/fuel mixture.
the intensity of the engine knock vibration increases, The MAP/Intake Air Temperature sensor mounts to
the knock sensor output voltage also increases. the intake manifold (Fig. 13) and (Fig. 14).
POWER STEERING PRESSURE SWITCH—PCM PARK/NEUTRAL POSITION SWITCH—PCM INPUT
INPUT The park/neutral position switch is located on the
A pressure sensing switch is located on the power automatic transaxle housing (Fig. 17). Manual tran-
steering gear. The switch (Fig. 16) provides an input saxles do not use park/neutral switches. The switch
to the PCM during periods of high pump load and provides an input to the PCM to indicate whether
low engine RPM; such as during parking maneuvers. the automatic transaxle is in Park/Neutral, or a drive
When power steering pump pressure exceeds 2758 gear selection. This input is used to determine idle
kPa (400 psi), the switch is open. The PCM increases speed (varying with gear selection) and ignition tim-
idle air flow through the IAC motor to prevent ing advance. The park/neutral input is also used to
engine stalling. When pump pressure is low, the cancel vehicle speed control. The park/neutral switch
switch is closed. is sometimes referred to as the neutral safety switch.
Fig. 16 Power Steering Pressure Switch Fig. 17 Park/Neutral Switch

SENSOR RETURN—PCM INPUT THROTTLE POSITION SENSOR—PCM INPUT
The sensor return circuit provides a low electrical The throttle position sensor mounts to the side of
noise ground reference for all of the systems sensors. the throttle body (Fig. 18) and (Fig. 19).
The sensor return circuit connects to internal ground The Throttle Position Sensor (TPS) connects to the
circuits within the powertrain control module. throttle blade shaft. The TPS is a variable resistor
that provides the PCM with an input signal (voltage).
SPEED CONTROL SERVOS—PCM OUTPUT The signal represents throttle blade position. As the
The PCM controls the speed control vacuum servo. position of the throttle blade changes, the resistance
The PCM supplies power, through the brake switch, of the TPS changes.
to the servo. Based on the speed control switch The PCM supplies approximately 5 volts DC to the
inputs to the PCM and the speed control strategy, TPS. The TPS output voltage (input signal to the
the PCM provides ground to the servo vacuum or powertrain control module) represents throttle blade
vent circuit as required. When the PCM supplies a position. The TPS output voltage to the PCM varies
ground to the servo vacuum circuit, the speed control from approximately 0.35 to 1.03 volts at minimum
system opens the throttle plate to obtain or maintain throttle opening (idle) to a maximum of 3.1 to 4.0
the selected road speed. When the PCM supplies a volts at wide open throttle.
ground to the servo vent circuit, the speed control Along with inputs from other sensors, the PCM
system releases the throttle plate. Refer to Group 8H uses the TPS input to determine current engine oper-
for speed control information. ating conditions. The PCM also adjusts fuel injector
pulse width and ignition timing based on these
SCI RECEIVE—PCM INPUT inputs.
SCI Receive is the serial data communication
receive circuit for the DRB scan tool. The Powertrain VEHICLE SPEED SENSOR—PCM INPUT
Control Module (PCM) receives data from the DRB The vehicle speed sensor is located in the transmis-
through the SCI Receive circuit. sion extension housing (Fig. 20) and (Fig. 21). The
sensor input is used by the PCM to determine vehicle
speed and distance traveled.
• Daytime Running Lights (Canadian Vehicles
only).
Fig. 20 Vehicle Speed Sensor—Automatic

Fig. 18 Throttle Position Sensor and Idle Air Control Transmission
Motor—SOHC
Fig. 21 Vehicle Speed Sensor—Manual

Fig. 19 Throttle Position Sensor and Idle Air Control Transmission
Motor—DOHC
AIR CONDITIONING CLUTCH RELAY—PCM
The vehicle speed sensor generates 8 pulses per
OUTPUT
sensor revolution. These signals, in conjunction with
The PCM controls the air conditioning clutch relay
a closed throttle signal from the throttle position sen-
ground circuit. The A/C clutch relay coil side contains
sor, indicate a closed throttle deceleration to the
a 10 amp fuse between the buss bar in the Power
PCM. Under deceleration conditions, the PCM
Distribution Center (PDC) and the relay. The power
adjusts the Idle Air Control (IAC) motor to maintain
side of this relay is fused with a 40 amp fuse. When
a desired MAP value.
the PCM receives an air conditioning input, it
When the vehicle is stopped at idle, a closed throt-
grounds the A/C compressor clutch relay and the
tle signal is received by the PCM (but a speed sensor
radiator fan relay.
signal is not received). Under idle conditions, the
When the PCM senses low idle speeds or wide open
PCM adjusts the IAC motor to maintain a desired
throttle through the throttle position sensor, it
engine speed.
removes the ground for the A/C compressor clutch
The vehicle speed sensor signal is also used to
relay. When the relay de-energizes, the contacts open
operate the following functions or systems:
preventing air conditioning clutch engagement. Also,
• Speedometer
if the PCM senses a part throttle launch condition, it
• Speed control
disables the A/C compressor clutch for several sec- gizes the fuel pump. If the crankshaft position sensor
onds. does not detect engine rotation, the PCM de-ener-
The air conditioning clutch relay is located in the gizes the relay after approximately one second.
PDC. The inside top of the PDC cover has a label The fuel pump relay is located in the PDC. The
showing relay and fuse location. inside top of the PDC cover has a label showing relay
and fuse location.
AUTOMATIC SHUTDOWN RELAY—PCM OUTPUT
The automatic shutdown (ASD) relay supplies bat- DUTY CYCLE EVAP PURGE SOLENOID—PCM
tery voltage to the fuel injectors, electronic ignition OUTPUT
coil and the heating elements in the oxygen sensors. The duty cycle EVAP purge solenoid regulates the
A buss bar in the power distribution center (PDC) rate of vapor flow from the EVAP canister to the
supplies voltage to the solenoid side and contact side throttle body. The powertrain control module oper-
of the relay. The ASD relay power circuit contains a ates the solenoid.
20 amp fuse between the buss bar in the PDC and During the cold start warm-up period and the hot
the relay. The fuse also protects the power circuit for start time delay, the PCM does not energize the sole-
the fuel pump relay and pump. The fuse is located in noid. When de-energized, no vapors are purged.
the PDC. Refer to Group 8W, Wiring Diagrams for The engine enters closed loop operation after it
circuit information. reaches a specified temperature and the programmed
The PCM controls the relay by switching the time delay ends. During closed loop operation, the
ground path for the solenoid side of the relay on and PCM energizes and de-energizes the solenoid 5 to 10
off. The PCM turns the ground path off when the times per second, depending upon operating condi-
ignition switch is in the Off position unless the 02 tions. The PCM varies the vapor flow rate by chang-
Heater Monitor test is being run. Refer to Group 25, ing solenoid pulse width. Pulse width is the amount
On-Board Diagnostics. When the ignition switch is in of time the solenoid is energized.
the On or Crank position, the PCM monitors the The solenoid attaches to a bracket near the front
crankshaft position sensor and camshaft position sen- engine mount (Fig. 22). To operate correctly, the sole-
sor signals to determine engine speed and ignition noid must be installed with the electrical connector
timing (coil dwell). If the PCM does not receive the on top.
crankshaft position sensor and camshaft position sen-
sor signals when the ignition switch is in the Run
position, it will de- energize the ASD relay.
The ASD relay is located in the PDC. The inside
top of the PDC cover has a label showing relay and
fuse location.
CHARGING SYSTEM INDICATOR LAMP—PCM

OUTPUT
The PCM turns the instrument panel Charging
System Lamp on. Refer to Group 8C for charging sys-
tem information.
FUEL PUMP RELAY—PCM OUTPUT

The fuel pump relay supplies battery voltage to the
fuel pump. A buss bar in the Power Distribution Cen-
ter (PDC) supplies voltage to the solenoid side and
contact side of the relay. The fuel pump relay power
circuit contains a 20 amp fuse between the buss bar
in the PDC and the relay. The fuse also protects the
power circuit for the Automatic Shutdown (ASD)
relay. The fuse is located in the PDC. Refer to Group
8W, Wiring Diagrams for circuit information.
Fig. 22 Duty Cycle EVAP Purge Solenoid
The PCM controls the fuel pump relay by switch-
ing the ground path for the solenoid side of the relay ELECTRIC EGR TRANSDUCER—PCM OUTPUT
on and off. The PCM turns the ground path off when The Electric EGR Transducer contains an electri-
the ignition switch is in the Off position. When the cally operated solenoid and a back-pressure con-
ignition switch is in the On position, the PCM ener- trolled vacuum transducer (Fig. 23). The PCM
operates the solenoid based on inputs from the multi- The idle air control motor pintle protrudes into the
port fuel injection system. The transducer and EGR air bypass passage and regulates air flow through it.
valve are serviced as an assembly. The PCM adjusts engine idle speed by moving the
When the PCM energizes the solenoid, vacuum IAC motor pintle in and out of the bypass passage.
does not reach the transducer. Vacuum flows to the The adjustments are based on inputs the PCM
transducer when the PCM de-energizes the solenoid. receives. The inputs are from the throttle position
When exhaust system back-pressure becomes high sensor, crankshaft position sensor, coolant tempera-
enough, it fully closes a bleed valve in the vacuum ture sensor, MAP sensor, vehicle speed sensor and
transducer. When the PCM de-energizes the solenoid various switch operations (brake, park/neutral, air
and back-pressure closes the transducer bleed valve, conditioning).
vacuum flows through the transducer to operate the
EGR valve.
De-energizing the solenoid, but not fully closing the
transducer bleed hole (because of low back-pressure),
varies the strength of the vacuum signal applied to
the EGR valve. Varying the strength of the vacuum
signal changes the amount of EGR supplied to the
engine. This provides the correct amount of exhaust
gas recirculation for different operating conditions.
The transducer mounts to the clean air hose and
the EGR valve mount to the rear of the cylinder head
(Fig. 23).
Fig. 24 Idle Air Control Motor Air Bypass Passage—

Typical
DATA LINK CONNECTOR
The data link connector (diagnostic connector)
links the DRB scan tool with the powertrain control
module (PCM). Refer to On-Board Diagnostics in the
General Diagnosis section of this group. The data
link connector is located inside the vehicle, under the
instrument panel, left of the steering column (Fig.
25).
Fig. 23 Electric EGR Backpressure Transducer—

Typical
GENERATOR FIELD—PCM OUTPUT
The PCM regulates the charging system voltage
within a range of 12.9 to 15.0 volts. Refer to Group
8A for Battery system information and 8C for charg-
ing system information.
IDLE AIR CONTROL MOTOR—PCM OUTPUT

The Idle Air Control (IAC) motor is mounted on the
throttle body. The PCM operates the idle air control
motor (Fig. 24). The PCM adjusts engine idle speed
through the idle air control motor to compensate for
engine load, coolant temperature or barometric pres-
sure changes.
The throttle body has an air bypass passage that Fig. 25 Data Link Connector
provides air for the engine during closed throttle idle.
FUEL INJECTORS—PCM OUTPUT camshaft position sensor inputs. Refer to Auto Shut-
The 2.0L engine uses electrically operated top feed down (ASD) Relay—PCM Output in this section for
fuel injectors (Fig. 26). The Automatic Shutdown relay operation.
(ASD) relay supplies battery voltage to the fuel injec-
tors. The PCM controls the ground path for each
injector in sequence. By switching the ground paths
on and off, the PCM fine-tunes injector pulse width.
Injector pulse width refers to the amount of time an
injector operates.
The PCM determines injector synchronization from
the camshaft position sensor and crankshaft position
sensor inputs. The PCM grounds the ASD and fuel
pump relays after receiving the camshaft position
sensor and crankshaft position sensor inputs.
The PCM energizes the injectors in a sequential
order during all engine operating conditions except
start-up. For the first injector pulse width during
start-up, all injectors are energized at the same time.
Once the PCM determines crankshaft position, it
begins energizing the injectors in sequence. Fig. 27 Ignition Coil Pack—SOHC
Fig. 26 Fuel Injector Fig. 28 Ignition Coil Pack—DOHC

IGNITION COIL—PCM OUTPUT MALFUNCTION INDICATOR (CHECK ENGINE)
The coil assembly consists of 2 coils molded LAMP—PCM OUTPUT
together. The coil assembly is mounted over the valve The PCM supplies the malfunction indicator (check
cover (Fig. 27) or (Fig. 28). High tension leads route engine) lamp on/off signal to the instrument panel
to each cylinder from the coil. The coil fires two through the CCD Bus. The CCD Bus is a communi-
spark plugs every power stroke. One plug is the cyl- cations port. Various modules use the CCD Bus to
inder under compression, the other cylinder fires on exchange information.
the exhaust stroke. Coil number one fires cylinders 1 The Check Engine lamp comes on each time the
and 4. Coil number two fires cylinders 2 and 3. The ignition key is turned ON and stays on for 3 seconds
PCM determines which of the coils to charge and fire as a bulb test.
at the correct time. The Malfunction Indicator Lamp (MIL) stays on
The Auto Shutdown (ASD) relay provides battery continuously, when the PCM has entered a Limp-In
voltage to the ignition coil. The PCM provides a mode or identified a failed emission component. Dur-
ground contact (circuit) for energizing the coil. When ing Limp-in Mode, the PCM attempts to keep the
the PCM breaks the contact, the energy in the coil system operational. The MIL signals the need for
primary transfers to the secondary causing the immediate service. In limp-in mode, the PCM com-
spark. The PCM will de-energize the ASD relay if it pensates for the failure of certain components that
does not receive the crankshaft position sensor and
send incorrect signals. The PCM substitutes for the SCI RECEIVE—PCM OUTPUT
incorrect signals with inputs from other sensors. SCI Receive is the serial data communication
If the PCM detects active engine misfire severe receive circuit for the DRB scan tool. The Powertrain
enough to cause catalyst damage, it flashes the MIL. Control Module (PCM) receives data from the DRB
At the same time the PCM also sets a Diagnostic through the SCI Receive circuit.
Trouble Code (DTC).
For signals that can trigger the MIL (Check TACHOMETER—PCM OUTPUT
Engine Lamp) refer to Group 25, On-Board The PCM operates the tachometer on the instru-
Dianostics. ment panel. The PCM calculates engine RPM from
the crankshaft position sensor input.
SOLID STATE FAN RELAY—PCM OUTPUT
The radiator fan runs when coolant temperature TORQUE CONVERTOR CLUTCH SOLENOID—PCM
and A/C system pressure demand cooling. The radia- OUTPUT
tor fan circuit contains a Solid State Fan Relay Three-speed automatic transaxles use a torque con-
(SSFR). Refer to the Group 8W for a circuit sche- verter clutch solenoid. The PCM controls the engage-
matic. ment of the torque converter clutch through the
A 5 volt signal is supplied to the SSFR. The PCM solenoid (Fig. 29). The torque converter clutch is
provides a pulsed ground for the SSFR. Depending engaged up only in direct drive mode. Refer to Group
upon the amount of pulse on time, the SSFR puts out 21 for transmission information.
a proportional voltage to the fan motor at the lower
speed. For instance, if the on time is 30 percent, then
the voltage to the fan motor will be 3.6 volts.
When engine coolant reaches approximately 99°C
(210°F) the PCM grounds the SSFR relay. When the
PCM grounds the relay it operates at a 30% duty
cycle and immediately ramps up to 100% duty cycle.
The PCM de-energizes the SSFR relay when coolant
temperature drops to approximately 93°C (199°F).
Also, when the air conditioning pressure switch
closes, the PCM grounds the SSFR. The air condi-
tioning switch closes at 285 psi 610 psi. When air
conditioning pressure drops approximately 40 psi, the
pressure switch opens and the fan turns off.
The SSFR relay is located on the left front inner
frame just behind the radiator.
SPEED CONTROL—PCM INPUT Fig. 29 Torque Convertor Clutch Solenoid

The speed control system provides five separate DIAGNOSIS AND TESTING
voltages (inputs) to the Powertrain Control Module
(PCM). The voltages correspond to the ON/OFF, SET, VISUAL INSPECTION—SOHC
RESUME and CANCEL. Before diagnosing or servicing the fuel injection
The speed control ON voltage informs the PCM system, perform a visual inspection for loose, discon-
that the speed control system has been activated. nected, or misrouted wires and hoses (Fig. 30). A
The speed control SET voltage informs the PCM that thorough visual inspection that includes the following
a fixed vehicle speed has been selected. The speed checks saves unnecessary test and diagnostic time.
control RESUME voltage indicates the previous fixed (1) Inspect the battery connections. Clean corroded
speed is requested. The speed control CANCEL volt- terminals (Fig. 31).
age tells the PCM to deactivate but retain set speed (2) Check the 2 PCM 40-way connector for
in memory (same as depressing the brake pedal). The stretched wires on pushed out terminals (Fig. 31).
speed control OFF voltage tells the PCM that the
speed control system has deactivated. Refer to Group
8H for more speed control information.
Fig. 30 2.0L SOHC Engine Compartment Fig. 32 Power Distribution Center
Fig. 31 Battery, PCM, and PDC Fig. 33 Throttle Cable—Automatic Transmission

(3) Open the Power Distribution Center (PDC).
Check for blown fuses. Ensure the relays and fuses
are fully seated in the PDC (Fig. 32). A label on the
underside of the PDC cover shows the locations of
each relay and fuse.
(4) Verify the throttle cable operates freely (Fig.
33).
(5) Check the electrical connections at the idle air
control motor and throttle position sensor (Fig. 34).
(6) Check hose connections between the PCV
valve, vacuum port - intake manifold and the oil sep-
arator (Fig. 35).
(7) Inspect the electrical connections at the MAP
sensor/intake air temperature sensor and the (Fig.
36).
(8) Inspect the fuel injector electrical connections
(Fig. 37).
(9) Inspect the ignition coil electrical connector.
Ensure the spark plug insulators are firmly seated
over the spark plugs (Fig. 38). Fig. 34 Idle Air Control Motor and Throttle Position
Sensor—Typical
Fig. 37 Fuel Injectors
Fig. 35 PCV Valve
Fig. 38 Ignition Coil and Spark Plugs—Typical

(11) Check the electrical connection to the radiator
fan.
(12) Inspect for corrosion on the electrical connec-
tions at the starter motor solenoid. Check the ground
cable connection below the starter motor (Fig. 40).
Fig. 36 MAP/Intake Air Temperature Sensor
(13) Inspect the air cleaner filter element. Replace
(10) Inspect the electrical and hose connections at as necessary. Check the air induction system for
the duty cycle purge solenoid (Fig. 39). restrictions.
Fig. 39 Duty Cycle Purge Solenoid
Fig. 42 Camshaft Position Sensor and Engine

Coolant Temperature Sensor
Fig. 40 Starter Motor and Ground Strap

(14) Check the electrical connection at the knock
sensor (Fig. 41).
(15) Check the electrical connections at the cam-
shaft position sensor and engine coolant temperature
sensor (Fig. 42).
(16) Check the electrical connector at the Elec-
tronic EGR Transducer. Inspect the vacuum and back
pressure hoses at the solenoid and transducer for
leaks (Fig. 43).
(17) Inspect the electrical connections at the gen-
erator (Fig. 44). Check the generator belt for glazing
or damage. Fig. 43 Electronic EGR Transducer
(20) Check the electrical connection at the power
steering pressure switch on the power steering gear
housing (Fig. 47).
Fig. 44 Generator
(18) Inspect the electrical connector at the crank-
shaft position sensor (Fig. 45). Fig. 47 Power Steering Pressure Switch
(21) On vehicles with automatic transaxles, check
the electrical connections at the park/neutral switch
and the torque convertor clutch solenoid (Fig. 48).

(19) Check the electrical connection at the vehicle
speed sensor (Fig. 46).
Fig. 48 Park/Neutral Switch and Torque Convertor
Clutch Solenoid
(22) Inspect the electrical connections at the
upstream and downstream heated oxygen sensors
(Fig. 49) and (Fig. 50).
(23) Inspect the fuel pump module electrical con-
nection at the fuel tank for corrosion or damage (Fig.
51). Check for pinched, kinked or damaged fuel sup-
ply tube.
(24) Inspect the connections to the speed control
servo, if equipped (Fig. 31). Refer to Group 8H, Vehi-
cle Speed Control.
(25) Inspect the connection at the battery temper-
ature sensor (Fig. 52).
Fig. 46 Vehicle Speed Sensor

Fig. 49 Upstream Heated Oxygen Sensor
Fig. 52 Battery Temp. Sensor Connectors

thorough visual inspection that includes the following
checks saves unnecessary test and diagnostic time.
Fig. 50 Downstream Heated Oxygen Sensor
Fig. 53 2.0L DOHC Engine Compartment

(1) Inspect the battery connections. Clean corroded
terminals (Fig. 31).
(2) Check the 2 PCM 40-way connector for
stretched wires on pushed out terminals (Fig. 54).

VISUAL INSPECTION—DOHC
Before diagnosing or servicing the fuel injection
system, perform a visual inspection for loose, discon-
nected, or misrouted wires and hoses (Fig. 53). A
Fig. 54 Battery, PCM, and PDC Fig. 56 Throttle Cable—Automatic Transmission

(3) Open the Power Distribution Center (PDC). (5) Check the electrical connections at the idle air
Check for blown fuses. Ensure the relays and fuses control motor and throttle position sensor (Fig. 57).
are fully seated in the PDC (Fig. 55). A label on the
underside of the PDC cover shows the locations of
each relay and fuse.
Fig. 55 Power Distribution Center Fig. 57 Idle Air Control Motor and Throttle Position
(4) Verify the throttle cable operates freely (Fig. Sensor—Typical
56).
(6) Check hose connections between the PCV
valve, vacuum port - intake manifold and the oil sep-
arator (Fig. 58).
Fig. 60 Fuel Injectors—Typical
Fig. 58 PCV Valve

(7) Inspect the electrical connections at the MAP
sensor/intake air temperature sensor and the (Fig.
59).
Fig. 61 Ignition Coil and Spark Plugs
Fig. 59 MAP/Intake Air Temperature Sensor

(8) Inspect the fuel injector electrical connections
(Fig. 60).
(9) Inspect the ignition coil electrical connector.
Ensure the spark plug insulators are firmly seated
over the spark plugs (Fig. 61).
(10) Inspect the electrical and hose connections at
the duty cycle purge solenoid (Fig. 62).
(11) Check the electrical connection to the radiator
fan.
(12) Inspect for corrosion on the electrical connec-
tions at the starter motor solenoid. Check the ground
cable connection below the starter motor (Fig. 63). Fig. 62 Duty Cycle Purge Solenoid
Fig. 63 Starter Motor and Ground Strap Fig. 65 Camshaft Position Sensor
(13) Inspect the air cleaner filter element. Replace
as necessary. Check the air induction system for
restrictions.
(14) Check the electrical connection at the knock
sensor (Fig. 64).
Fig. 66 Engine Coolant Temperature Sensor

(15) Check the electrical connections at the cam-
shaft position sensor (Fig. 65) and engine coolant
temperature sensor (Fig. 66).
(16) Check the electrical connector at the Elec-
tronic EGR Transducer. Inspect the vacuum and back
pressure hoses at the solenoid and transducer for
leaks (Fig. 67).
(17) Inspect the electrical connections at the gen-
erator (Fig. 68). Check the generator belt for glazing
or damage.
Fig. 67 Electronic EGR Transducer
(19) Check the electrical connection at the vehicle
speed sensor (Fig. 70).
Fig. 68 Generator
(18) Inspect the electrical connector at the crank-
shaft position sensor (Fig. 69). Fig. 70 Vehicle Speed Sensor
(20) Check the electrical connection at the power
steering pressure switch on the power steering gear
housing (Fig. 71).
Fig. 71 Power Steering Pressure Switch

(21) On vehicles with automatic transaxles, check
the electrical connections at the park/neutral switch
and the torque convertor clutch solenoid (Fig. 72).

(23) Inspect the fuel pump module electrical con-
nection at the fuel tank for corrosion or damage (Fig.
Fig. 72 Park/Neutral Switch and Torque Convertor 75). Check for pinched, kinked or damaged fuel sup-
Clutch Solenoid ply tube.
(22) Inspect the electrical connections at the
upstream and downstream heated oxygen sensors
(Fig. 73) and (Fig. 74).

(24) Inspect the connections to the speed control
servo, if equipped (Fig. 54). Refer to Group 8H, Vehi-
Fig. 73 Upstream Heated Oxygen Sensor cle Speed Control.
Fig. 78 ASD and Fuel Pump Relay Terminals

• Terminal number 86 supplies voltage to the coil
side of the relay.
• When the PCM de-energizes the ASD and fuel
pump relays, terminal number 87A connects to termi-
Fig. 76 Battery Temp. Sensor Connectors
nal 30. This is the Off position. In the off position,
(25) Inspect the connection at the battery temper- voltage is not supplied to the rest of the circuit. Ter-
ature sensor (Fig. 76). minal 87A is the center terminal on the relay.
• When the PCM energizes the ASD and fuel
ASD AND FUEL PUMP RELAYS pump relays, terminal 87 connects to terminal 30.
The following description of operation and This is the On position. Terminal 87 supplies voltage
tests apply only to the Automatic Shutdown to the rest of the circuit.
(ASD) and fuel pump relays. The terminals on the
bottom of each relay are numbered (Fig. 77) or (Fig. TESTING
78). The following procedure applies to the ASD and
fuel pump relays.
(1) Remove relay from connector before testing.
(2) With the relay removed from the vehicle, use
an ohmmeter to check the resistance between termi-
nals 85 and 86. The resistance should be between 75
65 ohms.
(3) Connect the ohmmeter between terminals 30
and 87A. The ohmmeter should show continuity
between terminals 30 and 87A.
(4) Connect the ohmmeter between terminals 87
and 30. The ohmmeter should not show continuity at
this time.
(5) Connect one end of a jumper wire (16 gauge or
smaller) to relay terminal 85. Connect the other end
of the jumper wire to the ground side of a 12 volt
power source.
Fig. 77 ASD and Fuel Pump Relay Terminals (6) Connect one end of another jumper wire (16
gauge or smaller) to the power side of the 12 volt
OPERATION power source. Do not attach the other end of the
• Terminal number 30 is connected to battery volt- jumper wire to the relay at this time.
age. For both the ASD and fuel pump relays, termi-
nal 30 is connected to battery voltage at all times. WARNING: DO NOT ALLOW OHMMETER TO CON-
• The PCM grounds the coil side of the relay TACT TERMINALS 85 OR 86 DURING THIS TEST.
through terminal number 85.
(7) Attach the other end of the jumper wire to (2) Connect a high input impedance (digital) volt-
relay terminal 86. This activates the relay. The ohm- ohmmeter to terminals A and B (Fig. 81). The ohm-
meter should now show continuity between relay ter- meter should read as follows:
minals 87 and 30. The ohmmeter should not show • Engine/Sensor at normal operating temperature
continuity between relay terminals 87A and 30. around 200°F should read approximately 700 to
(8) Disconnect jumper wires. 1,000 ohms.
(9) Replace the relay if it did not pass the continu- • Engine/Sensor at room temperature around 70°F
ity and resistance tests. If the relay passed the tests, ohmmeter should read approximately 7,000 to 13,000
it operates properly. Check the remainder of the ASD ohms.
and fuel pump relay circuits. Refer to group 8W, Wir-
ing Diagrams.
CAMSHAFT AND CRANKSHAFT POSITION SENSOR

Refer to Group 8D, Ignition for Diagnosis and Test-
ing of Camshaft and Crankshaft Sensors.
ENGINE COOLANT TEMPERATURE SENSOR

(1) With the key off, disconnect wire harness con-
nector from coolant temperature sensor (Fig. 79) or
(Fig. 80).
Fig. 81 Engine Coolant Temperature Sensor

(3) Test the resistance of the wire harness between
the PCM 60-way connector terminal 28 and the sensor
harness connector. Also check for continuity between
PCM 60-way connector terminal 51 and the sensor har-
ness connector. Refer to Group 8W, Wiring diagrams for
circuit information. If the resistance is greater than 1
ohm, repair the wire harness as necessary.
HEATED OXYGEN SENSOR

Use an ohmmeter to test the heating element of
Fig. 79 Engine Coolant Temperature Sensor the oxygen sensors. Disconnect the electrical connec-
Location—SOHC tor from each oxygen sensor. The white wires in the
sensor connector are the power and ground circuits
for the heater. Connect the ohmmeter test leads to
terminals of the white wires in the heated oxygen
sensor connector. Replace the heated oxygen sensor if
the resistance is not between 4 and 7 ohms.
IDLE AIR CONTROL (IAC) MOTOR TEST

To preform a complete test of IAC motor and its
circuitry, refer to DRB scan tool and the appropriate
Powertrain Diagnostics Procedures manual.
KNOCK SENSOR
The engine knock sensor is affected by a number of
factors. A few of these are: ignition timing, cylinder
pressure, fuel octane, etc. The knock sensor generates
an AC voltage whose amplitude increases with the
Fig. 80 Engine Coolant Temperature Sensor increase of engine knock. The knock sensor can be
Location—DOHC tested with a digital voltmeter. The RMS voltage starts
at about 20mVac (at about 700 rpm) and increases to THROTTLE POSITION SENSOR
approximately 600 mVac (5000 rpm). If the output falls To perform a complete test of the this sensor and
outside of this range a DTC will be set. its circuitry, refer to the DRB scan tool and appropri-
ate Powertrain Diagnostics Procedures manual. To
MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR test the throttle position sensor only, refer to the fol-
To perform a complete test of the MAP sensor and lowing:
its circuitry, refer to the DRB scan tool and appropri- The Throttle Position Sensor (TPS) can be tested
ate Powertrain Diagnostics Procedures manual. To with a digital voltmeter (DVM). The center terminal
test the MAP sensor only, refer to the following: of the sensor is the output terminal. One of the other
terminals is a 5 volt supply and the remaining ter-
CAUTION: When testing the MAP sensor, be sure minal is ground.
that the harness wires are not damaged by the test Connect the DVM between the center and sensor
meter probes. ground terminal. Refer to Group 8W - Wiring Dia-
grams for correct pinout.
(1) Test the MAP sensor output voltage at the
With the ignition switch in the ON position, check
MAP sensor connector between terminals 1 and 4
the output voltage at the center terminal wire of the
(Fig. 82). With the ignition switch ON and the engine
connector. Check the output voltage at idle and at
not running, output voltage should be 4 to 5 volts.
Wide-Open-Throttle (WOT). At idle, TPS output volt-
The voltage should drop to 1.5 to 2.1 volts with a hot,
age should be approximately 0.38 volts to 1.2 volts.
neutral idle speed condition. If OK, go to next step. If
At wide open throttle, TPS output voltage should be
not OK, go to step 3.
approximately 3.1 volts to 4.4 volts. The output volt-
age should gradually increase as the throttle plate
moves slowly from idle to WOT.
Check for spread terminals at the sensor and PCM
connections before replacing the TPS.
THROTTLE BODY MINIMUM AIR FLOW

(1) Turn ignition key to Off.
(2) Disconnect the PCV valve hose from the intake
manifold nipple (Fig. 83). Cap the PCV vacuum nip-
ple.
Fig. 82 MAP Sensor Connector

(2) Test PCM terminal 36 for the same voltage
described in the previous step to verify wire harness
condition. Repair as required.
(3) Test the MAP sensor ground circuit at sensor Fig. 83 PCV Vacuum Nipple
connector terminal 1 and PCM terminal 43. If OK, go
(3) Disconnect purge hose from the nipple on the
to next step. If not OK, repair as required.
throttle body (Fig. 84).
(4) Test MAP sensor supply voltage between sen-
(4) Use a piece of hose to attach Air Metering Ori-
sor connector terminals 3 and 1 with the key ON.
fice 6457 (0.125 in. orifice) to the purge nipple on the
The voltage should be approximately 5 volts (6.5V).
throttle body (Fig. 85).
Five volts (6.5V) should also be at terminal 61 of the
(5) Ensure that all accessories are off.
PCM. If OK, replace MAP sensor. If not OK, repair or
replace the wire harness as required.
IDLE SPECIFICATION —2.0L ENGINE
Odometer Reading Idle RPM
Below 1000 Miles . . . . . . . . . . . . . . . . .550–1300 RPM
Above 1000 Miles . . . . . . . . . . . . . . . . .600–1300 Miles
(11) If idle RPM is above specifications, use the
DRB scan tool to check idle air control motor opera-
tion. If idle air control motor is OK, replace throttle
body. If idle air flow is below specification, shut off
the engine and clean the throttle body as follows:
WARNING: CLEAN THROTTLE BODY IN A WELL

VENTILATED AREA. WEAR RUBBER OR BUTYL
GLOVES, DO NOT LET MOPAR PARTS CLEANER
COME IN CONTACT WITH EYES OR SKIN. AVOID
INGESTING THE CLEANER. WASH THOROUGHLY
AFTER USING CLEANER.
Fig. 84 Purge Hose (a) Remove the throttle body from engine.
(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 bot-
tom of throttle body bore and the edges and mani-
fold 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 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 prob-
Fig. 85 Orifice 6457 Attached to Purge Nipple lem is not caused by the throttle body.
(12) Shut off engine.
(6) Connect the DRB scan tool to the data link
(13) Remove Air Metering Orifice 6457. Install
connector inside the passenger compartment.
purge hose.
(7) Run engine in Park or Neutral until the cooling
(14) Remove cap from PCV valve. Connect hose to
fan has cycled on and off at least once (180°F).
PCV valve.
(8) Using the DRB scan tool, access Minimum Air-
(15) Remove DRB scan tool.
flow Idle Speed.
(9) The following will then occur:
• Idle air control motor will fully close
VEHICLE SPEED SENSOR
To perform a complete test of the sensor and its
• Idle spark advance will become fixed
circuitry, refer to the DRB scan tool and appropriate
• PCM will go open loop enriched
Powertrain Diagnostics Procedures Manual.
• DRB scan tool displays engine RPM
(10) If idle RPM is within the range shown in the
Idle Specification chart, throttle body minimum air-
flow is set correctly.
REMOVAL AND INSTALLATION (9) Remove throttle body mounting bolts. Remove
throttle body.
THROTTLE BODY—MANUAL TRANSMISSION (10) The rubber O-ring gasket on the intake man-
Remove throttle body cables using the following ifold is reusable. Wipe the O-ring clean before install-
procedures. ing throttle body (Fig. 92).
REMOVAL INSTALLATION
(1) Remove throttle cable cover. (1) Connect the electrical connetion to the throttle
(2) Remove throttle cable from the throttle body body.
cam (Fig. 86) and (Fig. 87). (2) Install gasket.
(3) Install throttle body on intake manifold.
Tighten mounting bolts 11.8 N·m (105 in. lbs.).
(4) Attach cable mounting bracket and support
bracket with 2 screws.
(5) Connect the EVAP purge hose to the throttle
body.
(6) Install cable housing(s) retainer tabs into
bracket.
(7) If equipped with speed control, rotate the throt-
tle lever forward to the wide open position and
install speed control cable clasp (Fig. 87).
(8) Rotate throttle lever to wide open position and
install throttle cable clasp (Fig. 87).
(9) Install throttle cable cover. Tighten bolt to 4.5
N·m (40 ins. lbs.).
THROTTLE BODY—AUTOMATIC TRANSMISSION

Fig. 86 Throttle Cable Attachment to Throttle Body
REMOVAL
(1) Remove throttle cable cover.
(2) Remove throttle body cables using the following
procedures.
(3) Remove throttle cable from throttle body cam
(Fig. 88) and (Fig. 89).
Fig. 87 Disconnecting Throttle Cable

(3) Compress the retaining tabs on the cable and
slide cable out of bracket (Fig. 87).
(4) If equipped with speed control, remove speed
control cable from throttle lever by sliding clasp out
hole used for throttle cable.
(5) Remove 2 screws holding cable mounting Fig. 88 Throttle Body Cables Attachment to Throttle
bracket and support bracket. Body
(6) Remove TPS connector. (4) Compress the retaining tabs on the cable and
(7) Remove Idle Air Control motor connector. slide cable out of bracket (Fig. 89).
(8) Remove the EVAP purge hose. (5) Hold throttle lever in the wide open position.
Using finger pressure only, remove kickdown cable by
Fig. 89 Disconnecting Throttle Cable Fig. 91 Speed Control Cable Connector

PUSHING connector off the lever nail head (Fig. 88) (14) The rubber O-ring gasket on the intake man-
and (Fig. 90). DO NOT try to pull connector off per- ifold is reusable. Wipe the O-ring clean before install-
pendicular to the lever. ing throttle body (Fig. 92).
Fig. 90 Transmission Kickdown Cable Connector Fig. 92 Re-Usable Throttle Body Gasket
(6) Compress the retaining tabs on the cable and INSTALLATION
slide cable out of bracket (Fig. 89). (1) Connect electrical connection to throttle body.
(7) if equipped with speed control, hold throttle (2) Install throttle body on intake manifold.
lever in the wide open position. Using finger pressure Tighten mounting bolts 11.8 N.m (105 in. lbs.).
only, remove speed control cable by PUSHING con- (3) Attach cable mounting bracket and support
nector off the lever nail head (Fig. 88) and (Fig. 91). bracket with 2 screws.
DO NOT try to pull connector off perpendicular to (4) Connect the EVAP purge hose.
the lever. (5) Install cable housing(s) retainer tabs into
(8) Compress the retaining tabs on the cable and bracket.
slide cable out of bracket (Fig. 89). (6) Install throttle body cables using the following
(9) Remove 2 screws holding cable mounting procedures.
bracket and support bracket. (7) From the engine compartment, rotate the
(10) Remove TPS connector. throttle lever forward to the wide open position and
(11) Remove Idle Air Control motor connector. install throttle cable clasp (Fig. 89).
(12) Remove EVAP purge hose. (8) If equipped with speed control, rotate throttle
(13) Remove throttle body mounting bolts. Remove lever forward to the wide open position and slide
throttle body. speed control cable connector onto nail head.
(9) Rotate throttle lever forward to the wide open
position and slide kickdown cable connector onto nail
head.
(10) Install throttle cable cover. Tighten bolt to 5.6
N·m (50 ins. lbs.).
THROTTLE POSITION SENSOR (TPS)

The throttle position sensor attaches to the side of
the throttle body (Fig. 93).
Fig. 94 Throttle Position Sensor Installation

(4) Attach electrical connectors to idle air control
motor and throttle position sensor.
(5) Install EVAP purge hose to throttle body nip-
ple.
IDLE AIR CONTROL MOTOR

When servicing throttle body components, always
reassemble components with new O-rings and seals
Fig. 93 Throttle Position Sensor and Idle Air Control where applicable. Never use lubricants on O-rings or
Motor seals, damage may result. If assembly of component
is difficult, use water to aid assembly. Use care when
REMOVAL
removing hoses to prevent damage to hose or hose
(1) Disconnect EVAP purge hose from throttle
nipple.
body.
(2) Disconnect electrical connector from idle air REMOVAL
control motor and throttle position sensor. (1) Disconnect negative cable from battery.
(3) Remove throttle body. Refer to Throttle Body in (2) Remove throttle body. Refer to Throttle Body in
this section. this section.
(4) Remove throttle position sensor mounting (3) Remove electrical connector from idle air con-
screws. trol motor and throttle position sensor.
(5) Remove throttle position sensor. (4) Remove the EVAP purge hose from the throttle
body.
INSTALLATION
(5) Remove idle air control motor mounting screws
(1) The throttle shaft end of the throttle body
(Fig. 95).
slides into a socket in the TPS (Fig. 94). The socket
(6) Remove motor from throttle body. Ensure the
has two tabs inside it. The throttle shaft rests
O-ring is removed with the motor.
against the tabs. When indexed correctly, the TPS
can rotate clockwise a few degrees to line up the INSTALLATION
mounting screw holes with the screw holes in the (1) The new idle air control motor has a new
throttle body. The TPS has slight tension when O-ring installed on it. If pintle measures more than 1
rotated into position. If it is difficult to rotate the inch (25 mm) it must be retracted. Use the DRB Idle
TPS into position, install the sensor with the throttle Air Control Motor Open/Close Test to retract the
shaft on the other side of the tabs in the socket. pintle (battery must be connected.)
Tighten mounting screws to 2 N·m (17 in. lbs.) (2) Carefully place idle air control motor into
torque. throttle body.
(2) After installing the TPS, the throttle plate (3) Install mounting screws. Tighten screws to 2
should be closed. If the throttle plate is open, install N·m (17 in. lbs.) torque.
the sensor on the other side of the tabs in the socket. (4) Connect electrical connector to idle air control
(3) Install throttle body. Refer to Throttle Body in motor and throttle position sensor.
this section.
Fig. 95 Servicing Idle Air Control Motor Fig. 96 MAP/IAT Sensor—SOHC

(5) Install throttle body. Refer to Throttle Body in
this section.
(6) Connect the EVAP purge hose to the throttle
body nipple.
(7) Connect negative cable to battery.
MAP/IAT SENSOR—SOHC
The MAP/IAT sensor attaches to the intake mani-
fold plenum (Fig. 96).
REMOVAL
(1) Disconnect the electrical connector from the
MAP/IAT sensor.
(2) Remove sensor mounting screws.
(3) Remove sensor.
INSTALLATION
(1) Insert sensor into intake manifold while mak-
ing sure not to damage O-ring seal.
(2) Tighten mounting screws to 2 N·m (20 in. lbs)
torque for plastic manifold and 3 N·m (30 in. lbs.) for
aluminum manifold.
(3) Attach electrical connector to sensor. Fig. 97 Air Inlet Duct—DOHC
MAP/IAT SENSOR—DOHC (2) Tighten mounting screws to 2 N·m (20 in. lbs)
The MAP/IAT sensor attaches to the intake mani- torque foe a plastic manifold and 3 N·m (30 in. lbs)
fold plenum (Fig. 98). for a aluminum manifold.
(3) Attach electrical connector to sensor.
REMOVAL (4) Install air inlet duct wing nut and duct from
(1) Remove air inlet duct wing nut and duct from intake manifold, insure that the duct does not inter-
intake manifold (Fig. 97). fer with ignition cables.
(2) Disconnect the electrical connector from the
MAP/IAT sensor. DUTY CYCLE EVAP PURGE SOLENOID VALVE
(3) Remove sensor mounting screws. The solenoid attaches to a bracket near the front
(4) Remove sensor. engine mount (Fig. 99). The solenoid will not operate
unless it is installed correctly.
INSTALLATION
(1) Insert sensor into intake manifold while mak- REMOVAL
ing sure not to damage O-ring seals. (1) Disconnect electrical connector from solenoid.
(2) Disconnect vacuum tubes from solenoid.
REMOVAL
(1) Disconnect negative cable from battery.
(2) Disconnect positive cable from battery.
(3) Remove washer bottle neck.
(4) Squeeze tabs on PDC while pulling PDC up to
remove it from bracket. Lay PDC aside to gain access
to PCM bracket screws.
(5) Remove screws attaching PCM to body.
(6) Lift PCM up and disconnect the 2 40-way con-
nector.
(7) Remove PCM.
Fig. 98 MAP/IAT Sensor—DOHC
Fig. 100 Powertrain Control Module

INSTALLATION
(1) Attach the 2 40-way connector to PCM.
(2) Install PCM. Tighten mounting screws to 9
(3) Install PDC by pushing down into brackets.
(4) Install washer bottle neck.
(5) Connect positive cable to battery.
(6) Connect negative cable to battery.
CRANKSHAFT POSITION SENSOR

For removal/installation procedures refer to group
Fig. 99 Duty Cycle EVAP Purge Solenoid Valve 8D - Ignition System, Service Procedures.
(3) Remove solenoid from bracket.
CAMSHAFT POSITION SENSOR
INSTALLATION For removal/installation procedures refer to group
The top of the solenoid has TOP printed on it. The 8D - Ignition System, Service Procedures.
solenoid will not operate unless it is installed cor-
rectly. UPSTREAM HEATED OXYGEN SENSOR
(1) Install solenoid on bracket.
(2) Connect vacuum tube to solenoid. REMOVAL
(3) Connect electrical connector to solenoid. (1) Raise and support vehicle.
(2) Unplug sensor connector.
POWERTRAIN CONTROL MODULE (PCM) (3) Remove sensor using an oxygen sensor crow
The PCM attaches to the inner fender panel next foot wrench such as Snap-On tool YA8875 or equiva-
to the washer fluid bottle on the passenger side (Fig. lent (Fig. 101).
100). (4) After removing the sensor, the exhaust manifold
threads must be cleaned with an 18 mm X 1.5 + 6E tap.
If reusing the original sensor, coat the sensor threads
with an anti-seize compound such as Loctitet 771-64 or (2) Connect sensor electrical harness from clips
equivalent. along body.
(3) Connect electrical connector from sensor.
INSTALLATION (4) Lower vehicle.
New sensors have compound on the threads and do
not require an additional coating.
(1) Install sensor using an oxygen sensor crow foot
wrench such as Snap-On tool YA8875 or equivalent
(Fig. 101). Tighten the sensor to 28 N·m (20 ft. lbs.)
torque.
(2) Plug sensor connector.
(3) Lower vehicle.
Fig. 101 Upstream Heated Oxygen Sensor Removal/

Installation
DOWNSTREAM HEATED OXYGEN SENSOR
The downstream heated oxygen sensor threads into
the exhaust outlet pipe behind the catalytic convertor
(Fig. 102).
REMOVAL
(1) Raise vehicle.
(2) Disconnect electrical connector from sensor. Fig. 103 Downstream Heated Oxygen Sensor
(3) Disconnect sensor electrical harness from clips Removal/Installation
along body.
(4) Remove sensor using an oxygen sensor crow
AIR CLEANER ELEMENT
Neon vehicles do not use a heated air inlet system.
foot wrench such as Snap-On tool YA8875 or equiva-
The PCM adjusts fuel injector pulse width and igni-
lent (Fig. 103).
tion timing to compensate for different ambient tem-
(5) After removing the sensor, the exhaust mani-
peratures.
fold threads must be cleaned with an 18 mm X 1.5 +
The air cleaner attaches to a bracket on the rear of
6E tap. If reusing the original sensor, coat the sensor
the cylinder head. An ambient air duct supplies
threads with an anti-seize compound such as Loctitet
underhood air for the engine.
771-64 or equivalent.
INSTALLATION REMOVAL
(1) Remove air intake tube (Fig. 104) from air
New sensors have compound on the threads and do
cleaner and intake manifold (Fig. 105).
not require an additional coating.
(2) Unfasten clasps on top of air cleaner housing.
(1) Install sensor using an oxygen sensor crow foot
Rotate front of housing forward then lift front away
wrench such as Snap-On tool YA8875 or equivalent
from air cleaner housing (Fig. 106).
(Fig. 103). Tighten the sensor to 28 N·m (20 ft. lbs.)
torque.
INSTALLATION
(1) Install air cleaner element into front housing.
(2) Rotate front of housing forward then lower into
place and locate tabs in slots. Fasten clasps on top of
air cleaner housing.
(3) Install air intake duct at air cleaner and intake
manifold.
ENGINE COOLANT TEMPERATURE SENSOR

The engine coolant temperature sensor threads
into the rear of the cylinder head (Fig. 107) or (Fig.
108).
REMOVAL
(1) With the engine cold, drain coolant until level
drops below cylinder head. Refer to Group 7, Cooling
Fig. 104 Air Intake Duct System.
(2) Disconnect coolant sensor electrical connector.
(3) Remove coolant sensor.
INSTALLATION
(1) Install coolant sensor. Tighten sensor to 18
(2) Attach electrical connector to sensor.
(3) Fill cooling system. Refer to Group 7, Cooling
System.
Fig. 105 Removal/Installation of Air Inlet Duct
Fig. 107 Engine Coolant Temperature Sensor—

SOHC
VEHICLE SPEED SENSOR
The vehicle speed sensor is located in the transmis-
sion extension housing (Fig. 109).
REMOVAL
(1) Disconnect electrical connector from sensor.
(2) Remove the sensor mounting bolt.
Fig. 106 Removal/Installation Air Cleaner Front
(3) Lift the sensor out of the transaxle extension
Housing and Element
housing. Ensure the O-ring was removed with the
(3) Remove air cleaner element from front housing sensor.
(Fig. 106).
Fig. 108 Engine Coolant Temperature Sensor— Fig. 109 Vehicle Speed Sensor
DOHC
TORQUE
INSTALLATION
The speed sensor gear meshes with a gear on the DESCRIPTION TORQUE
output shaft. Air Cleaner Wingnut . . . . . . . . . .1.5 N·m (15 in. lbs.)
(1) With O-ring in place, install sensor. Air Cleaner Mount. Stud-To-Thrott. Body.10 N·m (90
(2) Install mounting bolt. in. lbs.)
(3) Connect electrical connector to sensor. Crankshaft Position Sensor Mounting Bolts.8 N·m (70
in. lbs.)
KNOCK SENSOR Engine Coolant Temperature Sensor .18 N·m (165 in.
For removal/installation procedures refer to Group lbs.)
8D- Ignition System, Service Procedures. IAC Motor-To-Throttle Body Bolts .7 N·m (60 in. lbs.)
MAP/IAT Sensor . . . . . . . . . . . . . .2 N·m (20 in. lbs.)
SPECIFICATIONS MAP/IAT Sensor . . . . . . . . . . . . . .3 N·m (30 in. lbs.)
Oxygen Sensor . . . . . . . . . . . . . . .28 N·m (20 ft. lbs.)
VECI LABEL Powertrain Control Module (PCM) Mounting Screws.4
If anything differs between the specifications found N·m (35 in. lbs.)
on the Vehicle Emission Control Information (VECI) Throttle Cable Cover . . . . . . . . .4.5 N·m (40 in. lbs.).
label and the following specifications, use specifica- Throttle Body Mounting Bolts . .23 N·m (200 in. lbs.)
tions on VECI label. The VECI label is located in the Throttle Position Sensor Mounting Screws .2 N·m (20
engine compartment. in. lbs.)
Vehicle Speed Sensor Mounting Bolt .2.2 N·m (20 in.
lbs.)
SPECIAL TOOLS
FUEL
Extractor C–4334
Pressure Gauge Assembly C–4799–B
SPECIAL TOOLS (Continued)
Fuel Line Tool
Fuel Pressure Test Adapter 6539
Fuel Line Adapter
Spanner Wrench 6856
Fuel Line Adapter 1/4
Metering Orifice
O2S (Oxygen Sensor) Remover/Installer—C-4907

Epl 14 PDF

Încărcat de

Informații document

Titlu original

Drepturi de autor

Formate disponibile

Partajați acest document

Partajați sau inserați document

Opțiuni de partajare

Vi se pare util acest document?

Este necorespunzător acest conținut?

Drepturi de autor:

Formate disponibile

Epl 14 PDF

Încărcat de

Drepturi de autor:

Formate disponibile

PL FUEL SYSTEM 14 - 1

FUEL DELIVERY SYSTEM . . . . . . . . . . . . . . . . . . . 3 GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . 1

GENERAL INFORMATION INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . 1

GENERAL INFORMATION dealer immediately. Engine damage as a result of

PCM REPLACEMENT GASOLINE/OXYGENATE BLENDS

FUEL DELIVERY SYSTEM

DESCRIPTION AND OPERATION HOSES AND CLAMPS . . . . . . . . . . . . . . . . . . . . 10

DESCRIPTION AND OPERATION • Electric fuel pump

FUEL PUMP MODULE

FUEL GAUGE SENDING UNIT

Fig. 3 Fuel Rail—Typical

CAUTION: The interior components (o-rings, spac-

Fuel tubes connect fuel system components with

CAUTION: Quick-connect fittings are not serviced

Fig. 8 Checking Fuel Pressure at Intake Manifold—

FUEL LEVEL SENSOR

Fig. 9 Fuel Pressure Diagnosis Chart

Fig. 10 Level Sensor Diagnosis

FUEL INJECTOR DIAGNOSIS

(1) Disconnect negative cable from battery.

Fig. 12 Releasing Fuel Pressure

Fig. 11 Fuel Pressure Test Port—Typical

CAUTION: Never install a quick-connect fitting

(2) Disconnect fuel line from fuel pump module by

(1) Refer to Fuel System Pressure Release in the

Fig. 20 Inlet Strainer Removal

FUEL LEVEL SENSOR

Fig. 19 Spring Tab In Locating Slot

Fig. 22 Wire Terminal Locking Wedge

Fig. 23 Wire Terminal Locking Finger

Fig. 26 Level Sensor Removal/Installation

Fig. 30 Fuel Tank

WARNING: WRAP SHOP TOWELS AROUND

(4) Disconnect fuel pump module electrical connec-

FUEL FILLER NECK

Fig. 31 Fuel Pump Module Electrical Connector

Fig. 33 Fuel Filler Neck

CAUTION: When using the ASD Fuel System Test, the

Fig. 35 Accelerator Pedal and Throttle Cable—Front

THROTTLE CABLE—AUTOMATIC TRANSMISSION

Fig. 38 Throttle Cable Attachment to Throttle Body

Fig. 40 Throttle Body Cables Attachment to Throttle

Fig. 39 Disconnecting Throttle Cable

FUEL INJECTION SYSTEM

GENERAL INFORMATION SCI RECEIVE—PCM INPUT . . . . . . . . . . . . . . . . 30

GENERAL INFORMATION During CLOSED LOOP modes the PCM monitors

AIR CONDITIONING PRESSURE TRANSDUCER—

AUTOMATIC SHUTDOWN (ASD) SENSE—PCM

BATTERY VOLTAGE—PCM INPUT

ENGINE COOLANT TEMPERATURE SENSOR—PCM

Fig. 7 Timing Reference Notches

Fig. 8 Crankshaft Position Sensor

Fig. 10 Engine Coolant Temperature Sensor—DOHC

HEATED OXYGEN SENSOR (O2S SENSOR)—PCM

Fig. 15 Knock Sensor

Fig. 16 Power Steering Pressure Switch Fig. 17 Park/Neutral Switch

Fig. 20 Vehicle Speed Sensor—Automatic

Fig. 21 Vehicle Speed Sensor—Manual

CHARGING SYSTEM INDICATOR LAMP—PCM

FUEL PUMP RELAY—PCM OUTPUT

Fig. 24 Idle Air Control Motor Air Bypass Passage—

Fig. 23 Electric EGR Backpressure Transducer—

IDLE AIR CONTROL MOTOR—PCM OUTPUT