Chrysler Cirrus, Dodge Stratus, Plymouth Breeze Haynes. Instruction - page 19

4-10

Chapter 4 Fuel and exhaust systems

9.2 Four-cylinder engines - air inlet resonator clamp

at the throttle body

9.4a Loosening the air duct clamp at the air filter housing

(V6 engine shown, others similar)

the housing and remove it from the engine

vehicle, use pliers to compress the cable

compartment.

retainer clips, then push the cable retainer
out of the accelerator pedal arm. Next, slide
the cable out of the slot in the accelerator
pedal arm (see illustration).
7

Push the cable through the firewall into

the engine compartment and remove it from
the vehicle.
8

Installation is the reverse of removal.

2

On four-cylinder engines, loosen the

clamp and detach the air inlet resonator from

the throttle body (see illustration).
3

On four-cylinder engines, loosen the air

duct clamp at the air cleaner housing and

remove the air ducting with air inlet resonator

attached.
4

On V6 engines, loosen the air duct

clamps at the air cleaner housing and throttle

body (see illustrations) then remove the air

ducting with air inlet resonator attached.

Installation

5

Installation is the reverse of removal.

Air filter housing

Removal

Refer

to illustration 9.8

6

Loosen the air duct clamp and detach it

from the air cleaner top cover (see illustra-
tion 9.4a).
7

Remove the air filter top cover and filter

element (see Chapter 1 if necessary).
8

Remove the three bolts securing the air

filter lower housing to the inner fender panel
(see illustration).
9

Detach the air inlet duct at the front of

Installation

10 Installation is the reverse of removal.
Make sure the lower housing is free of dirt
and contamination prior to installation.

10 Accelerator cable - replacement

information

The sequential Multi-Port Fuel Injection

( MPFI) system consists of three sub-systems:
air intake, engine control and fuel delivery.

The MPFI system is controlled by the Power-
train Control Module (PCM) which uses the

information from various sensors to deter-
mine the proper air/fuel ratio under all operat-
ing conditions.

The fuel injection system, emissions and

engine control systems work together to pro-
vide maximum performance, fuel economy
and the lowest exhaust emissions. For com-
plete information on the emissions and
engine control system, refer to Chapter 6.

Refer

to illustrations 10.2, 10.3, 10.4, 10.5

11

Fuel injection system - general

and 10.6

1

On four-cylinder engines, remove the air

cleaner assembly (see Section 9).
2

Rotate the throttle valve cam to the full

throttle position and disconnect the accelera-
tor cable from the slot in the throttle valve
cam (see illustration).
3

On four-cylinder engines, compress the

cable retaining tabs and push the accelerator
cable out of the bracket (see illustration).
4

On V6 engines, compress the cable

retaining tab and slide the cable out of the
side of the bracket (see illustration).
5

Disconnect the accelerator cable from

the bracket on the firewall (see illustration).
6

At the accelerator pedal arm inside the

9.4b Loosening the air duct clamp at

the throttle body (V6 engine)

9.8 Remove the three bolts then remove

the air filter lower housing from

the fender panel

10.2 Disconnecting the accelerator cable

from the throttle lever at the throttle body

(V6 engine shown)

Chapter 4 Fuel and exhaust systems

4-11

10.3 On four-cylinder engines, after detaching the cable from the

throttle lever, compress the tab on the cable outer housing

and push it through the bracket

10.4 On V6 engines, compress the retaining tab on the cable

housing and slide the cable from the bracket

Air intake system

The air intake system consists of the air

filter, the air ducts, air inlet resonator, the
throttle body, the idle control system and the

intake manifold.

The engine idle speed is controlled by

the PCM via the Idle Air Control (IAC) motor.
The IAC motor regulates the flow of air
allowed to by-pass the throttle valve in the
throttle body thereby increasing engine
speed. The PCM uses information from vari-
ous sensors to determine the correct amount
of airflow required to maintain the proper
engine speed during engine warm-up and
when a load is placed on the engine, such as
engaging the air conditioning compressor,

low speed steering or when an automatic

transaxle is placed in gear.

Engine control system

For information on the engine control

system, refer to Chapter 6.

Fuel delivery system

The fuel delivery system consists of the

following components: an electric fuel pump,
a fuel pressure regulator, an in-line fuel filter,
the fuel rail, the fuel injectors, various metal
and plastic lines, the Automatic Shutdown

(ASD) relay and the fuel pump relay.

The fuel pump and fuel pressure regula-

tor are located inside the fuel tank. Fuel is

drawn through the fuel inlet strainer into the
pump, pumped past the fuel pressure regula-
tor, then through the fuel filter and delivered

to the injectors.

The fuel pressure regulator maintains a

constant fuel pressure to the injectors.
Excess fuel is released back into the fuel tank
through the fuel pressure regulator. This sys-
tem is called a "returnless" system.

The fuel rail supplies the regulated fuel

to each electronically controlled fuel injector.

The injectors are solenoid types consisting of

a solenoid, plunger, needle valve and hous-
ing. When the PCM sends a voltage signal to

the fuel injector, the needle valve raises off its

seat and lets metered fuel enter the intake

4

10.5 Accelerator cable bracket at firewall (V6 engine shown,

typical routing for all models)

10.6 Use pliers to compress the cable retainer tabs and push the

cable retainer from the accelerator pedal arm, then remove the

cable through the slot in the pedal arm and remove the

cable from inside the engine compartment

4-12

Chapter 4 Fuel and

exhaust systems

manifold. The injection quantity is determined
by the length of time which current is sup-
plied to the injector.

The Automatic Shutdown (ASD) and the

fuel pump relays are located in the Power

Distribution Center, which is located in the

engine compartment on the left (driver's)
side. The ASD relay connects battery voltage
to the fuel injectors and the ignition coil while
the fuel pump relay connects battery voltage
only to the fuel pump. If the PCM senses
there is NO signal from the camshaft or
crankshaft sensors while the ignition key is
RUN or cranking, the PCM will de-energize
both relays in approximately one second.

12 Fuel injection system - general

check

Refer to illustration 12.6
Warning: Gasoline is extremely flammable,

so take extra precautions when you work on
any part of the fuel system)
see the Warning
in Section 2).

Note: The following procedure is based on
the assumption that the fuel pump/pressure

is acceptable (see Section 3).

1

Visually check all electrical connectors

that are related to the system. Check ground
wire connections on the intake manifold and
engine for tightness. Loose connectors and

poor grounds can cause many problems that
resemble more serious component malfunc-

tions.
2

Check to see that the battery is fully

charged, as the PCM and information sen-
sors depend on proper battery voltage in
order to operate correctly.
3

Check the air filter element - a dirty or

partially blocked filter will severely impede
performance and economy (see Chapter 1).
4

Check the air intake ducts for cracks or

loose connections. Also check the condition
of all vacuum hoses connected to the intake
manifold. Make sure they fit tightly on the
vacuum ports and are free from cracks or
other defects.
5

Remove the air intake duct (V6 engine)

or air inlet resonator (four-cylinder engines)
from the throttle body and inspect for dirt,
carbon or other residue build-up around the
throttle valve and Idle Air Control by-pass
port. If the throttle body is dirty, clean it with
a spray-type carburetor cleaner and a tooth-
brush or clean rag. Note: If the throttle body
cannot be cleaned properly while installed on
the vehicle, remove it
(see Section 13).
6

With the engine running, place an auto-

motive stethoscope against each injector,
one at a time, and listen for a clicking sound,
indicating operation (see illustration). If you
don't have a stethoscope, place the tip of a
screwdriver against the injector and listen
through the handle. Note: On V6 engines, the

air inlet resonator must be removed to access

the left bank of fuel injectors. The right bank

of fuel injectors CANNOT be checked using

this procedure, as they are covered by the

upper intake manifold.

12.6 Use a stethoscope to determine if

the injectors are working properly - they

should make a steady clicking sound

that rises and falls with engine speed

changes (V6 engine shown)

7

Individual component checks can be

found in their appropriate Sections.

13 Throttle body - check, removal

and installation

Check

1

Remove the air cleaner assembly (see

Section 9).
2

Verify the accelerator cable, cruise con-

trol cable (if equipped) and throttle valve

operate smoothly without binding or sticking.
3

Inspect the throttle bore, throttle valve,

IAC by-pass port and canister purge vacuum
port for carbon deposits. If carbon build-up is
present, remove the throttle body from the

vehicle (see below) and remove the IAC

motor (see Section 17). Clean the throttle
body and IAC motor pintle with a spray-type

carburetor cleaner and a toothbrush.
4

If the throttle valve does not operate

freely after cleaning, replace the throttle
body.

13.10a Four-cylinder engine IAC,

TPS and throttle body bolts

1

Idle Air Control motor

2

Throttle Position Sensor

3

Throttle body bolts

13.7 Disconnect the canister purge

control vacuum hose from the throttle

body (V6 engine shown, others similar)

Removal

Refer to illustrations 13.7, 13.10a, 13.10b and

13.11

Warning: Wait until the engine is completely
cool before beginning this procedure.
5

Disconnect the negative battery cable

from the ground stud on the left shock tower.
6

Remove the air cleaner assembly (see

Section 9).
7

Disconnect the canister purge vacuum

hose from the throttle body (see illustration).
8

Detach the accelerator cable and cruise

control cable (if equipped), from the throttle
valve lever (see Section 10).
9

On four-cylinder engines, remove the

accelerator and cruise control cable bracket
and position the bracket (with cable) out of
the way.
10

Disconnect the TPS and IAC sensor

connectors from the throttle body, remove

the mounting bolts and then withdraw the
throttle body and gasket from the manifold

(see illustrations).
11

The throttle body 0-ring seal on 2.0L

four-cylinder engines is reusable (see illus-
tration).
Remove it from the manifold and

13.10b V6 engine IAC, TPS and throttle

body bolts

1

Throttle Position Sensor

2

Idle Air Control motor

3

Throttle body bolts

Chapter 4 Fuel and exhaust systems

4®13

inspect it for hardness and cracks. If visual
inspection does not reveal any defects, the
0-ring seal may be reused.
12

On all other models, remove all traces of

gasket material from the throttle body and
manifold.
13 If necessary, clean the throttle body as

outlined in Step 3.

Installation

14 Install the throttle body with a new gas-
ket (2.0L four-cylinder engines may reuse the

0-ring seal) onto the intake manifold.

15

Tighten the throttle body mounting bolts

to the torque listed in this Chapter's Specifi-
cations.

16

The remaining installation steps are the

reverse of removal. After installation, check to
see that the throttle body operates freely.

14 Fuel pressure regulator and fuel

inlet strainer - replacement

Warning: Gasoline is extremely flammable,
so take extra precautions when you work on
any part of the fuel system (see the
Warning
in Section 2).
Note: The fuel pump module consists of the
following components; fuel pump, fuel pres-
sure regulator, fuel inlet strainer and fuel level
sending unit.

Fuel pressure regulator

Replacement

Refer to illustrations 14.3a, 14.3b and 14.4
1

Perform the fuel pressure relief proce-

dure (see Section 2).
2

Remove the fuel pump module (see

Section 7).
3

Spread the tabs on the pressure regula-

tor retainer and remove the retainer, then
carefully pry the pressure regulator out of the
fuel pump module housing (see illustra-
tions).
Ensure that both upper and lower
0-ring seals come out with the regulator. Dis -

13.11 On 2.0L four-cylinder engines, the

throttle body 0-ring gasket (arrow)

is reusable

card the old 0-ring seals.
4

Apply a light coat of clean engine oil to

the new 0-ring seals and install them in the
receptacle in the fuel pump module (see
illustration).
Ensure they are properly seated.
5

Install the new pressure regulator into

the fuel pump module.
6

Install the regulator retainer and fold the

retainer tangs over the tabs on the fuel pump
module. Make sure the retainer is securely
attached.
7

Install the fuel pump module (see Sec-

tion 7).

Fuel inlet strainer

Replacement

Refer to illustration 14.10
8

Perform the fuel pressure relief proce-

dure (see Section 2).
9

Remove the fuel pump module (see

Section 7).
10

Using a flat-blade screwdriver, pry the

tangs on the fuel inlet strainer away from the
tabs on the fuel pump reservoir and remove
the strainer and 0-ring seal (see illustration).
11

Before installing the new 0-ring seal,

apply a light coating of clean engine oil to the

14.3a Spread the four tabs and remove

the retainer

14.3b Using a screwdriver, carefully pry

the fuel pressure regulator out of

the fuel pump module

0-ring seal and install it in onto the fuel pump
reservoir.

12 Install the fuel inlet strainer onto the fuel

pump reservoir and make sure it is securely
locked in place.

13 Install the fuel

pump

module (see Sec-

tion 7).

4

LOWER 0-RING

14.4 Apply a light coating of clean engine oil to the new 0-ring

seals and install them into the fuel pump module

14.10 To remove the inlet strainer, use a screwdriver to pry the

retaining tabs away from the fuel pump module

and then detach the strainer

4-14

Chapter 4 Fuel and exhaust systems

15 Fuel filter - removal and

installation

Warning: Gasoline is extremely flammable,

so take extra precautions when you work on
any part of the fuel system (see the
Warning
in Section 2).

Removal

Refer to illustration. 15.1

1

The in-line fuel filter mounts to the frame

above the rear of the fuel tank, near the filler

neck (see illustration).

2

Remove the fuel tank filler cap to relieve

fuel tank pressure.
3

Perform the fuel pressure relief proce-

dure (see Section 2).
4

Disconnect the negative battery cable

from the ground stud on the left shock tower
(see Chapter 5, Section 1).
5

Working inside the trunk, fold back the

trunk mat near the base of the left shock
tower. Locate the fuel pump wiring harness
4-pin connector and disconnect it from the
wiring harness (see illustration 2.3). Follow
the fuel pump wiring to the grommet at the
base of the rear seat. Tie a length of string to
the fuel pump wiring harness and secure the
other end somewhere in the trunk (this will
allow you to easily retrieve the wiring har-
ness). Push the grommet through the floor-
pan and feed the wiring and 4 pin connector
through the hole.
6

Raise the vehicle and support it securely

on jackstands.
7

Position an approved gasoline container

under the fuel tank drain plug. If necessary,
use a funnel to prevent spilling fuel. Warning:
The fuel tank capacity is 16 gallons. Unless
the fuel tank is almost empty, be prepared to
collect a significant amount of fuel.
Do not

leave the fuel tank draining operation unat-

tended. Be prepared to replace the drain plug

in case the fuel tank capacity exceeds the

container capacity. Remove the drain plug
(see illustration 5.6) and drain the fuel into

the container.

8

After the fuel has finished draining, rein-

stall the drain plug and tighten it to the torque

li sted in this Chapter's Specifications.
9

Support the fuel tank with a floor jack.

Place a piece of wood between the jack head

and the fuel tank to protect the tank.

10

Remove the driver's side fuel tank strap

(the long strap).

11

Loosen, but do not remove, the passen-

ger side fuel tank strap so the fuel tank filler
neck just touches the rear suspension cross-
member. Caution: Do not let the weight of
the fuel tank rest on the filler
neck! Support it
with the jack at all times.

12

Label and disconnect the quick-connect

fuel line fittings (see Section 4 if necessary)
connecting the fuel filter to the fuel system.
13

Detach the fuel filter from its mounting

and remove it from the vehicle.

Installation

14 Installation is the reverse of removal.

15.1 The fuel filter (arrow) is tucked up

behind the fuel tank and mounted to

the frame above the rear

suspension crossmember

15

Assemble the fuel line quick-connect fit-

tings as described in Section 4. Verify the fit-
tings are securely assembled by trying to pull
them apart. Note: The fuel filter larger line fit-
ting attaches to the fuel pump module "sup-
ply" port and the smaller fitting attaches to
the "return" port.

16

Tighten the fuel tank strap bolts to the

torque given in this Chapter's Specifications.

17

Pressurize the system and check for

leaks.

16 Fuel rail and injectors - check,

removal and installation

Warning: Gasoline is extremely flammable,
so take extra precautions when you work on
any part of the fuel system (see the
Warning
in Section 2).

Fuel injector operation check

Refer to illustrations 16.6 and 16.7
1

Start the engine and allow it warm up to

normal operating temperature.
2

Remove the air cleaner assembly (see

Section 9).
3

If the vehicle is not equipped with a

tachometer, connect one to the engine in

accordance with the tool manufacturer's
instructions.
4

Make sure all test equipment is posi-

tioned away from the drivebelts and cooling
fans, then start the engine. With the engine

idling, detach each fuel injector electrical

connector one-at-a-time, and note the rpm
change on the tachometer, then reconnect
the injector. Note: On V6 engines, this test
can only be applied to the left bank of fuel
injectors and only after removing the air inlet
resonator (see Section 9). If the rpm change

is approximately the same for each cylinder,

the injectors are operating correctly. If dis-
connecting a particular injector fails to

16.6 Measure the resistance of each

injector. It should be approximately

12 ohms

change the engine rpm, proceed to the next
Step. If the fuel injectors are operating prop-
erly, check the ignition system (see Chap-

ter 5), condition of the spark plugs and wires

(see Chapter 1) and, if necessary, perform a

compression check (see Chapter 2C) to
determine the cause of the dead cylinder.
5

On V6 engines, remove the upper intake

manifold (see Chapter 2B).

6

Disconnect the injector electrical con-

nectors and using an ohmmeter, measure the

resistance of each injector (see illustration).
Compare the measured resistance to the
value given this Chapter's Specifications. If
the resistance is not within specifications,
replace the injector.
7

If the resistance is as specified, connect

a special injector harness test light (com-
monly known as a "noid light" which is avail-
able at most auto parts stores) to the injector
electrical connector (see illustration). If the
li ght flashes, the injector is receiving voltage.
If there is no voltage, check the ASD relay
operation (see Section 3). If the ASD relay is
OK, check the injector wiring circuit for a
short, a break in the wire or a bad connection
(see Chapter 12 if necessary).
8

With the electrical connector removed

from the injector, use a fused jumper wire to
connect one terminal of the injector to the
positive remote terminal of the battery near
the Power Distribution Center (PDC). Attach
another jumper wire to the other terminal on
the fuel injector. Make sure the jumper wires
are properly insulated from each other! Using
the grounded jumper wire, quickly connect
and disconnect it to a solid ground on the
engine. Note: Do not subject the fuel injector
to battery voltage any longer than necessary.
Each time the injector is energized and de-
energized, the injector should make an audi-
ble "clicking" sound. If no sound is heard.
replace the injector. Repeat the test for each
injector.

9

If the fuel injectors are operating prop-

erly, install all removed components in the

reverse order of removal.

Chapter 4 Fuel and exhaust systems

4-15

16.7 Install a "noid" light (available at most auto part stores) into

each injector electrical connector and confirm that it illuminates

when the engine is cranking or running

16.21a Disconnecting the fuel supply line quick-connect fitting at

the fuel rail (four-cylinder engine shown)

Fuel injector leak check

Warning: Wear eye protection during this
check.
Note: After identifying that a fuel injector is
leaking (see Section 3),
use the following pro-
cedure to determine which one (or more) of
the fuel injectors is defective.
10

Perform the fuel pressure relief proce-

dure (see Section 2).
11

Remove the fuel rail and injector assem-

bly from the intake manifold as described
below, however, do not disconnect the fuel
supply line or the fuel injectors from the fuel
rail.
12

With the fuel rail resting on the intake

manifold (injectors nozzles exposed), place
some clean shop rags under the fuel injectors

to catch the fuel that will leak out of the

defective injectors ).
13

Attach the fuel pump module electrical

connector to the wiring harness and the bat-

tery negative cable to the remote battery ter-

minal.
14

Turn the ignition key to the ON position

(engine OFF) several times to pressurize the
fuel system. Warning: Do not crank the
engine over.
With the system under pressure,
inspect each injector for fuel leaking out of
the nozzle. Label the faulty injectors ).
15

Next, relieve the fuel pressure via a

faulty fuel injector by using a small Phillips
head screwdriver (or equivalent) to push the
injector pintle off its seat to release the fuel
pressure through the injector nozzle. Wrap a
dry shop rag around the faulty injector to
catch the fuel as it escapes.
16

Once the fuel pressure has been

relieved, detach the fuel supply line quick-
connect fitting from the fuel rail (see Section
4 if necessary) and replace the faulty fuel
injector(s) (see below).

Removal

Refer to illustrations 16.21a, 16.21b, 16.24a,

16.24b, 16.25a, 16.25b, 16.25c, 16.26a,
16.26b and 16.26c
17

Perform the fuel pressure relief proce

-

dure (see Section 2).

18

Disconnect the negative battery cable

from the ground stud on the left shock tower
(see Chapter 5, Section 1).

19

Remove the air cleaner assembly (see

Section 9).
20

On V6 engines, remove the upper intake

manifold (see Chapter 2B).
21

Detach the fuel supply line quick-con-

nector fitting (see Section 4 if necessary) from
the fuel rail (see illustrations).
22

Disconnect the wiring harness electrical

connectors from the fuel injectors. Clearly
label and remove any vacuum hoses or elec-
trical wiring that will interfere with the fuel rail
removal.
23

Clean the injector-to-manifold area

using compressed air (a can of compressed-
gas duster like those used to blow out electri-
cal components will work just as well) or
spray-type carburetor cleaner to remove any
dirt or debris from around the injectors.
24

Remove the fuel rail mounting bolts (see

illustrations).
25

Remove the fuel rail assembly (with the

fuel injectors attached) from the engine (see

4

16.21b Disconnecting the fuel supply line quick-connect fitting at

the fuel rail (V6 engine shown)

16.24a Fuel rail mounting bolts (arrows) (four-cylinder engines)

4-16

Chapter 4 Fuel and exhaust systems

16.24b Fuel rail mounting bolts (arrows) (V6 engine)

16.25a Removing the fuel rail/injectors (four-cylinder engines)

16.25c On V6 engines, these plastic spacers must be installed

between the fuel rail and the lower intake manifold

16.25b Removing the fuel rail/injectors (V6 engine)

illustrations). Note: On V6 engines, there are
spacers located between the fuel rail and the
lower intake manifold, if they become dis-
lodged, make
sure you reinstall them (see

illustration).

26

Remove the retaining clips and with-

seal, it's standard practice to replace all 0-

draw the injectors from the fuel rail (see illus-

ring seals at this time.

trations). Remove the 0-ring seals and dis-

27

On V6 engines, clean and inspect the

card them (see illustration). Note: Whether

upper-to-lower manifold gasket surfaces (see

you're replacing an injector or a bad 0-ring

Chapter 2B).

16.26a Using a screwdriver or pliers,

remove the injector retaining clip securing

the injector to the fuel rail .. .

16.26b ... then withdraw the injector

from the fuel rail

16.26c Remove the old 0-ring seals from

the fuel injector and discard them

Chapter 4 Fuel and exhaust systems

4-17

Installation

28

Apply a light coating of clean engine oil

to the new 0-ring seals and carefully install
them onto the injectors.
29 Insert each injector into its correspond-
ing bore in the fuel rail. Position the electrical
terminals appropriately and secure the fuel
injectors to the fuel rail with the retaining
clips.
30

On V6 engines, make sure the fuel rail

spacers are installed (see illustration 16.25c).
31

Apply a light coating of clean engine oil

to the injector-to-manifold 0-ring seals and
install the injector/fuel rail assembly onto the
intake manifold. Make sure the injectors are
fully seated, then tighten the fuel rail mount-
ing bolts to the torque listed in this Chapter's
Specifications.
32

Connect the fuel supply line quick-con-

nect fitting to the fuel rail (see Section 4).
33

Attach the fuel pump module electrical

connector to the wiring harness and the bat-
tery negative cable to the ground stud on the
left shock tower.
34

Turn the ignition key to the ON position

(engine OFF) several times to pressurize the

fuel system. Inspect the fuel rail and injectors
for leaks. If leakage is evident, perform the
fuel pressure relief procedure (see Section 2)

and rectify the problem. Warning: On V6

engines, before performing the fuel relief pro-
cedure, disconnect the spark plug wires from

the spark plugs and make sure all loose

objects or rags have been removed from
inside or around the lower intake manifold
ports.
35

The remaining installation steps are the

reverse of removal. On V6 engines, make

sure to install a new upper intake manifold
gasket and tighten the upper intake manifold

bolts to the torque listed in the Chapter 2B

Specifications.

17 Idle Air Control (IAC) motor -

check and replacement

General description

The engine idle speed is controlled by

the PCM via the Idle Air Control motor. The
IAC motor regulates the flow of air allowed to
by-pass the throttle valve in the throttle body
thereby increasing engine speed. The PCM
uses information from various sensors to
determine the correct amount of airflow
required to maintain the proper engine speed
during engine warm-up and when a load is
placed on the engine, such as engaging the
air conditioning compressor, low speed
steering or when an automatic transaxle is
placed in gear.

Check

1

Run the engine until it reaches normal

operating temperature, then shut off the
engine.
2

Locate a vacuum fitting on the intake

manifold. Remove the hose from the fitting

and attach a vacuum gauge in its place. Posi-
tion the vacuum gauge so you can see it from
inside the vehicle.
3

If the vehicle is not equipped with a

tachometer, connect one to the engine per
the manufacturer's instructions and place it
so you can see the meter from inside the
vehicle.
4

Inside the vehicle, start the engine and

note the reading on the vacuum gauge and
the engine speed on the tachometer.
5

If the vehicle is equipped with an auto-

matic transaxle, apply the brakes and place
the transaxle in DRIVE. If the vehicle is
equipped with air conditioning, turn it on. If
the vehicle does not have either of the previ-
ously mentioned options, turn the steering
wheel all the way to the left and hold it in
there. Observe the reading on the vacuum
gauge. It should drop slightly as the IAC
motor opens the throttle by-pass airway. The
engine speed should drop momentarily and
then rise to the previously noted rpm. If the
vacuum reading remains the same and the
engine speed drops, turn off the engine and
proceed to the next step.
6

Remove the air cleaner assembly (see

Section 9) and inspect the by-pass airway for
obstructions or carbon build-up, clean if nec-
essary.
7

If the by-pass airway appears to be

clear, remove the IAC motor from the throttle
body (see below).
8

Next, turn the ignition key to the ON

position (engine OFF). Note: Perform this

check when the engine is completely COLD.
9

While observing the IAC pintle, attach

the electrical connector to the IAC motor. The

IAC pintle should retract. If it doesn't, use a

voltmeter or a test light to verify voltage is

present at the RED wire terminal in the female

connector. If voltage is present, replace the

IAC motor. If no voltage is present, check for

a blown fuse. If a fuse was blown, replace it
and see if it blows again. If it does, check the
circuit for a short (see Chapter 12).

Removal

10

Remove the air cleaner assembly (see

Section 9).

11

Remove the throttle body (see Sec-

tion 13).
12

Remove the IAC motor from the throttle

body (see illustrations 13.10a and 13.10b).
Make sure the 0-ring seal is removed with
the IAC motor, if not, retrieve it from the throt-
tle body orifice.

Installation

13 If the new IAC motor pintle is protruding
more than 1 inch, it must be retracted before
it can be installed. If this is the case, turn the
ignition key to the ON position (engine OFF).
Note: Perform this procedure when the

engine is completely COLD.

14

Attach the electrical connector to the

IAC motor, the pintle will retract.
15

With the pintle retracted and the 0-ring

seal in place, carefully install the IAC motor

into the throttle body and secure it with the

mounting screws. Tighten the screws to the
torque given in this Chapter's Specifications.
Note: The ignition key may be turned OFF
after the IAC motor is installed on the throttle
body.
16 Install the throttle body (see Section 13).
Tighten the throttle body bolts to the torque
listed in this Chapter's Specifications.
17 Install the air cleaner assembly (see
Section 9).

4

18 Exhaust system servicing -

general information

Refer to illustration 18.1
Warning: Inspection and repair of exhaust
system components should be done only
after enough time has elapsed after driving

the vehicle to allow the system components
to cool completely. Also, when working under
the vehicle, make
sure it is securely sup-

ported on jackstands.

1

The exhaust system consists of the

exhaust manifold, the catalytic converter, the

resonator, exhaust pipe, muffler and all
brackets, hangers and clamps. The exhaust

system is attached to the body with mounting
brackets and rubber hangers (see illustra-
tion).
If any of the parts are improperly
installed, excessive noise and vibration will
be transmitted to the body.

Muffler and pipes

2

Conduct regular inspections of the

exhaust system to keep it safe and quiet.
Look for any damaged or bent parts, open
seams, holes, loose connections, excessive
corrosion or other defects which could allow
exhaust fumes to enter the vehicle. Also
check the catalytic converter when you
inspect the exhaust system (see following).
Deteriorated exhaust system components
should not be repaired; they should be
replaced with new parts.

18.1 Inspect the exhaust system

mounting brackets, clamps and

rubber hangers for damage

or improper installation

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