Chrysler Le Baron, Dodge Dynasty, Plymouth Acclaim. Manual — part 64

(5) Install

fuel

tube

retaining

bracket

screw.

Tighten screw to 4 N

Im (35 in. lbs.) torque.

(6) Connect electrical connectors to camshaft posi-

tion sensor, coolant temperature sensor and engine
temperature sensors (Fig. 13).

(7) Install fuel injector harness wiring clips on the

generator bracket and intake manifold water tube
(Fig. 13).

(8) Connect vacuum line to fuel pressure regulator.
(9) Remove covering on lower intake manifold and

clean surface.

(10) Place intake manifold gasket on lower mani-

fold. Put upper manifold into place and install bolts
finger tight.

(11) Install the generator bracket to intake mani-

fold bolt and the cylinder head to intake manifold
strut bolts. (Do not tighten.)

(12) Following the tightening sequence in Figure

11, tighten intake manifold bolts to 28 N

Im (250 in.

lbs.) torque.

(13) Tighten generator bracket to intake manifold

bolt to 54 N

Im (40 ft. lbs.) torque (Fig. 13).

(14) Tighten the cylinder head to intake manifold

strut bolts to 54 N

Im (40 ft. lbs.) torque (Fig. 8).

(15) Connect ground strap, MAP and heated oxy-

gen sensor electrical connectors.

(16) Connect vacuum harness to intake plenum.

Connect PCV system hoses.

(17) Using a new gasket, connect the EGR tube to

the intake manifold plenum. Tighten screws to 22
N

Im (200 in. lbs.) torque.

(18) Clip wiring harness into the hole in the throt-

tle cable bracket.

(19) Connect electrical connectors to the throttle

position sensor (TPS) and idle air control motor.

(20) Connect vacuum harness to throttle body.
(21) Install the direct ignition system (DIS) coils.

Tighten fasteners to 12 N

Im (105 in. lbs.) torque.

(22) Install fuel hose quick connectors fittings to

chassis tubes. Refer to Fuel Hoses, Clamps and
Quick Connect Fittings in the Fuel Delivery Sec-
tion of this Group. Push the fittings onto the chas-
sis tubes until they click into place. Pull on the
fittings to ensure complete insertion. Fuel supply fit-
ting is 5/16 inch and fuel return fitting is 1/4 inch.

(23) Install throttle cable.
(24) Install air cleaner and hose assembly.
(25) Connect negative cable to battery.

CAUTION: When using the ASD Fuel System Test,
the Auto Shutdown (ASD) Relay remains energized
for either 7 minutes, until the test is stopped, or un-
til the ignition switch is turned to the Off position.

(26) With the ignition key in ON position, access

the DRBII scan tool ASD Fuel System Test to pres-
surize the fuel system. Check for leaks.

FUEL PRESSURE REGULATOR

REMOVAL

(1) Perform fuel system pressure release procedure

before attempting any repairs. Refer to Fuel Pressure
Regulator Procedure in this section.

(2) Remove fuel pressure regulator vacuum connec-

tor. (Fig. 15).

(3) Remove regulator retainer screw (Fig. 15).
(4) Remove the fuel pressure regulator retainer

(Fig. 15).

Fig. 13 Fuel Injector Wiring Clip

Fig. 14 Fuel Rail Removal

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FUEL SYSTEMS

14 - 173

WARNING: PLACE A SHOP TOWEL UNDER FUEL
PRESSURE REGULATOR TO ABSORB ANY FUEL
SPILLAGE.

(5) Remove fuel pressure regulator and O-rings

(Fig. 16).

INSTALLATION

(1) Ensure fuel pressure regulator has two plastic

spacers (Fig. 16). Place O-rings in the fuel pressure
regulator cavity (Fig. 17). Do not install O-rings on
the fuel pressure regulator.

(2) Insert fuel pressure regulator into the fuel rail.
(3) Install fuel pressure regulator retainer (Fig.

15).

(4) Install retainer screw. Tighten to 7 N

Im (60 in.

lbs.) torque.

(5) Connect vacuum line to the fuel pressure regu-

lator.

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 un-
til the ignition switch is turned to the Off position.

(6) With the ignition key in ON position, access

the DRBII scan tool ASD Fuel System Test to pres-
surize the fuel system. Check for leaks.

FUEL INJECTOR

The fuel rail must be removed first. Refer to Fuel

Injector Rail Assembly Removal in this section.

REMOVAL

(1) Disconnect injector wiring connector from injec-

tor.

(2) Position fuel rail assembly so that the fuel in-

jectors are easily accessible (Fig. 18).

Fig. 15 Fuel Pressure Regulator

Fig. 16 Fuel Pressure Regulator

Removal/Installation

Fig. 17 Fuel Pressure Regulator O-Rings

Fig. 18 Fuel Injector and Rail—Typical

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FUEL SYSTEMS

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(3) Rotate injector and pull injector out of fuel rail.

The clip will stay on the injector.

(4) Check injector O-ring for damage. If O-ring is

damaged, it must be replaced. If injector is reused, a
protective cap must be installed on the injector tip to
prevent damage. Replace the injector clip if it is
damaged.

(5) Repeat for remaining injectors.

INSTALLATION

(1) Before installing an injector the rubber O-ring

must be lubricated with a drop of clean engine oil to
aid in installation.

(2) Install injector clip by sliding open end into top

slot of the injector. The edge of the receiver cup will
slide into the side slots of clip (Fig. 19).

(3) Install injector top end into fuel rail receiver

cap. Be careful not to damage O-ring during instal-
lation (Fig. 19).

(4) Repeat steps for remaining injectors.
(5) Connect fuel injector wiring.

MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR

The alignment of the MAP sensor is critical to the

sensors performance. The top of the sensor is marked
This Side Up (Fig. 20).

(1) Disconnect electrical connector from MAP sen-

sor.

(2) Remove sensor by unscrewing from the intake

manifold (Fig. 20).

(3) Reverse the above procedure for installation.

EVAP CANISTER PURGE SOLENOID SERVICE

(1) Remove vacuum hose and electrical connector

from solenoid (Fig. 21).

(2) Depress tab on top of solenoid and slide the so-

lenoid downward out of mounting bracket.

(3) Reverse above procedure for installation.

PCM SERVICE

(1) Remove air cleaner duct from PCM.
(2) Remove battery.
(3) Remove PCM mounting screws (Fig. 22).

(4) Remove 60-way electrical connector from PCM.

Fig. 19 Servicing Fuel Injector—Typical

Fig. 20 Manifold Absolute Pressure Sensor

Fig. 21 Canister Purge Solenoid

Fig. 22 PCM Removal

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FUEL SYSTEMS

14 - 175

(5) Reverse the above procedure for installation.

CRANKSHAFT POSITION SENSOR

REMOVAL

(1) Disconnect crankshaft position sensor electrical

connector from the wiring harness connector (Fig. 23).

(2) Remove crankshaft position sensor retaining

bolt.

(3) Pull sensor straight up out of the transaxle

housing.

INSTALLATION

If installing the original sensor, clean off the

old spacer on the sensor face. A NEW SPACER
must be attached to the sensor face before instal-
lation. If the sensor is being replaced, confirm
that the paper spacer is attached to the face of
the new sensor (Fig. 24).

(1) Install sensor in transaxle and push sensor down

until contact is made with the drive plate. While
holding the sensor in this position, and install and
tighten the retaining bolt to 12 N

Im (105 in. lbs.)

torque.

(2) Connect crankshaft position sensor electrical

connector to the wiring harness connector.

CAMSHAFT POSITION SENSOR SERVICE

REMOVAL

(1) Disconnect camshaft position sensor electrical

connector from the wiring harness connector (Fig. 25).

(2) Loosen camshaft position sensor retaining bolt

enough to allow slot in sensor to slide past the bolt.

(3) Pull sensor up out of the chain case cover. Do not

pull on the sensor lead. There is an O-ring on the
sensor case. The O-ring may make removal difficult. A
light tap to top of sensor prior to removal may reduce
force needed for removal.

INSTALLATION

If installing the original sensor, clean off the

old spacer on the sensor face. A NEW SPACER
must be attached to the face before installation.
Inspect O-ring for damage, replace if necessary.
If the sensor is being replaced, confirm that the
paper spacer is attached to the face and O-ring is
positioned in groove of the new sensor (Fig. 26).

(1) Apply a couple drops of clean engine oil to the

O-ring prior to installation. Install sensor in the chain
case cover and push sensor down until contact

Fig. 23 Crankshaft Position Sensor

Fig. 24 Crankshaft Position Sensor and Spacer

Fig. 25 Camshaft Position Sensor

Fig. 26 Camshaft Position Sensor

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FUEL SYSTEMS

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