Chrysler Town & Country/Voyager, Dodge Caravan, Plymouth Voyager. Manual — part 25
(5) Remove throttle cable. If equipped, remove the
speed control and transmission kickdown cables.
(6) Remove return spring.
(7) Loosen fuel tube clamp on valve cover (Fig. 4).
(8) Wipe quick connect fittings to remove any dirt.
Remove fuel intake and return tubes. Refer to Fuel
Hoses, Clamps and Quick Connect Fittings in the
Fuel Delivery Section of this Group. Place a shop
towel under the connections to absorb any fuel spilled.
(9) Remove throttle body mounting screws and lift
throttle body from vehicle. Remove throttle body gas-
ket from intake manifold.
INSTALLATION
(1) Using a new gasket, install throttle body and
tighten mounting screws to 20 N
Im (175 in. lbs.)
torque.
(2) Lubricate the ends of the fuel supply and return
tubes with 30 weight oil. Connect fuel lines to quick
connect fittings. Refer to Fuel Hoses, Clamps and
Quick Connect Fittings in the Fuel Delivery Sec-
tion of this Group. After the fuel tubes are connected
to the fittings, pull on the tubes to ensure that they are
fully inserted and locked into position.
(3) Tighten the fuel tube clamp on the valve cover.
(4) Install return spring.
(5) Install throttle cable. If equipped, install kick-
down and speed control cables.
(6) Install wiring connectors and vacuum hoses.
(7) Install air cleaner.
(8) Reconnect negative battery cable.
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 the
ignition switch is turned to the Off position.
(9) With the ignition key in ON position, access the
DRB II ASD Fuel System Test to pressurize the fuel
system. Check for leaks.
FUEL FITTING
REMOVAL
(1) Remove air cleaner assembly.
(2) Perform Fuel System Pressure Release proce-
dure.
(3) Disconnect negative battery cable.
(4) Loosen fuel tube clamp on valve cover.
(5) Wipe any dirt from around quick connect fittings.
(Fig. 5) Place a shop towel under the connections to
catch any spilled fuel. Remove fuel tubes from quick
connect fittings. Refer to Fuel Hoses, Clamps and
Quick Connect Fittings in the Fuel Delivery Sec-
tion of this Group.
(6) Remove each fitting from throttle body and note
inlet diameter. Remove copper washers.
INSTALLATION
(1) Replace copper washers with new washers.
(2) Install fuel fittings in proper ports and tighten to
20 N
Im (175 in. lbs.) torque.
(3) Lubricate ends of the fuel tubes with 30 weight
oil. Insert the tubes into the quick connect fittings.
Refer to Fuel Hoses, Clamps and Quick Connect
Fittings in the Fuel Delivery Section of this
Group. After the fuel tubes are connected to the
fittings, pull on the tubes to ensure that they are fully
inserted and locked into position.
(4) Tighten fuel tube clamp on valve cover.
(5) Reconnect negative battery cable.
Fig. 4 Fuel Line Clamp
Fig. 5 Servicing Fuel Fitting
.
FUEL SYSTEM
14 - 47
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 the
ignition switch is turned to the Off position.
(6) With the ignition key in ON position, access the
DRB II ASD Fuel System Test to pressurize the fuel
system. Check for leaks.
(7) Reinstall air cleaner assembly.
FUEL PRESSURE REGULATOR
The fuel pressure regulator is mounted on top of the
throttle body (Fig. 6).
REMOVAL
(1) Remove air cleaner assembly.
(2) Perform Fuel System Pressure Release proce-
dure.
(3) Disconnect battery negative cable.
(4) Remove pressure regulator mounting screws
(Fig. 6).
WARNING: PLACE A SHOP TOWEL AROUND FUEL
INLET CHAMBER TO CONTAIN ANY FUEL REMAIN-
ING IN THE SYSTEM.
(5) Pull pressure regulator from the throttle body.
(6) Carefully remove O-ring from pressure regulator
and remove gasket.
INSTALLATION
(1) Place new gasket on pressure regulator. Care-
fully install new O-ring.
(2) Position pressure regulator on throttle body.
Press regulator into place and install mounting screws.
Tighten screws to 5 N
Im (40 in. lbs.) torque.
(3) Connect negative cable to battery.
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 the
ignition switch is turned to the Off position.
(4) With the ignition key in ON position, access the
DRB II ASD Fuel System Test to pressurize the fuel
system. Check for leaks.
(5) Reinstall air cleaner assembly.
FUEL INJECTOR
The fuel injector is installed in the top of the throttle
body. The injector is covered by a cap.
REMOVAL
(1) Remove air cleaner assembly.
(2) Perform Fuel System Pressure Release proce-
dure.
(3) Disconnect negative cable from battery.
(4) Remove injector cap holddown screw (Torx-head).
(5) With two small screwdrivers, lift the top off the
injector using the slots provided (Fig. 7).
(6) Using a small screwdriver placed in the hole in
the front of the electrical connector, gently pry the
injector from the pod (Fig. 8).
(7) Ensure the injector lower O-ring has been re-
moved from the pod (Fig. 9).
Fig. 6 Servicing Fuel Pressure Regulator
Fig. 7 Removing Injector Cap
Fig. 8 Removing Fuel Injector
14 - 48
FUEL SYSTEM
.
INSTALLATION
(1) Place a new O-ring on the injector cap. The
injector will have the upper and lower O-rings already
installed (Fig. 9).
(2) Apply a light coating of clean engine oil on the
O-rings.
(3) Place assembly in the pod. Align the injector
wiring terminals with the injector cap fastener hole
(Fig. 10).
(4) Install injector cap with locating notch aligned
with the locating lobe on the injector (Fig. 11).
(5) Push down on the cap to ensure a good seal.
(6) Rotate the cap and injector to line up the attach-
ment hole (Fig. 12).
(7) Install injector cap holddown screw (torx-head
screw). Tighten screw to 4-5 N
Im (35-45 in. lbs.)
torque.
(8) Connect negative cable to battery.
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 the
ignition switch is turned to the Off position.
(9) With the ignition key in ON position, access the
DRB II ASD Fuel System Test to pressurize the fuel
system. Check for leaks.
(10) Reinstall the air cleaner assembly.
THROTTLE POSITION SENSOR
REMOVAL
(1) Disconnect negative cable from battery.
(2) Remove air cleaner.
(3) Disconnect harness connector from throttle posi-
tion sensor (Fig. 13).
(4) Remove
throttle
position
sensor
mounting
screws.
(5) Remove throttle position sensor from throttle
shaft.
Fig. 9 Servicing Fuel Injector
Fig. 11 Installing Fuel Injector Cap
Fig. 12 Fuel Injector Installed
Fig. 10 Fuel Injector Installation
.
FUEL SYSTEM
14 - 49
INSTALLATION
(1) Install throttle position sensor to throttle body,
position toward the front of the vehicle. Tighten screws
to 2 N
Im (20 in. lbs.) torque.
(2) Connect harness connector to throttle position
sensor.
(3) Install air cleaner.
(4) Connect negative cable to battery.
AUTOMATIC IDLE SPEED (AIS) MOTOR
The automatic idle speed (AIS) motor is mounted on
the throttle body (Fig. 14).
REMOVAL
(1) Remove air cleaner.
(2) Disconnect negative cable from battery.
(3) Disconnect AIS motor connector.
(4) Remove AIS motor mounting screws (Torx head
screws, 25 mm long).
(5) Remove AIS from throttle body housing. Ensure
O-ring is with AIS (Fig. 14).
INSTALLATION
(1) Ensure that AIS motor pintle is in the retracted
position. If pintle measures more than 1 inch (25
mm) as shown in Fig. 14, it must be retracted. Use the
DRB
II
Actuate
Outputs
Test,
AIS
MOTOR
OPEN/CLOSE (battery must be connected for this
operation).
(2) Install new O-ring on AIS.
(3) Install AIS motor into housing, ensuring the
O-ring is in place.
(4) Tighten mounting screws to 2 N
Im (20 in. lbs.)
torque.
(5) Connect harness electrical connector to AIS mo-
tor.
(6) Connect negative cable to battery.
MANIFOLD ABSOLUTE PRESSURE SENSOR
The MAP sensor is mounted underhood on the dash
panel (Fig. 15)
REMOVAL
(1) Remove vacuum hose and electrical connector
from sensor (Fig. 15).
(2) Remove sensor mounting screws. Remove sensor.
(3) Reverse the above procedure for installation.
Check the vacuum hose and electrical connections to
the sensor.
CANISTER PURGE SOLENOID
(1) Remove vacuum hose and electrical connector
from solenoid (Fig. 16).
(2) Depress tab on top of solenoid and slide the
solenoid downward out of mounting bracket.
(3) Reverse the above procedure for installation.
ENGINE CONTROLLER
The engine controller is mounted underhood on the
drivers side inner fender panel.
(1) Remove air cleaner duct from engine controller.
(2) Remove battery.
Fig. 13 Servicing Throttle Position Sensor
Fig. 14 Servicing Automatic Idle Speed (AIS) Motor
Fig. 15 Manifold Absolute Pressure (MAP) Sensor
14 - 50
FUEL SYSTEM
.
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