Chrysler Town & Country/Voyager, Dodge Caravan, Plymouth Voyager. Manual — part 8
|INTAKE AND EXHAUST MANIFOLDS
SERVICE—TBI ENGINE
Intake and exhaust manifolds use a one piece gasket.
Service procedures requiring removal and installation
(of either) must include both manifolds.
FUEL SYSTEM PRESSURE RELEASE PROCE-
DURE
The Fuel System is under a constant pressure
of at least 265 kPa (39 psi). Before servicing the
fuel pump, fuel lines, fuel filter, throttle body or
fuel injector, the fuel system pressure must be
released.
(a) Loosen fuel filler cap to release fuel tank pres-
sure.
(b) Disconnect injector wiring harness from engine
harness.
(c) Connect a jumper wire to ground terminal
Number 1 of the injector harness (Fig. 8) to engine
ground.
(d) Connect a jumper wire to the positive terminal
Number 2 of the injector harness (Fig. 8) and touch
the battery positive post for no longer than 5 seconds.
This releases system pressure.
(e) Remove jumper wires.
(f) Continue fuel system service.
REMOVAL
(1) Perform fuel system pressure release procedure
before attempting any repairs.
(2) Disconnect negative battery cable. Drain cooling
system. Refer to Cooling System, Group 7 for proce-
dure.
(3) Remove air cleaner and disconnect all vacuum
lines, electrical wiring and fuel lines from throttle body.
(4) Remove throttle linkage.
(5) Loosen power steering pump and remove belt.
(6) Remove power brake vacuum hose from intake
manifold.
(7) Disconnect EGR tube from intake manifold and
remove water hoses from water crossover.
(8) Raise vehicle and remove exhaust pipe from
manifold.
(9) Remove power steering pump assembly and set
aside.
(10) Remove intake manifold retaining screws (Fig.
9).
(11) Lower vehicle and remove intake manifold.
(12) Remove exhaust manifold retaining nuts (Fig.
9).
(13) Remove exhaust manifold.
Fig. 7 Air Heater TBI Engines
Fig. 8 Injector Harness Connector
Fig. 9 Intake and Exhaust Manifold Attaching
Points—2.5L Engines
.
EXHAUST SYSTEM AND INTAKE MANIFOLD
11 - 5
CLEANING AND INSPECTION
(1) Discard gaskets and clean all gasket surfaces on
both manifolds and on cylinder head.
(2) Test gasket surfaces of manifolds for flatness
with a straight edge. Surfaces must be flat within
0.15mm per 300mm (.006 in. per foot) of manifold
length.
(3) Inspect manifolds for cracks and distortion.
INSTALLATION
(1) Install a new intake and exhaust manifold gas-
ket. Coat steel gasket lightly with Gasket Sealer on
manifold side. Do not coat composition gasket with
(any) sealer.
(2) Set exhaust manifold in place. Tighten retaining
nuts starting at center and progressing outward in
both directions to 23 N
Im (200 in. lbs.) (Fig. 9). Repeat
this procedure until all nuts are at specified torque.
(3) Set intake manifold in place.
(4) Raise vehicle and tighten retaining screws start-
ing at center and progressing outward in both direc-
tions to 23 N
Im (200 in. lbs.) (Fig. 9). Repeat this
procedure until all screws are at specified torque.
(5) Reverse removal procedures 1-9 for installation.
(6) With the DRB II use ASD Fuel System Test to
pressurize system to check for leaks.
CAUTION: When using the ASD Fuel System Test,
The Auto Shutdown (ASD) Relay will remain ener-
gized for 7 minutes or until the ignition switch is
turned to the OFF position, or Stop All Test is se-
lected.
INTAKE AND EXHAUST MANIFOLDS—3.0L ENGINE
The intake system has a large air intake plenum of
aluminum alloy and a cross type intake manifold (Fig.
2).
The exhaust manifolds are made of ductile cast iron
with the front bank and rear bank independent of each
other. The exhaust from the front bank exhaust mani-
fold is led through on exhaust crossover pipe to be
combined with the rear bank exhaust at the exhaust
outlet to the exhaust pipe (Fig. 2).
INTAKE PLENUM/MANIFOLD
REMOVAL
(1) Perform fuel system pressure release procedure
(before attempting any repairs).
(2) Disconnect negative battery cable. Drain cooling
system. See Cooling System, Group 7.
(3) Remove air cleaner to throttle body hose (Fig. 3).
FUEL SYSTEM PRESSURE RELEASE PROCE-
DURE
The MPI fuel system is under a constant pres-
sure of approximately 330 kPa (48 psi). Before
servicing the fuel pump, fuel lines, fuel filter,
throttle body or fuel injector, the fuel system
pressure must be released.
(a) Loosen fuel filler cap to release fuel tank pres-
sure.
(b) Disconnect injector wiring harness from engine
harness.
(c) Connect a jumper wire to ground terminal
Number 1 of the injector harness (Fig. 1) to engine
ground.
(d) Connect a jumper wire to the positive terminal
Number 2 of the injector harness (Fig. 1) and touch
the battery positive post for no longer than 5 seconds.
This releases system pressure.
(e) Remove jumper wires.
(f) Continue fuel system service.
(4) Remove throttle cable and transaxle kickdown
linkage (Fig. 4).
(5) Remove automatic idle speed (AIS) motor and
throttle position sensor (TPS) wiring connectors from
throttle body (Fig. 5).
(6) Remove vacuum hose harness from throttle body
(Fig. 5).
(7) Remove PCV and Brake booster hoses from Air
Intake Plenum.
(8) Remove Ignition Coil from Intake Plenum (Fig.
6).
(9) Remove wiring connectors from coolant tempera-
ture sensor (Fig. 7).
(10) Remove vacuum connections from Air Intake
Plenum vacuum connector.
(11) Remove fuel hoses from fuel rail (Fig. 7).
WARNING: WRAP SHOP TOWELS AROUND
HOSES TO CATCH ANY GASOLINE SPILLAGE.
Fig. 1 Injector Harness Connector
11 - 6
EXHAUST SYSTEM AND INTAKE MANIFOLD
.
(12) Remove (8) Fasteners from Air Intake Plenum
to Intake Manifold (Fig. 8).
(13) Remove Air Intake Plenum (Fig. 9).
(14) Cover intake manifold with suitable cover when
servicing.
(15) Remove vacuum hoses from fuel rail and fuel
pressure regulator (Fig. 10).
(16) Disconnect Fuel Injector wiring harness from
engine wiring harness (Fig. 11).
(17) Remove fuel pressure regulator attaching bolts
and remove regulator from rail (Fig. 12). Be careful
not to damage the rubber injector O-rings upon
removal from the ports.
(18) Remove fuel rail attaching bolts and lift fuel rail
assembly from intake manifold.
(19) Separate radiator hose from thermostat hous-
ing and heater hose from heater pipe.
(20) Remove (8) nut and washer assemblies and
remove intake manifold (Fig. 2).
INSPECTION
Check for:
• Damage and cracks of each section (Fig. 13).
• Clogged water passages in end cross overs.
• Check for distortion of the cylinder head mounting
surface using a straightedge and thickness gauge (Fig.
14). Refer to (Fig. 15) for Specifications.
Fig. 2 Intake and Exhaust Manifolds—3.0L Engine
Fig. 3 Throttle Body Assembly—3.0L
.
EXHAUST SYSTEM AND INTAKE MANIFOLD
11 - 7
INSTALLATION
(1) Position new intake manifold gaskets on cylinder
head and install intake (cross) manifold.
(2) Install (8) nuts and washers and tighten in
several steps in order shown in (Fig. 16) to 20 N
Im
(174 in. lbs.).
(3) Make sure the injector holes are clean and all
plugs have been removed.
(4) Lube injector O-ring with a drop of clean engine
oil to ease installation.
(5) Put the tip of each injector into their ports. Push
the assembly into place until the injectors are seated in
the ports.
(6) Install the (3) fuel rail attaching bolts and torque
to 13 N
Im (115 in. lbs.).
(7) Install fuel pressure regulator onto fuel rail.
Install attaching bolts to intake manifold. Torque regu-
lator nuts and bracket bolts to 10 N
Im (95 in. lbs.) (Fig.
12).
(8) Install fuel supply and return tube hold-down
bolt and the vacuum crossover tube hold-down bolt and
torque to 10 N
Im (95 in. lbs.).
(9) Connect fuel injector wiring harness to engine
wiring harness (Fig. 11).
(10) Connect vacuum harness to fuel pressure regu-
lator and fuel rail assembly (Fig. 10).
(11) Remove covering from lower intake manifold
and clean surface.
(12) Place intake manifold gaskets with beaded
sealant side up on lower manifold. Put air intake in
place. Install attaching fasteners (8) and tighten in
several steps in sequence shown (Fig. 17) to 13 N
Im
(115 in. lbs.).
(13) Connect fuel line to fuel rail (Fig. 7). Torque
hose clamps to 1 N
Im (10 in. lbs.).
(14) Connect vacuum harness to air intake plenum.
Fig. 4 Throttle Cable Attachment
Fig. 5 Electrical and Vacuum Connections to
Throttle Body
Fig. 6 Ignition Coil Removal
Fig. 7 Coolant Temperature Sensor Electrical Con-
nections
11 - 8
EXHAUST SYSTEM AND INTAKE MANIFOLD
.
Нет комментариевНе стесняйтесь поделиться с нами вашим ценным мнением.
Текст