Chrysler Town & Country/Voyager, Dodge Caravan, Plymouth Voyager. Manual — part 24
Stop All Tests
Ignition Coil #1
Fuel Injector #1
AIS Motor Open/Close
Radiator Fan Relay
A/C Clutch Relay
Auto Shutdown Relay
Purge Solenoid
S/C Servo Solenoids
Alternator Field
Tachometer Output
PTU Solenoid (Automatic Only)
All Solenoids/Relays
ASD Fuel System Test
THROTTLE BODY MINIMUM AIR FLOW CHECK
PROCEDURE
(1) Connect Diagnostic Readout Box II (DRB II).
(2) Remove air cleaner assembly. Plug the heated air
door vacuum hose.
(3) Warm engine in Park or Neutral until the cooling
fan has cycled on and off at least once.
(4) Hook-up timing check device and tachometer.
(5) Disconnect the coolant temperature sensor and
set basic timing to 12°BTDC
6 2°BTDC.
(6) Shut off engine. Reconnect coolant temperature
sensor.
(7) Disconnect the PCV valve hose from the intake
manifold nipple.
(8) Attach Air Metering Fitting #6457 (Fig. 23) to the
intake manifold PCV nipple.
(9) Restart the engine, allow engine to idle for at
least one minute.
(10) Using the DRBII, Access Min Airflow Idle Spd
in the sensor read test mode.
(11) The following will then occur:
• AIS motor will fully close.
• Idle spark advance will become fixed.
• Idle fuel will be provided at a set value.
• Engine RPM will be displayed on Diagnostic Read-
out Box II (DRBII).
(12) Check idle RPM with tachometer. If idle RPM is
within the specifications listed below, then the throttle
body min. air flow is set correctly.
If idle RPM is not within specification replace
throttle body.
(13) Shut off engine.
(14) Remove Special Tool number 6457 from intake
manifold PCV nipple. Reinstall the PCV valve hose.
(15) Remove DRBII.
(16) Reinstall air cleaner assembly. Reinstall heated
air door vacuum hose.
(17) Disconnect timing check device and tachometer.
IGNITION TIMING PROCEDURE
Refer to Group 8D Ignition System
60-WAY ENGINE CONTROLLER WIRING CONNEC-
TOR
Refer to the engine controller wiring connector dia-
grams (Fig. 24) for information regarding wire colors
and cavity numbers.
Fig. 23 Air Metering Fitting
IDLE SPECIFICATIONS
.
FUEL SYSTEM
14 - 43
Fig.
24
Engine
Controller
W
iring
Connector
Cavity
Description
14 - 44
FUEL SYSTEM
.
2.5L SINGLE POINT FUEL INJECTION—SERVICE PROCEDURES
INDEX
page
page
Automatic Idle Speed (AIS) Motor
. . . . . . . . . . . . . 50
Canister Purge Solenoid . . . . . . . . . . . . . . . . . . . . 50
Engine Controller
. . . . . . . . . . . . . . . . . . . . . . . . . 50
Fuel Fitting
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Fuel Injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Fuel Lines and Hoses
. . . . . . . . . . . . . . . . . . . . . . 1
Fuel Pressure Regulator . . . . . . . . . . . . . . . . . . . . 48
Fuel System Pressure Release Procedure
. . . . . . . 1
Manifold Absolute Pressure Sensor
. . . . . . . . . . . 50
Oxygen Sensor (O
2
Sensor)
. . . . . . . . . . . . . . . . . 51
Throttle Body
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Throttle Position Sensor
. . . . . . . . . . . . . . . . . . . . 49
FUEL LINES AND HOSES
Release fuel system pressure before servicing the
fuel system. Preform the ‘‘Fuel System Pressure Relief
Procedure’’.
Do not damage the hose or hose nipple when remov-
ing the fuel hoses. Always use new hose clamps, of the
correct type, during reassembly. Tighten hose clamps
to 1 N
Im (10 in. lbs.) torque. Do not use aviation
style clamps on this system or hose damage may
result.
FUEL SYSTEM PRESSURE RELEASE PROCEDURE
CAUTION: Before servicing the fuel pump, fuel lines,
fuel filter, throttle body, or fuel injector, the fuel
system pressure must be released.
(1) Loosen fuel filler cap to release fuel tank pres-
sure.
(2) Disconnect injector wiring harness connector
(Fig. 1).
(3) Connect a jumper wire between terminal Num-
ber 1 of the injector harness and engine ground.
(4) Connect a jumper wire to the positive terminal
Number 2 of the injector harness and touch the battery
positive post for no longer than 5 seconds. This
releases system pressure.
(5) Remove jumper wires.
(6) Continue fuel system service.
THROTTLE BODY
CAUTION: The fuel system is under a constant pres-
sure of 270 kPa (39 psi). Perform the Fuel Pressure
Release Procedure before servicing the throttle body.
Always reassemble throttle body components with
new O-rings and seals where applicable. Never use
silicone lubricants on O-rings or seals, damage may
result. Use care when removing fuel tubes to prevent
damage to quick connect fittings or tube ends. Refer to
Fuel Hoses, Clamps, and Quick Connect Fittings in the
Fuel Delivery Section of this Group.
REMOVAL
(1) Remove air cleaner (Fig. 2).
(2) Perform fuel system pressure release.
(3) Disconnect negative battery cable.
(4) Disconnect vacuum hoses and electrical connec-
tors (Fig. 3).
Fig. 1 Injector Harness Connector
Fig. 2 Throttle Body and Air Cleaner Assembly
.
FUEL SYSTEM
14 - 45
Fig.
3
Throttle
Body
14 - 46
FUEL SYSTEM
.
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