POWERTRAIN CONTROL MODULE (PCM)
| CAUTION | Electronic components used in control systems are designed to carry very low voltages. As little as a 30-volt charge created by static electricity can cause a total or degrading failure in PCM or other electronic components containing integrated circuits. Before servicing PCM, technician must ground himself and the work area to discharge static electricity. |
| CAUTION | DO NOT remove part from packaging until ready to install. Ground any static-proof package before opening. DO NOT touch electrical terminals of components unless properly grounded. DO NOT lay electrical components on car seat, carpeting or dashboard. Use electrostatic protection mat and ground strap whenever possible. |
Note. Before replacing PCM, carefully inspect all wiring and control components. Failure to test for short circuits may result in repeated PCM failure due to shorts. To prevent internal damage to PCM, ensure ignition switch is in OFF position when connecting or disconnecting PCM connectors or any electrical components.
ELECTRONICALLY ERASABLE PROGRAMMABLE READ ONLY MEMORY (EEPROM)
EEPROM is a permanent memory that is part of PCM. EEPROM cannot be replaced. EEPROM contains program and calibration information that PCM uses to control powertrain. If PCM is replaced, ensure NEW PCM software/calibration is correct and most recent version for vehicle. EEPROM must be programmed when NEW PCM is installed. Program EEPROM using latest software for that specific vehicle.
CAMSHAFT POSITION SENSOR
Note. On 1.0L, camshaft position sensor is located in distributor housing and may also be referred to as a pick-up coil. see scheme 4 Adjust signal rotor air gap to.008-.016" (0.2-0.4 mm) by moving camshaft position sensor in relation to signal rotor.
Installing Distributor When Position Has Been Lost
- Remove FI fuse from fuse and relay box. Rotate crankshaft until piston No. 1 is at TDC of compression stroke. Align timing mark on crankshaft pulley to zero position on timing cover.
- Position rotor to cylinder No. 1 position. Install distributor. Reinstall FI fuse. Ensure timing is correct. See IGNITION TIMING in appropriate ON-VEHICLE ADJUSTMENTS article.
FUEL PRESSURE RELIEF
| WARNING | Always relieve fuel pressure before disconnecting any fuel injection-related component. DO NOT allow fuel to contact engine or electrical components. |
Fuel system is under pressure. Pressure must be relieved prior to servicing fuel system. Fuel pressure may be relieved by using one of the following methods.
- On 1.0L, 1.3L and 1.8L, loosen fuel filler cap to relieve tank pressure (do not tighten at this time). On 1.0L, remove circuit opening relay. On 1.3L and 1.8L, remove fuel pump relay. On all models, start and run engine until it stalls. Crank starter for 3 seconds to remove remaining fuel from fuel lines. Turn ignition off. Reinstall circuit opening relay or fuel pump relay. Disconnect negative battery cable to avoid possible fuel discharge in accidental attempt to start engine.
- On 1.9L, 3.0L, 3.1L, 3.4L, 3.5L, 3.8L, 4.0L, 4.6L and 5.7L, disconnect negative battery terminal. Loosen fuel filler cap. Install Fuel Pressure Gauge (J-34730-1A) on fuel pressure connector of fuel rail. Wrap shop towel around pressure connection when installing fuel pressure gauge to absorb fuel leakage. Install gauge bleed hose in container. Open bleed valve to bleed fuel pressure.
- On 2.2L and 2.4L, loosen fuel filler cap to relieve tank pressure (do not tighten at this time). Disconnect fuel pump connector. Start and run engine until it stalls. Crank starter for 3 seconds to remove remaining fuel from fuel lines. Turn ignition off. Reconnect fuel pump connector. Disconnect negative battery cable to avoid possible fuel discharge in accidental attempt to start engine.
Fuel Filter Components View (On Vehicle). Scheme 53
The fuel filter (2) is located under the rear of the car, behind the fuel tank. There is no service interval for fuel filter replacement. Replacement is required only if the fuel filter becomes restricted.
| CAUTION | Unless directed otherwise, the ignition and start switch must be in the OFF or LOCK position, and all electrical loads must be OFF before servicing any electrical component. Disconnect the negative battery cable to prevent an electrical spark should a tool or equipment come in contact with an exposed electrical terminal. Failure to follow these precautions may result in personal injury and/or damage to the vehicle or its components. |
Scheme 54
- Disconnect the negative battery cable.
- Relieve the fuel system pressure. Refer to «FUEL PRESSURE RELIEF»(ref-2157-S28293342902000031700000). CAUTION: Provide additional support when a vehicle is on a hoist in the following ways: Before removing parts, support the opposite end. This helps prevent the vehicle from slipping off. Before removing major components, chain the vehicle frame to the hoist pads at the same end as the removal. This helps avoid a tip-off. Failure to follow these precautions could cause vehicle damage, serious personal injury, or death.
- Raise the vehicle and suitably support. (Scheme 54): Identifying Fuel Filter CAUTION: In order to Reduce the Risk of Fire and Personal Injury: If nylon fuel pipes are nicked, scratched or damaged during installation, Do Not attempt to repair the sections of the nylon fuel pipes. Replace them. When installing new fuel pipes, Do Not hammer directly on the fuel harness body clips as it may damage the nylon pipes resulting in a possible fuel leak. Always cover nylon vapor pipes with a wet towel before using a torch near them. Also, never expose the vehicle to temperatures higher than 115°C (239°F) for more than one hour, or more than 90°C (194°F) for any extended period. Before connecting fuel pipe fittings, always apply a few drops of clean engine oil to the male pipe ends. This will ensure proper reconnection and prevent a possible fuel leak. (During normal operation, the O-rings located in the female connector will swell and may prevent proper reconnection if not lubricated.)
- Using back-up wrench to remove the fuel filter fitting.
- Grasp the fuel filter and the fuel pipe quick-connect fitting. Twist the quick-connect fitting 1/4 turn in each direction to loosen any dirt within fitting. Using compressed air, blow out dirt from quick-connect fittings at end of fuel filter.
- Remove the quick connect fitting by pushing inward toward the fuel filter and grasping the plastic tab around the connector and pull apart.
- Remove the fuel filter.
THROTTLE BODY (SFI)
| WARNING | Ensure residual fuel pressure is relieved before working on throttle body. |
- Relieve fuel pressure. See «FUEL PRESSURE RELIEF»(ref-2157-S28293342902000031700000) . Disconnect negative battery cable. Remove air intake ducts. Disconnect and mark harness connections and vacuum hoses from throttle body. Disconnect control cables from throttle body.
- Drain cooling system and remove coolant hoses to throttle body (if applicable). Remove throttle body retaining bolts. Remove throttle body and gasket.
Note. Identification number is stamped on throttle body. Use identification number to order replacement components.
- To install, reverse removal procedure using NEW gasket. Tighten throttle body retaining bolts to specification. See «TORQUE SPECIFICATIONS»(ref-2157-S20938447872000031700000) . Refill cooling system (if drained).
- If installing NEW Idle Air Control (IAC) valve, ensure IAC pintle length setting is adjusted before installation (if applicable). See «IDLE AIR CONTROL (IAC) VALVE»(ref-2157-S24736185102000031700000) . Adjust idle speed and TP sensor (if removed, and if adjustable). See appropriate ON-VEHICLE ADJUSTMENTS article.
FUEL PRESSURE REGULATOR
Note. On 1.0L, fuel pressure regulator and throttle body are serviced as an assembly. DO NOT remove pressure regulator from throttle body. See THROTTLE BODY (TBI) .
Note. On 3.0L, fuel pressure regulator and fuel rail are serviced as an assembly only. DO NOT remove pressure regulator or pressure regulator cover from fuel rail. See FUEL RAIL & INJECTORS .
FUEL RAIL & INJECTORS
Note. If injector is replaced, ensure replacement injector has the same part number as injector removed.
FUEL INJECTOR (TBI)
Note. Remove injector only for cleaning, "O" ring replacement or injector replacement.
IDLE SPEED CONTROL (ISC) MOTOR
Note. Open throttle lever to full open position and check if Yellow paint has come off of throttle lever screw. Turn throttle stop screw resin cap on throttle body side with fingers and check entire cap for damage. If throttle lever screw and throttle stop screw has been tampered with, replace throttle body assembly. DO NOT replace ISC motor if Yellow paint has come off throttle lever screw or throttle stop screw resin cap is damaged.
OXYGEN SENSOR
Note. Oxygen sensor is mounted in exhaust pipe, below exhaust manifold and is equipped with a permanent pigtail which must remain intact when removing sensor.
- Ensure oxygen sensor is free of contaminants. DO NOT use cleaning solvents of any type. Oxygen sensor may be difficult to remove when engine temperature is less than 120°F (48°C). Excessive removal force may damage threads in exhaust manifold or pipe.
- Disconnect negative battery cable. Disconnect harness connector from oxygen sensor. Carefully remove oxygen sensor from exhaust pipe.
| CAUTION | Correct torque of oxygen sensor is critical to prevent crushing glass beads in graphite anti-seize compound. Crushing glass beads will cause sensor to seize in exhaust manifold. This may necessitate replacement of exhaust manifold upon next removal. |
- Whenever an oxygen sensor is removed, coat threads with anti-seize compound before installation. New oxygen sensors already have this compound applied to threads.
- Install oxygen sensor in exhaust pipe. Tighten oxygen sensor to specification. See «TORQUE SPECIFICATIONS»(ref-2157-S20938447872000031700000) . Reconnect harness connector to oxygen sensor. Reconnect negative battery cable.
SUPERCHARGER
Note. Servicing of supercharger unit is limited to replacement only.