Tune-Up - 4-cyl Dodge Aries I

VEHICLE IDENTIFICATION

Engine can be identified by the eighth character of Vehicle Identification Number (VIN). VIN number is located on a plate attached to top left corner of instrument panel and is visible through windshield.

VIN ENGINE CODES

TUNE-UP NOTES

Note. When performing tune-up procedures described in this article, the following notes and precautions must be followed

Due to late changes and corrections, always refer to Engine Tune-Up Decal in engine compartment, before performing tune-up. If manual and decal differ, always use decal specifications.

Do not allow or create a condition of engine misfire in more than one cylinder for an extended period of time. Damage to converter may occur due to loading converter with unburned air/fuel mixture.

Do not add fuel system cleaning agents to fuel tank or carburetor as they can damage the catalytic converter.

Before making a compression test or cranking engine using a remote starting switch, disconnect coil wire from distributor and secure to a good ground.

ENGINE COMPRESSION

Check compression pressure with engine warm, spark plugs removed, and throttle valve wide open.

COMPRESSION SPECIFICATIONS

SPARK PLUGS

SPARK PLUG TYPE

SPARK PLUG INSTALLATION

Spark Plug Wires

1. Carefully remove spark plug wire from spark plug. Remove distributor cap from distributor with spark plug wires connected.
2. Connect one ohmmeter lead to spark plug end of wire. Connect other ohmmeter lead to electrode inside distributor cap.
3. If resistance is more than 7200 ohms per foot, remove wire from distributor cap and connect ohmmeter lead to wire. If resistance is still more than 7200 ohms per foot, replace with wire identified as Electronic Suppression".

Note. When replacing spark plug wires on models equipped with 1.6L or 2.2L engines, do not pull on wires. These models are equipped with spark plug wires with positive locking terminals. Positive locking terminals must be released from inside distributor cap.

Ignition Coil Wire

1. Remove distributor cap from distributor. Leave wires connected to distributor cap and to ignition coil.
2. Connect ohmmeter leads to center contact inside distributor cap and to either positive or negative terminal of ignition coil.
3. If resistance is more than 25,000 ohms, remove wire from ignition coil tower and again check resistance. If resistance is more than 15,000 ohms, replace ignition coil wire.

HIGH TENSION WIRE RESISTANCE (OHMS)

ELECTRONIC SPARK ADVANCE CHECK

1. Set basic timing. Obtain engine operating temperature. The temperature sensor must be connected and operating properly.
2. Remove and plug vacuum hose at vacuum transducer. Connect an auxiliary vacuum supply to vacuum transducer and set for 16 in. Hg.
3. Raise engine speed to 2000 RPM, wait one minute and check. Advance specifications are in addition to basic advance. If specified readings are not obtained, replace computer.

ELECTRONIC SPARK ADVANCE TEST (1)

VALVE CLEARANCE

VALVE CLEARANCE ADJUSTMENT

1.6L

I-E-I-E-E-I-E-I (Front-to-Rear)

2.2L

E-I-E-I-E-I-E-I (Front-to-Rear)

2.6L

1. Right Side - All Exhaust
2. Left Side - All Intake

DISTRIBUTOR

All 1.6L & 2.2L engines are equipped with Chrysler Corp. Hall Effect Electronic Spark Control Ignition system. All 2.6L engines are equipped with Mitsubishi Electronic Ignition system. The only adjustments that can be made to either system are initial ignition timing (changing distributor position) and spark plug gap.

1.6L Firing Order and Timing Marks. Scheme 1

2.2L Firing Order and Timing Marks. Scheme 2

2.6L Firing Order and Timing Marks. Scheme 3

IGNITION TIMING

Carbureted Models

1. If a magnetic probe timing light is being used, refer to equipment manufacturers instructions for proper hookup. If a conventional timing light is being used, connect a timing light to number 1 cylinder.
2. Connect a tachometer to engine. Start engine and warm to normal operating temperature. Momentarily open throttle to ensure that linkage does not bind and that idle speed screw is against its stop.
3. If vehicle is equipped with a carburetor switch, connect a jumper wire between switch and ground. Disconnect and plug vacuum line at Spark Control Computer. On 2.6L engines, disconnect distributor vacuum hose.
4. Make sure that engine is operating at curb idle RPM. If not, adjust using appropriate procedures under Hot (Slow) Idle RPM. Check timing. If timing is within 2° of specified timing, do not adjust.
5. If timing is not correct, loosen distributor hold down bolt and turn distributor housing until specified timing is reached. Recheck timing after distributor hold down bolt has been tightened.

Note. On all engines except 1.6L, magnetic probe timing socket is located at 10° ATDC. This socket is only for use with special electronic timing equipment. Do not use this socket when checking timing with a conventional timing light.

Fuel Injected Models

1. Connect timing light and tachometer to the engine. Run engine until operating temperature is reached.
2. On the thermostat housing, disconnect and reconnect the water temperature sensor. The power loss lamp must come on and stay on. Adjust idle RPM.
3. At the timing hole in the bell housing, aim the timing light or read the magnetic timing unit. Adjust distributor to proper timing.
4. Turn off engine, detach and attach positive battery quick disconnect. Start engine. The power loss lamp should be off. Reset idle speed if necessary.
5. Turn off engine, then operate ignition on, off, on, off, on. On dash, power loss lamp should flash code numbers 88-51-55, signifying fault codes have been cleared.

IGNITION TIMING SPECIFICATIONS (DEGREES BTDC @ RPM)

HOT (SLOW) IDLE RPM - 1.6L & 2.2L CARBURETED ENGINES

Note. 1.6L and 2.2L carbureted engines with air conditioning are equipped with either a vacuum kicker or a solenoid kicker. It is not necessary to adjust air conditioning idle speed but kicker operation should be checked.

Air Conditioning Kicker Check

1. Start engine and warm to normal operating temperature. Set temperature control lever in coldest position. The kicker should move in and out as the A/C compressor clutch cycles on and off.
2. If the kicker does not move in and out, check kicker system for vacuum leaks or electrical problems and repair as necessary. If kicker still does not operate, replace kicker. Proceed to Curb Idle Speed adjustment.

Curb Idle Speed

1. Ensure that ignition timing is properly adjusted. Disconnect and plug vacuum connector at the Coolant Vacuum Switch Cold Closed (CVSCC). Unplug connector at radiator fan and install a jumper wire so that fan runs continuously.
2. Disconnect PCV valve from rubber connector and allow valve to draw in fresh air. Connect tachometer to engine. Ground the carburetor switch with a jumper wire.
3. Disconnect O2 system test connector located on left fender shield on vehicles equipped with Holley 6520 carburetors. Start engine and warm to normal operating temperature. Adjust idle speed using idle speed screw (vehicles without A/C) or idle set screw on A/C solenoid or kicker (vehicles with A/C). (Scheme 4)
4. Turn engine off and remove tachometer. Reconnect cooling fan connector. Remove jumper wire grounding carburetor switch. Reinstall PCV valve. Reconnect connector to CVSCC.

1.6L & 2.2L Carbureted Engine Curb Idle Speed Adjustment Locations. Scheme 4

1.6L & 2.2L CARBURETED MODELS CURB IDLE SPEED (RPM)

HOT (SLOW) IDLE RPM - 2.2L TBI AND EFI

Note. No idle adjustment is possible on 2.2L engines with single-point or multi-point fuel injection.

EFI CURB IDLE SPEED

HOT (SLOW) IDLE RPM - 2.6L

1. Set parking brake and place transaxle in Neutral. Turn all lights and accessories off. Disconnect engine cooling fan. Connect tachometer to engine. Start engine and run at fast idle until normal operating temperature is reached.
2. Check and/or adjust timing as necessary. Open throttle and allow engine to run at 2500 RPM for 10 seconds. Return engine to idle. Wait 2 minutes and read engine RPM. If RPM is not as specified, turn adjusting screw until correct RPM is obtained. (Scheme 5) Remove idle switch connector on feedback models.
3. On air conditioned models, set temperature control lever to coldest position and turn on A/C. With compressor running, set engine speed to 900 RPM by turning idle-up screw. (Scheme 6)
4. Turn off engine. Reconnect fan, disconnect tachometer, and plug in idle switch connector.

2.6L Curb Idle Speed Adjusting Screw Location. Scheme 5

2.6L Idle-Up and Fast Idle Adjusting Screw Location. Scheme 6

2.6L CURB IDLE SPEED

Scheme 7

1. Remove air cleaner crossover. Remove canister purge and air pump diverter valve vacuum hoses from carburetor. Locate and center punch a mark 1/4" from end of mixture screw housing. Punch mark should be at 10 o'clock position. (Scheme 7) (Scheme 7): 1.6L & 2.2L Mixture Screw Plug Removal
2. Drill through outer section of housing using a 3/16" drill bit. Concealment plug should drop out. If not, use a small drift punch to remove plug. CAUTION: Do not allow drift to contact mixture screw.
3. Reinstall vacuum hoses and air cleaner crossover. Perform propane idle mixture adjustment and reinstall plug.

Mixture Screw Plug Removal - 2.6L

1. Remove impact plate, if equipped. Remove vacuum connector from high altitude compensator (HAC) fitting on carburetor, if equipped.
2. Drill out concealment plug using an 8" long, 1/4" drill bit. (Scheme 8)

2.6L Mikuni Mixture Screw Plug Removal (Drill Hole Through Carburetor Base At 45 Degrees Angle Behind Plug). Scheme 8

1.6L & 2.2L Carbureted Models (Propane Enrichment Procedure)

1. Set parking brake and place transaxle in Neutral. Turn all lights and accessories off. Connect tachometer to engine. Remove concealment plug. Start engine and warm to normal operating temperature. Be sure engine is at curb idle.
2. Disconnect and plug vacuum connector at CVSCC. Disconnect vacuum hose from heated air door at 3-way connector. Install in its place a supply hose from a propane bottle. Make sure the valves are closed, the bottle is upright, and in a safe place.
3. Disconnect connector at cooling fan and install a jumper wire so that fan will run continuously. Remove PCV valve from valve cover so that valve can draw fresh air.
4. Connect a jumper wire between carburetor switch and ground. Disconnect test connector on left fender shield.
5. Open main valve on propane bottle. With air cleaner installed, slowly open propane metering valve until maximum engine RPM is reached. Carefully adjust metering valve to obtain a steady maximum RPM. If too much propane is added, the engine speed will drop.
6. While propane is flowing, adjust idle speed screw on top of solenoid to specified RPM. Fine tune propane metering valve and idle adjustment screw to specified RPM.
7. Turn main valve off and allow engine speed to stabilize. With air cleaner in place, adjust idle to specified RPM using mixture adjusting screw. (Scheme 7) Allow engine to stabilize between adjustments.
8. Turn main valve back on and note maximum RPM reading. If propane enriched RPM is not within 25 RPM of specified RPM, repeat steps 5) through 8) until proper propane idle RPM is obtained.
9. Turn both propane bottle valves off. Remove test equipment and jumper wires. Reconnect vacuum lines and install new concealment plug.

PROPANE ENRICHED IDLE SPEED

2.6L Idle Check Procedure (Propane Enrichment Procedure)

1. Place transaxle in Neutral. Turn all lights and accessories off. Connect tachometer to engine. Start engine and warm to normal operating temperature. Ensure engine timing is correct.
2. Shut off engine, detach negative battery cable for 3 seconds, then reconnect. Disconnect O2 sensor from engine harness lead. CAUTION: Ensure no pulling force is placed on sensor wire. Unplug at connector 4 in. from sensor. Be careful around sensor for exhaust manifold is extremely hot.
3. Start engine, allow to operate between 2000 and 3000 RPM for 10 seconds. Return to idle. Disconnect radiator fan. Let engine idle for 2 minutes. Detach air duct from air cleaner. Place supply hose of propane 4 inches into air cleaner. Be sure propane bottle is upright, in a safe place, and both valves are fully closed.
4. Open main valve of propane. Slowly open metering valve of propane until highest engine RPM is reached. Engine will decrease speed if too much propane is added. Fine tune for highest RPM. Engine RPM should increase 40-90 RPM.
5. If RPM increase is not correct, go to Idle Set Procedure. If RPM increase is correct, turn off both propane valves. Remove propane supply hose and reinstall fresh air duct. Connect O2 sensor wire and radiator fan. Remove tachometer.

2.6L Idle Set Procedure

1. Remove concealment plug. Reconnect cooling fan. Start engine and warm to normal operating temperature. Shut off engine, detach negative battery cable for 3 seconds, then reconnect. Start engine. Open throttle and allow engine 2500 RPM for 10 seconds. Return engine to idle.
2. Remove idle switch connector from idle speed adjustment screw. Allow engine to idle for 2 minutes. Insert propane supply hose from propane bottle into air cleaner snorkel approximately 4". Ensure both valves are fully closed and bottle is upright.
3. Open propane valve until maximum engine RPM is reached. When too much propane is added, engine speed will decrease. Adjust propane metering valve to get highest engine RPM.
4. If maximum RPM changed, readjust engine speed to specified propane RPM. Turn off propane and allow engine speed to stabilize. Slowly adjust mixture screw to achieve specified idle RPM. Pause between adjustments to allow engine speed to stabilize.
5. Turn on propane valve. Adjust metering valve to get highest RPM. If maximum engine speed is more than 25 RPM different than specified propane RPM, repeat steps 3) through 5).
6. Turn both valves of propane off. Remove propane hose and reinstall air duct. Connect O2 sensor to engine harness lead. Install new concealment plug and impact plate. Connect idle switch connector.
7. If vehicle has air conditioning, set control to maximum cooling and turn on. Set engine speed to 900 RPM when compressor is running, by adjusting idle-up screw. (Scheme 6)

IDLE MIXTURE ADJUSTMENT - FUEL INJECTION

Note. No idle speed adjustment is available for the Fuel Injected Models

COLD (FAST) IDLE RPM

Note. No fast idle speed adjustment is possible on 2.2L TBI & EFI engines.

Scheme 9

1. Ensure timing is correct. Disconnect connector from radiator cooling fan and connect a jumper wire to fan so that it will run continuously. Remove PCV valve from valve cover and allow it to draw fresh air.
2. Disconnect and plug vacuum connector at CVSCC. Connect tachometer to engine. Using a jumper wire, ground carburetor switch.
3. If equipped, disconnect O2 system test connector on left fender shield near shock tower.
4. Start engine and warm to normal operating temperature. Open throttle and place fast idle adjusting screw on lowest step of fast idle cam. (Scheme 9) (Scheme 9): 1.6L & 2.2L Fast Idle Speed Adjusting Screw Location
5. Adjust fast idle speed using fast idle adjusting screw. Turn engine off and remove tachometer. Unplug and reconnect vacuum connector. Remove jumper wires and reconnect all connectors.

Scheme 10

1. Ensure timing is correct. Set parking brake and put transaxle in Neutral. Shut off lights and accessories. Disconnect radiator fan. Install tachometer to engine.
2. Run engine until operating temperature is reached. Disconnect and plug vacuum advance line.
3. With throttle open slightly, install spacing tool (C-4812) on choke cam follower pin. (Scheme 10) Lift throttle lever and adjust speed to specification. (Scheme 6) (Scheme 10): 2.6L Spacing Tool (C-4812 2C) In Position
4. Remove tool and tachometer. Stop engine, reconnect fan, unplug and reconnect vacuum advance hose.

FAST IDLE SPEED (RPM)

AUTOMATIC CHOKE

All models are equipped with non-adjustable choke covers.

FUEL PUMP

FUEL PUMP PERFORMANCE

All 1.6L and 2.2L engines are equipped with Chrysler Corp. Hall Effect Electronic Spark Control Ignition system. All 2.6L engines are equipped with Mitsubishi Electronic Ignition system. The only adjustments that can be made to either system are initial ignition timing (changing distributor position) and spark plug gap.

IGNITION COIL RESISTANCE (OHMS) (1)

PICK-UP COIL RESISTANCE (OHMS)

FUEL SYSTEMS

CARBURETORS

FUEL INJECTION

ELECTRICAL SYSTEM

BATTERY SPECIFICATIONS

STARTER

1.6L engines use Mitsubishi, 2.2L engines use either Bosch or Nippondenso direct drive starters, and 2.6L engines use a Nippondenso gear reduction starter.

STARTER SPECIFICATIONS

ALTERNATOR

1.6L engines use a Bosch alternator. 2.2L engines use Chrysler Corp. or Bosch alternators. 2.6L engines use a Mitsubishi alternator.

ALTERNATOR SPECIFICATIONS

ALTERNATOR REGULATOR

1.6L and 2.2L models with external regulator have a Chrysler Corp. Electronic Voltage Regulator. 2.2L EFI models have a Bosch IC Regulator, integral with alternator. 2.6L models have a Mitsubishi IC Regulator, integral with alternator.

REGULATOR OPERATING VOLTAGE

SERVICE INTERVALS

REPLACEMENT INTERVALS

ENGINE OIL & FUEL CAPACITIES

BELT ADJUSTMENT

BELT ADJUSTMENT (1)

CAPACITIES

COOLING SYSTEM CAPACITIES

TRANSAXLE CAPACITIES

SYSTEM REFRIGERANT CAPACITIES