Engine Controls - Remove/install/overhaul - Gasoline Dodge Caravan II

INTRODUCTION

Removal, overhaul and installation procedures (when provided by manufacturer) are covered in this article. If component removal and installation is basically an unbolt and bolt-on procedure, only a torque specification may be provided.

Removal

1. Disconnect distributor lead wire at wiring harness connector. Loosen distributor cap retaining screws. (Scheme 1) Lift off distributor cap.
2. Rotate engine crankshaft until distributor rotor is pointing toward intake plenum. Scribe a mark on plenum, as reference, to indicate rotor position when reinstalling distributor. Remove distributor hold-down nut. Carefully lift distributor from engine.

Scheme 1

Installation

1. Position distributor in engine. Ensure "O" ring is properly seated on distributor. Replace "O" ring if it is cracked or nicked.
2. Carefully engage distributor drive with camshaft drive so, when distributor is installed properly, rotor aligns with reference mark on intake plenum.
3. Install distributor cap. Check all high tension wires for good connections. Install and finger-tighten hold-down nut. Connect distributor lead wire at wiring harness connector. Set ignition timing.

1. Disconnect distributor lead wire at wiring harness connector. Loosen distributor cap retaining screws. Lift off distributor cap.
2. Rotate engine crankshaft toward TDC until distributor rotor is pointing toward alignment mark on distributor body. Remove distributor hold-down nut. Carefully lift distributor from engine.

1. With engine at TDC, position distributor in engine. Ensure mounting base is free of debris. Ensure "O" ring is properly seated on distributor. Replace "O" ring if it is cracked or nicked.
2. Carefully engage distributor drive with camshaft drive so when distributor is installed properly, rotor aligns with reference mark on distributor body.
3. Install and finger-tighten hold-down nut. Install distributor cap. Check all high tension wires for good connections. Connect distributor lead wire at wiring harness connector. Set ignition timing. Tighten hold-down nut.

Removal & Installation (2.5L, 3.9L, 5.2L & 5.9L)

1. Disconnect distributor pick-up lead wire at wiring harness connectors. Remove splash shield retaining screws, and remove splash shield (if equipped).
2. Loosen distributor cap retaining screws or unfasten distributor cap retaining clips. Remove distributor cap. Scribe a mark on edge of distributor housing to indicate position of rotor as reinstallation reference.
3. Remove ignition rotor from distributor shaft. On 3.9L, 5.2L and 5.9L, remove Hall Effect pick-up attaching screws on opposite sides of distributor housing.
4. On all models, carefully lift Hall Effect pick-up assembly from distributor housing. (Scheme 2) To install, reverse removal procedure.

Scheme 2

Removal & Installation

Remove spark plug cables from coil. Remove electrical connector and ignition coil fasteners. (Scheme 3) To install, reverse removal procedure. Tighten fasteners to 105 INCH lbs. (12 N.m).

Scheme 3

1. Disconnect Camshaft Angle Sensor (CAS) lead at wiring harness connector. Loosen CAS retaining bolt far enough to allow slot in CAS to slide past bolt.
2. Pull CAS up out of chain case cover. DO NOT pull on CAS lead. Removal effort will be great due to "O" ring seal on CAS. A light tap to top of CAS before removal may reduce effort.

1. If reinstalling removed CAS, clean off old spacer from CAS face. A new spacer must be attached to face before installation. Inspect "O" ring for damage and replace if necessary.
2. If replacing CAS, ensure paper spacer is attached to CAS face and "O" ring is positioned in groove of new CAS. Apply a couple drops of clean engine oil to "O" ring before installation.
3. Install CAS in chain case cover. Push CAS down until it contacts cam timing gear. Hold CAS in this position, and tighten retaining bolt to 105 INCH lbs. (12 N.m).
4. Connect CAS lead wire at wiring harness connector. Position lead wire away from accessory belt.

1. Disconnect crankshaft angle sensor pick-up lead at wiring harness connector. (Scheme 4) Remove sensor retaining bolt. Pull sensor straight up out of transaxle housing.
2. If reinstalling removed sensor, clean off old spacer from sensor face. New spacer must be attached to sensor face before installation. If replacing sensor, paper spacer is attached to face of new sensor.

Install sensor in transaxle, and push sensor down until it contacts drive plate. Hold in this position, and install retaining bolt. While holding sensor down, tighten bolt to 105 INCH lbs. (12 N.m). Connect sensor lead wire to wiring harness connector.

Scheme 4

FUEL SYSTEM PRESSURE RELEASE

2.5L, 3.0L, 3.3L & 5.9L

1. Loosen fuel filler cap to release tank pressure. Disconnect injector wiring harness from engine harness. Connect a jumper wire between terminal No. 1 of injector harness and engine ground. (Scheme 5)
2. Connect one end of second jumper wire to terminal No. 2 of injector harness, and touch other end to battery positive for no more than 5 seconds. This releases system pressure. Remove jumper wires. Continue fuel system service.

Scheme 5

3.9L & 5.2L

1. Disconnect negative battery cable. Loosen fuel filler cap to release tank pressure. Remove protective cap from pressure test port on fuel rail. CAUTION: To minimize fuel spill, wrap a shop towel around and under pressure test port.
2. Using Fuel Pressure Gauge/Hose Tool (5069) with gauge removed, place gauge end of hose into approved gasoline container. To release pressure, screw other end of hose onto pressure test port. After pressure is released, remove hose from test port and install protective cap.

Removal (Caravan, Town & Country, & Voyager)

Remove fuel tank. See FUEL TANK. Using a hammer and a brass drift punch, carefully tap lock ring counterclockwise to release pump. (Scheme 6) Remove fuel pump from tank.

Wipe seal area of tank clean. Install a new "O" ring seal in position on pump. Position fuel pump in tank so fuel return hose is not kinked. Install lock ring. Using a hammer and brass drift punch, drive ring clockwise to lock pump in place. DO NOT overtighten pump lock ring as it may leak. Install fuel tank. See FUEL TANK.

Scheme 6

Removal (Caravan, Town & Country, & Voyager AWD)

Release fuel system pressure. See FUEL SYSTEM PRESSURE RELEASE. Disconnect negative battery cable. Remove fuel tank. See FUEL TANK. Unclip fuel vapor hose and fuel drain hose from fuel tank. (Scheme 7) Remove fuel pump module retaining clamp. Remove fuel pump module.

Wipe seal area of tank clean, and place new seal in position on pump. Position fuel pump module so arrow on edge of module is between 2 lines on fuel tank. Compress fuel pump module, and install retaining clamp. Tighten clamp to 40 INCH lbs. (4.5 N.m). Install fuel tank. See FUEL TANK.

Scheme 7

Removal (Dakota, Pickup, Ramcharger & RWD Van)

Release fuel system pressure. See FUEL SYSTEM PRESSURE RELEASE. Disconnect negative battery cable. Remove fuel tank. See FUEL TANK. Remove fuel pump module lock nut. Lock nut is threaded onto fuel tank. (Scheme 8) Fuel pump module will spring up from its position when lock nut is removed. Remove module from tank.

Install fuel pump module into fuel tank. Push module down, and install lock nut. Install fuel tank. See FUEL TANK.

Scheme 8

Draining Fuel Tank (Caravan, Town & Country, & Voyager)

1. Remove fuel filler cap to release fuel tank pressure. Release fuel system pressure. See FUEL SYSTEM PRESSURE RELEASE. Disconnect negative battery cable. Raise vehicle on hoist.
2. Remove drain tube rubber cap located on left frame rail, and connect either a portable holding tank or a siphon hose to drain tube. Drain fuel into an appropriate gasoline safety container.

1. Disconnect negative battery cable. Remove fuel tank filler cap to release any tank pressure. Drain fuel tank into a suitable holding tank. See DRAINING FUEL TANK (CARAVAN, TOWN & COUNTRY, & VOYAGER). Position vehicle on hoist. Remove screws holding filler tube to inner and outer quarter panels.
2. Raise vehicle on hoist. Disconnect all wiring and lines from tank. Use a transmission jack to support fuel tank, and remove bolts from fuel tank straps. Lower tank slightly and carefully work filler tube from tank. Lower fuel tank. Disconnect vapor separator rollover valve hose, and remove fuel tank from vehicle.

1. Place fuel tank on top of transmission jack. Connect vapor separator rollover valve hose. Raise tank into position, and carefully work filler tube into tank. Transmission fluid may be used to lubricate tube as an aid in assembly. CAUTION: Ensure vapor vent hose is clipped to tank and is not pinched between tank and floor pan during installation. Ensure straps are not twisted or bent before and after tightening strap nuts.
2. Install strap bolts, and tighten to 40 ft. lbs. (54 N.m). Remove transmission jack. Connect lines, drain tube cap and wiring connector. Use new hose clamps, and tighten to 10 INCH lbs. (1 N.m).
3. Install filler tube and tighten filler tube-to-inner and outer quarterpanel screws to 17 INCH lbs. (1.9 N.m). On affected models, install gasket between filler tube and inner quarterpanel before installing mounting screws.
4. Replace cap on drain tube using new hose clamp. Fill fuel tank, and replace filler cap. Connect negative battery cable. Check for proper operation.

Draining Fuel Tank (Dakota, Pickup, Ramcharger & RWD Van)

1. Remove fuel filler cap to release fuel tank pressure. Release fuel system pressure. See FUEL SYSTEM PRESSURE RELEASE. Disconnect negative battery cable. Raise vehicle on hoist.
2. Drain fuel into an appropriate gasoline safety container. If fuel pump operates, fuel can be drained through fuel supply hose. If fuel pump does not operate but fuel level in tank is below fuel filler hose, fuel can be siphoned through fuel filler hose. Disconnect hose from filler neck. If fuel tank is full and fuel pump does not operate, drain fuel from filler neck.
3. To drain fuel tank from filler neck, support fuel tank using transmission jack. Loosen fuel tank mounting straps with passenger-side strap loosened more than driver-side strap. Lower tank slightly. Loosen filler neck to filler hose clamp. Slide clamp back on hose. To minimize fuel spill, wrap shop towels around filler hose. Disconnect filler hose from filler neck. Drain fuel tank through filler hose.

1. Disconnect negative battery cable. Remove fuel tank filler cap to release fuel tank pressure. Drain fuel tank into a suitable holding tank. See DRAINING FUEL TANK (DAKOTA, PICKUP, RAMCHARGER & RWD VAN). Raise vehicle on hoist. Disconnect all vent hoses and filler hose.
2. Place a transmission jack under center of fuel tank, and apply slight pressure. Remove fuel tank retaining straps. Lower tank on transmission jack far enough to access fuel pump module connectors.
3. Disconnect fuel tubes and fuel gauge sending unit connections from fuel pump module. Remove ground strap (if equipped). Remove fuel tank.

1. Place fuel tank on top of transmission jack, and raise it high enough to connect fuel tubes and fuel gauge wire to fuel pump module. Connect fuel tubes and fuel gauge wire to fuel pump module.
2. Raise tank into position. Install ground strap (if equipped). Install fuel tank mounting straps. On Ramcharger, connect and tighten nuts to end of threads on "J" bolts. On all other models, tighten mounting straps to 35 ft. lbs. (47 N.m). On all models, remove transmission jack.
3. Connect vent hoses, filler tube and drain tube cap. Install new hose clamps, and tighten clamps securely. Connect fuel line if disconnected earlier. Refill tank, and inspect all hoses and lines for leaks. Reconnect negative battery cable. Pressurize system, and check for leaks.

1. Release fuel system pressure. See FUEL SYSTEM PRESSURE RELEASE. Disconnect negative battery cable.
2. Remove air cleaner-to-throttle body hose. Remove throttle cable and transaxle kickdown linkage (if equipped). Remove wiring connectors for automatic idle speed motor and throttle position sensor from throttle body.
3. Remove vacuum/vapor harness from throttle body. Remove brake booster hose from air intake plenum. Remove ignition coil from air intake plenum. Disconnect coolant temperature sensor.
4. Remove vacuum connections from air intake plenum vacuum connector. Remove fuel hoses from fuel rail. Remove fasteners attaching air intake plenum to intake manifold. Remove air intake plenum.
5. Cover intake manifold using suitable cover when servicing. Remove vacuum hoses from fuel rail. Disconnect fuel injector wiring harness from engine wiring harness.
6. Remove fuel pressure regulator attaching bolts. Remove regulator from rail. Remove fuel rail attaching bolts and lift fuel rail assembly from intake manifold.

1. Ensure injectors are seated into receiver cups on rail with lock rings in place. See FUEL INJECTORS. Ensure injector holes are clean and all plugs have been removed.
2. Lubricate injector "O" rings with a drop of clean engine oil to ease installation. Push tip of each injector into its port. Push entire assembly into place until injectors are seated in ports.
3. Install 3 fuel rail attaching bolts, and tighten to 10 ft. lbs. (14 N.m). Lubricate fuel pressure regulator "O" ring with a drop of clean engine oil. Install fuel pressure regulator onto fuel rail.
4. Install fuel pressure regulator attaching bolts, and tighten bolts to 77 INCH lbs. (8.7 N.m). Install fuel supply and return tube hold-down bolt. Install vacuum crossover tube hold-down bolt. Tighten both bolts to 95 INCH lbs. (11 N.m).
5. Tighten pressure regulator hose clamps to 10 INCH lbs. (1 N.m). Connect fuel injector wiring harness to engine wiring harness. Connect vacuum harness to fuel rail assembly. Remove covering from lower intake manifold. Clean manifold surface.
6. Place intake manifold gaskets with beaded sealer up on lower manifold. Place air intake plenum in position. Loosely install ignition coil to intake manifold. Install manifold attaching fasteners.
7. Tighten 8 manifold fasteners to 10 ft. lbs. (14 N.m). Tighten 2 ignition coil fasteners to 95 INCH lbs. (11 N.m). Connect fuel line to fuel rail. Tighten hose clamps to 10 INCH lbs. (1 N.m).
8. Connect vacuum harness to air intake plenum and fuel pressure regulator. Reconnect coolant temperature sensor electrical connector. Connect brake booster supply hose to intake plenum.
9. Reconnect automatic idle speed motor and throttle position sensor wiring connectors. Connect vacuum/vapor hose harness to throttle body.
10. Install throttle cable and transaxle kickdown linkage (if equipped). Install air inlet hose assembly. Connect negative battery cable. Pressure test system for leaks.

1. Release fuel system pressure. See FUEL SYSTEM PRESSURE RELEASE. Disconnect negative battery cable.
2. Remove air cleaner-to-throttle body hose. Remove throttle cable. Remove wiring harness from throttle cable bracket and intake manifold water tube. Remove wiring connectors for automatic idle speed motor and throttle position sensor from throttle body.
3. Remove vacuum hose harness from throttle body. Remove PCV and brake booster hoses from air intake plenum. Remove EGR tube flange from intake plenum. Disconnect charge temperature sensor.
4. Remove vacuum harness connections from air intake plenum. Remove cylinder head-to-intake plenum strut. Disconnect MAP sensor and oxygen sensor electrical connectors.
5. Remove engine-mounted ground strap. Remove fuel hose quick-connect fitting from fuel rail by pushing in on plastic ring located on end of fittings. Gently pull fittings from fuel rail. CAUTION: To minimize fuel spill, wrap a shop towel around and under fuel rail fittings.
6. Remove direct ignition system coils. See IGNITION COIL (3.3L DIS) under IGNITION SYSTEM. Remove alternator bracket-to-intake manifold bolt. Remove intake manifold bolts, and rotate manifold back over rear valve cover.
7. Cover intake manifold using a suitable cover when servicing. Remove vacuum hose harness connector from fuel pressure regulator. Remove fuel tube retainer bracket screw and fuel rail attaching bolts. Spread retainer bracket to allow fuel tube removal clearance.
8. Remove fuel rail injector wiring clip from alternator bracket. Disconnect cam sensor, coolant temperature sensor and engine temperature sensor connectors.
9. Remove fuel rail. DO NOT damage rubber "O" rings on injectors when removing injectors from ports. Replace any damaged "O" rings.

Scheme 9

1. Ensure injectors are seated into receiver cups on rail with lock rings in place. See FUEL INJECTORS. Ensure injector holes are clean and all plugs have been removed. Replace any damaged "O" rings.
2. Lubricate injector "O" rings with a drop of clean engine oil to ease installation. Push tip of each injector into its port. Push entire assembly into place until injectors are seated in ports.
3. Install 4 fuel rail attaching bolts, and tighten to 17 ft. lbs. (23 N.m). Install fuel tube retaining bracket screw, and tighten to 35 INCH lbs. (4 N.m). Reconnect cam sensor, coolant temperature sensor and engine temperature sensor.
4. Reconnect fuel injector wiring harness to engine harness. Install fuel injector wiring harness wiring clips on alternator bracket and intake manifold water tube. Connect fuel pressure regulator vacuum hose. Remove covering on lower intake manifold, and clean manifold surface.
5. Place intake manifold gasket on lower manifold. Put upper manifold into place, and install bolts finger tight. Install and finger-tighten alternator bracket-to-intake manifold bolt and cylinder head-to-intake manifold strut bolts.
6. Tighten upper-to-lower intake manifold bolts to 21 ft. lbs. (28 N.m) in sequence. (Scheme 9) Tighten alternator bracket-to-intake manifold bolt to 40 ft. lbs. (54 N.m). Tighten cylinder head-to-intake manifold strut bolts to 40 ft. lbs. (54 N.m).
7. Install ground strap. Reconnect MAP sensor, oxygen sensor and charge temperature sensor electrical connectors. Connect vacuum hose harness to intake plenum.
8. Connect PCV system. Using a new gasket, connect EGR tube flange to intake manifold and tighten to 17 ft. lbs. (23 N.m).
9. Clip wiring harness into hole in throttle cable bracket. Connect wiring connectors to throttle position sensor and automatic idle speed motor. Connect vacuum harness to throttle body.
10. Install direct ignition system coils. See IGNITION COIL under IGNITION SYSTEM. Tighten fasteners to 105 INCH lbs. (12 N.m). Install fuel hose quick-connect fittings to fuel rail. Push each fitting onto rail until it clicks into place. Fuel supply fitting is 5/16" and fuel return fitting is 1/4".
11. Install throttle cable. Install air cleaner and hose assembly. Connect negative battery cable. Pressure test system for leaks.

1. Release fuel system pressure. See FUEL SYSTEM PRESSURE RELEASE. Disconnect negative battery cable. Remove air cleaner. Remove throttle body from intake manifold. Remove air conditioning compressor-to-intake manifold support bracket (if equipped).
2. Disconnect fuel injector wiring connectors (injector connectors are numerically tagged for installation reference). Remove vacuum line from fuel pressure regulator.
3. On 3.9L, disconnect intake manifold charge air temperature sensor connector. DO NOT remove sensor.
4. On all models, remove EVAP canister purge solenoid/bracket assembly from intake manifold. Disconnect 2 rear fuel rail fuel lines, and remove remaining fuel rail mounting bolts.
5. Gently rock and pull on left fuel rail and then right fuel rail until injectors start to clear intake manifold. Repeat procedure until injectors clear intake manifold, and remove fuel rail with injectors attached. Remove injector-to-fuel rail clips. (Scheme 12)

1. Lubricate injector "O" rings with a drop of clean engine oil. Install injectors and clips into fuel rail receiver cups. Ensure injectors and clips are fully seated. Position fuel rail/injector assembly on intake manifold openings. Using care not to tear "O" rings, guide each injector into intake manifold. Push right and then left fuel rail down until injectors are bottomed on injector shoulder.
2. To complete installation, reverse removal procedure. Connect negative battery cable, and check for leaks.

1. Remove air cleaner assembly. Release fuel system pressure. See FUEL SYSTEM PRESSURE RELEASE. Disconnect negative battery cable. Remove injector hold-down clamp Torx screw.
2. With 2 small screwdrivers, lift top off injector using slots provided. (Scheme 10) Using a small screwdriver placed in hole in front of electrical connector, gently pry injector from pod. Ensure lower "O" ring has been removed from pod.

Scheme 10

1. Place a new "O" ring on injector cap. New injector has new upper and lower "O" ring already installed. Apply a light coating of clean engine oil on "O" rings.
2. Place assembly in pod, and align injector wiring terminals with injector cap fastener hole. (Scheme 11) Install injector cap with locating notch aligned with locating lobe on injector.
3. Push down on cap to ensure good seal. Rotate cap and injector to line up attachment hole. Install Torx screw; tighten to 35-45 INCH lbs. (4-5 N.m). Reconnect negative battery cable. Pressure test system for leaks. Reinstall air cleaner assembly.

Scheme 11

1. Remove fuel rail. See FUEL INJECTOR RAILS (PFI). Disconnect injector wiring connector from injector. Position fuel rail assembly so injectors are accessible.
2. Rotate and pull injector out of fuel rail (clip will remain on injector). (Scheme 12) Inspect injector "O" ring and clip for damage. Replace "O" ring if it is damaged. If injector is to be reused, install a protective cap on injector tip to prevent damage. Replace clip if it is damaged. Repeat for remaining injectors.

Scheme 12

1. Lubricate "O" ring of each injector with a drop of clean engine oil to aid in installation. Install injector top end into fuel rail receiver cup. Be careful not to damage "O" ring during installation.
2. Repeat for remaining injectors. Install wiring harness to injectors. Fasten wiring harness into wiring clips (if equipped).

1. Remove air cleaner assembly. Release fuel system pressure. See FUEL SYSTEM PRESSURE RELEASE. Disconnect negative battery cable. Remove injector hold-down clamp Torx screw. (Scheme 13) CAUTION: DO NOT damage loose spacer under clamp.
2. Using a small screwdriver and area in front of hold-down clamp for leverage, lift caps off injectors. Using a small screwdriver placed in hole in front of electrical connector, gently pry injectors from pods. (Scheme 14) Ensure each injector lower "O" ring has been removed from pod.

Scheme 13

Scheme 14

1. Install lower "O" ring on injector. "O" ring should butt against plastic filter assembly. Inspect both "O" rings for cuts and tears, and replace if necessary. Align injector terminal housing with locating socket in injector cap.
2. Press injector into cap so upper "O" ring flange is flush with lower surface of cap. Spray inner surfaces of injector pod with Mopar Brake and Carburetor Parts Cleaner to remove residual gasoline.
3. Lightly lubricate upper and lower "O" rings with petroleum jelly. Place injector and cap in injector pod, and align cap locating pin with locating hole in casting. (Scheme 14) CAUTION: Passenger-side cap locating pin is 5 mm in diameter and will only fit in passenger-side locating hole. Driver-side locating pin is 4 mm in diameter.
4. Repeat steps 1)-3) for other injector and cap. Press firmly on injector caps until flush with casting surface. Place injector hold-down clamp with spacer on rear portion of caps, aligning holes in clamp with pins on caps. Install clamp screw. Ensure spacer is in place. CAUTION: "O" ring may cause caps to lift up; press firmly on both caps with one hand to ensure caps are flush while installing clamp screw.
5. Tighten screw to 35 INCH lbs. (4 N.m). Connect negative battery cable. Pressure test system for leaks. Reinstall air cleaner assembly.

Removal & Installation (3.0L, 3.3L, 3.9L & 5.2L)

See FUEL INJECTOR RAILS (PFI).

Removal (2.5L)

Release fuel system pressure. See FUEL SYSTEM PRESSURE RELEASE. Disconnect negative battery cable. Remove fuel pressure regulator vacuum connector. Remove regulator retainer screw. Remove fuel pressure regulator retainer. Remove fuel pressure regulator.

1. Ensure fuel pressure regulator has 2 plastic spacers. Ensure fuel rail has 2 "O" rings installed in fuel pressure regulator cavity. (Scheme 15) Lubricate "O" rings with clean engine oil. Insert fuel pressure regulator into fuel rail. Install fuel pressure regulator retainer.
2. Install retainer screw. Tighten to 50 INCH lbs. (5.6 N.m). Connect fuel pressure regulator vacuum connection. Pressure test system for leaks.

Scheme 15

Removal (5.9L)

1. Remove air cleaner assembly. Release fuel system pressure. See FUEL SYSTEM PRESSURE RELEASE. Disconnect negative battery cable. Remove vacuum hose from throttle body.
2. Remove screws attaching pressure regulator to throttle body. Remove pressure regulator from throttle body. Carefully remove "O" ring from pressure regulator. Remove gasket.

Place new gasket on pressure regulator, and carefully install new "O" ring. Position pressure regulator on throttle body, and press regulator into place. Install mounting screws, and tighten screws to 40 INCH lbs. (4.5 N.m). Install vacuum hose to throttle body. Pressure test system for leaks. Reinstall air cleaner assembly.

1. O2 sensor is mounted in exhaust pipe just below exhaust header. It is equipped with a permanent pigtail, which must be protected from damage when sensor is removed. Carefully disconnect engine harness from O2 sensor connector. DO NOT pull on O2 sensor wiring when disconnecting sensor connector. Remove O2 sensor using Socket (C-4907). Sensor may be difficult to remove when engine temperature is less than 120°F (48°C).
2. Ensure sensor is free of contaminants; avoid using cleaning solvents. Use an 18 mm x 1.5 x 6E tap to clean threads in exhaust manifold. If installing original sensor, sensor threads must be coated with anti-seize compound. New O2 sensors are packaged with compound already on threads. Tighten sensor to 20 ft. lbs. (27 N.m).

Removal & Installation (PFI)

1. Disconnect negative battery cable. Remove air cleaner-to-throttle body hose and clamp.
2. Remove throttle cable, speed control cables and transaxle linkage (if equipped). Disconnect wiring connectors for automatic idle speed motor and throttle position sensor. Disconnect vacuum hoses from throttle body.
3. Remove throttle body-to-intake manifold attaching nuts. Remove throttle body and gasket. To install, reverse removal procedure. Tighten throttle body attaching nuts to 19 ft. lbs (26 N.m).

Removal (TBI)

1. Remove air cleaner. Release fuel system pressure. See FUEL SYSTEM PRESSURE RELEASE. Disconnect negative battery cable. Disconnect vacuum hoses and electrical connectors from throttle body.
2. Remove throttle cable, speed control cable and transmission kickdown cables (if equipped). Remove throttle return spring. Remove fuel intake and return hoses.
3. Remove throttle body mounting screws, and lift throttle body from vehicle. Remove throttle body gasket from intake manifold.

1. Using a new gasket, install throttle body and tighten mounting screws to 15 ft. lbs. (20 N.m). Install fuel intake and return hoses using new original-equipment type clamps.
2. Install throttle return spring. Install throttle cable. Install speed control and transmission kickdown cables (if equipped). Install wiring connectors and vacuum hoses. Install air cleaner. Reconnect negative battery cable.

Disconnect negative battery cable. Remove air cleaner (if necessary). Disconnect TPS electrical connector. Remove TPS mounting screws. Lift TPS off throttle shaft.

Install TPS on throttle body. Tighten mounting screws. See TORQUE SPECIFICATIONS table. Connect TPS electrical connector. Install air cleaner (if removed). Connect negative battery cable.

Remove air cleaner. Disconnect throttle body temperature sensor electrical connector. Remove sensor.

Apply heat transfer compound (provided with new sensor) to tip of new sensor. Install sensor, and tighten it to 110 INCH lbs. (12 N.m).

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS