Engine Controls - Remove/install/overhaul Dodge Shadow I

INTRODUCTION

Removal, overhaul and installation procedures (when given by manufacturer) are covered in this article. If component removal and installation is primarily an unbolt and bolt on procedure, a simple tightening specification may be all that is furnished.

REMOVAL

Camshaft sensor is mounted on top of timing chain cover. Disconnect camshaft sensor wiring harness connector. Loosen camshaft sensor bolt and remove sensor. Removal force may be high due to "O" ring seal on sensor. DO NOT pull on sensor lead to remove sensor.

INSTALLATION

1. If old sensor is to be reused, remove old paper spacer from sensor face. Install a new paper spacer to sensor face before installing sensor. Install new "O" ring on sensor. If installing a new sensor, ensure paper spacer is attached to sensor face and "O" ring is positioned correctly. NOTE: If reusing old camshaft sensor, a new paper spacer MUST be installed on sensor face before installation.
2. Apply oil to sensor "O" ring. Install sensor and push down on sensor until paper spacer makes contact with cam timing gear. Hold sensor in position and tighten sensor bolt to specification. See «TORQUE SPECIFICATIONS»(/dodge/shadow/i-1986-1994/remont/removal-installation/#engine-controls-removeinstalloverhaul__torque-specifications) at end of article. Connect sensor wiring harness connector.

Crank angle sensor is located in transaxle housing. Disconnect crank angle sensor wiring harness connector. Remove crank angle sensor bolt and sensor.

1. If old sensor is to be reused, remove old paper spacer from sensor face. Install a new paper spacer to sensor face before installing sensor. If installing a new sensor, ensure paper spacer is attached to sensor face. NOTE: If reusing old crankshaft sensor, a new paper spacer MUST be installed on sensor face before installation.
2. Install sensor in transaxle and push down on sensor until paper spacer makes contact with drive plate. Hold sensor in position and tighten sensor bolt to specification. See «TORQUE SPECIFICATIONS»(/dodge/shadow/i-1986-1994/remont/removal-installation/#engine-controls-removeinstalloverhaul__torque-specifications) at end of article. Connect sensor wiring harness connector.

REMOVAL & INSTALLATION

1. Disconnect distributor pick-up wire(s) at distributor. Remove splash shield retaining screws. Remove splash shield.
2. Remove distributor cap retaining screws. Remove distributor cap. Rotate engine crankshaft until rotor points toward engine block. Use distributor rotor as a reference for installation of distributor.
3. Remove distributor hold-down bolt. Remove distributor from engine. To install, reverse removal procedure. During installation, ensure "O" ring is properly seated on engine block.

1. Disconnect distributor lead wire at distributor harness connector. Loosen distributor cap retaining screws. Remove distributor cap.
2. Rotate engine crankshaft until distributor is pointing toward intake plenum. Scribe intake plenum to indicate position of rotor. Use scribe mark during installation as a reference during installation.
3. Remove distributor hold-down nut. Remove distributor from engine. To install, reverse removal procedure. During installation, ensure "O" ring is properly seated on engine block.

Scheme 1

FUEL SYSTEM PRESSURE RELEASE

1. Fuel pressure must be fully released before opening fuel system or removing any fuel carrying components. To release pressure in tank, open fuel tank cap slowly.
2. To release remaining pressure in system, disconnect injector wiring harness. Using jumper wire, connect injector harness ground terminal No. 1 to ground. Connect injector harness positive terminal No. 2 to positive battery terminal with second jumper wire. (Scheme 2)or (Scheme 3).
3. DO NOT keep injector connector to positive battery terminal for longer than 5 seconds. Remove jumper wires. Fuel injection system can now be opened and fuel carrying components removed as pressure is fully released.

Scheme 2

Scheme 3

* PLEASE READ THIS FIRST *

1. Release fuel system pressure. See «FUEL SYSTEM PRESSURE RELEASE»(/dodge/shadow/i-1986-1994/remont/removal-installation/#engine-controls-removeinstalloverhaul__fuel-system-pressure-release) in this article. Disconnect negative battery cable.
2. Loosen clamps on fuel supply and return lines. Place a shop rag under hoses to catch fuel spillage. Remove fuel supply and return hoses.
3. Disconnect fuel vacuum/vapor hose from intake plenum. (Scheme 4) Disconnect fuel pressure regulator vacuum hose. On Turbo IV, disconnect 2-pin electrical connector from charge temperature sensor.
4. On all engines, remove screws attaching fuel rail to intake manifold. Pulling rail, remove fuel rail and injector assembly. Use care to not damage "O" rings on fuel injectors. Cover injector ports with a suitable cover.
5. DO NOT remove fuel injectors from rail until assembly is out of vehicle. Disconnect electrical connector from injector. Remove injector lock ring. Remove fuel injector from fuel rail. (Scheme 5)
6. To install, reverse removal procedure. Apply a light coating of clean engine oil on "O" rings. This will aid installation of fuel rail assembly. Tighten components to specification. See «TORQUE SPECIFICATIONS»(/dodge/shadow/i-1986-1994/remont/removal-installation/#engine-controls-removeinstalloverhaul__torque-specifications) in this article.

Scheme 4

1. Release fuel system pressure. See «FUEL SYSTEM PRESSURE RELEASE»(/dodge/shadow/i-1986-1994/remont/removal-installation/#engine-controls-removeinstalloverhaul__fuel-system-pressure-release) in this article. Disconnect negative battery cable.
2. Remove hose between air cleaner and throttle body. Remove throttle cable. Remove AIS and TPS electrical connectors from throttle body. Remove vacuum hose harness from throttle body.
3. Remove vacuum hoses from air intake plenum. Remove EGR tube flange from intake plenum (CA vehicles). Remove electrical connector from coolant temperature sensor.
4. Remove fuel hoses from fuel rail. Remove upper intake plenum assembly. Cover intake manifold openings during service.
5. Remove vacuum hoses from fuel rail. Disconnect fuel injector wiring harness from engine wiring harness. Remove fuel pressure regulator from fuel rail.
6. Remove bolts attaching fuel rail to intake manifold. Pulling rail, remove fuel rail and injector assembly. Use care to not damage "O" rings on fuel injectors. Cover injector ports with a suitable cover.
7. DO NOT remove fuel injectors from rail until assembly is out of vehicle. Disconnect electrical connector from injector. Remove injector lock ring. Remove fuel injector from fuel rail. (Scheme 5)
8. To install, reverse removal procedure. Apply a light coating of clean engine oil on "O" rings. This will aid installation of fuel rail assembly. Tighten components to specification. See «TORQUE SPECIFICATIONS»(/dodge/shadow/i-1986-1994/remont/removal-installation/#engine-controls-removeinstalloverhaul__torque-specifications) in this article.

1. Release fuel system pressure. See «FUEL SYSTEM PRESSURE RELEASE»(/dodge/shadow/i-1986-1994/remont/removal-installation/#engine-controls-removeinstalloverhaul__fuel-system-pressure-release) in this article. Disconnect negative battery cable.
2. Remove hose between air cleaner and throttle body. Remove throttle cable. Remove AIS and TPS electrical connectors from throttle body. Remove vacuum hose harness from throttle body.
3. Remove vacuum hoses from air intake plenum. Remove EGR tube flange from intake plenum. Remove electrical connector from charge temperature sensor.
4. Remove cylinder head to intake plenum strut. Disconnect MAP sensor and O2 sensor electrical connectors. Remove engine mounted ground strap.
5. Remove fuel hose quick connect fittings from fuel rail by pushing in on plastic ring at end of fittings. Gently pull fittings from fuel rail.
6. Remove DIS coils and alternator bracket to intake manifold bolt. Remove intake manifold bolts and rotate manifold back over rear valve cover. Cover intake ports while servicing vehicle.
7. Remove vacuum hose from fuel pressure regulator. Remove fuel tube retainer bracket screw and fuel rail attaching bolts. Spread retainer bracket to remove fuel tube.
8. Remove fuel rail injector wiring clip from alternator bracket. Disconnect cam sensor, coolant temperature sensor and engine temperature sensors. Remove fuel rail.
9. Use care to not damage "O" rings on fuel injectors. Cover injector ports with a suitable cover. Disconnect electrical connector from injector. Remove injector lock ring. Remove fuel injector from fuel rail. (Scheme 5)
10. To install, reverse removal procedure. Apply a light coating of clean engine oil on "O" rings. This will aid installation of fuel rail assembly. Tighten components to specification. See «TORQUE SPECIFICATIONS»(/dodge/shadow/i-1986-1994/remont/removal-installation/#engine-controls-removeinstalloverhaul__torque-specifications) in this article.

Scheme 5

1. Release fuel system pressure. See «FUEL SYSTEM PRESSURE RELEASE»(/dodge/shadow/i-1986-1994/remont/removal-installation/#engine-controls-removeinstalloverhaul__fuel-system-pressure-release) in this article. Disconnect negative battery cable. Remove air cleaner assembly. Remove Torx screw holding injector cap.
2. Using 2 small screwdrivers, remove injector cap. Using a small screwdriver in front of electrical connector, gently pry injector from pod. Ensure bottom injector "O" ring is removed with injector.

1. Install a new "O" ring on injector cap. Injector will have "O" rings already installed. Apply a light coating of clean engine oil on "O" rings.
2. Place injector into pod assembly, aligning injector wiring terminals with injector cap fastener hole. (Scheme 6) Install injector cap with locating notch aligned with locating hole on injector.
3. Push down on injector cap to ensure a good seal. Rotate injector cap and injector to align attachment hole. Install Torx screw. To complete installation, reverse removal procedure. See «TORQUE SPECIFICATIONS»(/dodge/shadow/i-1986-1994/remont/removal-installation/#engine-controls-removeinstalloverhaul__torque-specifications) in this article.

Scheme 6

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 the sensor is removed. Ensure sensor is free of contaminants, avoid using cleaning solvents of any type.
2. Sensor may be difficult to remove when engine temperature is less than 120°F (48°C). Use Wrench (C-4907) to remove sensor. Threads in exhaust manifold must be cleaned with a tap prior to installation of sensor.
3. If old sensor is being reinstalled, threads on sensor must be coated with anti-seize compound. New sensors are packaged with anti-seize compound on threads. Tighten O2 sensor to specification. See «TORQUE SPECIFICATIONS»(/dodge/shadow/i-1986-1994/remont/removal-installation/#engine-controls-removeinstalloverhaul) in this article.

1. Remove air cleaner. See «FUEL SYSTEM PRESSURE RELEASE»(/dodge/shadow/i-1986-1994/remont/removal-installation/#engine-controls-removeinstalloverhaul__fuel-system-pressure-release) in this article. Disconnect negative battery cable. Disconnect vacuum hoses and electrical connectors.
2. Remove throttle cable. Remove speed control and transmission kickdown cable (if equipped). Disconnect fuel supply and return hoses. Remove throttle body mounting screws. Remove throttle body. To install, reverse removal procedure. See «TORQUE SPECIFICATIONS»(/dodge/shadow/i-1986-1994/remont/removal-installation/#engine-controls-removeinstalloverhaul__torque-specifications) in this article.

1. Disconnect negative battery cable. Remove clamp from air inlet hose. Remove air inlet hose. Disconnect Automatic Idle Speed (AIS) and Throttle Position Sensor (TPS) wiring connectors.
2. Disconnect vacuum hoses from throttle body. Remove bolts attaching throttle body to intake plenum. Remove throttle body. To install, reverse removal procedure. See «TORQUE SPECIFICATIONS»(/dodge/shadow/i-1986-1994/remont/removal-installation/#engine-controls-removeinstalloverhaul__torque-specifications) in this article.

1. Disconnect negative battery cable. Remove clamp from air inlet hose. Remove air inlet hose. Remove throttle cable and transaxle linkage.
2. Disconnect Automatic Idle Speed (AIS) motor and Throttle Position Sensor (TPS) wiring connectors. Disconnect vacuum hoses from throttle body. Remove bolts attaching throttle body to intake plenum.
3. Remove engine wiring harness bracket. Remove throttle body and gasket. To install, reverse removal procedure. See «TORQUE SPECIFICATIONS»(/dodge/shadow/i-1986-1994/remont/removal-installation/#engine-controls-removeinstalloverhaul__torque-specifications) in this article.

1. Disconnect negative battery cable. Remove clamp from air inlet hose. Remove air inlet hose. Remove throttle and speed control cables.
2. Disconnect Automatic Idle Speed (AIS) motor and Throttle Position Sensor (TPS) wiring connectors. Disconnect vacuum hoses from throttle body. Remove bolts attaching throttle body to intake plenum.
3. Remove throttle body and gasket. To install, reverse removal procedure. See «TORQUE SPECIFICATIONS»(/dodge/shadow/i-1986-1994/remont/removal-installation/#engine-controls-removeinstalloverhaul__torque-specifications) in this article.

Disconnect negative battery cable. Remove air cleaner. Disconnect 3-pin connector at sensor. Remove 2 screws attaching TPS to throttle body. Remove TPS. To install, reverse removal procedure. See TORQUE SPECIFICATIONS in this article.

1. From top of engine, remove front engine mount through bolt. Rotate engine top away from cowl. Disconnect coolant line from water box and turbocharger housing. Remove line and fitting from turbocharger.
2. Disconnect oil feed line from turbocharger housing. Remove wastegate rod retaining clip. Remove 3 nuts (2 upper, one lower on driver's side) retaining turbocharger to manifold.
3. Disconnect O2 sensor electrical connector. Disconnect vacuum lines. Remove right front wheel and driveshaft. From under vehicle, remove support bracket between turbocharger and block.
4. Disconnect oil drain back tube fitting from turbocharger housing. Remove fitting and hose. Remove last turbocharger attaching nut. Disconnect exhaust pipe joint from turbocharger housing.
5. Remove lower coolant line and turbocharger inlet fitting. From under vehicle, remove turbocharger.

1. From under vehicle, position turbocharger on exhaust manifold. Apply anti-seize compound on threads. Install one lower passenger side retaining nut. Apply thread sealant to inlet coolant line fitting. Install fitting into turbocharger housing.
2. Install bracket between turbocharger and block. Install screws finger tight. Tighten block screw to specification first, then tighten turbocharger screw.
3. Install exhaust pipe onto turbocharger. Install driveshaft and wheel. After applying anti-sieze compound, install 3 remaining turbocharger retaining nuts. Reconnect O2 sensor electrical connector and vacuum lines.
4. Install wastegate rod retaining clip. Connect oil feed line to turbocharger housing. Apply sealant to water box and turbocharger coolant line fittings.
5. Align front engine mount in crossmember bracket. Install through bolt. See «TORQUE SPECIFICATIONS»(/dodge/shadow/i-1986-1994/remont/removal-installation/#engine-controls-removeinstalloverhaul__torque-specifications) in this article.

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

See also:
• TORQUE SPECIFICATIONS
• FUEL SYSTEM PRESSURE RELEASE
• TORQUE SPECIFICATIONS