Engine Controls - Remove/install/overhaul Dodge Spirit I

INTRODUCTION

Note. Monaco and Premier models (VIN U) are manufactured with either an early or late design. Only late design models are covered in this article. Late design models are equipped with DIS, with engine controller (SBEC) located next to battery. Service procedures for early design models, with engine code Z7X711, are the same as those found in 1990 Monaco and Premier ENGINE PERFORMANCE Section.

Note. Shadow and Sundance Convertible models equipped with 2.5L TBI engine are manufactured with either early or late design fuel, ignition and emission systems. Late design vehicles use an epoxy ignition coil, mounted on thermostat housing, and a high pressure fuel system requiring quick-connect fuel fittings. Early design vehicles use an oil-filled ignition coil, mounted on right inner fender, and a low pressure fuel system using hoses and clamps.

Removal, overhaul and installation procedures are covered in this article. If component removal and installation is primarily an unbolt and bolt-on procedure, only a torque specification may be furnished.

Removal

1. Disconnect distributor pick-up wire(s) at distributor. Remove splash shield screws and splash shield. Rotate crankshaft until No. 1 piston is at TDC of compression stroke.
2. Ensure pointer on clutch housing is in-line with zero mark (TDC) on flywheel. Remove distributor cap screws and distributor cap. (Scheme 1) Reference mark distributor rotor-to-distributor housing. Remove distributor hold-down bolt and distributor from engine.

Scheme 1

Installation

1. Ensure No. 1 piston is still at TDC of compression stroke. Install distributor. Ensure distributor "O" ring is properly seated on engine block. To complete installation, reverse removal procedure.
2. Adjust ignition timing. See appropriate ON-VEHICLE ADJUSTMENTS article. Tighten distributor hold-down bolt to specification. See «TORQUE SPECIFICATIONS»(/dodge/spirit/i-1988-1995/remont/removal-installation/#engine-controls-removeinstalloverhaul__torque-specifications) table at end of this article.

Camshaft sensor is mounted in front of cylinder head. Disconnect camshaft sensor wiring harness connector. Remove camshaft 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 camshaft sensor, a new paper spacer MUST be installed on sensor face before installation.
2. 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/spirit/i-1988-1995/remont/removal-installation/#engine-controls-removeinstalloverhaul) at end of article. Connect sensor wiring harness connector.

Removal & Installation

1. Camshaft sensor is located on left rear side of cylinder head. Disconnect sensor wiring harness connector. Remove sensor retaining bolts and sensor.
2. To install, reverse removal procedure. Install sensor with tab facing rear of engine. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(/dodge/spirit/i-1988-1995/remont/removal-installation/#engine-controls-removeinstalloverhaul) at end of article. Connect sensor wiring harness connector.

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.

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/spirit/i-1988-1995/remont/removal-installation/#engine-controls-removeinstalloverhaul) 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(s) and sensor.

Install crank angle sensor in transaxle and push sensor down until contact is made with transaxle housing. Install and tighten sensor hold-down bolt(s) to specification. See TORQUE SPECIFICATIONS at end of this 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/spirit/i-1988-1995/remont/removal-installation/#engine-controls-removeinstalloverhaul) at end of article. Connect sensor wiring harness connector.

FUEL SYSTEM PRESSURE RELEASE ALL EXCEPT 3.0L VIN U

1. Slowly open fuel tank cap to release pressure in tank. To release remaining pressure in system, disconnect injector wiring harness connector.
2. Using jumper wire, ground injector harness terminal No. 1. Using a second jumper wire, apply battery voltage to injector harness terminal No. 2. (Scheme 2)or (Scheme 3).
3. DO NOT apply battery voltage to terminal No. 2 for longer than 5 seconds. Remove jumper wires. Connect injector wiring harness connector.

Scheme 2

Scheme 3

FUEL SYSTEM PRESSURE RELEASE 3.0L VIN U

Disconnect negative battery cable. Remove fuel tank filler cap to release fuel pressure in tank. Wrap shop towel around fuel line prior to disconnecting fuel line. Using Fuel Line Disconnect (6182), slowly remove Black fuel supply line from fuel rail. Release system fuel pressure by removing fuel line.

FUEL PUMP (ALL EXCEPT 3.0L VIN U)

Remove fuel tank. See FUEL TANK under FUEL SYSTEM in this article. Using a hammer and brass drift punch, carefully tap fuel pump lock ring counterclockwise. (Scheme 4)Remove lock ring, fuel pump and "O" ring seal from tank. Discard "O" ring and fuel inlet filter.

Scheme 4

Clean fuel pump mating surfaces. Install new "O" ring and inlet fuel filter on pump. Install fuel pump and locking ring. Using a hammer and brass drift punch, drive lock ring around clockwise to lock pump in place. To complete installation, reverse removal procedure. Fill fuel tank. Turn ignition switch to ON position to pressurize fuel system. Check fuel system for leaks.

1. Fuel pump is attached to fuel gauge sending unit and is located inside fuel tank. Release fuel system pressure. See FUEL SYSTEM PRESSURE RELEASE in this article.
2. Disconnect negative battery cable. Remove fuel tank. See FUEL TANK under FUEL SYSTEM in this article. Using a screwdriver, loosen fuel pump retaining clamp. Note position of fuel pump/sending unit and carefully pull fuel pump/sending unit out from fuel tank.

1. Ensure gasket mating surfaces are clean. Position new gasket on fuel pump. Install fuel pump. Ensure pump is positioned with fuel and vapor tubes pointing to the right side of the tank (when tank is installed). Hold fuel pump in position and tighten fuel pump clamp.
2. Install fuel tank. To complete installation, reverse removal procedure. Lightly lubricate fuel line quick-connectors with engine oil prior to reconnecting fuel line retainer tabs. Fill fuel tank. Turn ignition switch to ON position to pressurize fuel system. Check fuel system for leaks.

1. Release fuel pressure. See FUEL SYSTEM PRESSURE RELEASE in this article. Disconnect negative battery cable. Raise vehicle on hoist. Remove drain cap located on sending unit and drain fuel from tank into a suitable container.
2. Lower vehicle. Remove screws that secure fuel filler tube-to-quarter panel. Raise vehicle. Remove right rear wheel, if necessary. Disconnect wiring harness connectors and fuel hoses from fuel tank.
3. Support fuel tank. Loosen tank mounting straps and lower tank slightly. Remove hose from pressure relief/rollover valve. Carefully remove fuel filler tube from tank. Remove tank mounting straps and lower tank.

To install fuel tank, reverse removal procedure. Fill fuel tank. Turn ignition switch to ON position to pressurize fuel system. Check fuel system for leaks.

1. Release fuel pressure. See FUEL SYSTEM PRESSURE RELEASE in this article. Disconnect negative battery cable. Raise vehicle on hoist. Drain fuel from tank into a suitable container.
2. Remove right rear wheel and splash shield from wheel well. Remove ground wire from fuel tank filler neck. Remove ground wire retaining screw and ground wire from fuel tank filler neck. Disconnect fuel tank vent hose from fuel tank filler neck. Slide fuel tank vent hose out of retainer clip on frame.
3. Remove nuts securing fuel tank support strap. Push other end of strap up and out left side of frame rail. Support fuel tank. Disconnect fuel line quick-connector tabs at fuel filter inlet and fuel return line. Pull fuel tank to fuel filter supply tube through access hole in frame toward fuel tank. Disconnect fuel pump/sending unit electrical connector.
4. Disconnect fuel vapor hose and fuel return tube. Remove fuel tank mounting bolts. Lower fuel tank 2 to 3 inches. Push fuel tank vent hose toward fuel tank through access hole in frame. Tip rear of fuel tank down to allow mounting flanges to slide out from above rear axle while lowering fuel tank.

1. To install, reverse removal procedure. Tighten fuel tank mounting bolts to specification. See «TORQUE SPECIFICATIONS»(/dodge/spirit/i-1988-1995/remont/removal-installation/#engine-controls-removeinstalloverhaul) at end of article. Install fuel tank support strap.
2. Tighten top nut until distance between bottom of strap bolt and strap is 2" (54 mm). Reconnect negative battery cable. Turn ignition switch to ON position to pressurize fuel system. Check fuel system for leaks.

1. Release fuel system pressure. See FUEL SYSTEM PRESSURE RELEASE in this article. Disconnect negative battery cable.
2. Disconnect fuel injector wiring harness connector. 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.
3. Disconnect fuel pressure regulator vacuum hose. Remove screws attaching fuel rail to intake manifold. Remove fuel rail and injectors as an assembly. Cover injector ports with a suitable cover.
4. 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)

Scheme 5

To install, reverse removal procedure. Inspect fuel injector "O" ring for damage and replace as necessary. Apply light coating of clean engine oil on "O" rings. Install injector(s). Tighten bolts to specification. See TORQUE SPECIFICATIONS at end of article. Turn ignition switch to ON position to pressurize fuel system. Check fuel system for leaks.

1. Disconnect negative battery cable. Release fuel system pressure. See FUEL SYSTEM PRESSURE RELEASE in this article. Using Fuel Line Disconnect (6182), disconnect Gray fuel return tube from fuel pressure regulator and Black fuel supply tube from fuel rail.
2. Slide fuel disconnect tube onto nipple and push it forward into quick-connector until handle stops on connector casing. Pull fuel tubes off. Disconnect wiring harness connector.
3. Disconnect throttle cable from throttle body and holding bracket. Using finger pressure only, remove cruise control connector (if equipped). Remove fuel rail and fuel pressure regulator mounting bolts. CAUTION: Use only finger pressure to remove cruise control cable connector. If connector is damaged, cruise control servo and cable assembly must be replaced.
4. Disconnect vacuum line from pressure regulator. Remove fuel rails, regulator and injectors as an assembly. Remove injector lock ring. Remove fuel injector from fuel rail. (Scheme 5)

To install, reverse removal procedure. Inspect fuel injector "O" ring for damage and replace as necessary. Apply light coating of clean engine oil on "O" rings. Install injector(s). Turn ignition switch to ON position to pressurize fuel system. Check fuel system for leaks.

1. Release fuel system pressure. See FUEL SYSTEM PRESSURE RELEASE in this article. Disconnect negative battery cable. Remove hose between air cleaner and throttle body. Remove throttle cable.
2. Remove wiring harness connectors from throttle body. Remove vacuum hose harness from throttle body. Remove vacuum hoses from air intake plenum. Remove EGR tube flange from intake plenum (California vehicles). Remove wiring harness connector from coolant temperature sensor.
3. Remove fuel hoses from fuel rail. Remove upper intake manifold assembly. Cover intake manifold openings during service. Remove vacuum hoses from fuel rail. Disconnect fuel injector wiring harness from engine wiring harness. Remove fuel pressure regulator from fuel rail.
4. Remove bolts attaching fuel rail to intake manifold. Remove fuel rail and injectors as an 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)

To install, reverse removal procedure. Inspect fuel injector "O" ring for damage and replace as necessary. Apply light coating of clean engine oil on "O" rings. Install injector(s). Tighten bolts to specification. See TORQUE SPECIFICATIONS at end of article. Turn ignition switch to ON position to pressurize fuel system. Check fuel system for leaks.

1. Release fuel system pressure. See FUEL SYSTEM PRESSURE RELEASE in this article. Disconnect negative battery cable. Remove air cleaner assembly and air duct. Remove throttle cable.
2. Remove Automatic Idle Speed (AIS) and Throttle Position Sensor (TPS) wiring connectors from throttle body. Remove vacuum hose harness from throttle body.
3. Remove PCV and brake booster hoses from air intake plenum. Remove EGR tube flange from intake plenum. Remove electrical connector from charge temperature sensor. Remove cylinder head to intake plenum strut.
4. Disconnect MAP sensor and O2 sensor electrical connectors. Remove engine mounted ground strap. 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.
5. 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. Remove vacuum hose from fuel pressure regulator.
6. Remove fuel tube retainer bracket screw and fuel rail attaching bolts. Spread retainer bracket to remove fuel tube. Remove fuel rail injector wiring clip from alternator bracket. Disconnect cam sensor, coolant temperature sensor and engine temperature sensors.
7. Remove fuel rail and injectors as an assembly. Use care to not damage "O" rings on fuel injectors. Disconnect electrical connector from injector. Remove injector lock ring. Remove fuel injector from fuel rail. (Scheme 5)

To install, reverse removal procedure. Inspect fuel injector "O" ring for damage and replace as necessary. Apply light coating of clean engine oil on "O" rings. Install injector(s). Tighten bolts to specification. See TORQUE SPECIFICATIONS at end of article. Turn ignition switch to ON position to pressurize fuel system. Check fuel system for leaks.

1. Release fuel system pressure. See 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 throttle body. Ensure bottom injector "O" ring is removed with injector.

Scheme 6

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 throttle body assembly. Align 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. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(/dodge/spirit/i-1988-1995/remont/removal-installation/#engine-controls-removeinstalloverhaul) at end of this article.

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 Socket (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/spirit/i-1988-1995/remont/removal-installation/#engine-controls-removeinstalloverhaul) at end of article.

1. Remove air cleaner. Release fuel pressure. See 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). Remove return spring (if equipped). Loosen fuel hose-to valve cover clamp. Disconnect fuel supply and return hoses.
3. Remove throttle body mounting screws. Remove throttle body. To install, reverse removal procedure. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(/dodge/spirit/i-1988-1995/remont/removal-installation/#engine-controls-removeinstalloverhaul) at end of this article.

1. Disconnect negative battery cable. Remove air cleaner-to-throttle body mounting screws. Disconnect wiring harness connectors as necessary from throttle body. Disconnect throttle and transaxle cables.
2. Using finger pressure, remove cruise control connector (if equipped). Remove throttle return spring (if equipped). Remove throttle body mounting nuts, throttle body and gasket.

Ensure gasket mating surfaces are clean. Install new gasket and throttle body. Tighten to specification. See TORQUE SPECIFICATIONS at end of article. To complete installation, reverse removal procedure.

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. Tighten to specification. See TORQUE SPECIFICATIONS at end of article.

TURBOCHARGER

Note. Turbocharger is removed from bottom of vehicle.

1. From top of engine, disconnect negative battery cable. 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. Raise and support vehicle. Remove right front wheel and driveshaft. 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-seize 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. Tighten bolts to specification. See the «TORQUE SPECIFICATIONS»(/dodge/spirit/i-1988-1995/remont/removal-installation/#engine-controls-removeinstalloverhaul) .

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

See also:
• TORQUE SPECIFICATIONS
• TORQUE SPECIFICATIONS