Engine Controls - Remove/install/overhaul Eagle Talon I

INTRODUCTION

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

Remove spark plug wires and distributor cap. Disconnect distributor electrical connector. Rotate crankshaft clockwise until No. 1 piston is at TDC of compression stroke. Ensure timing marks are aligned. Mark distributor rotor to distributor housing for reference. Remove distributor hold-down bolt and distributor.

Installation

1. If reference mark was not made as described in removal procedure, go to next step. If reference mark was made, install distributor by reversing removal procedure, then go to step 4.
2. Rotate crankshaft clockwise until No. 1 piston is at TDC of compression stroke. Align distributor housing and gear mating marks. Perform STEP 1. (Scheme 1)
3. Install distributor to engine while aligning housing mating mark with center of distributor installation stud. Perform STEP 2. (Scheme 1)
4. Adjust ignition timing. See appropriate ADJUSTMENTS article in the ENGINE PERFORMANCE Section. Tighten distributor hold-down bolt to specification. See «TORQUE SPECIFICATIONS»(/eagle/talon/i-1989-1994/remont/removal-installation/#engine-controls-removeinstalloverhaul) at end of article.

Scheme 1

1. Disconnect crank angle sensor. Rotate crankshaft clockwise until No. 1 piston is at TDC of compression stroke. Ensure crankshaft timing marks are aligned.
2. Mark crank angle sensor for installation reference. Remove crank angle sensor hold-down bolt and crank angle sensor.

1. If reference mark was not made as described in removal procedure, go to next step. If reference mark was made, install distributor by reversing removal procedure, then go to step 3.
2. Rotate crankshaft clockwise until No. 1 piston is at TDC of compression stroke. Align punch mark on crank angle sensor housing with notch in plate. (Scheme 2) Install crank angle sensor on cylinder head.
3. Adjust ignition timing. See appropriate ADJUSTMENTS article in the ENGINE PERFORMANCE Section. Tighten crank angle sensor hold-down bolt to specification. See «TORQUE SPECIFICATIONS»(/eagle/talon/i-1989-1994/remont/removal-installation/#engine-controls-removeinstalloverhaul) at end of this article.

Scheme 2

FUEL SYSTEM PRESSURE RELEASE

Disconnect fuel pump wiring harness connector at fuel tank. Start engine. Let engine run until fuel is exhausted and engine stops. Turn ignition off. Disconnect negative battery cable. Connect fuel pump wiring harness connector.

1. Fuel pump and fuel gauge is contained in one unit and is located inside fuel tank. Release fuel pressure. See «FUEL SYSTEM PRESSURE RELEASE»(/eagle/talon/i-1989-1994/remont/removal-installation/#engine-controls-removeinstalloverhaul__fuel-system-pressure-release). Drain fuel from tank.
2. Remove fuel pump access cover. (Scheme 3) Disconnect high pressure fuel line. Disconnect fuel pump connector. Remove fuel pump bolts and pump from fuel tank.

Scheme 3

To install, reverse removal procedure. Line up the alignment pins with fuel pump cover and install pump. (Scheme 4) Apply sealer to fuel pump access cover, and install cover. Fill fuel tank. Start engine and check for leaks.

Scheme 4

1. Fuel pump is located inside fuel tank. Release fuel pressure. See «FUEL SYSTEM PRESSURE RELEASE»(/eagle/talon/i-1989-1994/remont/removal-installation/#engine-controls-removeinstalloverhaul__fuel-system-pressure-release). Drain fuel from tank. Disconnect high pressure fuel hose. (Scheme 5) Disconnect fuel pump connector.
2. Lower fuel tank by loosening tank strap self-locking nuts to end of stud bolt. DO NOT remove self-locking nuts completely. (Scheme 5) Remove lateral rod bolt. Disconnect lateral rod from body bracket. Remove bolt and "O" ring from bottom of fuel tank. Remove bolts and fuel pump.

Scheme 5

1. To install, reverse removal procedure. Line up the alignment pins with fuel pump cover, and install fuel pump. (Scheme 4)
2. Install new "O" ring and bolt securing fuel pump to bottom of fuel tank, and tighten bolt before tightening remaining fuel pump bolts. Ensure "O" ring is not pinched. Fill fuel tank. Start engine and check for leaks.

1. Release fuel pressure. See «FUEL SYSTEM PRESSURE RELEASE»(/eagle/talon/i-1989-1994/remont/removal-installation/#engine-controls-removeinstalloverhaul__fuel-system-pressure-release). Disconnect negative battery cable. On 1.8L, disconnect breather hose. (Scheme 6) On 2.0L and 2.0L Turbo, remove center cover from top of injectors. (Scheme 7)
2. On all models, disconnect PCV hose. Disconnect accelerator cable clamps. Wrap fuel lines with shop towel and disconnect fuel lines at fuel rail. Disconnect injector harness connector.
3. Disconnect vacuum hose at fuel pressure regulator. Remove fuel rail bolts. Remove fuel rail and injectors as an assembly from intake manifold by lifting assembly straight upward.

1. To install, reverse removal procedure. Use new insulators, "O" rings and grommets for injectors. Ensure injector holes are clean.
2. Lubricate injector and fuel line "O" rings with engine oil before in-stalling. Install injector until firmly seated in port. Pressurize fuel system and check for leaks. Tighten all bolts to specification. See «TORQUE SPECIFICATIONS»(/eagle/talon/i-1989-1994/remont/removal-installation/#engine-controls-removeinstalloverhaul__torque-specifications) at end of article.

Scheme 6

Scheme 7

Removal & Installation

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.
2. Ensure sensor is free of contaminants. Avoid using cleaning solvents of any type. Sensor may be difficult to remove when engine temperature is less than 120°F (48°C).
3. Before installing O2 sensor, always use anti-seize compound on threads. Tighten O2 sensor to specification. See «TORQUE SPECIFICATIONS»(/eagle/talon/i-1989-1994/remont/removal-installation/#engine-controls-removeinstalloverhaul__torque-specifications) at end of article.

THROTTLE BODY

Note. (Scheme 8)- (Scheme 10) during the following removal and installation procedure.

1. Drain coolant. Disconnect accelerator cable. Disconnect breather, air intake (turbo air hose on turbo models) and vacuum hoses. Disconnect wiring harness connectors as necessary.
2. On 2.0L and 2.0L Turbo, remove throttle body bracket. On all models, disconnect water hoses. Remove bolts attaching throttle body to manifold. Remove throttle body.
3. To install, reverse removal procedure. Install new throttle body-to-manifold gasket. Fill cooling system and check for leaks. Tighten all bolts to specification. See «TORQUE SPECIFICATIONS»(/eagle/talon/i-1989-1994/remont/removal-installation/#engine-controls-removeinstalloverhaul__torque-specifications) at end of article.

Scheme 8

Scheme 9

Scheme 10

Removal (2.0L Turbo)

1. Disconnect negative battery cable. Drain cooling system and engine oil. On A/C-equipped models, remove condenser fan motor assembly. Disconnect oxygen sensor connector.
2. Remove oil dipstick tube and "O" ring. Disconnect air intake hose and vacuum hoses at turbo. (Scheme 11) Remove heat shields from turbo and exhaust manifold.
3. Disconnect power steering pump hoses from clamp. Remove power steering pump with hoses attached and secure away from manifold.
4. Remove power steering pump mounting bracket from engine. Remove nuts and engine hanger bracket for access to exhaust manifold. Disconnect oil and coolant lines at turbo.
5. Disconnect exhaust pipe from turbo. Remove exhaust manifold nuts, exhaust manifold and gasket with turbo. Separate turbo from exhaust manifold.

Scheme 11

Disassembly

1. Remove snap pin. (Scheme 12) Remove wastegate actuator bolts and actuator. Remove coupling from turbine housing. Remove turbine housing. Position compressor cover assembly with end surface facing down, and carefully remove snap ring.
2. To remove turbine cartridge, hold turbine cartridge and tap on compressor cover with a soft-faced hammer. Remove "O" ring from turbine cartridge.

Scheme 12

Inspection

1. Check turbine housing for damage, cracks or signs of contact between turbine blades. Ensure wastegate operates freely by manually opening and closing wastegate valve.
2. Check turbine and compressor wheels for signs of wear and damage. Check oil passage in turbine cartridge and clean as necessary. Check compressor cover for signs of contact with compressor turbine. Replace turbocharger as necessary.

Reassembly

1. To reassemble, reverse disassembly procedure. Apply a light coat of oil to new "O" ring and install on turbine cartridge. Align dowel pin and install turbine cartridge into compressor cover. Install snap ring with chamfered side up. (Scheme 13)
2. Align dowel pin and install compressor cover and turbine cartridge assembly onto turbine housing. Install wastegate actuator. Test wastegate actuator. See AIR INDUCTION SYSTEMS in appropriate I - SYS/COMP TESTS article in the ENGINE PERFORMANCE Section.

Scheme 13

1. To install, reverse removal procedure. Use new gaskets and seals on turbo oil lines. Use new exhaust manifold and exhaust pipe retaining nuts.
2. Apply oil to flared portion of turbo coolant inlet pipe prior to installation on cylinder block. Pour clean oil in turbo prior to installing oil supply line.
3. Fill crankcase and cooling system. Check for leaks. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(/eagle/talon/i-1989-1994/remont/removal-installation/#engine-controls-removeinstalloverhaul__torque-specifications) at end of article.

1. Disconnect negative battery cable. Drain coolant. Disconnect vacuum hoses. Disconnect air by-pass hose. Remove air intake hose and air cleaner. (Scheme 14)
2. Remove coolant pipe and air hoses. Remove splash shield. Remove intercooler bolts and intercooler.
3. To install, reverse removal procedure. Tighten bolts to specification. See «TORQUE SPECIFICATIONS»(/eagle/talon/i-1989-1994/remont/removal-installation/#engine-controls-removeinstalloverhaul). Fill cooling system. Check for leaks.

Scheme 14

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

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