Engine Controls - Remove/install/overhaul Jeep Wrangler I

INTRODUCTION

Removal, overhaul and installation procedures (when provided 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.

COMPONENT LOCATIONS

COMPONENT LOCATIONS

Removal

1. Drain the cooling system.
2. Remove air cleaner assembly.
3. Disconnect the CTS wire connector. (Scheme 1)
4. Remove the CTS from the left side of the engine block.

Scheme 1

Installation

1. Install the CTS to the cylinder block. Tighten the CTS to 21 Ft. Lbs. (28 Nm).
2. Connect the CTS wire connector.
3. Install air cleaner assembly.
4. Fill the cooling system.

Removal & Installation

4.0L and 5.9L vehicles have a transducer integral with EGR valve. Disconnect vacuum hose from EGR valve or transducer. Remove mounting bolts. Remove valve assembly and gasket. Discard gasket. To install, reverse removal procedure using a new gasket. Tighten mounting bolts to 20 ft. lbs. (27 N.m).

1. Remove engine speed sensor wire connector. (Scheme 2)
2. Remove the engine speed sensor-to-transmission housing attaching bolts. Remove engine speed sensor from transmission housing.

Scheme 2

1. Install the engine speed sensor to the transmission housing with 2 shoulder bolts. Tighten the engine speed sensor shoulder bolts.
2. Connect the engine speed sensor wire connector.

Note. The ECU is located below the instrument panel, between the steering column and the A/C-Heater housing. (Scheme 3) Three screws mount the ECU to a bracket.

1. Disconnect the negative battery cable.
2. Remove the 3 ECU attaching screws. (Scheme 3)
3. Disconnect the ECU wiring harness connector.
4. Remove the ECU.

Scheme 3

Scheme 4

1. Connect the ECU wiring harness connector.
2. While holding the ECU in position, attach the 3 ECU attaching screws. (Scheme 4)
3. Connect the negative battery cable.

FUEL SYSTEM

1. Disconnect negative battery cable. Remove fuel filler cap. Remove air cleaner. Identify and tag all hoses attached to carburetor. Remove throttle cable from throttle lever. Disconnect all hoses, lines, springs, and electrical connectors from carburetor.
2. Disconnect bowl cooler deflector (if equipped). Remove carburetor mounting nuts. Remove carburetor. Remove carburetor gasket from spacer.

Scheme 5

1. Place carburetor on a repair stand. Remove stepper motor (if equipped). Remove retaining clip from accelerator pump arm link. (Scheme 5) Remove link.
2. Remove cover and gasket from top of air horn. Remove screws and locks from accelerator pump arm and vacuum piston rod lifter. Slide pump lever out of air horn. Remove pump arm and rod lifter, and "S" link. (Scheme 5)
3. Remove vacuum piston and metering rods as an assembly. Remove vacuum piston spring. Remove valve seal from lever if air horn is to be immersed in cleaning solution. Disconnect clips and remove link from choke housing lever and choke lever arm.
4. Remove screw and lever from choke shaft. Remove choke vacuum diaphragm hose. Remove choke diaphragm, linkage and bracket assembly. Remove fast idle cam retaining screw. Remove fast idle cam, choke linkage and clip. Grind heads off choke cover rivets. Remove choke cover, retainers and remaining portions of rivets.
5. Remove gasket and baffle. Remove choke housing from throttle body. Remove screws and separate air horn from main body. Discard gasket. Remove sole-vac solenoid. Remove accelerator pump, spring and ball.
6. Remove fuel inlet needle valve, seat and gasket from main body. Remove float fulcrum pin retainer and baffle. Lift out floats and fulcrum pin. Remove main metering jets.
7. Remove venturi cluster screws. Remove cluster and gaskets from main body and discard gaskets. DO NOT remove idle orifice tubes or main vent tubes from cluster. They can be cleaned with solvent and dried with compressed air while assembled.
8. Turn carburetor upside-down and catch accelerator pump discharge check ball as it falls out. Turn idle limiter caps to stop position. Remove plastic caps from idle air mixture screws. Count number of turns necessary to fully seat screws. This will ease reassembly adjustment. Remove screws and springs from throttle body.
9. Remove screws and separate throttle body from main body. Discard gasket. Check choke plate in air horn for freedom of movement. If sticking or binding is evident, clean thoroughly.

Cleaning & Inspection

When cleaning or inspecting carburetor, note the following

1. Use a regular carburetor cleaning solution. Soak components long enough to thoroughly clean all surfaces and passages of foreign matter.
2. DO NOT soak components containing rubber, leather or plastic.
3. Remove all residue after cleaning by rinsing components in a suitable solvent.
4. DO NOT use a wire or drill to clean jets or passageways.
5. Blow out all passages with dry compressed air. DO NOT apply compressed air to diaphragm.

Note. Ensure only NEW gaskets are used when reassembling carburetor. Reverse disassembly procedure to reassemble.

Scheme 6

Scheme 7

Scheme 8

Scheme 9

Scheme 10

Scheme 11

Scheme 12

1. Install idle mixture screws and springs in body. Tapered portion must be straight and smooth. If tapered portion is grooved or ridged, use a new screw. DO NOT use a screwdriver for installation.
2. Turn screws lightly against their seats with fingers. Back off number of turns recorded at disassembly. Invert main body. Place gasket and throttle body on main body and align. Install screws and tighten securely. Install accelerator pump ball, accelerator pump and spring assembly.
3. Install accelerator pump discharge check valve ball in discharge passage. Pour clean unleaded gasoline into carburetor bowl approximately 1/2" deep. Insert pump plunger into pump cylinder. Operate accelerator pump plunger several times to expel air from pump passage.
4. Using a small brass rod, hold discharge check ball down firmly on its seat. (Scheme 6) Raise plunger and press downward. No fuel should be emitted from either intake or discharge passage.
5. If leakage is evident, clean passage and accelerator discharge check ball seat and retest. If leakage persists, replace main body.
6. Install replacement gaskets on venturi cluster. (Scheme 5) Install cluster screws and tighten securely. Install main metering jets. Install floats with fulcrum pin and fulcrum retainer in main body. Install inlet needle, seat, and gasket assembly. Tighten securely.
7. Adjust float level. Remove air horn. Hold float gently against inlet needle to raise float. Place a straightedge across float bowl to measure float level. See «CARBURETOR ADJUSTMENT SPECIFICATIONS»(/jeep/wrangler/i-1986-1995/remont/removal-installation/#engine-controls-removeinstalloverhaul) table. (Scheme 7) If adjustment is necessary, release floats and bend float lever. Install air horn. NOTE: Never bend float lever while it is resting against inlet needle. Pressure may damage synthetic tip and cause incorrect adjustment.
8. Install baffle plate. Install accelerator pump ball into main body, if not previously installed. Place accelerator pump drive spring on pump plunger shaft and insert shaft into air horn. Compress spring and insert "S" link. Position replacement gasket on main body and install air horn and sole-vac solenoid.
9. Tighten retaining screws alternately to compress gasket evenly. Place vacuum piston spring in vacuum piston bore. Install vacuum piston and metering rod assembly into air horn. Ensure that rods move freely on each side of vertical position. Rotate bowl vent assembly up and out of bowl and install vent seal, if removed.
10. Install pump arm onto "S" link. Place 2 plastic rod lifter tangs under vacuum piston yoke. Slide accelerator pump lever shaft through rod lifter and pump arm. Install, but do not tighten, accelerator pump shaft locks and adjusting screws. Install fast idle cam, choke linkage and clip. Tighten retaining screw securely.
11. Connect accelerator pump linkage to accelerator pump lever and throttle lever. Install retaining clip at throttle lever end of linkage. Adjust vacuum piston gap, vacuum piston, and accelerator pump.
12. Turning adjustment screw clockwise enriches air/fuel mixture. Turning adjustment screw counterclockwise leans the air/fuel mixture. (Scheme 8) Turn adjustment screw to adjust gap to specification. See «CARBURETOR ADJUSTMENT SPECIFICATIONS»(/jeep/wrangler/i-1986-1995/remont/removal-installation/#engine-controls-removeinstalloverhaul) table. NOTE: When adjusting vacuum piston and accelerator pump, it is necessary to change curb idle speed adjustment screw setting. Count and record the number of turns so the screw can be returned to its original position.
13. Adjust vacuum piston. Turn curb idle speed adjustment screw counterclockwise until throttle valves are completely closed. Fully depress vacuum piston while holding moderate finger pressure on rod lifter tab. In this position, tighten rod lifter lock screw.
14. Release piston and rod lifter. Adjust accelerator pump. Return curb idle speed adjustment screw to its original position. Adjust accelerator pump. Turn curb idle speed adjustment screw counterclockwise until throttle valves are completely closed.
15. Open choke valve so that fast idle cam allows throttle valves to seat in the bores. Turn curb idle speed adjustment screw clockwise until it just barely contacts stop, then turn it in 2 complete turns more.
16. Measure distance between surface of air horn and top of accelerator pump shaft with a "T" scale. (Scheme 9) Loosen pump arm adjusting lock screw and rotate sleeve to adjust pump travel to correct specification.
17. Tighten lock screw and return curb idle speed adjustment screw to its original position.
18. Using a new gasket, install rollover check valve and bowl vent. Install diaphragm assembly and secure with attaching screws. Engage diaphragm link with slot in choke lever. Install choke lever and screw on choke shaft. Install choke housing on throttle body. Install baffle, gasket and cover on choke housing. Turn cover 1/4 turn rich and tighten one straight-slot screw.
19. Install choke rod and clips between choke lever and choke housing lever. Adjust choke valve, fast idle cam, and choke unloader clearances. Open throttle valve slightly and place fast idle speed adjustment screw on high step of cam. Apply vacuum to force diaphragm against stop. (Scheme 10)
20. Measure clearance between choke valve and air horn wall with a plug gauge. See «CARBURETOR ADJUSTMENT SPECIFICATIONS»(/jeep/wrangler/i-1986-1995/remont/removal-installation/#engine-controls-removeinstalloverhaul) table. Adjust clearance by bending vacuum diaphragm connector link.
21. Place fast idle speed adjustment screw on second step of fast idle cam. Measure distance between choke valve and air horn wall with a plug gauge. See the «CARBURETOR ADJUSTMENT SPECIFICATIONS»(/jeep/wrangler/i-1986-1995/remont/removal-installation/#engine-controls-removeinstalloverhaul) table. (Scheme 11) Adjust clearance by bending fast choke link down to increase distance or up to decrease distance. Install and tighten retaining screws.
22. Hold throttle fully open and apply pressure on choke valve toward closed position. Measure clearance between lower edge of choke valve and air horn wall. (Scheme 12) Also, refer to the «CARBURETOR ADJUSTMENT SPECIFICATIONS»(/jeep/wrangler/i-1986-1995/remont/removal-installation/#engine-controls-removeinstalloverhaul) table. Adjust clearance by bending unloader tang. DO NOT bend unloader tang so that it binds or interferes with any other component.
23. Remove choke cover screw and position cover according to color on housing. If color on housing is Gold, set choke index at zero (0). If color of housing is Red, set choke index at one notch rich. If color of housing is Green, set choke index at 2 notches rich. Tighten replacement cover screws. Install stepper motor with replacement gasket.

1. Clean gasket mating surfaces. Install replacement gaskets and spacer. Position carburetor on spacer and gasket. Install carburetor mounting nuts and tighten, in a crisscross pattern, to 84 INCH lbs. (9 N.m). Tighten nuts in this pattern further to 16 ft. lbs. (22 N.m).
2. Reconnect all hoses, lines, springs, and electrical connectors to carburetor. Install air cleaner. Adjust engine idle speed and idle mixture, if necessary. See the ADJUSTMENTS article in this section.

Remove air cleaner. Remove throttle cable from throttle lever. Disconnect all hoses, lines, springs, and electrical connectors from carburetor. Remove carburetor mounting nuts. Remove carburetor. Remove carburetor gasket from intake manifold.

Scheme 13

1. Remove air cleaner anchor screw. Note position of choke control rod and remove from choke valve lever shaft. Remove choke valve lever retaining screw. Slide choke rod out of choke lever. Remove air horn attaching screws, identification tag, air horn, and gasket. (Scheme 13)
2. Remove choke rod seal from air horn. Remove fast idle cam retaining clip and choke shield. Grind off choke cover rivet heads. Remove retainer, cover and coil, and gasket. Remove remaining portion of rivets. Remove fast idle cam rod from fast idle cam lever. Remove choke housing assembly retaining screws, housing, and gasket. Remove fast idle cam.
3. Remove coil lever retaining screw, coil lever, and fast idle cam lever from choke housing. Using a screwdriver, pry float shaft retainer from fuel inlet seat. Remove float, float shaft retainer, and fuel inlet needle assembly. (Scheme 13)
4. Remove retainer, float shaft, and float damper spring (if equipped) from float lever. Remove fuel inlet needle seat and gasket. Remove main jets. Remove accelerator pump discharge screw, air distribution plate, booster venturi, and gasket. (Scheme 13) DO NOT attempt to remove tubes from venturi.
5. Invert main body and catch accelerator pump discharge weight and check ball. Disconnect accelerator pump operating rod from overtravel lever. Remove rod and retainer. Remove inlet check valve by grasping it firmly and pulling out. NOTE: If tip of inlet check valve breaks off during removal, make sure it is removed from fuel bowl. Inlet check valve must be replaced whenever it is removed.
6. Invert main body and remove power valve cover screws, cover and gasket. (Scheme 13) Using an 8-point socket, remove power valve. Remove and discard power valve gasket. Remove altitude compensator assembly and gasket.
7. Remove idle mixture screw caps. Turn idle mixture screws inward, counting turns for reassembly reference, until lightly seated. Remove idle mixture screws and springs. Remove fast idle lever assembly from throttle shaft. Remove throttle solenoid. Remove choke diaphragm.

When cleaning or inspecting carburetor, note the following

1. Use a regular carburetor cleaning solution. Soak components long enough to thoroughly clean all surfaces and passages of foreign matter.
2. DO NOT soak components containing rubber, leather or plastic.
3. Remove all residue after cleaning by rinsing components in a suitable solvent.
4. DO NOT use a wire or drill to clean jets or passageways.
5. Blow out all passages with dry compressed air. DO NOT apply compressed air to diaphragm.

Scheme 14

Scheme 15

Scheme 16

1. To assemble carburetor, reverse disassembly procedure. Use new gaskets and seals. Make sure that new gaskets fit correctly and that all slots are punched through and are correctly located.
2. When installing replacement inlet check valve, lubricate tip of new valve, and insert tip into center hole of accelerator pump cavity. Insert needle nose pliers in fuel bowl, and pull valve in until fully seated. Cut off excess valve tip at retaining shoulder, and remove tip from fuel bowl.
3. When installing idle mixture screws, turn screws in with fingers until lightly seated. DO NOT install idle screw limiter caps at this time. Adjust idle mixture with carburetor installed on vehicle. Adjust float level. Remove air horn assembly and gasket. Raise float by pressing down on float tab until inlet needle is slightly seated.
4. Use a "T" scale to measure distance from fuel bowl machined top surface to a flat surface on either corner of the float at the free end. Refer to the «CARBURETOR ADJUSTMENT SPECIFICATIONS»(/jeep/wrangler/i-1986-1995/remont/removal-installation/#engine-controls-removeinstalloverhaul) table. (Scheme 14) Hold fuel inlet needle off its seat while adjusting to prevent damage to synthetic tip of needle. Bend float tab to adjust float level.
5. Adjust choke valve and fast idle cam clearances. Open throttle to allow choke mechanism to set and fast idle screw to set on top stem of cam. Apply vacuum to hold choke diaphragm against setscrew while using finger pressure to load choke diaphragm stem in direction opposite diaphragm. DO NOT press on linkage rods.
6. Measure clearance between top of choke valve and air horn. See «CARBURETOR ADJUSTMENT SPECIFICATIONS»(/jeep/wrangler/i-1986-1995/remont/removal-installation/#engine-controls-removeinstalloverhaul) table. Adjust clearance by turning screw at rear of choke vacuum diaphragm. Push down on fast idle cam lever until fast idle speed adjustment screw is in contact with second step of fast idle cam and against shoulder of high step.
7. Measure clearance between upper edge of choke valve and air horn wall. See «CARBURETOR ADJUSTMENT SPECIFICATIONS»(/jeep/wrangler/i-1986-1995/remont/removal-installation/#engine-controls-removeinstalloverhaul) table. Adjust clearance by turning fast idle cam lever screw. (Scheme 15)
8. Adjust choke unloader. Hold throttle fully open and apply pressure on choke valve toward closed position. Measure clearance between lower edge of choke valve and air horn wall. See the «CARBURETOR ADJUSTMENT SPECIFICATIONS»(/jeep/wrangler/i-1986-1995/remont/removal-installation/#engine-controls-removeinstalloverhaul) table.
9. Adjust clearance by bending unloader tang toward cam to increase clearance and away from the cam to decrease clearance. (Scheme 16) DO NOT bend unloader tang downward from horizontal plane. After completing adjustment, open throttle until unloader tang is directly below fast idle cam pivot. Clearance between unloader tang and edge of fast idle cam must be.07" (1.8 mm).
10. Operate throttle and ensure smooth operation of unloader tang. After carburetor has been installed, check for full throttle opening when throttle is operated from inside vehicle. If full throttle opening is not obtainable, it may be necessary to remove excess padding under floormat or reposition throttle cable bracket located on engine.

1. Clean gasket mating surfaces. Install replacement gaskets and spacer. Position carburetor on spacer and gasket. Install carburetor mounting nuts and tighten, in a crisscross pattern, to 84 INCH lbs. (9 N.m). Tighten nuts in this pattern further to 16 ft. lbs. (22 N.m).
2. Reconnect all hoses, lines, springs, and electrical connectors to carburetor. Adjust engine idle speed and idle mixture, if necessary. See the ADJUSTMENTS article. Install air cleaner.

Scheme 17

1. Remove filler cap to relieve tank pressure. Disconnect negative battery cable. Remove air cleaner assembly. Remove throttle body lower bonnet. Remove injector connector by compressing lock tabs and lifting. Remove injector retainer screws. Remove retainer. CAUTION: Injector has a small locating tab that fits into a slot in bottom of injector bore or throttle body. (Scheme 17) DO NOT twist injector during removal.
2. Using a small pair of pliers, gently grasp center collar of injector and carefully remove injector by rocking it back and forth while lifting upward. Remove and discard centering ring, and upper and lower "O" rings. (Scheme 17)

Scheme 18

1. Lubricate replacement lower "O" ring with silicone dielectric grease. Install replacement lower "O" ring into bottom of housing bore. Repeat for upper "O" ring and install centering ring on top of upper "O" ring.
2. Ensure throttle valve is closed. Position Installer (6172) on top of lower "O" ring seal. (Scheme 18) Align locating tab on bottom of injector with slot in bottom of injector housing. Lower injector until discharge nozzle pilots into installer.
3. Push injector down until installer drops onto throttle valve and injector seats in throttle body. Remove installer with a magnet. Install retainer and tighten screws. Connect injector wire connector. Install lower and upper bonnets. Install fuel filler cap. Connect negative battery cable.

Remove fuel injector rail. See FUEL INJECTOR RAIL (4.0L) under REMOVAL & INSTALLATION. Remove clips retaining injectors to fuel rail. Remove injectors. To install, place injectors into fuel rail assembly and install retaining clips.

Scheme 19

1. Remove fuel filler cap. See FUEL PRESSURE RELEASE (4.0L) and perform procedure. Remove, and numerically tag, injector harness connectors from each injector. (Scheme 19) Disconnect vacuum tube from fuel pressure regulator. Disconnect fuel supply hose from fuel rail and fuel return tube from fuel pressure regulator.
2. Remove fuel rail mounting bolts. On vehicles equipped with automatic transmissions, it may be necessary to remove automatic transmission throttle line pressure cable and bracket to remove fuel rail assembly. Remove fuel rail by gently rocking until all injectors are out of intake manifold.

1. Position tips of injectors into corresponding injector bore in intake manifold. Seat injectors into manifold. Install and tighten fuel rail retaining bolts to 20 ft. lbs. (27 N.m). Connect injector harness connectors to appropriate injectors.
2. Connect fuel return tube to fuel pressure regulator and fuel supply hose to fuel rail using a new "O" ring, spacer and retainer repair kit. Connect vacuum supply tube to fuel pressure regulator. Install cap over pressure test port fitting. Install fuel filler cap. Connect negative battery cable.

Remove throttle body. See THROTTLE BODY (2.5L) under REMOVAL & INSTALLATION. Remove 3 Torx screws mounting fuel body to throttle body. Remove fuel body. Remove pressure regulator mounting screws. Remove housing, spring and seats, diaphragm, and pivot. (Scheme 20) Clean housing of any foreign material. To install, reverse removal procedure. Use new fuel body-to-throttle body gasket.

Scheme 20

Remove fuel filler cap. See FUEL PRESSURE RELEASE (4.0L) and perform procedure. Remove fuel injector rail. See FUEL INJECTOR RAIL (4.0L) under REMOVAL & INSTALLATION. Remove fuel pressure regulator retaining screws and remove regulator from fuel rail. (Scheme 21)

Scheme 21

Install new "O" ring seals to fuel pressure regulator before installation. Install fuel pressure regulator into fuel rail. Tighten screws securely. Install fuel injector rail. See FUEL INJECTOR RAIL (4.0L) under REMOVAL & INSTALLATION. Install fuel filler cap. Connect negative battery cable.

FUEL PRESSURE RELEASE (4.0L) R & I

1. Disconnect negative battery cable. Remove fuel filler cap. Remove cap from pressure test port on fuel rail. Position shop towels to soak up any spilled fuel.
2. Using a small screwdriver or pin punch, push test port valve in to relieve fuel pressure. (Scheme 22) Install cap over test port.

Scheme 22

Disconnect throttle return springs from throttle lever. Disconnect wire harness connector from Idle Speed Actuator (ISA) motor. Remove motor-to-bracket retaining nuts. Use another wrench to prevent ISA motor mounting studs from turning. Remove ISA motor from bracket. To install, reverse removal procedure. Adjust ISA motor after installation.

Scheme 23

Scheme 24

1. Remove air inlet bonnet. Start engine and warm to operating temperature. Ensure A/C is off. Connect a digital tachometer to diagnostic terminals D1-1 and D1-3. (Scheme 23)
2. Disconnect ISA motor wire connector. Connect Exerciser Tool (7008) to ISA motor. (Scheme 24)
3. Connect exerciser power leads to vehicle battery terminals. Fully extend ISA motor plunger. Turn adjustment screw until engine speed is 3500 RPM. (Scheme 25) Remove exerciser and connect ISA motor wire connector. Idle speed should return to normal in a few seconds. Install air inlet bonnet.

Scheme 25

Disconnect electrical connector from idle speed stepper motor. Remove retaining screws and remove motor. To install, reverse removal procedure.

1. Disconnect negative battery cable. Disconnect vacuum hoses from throttle body upper bonnet. Release bonnet retaining clips and remove upper bonnet. Remove lower bonnet retaining bolts and lower bonnet. Disconnect Idle Speed Actuator (ISA) motor.
2. Disconnect fuel supply and return tubes from throttle body. Remove throttle cable and return spring. Disconnect wire harness connector from injector. Identify and tag vacuum hoses at back of throttle body for installation reference.
3. Disconnect vacuum tubes from throttle body. Disconnect Throttle Position Sensor (TPS) and Wide Open Throttle (WOT) switch connectors (if equipped). Remove throttle body mounting nuts. Remove throttle body. Clean intake manifold and throttle body mating surfaces of old gasket material and grime.

Note. If throttle body assembly is being replaced and WOT switch, ISA motor and TPS are transferred to replacement throttle body, they all must be adjusted after installation. See ADJUSTMENTS article for TPS adjustment procedure. See WOT SWITCH and ISA MOTOR ADJUSTMENT procedures in this article.

1. With a new gasket, install throttle body assembly on intake manifold. Tighten mounting nuts to 16 ft. lbs. (22 N.m). Reconnect all vacuum hoses, fuel supply and return tubes, and electrical connectors.
2. Install throttle cable and return spring. Install lower bonnet assembly and retaining nuts. Install upper bonnet assembly. Connect negative battery cable.

Release fuel system pressure. See FUEL PRESSURE RELEASE. Disconnect negative battery cable. Disconnect air cleaner snorkel from throttle body. Disconnect idle speed stepper motor and TPS wire connectors. Disconnect MAP sensor vacuum tube from throttle body. Disconnect throttle linkage at throttle arm. Disconnect automatic transmission line pressure cable at throttle arm (if equipped). (Scheme 26) Remove throttle body mounting bolts, throttle body and gasket. Discard gasket.

Scheme 26

Install throttle body with new gasket. Tighten throttle body mounting nuts to 23 ft. lbs. (30 N.m). Connect MAP sensor vacuum tube, idle speed stepper motor and TPS connectors. Connect throttle linkage to throttle arm. Connect and adjust automatic transmission line pressure cable. See AUTOMATIC TRANSMISSION SERVICING article. Install air cleaner snorkel. Connect negative battery cable.

Remove upper and lower air inlet bonnet. If necessary, remove throttle body assembly. Remove mounting screws. Remove Throttle Position Sensor (TPS) from throttle shaft lever. Disconnect TPS electrical connector(s). To install, reverse removal procedure. Adjust TPS. See ON-VEHICLE ADJUSTMENTS article. Connect TPS electrical connector(s).

Disconnect Throttle Position Sensor (TPS) electrical connector(s). Bend lock tabs back. Remove retaining screws. Remove TPS. To install, reverse removal procedure. Adjust TPS. See ON-VEHICLE ADJUSTMENTS article. Connect TPS electrical connector(s).

1. Remove air inlet bonnet. Disconnect throttle return spring from throttle lever. Disconnect accelerator cable from throttle lever. Disconnect wire harness from Wide Open Throttle (WOT) switch connector. Remove WOT switch mounting screws. Remove switch.
2. To install, reverse removal procedure. Adjust WOT switch. DO NOT tighten mounting screws completely until switch has been adjusted.

Scheme 27

1. Block or tie throttle linkage in wide open throttle position. Attach Choke Angle Measuring Gauge (7785) or equivalent to flat surface of throttle lever. (Scheme 27) Center gauge bubble between alignment marks using bubble adjusting screw.
2. Rotate degree scale of gauge until 15 degree mark is aligned with gauge pointer. Rotate gauge degree scale until zero degree mark is aligned with gauge pointer. Close throttle until gauge bubble is again centered between alignment marks.
3. Rotate WOT switch until switch lever contacts throttle cam. Stop rotating switch when lever starts closing switch plunger (plunger will click). Tighten screws to 88 INCH lbs. (9 N.m). Verify WOT throttle switch position adjustment. Switch plunger should click when throttle plate is 15 degrees, plus or minus 3 degrees, before wide open throttle position. Remove gauge.

1. Unfasten distributor cap retaining screws. Remove distributor cap, and place out of the way, with coil and spark plug wires connected. Disconnect distributor primary wiring connector. Scribe a mark on distributor housing in-line with tip of rotor.
2. Scribe a mark on distributor housing near clamp and continue scribe mark onto engine block in line with distributor housing mark. Note position of rotor and distributor housing in relation to surrounding engine components.
3. Remove distributor hold-down bolt and clamp. Lifting distributor straight up, carefully remove distributor from engine. (Scheme 28)

Scheme 28

Installation (Engine Not Rotated After Removal)

1. Clean distributor mounting area of cylinder block. Install replacement gasket.
2. Position distributor shaft in cylinder block. Align rotor tip with scribe mark on distributor housing. Turn rotor approximately 1/8 turn counterclockwise past scribe mark. CAUTION: Ensure distributor shaft fully engages oil pump drive gear shaft. It may be necessary to slightly rotate engine while applying downward hand force on distributor body to fully engage distributor shaft with oil pump drive gear shaft.
3. Slide distributor shaft into engine. Align scribe mark on distributor housing with corresponding mark on cylinder block. NOTE: It may be necessary to move rotor and shaft slightly to start gear into mesh with camshaft gear and to engage oil pump drive tang, but rotor should align with scribe mark when distributor shaft is in place.
4. Install distributor hold-down bolt and clamp. Tighten to 17 ft. lbs. (23 N.m). Install distributor cap, with ignition wires still attached. Ensure pick-up coil wire rubber grommet in distributor housing aligns with depression in distributor cap and that cap fits on rim of housing. NOTE: Two different diameter screws are used to retain distributor cap.
5. Apply silicone dielectric compound to connector terminal blades and cavities. Connect distributor primary wiring connector.

Scheme 29

1. Clean distributor mounting area of cylinder block. Install replacement gasket. Remove No. 1 spark plug and hold finger over spark plug hole. Rotate engine until compression pressure is felt. Slowly continue to rotate engine until timing index on vibration damper pulley aligns with TDC mark on timing degree scale.
2. Using a flat blade screwdriver, rotate oil pump gear so that gear slot on oil pump shaft is slightly past 3 o'clock position. With distributor cap removed, install distributor with rotor located at 5 o'clock position. (Scheme 29)
3. When distributor is fully engaged in correct location, rotor should be at 6 o'clock position. (Scheme 29) Install distributor hold-down bolt and clamp. Tighten bolt to 17 ft. lbs. (23 N.m). CAUTION: If distributor cap is incorrectly positioned on distributor housing, cap or rotor may be damaged when engine is rotated with starter.
4. Install distributor cap, with ignition wires attached, on distributor housing. Ensure pick-up coil wire rubber grommet in distributor housing aligns with depression in distributor cap and that cap fits on rim of housing. NOTE: Two different diameter screws are used to retain distributor cap.
5. Apply silicone dielectric compound to connector terminal blades and cavities. Connect distributor primary wiring connector.

Scheme 30

Scheme 31

1. Disconnect the battery negative cable.
2. On vehicles equipped with A/C, remove the electrical cooling fan and shroud assembly from the radiator to allow room to rotate the engine with a socket and ratchet using the vibration damper bolt.
3. Scribe a mark on the distributor housing below the left side (past) the number one spark plug wire post of the distributor cap for reassembly reference for No 1 cylinder firing position.
4. Remove the distributor cap.
5. Turn the engine in a clockwise direction until the rotor is approaching the scribed mark on the dintributor housing. Then slowly turn the engine until the timing mark on the crankshaft vibration damper lines up with zero on the front cover timing scale. (Scheme 30) NOTE: The timing mark is located on the edge of the vibration damper closest to the front cover.
6. Align the trailing edge of the rotor blade with the mark previously scribed on the distributor housing. (Scheme 31)
7. Remove the distributor hold-down bolt and clamp.
8. Remove the distributor from the engine.

Scheme 32

1. With distributor removed from engine, remove rotor. Position distributor in a vise. Remove distributor gear from shaft using a small punch and hammer to drive out retaining roll pin. (Scheme 32) Remove distributor shaft from housing.
2. Remove stator retaining screw. (Scheme 33) Mark location of stator position for assembly reference. Remove stator harness by pushing grommet through housing. Remove stator assembly.

Scheme 33

Reassembly

1. Install stator assembly and retaining screw. Position stator assembly harness through distributor housing and push grommet into position. (Scheme 33) Install distributor shaft into distributor housing. Ensure seals are in place and not damaged (if equipped).
2. Install distributor gear washer and distributor gear onto shaft. (Scheme 34) Install distributor gear retaining roll pin. Install distributor rotor. Install distributor to engine.

Scheme 34

Scheme 35

Scheme 36

1. If needed, use a flat blade screwdriver to turn the oil pump gear shaft until the slot is slightly past the 11 o'clock position. (Scheme 34) The oil pump shaft is located down in the distributor hole.
2. InstalI the rotor.
3. Without engaging the distributor gear into the cam gear and ensuring the distributor gasket is istalled, position the distributor into the hole in the engine block.
4. Visually line up the hold down ear of the distributor housing with the hold down clamp hole. (Scheme 35)
5. Turn the rotor to the 4 o'clock position. (Scheme 36)
6. Carefully slide the distributor into the block until it seats, keeping the hold down ear aligned to the hole in the block.
7. The rotor should be in the 5 o'clock position with the trailing edge of the rotor blade lined up with the mark previously scribed on the distributor housing (number one spark plug wire post location).
8. install the distributor hold-down clamp bolt and tighten to 9.5-14 Ft. Lbs. (13-19 N.m).
9. Install the distributor cap. Connect the distributor electrical connector.
10. Install the electric cooling fan and shroud if applicable.
11. Connect the negative battery cable.

1. Unfasten distributor cap retaining screws. Remove distributor cap and place out of the way with coil and spark plug wires still connected. Disconnect and plug distributor vacuum advance hose. Disconnect distributor primary wiring connector.
2. Scribe a mark on distributor housing in-line with tip of rotor. Scribe a mark on distributor housing near clamp and continue scribe mark on engine block in line with distributor housing mark. Note position of rotor and distributor housing in relation to surrounding engine components.
3. Remove distributor hold-down bolt and clamp. Lift distributor straight up and carefully remove from engine.

Scheme 37

1. Place distributor in holding device. Remove rotor. (Scheme 37) Remove trigger wheel with Trigger Wheel Puller (7804). Use a flat washer to prevent puller from contacting inner shaft. Remove pin.
2. Remove pick-up coil retainer and washers from pivot pin on base plate. Remove 2 pick-up coil plate screws. Lift pick-up coil assembly from distributor housing.
3. If vacuum advance mechanism is to be replaced, remove screws and lift mechanism out of distributor housing. Tilt unit to disengage link from pick-up coil pin protruding through distributor housing. Loosen base plate for clearance, if necessary.

1. Insert Allen wrench into vacuum hose tube of original vacuum advance mechanism. Count number of clockwise turns necessary to bottom out adjusting screw. Turn replacement mechanism adjusting screw clockwise to bottom, then back off counterclockwise the same number of turns counted earlier.
2. Install vacuum advance mechanism on distributor housing. Ensure that link is engaged on pin of pick-up coil. Install retaining screws. Tighten base plate screws, if loosened. Position pick-up coil assembly into distributor housing. Install washers and retainer onto pivot pin to secure pick-up coil assembly to base plate.
3. Position wiring harness in slot in distributor housing. Install 2 pick-up coil plate screws and tighten. Using hand pressure, install trigger wheel on shaft with long portion of teeth up. (Scheme 37) When trigger wheel and slot in shaft are properly aligned, use a drift and hammer to tap pin into locating groove in trigger wheel and shaft. Support shaft while installing trigger wheel pin. Install rotor.

1. Clean distributor mounting area of cylinder block. Install a replacement distributor gasket. Position distributor shaft in cylinder block. Align rotor tip with scribe mark on distributor housing. Turn rotor approximately 1/8 turn counterclockwise past scribe mark. CAUTION: Ensure distributor shaft fully engages oil pump drive gear shaft. It may be necessary to slightly rotate engine while applying downward hand force on distributor body to fully engage distributor shaft with oil pump drive gear shaft.
2. Slide distributor shaft into engine. Align scribe mark on distributor housing with corresponding mark on cylinder block. NOTE: It may be necessary to move rotor and shaft slightly to start gear into mesh with camshaft gear and to engage oil pump drive tang, but rotor should align with scribe mark when distributor shaft is in place.
3. Install distributor hold-down bolt and clamp. Tighten bolt to 17 ft. lbs. (23 N.m). Install distributor cap. Ensure pick-up coil wire rubber grommet in distributor housing aligns with depression in distributor cap and that cap fits on rim of housing. NOTE: Two different diameter screws are used to retain distributor cap.
4. Apply silicone dielectric compound to connector terminal blades and cavities. Connect distributor primary wiring connector. Connect vacuum hose to vacuum advance mechanism. Adjust ignition timing. See ADJUSTMENTS article.

Installation (Engine Rotated After Removal)

1. Clean distributor mounting area of cylinder block. Install a replacement distributor gasket. Remove No. 1 spark plug and hold finger over spark plug hole. Rotate engine until compression pressure is felt.
2. Slowly continue to rotate engine until timing index on vibration damper pulley aligns with TDC mark on timing degree scale. Reinstall spark plug and tighten to 27 ft. lbs. (37 N.m). Turn distributor shaft until rotor tip points in direction of No. 1 terminal in distributor cap. Turn rotor 1/8 turn counterclockwise past No. 1 terminal.
3. Slide distributor shaft into engine and position distributor vacuum advance mechanism housing in approximately the same location (in relation to other engine components) as when removed.
4. Align scribe mark on distributor housing with corresponding scribe mark on cylinder block. It may be necessary to rotate oil pump shaft with a long, flat blade screwdriver to engage oil pump drive tang, but rotor should align with position No. 1 terminal when distributor shaft is in place. Install distributor hold-down bolt and clamp. Tighten bolt to 17 ft. lbs. (23 N.m). Install distributor cap. CAUTION: If distributor cap is incorrectly positioned on distributor housing, cap or rotor may be damaged when engine is rotated with starter.
5. Ensure pick-up coil wire rubber grommet in distributor housing aligns with depression in distributor cap and that cap fits on rim of housing. NOTE: Two different diameter screws are used to retain distributor cap.
6. Apply silicone dielectric compound to connector terminal blades and cavities. Connect distributor primary wiring connector. Connect vacuum hose to vacuum advance mechanism.

Using care, disconnect the spark plug and coil wire boots and wires. Twist the boot one half turn and pull on the boot to disconnect the wire.

When replacing the spark plug and coil wires, carefully route the wires correctly and secure them in their proper channels retainers.

Failure to route the wires properly can cause the radio to reproduce ignition noise, cross ignition of the plugs, or can short circuit the wires to ground.

1. Raise and support the vehicle.
2. Disconnect the knock sensor wire connector located below and to the rear of the Coolant Temperature Sensor. see scheme 38
3. Remove knock sensor from left side of the engine block.

1. Install the knock sensor to the cylinder block. Tighten the knock sensor to 89 INCH Lbs. (10 Nm).
2. Connect the knock sensor wire connector.
3. Lower vehicle.

1. Disconnect the MAT sensor wire connector. (Scheme 38)
2. Remove the MAT from the intake manifold.

Scheme 38

1. Install the MAT sensor to the cylinder block. Tighten the MAT sensor to 21 Ft. Lbs. (28 Nm).
2. Connect the MAT sensor wire connector.

1. Disconnect the MAP sensor wire connector. (Scheme 39)
2. Disconnect MAP sensor vacuum supply hose from MAP sensor.
3. Remove the MAP sensor attaching nuts. Remove MAP sensor from the firewall.

Scheme 39

1. Install the MAP sensor to the firewall. Tighten the MAP sensor attaching nuts.
2. Connect the MAP sensor vacuum supply hose.
3. Connect the MAP sensor wire connector.

O2 sensor is mounted in the exhaust pipe just below the exhaust header. It is equipped with a permanent pigtail which must be protected from damage when the sensor is removed. Disconnect harness connector and remove sensor. Always use anti-seize compound on threads prior to installation. Tighten sensor to 22 ft. lbs. (30 N.m).

CARBURETOR ADJUSTMENT SPECIFICATIONS

CARBURETOR ADJUSTMENT SPECIFICATIONS

TORQUE SPECIFICATIONS

TORQUE SPECIFICATIONS

See also:
• CARBURETOR ADJUSTMENT SPECIFICATIONS