Ezg 14

FUEL SYSTEM
CONTENTS
page page
FUEL DELIVERY SYSTEM . . . . . . . . . . . . . . . . . . . 3
FUEL INJECTION SYSTEM . . . . . . . . . . . . . . . . . 25
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . 1
GENERAL INFORMATION
INDEX
page page
GENERAL INFORMATION
FUEL REQUIREMENTS . . . . . . . . . . . . . . . . . . . . 1
GASOLINE/OXYGENATE BLENDS . . . . . . . . . . . . 1
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . 1
GENERAL INFORMATION
INTRODUCTION
Throughout thi s group, references may be made to
a parti cul ar vehi cl e by l etter or number desi gnati on.
A chart showi ng the breakdown of these desi gnati ons
i s i ncl uded i n the I ntroducti on Secti on at the front of
thi s servi ce manual .
The Evaporati on Control System, i s al so consi dered
part of the fuel system. The system reduces the emi s-
si on of fuel vapor i nto the atmosphere.
The descri pti on and functi on of the Evaporati on
Control System i s found i n Group 25 of thi s manual .
FUEL REQUIREMENTS
Your vehi cl e was desi gned to meet al l emi ssi on reg-
ul ati ons and provi de excel l ent fuel economy when
usi ng hi gh qual i ty unl eaded gasol i ne.
Use unl eaded gasol i nes havi ng a mi ni mum posted
octane of 87.
I f your vehi cl e devel ops occasi onal l i ght spark
knock (pi ng) at l ow engi ne speeds thi s i s not harm-
ful . However; conti nued heavy knock at hi gh speeds
can cause damage and shoul d be reported to your
deal er i mmedi atel y. Engi ne damage as a resul t of
heavy knock operati on may not be covered by the
new vehi cl e warranty.
I n addi ti on to usi ng unl eaded gasol i ne wi th the
proper octane rati ng, those that contai n detergents,
corrosi on and stabi l i ty addi ti ves are recommended.
Usi ng gasol i nes that have these addi ti ves wi l l hel p
i mprove fuel economy, reduce emi ssi ons, and mai n-
tai n vehi cl e performance.
Poor qual i ty gasol i ne can cause probl ems such as
hard starti ng, stal l i ng, and stumbl e. I f you experi -
ence these probl ems, try another brand of gasol i ne
before consi deri ng servi ce for the vehi cl e.
GASOLINE/OXYGENATE BLENDS
Some fuel suppl i ers bl end unl eaded gasol i ne wi th
materi al s that contai n oxygen such as al cohol , MTBE
(Methyl Terti ary Butyl Ether) and ETBE (Ethyl Ter-
ti ary Butyl Ether). Oxygenates are requi red i n some
areas of the country duri ng wi nter months to reduce
carbon monoxi de emi ssi ons. The type and amount of
oxygenate used i n the bl end i s i mportant.
The fol l owi ng are general l y used i n gasol i ne
bl ends:
Ethanol - (Ethyl or Grai n Al cohol ) properl y
bl ended, i s used as a mi xture of 10 percent ethanol
and 90 percent gasol i ne. Gasol i ne bl ended wi th etha-
nol may be used i n your vehi cl e.
MTBE/ETBE - Gasol i ne and MTBE (Methyl Ter-
ti ary Butyl Ether) bl ends are a mi xture of unl eaded
gasol i ne and up to 15 percent MTBE. Gasol i ne and
ETBE (Ethyl Terti ary Butyl Ether) are bl ends of gas-
ol i ne and up to 17 percent ETBE. Gasol i ne bl ended
wi th MTBE or ETBE may be used i n your vehi cl e.
Methanol - Methanol (Methyl or Wood Al cohol ) i s
used i n a vari ety of concentrati ons bl ended wi th
unl eaded gasol i ne. You may encounter fuel s contai n-
i ng 3 percent or more methanol al ong wi th other
al cohol s cal l ed cosol vents.
DO NOT USE GASOLINES CONTAINING
METHANOL.
ZJ FUEL SYSTEM 14 - 1
Use of methanol /gasol i ne bl ends may resul t i n
starti ng and dri veabi l i ty probl ems and damage cri ti -
cal fuel system components.
Probl ems that are the resul t of usi ng methanol /
gasol i ne bl ends are not the responsi bi l i ty of Chrysl er
Corporati on and may not be covered by the vehi cl e
warranty.
Reformulated Gasoline
Many areas of the country are requi ri ng the use of
cl eaner-burni ng fuel referred to as Reformulated
Gasoline. Reformul ated gasol i nes are speci al l y
bl ended to reduce vehi cl e emi ssi ons and i mprove ai r
qual i ty.
Chrysl er Corporati on strongl y supports the use of
reformul ated gasol i nes whenever avai l abl e. Al though
your vehi cl e was desi gned to provi de opti mum perfor-
mance and l owest emi ssi ons operati ng on hi gh qual -
i ty unl eaded gasol i ne, i t wi l l perform equal l y wel l
and produce even l ower emi ssi ons when operati ng on
reformul ated gasol i ne.
Materials Added to Fuel
I ndi scri mi nate use of fuel system cl eani ng agents
shoul d be avoi ded. Many of these materi al s i ntended
for gum and varni sh removal may contai n acti ve sol -
vents of si mi l ar i ngredi ents that can be harmful to
fuel system gasket and di aphragm materi al s.
14 - 2 FUEL SYSTEM ZJ
GENERAL INFORMATION (Continued)
FUEL DELIVERY SYSTEM
INDEX
page page
DESCRIPTION AND OPERATION
FUEL DELIVERY SYSTEM . . . . . . . . . . . . . . . . . . 3
FUEL FILTER/FUEL PRESSURE REGULATOR . . . 4
FUEL GAUGE SENDING UNIT . . . . . . . . . . . . . . . 4
FUEL INJECTORS . . . . . . . . . . . . . . . . . . . . . . . . 5
FUEL PUMP MODULE . . . . . . . . . . . . . . . . . . . . . 4
FUEL PUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
FUEL RAIL4.0L ENGINE . . . . . . . . . . . . . . . . . . 6
FUEL RAIL5.2L/5.9L ENGINES . . . . . . . . . . . . . 6
FUEL TANK FILLER TUBE CAP . . . . . . . . . . . . . . 6
FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
QUICK-CONNECT FITTINGS . . . . . . . . . . . . . . . . 6
ROLLOVER VALVE(S) . . . . . . . . . . . . . . . . . . . . . 5
DIAGNOSIS AND TESTING
FUEL GAUGE SENDING UNIT . . . . . . . . . . . . . . 10
FUEL INJECTOR TEST . . . . . . . . . . . . . . . . . . . 10
FUEL PRESSURE LEAK DOWN TEST . . . . . . . . . 8
FUEL PUMP AMPERAGE TEST . . . . . . . . . . . . . . 9
FUEL PUMP CAPACITY TEST . . . . . . . . . . . . . . . 7
FUEL PUMP PRESSURE TESTALL ENGINES
WITH PRESSURE TEST PORT . . . . . . . . . . . . . 7
SERVICE PROCEDURES
FUEL SYSTEM PRESSURE RELEASE
PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . 10
FUEL TUBES/LINES/HOSES AND CLAMPS . . . . 11
QUICK-CONNECT FITTINGS . . . . . . . . . . . . . . . 11
REMOVAL AND INSTALLATION
ACCELERATOR PEDAL . . . . . . . . . . . . . . . . . . . 22
FUEL FILTER/FUEL PRESSURE REGULATOR . . 14
FUEL GAUGE SENDING UNIT . . . . . . . . . . . . . . 16
FUEL INJECTOR RAIL4.0L ENGINE . . . . . . . . 19
FUEL INJECTOR RAIL5.2L/5.9L ENGINES . . . 17
FUEL INJECTOR(S) . . . . . . . . . . . . . . . . . . . . . . 19
FUEL PUMP INLET FILTER . . . . . . . . . . . . . . . . 16
FUEL PUMP MODULE . . . . . . . . . . . . . . . . . . . . 15
FUEL TANK FILLER TUBE CAP . . . . . . . . . . . . . 22
FUEL TANK . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
THROTTLE CABLE . . . . . . . . . . . . . . . . . . . . . . 22
SPECIFICATIONS
FUEL SYSTEM PRESSURE . . . . . . . . . . . . . . . . 24
FUEL TANK CAPACITY . . . . . . . . . . . . . . . . . . . 24
TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . . 24
VECI LABEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
FUEL DELIVERY SYSTEM
The fuel del i very system consi sts of:
the fuel pump modul e contai ni ng the el ectri c
fuel pump, fuel fi l ter/fuel pressure regul ator, fuel
gauge sendi ng uni t (fuel l evel sensor) and a separate
fuel fi l ter l ocated at bottom of pump modul e
fuel tubes/l i nes/hoses
qui ck-connect fi tti ngs
fuel i njector rai l
fuel i njectors
fuel tank
fuel tank fi l l er/vent tube assembl y
fuel tank fi l l er tube cap
accel erator pedal
throttl e cabl e
Fuel i s returned through the fuel pump modul e
and back i nto the fuel tank through the fuel fi l ter/
fuel pressure regul ator. A separate fuel return l i ne
from the engi ne to the tank i s not used.
The fuel tank assembl y consi sts of: the fuel tank,
fuel pump modul e assembl y, fuel pump modul e l ock-
nut/gasket, and rol l over val ve (refer to Group 25,
Emi ssi on Control System for rol l over val ve i nforma-
ti on).
A fuel fi l l er/vent tube assembl y usi ng a pressure/
vacuum fuel fi l l er cap i s used. The fuel fi l l er tube
contai ns a spri ng-l oaded fl ap (door) l ocated bel ow the
fuel fi l l cap. The fl ap i s used as a secondary way of
seal i ng the fuel tank i f the fuel fi l l cap has not been
properl y ti ghtened. The fl ap i s used as part of the
EVAP moni tor system when the vehi cl e i s equi pped
wi th a Leak Detecti on Pump (LDP). The fl ap wi l l be
i nstal l ed to al l fuel fi l l er tubes (equi pped/not
equi pped wi th LDP and EVAP moni tor system).
Al so to be consi dered part of the fuel system i s the
evaporati on control system. Thi s i s desi gned to
reduce the emi ssi on of fuel vapors i nto the atmo-
sphere. The descri pti on and functi on of the Evapora-
ti ve Control System i s found i n Group 25, Emi ssi on
Control Systems.
Both fuel fi l ters (at bottom of fuel pump modul e
and wi thi n fuel pressure regul ator) are desi gned for
extended servi ce. They do not requi re normal sched-
ul ed mai ntenance. Fi l ters shoul d onl y be repl aced i f
a di agnosti c procedure i ndi cates to do so.
FUEL PUMP MODULE
The fuel pump modul e i s i nstal l ed i n the top of the
fuel tank (Fi g. 1) or (Fi g. 2). The fuel pump modul e
contai ns the fol l owi ng components:
A combi nati on fuel fi l ter/fuel pressure regul ator
A separate fuel pi ck-up fi l ter (strai ner)
An el ectri c fuel pump
A threaded l ocknut to retai n modul e to tank
A gasket between tank fl ange and modul e
Fuel gauge sendi ng uni t (fuel l evel sensor)
Fuel suppl y tube (l i ne) connecti on
The fuel gauge sendi ng uni t, pi ck-up fi l ter and fuel
fi l ter/fuel pressure regul ator may be servi ced sepa-
ratel y. I f the el ectri cal fuel pump requi res servi ce,
the enti re fuel pump modul e must be repl aced.
FUEL PUMP
The fuel pump used i n thi s system has a perma-
nent magnet el ectri c motor. The pump i s part of the
fuel pump modul e. Fuel i s drawn i n through a fi l ter
at the bottom of the modul e and pushed through the
el ectri c motor gearset to the pump outl et.
Check Valve Operation: The pump outl et con-
tai ns a one-way check val ve to prevent fuel fl ow back
i nto the tank and to mai ntai n fuel suppl y l i ne pres-
sure (engi ne warm) when pump i s not operati onal . I t
i s al so used to keep the fuel suppl y l i ne ful l of gaso-
l i ne when pump i s not operati onal . After the vehi cl e
has cool ed down, fuel pressure may drop to 0 psi
(col d fl ui d contracts), but l i qui d gasol i ne wi l l remai n
i n fuel suppl y l i ne between the check val ve and fuel
i njectors. Fuel pressure that has dropped to 0
psi on a cooled down vehicle (engine off) is a
normal condition. Refer to the Fuel Pressure Leak
Down Test i n thi s group for more i nformati on.
Vol tage to operate the el ectri c pump i s suppl i ed
through the fuel pump rel ay.
FUEL GAUGE SENDING UNIT
The fuel gauge sendi ng uni t (fuel l evel sensor) i s
attached to the si de of the fuel pump modul e. The
sendi ng uni t consi sts of a fl oat, an arm, and a vari -
abl e resi stor (track). The resi stor track i s used to
send el ectri cal si gnal s to the Powertrai n Control
Modul e (PCM) for fuel gauge operati on and for OBD
I I emi ssi on requi rements.
For fuel gauge operation: As fuel l evel
i ncreases, the fl oat and arm move up. Thi s decreases
the sendi ng uni t resi stance, causi ng the fuel gauge to
read ful l . As fuel l evel decreases, the fl oat and arm
move down. Thi s i ncreases the sendi ng uni t resi s-
tance causi ng the fuel gauge to read empty.
After thi s fuel l evel si gnal i s sent to the PCM, the
PCM wi l l transmi t the data across the CCD bus ci r-
cui ts to the i nstrument panel . Here i t i s transl ated
i nto the appropri ate fuel gauge l evel readi ng.
For OBD II emission monitor requirements: A
vol tage si gnal i s sent from the resi stor track on the
sendi ng uni t to the PCM to i ndi cate fuel l evel . The
purpose of thi s feature i s to prevent the OBD I I sys-
tem from recordi ng/setti ng fal se mi sfi re and fuel sys-
tem moni tor troubl e codes. The feature i s acti vated i f
the fuel l evel i n the tank i s l ess than approxi matel y
15 percent of i ts rated capaci ty. I f equi pped wi th a
Leak Detecti on Pump (EVAP system moni tor), thi s
feature wi l l al so be acti vated i f the fuel l evel i n the
tank i s more than approxi matel y 85 percent of i ts
rated capaci ty.
FUEL FILTER/FUEL PRESSURE REGULATOR
A combi nati on fuel fi l ter and fuel pressure regul a-
tor i s used on al l engi nes. I t i s l ocated on the top of
fuel pump modul e (Fi g. 1). A separate frame mounted
fuel fi l ter i s not used wi th any engi ne.
Fig. 1 Fuel Tank/Fuel Pump Module (Top View)
Fig. 2 Fuel Pump Module Components
DESCRIPTION AND OPERATION (Continued)
Fuel Pressure Regulator Operation: The pres-
sure regul ator i s a mechani cal devi ce that i s not con-
trol l ed by engi ne vacuum or the Powertrai n Control
Modul e (PCM).
The regul ator i s cal i brated to mai ntai n fuel system
operati ng pressure of approxi matel y 339 kPa 34
kPa (49.2 psi 5 psi ) at the fuel i njectors. I t con-
tai ns a di aphragm, cal i brated spri ngs and a fuel
return val ve. The i nternal fuel fi l ter i s al so part of
the assembl y.
Fuel i s suppl i ed to the fi l ter/regul ator by the el ec-
tri c fuel pump through an openi ng tube at the bot-
tom of fi l ter/regul ator (Fi g. 3).
The regul ator acts as a check val ve to mai ntai n
some fuel pressure when the engi ne i s not operati ng.
Thi s wi l l hel p to start the engi ne. A second check
val ve i s l ocated at the outl et end of the el ectri c fuel
pump. Refer to Fuel PumpDescription and
Operation for more information. Also refer to
the Fuel Pressure Leak Down Test and the Fuel
Pump Pressure Tests.
I f fuel pressure at the pressure regul ator exceeds
approxi matel y 49 psi , an i nternal di aphragm cl oses
and excess fuel i s routed back i nto the tank through
the pressure regul ator. A separate fuel return l i ne i s
not used.
FUEL TANK
Al l model s pass a ful l 360 degree rol l over test
wi thout fuel l eakage. To accompl i sh thi s, fuel and
vapor fl ow control s are requi red for al l fuel tank con-
necti ons.
Al l model s are equi pped wi th ei ther one or two
rol l over val ves mounted i nto the top of the fuel tank
(or pump modul e). Refer to Group 25, Emi ssi on Con-
trol System for rol l over val ve i nformati on.
An evaporati on control system i s connected to the
rol l over val ve(s) to reduce emi ssi ons of fuel vapors
i nto the atmosphere. When fuel evaporates from the
fuel tank, vapors pass through vent hoses or tubes to
a charcoal cani ster where they are temporari l y hel d.
When the engi ne i s runni ng, the vapors are drawn
i nto the i ntake mani fol d. Certai n model s are al so
equi pped wi th a sel f-di agnosi ng system usi ng a Leak
Detecti on Pump (LDP). Refer to Group 25, Emi ssi on
Control System for addi ti onal i nformati on.
ROLLOVER VALVE(S)
Refer to Group 25, Emi ssi on Control System for
i nformati on.
FUEL INJECTORS
The fuel i njectors (Fi g. 4) are el ectri cal sol enoi ds.
The i njector contai ns a pi ntl e that cl oses off an ori -
fi ce at the nozzl e end. When el ectri c current i s sup-
pl i ed to the i njector, the armature and needl e move a
short di stance agai nst a spri ng, al l owi ng fuel to fl ow
out the ori fi ce. Because the fuel i s under hi gh pres-
sure, a fi ne spray i s devel oped i n the shape of a pen-
ci l stream. The sprayi ng acti on atomi zes the fuel ,
addi ng i t to the ai r enteri ng the combusti on chamber.
An i ndi vi dual fuel i njector i s used for each i ndi vi d-
ual cyl i nder. The top (fuel entry) end of the i njector i s
attached i nto an openi ng on the fuel rai l .
The nozzl e (outl et) ends of the i njectors are posi -
ti oned i nto openi ngs i n the i ntake mani fol d just
above the i ntake val ve ports of the cyl i nder head.
The engi ne wi ri ng harness connector for each fuel
i njector i s equi pped wi th an attached numeri cal tag
(I NJ 1, I NJ 2 etc.). Thi s i s used to i denti fy each fuel
i njector.
The i njectors are energi zed i ndi vi dual l y i n a
sequenti al order by the powertrai n control modul e
(PCM). The PCM wi l l adjust i njector pul se wi dth by
swi tchi ng the ground path to each i ndi vi dual i njector
Fig. 3 Fuel Filter/Fuel Pressure Regulator
Fig. 4 Fuel InjectorTypical
on and off. I njector pul se wi dth i s the peri od of ti me
that the i njector i s energi zed. The PCM wi l l adjust
i njector pul se wi dth based on vari ous i nputs i t
recei ves.
Duri ng start up, battery vol tage i s suppl i ed to the
i njectors through the ASD rel ay. When the engi ne i s
operati ng, vol tage i s suppl i ed by the chargi ng sys-
tem. The PCM determi nes i njector pul se wi dth based
on vari ous i nputs.
FUEL RAIL 4. 0L ENGINE
The fuel rai l suppl i es the necessary fuel to each
i ndi vi dual fuel i njector and i s mounted to the i ntake
mani fol d (Fi g. 5). The fuel pressure regul ator i s not
mounted to the fuel rai l on any 4.0L engi ne. I t i s
l ocated on the fuel tank mounted fuel pump modul e.
Refer to Fuel Fi l ter/Fuel Pressure Regul ator i n thi s
group for i nformati on.
Dependi ng on vehi cl e model /engi ne, the fuel rai l
may/may not be equi pped wi th a fuel pressure test
port. Refer to the Fuel Pump Pressure Test for addi -
ti onal i nformati on.
The fuel rai l i s not repai rabl e.
FUEL RAIL 5. 2L/5. 9L ENGINES
The fuel rai l suppl i es the necessary fuel to each
i ndi vi dual fuel i njector and i s mounted to the i ntake
mani fol d (Fi g. 6). The fuel pressure regul ator i s not
mounted to the fuel rai l on any 5.2L/5.9L V-8 engi ne.
I t i s l ocated on the fuel tank mounted fuel pump
modul e. Refer to Fuel Fi l ter/Fuel Pressure Regul ator
i n thi s group for i nformati on.
Dependi ng on vehi cl e model /engi ne, the fuel rai l
may/may not be equi pped wi th a fuel pressure test
port. I f equi pped, i t wi l l be l ocated on the l eft si de of
fuel rai l . Refer to the Fuel Pump Pressure Test for
addi ti onal i nformati on.
The fuel rai l i s not repai rabl e.
CAUTION: 5.2L/5.9L Engines Only: The left and
right sections of the fuel rail are connected with a
flexible connecting hose. Do not attempt to sepa-
rate the rail halves at this connecting hose. Due to
the design of this connecting hose, it does not use
any clamps. Never attempt to install a clamping
device of any kind to the hose. When removing the
fuel rail assembly for any reason, be careful not to
bend or kink the connecting hose.
FUEL TANK FILLER TUBE CAP
The l oss of any fuel or vapor out of fi l l er neck i s
prevented by the use of a pressure-vacuum fuel tank
fi l l er tube cap. Rel i ef val ves i nsi de cap wi l l rel ease
onl y under si gni fi cant pressure of 6.58 to 8.44 kPa
(1.95 to 2.5 psi ). The vacuum rel ease for al l fuel fi l l er
tube caps i s between .97 and 5.0 kPa (.14 and .72
psi ). Thi s cap must be repl aced by a si mi l ar uni t i f
repl acement i s necessary. Thi s i s i n order for the sys-
tem to remai n effecti ve.
CAUTION: Remove fuel tank filler tube cap before
servicing any fuel system component. This is done
to help relieve tank pressure.
QUICK-CONNECT FITTINGS
Di fferent types of qui ck-connect fi tti ngs are used to
attach vari ous fuel system components. These are: a
si ngl e-tab type, a two-tab type or a pl asti c retai ner
ri ng type. Some are equi pped wi th safety l atch cl i ps.
Fig. 5 Fuel Rail4.0L Engine
Fig. 6 Fuel RailTypical 5.2L/5.9L Engine
Refer to the Removal /I nstal l ati on secti on for more
i nformati on.
CAUTION: The interior components (o-rings, spac-
ers) of quick-connect fitting are not serviced sepa-
rately, but new pull tabs are available for some
types. Do not attempt to repair damaged fittings or
fuel lines/tubes. If repair is necessary, replace the
complete fuel tube assembly.
FUEL PUMP PRESSURE TEST ALL ENGINES
WITH PRESSURE TEST PORT
Use thi s test i n conjuncti on wi th the Fuel Pump
Capaci ty Test, Fuel Pressure Leak Down Test and
Fuel Pump Amperage Test found el sewhere i n thi s
group.
Check Valve Operation: The el ectri c fuel pump
outl et contai ns a one-way check val ve to prevent fuel
fl ow back i nto the tank and to mai ntai n fuel suppl y
l i ne pressure (engi ne warm) when pump i s not oper-
ati onal . I t i s al so used to keep the fuel suppl y l i ne
ful l of gasol i ne when pump i s not operati onal . After
the vehi cl e has cool ed down, fuel pressure may drop
to 0 psi (col d fl ui d contracts), but l i qui d gasol i ne wi l l
remai n i n fuel suppl y l i ne between the check val ve
and fuel i njectors. Fuel pressure that has
dropped to 0 psi on a cooled down vehicle
(engine off) is a normal condition. When the el ec-
tri c fuel pump i s acti vated, fuel pressure shoul d
immediately (12 seconds) ri se to speci fi cati on.
Al l fuel systems are equi pped wi th a fuel tank
modul e mounted, combi nati on fuel fi l ter/fuel pressure
regul ator. The fuel pressure regul ator i s not con-
trol l ed by engi ne vacuum.
WARNING: THE FUEL SYSTEM IS UNDER CON-
STANT FUEL PRESSURE EVEN WITH THE ENGINE
OFF. BEFORE DISCONNECTING FUEL LINE AT
FUEL RAIL, THIS PRESSURE MUST BE RELEASED.
REFER TO THE FUEL SYSTEM PRESSURE
RELEASE PROCEDURE.
(1) Remove protecti ve cap at fuel rai l test port.
Connect the 0414 kPa (0-60 psi ) fuel pressure gauge
(from gauge set 5069) to test port pressure fi tti ng on
fuel rai l (Fi g. 7).
(2) Start and warm engi ne and note pressure
gauge readi ng. Fuel pressure shoul d be 339 kPa 34
kPa (49.2 psi 5 psi ) at i dl e.
(3) I f engi ne runs, but pressure i s bel ow 44.2 psi ,
check for a ki nked fuel suppl y l i ne somewhere
between fuel rai l and fuel pump modul e. I f l i ne i s not
ki nked, but speci fi cati ons for ei ther the Fuel Pump
Capaci ty, Fuel Pump Amperage or Fuel Pressure
Leak Down Tests were not met, repl ace fuel pump
modul e assembl y. Refer to Fuel Pump Modul e
Removal /I nstal l ati on.
(4) I f operati ng pressure i s above 54.2 psi , el ectri c
fuel pump i s OK, but fuel pressure regul ator i s defec-
ti ve. Repl ace fuel fi l ter/fuel pressure regul ator. Refer
to Fuel Fi l ter/Fuel Pressure Regul ator Removal /I n-
stal l ati on for more i nformati on.
(5) I nstal l protecti ve cap to fuel rai l test port.
FUEL PUMP CAPACITY TEST
Before performing this test, verify fuel pump
pressure by performing the Fuel Pump Pres-
sure Test. Use this test in conjunction with the
Fuel Pressure Leak Down Test found elsewhere
in this group.
(1) Rel ease fuel system pressure. Refer to the Fuel
Pressure Rel ease Procedure i n thi s group.
(2) Di sconnect fuel suppl y l i ne at fuel rai l . Refer to
Qui ck-Connect Fi tti ngs i n the Servi ce Procedures
secti on of thi s group for procedures. Some engi nes
may requi re ai r cl eaner housi ng removal before l i ne
di sconnecti on.
(3) Connect appropri ate Fuel Li ne Pressure Test
Adapter Tool Hose (number 6631, 6923, 6541 or
6539) i nto di sconnected fuel suppl y l i ne. I nsert other
end of Adaptor Tool hose i nto a graduated contai ner.
(4) Remove fuel fi l l cap.
(5) To acti vate fuel pump and pressuri ze system,
obtai n DRB scan tool and actuate ASD Fuel System
Test.
(6) A good fuel pump wi l l del i ver at l east 1/4 l i ter
of fuel i n 7 seconds. Do not operate fuel pump for
l onger than 7 seconds wi th fuel l i ne di sconnected as
fuel pump modul e reservoi r may run empty.
(a) I f capaci ty i s l ower than speci fi cati on, but
fuel pump can be heard operati ng through fuel fi l l
cap openi ng, check for a ki nked/damaged fuel sup-
Fig. 7 Fuel Pressure Test Gauge (Typical Gauge
Installation at Test Port)
pl y l i ne somewhere between fuel rai l and fuel
pump modul e.
(b) I f l i ne i s not ki nked/damaged, and fuel pres-
sure i s OK, but capaci ty i s l ow, repl ace fuel fi l ter/
fuel pressure regul ator. The fi l ter/regul ator may be
servi ced separatel y on certai n appl i cati ons. Refer
to Fuel Fi l ter/Fuel Pressure Regul ator Removal /I n-
stal l ati on for addi ti onal i nformati on.
(c) I f both fuel pressure and capaci ty are l ow,
repl ace fuel pump modul e assembl y. Refer to Fuel
Pump Modul e Removal /I nstal l ati on.
FUEL PRESSURE LEAK DOWN TEST
Use thi s test i n conjuncti on wi th the Fuel Pump
Pressure Test and Fuel Pump Capaci ty Test.
Check Valve Operation: The el ectri c fuel pump
outl et contai ns a one-way check val ve to prevent fuel
fl ow back i nto the tank and to mai ntai n fuel suppl y
l i ne pressure (engi ne warm) when pump i s not oper-
ati onal . I t i s al so used to keep the fuel suppl y l i ne
ful l of gasol i ne when pump i s not operati onal . After
the vehi cl e has cool ed down, fuel pressure may drop
to 0 psi (col d fl ui d contracts), but l i qui d gasol i ne wi l l
remai n i n fuel suppl y l i ne between the check val ve
and fuel i njectors. Fuel pressure that has
dropped to 0 psi on a cooled down vehicle
(engine off) is a normal condition. When the el ec-
tri c fuel pump i s acti vated, fuel pressure shoul d
immediately (12 seconds) ri se to speci fi cati on.
Abnormal l y l ong peri ods of cranki ng to restart a
hot engi ne that has been shut down for a short
peri od of ti me may be caused by:
Fuel pressure bl eedi ng past a fuel i njector(s).
Fuel pressure bl eedi ng past the check val ve i n
the fuel pump modul e.
(1) Di sconnect the fuel i nl et l i ne at fuel rai l . Refer
to Fuel Tubes/Li nes/Hoses and Cl amps i n thi s secti on
of the group for procedures. On some engi nes, ai r
cl eaner housi ng removal may be necessary before
fuel l i ne di sconnecti on.
(2) Connect the appropri ate Fuel Li ne Pressure
Test Adapter Tool (number 6539, 6631, 6541 or 6923)
between the di sconnected fuel l i ne and fuel rai l (Fi g.
8) or (Fi g. 9).
(3) Connect the 0-414 kPa (0-60 psi ) fuel pressure
test gauge (from Gauge Set 5069) to the test port on
the appropri ate Adaptor Tool . The fittings on both
tools must be in good condition and free from
any small leaks before performing the proceed-
ing test.
(4) Start engi ne and bri ng to normal operati ng
temperature.
(5) Observe test gauge. Normal operati ng pressure
shoul d be 339 kPa 34 kPa (49.2 psi 5 psi ).
(6) Shut engi ne off.
(7) Pressure shoul d not fal l bel ow 30 psi for five
minutes.
(8) I f pressure fal l s bel ow 30 psi , i t must be deter-
mi ned i f a fuel i njector, the check val ve wi thi n the
fuel pump modul e, or a fuel tube/l i ne i s l eaki ng.
(9) Agai n, start engi ne and bri ng to normal oper-
ati ng temperature.
(10) Shut engi ne off.
(11) Testing for fuel injector or fuel rail leak-
age: Cl amp off the rubber hose porti on of Adaptor
Tool between the fuel rai l and the test port T on
Adapter Tool . I f pressure now hol ds at or above 30
psi , a fuel i njector or the fuel rai l i s l eaki ng.
(12) Testing for fuel pump check valve, filter/
regulator check valve or fuel tube/line leakage:
Fig. 8 Connecting Adapter ToolTypical
Fig. 9 Connecting Adapter ToolTypical
DIAGNOSIS AND TESTING (Continued)
Cl amp off the rubber hose porti on of Adaptor Tool
between the vehi cl e fuel l i ne and test port T on
Adapter Tool . I f pressure now hol ds at or above 30
psi , a l eak may be found at a fuel tube/l i ne. I f no
l eaks are found at fuel tubes or l i nes, one of the
check val ves i n ei ther the el ectri c fuel pump or fi l ter/
regul ator may be l eaki ng.
Note: A qui ck l oss of pressure usual l y i ndi cates a
defecti ve check val ve i n the fi l ter/regul ator. A sl ow
l oss of pressure usual l y i ndi cates a defecti ve check
val ve i n the el ectri c fuel pump.
The el ectri c fuel pump i s not servi ced separatel y.
Repl ace the fuel pump modul e assembl y. The fi l ter/
regul ator may be repl aced separatel y on certai n appl i -
cati ons. Refer to Fuel Fi l ter/Fuel Pressure Regul ator
Removal /I nstal l ati on for addi ti onal i nformati on.
FUEL PUMP AMPERAGE TEST
Thi s amperage (current draw) test i s to be done i n
conjuncti on wi th the Fuel Pump Pressure Test, Fuel
Pump Capaci ty Test and Fuel Pressure Leak Down
Test. Before performi ng the amperage test, be sure
the temperature of the fuel tank i s above 50 F (10
C).
The DRB Scan Tool al ong wi th the DRB Low Cur-
rent Shunt (LCS) adapter (Fi g. 10) and i ts test l eads
wi l l be used to check fuel pump amperage speci fi ca-
ti ons.
(1) Obtai n LCS adapter.
(2) Pl ug cabl e from LCS adapter i nto DRB scan
tool at SET 1 receptacl e.
(3) Pl ug DRB i nto vehi cl e 16way connector (data
l i nk connector).
(4) Connect (-) and (+) test cabl e l eads i nto LCS
adapter receptacl es. Use 10 amp (10A +) receptacl e
and common (-) receptacl es.
(5) Gai n access to MAI N MENU on DRB screen.
(6) Press DVOM button on DRB.
(7) Usi ng l eft/ri ght arrow keys, hi ghl i ght CHAN-
NEL 1 functi on on DRB screen.
(8) Press ENTER three ti mes.
(9) Usi ng up/down arrow keys, hi ghl i ght RANGE
on DRB screen (screen wi l l defaul t to 2 amp scal e).
(10) Press ENTER to change 2 amp scal e to 10
amp scal e. This step must be done to prevent
damage to DRB scan tool or LCS adapter
(blown fuse).
(11) Remove cover from Power Di stri buti on Center
(PDC).
(12) Remove fuel pump rel ay from PDC. Refer to
l abel on PDC cover for rel ay l ocati on.
WARNING: BEFORE PROCEEDING TO NEXT STEP,
NOTE THE FUEL PUMP WILL BE ACTIVATED AND
SYSTEM PRESSURE WILL BE PRESENT. THIS WILL
OCCUR AFTER CONNECTING TEST LEADS FROM
LCS ADAPTER INTO FUEL PUMP RELAY CAVITIES.
THE FUEL PUMP WILL OPERATE EVEN WITH IGNI-
TION KEY IN OFF POSITION. BEFORE ATTACHING
TEST LEADS, BE SURE ALL FUEL LINES AND FUEL
SYSTEM COMPONENTS ARE CONNECTED.
CAUTION: TO PREVENT POSSIBLE DAMAGE TO
THE VEHICLE ELECTRICAL SYSTEM AND LCS
ADAPTER, THE TEST LEADS MUST BE CON-
NECTED INTO RELAY CAVITIES EXACTLY AS
SHOWN IN FOLLOWING STEPS.
Dependi ng upon vehi cl e model , year or engi ne con-
fi gurati on, three di fferent types of rel ays may be
used: Type-1, type-2 and type3.
(13) I f equi pped wi th type1 relay (Fi g. 11),
attach test l eads from LCS adapter i nto PDC rel ay
cavi ti es number 30 and 87. For l ocati on of these cav-
i ti es, refer to numbers stamped to bottom of rel ay
(Fi g. 11).
Fig. 11 Type1 Relay
Fig. 10 Low Current Shunt Adapter
cavi ti es number 30 and 87. For l ocati on of these cav-
i ti es, refer to numbers stamped to bottom of rel ay
(Fi g. 12).
cavi ti es number 3 and 5. For l ocati on of these cavi -
ti es, refer to numbers stamped to bottom of rel ay
(Fi g. 13).
(16) When LCS adapter test l eads are attached
i nto rel ay cavi ti es, fuel pump will be activated.
Determi ne fuel pump amperage on DRB screen.
Amperage shoul d be bel ow 10.0 amps. I f amperage i s
bel ow 10.0 amps, and speci fi cati ons for the Fuel
Pump Pressure, Fuel Pump Capaci ty and Fuel Pres-
sure Leak Down tests were met, the fuel pump mod-
ul e i s OK.
(17) I f amperage i s more than 10.0 amps, repl ace
fuel pump modul e assembl y. The el ectri c fuel pump
i s not servi ced separatel y.
(18) Di sconnect test l eads from rel ay cavi ti es
i mmedi atel y after testi ng.
The fuel gauge sendi ng uni t contai ns a vari abl e
resi stor (track). As the fl oat moves up or down, el ec-
tri cal resi stance wi l l change. Refer to Group 8E,
I nstrument Panel and Gauges for Fuel Gauge test-
i ng. To test the gauge sendi ng uni t onl y, i t must be
removed from vehi cl e. The uni t i s part of the fuel
pump modul e. Refer to Fuel Pump Modul e Removal /
I nstal l ati on for procedures. Measure the resi stance
across the sendi ng uni t termi nal s. Wi th fl oat i n up
posi ti on, resi stance shoul d be 20 ohms. Wi th fl oat i n
down posi ti on, resi stance shoul d be 220 ohms.
FUEL INJECTOR TEST
To perform a compl ete test of the fuel i njectors and
thei r ci rcui try, refer to DRB scan tool and appropri -
ate Powertrai n Di agnosti cs Procedures manual . To
test the i njector onl y, refer to the fol l owi ng:
Di sconnect the fuel i njector wi re harness connector
from the i njector. Pl ace an ohmmeter across the
i njector el ectri cal termi nal s. Resi stance readi ng
shoul d be approxi matel y 12 ohms 1.2 ohms at 20C
(68F).
SERVICE PROCEDURES
FUEL SYSTEM PRESSURE RELEASE PROCEDURE
Use the following procedure if the fuel rail is
or is not equipped with a fuel pressure test
port.
(1) Remove the Fuel Pump rel ay from the Power
Di stri buti on Center (PDC). For l ocati on of the rel ay,
refer to the l abel on the undersi de of the PDC cover.
(2) Start and run engi ne unti l i t stal l s.
(3) Attempt restarti ng engi ne unti l i t wi l l no
l onger run.
Fig. 12 Type2 Relay
Fig. 13 Type3 Relay
Fig. 14 Fuel Injector Internal ComponentsTypical
(4) Turn i gni ti on key to OFF posi ti on.
CAUTION: Steps 1, 2, 3 and 4 must be performed to
relieve high pressure fuel from within the fuel rail.
Do not attempt to use the following steps to relieve
this pressure as excessive fuel will be forced into a
cylinder chamber.
(5) Unpl ug connector from any i njector.
(6) Attach one end of a jumper wi re wi th al l i gator
cl i ps (18 gauge or smal l er) to ei ther i njector termi nal .
(7) Connect the other end of the jumper wi re to
the posi ti ve si de of the battery.
(8) Connect one end of a second jumper wi re to the
remai ni ng i njector termi nal .
CAUTION: Powering an injector for more than a few
seconds will permanently damage the injector.
(9) Momentari l y touch the other end of thi s
jumper wi re to the negati ve termi nal of the battery
for no more than a few seconds.
(10) Pl ace a rag or towel bel ow the fuel l i ne at the
qui ck connect to the rai l .
(11) Di sconnect the qui ck connect fi tti ng to the
rai l . Refer to Qui ck-Connect Fi tti ngs i n thi s secti on.
(12) Return the fuel pump rel ay to the PDC.
(13) One or more Di agnosti c Troubl e Codes (DTCs)
may have been stored i n the PCM memory due to
fuel pump rel ay removal . The DRB scan tool must be
used to erase a DTC. Refer to Group 25, Emi ssi on
Control System. See On-Board Di agnosti cs.
FUEL TUBES/LINES/HOSES AND CLAMPS
Al so refer to the secti on on Qui ck-Connect Fi tti ngs.
WARNING: THE FUEL SYSTEM IS UNDER A CON-
STANT PRESSURE (EVEN WITH THE ENGINE OFF).
BEFORE SERVICING ANY FUEL SYSTEM HOSES,
FITTINGS OR LINES, THE FUEL SYSTEM PRES-
SURE MUST BE RELEASED. REFER TO THE FUEL
SYSTEM PRESSURE RELEASE PROCEDURE IN
THIS GROUP.
I nspect al l hose connecti ons such as cl amps, cou-
pl i ngs and fi tti ngs to make sure they are secure and
l eaks are not present. The component shoul d be
repl aced i mmedi atel y i f there i s any evi dence of deg-
radati on that coul d resul t i n fai l ure.
Never attempt to repai r a pl asti c fuel l i ne/tube.
Repl ace as necessary.
Avoi d contact of any fuel tubes/hoses wi th other
vehi cl e components that coul d cause abrasi ons or
scuffi ng. Be sure that the pl asti c fuel l i nes/tubes are
properl y routed to prevent pi nchi ng and to avoi d heat
sources.
The l i nes/tubes/hoses used on fuel i njected vehi cl es
are of a speci al constructi on. Thi s i s due to the
hi gher fuel pressures and the possi bi l i ty of contami -
nated fuel i n thi s system. I f i t i s necessary to repl ace
these l i nes/tubes/hoses, onl y those marked EFM/EFI
may be used.
If equipped: The hose cl amps used to secure rub-
ber hoses on fuel i njected vehi cl es are of a speci al
rol l ed edge constructi on. Thi s constructi on i s used to
prevent the edge of the cl amp from cutti ng i nto the
hose. Onl y these rol l ed edge type cl amps may be
used i n thi s system. Al l other types of cl amps may
cut i nto the hoses and cause hi gh-pressure fuel l eaks.
Use new ori gi nal equi pment type hose cl amps.
Ti ghten hose cl amps to 3 Nm (25 i n. l bs.) torque.
QUICK-CONNECT FITTINGS
Al so refer to the Fuel Tubes/Li nes/Hoses and
Cl amps secti on.
Di fferent types of qui ck-connect fi tti ngs are used to
attach vari ous fuel system components. These are: a
si ngl e-tab type, a two-tab type, a pl asti c retai ner ri ng
type or a l atch cl i p type. Certai n fi tti ngs may requi re
the use of a speci al tool for di sconnecti on.
SINGLE-TAB TYPE
Thi s type of fi tti ng i s equi pped wi th a si ngl e pul l
tab (Fi g. 15). The tab i s removabl e. After the tab i s
removed, the qui ck-connect fi tti ng can be separated
from the fuel system component.
ers) of this type of quick-connect fitting are not ser-
viced separately, but new pull tabs are available. Do
not attempt to repair damaged fittings or fuel lines/
tubes. If repair is necessary, replace the complete
fuel tube assembly.
Fig. 15 Single-Tab Type Fitting
SERVICE PROCEDURES (Continued)
THIS GROUP.
DISCONNECTION/CONNECTION
(1) Perform fuel pressure rel ease procedure. Refer
to Fuel Pressure Rel ease Procedure i n thi s group.
(2) Di sconnect negati ve battery cabl e from battery.
(3) Cl ean fi tti ng of any forei gn materi al before di s-
assembl y.
(4) Press rel ease tab on si de of fi tti ng to rel ease
pul l tab (Fi g. 16).
CAUTION: If this release tab is not pressed prior
to releasing the pull tab, the pull tab will be dam-
aged.
(5) Whi l e pressi ng rel ease tab on si de of fi tti ng,
use a screwdri ver to pry up pul l tab (Fi g. 16).
(6) Rai se pul l tab unti l i t separates from qui ck-
connect fi tti ng (Fi g. 17). Di scard ol d pul l tab.
(7) Di sconnect qui ck-connect fi tti ng from fuel sys-
tem component bei ng servi ced.
(8) I nspect qui ck-connect fi tti ng body and fuel sys-
tem component for damage. Repl ace as necessary.
(9) Pri or to connecti ng qui ck-connect fi tti ng to
component bei ng servi ced, check condi ti on of fi tti ng
and component. Cl ean parts wi th a l i nt-free cl oth.
Lubri cate wi th cl ean engi ne oi l .
(10) I nsert qui ck-connect fi tti ng i nto fuel tube or
fuel system component unti l bui l t-on stop on fuel
tube or component rests agai nst back of fi tti ng.
(11) Obtai n a new pul l tab. Push new tab down
unti l i t l ocks i nto pl ace i n qui ck-connect fi tti ng.
(12) Veri fy a l ocked condi ti on by fi rml y pul l i ng on
fuel tube and fi tti ng (15-30 l bs.).
(13) Connect negati ve cabl e to battery.
(14) Start engi ne and check for l eaks.
TWO-TAB TYPE FITTING
Thi s type of fi tti ng i s equi pped wi th tabs l ocated on
both si des of the fi tti ng (Fi g. 18). These tabs are sup-
pl i ed for di sconnecti ng the qui ck-connect fi tti ng from
component bei ng servi ced.
ers) of this type of quick-connect fitting are not ser-
viced separately, but new plastic retainers are
available. Do not attempt to repair damaged fittings
or fuel lines/tubes. If repair is necessary, replace
the complete fuel tube assembly.
Fig. 16 Disconnecting Single-Tab Type Fitting
Fig. 17 Removing Pull Tab
Fig. 18 Typical Two-Tab Type Quick-Connect Fitting
PRESSURE RELEASE PROCEDURE IN THIS
GROUP.
assembl y.
(4) To di sconnect qui ck-connect fi tti ng, squeeze
pl asti c retai ner tabs (Fi g. 18) agai nst si des of qui ck-
connect fi tti ng wi th your fi ngers. Tool use i s not
requi red for removal and may damage pl asti c
retai ner. Pul l fi tti ng from fuel system component
bei ng servi ced. The pl asti c retai ner wi l l remai n on
component bei ng servi ced after fi tti ng i s di scon-
nected. The o-ri ngs and spacer wi l l remai n i n qui ck-
connect fi tti ng connector body.
(5) I nspect qui ck-connect fi tti ng body and compo-
nent for damage. Repl ace as necessary.
CAUTION: When the quick-connect fitting was dis-
connected, the plastic retainer will remain on the
component being serviced. If this retainer must be
removed, very carefully release the retainer from
the component with two small screwdrivers. After
removal, inspect the retainer for cracks or any dam-
age.
(7) I nsert qui ck-connect fi tti ng to component bei ng
servi ced and i nto pl asti c retai ner. When a connecti on
i s made, a cl i ck wi l l be heard.
PLASTIC RETAINER RING TYPE FITTING
Thi s type of fi tti ng can be i denti fi ed by the use of a
ful l -round pl asti c retai ner ri ng (Fi g. 19) usual l y bl ack
i n col or.
ers, retainers) of this type of quick-connect fitting
are not serviced separately. Do not attempt to repair
damaged fittings or fuel lines/tubes. If repair is nec-
essary, replace the complete fuel tube assembly.
THIS GROUP.
to Fuel Pressure Rel ease Procedure i n thi s secti on.
assembl y.
(4) To rel ease fuel system component from qui ck-
connect fi tti ng, fi rml y push fi tti ng towards compo-
nent bei ng servi ced whi l e fi rml y pushi ng pl asti c
retai ner ri ng i nto fi tti ng (Fi g. 19). Wi th pl asti c ri ng
depressed, pul l fi tti ng from component. The plastic
retainer ring must be pressed squarely into fit-
ting body. If this retainer is cocked during
removal, it may be difficult to disconnect fit-
ting. Use an open-end wrench on shoulder of
plastic retainer ring to aid in disconnection.
(5) After di sconnecti on, pl asti c retai ner ri ng wi l l
remai n wi th qui ck-connect fi tti ng connector body.
(6) I nspect fi tti ng connector body, pl asti c retai ner
ri ng and fuel system component for damage. Repl ace
as necessary.
Fig. 19 Plastic Retainer Ring Type Fitting
(8) I nsert qui ck-connect fi tti ng i nto component
bei ng servi ced unti l a cl i ck i s fel t.
(10) Connect negati ve battery cabl e to battery.
LATCH CLIP FITTING (FUEL LINE-TO-FUEL
RAIL)
A tethered l atch cl i p (Fi g. 20) i s used to secure the
fuel l i ne to the fuel rai l . A speci al tool wi l l be neces-
sary to separate fuel l i ne from fuel rai l after l atch
cl i p i s removed. Thi s same l atch cl i p may al so be
used to secure other di fferent fuel system compo-
nents.
ers, retainers) of this type of quick-connect fitting
are not serviced separately. Do not attempt to repair
damaged fittings or fuel lines/tubes. If repair is nec-
essary, replace the complete fuel tube assembly.
THIS GROUP.
assembl y.
(4) Pry up on l atch cl i p wi th a screwdri ver (Fi g.
20).
(5) Sl i de l atch cl i p toward fuel rai l whi l e l i fti ng
wi th screwdri ver.
(6) I nsert speci al fuel l i ne removal tool (Snap-On
number FI H 9055-1 or equi val ent) i nto fuel l i ne (Fi g.
21). Use thi s tool to rel ease l ocki ng fi ngers i n end of
l i ne.
(7) Wi th speci al tool sti l l i nserted, pul l fuel l i ne
from fuel rai l .
(8) After di sconnecti on, l ocki ng fi ngers wi l l remai n
wi thi n qui ck-connect fi tti ng at end of fuel l i ne.
(9) Pri or to connecti ng fuel l i ne to fuel rai l , check
condi ti on of both fi tti ngs. Cl ean parts wi th a l i nt-free
cl oth. Lubri cate wi th cl ean engi ne oi l .
(10) I nsert fuel l i ne onto fuel rai l unti l a cl i ck i s
fel t.
(11) I nstal l l atch cl i p (snaps i nto posi ti on). If latch
clip will not fit, this indicates fuel line is not
properly installed to fuel rail. Recheck fuel line
connection.
fuel l i ne and fi tti ng (15-30 l bs.).
FUEL FILTER/FUEL PRESSURE REGULATOR
The combi nati on Fuel Fi l ter/Fuel Pressure Regul a-
tor i s l ocated on the fuel pump modul e. The fuel
pump modul e i s l ocated on top of fuel tank.
The fi l ter/regul ator may be removed wi thout
removi ng fuel pump modul e al though fuel tank must
be removed.
Fig. 20 Latch Clip Removal
Fig. 21 Fuel Line Disconnection
REMOVAL
(1) Remove fuel tank. Refer to Fuel Tank Removal /
I nstal l ati on.
(2) Cl ean area around fi l ter/regul ator.
(3) Remove retai ner cl amp from top of fi l ter/regu-
l ator (Fi g. 22). Cl amp snaps to tabs on pump modul e.
Di scard ol d cl amp.
(4) Pry fi l ter/regul ator from top of pump modul e
wi th 2 screwdri vers. Uni t i s snapped i nto modul e.
(5) Di scard gasket bel ow fi l ter/regul ator (Fi g. 23).
(6) Before di scardi ng fi l ter/regul ator assembl y,
i nspect assembl y to veri fy that o-ri ngs (Fi g. 24) are
i ntact. I f the smal l est of the two o-ri ngs can not be
found on bottom of fi l ter/regul ator, i t may be neces-
sary to remove i t from the fuel i nl et passage i n fuel
pump modul e.
INSTALLATION
(1) Cl ean recessed area i n pump modul e where fi l -
ter/regul ator i s to be i nstal l ed.
(2) Obtai n new fi l ter/regul ator (two new o-ri ngs
shoul d al ready be i nstal l ed).
(3) Appl y a smal l amount of cl ean engi ne oi l to
o-ri ngs. Do not install o-rings separately into
fuel pump module. They will be damaged when
installing filter/regulator.
(4) I nstal l new gasket to top of fuel pump modul e.
(5) Press new fi l ter/regul ator i nto top of pump
modul e unti l i t snaps i nto posi ti on (a posi ti ve cl i ck
must be heard or fel t).
(6) The mol ded arrow (Fi g. 22) on top of fuel pump
modul e shoul d be poi nted towards front of vehi cl e (12
ocl ock posi ti on).
(7) Rotate fi l ter/regul ator unti l fuel suppl y tube
(fi tti ng) i s poi nted to 11 ocl ock posi ti on.
(8) I nstal l new retai ner cl amp (cl amp snaps over
top of fi l ter/regul ator and l ocks to fl anges on pump
modul e).
(9) I nstal l fuel tank. Refer to Fuel Tank Removal /
I nstal l ati on.
FUEL PUMP MODULE
Fuel tank removal wi l l be necessary for fuel pump
modul e removal .
REMOVAL
BEFORE SERVICING THE FUEL PUMP MODULE, THE
FUEL SYSTEM PRESSURE MUST BE RELEASED.
Fig. 22 Fuel Filter/Fuel Pressure Regulator
Fig. 23 Fuel Filter/Fuel Pressure Regulator Gasket
Fig. 24 Fuel Filter/Fuel Pressure Regulator O-Rings
REMOVAL AND INSTALLATION (Continued)
(1) Drai n fuel tank and remove tank. Refer to the
Fuel Tank Removal /I nstal l ati on secti on of thi s group.
(2) Thoroughl y wash and cl ean area around pump
modul e to prevent contami nants from enteri ng tank.
(3) The pl asti c fuel pump modul e l ocknut i s
threaded onto fuel tank (Fi g. 25). I nstal l Speci al Tool
6856 to fuel pump modul e l ocknut and remove l ock-
nut (Fi g. 26). The fuel pump modul e wi l l spri ng up
when l ocknut i s removed.
(4) Remove modul e from fuel tank.
INSTALLATION
CAUTION: Whenever the fuel pump module is ser-
viced, the module gasket must be replaced.
(1) Usi ng a new gasket, posi ti on fuel pump modul e
i nto openi ng i n fuel tank.
(2) Posi ti on l ocknut over top of fuel pump modul e.
(3) Rotate modul e unti l arrow (Fi g. 22) i s poi nted
toward front of vehi cl e (12 ocl ock posi ti on). Thi s step
must be done to prevent fl oat/fl oat rod assembl y from
contacti ng si des of fuel tank.
(4) I nstal l Speci al Tool 6856 to l ocknut.
(5) Ti ghten l ocknut to 62 Nm (45 ft. l bs.) torque.
(6) Rotate fuel fi l ter/fuel pressure regul ator unti l
i ts fi tti ng i s poi nted to 11 ocl ock posi ti on.
(7) I nstal l fuel tank. Refer to Fuel Tank I nstal l a-
ti on i n thi s secti on.
FUEL PUMP INLET FILTER
The fuel pump i nl et fi l ter (strai ner) i s l ocated on
the bottom of fuel pump modul e (Fi g. 27). The fuel
pump modul e i s l ocated on top of fuel tank.
REMOVAL
I nstal l ati on.
(2) Remove fuel pump modul e. Refer to Fuel Pump
Modul e Removal /I nstal l ati on.
(3) Remove fi l ter by pryi ng from bottom of modul e
wi th 2 screwdri vers. Fi l ter i s snapped to modul e.
(4) Cl ean bottom of pump modul e.
INSTALLATION
(1) Snap new fi l ter to bottom of modul e.
(2) I nstal l fuel pump modul e. Refer to Fuel Pump
I nstal l ati on.
The fuel gauge sendi ng uni t (fuel l evel sensor) and
fl oat assembl y i s l ocated on the si de of fuel pump
modul e (Fi g. 28). The fuel pump modul e i s l ocated
wi thi n the fuel tank.
Fig. 25 Top View of Fuel Tank and Fuel Pump
Module
Fig. 26 Locknut Removal/InstallationTypical
Fig. 27 Fuel Pump Inlet Filter
REMOVAL
I nstal l ati on.
(2) Remove fuel pump modul e. Refer to Fuel Pump
(3) Remove el ectri cal wi re connector at sendi ng
uni t termi nal s.
(4) Press on rel ease tab (Fi g. 29) to remove send-
i ng uni t from pump modul e.
INSTALLATION
(1) Posi ti on sendi ng uni t to pump modul e and
snap i nto pl ace.
(2) Connect el ectri cal connector to termi nal s.
(3) I nstal l fuel pump modul e. Refer to Fuel Pump
I nstal l ati on.
FUEL INJECTOR RAIL 5. 2L/5. 9L ENGINES
STANT PRESSURE (EVEN WITH THE ENGINE
TURNED OFF). BEFORE SERVICING THE FUEL
RAIL ASSEMBLY, THE FUEL SYSTEM PRESSURE
MUST BE RELEASED.
To rel ease fuel pressure, refer to the Fuel System
Pressure Rel ease Procedure found i n thi s group.
CAUTION: The left and right fuel rails are replaced
as an assembly. Do not attempt to separate the rail
halves at the connecting hose (Fig. 30). Due to the
design of this connecting hose, it does use any
clamps. Never attempt to install a clamping device
of any kind to the hose. When removing the fuel rail
assembly for any reason, be careful not to bend or
kink the connecting hose.
REMOVAL
(1) Remove negati ve battery cabl e at battery.
(2) Remove ai r duct at throttl e body.
(3) Perform the fuel pressure rel ease procedure.
(4) Remove throttl e body from i ntake mani fol d.
Refer to Throttl e Body removal i n thi s group.
(5) I f equi pped wi th ai r condi ti oni ng, remove the
A-shaped A/C compressor-to-i ntake mani fol d support
bracket (three bol ts) (Fi g. 31).
(6) Di sconnect el ectri cal connectors at al l fuel
i njectors (Fi g. 32). The factory fuel i njecti on wi ri ng
harness i s numeri cal l y tagged (I NJ 1, I NJ 2, etc.) for
i njector posi ti on i denti fi cati on.
(7) Di sconnect fuel tube (l i ne) at si de of fuel rai l .
Refer to Qui ck-Connect Fi tti ngs for procedures,
(8) Remove the remai ni ng fuel rai l mounti ng bol ts.
Fig. 28 Fuel Gauge Sending Unit Location
Fig. 29 Fuel Gauge Sending Unit Release Tab
Fig. 30 Fuel Rail AssemblyTypical
(9) Gentl y rock and pul l the left fuel rai l unti l the
fuel i njectors just start to cl ear the i ntake mani fol d.
Gentl y rock and pul l the right fuel rai l unti l the fuel
i njectors just start to cl ear the i ntake mani fol d.
Repeat thi s procedure (l eft/ri ght) unti l al l fuel i njec-
tors have cl eared the i ntake mani fol d.
(10) Remove fuel rai l (wi th i njectors attached)
from engi ne.
(11) Remove the cl i p(s) retai ni ng the i njector(s) to
fuel rai l (Fi g. 33) or (Fi g. 34).
INSTALLATION
(1) Appl y a smal l amount of engi ne oi l to each fuel
i njector o-ri ng. Thi s wi l l hel p i n fuel rai l i nstal l ati on.
(2) I nstal l i njector(s) and i njector cl i p(s) to fuel
rai l .
(3) Posi ti on the fuel rai l /fuel i njector assembl y to
the i njector openi ngs on the i ntake mani fol d.
(4) Gui de each i njector i nto the i ntake mani fol d.
Be careful not to tear the i njector o-ri ng.
(5) Push the right fuel rai l down unti l fuel i njec-
tors have bottomed on i njector shoul der. Push the
left fuel rai l down unti l fuel i njectors have bottomed
on i njector shoul der.
(6) I nstal l fuel rai l mounti ng bol ts.
(7) Connect el ectri cal connector to i ntake mani fol d
ai r temperature sensor.
(8) Connect wi ri ng to al l fuel i njectors. The i njec-
tor wi ri ng harness i s numeri cal l y tagged.
(9) I nstal l the A/C support bracket (i f equi pped).
(10) I nstal l throttl e body to i ntake mani fol d. Refer
to Throttl e Body i nstal l ati on i n thi s secti on of the
group.
Fig. 31 A/C Compressor Support BracketTypical
Fig. 32 Fuel Injector ConnectorsTypical
Fig. 33 Fuel Injector MountingTypical
Fig. 34 Injector Retaining ClipsTypical Injector
(11) I nstal l fuel tube (l i ne) at si de of fuel rai l .
Refer to Qui ck-Connect Fi tti ngs for procedures.
(12) I nstal l ai r duct to throttl e body.
(13) Connect battery cabl e to battery.
FUEL INJECTOR RAIL 4. 0L ENGINE
REMOVAL
STANT FUEL PRESSURE EVEN WITH ENGINE OFF.
THIS PRESSURE MUST BE RELEASED BEFORE
SERVICING FUEL RAIL.
(1) Remove fuel tank fi l l er tube cap.
(2) Perform Fuel System Pressure Rel ease Proce-
dure as descri bed i n thi s Group.
(4) Remove ai r tube at top of throttl e body. Note:
Some engi ne/vehi cl es may requi re removal of ai r
cl eaner ducts at throttl e body.
(5) Remove i njector harness el ectri cal connectors
at each i njector. Each i njector connector shoul d have
a numeri cal tag attached i denti fyi ng i ts correspond-
i ng cyl i nder (Fi g. 35). I f not, i denti fy each connector
before removal .
(6) Di sconnect fuel suppl y l i ne l atch cl i p and fuel
l i ne at fuel rai l . Refer to Qui ck-Connect Fi tti ngs i n
thi s group for procedures.
(7) Di sconnect throttl e cabl e at throttl e body. Refer
to Throttl e Cabl e Removal /I nstal l ati on i n thi s group
for procedures.
(8) Di sconnect speed control cabl e at throttl e body
(i f equi pped). Refer to Speed Control Cabl e i n Group
8H, Speed Control System for procedures.
(9) Di sconnect automati c transmi ssi on cabl e at
throttl e body (i f equi pped).
(10) Remove cabl e routi ng bracket (Fi g. 35) at
i ntake mani fol d.
(11) Cl ean di rt/debri s from each fuel i njector at
i ntake mani fol d.
(12) Remove fuel rai l mounti ng nuts/bol ts (Fi g.
35).
(13) Remove fuel rai l by gentl y rocki ng unti l al l
the fuel i njectors are out of i ntake mani fol d.
INSTALLATION
(1) Cl ean each i njector bore at i ntake mani fol d.
(2) Appl y a smal l amount of cl ean engi ne oi l to
each i njector o-ri ng. Thi s wi l l ai d i n i nstal l ati on.
(3) Posi ti on ti ps of al l fuel i njectors i nto the corre-
spondi ng i njector bore i n i ntake mani fol d. Seat i njec-
tors i nto mani fol d.
(4) I nstal l and ti ghten fuel rai l mounti ng bol ts to
11 3 Nm (100 25 i n. l bs.) torque.
(5) Connect tagged i njector harness connectors to
appropri ate i njector.
(6) Connect fuel l i ne and fuel l i ne l atch cl i p to fuel
rai l . Refer Qui ck-Connect Fi tti ngs i n thi s group for
procedures.
(7) I nstal l protecti ve cap to pressure test port fi t-
ti ng (i f equi pped).
(8) I nstal l cabl e routi ng bracket to i ntake mani -
fol d.
(9) Connect throttl e cabl e at throttl e body.
(10) Connect speed control cabl e at throttl e body
(i f equi pped).
(11) Connect automati c transmi ssi on cabl e at
throttl e body (i f equi pped).
(12) I nstal l ai r tube (or duct) at top of throttl e
body.
(13) I nstal l fuel tank cap.
(15) Start engi ne and check for fuel l eaks.
FUEL INJECTOR(S)
STANT PRESSURE EVEN WITH THE ENGINE
TURNED OFF. BEFORE SERVICING THE FUEL
INJECTOR(S), THE FUEL SYSTEM PRESSURE
MUST BE RELEASED.
To rel ease fuel pressure, refer to the Fuel System
Pressure Rel ease Procedure.
To remove one or more fuel i njectors, the fuel rai l
assembl y must be removed from engi ne.
REMOVAL
(2) Remove fuel i njector rai l assembl y. Refer to
Fuel I njector Rai l removal i n thi s secti on.
Fig. 35 Fuel Rail Mounting4.0L Engine
(3) Remove the cl i p(s) retai ni ng the i njector(s) to
fuel rai l (Fi g. 33) or (Fi g. 34).
(4) Remove i njector(s) from fuel rai l .
INSTALLATION
(1) Appl y a smal l amount of engi ne oi l to each fuel
i njector o-ri ng. Thi s wi l l hel p i n fuel rai l i nstal l ati on.
(2) I nstal l i njector(s) and i njector cl i p(s) to fuel
rai l .
(3) I nstal l fuel rai l assembl y. Refer to Fuel I njector
Rai l i nstal l ati on.
(4) I nstal l ai r duct at throttl e body.
FUEL TANK
STANT FUEL PRESSURE EVEN WITH THE ENGINE
OFF. THIS PRESSURE MUST BE RELEASED
BEFORE SERVICING FUEL TANK.
Two di fferent procedures may be used to drai n fuel
tank (l oweri ng tank or usi ng DRB scan tool ).
The qui ckest drai ni ng procedure i nvol ves l oweri ng
the fuel tank.
As an al ternati ve procedure, the el ectri c fuel pump
may be acti vated al l owi ng tank to be drai ned at fuel
rai l connecti on. Refer to DRB scan tool for fuel pump
acti vati on procedures. Before di sconnecti ng fuel l i ne
at fuel rai l , rel ease fuel pressure. Refer to the Fuel
System Pressure Rel ease Procedure i n thi s group for
procedures. Attach end of speci al test hose tool num-
ber 6541, 6539, 6631 or 6923 at fuel rai l di sconnec-
ti on (tool number wi l l depend on model and/or engi ne
appl i cati on). Posi ti on opposi te end of thi s hose tool to
an approved gasol i ne drai ni ng stati on. Acti vate fuel
pump and drai n tank unti l empty.
I f el ectri c fuel pump i s not operati ng, tank must be
l owered for fuel drai ni ng. Refer to fol l owi ng proce-
dures.
REMOVAL
(1) Di sconnect negati ve battery cabl e at battery.
(2) Rel ease fuel system pressure. Refer to the Fuel
System Pressure Rel ease Procedure i n thi s group.
(3) Rai se and support vehi cl e.
(4) Remove fuel tank fi l l hose and vent hose
cl amps at fuel tank fi l l er tube (Fi g. 36). Remove both
hoses at fuel fi l l er tube (Fi g. 36).
(5) Remove rear tow hooks (i f equi pped).
(6) Remove fuel tank ski d pl ate mounti ng nuts/
bol ts and remove ski d pl ate (Fi g. 37) (i f equi pped).
(7) Remove opti onal trai l er hi tch (i f equi pped).
(8) Remove exhaust tai l pi pe heat shi el d mounti ng
bol ts and remove shi el d.
Fig. 36 Fuel Filler Tube and Hoses
Fig. 37 Fuel Tank Mounting
CAUTION: To protect fuel tank from exhaust heat,
this shield must reinstalled after tank installation.
(9) Pl ace a hydraul i c jack to bottom of fuel tank.
WARNING: PLACE A SHOP TOWEL AROUND FUEL
LINES TO CATCH ANY EXCESS FUEL.
(10) Di sconnect fuel suppl y l i ne near front of fuel
tank (Fi g. 38). Refer to Fuel Tubes/Li nes/Hoses and
Cl amps i n thi s group. Al so refer to Qui ck-Connect
Fi tti ngs for procedures.
(11) Di sconnect EVAP cani ster vent l i ne near
front of tank (Fi g. 38).
(12) Di sconnect fuel pump modul e el ectri cal con-
nector (pi gtai l harness) near front of tank (Fi g. 38).
Harness connector i s cl i pped to body.
(13) Remove two fuel tank strap nuts (Fi g. 37).
Posi ti on both tank support straps away from tank.
(14) Careful l y l ower ri ght si de of tank whi l e feed-
i ng both fuel hoses through access hol e i n body. Fuel
Tank Full And Not Drained Using DRB Scan
Tool: To prevent fuel l oss through hoses, keep l eft
si de of tank hi gher than ri ght si de whi l e l oweri ng.
Do not al l ow hose openi ngs to drop l ower than top of
tank.
(15) Conti nue l oweri ng tank unti l cl ear of vehi cl e.
Pl ace tank on fl oor wi th l eft si de (hose si de) hi gher
than ri ght si de.
(16) Drai n tank by removi ng fuel fi l l hose at tank.
Fuel fi l l hose i s l argest of 2 hoses (Fi g. 39). I nsert the
drai n hose (from an approved gasol i ne drai ni ng sta-
ti on) i nto hose openi ng. Drai n tank unti l empty.
(17) I f fuel pump modul e removal i s necessary,
refer to Fuel Pump Modul e Removal /I nstal l ati on i n
thi s group for procedures.
INSTALLATION
(1) I f fuel pump modul e i s bei ng i nstal l ed, refer to
Fuel Pump Modul e Removal /I nstal l ati on i n thi s
group for procedures.
(2) I nstal l fuel fi l l /vent hoses to tank fi tti ngs. To
prevent hose from ki nki ng, rotate each hose unti l
i ndex mark on hose i s al i gned to i ndex tang on fuel
tank (Fi g. 39).
(3) I nstal l hose cl amps to hoses. Posi ti on cl amps
between i ndex marks on each hose (Fi g. 39).
(4) Posi ti on fuel tank to hydraul i c jack.
(5) Rai se tank i nto posi ti on whi l e gui di ng fuel fi l l
and vent hoses i nto and through access hol e i n body.
(6) Conti nue rai si ng tank unti l posi ti oned to body.
(7) Attach two fuel tank mounti ng straps and
mounti ng nuts.
CAUTION: The two mounting nuts must be tight-
ened until 8386 mm (3.27 in.3.39 in.) is attained
between end of mounting bolt and bottom of strap.
See insert (Fig. 37). Do not over tighten nuts.
(8) I nstal l both fuel hoses to fuel fi l l tube. Ti ghten
both retai ni ng cl amps.
(9) Connect fuel pump modul e pi gtai l harness el ec-
tri cal connector near front of tank.
(10) Connect fuel pump modul e suppl y l i ne near
front of tank. Refer to Fuel Tubes/Li nes/Hoses and
Cl amps i n thi s group. Al so refer to Qui ck-Connect
Fi tti ngs for procedures.
(11) Connect EVAP hose near front of tank.
(12) I nstal l exhaust tai l pi pe heat shi el d.
(13) I nstal l fuel tank ski d pl ate and trai l er hi tch
(i f equi pped).
(14) I nstal l rear tow hooks (i f equi pped).
(15) Lower vehi cl e and connect battery cabl e to
battery.
Fig. 38 Fuel Tank Connections at Front of Fuel Tank
Fig. 39 Fuel Fill/Vent Hose Index Marks
FUEL TANK FILLER TUBE CAP
I f repl acement of the fuel tank fi l l er tube cap i s
necessary, i t must be repl aced wi th an i denti cal cap
to be sure of correct system operati on.
CAUTION: Remove the fuel tank filler tube cap to
relieve fuel tank pressure. The cap must be
removed prior to disconnecting any fuel system
component or before draining the fuel tank.
ACCELERATOR PEDAL
The accel erator pedal i s connected to the throttl e
body l i nkage by the throttl e cabl e. The cabl e i s pro-
tected by a pl asti c sheathi ng and i s connected to the
throttl e body l i nkage by a bal l socket. I t i s connected
to the accel erator pedal arm by a pl asti c retai ner
(cl i p) (Fi g. 40). Thi s retai ner (cl i p) snaps i nto the top
of the accel erator pedal arm. Retai ner tabs (bui l t i nto
the cabl e sheathi ng) fasten the cabl e to the dash
panel .
Dual throttl e return spri ngs (attached to the throt-
tl e shaft) are used to cl ose the throttl e.
CAUTION: Never attempt to remove or alter these
springs.
REMOVAL
CAUTION: Be careful not to damage or kink the
cable core wire (within the cable sheathing) while
servicing accelerator pedal or throttle cable.
(1) From i nsi de the vehi cl e, hol d up accel erator
pedal . Remove pl asti c cabl e retai ner (cl i p) and throt-
tl e cabl e core wi re from upper end of pedal arm.
Pl asti c cabl e retai ner (cl i p) snaps i nto pedal arm.
(2) Remove accel erator pedal bracket nuts. Remove
accel erator pedal assembl y.
INSTALLATION
(1) Pl ace accel erator pedal assembl y over studs
protrudi ng from fl oor pan. Ti ghten mounti ng nuts to
8.5 Nm (75 i n. l bs.) torque.
(2) Sl i de throttl e cabl e i nto openi ng i n top of pedal
arm. Push pl asti c cabl e retai ner (cl i p) i nto pedal arm
openi ng unti l i t snaps i nto pl ace.
(3) Before starti ng engi ne, operate accel erator
pedal to check for any bi ndi ng.
THROTTLE CABLE
REMOVAL
(1) From i nsi de the vehi cl e, hol d up accel erator
pedal . Remove pl asti c cabl e retai ner (cl i p) and throt-
tl e cabl e core wi re from upper end of pedal arm (Fi g.
40). Pl asti c cabl e retai ner (cl i p) snaps i nto pedal arm.
(2) Remove the cabl e core wi re at pedal arm.
(3) From i nsi de the vehi cl e, pi nch both si des of the
cabl e housi ng retai ner tabs (Fi g. 40). at the dash
panel . Remove cabl e housi ng from dash panel and
pul l i nto the engi ne compartment.
(4) 4.0L Engi ne: Remove cabl e from cl i p on engi ne
val ve cover (Fi g. 41)
(5) Remove the throttl e cabl e bal l end socket at
throttl e body l i nkage (Fi g. 42) or (Fi g. 43) (snaps off).
Fig. 40 Accelerator Pedal Mounting
Fig. 41 Throttle Cable Routing4.0L Engine
.
(6) 4.0L Engi ne: Remove throttl e cabl e from throt-
tl e body mounti ng bracket by compressi ng retai ner
tabs and pushi ng cabl e through hol e i n bracket.
Remove throttl e cabl e from vehi cl e.
(7) 5.2L/5.9L Engi nes: Remove cabl e housi ng at
throttl e body mounti ng bracket by pressi ng forward
on rel ease tab wi th a smal l screwdri ver (Fi g. 44). To
prevent cable housing breakage, press on the
tab only enough to release the cable from the
bracket. Li ft the cabl e housi ng strai ght up from
bracket whi l e pressi ng on rel ease tab. Remove throt-
tl e cabl e from vehi cl e.
INSTALLATION
(1) 4.0L Engi ne: Sl i de throttl e cabl e through hol e
i n throttl e body bracket unti l retai ner tabs l ock i nto
bracket. Connect cabl e bal l end to throttl e body l i nk-
age bal l (snaps on).
(2) 5.2L/5.9L Engi nes: Connect cabl e bal l end to
throttl e body l i nkage bal l (snaps on). Connect cabl e
to throttl e body bracket (push down and l ock).
(3) 4.0L Engi ne: Snap cabl e i nto cl i p on engi ne
val ve cover.
(4) Push other end of cabl e through openi ng i n
dash panel unti l retai ni ng tabs l ock i nto panel .
(5) From i nsi de dri vers compartment, sl i de throttl e
cabl e core wi re i nto openi ng i n top of pedal arm.
Push cabl e retai ner (cl i p) i nto pedal arm openi ng
unti l i t snaps i n pl ace.
(6) Before starti ng engi ne, operate accel erator
pedal to check for any bi ndi ng.
Fig. 42 Throttle Cable at Throttle Body4.0L Engine
Fig. 43 Throttle Cable at Throttle Body5.2L/5.9L
V-8 Engines
Fig. 44 Cable Release Tab5.2L/5.9L Engines
Typical
SPECIFICATIONS
VECI LABEL
I f anythi ng di ffers between the speci fi cati ons found
on the Vehi cl e Emi ssi on Control I nformati on (VECI )
l abel and the fol l owi ng speci fi cati ons, use speci fi ca-
ti ons on VECI l abel . The VECI l abel i s l ocated i n the
engi ne compartment.
FUEL TANK CAPACITY
Models Liters U.S. Gallons
All 87 23
Nominal refill capacities are shown. A variation may
be observed from vehicle to vehicle due to
manufacturing tolerance and refill procedure.
FUEL SYSTEM PRESSURE
339 kPa 34 kPa (49.2 psi 5 psi ).
TORQUE CHART
DESCRIPTION TORQUE
Accel erator Pedal Bracket
Mounti ng Nuts . . . . . . . . . . . .8.5 Nm (75 i n. l bs.)
Fuel Pump Modul e Locknut . . . . .62 Nm (45 ft. l bs.)
Fuel Rai l Mounti ng Bol ts4.0L Engi ne . . . . .11 Nm
(100 i n. l bs.)
Fuel Rai l Mounti ng Bol ts
5.2L/5.9L Engi nes . . . . . . . . .23 Nm (200 i n. l bs.)
Fuel Tank Mounti ng Nuts . . . .Refer To Manual Text
Fuel Hose Cl amps . . . . . . . . . . . . .3 Nm (25 i n. l bs.)
FUEL INJ ECTION SYSTEM
INDEX
page page
GENERAL INFORMATION
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . 26
MODES OF OPERATION . . . . . . . . . . . . . . . . . . 26
OXYGEN SENSOR (O2S)PCM INPUT . . . . . . . 33
AIR CONDITIONING (A/C) CLUTCH RELAY
PCM OUTPUT . . . . . . . . . . . . . . . . . . . . . . . . . 36
AIR CONDITIONING (A/C) CONTROLSPCM
INPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
AUTO SHUTDOWN (ASD) RELAYPCM
OUTPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
AUTOMATIC SHUTDOWN (ASD) RELAY
SENSEPCM INPUT . . . . . . . . . . . . . . . . . . . 30
BATTERY TEMPERATURE SENSORPCM
INPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
BATTERY VOLTAGEPCM INPUT . . . . . . . . . . . 30
BRAKE SWITCHPCM INPUT . . . . . . . . . . . . . . 31
CAMSHAFT POSITION SENSORPCM INPUT . 31
CCD BUS (+/-) CIRCUITS-PCM OUTPUTS . . . . . 37
CRANKSHAFT POSITION SENSOR4.0L
ENGINEPCM INPUT . . . . . . . . . . . . . . . . . . 31
CRANKSHAFT POSITION SENSOR5.2L/5.9L
ENGINESPCM INPUT . . . . . . . . . . . . . . . . . 31
DATA LINK CONNECTORPCM INPUT AND
OUTPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
DUTY CYCLE EVAP PURGE SOLENOID
VALVE-PCM OUTPUT . . . . . . . . . . . . . . . . . . . 37
ENGINE COOLANT TEMPERATURE SENSOR
4.0L ENGINEPCM INPUT . . . . . . . . . . . . . . 32
5.2L/5.9L ENGINESPCM INPUT . . . . . . . . . . 32
FIVE VOLT SENSOR SUPPLYPRIMARY . . . . . 31
FIVE VOLT SENSOR SUPPLYSECONDARY . . 31
FUEL INJECTORS4.0L ENGINEPCM
OUTPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
FUEL INJECTORS5.2L/5.9L ENGINESPCM
OUTPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
FUEL LEVEL SENSORPCM INPUT . . . . . . . . . 31
FUEL PUMP RELAY-PCM OUTPUT . . . . . . . . . . 38
GENERATOR FIELD DRIVER (-)PCM
OUTPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
GENERATOR FIELD SOURCE (+)PCM
OUTPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
GENERATOR LAMPPCM OUTPUT . . . . . . . . . 38
GENERATOR OUTPUTPCM INPUT . . . . . . . . . 32
GOVERNOR PRESSURE SOLENOIDPCM
OUTPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
IDLE AIR CONTROL (IAC) MOTOR4.0L
ENGINEPCM OUTPUT . . . . . . . . . . . . . . . . . 38
IDLE AIR CONTROL (IAC) MOTOR5.2L/5.9L
ENGINESPCM OUTPUT . . . . . . . . . . . . . . . 38
IGNITION CIRCUIT SENSEPCM INPUT . . . . . 33
IGNITION COIL4.0L ENGINESPCM
OUTPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
IGNITION COIL5.2L/5.9L ENGINESPCM
OUTPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
INTAKE MANIFOLD AIR TEMPERATURE
SENSOR4.0L ENGINEPCM INPUT . . . . . . 33
SENSOR5.2L/5.9L ENGINESPCM INPUT . 33
LEAK DETECTION PUMP (SWITCH) SENSE
PCM INPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
LEAK DETECTION PUMPPCM OUTPUT . . . . . 39
MALFUNCTION INDICATOR LAMPPCM
OUTPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
MANIFOLD ABSOLUTE PRESSURE (MAP)
SENSOR4.0L ENGINEPCM INPUT . . . . . . 34
SENSOR5.2L/5.9L ENGINESPCM INPUT . 34
OIL PRESSURE SENSORPCM INPUT . . . . . . 34
OUTPUT SHAFT SPEED SENSORPCM
INPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
OVERDRIVE LAMPPCM OUTPUT . . . . . . . . . . 39
OVERDRIVE/OVERRIDE SWITCH-PCM INPUT . 34
POWER GROUND . . . . . . . . . . . . . . . . . . . . . . . 35
POWERTRAIN CONTROL MODULE (PCM) . . . . 29
SENSOR RETURNPCM INPUT . . . . . . . . . . . . 35
SIGNAL GROUNDPCM INPUT . . . . . . . . . . . . 35
SPEED CONTROL SOLENOIDSPCM OUTPUT . 40
SPEED CONTROL SWITCHESPCM INPUT . . . 35
TACHOMETERPCM OUTPUT . . . . . . . . . . . . . 40
THREE-FOUR SHIFT SOLENOIDPCM
OUTPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
THROTTLE BODY4.0L ENGINE . . . . . . . . . . . 41
THROTTLE BODY5.2L/5.9L ENGINES . . . . . . . 40
THROTTLE POSITION SENSOR (TPS)4.0L
ENGINEPCM INPUT . . . . . . . . . . . . . . . . . . 35
THROTTLE POSITION SENSOR (TPS)5.2L/
5.9L ENGINESPCM INPUT . . . . . . . . . . . . . 35
TORQUE CONVERTOR CLUTCH (TCC)
SOLENOIDPCM OUTPUT . . . . . . . . . . . . . . 40
TRANSMISSION GOVERNOR PRESSURE
SENSORPCM INPUT . . . . . . . . . . . . . . . . . . 35
TRANSMISSION PARK/NEUTRAL SWITCH
PCM INPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
TRANSMISSION RELAYPCM OUTPUT . . . . . . 40
TRANSMISSION TEMPERATURE SENSOR
PCM INPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
VEHICLE SPEED AND DISTANCE SENSOR
PCM INPUT . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
ASD AND FUEL PUMP RELAYS . . . . . . . . . . . . . 47
CAMSHAFT AND CRANKSHAFT POSITION
SENSORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
4.0L ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . 51
5.2L/5.9L ENGINES . . . . . . . . . . . . . . . . . . . . . 51
IDLE AIR CONTROL (IAC) MOTOR4.0L ENGINE . 52
ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
SENSOR4.0L ENGINE . . . . . . . . . . . . . . . . . 52
SENSOR5.2L/5.9L ENGINE . . . . . . . . . . . . . 52
SENSOR TEST4.0L ENGINE . . . . . . . . . . . . 49
SENSOR TEST5.2L.5.9L ENGINES . . . . . . . 48
OXYGEN (O2S) SENSORS4.0L ENGINE . . . . . 50
OXYGEN (O2S) SENSORS5.2L/5.9L ENGINES . 50
THROTTLE BODY MINIMUM AIR FLOW CHECK
PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . 53
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
5.9L ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . 53
VEHICLE SPEED SENSOR . . . . . . . . . . . . . . . . 52
VISUAL INSPECTION4.0L ENGINE . . . . . . . . . 44
VISUAL INSPECTION5.2L/5.9L ENGINES . . . . 41
AIR CLEANER ELEMENT (FILTER) . . . . . . . . . . 62
AIR CLEANER HOUSING . . . . . . . . . . . . . . . . . . 61
AUTOMATIC SHUTDOWN (ASD) RELAY . . . . . . 54
CAMSHAFT POSITION SENSOR . . . . . . . . . . . . 60
CRANKSHAFT POSITION SENSOR . . . . . . . . . . 60
DUTY CYCLE EVAP CANISTER PURGE
SOLENOID . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
4.0L ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . 63
5.2L/5.9L ENGINES . . . . . . . . . . . . . . . . . . . . . 62
FUEL PUMP RELAY . . . . . . . . . . . . . . . . . . . . . . 55
IDLE AIR CONTROL (IAC) MOTOR4.0L
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
SENSOR4.0L ENGINE . . . . . . . . . . . . . . . . . 64
SENSOR5.2L/5.9L ENGINES . . . . . . . . . . . . 63
SENSOR4.0L ENGINE . . . . . . . . . . . . . . . . . 58
SENSOR5.2L/5.9L ENGINES . . . . . . . . . . . . 58
OXYGEN SENSOR4.0L ENGINE . . . . . . . . . . . 61
OXYGEN SENSOR5.2L/5.9L ENGINES . . . . . . 60
POWERTRAIN CONTROL MODULE (PCM) . . . . 59
THROTTLE BODY4.0L ENGINE . . . . . . . . . . . 56
THROTTLE BODY5.2L/5.9L ENGINES . . . . . . . 55
ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
5.9L ENGINES . . . . . . . . . . . . . . . . . . . . . . . . . 56
VEHICLE SPEED SENSOR . . . . . . . . . . . . . . . . 64
SPECIFICATIONS
TORQUE CHART . . . . . . . . . . . . . . . . . . . . . . . . 65
VECI LABEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
SPECIAL TOOLS
FUEL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . 66
GENERAL INFORMATION
INTRODUCTION
Al l engi nes are equi pped wi th sequenti al Mul ti -
Port Fuel I njecti on (MFI ). The MFI system provi des
preci se ai r/fuel rati os for al l dri vi ng condi ti ons.
The powertrai n control modul e (PCM) (Fi g. 1) oper-
ates the fuel system.
MODES OF OPERATION
As i nput si gnal s to the powertrai n control modul e
(PCM) change, the PCM adjusts i ts response to the
output devi ces. For exampl e, the PCM must cal cul ate
di fferent i njector pul se wi dth and i gni ti on ti mi ng for
i dl e than i t does for wi de open throttl e (WOT).
The PCM wi l l operate i n two di fferent modes:
Open Loop and Closed Loop.
Duri ng Open Loop modes, the powertrai n control
modul e (PCM) recei ves i nput si gnal s and responds
onl y accordi ng to preset PCM programmi ng. I nput
from the oxygen (O2S) sensors i s not moni tored dur-
i ng Open Loop modes.
Duri ng Cl osed Loop modes, the PCM wi l l moni tor
the oxygen (O2S) sensors i nput. Thi s i nput i ndi cates
to the PCM whether or not the cal cul ated i njector
pul se wi dth resul ts i n the i deal ai r-fuel rati o. Thi s
rati o i s 14.7 parts ai r-to-1 part fuel . By moni tori ng
the exhaust oxygen content through the O2S sensor,
the PCM can fi ne tune the i njector pul se wi dth. Thi s
i s done to achi eve opti mum fuel economy combi ned
wi th l ow emi ssi on engi ne performance.
The fuel i njecti on system has the fol l owi ng modes
of operati on:
I gni ti on swi tch ON
Engi ne start-up (crank)
Engi ne warm-up
I dl e
Crui se
Accel erati on
Decel erati on
Wi de open throttl e (WOT)
I gni ti on swi tch OFF
The i gni ti on swi tch On, engi ne start-up (crank),
engi ne warm-up, accel erati on, decel erati on and wi de
open throttl e modes are Open Loop modes. The i dl e
and crui se modes, (wi th the engi ne at operati ng tem-
perature) are Cl osed Loop modes.
IGNITION SWITCH (KEY-ON) MODE
Thi s i s an Open Loop mode. When the fuel system
i s acti vated by the i gni ti on swi tch, the fol l owi ng
acti ons occur:
The powertrai n control modul e (PCM) pre-posi -
ti ons the i dl e ai r control (I AC) motor.
The PCM determi nes atmospheri c ai r pressure
from the MAP sensor i nput to determi ne basi c fuel
strategy.
The PCM moni tors the engi ne cool ant tempera-
ture sensor i nput. The PCM modi fi es fuel strategy
based on thi s i nput.
I ntake mani fol d ai r temperature sensor i nput i s
moni tored.
Throttl e posi ti on sensor (TPS) i s moni tored.
The auto shutdown (ASD) rel ay i s energi zed by
the PCM for approxi matel y three seconds.
The fuel pump i s energi zed through the fuel
pump rel ay by the PCM. The fuel pump wi l l operate
for approxi matel y three seconds unl ess the engi ne i s
operati ng or the starter motor i s engaged.
The O2S sensor heater el ement i s energi zed vi a
the ASD rel ay. The O2S sensor i nput i s not used by
the PCM to cal i brate ai r-fuel rati o duri ng thi s mode
of operati on.
ENGINE START-UP MODE
Thi s i s an Open Loop mode. The fol l owi ng acti ons
occur when the starter motor i s engaged.
The powertrai n control modul e (PCM) recei ves
i nputs from:
Battery vol tage
Engi ne cool ant temperature sensor
Crankshaft posi ti on sensor
I ntake mani fol d ai r temperature sensor
Mani fol d absol ute pressure (MAP) sensor
Throttl e posi ti on sensor (TPS)
Starter motor rel ay
Camshaft posi ti on sensor si gnal
The PCM moni tors the crankshaft posi ti on sensor.
I f the PCM does not recei ve a crankshaft posi ti on
sensor si gnal wi thi n 3 seconds of cranki ng the
engi ne, i t wi l l shut down the fuel i njecti on system.
The fuel pump i s acti vated by the PCM through
the fuel pump rel ay.
Vol tage i s appl i ed to the fuel i njectors wi th the
ASD rel ay vi a the PCM. The PCM wi l l then control
the i njecti on sequence and i njector pul se wi dth by
turni ng the ground ci rcui t to each i ndi vi dual i njector
on and off.
The PCM determi nes the proper i gni ti on ti mi ng
accordi ng to i nput recei ved from the crankshaft posi -
ti on sensor.
ENGINE WARM-UP MODE
Thi s i s an Open Loop mode. Duri ng engi ne warm-
up, the powertrai n control modul e (PCM) recei ves
i nputs from:
Battery vol tage
Camshaft posi ti on sensor si gnal (i n the di stri bu-
tor)
Park/neutral swi tch (gear i ndi cator si gnal auto.
trans. onl y)
Ai r condi ti oni ng sel ect si gnal (i f equi pped)
Ai r condi ti oni ng request si gnal (i f equi pped)
Based on these i nputs the fol l owi ng occurs:
on and off.
The PCM adjusts engi ne i dl e speed through the
i dl e ai r control (I AC) motor and adjusts i gni ti on ti m-
i ng.
Fig. 1 Powertrain Control Module (PCM)
The PCM operates the A/C compressor cl utch
through the cl utch rel ay. Thi s i s done i f A/C has been
sel ected by the vehi cl e operator and requested by the
A/C thermostat.
When engi ne has reached operati ng tempera-
ture, the PCM wi l l begi n moni tori ng O2S sensor
i nput. The system wi l l then l eave the warm-up mode
and go i nto cl osed l oop operati on.
IDLE MODE
When the engi ne i s at operati ng temperature, thi s
i s a Cl osed Loop mode. At i dl e speed, the powertrai n
control modul e (PCM) recei ves i nputs from:
Battery vol tage
tor)
Battery vol tage
trans. onl y)
Oxygen sensors
Based on these i nputs, the fol l owi ng occurs:
i njecti on sequence and i njector pul se wi dth by turn-
i ng the ground ci rcui t to each i ndi vi dual i njector on
and off.
The PCM moni tors the O2S sensor i nput and
adjusts ai r-fuel rati o by varyi ng i njector pul se wi dth.
I t al so adjusts engi ne i dl e speed through the i dl e ai r
control (I AC) motor.
The PCM adjusts i gni ti on ti mi ng by i ncreasi ng
and decreasi ng spark advance.
through the cl utch rel ay. Thi s happens i f A/C has
been sel ected by the vehi cl e operator and requested
by the A/C thermostat.
CRUISE MODE
i s a Cl osed Loop mode. At crui si ng speed, the power-
trai n control modul e (PCM) recei ves i nputs from:
Battery vol tage
tor)
trans. onl y)
Oxygen (O2S) sensors
Based on these i nputs, the fol l owi ng occurs:
ASD rel ay vi a the PCM. The PCM wi l l then adjust
the i njector pul se wi dth by turni ng the ground ci rcui t
to each i ndi vi dual i njector on and off.
The PCM moni tors the O2S sensor i nput and
adjusts ai r-fuel rati o. I t al so adjusts engi ne i dl e
speed through the i dl e ai r control (I AC) motor.
The PCM adjusts i gni ti on ti mi ng by turni ng the
ground path to the coi l on and off.
through the cl utch rel ay. Thi s happens i f A/C has
been sel ected by the vehi cl e operator and requested
by the A/C thermostat.
ACCELERATION MODE
Thi s i s an Open Loop mode. The powertrai n control
modul e (PCM) recogni zes an abrupt i ncrease i n
throttl e posi ti on or MAP pressure as a demand for
i ncreased engi ne output and vehi cl e accel erati on. The
PCM i ncreases i njector pul se wi dth i n response to
i ncreased throttl e openi ng.
DECELERATION MODE
i s an Open Loop mode. Duri ng hard decel erati on, the
powertrai n control modul e (PCM) recei ves the fol l ow-
i ng i nputs.
Battery vol tage
tor)
trans. onl y)
Vehi cl e speed sensor
I f the vehi cl e i s under hard decel erati on wi th the
proper rpm and cl osed throttl e condi ti ons, the PCM
wi l l i gnore the oxygen sensor i nput si gnal . The PCM
wi l l enter a fuel cut-off strategy i n whi ch i t wi l l not
suppl y a ground to the i njectors. I f a hard decel era-
ti on does not exi st, the PCM wi l l determi ne the
proper i njector pul se wi dth and conti nue i njecti on.
Based on the above i nputs, the PCM wi l l adjust
engi ne i dl e speed through the i dl e ai r control (I AC)
motor.
WIDE OPEN THROTTLE MODE
Thi s i s an Open Loop mode. Duri ng wi de open
throttl e operati on, the powertrai n control modul e
(PCM) recei ves the fol l owi ng i nputs.
Battery vol tage
tor)
Duri ng wi de open throttl e condi ti ons, the fol l owi ng
occurs:
on and off. The PCM i gnores the oxygen sensor i nput
si gnal and provi des a predetermi ned amount of addi -
ti onal fuel . Thi s i s done by adjusti ng i njector pul se
wi dth.
IGNITION SWITCH OFF MODE
When i gni ti on swi tch i s turned to OFF posi ti on,
the PCM stops operati ng the i njectors, i gni ti on coi l ,
ASD rel ay and fuel pump rel ay.
POWERTRAIN CONTROL MODULE (PCM)
The powertrai n control modul e (PCM) (Fi g. 1) oper-
ates the fuel system. The PCM was formerl y referred
to as the SBEC or engi ne control l er. The PCM i s a
pre-programmed, tri pl e mi croprocessor di gi tal com-
puter. I t regul ates i gni ti on ti mi ng, ai r-fuel rati o,
emi ssi on control devi ces, chargi ng system, certai n
transmi ssi on features, speed control , ai r condi ti oni ng
compressor cl utch engagement and i dl e speed. The
PCM can adapt i ts programmi ng to meet changi ng
operati ng condi ti ons.
The PCM recei ves i nput si gnal s from vari ous
swi tches and sensors. Based on these i nputs, the
PCM regul ates vari ous engi ne and vehi cl e operati ons
through di fferent system components. These compo-
nents are referred to as Powertrai n Control Modul e
(PCM) Outputs. The sensors and swi tches that pro-
vi de i nputs to the PCM are consi dered Powertrai n
Control Modul e (PCM) I nputs.
The PCM adjusts i gni ti on ti mi ng based upon
i nputs i t recei ves from sensors that react to: engi ne
rpm, mani fol d absol ute pressure, engi ne cool ant tem-
perature, throttl e posi ti on, transmi ssi on gear sel ec-
ti on (automati c transmi ssi on), vehi cl e speed and the
brake swi tch.
The PCM adjusts i dl e speed based on i nputs i t
recei ves from sensors that react to: throttl e posi ti on,
vehi cl e speed, transmi ssi on gear sel ecti on, engi ne
cool ant temperature and from i nputs i t recei ves from
the ai r condi ti oni ng cl utch swi tch and brake swi tch.
Based on i nputs that i t recei ves, the PCM adjusts
i gni ti on coi l dwel l . The PCM al so adjusts the gener-
ator charge rate through control of the generator
fi el d and provi des speed control operati on.
NOTE: PCM Inputs:
A/C request (i f equi pped wi th factory A/C)
A/C sel ect (i f equi pped wi th factory A/C)
Auto shutdown (ASD) sense
Battery temperature
Battery vol tage
Brake swi tch
CCD bus (+) ci rcui ts
CCD bus (-) ci rcui ts
Camshaft posi ti on sensor si gnal
Data l i nk connecti on for DRB scan tool
Fuel l evel
Generator (battery vol tage) output
I gni ti on ci rcui t sense (i gni ti on swi tch i n on/off/
crank/run posi ti on)
Leak detecti on pump (swi tch) sense (i f equi pped)
Oi l pressure
Output shaft speed sensor
Overdri ve/overri de swi tch
Oxygen sensors
Park/neutral swi tch (auto. trans. onl y)
Power ground
Sensor return
Si gnal ground
Speed control mul ti pl exed si ngl e wi re i nput
Throttl e posi ti on sensor
Transmi ssi on governor pressure sensor
Transmi ssi on temperature sensor
Vehi cl e speed sensor
NOTE: PCM Outputs:
A/C cl utch rel ay
Auto shutdown (ASD) rel ay
CCD bus (+) ci rcui ts
CCD bus (-) ci rcui ts
Data l i nk connecti on for DRB scan tool
EGR val ve control sol enoi d (i f equi pped)
EVAP cani ster purge sol enoi d
Fi ve vol t sensor suppl y (pri mary)
Fi ve vol t sensor suppl y (secondary)
Fuel i njectors
Fuel pump rel ay
Generator fi el d dri ver (-)
Generator fi el d dri ver (+)
Generator l amp (i f equi pped)
I dl e ai r control (I AC) motor
I gni ti on coi l
Leak detecti on pump
Mal functi on i ndi cator l amp (Check engi ne l amp).
Dri ven through CCD ci rcui ts.
Overdri ve i ndi cator l amp (i f equi pped)
Speed control vacuum sol enoi d
Speed control vent sol enoi d
Tachometer (i f equi pped). Dri ven through CCD
ci rcui ts.
Transmi ssi on convertor cl utch ci rcui t
Transmi ssi on 34 shi ft sol enoi d
Transmi ssi on rel ay
Transmi ssi on temperature l amp (i f equi pped)
Transmi ssi on vari abl e force sol enoi d
AIR CONDITIONING (A/C) CONTROLS PCM INPUT
The A/C control system i nformati on appl i es to fac-
tory i nstal l ed ai r condi ti oni ng uni ts.
A/C SELECT SIGNAL: When the A/C swi tch i s i n
the ON posi ti on, an i nput si gnal i s sent to the pow-
ertrai n control modul e (PCM). The si gnal i nforms the
PCM that the A/C has been sel ected. The PCM
adjusts i dl e speed to a pre-programmed rpm through
the i dl e ai r control (I AC) motor to compensate for
i ncreased engi ne l oad.
A/C REQUEST SIGNAL: Once A/C has been
sel ected, the powertrai n control modul e (PCM)
recei ves the A/C request si gnal from the cl utch
cycl i ng pressure swi tch. The i nput i ndi cates that the
evaporator pressure i s i n the proper range for A/C
appl i cati on. The PCM uses thi s i nput to cycl e the A/C
compressor cl utch (through the A/C rel ay). I t wi l l
al so determi ne the correct engi ne i dl e speed through
the i dl e ai r control (I AC) motor posi ti on.
I f the A/C l ow-pressure swi tch or hi gh-pressure
swi tch opens (i ndi cati ng a l ow or hi gh refri gerant
pressure), the PCM wi l l not recei ve an A/C request
si gnal . The PCM wi l l then remove the ground from
the A/C rel ay. Thi s wi l l deacti vate the A/C compres-
sor cl utch.
I f the swi tch opens, (i ndi cati ng that evaporator i s
not i n proper pressure range), the PCM wi l l not
recei ve the A/C request si gnal . The PCM wi l l then
remove the ground from the A/C rel ay, deacti vati ng
the A/C compressor cl utch.
AUTOMATIC SHUTDOWN (ASD) RELAY SENSE
PCM INPUT
A 12 vol t si gnal at thi s i nput i ndi cates to the PCM
that the ASD has been acti vated. The ASD rel ay i s
l ocated i n the Power Di stri buti on Center (PDC). The
PDC i s l ocated i n the engi ne compartment (Fi g. 2).
Refer to l abel on PDC cover for rel ay l ocati on. The
rel ay i s used to connect the oxygen sensor heater el e-
ment, i gni ti on coi l and fuel i njectors to 12 vol t +
power suppl y.
Thi s i nput i s used onl y to sense that the ASD rel ay
i s energi zed. I f the powertrai n control modul e (PCM)
does not see 12 vol ts at thi s i nput when the ASD
shoul d be acti vated, i t wi l l set a di agnosti c troubl e
code (DTC).
BATTERY TEMPERATURE SENSOR PCM INPUT
Provi des a si gnal to the PCM correspondi ng to the
battery temperature. Refer to Group 8C, Chargi ng
System for addi ti onal i nformati on.
BATTERY VOLTAGE PCM INPUT
The battery vol tage i nput provi des power to the
Powertrai n Control Modul e (PCM). I t al so i nforms
the PCM what vol tage l evel i s suppl i ed to the i gni -
ti on coi l and fuel i njectors.
I f battery vol tage i s l ow, the PCM wi l l i ncrease
i njector pul se wi dth (peri od of ti me that the i njector
i s energi zed). Thi s i s done to compensate for the
reduced fl ow through i njector caused by the l owered
vol tage.
Fig. 2 Power Distribution Center (PDC)
BRAKE SWITCH PCM INPUT
When the brake l i ght swi tch i s acti vated, the Pow-
ertrai n Control Modul e (PCM) recei ves an i nput i ndi -
cati ng that the brakes are bei ng appl i ed. After
recei vi ng thi s i nput, the PCM mai ntai ns i dl e speed to
a schedul ed rpm through control of the I dl e Ai r Con-
trol (I AC) motor. The brake swi tch i nput i s al so used
to suppl y/deny power to the speed control servo sol e-
noi ds.
FIVE VOLT SENSOR SUPPLY PRIMARY
Suppl i es the requi red 5 vol t power source to the
crankshaft posi ti on sensor, camshaft posi ti on sensor,
MAP sensor and throttl e posi ti on sensor.
FIVE VOLT SENSOR SUPPLY SECONDARY
Suppl i es the requi red 5 vol t source to the vehi cl e
speed sensor.
FUEL LEVEL SENSOR PCM INPUT
The Powertrai n Control Modul e (PCM) sends a 5
vol t si gnal to the fuel l evel sensor (fuel gauge send-
i ng uni t). The fuel l evel sensor wi l l then return a si g-
nal to the PCM to i ndi cate fuel l evel . The purpose of
thi s feature i s to prevent a fal se setti ng of mi sfi re
and fuel system moni tor troubl e codes. Thi s i s i f the
fuel l evel i s l ess than approxi matel y 15 percent, or, i f
equi pped wi th a Leak Detecti on Pump (LDP), more
than approxi matel y 85 percent of i ts rated capaci ty.
Thi s i nput i s al so used to send a si gnal to the PCM
for fuel gauge operati on vi a the CCD bus ci rcui ts.
CAMSHAFT POSITION SENSOR PCM INPUT
A sync si gnal i s provi de by the camshaft posi ti on
sensor. The sensor l ocated i n the di stri butor on al l
4.0L/5.2L/5.9L engi nes (Fi g. 3). The sync si gnal from
thi s sensor works i n conjuncti on wi th the crankshaft
posi ti on sensor to provi de the powertrai n control
modul e (PCM) wi th i nputs. Thi s i s done to establ i sh
and mai ntai n correct i njector fi ri ng order.
Refer to Camshaft Posi ti on Sensor i n Group 8D,
I gni ti on System for more i nformati on.
CRANKSHAFT POSITION SENSOR 5. 2L/5. 9L
ENGINES PCM INPUT
Thi s sensor i s a hal l effect devi ce that detects
notches i n the fl ywheel (manual transmi ssi on) or
fl expl ate (automati c transmi ssi on).
Thi s sensor i s used to i ndi cate to the powertrai n
control modul e (PCM) that a spark and or fuel i njec-
ti on event i s to be requi red. The output from thi s
sensor, i n conjuncti on wi th the camshaft posi ti on sen-
sor si gnal , i s used to di fferenti ate between fuel i njec-
ti on and spark events. I t i s al so used to synchroni ze
the fuel i njectors wi th thei r respecti ve cyl i nders.
The sensor i s bol ted to the cyl i nder bl ock near the
rear of the ri ght cyl i nder head (Fi g. 4).
Refer to Group 8D, I gni ti on System for more
crankshaft posi ti on sensor i nformati on.
The engi ne wi l l not operate i f the PCM does not
recei ve a crankshaft posi ti on sensor i nput.
CRANKSHAFT POSITION SENSOR 4. 0L
ENGINE PCM INPUT
Thi s sensor i s a hal l effect devi ce that detects
notches i n the fl ywheel (manual transmi ssi on) or
fl expl ate (automati c transmi ssi on).
Thi s sensor i s used to i ndi cate to the powertrai n
control modul e (PCM) that a spark and or fuel i njec-
ti on event i s to be requi red. The output from thi s
sensor, i n conjuncti on wi th the camshaft posi ti on sen-
Fig. 3 Camshaft Position SensorTypical (5.2L/5.9L
Distributor Shown)
Fig. 4 Crankshaft Position Sensor5.2L/5.9L
Engines
sor si gnal , i s used to di fferenti ate between fuel i njec-
ti on and spark events. I t i s al so used to synchroni ze
the fuel i njectors wi th thei r respecti ve cyl i nders.
The sensor i s bol ted to the transmi ssi on bel l hous-
i ng (Fi g. 5).
Refer to Group 8D, I gni ti on System for more
crankshaft posi ti on sensor i nformati on.
The engi ne wi l l not operate i f the PCM does not
recei ve a crankshaft posi ti on sensor i nput.
ENGINE COOLANT TEMPERATURE SENSOR 5. 2L/
5. 9L ENGINES PCM INPUT
The engi ne cool ant temperature sensor i s i nstal l ed
next to the thermostat housi ng (Fi g. 6) and protrudes
i nto the water jacket. The sensor provi des an i nput
vol tage to the powertrai n control modul e (PCM)
rel ati ng cool ant temperature. The PCM uses thi s
i nput al ong wi th i nputs from other sensors to deter-
mi ne i njector pul se wi dth and i gni ti on ti mi ng. As
cool ant temperature vari es, the cool ant temperature
sensor resi stance wi l l change. Thi s change i n resi s-
tance resul ts i n a di fferent i nput vol tage to the PCM.
When the engi ne i s col d, the PCM wi l l operate i n
Open Loop cycl e. I t wi l l demand sl i ghtl y ri cher ai r-
fuel mi xtures and hi gher i dl e speeds. Thi s i s done
unti l normal operati ng temperatures are reached.
ENGINE COOLANT TEMPERATURE SENSOR 4. 0L
ENGINE PCM INPUT
The engi ne cool ant temperature sensor i s i nstal l ed
i n the thermostat housi ng (Fi g. 7) and protrudes i nto
the water jacket. The sensor provi des an i nput vol t-
age to the powertrai n control modul e (PCM) rel ati ng
cool ant temperature. The PCM uses thi s i nput al ong
wi th i nputs from other sensors to determi ne i njector
pul se wi dth and i gni ti on ti mi ng. As cool ant tempera-
ture vari es, the cool ant temperature sensors resi s-
tance changes. The change i n resi stance resul ts i n a
di fferent i nput vol tage to the PCM.
When the engi ne i s col d, the PCM wi l l operate i n
Open Loop cycl e. I t wi l l demand sl i ghtl y ri cher ai r-
fuel mi xtures and hi gher i dl e speeds. Thi s i s done
unti l normal operati ng temperatures are reached.
Refer to Open Loop/Cl osed Loop Modes of Opera-
ti on i n thi s secti on of the group for more i nformati on.
GENERATOR OUTPUT PCM INPUT
Provi des a chargi ng system vol tage i nput to the
Powertrai n Control Modul e (PCM). I t i s sensed at the
battery i nput to the PCM.
Fig. 5 Crankshaft Position Sensor4.0L Engine
Fig. 6 Engine Coolant Temperature Sensor5.2L/
5.9L Engines
Fig. 7 Engine Coolant Temperature Sensor4.0L
EngineTypical
OXYGEN SENSOR (O2S) PCM INPUT
Two heated O2S sensors are used. The sensors pro-
duce vol tages from 0 to 1 vol t, dependi ng upon the
oxygen content of the exhaust gas i n the exhaust
mani fol d. When a l arge amount of oxygen i s present
(caused by a l ean ai r/fuel mi xture), the sensors pro-
duces a l ow vol tage. When there i s a l esser amount
present (ri ch ai r/fuel mi xture) i t produces a hi gher
vol tage. By moni tori ng the oxygen content and con-
verti ng i t to el ectri cal vol tage, the sensors act as a
ri ch-l ean swi tch.
I n Cl osed Loop operati on, the PCM moni tors the
O2S sensor i nput (al ong wi th other i nputs) and
adjusts the i njector pul se wi dth accordi ngl y. Duri ng
Open Loop operati on, the PCM i gnores the O2 sensor
i nput. The PCM adjusts i njector pul se wi dth based
on preprogrammed (fi xed) val ues and i nputs from
other sensors.
The oxygen sensors are equi pped wi th a heati ng
el ement that keeps the sensors at proper operati ng
temperature duri ng al l operati ng modes. Mai ntai ni ng
correct sensor temperature at al l ti mes al l ows the
system to enter i nto cl osed l oop operati on sooner.
Al so, i t al l ows the system to remai n i n cl osed l oop
operati on duri ng peri ods of extended i dl e.
The Automati c Shutdown (ASD) rel ay suppl i es bat-
tery vol tage to both the upstream and downstream
heated oxygen sensors. The oxygen sensors are
equi pped wi th a heati ng el ement. The heati ng el e-
ments reduce the ti me requi red for the sensors to
reach operati ng temperature.
UPSTREAM HEATED OXYGEN SENSOR
The upstream O2S sensor i s l ocated near the i nl et
end of the catal yti c converter. I t provi des an i nput
vol tage to the PCM. The i nput tel l s the PCM the oxy-
gen content of the exhaust gas. The PCM uses thi s
i nformati on to fi ne tune the ai r/fuel rati o by adjust-
i ng i njector pul se wi dth.
DOWNSTREAM HEATED OXYGEN SENSOR
The downstream heated oxygen sensor i s l ocated
near the outl et end of the catal yti c converter. The
downstream heated oxygen sensor i nput i s used to
detect catal yti c convertor deteri orati on. As the con-
vertor deteri orates, the i nput from the downstream
sensor begi ns to match the upstream sensor i nput
except for a sl i ght ti me del ay. By compari ng the
downstream heated oxygen sensor i nput to the i nput
from the upstream sensor, the PCM cal cul ates cata-
l yti c convertor effi ci ency.
When the catal yti c converter effi ci ency drops bel ow
emi ssi on standards, the PCM stores a di agnosti c
troubl e code and i l l umi nates the Mal functi on I ndi ca-
tor Lamp (MI L). For more i nformati on, refer to
Group 25, Emi ssi on Control Systems.
IGNITION CIRCUIT SENSE PCM INPUT
The i gni ti on ci rcui t sense i nput tel l s the Power-
trai n Control Modul e (PCM) the i gni ti on swi tch has
energi zed the i gni ti on ci rcui t. Refer to the wi ri ng di a-
grams for ci rcui t i nformati on.
INTAKE MANIFOLD AIR TEMPERATURE SENSOR
5. 2L/5. 9L ENGINES PCM INPUT
The i ntake mani fol d ai r temperature sensor i s
i nstal l ed i n the i ntake mani fol d wi th the sensor el e-
ment extendi ng i nto the ai r stream (Fi g. 8). The sen-
sor provi des an i nput vol tage to the powertrai n
control modul e (PCM) i ndi cati ng i ntake mani fol d ai r
temperature. The i nput i s used al ong wi th i nputs
from other sensors to determi ne i njector pul se wi dth.
As the temperature of the ai r-fuel stream i n the
mani fol d vari es, the sensor resi stance changes. Thi s
resul ts i n a di fferent i nput vol tage to the PCM.
4. 0L ENGINE PCM INPUT
i nstal l ed i n the i ntake mani fol d wi th the sensor el e-
ment extendi ng i nto the ai r stream (Fi g. 9). The sen-
sor provi des an i nput vol tage to the powertrai n
control modul e (PCM) i ndi cati ng i ntake mani fol d ai r
temperature. The i nput i s used al ong wi th i nputs
from other sensors to determi ne i njector pul se wi dth.
As the temperature of the ai r-fuel stream i n the
mani fol d vari es, the sensor resi stance changes. Thi s
resul ts i n a di fferent i nput vol tage to the PCM.
Fig. 8 Intake Manifold Air Temperature Sensor
5.2L/5.9L V-8 EnginesTypical
LEAK DETECTION PUMP (SWITCH) SENSE PCM
INPUT
Provi des an i nput to the PCM that the l eak detec-
ti on pump (LDP) has been acti vated. Refer to Group
25, Emi ssi on Control System for LDP i nformati on.
SENSOR 5. 2L/5. 9L ENGINES PCM INPUT
The MAP sensor reacts to absol ute pressure i n the
i ntake mani fol d. I t provi des an i nput vol tage to the
powertrai n control modul e (PCM). As engi ne l oad
changes, mani fol d pressure vari es. The change i n
mani fol d pressure causes MAP sensor vol tage to
change. The change i n MAP sensor vol tage resul ts i n
a di fferent i nput vol tage to the PCM. The i nput vol t-
age l evel suppl i es the PCM wi th i nformati on about
ambi ent barometri c pressure duri ng engi ne start-up
(cranki ng) and engi ne l oad whi l e the engi ne i s run-
ni ng. The PCM uses thi s i nput al ong wi th i nputs
from other sensors to adjust ai r-fuel mi xture.
The MAP sensor i s mounted on the si de of the
engi ne throttl e body (Fi g. 10). The sensor i s connected
to the throttl e body wi th a rubber L-shaped fi tti ng.
SENSOR 4. 0L ENGINE PCM INPUT
The MAP sensor reacts to absol ute pressure i n the
i ntake mani fol d. I t provi des an i nput vol tage to the
powertrai n control modul e (PCM). As engi ne l oad
changes, mani fol d pressure vari es. The change i n
mani fol d pressure causes MAP sensor vol tage to
change. The change i n MAP sensor vol tage resul ts i n
a di fferent i nput vol tage to the PCM. The i nput vol t-
age l evel suppl i es the PCM wi th i nformati on about
ambi ent barometri c pressure duri ng engi ne start-up
(cranki ng) and engi ne l oad whi l e the engi ne i s run-
ni ng. The PCM uses thi s i nput al ong wi th i nputs
from other sensors to adjust ai r-fuel mi xture.
The MAP sensor i s mounted on the si de of the
engi ne throttl e body (Fi g. 9). The sensor i s connected
to the throttl e body wi th a rubber L-shaped fi tti ng.
OIL PRESSURE SENSOR PCM INPUT
Sends a si gnal from the oi l pressure sendi ng uni t
to the Powertrai n Control Modul e (PCM) rel ati ng to
engi ne oi l pressure.
OUTPUT SHAFT SPEED SENSOR PCM INPUT
Thi s sensor generates a si gnal to the PCM rel ati ng
to the speed of the transmi ssi on mai n dri ve shaft.
Thi s i nput i s used wi th 4speed el ectroni c transmi s-
si ons onl y.
OVERDRIVE/OVERRIDE SWITCH-PCM INPUT
On vehi cl es equi pped wi th an automati c transmi s-
si on and overdri ve, the powertrai n control modul e
(PCM) regul ates the 3-4 overdri ve up-shi ft and down-
shi ft through the overdri ve sol enoi d. Thi s sol enoi d i s
l ocated i n the transmi ssi on. An overdri ve/overri de
push-button swi tch i s l ocated on the i nstrument
panel .
The overdri ve/overri de push-button swi tch i s nor-
mal l y open (overdri ve al l owed) when the l amp i s not
i l l umi nated. I t momentari l y cl oses (overdri ve not
al l owed) when the operator presses the swi tch and
the l amp i s i l l umi nated. Overdri ve wi l l revert to ON
(l amp off) each ti me the i gni ti on swi tch i n turned on.
The transmi ssi on downshi fts i f the operator presses
the overri de swi tch whi l e i n overdri ve.
Refer to Group 21 for more transmi ssi on i nformati on.
Fig. 9 Throttle Body Sensor Locations4.0L Engine Fig. 10 MAP and Throttle Position Sensor
Location5.2L/5.9L Engines
POWER GROUND
The power ground i s used to control ground ci r-
cui ts for the fol l owi ng powertrai n control modul e
(PCM) l oads:
Generator fi el d wi ndi ng
Fuel i njectors
I gni ti on coi l
Certai n rel ays/sol enoi ds
SENSOR RETURN PCM INPUT
Sensor Return provi des a l ow noi se ground refer-
ence for al l engi ne control system sensors.
SIGNAL GROUND PCM INPUT
Si gnal ground provi des a l ow noi se ground to the
data l i nk connector.
SPEED CONTROL SWITCHES PCM INPUT
Two separate speed control swi tch modul es are
mounted on the steeri ng wheel to the l eft and ri ght
si de of the dri vers ai rbag modul e. Wi thi n the two
swi tch modul es, fi ve momentary contact swi tches,
supporti ng seven di fferent speed control functi ons
are used. The outputs from these swi tches are fi l -
tered i nto one i nput. The Powertrai n Control Modul e
(PCM) determi nes whi ch output has been appl i ed
through resistive multiplexing. The i nput ci rcui t
vol tage i s measured by the PCM to determi ne whi ch
swi tch functi on has been sel ected.
A speed control i ndi cator l amp, l ocated on the
i nstrument panel cl uster i s energi zed by the PCM vi a
the CCD Bus. Thi s occurs when speed control system
power has been turned ON, and the engi ne i s run-
ni ng.
The two swi tch modul es are l abel ed: ON/OFF, SET,
RESUME/ACCEL, CANCEL and COAST. Refer to
Group 8H, Speed Control System for more i nforma-
ti on.
TRANSMISSION PARK/NEUTRAL SWITCH PCM
INPUT
The park/neutral swi tch i s l ocated on the transmi s-
si on housi ng and provi des an i nput to the Powertrai n
Control Modul e (PCM). Thi s wi l l i ndi cate that the
automati c transmi ssi on i s i n Park, Neutral or a dri ve
gear sel ecti on. Thi s i nput i s used to determi ne i dl e
speed (varyi ng wi th gear sel ecti on), fuel i njector
pul se wi dth and i gni ti on ti mi ng advance. Refer to
Group 21, Transmi ssi ons, for testi ng, repl acement
and adjustment i nformati on.
TRANSMISSION GOVERNOR PRESSURE
SENSOR PCM INPUT
Provi des a si gnal proporti onal to the transmi ssi on
governor pressure. I t provi des feedback for control of
the governor pressure sol enoi d, whi ch regul ates
transmi ssi on governor pressure. Thi s i nput i s used
wi th 4speed el ectroni c transmi ssi ons onl y.
TRANSMISSION TEMPERATURE SENSOR PCM
INPUT
Thi s i nput i s used i n the shi ft operati on for
4speed el ectroni c transmi ssi ons onl y. The tempera-
ture data i s used for: torque converter cl utch opera-
ti on, overdri ve shi ft, l ow temperature shi ft
compensati on, wi de open throttl e shi ft strategy and
governor pressure transducer cal i brati on.
THROTTLE POSITION SENSOR (TPS) 5. 2L/5. 9L
ENGINES PCM INPUT
The throttl e posi ti on sensor (TPS) i s mounted on
the throttl e body (Fi g. 10). The TPS i s a vari abl e
resi stor that provi des the powertrai n control modul e
(PCM) wi th an i nput si gnal (vol tage) that represents
throttl e bl ade posi ti on. The sensor i s connected to the
throttl e bl ade shaft. As the posi ti on of the throttl e
bl ade changes, the resi stance of the TPS changes.
The PCM suppl i es approxi matel y 5 vol ts to the
TPS. The TPS output vol tage (i nput si gnal to the
PCM) represents the throttl e bl ade posi ti on. The
PCM recei ves an i nput si gnal vol tage from the TPS.
Thi s wi l l vary i n an approxi mate range of from .25
vol ts at mi ni mum throttl e openi ng (i dl e), to 4.8 vol ts
at wi de open throttl e. Al ong wi th i nputs from other
sensors, the PCM uses the TPS i nput to determi ne
current engi ne operati ng condi ti ons. I n response to
engi ne operati ng condi ti ons, the PCM wi l l adjust fuel
i njector pul se wi dth and i gni ti on ti mi ng.
THROTTLE POSITION SENSOR (TPS) 4. 0L
ENGINE PCM INPUT
The throttl e posi ti on sensor (TPS) i s mounted on
the throttl e body (Fi g. 9). The TPS i s a vari abl e resi s-
tor that provi des the powertrai n control modul e
(PCM) wi th an i nput si gnal (vol tage) that represents
throttl e bl ade posi ti on. The sensor i s connected to the
throttl e bl ade shaft. As the posi ti on of the throttl e
bl ade changes, the resi stance of the TPS changes.
The PCM suppl i es approxi matel y 5 vol ts to the
TPS. The TPS output vol tage (i nput si gnal to the
PCM) represents the throttl e bl ade posi ti on. The
PCM recei ves an i nput si gnal vol tage from the TPS.
Thi s wi l l vary i n an approxi mate range of from .25
vol ts at mi ni mum throttl e openi ng (i dl e), to 4.8 vol ts
at wi de open throttl e. Al ong wi th i nputs from other
sensors, the PCM uses the TPS i nput to determi ne
current engi ne operati ng condi ti ons. I n response to
engi ne operati ng condi ti ons, the PCM wi l l adjust fuel
i njector pul se wi dth and i gni ti on ti mi ng.
VEHICLE SPEED AND DISTANCE SENSOR PCM
INPUT
The vehi cl e speed sensor i s l ocated on the speed-
ometer pi ni on gear adapter (Fi g. 11) or (Fi g. 12). The
pi ni on gear adapter i s l ocated on the extensi on hous-
i ng of the transmi ssi on (dri vers si de2WD), or on
the transfer case (4WD). The sensor i nput i s used by
the powertrai n control modul e (PCM) to determi ne
vehi cl e speed and di stance travel ed.
The speed sensor generates 8 pul ses per sensor
revol uti on. These si gnal s, i n conjuncti on wi th a
cl osed throttl e si gnal from the throttl e posi ti on sen-
sor, i ndi cate a cl osed throttl e decel erati on to the
PCM. When the vehi cl e i s stopped at i dl e, a cl osed
throttl e si gnal i s recei ved by the PCM (but a speed
sensor si gnal i s not recei ved).
Under decel erati on condi ti ons, the PCM adjusts
the i dl e ai r control (I AC) motor to mai ntai n a desi red
MAP val ue. Under i dl e condi ti ons, the PCM adjusts
the I AC motor to mai ntai n a desi red engi ne speed.
AIR CONDITIONING (A/C) CLUTCH RELAY PCM
OUTPUT
The A/C rel ay i s l ocated i n the Power Di stri buti on
Center (PDC). The PDC i s l ocated i n the engi ne com-
partment (Fi g. 13). Refer to l abel on PDC cover for
rel ay l ocati on.
The powertrai n control modul e (PCM) acti vates the
A/C compressor through the A/C cl utch rel ay. The
PCM regul ates A/C compressor operati on by swi tch-
i ng the ground ci rcui t for the A/C cl utch rel ay on and
off.
When the PCM recei ves a request for A/C from A/C
evaporator swi tch, i t wi l l adjust i dl e ai r control (I AC)
motor posi ti on. Thi s i s done to i ncrease i dl e speed.
The PCM wi l l then acti vate the A/C cl utch through
the A/C cl utch rel ay. The PCM adjusts i dl e ai r control
(I AC) stepper motor posi ti on to compensate for
i ncreased engi ne l oad from the A/C compressor.
Fig. 11 Vehicle Speed Sensor Location2WD
Typical
Typical
By swi tchi ng the ground path for the rel ay on and
off, the PCM i s abl e to cycl e the A/C compressor
cl utch. Thi s i s based on changes i n engi ne operati ng
condi ti ons. I f, duri ng A/C operati on, the PCM senses
abnormal l y l ow i dl e speeds i t wi l l de-energi ze the
rel ay. Thi s prevents A/C cl utch engagement. The
rel ay wi l l remai n de-energi zed unti l the i dl e speed
i ncreases. The PCM wi l l al so de-energi ze the rel ay i f
cool ant temperature exceeds 125C (257F) or l ow or
hi gh system pressure exi sts.
AUTO SHUTDOWN (ASD) RELAY PCM OUTPUT
The ASD rel ay i s l ocated i n the Power Di stri buti on
Center (PDC).
The ASD suppl i es battery vol tage to the fuel i njec-
tors, i gni ti on coi l and oxygen (O2S) sensor heati ng
el ements. The ground ci rcui t for the coi l i n the ASD
rel ay i s control l ed by the powertrai n control modul e
(PCM). The PCM operates the rel ay by swi tchi ng the
ground ci rcui t on and off.
CCD BUS (+/-) CIRCUITS-PCM OUTPUTS
The Powertrai n Control Modul e (PCM) sends cer-
tai n output si gnal s through the CCD bus ci rcui ts.
These si gnal s are used to control certai n i nstrument
panel l ocated i tems and to determi ne certai n i denti -
fi cati on numbers.
Refer to Group 8E, I nstrument Panel and Gauges
for addi ti onal i nformati on.
DATA LINK CONNECTOR PCM INPUT AND
OUTPUT
The 16way data l i nk connector (di agnosti c scan
tool connector) l i nks the Di agnosti c Readout Box
(DRB) scan tool or the Mopar Di agnosti c System
(MDS) wi th the powertrai n control modul e (PCM).
The data l i nk connector i s l ocated under the i nstru-
ment panel to the l eft of the steeri ng col umn (Fi g.
14). For operati on of the DRB scan tool , refer to the
appropri ate Powertrai n Di agnosti c Procedures ser-
vi ce manual .
DUTY CYCLE EVAP PURGE SOLENOID VALVE-PCM
OUTPUT
i nformati on.
FUEL INJECTORS 5. 2L/5. 9L ENGINES PCM
OUTPUT
The fuel i njectors are attached to the fuel rai l (Fi g.
15). 5.2L/5.9L V-8 engi nes use ei ght i njectors.
The nozzl e ends of the i njectors are posi ti oned i nto
openi ngs i n the i ntake mani fol d just above the i ntake
val ve ports of the cyl i nder head. The engi ne wi ri ng
harness connector for each fuel i njector i s equi pped
wi th an attached numeri cal tag (I NJ 1, I NJ 2 etc.).
Thi s i s used to i denti fy each fuel i njector wi th i ts
respecti ve cyl i nder number.
recei ves.
Fig. 14 Data Link Connector Location
Fig. 15 Fuel Injectors5.2L/5.9L EnginesTypical
FUEL INJECTORS 4. 0L ENGINE PCM OUTPUT
Si x i ndi vi dual fuel i njectors are used wi th the 4.0L
6-cyl i nder engi ne. The i njectors are attached to the
fuel rai l (Fi g. 16).
The nozzl e ends of the i njectors are posi ti oned i nto
openi ngs i n the i ntake mani fol d just above the i ntake
val ve ports of the cyl i nder head. The engi ne wi ri ng
harness connector for each fuel i njector i s equi pped
wi th an attached numeri cal tag (I NJ 1, I NJ 2 etc.).
Thi s i s used to i denti fy each fuel i njector.
recei ves.
FUEL PUMP RELAY-PCM OUTPUT
The PCM energi zes the el ectri c fuel pump through
the fuel pump rel ay. Battery vol tage i s appl i ed to the
fuel pump rel ay when the i gni ti on key i s ON. The
rel ay i s energi zed when a ground si gnal i s provi ded
by the PCM.
The fuel pump wi l l operate for approxi matel y three
seconds unl ess the engi ne i s operati ng or the starter
motor i s engaged.
The fuel pump rel ay i s l ocated i n the Power Di stri -
buti on Center (PDC).
GENERATOR FIELD SOURCE (+) PCM OUTPUT
Thi s output from the Powertrai n Control Modul e
(PCM) regul ates chargi ng system vol tage to the gen-
erator fi el d source (+) ci rcui t. The vol tage range i s
12.9 to 15.0 vol ts. Model s of previ ous years had used
the ASD rel ay (di rectl y) to appl y the 12 vol t + power
suppl y to the generator fi el d source (+) ci rcui t. Refer
to Groups 8A and 8C for chargi ng system i nforma-
ti on.
GENERATOR FIELD DRIVER (-) PCM OUTPUT
Thi s output from the Powertrai n Control Modul e
(PCM) regul ates chargi ng system ground control to
the generator fi el d dri ver (-) ci rcui t. Refer to Groups
8A and 8C for chargi ng system i nformati on.
GENERATOR LAMP PCM OUTPUT
I f the powertrai n control modul e (PCM) senses a
l ow chargi ng condi ti on i n the chargi ng system, i t wi l l
i l l umi nate the generator l amp (i f equi pped) on the
i nstrument panel . Thi s i s done through the CCD Bus
ci rcui ts. For exampl e, duri ng l ow i dl e wi th al l acces-
sori es turned on, the l amp may momentari l y go on.
Once the PCM corrects i dl e speed to a hi gher rpm,
the l amp wi l l go out. Refer to Groups 8A and 8C for
chargi ng system i nformati on.
IDLE AIR CONTROL (IAC) MOTOR 5. 2L/5. 9L
ENGINES PCM OUTPUT
The I AC motor i s mounted to the back of the throt-
tl e body (Fi g. 10) and i s control l ed by the powertrai n
control modul e (PCM).
The throttl e body has an ai r control passage that
provi des ai r for the engi ne at i dl e (the throttl e pl ate
i s cl osed). The I AC motor pi ntl e protrudes i nto the
ai r control passage (Fi g. 17) and regul ates ai r fl ow
through i t. Based on vari ous sensor i nputs, the pow-
ertrai n control modul e (PCM) adjusts engi ne i dl e
speed by movi ng the I AC motor pi ntl e i n and out of
the ai r control passage. The I AC motor i s posi ti oned
when the i gni ti on key i s turned to the On posi ti on.
A (factory adjusted) set screw i s used to mechani -
cal l y l i mi t the posi ti on of the throttl e body throttl e
pl ate. Never attempt to adjust the engine idle
speed using this screw. Al l i dl e speed functi ons are
control l ed by the PCM.
IDLE AIR CONTROL (IAC) MOTOR 4. 0L
ENGINE PCM OUTPUT
The I AC motor i s mounted on the throttl e body
(Fi g. 9) and i s control l ed by the powertrai n control
modul e (PCM).
Fig. 16 Fuel Injectors4.0L Engine
The throttl e body has an ai r control passage that
provi des ai r for the engi ne at i dl e (the throttl e pl ate
i s cl osed). The I AC motor pi ntl e protrudes i nto the
ai r control passage and regul ates ai r fl ow through i t.
Based on vari ous sensor i nputs, the powertrai n con-
trol modul e (PCM) adjusts engi ne i dl e speed by mov-
i ng the I AC motor pi ntl e i n and out of the ai r control
passage. The I AC motor i s posi ti oned when the i gni -
ti on key i s turned to the On posi ti on.
IGNITION COIL 5. 2L/5. 9L ENGINES PCM
OUTPUT
System vol tage i s suppl i ed to the i gni ti on coi l pos-
i ti ve termi nal . The powertrai n control modul e (PCM)
operates the i gni ti on coi l . Base (initial) ignition
timing is not adjustable. The PCM adjusts i gni ti on
ti mi ng to meet changi ng engi ne operati ng condi ti ons.
The i gni ti on coi l i s l ocated near the front of the
ri ght cyl i nder head (Fi g. 18).
Refer to Group 8D, I gni ti on System for addi ti onal
i nformati on.
IGNITION COIL 4. 0L ENGINES PCM OUTPUT
System vol tage i s suppl i ed to the i gni ti on coi l pos-
i ti ve termi nal . The powertrai n control modul e (PCM)
operates the i gni ti on coi l . Base (initial) ignition
timing is not adjustable. The PCM adjusts i gni ti on
ti mi ng to meet changi ng engi ne operati ng condi ti ons.
The i gni ti on coi l i s l ocated near the di stri butor
(Fi g. 19).
Refer to Group 8D, I gni ti on System for addi ti onal
i nformati on.
LEAK DETECTION PUMP PCM OUTPUT
Certai n engi nes wi th certai n emi ssi ons packages
are equi pped wi th a l eak detecti on pump (LDP). The
LDP i s acti vated through thi s PCM output. Refer to
Group 25, Emi ssi on Control System for addi ti onal
i nformati on.
MALFUNCTION INDICATOR LAMP PCM OUTPUT
i nformati on.
OVERDRIVE LAMP PCM OUTPUT
Thi s ci rcui t control s a si gnal for the operati on of
the i nstrument panel mounted push-button overdri ve
l amp swi tch. When the l amp i s i l l umi nated, the over-
dri ve i s di sengaged.
Fig. 17 Throttle Body Air Control Passage5.2L/
5.9L EnginesTypical
Fig. 18 Ignition Coil5.2L/5.9L EnginesTypical
Fig. 19 Ignition Coil4.0L Engine
SPEED CONTROL SOLENOIDS PCM OUTPUT
Speed control operati on i s regul ated by the power-
trai n control modul e (PCM). The PCM control s the
vacuum to the throttl e actuator through the speed
control vacuum and vent sol enoi ds. Refer to Group
8H for Speed Control I nformati on.
TACHOMETER PCM OUTPUT
The powertrai n control modul e (PCM) suppl i es
engi ne rpm val ues to the i nstrument cl uster tachom-
eter. Refer to Group 8E for tachometer i nformati on.
THREE-FOUR SHIFT SOLENOID PCM OUTPUT
Thi s output i s used to control the transmi ssi on
three-four shi ft sol enoi d. I t i s used on 4speed el ec-
troni cal l y control l ed automati c transmi ssi ons onl y.
TORQUE CONVERTOR CLUTCH (TCC) SOLENOID
PCM OUTPUT
Thi s ci rcui t control s operati on of the transmi ssi on
mounted torque convertor cl utch (TCC) sol enoi d used
for torque convertor engagement.
The powertrai n control modul e (PCM) wi l l deter-
mi ne when to engage and di sengage the sol enoi d by
moni tori ng vehi cl e mi l es per hour (mph) versus the
output vol tage of the throttl e posi ti on sensor. Al so
needed are vari ous i nputs from:
Transmi ssi on temperature sensor
Output shaft speed sensor
Modul e ti mer
Engi ne rpm
MAP sensor
Brake swi tch
MANUAL TRANSMISSION
I f equi pped wi th a manual transmi ssi on, thi s PCM
output wi l l control operati on of the shi ft i ndi cator
l amp (i f equi pped wi th l amp). The l amp i s control l ed
by the powertrai n control modul e (PCM). The l amp
i l l umi nates on the i nstrument panel to i ndi cate when
the dri ver shoul d shi ft to the next hi ghest gear for
best fuel economy. The PCM wi l l turn the l amp OFF
after 3 to 5 seconds i f the shi ft of gears i s not per-
formed. The l amp wi l l remai n off unti l vehi cl e stops
accel erati ng and i s brought back to range of up-shi ft
l amp operati on. Thi s wi l l al so happen i f vehi cl e i s
shi fted i nto fi fth gear.
The i ndi cator l amp i s normal l y i l l umi nated when
the i gni ti on swi tch i s turned on and i t i s turned off
when the engi ne i s started up. Wi th the engi ne run-
ni ng, the l amp i s turned ON/OFF dependi ng upon
engi ne speed and l oad.
TRANSMISSION RELAY PCM OUTPUT
The output to thi s rel ay provi des battery vol tage to
the overdri ve (OD), torque converter cl utch (TCC)
and governor pressure sol enoi ds. Once battery vol t-
age i s appl i ed to the sol enoi ds, they are i ndi vi dual l y
acti vated by the PCM through OD, TCC and gover-
nor pressure outputs. The rel ay i s l ocated i n the
Power Di stri buti on Center (PDC). Refer to l abel on
PDC cover for rel ay l ocati on.
GOVERNOR PRESSURE SOLENOID PCM OUTPUT
Thi s sol enoi d regul ates the transmi ssi on fl ui d l i ne
pressure to produce the governor pressure necessary
for transmi ssi on shi ft control . I t i s used on 4speed
el ectroni c transmi ssi ons onl y.
THROTTLE BODY 5. 2L/5. 9L ENGINES
Fi l tered ai r from the ai r cl eaner enters the i ntake
mani fol d through the throttl e body (Fi g. 20). Fuel
does not enter the i ntake mani fol d through the throt-
tl e body. Fuel i s sprayed i nto the mani fol d by the fuel
i njectors. The throttl e body i s mounted on the i ntake
mani fol d. I t contai ns an ai r control passage (Fi g. 21)
control l ed by an i dl e ai r control (I AC) motor. The ai r
control passage i s used to suppl y ai r for i dl e condi -
ti ons. A throttl e val ve (pl ate) i s used to suppl y ai r for
above i dl e condi ti ons.
The throttl e posi ti on sensor (TPS), i dl e ai r control
(I AC) motor and mani fol d absol ute pressure sensor
(MAP) are attached to the throttl e body. The accel er-
ator pedal cabl e, speed control cabl e and transmi s-
si on control cabl e (when equi pped) are connected to
the throttl e arm.
Fig. 20 Throttle Body5.2L/5.9L EnginesTypical
THROTTLE BODY 4. 0L ENGINE
Fi l tered ai r from the ai r cl eaner enters the i ntake
mani fol d through the throttl e body (Fi g. 22). Fuel
does not enter the i ntake mani fol d through the throt-
tl e body. Fuel i s sprayed i nto the mani fol d by the fuel
i njectors. The throttl e body i s mounted on the i ntake
mani fol d. I t contai ns an ai r control passage (Fi g. 22)
control l ed by an i dl e ai r control (I AC) motor. The ai r
control passage i s used to suppl y ai r for i dl e condi -
ti ons. A throttl e val ve (pl ate) i s used to suppl y ai r for
above i dl e condi ti ons.
The throttl e posi ti on sensor (TPS), i dl e ai r control
(I AC) motor and mani fol d absol ute pressure sensor
(MAP) are attached to the throttl e body. The accel er-
ator pedal cabl e, speed control cabl e and transmi s-
si on control cabl e (when equi pped) are connected to
the throttl e arm.
VISUAL INSPECTION 5. 2L/5. 9L ENGINES
A vi sual i nspecti on for l oose, di sconnected or i ncor-
rectl y routed wi res and hoses shoul d be made. Thi s
shoul d be done before attempti ng to di agnose or ser-
vi ce the fuel i njecti on system. A vi sual check wi l l
hel p spot these faul ts and save unnecessary test and
di agnosti c ti me. A thorough vi sual i nspecti on wi l l
i ncl ude the fol l owi ng checks:
(1) Veri fy that the three 32way el ectri cal connec-
tors are ful l y i nserted i nto the connector of the pow-
ertrai n control modul e (PCM) (Fi g. 23).
(2) I nspect the battery cabl e connecti ons. Be sure
that they are cl ean and ti ght.
(3) I nspect fuel pump rel ay and ai r condi ti oni ng
compressor cl utch rel ay (i f equi pped). I nspect the
ASD rel ay connecti ons. I nspect starter motor rel ay
connecti ons. I nspect rel ays for si gns of physi cal dam-
age and corrosi on. The rel ays are l ocated i n the
Fig. 21 Air Control Passage5.2L/5.9L Engines
Typical
Fig. 22 Throttle Body4.0L Engine
Power Di stri buti on Center (PDC) (Fi g. 24). Refer to
(4) I nspect i gni ti on coi l connecti ons. Veri fy that
coi l secondary cabl e i s fi rml y connected to coi l (Fi g.
25).
(5) Veri fy that di stri butor cap i s correctl y attached
to di stri butor. Be sure that spark pl ug cabl es are
fi rml y connected to the di stri butor cap and the spark
pl ugs are i n thei r correct fi ri ng order. Be sure that
coi l cabl e i s fi rml y connected to di stri butor cap and
coi l . Be sure that camshaft posi ti on sensor wi re con-
nector (at the di stri butor) i s fi rml y connected to har-
ness connector. I nspect spark pl ug condi ti on. Refer to
Group 8D, I gni ti on. Connect vehi cl e to an osci l l oscope
and i nspect spark events for foul ed or damaged spark
pl ugs or cabl es.
(6) Veri fy that generator output wi re, generator
connector and ground wi re are fi rml y connected to
the generator.
(7) I nspect the system body grounds for l oose or
di rty connecti ons. Refer to Group 8, Wi ri ng for
ground l ocati ons.
(8) Veri fy posi ti ve crankcase venti l ati on (PCV)
val ve operati on. Refer to Group 25, Emi ssi on Control
System for addi ti onal i nformati on. Veri fy PCV val ve
hose i s fi rml y connected to PCV val ve and mani fol d
(Fi g. 26).
(9) I nspect fuel tube qui ck-connect fi tti ng-to-fuel
rai l connecti ons.
(10) Veri fy that hose connecti ons to al l ports of
vacuum fi tti ngs on i ntake mani fol d are ti ght and not
l eaki ng.
(11) I nspect accel erator cabl e, transmi ssi on throt-
tl e cabl e (i f equi pped) and crui se control cabl e con-
necti ons (i f equi pped). Check thei r connecti ons to the
throttl e arm of throttl e body for any bi ndi ng or
restri cti ons.
(12) I f equi pped wi th vacuum brake booster, veri fy
that vacuum booster hose i s fi rml y connected to fi t-
ti ng on i ntake mani fol d. Al so check connecti on to
brake vacuum booster.
(13) I nspect the ai r cl eaner i nl et and ai r cl eaner
el ement for di rt or restri cti ons.
(14) I nspect radi ator gri l l e area, radi ator fi ns and
ai r condi ti oni ng condenser for restri cti ons.
(15) Veri fy that the i ntake mani fol d ai r tempera-
ture sensor wi re connector i s fi rml y connected to har-
ness connector (Fi g. 27).
(16) Veri fy that MAP sensor el ectri cal connector i s
fi rml y connected to MAP sensor (Fi g. 28). Al so veri fy
Fig. 25 Ignition Coil5.2L/5.9L Engines
Fig. 26 PCV Valve Hose Connections5.2L/5.9L
EnginesTypical
that rubber L-shaped fi tti ng from MAP sensor to the
throttl e body i s fi rml y connected (Fi g. 29).
(17) Veri fy that fuel i njector wi re harness connec-
tors are fi rml y connected to i njectors i n the correct
order. Each harness connector i s numeri cal l y tagged
wi th the i njector number (I NJ 1, I NJ 2 etc.) of i ts
correspondi ng fuel i njector and cyl i nder number.
(18) Veri fy harness connectors are fi rml y con-
nected to i dl e ai r control (I AC) motor, throttl e posi -
ti on sensor (TPS) and mani fol d absol ute pressure
(MAP) sensor (Fi g. 28).
(19) Veri fy that wi re harness connector i s fi rml y
connected to the engi ne cool ant temperature sensor
(Fi g. 30).
(20) Rai se and support the vehi cl e.
(21) Veri fy that both the upstream and down-
stream oxygen sensor wi re connectors are fi rml y con-
nected to the sensors. I nspect sensors and connectors
for damage (Fi g. 31) or (Fi g. 32).
(22) I nspect for pi nched or l eaki ng fuel tubes.
I nspect for pi nched, cracked or l eaki ng fuel hoses.
(23) I nspect for exhaust system restri cti ons such
as pi nched exhaust pi pes, col l apsed muffl er or
pl ugged catal yti c convertor.
(24) I f equi pped wi th automati c transmi ssi on, ver-
i fy that el ectri cal harness i s fi rml y connected to park/
neutral swi tch. Refer to Automati c Transmi ssi on
secti on of Group 21.
Fig. 27 Air Temperature Sensor5.2L/5.9L Engines
Fig. 28 Sensor and IAC Motor Location5.2L/5.9L
Engines
Fig. 29 Rubber L-Shaped FittingMAP Sensor-to-
Throttle Body
5.9L EnginesTypical
(25) Veri fy that the el ectri cal harness connector i s
fi rml y connected to the vehi cl e speed sensor (Fi g. 33)
or (Fi g. 34).
(26) Veri fy that fuel pump/gauge sender uni t wi re
connector i s fi rml y connected to harness connector.
(27) I nspect fuel hoses at fuel pump/gauge sender
uni t for cracks or l eaks.
(28) I nspect transmi ssi on torque convertor housi ng
(automati c transmi ssi on) or cl utch housi ng (manual
transmi ssi on) for damage to ti mi ng ri ng on dri ve
pl ate/fl ywheel .
(29) Veri fy that battery cabl e and sol enoi d feed
wi re connecti ons to the starter sol enoi d are ti ght and
cl ean. I nspect for chaffed wi res or wi res rubbi ng up
agai nst other components.
VISUAL INSPECTION 4. 0L ENGINE
A vi sual i nspecti on for l oose, di sconnected or i ncor-
rectl y routed wi res and hoses shoul d be made. Thi s
shoul d be done before attempti ng to di agnose or ser-
vi ce the fuel i njecti on system. A vi sual check wi l l
Fig. 31 Upstream Oxygen Sensor5.2L.5.9L
Engines
Fig. 32 Downstream Oxygen Sensor5.2L/5.9L
Engines
Fig. 33 Vehicle Speed Sensor2WDTypical
hel p spot these faul ts and save unnecessary test and
di agnosti c ti me. A thorough vi sual i nspecti on wi l l
i ncl ude the fol l owi ng checks:
(1) Veri fy that the three 32way el ectri cal connec-
tors are ful l y i nserted i nto the connector of the pow-
ertrai n control modul e (PCM) (Fi g. 35).
(2) I nspect the battery cabl e connecti ons. Be sure
that they are cl ean and ti ght.
(3) I nspect fuel pump rel ay and ai r condi ti oni ng
compressor cl utch rel ay (i f equi pped). I nspect the
ASD rel ay connecti ons. I nspect starter motor rel ay
connecti ons. I nspect rel ays for si gns of physi cal dam-
age and corrosi on. The rel ays are l ocated i n the
Power Di stri buti on Center (PDC) (Fi g. 36). Refer to
(4) I nspect i gni ti on coi l connecti ons. Veri fy that
coi l secondary cabl e i s fi rml y connected to coi l (Fi g.
37).
(5) Veri fy that di stri butor cap i s correctl y attached
to di stri butor. Be sure that spark pl ug cabl es are
fi rml y connected to the di stri butor cap and the spark
pl ugs are i n thei r correct fi ri ng order. Be sure that
coi l cabl e i s fi rml y connected to di stri butor cap and
coi l . Be sure that camshaft posi ti on sensor wi re con-
nector (at the di stri butor) i s fi rml y connected to har-
ness connector. I nspect spark pl ug condi ti on. Refer to
Group 8D, I gni ti on. Connect vehi cl e to an osci l l oscope
and i nspect spark events for foul ed or damaged spark
pl ugs or cabl es.
(6) Veri fy that generator output wi re, generator
connector and ground wi re are fi rml y connected to
the generator.
(7) I nspect the system body grounds for l oose or
di rty connecti ons. Refer to Group 8, Wi ri ng for
ground l ocati ons.
(8) Veri fy crankcase venti l ati on (CCV) operati on.
Refer to Group 25, Emi ssi on Control System for addi -
ti onal i nformati on.
(9) I nspect fuel tube qui ck-connect fi tti ng-to-fuel
rai l connecti ons.
(10) Veri fy that hose connecti ons to al l ports of
vacuum fi tti ngs on i ntake mani fol d are ti ght and not
l eaki ng.
(11) I nspect accel erator cabl e, transmi ssi on throt-
tl e cabl e (i f equi pped) and crui se control cabl e con-
Fig. 37 Ignition Coil4.0L Engine
necti ons (i f equi pped). Check thei r connecti ons to the
throttl e arm of throttl e body for any bi ndi ng or
restri cti ons.
(12) I f equi pped wi th vacuum brake booster, veri fy
that vacuum booster hose i s fi rml y connected to fi t-
ti ng on i ntake mani fol d. Al so check connecti on to
brake vacuum booster.
(13) I nspect the ai r cl eaner i nl et and ai r cl eaner
el ement for di rt or restri cti ons.
(14) I nspect radi ator gri l l e area, radi ator fi ns and
ai r condi ti oni ng condenser for restri cti ons.
(15) Veri fy that the i ntake mani fol d ai r tempera-
ture sensor wi re connector i s fi rml y connected to har-
ness connector (Fi g. 38).
(16) Veri fy that MAP sensor el ectri cal connector i s
fi rml y connected to MAP sensor (Fi g. 38). Al so veri fy
that rubber L-shaped fi tti ng from MAP sensor to the
throttl e body i s fi rml y connected (Fi g. 39).
(17) Veri fy that fuel i njector wi re harness connec-
tors are fi rml y connected to i njectors i n the correct
order. Each harness connector i s numeri cal l y tagged
wi th the i njector number (I NJ 1, I NJ 2 etc.) of i ts
correspondi ng fuel i njector and cyl i nder number.
(18) Veri fy harness connectors are fi rml y con-
nected to i dl e ai r control (I AC) motor and throttl e
posi ti on sensor (TPS) (Fi g. 38).
(19) Veri fy that wi re harness connector i s fi rml y
connected to the engi ne cool ant temperature sensor
(Fi g. 40).
(20) Rai se and support the vehi cl e.
(21) Veri fy that both of the oxygen sensor wi re
connectors are fi rml y connected to the sensors.
I nspect sensors and connectors for damage (Fi g. 41)
or (Fi g. 42).
(22) I nspect for pi nched or l eaki ng fuel tubes.
I nspect for pi nched, cracked or l eaki ng fuel hoses.
(23) I nspect for exhaust system restri cti ons such
as pi nched exhaust pi pes, col l apsed muffl er or
pl ugged catal yti c convertor.
(24) I f equi pped wi th automati c transmi ssi on, ver-
i fy that el ectri cal harness i s fi rml y connected to park/
neutral swi tch. Refer to Automati c Transmi ssi on
secti on of Group 21.
(25) Veri fy that the el ectri cal harness connector i s
fi rml y connected to the vehi cl e speed sensor (Fi g. 43)
or (Fi g. 44).
(26) Veri fy that fuel pump/gauge sender uni t wi re
connector i s fi rml y connected to harness connector.
(27) I nspect fuel hoses at fuel pump/gauge sender
uni t for cracks or l eaks.
Fig. 38 Sensor Locations4.0L Engine
Throttle Body
Fig. 40 Engine Coolant Temp. Sensor4.0L Shown
(28) I nspect transmi ssi on torque convertor housi ng
(automati c transmi ssi on) or cl utch housi ng (manual
transmi ssi on) for damage to ti mi ng ri ng on dri ve
pl ate/fl ywheel .
(29) Veri fy that battery cabl e and sol enoi d feed
wi re connecti ons to the starter sol enoi d are ti ght and
cl ean. I nspect for chaffed wi res or wi res rubbi ng up
agai nst other components.
ASD AND FUEL PUMP RELAYS
The following description of operation and
tests apply only to the Automatic Shutdown
(ASD) and fuel pump relays. The termi nal s on the
bottom of each rel ay are numbered (Fi g. 45) or (Fi g.
46).
OPERATION
Termi nal number 30 i s connected to battery vol t-
age. For both the ASD and fuel pump rel ays, termi -
nal 30 i s connected to battery vol tage at al l ti mes.
The PCM grounds the coi l si de of the rel ay
through termi nal number 85.
Termi nal number 86 suppl i es vol tage to the coi l
si de of the rel ay.
When the PCM de-energi zes the ASD and fuel
pump rel ays, termi nal number 87A connects to termi -
Fig. 41 Upstream Oxygen Sensor4.0L Engine
Fig. 42 Downstream Oxygen Sensor4.0L Engine
nal 30. Thi s i s the Off posi ti on. I n the off posi ti on,
vol tage i s not suppl i ed to the rest of the ci rcui t. Ter-
mi nal 87A i s the center termi nal on the rel ay.
When the PCM energi zes the ASD and fuel
pump rel ays, termi nal 87 connects to termi nal 30.
Thi s i s the On posi ti on. Termi nal 87 suppl i es vol tage
to the rest of the ci rcui t.
TESTING
The fol l owi ng procedure appl i es to the ASD and
fuel pump rel ays.
(1) Remove rel ay from connector before testi ng.
(2) Wi th the rel ay removed from the vehi cl e, use
an ohmmeter to check the resi stance between termi -
nal s 85 and 86. The resi stance shoul d be between 75
5 ohms.
(3) Connect the ohmmeter between termi nal s 30
and 87A. The ohmmeter shoul d show conti nui ty
between termi nal s 30 and 87A.
(4) Connect the ohmmeter between termi nal s 87
and 30. The ohmmeter shoul d not show conti nui ty at
thi s ti me.
(5) Connect one end of a jumper wi re (16 gauge or
smal l er) to rel ay termi nal 85. Connect the other end
of the jumper wi re to the ground si de of a 12 vol t
power source.
(6) Connect one end of another jumper wi re (16
gauge or smal l er) to the power si de of the 12 vol t
power source. Do not attach the other end of the
jumper wire to the relay at this time.
WARNING: DO NOT ALLOW OHMMETER TO CON-
TACT TERMINALS 85 OR 86 DURING THIS TEST.
(7) Attach the other end of the jumper wi re to
rel ay termi nal 86. Thi s acti vates the rel ay. The ohm-
meter shoul d now show conti nui ty between rel ay ter-
mi nal s 87 and 30. The ohmmeter shoul d not show
conti nui ty between rel ay termi nal s 87A and 30.
(8) Di sconnect jumper wi res.
(9) Repl ace the rel ay i f i t di d not pass the conti nu-
i ty and resi stance tests. I f the rel ay passed the tests,
i t operates properl y. Check the remai nder of the ASD
and fuel pump rel ay ci rcui ts. Refer to group 8W, Wi r-
i ng Di agrams.
MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR
TEST 5. 2L. 5. 9L ENGINES
To perform a compl ete test of MAP sensor (Fi g. 47)
and i ts ci rcui try, refer to DRB scan tool and appro-
pri ate Powertrai n Di agnosti cs Procedures manual . To
test the MAP sensor onl y, refer to the fol l owi ng:
(1) I nspect the rubber L-shaped fi tti ng from the
MAP sensor to the throttl e body (Fi g. 48). Repai r as
necessary.
CAUTION: When testing the MAP sensor, be sure
that the harness wires are not damaged by the test
meter probes.
Fig. 45 ASD and Fuel Pump Relay Terminals
Fig. 46 ASD and Fuel Pump Relay Terminals
Fig. 47 MAP Sensor5.2L/5.9L EnginesTypical
(2) Test the MAP sensor output vol tage at the
MAP sensor connector between termi nal s A and B
(Fi g. 49). Wi th the i gni ti on swi tch ON and the engi ne
OFF, output vol tage shoul d be 4-to-5 vol ts. The vol t-
age shoul d drop to 1.5-to-2.1 vol ts wi th a hot, neutral
i dl e speed condi ti on.
(3) Test powertrai n control modul e (PCM) cavi ty
A-27 for the same vol tage descri bed above to veri fy
the wi re harness condi ti on. Repai r as necessary.
(4) Test MAP sensor suppl y vol tage at sensor con-
nector between termi nal s A and C (Fi g. 49) wi th the
i gni ti on ON. The vol tage shoul d be approxi matel y 5
vol ts (0.5V). Fi ve vol ts (0.5V) shoul d al so be at
cavi ty A-17 of the PCM wi re harness connector.
Repai r or repl ace the wi re harness as necessary.
(5) Test the MAP sensor ground ci rcui t at sensor
connector termi nal A (Fi g. 49) and PCM connector
A-4. Repai r the wi re harness i f necessary.
Refer to Group 8W, Wi ri ng Di agrams for cavi ty
l ocati ons.
MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR
TEST 4. 0L ENGINE
To perform a compl ete test of MAP sensor (Fi g. 50)
and i ts ci rcui try, refer to DRB scan tool and appro-
test the MAP sensor onl y, refer to the fol l owi ng:
(1) I nspect the rubber L-shaped fi tti ng from the
MAP sensor to the throttl e body (Fi g. 51). Repai r as
necessary.
CAUTION: When testing the MAP sensor, be sure
that the harness wires are not damaged by the test
meter probes.
(2) Test the MAP sensor output vol tage at the
MAP sensor connector between termi nal s A and B
(Fi g. 49). Wi th the i gni ti on swi tch ON and the engi ne
OFF, output vol tage shoul d be 4-to-5 vol ts. The vol t-
age shoul d drop to 1.5-to-2.1 vol ts wi th a hot, neutral
i dl e speed condi ti on.
(3) Test powertrai n control modul e (PCM) cavi ty
A-27 for the same vol tage descri bed above to veri fy
the wi re harness condi ti on. Repai r as necessary.
(4) Test MAP sensor suppl y vol tage at sensor con-
nector between termi nal s A and C (Fi g. 49) wi th the
i gni ti on ON. The vol tage shoul d be approxi matel y 5
vol ts (0.5V). Fi ve vol ts (0.5V) shoul d al so be at
cavi ty A-17 of the PCM wi re harness connector.
Repai r or repl ace the wi re harness as necessary.
Throttle Body
Fig. 49 MAP Sensor Connector TerminalsTypical
Fig. 50 Sensor Location4.0L Engine
(5) Test the MAP sensor ground ci rcui t at sensor
connector termi nal A (Fi g. 49) and PCM connector
A-4. Repai r the wi re harness i f necessary.
Refer to Group 8W, Wi ri ng Di agrams for cavi ty
l ocati ons.
OXYGEN (O2S) SENSORS 5. 2L/5. 9L ENGINES
To perform a compl ete test of the O2S sensors and
thei r ci rcui try, refer to the DRB scan tool and appro-
test the O2S sensors onl y, refer to the fol l owi ng:
The upstream O2S sensor i s l ocated on the exhaust
pi pe (Fi g. 52).
The downstream O2S sensor i s l ocated on the out-
l et end of the catal yti c converter (Fi g. 53).
Each O2S heati ng el ement can be tested wi th an
ohmmeter as fol l ows:
Di sconnect the O2S sensor connector. Connect the
ohmmeter test l eads across the whi te wi re termi nal s
of the sensor connector. Resi stance shoul d be
between 4.5 .5 ohms and 7 ohms. Repl ace the sen-
sor i f the ohmmeter di spl ays an i nfi ni ty (open) read-
i ng.
OXYGEN (O2S) SENSORS 4. 0L ENGINE
To perform a compl ete test of the O2S sensors and
thei r ci rcui try, refer to the DRB scan tool and appro-
test the O2S sensors onl y, refer to the fol l owi ng:
The upstream O2S sensor i s l ocated on the exhaust
pi pe (Fi g. 54).
The downstream O2S sensor i s l ocated on the out-
l et end of the catal yti c converter (Fi g. 53).
Each O2S heati ng el ement can be tested wi th an
ohmmeter as fol l ows:
Di sconnect the O2S sensor connector. Connect the
ohmmeter test l eads across the whi te wi re termi nal s
of the sensor connector. Resi stance shoul d be
between 4.5 .5 ohms and 7 ohms. Repl ace the sen-
sor i f the ohmmeter di spl ays an i nfi ni ty (open) read-
i ng.
Throttle Body
Fig. 52 Upstream Oxygen Sensor Location5.2L/
5.9L Engines
Fig. 53 Downstream Oxygen Sensor LocationAll
Engines
CAMSHAFT AND CRANKSHAFT POSITION
SENSORS
Refer to Group 8D, I gni ti on System for i nforma-
ti on.
5. 2L/5. 9L ENGINES
To perform a compl ete test of the engi ne cool ant
temperature sensor and i ts ci rcui try, refer to DRB
scan tool and appropri ate Powertrai n Di agnosti cs
Procedures manual . To test the sensor onl y, refer to
the fol l owi ng:
(1) Di sconnect wi re harness connector from cool ant
temperature sensor (Fi g. 55).
(2) Engines with air conditioning: When
removi ng the connector from sensor, do not pul l
di rectl y on wi ri ng harness. Fabri cate an L-shaped
hook tool from a coat hanger (approxi matel y ei ght
i nches l ong). Pl ace the hook part of tool under the
connector for removal . The connector i s snapped onto
the sensor. I t i s not equi pped wi th a l ock type tab.
(3) Test the resi stance of sensor wi th a hi gh i nput
i mpedance (di gi tal ) vol t-ohmmeter. Refer to SENSOR
RESI STANCE (OHMS)COOLANT TEMPERA-
TURE SENSOR/I NTAKE AI R TEMPERATURE
SENSOR chart. The resi stance (as measured across
sensor termi nal s) shoul d be wi thi n range shown i n
chart. I f not, repl ace sensor.
(4) Test conti nui ty of the wi re harness between the
PCM wi re harness connector and the cool ant sensor
connector termi nal s. Refer to Group 8, Wi ri ng for ter-
mi nal /cavi ty l ocati ons. Repai r the wi re harness i f an
open ci rcui t i s i ndi cated.
(5) After tests are compl eted, connect el ectri cal
connector to sensor. The sensor connector i s symmet-
ri cal (not i ndexed). I t can be i nstal l ed to the sensor
i n ei ther di recti on.
4. 0L ENGINE
To perform a compl ete test of the engi ne cool ant
temperature sensor and i ts ci rcui try, refer to DRB
scan tool and appropri ate Powertrai n Di agnosti cs
Procedures manual . To test the sensor onl y, refer to
the fol l owi ng:
(1) Di sconnect wi re harness connector from cool ant
temperature sensor (Fi g. 56).
Fig. 54 Upstream Oxygen Sensor Location4.0L
Engine
5.9L Engines
SENSOR RESISTANCE (OHMS)COOLANT
TEMPERATURE SENSOR/INTAKE AIR
TEMPERATURE SENSOR
TEMPERATURE RESISTANCE (OHMS)
CEL. FAHR. MIN. MAX.
-40 -40 291,490 381,710
-20 -4 85,850 108,390
-10 14 49,250 61,430
0 32 29,330 35,990
10 50 17,990 21,810
20 68 11,370 13,610
25 77 9,120 10,880
30 86 7,370 8,750
40 104 4,900 5,750
50 122 3,330 3,880
60 140 2,310 2,670
70 158 1,630 1,870
80 176 1,170 1,340
90 194 860 970
100 212 640 720
110 230 480 540
120 248 370 410
(3) Test conti nui ty of the wi re harness between the
PCM wi re harness connector and the cool ant sensor
connector termi nal s. Refer to Group 8, Wi ri ng for ter-
mi nal /cavi ty l ocati ons. Repai r the wi re harness i f an
open ci rcui t i s i ndi cated.
IDLE AIR CONTROL (IAC) MOTOR
5. 2L/5. 9L ENGINES
To perform a compl ete test of the I AC motor and
i ts ci rcui try, refer to DRB scan tool and appropri ate
Powertrai n Di agnosti cs Procedures manual .
IDLE AIR CONTROL (IAC) MOTOR 4. 0L ENGINE
To perform a compl ete test of the I AC motor and
i ts ci rcui try, refer to DRB scan tool and appropri ate
5. 2L/5. 9L ENGINE
To perform a compl ete test of the i ntake mani fol d
ai r temperature sensor and i ts ci rcui try, refer to DRB
tester and appropri ate Powertrai n Di agnosti cs Proce-
dures manual . To test the sensor onl y, refer to the
fol l owi ng:
(1) Di sconnect the wi re harness connector from the
i ntake mani fol d ai r temperature sensor (Fi g. 57).
(3) Test the resi stance of the wi re harness. Do thi s
between the PCM wi re harness connector A-15 and
the sensor connector termi nal . Al so check between
PCM connector A-4 to the sensor connector termi nal .
Repai r the wi re harness as necessary i f the resi s-
tance i s greater than 1 ohm.
4. 0L ENGINE
To perform a compl ete test of the i ntake mani fol d
ai r temperature sensor and i ts ci rcui try, refer to DRB
tester and appropri ate Powertrai n Di agnosti cs Proce-
dures manual . To test the sensor onl y, refer to the
fol l owi ng:
(1) Di sconnect the wi re harness connector from the
i ntake mani fol d ai r temperature sensor (Fi g. 58).
(3) Test the resi stance of the wi re harness. Do thi s
between the PCM wi re harness connector A-15 and
the sensor connector termi nal . Al so check between
PCM connector A-4 to the sensor connector termi nal .
Repai r the wi re harness as necessary i f the resi s-
tance i s greater than 1 ohm.
VEHICLE SPEED SENSOR
To perform a compl ete test of the sensor and i ts
ci rcui try, refer to DRB scan tool and appropri ate
Engine
Fig. 57 Air Temperature Sensor5.2L/5.9L Engines
ENGINES
To perform a compl ete test of the TPS and i ts ci r-
cui try, refer to the DRB scan tool and appropri ate
Powertrai n Di agnosti cs Procedures manual . To test
the TPS onl y, refer to the fol l owi ng:
The TPS (Fi g. 59) can be tested wi th a di gi tal vol t-
meter. The center el ectri cal termi nal of the TPS i s
the output termi nal .
Wi th the i gni ti on key i n the ON posi ti on, check the
TPS output vol tage at the center termi nal wi re of the
connector. Check thi s at i dl e (throttl e pl ate cl osed)
and at wi de open throttl e (WOT). At i dl e, TPS output
vol tage shoul d be greater than .350 mi l l i vol ts but
l ess than 900 mi l l i vol ts. At wi de open throttl e, TPS
output vol tage must be l ess than 4.5 vol ts. The out-
put vol tage shoul d i ncrease gradual l y as the throttl e
pl ate i s sl owl y opened from i dl e to WOT.
ENGINE
To perform a compl ete test of the TPS (Fi g. 58) and
i ts ci rcui try, refer to the DRB scan tool and appropri -
ate Powertrai n Di agnosti cs Procedures manual . To
test the TPS onl y, refer to the fol l owi ng:
The TPS can be tested wi th a di gi tal vol tmeter.
The center termi nal of the TPS i s the output termi -
nal .
Wi th the i gni ti on key i n the ON posi ti on, check the
TPS output vol tage at the center termi nal wi re of the
connector. Check thi s at i dl e (throttl e pl ate cl osed)
and at wi de open throttl e (WOT). At i dl e, TPS output
vol tage shoul d be greater than .350 mi l l i vol ts and
l ess than 900 mi l l i vol ts. At wi de open throttl e, TPS
output vol tage must be l ess than 4.5 vol ts. The out-
put vol tage shoul d i ncrease gradual l y as the throttl e
pl ate i s sl owl y opened from i dl e to WOT.
THROTTLE BODY MINIMUM AIR FLOW CHECK
PROCEDURE
5.2L/5.9L ENGINE
The fol l owi ng test procedure has been devel oped to
check throttl e body cal i brati ons for correct i dl e condi -
ti ons. The procedure shoul d be used to di agnose the
throttl e body for condi ti ons that may cause i dl e prob-
l ems. This procedure should be used only after
normal diagnostic procedures have failed to
produce results that indicate a throttle body
related problem. Be sure to check for proper
operation of the idle air control motor before
performing this test.
A speci al fi xed ori fi ce tool (number 6714) (Fi g. 60)
must be used for the fol l owi ng test.
(1) Start the engi ne and bri ng to operati ng tem-
perature. Be sure al l accessori es are off before per-
formi ng thi s test.
Fig. 58 Intake Manifold Air Temperature Sensor
4.0L Engine
Fig. 59 TPS5.2L/5.9L Engines
Fig. 60 Fixed Orifice Tool
(2) Shut off the engi ne and remove the ai r duct at
throttl e body.
(3) Di sconnect the vacuum l i ne at the PCV val ve
(Fi g. 61).
(4) I nstal l the 0.185 i nch ori fi ce tool (number 6714)
i nto the di sconnected vacuum l i ne i n pl ace of the
PCV val ve (Fi g. 61).
(5) Di sconnect the i dl e purge vacuum l i ne from fi t-
ti ng at throttl e body. Thi s vacuum l i ne i s l ocated on
the front of throttl e body next to the MAP sensor
(Fi g. 62). Cap the fi tti ng at throttl e body after vac-
uum l i ne has been removed.
(6) Connect the DRB scan tool to the 16way data
l i nk connector. Thi s connector i s l ocated under the
i nstrument panel to the l eft of the steeri ng col umn.
Refer to the appropri ate Powertrai n Di agnosti c Pro-
cedures servi ce manual for DRB operati on.
(7) Start the engi ne and al l ow to warm up.
(8) Usi ng the DRB scan tool , scrol l through the
menus as fol l ows: sel ectStand Al one DRB I I I , sel ect
19941997 Di agnosti cs, sel ectEngi ne, sel ectSys-
tem Test, sel ectMi ni mum Ai r Fl ow.
(9) The DRB scan tool wi l l count down to stabi l i ze
the i dl e rpm and di spl ay the mi ni mum ai r fl ow i dl e
rpm. The i dl e rpm shoul d be between 500 and 900
rpm. I f the i dl e speed i s outsi de of these speci fi ca-
ti ons, repl ace the throttl e body. Refer to Throttl e
Body i n the Component Removal /I nstal l ati on secti on
of thi s group.
(10) Di sconnect the DRB scan tool from the vehi -
cl e.
(11) Remove cap from i dl e purge fi tti ng at throttl e
body and i nstal l vacuum l i ne.
(12) Remove ori fi ce tool and connect vacuum l i ne
to PCV val ve.
(13) I nstal l ai r duct to throttl e body.
AUTOMATIC SHUTDOWN (ASD) RELAY
The ASD rel ay i s l ocated i n the Power Di stri buti on
Center (PDC) (Fi g. 63). Refer to l abel on PDC cover
for rel ay l ocati on.
REMOVAL
(1) Remove PDC cover.
(2) Remove rel ay from PDC.
Fig. 61 Install Orifice Tool
Fig. 62 Idle Purge Line
Fig. 63 Power Distribution Center (PDC) Location
(3) Check condi ti on of rel ay termi nal s and PDC
connector termi nal s for damage or corrosi on. Repai r
i f necessary before i nstal l i ng rel ay.
(4) Check for pi n hei ght (pi n hei ght shoul d be the
same for al l termi nal s wi thi n the PDC connector).
Repai r i f necessary before i nstal l i ng rel ay.
INSTALLATION
(1) I nstal l rel ay to PDC.
(2) I nstal l cover to PDC.
FUEL PUMP RELAY
The fuel pump rel ay i s l ocated i n the Power Di stri -
buti on Center (PDC) (Fi g. 63). Refer to l abel on PDC
cover for rel ay l ocati on.
REMOVAL
(1) Remove PDC cover.
(2) Remove rel ay from PDC.
(3) Check condi ti on of rel ay termi nal s and PDC
connector termi nal s for damage or corrosi on. Repai r
i f necessary before i nstal l i ng rel ay.
(4) Check for pi n hei ght (pi n hei ght shoul d be the
same for al l termi nal s wi thi n the PDC connector).
Repai r i f necessary before i nstal l i ng rel ay.
INSTALLATION
(1) I nstal l rel ay to PDC.
(2) I nstal l cover to PDC.
THROTTLE BODY 5. 2L/5. 9L ENGINES
control l ed by the powertrai n control modul e (PCM).
REMOVAL
(1) Remove the ai r duct at throttl e body.
(2) Di sconnect throttl e body el ectri cal connectors
at MAP sensor, I AC motor and TPS (Fi g. 64).
(3) Remove vacuum l i ne at throttl e body.
(4) Remove al l control cabl es from throttl e body
(l ever) arm. Refer to the Accel erator Pedal and Throt-
tl e Cabl e secti on of thi s group for addi ti onal i nforma-
ti on.
(5) Remove four throttl e body mounti ng bol ts (Fi g.
65).
(7) Di scard ol d throttl e body-to-i ntake mani fol d
gasket.
INSTALLATION
(1) Cl ean the mati ng surfaces of the throttl e body
and the i ntake mani fol d.
(2) I nstal l new throttl e body-to-i ntake mani fol d
gasket.
(3) I nstal l throttl e body to i ntake mani fol d.
(4) I nstal l four mounti ng bol ts. Ti ghten bol ts to 23
Nm (200 i n. l bs.) torque.
(5) I nstal l control cabl es.
(6) I nstal l vacuum l i ne to throttl e body.
(7) I nstal l el ectri cal connectors.
Fig. 64 Sensor Electrical Connectors5.2L/5.9L
EnginesTypical
Fig. 65 Throttle Body Mounting Bolts5.2L/5.9L
EnginesTypical
THROTTLE BODY 4. 0L ENGINE
control l ed by the powertrai n control modul e (PCM).
REMOVAL
(1) Remove the ai r cl eaner duct at throttl e body.
(2) Di sconnect throttl e body el ectri cal connectors
at MAP sensor, I AC motor and TPS (Fi g. 66).
(3) Remove al l control cabl es from throttl e body
(l ever) arm. Refer to the Accel erator Pedal and Throt-
tl e Cabl e secti on of thi s group for addi ti onal i nforma-
ti on.
(4) Remove four throttl e body mounti ng bol ts.
(6) Di scard ol d throttl e body-to-i ntake mani fol d
gasket.
INSTALLATION
(1) Cl ean the mati ng surfaces of the throttl e body
and the i ntake mani fol d.
(2) I nstal l new throttl e body-to-i ntake mani fol d
gasket.
(3) I nstal l throttl e body to i ntake mani fol d.
(4) I nstal l four mounti ng bol ts. Ti ghten bol ts to 11
(5) I nstal l control cabl es.
(6) I nstal l el ectri cal connectors.
ENGINES
REMOVAL
The TPS i s l ocated on the si de of the throttl e body.
(2) Di sconnect TPS el ectri cal connector.
(3) Remove two TPS mounti ng bol ts (Fi g. 67).
(4) Remove TPS from throttl e body.
INSTALLATION
The throttl e shaft end of the throttl e body sl i des
i nto a socket i n the TPS (Fi g. 68). The TPS must be
i nstal l ed so that i t can be rotated a few degrees. I f
the sensor wi l l not rotate, i nstal l the sensor wi th the
throttl e shaft on the other si de of the socket tangs.
The TPS wi l l be under sl i ght tensi on when rotated.
(1) I nstal l the TPS and two retai ni ng bol ts.
(2) Ti ghten bol ts to 7 Nm (60 i n. l bs.) torque.
Fig. 66 Throttle Body and Sensor Locations4.0L
Engine
Fig. 67 TPS Mounting Bolts5.2L/5.9L Engines
Typical
Fig. 68 Installation5.2L/5.9L EnginesTypical
(3) Manual l y operate the throttl e control l ever by
hand to check for any bi ndi ng of the TPS.
(4) Connect TPS el ectri cal connector to TPS.
ENGINE
The TPS i s mounted to the throttl e body.
REMOVAL
(1) Di sconnect TPS el ectri cal connector.
(2) Remove TPS mounti ng screws (Fi g. 69).
(3) Remove TPS.
INSTALLATION
The throttl e shaft end of the throttl e body sl i des
i nto a socket i n the TPS (Fi g. 70). The TPS must be
i nstal l ed so that i t can be rotated a few degrees. (I f
the sensor wi l l not rotate, i nstal l the sensor wi th the
throttl e shaft on the other si de of the socket tangs).
The TPS wi l l be under sl i ght tensi on when rotated.
(1) I nstal l the TPS and retai ni ng screws.
(2) Ti ghten screws to 7 Nm (60 i n. l bs.) torque.
(3) Connect TPS el ectri cal connector to TPS.
(4) Manual l y operate the throttl e (by hand) to
check for any TPS bi ndi ng before starti ng the engi ne.
IDLE AIR CONTROL (IAC) MOTOR 5. 2L/5. 9L
ENGINES
The I AC motor i s l ocated on the back of the throt-
tl e body.
REMOVAL
(2) Di sconnect el ectri cal connector from I AC motor.
(3) Remove two mounti ng bol ts (screws) (Fi g. 71).
(4) Remove I AC motor from throttl e body.
INSTALLATION
(1) I nstal l I AC motor to throttl e body.
(2) I nstal l and ti ghten two mounti ng bol ts (screws)
to 7 Nm (60 i n. l bs.) torque.
(3) I nstal l el ectri cal connector.
IDLE AIR CONTROL (IAC) MOTOR 4. 0L ENGINE
The I AC motor i s l ocated on the si de of the throttl e
body.
REMOVAL
(1) Remove ai r cl eaner tube at throttl e body.
(2) Di sconnect el ectri cal connector from I AC motor.
(3) Remove two mounti ng bol ts (screws) (Fi g. 72).
(4) Remove I AC motor from throttl e body.
INSTALLATION
(1) I nstal l I AC motor to throttl e body.
(2) I nstal l and ti ghten two mounti ng bol ts (screws)
to 7 Nm (60 i n. l bs.) torque.
Fig. 69 TPS Mounting Screws4.0L Engine
Fig. 70 Throttle Position Sensor Installation4.0L
Engine
Fig. 71 Mounting Bolts (Screws)IAC Motor5.2L/
5.9L EnginesTypical
(4) I nstal l ai r cl eaner tube to throttl e body.
SENSOR 5. 2L/5. 9L ENGINES
The MAP sensor i s l ocated on the front of the
throttl e body (Fi g. 73). An L-shaped rubber fi tti ng i s
used to connect the MAP sensor to throttl e body (Fi g.
74).
REMOVAL
(2) Di sconnect el ectri cal connector at sensor.
(3) Remove two MAP sensor mounti ng bol ts
(screws) (Fi g. 74).
(4) Whi l e removi ng MAP sensor, sl i de the vacuum
rubber L-shaped fi tti ng (Fi g. 74) from the throttl e
body.
(5) Remove rubber L-shaped fi tti ng from MAP sen-
sor.
INSTALLATION
(1) I nstal l rubber L-shaped fi tti ng to MAP sensor.
(2) Posi ti on sensor to throttl e body whi l e gui di ng
rubber fi tti ng over throttl e body vacuum ni ppl e.
(3) I nstal l MAP sensor mounti ng bol ts (screws).
Ti ghten screws to 3 Nm (25 i n. l bs.) torque.
(4) Connect el ectri cal connector.
SENSOR 4. 0L ENGINE
The MAP sensor i s mounted to the si de of the
throttl e body (Fi g. 75). An L-shaped rubber fi tti ng i s
used to connect the MAP sensor to throttl e body (Fi g.
76).
REMOVAL
(1) Remove ai r cl eaner i ntake tube at throttl e
body.
(2) Remove two MAP sensor mounti ng bol ts
(screws) (Fi g. 76).
(3) Whi l e removi ng MAP sensor, sl i de the rubber
L-shaped fi tti ng (Fi g. 76) from the throttl e body.
(4) Remove rubber L-shaped fi tti ng from MAP sen-
sor.
INSTALLATION
(1) I nstal l rubber L-shaped fi tti ng to MAP sensor.
Fig. 72 Mounting Bolts (Screws)IAC Motor4.0L
Engine
Fig. 73 MAP Sensor Mounting Screws5.2L/5.9L
Engines
Fig. 74 MAP Sensor L-Shaped Rubber Fitting5.2L/
5.9L Engines
(2) Posi ti on sensor to throttl e body whi l e gui di ng
rubber fi tti ng over throttl e body vacuum ni ppl e.
(3) I nstal l MAP sensor mounti ng bol ts (screws).
Ti ghten screws to 3 Nm (25 i n. l bs.) torque.
(4) I nstal l ai r cl eaner i ntake tube.
DUTY CYCLE EVAP CANISTER PURGE SOLENOID
removal /i nstal l ati on procedures.
POWERTRAIN CONTROL MODULE (PCM)
The PCM i s l ocated on the cowl panel i n the ri ght/
rear si de of the engi ne compartment (Fi g. 77).
REMOVAL
To avoi d possi bl e vol tage spi ke damage to the
PCM, i gni ti on key must be off, and negati ve battery
cabl e must be di sconnected before unpl uggi ng PCM
connectors.
(1) Di sconnect negati ve battery cabl e at battery.
(2) Remove cover over el ectri cal connectors. Cover
snaps onto PCM.
(3) Remove the cool ant reserve/overfl ow tank (one
bol t and two nuts) (Fi g. 78).
Fig. 75 MAP Sensor Location4.0L Engine
Throttle Body4.0L Engine
Fig. 77 Powertrain Control Module (PCM) Location
Fig. 78 Coolant Reserve/Overflow Tank Mounting
(4) Careful l y unpl ug the three 32way connectors
at PCM.
(5) Remove the three PCM mounti ng bol ts (Fi g.
79).
(6) Remove PCM.
INSTALLATION
(1) Check the pi ns i n the three 32way el ectri cal
connectors for damage. Repai r as necessary.
(2) I nstal l PCM. Ti ghten three mounti ng bol ts to 1
(3) I nstal l three 32way connectors.
(4) I nstal l cover over el ectri cal connectors. Cover
snaps onto PCM.
(5) I nstal l cool ant reserve/overfl ow tank.
(7) Use the DRB scan tool to reprogram new PCM
wi th vehi cl es ori gi nal I denti fi cati on Number (VI N)
and ori gi nal vehi cl e mi l eage.
CRANKSHAFT POSITION SENSOR
Refer to Group 8D, I gni ti on System for removal /i n-
stal l ati on procedures.
CAMSHAFT POSITION SENSOR
For removal /i nstal l ati on procedures, refer to Group
8D, I gni ti on System. See Camshaft Posi ti on Sensor.
OXYGEN SENSOR 5. 2L/5. 9L ENGINES
The upstream O2S sensor i s l ocated i n the exhaust
downpi pe. The downstream sensor i s l ocated near
outl et end of catal yti c converter. Refer to (Fi g. 80) or
(Fi g. 81).
REMOVAL
WARNING: THE EXHAUST MANIFOLD, EXHAUST
PIPES AND CATALYTIC CONVERTER BECOME
VERY HOT DURING ENGINE OPERATION. ALLOW
ENGINE TO COOL BEFORE REMOVING OXYGEN
SENSOR.
Fig. 79 Powertrain Control Module (PCM) Mounting
Fig. 80 Upstream Oxygen Sensor Location5.2L/
5.9L Engines
Fig. 81 Downstream Oxygen Sensor LocationAll
Engines
(2) Downstream Sensor Onl y: Di sconnect O2S wi r-
i ng connector cl i p (Fi g. 81) at body. Remove cl i p from
O2S el ectri cal connector and di scard.
(3) Di sconnect O2S pi gtai l harness wi re connector
from mai n connector.
CAUTION: When disconnecting the sensor electri-
cal connector, do not pull directly on wire going
into sensor.
(4) Remove O2S sensor. Snap-On oxygen sensor
wrench (number YA 8875) may be used for removal
and i nstal l ati on.
INSTALLATION
Threads of new oxygen sensors are factory coated
wi th anti -sei ze compound to ai d i n removal . DO
NOT add any additional anti-seize compound to
threads of a new oxygen sensor.
(1) I nstal l O2S sensor. Ti ghten to 30 Nm (22 ft.
l bs.) torque.
(2) Connect O2S sensor wi re connector to mai n
wi ri ng harness.
(3) Downstream Sensor Onl y: I nstal l new wi ri ng
connector cl i p i nto O2S el ectri cal connector. Snap
thi s cl i p to body. The O2S pi gtai l harness must be
cl i pped to body to prevent mechani cal damage from
propshaft.
(4) Lower the vehi cl e.
OXYGEN SENSOR 4. 0L ENGINE
The upstream O2S sensor i s l ocated i n the exhaust
downpi pe. The downstream sensor i s l ocated near
outl et end of catal yti c converter. Refer to (Fi g. 82) or
(Fi g. 81).
REMOVAL
WARNING: THE EXHAUST MANIFOLD, EXHAUST
PIPES AND CATALYTIC CONVERTER BECOME
VERY HOT DURING ENGINE OPERATION. ALLOW
ENGINE TO COOL BEFORE REMOVING OXYGEN
SENSOR.
(2) Downstream Sensor Onl y: Di sconnect O2S wi r-
i ng connector cl i p (Fi g. 81) at body. Remove cl i p from
O2S el ectri cal connector and di scard.
(3) Di sconnect O2S pi gtai l harness wi re connector
from mai n connector.
CAUTION: When disconnecting the sensor electri-
cal connector, do not pull directly on wire going
into sensor.
(4) Remove O2S sensor. Snap-On oxygen sensor
wrench (number YA 8875) may be used for removal
and i nstal l ati on.
INSTALLATION
Threads of new oxygen sensors are factory coated
wi th anti -sei ze compound to ai d i n removal . DO
NOT add any additional anti-seize compound to
the threads of a new oxygen sensor.
(1) I nstal l the O2S sensor. Ti ghten to 30 Nm (22
ft. l bs.) torque.
(2) Connect O2S sensor wi re connector to mai n
wi ri ng harness.
(3) Downstream Sensor Onl y: I nstal l new wi ri ng
connector cl i p i nto O2S el ectri cal connector. Snap
thi s cl i p to body. The O2S pi gtai l harness must be
cl i pped to body to prevent mechani cal damage from
propshaft.
(4) Lower the vehi cl e.
AIR CLEANER HOUSING
REMOVAL
(1) Unl ock cl ean ai r hose cl amp (Fi g. 83) at ai r
cl eaner cover. To unl ock the cl amp, attach adjustabl e
pl i ers to cl amp and rotate pl i ers as shown i n (Fi g.
84). Remove cl ean ai r hose at cover.
(2) Remove crankcase breather/fi l ter hose at ai r
cl eaner cover.
(3) From under vehi cl e, remove three housi ng nuts
(Fi g. 83).
(4) Rel ease the ai r cl eaner housi ng from the ambi -
ent ai r duct and remove housi ng from vehi cl e.
INSTALLATION
(1) Posi ti on ai r cl eaner housi ng to body and ambi -
ent ai r duct (Fi g. 83).
(2) I nstal l three nuts and ti ghten to 10 Nm (93 i n.
l bs.) torque.
Fig. 82 Upstream Oxygen Sensor Location4.0L
Engine
(3) I nstal l crankcase breather/fi l ter hose to cover.
(4) I nstal l cl amp to cover. Compress the cl amp
snugl y wi th adjustabl e pl i ers as shown i n (Fi g. 85).
AIR CLEANER ELEMENT (FILTER)
REMOVAL/INSTALLATION
(1) Pry back the si x cl i ps retai ni ng the ai r cl eaner
cover to the ai r cl eaner housi ng (Fi g. 86).
(2) Li ft the cover up and posi ti on to the si de.
(3) Remove ai r cl eaner el ement.
(4) Cl ean the i nsi de of ai r cl eaner housi ng before
i nstal l i ng new el ement.
(5) Reverse the precedi ng operati on for i nstal l a-
ti on. Be sure the ai r cl eaner cover i s properl y seated
to ai r cl eaner housi ng.
ENGINE COOLANT TEMPERATURE SENSOR 5. 2L/
5. 9L ENGINES
REMOVAL
WARNING: HOT, PRESSURIZED COOLANT CAN
CAUSE INJURY BY SCALDING. COOLING SYSTEM
MUST BE PARTIALLY DRAINED BEFORE REMOV-
ING THE COOLANT TEMPERATURE SENSOR.
REFER TO GROUP 7, COOLING.
(1) Parti al l y drai n cool i ng system. Refer to Group
7, Cool i ng.
(2) Di sconnect el ectri cal connector from sensor
(Fi g. 87).
Fig. 83 Air Cleaner5.2L V-8 Engine Shown
Fig. 84 Clamp Removal
Fig. 85 Clamp Installation
Fig. 86 Air Cleaner Element Removal/Installation
(3) Engines with air conditioning: When
removi ng the connector from sensor, do not pul l
di rectl y on wi ri ng harness. Fabri cate an L-shaped
hook tool from a coat hanger (approxi matel y ei ght
i nches l ong). Pl ace the hook part of tool under the
connector for removal . The connector i s snapped onto
the sensor. I t i s not equi pped wi th a l ock type tab.
(4) Remove sensor from i ntake mani fol d.
INSTALLATION
(1) I nstal l sensor.
(2) Ti ghten to 11 Nm (8 ft. l bs.) torque.
(3) Connect el ectri cal connector to sensor. The sen-
sor connector i s symmetri cal (not i ndexed). I t can be
i nstal l ed to the sensor i n ei ther di recti on.
(4) Repl ace any l ost engi ne cool ant. Refer to Group
7, Cool i ng System.
ENGINE COOLANT TEMPERATURE SENSOR 4. 0L
ENGINE
The cool ant temperature sensor i s i nstal l ed i n the
thermostat housi ng (Fi g. 88).
REMOVAL
(1) Parti al l y drai n cool i ng system unti l the cool ant
l evel i s bel ow the cyl i nder head. Observe the WARN-
INGS i n Group 7, Cool i ng.
(2) Di sconnect the cool ant temperature sensor wi re
connector.
(3) Remove the sensor from the thermostat hous-
i ng.
INSTALLATION
(1) Appl y seal ant to sensor threads.
(2) I nstal l cool ant temperature sensor i nto the
thermostat housi ng. Ti ghten to 11 Nm (8 ft. l bs.)
torque.
(3) Connect the wi re connector.
(4) Fi l l the cool i ng system. Refer to Group 7, Cool -
i ng System.
5. 2L/5. 9L ENGINES
l ocated i n the front/si de of the i ntake mani fol d (Fi g.
89).
REMOVAL
(1) Di sconnect el ectri cal connector at sensor (Fi g.
89).
(2) Remove sensor from i ntake mani fol d.
5.9L Engines
Engine
Fig. 89 Air Temperature Sensor5.2L/5.9L
EnginesTypical
INSTALLATION
(1) I nstal l sensor to i ntake mani fol d. Ti ghten to 28
Nm (20 ft. l bs.) torque.
4. 0L ENGINE
i nstal l ed i nto the i ntake mani fol d pl enum near the
throttl e body (Fi g. 90).
REMOVAL
(1) Di sconnect the el ectri cal connector from the
sensor.
(2) Remove the sensor from the i ntake mani fol d.
INSTALLATION
(1) I nstal l the sensor i nto the i ntake mani fol d.
Ti ghten the sensor to 28 Nm (20 ft. l bs.) torque.
(2) Connect the el ectri cal connector to the sensor.
VEHICLE SPEED SENSOR
The vehi cl e speed sensor i s l ocated on the speed-
ometer pi ni on gear adapter (Fi g. 91) or (Fi g. 92). The
pi ni on gear adapter i s l ocated on the extensi on hous-
i ng of the transmi ssi on (dri vers si de).
REMOVAL
(2) Di sconnect the el ectri cal connector from the
sensor.
(3) Remove the sensor mounti ng bol t (Fi g. 93).
(4) Remove the sensor (pul l strai ght out) from the
speedometer pi ni on gear adapter (Fi g. 93). Do not
remove the gear adapter from the transmi ssi on.
INSTALLATION
(1) Cl ean the i nsi de of speedometer pi ni on gear
adapter before i nstal l i ng speed sensor.
(2) I nstal l sensor i nto speedometer gear adapter
and i nstal l mounti ng bol t. Before tightening bolt,
verify speed sensor is fully seated (mounted
flush) to speedometer pinion gear adapter.
Fig. 90 Intake Air Sensor Location4.0L Engine
Typical
Typical
(3) Ti ghten sensor mounti ng bol t to 2.2 Nm (20 i n.
l bs.) torque.
(4) Connect el ectri cal connector to sensor.
SPECIFICATIONS
VECI LABEL
I f anythi ng di ffers between the speci fi cati ons found
on the Vehi cl e Emi ssi on Control I nformati on (VECI )
l abel and the fol l owi ng speci fi cati ons, use speci fi ca-
ti ons on VECI l abel . The VECI l abel i s l ocated i n the
engi ne compartment.
TORQUE CHART
DESCRIPTION TORQUE
Ai r Cl eaner Housi ng Mount. Nuts . . . . . . . . .10 Nm
(93 i n. l bs.)
Engi ne Cool ant Temperature Sensor
Al l Engi nes. . . . . . . . . . . . . . . .11 Nm (96 i n. l bs.)
Fuel Hose Cl amps . . . . . . . . . . . . .1 Nm (10 i n. l bs.)
I AC Motor-To-Throttl e
Body Bol ts . . . . . . . . . . . . . . . . .7 Nm (60 i n. l bs.)
I ntake Mani fol d Ai r Temp. Sensor
Al l Engi nes . . . . . . . . . . . . . . . .28 Nm (20 ft. l bs.)
MAP Sensor Mounti ng Screws
Al l Engi nes . . . . . . . . . . . . . . . .3 Nm (25 i n. l bs.)
Oxygen SensorAl l Engi nes . . . .30 Nm (22 ft. l bs.)
Powertrai n Control Modul e
Mounti ng Screws . . . . . . . . . . . . .1 Nm (9 i n. l bs.)
Throttl e Body Mounti ng Bol ts
5.2L/5.9L Engi ne . . . . . . . . . .23 Nm (200 i n. l bs.)
Throttl e Body Mounti ng Bol ts
4.0L Engi ne . . . . . . . . . . . . . .11 Nm (100 i n. l bs.)
Throttl e Posi ti on Sensor Mounti ng
ScrewsAl l Engi nes . . . . . . . . . 7 Nm (60 i n. l bs.)
Vehi cl e Speed Sensor
Mounti ng Bol t . . . . . . . . . . . . .2.2 Nm (20 i n. l bs.)
Fig. 93 Sensor Removal/Installation
SPECIAL TOOLS
FUEL SYSTEM
Spanner Wrench6856
Fitting, Air Metering6714
Adapters, Fuel Pressure Test6541, 6539, 6631 or
6923
O2S (Oxygen Sensor) Remover/InstallerC-4907
Test Kit, Fuel Pressure5069
Test Kit, Fuel PressureC-4799-B
Fuel Line Removal Tool6782

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