THROTTLE POSITION SENSOR (TPS)

Fig. 3 Servicing Throttle Position Sensor

INSTALLATION

(1)Install throttle position sensor on throttle shaft. Install mounting screws. Tighten screws to 2 NIm (17 in. lbs.) torque.

(2)Attach harness connector to sensor.

(3)Connect negative cable to negative post of the battery.

AUTOMATIC IDLE SPEED (AIS) MOTOR

REMOVAL

(1)Disconnect negative cable from battery.

(2)Disconnect harness connector from AIS (Fig. 4).

(3)Remove AIS motor mounting screws.

(4)Remove the AIS motor from throttle body (make certain that the O-ring is on the AIS motor).

INSTALLATION

(1)New AIS motors have a new O-ring installed on them. If pintle measures more than 1 inch (25 mm) it must be retracted. Use the AIS MOTOR OPEN/CLOSE mode of the DRBII (battery must be reconnected for this operation).

(2)Carefully place AIS motor into throttle body.

(3)Install 2 mounting screws. Tighten screws to 2 NIm (17 in. lbs.) torque.

(4)Connect harness connector to AIS motor.

Fig. 4 Servicing Automatic Idle Speed (AIS) Motor

(5) Connect negative cable to battery.

THROTTLE BODY REMOVAL

(1)Disconnect negative cable from battery.

(2)Remove clamp from air hose. Remove hose (Fig.

5).

(3)Remove accelerator cable.

(4)Disconnect automatic idle speed (AIS) motor and throttle position sensor (TPS) electrical connectors.

(5)Disconnect vacuum hoses from throttle body.

(6)Remove throttle body to intake manifold attaching nuts (2).

(7)Remove throttle body and gasket.

(8)Reverse the above procedures for installation.

Fig. 5 Air Cleaner and Throttle Body Assembly

FUEL INJECTOR RAIL ASSEMBLY

WARNING: THE 2.5L TURBO I FUEL SYSTEM IS UNDER A CONSTANT PRESSURE OF APPROXIMATELY 380 KPA (55 PSI). PERFORM FUEL PRESSURE RELEASE PROCEDURE BEFORE SERVICING THE FUEL RAIL OR FUEL INJECTORS.

14 - 72 FUEL SYSTEMS

REMOVAL

(1)Perform fuel system pressure release procedure.

(2)Disconnect negative cable from battery.

(3)Disconnect the fuel injector harness connector from the main harness (Fig. 6).

Fig. 6 Injector Harness Connections

(4)Remove the quick connect fittings from the chassis fuel tubes. Refer to Fuel Hoses, Clamps, and Quick Connect Fittings in the Fuel Delivery section of this group.

(5)Remove vacuum and vapor hose connections (Fig. 7).

(6)Disconnect vacuum hose from the pressure regulator (Fig. 7).

Fig. 7 Electrical, Fuel, and Vacuum Connections

(7)Remove screw from the fuel tube clamp (Fig. 8).

(8)Remove fuel rail mounting screws (Fig. 8).

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Fig. 8 Fuel Rail Attaching Screws

(9)Pull up on the injector rail. The injectors will pull straight out of the ports. Do not damage the injector O-rings.

(10)Remove fuel rail assembly from vehicle. Do not remove fuel injectors until fuel rail assembly has been completely removed from vehicle.

(11)Plug or cover intake manifold injector ports to prevent dirt from entering the openings (Fig. 9).

Fig. 9 Fuel Injector Ports

INSTALLATION

(1)Ensure injectors are seated into the receiver cup, with lock ring in place.

(2)Attach harness connectors to injectors. Fasten the harness into wiring clips.

(3)Ensure the injector holes are clean and all plugs have been removed.

(4)Lubricate the injector O-rings with a drop of clean engine oil to ease installation.

(5)Install the injector assembly into their holes. Install mounting screws. Fuel rail assembly must be drawn into the intake manifold evenly making sure

each injector enters its own hole. Once all injectors are seated, tighten bolts to 22.5 NIm (200 in. lbs) torque (Fig. 8).