
- •GENERAL INFORMATION
- •FUEL REQUIREMENTS
- •VEHICLES WITHOUT TURBOCHARGED ENGINES
- •VEHICLES WITH 2.2L 16 VALVE ENGINES
- •THE FOLLOWING IS APPLICABLE TO ALL VEHICLES
- •FUEL DELIVERY SYSTEM
- •FUEL HOSES, CLAMPS, AND QUICK CONNECT FITTINGS
- •HOSES AND CLAMPS
- •QUICK CONNECT FITTINGS
- •FUEL PUMP ASSEMBLY
- •FUEL SYSTEM PRESSURE
- •MECHANICAL MALFUNCTIONS
- •FUEL PUMP REMOVAL
- •FUEL PUMP STRAINER SERVICE
- •FUEL PUMP INSTALLATION
- •REMOVAL
- •INSTALLATION
- •CHASSIS FUEL TUBES
- •FUEL TANKS
- •GENERAL INFORMATION
- •FUEL TANK FILLER TUBE
- •PRESSURE VACUUM FILLER CAPS
- •FUEL SYSTEM PRESSURE RELEASE PROCEDURE
- •FUEL TANK
- •DRAINING FUEL TANK
- •FUEL TANK CAPACITIES
- •FUEL TANK REMOVAL
- •INSTALLATION
- •FUEL PUMP
- •FUEL RESERVOIR
- •FUEL LEVEL SENDING UNIT
- •DIAGNOSIS
- •REMOVAL
- •INSTALLATION
- •REMOVAL
- •INSTALLATION
- •ACCELERATOR PEDAL AND THROTTLE CABLE
- •ACCELERATOR PEDAL
- •REMOVAL
- •INSTALLATION
- •THROTTLE CABLE
- •REMOVAL
- •INSTALLATION
- •GENERAL INFORMATION
- •SYSTEM DIAGNOSIS
- •ENGINE CONTROLLER
- •MODES OF OPERATION
- •FUEL PRESSURE REGULATOR
- •THROTTLE BODY
- •FUEL SYSTEM DIAGRAM
- •VISUAL INSPECTION
- •ON BOARD DIAGNOSTICS
- •MONITORED CIRCUITS
- •HIGH AND LOW LIMITS
- •FAULT CODE DESCRIPTION
- •SYSTEMS TEST
- •OBTAINING FAULT CODES
- •STATE DISPLAY TEST MODE
- •STATE DISPLAY INPUTS AND OUTPUTS
- •STATE DISPLAY SENSORS
- •CIRCUIT ACTUATION TEST MODE
- •OBTAINING CIRCUIT ACTUATION TEST
- •THROTTLE BODY MINIMUM AIR FLOW CHECK PROCEDURE
- •IGNITION TIMING PROCEDURE
- •IDLE SPECIFICATIONS
- •FAULT CODE DESCRIPTION
- •FAULT CODE DESCRIPTION
- •FUEL LINES AND HOSES
- •FUEL SYSTEM PRESSURE RELEASE PROCEDURE
- •THROTTLE BODY
- •REMOVAL
- •INSTALLATION
- •FUEL FITTING
- •REMOVAL
- •INSTALLATION
- •FUEL PRESSURE REGULATOR
- •REMOVAL
- •INSTALLATION
- •FUEL INJECTOR
- •REMOVAL
- •INSTALLATION
- •THROTTLE POSITION SENSOR
- •REMOVAL
- •INSTALLATION
- •AUTOMATIC IDLE SPEED (AIS) MOTOR
- •REMOVAL
- •INSTALLATION
- •MANIFOLD ABSOLUTE PRESSURE SENSOR
- •REMOVAL
- •CANISTER PURGE SOLENOID
- •REMOVAL
- •INSTALLATION
- •ENGINE CONTROLLER SERVICE
- •OXYGEN SENSOR (O2 SENSOR)
- •GENERAL INFORMATION
- •SYSTEM DIAGNOSIS
- •ENGINE CONTROLLER
- •MODES OF OPERATION
- •IGNITION SWITCH ON (ZERO RPM) MODE
- •CRUISE OR IDLE MODE
- •ACCELERATION MODE
- •DECELERATION MODE
- •WIDE OPEN THROTTLE MODE
- •IGNITION SWITCH OFF MODE
- •THROTTLE BODY
- •FUEL SUPPLY CIRCUIT
- •FUEL INJECTORS AND FUEL RAIL ASSEMBLY
- •FUEL PRESSURE REGULATOR
- •FUEL SYSTEM DIAGRAM
- •VISUAL INSPECTION
- •ON BOARD DIAGNOSTICS
- •MONITORED CIRCUITS
- •HIGH AND LOW LIMITS
- •FAULT CODE DESCRIPTION
- •FAULT CODE DESCRIPTION
- •SYSTEM TESTS
- •OBTAINING FAULT CODES
- •STATE DISPLAY TEST MODE
- •STATE DISPLAY INPUTS AND OUTPUTS
- •STATE DISPLAY SENSORS
- •CIRCUIT ACTUATION TEST MODE
- •OBTAINING CIRCUIT ACTUATION TEST
- •THROTTLE BODY MINIMUM AIR FLOW CHECK PROCEDURE
- •IGNITION TIMING PROCEDURE
- •IDLE SPECIFICATIONS
- •THROTTLE BODY
- •FUEL SYSTEM PRESSURE RELEASE PROCEDURE
- •THROTTLE POSITION SENSOR (TPS)
- •REMOVAL
- •INSTALLATION
- •AUTOMATIC IDLE SPEED (AIS) MOTOR
- •REMOVAL
- •INSTALLATION
- •THROTTLE BODY REMOVAL
- •FUEL INJECTOR RAIL ASSEMBLY
- •REMOVAL
- •INSTALLATION
- •FUEL INJECTOR
- •REMOVAL
- •INSTALLATION
- •FUEL PRESSURE REGULATOR
- •REMOVAL
- •INSTALLATION
- •MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR SERVICE
- •WASTEGATE SOLENOID AND CANISTER PURGE SOLENOID
- •ENGINE CONTROLLER SERVICE
- •HEATED OXYGEN SENSOR (O2 SENSOR)
- •GENERAL INFORMATION
- •SYSTEM DIAGNOSIS
- •ENGINE CONTROLLER
- •MODES OF OPERATION
- •IGNITION SWITCH ON (ZERO RPM) MODE
- •CRUISE OR IDLE MODE
- •ACCELERATION MODE
- •DECELERATION MODE
- •WIDE OPEN THROTTLE MODE
- •IGNITION SWITCH OFF MODE
- •THROTTLE BODY
- •FUEL SUPPLY CIRCUIT
- •FUEL INJECTORS AND FUEL RAIL ASSEMBLY
- •FUEL PRESSURE REGULATOR
- •FUEL SYSTEM DIAGRAM
- •VISUAL INSPECTION
- •ON BOARD DIAGNOSTICS
- •MONITORED CIRCUITS
- •HIGH AND LOW LIMITS
- •FAULT CODE DESCRIPTION
- •FAULT CODE DESCRIPTION
- •SYSTEM TESTS
- •OBTAINING FAULT CODES
- •STATE DISPLAY TEST MODE
- •STATE DISPLAY INPUTS AND OUTPUTS
- •STATE DISPLAY SENSORS
- •CIRCUIT ACTUATION TEST MODE
- •OBTAINING CIRCUIT ACTUATION TEST
- •THROTTLE BODY MINIMUM AIR FLOW CHECK PROCEDURE
- •IGNITION TIMING PROCEDURE
- •IDLE SPECIFICATIONS
- •THROTTLE BODY
- •FUEL SYSTEM PRESSURE RELEASE PROCEDURE
- •THROTTLE POSITION SENSOR (TPS)
- •REMOVAL
- •INSTALLATION
- •AUTOMATIC IDLE SPEED (AIS) MOTOR
- •REMOVAL
- •INSTALLATION
- •THROTTLE BODY REMOVAL
- •INSTALLATION
- •FUEL INJECTOR RAIL ASSEMBLY
- •REMOVAL
- •INSTALLATION
- •FUEL INJECTORS
- •REMOVAL
- •INSTALLATION
- •FUEL PRESSURE REGULATOR
- •REMOVAL
- •INSTALLATION
- •MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR SERVICE
- •WASTEGATE AND CANISTER PURGE SOLENOID SERVICE
- •ENGINE CONTROLLER SERVICE
- •HEATED OXYGEN SENSOR (O2 SENSOR)
- •GENERAL INFORMATION
- •SYSTEM DIAGNOSIS
- •ENGINE CONTROLLER
- •MODES OF OPERATION
- •THROTTLE BODY
- •FUEL SUPPLY CIRCUIT
- •FUEL PRESSURE REGULATOR
- •FUEL SYSTEM DIAGRAM
- •VISUAL INSPECTION
- •ON BOARD DIAGNOSTICS
- •MONITORED CIRCUITS
- •HIGH AND LOW LIMITS
- •FAULT CODE DESCRIPTION
- •FAULT CODE DESCRIPTION
- •SYSTEM TESTS
- •OBTAINING FAULT CODES
- •STATE DISPLAY TEST MODE
- •STATE DISPLAY INPUTS AND OUTPUTS
- •STATE DISPLAY SENSORS
- •CIRCUIT ACTUATION TEST MODE
- •OBTAINING CIRCUIT ACTUATION TEST
- •THROTTLE BODY MINIMUM AIR FLOW CHECK PROCEDURE
- •IDLE SPECIFICATIONS
- •IGNITION TIMING PROCEDURE
- •THROTTLE BODY SERVICE
- •THROTTLE BODY
- •FUEL SYSTEM PRESSURE RELEASE PROCEDURE
- •THROTTLE POSITION SENSOR
- •REMOVAL
- •INSTALLATION
- •AUTOMATIC IDLE SPEED (AIS) MOTOR
- •REMOVAL
- •INSTALLATION
- •FUEL INJECTOR RAIL ASSEMBLY
- •REMOVAL
- •INSTALLATION
- •FUEL PRESSURE REGULATOR SERVICE
- •REMOVAL
- •INSTALLATION
- •FUEL INJECTORS
- •REMOVAL
- •INSTALLATION
- •MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR
- •CANISTER PURGE SOLENOID SERVICE
- •ENGINE CONTROLLER
- •HEATED OXYGEN SENSOR (O2 SENSOR)
- •GENERAL INFORMATION
- •SYSTEM DIAGNOSIS
- •ENGINE CONTROLLER
- •MODES OF OPERATION
- •THROTTLE BODY
- •FUEL SUPPLY CIRCUIT
- •FUEL INJECTORS AND FUEL RAIL ASSEMBLY
- •FUEL PRESSURE REGULATOR
- •FUEL SYSTEM DIAGRAM
- •VISUAL INSPECTION
- •ON BOARD DIAGNOSTICS
- •MONITORED CIRCUITS
- •HIGH AND LOW LIMITS
- •FAULT CODE DESCRIPTION
- •SYSTEM TESTS
- •OBTAINING FAULT CODES
- •STATE DISPLAY TEST MODE
- •STATE DISPLAY INPUTS AND OUTPUTS
- •STATE DISPLAY SENSORS
- •CIRCUIT ACTUATION TEST MODE
- •OBTAINING CIRCUIT ACTUATION TEST
- •THROTTLE BODY MINIMUM AIR FLOW CHECK PROCEDURE
- •IDLE SPECIFICATIONS
- •FAULT CODE DESCRIPTION
- •THROTTLE BODY REMOVAL
- •THROTTLE BODY
- •FUEL SYSTEM PRESSURE RELEASE PROCEDURE
- •THROTTLE POSITION SENSOR
- •REMOVAL
- •INSTALLATION
- •AUTOMATIC IDLE SPEED (AIS) MOTOR
- •REMOVAL
- •INSTALLATION
- •FUEL INJECTOR RAIL ASSEMBLY
- •REMOVAL
- •INSTALLATION
- •FUEL PRESSURE REGULATOR
- •REMOVAL
- •INSTALLATION
- •FUEL INJECTOR
- •REMOVAL
- •INSTALLATION
- •MANIFOLD ABSOLUTE PRESSURE (MAP) SENSOR
- •CANISTER PURGE SOLENOID SERVICE
- •ENGINE CONTROLLER SERVICE
- •CRANKSHAFT TIMING SENSOR
- •REMOVAL
- •INSTALLATION
- •CAMSHAFT SENSOR SERVICE
- •REMOVAL
- •INSTALLATION
- •HEATED OXYGEN SENSOR (O2 SENSOR) SERVICE
- •SPECIFICATIONS
- •TEMPERATURE SENSOR SPECIFICATIONS
- •TORQUE

14 - 86 FUEL SYSTEMS
Once the ASD and fuel pump relays have been energized, the engine controller:
²Determines injector pulse width based on coolant temperature, manifold absolute pressure (MAP) and the number of engine revolutions since cranking was initiated.
²Monitors the coolant temperature sensor, camshaft sensor, crankshaft sensor, MAP sensor, and throttle position sensor to determine correct ignition timing.
ENGINE WARM-UP MODE
This is a OPEN LOOP mode. The following inputs are received by the engine controller:
²coolant temperature
²detonation sensor
²manifold absolute pressure (MAP)
²engine speed (crankshaft sensor)
²throttle position
²A/C switch
²battery voltage
The engine controller provides a ground path for the injectors to precisely control injector pulse width (by switching the ground on and off). The engine controller adjusts engine idle speed through the automatic idle speed motor. Also, the controller regulates ignition timing.
CRUISE OR IDLE MODE
When the engine is at operating temperature, this is a CLOSED LOOP mode. During cruising speed the following inputs are received by the engine controller:
²coolant temperature
²detonation sensor
²manifold absolute pressure
²engine speed (crankshaft sensor)
²throttle position
²exhaust gas oxygen content
²A/C control positions
²battery voltage
The engine controller provides a ground path for the injectors to precisely control injector pulse width. The engine controller adjusts engine idle speed and ignition timing. The engine controller controls the air/fuel ratio according to the oxygen content in the exhaust gas.
ACCELERATION MODE
This is a CLOSED LOOP mode. The engine controller recognizes an abrupt increase in throttle position or MAP pressure as a demand for increased engine output and vehicle acceleration. The engine controller increases injector pulse width in response to increased fuel demand.
Ä
DECELERATION MODE
This is a CLOSED LOOP mode. During deceleration the following inputs are received by the engine controller:
²coolant temperature
²detonation sensor
²manifold absolute pressure
²engine speed (crankshaft sensor)
²throttle position
²exhaust gas oxygen content
²A/C control positions
²battery voltage
The engine controller may receive a closed throttle input from the throttle position sensor (TPS) at the same time it senses an abrupt decrease in manifold pressure. This indicates a hard deceleration. The engine controller modifies the injector sequence. This helps maintain better control of the air-fuel mixture.
WIDE OPEN THROTTLE MODE
This is an OPEN LOOP mode. During wide-open- throttle operation, the following inputs are received by the engine controller:
²coolant temperature
²detonation sensor
²manifold absolute pressure
²engine speed (crankshaft sensor)
²throttle position
When the engine controller senses a wide open throttle condition it will de-energize the air conditioning relay. This disables the air conditioning system.
The exhaust gas oxygen content input is not accepted by the engine controller during wide open throttle operation. The engine controller will enrichen the air/fuel ratio to increase performance and compensate for increased combustion chamber temperature.
IGNITION SWITCH OFF MODE
This is an OPEN LOOP mode. When the ignition switch is turned to the OFF position, the following occurs:
²All outputs are turned off.
²No inputs are monitored.
²The engine controller shuts down.
THROTTLE BODY
The throttle body assembly is located on the left end of the intake manifold plenum (Fig. 21). The throttle body houses the throttle position sensor and the automatic idle speed motor. Air flow through the throttle body is controlled by a cable operated throttle blade located in the base of the throttle body.
FUEL SUPPLY CIRCUIT
Fuel is pumped to the fuel rail by an electrical pump in the fuel tank. The pump inlet is fitted with

Ä |
|
FUEL SYSTEMS 14 - 87 |
|
Fig. 21 Throttle Body
a strainer to prevent water and other contaminants from entering the fuel supply circuit.
Fuel pressure is controlled to a preset level above intake manifold pressure by a pressure regulator. The regulator is mounted on the fuel rail (Fig. 22). The regulator uses intake manifold pressure as a reference.
FUEL PRESSURE REGULATOR
The pressure regulator is a mechanical device located on the fuel rail, downstream of the fuel injectors (Fig. 23). The regulator maintains a constant 380 kPa (55 psi) across the fuel injector tip.
The regulator contains a spring loaded rubber diaphragm that covers the fuel return port. When the fuel pump is operating, fuel flows past the injectors into the regulator, and is restricted from flowing any further by the blocked return port. When fuel pressure reaches 380 kPa (55 psi) it pushes on the diaphragm, compresses the spring, and uncovers the fuel return port. The diaphragm and spring constantly move from an open to closed position to keep the fuel pressure constant.
Fig. 22 Fuel Supply Circuit
FUEL INJECTORS AND FUEL RAIL ASSEMBLY
Four fuel injectors are retained in the fuel rail by lock rings. The rail and injector assembly are installed with the injectors inserted into recessed holes in the intake manifold.
Fig. 23 Fuel Pressure Regulator

14 - 88 FUEL SYSTEMS |
|
|
|
|
Ä |
|
|
|
|
||
2.2L TURBO III MULTI-POINT FUEL INJECTIONÐGENERAL DIAGNOSIS |
|
|
|||
|
|
INDEX |
|
|
|
|
|
page |
|
page |
|
60-Way Engine Controller Wiring Connector |
. . . . . 97 |
State Display Test Mode . . . . . . . . . . . . . . . . . . |
. . 96 |
||
Circuit Actuation Test Mode . . . . . . . . . . . . |
. . . . . 97 |
System Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . |
. 96 |
||
Fault Code Description . . . . . . . . . . . . . . . . . |
. . . . 93 |
Throttle Body Minimum Air Flow Check Procedure |
. . 97 |
||
Fuel System Diagram . . . . . . . . . . . . . . . . . . |
. . . . 88 |
Visual Inspection . . . . . . . . . . . . . . . . . . . . . . . . |
. 88 |
||
On Board Diagnostics . . . . . . . . . . . . . . . . . |
. . . . 91 |
|
|
|
FUEL SYSTEM DIAGRAM
Refer to the System Operation portion of this section for descriptions of the components shown in Fig. 1.
VISUAL INSPECTION
Perform a visual inspection for loose, disconnected, or misrouted wires and hoses before diagnosing or servicing the fuel injection system. A visual check helps save unnecessary test and diagnostic time. A thorough visual inspection includes the following checks:
(1)Check the ignition coil electrical connections (Fig. 2).
(2)Verify the harness connector is attached to the canister purge solenoid (Fig. 3).
(3) Verify the harness connector is attached to the |
Fig. 2 Ignition Coil Electrical Connection |
wastegate solenoid (Figs. 3). |
|
Fig. 1 Multi-point Fuel Injection Components

Ä |
|
FUEL SYSTEMS 14 - 89 |
|
(8) Check ignition cable routing and attachment (Fig. 6).
Fig. 3 Solenoid Connections
(4) Verify the harness connector is attached to the MAP sensor (Fig. 4).
Fig. 4 Baro/MAP Solenoid Hose Connections
(5)Check vacuum hose connections between vacuum source and canister purge, wastegate, and barometric read solenoids (Figs. 3 and 4).
(6)Verify hoses are securely attached to vapor canister (Fig. 5).
Fig. 5 Vapor Canister
(7) Verify the alternator wiring and belt are correctly installed and tightened.
Fig. 6 Ignition Cable Mounting and Attachment
(9) Check oil pressure sending unit electrical connection (Fig. 7).
Fig. 7 Oil Pressure Sending Unit and Crankshaft
Sensor Electrical Connections
(10)Check the camshaft and crankshaft sensor electrical connections (Figs. 7 and 8).
(11)Check radiator fan electrical connector.
(12)Check electrical connector at the coolant temperature sensor (Fig. 9).
(13)Inspect the engine temperature sensor electrical connection (Fig. 9).
(14)Check the power brake booster and speed control connections (Fig. 10).
(15)Inspect the engine and fuel injector harness to main harness electrical connections.

14 - 90 FUEL SYSTEMS |
|
Ä |
|
Fig. 8 Camshaft Electrical Connection
Fig. 9 Coolant Temperature and Engine Temperature
Sensor
Fig. 10 Power Brake Booster and Speed Control
Vacuum Hose Connections
(16) Verify that all electrical connectors are fully inserted into relays and that battery connections are clean and tight (Fig. 11 or Fig. 12).
Fig. 11 Engine Compartment Relay Identification AA
Body
Fig. 12 Power Distribution Center AG Body
(17)Check the 60-way electrical connection at the engine controller for damage or spread terminals. Verify that the 60-way connector is fully inserted into the socket on the engine controller (Fig. 13). Ensure that wires are not stretched or pulled out of the connector.
(18)Verify the harness connector is attached to AIS motor. (Fig. 14).
(19)Verify the harness connector is attached to the throttle position sensor. (Fig. 14).
(20)Inspect the hose connections at throttle body (Fig. 14).
(21)Verify all hose connections at the intake manifold are secure (Fig. 15).