1993 CHEVROLET DYNASTY fuel cap release

2.5L FLEXIBLE FUEL MULTI-PORT FUEL INJECTIONÐSERVICE PROCEDURES INDEX
page page
Fuel Injector ............................. 80
Fuel Injector Rail Assembly ................. 79
Fuel Pressure Regulator .................... 81
Fuel System Pressure Release Procedure ...... 78
General Information ....................... 77
Heated Oxygen Sensor (O
2Sensor) ........... 82
Identifying Flexible Fuel Components .......... 77
Idle Air Control Motor ...................... 78 Manifold Absolute Pressure (MAP) Sensor
Service ............................... 82
Methanol Concentration Sensor .............. 82
PCM Service ............................ 82
Service Precautions for Flexible Fuel Vehicles .... 77
Throttle Body ............................ 77
Throttle Body Removal ..................... 79
Throttle Position Sensor (TPS) ............... 78
GENERAL INFORMATION
In this model year Chrysler began producing AA-
Body vehicles designed to operate on a mixture of
gasoline and methanol. These automobiles are referred
to as Flexible Fuel vehicles. Fuel system components
designed for use in flexible fuel vehicles are referred to
as Methanol Compatible. Flexible fuel vehicles can operate on a mixture of up
to 85 percent methanol, 15 percent unleaded gasoline.
These vehicles also operate on mixtures containing a
lower percentage of methanol or just pure unleaded
gasoline.
SERVICE PRECAUTIONS FOR FLEXIBLE FUEL
VEHICLES
Methanol is more toxic than gasoline. Always release
fuel system pressure before servicing fuel system com-
ponents and wear methanol resistant gloves and eye
protection. Avoid breathing methanol vapors or ingesting
methanol. Headaches, dizziness and even unconscious-
ness could result from breathing these vapors. Serious
injury, blindness and even death could result from
ingesting methanol. Methanol vapors are extremely flammable and can
travel along the ground. Service vehicles in well ven-
tilated areas and avoid ignition sources. Never smoke
while servicing the vehicle. Do not allow methanol to contact skin. Prolonged
contact with methanol can cause dry skin or an allergic
skin reaction. Also, prolonged contact could result in
absorption through the skin.
IDENTIFYING FLEXIBLE FUEL COMPONENTS
Flexible Fuel vehicles have unique methanol compat-
ible fuel system components. Chrysler identifies methanol
compatible components that could be physically inter-
changed with gasoline only parts by coloring them green
or applying a green label or tag to them. Even though
they may appear physically identical, components
for gasoline only AA-body vehicles must not be used
on flexible fuel vehicles.
FLEXIBLE FUEL COMPONENTS
The fuel system of flexible fuel AA-body vehicles have
the following unique methanol compatible components.
² Duty cycle EVAP purge solenoid
² EVAP canister
² Fuel pump module
² Fuel level sensor
² Fuel gauge (gauge cluster).
² Fuel tank
² Fuel pressure regulator (including O-rings)
² Fuel rail
² Fuel injectors (including O-rings)
² Fuel tubes
² Fuel filter
² Fuel filler cap
² Fuel filler tube
² Methanol concentration sensor
² Pressure relief/rollover valve
² PCV Valve
² All fuel system and emission system hoses and tubes
THROTTLE BODY
WARNING: THROTTLE BODIES DESIGNED FOR
GASOLINE ONLY VEHICLES CANNOT BE USED ON
FLEXIBLE FUEL AA-BODY VEHICLES. WHEN RE-
PLACING THE THROTTLE BODY OF A FLEXIBLE
FUEL VEHICLE, ONLY USE AN ORIGINAL EQUIP-
MENT REPLACEMENT.
When servicing throttle body components, always
reassemble components with new O-rings and seals
where applicable. Never use lubricants on O-rings or
seals, damage may result. If assembly of component is
difficult, use water to aid assembly. Use care when
removing hoses to prevent damage to hose or hose
nipple.
Ä FUEL SYSTEMS 14 - 77

FUEL SYSTEM PRESSURE RELEASE PROCEDURE
WARNING: RELEASE FUEL SYSTEM PRESSURE
BEFORE SERVICING FUEL SYSTEM COMPONENTS.
WHEN SERVICING FLEXIBLE FUEL VEHICLES,
WEAR METHANOL RESISTANT GLOVES AND EYE
PROTECTION AND AVOID BREATHING FUMES. DO
NOT ALLOW METHANOL/GASOLINE MIXTURES TO
CONTACT SKIN. SERVICE VEHICLES IN WELL VEN-
TILATED AREAS AND AVOID IGNITION SOURCES.
NEVER SMOKE WHILE SERVICING THE VEHICLE.
(1) Disconnect negative cable from battery.
(2) Remove fuel filler cap.
(3) Remove the protective cap from the fuel pres-
sure test port on the fuel rail (Fig. 2).
(4) Place the open end of fuel pressure release
hose, tool number C-4799-1, into a container ap-
proved for methanol/gasoline mixtures. Connect the
other end of hose C-4799-1 to the fuel pressure test
port (Fig. 3). Fuel pressure will bleed off through the
hose into the gasoline container. Fuel gauge
C-4799-A contains hose C-4799-1.
THROTTLE POSITION SENSOR (TPS)
REMOVAL
(1) Disconnect the negative cable from the battery.
(2) Disconnect harness connector from throttle po-
sition sensor (Fig. 4). (3) Remove throttle position sensor mounting
screws. (4) Lift throttle position sensor off throttle shaft.
INSTALLATION
(1) Install throttle position sensor on throttle shaft.
Install mounting screws. Tighten screws to 2 N Im (17
in. lbs.) torque. (2) Attach harness connector to sensor.
(3) Connect negative cable to negative post of the
battery.
IDLE AIR CONTROL MOTOR
REMOVAL
(1) Disconnect negative cable from battery.
(2) Disconnect harness connector from idle air con-
trol motor (Fig. 5).
Fig. 1 Throttle Body
Fig. 2 Fuel Pressure Test Port
Fig. 3 Releasing Fuel Pressure
Fig. 4 Servicing Throttle Position Sensor
14 - 78 FUEL SYSTEMS Ä

(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 23 N Im (200 in. lbs) torque.
(6) Connect vacuum hose to fuel pressure regulator.
(7) Close fuel tube clip around fuel tubes and install
fastener. (8) Lubricate the ends of the chassis fuel tubes with
a light coating of clean 30 weight engine oil. Connect
fuel supply and return hoses to chassis fuel tube
assembly. Pull back on the quick connect fittings to
ensure complete insertion. Refer to Quick Connect
Fittings in the Fuel Delivery section of this group. (9) Connect vacuum hose intake manifold nipple.
(10) Connect negative cable to battery.
CAUTION: When using the ASD Fuel System Test, the
Auto Shutdown (ASD) Relay remains energized for
either 7 minutes, until the test is stopped, or until the
ignition switch is turned to the Off position.
(11) With the DRBII scan tool, use the ASD Fuel
System Test to pressurize system and check for leaks.
FUEL INJECTOR
The fuel rail must be removed to service the injec-
tors. Refer to Fuel Injector Rail Assembly in this
section.
REMOVAL
WARNING: RELEASE FUEL SYSTEM PRESSURE BE-
FORE SERVICING FUEL SYSTEM COMPONENTS.
WHEN SERVICING FLEXIBLE FUEL VEHICLES,
WEAR METHANOL RESISTANT GLOVES AND EYE
PROTECTION AND AVOID BREATHING FUMES. DO NOT ALLOW METHANOL/GASOLINE MIXTURES TO
CONTACT SKIN. SERVICE VEHICLES IN WELL VEN-
TILATED AREAS AND AVOID IGNITION SOURCES.
NEVER SMOKE WHILE SERVICING THE VEHICLE.
(1) Disconnect electrical connector from injector
(Fig. 8).
(2) Position fuel rail assembly so that the fuel injec-
tors are easily accessible (Fig. 9). (3) Remove injector lock ring from fuel rail and
injector. Pull injector straight out of fuel rail receiver
cup. (4) Check injector O-ring for damage. Replace dam-
aged O-rings. If injector is reused, install a protective
cap on the injector tip to prevent damage. (5) Repeat steps for remaining injectors.
INSTALLATION
WARNING: FUEL INJECTORS AND INJECTOR
O-RINGS DESIGNED FOR GASOLINE ONLY VE-
HICLES CANNOT BE USED ON FLEXIBLE FUEL AA-
BODY VEHICLES. WHEN SERVICING THE FUEL SYS-
TEM OF A FLEXIBLE FUEL VEHICLE, ONLY USE
ORIGINAL EQUIPMENT OR EQUIVALENT REPLACE-
MENT COMPONENTS.
Fig. 7 Fuel Injector Ports
Fig. 8 Servicing Fuel Injectors
14 - 80 FUEL SYSTEMS Ä

2.2L TURBO III MULTI-PORT FUEL INJECTIONÐSERVICE PROCEDURES INDEX
page page
Fuel Injector Rail Assembly ................ 109
Fuel Injectors .......................... 110
Fuel Pressure Regulator .................. 111
Fuel System Pressure Release Procedure ..... 107
Heated Oxygen Sensor (O
2Sensor) ......... 112
Idle Air Control Motor .................... 108
Manifold Absolute Pressure (MAP) Sensor Service .............................. 111 PCM Service
........................... 111
Throttle Body ........................... 107
Throttle Body Removal ................... 108
Throttle Position Sensor (TPS) ............. 107
Wastegate and Canister Purge Solenoid Service . 111
THROTTLE BODY
When servicing throttle body components, always
reassemble components with new O-rings and seals
where applicable (Fig. 1). Never use lubricants on
O-rings or seals, damage may result. If assembly of
component is difficult, use water to aid assembly.
Use care when removing hoses to prevent damage to
hose or hose nipple.
FUEL SYSTEM PRESSURE RELEASE PROCEDURE
CAUTION: The fuel system is under a constant
pressure of approximately 380 kPa (55 psi). Before
servicing the fuel pump, fuel lines, fuel filter, throt-
tle body, or fuel injectors, the fuel system pressure
must be released.
(1) Disconnect negative cable from battery.
(2) Remove fuel filler cap. (3) Remove the protective cap from the fuel pres-
sure test port on the fuel rail (Fig. 2). (4) Place the open end of fuel pressure release
hose, tool number C-4799-1, into an approved gaso-
line container. Connect the other end of hose
C-4799-1 to the fuel pressure test port. Fuel pressure
will bleed off through the hose into the gasoline con-
tainer. Fuel gauge C-4799-A contains hose C-4799-1. (5) Continue fuel system service.THROTTLE POSITION SENSOR (TPS)
REMOVAL
(1) Disconnect the negative cable from the battery.
(2) Disconnect harness connector from throttle po-
sition sensor (Fig. 3). (3) Remove throttle position sensor mounting
screws. (4) Lift throttle position sensor off throttle shaft.
Fig. 1 Throttle Body
Ä FUEL SYSTEMS 14 - 107

3.0L MULTI-PORT FUEL INJECTIONÐSERVICE PROCEDURES INDEX
page page
Idle Air Control Motor .................... 138
Canister Purge Solenoid Service ............ 143
Fuel Injector Rail Assembly ................ 139
Fuel Injectors .......................... 142
Fuel Pressure Regulator Service ............ 141
Fuel System Pressure Release Procedure ..... 138 Heated Oxygen Sensor (O
2Sensor)
......... 144
Manifold Absolute Pressure (MAP) Sensor ..... 143
PCM ................................. 143
Throttle Body ........................... 138
Throttle Body Service .................... 138
Throttle Position Sensor .................. 138
THROTTLE BODY SERVICE
(1) Disconnect negative battery cable.
(2) Remove air cleaner hose clamp to throttle body
and remove hose. (Fig. 1) (3) Remove throttle cable and transaxle linkage.
(4) Disconnect idle air control motor and throttle
position sensor (TPS) wiring connectors. (5) Disconnect vacuum hoses from throttle body.
(6) Remove throttle body to intake manifold attach-
ing nuts. Remove engine harness wiring bracket. (7) Remove throttle body and gasket.
(8) Reverse the above procedures for installation.
Tighten throttle body mounting nuts to 25 N Im (225
in. lbs.) torque.
THROTTLE BODY
When servicing body components, always assemble
components with new O-rings and seals where appli-
cable (Fig. 2). Never use lubricants on O-rings or seals,
damage may result. If assembly of component is diffi-
cult, use water to aid assembly. Use care when remov-
ing hoses to prevent damage to hose or hose nipple.
FUEL SYSTEM PRESSURE RELEASE PROCEDURE
The 3.0L MPI fuel system is under a constant
pressure of approximately 330 kPa (48 psi). Be-
fore servicing the fuel pump, fuel lines, fuel fil- ter, throttle body or fuel injectors, the fuel sys-
tem pressure must be released. (1) Loosen fuel filler cap to release fuel tank pres-
sure. (2) Disconnect injector wiring harness from engine
harness. Refer to Group 8W, Wiring Diagrams. (3) Connect one end of a jumper wire to the A142
circuit terminal of the fuel rail harness connector. (4) Connect the other end of the jumper wire to a 12
volt power source. (5) Connect one end of a jumper wire to a good
ground source. (6) Momentarily ground one of the injectors by con-
necting the other end of the jumper wire to an injector
terminal in the harness connector. Repeat procedure
for 2 to 3 injectors. (7) Continue fuel system service.
THROTTLE POSITION SENSOR
REMOVAL
(1) Disconnect negative cable from battery.
(2) Remove electrical connector from throttle posi-
tion sensor. (3) Remove throttle position sensor mounting screws
(Fig. 3). (4) Lift throttle position sensor off throttle shaft.
INSTALLATION
(1) Install throttle position sensor on throttle shaft.
Install mounting screws. Tighten screw to 2 N Im (17
in. lbs.) torque. (2) Connect electrical connector to throttle position
sensor. (3) Connect negative cable to battery.
IDLE AIR CONTROL MOTOR
REMOVAL
(1) Disconnect negative cable from battery.
(2) Remove electrical connector from idle air control
motor. (3) Remove idle air control motor mounting screws
(Fig. 4).
Fig. 1 Throttle Body
14 - 138 FUEL SYSTEMS Ä

3.3L AND 3.8L MULTI-PORT FUEL INJECTIONÐSERVICE PROCEDURES INDEX
page page
Camshaft Position Sensor Service ........... 176
Crankshaft Position Sensor ................ 176
EVAP Canister Purge Solenoid Service ....... 175
Fuel Injector ........................... 174
Fuel Injector Rail Assembly ................ 170
Fuel Pressure Regulator .................. 173
Fuel System Pressure Release Procedure ..... 169 Heated Oxygen Sensor (O
2Sensor) Service . . . 177
Idle Air Control Motor .................... 170
Manifold Absolute Pressure (MAP) Sensor ..... 175
PCM Service ........................... 175
Throttle Body ........................... 169
Throttle Body Removal ................... 169
Throttle Position Sensor .................. 169
THROTTLE BODY REMOVAL
(1) Disconnect negative battery cable.
(2) Remove the air cleaner to throttle body hose
clamp. Remove the nut holding the air cleaner as-
sembly to the air cleaner bracket. Remove the air
cleaner (Fig. 1). (3) Remove throttle and the speed control cables.
(4) Disconnect electrical connectors from the idle
air control motor and throttle position sensor (TPS). (5) Disconnect vacuum hoses from throttle body.
(6) Remove throttle body to intake manifold at-
taching nuts. (7) Remove throttle body and gasket.
(8) Reverse the above procedure for installation.
THROTTLE BODY
When servicing throttle body components, always
reassemble components with new O-rings and seals
where applicable (Fig. 2). Never use lubricants on
O-rings or seals, damage may result. If assembly of component is difficult, use water to aid assembly.
Use care when removing hoses to prevent damage to
hose or hose nipple.
FUEL SYSTEM PRESSURE RELEASE PROCEDURE
WARNING: THE 3.3L AND 3.8L MPI FUEL SYSTEMS
ARE UNDER A CONSTANT PRESSURE OF AP-
PROXIMATELY 330 KPA (48 PSI). RELEASE FUEL
SYSTEM PRESSURE BEFORE SERVICING THE
FUEL PUMP, FUEL LINES, FUEL FILTER, THROT-
TLE BODY OR FUEL INJECTORS.
(1) Disconnect negative cable from battery.
(2) Remove fuel filler cap.
(3) Remove the protective cap from the fuel pres-
sure test port on the fuel rail (Fig. 3). (4) Place the open end of fuel pressure release
hose, tool number C-4799-1, into an approved gaso-
line container. Connect the other end of hose
C-4799-1 to the fuel pressure test port. Fuel pressure
will bleed off through the hose into the gasoline con-
tainer. Fuel gauge C-4799-A contains hose C-4799-1. (5) Continue fuel system service.
THROTTLE POSITION SENSOR
REMOVAL
(1) Disconnect negative cable from battery.
(2) Remove electrical connector from throttle posi-
tion sensor. (3) Remove throttle position sensor mounting
screws (Fig. 4). (4) Lift throttle position sensor off throttle shaft.
INSTALLATION
(1) Install throttle position sensor on throttle shaft.
Install mounting screws. Tighten screw to 2 N Im (17
in. lbs.) torque. (2) Connect electrical connector to throttle position
sensor. (3) Connect negative cable to battery.Fig. 1 Throttle Body Assembly
Ä FUEL SYSTEMS 14 - 169