1993 CHEVROLET DYNASTY battery replacement

(5) Reset the terminal locking tang, if it has one.
(6) Insert the removed wire in the same cavity on
the repair connector. (7) Repeat steps four thru six for each wire in the
connector. Check that all wires are inserted into the
proper cavities. For connector pin out identification
refer to the wiring diagrams. (8) Insert the connector locking wedge into the re-
paired connector. (9) Connect connector to its mating half.
(10) Connect battery and test all affected systems.
CONNECTOR AND TERMINAL ASSEMBLY REPLACEMENT
(1) Disconnect Battery.
(2) Disconnect the connector being repaired form
its mating half. (3) Cut off the existing wire connector directly be-
hind the insulator. Remove six inches of tape from
the harness. (4) Stagger cut all wires on the harness side about
1/2 inch apart (Fig. 14). (5) Remove 1 inch of insulation from each wire on
the harness side. (6) Stagger cut the matching wires on the repair
connector assembly in the opposite order as was done
on the harness side of the repair. Allow extra length
for soldered connections. Check that the overall
length is the same as the original (Fig. 14). (7) Remove 1 inch of insulation from each wire.
(8) Place a piece of heat shrink tubing over one
side of the wire. Make sure the tubing will be long
enough to cover and seal the entire repair area. (9) Spread the strands of the wire apart on each
part of the exposed wires (Fig. 11 example 1). (10) Push the two ends of wire together until the
strands of wire are close to the insulation (Fig. 11 ex-
ample 2). (11) Twist the wires together (Fig. 11 example 3). (12) Solder the connection together using rosin
core type solder only. Do not use acid core solder.
(13) Center the heat shrink tubing over the joint
and heat using a heat gun. Heat the joint until the
tubing is tightly sealed and sealant comes out of both
ends of the tubing. (14) Repeat steps 8 thru 13 for each wire.
(15) Re-tape the wire harness starting 1-1/2 inches
behind the connector and 2 inches past the repair. (16) Reconnect the repaired connector.
(17) Connect battery and test all affected systems.
TERMINAL REPLACEMENT
(1) Disconnect battery.
(2) Disconnect the connector being repaired form
its mating half. (3) Remove connector locking wedge (Fig. 12).
(4) Position the connector locking finger away from
the terminal. Pull on the wire to remove the termi-
nal from the connector (Fig. 13). (5) Cut the wire 6 inches from the back of the con-
nector. (6) Remove 1 inch of insulation from the wire on
the harness side. (7) Select a wire from the terminal repair assem-
bly that best matches the color wire being repaired. (8) Cut the repair wire to the proper length and re-
move 1 inch of insulation. (9) Place a piece of heat shrink tubing over one
side of the wire. Make sure the tubing will be long
enough to cover and seal the entire repair area. (10) Spread the strands of the wire apart on each
part of the exposed wires (Fig. 11 example 1). (11) Push the two ends of wire together until the
strands of wire are close to the insulation (Fig. 11 ex-
ample 2). (12) Twist the wires together (Fig. 11 example 3).
(13) Solder the connection together using rosin
core type solder only. Do not use acid core solder.
Fig. 13 Connector Locking Finger and Locking
Wedge
Fig. 14 Stagger Cutting Wires
8W - 6 GENERAL INFORMATION Ä

² Drive shaft distress: See Driveshafts in Suspension,
Group 2.
² Any front end structural damage (after repair).
² Insulator replacement.
ENGINE MOUNT INSULATOR ADJUSTMENT
(1) Remove the load on the engine motor mounts by
carefully supporting the engine and transmission as-
sembly with a floor jack. (2) Loosen the right engine mount insulator vertical
fasteners, and the front engine mount bracket to front
crossmember screws and nuts. Left engine mount insulator is sleeved over
shaft and long support bolt to provide lateral
movement adjustment with engine weight re-
moved or not. (3) Pry the engine right or left as required to achieve
the proper drive shaft assembly length. See Drive
Shaft in Suspension Group 2 for driveshaft identifica-
tion and related assembly length measuring. (4) Tighten right engine mount insulator vertical
bolts to 68 N Im (50 ft. lbs.). Then tighten front engine
mount screws and nuts to 54 N Im (40 ft. lbs.) and
center left engine mount insulator. (5) Recheck drive shaft length.
ENGINE ASSEMBLY
REMOVAL
(1) Disconnect battery.
(2) Scribe hood hinge outline on hood and remove
hood. (3) Drain cooling system.
(4) Remove hoses from radiator and engine.
(5) Remove radiator and fan assembly.
(6) Remove air cleaner and hoses.
(7) Remove air conditioning compressor mounting
bolts and set compressor aside, if equipped. (8) Remove power steering pump mounting bolts
and set pump aside (9) Remove oil filter.
(10) Disconnect fuel line, heater hose and acceler-
ator cable. (11) Disconnect all electrical connections and har-
nesses at throttle body and engine. (12) Manual Transmission
(a) Disconnect clutch cable.
(b) Remove transmission case lower cover.
(c) Disconnect exhaust pipe at manifold.
(d) Disconnect starter and lay aside.
(e) Install transmission holding fixture.
(13) Automatic Transmission
(a) Disconnect exhaust pipe at manifold.
(b) Disconnect starter and lay aside.
(c) Remove transmission case lower cover.
(d) Mark flex plate to torque converter.
(e) Remove screws holding torque converter to
flex plate.
(14) Attach C clamp on front bottom of torque con-
verter housing to prevent torque converter from com-
ing out. (15) Install transmission holding fixture.
(16) Remove right inner splash shield (Fig. 5).
(17) Remove ground strap.
(18) To lowerengine separate right engine
bracket from yoke bracket To raiseengine remove
long bolt through yoke and insulator. IF INSULA-
TOR TO RAIL SCREWS ARE TO BE REMOVED,
MARK INSULATOR POSITION ON SIDE RAIL TO
INSURE EXACT INSTALLATION (Fig. 4). (19) Remove transmission case to cylinder block
mounting screws.Fig. 5 Right Inner Splash Shield
Fig. 4 Left Insulator Movement
Ä 2.2/2.5L ENGINE 9 - 13

LEFT SIDE MOUNT
(1) Raise vehicle on hoist and remove left front
wheel. (2) Remove inter splash shield.
(3) Support the transmission with a transmission
jack. (4) Remove the insulator thru bolt from the mount.
(5) Remove the transmission mount fasteners and
remove mount. (6) Reverse removal procedure for installation. En-
sure that the slide tube is seated into the rail
bracket guides. Refer to (Fig. 3) for bolt tightening
specifications. (7) Engine mount adjustment, Refer to Engine
Mount Insulator Adjustment of this section.
ENGINE MOUNT RUBBER INSULATORS
Insulator location on (right side) and transmission
bracket (left side) are adjustable to allow right/left
drive train adjustment in relation to drive shaft as-
sembly length. Check and reposition right engine mount insulator
(left engine mount insulator is floating type and will
adjust automatically (Fig. 3). Adjust drive train posi-
tion, if required, for the following conditions:
² Drive shaft distress: See Driveshafts in Suspen-
sion, Group 2.
² Any front end structural damage (after repair).
² Insulator replacement.
ENGINE MOUNT INSULATOR ADJUSTMENT
(1) Remove the load on the engine motor mounts
by carefully supporting the engine and transmission
assembly with a floor jack. (2) Loosen the right engine mount insulator yoke
screw and two turns on yoke nut, then loosen the
front engine mount bracket to front crossmember
screws and nuts. Left engine mount insulator is sleeved over
shaft and long support bolt to provide lateral
movement adjustment with engine weight re-
moved or not. (3) Pry the engine right or left as required to
achieve the proper drive shaft assembly length. See
Drive Shaft in Suspension Group 2 for driveshaft
identification and related assembly length measur-
ing. (4) Tighten right engine mount insulator yoke nut
to 102 N Im (75 ft. lbs.). Then tighten front engine
mount screws and nuts to 54 N Im (40 ft. lbs.) and
center left engine mount insulator. (5) Recheck drive shaft length.
ENGINE ASSEMBLY
REMOVAL
(1) Disconnect battery.
(2) Mark hood position at hinges and remove hood. (3) Drain cooling system. Refer to Cooling System
Group 7 for draining procedure. (4) Disconnect all electrical connections.
(5) Remove coolant hoses from radiator and en-
gine. (6) Remove radiator and fan assembly.
(7) See Fuel System Group 14, For procedures to
release fuel pressure, disconnect fuel lines and accel-
erator cable. (8) Remove air cleaner assembly.
(9) Hoist vehicle and drain engine oil.
(10) Remove air conditioning compressor mounting
bolts and set compressor aside. (11) Disconnect exhaust pipe at manifold.
(12) Remove transmission inspection cover and
mark flex plate to torque converter position. (13) Remove screws holding torque converter to
flex plate and attach C-clamp on bottom of converter
housing to prevent torque converter from coming out. (14) Remove power steering pump mounting bolts
and set pump aside. (15) Remove two lower transmission to block
screws. (16) Remove starter.
(17) Lower vehicles and disconnect vacuum lines
and ground strap. (18) Install transmission holding fixture.
(19) Attach engine lifting hoist and support en-
gine. (20) Remove upper transmission case to block
bolts. (21) See Engine Mounting in (Fig. 2) and separate
mount/insulators as follows: (a) Mark RIGHT insulator on right yoke and en-
gine plate supports. Remove insulator to rails
screws. (b) Remove FRONT engine mount through bolt
and nut.
Fig. 3 Left Insulator Movement
Ä 3.0L ENGINE 9 - 69

(15) Install hood.
(16) Connect battery.
(17) Start engine and run until operating temper-
ature is reached. (18) Adjust transmission or linkage if necessary.
ROCKER ARMS AND SHAFT ASSEMBLY
REMOVAL
(1) Remove upper intake manifold assembly. Refer
to Intake and Exhaust Manifolds, Group 11. (2) Disconnect spark plug wires by pulling on the
boot straight out in line with plug. (3) Disconnect closed ventilation system and evap-
oration control system from cylinder head cover. (4) Remove cylinder head cover and gasket.
(5) Remove four rocker shaft bolts and retainers.
(6) Remove rocker arms and shaft assembly.
(7) If rocker arm assemblies are disassembled for
cleaning or replacement. Assemble rocker arms in
their original position.Refer to (Fig. 5) for rocker arm
for positioning on the shaft.
INSTALLATION
(1) Install rocker arm and shaft assemblies with
the stamped steel retainers in the four positions,
tighten to 28 N Im (250 in. lbs.) (Fig. 5).
WARNING: THE ROCKER ARM SHAFT
SHOULD BE TORQUED DOWN SLOWLY,
STARTING WITH THE CENTERMOST BOLTS.
ALLOW 20 MINUTES TAPPET BLEED DOWN
TIME AFTER INSTALLATION OF THE
ROCKER SHAFTS BEFORE ENGINE OPERA-
TION. (2) Clean cylinder head cover gasket surface. In-
spect cover for distortion and straighten if necessary. (3) Clean head rail if necessary. Install a new gas-
ket and tighten cylinder head cover fasteners to 12
N Im (105 in. lbs.).
(4) Install closed crankcase ventilation system and
evaporation control system. (5) Install spark plug wires.
(6) Install upper intake manifold assembly. Refer to
Exhaust Systems and Intake Manifolds Group 11.
CYLINDER HEADS
The alloy aluminum cylinder heads shown in (Fig. 6)
are held in place by 9 bolts. The spark plugs are located
in peak of the wedge between the valves.
REMOVAL
(1) Drain cooling system refer to Cooling System
Group 7 for procedure and disconnect negative battery
cable. Remove intake manifold, and throttle body. Refer to
Group 11 Exhaust System and Intake Manifold. (2) Disconnect coil wires, sending unit wire, heater
hoses and by-pass hose. (3) Remove closed ventilation system, evaporation
control system and cylinder head covers. (4) Remove exhaust manifolds.
(5) Remove rocker arm and shaft assemblies. Re-
move push rods and identify to insure installation
in original locations. (6) Remove the 9 head bolts from each cylinder head
and remove cylinder heads (Fig. 7).
Fig. 5 Rocker Arm Location Left Blank
Fig. 6 Cylinder Head Assembly
Fig. 7 Cylinder Head Bolts Location
9 - 102 3.3/3.8L ENGINE Ä

fuel tube enters the fitting, the retainer locks the shoul-
der of the nipple in place and the O-rings seal the tube.
CAUTION: Quick-connect fittings are not serviced
separately. Do not attempt to repair damaged quick-
connect fittings or fuel tubes. Replace the complete
fuel tube/quick-connect fitting assembly.
When installing fuel tubes, route them in the holders
along the frame rail, fuel tank and the rear of the en-
gine.
REMOVAL
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 the battery.
(2) Perform the Fuel Pressure Release Procedure.
Refer to the Fuel Pressure Release Procedure in this
section. (3) Remove any loose dirt from quick connect fit-
tings.
WARNING: WRAP SHOP TOWELS AROUND HOSES
TO CATCH ANY FUEL SPILLAGE.
(4) Push the quick connect fitting toward the fuel
tube while depressing the built-in release tool. Then
slightly twist the fitting and pull it off the fuel tube
(Fig. 14). (5) Cover the fitting to prevent contamination.
TUBE/FITTING SERVICE
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.
If a quick connect fitting needs service, the follow-
ing procedure must be followed: (1) Disconnect the battery negative battery cable.
(2) Perform the Fuel System Pressure Release Pro-
cedure.
WARNING: WRAP SHOP TOWELS AROUND HOSES
TO CATCH ANY FUEL SPILLAGE. (3) Remove the quick connect fitting from the fuel
tube by pushing in on the plastic ring located on the
end of the fitting. Gently pull the fitting from the
fuel tube. (4) Cut off the crimp ferrules at each end of the
hose, taking care not to damage the quick connect
fitting or the fuel tube. (5) Discard the ferrules and hose.
WARNING: FUEL SYSTEM HOSES AND TUBES DE-
SIGNED FOR GASOLINE ONLY VEHICLES CANNOT
BE USED ON FLEXIBLE FUEL VEHICLES. WHEN
SERVICING THE FUEL SYSTEM OF A FLEXIBLE
FUEL VEHICLE, ONLY USE ORIGINAL EQUIPMENT
OR EQUIVALENT REPLACEMENT COMPONENTS.
(6) Replace the hose using original equipment or
equivalent hose. (7) Attach the replacement hose to the quick con-
nect fitting and fuel tube using the correct hose
clamps (Fig. 15). Original equipment hose clamps
have a special rolled edge construction to prevent the
edge of the clamp cutting into the hose. Only original
equipment clamps or equivalent may be used in this
system. Other types of clamps may cut into the hoses
and cause high pressure fuel leaks. (8) Tighten hose clamps to 1 N Im (10 in. lbs.)
torque.
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 un-
til the ignition switch is turned to the Off position.
(9) Use the DRBII scan tool ASD Fuel System Test
to pressurize the fuel system. Check for leaks.
CHASSIS FUEL TUBES
Figures 16 and 17 show fuel system component lo-
cations and chassis fuel tube routings.
Fig. 15 Quick Connect Fuel Fittings
Ä FUEL SYSTEMS 14 - 11

WARNING: FUEL FILLER TUBE CAPS DESIGNED
FOR GASOLINE ONLY VEHICLES CANNOT BE
USED ON FLEXIBLE FUEL AA-BODY VEHICLES.
WHEN SERVICING THE FUEL SYSTEM OF A FLEX-
IBLE FUEL VEHICLE, ONLY USE ORIGINAL EQUIP-
MENT OR EQUIVALENT REPLACEMENT
COMPONENTS.
FUEL SYSTEM PRESSURE RELEASE
PROCEDUREÐEXCEPT 2.2L/2.5L TBI AND 3.0L
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. 1).
(4) Place the open end of fuel pressure release
hose, tool number C-4799-1, into an approved gaso- line container or a container approved for methanol/
gasoline mixtures. Connect the other end of hose
C-4799-1 to the fuel pressure test port (Fig. 2). Fuel
pressure will bleed off through the hose into the gas-
oline container. Fuel gauge C-4799-A contains hose
C-4799-1.
FUEL SYSTEM PRESSURE RELEASE
PROCEDUREÐ2.2L/2.5L TBI
CAUTION: Before servicing the fuel pump, fuel
lines, fuel filter, throttle body, or fuel injector, re-
lease fuel system pressure.
(1) Loosen fuel filler cap to release fuel tank pres-
sure. (2) Disconnect injector wiring harness connector at
edge of throttle body (Fig. 3). (3) Connect a jumper wire between terminal Num-
ber 1 of the injector harness and engine ground. (4) Connect a jumper wire to the positive terminal
Number 2 of the injector harness and touch the bat-
tery positive post for no longer than 5 seconds .
This releases system pressure. (5) Remove jumper wires.
(6) Continue fuel system service.
FUEL SYSTEM PRESSURE RELEASE
PROCEDUREÐ3.0L
(1) Disconnect the fuel rail electrical harness from
the engine harness. Refer to Group 8W, Wiring Dia-
grams. (2) Connect one end of a jumper wire to the A142
circuit terminal of the fuel rail harness connector. (3) Connect the other end of the jumper wire to a
12 volt power source. (4) Connect one end of a jumper wire to a good
ground source. (5) Momentarily ground one of the injectors by
connecting the other end of the jumper wire to an in-
FUEL TANK CAPACITIES
Fig. 1 Fuel Pressure Test PortÐTypical
Fig. 2 Releasing Fuel PressureÐEngines With Test Ports On Fuel Rail
Ä FUEL SYSTEMS 14 - 15

INSTALLATION
WARNING: FUEL TANKS DESIGNED FOR GASO-
LINE ONLY VEHICLES CANNOT BE USED ON
FLEXIBLE FUEL AA-BODY VEHICLES. WHEN SER-
VICING THE FUEL SYSTEM OF A FLEXIBLE FUEL
VEHICLE, ONLY USE ORIGINAL EQUIPMENT OR
EQUIVALENT REPLACEMENT COMPONENTS. (1) Position fuel tank on transmission jack. Con-
nect vapor separator/rollover valve hose and position
insulator pad on fuel tank. Position vapor vent so
that it is not pinched between tank and floor pan
during installation. (2) Raise tank and fuel filler tube carefully into
position. Use a light coating of power steering fluid
to ease fuel filler tube installation. Ensure filler tube
grommet is not damaged. Verify that the tube is in-
stalled correctly. (3) Tighten fuel tank strap nuts to 23 N Im (250 in.
lbs.) torque. Remove transmission jack. Ensure
straps are not twisted or bent. (4) Lubricate the metal tubes on the fuel pump
with clean 30 weight engine oil. Install the quick
connect fuel fittings. Refer to Quick Connect Fittings
in the Fuel Delivery section of this Group. (5) Attach electrical connector to fuel pump mod-
ule and level sensor unit. (6) Lower the vehicle.
(7) Attach filler tube to filler neck opening in
quarter panel. Tighten quarter panel screws to 2
N Im (17 in. lbs.) torque.
(8) Fill fuel tank, install filler cap, and connect
battery cable.
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 un-
til the ignition switch is turned to the Off position.
(9) Use the DRBII scan tool ASD Fuel System Test
to pressurize the fuel system. Check for leaks.
FUEL PUMP MODULE
Refer to the Fuel Delivery section of this group.
METHANOL CONCENTRATION SENSOR
Refer to the Fuel Delivery section of this group.
FUEL RESERVOIR
The fuel reservoir is internal to the fuel pump as-
sembly (Fig. 6). The purpose is to provide fuel at the
fuel pump intake during all driving conditions, espe-
cially when low fuel levels are present.
FUEL TANK LEVEL SENSOR
DIAGNOSIS
This procedure test the resistance of the level sen-
sor itself. It does not test the level sensor circuit. Re-
fer to Group 8W, Wiring Diagrams for circuit
identification and Group 8E, Instrument Panel and
Gauges for fuel gauge information. The level sensor is a variable resistor. Its resis-
tance changes with the amount of fuel in the tank.
The float arm attached to the sensor moves as the
fuel level changes. To test the level sensor, connect
an ohmmeter across the sensor signal and sensor
ground terminals of the fuel level sensor connector
(Fig. 7 or Fig. 8). Move the float lever to the full stop
and empty stop positions shown in the resistance
chart (Fig. 7 or Fig. 8). Record the resistance at each
point. Replace the level sensor if the resistance is not
within specifications. The low fuel warning light specifications determine
if the level sensor portion of the warning light circuit
functions properly. It does not test the complete
warning light circuit. Refer to Group 8W, Wiring Diagrams for circuit
identification and Group 8E, Instrument Panel and
Gauges for fuel gauge information.
REMOVAL
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.
Fig. 6 Fuel Reservoir
14 - 18 FUEL SYSTEMS Ä

(3) Remove idle air control motor mounting screws.
(4) Remove idle air control motor from throttle
body (make certain that the O-ring is on motor).
INSTALLATION
(1) New idle air control motors have a new O-ring
installed on them. If pintle measures more than 1
inch (25 mm) it must be retracted. Use the IDLE
AIR CONTROL MOTOR OPEN/CLOSE mode of the
DRBII scan tool (battery must be reconnected for this
operation). (2) Carefully place idle air control motor into
throttle body. (3) Install 2 mounting screws. Tighten screws to 2
N Im (17 in. lbs.) torque.
(4) Connect harness connector to 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.
1). (3) Remove accelerator cable.
(4) Disconnect idle air control motor and throttle
position sensor (TPS) electrical connectors. (5) Remove throttle body mounting nuts.
(6) Remove throttle body and gasket.
(7) Reverse the above procedures for installation.
FUEL INJECTOR RAIL ASSEMBLY
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.
REMOVAL
(1) Perform fuel system pressure release procedure.
(2) Disconnect negative cable from battery.
(3) Disconnect the fuel injector harness connector
from the engine harness (Fig. 6).
(4) Remove the quick connect fittings from the
chassis fuel tubes. Refer to Quick Connect Fittings in
the Fuel Delivery section of this group. (5) Disconnect the vacuum hose from the top of the
intake manifold (Fig. 6). (6) Disconnect vacuum hose from the pressure reg-
ulator (Fig. 6). (7) Remove screw from the fuel tube clamp (Fig.
6). (8) Remove fuel rail mounting screws.
(9) Pull up on the injector rail. The injectors will
pull straight out of the ports. Do not damage the in-
jector 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. 7).
INSTALLATION
WARNING: FUEL RAILS, INJECTORS AND PRES-
SURE REGULATORS DESIGNED FOR GASOLINE
ONLY VEHICLES CANNOT BE USED ON FLEXIBLE
FUEL AA-BODY VEHICLES. WHEN SERVICING THE
FUEL SYSTEM OF A FLEXIBLE FUEL VEHICLE,
ONLY USE ORIGINAL EQUIPMENT OR EQUIVA-
LENT REPLACEMENT COMPONENTS.
(1) Ensure injectors are seated into the receiver
cup on the fuel rail with the lock ring in place. (2) Attach harness connectors to injectors. Fasten
the harness into wiring clips.
Fig. 5 Servicing Idle Air Control Motor
Fig. 6 Injector Harness and Engine Harness Connection
Ä FUEL SYSTEMS 14 - 79