1993 CHEVROLET PLYMOUTH ACCLAIM brake sensor

for diagnostic and service procedures on the air control
valve and temperature sensor located in the air
cleaner.
INTAKE AND EXHAUST MANIFOLDS SERVICEÐTBI
ENGINE
Intake and exhaust manifolds use a one piece gasket.
Service procedures requiring removal and installation
( of either ) must include both manifolds.
FUEL SYSTEM PRESSURE RELEASE PROCE- DURE
The Fuel System is under a constant pressure
of at least 265 kPa (39 psi). Before servicing the
fuel pump, fuel lines, fuel filter, throttle body or
fuel injector, the fuel system pressure must be
released. (a) Loosen fuel filler cap to release fuel tank pres-
sure. (b) Disconnect injector wiring harness from engine
harness. (c) Connect a jumper wire to ground terminal
Number 1 of the injector harness (Fig. 2) to engine
ground. (d) Connect a jumper wire to the positive terminal
Number 2 of the injector harness (Fig. 2) and touch
the battery positive post for no longer than 5 seconds.
This releases system pressure. (e) Remove jumper wires.
(f) Continue fuel system service.
REMOVAL
(1) Perform fuel system pressure release procedure
before attempting any repairs. (2) Disconnect negative battery cable. Drain cool-
ing system. Refer to Cooling System, Group 7 for pro-
cedure. (3) Remove air cleaner and disconnect all vacuum
lines, electrical wiring and fuel lines from throttle
body. (4) Remove throttle linkage.
(5) Loosen power steering pump and remove belt.
(6) Remove power brake vacuum hose from intake
manifold. (7) Disconnect EGR tube from intake manifold and
remove water hoses from water crossover. (8) Raise vehicle and remove exhaust pipe from
manifold. (9) Remove power steering pump assembly and set
aside. (10) Remove intake manifold retaining screws
(Fig. 3). (11) Lower vehicle and remove intake manifold.
(12) Remove exhaust manifold retaining nuts (Fig.
3). (13) Remove exhaust manifold.
Fig. 2 Injector Harness Connector
Fig. 3 Intake and Exhaust Manifold Attaching PointsÐ2.2/2.5L Engines
Fig. 1 Air HeaterÐTBI Engine
11 - 6 EXHAUST SYSTEM AND INTAKE MANIFOLD Ä

INTAKE MANIFOLD
REMOVAL (1) Perform fuel system pressure release procedure
before attempting any repairs. (2) Disconnect negative battery cable.
(3) Remove air cleaner hose to throttle body (Fig.
6).
(4) Remove accelerator and speed control cables.
(5) Disconnect automatic idle speed (AIS) motor
and throttle position sensor (TPS) wiring connectors
(Fig. 7). (6) Disconnect fuel injectors wiring connector.
(7) Remove supply and return lines from the fuel
tube assembly quick connect at frame rail. Open fuel
tube clip around fuel tubes. WARNING: WRAP SHOP TOWELS AROUND HOSES
TO CATCH ANY FUEL SPILLAGE.
(8) Disconnect fuel pressure regulator vacuum hose
from regulator (Fig. 8). (9) Remove PCV vacuum harness, brake booster,
and vacuum vapor harness from intake manifold
(Fig. 8). (10) Remove 8 intake manifold screws and washer
assemblies and remove intake manifold assembly
(Fig. 9).
Fig. 5 Releasing Fuel Pressure
Fig. 6 Air Cleaner Hose to Throttle Body Assembly
Fig. 7 Throttle Position Sensor and Air Idle Control Motor Electrical Connections
Fig. 8 Electrical and Vacuum Hose Connection
11 - 8 EXHAUST SYSTEM AND INTAKE MANIFOLD Ä

EXHAUST MANIFOLD
REMOVAL (1) Disconnect exhaust pipe from manifold articu-
late joint. (2) Disconnect the heated oxygen sensor electrical
connection. (3) Remove 8 exhaust manifold retaining nuts and
remove exhaust manifold (Fig. 9).
CLEANING AND INSPECTION
(1) Discard gasket and clean all gasket surfaces of
manifolds and cylinder head. (2) Test gasket surfaces for flatness with straight
edge. Surface must be flat within 0.15 mm per 300
mm (.006 in. per foot) of manifold length. (3) Inspect manifolds for cracks or distortion.
EXHAUST MANIFOLD
INSTALLATION
(1) Install new two-sided grafoil or equivalent in-
take/exhaust manifold gasket. DO NOT APPLY
SEALER. (2) Set exhaust manifold in place. Install and
tighten retaining nuts, starting at center and pro-
gressing outward in both directions to 23 N Im (200
in. lbs.) torque. Repeat this procedure until all nuts
are at specified torque.
INTAKE MANIFOLD
INSTALLATION
(1) Position intake manifold, install, and tighten 8
retaining screws starting at center and progressing
outward in both directions to 23 N Im (200 in. lbs.)
torque. Repeat this procedure until all screws are at
specified torque (Fig. 9). (2) Install PCV vacuum harness and vacuum vapor
harness (Fig. 8). (3) Connect vacuum hose from fuel pressure regu-
lator. (4) Connect fuel injector wiring connector (Fig. 8).
(5) Close fuel tube clip around fuel tubes and in-
stall fastener. (6) Lubricate the ends of the chassis fuel tubes
with 30 wt oil. Connect fuel supply and return hoses
to chassis fuel tube assembly. pull back on the quick
connect fitting to ensure complete insertion. (Refer to
Fuel Hoses, Clamps and Quick Connect Fittings in
Group 14 Fuel Systems). (7) Connect automatic idle speed (AIS) motor and
throttle position sensor (TPS) wiring connectors (Fig.
7). (8) Connect accelerator and speed control cables.
Install brake booster vacuum supply hoses. (9) Reconnect negative battery cable.
(10) Install air cleaner hose to throttle body assem-
bly (Fig. 6). (11) With the DRBII Scan Tool use ASD Fuel Sys-
tem Test to pressurize system to check for leaks.
CAUTION: When using the ASD Fuel System Test,
the Auto Shutdown (ASD) relay will remain ener-
gized for 7 minutes or until the ignition switch is
turned to the OFF position, or Stop All Test is se-
lected.
INTAKE/EXHAUST MANIFOLDS AND
TURBOCHARGER SERVICEÐTURBO III ENGINE
INTAKE MANIFOLD
REMOVAL
(1) Perform fuel system pressure release procedure
before attempting any repairs. (2) Disconnect negative battery cable. Drain cool-
ing system. Refer to Cooling System, Group 7. (3) Remove fresh air duct from air filter housing.
Remove inlet hose from the intercooler (Fig. 1). (4) Remove radiator hose to cylinder head (Fig. 2).
(5) Remove DIS Ignition Coils from intake mani-
fold (Fig. 3). (6) Remove accelerator and speed control cables
(Fig. 4).
Fig. 9 Intake and Exhaust Manifolds Attaching Points
Ä EXHAUST SYSTEM AND INTAKE MANIFOLD 11 - 9

(7) Disconnect Intercooler to throttle body outlet
hose. Disconnect vacuum hoses from throttle body
and remove harness (Fig. 5).
(8) Disconnect automatic idle speed (AIS) motor
and throttle position sensor (TPS) wiring connectors
(Fig. 6). (9) Remove PCV Breather/Separator box and vac-
uum harness assembly. Remove brake booster, vac-
uum vapor harness and fuel pressure regulator
harness from intake manifold (Fig. 7). (10) Disconnect Fuel Injector Wiring Connector
(Fig. 8). Charge Temperature Wiring Connector (Fig.
7). (11) Remove fuel supply and return hose quick
connect at fuel tube assembly (Fig. 9). WARNING: WRAP SHOP TOWELS AROUND HOSES
TO CATCH ANY GASOLINE SPILLAGE
.
(12) Remove 8 intake manifold screws and washer
assemblies and remove intake manifold (Fig. 10).
INSTALLATION
Before installing manifold. Refer to Cleaning and
Inspection of this section to check manifold for dam-
age. (1) Install new intake manifold gasket and intake
manifold onto cylinder head and tighten fasteners to
23 N Im (200 in. lbs.) torque (Fig. 10).
(2) Install PCV Breather/Separator box and vac-
uum harness assembly. Connect brake booster, vac-
uum vapor harness and vacuum hose to fuel pressure
regulator (Fig. 7).
Fig. 1 Air Cleaner and Throttle Body AssemblyÐTurbo III Engine
Fig. 2 Radiator to Cylinder Head Hose
Fig. 3 Distributorless Ignition Coil (DIS) Location
Fig. 4 Accelerator and Speed Control Cables
11 - 10 EXHAUST SYSTEM AND INTAKE MANIFOLD Ä

(e) Remove jumper wires.
(f) Continue fuel system service.
(4) Remove throttle cable and transaxle kickdown
linkage (Fig. 4). (5) Remove automatic idle speed (AIS) motor and
throttle position sensor (TPS) wiring connectors from
throttle body (Fig. 5). (6) Remove vacuum hose harness from throttle body
(Fig. 5). (7) Remove PCV and Brake booster hoses from Air
Intake Plenum. (8) Remove ignition coil from intake plenum (Fig. 6).
(9) Remove wiring connectors from coolant tempera-
ture sensor (Fig. 7). (10) Remove vacuum connections from air intake
plenum vacuum connector. (11) Remove fuel hoses from fuel rail (Fig. 7).
WARNING: WRAP SHOP TOWELS AROUND HOSES
TO CATCH ANY GASOLINE SPILLAGE. (12) Remove (8) Fasteners from Air Intake Plenum
to Intake Manifold (Fig. 8). (13) Remove air intake plenum (Fig. 9).
(14) Cover intake manifold with suitable cover when
servicing. (15) Remove vacuum hoses from fuel rail and fuel
pressure regulator (Fig. 10). (16) Disconnect Fuel Injector wiring harness from
engine wiring harness (Fig. 11). (17) Remove fuel pressure regulator attaching bolts
and remove regulator from rail (Fig. 12). Be careful
not to damage the rubber injector O-rings upon
removal from the ports. (18) Remove fuel rail attaching bolts and lift fuel rail
assembly from intake manifold. (19) Separate radiator hose from thermostat hous-
ing and heater hose from heater pipe. (20) Remove (8) nut and washer assemblies and
remove intake manifold (Fig. 2).
INSPECTION
Check for:
² Damage and cracks of each section (Fig. 13).
² Clogged water passages in end cross overs.
² Check for distortion of the cylinder head mounting
surface using a straightedge and thickness gauge (Fig.
14). Refer to (Fig. 15) for Specifications.
INSTALLATION
(1) Position new intake manifold gaskets on cylinder
head and install intake (cross) manifold. (2) Install (8) nuts and washers and tighten in
several steps in order shown in (Fig. 16) to 20 N Im
(174 in. lbs.). (3) Make sure the injector holes are clean and all
plugs have been removed. (4) Lube injector O-ring with a drop of clean en-
gine oil to ease installation. (5) Put the tip of each injector into their ports.
Push the assembly into place until the injectors are
seated in the ports. (6) Install the (3) fuel rail attaching bolts and
torque to 13 N Im (115 in. lbs.).
(7) Install fuel pressure regulator onto fuel rail. In-
stall attaching bolts to intake manifold. Torque reg-
ulator nuts and bracket bolts to 10 N Im (95 in. lbs.)
(Fig. 12). (8) Install fuel supply and return tube hold-down
bolt and the vacuum crossover tube hold-down bolt
and torque to 10 N Im (95 in. lbs.).
(9) Connect fuel injector wiring harness to engine
wiring harness (Fig. 11). (10) Connect vacuum harness to fuel pressure reg-
ulator and fuel rail assembly (Fig. 10). (11) Remove covering from lower intake manifold
and clean surface. (12) Place intake manifold gaskets with beaded
sealant side up on lower manifold. Put air intake in
Fig. 3 Throttle Body Assembly 3.0L
Fig. 4 Throttle Cable Attachment
Ä EXHAUST SYSTEM AND INTAKE MANIFOLD 11 - 15

place. Install attaching fasteners (8) and tighten in
several steps in sequence shown (Fig. 17) to 13 N Im
(115 in. lbs.). (13) Connect fuel line to fuel rail (Fig. 7). Torque
hose clamps to 1 N Im (10 in. lbs.).
(14) Connect vacuum harness to air intake ple-
num. (15) Connect coolant temperature sensor electrical
connector to sensor (Fig. 7). (16) Connect PCV and brake booster supply hose
to intake plenum. (17) Connect automatic idle speed (AIS) motor and
throttle position sensor (TPS) electrical connectors
(Fig. 5). (18) Connect vacuum vapor harness to throttle
body (Fig. 5). (19) Install throttle cable and transaxle kickdown
linkage (Fig. 4). (20) Install air inlet hose assembly (Fig. 3).
(21) Install radiator to thermostat housing hose
and heater hose to heater pipe nipple. (22) Fill cooling system, see Refilling System in
Cooling, Group 7. (23) Connect negative battery cable.
(24) With the DRBII Scan Tool use ASD Fuel Sys-
tem Test to pressurize system to check for leaks.
Fig. 5 Electrical and Vacuum Connections to Throttle Body
Fig. 6 Ignition Coil Removal
Fig. 7 Coolant Temperature Sensor Electrical Connections
Fig. 8 Air Intake Plenum to Intake ManifoldAttaching Bolts
Fig. 9 Removing Air Intake Plenum
11 - 16 EXHAUST SYSTEM AND INTAKE MANIFOLD Ä

(4) Remove throttle cable (Fig. 3). Remove wiring
harness from throttle cable bracket.
(5) Remove automatic idle speed (AIS) motor and
throttle position sensor (TPS) wiring connectors from
throttle body (Fig. 4). (e) Remove jumper wires.
(f) Continue fuel system service.
(6) Remove vacuum hose harness from throttle
body (Fig. 4). (7) Remove PCV and brake booster hoses from air
intake plenum (Fig. 5). (8) Remove EGR tube flange from intake plenum
(Fig. 5). (9) Disconnect Charge Temperature Sensor electri-
cal connector. Remove vacuum harness connectors
from Intake Plenum (Fig. 5).
(10) Remove cylinder head to intake plenum strut
(Fig. 5). (11) Disconnect MAP Sensor and heated Oxygen
Sensor electrical connection. Remove the engine
mounted ground strap (Fig. 6).
Fig. 3 Throttle Cable Attachment
Fig. 4 Electrical and Vacuum Connection to Throttle Body
Fig. 5 Electrical and Vacuum Connections To IntakeManifold
Fig. 6 MAP Sensor Electrical Connector
11 - 20 EXHAUST SYSTEM AND INTAKE MANIFOLD Ä

2.2L/2.5L SINGLE POINT FUEL INJECTIONÐSYSTEM OPERATION INDEX
page page
Air Conditioning (A/C) Clutch RelayÐPCM Output.28
Air Conditioning Switch SenseÐPCM Input ..... 26
Auto Shutdown (ASD) Relay and Fuel Pump RelayÐPCM Output ..................... 29
Battery VoltageÐPCM Input ................ 26
Brake SwitchÐPCM Input .................. 26
EVAP Canister Purge SolenoidÐPCM Output . . . 29
CCD Bus .............................. 25
Coolant Temperature SensorÐPCM Input ...... 26
Data Link ConnectorÐPCM Output ........... 30
Distributor (Hall Effect) Pick-UpÐPCM Input .... 26
Electric Electronic Gas RecirculationÐPCM Output.30
Fuel InjectorÐPCM Output ................. 31
Fuel Pressure Regulator ................... 33
General Information ....................... 24
Generator FieldÐPCM Output ............... 31
Heated Oxygen Sensor (O
2Sensor)ÐPCM Input . 27
Idle Air Control MotorÐPCM Output .......... 29 Ignition CoilÐPCM Output
.................. 31
Malfunction Indicator Lamp (Check Engine)ÐPCM Output ............................... 30
Manifold Absolute Pressure (MAP) SensorÐPCM Input ................................ 27
Modes of Operation ....................... 32
Part Throttle Unlock SolenoidÐPCM Output .... 31
Powertrain Control Module ................. 25
Radiator Fan RelayÐPCM Output ............ 31
Speed Control SolenoidsÐPCM Output ........ 31
Speed ControlÐPCM Input ................. 27
System Diagnosis ........................ 25
TachometerÐPCM Output .................. 32
Throttle Body ............................ 33
Throttle Position Sensor (TPS)ÐPCM Input ..... 28
Transaxle Park/Neutral SwitchÐPCM Input ..... 28
Vehicle Speed SensorÐPCM Input ........... 28
GENERAL INFORMATION
The computer regulated, Electronic Fuel Injection
System (Fig. 1) provides a precise air/fuel ratio for
all driving conditions. The fuel injection system is
controlled by the powertrain control module (PCM).
The PCM is a pre-programmed digital computer. The
PCM regulates ignition timing, air-fuel ratio, emission
control devices, cooling fan, charging system, speed con-
trol, and idle speed. The PCM can adapt its requirement
to meet changing operating conditions.
Fig. 1 Electronic Fuel Injection Components
14 - 24 FUEL SYSTEMS Ä