Chrysler Full-Size Vans 1989-1998 Repair Guide

Fuel Injector(s)

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TESTING



See Figures 1, 2, 3 and 4


CAUTION
Observe all applicable safety precautions when working around fuel. Whenever servicing the fuel system, always work in a well ventilated area. Do not allow fuel spray or vapors to come in contact with a spark or open flame. Keep a dry chemical fire extinguisher near the work area. Always keep fuel in a container specifically designed for fuel storage; also, always properly seal fuel containers to avoid the possibility of fire or explosion.

  1. Remove the engine cover.
  2.  
  3. Remove the air cleaner assembly.
  4.  
  5. Disconnect the injector harness connector. Inspect the connector; if damaged, repair or replace it as necessary.
  6.  
  7. Probe the injector connector, using the schematics supplied in this guide, into the circuits from the ASD relay. Turn the ignition to RUN , and the fuel pump will run for a few seconds until the ECM ungrounds it. (Voltage will only be present for a few seconds.) If voltage is above 10.0v, proceed to the next test; if voltage is not 10.0v or above, repair the circuit and retest.
  8.  

There are two ASD relay circuits in the injector harness connector, and both have to be checked for voltage. Use the schematics supplied in this guide to find them.

  1. Turn the ignition OFF .
  2.  
  3. Disconnect the negative battery cable.
  4.  
  5. Unfasten the ECM harness connector.
  6.  
  7. Using the schematics supplied in this guide, probe the ECM connector and injector connector driver circuits and check for resistance. If resistance is more than 10.0 ohms, repair circuit(s) and retest. If resistance is less than 10.0 ohms, proceed to the next test.
  8.  
  9. Remove the injector caps and inspect the injector terminals. If the terminals are damaged, repair as necessary. If the terminals are OK, proceed to the next test.
  10.  
  11. Connect the negative battery cable.
  12.  
  13. Connect a jumper wire between either terminal of injector #1 and the positive battery terminal.
  14.  
  15. Watch the injector for fuel spray while grounding the other terminal of the injector for no more than three seconds. If there is fuel spray, proceed to the next test; if no spray was detected, replace the injector and retest.
  16.  
  17. Connect the positive battery lead to either terminal on injector #2. Ground the other terminal for no more than three seconds, while watching for fuel spray. If no spray was detected, replace the injector and retest; if spray occurred, replace the ECM and retest.
  18.  
  19. Install the caps on the injectors.
  20.  
  21. Plug in the injector wiring harness connector.
  22.  
  23. Fasten the ECM harness connector.
  24.  
  25. Install the air cleaner assembly.
  26.  
  27. Install the engine cover.
  28.  



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Fig. Fig. 1: Typical TBI fuel injector schematic



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Fig. Fig. 2: Location of the fuel injector electrical connector on a TBI system



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Fig. Fig. 3: Terminal view of the TBI system's fuel injector electrical connector



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Fig. Fig. 4: Attach a jumper wire from the battery's positive terminal and momentarily ground the injector's other terminal to test injector operation

REMOVAL & INSTALLATION



See Figures 5, 6 and 7


CAUTION
Observe all applicable safety precautions when working around fuel. Whenever servicing the fuel system, always work in a well ventilated area. Do not allow fuel spray or vapors to come in contact with a spark or open flame. Keep a dry chemical fire extinguisher near the work area. Always keep fuel in a container specifically designed for fuel storage; also, always properly seal fuel containers to avoid the possibility of fire or explosion.

  1. Remove the engine cover.
  2.  
  3. Properly relieve the fuel system pressure.
  4.  
  5. Disconnect the negative battery cable.
  6.  
  7. Remove the air cleaner assembly.
  8.  
  9. Remove the fuel pressure regulator.
  10.  
  11. Remove the retaining clamp on the injector caps.
  12.  
  13. With two small screwdrivers, lift the cap off the injector using the slots provided.
  14.  
  15. Using a small screwdriver placed in the hole in the front of the electrical connector, gently pry the injector from pod.
  16.  
  17. Make sure the injector lower O-ring has been removed from the pod.
  18.  

To install:
  1. Place a new lower O-ring on the injector and a new O-ring on the injector cap. The injector will have the upper O-ring already installed.
  2.  
  3. Put the injector cap on the injector. (The injector and cap are keyed). The cap should sit on the injector without interference. Apply a light coating of castor oil or petroleum jelly on the O-rings. Place the assembly in the pod.
  4.  
  5. Rotate the cap and injector to line up the attachment hole.
  6.  
  7. Push down on the cap until it contacts the injector pod.
  8.  
  9. Install the retaining screws and tighten them to 35-45 inch lbs. (4-5 Nm).
  10.  
  11. Install the fuel pressure regulator.
  12.  
  13. Connect the negative battery cable.
  14.  
  15. Start the engine and check for leaks.
  16.  
  17. Reinstall the air cleaner assembly.
  18.  
  19. Install the engine cover.
  20.  



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Fig. Fig. 5: The TBI injectors are covered by caps, and the caps are retained by a hold-down clamp



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Fig. Fig. 6: After the caps are removed, the injectors can be removed by gently prying them out of the throttle body



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Fig. Fig. 7: Grasp the fuel injector and remove it from its pod in the throttle body

 
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