TURBONutter Lada Niva 4x4 Service Manual Fuel Injection This manual and a host of other wonderful Lada Niva documentation is available free of charge at http: /ww.turbo-nutter.com You can do anything you like with this manual except sell it or otherwise make money from it. While | can't stop you sticking it on your own website I would much prefer you linked to its original location on turbo-nutter.com You use the information contained with this manual at you own risk. If you're not sure how to do something either don't do it or ask someone who knows about such things. The font of all Lada knowledge can be found at: http: //www.lada.co.uk/forum For Lada parts, advice and general all round Lada wonderfulness these blokes aren't bad: Lada UK Ltd Lada Parts Australia P/L Askew Rigg 42 Aerodrome Road Troutbeck Caboolture Penrith, Cumbria Queensland CA11 OSZ 4510 United Kingdom Australia T: +44 (0) 17 6877 9794 T: +61 7 5495 5100 F: +44 (0) 17 6877 9197 F: +61 7 5495 5152 E: [email protected] E: [email protected] W: http://www. lada.co.uk W: http:/www.ladaparts.comENGINE MANAGEMENT SYSTEMS 1.7L THROTTLE BODY INJECTION 3-1 3. SERVICE OPERATIONS NOTICE: When fasteners are removed, always reinstall them 2t the same location from which they ‘were removed. If ¢ fasener needs to be teplaced, use the correct part number fastener for that applica tion, If the correct part number fastener is not available, a fastener of equal size and strength (or stronger) may be used. Fasteners that are not reused, and those requiring thread locking compound wil bbe called out. The conrect torque value must be used when installing fasteners unat require it. If the above conditions are not followed, parts of system damage could result SERVICE PRECAUTIONS DRIVEABILITY AND EMISSIONS CONTROL ‘An electronic control module is designed 10 main: tain exhaust emission levels at goverment standards ‘while providing good driveability and fuel efficiency, “Te functions of the system are based on data gathered by sensors and switches located throughout the vehicle. ‘The electronic control module maintains contro! over fuel delivery, ignition, idle air flow, the fuel pump and: ‘other system components, while monitoring the system for faulty operation with its diagnostic capabilites. Ic is imponant to review the compénent sections and ‘wiring diagrams 10 detemine which systems are con- trolled by the electronic control module. MAINTENANCE SCHEDULE Refer to the Maintenance Schedule in the owner's handbook for the maintenance service that should be performed to retain performance. BLOCKING DRIVE WHEELS ‘The vehicle drive wheels should always be blocked and parking brake firmly set while checking the system. WHAT THIS SECTION CONTAINS. “Driveability and Emissions Service Operations.” Section "3" describes the proper service procedures to fepair components of the Engine Management system that controls the driveability and emissions of the vehi- cle. Emphasis is placed on the proper procedures and repair of components related to the system. VISUAL/PHYSICAL UNDERHOOD INSPECTION ‘A careful visval and physical undeshood inspec- tion must be performed as part of any diagnostic procedure of In finding the cause of an emissions fest failure. This can often lead to fixing a problem ‘without further steps. Inspect all vacuum hoses for cot tect routing, pinches, cuts. ot disconnects. Be sure to spect hoses that are difficult t0 see beneath tie alr cleaner, compressor. alternator, et. Inspect all tie wires in the engine compartment for proper connections, bumed or chafed spots. pinched wires, or contact with sharp edges or hot exhaust manifolds. This visuals ‘eal inspection is very important. It mast be done careful ly and thoroughly. SERVICE PRECAUTIONS. ‘The following requirements must be observed when ‘working on vehicles: 1, Before removing any eleciconic control module 5y5- tem component, disconnect the battery ground cable. 2, Never'star the engine without the battery cables being solidly connected. 3. Never separde the battery from be on-board electr- cal system while the engine is running, 4. When charging the battery, disconnect it from the vehicle's electrical system, ‘5. Never subject the electronic control module to tem- peratures above 80°C i.e., paint oven, Always Temove the electronic control module first if this temperature is to be exceeded. 6. Ensure ttiat all cable hamess plugs are connected solidly and that baitery terminals are thoroughly lean. VAL SERVICE MANUAL THROTTLE BODY INJECTION NIV 38& el 3:2 ENGINE MANAGEMENT SYSTEMS 1.7L THROTTLE BODY INJECTION 7. The engine management system hamess comectors are designed to At only one way: there are indexing {bs and slots on both halves of the connector. Fore- ang the connector into place'is nox necessary if itis installed with the proper orientation. Failure to match the indexing tabs and slots on the connector can cause damage to the connector. the module, oF cther venicie components or systems. 8. Never connect of disconnect the electronic control module coanectors when the ignition is switched “ON, 9. Before anempting any electric arc welding on the Vehicle, disconnect the battery leads and the elec- tronic control module connectors. 1 When steam cleaning erigines, do not direct the sitam cleaning nozzle at electronie control module system components. If this happens, corrosion of the terminals can take place. 11. Use only the test equipment specified in the diag- nostic chars, other test equipment may give incor- rect results or damage good components. 12, Make all voltage measurements using a digital volt- ‘meter with an internal impedance rating of at east 10 mittion oluns per volt, 13. When a test light 8 specified, a “low-power” test Hight must be used. Do’ not use a high wanage test light (ie: headlight). While a panicular brand of test Tight is noe suggested a simple check of any est 1 will ensure it is safe for electronic control ‘module circuit testing. Connect an accurate ammeter ‘uch as the high-impedance digital multimeter) in senes with the test light and power the test light- atumeter circuit with the vehicle battery. 1 the ammeter indicates fess than 1/4 amp current flow (25.4 of 250 nia) ne test light is SAFE to ise. Ifthe ammeter indicates more than 14 amp cient flow (25 A of 250-ma),.the test light is NOT SAFE to ose Electrostatic Discharge Damage 1k is possible for less dian 100 vols of static eles- tricity (0 cause damage to some electronic components Electronic components used in contra sytem are often designed 0 cary very low voltage. and are very suscep: tible to damage caused by electrostatic discharge. By ‘ommparison, i takes as much as 4,000 vols fora person to even fel the zap of a static discharge. ‘There are several ways for a person to become stati- cally charged. The most common methods of chargirs, are by fiction and by induction. An example of char2- ing by friction is « person sliding actoss a car seat whe-e a charge of as much as 25,000 voits can build up. Charg- ing by Induction occurs when a person with well insulat- ‘ed shoes stands near a highly charged object and mo- mentarily touches ground. Charges of une same polarity are drained off leaving the person highly charged with the opposite polarity. Static charges of efther type can ‘cause damage: therefore, it is important 10 use care when handling and testing electronic components. NOTICE: To prevent possible Electrostatic Discharge damage: ‘© Do Not touch the electronic control module connes: tor pins or soldered components on the electronic ‘control module circuit board. Never disassemble the electronic cont) module metal case, except for the calibrator cover ‘* When handling an engine calibrator, Do Not remove integrated circuit from carncr. REPAIR PROCEDURES ELECTRICAL REPAIRS This part provides instruction in the following repairs: © Circuit Protection. © Typical Electrical Repairs. Replacing terminals on unsealed components Replacing pigtails on sealed components Replacing connector housiigs on unsealed compo- ents, Splicing Copper Wire. Splicing Twisted/Shielded Cable. Repairing Connectors (Except Weather Pack?) Repairing Weather Pack? (Environmental) Autofuse Corinectors. ‘Terminal Repair. Vaz SERVICE MANUAL THROTTLE BODY NECTION HVAENGINE MANAGEMENT SYSTEMS. After any electrical repair is made, always test the ‘itcait by operating the devices in the cireuit, This con- finns not only tat she repair is corect, ut also that it seas the cause ofthe complaint GIRCUIT PROTECTION ‘The purpose of circuit protection is to protect the wiring assembly during normal and overload conditions, ‘An overload is defined as a current requirement that is higher than normal, The overload could be caused by a shon citcuit or system malfunction. The shont circuit ‘ould be the result of a pinched or cut wire, or an inter~ nal device short circuit, such as an electronic module failure ‘The circuit protection device is only applied tp pro- tect the wiring assembly. and not the electrical load at the end of the assembly. For example, if an electronic component short citcuits, the circuit protection device will assure a minimal amount of damage to the wiring assembly, However, i will not necessarily prevent dam- age to wie component GRCUIT PROTECTION DEVICES ‘There are two basic types of circuit protection devices: Puse, and Fusible Link FUSES ‘The most common method of automotive wiring cir- ‘cuit protection is the fuse (Figure 3-1). A fuse is a device that, by the meling of its element, opens an elec tmical circuit when the current exceeds a given level for a sufficient time. The action is non-reversible and the fuse rust be replaced each time a circuit is overloaded or after a malfunction is repaired. Fuses are color coded. The standardized color iden- tification and ratings are shown in Figure 3-2. For ser- vice replacement, non-color coded fuses of he same respective current rating can be used. [Examine a suspect fuse for a break in the element. If the element is broken of melted, replace the fuse with fone of equal current rating. ‘Tiiere are additional specific circuits with in-line fuses, These fuses are located within the individual wiring hamess and will appear to be an open circuit if blown, LTHROTTLE BODY INJECTION 3:3 Autofuse The Autofuse, normally referred to simply 2s “Fase,” is the most common circuit protection device in today’s vehicle, The Autofuse is most often used to pro tect the wiring asserably between the Fuse Block and the system components. Autofuse Figure 5-1 Fuse Devices Maxifuse ‘The Maxifuse was designed 10 replace the fusible link, The Maxifuse is designed to provect cables, not~ mally between the Battery and Fuse Block, from both direct shor circuits and resistive short circuits ‘Compared to a fusible link, the Maxifuse performs much more like an Autofuse, although the average ‘pening time is slightly longer. This is because the Maxifuse was designed to be 2 slower blowing fuse with less chance of nuisance blows, Fusible Links In addition to fuses, some circuits use fusible Tinks to protect the wirmg, Vaz SERVICE MANUAL THROTTLE BODY IKIECTION NVA aay B of 3:4 ENGINE MANAGEMENT SYSTEMS 1.7L THROTTLE BODY INJECTION Om—_\ PUSILE Ul BEFORE SHORT ORGUT BROKEN cxtcurr INSIDE NSULATION Figure 3-2 Fuse Rating and Calor Like fuses, fusible links are-“one-time” protection dlevices.that will melt and create an open cieuit (see Each fusible link is four wire gauges smaller than the cable it is designed to protect. Service fusible links are available in many lengths. Choose the shorest length that is suitable, Ifthe fusible link is to be cut from a spool, it should be cut 150-225 ram Jong. NEVER make a fusible link longer than 225 mn, Figure 3-4 Single Wire Feed Fusible Unk \VAZ SERVICE MANUAL THROTTLE BOY INJECTION NIVA,ENGINE MANAGEMENT SYSTEMS 1.7L THROTTLE BODY INJECTION 3-5 CAUTION: Fusible links cut longer than 225 mm will not provide sufficient over- toad protection. “To replace a damaged fusible link (Figure 3), cut it off beyond the splice. Replace with a repair link. For Splicing see “Splicing Copper Wire Using Splice Clips.” ‘Po seal the splices do not use shrink tube with hot mek. there is special tubing required for fusible link applica: tions. This special tubing is not included im Terminal Repair Kit 1 39745. It is available, however, through Packard Electric and is referred to as "Heat Shrinking ‘Dual Wall Tube.” (ES M-2310 code 400, 500, 700.) “TYPICAL ELECTRICAL REPAIRS ‘An open cireuit is an incomplete cirout Power can rot reach the load or reach ground. [fa circuit is open. fotive components do not energize. A shor circuit is at inwanted connection between one part of the circuit and ‘ier ground ot another part of the circuit A short cit- cuit causes a fuse 10 Blow. Short Grcults Caused By Damaged Wire Insulation ‘+ Locate the damaged wire. + Find and correct the cause of the wire insulation damage. REPLACING TERMINALS ON UNSEALED COMPONENTS step Remove damaged terminal from the connector rousing, To determine the correct removal, tool to use, refer to the manual included in Terminal Repair Kit 539745. step2: ‘Cut off damaged terminal. Do not cut off unneces- sary amounis of wire. Cut off as lite as possible. step 3: ‘Remove wire insulation using the wire stripper pro vided in Terminal Repair Kit J 39745. Extreme caution ‘must be used not i cut wire strands as the insulation is removed. Step& ‘Select the correct erminal (refer to Te- minal Repait Kit J 39745) and positon the sip in the terminal, ‘Step 5: ‘Using the correct crimp tool provided in Terminal Repair Kit 3 39745, crimp the terminal. Solder all hand ‘crimped terminals to ensure a clean, dry connection. step 6 Plug the terminal into the connector housing. Be sure that the wires are plugged inso the correct cavity. A properly seated terminal will “Click” when seated. REPLACING PIGTAILS ON SEALED COMPONENTS iguals att cotinectors with crimped wires. They are appromimacly 20 em long. Pigails are included in the ‘Terminal Repair Kit} 3974S for allof the sealed compo- nents in the Engine Management System Wiring Har- ness. Repair Procedure step ti ‘Select the correct pigtail using the manual included in Terminal Repair Kit 39745. Step 2: ‘Cutoff the damaged connector not more than 20 em from the top of the connector. Step 3: ‘Splice the new pigtail into the hamess. To make 3 sealed splice see “Splicing Copper Wire Using Splice (Clips, Shrink Tube and Hot Met.” included in Section 3 cof this manual. © ‘Be sure thatthe color ofthe gail isthe same color as the wire on the wiring hamess. ‘AM pigails are marked with a white dot so that he replaced component can be identified for service rea- sons, \VAZ SERVICE MANUAL THROTTLE BODY INSECTION NVAen cn i 3:8 ENGINE MANAGEMENT SYSTEMS 1.7L THROTTLE BODY INJECTION Step &: If the sealed splices are ot protected by conduit or tubing, wrap the splices with electrical tape to ensure a dry, clean connection. REPLACING CONNECTOR HOUSINGS ON UNSEALED COMPONENTS Step 1: Remove damaged terminals from the connector housing. To determine the comect removal tool t0 use. refer to the manual included in Terminal Repair Kit 339745. Step 2: Select the correct connector housing using the man- val included in Terminal Repair Kit] 39745 as 2 guide. Step 3: ‘Making sure that the terminals are indexed corect- 1y, plug the terminals into the selected connector bous- ing, Ensure that the wires are plugged into the correct ‘eavity. A propetly seated terminal will “Click” when seated. ‘SPLICING COPPER WIRE USING SPLICE CLIPS Splice Clips are included in Terminal Repair Kit 439745. The splice clip should only be used as a general purpose wire repair device. It should only be used for applications in the passen- ‘ger compartment that do not need special requirements ‘Such as moisture sealing, Step 1: Open the Harness If the hamess is taped, remove the wpe. Ifthe har- ness has a black plastic conduit, simply pull ous the desired wire. Step 2: Cut the Wire Begin by coming as litle shire off the hamess as pos- sible, You may'need the exia length of the wir later if You decide to cut more wire off to change the location of a splice. You may have to adjust splice locations to ‘make certain that each splice is at least 40 mm away from an outlet(s) and 6S tum from anather splice. ‘Step 3: Strip the Insulation ‘When replacing a wire, use a wire of the same size a the original wire or larger. The schematics list wire size in metric units. If you aren't sure of the wire size, start with the. Jargest opening in the wire stripper and work down until a clean stip of the insulation is removed. Be careful 10 avoid nicking or cating any of the wires. ‘Step 4: Crimp the Wies Sclect the proper clip to secure the splice. To deter- ‘ine the proper clip size for the wire being spliced, see splice crimp matrix below. ‘SPLICE CRIMP MATRIX Figure 3-5 Splice Crimp Matix ‘To select the correct crimp tool consult the instruc- tons included in the Terminal Repair Kit J 39745. Select the correct anvil on the ctimper. On most ‘rimpers your choice is limiued to either a smal or large anvil. Overlap the stripped wire ends and hold them ‘between your thumb-and forefinger as shown in Figure 3-6. Then, center the splice clip under the stripped wires and bold iin place, © Open he crimping soo 1 ts full width and rest one handle ona firm at surface. ‘© Center the back ofthe splice clip on the proper anvil and close the crimping tool to the point where the former touches the wings of the clip. ‘+ Make sure that the clip and wires are still in the cor- eet postion. Then, apply steady pressure until the crimping tool closes. \VAR SERVICE MANUAL THROTTLE BOOT INIECTION NVA 208ENGINE MANAGEMENT SYSTEMS 1.7L THROTTLE BODY INJECTION 3-7 ‘AUN TooL Wm EDGE OF CUP ‘G9 Guar eNOS OF SPUCE Figure 3-8 Completing the Crimp ‘¢ Before crimping the ends of the clip, be sure that: = The wires extend beyond the clip in each diree- ‘ion. _=No stands of wire are cut loose, and, No insulation is caught under the clip. (Crimp the spice again, once on each end. Do not et ste crimping tool extend beyond the edge of the lip oF "you may damage of nick the wires (Figure 3-8). Step 5: Solder ‘Apply 60/40 rosin core solder to the opening in the back of the clip (see Figure 3.9). Follow the manufac: turer's instruction for the solder equipment you are sing. ‘Step 6: Tape the Cable (Center and rll the splicing tape. The tape should cover the entre splice. Roll on enough tape to duplicate the thickness ofthe insulation on the existing wires. Do rot flag the tape. Flagged tape may not provide enough insulation, and the Aagged ends will tangle with the ther wires inthe hamess (see Figure 3-10), Figure 37 Crimping the Splice Gip |VAZ SERVICE MANUAL THROTTLE BODY INJECTION NIVA ae£8 ENGINE MANAGEMENT SYSTEMS 1.7L THROTTLE BODY INJECTION Figure 3-9 Applying the Solder i [fthe wire does not belong in a conduit or other har- fess covering, tape the wire again. Use a winding motion to cover the first piece of tape (Figure 3-11). t SPLICING COPPER WIRE USING SPLICE CUR, ‘SHRINK TUBE AND HOT MELT. For applications in the engine compartment it is ecessary 10 have sealed splices because of the potential of moisture invading the splice, Splice clips, shrink tube “and hot melt are included in Terminal Repair Kit 139745, Step 1: Open the Hames Ii the hamess is taped, remove the tape. Ifthe bar- z ness has a block plastic condui, simply pull out the wire. rn Step 2: Cut the Wire Begin by cutting as Linde wire off the hamess as pos- sible. You may need the extra length of wire late if you . ai decide to cut more wire to change the location of a Figure 340 Proper First Taping splice. You may have o adjust splice locations to make certain that each splice is at least 40 mm away from an ‘oulet(s) and 65 mm away from other splices, Figure 3-11 Proper Second Taping \VAZ SERVICE MANUAL THROTTLE BODY INJECTION MIVANGINE MANAGEMENT SYSTEMS. THROTTLE BODY INJECTION 3-9 _____ ENGINE MANAGEMENT SYSTEMS LS “This will help prevent moisture from bridging adja cent spices and causing damage. Step 3 Strip the insulation ‘When replacing a wire, use a wire of the same size as the original wire or larger. The schematics list wire size in metzic units. If you aren’t sure of the wire size, start with the lrgest opening in the wire stripper and work down until a clean stip of the insulation is removed, Be careful (0 void nicking or cutting any of the wires. Step 4: Crimp the Wires Remove the appropriate size stink tube from Ter minal Repair Kit} 39745 and sip it over the end of the ure. Select the proper clip to secure the splice. To {etetmine the proper clip size for the wire being spliced, see splice crimp manix below. SPLICE CRIMP MATRIX Figure 3-12 Splice Crimp Matrix ‘To select the correct crimp toot consult the insu tions included in the Terminal repair kit J 3974. ‘Select the correct anvil on the crimper. On most Ceimpers your choice is limited (0 either a small or farge anvil, Overlap the stripped wire ends and hold them between your thamb and forefinger as shown {n Figure 3-6. Then, center the splice clip under the ‘uipped wires and hold it in place. © Open the ctimping tool tits full width and rest one Thandle on a firm flat surface. ‘s) Cemer the back of the splice clip on the proper arvit tnd close the erimping,tool to the point where the former touches the wings ofthe clip 4¢-Make sure thatthe clip and wires ae stil in the cor- reat position, Then, apply steady pressure until the crimping tool closes. 'e Before crimping the ends of the clip, be sure that: 2th wires extend beyond the clip in each direc- ton. _=No strands of wire are cut loose, and Z'No insulation is caught under the clip. ‘Ctimp the splice again, once on each end, Do not let the crimping tool extend beyond the edge of the clip oF you may damage OF nick the wires (Figure 3-8). ‘Step 5: Solder ‘Apply 60/40 rosin core solder to the opersng in the ‘back OF the clip (see Figure 3-9). Follow the manofec- turer's instruction for the solder equipment you are ‘sing. Az SERVICE MANUAL THROTTLE BODY NECTION NIVA= 4 = = 3:10 ENGINE MANAGEMENT SYSTEMS 1.7L THROTTLE BODY INJECTION Step 6: Shrink TuberHot Melt Shrink tube should now be applied to ensure tht the splice remains clean and dry. Position the proper size shrink tube so tha the splice clip and any bare copper Wire is covered. Lay several pieces of hot melt under the shrink ube a5 ¢lose as possible to the middle of the splice. Shrink tube and hot melt are available in Teami- nal Repair Kit} 39745, Step 7: Apply Heat Using an appropriate low heat source, apply heat to the shrink tube. Be extremely careful not to position the heat solitce too close to the shrink ube, it will melt if ‘overexposed to heat. ‘After a few seconds of moderate heat the shrink tube will met and a small amount of hot melt will come ‘out the-end of the tube. The shrink tube will conform to ‘he splice providing a ciean, dry seal. Figure 3-14 The Untwisted Conductors ea ware =u us rss Figure 3-15 The Re-assembled Cable CTL us 1155 Figure 3-16 Proper Taping SPLICING TWISTED/SHIELDED CABLE ‘Twisted/shielded cable is sometimes used to protect wiring from electrical noise (stray signals). For exam- ple, two-conductor cable of this construction 15 used between the electronic control module and the ignition module. See Figure 3-13 for a breakdown of twisted? shielded cable construction. Step 1:Remove Outer Jacket Remove the outer jacket and discant it Be careful 10 void cuning into the drain wite or the mylar tape. Step 2: Unwrap the Tape. ‘Unwrap the aluminum mylar tape, but do not remove it. The tape will be used to rewrap the twisted conductors afer the splices have been made. ‘Step 3: Prepare the Splice ‘Untwist the conductors. Then, prepare the splice by following the splicing instwctions for copper wire pre- sented earlier, Remember 10 stagger splices to avoid shons (Figure 314). \VAZ SERVICE MANUAL THROTTLE BODY NECTION NIVA, aorENGINE MANAGEMENT SYSTEMS 1.7L THROTTLE BODY INJECTION 3-11 ‘Step 4: Re-assemble the Cable ‘After you have spliced and taped each wire, rewrap the conductors with the mylar tape. Be careful to avoid ‘wrapping the drain wire in the tape Next, splice the drain wire following the splicing instructions for copper wire. Then, wrap the drain wire around the conductors and mylar tape (Figure 3-15). Step $: Tape the Cable ‘Tape over the entire cable using a winding motion (eee Figure 3-16). This tape will replace the section of the jacket you removed to make the Fepair REPAIRING CONNECTORS «The following general repair procedures can be sed to repait most types of connectors. The repair proce dures are divided into three general groups: Pust-10- ‘Seat and Pull-to-Seat and Weather Pack®. «See “Terminal Repair Kit Instruction Manual,” 39745) to determine which type of connector is 0 be serviced. © Use the proper Pick(s) or Tool(s) that apply to the ‘terminal. PUSH-TO-SEAT AND PULL-TO-SEAT Follow the steps below to repair Push-to-Seat (Fig ure 3-17) of Pull-to-Seat (Figure 3-18) connectors. The steps are illustrated with typical connectors. Your con- rector may differ, bt the repair steps are similar. Some ‘connectors do not require all the steps shown. Skip those ‘that don’t apply. Step 1: Remove any connector position assurance Jocks, Connector position assurances are designed to retain connectors when mated. Remove any terminal position assufance Locks, Terminal position assurances are designed to keep the terminal from backing ‘out ofthe connector NOTICE: The terminal position assurance aust be removed prior to terminal removal ‘and must be replaced when the terminal is. repaired and reseated. ‘Open any secondary locks. A secondary lock ‘aids in terminal retention and is usually ‘molded 19 the connector. Step 2: Step 3: TbserTion Figure 3-17 Typical Push-to-Seat Connector fand Terminal jure 518 Typical a Mena Terminal ‘Separate the éorinectot halves anid back out seals. Grasp the lead and push the terminal 10 the forward most position. Hold the lead at this positon. ‘Locate the terminal lock tang in the connec- tor canal. Insert the proper size pick (refer to Terminal Repair Kit ] 39745) straight into the connec tor canal atthe mating end of the connector. Depress the locking tang to unseat the termi- nal. Step &: Step 5: Step 6: Step 7: Step & Push-to-Seat - Gently pull om the lead to remove the terminal though the back of the connector. ‘Vad SERVICE MANUAL THROTTLE BOOY NECTION NIV£ 3:12 ENGINE MANAGEMENT SYSTEMS 1.7L THROTTLE BODY INJECTION Step 9: ‘Step 10: Step tt: Pull-to-Seat - Gently push on the lead to remove the terminal through the front of the connector. NOTICE: Never use force to remove a termi- ‘al from a connector. Inspect terminal and connector for damage. Repair as necessary. Reform lock tang and reseat terminal in con- rector body. Apply grease if connector was Originally equipped with grease. Install any connector position assurances or terminal position assurances, close any sec- ‘ondary locks and join connector halves, WEATHER PACK Follow the steps below to repair Weather Pack® connectors (Figure 3-19), Step 1: Step 2: ‘Separate the connector halves. ‘Open secondary Jock, A secondary lock aids in terminal retention and is usually molded to the connector. Figure 319 Typial Weather Pa? Convector 'a od eet Step 3: Step: Step 5: Step 6: Step 7: ‘Step 8 ‘Grasp the lead and push the terminal t0 the forward most position. Hold the lead at this position. Insert the Weather Pack® terminal removal tool into the front (mating end) of the con rector cavity until i rests on the cavity sboul- der, Gently pull on the lead t9 remove the termi= nal through the back of the connector. NOTICE: Never use force to remove 2 temni- nal from a connector. Inspect the terminal and connector for dam- age. Repair as necessary (see “Terminal Re- pair," on following page). Reform the lock tang and reseat emminal in connector body. Chose secondary locks and join cobnector halves. ‘TERMINAL REPAIR ‘The following repair procedures canbe used 10 Pull-to-Seat or Weather Pack® ter- repair minals (Figure 3-20). Some terminals do not require all ‘Steps shown. Skip those that don’t apply, The Terminal Repair Kit (I 39745) comtains additional information. Step 1: (Cut off terminal between core and insulation crimp (minimize wire loss) and Femove seal for Weather Pack? erminals. ‘Apply corect seal per gauge sizeof wire and slide back along wire to enable insulation feinoval (Weather Paek® terminals only) ‘Remove insulation. ‘Align seal with end of cable insulation (Weather Pack® terminals onty). Position sirip (and seal for Weather Pack®) in terminal \VAR SERVICE MANUAL THROTTLE BODY NECTION NIVA 208ENGINE MANAGEMENT SYSTEMS 1.7L THROTTLE BODY INJECTION 3:13 Step 6: Hand crimp core wings. Step7: Hand crimp insulation wings (non-Weather Pack®), Hand crimp insulation wings around seal and cable (Weather Pack®). Step Solderall hand crimped terminals. WIRING CONNECTOR SERVICE ‘Most connectors int the engine compartment are pro- tected against moisture and dirt which could create oxi- dation and deposits on the teminals. This protection is ‘imponant because of the very low voltage ard current levels found in the electronic system, The connectors have a lock which secures the male and female termi- nals together. A secondary lock holds the seal and termi- nal into the connector. ‘When diagnosing, open circuits are often difficult 10 locate by sight because oxidation or terminal misalign- ment are hidden by the connectors. Merely wiggling @ Connector on a sensor or in the wiring hamess may Tocate the open circuit condition. ‘This should always be considered when an open cit- ‘cut or failed sensor is indicated. Intermittent problems may also be caused by oxidized or loose connections. [Before making a connector repair, be cectain of the type of connector. Weather-Pack and Compact Three connectors look similar but are serviced differently Metri-Pack Series 150 Terminals ‘Some electronic control module thamess connectors contain terminals called Metr-Pack (see Figure 3-21). ‘These are used af the cdolant temperature sensor. Metri-Pack terminals are also called “Pullo-Seat” terminals because 10 install a terminal on a wire, the wire is first inserted through the seal and connectot. The terminal is then crimped on the wire, and the terminal pulled back into the connector to seat it in place. cone wc MsuLATION wines: MATING END cae TYPICAL PUSH-TO-SEAT TERMINAL ‘coREWaNGs — MATINGEND mnsbuaTion seal ‘wanes ‘TYPICAL WEATHER PACK® TERMINAL Ms nisst Figure $20 Terminal Repair ‘To remove a terminal: ‘Slide the seal back on the wire. Insert tool as shown in Figure 3-21 insert “A”. to release the terminal locking tang. Weather-Pack Connectors Figure 3-22 shows a Weather-Pack connector and the tool required to service it, This tool is used to femove the pin and sleeve terminals. If terminal removal is attempted with an ordinary pick. there is a good chance that the terminal will be bent or deformed, and unlike standard blade type terminals, these terminals ‘cannot be straightened once they are bent \VAz SERVICE MANUAL THROTTLE BODY BVECTION NVA 20| 3:14 ENGINE MANAGEMENT SYSTEMS 1.7L THROTTLE BODY INJECTION 2 seal 2. REMOVE TERMINAL USING TOOL TERMINATREMOVAL TOOL 28125-10 ‘3 GT WRE IMMEDIATELY BEAD CABLE SEAL 5. PUSH TERMINAL AND CONNECTOR ENGAGE LOCKING TANS 6. CLOSE SECONDARY LOCK HINGE Figure 3-22 Weather-Pack Terminal Repair c s J 1 METRLPACK SERS {SO FEMALE TERMINAL 3 CONNECTOR B00y 4 toouwe TANG 5 TOOL sE1514 tans as tect Figure 3-21: Metri-Pack Series 150 Terminal Removal ‘Make certain that the connectors are properly seated and all of the sealing rings in place when connecting eads. The hinge-type flap provides a secondary locking ‘feature for the connector. improves the connector reli- ability by retaining the terminals if the small terminal Tock tangs are not positioned properly. Weather-Pack connections cannot be replaced with standard connections, Instructions are provided with ‘Weather-Pack connector and terminal packages. Compact Thrée Connectors ‘The Compact Three connector, which looks similar to a Weather-Pack connector, is not sealed and is used ‘where resistance 10 the environment is nex required. Use the standard method when repairing a terminal, Micro-Pack Connectors, ‘Micro-Pack reminal (see Figure 3:23) replacement -Fequires the use of th special tool shown: TOOLS NEEDED TO SERVICE THE SYSTEM ‘The system requires Tech 1 Scan’ too, tet light, ‘ohmmeter, digital volumeter with 10 megobras imped- ance, vacuum gage and jumper wires for diagnosis. A test light or volimetermiust be used when speciied in the procedures (Figure 3-24). See Section 6 - Special ‘Tools needed to diagnose or repair 2 system. For more complete information on the operation of these tls, ‘consult the tool manufacturers instructions. LAE SERVICE MANUAL THROTTLE BODY JECTION NVA, aENGINE MANAGEMENT SYSTEMS 1.7L THROTTLE BODY INJECTION 3-15 WIRING HARNESS SERVICE ‘To mect GM engineering repair standards, use Ter- minal Repair Kit, | 39745, 10 repair wiring and replace Connectors. The kit includes crimping tools, hardware, {emminal emoval tools, heat torch and instruction manu- fl. Wire hamesses should be replaced with proper part umber harnesses. When signal wires are spliced into 8 Famess, use wire oth high temperanie insulanon only See Figure 3-25 for instuctions. With the low current and voltage levels found in the system, tt 8 important that the best possible bond be made at all wite splices by soldering the splices as shown, ‘Use care when probing a connector or replacing connector terminals. It is possible to short between ‘opposite terminals. If this happens, certain components can be damaged. Always use fused jumper wires be tween connectors for circuit checking. NEVER probe through connector seals, wire insulation, secondary igni- tion wires, boots, nipples, or covers. Even microscopic damage of boles may result in evennual water intrusion, ‘corrosion and/or component or circuit failure. CHECKING TERMINAL CONTACT ‘When diagnosing an electrical system that utilizes Metri-Pack 150/280/480 series terminals (refer to Ter- ‘minal Repair Kit J 3974S instruction manual for termi- zal identification), itis important to check terminal con- tact between a connector and component, or between if- line connectors, before replacing a suspect component. ‘This is especially true for the Metri-Pack 150 series {female terminal. Frequently, a diagnostic char leads to a step that reads. "Check for poor connection or replace..." Re- placing a component may, at best, temporarily cire a Connection problem. Eventually the connection will Weaken and cause a repeat failure. Mating terminals ‘must be inspected to assure good terminal contact or Correct a poor connection. Poor connection between the ‘male and female terminal at a connector is the result of contamination or deformation. Contamination i¢ caused by the connector halves being improperty joined, a missing or damaged connec tor seal, or damage to the connector itself, exposing the temminais to moisture ark’ din. Contamination, usually t© tunderhood or underbody connectors, teads to terminal ‘corrosion, causing an open circuit or intemnittently open circuit. ‘Deformation is caused by probing the matina side of ‘a connector terminal without the proper adapter, improperly joining the connector halves or repeatedly separating and joining the connector halves. Deforms tion, usually to the female terminal contact tang. c3n result in poor terminal contact causing an open of inter rmigenily open circuit. Follow the procedure below 10 check terminal con et 1. Separate the connector halves. refer 10 Terminal Repair Kit 139745 iosuruction manual 2, Inspect the connector halves for contamination. ‘Contamination will result in a white or green build- ‘up within the connector body or between terminals, causing high terminal resistance, intermittent con nection or af open circuit. An underhood or under- ‘body connector that shows signs of contamination should be replaced in its entirety, terminals, seals and connector body. 3. Using an equivalent male terminal from the Termi- nal Repair Kit J 39745, check ue retention forcr of the female terminal in question by inserting ané removing the male terminal to the female termine! in the connector body. Good terminal contact will require a cerain amount of force to separate the ter rminals. 4, Using an equivalent female terminal from the Tee- ‘minal Repair Kit J°39745, compare the retention fotce of tis terminal to the female terminal in ques tion by joining and separating the male terminal 10 the good female terminal, and then joining and sep2- rating the male terminal to the female terminal in question, [f the retention force is significantly differ- ‘ent between the two female verminals, feplace the female terminal in question, refer to Terminal Repair Kit} 39745. “ss '5. Push the wire and terminal out through the connec tor. If the terminal is being reused, reshape the locking tang. \VAZ SERVICE MANUAL THROTTLE BODY INJECTION NVA an£ £ =“ oy |} HTL TOOL I PLACE, GENTLY PULL ON THE CABLE TO REMOVE Tiana - ——— 4 VISUALLY ceo TERMINAL AND REPLAGEIF 1. ASR CAME AND Pst TERMENAL TO THE MOST “TREALINRTY OR TANG DAMAGED. fonwant ‘S MSTAUL TERMINAL WTO CONNECTOR CAVITY 2 mse Toot seus. sas po Tae RET LOGRING TANG HAS SNAPPED INTO POSTION. {FRONT Orme CONNECTOR CAUTYDO WOT USE ‘CONVENTIONAL PEK TO REMOVE FERMONAL Ms r0016 ce Figure 3-23 Micro-Pack Terminal Replacement Ifthe ammeter indicates fess than 1/4 amp cirrent low (25 6r250 ma), the tesight is safe w use. Ifthe ammeter indicates more than 1 amp current flow (25a or 250 ma), the testight is not safe to use. Figure 3:24 Test Light Check 'VAZ SERVICE MANUAL THROTTLE BODY INJECTION NVA,ENGINE MANAGEMENT SYSTEMS 1.7L THROTTLE BODY INJECTION 3-17 1. REMOVE OUTER JACKET, SS SCE 1. tocaTe DAMAGE WiRe. 2. UNWRAP ALUMINUM/HKYLAR TAPE. DO NOTREMOVE MYLAR. | 2. REMOVE MGSULATION AS REQUIRED. Tra ees 2. SPUCE TWO Waites TOGETHER USING SPLICE CLIPS 3. UNTWIST CONDUCTORS. STRIP INSULATION AS NECESSARY. Srpcemvo wanss rose (Sez VES} 4. SPucE Wines ustuG sPucE cus AND ROSIN CORE SOLDER. Winae AGH sPiles 10 RGULATE. [5 WRAP WITH MYLAR AND DRAIN (UGRSLATEDD WE. “4 gover sae wr rare ro msuLaTe mM 5. REMWST AS BEFORE AND TAPE WATH ELECTRICAL cA onereees {TAPE OVER WHOLE BUNDLE TO SECURE AS BEFORE. Figure 3-25 Wiring Hamess Repeir Figure 3-26 Electronic control Module Terminal Probe Technique ‘Vaz SERVICE MANUAL THROTTLE BODY INAECTION IVA &cay y Pa 79 e 3.1 ELECTRONIC CONTROL MODULE AND SENSORS ELECTRONIC CONTROL MODULE If the diagnostic procedures call for the electronic ‘control module to be replaced, the engine calibfator and electronic controi module shouldbe checked first to see if they are the comect pans. If they are, remove the ‘engine calibrator from the faulty electronic conerol mod ule and install it in the new service electronic control module. THE SERVICE electronic control module WILL NOT CONTAIN AN engine calibrator. Code 61 indicates the engine calibrator is installed impcoperty or hhas malfunctioned. When Code 51 is obtained, check the engine ¢alibrator installation for bent pins or pins ‘not fully seated in the socket. If the engine calibrator is ‘installed correctly and Code 5t still shows, replace the ‘engine calibrator. LOCATION: Driver's side of vehicle, behind kick panel LZ] important ‘+ When replacing the production electronic controt ‘module with a service electronic control module, it is linporant to transfer the calibrator identification and production electronic control modiile number to the service electronic control module Tabel (see Fig- ‘ure 3.1-1), Pléase do not record on electronic con- ‘ok module cover. This will allow positive identifi ‘cation of electronic control module parts throughout the service life of the vehicle. NOTICE: To prevent intemal electronic control mod- “le damage, the ignition must be “OFF” when dis- [EW] Remove or Disconnect 1, Negative banery cable. . 2Driver’s kick panel. 3. Electronic control module from bracket and connec- tors. (See Figure 31-2.) 4. Engine calibrator access cover (Soe Figure 3.1-3) 5. Engine calibrator from electronic control module. 18 ENGINE MANAGEMENT SYSTEMS 1.7L THROTTLE BODY INJECTION Figure 3.1-2 Electronic Control Module Location View \VAZ SERVICE MANUAL THROTTLE BODY WHECTON KIVA,ENGINE MANAGEMENT SYSTEMS 1.7L THROTTLE BODY INJECTION 3-19 Figure 3.1.3 Electronic control Module Engine ‘allbeator Access Cover ‘© Using two fingers, push both retaining clips back away from the engine calibrator at the same time (Gee Figure 3.1-4). Grasp the engine calibrator at both ends and lift up out of socket. Do not remove the cover ofthe engine cali- trator. Use of unapproved engine calibrator removal methods will cause damage tothe engine calibrator or engine calibrator socket. ‘© For alignment noiches-of the engine calibrator and ‘carefully set aside. Do not open the engine calibra (¢ The engine calibrator wo determine if a cork spacer is glued to the top side of the engine calibrator assembly. If yes, remove it prior to installation. fog install or Connect 1. Old engine calibrator in new electronic control module. PRApN Figure 3.14 Engine Calibrator Removal [¥] important ‘© Align the seal notches with maiching notches in-the electronic control module's engine cali ‘VERY GENTLY press down on the ends of the engine calibrator until the locking levers 27 ‘orated toward the sides of the engine calfbratot Figure 31-5) NOTICE: To avoid electron contol module dam- sage, DO NOT press on the ends of the exgie cali- ‘brator until the levers snap into place, DO NOT use aay vertical force beyond the minimum required engage the engine calibrator into its socket. ‘While concinuing light pressure on the ends of the engine calibrator, use your index fingers t0 ‘press the locking levers inward until they are ‘snapped into place. Listen forthe click. Engine calibrator cover. ‘Hlectronic control modile into vehicle. Connectors. Driver's kick pane. Negative banery cable. \VAR SERVICE MANUAL THROTTLEBOOY BUECTION NVA—y e i 23 Sao 7 Bey tastalt or Connect “1, “Old engine calibrator in new electronic control 3:20 ENGINE MANAGEMENT SYSTEMS 1.7L THROTTLE BODY INJECTION ENGINE CAUBRATOR Code $1 indicates a faulty engine calibrator, bent pins, or incorrect installation, LZ] tmportant * The engine calibrator is “keyed 1 probit improp- insertion, However, itis essential thatthe comect ‘engine calibrator be used with a specific model NOTICE: The ignition should always be “OFF” ‘when installing or removing the electronic control ‘module connectors, LOCATION: Under access cover of electronic control module. Figure 3.13), [Ey] Remove or Disconnect 1 Negative banery cable. 2 Driver's Kick panel, Electronic control module mounting hatware ‘Connectors from electron conto module. “Blectronie control module from passenger compan- ment Eleewonic control modale acess cover ‘Remove engine calibrator assembly. Figure 3.1-4). 72) Inspect ‘©The engine calibrator to determine if a cork spacet is glued to the top side of the engine calibrator assembly. If yes, remove it prior to installation. vee pe Do tmportant ‘Align the small notches with matching notches in the electronic controt module's engive call trator socket YERY GENTLY pres down on he cds of he engine calibrator until the locking levers, are rotated toward the sides of the engine cSlibrator. Figure 3.1-5), NOTICE: To avoid electronic contol module damage, DONGT press on the Ends of the engine calibrator until ‘the levers snap into place. DO NOT use any vertical force beyond the minimum required to engage the engine calibrator ino its socket. | PLAGE BVGNE CALIBRATOR IN CALIBRATOR SOCKET 2 PUSH DOWN Gey 2 PUSH INWARD UNTIL LATOIES ARE SECURE Figure 3.1-5 Engine Calibrator installation ‘While continuing tight pressure on the ends of the engine calibrator, use your index fingers 10 ‘ress the locking levers inward until they are ‘snapped into place. Listen for the click. 4i¢ Control module into vehicle. Driver's kick panel. 5. Negative banery cable, FUNCTIONAL CHECK 1. Tum ignition “ON.” 2. Enver diagnostics (see diagnostic circuit check for procedure). A.Code 12 should flash at least four times. (No other codes present), This indicates the engine calloratoris installed properly. oe ‘BI Code $1 occurs or if the “Check Engine” ligh, is “ON* constantly with no codes, the engine cal- Fbrator i not fully seated, has bent pins, or is defeczive. 1 If not fully seated, press firmly on engine cali- brator assembly (Figure 3.1-5). + If pins bend, remove engine calibrator, straighten pins, and reinstall \VAZ SERVICE MANUAL THROTTLE BODY INJECTION NVA, TS meas #80 rte ane ae aENGINE MANAGEMENT SYSTEMS 1.7L THROTTLE BODY INJECTION, 3:27 COOLANT TEMPERATURE SENSOR Figures 3.1-6 and 3.1-7 [U] important © Care must be taken when handling coolant sensor. Damage to coolant sensor wil! affect proper opera- tion of the Foe! Injection system. fe Remove or Disconnect 1, Ignition “OFE” 2. Exectrical connector. 3. Carefully back out coolant temperature sensor. Figure 3.¥6 Coolant Temperature Sensor Beg Install or Connect 1. Sensor in engine. 2) Blecrical connector | COOLANT TEMPERATURE SENSOR LOCATION. 2 THROTTLE BODY INJECTION UNIT | ENGINE RADIATOR, Figure 3:1-7 Coolant Temperature Sensor Location \VAZ SERVICE MANUAL THROTTLE BOOY INJECTION MIVAoye oy ie i) baal “3 oy 3-22_ENGINE MANAGEMENT SYSTEMS 4.7L THROTTLE BODY INJECTION Figure 3.1-8 Octane Adjust Potentiometar ‘oeation | OCTANE ADJUSTMENT POTENTIOMETER Figures 3.1-8 and 3.1-9 FA] Remove or Disconnect: Beg install or Connect ‘Octane adjustment pétentiometer. ‘Mounting serew(s). Electrical connector. ‘The octane adjust potentiometer is preset atthe fac- tory at 0° of retard. If an adjustment is needed, refer 1 CHART C15. Tigre 31-11, Manifold Absolute Pressure ‘Sensor Location MANIFOLD ABSOLUTE PRESSURE SENSOR Figure 3.1-90 aod 3.1-19 Other than checking for loose hoses and electrical connections, the only service possible is unit replace- ‘ment if diagnosis shows sensor tobe faulty. [Remove or Disconnect 1. Remove ar cleaner, 2. Manifold absolute pressure tose. 3. Manifold absolute pressure eleerical connector. 4, Mounting screws. 'S. Manifold absolute pressure sensor. Beg install of Connect {L, Manifold absolute pressure sensor. 2, Mounting serews. 3. Manifold absolute pressure electrical connector, 4. Manifold absolute pressure hose. 5. Aircleaner. \VAE SERVICE MANUAL THROTTLE BODY JECTION NIVA onENGINE MANAGEMENT SYSTEMS 1.7L THROTTLE BODY INJECTION 3-23 “TEL METER ASSEMBLY 2 THROTTLE BODY ASSEMBLY 3 THROTTLE POSTON sexsOR 4 THROTTLE POSTION SENSOR SCREW &. Figure 3.143 Throttle Position Sensor Location ‘THROTTLE POSITION SENSOR Figure 3.1-12 and 3.1-13 [Ey Remove or Disconnect 1. Aircleanes 2. Electrical connectox 3. Two throttle position sensor attaching screws and Jock washers. 4. Sensor fq Install or connect ‘Thretde position sensor on throttle body assembly with throttle valve in normal closed position, and throtle position sensor drive tangs aligned with Nats com end of the shaft. 2. Throttle position sensor attaching screw and washer assembly on throtle position sensor assembly. 3. Electrical connector. 4 Aircleaner {ELECTRICAL CONNECTOR 2 VEHICLE SPEED SENSOR ns 13180 “TRANSFER GEARCASE 4 SPECDOMETER CABLE 2 VEMGESREED SENSOR 5 CAP 2 WE TE CANE RETAINER Figure 3.115 Vehicle Speed Sensor Location Tighten ‘© Attaching screws to 2.0 N-m (18 Ib. in.). VEHICLE SPEED SENSOR Figure 3.1-14 and 3.1.-15, [Fy Remove or Disconnect 1. Three wire hamess connectors. 2. Wire tie cable retainer that secures the vehicle speed. sensor connector to the rable. 3, Vehicle speed sensor from transmission connection. faq install or Connect 1, Vehicle speed sensor to transmission connection. 2. Cable that secures the vehicle speed sensor to the speedometer. 3, Three wire hamess connectors. \VAZ SERVICE MANUAL THROTILE BODY INIECTION MIVASeb oa my yy ae sy Figure 3.1-17 Oxygen Sensor Location 3:24 ENGINE MANAGEMENT SYSTEMS 1.7L THROTTLE BODY INJECTION OXYGEN SENSOR Figures 3.1-16 and 3.1-17 [FJ Remove or Disconnect 1, Negative batery cable 2. Electrical connector. 3. Carefully back out oxygen sensor. ©The oxygen sensor may be difficult to remove when engine temperauire is below 48°C. Excessive fore: tay damage threads in exhaust manifold or exhaust ire, 1 tmportant @ Take care when handling the new oxyBen sensor Toe inline electrical connector and louvered end ‘Bust be kept fice of grease, dirt or other conai- ams. Also, void using cleaning solvens of any type, Do not drop or roughly handle the onygen sensor. Beg install or connect [important © A special anti-seize compound is used on the ‘oxygen sensof Uneads. The compound consists ofa liquid graphite and glass beads. The graphite wil bum away, but the glass beads-wil Femain, making the sensor easier w remove New of service sensors will already have the compound applied to the treads. 1. Sensor and torque 9-41 Nim. QO 1b. ft). ‘VAT SERVICE MANUAL THROTILE BODY INIECTION NIVA22 ENGINE MANAGEMENT SYSTEMS 1.7L THROTTLE BODY INJECTION 3-25 INTAKE AIR TEMPERATURE SENSOR Figures 3.1-18 and 3.1-19 ‘The intake air temperature sensor is located in the air cleanes, The sensor is threaded imo the arr cleaner a, shown in Figure 31-19. Be careful not to over igen the sensor as you insall it nto te ar cleaner. fx] Remove or Disconnect 1. Blectrical connector 2. Sensor Fe Install or Connect 1. Sensor 2, Blectrcal connector. is 1506 Figure 31-18 intake Air Temperature Sensor 1 RLTER ELEMENT LD. NO. 2 GROMMET 13 TAKE AIR THAPERATURE SENSOR. Figure 3.1-19 Intake Air Temperature Sensor Location View \VAZ SERVICE MANUAL THROTTLE BODY INIECTION MIVASey ee ey my 3:26_ENGINE MANAGEMENT SYSTEMS 1.7L THROTTLE BODY INJECTION 3.2 FUEL CONTROL SYSTEM FUEL CONTROL ‘Always start with the “Diagnostic Circuit Check” in Section “2”. This will reduce disgnosis time and prevent vnnecessary replacement of parts. The information in this check will direct diagnosis conceming "Engine (Cranks But Won't Run" and the Fuel Consol Systema, including diagnosis of the injector, pressure regulator, fuel pump and fuel system relay, Idle Air Control valve ‘A Tech 1 “Scan” tool reads ile air control valve position in “Counts” (or steps). "0" steps indicates the electronic control module is commanding the idle air control valve to be driven in, o a fully seated position ‘(quinimum idle ait). The higher the number of steps, the ‘more idle air is being allowed to pass by the idle aircon- ‘wol vale. Refer to CHART C-2C to diagnose the operation of the idle air control valve. +1 THROTTLE BODY HUECTOR UNIT 2 FURLPUMP 1 RIEL SUPALY PRESSURE UNE ON-VEHICLE SERVICE GENERAL SERVICE INFORMATION. ‘CAUTION: © To prevent personal injury or damage to the vehicle as the result of an accidental start, dis- connect and reconnect the negative battery ‘able before and after service is performed. ‘© To minimize the Fisk of fire or personal injury. relieve the fuel system pressure before servicing the throttle body injection unit or any of its fuel handling components. (See “Fuel Pressure Relief Procedure," page 3-28) ‘© Also, catch any fuel that leaks out when discon- necting the fuel lines by covering the fittings ‘with a shop doth. Place the cloth in an approved Container when work is complete, 4 FUE FTE 5 FUEL PRESSURE. Test SITTING PARPOP SEGAL TOOL! 38970) (6 PUBL RETURN LE Figure 3.244 Fuel System {AZ SERVICE MANUAL THROTTLE BODY WWECTION NIVA aaENGINE MANAGEMENT SYSTEMS 1.7L THROTTLE BODY INJECTION 3-27 +1 VAPOR UQUID SEPARATOR 2 ROLLOVER VALVE 21 TANK PRESSURE CONTROL VALVE 4 sioworrvaive oavorvenst | a ssseuner nator | wurSarnaethoy Bee 2 THROTTLE BODY INJECTION ~ IDENTIFICATION 150047. Figure 3.2-3 Throttle Body injection Mentification raTeR 6 EVAPORATIVE Loss caMSTER 1 AIR VENT PE 1 PUMPIN TANK. is tua Figure 3.2-2 Additional Fuel System Components in Relation to Location on NiVA ‘The throttle body injection unit repair procedures ‘cover component replacement with the unit on the vehi- le. However, throttle body replacement requires that ‘the complete unit be removed from the engine. Refer 10 the disassembled view (Figure 3.2-2, see Page 3-31) for identification of pans during repair pro- ‘cedures: Service repair of individual componeris is per- formed without removing the throite body injection unit from the engine. SERVICE IDENTIFICATION “The Model 700 throtle body injection unit is sup- plied with the following standard markings: + Model Number. + Day, Year, Plant, Shift and Source code. \VAZ SERVICE MANUAL THROTTLE BODY IVECTION NIVA3:28_ENGINE MANAGEMENT SYSTEMS 1.7L THROTTLE BODY INJECTION Figure 3.2-5 Fuel Pump Connector FUEL PRESSURE RELIEF PROCEDURE ‘The throtle body injection Model 700 contains 2 “checking” fuel feature. This means that fuel pressure is maintained after the engine is shut “OFF.” Ia order e bed the system, the following procedure must be fol- 5 lowed. 1. Place transmission selector in neutral, set parking c 1 REAR SEATIN FORWARD" POSTION brake, and block drive wheels p 2 MATICARPETING COVERING REAR STORAGE AREA cee ries Sra Comerar at fel pump Fig - 9 rUELeUMe Accass cove 3. Sam engine and alow oie ant tsps ming 4. Engage stare for three seconds to dissipate fuet pressure in lings. Fuel connéctions are now sife for a Tigre 32-4 Fuel Pump Accass Panel Location View servicing. F 5. When pressure is relieved and servicing is complete, # reconnect fuel pump connecto, ‘The fuel meter assembly is rollmarked with an eight (®) digit model number, date (lulian), year, assembly FUEL SYSTEM PRESSURE TEST = Plant code, shift identification and source code. Figure fue) re tests pat of several of te 3.23 shows the rollmatk fommat. Refer to tis model giagnosuc shane and symptom checks fo portant hnomber whien replacement is tequired. If the throme test follow ths procea re, ‘body injection Xs. removed, itis essential chat cate is ase taken’to prevent damage tothe tote valve or sealing 1. Tum engiie “OFF” and relieve fuel pressure, fo- surface while performing any service. lowing previous instructions under “Fuel Pressure ; “ Relief Procedure.” E ‘Whenever service is performed oft the throule body 2. Install fuel pressure gauge onto fuel pressure test fi- injection, first remove the air cleaner and air cleaner _‘ting making certain the connection is secure to e gasket. Discard the gasket and replace it with anew one avoid leaking fuel (Figures 32-6 and 3.2-7). before replacing the air cleaner after Service is complete. \Va2 SERVICE MANUAL THROTTLE BODY INJECTION RIVA,ENGINE MANAGEMENT SYSTEMS 1.7L THROTTLE BODY INJECTION 3-29 1 THROTTLE BODY MUECTION UN 2 FuRLPUNe 2 UEL SUPPLY PRESSURE UNE ' FUELPRESSURE TEST TING. (PART OF FOOL 38870¥) 6 FRUEL RETURN UNE 7 URL PRESSURE GAUGE (aRTOF TOOL 1289704) Figure 2.2-6 Fuel Pressure Test Figure 3.2-7 Fuel Pressure Fitting Location Energize fuel system relay by tuming ignition key 10 the "ON" position, Observe fuel pressure reading, it should be 191.6 10 206.8 kPa (27.8 10 30 psi, 19 to 2.1 bar), Ifnot, refer to Chart A-5 or A“7. Relieve fuel pressure. (See “Fuel Pressure Relief") Remove fuel pressure gauge from fuel pressure west 1 UWECTOR ASSEMBLY -T8 FUEL 2 SENSOR-THROTE POSTION (77) 3 BODY ASSEMILY - THROTTLE {¢ MODULE ASSEMBLY - TUBE 5 VALVE ASSEMBLY = IDLE AR CONTROL (AQ) 1 BODY ASSEMBLY - FUEL METER 7 REGULATOR ASSEMBLY - FUEL PRESSURE fing 6, Start vehicle and check for fuel leaks. aie 4 sta cleaner Figure 328 Thvotie Body wjecton 700 Components \VAZ SERVICE MANUAL THROTTLE BODY INJECTION NVA= =) Ei = yor = ~y 2 THROTTLE POSITION SENSOR (TPS) CONNECTOR as 19130] Figura 32-10 Throttle Body injection Wiring THROTTLE BODY INJECTION UNIT: If the tiroile body injection unit is removed, itis essential that care is taken to prevent damage to the throttle valve or sealing surface while perfonaing any service. When a service throttle body injection unit is installed, first remove the air cleaner and ar cleaner gas- ket. Discard the gasket and replace it with a new orie before replacing the air cleaner after service is complete, [Ey Remove or Disconnect 1 Electrical connectors for idle air control valve, throttle position sensor, and fuel injector (Figure 3.2410); 2 CRANKCASE VENTILATION 23 EVAPORATIVE EMISSION CONTROL SYSTEM es cer Figure 32-11 Vacuum Hoves: 2. Grommet with injector wires from throttle body injection assembly (Figure 32-9); 3. Throutle linkage. 4. Vacuum hoses, noting positions of hoses (Figure 32-11); $. Infet and outlet fuel hose nuts, using back-up ‘wrench (Figure 3.2-12), CAUTION: Refer to fuel, pressure relief procedure before servicing fuel systems. ‘See page 3-28. 6, Fuel line O-rings from nuts and discard. 7. Thromle body injection mounting hardware. 8. Thronle body injection unit from intake manifold Figure 32-13), 9. Throttle body injection flange (manifold mounting) gasket and discard, (NOTICE: Stuff the manifold opening with a rag to Prevent material from entering the engine, and Temove the old gasket materials from surface of intake manifold. \VAZ SERVICE MANUAL THROTTLE RODY INJECTION NIVA,ENGINE MANAGEMENT SYSTEMS 1.7L THROTTLE BODY INJECTION 3-31 1 SCREW = INJECTOR RETAINER ATTACHING 2 RETAINER -INIECTOR 2 SCEW- FUELMETER HODY THROTTLE BODY 4 RUEL METER BODY ASSEMBLY ‘5 SEAL- FUEL FITING 6 FRFTING FUEL LET 7 O-RING, FUEL UNE INLET NUT 15 GASKET - FUEL METER BODY TO THROTTLE BODY {9 THROTTLE BODY ASSEMBLY 40 ATMNG. FuELOUTLET 111 O-RING, FUELUINE OUTEET NUT {2 SENSOR, THROTTLEFOSTION (TPS) 13 SCREW ASSEMBLY -TPS ATTACHING 1 GASKET- ANGE 15 TUBE MODULE ASSEMBLY 16 SCREW TUBE MODULE ASSEMBLY Figure 32-28 Model 700 Throttle Body Injection Farts Klentification 17 FING, IAC VALVE | SCREW IAC VALVE ATTAQUNG “9 1OLE AM CONTROL GAC VALVE ASSEMBLY ‘29 Pu -1OUE STOP scREW 21 $OLE STOP SCREW ASSENLY 22 SPRING ILE STOP SCREW 23 SCREW - PRESSURE REGULATOR ATTACHING 24 PRESSURE REGULATOR COVER ASSEMBLY 25 SEAT PRESSURE REGULATOR SPRING. 26 SPRING- PRESSURE REGULATOR, 27 PRESSURE REGULATOR DAPHERAGM ASSEMBLY 28 O-RING. PUELINJECTOR -LOWER. 28 O-RING -FUELINIECTOR - UPPER 230 GASKET- AIR CLEANER 21 TBIMUECTOR ASSEMILY \VAZ SERVICE MANUAL THROTTLE BODY INJECTION NIVA,& 3:32 ENGINE MANAGEMENT SYSTEMS 1.7L THROTTLE BODY INJECTION 1 FunLsuerty 2 PUELRETURN Figure 32-12 Fuel Hoses {THROTTLE BOY NIECTOR ASSEMBLY 2 GasKeT 3 BOLT QT Hm se Figure 3.2-13 Removing Throttle Body Injection 700 unit 11 RUECTOR RETAINER SCREW 2 INUECTOR RETAINER 1 FUEL METER ASSEMILY ‘rULeUtcTORONKG LOWER ‘5 PUELNUECTOR O-AING UPPER) (6 FUGLHUECTOR ASSEMBLY Figure 3.2-14 Fuel injector Components FBI LB] ctean and inspect NOTICE: The throttle position sensor, idle air control ‘valve, pressurt regulator diaphragm assembly, fuel inctor, or other components containing rubber, SHOULD NOT te placed in a solvent or cleaner ‘buh. A chemica!reacton will cause thse pans © swell, harden or distort. Do not soak the tote body wih the above pans atached I the throtle body requires cleaning, soaking ime in he cleaner should be kept to a minimum. Some models have hidden throne shaft dus seals at could lose their effectiveness by extended soaking. 1. Clean al metal pans thoroughly, and blow dry with shop air. Be sure that all fuel ahd air passages aze free of din or burs, 2. Inspect mating casting surfaces for damage that could affect gasket sealing. ‘© Manifold bore for toose pans, foreign material, ete © Imake manifold sealing surfaces for cleanliness. \VAZ SERVICE MANUAL THROTTLE 8OOY NECTION KIVA,ENGINE MANAGEMENT SYSTEMS 1.71 THROTTLE BODY INJECTION 3:33 faq install or Connect 7, New throttle body injection flange (manifold mounting) gasket 2, Trot body injection with mounting hardware. Tighten {© Mounting hardware to 17 No (121b. ft). 3, New O-rings on fue line aus, 1h ScnSWoRTVE BLADE 2 Fuel line indt and outlet mus by hand. 8 cM 1 FUELINJETOR ASSEMALY Tighten © Inlet and outlet nuts to 27 Nem (20 Ib. ft.) (Use bacicap wrench to keep thronle body injec ‘on rus from taming.) Vacuum hoses. ‘Throttle Linkage. ‘Grommet with wires to fuel meter assembly. Electrical connectors, making sure“connectors are fully seated and latched. ‘Check to see if accelerator pedal is tree by depress- ‘ng pecal wo the floor and releasing while engine is “OFF.” Check for correct Wide Open Throttle adjusument. 10, Energize the fuel system relay by tuming the igni- tion key to the “ON” position and check for leaks. 11. Start engine and check for fuel leaks. FUEL INJECTOR ASSEMBLY Figures 3.2-14, 3.2-15, 3.2-16 and 3.2-17 CAUTION: Refer to.fuel pressure relief procedure before servicing fuel systems. See page 3-28. Replacement ‘The fuel injector is serviced only as @ complete assembly. NOTICE: Use care in removing injector, to prevent ‘damage to the electrical connector on top of the ‘injector, and nozzle. Also, because the fuel injector ig an electrical component, it should not be immersed in any type of liquid solvent or cleaner, as damage may occur. Figure 32-17 Fuel injector Part Number Location \VAZ SERVICE MANUAL THROTTLE BODY IXECTION NIVA 20a) oY, a) ey rc b moe nq my |. Electrical connector to fuel injector. 2. Injector retainer screw and retainer, 3 Using a fulcrum, place screwdriver blade under {dec Opposite connector end and carefully pry injector out (Figure 32-15), 4 Remove upper and Jower O-rings from injector and in fuel injector cavity and discard. Inspect * Fuel injector fers for evidence of dit and contam. ination. The upper (large diameter) filter is the urge filter, the lower (smaller diameter) filter is the inlet fer. If present, check for presence of dint iq fuel lines ahd fuel tank. important . Be sure to replace the injector with an i identical pan. Injectors from other models can fit in the Model 100 {htoitle body injection, but are calibrated for ditfer {mt flow rates, (See Figure 3.2-17 for part number ) FE instant or connect 1. Latricate new upper ard lower O:tings with auto- ‘Wansmission fh “age [EJ important * Be sure the electrical connector end 9 the injector is.fa in the general. ‘Of the athe onan ‘grommet. 3. Injector retainer, using’ iate thread coot retdines using appropri Tocking 4. ‘Electrical connector to fuel injector. Ey Tighten © Injector retainer attaching screw to 3.0 Num (280%. in). Energize the fuel system relay by niming the tgni: Sion Key tthe “ON” posion and check for leaks 1 PRESSURE REGULATOR COVER ASseMELY 2 COVER SCREW AND WASHER ASSEMaLY 3 snc seat ie 700 snare taglcor =" PRESSURE REGULATOR ASSEMBLY CAUTION: Refer to fuel Pressure relief procedure before servicing fuel systems. See page 3-28. Replac nt Figure 312-18 NOTICE: To prevent leaks, the pressure eguletor assembly must be replaced whenever the covers reoved, Fy Remove or disconnect 1. Four pressure regulator attaching Screws, while ‘keeping pressure regulator compressod. CAUTION: The pressure regulator con: tains latge spring under heavy com. Pression. Use’ tare'when removing the Screws to prevent personal injury. TE osoec + Pes el ery ny pitting, irregularities. (Use magnifying © glass: )). If any Of above is present. the body casting. must be replaced. \VAZ SERVICE MANUAL THROTTLE BODY IVECTION NVAENGINE MANAGEMENT SYSTEMS 1.7L THRQTTLE BODY INJECTION 3:35 1 FUELINECTOR 2 INJECTOR RETAINER 2 FUEL METER BODY ATTACHING SCREW AND WASHER ASSEMBLY 4 FUEL METER ASSEMBLY ‘5 FUEL METER BODY TO THROTTLE BODY GASKET 6 FUEL OUTLET KUT 7 FUEL UNE OUTLET HUT OG. 1 FUEL NUT SEAL 19 PRESSURE REGULATOR COVER ASSEMBLY 10 AIR FRTER GASEET Figure 32-19 Fuel Meter Assembly fig Install of Connect 1. New pressure regulator diaphragm assembly, mak- ing sure it is seated in groove in fuel meter body: 2.’ Regulator spring seat and Spring ino cover assem- ba 3. Cover assembly over diaphragm, while aligning mourting holes, NOTICE: Use care while installing the pressure reeu- Jatorto prevent misalignment of diaphragm and pos: sible leaks ‘© Attaching screw assembiies to 2.5 Neat 22.0 16. in). 5. Energize the fuel system relay by cuming the igni- tion key to the “ON" position and check for leaks. FUEL METER ASSEMBLY CAUTION: Refer to fuel pressure relief procedure before servicing fuel systems. ‘See page 3-28. Replacement Figure 3.2-19 Fy Remove or Disconnect ‘Blecrical connector from fuel injector ‘Growmimet with witts from fuel meter assembly. Tplet and outlet fuel line nuts, using back-up wrench. Fuel ine O-rings from nuts and discard. "Thrvitle body injection mounting hardware. ‘Two fuel meter body attaching screw and washer assemblies. Fuel meter assembly from throttle body assembly Fuel meter body to throte body gasket and discard Ee Install or Connect 1, New fuel meter body to thronle body gasket. Match fea-out portions of gasket with openings in throte ‘body assembly. 2, Fuel meter assembly. 3. Two fuel meter body attaching screw and washer assemblies that have been coated with appropriate locking compound. Batignten ‘© Attaching screws to 6.0 Nem (53 Ib. in.). 4. Thyotile body injection unit mounting hardware, px aye ENE © Mounting hardware to 17 N-m (12 tb. ft). 5, New O-rings on fuel Tine nuts. ‘6. Fuel line inlet and oudet nuts by hand. ighten fe Inlet and outlet nuts to 27 Nem (20 b, f.). (Use ‘back-up wrench to keep throtle body injection ‘us from taming.) Grommet with wires to fuel meter assembly. Bleetrical connector to fuel injector, making sure it 4s fully seated and latched. : 9. Bhergze the fuel system relay by turing de fis tion key tothe “ON” position and check for leaks. es Vad SERVICE MANUAL THROTTLE 8O0Y INJECTION NVA ae fos Bao ec "y 3:36_ENGINE MANAGEMENT SYSTEMS 1.7L THROTTLE BODY INJECTION, ‘THROTTLE POSITION SENSOR Replacement Figure 3.2-20 fea] Remove or Disconnect 1. Electrical connector from throtle position sensor. 2. Screw assemblies and throtle position sensor. NOTICE: The throttle position sensor is an electrical component and should not be immersed in any type Of liquid solvent or cleaner, as damage may result. fq install or Connect 1. With throttle valve in normally closed position, ‘install throule position sensor on throte shaft and rotate counterclockwise to align mounting holes. 2. Amtaching screw and washer assemblies. 3.. Electrical connector to throttle position sensor. 4. Check for throttle position sensor ourput as follows: © Connect Tech 1 10 read throtle position sensor ‘output voltage. “ *. With ignition "ON" and engine stopped, throne position sensor voliage should be less than 1.25 Volts. &f more than 1.25 volts, replace throttle position sensor. IDLE AIR CONTROL VALVE Replacement Figure 3.2-21 NOTICE: The idle air control valve is an electrical Somponent and must-not be soaked in’ any liquid ‘leaner oF solvent. Otherwise, damage could result [1] important ‘* On throttle body injection Model 700, the idle air control valve is lange mounted, with a dual taper 10 mm diameter pine. Lf replacement is necessary. ‘only an idle air controt valve identified with the cor- fect part number (having the appropriate pintle shape and diametet)shotld be used. 1 FUEL METER ASSEMBLY a TMRoTTEE sony ASSEMBLY 3 ToTME Poston SENSOR ACTS ATTAGANG ScREW AND, [WASHER ASSEMELY 1 IDLE AMR CONTROL VALVE O-RING 2 IDLE AIR CONTROL VALVE ATTACHING SCREW ASSEMBLY ‘A DISTANCE OF IUTLE EXTENSION 1 UAMETER OF PNTLE Figure 32-21 Flange Mount Idle Air Control Valve fy Remove or Disconnect ‘Electrical connector from idle air control valve. 2. Screw assemblies and idle air control valve. 3. Ile air control valve O-ring and discard. New O- ‘ing is included in service replacement kit, NOTICE: Before inserting the idle air conzol valve assembly, measure the distance from the idle ait ‘conti valve mounting flange to the point of the ile ait contol Valve pinte. Ifthe pile is extended too fat, damage to the idle air control valve asser- bly may result (Figure 32-21), Vaz SERVICE MANUAL THROTTLE BODY NECTION MvENGINE MANAGEMENT SYSTEMS 1.7L THROTTLE BODY INJECTION 3:37 Measure Distance from idle air control valve mounting flange to the point of pintle. Distance must be less than 28 mm, A Adjust, if necessary © If distance is greater than 28 mm, apply firm hand pressure to retract it. (A slight side-to-side ‘motion, may be helpful) fog Install or Connect T,_ New O-ring om idle air control valve. 2 Idle air conurol assembly in throttle body assembly swith attaching screws, 3, Electrical connector to idle aircontrl valve. [H] important No adjustment of tei aircon valve is mad after installation, With the Tech 1 connected and Signe roning eet “Maceo Tes" en She’spuem en "ide Rest Tis wil com- stad ie cern corgol moat wee te We air contol valve. ~ TUBE MODULE ASSEMBLY Replacement Figure 3.2-22 [Ay Remove or Disconnect .. Tibe module assetubly attaching screws. 2 Tube module assembly, 3. Tube module assembly gasket (O-ring) and discard. EB clean Old gasket (O-ring) material from surface of throtie body assembly to ensure proper seal of new gasket (Ong) Bq Install of Connect 1. New aube module assembly gasket (O-ring). 2) Tube module assembly. 3. Tube module assembly attaching sorews. Tighten ‘Screw assemblies to 3.0N-m (28.0 bin). {1 THMOTILE RODY ASSEMBLY 2 TURE MODULE ASSEMBLY 13 TURE MODULE ScREW ASSEMLY Figure 32-22 Tube Module Assembly THROTTLE BODY ASSEMBLY CAUTION: Refer to fuel pressure relief procedure before servicing fuel systems. ‘See page 3-28. Replacement Figure 3.2-23 NOTICE: Procedures related to replacement of the individual components below have been described previously and should be followed or damage could ‘occu, [9] Remove or Disconnect T. Tarot body injection unit. as described above. 2 Puel meter body-to-throtle body attaching screw and washer assemblies. 3, Fuel meter asembly. 4 Fuel meter body wo thronde body gasket and discard. [BA Disassemble ‘¢ Throitle positon sensor, idle air control valve and tube module assembly from old throtle body asser- bly, according 10 previous instructions. Assemble + Doi pon ses, ‘control valve, and tube module assembly onto replacement throwtle ‘body assembly, according to previous instructions. fag Install or Connect 1, New fuel meter body to throttle body gasket. 2 Feel meter assembly on throtie body assembly 3. Fuel meter body-to-throttle body attaching screw and washer assemblies. ‘Vaz SERVICE MANUAL THROTTLE BODY IIECTION NIVA bas te 4 ber be bes. besz an ey oy = 3:38 ENGINE MANAGEMENT SYSTEMS 1.7L THROTTLE BODY INJECON ‘8 THROTE BORE 1 MOTTE soDY ASSEMBLY 2 THROTTLE POSMON SENSOR ATTACHING SCREW A WASHER ASSEMBLY 3 THROTTLE POSTION SENSOR 4 TURE MODULE ASSEMALY, 'S TURE MODULE ATTAGING scnew ASSEMBLY ' IDLE AIR CONTROL VALVE ATTACHING SCREW 7 (DLE AR CONTROL VALVE {DLE stor ScxEW PLUG {9 IDLE STOP SCREW AND WASHER ASSEMBLY Figure 3.224 Fuel Pump Tighten ‘Screws to 6.0 N-m ($3 1b. in.). 4, Throttle body injection unit onto engine, as described in “Throtle Body Injection Unit.” FUEL PUMP CAUTION: Refer to fuel pressure relief procedure before servicing fuel systems. See page 3-28. Replacement. ‘The fuel pump (see Figure 32-24) is a roller vane type, electric pump, mounted inside of the fuet tank. Fuel is pumped at a positive pressure above 190.2 KPa 276 psi, 1.9 bar) from the fuel pump through the in-line filter tothe pressure regulator in the throule body injection assembly. Excess fuel is returned to the fuel ‘nk through the fuel return Tine. Yapor lock problems are reduced when using an electric pump because the fuel is pushed under pressure rather than pulled under vacuum, 4 condition that pro- ‘duces vapor: fe] Remove or Disconnect 1. Fold rear seat forward and lift up mat covering stor- age area, Fuel pump access cover, Fuel pump electrical connector (Figure 3.2-4 and 3225, Fuelllines. Fuel tank from vehicle after removing hold down straps and bolts. Fuel pump retaining bolts and carefully remove ‘pomp from tank, fig install or Connect 1. New fuet pump into fuel tank 2 Fuel pump retaining bolis, Tighten securely. 3. Fuel tank under vebicle and secure using hold down ‘Straps and bolts. 4. Fuel lines. eS Figure 33.35 Fuel Pump Connector Vaz SERVICE MANUAL THROTTLE BODY INIECTION NVA,pa ENGINE MANAGEMENT SYSTEMS 1.7L THROTTLE BODY INJECTION 3-39 ELECTRONIC ‘CONTROL 5. Fuel pump electical connector. 6. uel pump azoess cover. 7 Retum rar seat to normal positon. Energize the fuel system rélay by taming the igni- tion key to the “ON” position and check for leaks. FUEL PUMP ELECTRICAL CIRCUIT Figure 3.2-26 ‘When the ignition is first sumed “ON” without the ‘engine running, the electronic control module will tum the fuel pump relay “ON” for two seconds. This builds tp the fel pressure quickly Ifthe engine isnot cranked ‘within two seconds, the elesronic control module wil Shut the fuel pump “OFF” and wait for he reference sig ‘al. Aa soon as te engine is cranked, the eleeuonic con- Grol module will tn he relay “ON” and ren the fuek pump. FUEL SYSTEM RELAY Figure 3.2-27 “The fuel system relay is mounted in the fuse pane ‘Other than checking for loose connectors, the only $er- vice possible is replacement (see Figure 3.2227). \VAZ SERVICE MANUAL THROTTLE BOOY INJECTION RIVA be3:40_ENGINE MANAGEMENT SYSTEMS 1.7L THROTTLE BODY INJECTION. FUEL RcTER fected, GxoorNearTi SPaneTRE) Figure 3.2-28 Fuel Fitter FUEL FILTER: \UTION: Refer to fuel pressure relief procedure before servicing fuel systems. See page 3-28. Replacement Figure 3.2-28 [2] tmeortant ‘© Before proceeding, refer to the “Fuel Pressure Relief" procedute fotisd eater inthis section. =, FE Remove or Disconnect - 1. Fuet line to fuel filter atachment nuts. (Be careful ‘not to lose the O-rings that are installed between the fuel filter and fuet lines.) 2. Fuel filter hold down strap. [1 tmportant ‘Inspect O-rings for cuts, nicks or abrasions. Replace ‘if mecessary. fed instal or connect 1. Fuel filter hold-down strap. 2. Fuel line to fuel filter atachment ruts, including the rubber O-rings, Energize the fuel system relay by turing the igni- tuon key to the “ON” position and check for leaks. \VAZ SERVICE MANUAL THROTTLE BODY INJECTION NIVA coENGINE MANAGEMENT SYSTEMS 1.7L THROTTLE BODY INJECTION 3-41 3.3 EVAPORATIVE EMISSION CONTROL SYSTEM ON-VEHICLE SERVICE VISUAL CHECK OF CANISTER ‘¢ Cracked or damaged, replace canister. ‘+ Fuel leaking from bottom of canister vent hose, replace canister and check hoses and hose routing. FUEL VAPOR CANISTER [Ey Remove or Disconnect Tr Electrical connector. 2. Hoses from fuel vapor canister. 3, Attaching screws 2). 4. Fuel vapor canister 5. Reining clips. fq install or connect 1 Retaining eips. 2, Fuel vapor canister 25 removed. 3. Auaching screws (2) Fuel vapor canister attaching screws 3 Nem QT b. in). Figure 33-1 Vapor Canister FUEL VAPOR CANISTER HOSES Refer to “Vehicle Emission Control Information” label for routing of fuel vapor canister hoses. AZ SERVICE MANUAL THROTTLE BODY INJECTION SIVA be i3.42_ ENGINE MANAGEMENT SYSTEMS 1.7L THROTTLE BODY INJECTION 7 f rc ! o 1 COLD AR INTAKE 1 fuecrmc rue POM e 2 arr {2 FUELIALETTo THROTTLE BODY HUECTON UNTT : 2 TROTTE BOOT NUECTION UneT 18 FUGLACTURN ROM THROTTLE BOOY MMIECTON UT - 4 fuel sum {TANK PRESSURE CONTROL VALVE R 5 CANISTER PURGE 15 FUEL TANK VENT TO CAMESTER {6 ROLL OVER FUEL SHUT OFF VALVE 6 caNsTER 5 2 TANK PRESSURE RELIEF VALVE 1 RESHAR * 1 seraratoR 8 CAMSTER ELECTROWC VALVE 8 AROUTET PPE ‘9 FUELRETURN 10 FULPRE 20 HOT AR TAKE Figure 33-2 Evaporative Emission Control System ©” 24 Figure 3.33 Canistes Purge Solenoid - Removal \VAZ SERVICE MANUAL THROTTLE BODY INAECTION NIVAENGINE MANAGEMENT SYSTEMS 1.7L THROTTLE BODY INJECTION 3-43 3.4 DIRECT IGNITION SYSTEM ON-VEHICLE SERVICE DIRECT IGNITION SYSTEM ASSEMBLY Figures 3.4-1 and 3.4-2 [5 Remove ot bi 1. Negative battery cable 2. Direct ignition system electrical connectors, includ ‘ng hamess ground terminals from bracket. ‘Spark plug Wires. (Note proper relationship of wires to coils.) Direct ignition system assembly to engine bolts (3). Direct ignition system assembly from engine. 3 4 5 faq Install or Connect 1 2 Direct ignition system assembly to engine. Direct ignition system assembly to block bolis(3). ten ‘© Torque to 20-30 Nem (15-22 Ib f.). 3. Spark plug wires 1 proper coils. 4. Direct ignition system elecrical connectors hamess teminals 5. Negative batery cable. IGNITION COIL [5] Remove or Disconnect 1. Coil retaining screws (2 per coil) 2 Col from module, faq install or connect 1. Coil o module. 2 Coil retaining screws. fighten “Torque 104.5 Nm (40 bin). IGNITION MODULE fe Remove or Disconnect 1. Negative bartery cable. 2. Direct ignition system assembly from engine. (See previous procedure.) 3. Coils from assembly. (See previous procedure) 4. Module from assembly plate. 1 FGNTION SYSTEM MODULE. 12 ENGIME MANAGEMENT SYSTEM SIGHS Gnouno row as 13107 Figure 3.4-1 Ignition Components \VAZ SERVICE MANUAL THROTTLE BODY INJECTION NIVA 293-44_ENGINE MANAGEMENT SYSTEMS 1.7L THROTTLE BODY INJECTION, ns usta Figure 3.42 Direct ignition system Col Removal ‘fog Install or Connect Module ro assembly plate. 2. Coils. (See previous; Figure 34-4 Crankshaft Sensor Location View fq Install or Connect 1. Sensor into hold in block. 2. Sensor to block bolt (1). procedure.) 3. Direct ignition system assembly to engine. (See pre- ) ‘© Torque to 6-12 Nim (53-107 1b. in). 3. Sensorhamess connector at module. “ery ‘Figure 34-3 Crankshaft Sensor cea (CRANKSHAFT SENSOR Figures 3.4-3 and 3.4-4 FA] Remove or Disconnect e 1. Sensor hamess connector at module. ; 2. Sensor to block bolt (1). 3, Sensor from engine. E [BF inspect ‘* Sensor O-ring for wear, cracks or leakage. Replace n if necessary. Lube new O-ring with engine off a before installing. AZ SERVICE MANUAL THROTTLE BODY INJECTION RIVAENGINE MANAGEMENT SYSTEMS 1.7L THROTTLE BODY INJECTION 3-65 {INTAKE MANTFOLD HEATER CONNECTOR is 14s] 3.9 INTAKE MANIFOLD HEATER ON-VEHICLE SERVICE INTAKE MANIFOLD HEATER ASSEMBLY Figures 3.9-1 and 3.9-2 Fy Remove or Disconnect Negative bavery cable. 2, Inake manifold heater connector (Figure 39-1) 3. GQ) manifold hester to Intake manifold connecting bolts. 44, Intake manifold heater and gasket from underside of intake manifold (Figure 3.9-2) [EI important Figure 392 Wake Manifold Heater Removal Inspect gasket for cracks or tears. Replace if nces- sary. faq Install or Connect 1. Intake manifold heater and gasket 10 intake mani- to. 2. G) manifold heater to intake manifold connecting bots. 3. Intake manifold heater connector. 4. Negative battery cable. \VAZ SERVICE MANUAL THROTTLE BODY INFECTION NIVA