Repair Procedure
Figure 1 - VACUUM OPERATED SECONDARY CARBURETOR:
NOTE: SHELBY ONLY - BEFORE PROCEEDING MODIFY PN 4331609 WIRING HARNESS OVERLAY AS FOLLOWS:
A. Remove C2-16DB jumper lead from male blade 6-way and extract from assembly (Figure 1).
B. Insert PN 4304899 assembly in its place (Figure 1).
1. Using service manual procedures, unplug all vacuum lines, disconnect throttle linkages, and remove carburetor. Take special care to note where the CVSCO and CVSCC vacuum lines to the carburetor are connected. Also, note where the solekicker (if applicable) is attached. These vacuum lines are installed in the identical locations on the new carburetor. Return old carburetor by normal parts return procedure.
2. Remove flow control valve and hoses then discard.
3. Remove brake booster hose, discard the hose, clamps (and filter if applicable).
4. Install applicable new brake booster hose between brake booster and nipple at the rear of manifold (formerly flow control valve nipple). Use new clamps and secure.
5. Remove crankcase vent hose (air cleaner to [1][2]PCV) and discard.
6. Remove air cleaner-to-ESA hose for engine wiring connector access. Remove battery hold-down and move battery aside so as to allow clear access to the ESA module.
7. Remove ESA module and return old module by normal parts return procedure.
8. Install new ESA module, but do not connect wiring.
9. Remove EGR valve and discard. Clean gasket surface.
10. Install new EGR valve (and gaskets) corresponding to this application.
11. Install new carburetor making sure to replace the Carburetor Flange Gasket PN 4095975.
Figure 1 - VACUUM OPERATED SECONDARY CARBURETOR:
12. Route all vacuum lines to the same ports as original carburetor (Figure 1).
13. Connect the "pigtail" end of the Harness Overlay, PN 4331609, to the carburetor and main wiring assembly as shown (Figure 1). On Shelby only, mate the 2-way to the carburetor WOT (wide open throttle) switch.
Figure 2 - 2.2L-2V WIRING:
14. Route the 18 BK* wire of overlay harness along the cowl as shown (Figure 2) and tie wrap the wire to existing harness. Tie wrap the 18 BK* wire to the main harness along the shock tower.
Figure 3 - 2.2L-2V WIRING:
Figure 4 - 2.2L-2V WIRING WITH OVERLAY:
15. Locate the engine wiring harness connector (Figure 3) behind and below battery, Locate the 8-way connector and extract the male terminal (engine side) on the N8- 18BK/RD* wire. This is done by disconnecting the connector and, with a small screwdriver, lifting the locking finger from the terminal surface and then pulling the red and black wire straight back. Remove the loose single male insulator from the end of the new overlay and snap the extracted terminal (N8-18BK/RD*) into it. Mate the overlay harness to the extracted circuit on the engine harness (Figure 4). Tie wrap this connection around the existing engine wiring harness.
16. Plug the 8-way male connector back into the female end. (Be sure connector is full of grease. Use PN 4318063 Mopar Multipurpose Grease as required.
ESA/EFC CONNECTOR TO OVERLAYFIGURE 5.:
ESA/EFC CONNECTION LOCATIONFIGURE 6.:
17. Locate the 12-way connector at ESA module (Figures 5 and 6) and split this connector into two halves. Snap on the new connector from overlay wiring and tape back the old one to the original harness. Be sure overlay wiring is properly dressed and tie wrapped to main harness in this area.
18. Reinstall air cleaner to ESA hose.
19. Plug in 12 and 10-way connectors to ESA module. Install hose to vacuum transducer.
NOTE: APPLY TO THE ENDS OF 12-WAY AND 10-WAY INSULATORS A QUARTER INCH LAYER OF PN 4318063 MOPAR MULTIPURPOSE GREASE, USING A KNIFE JUST PRIOR TO ASSEMBLY.
19. Plug in 12-way connector to ESA module. Plug in 10-way connector and install hose to vacuum transducer.
20. Reinstall battery hold-down and put battery back into its tray. Tighten battery hold-down.
Figure 7 - O2 SENSOR TEST CONNECTION:
21. Locate O2 system test connector near left front shock tower (green* and black wires) (Figure 7).
22. Disconnect this connector and plug in the male plug from the overlay as shown. Tape over the old connector and tie wrap wiring harness (Figure 7).
Figure 8 - AN OVERVIEW OF WIRING OVERLAY:
23. The wiring is now complete. Recheck your work, the connections should be tight and installed correctly (Figure 8). All wiring should be dressed neatly.
24. Install new crankcase vent hose on PCV valve and route back underneath the new brake booster hose.
25. On vehicles equipped with high altitude compensator, install new compensator harness. Compensator ports on the V.O.S. carburetor are at the same general location as original carburetor.
26. Reinstall air cleaner and install Crankcase Vent Hose, PN 4343637, into crankcase vent hose nipple on air cleaner.
27. Wipe off old hose routing and VECI labels. Install new labels over the old ones.
28. Start engine and check for leaks.
29. Set curb idle and high fast idle to specifications.
FIGURE 9:
Type the Authorized Modification Label, PN 4275086, as shown in Figure 9 and install label next to or near the new VECI label.
POLICY: Reimbursable within the provisions of the warranty
TIME ALLOWANCE:
Labor Operation No 14-30-02-90 .. . ... ........... ... ..... 1.7 Hrs.
FAILURE CODE: AM - Authorized Modification