Service Procedure
FIGURE 1:
A. Injector test procedure using DRBII diagnostic tool:
1. Connect DRBII diagnostic tool to car using the SCI adapter cable (Figure 1).
Attach the adaptor cable red power supply lead to the battery positive post and the silver lead to the diagnostic plug.
2. When the DRBII is connected to the car, it will perform a self test to insure proper operation of the tool. When the test is complete, the display will read:
SELECT MODEL YEAR 1983-1985
PRESS F1, F2 FOR MORE
Service Procedure (Continued)
Press the [F2] key until the display reads:
SELECT MODEL YEAR 1986
PRESS F1, F2 FOR MORE
NOTE: The display must read 1986 even if an early 1987 model year
Sundance or Shadow is being tested
Once the display reads 1986, press the [YES] key.
3. After the model year is selected, the display will read:
SELECT ENGINE EFI -- TURBO
PRESS F1, F2 FOR MORE
If the display reads EFI -- TURBO, press the [YES] key. If the display reads CARBURETED, press the [F2] key until EFI -- TURBO appears and then press the [YES] key.
4. After the engine is selected, the display will read:
SELECT TEST ENGINE OFF
PRESS F1, F2 FOR MORE
Press the [F2] key until the display reads CAMPAIGN 397. Press the
[YES] key.
Service Procedure (Continued)
5. After CAMPAIGN 397 is selected, the display will read:
TURN OFF ACCESSORIES. REMOVE & PLUG PURGE LINE. START ENGINE USE NEUTRAL OR PARK.
FIGURE 2:
Make sure that all accessories are off.
Remove and plug the purge line shown in Figure 2. Place car in neutral or park and start engine.
6. The DRBII will automatically check the logic module to insure that the car is involved in this recall. If the car is not involved, the display will read:
CAMPAIGN 397 DOES NOT APPLY TO THIS VEHICLE
The DRBII will also check the logic module memory for fault code 52. If code 52 is set, the display will read:
INJECTOR TESTS RICH:
REPLACE INJECTOR.
Abort the test and proceed to Section A 10 (injector fails).
Service Procedure (Continued)
7. After the DRBII completes the fault code check, the display will read:
HAS THE INJECTOR BEEN CHANGED?
USE YES OR NO KEY
Press the [NO] key.
8. Next the DRBII will monitor the engine temperature.
- If the engine temperature is below 180~F, the display will read:
MONITORING ENGINE TEMPERATURE
TEMP= DEGREES F
- Once the engine temperature reaches 180~F, the display will read:
TURN ENGINE OFF AND THEN RESTART ENGINE
Shut off and immediately restart the car. If the car is shut off for over 3 minutes, the test will abort.
Service Procedure (Continued)
9. Once the car is restarted, the injector check procedure is automatic and requires no action by the mechanic. The following messages will appear on the display:
WAITING FOR CLOSED LOOP MODE
WAITING FOR (O2) SENSOR SWITCHING
TESTING FUEL INJECTOR FOR 30 SECONDS
The following messages will appear if the radiator cooling fan starts running during the test. The test will return to the above step when the fan stops.
PAUSE WHILE FAN ON
PAUSE 15 SECONDS WHILE ENGINE STABILIZES
Service Procedure (Continued)
10. When the test is complete, one of two messages will be displayed, - If the injector passes, a green light will appear and the display will read:
INJECTOR PASSES; RECONNECT PURGE LINE
Reconnect the purge line that was disconnected in Step A5 and disconnect the DRBII. Proceed to Section C.
- If the injector fails, a red light will appear and the following message will be displayed:
INJECTOR TESTS RICH; REPLACE INJECTOR.
Press the [NO] key and the display will read:
RECONNECT PURGE LINE DISCONNECT BATTERY AT BULLET CONNECTOR
Turn the engine off and reconnect the purge line. Disconnect the bullet connector located on the battery positive lead. Do not disconnect the
DRBII. Proceed to Section B for injector replacement.
Service Procedure (Continued)
B. Replace injector:
1. Remove the air cleaner assembly.
2. Perform fuel system pressure release as follows:
- Loosen gas cap to release tank pressure.
FIGURE 3:
- Disconnect injector wiring harness connector at locations shown in
Figure 3.
- Ground one terminal of the throttle body side connector.
- Connect a jumper wire to second terminal and touch the battery positive post for no longer than 10 seconds. This releases system pressure.
- Remove the jumper wires but leave the wiring harness disconnected.
3. Remove #20 Torx screw holding down the injector cap.
FIGURE 4:
4. With two small screwdrivers, lift the cap off the injector using the slots provided
(Figure 4).
FIGURE 5:
Service Procedure (Continued)
5. Using a screwdriver placed in the hole in the rear of the electrical connector, gently pry the injector from the pod
(Figure 5).
6. Make sure the injector lower O-ring has been removed from the pod.
7. Clean the throttle body fuel injector pod with carburetor cleaner.
8. From the parts package, place a new lower O-ring on the supplied injector and a new O-ring on the injector cap. The injector will have the
upper O-ring already installed.
9. Use a thin film of white petroleum jelly to lubricate the new O-rings. It is important to lubricate only the O-rings.
Note: Failure to do this step may result in fuel leaking past the O-rings.
FIGURE 6:
10. Place the injector in the pod. Position the injector so that the cap can be installed without interference (Figure 6).
11. Reinstall the cap and push down on it to ensure a good seal.
12. Install the Torx screw and torque to 40 inch pounds.
13. Reconnect the bullet connector removed in Step A 10 and tighten the gas cap.
Service Procedure (Continued)
14. Press the [NO] key on the DRBII
15. The display will read:
SELECT TEST CAMPAIGN 397
PRESS F1, F2 FOR MORE
Press the [F2] key until the display reads ENGINE OFF. Press the [YES] key.
16. After ENGINE OFF is selected, the display will read:
CYCLE KEY 3 TIMES
Turn the ignition switch on/off, on/off, on within 5 seconds.
17. Wait for the display to read:
55
READ
READ
Make sure READ is displayed. If not, press the HOLD key until READ is displayed.
Caution: Make sure that injector wiring harness connector disconnected in Step B 2 is still disconnected before going to next step.
Service Procedure (continued)
18. Press and hold the [ATM] key until the display reads:
(O2)
READ
Test (O2) activates the pump and pressurizes the system. Check to insure that there is no fuel leakage from the injector.
19. Tum off the ignition switch. Disconnect the DRBII. Reconnect the injector wiring harness connector that was disconnected in Step B 2.
Reinstall the air cleaner assembly.
C. Install the Recall Completion Label (California cars only):
1. With a ball point pen, print your dealer code (5 digits) on the owner supplied Recall Completion Label.
2. Peel the label from its backing and apply it next to the Vehicle Emission
Control Information Label.