Intake Manifold - Driveability Concerns

NO.:
18-13-92 Rev. A

GROUP:
Driveability

DATE:
Sep.21, 1992



SUBJECT:
Long Crank Time/Rough Idle/Tip-In Sag Or Hesitation When Cold



THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-13-92 WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS*.


NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 2.2L OR 2.5L TBI ENGINE.


MODELS:

1992
(AA) Acclaim/Spirit
(AC) Dynasty
(AG) Daytona
(AJ) Lebaron Coupe/Lebaron Convertible
(AP) Sundance/Shadow/Shadow Convertible
(AS) Caravan/Caravan CV/Voyager


SYMPTOM/CONDITION:

In cold ambient temperatures (below 35~F or 2~C), vehicles equipped with 4 cylinder TBI engines may exhibit one or more of the following conditions during initial start up:


- long crank times

- rough idle (for 2-3 minutes after starting vehicle)

- slight sag or hesitation on tip in from idle (for 2-3 minutes after starting vehicle)


These symptoms may be caused by poor fuel distribution within the intake manifold, when the engine is cold.



DIAGNOSIS:





Verify the customer complaint by cold starting the vehicle in conditions that are as close as possible to those described in under the Symptom/Condition heading (ambient temperature, soak time, etc.). Once the complaint has been verified, use the DRB II (Scan Tool) and the appropriate diagnostic procedures manual to verify that all of the vehicle engine systems are functioning properly (no fault codes [diagnostic trouble codes] are present). If no trouble codes are present inspect the intake manifold for a raised "X" cast into the number 1 runner. The "X" is located under the letter "F" in the words "FIRING ORDER" on the top of the number 1 intake manifold runner as illustrated. Intake manifolds that DO NOT have a "X" should be replaced using the following procedure.



PARTS REQUIRED:

1 Intake Manifold Assembly

Non EGR Equipped **4667173**
EGR Equipped **4667172**

1 Intake And Exhaust Manifold Gasket 4240096



REPAIR PROCEDURE:

This bulletin involves replacement of the intake manifold assembly.

1. Remove the intake and exhaust manifold as described in the appropriate service manual.

2. Install a new intake and exhaust manifold gasket, PN 4240096.

3. Install the new intake manifold and the original exhaust manifold.

4. Verify proper vehicle operation.


POLICY:
Reimbursable within the provisions of the warranty.


TIME ALLOWANCE:
Labor Operation No. 09-50-01-90 ...... 2.6 Hrs.


FAILURE CODE:
58 - Internal Defect