Engine - Hard Start/Rough Idle

Models -


All 1984 & 1985 2.2L Turbo Vehicles (With Engine Build Date Before 1-452)


Subject


Long Crank Time & Rough Idle After Hot Soak Restart


Index


FUEL

Date


January 29, 1985

No.


14-03-85
SYMPTOM/CONDITION

A condition may exist on certain subject model vehicles of long crank times (3-6 seconds) and rough idle after a hot soak restart.

The rough idle lasts about 1/2 to 1-1/2 minutes after a 10 to 20 minute engine-off hot soak (preceded by a 15 to 60 minute drive at highway speeds). This condition is the result of the fuel injector housing contacting the intake manifold.

NOTE: This service applies to 1985 2.2L turbocharged vehicles with engine build date prior to 1-145.

The engine build date label is found on the left (driver's side) rear surface of the cam cover below the throttle cable. The engine build date is the upper set of numbers (i.e., 1-145).

DIAGNOSIS

Fuel injector housing to intake manifold contact can be determined by the following procedures:

With fuel rail assembly still installed in the intake manifold, hold injector at wiring terminal and rotate it in the intake bore. The injector, once loosened up, should rotate freely.

If injector is difficult to rotate, injector housing to intake manifold contact can be suspected. This procedure should be repeated for the remaining three injectors.

PARTS REQUIRED

2 - Fuel Rail Spacer PN 4307245

FIGURE 2 - Authorized Modifications Label:

Must be ordered separately:

1 - Authorized Modification Label PN 4275086

Fuel Rail Spacer:

Installation Procedure

1. Locate and remove the fuel rail-to-valve cover bracket attachment screw (Figure 1).
2. Loosen (but do not remove) four fuel rail-to-intake manifold attachment screws.

3. Locate and remove fuel pressure regulator bracket-to-intake manifold attachment screws (1985 models only).

4. Loosen fuel rail from intake manifold just enough to not allow the fuel injectors to exit their bores in the manifold.

Fuel Rail Spacer:

5. Install fuel rail-to-intake manifold spacers, PN 4307245, between fuel rail and manifold mounting pads (Figure 1).

Tighten fuel rail-to-manifold screws to 200-300 inch pounds.

Attach pressure regulator bracket to intake manifold and tighten attachment screws to 85-125 inch pounds (1985 models only).

6. Attach fuel rail-to-valve cover bracket and tighten screw to 19-29 inch pounds (Figure 1).

7. Start vehicle and inspect for fuel leaks.

8. Type information on Authorized Modification Label as illustrated.


POLICY: Reimbursable within the provisions of the warranty

TIME ALLOWANCE:
Labor Operation No. 09-50-17-90 . . . . . . . . . . . . . . . . . . . . . . . .0.3 Hrs.

FAILURE CODE: AM -Authorized Modification