Visual Inspection

VISUAL INSPECTION

NOTE:
A visual inspection for loose, disconnected, or incorrectly routed wires and hoses should be made. This should be done before attempting to diagnose or service the fuel injection system. A visual check will help spot these faults and save unnecessary test and diagnostic time. A thorough visual inspection will include the following checks:

PROCEDURE

Engine Controller:

1. Verify that the 60-way connector is fully inserted into the connector of the PCM. Verify that the connector mounting screw is tightened to 4 Nm (35 in. lbs.) torque.

2. Inspect the battery cable connections. Be sure that they are clean and tight.

Engine Compartment Relays:

3. Inspect fuel pump relay and Automatic Shut Down (ASD) relays. Inspect the air conditioning compressor clutch relay (if equipped). Inspect the relay connections. Inspect starter motor relay connections. Inspect relays for signs of physical damage and corrosion.

Ignition Coil:

4. Inspect ignition coil connections. Verify that coil secondary cable is firmly connected to coil.

5. Verify that distributor cap is correctly attached to distributor. Be sure that spark plug cables are firmly connected to the distributor cap and the spark plugs are in their correct firing order. Be sure that coil cable is firmly connected to distributor cap and coil. Be sure that sync signal generator wire connector (at distributor) is firmly connected to harness connector. Inspect spark plug condition. Connect vehicle to an oscilloscope and inspect spark events for fouled or damaged spark plugs or cables.

6. Verify that alternator output wire, alternator connector, and ground wire are firmly connected to the alternator.

7. Inspect the system body ground connections for being loose or dirty. Refer to wiring diagrams for location of ground connections.

PCV Valve And Hose Connections:

8. Verify Positive Crankcase Ventilation ([1][2]PCV) valve operation. Refer to Emission Control Systems for additional information. Verify PCV valve hose is firmly connected to PCV valve and manifold.

Fuel Pump Module:

9. Inspect fuel pressure regulator.

10. Inspect fuel tube quick-connect fitting-to-fuel rail connections.

11. Verify that hose connections to all ports of vacuum fittings on intake manifold are tight and not leaking.

Throttle And Speed Control Cables:

12. Inspect accelerator cable, transmission throttle cable and cruise control cable connections (if equipped). Check their connections to the throttle arm of throttle body for any binding or restrictions.

13. If equipped with vacuum brake booster, verify that vacuum booster hose is firmly connected to fitting on intake manifold. Also check connection to brake vacuum booster.

14. Inspect the air cleaner inlet and air filter element for dirt or restrictions.

15. Inspect radiator grille area, radiator fins and air conditioning condenser (if equipped) for restrictions.

Charge Air Temperature Sensor And Connector:

16. Verify that Charge Air Temperature sensor wire connector is firmly connected to harness connector.

MAP Sensor And Connector:

17a. Verify that MAP sensor electrical connector is firmly connected to MAP sensor.

MAP Sensor Mounting:

17b. Also verify that rubber nipple from MAP sensor to the throttle body is firmly connected.

18. Verify that fuel injector wire harness connectors are firmly connected to injectors in the correct order. Each harness connector is numerically tagged with the injector number (INJ 1, INJ 2 etc.) of its corresponding fuel injector.

MAP Sensor Mounting:

19. Verify harness connectors are firmly connected to automatic idle speed (AIS) motor, throttle position sensor (TPS) and manifold absolute pressure (MAP) sensor.

Coolant Temperature Sensor:

20. Verify that wire harness connector is firmly connected to the coolant temperature sensor.

21. Raise and support the vehicle.

Dual Oxygen Sensor Locations:

22. Verify that Oxygen Sensor wire connector is firmly connected to the sensor. Inspect sensor and connector for damage.

23. Inspect for pinched or leaking fuel tubes. Inspect for pinched cracked or leaking fuel hoses.

24. Inspect for exhaust system restrictions such as pinched exhaust pipes, collapsed muffler or plugged catalytic convertor.

25. Verify that electrical harness is firmly connected to neutral safety switch (if equipped).

Vehicle Speed Sensor:

26. Verify that the harness connector is firmly connected to the vehicle distance (speed) sensor.

27. Verify that fuel pump/gauge sender unit wire connector is firmly connected to harness connector.

28. Inspect fuel hoses at fuel pump/gauge sender unit for cracks or leaks.

29. Inspect transmission torque convertor housing for damage to timing ring on drive plate/flywheel.

30. Verify that battery cable and solenoid feed wire connections to the starter solenoid are tight and clean. Inspect for chaffed wires or wires rubbing up against other components.