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:

Engine Controller:

1. Verify that the 60-way connector is fully inserted into the connector of the Engine Controller. Verify that the connector mounting screw is tightened to 4 Nm (35 in. lbs.) torque.
2. Verify that all hoses are securely attached to the vapor canister.
3. Verify that the alternator belt and wiring are correctly installed and tightened.
4. Verify that vacuum and electrical connections at canister purge solenoid are secure.

Solenoid Pack:

5. Verify that vacuum and electrical connections at EGR solenoid are secure.

MAP Sensor Location:

6. Verify that the three way connector is attached to the MAP sensor.
7. Verify MAP sensor vacuum hose is attached at MAP sensor.
8. Verify that the engine ground strap is attached at the dash panel.

Pressure Regulator And Vacuum Hose:

9. Check ignition coil electrical connections.
10. Verify that the throttle body wiring connection to the main harness is attached.

Vehicle Speed Sensor:

11. Check transmission electrical connections.

Throttle Body Wiring Connections:

12. Verify that the 4-way connector is attached to the Automatic Idle Speed (AIS) motor.
13. Verify that the 3-way connector is attached to the Throttle Position Sensor.
14. Verify that the 2-way connector is attached to the Throttle Body Temperature Sensor.
15. Verify that the 2-way connector is attached to the Fuel Injector.

PCV System:

16. Verify that the hose from the PCV Valve is securely attached to the intake manifold vacuum port. Also verify that the orifice plug is in the valve cover nipple.
17. Verify that vacuum connections on the front and rear of the throttle body are secure and not leaking.

Heated Inlet Air System Components:

18. Verify that heated air door vacuum connection is connected and not leaking.

EGR Control Valve and Back-Pressure Transducer:

19. Verify that hoses are attached to back pressure transducer.

Engine Components.:

20. Verify that the 3-way connector is attached to the distributor.
21. Verify that the 2-way connector is attached to the Coolant Temperature Sensor.
22. Verify that the negative battery ground eyelet is mounted to the rear of the cylinder head.
23. Verify that all ignition cables are in correct order and seated into place.
24. Verify that engine harness to main harness connections are fully inserted.
25. Verify that power brake vacuum connections are tight.

Power Distribution Center:

26. Verify that all relays are firmly inserted into the electrical connectors in the power distribution center. Be sure that battery connections are clean and tight.

Vehicle Speed Sensor:

27. Check 2-way distance sensor electrical connector.