Ford Taurus Page 1408 Manual Download

Page: 1408 / 2156

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29.

Install the backup light switch connector to the transaxle switch.

Click to enlarge

30.

Remove the seal plugs, then install the inner CV-joints into the transaxle.

Using a deep well socket, install the starter stud bolt, then tighten to specification

Attach the back-up lamp switch connector to the transaxle switch

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MANUAL TRANSAXLE

18.11.2005

http://www.chiltondiy.com/content/8687/8687_7_1.html

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Summary of Contents for Taurus

Page 1: ...ы 01 GENERAL INFORMATION MAINTENANCE 02 ENGINE PERFORMANCE TUNE UP 03 ENGINE ENGINE OVERHAUL 04 EMISSION CONTROLS 05 FUEL SYSTEM 06 CHASSIS ELECTRICAL 07 DRIVE TRAIN 08 SUSPENSION STEERING 09 BRAKES 10 BODY ...

Page 2: ...tions Engine Manual Transaxle Automatic Transaxle Cooling System Brake Master Cylinder Power Steering Pump Steering Rack Windshield Washer Pump Body Maintenance Rear Wheel Bearings General Recommendations Towing Tips Necessary Equipment 09 TOWING THE VEHICLE 10 JACKING 11 MAINTENANCE COMPONENT LOCATIONS 12 SPECIFICATION CHARTS 06 ROUTINE MAINTENANCE 01 GENERAL INFORMATION MAINTENANCE 07 FLUIDS AND...

Page 3: ...ent Replacement Introduction Timing Introduction Checking Adjustment Idle Speed Adjustment Idle Mixture Adjustment 08 SPECIFICATION CHARTS 04 ELECTRONIC IGNITION SYSTEMS 02 ENGINE PERFORMANCE TUNE UP 05 IGNITION TIMING 06 VALVE LASH 01 TUNE UP PROCEDURES 07 IDLE SPEED AND MIXTURE ADJUSTMENTS 03 DISTRIBUTOR IGNITION SYSTEM ВЕРНУТЬСЯ К ЗАГЛАВНОЙ СТРАНИЦЕ ВЕРНУТЬСЯ К ЗАГЛАВНОЙ СТРАНИЦЕ ...

Page 4: ...s Camshaft Balance Shaft Pistons And Connecting Rods Freeze Plugs Block Heater Rear Main Seal Crankshaft And Main Bearings FlywhееI FIexpIate Introduction General Information Safety Precautions Special Tools Resonator Assembly Muffler Catalytic Converter Tailpipe Engine Speed Oscillates At Idle Low Power Output Of Engine Poor High Speed Operation Poor Acceleration Back fire Intake Manifold Back fi...

Page 5: ...actor Air Injection System Pulse Air Injection System Service Interval Reminder Lights Oxygen Sensor General Information Computer Control Module Mass Air Flow MAF Sensor Idle Air Bypass Valve ldle Speed Control ISC Motor Throttle Position TP Sensor Air Charge Temperature ACT Sensor Engine Coolant Temperature ЕСТ Sensor Manifold Absolute Pressure MAP Sensor General Information Reading Codes Сlearin...

Page 6: ...osition TP Sensor Idle Air Bypass Valve General Information Relieving Fuel System Pressure Fuel Filter Electric Fuel Pump Throttle Body Fuel Charging Assembly Fuel Injectors Fuel Injection Supply Manifold Fuel Pressure Regulator ldle Air Control IAC Bypass Valve Fuel Pressure ReliefValve Throttle Position TP Sensor Flexible Fuel FF Sensor Spring Lock Coupling Push Connect Fittings 06 FUEL TANK 07 ...

Page 7: ...ier Servo Brake Light Switch And Circuit Vacuum Dump Valve Clutch Switch Radio Receive Tape Player Radio Receiver CD Player Speakers Windshield Wiper Blade And Arm Rear Window Wiper Blade And Arm Wndshield Wiper Motor Rear Window Wiper Motor lnternal Governor Windshield Wiper Control Module Wper Linkage Wndshield Washer Fluid Reservoir Windshield Washer Pump Rear Window Washer Pump And Fluid Reser...

Page 8: ...ch Pedal Driven Disc And Pressure Plate Cutch Cable Cutch Interlock Pedal Position Switch Identification Fluid Pan Adjustments Neutral Safety Switch Back Up Light Switch Shift Lever Cable Transaxle Halfshafts CV Joint ВЕРНУТЬСЯ К ЗАГЛАВНОЙ СТРАНИЦЕ ВЕРНУТЬСЯ К ЗАГЛАВНОЙ СТРАНИЦЕ 03 AUTOMATIC TRANSAXLE 01 MANUAL TRANSAXLE 07 DRIVE TRAIN 02 CLUTCH ...

Page 9: ...nt Coil Springs Shock Absorbers MacPherson Struts Control Arms Rear Wheel Bearings Rear Wheel Alignment Steering Wheel Multi Function Switch Ignition Switch Ignition Lock Cylinder Steering Column Steering Linkage Power Steering Rack Power Steering Pump 05 SPECIFICATION CHARTS ВЕРНУТЬСЯ К ЗАГЛАВНОЙ СТРАНИЦЕ ВЕРНУТЬСЯ К ЗАГЛАВНОЙ СТРАНИЦЕ 04 STEERING 03 REAR SUSPENSION 01 WHEELS 08 SUSPENSION STEERI...

Page 10: ...Pedal Description Component Operation Anti Lock Brake System Service Hydraulic Control Unit HCU Wheel Sensors Rear Speed Indicator Ring Front Speed Indicator Ring Pedal Travel Switch Electronic Control Unit ECU Anti Lock Brake ABS Control Module Filing And Bleeding Power Brake Booster 07 SPECIFICATION CHARTS ВЕРНУТЬСЯ К ЗАГЛАВНОЙ СТРАНИЦЕ 04 REAR DISC BRAKES 03 REAR DRUM BRAKES 01 BRAKE OPERATING ...

Page 11: ...im Panels Headliner Power Door Lock Actuator Front Door Latch Rear Door Latch Door Lock Assembly Liftgate Lock Trunk Lid Luggage Compartment Lock Front Window Regulator Rear Window Regulator Electric Window Motor Windshield Glass Front Door Glass Rear Door Glass Inside Rear View Mirror Manual Front Seats Power Front Seats Rear Seats Power Seat Motor Seat Belt Systems 03 SPECIFICATION CHARTS ВЕРНУТ...

Page 12: ... can often be rented from local automotive jobbers or places specializing in renting tools and equipment Check the yellow pages of your phone book Sections contain adjustments maintenance removal and installation procedures and repair or overhaul procedures When repair is not considered practical we tell you how to remove the failed part and then how to install the new or rebuilt replacement In th...

Page 13: ...bustion gases and consequent overheating of the plug and engine parts Too much torque can damage the threads or distort the plug which changes the spark gap There are many commercial chemical products available for ensuring that fasteners won t come loose even if they are not torqued just right a very common brand is Loctite If you re worried about getting something together tight enough to hold b...

Page 14: ...and mangled knuckles Certain tools plus a basic ability to handle tools are required to get started A basic mechanics tool set a torque wrench and a Torx bits set Torx bits are hexlobular drivers which fit both inside and outside on special Torx head fasteners used in various places on your vehicle Begin accumulating those tools that are used most frequently those associated with routine maintenan...

Page 15: ...st basic procedure will require an assortment of ratchets and sockets In addition to ratchets a good set of wrenches and hex keys will be necessary Стр 2 из 8 TOOLS AND EQUIPMENT 18 11 2005 http www chiltondiy com content 8687 8687_1_2 html ...

Page 16: ...ands are essential for lifting and supporting the vehicle An assortment of pliers will be handy especially for old rusted parts and stripped bolt heads Стр 3 из 8 TOOLS AND EQUIPMENT 18 11 2005 http www chiltondiy com content 8687 8687_1_2 html ...

Page 17: ...s a hammer chisels and prybars in your toolbox Many repairs will require the use of torque wrench to assure the components are properly fastened Стр 4 из 8 TOOLS AND EQUIPMENT 18 11 2005 http www chiltondiy com content 8687 8687_1_2 html ...

Page 18: ... battery z A container for draining oil z Many rags for wiping up the inevitable mess Although not always necessary using specialized brake tools will save time A few inexpensive lubrication tools will make regular service easier Стр 5 из 8 TOOLS AND EQUIPMENT 18 11 2005 http www chiltondiy com content 8687 8687_1_2 html ...

Page 19: ...nes A basic list of tune up equipment could include z Tach dwell meter z Spark plug wrench z Timing light a DC light that works from the vehicle s battery is best although an AC light that plugs into 110V house current will suffice with some sacrifice in brightness z Wire spark plug gauge adjusting tools z Set of feeler gauges In addition to these basic tools there are several other tools and gaug...

Page 20: ...ble tools it will be pointed out but occasionally a special tool was designed to perform a specific function and should be used Before substituting another tool you should be convinced that neither Dwell tachometer unit typical Inductive type timing light Compression gauge and a combination vacuum fuel pressure gauge Стр 7 из 8 TOOLS AND EQUIPMENT 18 11 2005 http www chiltondiy com content 8687 86...

Page 21: ...for each fastener will be given in the procedure in any case that a specific torque value is required If no torque specifications are given use the following values as a guide based upon fastener size Bolts marked 6T z 6mm bolt nut 5 7 ft lbs 7 9 Nm z 8mm bolt nut 12 17 ft lbs 16 23 Nm z 10mm bolt nut 23 34 ft lbs 31 46 Nm z 12mm bolt nut 41 59 ft lbs 56 80 Nm z 14mm bolt nut 56 76 ft lbs 76 103 N...

Page 22: ...hen working with any chemicals or hazardous materials Like carbon monoxide the asbestos dust resulting from brake lining wear can be poisonous in sufficient quantities z Do disconnect the negative battery cable when working on the electrical system The secondary ignition system can contain up to 40 000 volts z Do follow manufacturer s directions whenever working with potentially hazardous material...

Page 23: ...oils from the skin so that bone dry hands will suck up oil and grease z Don t service the air conditioning system unless you are equipped with the necessary tools and training The refrigerant R 12 or 134a extremely cold when compressed and when released into the air will instantly freeze any surface it contacts including your eyes Although the refrigerant is normally nontoxic R 12 becomes a deadly...

Page 24: ...onfirmed by locating the 6th and 7th positions of the VIN code Vehicle model year identification can be verified by locating the 10th position of the VIN code and using the Vehicle Identification Chart Chilton Automotive Information Systems 2004 Thomson Delmar Learning Стр 1 из 1 MODEL IDENTIFICATION 18 11 2005 http www chiltondiy com content 8687 8687_1_4 html ...

Page 25: ...m line series body type engine model year and consecutive unit number Certification Label The Vehicle Certification Label is found on the left door lock face panel or door pillar The upper half of the label contains the name of the manufacturer month and year of manufacture gross weight rating gross axle weight and the pertinent certification statements The certification also repeats the VIN numbe...

Page 26: ... equipped with the ATX automatic transaxle is located under one of the valve body cover retaining bolts The identification tag for vehicles equipped with the AXOD AXOD E AX4S and AX4N automatic transaxles is located on top of the torque converter housing Chilton Automotive Information Systems 2004 Thomson Delmar Learning Location of the Vehicle Certification Label Стр 2 из 2 SERIAL NUMBER IDENTIFI...

Page 27: ...For the 2 5L and 3 0L engines loosen the clamp at the throttle body only and leave the tube connected to the cover 2 On the 3 0L and the 3 0L SHO disengage the airflow sensor electrical connector 3 Release the air cleaner upper cover retaining clips or remove the retaining bolts 4 Remove the air cleaner cover then remove the air cleaner element Unfastening the air cleaner cover retaining clips ear...

Page 28: ... the retaining clips 7 If removed engage the airflow sensor electrical connector 8 Install the air cleaner outlet tube Click to enlarge Removing the air cleaner element early model 2 5L engine shown Exploded view of the air cleaner assembly and components late model 2 5L shown Стр 2 из 52 ROUTINE MAINTENANCE 18 11 2005 http www chiltondiy com content 8687 8687_1_6 html ...

Page 29: ...rge Exploded view of the air cleaner assembly and components 3 0L engine shown Air cleaner assembly components 3 0L 3 2L SHO engines shown Стр 3 из 52 ROUTINE MAINTENANCE 18 11 2005 http www chiltondiy com content 8687 8687_1_6 html ...

Page 30: ... then remove the air cleaner element To install 6 Clean all inside surfaces of the air cleaner and cover then install the air cleaner element 7 Position the air cleaner cover then install the retaining clips or fasten the bolts as applicable If equipped tighten the bolts to 20 30 inch lbs 2 5 3 5 Nm 8 If equipped connect the engine control sensor wiring to the mass air flow sensor and the intake a...

Page 31: ...inertia switch REMOVAL INSTALLATION The push connect fittings are designed with a retaining clip Clips should be replaced whenever a connector is removed 1 Disconnect the negative battery cable 2 Properly relieve the fuel system pressure For details refer to the procedure located earlier in this section 3 Remove the push connect fittings at both ends of the fuel filter This is accomplished by remo...

Page 32: ...e push connect fitting from the bottom of the fuel filter Early model 2 5L shown Removing the fuel line from the filter Стр 6 из 52 ROUTINE MAINTENANCE 18 11 2005 http www chiltondiy com content 8687 8687_1_6 html ...

Page 33: ...his is indicated by the legs of the hairpin clip being locked on the outside of the fitting body Apply a light coat of engine oil to the ends of the fuel filter then push the fittings onto the ends of the filter When the fittings are engaged a definite click will be heard Pull on the fittings to ensure that they are fully engaged 7 Tighten the worm gear mounting clamp to 15 25 inch lbs 1 7 2 8 Nm ...

Page 34: ...valve rattles when shaken reinstall and proceed to Step 2 If the valve does not rattle it is sticking and should be replaced 6 Start the engine and bring it to normal operating temperature 7 On the 2 5L engine remove the corrugated hose from the oil separator nipple On all other engines disconnect the hose from the remote air cleaner or air outlet tube 8 Place a stiff piece of paper over the nippl...

Page 35: ...l 3 Inspect the valve and grommet for deterioration and replace if necessary PCV system early model 2 5L engine shown Стр 9 из 52 ROUTINE MAINTENANCE 18 11 2005 http www chiltondiy com content 8687 8687_1_6 html ...

Page 36: ...l the PCV valve into the valve grommet then connect the fuel vapor and crankcase ventilation hoses PCV system late model 3 0L shown Стр 10 из 52 ROUTINE MAINTENANCE 18 11 2005 http www chiltondiy com content 8687 8687_1_6 html ...

Page 37: ... ventilation tube for deterioration and replace if necessary 4 Connect the tube to the valve cover fitting and the throttle body then secure with the retaining clamps 3 8L Engine 1 Disconnect the crankcase ventilation tube from the PCV valve 2 Remove the valve from the PCV valve grommet To install PCV system 3 0L 3 2L SHO shown Стр 11 из 52 ROUTINE MAINTENANCE 18 11 2005 http www chiltondiy com co...

Page 38: ...Evaporative Canister To prevent gasoline vapors from being vented into the atmosphere an evaporative emission system captures the vapors and stores them in a carbon filled canister The 3 0L Flexible Fuel FF vehicles utilize 4 separate canisters for this purpose PCV system late model 3 8L shown Стр 12 из 52 ROUTINE MAINTENANCE 18 11 2005 http www chiltondiy com content 8687 8687_1_6 html ...

Page 39: ... emission control system and related components 2 5L engine Evaporative emission control system and related components 3 0L engine Except Flexible Fuel Стр 13 из 52 ROUTINE MAINTENANCE 18 11 2005 http www chiltondiy com content 8687 8687_1_6 html ...

Page 40: ...porative emission control system and related components 3 0L Flexible Fuel FF engine Location of system components 3 0L Flexible Fuel FF engine Стр 14 из 52 ROUTINE MAINTENANCE 18 11 2005 http www chiltondiy com content 8687 8687_1_6 html ...

Page 41: ...e 3 0 FF which uses four evaporative emissions canisters mounted under the rear floor pan The canister should have no liquid fuel in it if it does replace it Replacement is simply a matter of disconnecting the hoses loosening the mount and replacing the canister Evaporative emission control system and related components 3 0L SHO shown 3 2L SHO similar Evaporative emission control system and relate...

Page 42: ...uipped auto store or parts department Side terminal batteries require a different tool to clean the threads in the battery case The accumulated white powder and corrosion can be cleaned from the top of the battery with an old toothbrush and a solution of baking soda and water Unless you have a maintenance free battery check the electrolyte level and the specific gravity of each cell Be sure that t...

Page 43: ...ng soda to neutralize spilled acid or with special tools such as this post and terminal cleaner The underside of this special battery tool has a wire brush to clean post terminals Стр 17 из 52 ROUTINE MAINTENANCE 18 11 2005 http www chiltondiy com content 8687 8687_1_6 html ...

Page 44: ... ring inside or the line marked on the outside of the case If the level is low add only distilled water or colorless odorless drinking water through the opening until the level is correct Each cell is completely separate from the others so each must be checked and filled individually Place the tool over the terminals and twist to clean the post Two devices used to maintain electrolyte level A self...

Page 45: ...with a bolt and do not require a puller Clean the cable clamps and the battery terminal with a wire brush until all corrosion grease etc is removed and the metal is shiny It is especially important to clean the inside of the clamp thoroughly since a small deposit of foreign material or oxidation there can prevent a sound electrical connection and inhibit starting and or charging Special tools are ...

Page 46: ...p to 10 minutes To determine whether a battery is accepting a charge follow the charger manufacturer s instructions for the use of the dead battery switch If the dead battery switch is the spring loaded type it should be held in the ON position for up to three minutes After releasing the dead battery switch and with the charger still on measure the battery voltage If it shows 12 volts or higher th...

Page 47: ...ween battery size and engine size As a general rule the cold power rating of a replacement battery should match or exceed your engine size in cubic inches 1 Carefully disconnect the negative battery cable from the battery terminal and position it aside 2 Carefully disconnect the positive cable from the battery terminal and position it aside 3 Clean the cable terminals using an acid neutralizing so...

Page 48: ...secure Do not overtighten For some vehicles when the battery is disconnected and reconnected abnormal driving symptoms may temporarily occur The reason for this is that the Powertrain Control Module PCM has to relearn its adaptive strategy Your vehicle may have to be driven 10 miles or more for the module to relearn the strategy 9 Secure the positive then the negative battery cables to the proper ...

Page 49: ...cator mark as well as MIN and MAX marks If the indicator mark is not between the MIN and MAX marks the belt is worn or an incorrect belt is installed 3 0L ENGINE WITHOUT AUTOMATIC TENSIONER EXCEPT SHO 1 Disconnect the negative battery cable 2 Loosen the alternator adjustment and pivot bolts 3 Apply tension to the belt using the adjusting screw 4 Using a belt tension gauge set the belt to the prope...

Page 50: ... a 1 2 in breaker bar into the square hole in the tensioner then rotate the tensioner counterclockwise and remove the belt from the pulleys Be careful when removing or installing belts that the tool doesn t slip To install 2 Install the belt over all pulleys except the alternator pulley 3 Rotate the tensioner as described in Step 1 and install the belt over the alternator pulley Check that all the...

Page 51: ...LT 1 Loosen the nut in the center of the idler pulley 2 Loosen the idler adjusting screw until the old belt can be removed then remove the belt To install 3 Install the new belt over the pulleys in proper contact with the pulleys 4 Adjust the new belt to specifications as follows Turn the idler pulley nut to the right to tighten the belt to a specification of 220 265 lbs 980 1180 N Torque the idle...

Page 52: ...ve the belt To install 4 Position the new belt over the proper pulleys making sure the V grooves are properly seated 5 Install the alternator belt 6 Adjust the power steering and air conditioning belt to a specification of 154 198 lbs 690 980 N with a belt tension gauge 7 Adjust the alternator belt 3 0L SHO accessory drive belts schematic Стр 26 из 52 ROUTINE MAINTENANCE 18 11 2005 http www chilto...

Page 53: ...ulley and rotate it clockwise downward then install the drive belt over the power steering pump pulley 3 0L Engine Except SHO and 3 8L Engine VEHICLES THROUGH 1993 WITH AUTOMATIC TENSIONER 1 Insert a 1 2 in breaker bar into the square hole in the tensioner On the 3 8L engine the tensioner has a 1 2 in square hole cast into the rear of the tension arm directly behind the pulley On the 3 0L engine t...

Page 54: ...e belt over the alternator pulley Make sure that all the V grooves make proper contact with the pulleys 5 On the 3 0L engine install the alternator belt for vehicles through 1992 6 For 1993 3 0L vehicles install the drive belt over the idler pulley 1994 95 VEHICLES WITH AUTOMATIC TENSIONER 3 0L belt schematic 1993 shown 3 8L belt schematic 1993 shown Стр 28 из 52 ROUTINE MAINTENANCE 18 11 2005 htt...

Page 55: ... rotate the drive belt tensioner pulley clockwise to relieve the tension 2 Remove the drive belt Click to enlarge 3 0L accessory drive belt schematic 1995 shown Стр 29 из 52 ROUTINE MAINTENANCE 18 11 2005 http www chiltondiy com content 8687 8687_1_6 html ...

Page 56: ...iming Belt INSPECTION Vehicles equipped with the 3 0L and 3 2L SHO engines are the only vehicles covered by this manual which utilize timing belts The timing belt should be inspected for cracks wear or other damage and should be replaced every 100 000 miles 160 000 km For timing belt removal and installation procedures please refer to Section 3 of this manual Hoses INSPECTION 3 8L accessory drive ...

Page 57: ... cable then place protective covers over the fenders 2 Place a suitable drain pan under the radiator If only the upper hose is to be replaced you need only drain off enough coolant so that the level is below the hose 3 Remove the radiator pressure cap Attach a 3 8 in 9 5mm diameter hose to the radiator draincock then open the draincock and drain the radiator CAUTION Never remove the pressure cap w...

Page 58: ...TION The engine should be cool before any hoses are replaced If engine is hot let it cool down for at least an hour When draining the coolant keep in mind that cats and dogs are attracted by ethylene glycol antifreeze and are quite likely to drink any that is left in an uncovered container or in puddles on the ground This will prove fatal in sufficient quantity Always drain the coolant into a seal...

Page 59: ...Click to enlarge Click to enlarge 7 To remove the heater hose s loosen the clamps then remove the hose s To install Engine cooling system schematic 3 0L engine Exploded view of the engine cooling system 3 8L engine Стр 33 из 52 ROUTINE MAINTENANCE 18 11 2005 http www chiltondiy com content 8687 8687_1_6 html ...

Page 60: ... clamps to 20 30 inch lbs 2 2 3 4 Nm Click to enlarge 11 Close the radiator draincock Fill the cooling system with a 50 50 mixture of Ford Premium Cooling System Fluid E2FZ 19549 AA or B CXC 8 B in Canada or equivalent and water Cooling system components 3 0L and 3 2L SHO engines Heater hose locations 3 0L engine Стр 34 из 52 ROUTINE MAINTENANCE 18 11 2005 http www chiltondiy com content 8687 8687...

Page 61: ... joint boots should be periodically inspected It would be a wise idea to examine the boot every time your vehicle is raised and supported Check the boot for signs of cracks tears or splits and repair replace as necessary For CV boot and joint repair as well as overhaul procedures please refer to Section 7 of this Heater hose assembly 3 8L engine Heater hose components 3 0L SHO engine Стр 35 из 52 ...

Page 62: ... have a vehicle equipped withR 134a it should be taken to a qualified technician for all A C service Some 1992 93 vehicles equipped with the 3 0L engine and all 1994 95 vehicles are using R 134a refrigerant rather than the conventional R 12 refrigerant The new R 134a refrigerant is not harmful to the ozone layer of the atmosphere It View of a torn CV boot View of a CV boot in good condition Стр 36...

Page 63: ...tes the flow of refrigerant to the evaporator the level of refrigerant there is fairly constant The receiver drier stores any excess refrigerant so a loss will first appear as a reduction in the level of liquid As this level nears the bottom of the vessel some refrigerant vapor bubbles will begin to appear in the stream of liquid supplied to the expansion valve This vapor decreases the capacity of...

Page 64: ...frigerant lines z When overhauling a compressor pour some oil into a clean glass and inspect it If there is evidence of dirt or metal particles or both flush all refrigerant components with clean refrigerant before evacuating and recharging the system In addition if metal particles are present the compressor should be replaced z Schrader valves may leak only when under full operating pressure Ther...

Page 65: ...reated by first gradually warming the area with cool water and then gently applying petroleum jelly A physician should be consulted z Always completely discharge the system into a suitable recovery system before painting the vehicle if the paint is to be baked on or before welding anywhere near the refrigerant lines z When servicing the system minimize the time that any refrigerant line or fitting...

Page 66: ... Remember that an adapter is necessary to connect the manifold gauge hose to the high pressure fitting DISCHARGING THE SYSTEM Air conditioning system R 12 refrigerant is a chlorofluorocarbon which when released into the atmosphere can contribute to the depletion of the ozonelayer in the upper atmosphere Ozone filters out harmful radiation from thesun ALWAYS use an approved recovery recycling machi...

Page 67: ... station hose s 5 If the system pressure rises repeat Steps 2 3 and 4 until the vacuum level remains stable for 2 minutes EVACUATING THE SYSTEM Some 1992 and later vehicles use R 134a refrigerant in place of theconventional R 12 refrigerant Refer to the information on R 134a refrigerantsystems in this Section Also any air conditioning equipment used to serviceR 12 refrigerant systems CANNOT be use...

Page 68: ...placed continue to operate the vacuum pump for another 20 30 minutes 8 When evacuation of the system is complete close the manifold gauge set valves and turn the vacuum pump OFF 9 Observe the low pressure gauge for 5 minutes to ensure that system vacuum is held If vacuum is held charge the system If vacuum is not held for 5 minutes leak test the system service the leaks and evacuate the system aga...

Page 69: ...oth valves are closed Both gauges should read about 122 163 in Hg 413 551 kPa with the engine not running If very little or no pressure is indicated leave the vacuum pump valve closed Open the refrigerant tank valve and set the low pressure gauge valve to the counterclockwise position This will open the system to tank pressure Check all system connections the compressor head gasket and shaft seal ...

Page 70: ...utton that is pushed down to allow the refill to slide out of the yoke jaws The new refill slides back into the frame and locks in place Some Trico refills are removed by locating where the metal backing strip or the refill is wider Insert a small prybar between the frame and metal backing strip Press down to release the refill from the retaining tab Other types of Trico refills have two metal tab...

Page 71: ...necessary to remove the wiper arm or blade This refill has a plastic backing strip with a notch about 1 in 25mm from the end Hold the blade frame on a hard surface so the frame is tightly bowed Grip the tip of the backing strip and pull up while twisting counterclockwise The backing strip will snap out of the retaining tab Do this for the remaining tabs until the refill is free of the arm The leng...

Page 72: ... will be scratched Tires and Wheels TIRE ROTATION Tire wear can be equalized by switching the position of the tires about every 7 500 miles 12 000 km Including a conventional spare tire in the rotation pattern can give up to 20 more tread life Do not include a SpaceSaver or other temporary spare tire in the rotation pattern Wiper blade replacement Tridon Стр 46 из 52 ROUTINE MAINTENANCE 18 11 2005...

Page 73: ...icators means that the tires should be replaced In fact many states have laws prohibiting the use of tires with less than 1 16 in 1 6mm of tread remaining Tread thickness under 1 16 in 1 6mm is very dangerous on wet roads due to hydroplaning Tire rotation patterns NEVER use the temporary spare for tire rotation or as a regular tire Стр 47 из 52 ROUTINE MAINTENANCE 18 11 2005 http www chiltondiy co...

Page 74: ...laced You can measure snow tires in the same manner by using the tail side of the Lincoln penny If you see the top of the Lincoln memorial it s time to replace the snow tires Tread depth can be checked using an inexpensive gauge If a gauge is not available a penny may be used to check for tire tread depth when the top of Lincoln s head is visible it is probably time for a new tire Стр 48 из 52 ROU...

Page 75: ... to enlarge When you replace tires never mix radial bias belted or bias type tires Use only the tire sizes listed on the tire decal attached to your vehicle on the driver s side door post Make sure that all tires are the same size speed rating and load carrying capacity Use only tire and wheel combinations as recommended on the tire decal or by your dealer Failure to follow these precautions can a...

Page 76: ...d be kept in a cool dry place If they are stored in the garage or basement do not let them stand on a concrete floor set them on strips of wood Click to enlarge Spare tire assembly and related components sedan Стр 50 из 52 ROUTINE MAINTENANCE 18 11 2005 http www chiltondiy com content 8687 8687_1_6 html ...

Page 77: ... inflation pressure should be checked when the tires are cool When the air becomes heated it expands and the pressure increases Every 10 F 12 C rise or drop in temperature means a difference of 1 psi 7 kPa which also explains why the tire appears to lose air on a very cold night When it is impossible to check the tires cold allow for pressure build up due to heat If the hot pressure exceeds the co...

Page 78: ...h clean water Do not use steel wool abrasive type cleaner or strong detergents containing high alkaline or caustic agents as damage to the protective coating and discoloration may result Chilton Automotive Information Systems 2004 Thomson Delmar Learning Стр 52 из 52 ROUTINE MAINTENANCE 18 11 2005 http www chiltondiy com content 8687 8687_1_6 html ...

Page 79: ... unleaded but some high performance engines may require higher ratings Fuel should be selected for the brand and octane which performs best with your engine Judge a gasoline by its ability to prevent pinging its engine starting capabilities cold and hot and general all weather performance For information regarding vehicles equipped with the Flexible Fuel FF system refer to your owner s manual for ...

Page 80: ...This is a decided advantage in changeable climates or in long distance driving The API American Petroleum Institute designation indicates the classification of engine oil used under certain given operating conditions Only oils designated for use Service SG or the latest superceding oil grade should be used Oils of the SG type perform a variety of functions inside the engine in addition to their ba...

Page 81: ...n this case synthetic oils which are certified and have the preferred viscosity may be used in your engine however the oil and filter must still be changed according to the maintenance schedule Cars used under harder stop and go short hop circumstances should always be serviced more frequently and for these cars synthetic oil may not be a wise investment Engine OIL LEVEL CHECK Every time you stop ...

Page 82: ...will raise the level from the ADD mark to the MAX mark Be sure not to overfill the crankcase and waste the oil Excess oil will generally be consumed at an accelerated rate OIL AND FILTER CHANGE Change the engine oil and oil filter every 6 months or 5 000 miles 8 000 km If the car is used in severe service or dusty conditions change the engine oil and oil filter every 3 months or 3 000 miles 4 800 ...

Page 83: ...5 Quickly withdraw the plug and move your hands out of the way but be careful not to drop the plug into the drain pan as fishing it out can be an unpleasant mess Allow all the old oil to drain completely into the pan then inspect the drain plug gasket and replace it if necessary 6 Install and carefully tighten the drain plug Be careful not to overtighten the drain plug otherwise you ll be buying a...

Page 84: ...arefully start the filter onto the threaded engine mount by hand When the filter touches the adapter surface give it another 1 2 1 turn no more or you ll squash the gasket and it will leak 10 Lower the vehicle to the ground Refill the crankcase to specification with the proper grade and type motor oil Install the filler cap and start the engine Allow the engine to idle and check for oil leaks Shut...

Page 85: ...freeze containers Then locate a service station or automotive parts store where you can pour it into their used oil tank for recycling Remove the oil filler cap located on the valve cover Refill the crankcase with the proper grade and capacity of engine oil WARNING Pouring used motor oil into a storm drain not only pollutes the environment it violates Federal law Dispose of waste oil properly Стр ...

Page 86: ...CK A dipstick is provided in the engine compartment to check the level of the automatic transaxle Check the Maintenance Component Location charts at the end of this section for the dipstick location on your vehicle Be sure the car is on level ground and that the car s engine and transaxle have reached normal operating temperatures 1 Start the engine set the parking brake and put the transaxle sele...

Page 87: ... and thoroughly clean it Remove the old gasket Make sure that the gasket mounting surfaces are clean 4 Unfasten the transaxle filter screen retaining bolt and remove the screen 5 Install a new filter screen and O ring Place a new gasket on the pan and install the pan to the transaxle Torque the transaxle pan to 15 19 ft lbs 20 26 Nm 6 Fill the transaxle to the correct level Remove the jackstands a...

Page 88: ...oft or cracked hoses replaced Damp spots or accumulations of rust or dye near the hoses water pump or other areas indicate possible leakage which must be corrected before filling the system with fresh coolant FLUID RECOMMENDATIONS This engine has an aluminum cylinder head and requires a corrosion inhibiting coolant formulation to avoid radiator damage Use only a permanent type coolant that meets F...

Page 89: ...e coolant connect a hose approximately 18 in 46cm long with an inside diameter of 3 8 in 9 5mm to the nipple on the drain valve located on the CAUTION Cover the radiator cap with a thick cloth before removing it from a radiatorin a vehicle that is hot Turn the cap counterclockwise slowly until pressurecan be heard escaping Allow all pressure to escape from the radiator beforecompletely removing th...

Page 90: ...evidence of rust or scaling in the cooling system the system should be flushed thoroughly before refilling Refer to the flushing cleaning procedure later in this section With the engine OFF and COOL 1 Using a funnel add the designated quantity of a 50 coolant and 50 water solution to the radiator Open the drain valve located on the bottom of the radiator Attaching a small hose to the draincock wil...

Page 91: ...ve the radiator cap and add water until the radiator is full Reinstall the radiator cap securely 5 Add coolant to the ADD mark on the reservoir then fill to the FULL HOT mark with water All vehicles covered by this manual should be equipped with a coolant reservoir Add coolant to the correct marks on the reservoir Стр 13 из 34 FLUIDS AND LUBRICANTS 18 11 2005 http www chiltondiy com content 8687 8...

Page 92: ...clockwise to the first stop If any hissing is noted indicating the release of pressure wait until the hissing stops completely then press down again and turn counterclockwise until the cap can be removed Check the coolant level to make sure it is sufficient Allow the engine to cool before attempting to remove the radiator cap DO NOT remove the cap while the engine is hot CAUTION Стр 14 из 34 FLUID...

Page 93: ...ngine block Close the drain valve plugs then refill the system with water at the radiator fill neck 2 Allow the engine to idle for about 5 minutes Turn the engine off Drain the cooling system again 3 Repeat the above steps until nearly clear water is drained from the radiator Allow the remaining water to drain and then close the draincock 4 Disconnect the overflow hose from the radiator filler nec...

Page 94: ...for the CAUTION Brake fluid damages paint It also absorbs moisture from the air never leave a container or the master cylinder uncovered any longer than necessary All parts in contact with the brake fluid master cylinder hoses plunger assemblies etc must be kept clean since any contamination of the brake fluid can adversely affect braking performance Brake master cylinder components sedan Brake ma...

Page 95: ...left side driver s side of the firewall Check the Maintenance Component Location charts at the end of this section for the exact location on your vehicle Before removing the master cylinder reservoir cap make sure the vehicle is resting on level ground and clean all the dirt away from the top of the master cylinder Remove the master cylinder cap Before taking the cap off of the master cylinder mak...

Page 96: ... the master cylinder If the master cylinder reservoir has a cap with an expanding rubber diaphragm be sure to push the diaphragm up into the cap before installing the cap Power Steering Pump FLUID RECOMMENDATIONS Use Ford Motor Company s premium power steering fluid E6AZ 19582 AA ESW M2C33 F or equivalent LEVEL CHECK You should check the level of the power steering fluid at least twice a year You ...

Page 97: ...prevent dirt from contaminating the system If checking the fluid when the engine is hot it should be within the proper marks of the FULL HOT side of the dipstick Стр 19 из 34 FLUIDS AND LUBRICANTS 18 11 2005 http www chiltondiy com content 8687 8687_1_7 html ...

Page 98: ...ly 50 85 F 10 30 C Steering Rack FLUID RECOMMENDATIONS Use Ford Motor Company s premium power steering fluid E6AZ 19582 AA ESW M2C33 F or equivalent Windshield Washer Pump Power steering dipstick fluid level marks for checking the fluid when the engine is cold Add power steering fluid in small amounts but do not overfill Стр 20 из 34 FLUIDS AND LUBRICANTS 18 11 2005 http www chiltondiy com content...

Page 99: ...ncentrate if so follow the manufacturer s instructions as this will adversely affect its ability to keep from freezing at low temperatures Also never place another fluid such as ethylene glycol antifreeze in the reservoir as other fluids could damage pump seals Click to enlarge Click to enlarge Body Maintenance Regular body maintenance preserves the vehicle s appearance during the life of the vehi...

Page 100: ...an the old grease from the bearingand hub before repacking Before handling the bearings there are a few things that you should remember to do and not to do Remember to DO the following z Remove all outside dirt from the housing before exposing the bearing z Treat a used bearing as gently as you would a new one z Work with clean tools in clean surroundings z Use clean dry canvas gloves or at least ...

Page 101: ...t at any time ADJUSTMENT The following procedure applies only to 1986 89 vehicles Adjustment is not possible on 1990 95 vehicles This procedure should be performed whenever the wheel is excessively loose on the spindle or it does not rotate freely The rear wheel uses a tapered roller bearing which may feel loose whenproperly adjusted this condition should be considered normal 1 Remove the wheel co...

Page 102: ...nd bend the ends around the retainer flange 10 Check the hub rotation If the hub rotates freely install the grease cap If not check the bearings for damage and replace as necessary 11 If applicable install the wheel and tire assembly as well as the wheel cover ornament then lower the vehicle REMOVAL PACKING INSTALLATION With Drum Brakes 1986 89 VEHICLES 1 Raise the vehicle and support it safely on...

Page 103: ...g nut and keyed flat washer from the spindle Discard the cotter pin Pry the grease cap from the hub Be careful not to distort or damage the flange After removing the grease cap unbend the cotter pin Стр 25 из 34 FLUIDS AND LUBRICANTS 18 11 2005 http www chiltondiy com content 8687 8687_1_7 html ...

Page 104: ...d pull or pry it free of the spindle Discard the cotter pin and replace it with a new one during installation Remove the adjusting nut from the spindle Стр 26 из 34 FLUIDS AND LUBRICANTS 18 11 2005 http www chiltondiy com content 8687 8687_1_7 html ...

Page 105: ...ing assembly 4 Remove the outer bearing assembly Remove the keyed washer from the spindle Remove the outer bearing assembly Note that this can be done with the hub and drum on or off the vehicle Стр 27 из 34 FLUIDS AND LUBRICANTS 18 11 2005 http www chiltondiy com content 8687 8687_1_7 html ...

Page 106: ...sembly from the hub Remove the hub and drum assembly from the spindle Removing the grease seal discard the seal after removing Note that the preferred method for removing the seal is with a proper seal remover tool Стр 28 из 34 FLUIDS AND LUBRICANTS 18 11 2005 http www chiltondiy com content 8687 8687_1_7 html ...

Page 107: ... cups are properly seated in the hub Do NOT use the cone and roller assembly to installthe cups This will result in damage to the bearing cup as well as the cone androller assembly 10 Make sure all of the spindle and bearing surfaces are clean 11 Using a bearing packer pack the bearing assemblies with a suitable wheel bearing grease If a packer is not available work in as much grease as possible b...

Page 108: ...b and drum 18 Carefully lower the vehicle then tighten the lug nuts with a hand tool to 85 105 ft lbs 115 142 Nm Do NOT use power tools to tighten the lug nuts Install the wheelcover 1990 95 VEHICLES 1 Loosen the rear wheel lug nuts 2 Raise and safely support the vehicle on jackstands 3 Remove the rear wheel and tire assembly 4 Remove the two pushnuts retaining the brake drum to the hub then remov...

Page 109: ...support it with a length of wire Do not allow the caliper assembly to hang from the brake hose 3 Remove the rotor from the hub by pulling it off the hub bolts If the rotor is difficult to remove strike the rotor sharply between the studs with a rubber or plastic hammer 4 Remove the grease cap from the hub Remove the cotter pin nut retainer adjusting nut and keyed flat washer from the spindle Disca...

Page 110: ... Make sure all of the spindle and bearing surfaces are clean 12 Pack the bearing assemblies with suitable wheel bearing grease using a bearing packer If a packer is not available work in as much grease as possible between the rollers and the cages with your hands Grease the cup surfaces Allow all of the cleaning solvent to dry before repackingthe bearings Do not spin dry the bearings with compress...

Page 111: ...ackstands 2 Remove the rear wheel and tire assembly 3 Remove the rear caliper assembly from the brake adapter Support the caliper assembly with a length of wire 4 Remove the push on nuts that retain the rotor to the hub then remove the rotor 5 Remove and discard the hub cap grease seal from the bearing and hub assembly 6 Remove and discard the rear axle bearing and hub assembly retainer 7 Remove t...

Page 112: ...ub cap grease seal is fully seated 11 Install the rear disc brake rotor on the hub Install the two push on nuts that retain the rotor 12 Install the rear disc brake caliper to the brake adapter 13 Install the wheel and tire assembly then carefully lower the vehicle Chilton Automotive Information Systems 2004 Thomson Delmar Learning Exploded view of the rear wheel assembly station wagon shown Стр 3...

Page 113: ...wing a trailer Towing Tips Before starting on a trip practice turning stopping and backing up in an area away from other traffic such as a deserted shopping center parking lot to gain experience in handling the extra weight and length of the trailer Take enough time to get the feel of the vehicle trailer combination under a variety of situations Skillful backing requires practice Back up slowly wi...

Page 114: ...celeration Allow at least the equivalent of one vehicle and trailer length combined for each 10 mph of road speed Finally remember to check the height of the loaded car trailer allowing for roof mounted luggage racks antenna etc and take note of low bridges or parking garage clearances Necessary Equipment Use the right equipment for the type of trailer you are going to tow and make sure that all o...

Page 115: ...ot connect your trailer s lighting system wiring directly to that of your vehicle Be sure you use the correct equipment and that you follow the manufacturer s directions carefully If you do not install the lighting system properly the warning lights on your vehicle s instrument panel may not function Chilton Automotive Information Systems 2004 Thomson Delmar Learning braking power and your chances...

Page 116: ...ld be used Never attach a strap or chain to any steering or suspension part Never try to start the vehicle when being towed as it might run into the back of the tow vehicle Do not allow too much slack in the tow line because the towed car could run over the line and cause damage to both vehicles If your car is being towed by a tow truck the towing speed should be limited to 50 mph 80 km h with the...

Page 117: ... Chilton Automotive Information Systems 2004 Thomson Delmar Learning Schematic of front towing connections Schematic of rear towing connections Стр 2 из 2 TOWING THE VEHICLE 18 11 2005 http www chiltondiy com content 8687 8687_1_9 html ...

Page 118: ... consider more practical equipment A small hydraulic screw or scissors jack or else a floor jack will raise the vehicle sufficiently for almost all the procedures in this guide The rolling floor jack is probably the easiest and most convenient of these to use But the vehicle must still be supported by at least two sturdy jackstands if you intend to work under the car at any time When using a floor...

Page 119: ...MAINTENANCE COMPONENT LOCATIONS Click to enlarge Engine component service points 2 5L engine Стр 1 из 5 MAINTENANCE COMPONENT LOCATIONS 18 11 2005 http www chiltondiy com content 8687 8687_1_11 html ...

Page 120: ...Click to enlarge Engine component service points 3 0L engine Стр 2 из 5 MAINTENANCE COMPONENT LOCATIONS 18 11 2005 http www chiltondiy com content 8687 8687_1_11 html ...

Page 121: ...Click to enlarge Engine component service points 3 0L Flexible Fuel FF engine Стр 3 из 5 MAINTENANCE COMPONENT LOCATIONS 18 11 2005 http www chiltondiy com content 8687 8687_1_11 html ...

Page 122: ...enlarge Engine component service points 3 0L 3 2L SHO engines Engine component service points 3 8L engine Стр 4 из 5 MAINTENANCE COMPONENT LOCATIONS 18 11 2005 http www chiltondiy com content 8687 8687_1_11 html ...

Page 123: ...Click to enlarge Chilton Automotive Information Systems 2004 Thomson Delmar Learning Стр 5 из 5 MAINTENANCE COMPONENT LOCATIONS 18 11 2005 http www chiltondiy com content 8687 8687_1_11 html ...

Page 124: ...SPECIFICATION CHARTS Click to enlarge Click to enlarge Vehicle Identification Chart Engine Identification Стр 1 из 4 SPECIFICATION CHARTS 18 11 2005 http www chiltondiy com content 8687 8687_1_12 html ...

Page 125: ...Click to enlarge Click to enlarge Engine Identification Capacities Capacities Стр 2 из 4 SPECIFICATION CHARTS 18 11 2005 http www chiltondiy com content 8687 8687_1_12 html ...

Page 126: ...ick to enlarge Click to enlarge Maintenance Inverval Schedule A 1986 93 Maintenance Interval Schedule B 1994 95 Maintenance Interval Schedule B Стр 3 из 4 SPECIFICATION CHARTS 18 11 2005 http www chiltondiy com content 8687 8687_1_12 html ...

Page 127: ...Chilton Automotive Information Systems 2004 Thomson Delmar Learning Стр 4 из 4 SPECIFICATION CHARTS 18 11 2005 http www chiltondiy com content 8687 8687_1_12 html ...

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Page 139: ...Your Current Chilton Manual Year 1986 1995 Mfg Ford Make Ford Model Taurus Print Content Стр 1 из 1 minor_frame 18 11 2005 http www chiltondiy com display minor_frame aspx CID 281 ...

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Page 188: ...tion the figures on the sticker must be used The sticker often reflects changes made during the production run or revised information that applies to the particular systems in that vehicle Spark Plugs A typical spark plug consists of a metal shell surrounding a ceramic insulator A metal electrode extends downward through the center of the insulator and protrudes a small distance Located at the end...

Page 189: ...ved Severe driving conditions are z Extended periods of idling or low speed operation such as off road or door to door delivery z Driving short distances less than 10 miles 16 km when the average temperature is below 10 F 12 C for 60 days or more z Excessive dust or blowing dirt conditions When you remove the spark plugs check their condition They are a good indicator of the condition of the engin...

Page 190: ... 1 600 km under normal conditions When and if a plug fouls and begins to misfire you will have to investigate correct the cause of the fouling and either clean or replace the plug There are several reasons why a spark plug will foul and you can learn which reason is at fault by just looking at the plug A few of the most common reasons for plug fouling and a description of fouled plug appearance ar...

Page 191: ...instances preignition may result Preignition takes place when plug tips get so hot that they glow sufficiently to ignite the fuel air mixture before the actual spark occurs This early ignition will usually cause a pinging during low speeds and heavy loads The general rule of thumb for choosing the correct heat range when selecting a spark plug is if most of your driving is long distance high speed...

Page 192: ...void removing the plug wires all at once because unless you number them they may get mixed up if you must or prefer to do so take a minute before removing the wires to number them with tape The time you spend doing this will pay off later when it comes time to reconnect the wires to the plugs The original spark plug wires are marked for cylinder location Ifreplacement wires have been installed be ...

Page 193: ...ion built in to help prevent plug breakage 5 Once the plug is out compare it with the spark plug illustrations to determine the engine condition This is crucial since spark plug readings are vital signs of engine condition and pending problems When possible use a special grasping tool for removing the spark plug wires WARNING NEVER pull on the wire itself as damage to the inside conductor couldocc...

Page 194: ...xt smaller and larger sizes The smaller gauge should go through easily and the larger should not go through at all If adjustment is necessary use the bending tool on the end of the gauge When adjusting the gap always bend the side electrode The center electrode is non adjustable Inspect the plug for signs of fouling or deposits Always use a wire gauge to check the electrode gap on used plugs Стр 7...

Page 195: ...nduct the hotter spark produced The boots on these wires are designed to cover the spark plug cavities on the cylinder head Inspect the wires without removing them from the spark plugs distributor cap or coil Look for visible damage such as cuts pinches cracks or torn boots Replace any wires that show damage If the boot is damaged it may be replaced by itself It is not necessary to replace the com...

Page 196: ...s with excessive resistance will cause misfiring and may make the engine difficult to start in damp weather To check resistance remove the distributor cap leaving the wires in place Connect one lead of an ohmmeter to an electrode within the cap connect the other lead to the corresponding spark plug terminal remove it from the spark plug for this test Any wire with a resistance over 7 000 ohms per ...

Page 197: ...spark plug wires one at a time 2 5L Engine Firing Order 1 3 4 2 Distributor Rotation Clockwise 3 0L Engine Except SHO and Flexible Fuel Firing Order 1 4 2 5 3 6 Distributor Rotation Clockwise Стр 1 из 2 FIRING ORDERS 18 11 2005 http www chiltondiy com content 8687 8687_2_2 html ...

Page 198: ...3 8L Engine Firing Order 1 4 2 5 3 6 Distributor Rotation Counterclockwise 3 0L and 3 2L SHO Engines 3 0L Flexible Fuel Engine Firing Order 1 4 2 5 3 6 Distributorless Ignition System Стр 2 из 2 FIRING ORDERS 18 11 2005 http www chiltondiy com content 8687 8687_2_2 html ...

Page 199: ...or that has a diecast housing with a Hall effect distributor stator z An E type ignition coil which transforms battery voltage on the primary circuit into about 28 000 volts on the secondary circuit each time the ignition coil receives a signal from the Ignition Control Module ICM z An ignition control module which features EEC IV or PCM controlled ignition coil charge times Some of the earlier mo...

Page 200: ...e signal is then used by the EEC IV or PCM as applicable for crankshaft position sensing and the computation of the desired spark advance based on engine demand and calibration The voltage distribution is accomplished through a conventional rotor cap and ignition wires Component Testing IGNITION COIL 1 Follow the coil wire from the center terminal on the distributor cap to the end at the ignition ...

Page 201: ...on coil See the corresponding figures for terminal locations 4 The ohmmeter reading should be 0 3 1 0 ohms If the reading is less than 0 3 ohms or greater than 1 0 ohms the ignition coil should be replaced 5 Using an ohmmeter measure the coil secondary resistance connect it to the negative terminal and the high voltage terminal 6 The resistance should be 6 500 11 500 ohms with the ohmmeter set on ...

Page 202: ...ery cable 2 If equipped remove the distributor cap cover then disengage the electrical connector if applicable Testing ignition coil secondary resistance If equipped remove the distributor cap cover Стр 4 из 18 DISTRIBUTOR IGNITION SYSTEM 18 11 2005 http www chiltondiy com content 8687 8687_2_3 html ...

Page 203: ...to prevent damage to the rotor blade and spring 6 Matchmark the position of the rotor then pull it upward to remove it from the distributor shaft and armature Disengage the electrical connector Lift the distributor cap straight up to prevent damage to the rotor blade and spring Стр 5 из 18 DISTRIBUTOR IGNITION SYSTEM 18 11 2005 http www chiltondiy com content 8687 8687_2_3 html ...

Page 204: ...tor with the hole on the armature then fully seat the rotor on the distributor shaft Matchmark the position of the rotor for installation purposes Pull the rotor upward to remove it from the distributor shaft and armature Стр 6 из 18 DISTRIBUTOR IGNITION SYSTEM 18 11 2005 http www chiltondiy com content 8687 8687_2_3 html ...

Page 205: ... cap as tagged during removal 10 If equipped install the distributor cap cover then connect the negative battery cable Ignition Coil 1 Disconnect the negative battery cable 2 Disconnect the distributor to ignition coil wire from the ignition coil View of the spring blade and the locating boss on the rotor Location of the square alignment indicator on the distributor cap Стр 7 из 18 DISTRIBUTOR IGN...

Page 206: ...ence capacitor 5 Remove the ignition coil retaining screws and the ignition coil and radio interference capacitor if equipped from the ignition coil mounting bracket Disconnect the distributor to ignition coil wire early model 2 5L shown Disengage the engine wiring connector from the coil early model 2 5L shown Стр 8 из 18 DISTRIBUTOR IGNITION SYSTEM 18 11 2005 http www chiltondiy com content 8687...

Page 207: ... tabs on both sides of the cover then remove the ignition coil Click to enlarge Remove the ignition coil retaining screws Ignition coil and related components late model 3 0L shown Стр 9 из 18 DISTRIBUTOR IGNITION SYSTEM 18 11 2005 http www chiltondiy com content 8687 8687_2_3 html ...

Page 208: ...Click to enlarge To install Ignition coil and related components late model 3 8L shown Стр 10 из 18 DISTRIBUTOR IGNITION SYSTEM 18 11 2005 http www chiltondiy com content 8687 8687_2_3 html ...

Page 209: ...es or the TFI IV harness connector from the ignition control module 3 Remove the distributor from the engine For details please refer to the procedure located later in this section 4 Place the distributor on a work bench then remove the two module retaining screws Do NOT attempt to lift the module from the mounting surface before moving the entire module toward the distributor flange This will cau...

Page 210: ...vered later in this section 3 8L ENGINE 1 Disconnect the negative battery cable 2 Remove the screws attaching the cowl vent screen to the top of the cowl 3 Separate the engine compartment cowl seal strip from the cowl vent screen and the cowl dash extension panel in the area of the ignition control module 4 Lift the cowl vent screen off to allow access to the ignition control module TFI module ass...

Page 211: ... connector to the module 15 Install the cowl vent screen and retaining screws then install the engine compartment cowl panel and seal strip 16 Connect the negative battery cable Distributor 1 Disconnect the negative battery cable 2 Disconnect the engine control sensor wiring from the distributor 3 With a marker chalk or crayon mark the position of the No 1 cylinder distributor cap wire tower on th...

Page 212: ...olt then remove the distributor from the engine by pulling it upward Position the cap with the wires intact out of the way for ease of removal Removing the distributor hold down bolt Note The preferred method requires the removal of the rotor when removing the distributor Стр 14 из 18 DISTRIBUTOR IGNITION SYSTEM 18 11 2005 http www chiltondiy com content 8687 8687_2_3 html ...

Page 213: ...d be free of nicks cracks and excessive wear When rotated the distributor should move freely without binding Lift the distributor from the engine once the distributor is lifted partly out it may be tilted slightly and removed CAUTION Before installing the distributor you must coat the entire drive gear and the camshaft distributor gear through the distributor hole with Engine Assembly Lubricant D9...

Page 214: ...bs 2 0 2 6 Nm 5 Connect a suitable timing light to the engine following the manufacturer s instructions and connect the negative battery cable then start the engine and set the initial timing Timing procedures are located later in this section 6 Turn the engine OFF then tighten the distributor hold down bolt to 17 25 ft lbs 23 34 Nm on the 2 5L engine 14 21 ft lbs 19 28 Nm on the 3 0L engine or 20...

Page 215: ...edge of the vane is centered in the distributor stator assembly 6 Rotate the distributor in the block to align the leading edge of the vane and distributor stator assembly Make sure the rotor is pointing toward the distributor cap No 1 spark plug tower position If the vane and distributor stator cannot be aligned by rotating the distributor in the block remove the distributor just enough to diseng...

Page 216: ... engine 14 21 ft lbs 19 28 Nm on the 3 0L engine or 20 29 ft lbs 27 40 Nm on the 3 8L engine 12 Start the engine and recheck the timing to verify it did not change while tightening the hold down bolt then stop the engine and remove the timing light Chilton Automotive Information Systems 2004 Thomson Delmar Learning Стр 18 из 18 DISTRIBUTOR IGNITION SYSTEM 18 11 2005 http www chiltondiy com content...

Page 217: ... sensor is called Crankshaft Position CKP The CKP signal provides base timing and crankshaft speed rpm information to the Ignition Control Module ICM and the Powertrain Control Module PCM Click to enlarge z A Camshaft Position sensor CMP sensor that is a single Hall effect magnetic switch also but is activated by a single vane driven by the camshaft This sensor provides camshaft rotational locatio...

Page 218: ...trol Module ICM which receives the CKP signal from the CKP sensor During normal operation the CKP signal is sent to the PCM from the CKP sensor and provides base ignition timing and RPM information The ICM receives the CMP signal from CMP sensor providing the ICM with the information required to synchronize the ignition coils in the proper sequence It also receives the Spark Output SPOUT from the ...

Page 219: ...ger wheel located on the crankshaft pulley and damper The signal generated from the CKP sensor is called the Crankshaft Position signal CKP signal This signal provides base timing and crankshaft speed rpm information to the Ignition Control Module ICM The ICM uses this information with the spark advance information from the PCM to determine ignition coil ON and OFF time The ignition control module...

Page 220: ... three coil leads Each ignition coil activates two spark plugs simultaneously one on the compression stroke this plug uses the majority of the ignition coil s energy and one on the exhaust stroke this plug uses very little of the ignition coil s stored energy Location of the crankshaft position sensor 3 0L FF engine Стр 4 из 15 ELECTRONIC IGNITION SYSTEMS 18 11 2005 http www chiltondiy com content...

Page 221: ...nce It outputs a Profile Ignition Pickup PIP signal and an Ignition Diagnostic Monitor IDM signal for use by the PCM It also sends information on system failures through the IDM signal to the PCM stores information for use during diagnostic test mode and provides the signal for the tachometer Component Replacement 3 0L 3 2L SHO VEHICLES Crankshaft Position CKP Sensor The spark plug wire numbers ar...

Page 222: ...Remove the center and lower outer timing belt cover 10 Rotate the crankshaft by hand to position the metal vane of the crankshaft sprocket outside of the crankshaft position sensor air gap 11 Remove the two CKP sensor retaining screws then remove the crankshaft position sensor from the engine Click to enlarge To install 12 Route the crankshaft position sensor wiring harness through the outer timin...

Page 223: ...ect the crankshaft position sensor wiring harness 18 Install the upper outer timing belt cover 19 Install the engine air inlet connector then engage the ignition control module 20 Install the A C compressor and power steering pump drive belts 21 Connect the negative battery cable Camshaft Position CMP Sensor 1 Disconnect the negative battery cable 2 Remove the front engine support damper 3 Remove ...

Page 224: ...nect the negative battery cable 2 Remove the ignition coil cover then disengage the engine control sensor wiring connector from the ignition coil and if equipped the radio ignition interference capacitor 3 Remove the ignition coil wires by squeezing the locking tabs together to release the ignition coil boot retainers 4 Remove the ignition coil retaining screws then remove the ignition coil and if...

Page 225: ...tion interference capacitor 7 Install the ignition coil cover then connect the negative battery cable Ignition Control Module 1 Disconnect the negative battery cable 2 Disengage both engine control sensor wiring connectors at the Ignition Control Module ICM by pressing down on the locking tabs stamped PUSH then remove the wiring connector 3 Unfasten the retaining bolts then remove the ICM Ignition...

Page 226: ...nnectors to the ignition control module 7 Connect the negative battery cable 3 0L FLEXIBLE FUEL FF VEHICLES Crankshaft Position Sensor 1 Disconnect the negative battery cable 2 Raise and safely support the vehicle 3 Disconnect the fuel charging wiring from the crankshaft position sensor 4 Remove the crankshaft position sensor retaining bolts then remove the crankshaft position sensor Ignition cont...

Page 227: ...etaining bolts or damage to thecrankshaft position sensor may result 6 Properly route the fuel charging wiring then connect it to the crankshaft position sensor 7 Lower the vehicle then connect the negative battery cable Ignition Coil Crankshaft position sensor 3 0L Flexible Fuel FF Стр 11 из 15 ELECTRONIC IGNITION SYSTEMS 18 11 2005 http www chiltondiy com content 8687 8687_2_4 html ...

Page 228: ... wires by squeezing the locking tabs together and twisting while pulling upward 4 Remove the four ignition coil retaining screws then remove the ignition coil and radio interference capacitor from the ignition coil bracket Save the capacitor for installation with the ignition coil Стр 12 из 15 ELECTRONIC IGNITION SYSTEMS 18 11 2005 http www chiltondiy com content 8687 8687_2_4 html ...

Page 229: ... interference capacitor to the ignition coil bracket and secure with the retaining screws Tighten the retaining screws to 44 61 inch lbs 5 7 Nm Ignition coil 3 0L FF vehicles Стр 13 из 15 ELECTRONIC IGNITION SYSTEMS 18 11 2005 http www chiltondiy com content 8687 8687_2_4 html ...

Page 230: ...s while grasping the connector body and pulling away from the ignition control module 3 Remove the two ignition control module retaining screws then remove the ignition control module Click to enlarge 4 Position the ignition control module to the ignition control bracket and secure using the retaining screws Tighten the screws to 24 32 inch lbs 2 7 3 6 Nm 5 Engage the ignition control module conne...

Page 231: ...onnect the negative battery cable Chilton Automotive Information Systems 2004 Thomson Delmar Learning Стр 15 из 15 ELECTRONIC IGNITION SYSTEMS 18 11 2005 http www chiltondiy com content 8687 8687_2_4 html ...

Page 232: ... changes electronically and no vacuum or mechanical advance is used The 3 0L and 3 2L SHO engines and the 3 0L Flexible Fuel engines use a distributorless electronic ignition system Operation of this system allows for full electronic control of the timing If the ignition is set too far advanced BTDC the ignition and expansion of the fuel in the cylinder will occur too soon and tend to force the pi...

Page 233: ... 2 5L engine with manual transaxle Timing pointer location 2 5L engine with manual transaxle Timing mark on flywheel 2 5L engine with automatic transaxle Стр 2 из 7 IGNITION TIMING 18 11 2005 http www chiltondiy com content 8687 8687_2_5 html ...

Page 234: ... pointer location 2 5L engine with automatic transaxle Timing mark location 3 0L expcept Flexible Fuel and SHO engines Стр 3 из 7 IGNITION TIMING 18 11 2005 http www chiltondiy com content 8687 8687_2_5 html ...

Page 235: ...ce the tangle of wires under the hood but may duplicate the functions of tools you already have Never pierce a spark plug wire in order to attach a timing light or perform tests The pierced insulation will eventually lead to an electrical arc and related ignition troubles Since your car has electronic ignition you should use a timing light with an inductive pickup This pickup simply clamps onto th...

Page 236: ... detach the inline Spark Output SPOUT connector or remove the shorting bar from the double wire SPOUT connector The spout connector is the center wire between the Electronic Control Assembly ECA connector and the Thick Film Integrated TFI or Ignition Control ICM module 5 Connect an inductive type timing light Rotunda tool No 059 00006 or equivalent to the No 1 spark plug wire DO NOT puncture the i...

Page 237: ...er the vehicle is started Reconnecting the start wire after the vehicle is running will not correct the timing 8 Check the engine idle rpm if it is not within specifications adjust as necessary Idle speed is not adjustable on 1991 95 vehicles After the rpm has been adjusted or checked aim the timing light at the timing marks If they are not aligned loosen the distributor clamp bolts slightly and r...

Page 238: ...ck of the wire harness connector A cut out is provided and the tachometer lead wire alligator clip can be connected to the dark green yellow dotted wire of the electrical harness plug Chilton Automotive Information Systems 2004 Thomson Delmar Learning Стр 7 из 7 IGNITION TIMING 18 11 2005 http www chiltondiy com content 8687 8687_2_5 html ...

Page 239: ...o 1 piston on TDC of the compression stroke The timing marks on the camshaft and crankshaft gears will be together Check the clearance in the No 1 intake No 1 exhaust No 2 intake and No 3 exhaust valves 2 Rotate the crankshaft 1 complete turn 360 or 180 for the camshaft gear Check the clearance on the No 2 exhaust No 3 intake No 4 intake and No 4 exhaust valves 3 The clearance between the rocker a...

Page 240: ...alves 2 No 3 intake and No 2 exhaust valves 3 No 6 intake and No 4 exhaust valves Click to enlarge Checking the valve clearance 3 0L engine except SHO Стр 2 из 6 VALVE LASH 18 11 2005 http www chiltondiy com content 8687 8687_2_6 html ...

Page 241: ...3 8L engine 3 0L AND 3 2L SHO ENGINES 1 Disconnect the negative battery cable 2 Remove the valve cover For the 3 2L SHO engine first remove the EGR valve to exhaust manifold tube to gain access to the right hand valve cover For details regarding these procedures please refer to Section 3 of this manual 3 Remove the intake manifold assembly For details regarding this procedure please refer to Secti...

Page 242: ...valve lash adjustments 3 0L AND 3 2L SHO ENGINES 1 Disconnect the negative battery cable 2 Remove the valve covers For the 3 2L SHO engine remove the EGR valve to exhaust manifold tube to gain access to the right hand valve cover For details regarding these procedures please refer to Section 3 of this manual 3 Remove the intake manifold assembly For details regarding this procedure please refer to...

Page 243: ... tool T71P 19703 C or equivalent lift the valve adjusting spacer and remove the spacer with a magnet Install the compressor tool under the cam next to the lobe and rotate it down to depress the valve lifter tappet Install the holding tool then remove the compressor tool Стр 5 из 6 VALVE LASH 18 11 2005 http www chiltondiy com content 8687 8687_2_6 html ...

Page 244: ...e crankshaft as necessary 11 After all of the valve clearances are checked and or adjusted inspect all of the spacers to ensure that they are fully seated in their valve lifters tappets 12 Inspect the valve cover gaskets and replace if necessary For details regarding this procedure please refer to Section 3 of this manual 13 Install the intake manifold and the valve covers as described in Section ...

Page 245: ... then reconnect it 4 Start the engine and let it run at idle speed for 2 minutes The idle rpm should now return to the specified idle speed The idle specifications can be found on the calibration sticker located under the hood 5 Lightly step on and off the accelerator The engine rpm should return to the specified idle speed If the engine does not idle properly proceed to Step 6 6 Shut the engine O...

Page 246: ... refer to Section 5 of this manual 12 Using a small punch or equivalent punch through and remove the aluminum plug which covers the throttle stop adjusting screw Click to enlarge 13 Remove and replace the throttle stop screw then install the throttle body assembly onto the vehicle 14 Start the engine and allow the idle to stabilize Set the idle rpm to that specified in Step 10 15 Turn the engine O...

Page 247: ... Install a 0 20 in 5mm diameter orifice tool T86P 9600 A or equivalent 5 Disengage the electrical connector from the idle speed control air bypass valve solenoid Click to enlarge 6 Start the engine and run it at 2 000 rpm for 30 seconds 7 If equipped with an automatic transaxle place the selector in D If equipped with a manual transaxle place the selector in Neutral 8 Check and or adjust if necess...

Page 248: ...e Canister Purge Solenoid CANP hose from the intake manifold then connect tool No T89P 9600 AH or equivalent between the PCV and CANP ports Click to enlarge 5 Disconnect the idle speed control air bypass solenoid 6 Start the engine and let it idle Place the transaxle selector lever in N 7 Check and or adjust the idle speed to 770 830 rpm by turning the throttle plate stop screw 8 Turn the engine O...

Page 249: ...nd unblock the wheels Click to enlarge 1989 90 Vehicles 1 Apply the parking brake block the drive wheels and place the vehicle in P 2 Start the engine and let it run until it reaches normal operating temperature then turn the engine OFF 3 Back the throttle plate stop screw clear off the throttle lever pad 4 Place a 0 010 in 0 25mm feeler gauge between the throttle plate stop screw and the throttle...

Page 250: ...Chilton Automotive Information Systems 2004 Thomson Delmar Learning Стр 6 из 6 IDLE SPEED AND MIXTURE ADJUSTMENTS 18 11 2005 http www chiltondiy com content 8687 8687_2_7 html ...

Page 251: ...TS Click to enlarge Chilton Automotive Information Systems 2004 Thomson Delmar Learning Gasoline Engine Tune Up Specifications Стр 1 из 1 SPECIFICATION CHARTS 18 11 2005 http www chiltondiy com content 8687 8687_2_8 html ...

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Page 285: ... energy is removed from the battery However if the charging circuit is in good condition and the operating conditions are normal the power removed from the battery will soon be replaced by the alternator which will force electrons back through the battery reversing the normal flow and restoring the battery to its original chemical state The battery and starting motor are linked by very heavy elect...

Page 286: ...or a solenoid mounted on the starter used to mechanically engage the starter drive gears The relay is used to mechanically engage the starter drive gears The relay is used to reduce the amount of current the starting switch must carry Charging System The automobile charging system provides electrical power for operation of the vehicle s ignition system starting system and all of the electrical acc...

Page 287: ...vehicles utilize a Distributor Ignition DI system which incorporates a conventional distributor The SHO and the 3 0L Flexible Fuel FF vehicles utilize a distributorless ignition system known as Electronic Ignition EI For more information testing and removal replacement procedures regarding the ignition systems please refer to Section 2 of this manual Safety Precautions Observing these precautions ...

Page 288: ... electrical connections within the system z NEVER separate the alternator on an open circuit Make sure all connections within the circuit are clean and tight z Disconnect the battery ground terminal when performing any service on electrical components z Disconnect the battery if arc welding is to be done on the vehicle REMOVAL INSTALLATION The different engine applications that the Ford Taurus and...

Page 289: ...alternator on the engine 7 Install the alternator pivot bolt and the adjusting bolt but do NOT tighten the bolts until the drive belt it tensioned 8 Engage the wiring terminals to the alternator as tagged during removal 9 Install the drive belt over the alternator drive pulley then adjust the belt tension using Belt Tension Gauge 021 00019 or equivalent When adjusting belt tension apply pressure o...

Page 290: ...ator 3 Loosen the pivot bolt then remove the mounting brace bolt from the alternator Disengage the wiring harness from the alternator early model 2 5L shown Disengage the wiring harness from the voltage regulator early model 2 5L shown Стр 6 из 46 ENGINE ELECTRICAL 18 11 2005 http www chiltondiy com content 8687 8687_3_1 html ...

Page 291: ... brace then remove the alternator voltage regulator assembly from the engine Loosen the mounting pivot bolts early model 2 5L shown Remove the mounting pivot bolts from the alternator early model 2 5L shown Стр 7 из 46 ENGINE ELECTRICAL 18 11 2005 http www chiltondiy com content 8687 8687_3_1 html ...

Page 292: ...the alternator regulator assembly from the vehicle early model 2 5L shown Alternator regulator assemblies late model 3 0L and 3 8L engines shown Стр 8 из 46 ENGINE ELECTRICAL 18 11 2005 http www chiltondiy com content 8687 8687_3_1 html ...

Page 293: ...0 Nm and the pivot bolt to 30 41 ft lbs 40 55 Nm 9 Engage the wiring harness connector s to the alternator voltage regulator as applicable If equipped tighten the output terminal nut to 80 97 inch lbs 9 11 Nm 10 Connect the negative battery cable 3 0L SHO ENGINE 1 Disconnect the negative battery cable 2 Remove the accessory drive belt from the alternator 3 Disengage the electrical harness connecto...

Page 294: ...connector and the output terminal wiring Tighten the output terminal nut to 80 97 inch lbs 9 11 Nm 8 Install the alternator drive belt on the alternator then connect the negative battery cable Internal Fan and Regulator VEHICLES THROUGH 1993 Alternator assembly 3 0L SHO engine equipped with the rear mount regulator and internal fan Стр 10 из 46 ENGINE ELECTRICAL 18 11 2005 http www chiltondiy com ...

Page 295: ...ease refer to the procedure later in this section 2 Tag and disengage the electrical wiring harness connector and the output terminal wiring from the alternator 3 Loosen the belt tensioner then remove the alternator belt from the pulley 4 Remove the mounting bolt on the front of the alternator and the two bolts from the rear of the alternator then remove the alternator from the vehicle Стр 11 из 4...

Page 296: ... front bolt to 36 53 ft lbs 48 72 Nm and the rear bolts to 26 36 ft lbs 34 50 Nm 6 Install the alternator belt then set the belt tension to 148 191 lbs 658 854 N for a Alternator assembly 3 0L and 3 2L SHO vehicles through 1993 Стр 12 из 46 ENGINE ELECTRICAL 18 11 2005 http www chiltondiy com content 8687 8687_3_1 html ...

Page 297: ...engage the electrical harness connector and the output terminal wiring 4 Remove the bolt from the rear alternator bracket to alternator then remove the two mounting brackets 5 Remove the alternator from the vehicle Click to enlarge To install 6 Position the alternator in the vehicle then install the two mounting brackets Tighten the bracket retaining bolts to 15 22 ft lbs 20 30 Nm 7 Install the bo...

Page 298: ... and the regulator 4 Installation is the reverse of the removal procedure 5 Connect the negative battery cable Test the system for proper voltage regulation Rear Mounted Regulator This voltage regulator is mounted on the rear of the alternator housing 1 Disconnect the negative battery cable 2 Remove the four retaining Torx screws attaching the voltage regulator to the alternator rear housing 3 Rem...

Page 299: ... and then the positive battery cable 2 Remove the battery hold down bracket retaining bolt then remove the hold down bracket Before removing the battery from the vehicle make sure to note the position of the positive and negative terminals 3 Carefully lift the battery from its mounting and remove it from the vehicle Voltage regulator mounting vehicles equipped with the rear mount regulator alterna...

Page 300: ... Battery and related components 3 0L except SHO and 3 8L shown 2 5L similar Battery and related components 3 0L and 3 2L SHO Стр 16 из 46 ENGINE ELECTRICAL 18 11 2005 http www chiltondiy com content 8687 8687_3_1 html ...

Page 301: ... the hold down hardware so the battery is secure Do NOT overtighten When the battery is disconnected and reconnected some abnormal driving symptoms may occur while the Powertrain Control Module PCM relearns its adaptive strategy The car may have to be driven 10 or more miles to relearn this strategy 7 Secure cables to the proper terminals securing the positive cable first but do NOT overtighten Ap...

Page 302: ... then tighten each to 6 8 ft lbs 8 12 Nm 5 Install the battery in the engine compartment as previously outlined in this section then tighten the hold down spacer bolt to 6 8 ft lbs 8 12 Nm Starter TESTING Before removing the starter for repair or replacement check the condition of all circuit wiring for damage Inspect all connections to the starter motor relay ignition switch and battery including...

Page 303: ...port and ground cable connection from the upper starter stud bolt 4 If equipped remove the starter brace from the cylinder block and the starter 5 On 2 5L engines remove the three starter to bell housing bolts On 3 0L engines remove the two starter to bell housing bolts Disengage the connection from the upper starter stud bolt early model 2 5L shown Стр 19 из 46 ENGINE ELECTRICAL 18 11 2005 http w...

Page 304: ... vehicles equipped with a manual transaxle remove the starter between the subframe and the engine Remove the starter retaining bolts early model 2 5L shown Remove the starter motor from the vehicle early model 2 5L shown Стр 20 из 46 ENGINE ELECTRICAL 18 11 2005 http www chiltondiy com content 8687 8687_3_1 html ...

Page 305: ...r block and starter 9 Engage the ground cable connection to the upper starter stud bolt then install the cable support 10 Lower the vehicle engage the cable connection at the starter then connect the negative battery cable Exploded view of starter motor Location of the starter motor and relay 1989 3 0L SHO shown Стр 21 из 46 ENGINE ELECTRICAL 18 11 2005 http www chiltondiy com content 8687 8687_3_...

Page 306: ...sten the starter cable and the relay connector to the motor Tighten the starter cable nut to 80 119 inch lbs 9 13 5 Nm 6 Lower the vehicle then connect the negative battery cable 1992 95 Vehicles 1 Disconnect the negative battery cable When the battery has been disconnected and reconnected some abnormal driveability symptoms may occur while the PCM relearns its Exploded view of starter motor assem...

Page 307: ... finger tight 6 Tighten the retaining bolts to 15 20 ft lbs 20 27 Nm 7 Engage the starter solenoid connector making sure to push straight on until the connector locks in position A noticeable click should be heard or detent felt 8 Install the starter cable nut to the starter solenoid B terminal Tighten the nut to 80 124 inch lbs 9 14 Nm then install the red starter solenoid safety cap 9 Lower the ...

Page 308: ...o battery electrical connectors 4 Disconnect the retaining screws then remove the relay from the vehicle Disengage the relay to ignition switch electrical connector early model 2 5L shown Unfasten the nut retaining the starter and battery connections early model 2 5L shown Стр 24 из 46 ENGINE ELECTRICAL 18 11 2005 http www chiltondiy com content 8687 8687_3_1 html ...

Page 309: ...and the 3 2L SHO engines the sensor is located at the rear of the right hand side cylinder head in the No 1 water hose connection directly below the throttle body The sensor signal is used to modify ignition timing EGR flow and the air fuel ratio as a function of the engine coolant temperature 1 Disconnect the negative battery cable 2 Drain the cooling system until its level is below that of the s...

Page 310: ...Click to enlarge Location of the engine coolant temperature sensor 3 0L engine shown except SHO Стр 26 из 46 ENGINE ELECTRICAL 18 11 2005 http www chiltondiy com content 8687 8687_3_1 html ...

Page 311: ...nstall the sensor to the intake manifold or water hose connection as applicable Tighten the sensor to 12 17 ft lbs 16 23 Nm Engine coolant temperature sensor mounting 3 0L 3 2L SHO engines Location of the engine coolant temperature sensor 3 8L engine shown Стр 27 из 46 ENGINE ELECTRICAL 18 11 2005 http www chiltondiy com content 8687 8687_3_1 html ...

Page 312: ...aner assembly on late model vehicles On early model vehicles the sensor is located at the rear of the intake manifold or on the side of the throttle body 1 Disconnect the negative battery cable 2 Disengage the electrical connector from the sensor 3 To remove the sensor from the throttle body or intake manifold unscrew the sensor then remove it from the engine 4 To remove the sensor from the air cl...

Page 313: ...Click to enlarge Intake air temperature sensor location 3 0L except Flexible Fuel FF and SHO vehicles Стр 29 из 46 ENGINE ELECTRICAL 18 11 2005 http www chiltondiy com content 8687 8687_3_1 html ...

Page 314: ...arge Click to enlarge IAT sensor mounting 3 0L Flexible Fuel FF shown Intake air temperature sensor late model SHO shown Стр 30 из 46 ENGINE ELECTRICAL 18 11 2005 http www chiltondiy com content 8687 8687_3_1 html ...

Page 315: ...the throttle body or mounted on the top of the air cleaner assembly 3 0L ENGINE EXCEPT SHO 1 Disconnect the negative battery cable 2 Remove the air cleaner outlet tube by loosening the retaining clamps then tag and disconnect any hoses or tubes 3 Disengage the engine control sensor wiring connector from the mass air flow sensor 4 Remove the four retaining bolts then carefully remove the sensor fro...

Page 316: ...ks Click to enlarge 3 0L AND 3 2L SHO ENGINES 1 Disconnect the negative battery cable 2 Remove the air cleaner outlet tube from the throttle body and the mass air flow sensor 3 Disengage the engine control sensor wiring connector from the mass air flow sensor 4 Remove the air cleaner cover from the air cleaner assembly Mass air flow sensor location 3 0L and 3 0L 3 2L SHO engines Стр 32 из 46 ENGIN...

Page 317: ...negative battery cable 3 8L ENGINE 1 Disconnect the negative battery cable 2 Disengage the engine control sensor wiring connector from the mass air flow sensor 3 Loosen the air cleaner tube clamps on the engine air outlet tube and the air cleaner outlet tube then disconnect the tubes from the mass air flow sensor 4 Remove the mass air flow sensor to mass air flow sensor bracket retaining bolt s th...

Page 318: ...e on the 3 0L and 3 0L 3 2L SHO engines Early model 3 8L engines utilize a heated oxygen sensor threaded on the left hand side exhaust pipe Later model 3 8L engines utilize two heated oxygen control sensors for the engine control system one located on the left hand exhaust manifold and the other located on the Y pipe 1 Disconnect the negative battery cable 2 If necessary raise and safely support t...

Page 319: ...emoval 4 Using Oxygen Sensor Wrench T94P 9472 A or equivalent remove the heated oxygen sensor s from the left hand exhaust manifold and or Y pipe as applicable Remove the heated oxygen sensor from the vehicle 2 5L engine shown Стр 35 из 46 ENGINE ELECTRICAL 18 11 2005 http www chiltondiy com content 8687 8687_3_1 html ...

Page 320: ...r wiring connector s to the heated oxygen sensor s 7 If raised carefully lower the vehicle then connect the negative battery cable Knock Sensor 3 0L and 3 2L SHO ENGINES View of heated oxygen sensor locations 3 0L 3 0L 3 2L SHO and 3 8L engines Стр 36 из 46 ENGINE ELECTRICAL 18 11 2005 http www chiltondiy com content 8687 8687_3_1 html ...

Page 321: ...r then connect the negative battery cable Manifold Absolute Pressure MAP Sensor The MAP sensor measures changes in manifold vacuum resulting from changes in engine load and speed then converts this to a voltage output This gives the PCM information on engine load It is used as a barometric sensor for altitude compensation updating the PCM during key ON engine OFF and every wide open throttle The P...

Page 322: ...haft and is used to supply a voltage output change proportional to the change in the throttle position It is used by the ECU to determine engine operation mode closed throttle part throttle and wide open throttle The proper fuel mixture spark and EGR will be output only when the operation mode has been determined correctly Manifold Absolute Pressure MAP sensor Стр 38 из 46 ENGINE ELECTRICAL 18 11 ...

Page 323: ...n sensor to indicated proper alignment during installation 3 Disengage the electrical connector from the throttle position sensor 4 Unfasten the mounting screws then remove the sensor Throttle position sensor 3 0L engine except SHO Стр 39 из 46 ENGINE ELECTRICAL 18 11 2005 http www chiltondiy com content 8687 8687_3_1 html ...

Page 324: ...rottle shaft blade then rotate the TP sensor clockwise ONLY to the installed position Failure to install the sensor in this way may result in excessive idle speeds 6 Align the scribe marks on the throttle body and the TP sensor Secure the sensor to the throttle body using the retaining screws Throttle position sensor SHO engines Стр 40 из 46 ENGINE ELECTRICAL 18 11 2005 http www chiltondiy com con...

Page 325: ... of the intake manifold z Air Charge Temperature Sensor 3 0L engine is on the top of the engine z Air Charge Temperature Sensor SHO engine is on the left side of the engine in the air cleaner z Alternator Output Control Relay is between the right front inner fender and the fender splash shield z Ambient Temperature Sensor is at the left front of the engine compartment on the left side of the radia...

Page 326: ... at the right front of the engine compartment at the alternator output control relay z Crankshaft Position Sensor is at the lower right rear of the engine z Daytime Running Lamps DRL Module Canadian vehicles is at the lower left front of the engine compartment z Diagnostic Warning Module is behind the right instrument panel above the glove box z Distributorless Ignition System DIS Module is on the...

Page 327: ... Heated Windshield Control Module is at the right side of the steering column behind the instrument panel z Heated Windshield Test Connector is at the left rear of the engine compartment z Horn Relay is behind the center of the instrument panel mounted on a brace z Idle Air Control is at the top rear of the engine z Idle Speed Control 2 5L engine is at the top rear of the engine z Ignition Suppres...

Page 328: ...er of the trunk lid near the hinge z Manifold Absolute Pressure MAP Sensor is at the right side of the firewall z Mass Air Flow Sensor is on the top left side of the engine on the air cleaner assembly z Moonroof Relay is behind the right side of the instrument panel z Neutral Safety Switch is at the left side of the engine on top of the transaxle z Oil Pressure Switch 2 5L engine is at the center ...

Page 329: ...on the left front fender apron in front of the shock tower z Stop Lamp Switch is behind the left side instrument panel on the pedal support z Sunload Sensor is behind the top left side of the instrument panel z TFI Ignition Module 2 5L engine is at the center front of the engine z TFI Ignition Module 3 0L engine is at the top left side of the engine connected to the distributor assembly z TFI Igni...

Page 330: ...ine compartment near the EEC module z Voltage Regulator is on the left front fender apron z Warning Chime Module is behind the lower left instrument panel z Window Safety Relay is behind the right kick panel Chilton Automotive Information Systems 2004 Thomson Delmar Learning Стр 46 из 46 ENGINE ELECTRICAL 18 11 2005 http www chiltondiy com content 8687 8687_3_1 html ...

Page 331: ... scope of the do it yourself mechanic s tools and abilities You will have to decide for yourself the depth of involvement you desire in an engine repair or rebuild TOOLS The tools required for an engine overhaul or parts replacement will depend on the depth of your involvement With few exceptions they will be the tools found in a mechanic s basic tool kit see Section 1 of this manual More in depth...

Page 332: ... exposed to frictional contact must be prelubed to provide lubrication at initial start up Any product specifically formulated for this purpose can be used but engine oil is not recommended as a prelube in most cases When semi permanent locked but removable installation of bolts or nuts is desired threads should be cleaned and coated with Loctite or other similar commercial non hardening sealant R...

Page 333: ...pliers or with a screw or stud extractor After the hole is clear the thread can be repaired as shown in the series of accompanying illustrations and in the kit manufacturer s instructions Damaged bolt hole threads can be replaced with thread repair inserts Standard thread repair insert left and spark plug thread insert Стр 3 из 211 18 11 2005 file C DOCUME 1 SILENT 1 LOCALS 1 Temp trsHIPBC htm ...

Page 334: ...letely through the hole or to the bottom of a blind hole Using the kit tap the hole in order to receive the thread insert Keep the tap well oiled and back it out frequently to avoid clogging the threads Стр 4 из 211 18 11 2005 file C DOCUME 1 SILENT 1 LOCALS 1 Temp trsHIPBC htm ...

Page 335: ... is 1 4 1 2 turn below the top surface then remove the tool and break off the tang using a punch CAUTION When draining the coolant keep in mind that cats and dogs are attracted by ethylene glycol antifreeze and are quite likely to drink any that is left in an uncovered container or in puddles on the ground This will prove fatal in sufficient quantity Always drain the coolant into a sealable contai...

Page 336: ...Disconnect the accelerator and throttle valve control cables at the throttle body 13 If equipped properly discharge the air conditioning system and remove the suction and discharge lines from the compressor 14 On manual transaxle equipped vehicles remove the engine damper brace 15 Remove the driver belt and water pump pulley 16 Remove the air cleaner to canister hose 17 Raise and safely support th...

Page 337: ...wer steering lines to the pump 36 Raise and safely support the vehicle 37 Connect the lower radiator hose to the tube 38 Install the lower engine to transaxle attaching bolts and tighten to 26 34 ft lbs 35 46 Nm 39 Connect the halfshaft and canister brackets to the engine 40 Connect the exhaust pipe to the manifold 41 Install the engine insulator nuts and tighten them to 40 55 ft lbs 54 75 Nm 42 P...

Page 338: ... remove the battery and the battery tray 6 Remove the integrated relay controller cooling fan and radiator with fan shroud Remove the engine bounce damper bracket on the shock tower 7 Remove the evaporative emission line upper radiator hose starter brace and lower radiator hose 8 Remove the exhaust pipes from both exhaust manifolds Disconnect and plug the power steering pump lines 9 Disconnect the...

Page 339: ...use a suitable engine hoist to remove the engine from the vehicle Remove the main wiring harness from the engine Click to enlarge Click to enlarge Click to enlarge Engine removal component disconnect points 3 0L gasoline engine Engine removal component disconnect points continued 3 0L gasoline engine Engine removal component disconnect points 3 0L Flexible Fuel FF engine Стр 9 из 211 18 11 2005 fi...

Page 340: ...roud Install the engine bounce damper bracket on the shock tower 24 Install the battery tray and the battery then install the air cleaner assembly 25 Charge the air conditioning system using the correct equipment and precautions 26 Fill the cooling system with the proper type and quantity of coolant Fill the crankcase with the correct type of motor oil to the required level 27 Install the hood acc...

Page 341: ...gine only loosen the accessory drive belt tensioner pulley then remove the belt from the A C compressor and the alternator 21 On the 3 2L SHO engine only loosen the accessory drive belt tensioner Remove the single accessory drive belt then remove the tensioner pulley 22 On the 3 0L SHO only loosen the accessory drive belt lower tensioner pulley then remove the power steering pump belt and the lowe...

Page 342: ...t subframe nuts 47 Install the lower transaxle to engine retaining bolts Tighten the bolts to 25 35 ft lbs 34 47 Nm 48 Install the starter motor assembly For details please refer to the procedure located earlier in this section 49 Install the 4 dual converter Y pipe to exhaust manifold retaining nuts then tighten them to 20 35 ft lbs 27 47 Nm 50 Apply anti seize compound to the threads then instal...

Page 343: ...ng fan and shroud assembly upper radiator hose air cleaner outlet tube computer control module relay radiator coolant recovery reservoir and the radiator upper sight shield 70 Engage the alternator and voltage regulator wiring 71 Install the oil level dipstick 72 Install the hood according to the marks made during removal then connect the underhood light wiring if equipped 73 Install the battery t...

Page 344: ...tle control valve cable Detach the bulkhead electrical connector and transaxle pressure switches 23 Remove the transaxle support assembly retaining bolts then remove the transaxle support assembly from the vehicle 24 Raise and safely support the vehicle Remove the wheel and tire assemblies 25 Position a drain pan under the car s oil pan then drain the engine oil and remove the filter Move the drai...

Page 345: ...ing bolts to 30 45 ft lbs 41 61 Nm Connect the compressor to condenser discharge line 48 Connect the A C clutch field coil to the engine control sensor wiring 49 Fasten the heater hoses and the fuel supply and return hoses then connect the vacuum hoses 50 Connect the engine control module wiring assembly 51 Attach the transaxle oil cooler inlet and outlet tubes 52 Install the radiator assembly 53 ...

Page 346: ...se and safely support the vehicle Install the wheel and tire assemblies then tighten the lug nuts to 85 105 ft lbs 115 142 Nm 78 Carefully lower the vehicle 79 Install the hood using the aligning marks made during removal and connect the negative battery cable 80 Fill the cooling system with the proper type and quantity of coolant Fill the crankcase with the proper type and viscosity of motor oil ...

Page 347: ...le safely Remove the tire and wheel assembly 2 Place a jack and a block of wood under the transaxle and support the transaxle 3 Remove the bolts attaching the insulator to the frame 4 Raise the transaxle with the jack enough to relieve the weight on the insulator 5 Remove the bolts attaching the insulator to the transaxle Remove the insulator 6 Installation is the reverse of the removal procedure ...

Page 348: ...ount and the bolts retaining the insulator to the transaxle and subframe 7 Raise the transaxle with the jack enough to unload the insulator 8 Remove the insulator and lower damper bracket 9 Installation is the reverse of the removal procedure Tighten the damper bracket to insulator nuts to 40 55 ft lbs 54 75 Nm and the insulator to transaxle bolts to 70 95 ft lbs 95 139 Nm Tighten the insulator to...

Page 349: ... the vehicle and support it safely 2 Remove the tire and wheel assembly 3 Place a jack and wood block under the transaxle and support the transaxle 4 Remove the 2 bolts retaining the vertical restrictor assembly 5 Remove the nut retaining the transaxle mount to the support assembly 6 Remove the 2 through bolts retaining the transaxle mount to the frame 7 Raise the transaxle with the jack enough to...

Page 350: ... top of the rocker arm cover 5 Remove the rocker arm cover bolts Remove the rocker cover and gasket assembly from the engine Disconnect the PCV hose then set it aside early model 2 5L shown Remove the rocker arm cover retaining bolts early model 2 5L shown Стр 20 из 211 18 11 2005 file C DOCUME 1 SILENT 1 LOCALS 1 Temp trsHIPBC htm ...

Page 351: ... the rocker arm cover from the engine early model 2 5L shown Inspect the rocker arm cover gasket for damage early model 2 5L shown Стр 21 из 211 18 11 2005 file C DOCUME 1 SILENT 1 LOCALS 1 Temp trsHIPBC htm ...

Page 352: ...sher or bolt and rubber isolator assembly If reusing the old rocker arm cover bolts always put a drop of adhesive threadlock ESE M2G260 AA or equivalent on the threads of the bolt prior to installation Only new bolts are pre applied with adhesive Failure to do so may result in an oil leak 9 Install the rocker arm cover assembly then tighten the retaining bolts to 6 9 ft lbs 8 12 Nm 10 If equipped ...

Page 353: ... removed remove the PCV valve and if equipped loosen the lower EGR tube retaining nut and rotate the tube aside Remove the throttle body and move the fuel injection harness aside 6 Remove the rocker arm cover attaching screws and the cover s and gasket s from the vehicle Click to enlarge To install 7 Lightly oil all bolt and stud threads before installation Using cleaning solvent clean the cylinde...

Page 354: ...ect the crankcase ventilation tube remove the oil filler cap and remove the the fuel charging wiring harness stand offs from the inboard valve cover studs then move the harness out of the way 5 If the right valve cover is being removed first remove the throttle body refer to Section 5 for this procedure Loosen the lower EGR valve to exhaust manifold tube retaining nut and rotate the EGR valve to e...

Page 355: ...stener collar If it s installed correctly all of the fasteners will be secured by the valve cover gasket and will not fall out 12 Before applying sealer clean all sealing surfaces with Metal Surface Cleaner F4AZ 19A536 RA or equivalent to remove any residues that may interfere with the sealer s ability to adhere 13 Apply a bead of Silicone Gasket and Sealant F1AZ 19562 A or equivalent at the cylin...

Page 356: ...rocedure in Section 1 or Section 5 of this manual 3 Tag and disengage all vacuum lines and electrical connectors from the intake manifold 4 Remove the upper intake manifold assembly For details please refer to the procedure later in this section 5 Tag and disconnect the spark plug wires 6 If the left cover is being removed remove the oil fill cap and the ignition coil plastic cover 7 If the right ...

Page 357: ...aks 3 8L Engine 1 Disconnect the negative battery cable 2 Tag and disconnect the ignition wires from the spark plugs 3 Remove the ignition wire separators from the valve cover retaining bolt studs 4 For 1993 95 vehicles remove the upper intake manifold For details please refer to the procedure located later in this section 5 If the left cover is being removed remove the oil fill cap 6 If the right...

Page 358: ...bs 9 12 Nm 10 If removed install the upper intake manifold For details please refer to the procedure located later in this section 11 If the left cover is being installed install the oil filler cap 12 If the right cover is being installed install the PCV valve then the air cleaner 13 Install the ignition wire separators then connect the ignition wires to the spark plugs as tagged during removal 14...

Page 359: ...ier in this section 3 Remove the rocker arm bolts fulcrums rocker arms and fulcrum washers Keep all parts in order so they can be reinstalled to their original position Loosen the rocker arm retaining bolts early 2 5L engine shown Remove the rocker arm bolts early 2 5L engine shown Стр 29 из 211 18 11 2005 file C DOCUME 1 SILENT 1 LOCALS 1 Temp trsHIPBC htm ...

Page 360: ...to 6 8 ft lbs 8 11 Nm then install connect the components to the rocker arm cover For details please refer to the rocker arm cover procedure located earlier in this section 10 Connect the negative battery cable 3 0L Engine Except SHO 1 Disconnect the negative battery cable Tag and disconnect the ignition wires from the spark plugs 2 Remove the rocker arm valve covers from the cylinder head For det...

Page 361: ...e procedure located earlier in this section 3 Remove the rocker arm bolt fulcrum and rocker arm Keep all parts in order so they can be reinstalled in their original positions To install 4 Lubricated all rocker arms with Engine Assembly Lubricant D9AZ 19579 D or equivalent Rocker arm seats must be fully seated in the cylinder head and pushrods must be seated in the rocker arm sockets before final t...

Page 362: ... then close the draincock CAUTION When draining the coolant keep in mind that cats and dogs are attracted byethylene glycol antifreeze and are quite likely to drink any that is left inan uncovered container or in puddles on the ground This will prove fatal insufficient quantity Always drain the coolant into a sealable container Coolant should be reused unless it is contaminated or several years ol...

Page 363: ...d cylinder head mating surfaces are clean and free from gasket material Make sure the water outlet connection pocket and air vent passage are clean and free from rust Clean the vent plug and gasket 6 Place the thermostat in position fully inserted to compress the gasket and pressed into the water outlet connection to secure Install the water outlet Remove the water outlet connection retaining bolt...

Page 364: ...aincock then drain the cooling system 4 Remove the upper radiator hose from the water outlet connection thermostat housing 5 Remove the three retaining bolts from the water outlet connection thermostat housing 6 Remove the housing and the thermostat as an assembly 7 Remove the thermostat from the housing water outlet connection then discard the water outlet hose gasket and carefully clean the mati...

Page 365: ...connection Any used hose clamps must be replaced withnew clamps to ensure proper sealing at the connection 11 Install the upper radiator hose and position the clamps between the alignment marks on both ends of the hose then slide the hose on the connections Tighten the screw clamps to 20 30 inch lbs 2 2 3 4 Nm 12 Fill and bleed the cooling system Connect the negative battery cable start the engine...

Page 366: ...mostat into the water outlet connection 8 Position the water outlet connection then install and tighten the two retaining nuts to 5 8 ft lbs 7 11 Nm 9 Install the air cleaner outlet tube 10 Refill the cooling system 11 Connect the negative battery cable Start the engine and check for leaks 12 Check the coolant level and add as necessary 3 8L Engine 1 Disconnect the negative battery cable 2 Place a...

Page 367: ...by rotating it counterclockwise in the water outlet connection until the thermostat becomes free to remove Do not pry the water outlet connection off Click to enlarge To install 5 Make sure the water outlet connection pocket and all mating surfaces are clean Thermostat and related components 3 8L engine Стр 37 из 211 18 11 2005 file C DOCUME 1 SILENT 1 LOCALS 1 Temp trsHIPBC htm ...

Page 368: ...ove the vent plug on the water connection outlet The vent plug must be removed before the radiator is filled or the engine may not fill completely Do not turn the plastic cap under the vent plug or the gasket may be damaged Do not try to add coolant through the vent plug hole Install the vent plug after filling the radiator and before starting the engine 2 Install the radiator cap to the first not...

Page 369: ...sconnect the negative battery cable 3 Drain the cooling system 4 Remove accelerator cable and if equipped the cruise control cable 5 Remove the air cleaner assembly and the heat stove tube at the heat shield Common intake manifold assembly late model 2 5L engine shown Стр 39 из 211 18 11 2005 file C DOCUME 1 SILENT 1 LOCALS 1 Temp trsHIPBC htm ...

Page 370: ...onnect the water inlet tube at the intake manifold On 1991 vehicles remove the exhaust manifold heat shroud assembly 10 Disconnect the EGR tube at the EGR valve 11 Unfasten the intake manifold retaining bolts and remove the intake manifold Remove the gasket and clean the gasket contact surfaces To install Remove the intake manifold retaining bolts After removing the intake manifold remove the gask...

Page 371: ...hing the air cleaner outlet flex hose to the throttle body then remove the flex hose 4 Identify tag and disengage and all vacuum connections to the throttle body 5 Loosen the lower EGR tube nut then rotate the tube away from the valve Disconnect the throttle cable and TV cable from the throttle linkage 6 Disengage the air charge temperature sensor throttle position sensor air by pass valve and pre...

Page 372: ...om the No 3 cylinder and rotate the rocker arm from the retainer then remove the pushrod 16 Using a Torx head socket remove the intake manifold attaching bolts then place a suitable prybar between the intake manifold near the thermostat and the transmission Use the prybar to carefully loosen the intake manifold from the sealing surfaces 17 Lift the intake manifold away from the engine Place clean ...

Page 373: ...18 The intake manifold cylinder head and cylinder block mating surfaces should be clean and free of old silicone rubber sealer Use a suitable solvent to clean these surfaces 19 Apply a Silicone Rubber Sealer D6AZ 19562 AA or equivalent to the intersection of the cylinder block end rails and cylinder heads 20 Install the front and rear intake manifold end seals in place and secure Install the intak...

Page 374: ... lifter on the base circle of the camshaft and tighten the rocker arm bolt in 2 steps first to 8 ft lbs 11 Nm and then to 24 ft lbs 32 Nm 26 Install the rocker arm covers For information regarding rocker arm installation please refer to the procedure located earlier in this section 27 Install the fuel injector harness Install the stand offs to the inboard rocker arm retaining studs then attach the...

Page 375: ... tube from the rocker arm valve cover and the air cleaner outlet tube 4 Remove the aspirator hose from the air cleaner outlet tube Remove the air cleaner from the throttle body and the air cleaner outlet tube Before relieving the fuel pressure cover the Schrader valve with a clean rag to prevent fuel from spraying into your eyes 5 Carefully relieve the fuel system pressure at the fuel pressure rel...

Page 376: ... refer to the procedure in Section 5 of this manual Click to enlarge Throttle body upper intake manifold removal 1994 3 0L unleaded gasoline engine shown Стр 46 из 211 18 11 2005 file C DOCUME 1 SILENT 1 LOCALS 1 Temp trsHIPBC htm ...

Page 377: ...inboard rocker arm cover studs Carefully disengage the electrical connections to each injector then remove the fuel charging wiring from the engine The intake manifold assembly may be removed with the fuel supply manifold and injectors in place Throttle body upper intake manifold removal 1994 3 0L flexible fuel FF engine shown Стр 47 из 211 18 11 2005 file C DOCUME 1 SILENT 1 LOCALS 1 Temp trsHIPB...

Page 378: ...axle as a leverage point to break the seal Remove the intake manifold from the engine To install 22 Lightly oil all retaining bolt and stud bolt threads before installation Be careful when scraping aluminum gasket surfaces because aluminum gouges easily and if scratched may cause gasket leaks 23 Clean the mating surfaces of the intake manifold and cylinder head Lay a clean cloth in the lifter vall...

Page 379: ...ankshaft lobe straight down and away from the valve lifter Tighten the retaining bolt to 5 11 ft lbs 7 15 Nm to seat the rocker arm fulcrum into the cylinder head Final tighten the bolt to 19 28 ft lbs 26 38 Nm in any position The fulcrum must be seated into the cylinder head and the push rod must be fully seated in the rocker arm and lifter sockets before final tightening 32 Install the rocker ar...

Page 380: ...Tighten the retaining clamps to 24 48 inch lbs 2 7 5 4 Nm 46 Install the PCV tube to the rocker arm cover and the air cleaner outlet tube 47 Connect the negative battery cable then start the engine and check for coolant oil fuel and or vacuum leaks Flexible Fuel FF base initial engine timing is NOT adjustable 48 Verify and if necessary correct the base initial engine timing to 10 BTDC before top d...

Page 381: ...asket on the cylinder head then position the intake manifold on the cylinder heads 12 Install the retaining bolts then tighten the bolts to 11 17 ft lbs 15 23 Nm Click to enlarge Intake manifold and bracket assembly 3 0L and 3 2L SHO engines For the SHO engines tighten the intake manifold retaining bolts to 11 17 ft lbs 15 23 Nm Стр 51 из 211 18 11 2005 file C DOCUME 1 SILENT 1 LOCALS 1 Temp trsHI...

Page 382: ...ct the fuel lines at the injector fuel rail assembly 9 Disconnect the radiator hose at the thermostat housing connection 10 Disconnect the coolant bypass hose at the intake manifold connection 11 Disconnect the heater tube at the intake manifold Remove the heater tube support bracket attaching nut Remove the heater hose at rear of heater tube Loosen hose clamp at heater elbow then remove the heate...

Page 383: ...m in order so they can be installed in their original positions 21 Remove the lower intake manifold attaching bolts studs then remove the lower intake manifold Remove the manifold side gaskets and end seals Discard and replace with new gaskets and end seals Upper intake manifold assembly 3 8L engine Стр 53 из 211 18 11 2005 file C DOCUME 1 SILENT 1 LOCALS 1 Temp trsHIPBC htm ...

Page 384: ...re installation When using silicone rubber sealer assembly must occur within 15 minutes after sealer application After this time the sealer may start to set up and its sealing effectiveness may be reduced The lower intake manifold cylinder head and cylinder block mating surfaces should be clean and free of oil gasketing material Use a suitable solvent to clean these surfaces Lower intake manifold ...

Page 385: ... the lower intake Use locating pins to secure position of gasket between manifolds 33 Install bolts and studs in their original locations Tighten the 4 center bolts then tighten the end bolts Repeat Steps 28 or 29 depending on vehicle year application 34 Install the EGR valve assembly on the manifold Tighten the attaching bolt to 15 22 ft lbs 20 30 Nm 35 Install the throttle body Cross tighten the...

Page 386: ...Tag and disconnect the vacuum lines from the fuel pressure regulator and the intake manifold 6 Disengage any necessary electrical connectors 7 Remove the drive belt For details regarding this procedure please refer to Section 1 of this manual 8 Disconnect the crankcase ventilation hoses located on the upper intake manifold 9 Remove the alternator mounting brace 10 If necessary disconnect the throt...

Page 387: ...o enlarge 14 Disconnect the upper radiator hose from the water hose connection Upper intake manifold assembly 1995 3 8L engine shown Стр 57 из 211 18 11 2005 file C DOCUME 1 SILENT 1 LOCALS 1 Temp trsHIPBC htm ...

Page 388: ... all retaining bolt and stud bolt threads before installation When using silicone rubber sealer assembly must occur within 15 minutes of sealer application After 15 minutes the sealer may start to set up and lose its sealing effectiveness 19 Use a suitable solvent to clean the gasket mating surfaces The mating surfaces of the lower intake manifold cylinder head and cylinder block should be clean a...

Page 389: ...e manifold retaining bolts and stud bolts 31 Install the upper manifold retaining bolts and stud bolts in there original location then tighten in numerical sequence in three steps 1 Step 1 8 ft lbs 10 Nm 2 Step 2 15 ft lbs 20 Nm 3 Step 3 24 ft lbs 32 Nm 32 If removed install the EGR valve on the intake manifold then tighten the retaining nuts to 15 22 ft lbs 20 30 Nm 33 If removed install the thro...

Page 390: ...mactor check valve hose at tube assembly remove bracket to EGR valve attaching nuts and disconnect water inlet tube at intake manifold 10 Disconnect EGR tube from the EGR valve 11 Remove the intake manifold For details regarding intake manifold removal please refer to the procedure located earlier in this section 12 Remove the exhaust manifold retaining nuts then remove the exhaust manifold from t...

Page 391: ...24 Install the air cleaner assembly and heat stove tube 25 Install accelerator cable and cruise control cable if equipped 26 Connect the negative battery cable then fill the cooling system to the proper level 27 Start engine and check for leaks then check the coolant level and add if necessary 3 0L Engine LEFT SIDE 1 Disconnect the negative battery cable Remove the oil level indicator support brac...

Page 392: ... the retaining nut to 11 15 ft lbs 15 20 Nm 11 If removed connect the power steering pump pressure and return hoses 12 Connect the negative battery cable then start the engine and check for leaks RIGHT SIDE 1 Disconnect the negative battery cable Remove the heater hose support bracket 2 Disconnect and plug the heater hoses 3 Disconnect the pressure feedback PFE or differential pressure feedback DP...

Page 393: ...nifold retaining bolts then remove the exhaust manifold from the vehicle Click to enlarge To install 8 Clean all exhaust manifold cylinder head and Y pipe mating surfaces then lightly oil all bolt and stud threads 9 If replacing the exhaust manifold remove the EGR valve to exhaust manifold tube Right side exhaust manifold mounting 3 0L engine except SHO Стр 63 из 211 18 11 2005 file C DOCUME 1 SIL...

Page 394: ...ve the exhaust manifold to dual converter Y pipe retaining nuts 5 Remove the heat shield retaining bolts 6 Remove the exhaust manifold retaining nuts then remove the exhaust manifold To install 7 Clean all exhaust manifold cylinder head and Y pipe mating surfaces then lightly oil all bolt and stud threads 8 Position the exhaust manifold on the cylinder head using a new gasket then install the reta...

Page 395: ...ngine and check for exhaust and or coolant leaks 3 8L Engine LEFT SIDE 1 Disconnect the negative battery cable 2 Remove the oil level dipstick tube support bracket 3 Tag and disconnect the spark plug wires 4 Raise and safely support the vehicle 5 Remove the exhaust manifold to exhaust pipe attaching nuts 6 Lower the vehicle 7 Remove the exhaust manifold retaining bolts then remove the exhaust mani...

Page 396: ...ngine and check for exhaust leaks RIGHT SIDE 1 Disconnect the negative battery cable 2 Remove the air cleaner and the air cleaner outlet tube assembly 3 If equipped disconnect the thermactor hose or the Secondary Air Injection AIR hose from the downstream air tube check valve 4 Tag and disconnect the ignition wire from the ignition coil then tag and disconnect the wires from the spark plugs Remove...

Page 397: ...ifold Tighten the retaining nuts to 16 24 ft lbs 22 33 Nm 16 For vehicles through 1990 position the thermactor hose to the downstream air tube and clamp tube to the underbody catalyst fitting 17 Install the transaxle dipstick tube then carefully lower the vehicle 18 If equipped install the outer heat shroud then tighten the retaining screws to 50 70 inch lbs 6 8 Nm 19 Install the spark plugs Conne...

Page 398: ...or and remove the hoses from the radiator tank connectors 7 If equipped with an automatic transaxle disconnect the transmission oil cooling lines from the transmission oil cooler radiator fittings using disconnect tool T82L 9500 AH or equivalent 8 For vehicles through 1992 if equipped with 3 0L or SHO engines remove the two CAUTION When draining the coolant keep in mind that cats and dogs are attr...

Page 399: ... remove the two retaining nuts from the left hand radiator support bracket then remove both brackets 10 For all 1995 vehicles remove the two hex nuts from the right hand side radiator support bracket then remove the bracket Remove the two screws from the left hand side radiator support bracket then remove the bracket 11 Tilt the radiator rearward approximately 1 in 25mm and lift it directly upward...

Page 400: ...ne end and using a twisting motion slip the hose off the connections 13 Remove the radiator lower support rubber pads if pad replacement is necessary Click to enlarge Radiator and related components 2 5L engine Стр 70 из 211 18 11 2005 file C DOCUME 1 SILENT 1 LOCALS 1 Temp trsHIPBC htm ...

Page 401: ...ck to enlarge Radiator and related components 3 0L engine except SHO Radiator and fan retainer locations 3 0L engine except SHO Стр 71 из 211 18 11 2005 file C DOCUME 1 SILENT 1 LOCALS 1 Temp trsHIPBC htm ...

Page 402: ...ge Click to enlarge Click to enlarge Radiator and related components 3 0L and 3 2L SHO Radiator and fan retainer locations 3 0L SHO engine Стр 72 из 211 18 11 2005 file C DOCUME 1 SILENT 1 LOCALS 1 Temp trsHIPBC htm ...

Page 403: ...ick to enlarge Click to enlarge Radiator and fan retainer locations 3 2L SHO engine Radiator and related components 3 8L engine Стр 73 из 211 18 11 2005 file C DOCUME 1 SILENT 1 LOCALS 1 Temp trsHIPBC htm ...

Page 404: ...ngs for damage Replace if damaged 18 On 3 8L engines through 1992 inspect the outer tank metallic pin bracket and the left and right hand support brackets Replace if necessary 19 On 3 8L engines through 1992 if the outlet tank pin bracket must be replaced remove the two retaining bolts Position the bracket on the outlet tank then install the two retaining bolts and tighten to 6 6 9 6 ft lbs 9 13 N...

Page 405: ...tension hose clamp between the alignment marks on the hoses 26 On vehicles equipped with automatic transaxles connect the oil cooler lines using Pipe Sealant with Teflon D8AZ 19554 A or equivalent oil resistant sealer 27 Install the fan and shroud assembly by connecting the motor wiring and positioning it on the lower retainer clips Attach the top of the shroud to the radiator with the two screw a...

Page 406: ...ition the transmission oil cooler to the radiator outlet tank then insert the inlet and outlet oil tube connectors through the holes in the radiator outlet tank 6 Install the flat washer and nut on each oil cooler connection to the retain the oil cooler in the radiator outlet tank Using a prybar to gently bend the tabs away from the radiator tank Exploded view of a common engine oil cooler and rel...

Page 407: ... clamps to compress the O ring gasket 5 If locking type pliers will be used to squeeze the header tabs against the radiator tank install a hex nut on the pliers adjusting screw With the jaws of the pliers closed and locked turn the adjusting screw to position the jaws against the shank of a 27 64 in 10 9mm drill bit Tighten the hex nut on the adjusting screw against the handle to lock the adjustme...

Page 408: ...It is important that the height of the crimp be 27 64 in 10 9mm maximum when measured from the bottom of the header to the top of the tab Crimping the tabs using locking type pliers Стр 78 из 211 18 11 2005 file C DOCUME 1 SILENT 1 LOCALS 1 Temp trsHIPBC htm ...

Page 409: ...ght shield 3 Disengage the electrical connector then remove the integrated relay control constant control relay module assembly located on the radiator support Crimping the tabs using a special crimping tool Disconnect the radiator upper sight shield retaining bolts Remove the radiator upper sight shield Стр 79 из 211 18 11 2005 file C DOCUME 1 SILENT 1 LOCALS 1 Temp trsHIPBC htm ...

Page 410: ...Location of the relay module Early model 2 5L engine Disconnect the relay retaining bolts Стр 80 из 211 18 11 2005 file C DOCUME 1 SILENT 1 LOCALS 1 Temp trsHIPBC htm ...

Page 411: ...Click to enlarge Remove the relay from the radiator support Constant control relay module location 3 0L engine except SHO Стр 81 из 211 18 11 2005 file C DOCUME 1 SILENT 1 LOCALS 1 Temp trsHIPBC htm ...

Page 412: ... remove the air bag crash sensor 6 Unbolt the fan shroud assembly from the radiator and remove Disengage the relay module electrical connector Disengage the fan electrical connector Стр 82 из 211 18 11 2005 file C DOCUME 1 SILENT 1 LOCALS 1 Temp trsHIPBC htm ...

Page 413: ...he reverse of the removal procedures Tighten the fan shroud retaining bolt to 23 33 inch lbs 2 6 3 7 Nm Tighten the fan shroud retaining nut to 71 106 inch lbs 8 12 Nm Unbolt the fan assembly from the radiator Remove the fan from the engine Стр 83 из 211 18 11 2005 file C DOCUME 1 SILENT 1 LOCALS 1 Temp trsHIPBC htm ...

Page 414: ...drain pan under the bottom radiator hose 3 Raise and safely support the vehicle Remove the lower radiator hose from the radiator and drain the coolant into the drain pan 4 Remove the water pump inlet tube Constant control relay module location 3 0L SHO 3 2L SHO and 3 8L engines Стр 84 из 211 18 11 2005 file C DOCUME 1 SILENT 1 LOCALS 1 Temp trsHIPBC htm ...

Page 415: ...e belt from the pulleys 6 Disconnect the heater hose from the water pump 7 Remove the water pump retaining bolts then remove the water pump assembly from the engine Remove the water pump inlet tube After removing the retaining bolts remove the water pump assembly from the engine Стр 85 из 211 18 11 2005 file C DOCUME 1 SILENT 1 LOCALS 1 Temp trsHIPBC htm ...

Page 416: ...r block 10 Install the three water pump retaining bolts Tighten the bolts to 15 22 ft lbs 20 30 Nm 11 Connect the heater hose to the water pump 12 Install the water pump belt on the pulley then adjust the tension For details If necessary removing the water pump to pulley retaining bolts then remove the pulley Remove all old gasket material from the water pump then use a new gasket during installat...

Page 417: ...t the negative battery cable then place a drain pan under the radiator draincock and properly drain the engine cooling system 2 Loosen the accessory belt idle then remove the drive belts 3 Remove the two nuts and bolt retaining the idler bracket to the engine then remove the bracket 4 Disconnect the heater hose at the water pump 5 Remove the four pulley to pump hub bolts The pulley will remain loo...

Page 418: ...on the water pump sealing surface using Gasket and Trim Adhesive D7AZ 19B508 AA or equivalent 9 With the pulley positioned on the water pump hub position the water pump on the front cover then install the retaining bolts Tighten the retaining bolts as specified on the accompanying figures Location of the water pump to engine retaining bolts Стр 88 из 211 18 11 2005 file C DOCUME 1 SILENT 1 LOCALS ...

Page 419: ... normal operating temperatures then check for leaks and check the coolant level 1990 95 VEHICLES 1 Disconnect the negative battery cable then place a drain pan under the radiator drain cock 2 Carefully remove the radiator cap then open the drain cock on the radiator and drain the cooling system 3 Loosen the four water pump pulley retaining bolts while the accessory drive belts are still tight Clic...

Page 420: ...er pump and front cover Lightly oil all bolt and stud threads except those requiring special sealant 11 Position a new water pump housing gasket on the water pump sealing surface using Gasket and Trim Adhesive D7AZ 19B508 B or equivalent to hold the gasket in place Apply Pipe Sealant with Teflon D8AZ 19554 A orequivalent to bolt No 3 see fig before installation 12 With the water pump pulley and re...

Page 421: ...s 2 2 3 4 Nm 18 Fill and bleed the cooling system with the appropriate quantity and coolant type 19 Connect the negative battery cable Start the engine and check for leaks 3 0L and 3 2L SHO Engines 1 Disconnect the battery cables then if necessary for access remove the battery and the battery tray For details please refer to the battery and battery tray removal procedures located earlier in this s...

Page 422: ...nd pulley 11 Disconnect the crankshaft position CKP sensor wiring harness then move it out of the way 12 Disconnect the bolts from the center outer timing belt cover then remove the cover 13 On the 3 0L SHO remove the right hand side drive belt tensioner idler pulley and bracket On the 3 2L SHO remove the drive belt tensioner 14 Remove the water pump attaching bolts then remove the water pump and ...

Page 423: ...connector tube 29 Install the two retaining bolts on the upper intake air inlet connector tube Tighten the bolts to 11 17 ft lbs 15 23 Nm then tighten the four screw clamps 30 Engage the ignition control module electrical connector 31 Install the accessory drive belts For details please refer to the belt installation procedure in Section 1 of this manual 32 Connect the negative battery cable then ...

Page 424: ...19B508 B or equivalent 9 With the water pump pulley positioned on the water pump hub position the water pump on the engine front cover then install the retaining bolts Tighten the retaining bolts to 15 22 ft lbs 20 30 Nm There are two different length of bolts used to retainthe water pump Install the bolts as shown in the accompanying figure or damageto the engine may occur Water pump and gasket m...

Page 425: ...then install the drive belt 13 Connect the negative battery cable then fill the cooling system with a 50 50 mixture of approved coolant and water Start and run the engine until in reaches 3 8L engine water pump retaining bolt locations Since two bolt lengths are used install the bolts as shown to prevent possible damage to the engine Стр 95 из 211 18 11 2005 file C DOCUME 1 SILENT 1 LOCALS 1 Temp ...

Page 426: ...nd spark plug wires then remove as an assembly 6 If necessary tag and disconnect the spark plugs 7 Disconnect the EGR tube at the EGR valve 8 Disconnect and tag the required vacuum hoses Remove the accessory drive belts 9 Disconnect the choke cap wire 10 Remove rocker arm cover retaining bolts then remove the cover 11 Remove the rocker arm fulcrum bolts the fulcrums rocker arms and pushrods Identi...

Page 427: ... head and gasket with the exhaust and intake manifolds attached Removing the cylinder head bolts 2 5L engine An assistant is handy when removing the cylinder head from the engine Стр 97 из 211 18 11 2005 file C DOCUME 1 SILENT 1 LOCALS 1 Temp trsHIPBC htm ...

Page 428: ...e corners of the block 17 Install the cylinder head and cylinder head bolts Start and run down several head bolts and remove the 2 guide bolts Replace them with the remaining head bolts Tighten the bolts in sequence in 2 steps first to 52 59 ft lbs 70 80 Nm and then to 70 76 ft lbs 95 103 Nm Remove the cylinder head gasket and replace with a new one when installing the head Clean the engine block ...

Page 429: ...ing fan switch at the connector 26 Connect the upper radiator hose and the heater hose Fill the cooling system Connect the negative battery cable 27 Start the engine and check for leaks After the engine has reached normal operating temperature check and if necessary add coolant 3 0L Engine Except SHO 1 For 1992 95 vehicles rotate the crankshaft to 0 TDC on the compression stroke 2 Disconnect the n...

Page 430: ... should be installed in their original position during reassembly 8 Remove the intake manifold For details please refer to the procedure located earlier in this section 9 Remove the cylinder head attaching bolts and remove the cylinder heads from the engine Remove and discard the old cylinder head gaskets To install 11 Lightly oil all bolt and stud bolt threads before installation Clean the cylind...

Page 431: ...ps following the proper torque sequence The first step is 37 ft lbs 50 Nm and the second step is 68 ft lbs 92 Nm Installing a new cylinder head gasket using the dowels in the block for alignment If the dowels are damaged they must be replaced Стр 101 из 211 18 11 2005 file C DOCUME 1 SILENT 1 LOCALS 1 Temp trsHIPBC htm ...

Page 432: ...ker arm and components and torque the rocker arm fulcrum bolts to 24 ft lbs 32 Nm Be sure the lifter is on the base circle of the cam for each rocker arm as it is installed The fulcrums must be fully seated in the cylinder headand the pushrods must be seated in the rocker arm sockets prior to the finaltightening 20 Install the exhaust manifold s For details please refer to the procedure located ea...

Page 433: ... cover 7 For the 3 0L SHO Remove the left hand side drive belt tensioner idler pulley and bracket assembly For the 3 2L SHO engine remove the left hand drive belt idler pulleys 8 Raise and safely support the vehicle 9 Remove the right wheel and tire assembly then remove the front fender splash shield 10 Remove the crankshaft vibration damper and pulley 11 Remove the lower timing belt cover 12 Alig...

Page 434: ...ioner with a hex head wrench When tension is released tighten the nut This will hold the tensioner in place Lower the vehicle until the wheels touch but keep the vehicle supported Timing alignment marks 3 0L and 3 2L SHO engines Стр 104 из 211 18 11 2005 file C DOCUME 1 SILENT 1 LOCALS 1 Temp trsHIPBC htm ...

Page 435: ...he timing belt noting the location of the letters KOA on the belt The belt must be installed in the same direction Use a hex head wrench to loosen the tensioner nut When removing the timing belt note the location of the letters KOA on the belt The belt Стр 105 из 211 18 11 2005 file C DOCUME 1 SILENT 1 LOCALS 1 Temp trsHIPBC htm ...

Page 436: ...olt threads before installation exceptthose specifying special sealant 24 Remove any foreign material or oil from the top of the cylinder block and or the lower surfaces of the cylinder head and clean the cylinder head and engine block mating surfaces of all old gasket material 25 Position the cylinder head and gasket on the engine block and align with the cylinder head to block dowels 26 Install ...

Page 437: ... refer to the procedure located earlier in this section 42 Install the air cleaner outlet tube 43 Connect the negative battery cable 44 Fill the engine cooling system with the proper type and quantity of coolant 45 Start the engine and check for coolant fuel or oil leaks 3 8L Engine 1 Drain the cooling system then disconnect the negative battery cable 2 Properly relieve the fuel system pressure 3 ...

Page 438: ...askets when replacing or reinstalling the cylinder head 12 Remove the cylinder head attaching bolts and discard Do NOT reuse the old bolts 13 Remove the cylinder head s Remove and discard old cylinder head gasket s To install 14 Lightly oil all bolt threads before installation 15 Clean cylinder head intake manifold valve rocker arm cover and cylinder head gasket contact surfaces If cylinder head w...

Page 439: ... to 11 18 ft lbs 15 25 Nm Then tighten the bolt an additional 85 105 and go to the next bolt in sequence 2 Short cylinder head bolts Loosen the bolts and back them out 2 3 turns Retighten to 11 18 ft lbs 15 25 Nm Then tighten the bolt an additional 65 85 18 For 1993 95 vehicles retighten the cylinder head bolts in sequence one at a time in the following manner 1 Long cylinder head bolts Loosen the...

Page 440: ... power steering pump mounting and support brackets and the alternator support bracket 31 If the right cylinder head is being installed perform the following install the PCV valve alternator bracket thermactor pump and pump pulley accessory drive idler thermactor air control valve or air bypass valve hose 32 Install the accessory drive belt Attach the thermactor tube s support bracket to the rear o...

Page 441: ...le automotive machine shop If the cylinder head was removed due to an overheatingcondition and a crack is suspected do not assume that the head is not crackedbecause a crack is not visually found A crack can be so small that it cannotbe seen by eye but can pass coolant when the engine is at operatingtemperature Consult an automotive machine shop that has pressure testingequipment to make sure the ...

Page 442: ... replaced Contact a reputable machine shop for machining service and recommendations When resurfacing the cylinder head s the intakemanifold mounting position is altered and must be corrected by machining aproportionate amount from the intake manifold flange Valves REMOVAL INSTALLATION Checking the cylinder head for flatness diagonally across the head surface Checking the cylinder head for flatnes...

Page 443: ...ire brush to clean carbon from the valve ports valves etc be sure that the deposits are actually removed rather than burnished 11 Wash and clean all valve spring keepers retaining caps etc in safe solvent 12 Clean the head with a brush and some safe solvent and wipe dry 13 Check the head for cracks Cracks in the cylinder head usually start around an exhaust valve seat because it is the hottest par...

Page 444: ...achined check the remaining valve train parts springs retainers keepers etc for wear Check the valve springs for straightness and tension 21 Reassemble the head in the reverse order of disassembly using new valve guide seals and lubricating the valve stems Check the valve spring installed height shim or replace as necessary Valve Stem Seals REPLACEMENT Most engines are equipped with a positive val...

Page 445: ...t excessively worn or distorted may in some cases be knurled rather than reamed However if the valve stem is worn reaming for an oversized valve stem is the answer since a new valve would be required Knurling is a process in which metal is displaced and raised thereby reducing clearance Knurling also produces excellent oil control The possibility of knurling instead of reaming the valve guides sho...

Page 446: ...emoval Rotate the lifter back and forth to loosen it from the gum or varnish that may have formed on the lifter To install 12 Clean all gasket mating surfaces Place a rag in the lifter valley to catch any stray gasket material 13 Lubricate each lifter and bore with heavy engine oil Install the lifter in the bore checking for free fit 14 If equipped with roller lifters align the lifter flat to the ...

Page 447: ...nder head and valve rocker arm cover sealing surfaces 9 Lubricate each lifter and bore with oil conditioner or heavy engine oil 10 Install each lifter in bore from which it was removed If a new tappet s is being installed check new lifter for a free fit in bore 11 If equipped with roller lifters align the flats on the sides of the lifters and install the 6 guide plates between the adjacent lifters...

Page 448: ...nt tube located at the lower radiator hose at the water pump and at the tabs on the oil pan Position air conditioner line off to the side CAUTION The EPA warns that prolonged contact with used engine oil may cause a number of skin disorders including cancer You should make every effort to minimize your exposure to used engine oil Protective gloves should be worn when changing the oil Wash your han...

Page 449: ...ct the retaining bolts then remove the oil pan Remove the coolant tube to oil pan retainers then remove the coolant tube from the pan Стр 119 из 211 18 11 2005 file C DOCUME 1 SILENT 1 LOCALS 1 Temp trsHIPBC htm ...

Page 450: ... of oil pan and cylinder block making certain all traces of RTV sealant are removed Remove the oil pan retaining bolts Carefully lower the oil pan from the engine Стр 120 из 211 18 11 2005 file C DOCUME 1 SILENT 1 LOCALS 1 Temp trsHIPBC htm ...

Page 451: ...l the starter then connect the starter cable 17 Carefully lower the vehicle then fill the crankcase and cooling system to the proper level 18 Start the engine and inspect for leaks 3 0L Engine Except SHO 1 Disconnect the negative battery cable and remove the oil level dipstick 2 Raise and safely support the vehicle If equipped with a low level sensor remove the retainer clip at the sensor Disengag...

Page 452: ...e oil pan gasket to the oil pan with sealing bends against the oil pan surface and secure with Gasket and Trim Adhesive D7AZ 19B508 B 11 Position the oil pan on the engine block and install the oil pan attaching bolts Torque the bolts to 8 ft lbs 10 Nm then back off the all of the bolts and retighten them 12 Install the lower engine flywheel dust cover to the torque converter housing Install the Y...

Page 453: ...rical connector from the sensor 5 Drain the engine oil 6 Remove the starter motor For details please refer to the procedure located earlier in this section 7 Disconnect the heated oxygen sensors 8 Remove the dual converter Y pipe assembly 9 Remove the lower flywheel dust cover from the converter housing 10 Remove the oil pan attaching bolts then carefully remove the oil pan 11 Remove the front oil...

Page 454: ...Стр 124 из 211 18 11 2005 file C DOCUME 1 SILENT 1 LOCALS 1 Temp trsHIPBC htm ...

Page 455: ... procedure located earlier in this section 18 Engage the low oil level sensor connector to the sensor Install the retainer clip 19 Carefully lower the vehicle 20 Replace the oil level dipstick and connect the negative battery cable 21 Fill the crankcase with the proper type and quantity of oil Start the vehicle and check for leaks 3 8L Engine 1 Disconnect the negative battery cable 2 Raise and saf...

Page 456: ...fter this time the sealer may start to harden and its sealing effectiveness may be reduced 11 Install the oil pan and secure to the block with the attaching screws Tighten the screws to 7 9 ft lbs 9 12 Nm 12 Install a new oil filter 13 Install the engine rear plate converter housing cover 14 Install the starter motor For details please refer to the procedure located earlier in this section 15 Inst...

Page 457: ...Install pump and shaft as an assembly Do NOT attempt to force the pump into position if it will not seat Theshaft hex may be misaligned with the distributor shaft To align remove theoil pump and rotate the intermediate driveshaft into a new position 7 Tighten the oil pump attaching bolts to 15 22 ft lbs 20 30 Nm 8 Install the oil pan 9 Fill the crankcase with the correct viscosity and amount of oi...

Page 458: ...Click to enlarge To install Exploded view of the oil pump and related components 3 0L engine except SHO Стр 128 из 211 18 11 2005 file C DOCUME 1 SILENT 1 LOCALS 1 Temp trsHIPBC htm ...

Page 459: ...e oil pump retaining bolts Tighten the bolts to 11 17 ft lbs 15 23 Nm 7 Install the timing belt 8 Install the oil pan 9 Fill the crankcase with the proper type and quantity of oil 10 Start the engine and check for leaks 3 8L Engine The oil pump oil pressure relief valve and drive intermediate shaft arecontained in the front cover assembly 1 Disconnect the negative battery cable 2 If necessary for ...

Page 460: ... grooved replace the pump 4 Check the inner rotor tip to outer rotor tip clearance using a feeler gauge The clearance must not exceed 0 0024 0 0071 in 0 06 0 18mm with the feeler gauge inserted 1 2 in 13mm minimum and the rotors removed from the pump housing 5 With the rotor assembly installed in the pump housing place a straight edge over the rotor assembly and the housing Measure the clearance r...

Page 461: ...r should be 1 504 1 507 in 38 20 38 28mm If the diameter is less than 1 504 in 38 20mm replace the front cover and measure the clearance as in Step 1 Timing Chain Cover REMOVAL INSTALLATION 2 5L Engine 1 Disconnect the negative battery cable 2 Remove the engine and transaxle assembly from the vehicle and position in a suitable holding fixture Remove the dipstick 3 If equipped remove the accessory ...

Page 462: ...he hub of the crankshaft pulley with polyethylene grease to prevent damage to the seal during installation and initial engine start 13 Install the crankshaft pulley 14 Install the oil pan 15 If equipped install the accessory drive pulley 16 Install crankshaft pulley attaching bolt and washer Tighten to 140 170 ft lbs 190 230 Nm 17 Install the engine and transaxle assembly in the vehicle Connect th...

Page 463: ...ation Damper Remover Adapter T82L 6316 B 5 Remove the timing cover crankshaft front seal from the engine front cover using Jet Plug Remover T77L 9533 B 7 Disengage the engine control sensor wiring from the crankshaft position CKP sensor and locating stud bolt Flexible Fuel FF only 8 Drain and remove the oil pan 9 Remove the water pump pulley retaining bolts and water pump pulley Click to enlarge 1...

Page 464: ...or damage and replace if necessary 14 Align a new timing cover gasket over the cylinder block dowels 15 Install the timing cover water pump assembly onto the cylinder block with the water pump pulley loosely attached to the water pump hub 16 Apply pipe sealant to bolt numbers 1 2 and 3 and hand start them along with the rest of the cover retaining bolts Tighten bolts 1 10 to 15 22 ft lbs 20 30 Nm ...

Page 465: ...gine oil Apply Silicone Rubber D6AZ 19562 AA or BA to the keyway of the damper before installation Install the damper using Vibration Damper and Seal Replacer T82L 6316 A 3 Install the damper retaining bolt and washer Tighten to 93 121 ft lbs 125 165 Nm 4 Install the crankshaft pulley then install the four retaining bolts Tighten the bolts to 30 44 ft lbs 40 60 Nm 5 If removed install the right ha...

Page 466: ...essory drive belts Torque the water pump pulley retaining bolts to 15 22 ft lbs 20 30 Nm 22 Install the lower radiator hose and the heater hose and tighten the clamps Location of the crankshaft vibration damper 3 0L engine except SHO Location of the crankshaft pulley 3 0L engine except SHO Стр 136 из 211 18 11 2005 file C DOCUME 1 SILENT 1 LOCALS 1 Temp trsHIPBC htm ...

Page 467: ...stributor out of the front cover 9 Raise and safely support the vehicle 10 Remove the crankshaft damper and pulley If the crankshaft pulley and vibration damper have to be separated mark the damper and pulley so they may be reassembled in the same relative position This is important as the damper and pulley are initially balanced as a unit If the crankshaft damper is being replaced check if the or...

Page 468: ... 19 Install the distributor drive gear 20 Lubricate the crankshaft front oil seal with clean engine oil 21 Position a new cover gasket on the cylinder block and install the front cover water pump assembly using dowels for proper alignment A suitable contact adhesive is recommended to hold the gasket in position while the front cover is installed 22 Position and install the ignition timing indicato...

Page 469: ...ghten the belt 39 Connect the negative battery cable Fill the crankcase and cooling system to the proper level 40 Install the air cleaner assembly and air intake duct 41 Start the engine and check for leaks 42 Check the ignition timing and adjust as required Timing Belt Cover REMOVAL INSTALLATION 3 0L SHO Engine The timing belt front cover on the 3 0L SHO engine is made up of 3 separate sections 1...

Page 470: ... 153 171 Nm Click to enlarge 3 2L SHO Engine The front cover on the 3 2L SHO engine is made up of 3 separate sections 1 Disconnect the battery cables then remove the battery from the engine 2 Remove the right hand engine roll damper 3 Disconnect the wiring to the ignition control module Remove the engine air inlet connector intake manifold crossover tube bolts loosen the crossover tube clamps then...

Page 471: ... Remove the bolt and washer at the crankshaft pulley then remove the crankshaft pulley 3 Using Differential Side Bearing Puller T77F 4220 B1 remove the front cover oil seal To install 4 Coat a new seal with Long Life Lubricant C1AZ 19590 BA or equivalent grease Using Pinion Oil Seal Installer T83T 4676 A or equivalent install the seal into the cover Make sure the seal is fully seated Check the sea...

Page 472: ... 3 8L Engine 1 Disconnect the negative battery cable 2 Loosen the accessory drive belt idler 3 Raise the vehicle and support safely 4 Disengage the accessory drive belt and remove crankshaft pulley 5 Remove the crankshaft vibration damper using Crankshaft Damper Remover T58P 6316 D and Vibration Damper Remover Adapter T82L 6316 B or equivalent suitable removal tools 6 Remove the seal from the fron...

Page 473: ...the crankshaft vibration damper and pulley 4 Using Steering Wheel Puller T67L 3600 A or equivalent puller remove the crankshaft vibration damper and pulley from the crankshaft Click to enlarge 5 Remove the timing belt For details please refer to the procedure located later in this section Be careful not to damage the crankshaft position CKP sensor or pulse wheel 6 Remove the crankshaft timing gear...

Page 474: ...ront cover and shaft seal surface of the crankshaft damper for damage nicks burrs or other roughness which may cause the new seal to fail Using a suitable steering wheel puller to remove the crankshaft sprocket To remove the front oil seal use a suitable locknut pin remover Стр 144 из 211 18 11 2005 file C DOCUME 1 SILENT 1 LOCALS 1 Temp trsHIPBC htm ...

Page 475: ...section 12 Install the crankshaft vibration damper and pulley using Front Crank Seal Installer T89P 6701 B Tighten the damper attaching bolt to 112 127 ft lbs 152 172 Nm 13 Position the drive belts over the crankshaft vibration damper and pulley 14 Install the front right side wheel and tire assembly Tighten the lug nuts to 85 105 ft lbs 152 172 Nm 15 Carefully lower the vehicle the install the dr...

Page 476: ...s are worn replace with new 6 Check timing chain tensioner blade for wear depth If the wear depth exceeds specification replace tensioner 7 Turn engine over until the timing marks are aligned Remove camshaft sprocket attaching bolt and washer Slide both sprockets and timing chain forward and remove as an assembly 8 If equipped check timing chain vibration damper for excessive wear Replace if neces...

Page 477: ... 8 11 Nm 17 Remove the front cover alignment tool 18 Install a new front cover oil seal using a suitable seal installer Lubricate the hub of the crankshaft pulley with polyethylene grease to prevent damage to the seal during installation and initial engine start Install crankshaft pulley 19 Install the oil pan 20 Install the accessory drive pulley if equipped 21 Install crankshaft pulley attaching...

Page 478: ...both sprockets and timing chain onto the camshaft and crankshaft with the timing marks aligned Install the camshaft bolt and washer and torque to 37 51 ft lbs 50 70 Nm Apply clean engine oil to the timing chain and sprockets after installation The camshaft bolt has a drilled oil passage in it fortiming chain lubrication If the bolt is damaged do NOT replace it with astandard bolt 6 Install the tim...

Page 479: ...t and washer from end of the camshaft 4 Remove the distributor drive gear 5 Remove the camshaft sprocket crankshaft sprocket and timing chain If the crankshaft sprocket is difficult to remove carefully pry to sprocket off of the shaft using a pair of large prybarspositioned on both sides of the crankshaft sprocket Click to enlarge 6 Remove the chain tensioner assembly from the front of the cylinde...

Page 480: ...ate the crankshaft as necessary to position piston No 1 at TDC and the crankshaft keyway at the 12 o clock position 10 Install the tensioner assembly Make sure the ratcheting mechanism is in the retracted position with the pin pointing outward from the hole in the bracket assembly Tighten the retaining bolts to 6 10 ft lbs 8 14 Nm 11 Lubricate timing chain with clean engine oil Install the camshaf...

Page 481: ... please refer to timing chain cover removal and installation earlier in this section 16 Connect battery ground cable Start the engine and check for leaks Timing Belt and Tensioner REMOVAL INSTALLATION 3 0L SHO Engine 1 Disconnect the battery cables 2 Remove the battery 3 Remove the right engine roll damper front engine support damper Position of the timing marks when the No 1 piston is at TDC Стр ...

Page 482: ...enlarge 6 Loosen the alternator air conditioning belt tensioner pulley and relieve the tension on the belt by backing out the adjustment screw Remove the alternator air conditioning belt 7 Loosen the water pump power steering belt tensioner pulley and relieve the Location of the front engine support damper 3 0L SHO engine Engine inlet air connector mounting 3 0L SHO engine Стр 152 из 211 18 11 200...

Page 483: ...ake camshaft pulleys align with the index marks on the metal timing belt cover Click to enlarge 14 Raise and safely support the vehicle 15 Remove the right front wheel and tire assembly 16 Loosen the fender splash shield and place it aside 17 Using a suitable puller remove the crankshaft damper 18 Remove the lower timing belt cover 19 Remove the center timing belt cover and disconnect the cranksha...

Page 484: ...lt over the crankshaft and camshaft pulleys The lettering on the belt KOA should be readable from the rear of the engine top of the lettering to the front of the engine Make sure the yellow lines are aligned with the index marks on the pulleys 24 Release the tensioner locknut and leave the nut loose 25 Raise the vehicle and support safely 26 Install the center timing belt cover Make sure the crank...

Page 485: ...he crankshaft sensor wiring and connect with the engine wiring harness 35 Install the upper timing belt cover Tighten the bolts to 62 97 inch lbs 7 11 Nm 36 Install the water pump power steering tensioner pulley Tighten the nut to 11 17 ft lbs 15 23 Nm 37 Install the alternator air conditioning tensioner pulley and bracket assembly Tighten the bolts to 11 17 ft lbs 15 23 Nm 38 Install the water pu...

Page 486: ...y Tighten the lug nuts to 85 105 ft lbs 115 142 Nm 45 Lower the vehicle 3 2L SHO Engine 1 Disconnect the battery cables then remove the battery 2 Remove the right hand engine roll damper engine support damper 3 Disengage the wiring to the ignition control module 4 Remove the engine air inlet intake manifold crossover tube bolts Loosen the tube hose clamps then remove the tube Click to enlarge 5 Ro...

Page 487: ...emove the bolts retaining the upper and lower idler pulleys to the engine then remove the pulleys Rotate the drive belt tensioner clockwise to relieve tension then remove the belt Стр 157 из 211 18 11 2005 file C DOCUME 1 SILENT 1 LOCALS 1 Temp trsHIPBC htm ...

Page 488: ...ering pump pulley remove the nut and the washer then remove the power steering pulley 9 Remove the retaining bolt from the belt tensioner then remove the tensioner Location of the upper and lower idler pulleys Стр 158 из 211 18 11 2005 file C DOCUME 1 SILENT 1 LOCALS 1 Temp trsHIPBC htm ...

Page 489: ...s with the 0 index mark on the lower timing belt cover and the marks on the intake camshaft sprockets align with the index marks on the metal timing belt cover Click to enlarge 14 Raise and safely support the vehicle then remove the right front wheel and tire assembly 15 Loosen the fender splash shield and place it aside Remove the retaining bolt from the belt tensioner then remove the tensioner L...

Page 490: ...nsioner housing aligns with the hole in the tensioner rod 22 Insert a 1 20 in 1 27mm hex wrench through the holes Click to enlarge 23 Release the timing belt tensioner from the vise 24 If a new belt is being installed loosen the timing belt idler bolt 25 Make sure the engine is at TDC on the No 1 cylinder Check that the camshaft sprocket marks line up with the index marks on the upper steel belt c...

Page 491: ...ex marks on the sprockets 27 Install the timing belt tensioner on the cylinder block while pushing the timing belt idler toward the belt Tighten the tensioner bolts to 12 17 ft lbs 16 23 Nm 28 Install the grommets between the timing belt tensioner and the oil pump Index marks on the camshaft sprockets and oil pump WARNING Do NOT install the timing belt tensioner with the rod extended Стр 161 из 21...

Page 492: ...using the power steering pump bracket holes 2 Hand tighten the timing belt idler bolt 3 Using a inch lbs torque wrench with belt tensioner attachment T93P 6254 A rotate clockwise to 4 3 inch lbs 0 5 Nm 4 Tighten the timing belt tensioner bolts to 27 37 ft lbs 36 50 Nm then remove the timing belt tensioning tool Location of the rubber grommets Стр 162 из 211 18 11 2005 file C DOCUME 1 SILENT 1 LOCA...

Page 493: ...hing bolt to 113 126 ft lbs 152 172 Nm 34 Rotate the crankshaft 2 revolutions in the clockwise direction until the white mark on the vibration damper aligns with the 0 marks on the lower timing belt cover Position the timing belt tensioner tool using the power steering pump bracket holes Using an inch lbs torque wrench with a belt tensioner attachment rotate clockwise to 4 3 inch lbs 0 5 Nm Стр 16...

Page 494: ...accessory drive belt tensioner clockwise 41 Install the surge tank fitting 42 Install the engine air inlet connector intake manifold crossover tube Tighten the bolts to 11 17 ft lbs 15 23 Nm 43 Install the engine roll damper support damper 44 Install the battery then connect the wiring to the ignition control module and connect the battery cable Rotate the crankshaft 2 revolutions clockwise until ...

Page 495: ...e refer to the procedure located earlier in this section 5 Remove the valve covers 6 Remove the camshaft sprocket retaining bolts and camshaft sprockets noting the position of the dowel pins To install 7 Align the timing marks on the camshaft sprockets with the camshafts then install the sprockets Tighten the retaining bolts to 10 13 ft lbs 14 18 Nm 8 Install the valve covers 9 Install the timing ...

Page 496: ...lt Please refer to the timing belt procedure located earlier in this section for details 6 Connect the negative battery Camshaft REMOVAL INSTALLATION 2 5L Engine 1 Drain the cooling system and the crankcase Relieve the fuel system pressure 2 Remove the engine from the vehicle and position in a suitable holding fixture Remove the engine oil dipstick 3 Remove necessary drive belts and pulleys 4 Remo...

Page 497: ...ove camshaft thrust plate Carefully remove the camshaft by pulling it toward the front of the engine Use caution to avoid damaging bearings journals and lobes To install 13 Clean and inspect all parts before installation 14 Lubricate camshaft lobes and journals with heavy engine oil Carefully slide the camshaft through the bearings in the cylinder block 15 Install the thrust plate Tighten attachin...

Page 498: ...ve the pushrod 9 Remove the alternator brackets drive belt tensioner and drive belt 10 Remove the intake manifold 11 Loosen the rocker arm fulcrum nuts and position the rocker arms to the side for easy access to the pushrods Remove the pushrods and label so they may be installed in their original positions 12 Using a suitable magnet or lifter removal tool remove the hydraulic lifters tappets and k...

Page 499: ...ain and sprockets Check the camshaft sprocket bolt for blockage of drilled oil passages prior to installation and clean if necessary 22 Install the front timing cover and crankshaft damper and pulley 23 Lubricate the lifters tappets and lifter bores with a heavy engine oil Install the lifters tappets into their original bores 24 Install the intake manifold assembly 25 For unleaded gasoline engines...

Page 500: ...ighten the distributor mounting bolt to 15 22 ft lbs 20 30 Nm 3 0L SHO Engine 1 Disconnect the negative battery cable Properly relieve the fuel system pressure 2 Set the engine on TDC on No 1 cylinder 3 Remove the intake manifold assembly 4 Remove the timing cover and belt 5 Remove the cylinder head covers 6 Remove the camshaft pulleys noting the location of the dowel pins 7 Remove the upper rear ...

Page 501: ...ise Set the chain tensioner between the sprockets and install the camshafts on the cylinder head The left and right chain tensioners are not interchangeable Camshaft sprocket mounting bolt locations SHO engines Align the white painted links with the timing mark on the camshaft sprockets Стр 171 из 211 18 11 2005 file C DOCUME 1 SILENT 1 LOCALS 1 Temp trsHIPBC htm ...

Page 502: ... point to the front of the engine when installed 18 Apply silicone sealer to outer diameter of the new camshaft seal and the seal seating area on the cylinder head Install the camshaft seal using Cam Seal Expander T89P 6256 B and Cam Seal Replacer T89P 6256 A Timing chain tensioner mounting SHO engines Стр 172 из 211 18 11 2005 file C DOCUME 1 SILENT 1 LOCALS 1 Temp trsHIPBC htm ...

Page 503: ...ap then install the bearing cap while holding the camshaft front seal in place with the Cam Seal Replacer Loosely install the bolts Installing the camshaft seal using the specified tools Стр 173 из 211 18 11 2005 file C DOCUME 1 SILENT 1 LOCALS 1 Temp trsHIPBC htm ...

Page 504: ...o 12 16 ft lbs 16 22 Nm For left camshaft installation apply pressure to the chain tensioner to avoid damage to the bearing caps Apply sealer to the No 1 cylinder head camshaft journal cap Camshaft journal cap tightening sequence Стр 174 из 211 18 11 2005 file C DOCUME 1 SILENT 1 LOCALS 1 Temp trsHIPBC htm ...

Page 505: ... fit and or timing marks will not line up repeat the procedure from Step 14 Click to enlarge 23 Install the timing belt rear cover and tighten the bolts to 70 inch lbs 7 8 Nm 24 Install the camshaft pulleys and tighten the bolts to 15 18 ft lbs 20 24 Nm 25 Install the timing belt and cover 26 Install the cylinder head covers and tighten the bolts to 7 12 ft lbs 10 16 Nm 27 Install the intake manif...

Page 506: ...e the cam lobes thrust plate and bearing surfaces with a suitable heavy engine oil 11 Install the camshaft being careful not to damage bearing surfaces while sliding into position Install the thrust plate and tighten the bolts to 6 10 ft lbs 8 14 Nm 12 Install the front cover and timing chain 13 Install the oil pan 14 Install the lifters 15 Install the upper and lower intake manifolds 16 Install t...

Page 507: ...le 2 Remove the intake manifolds 3 Remove the oil pan 4 Remove the front cover and timing chain and camshaft sprocket 5 Remove the balance shaft drive gear and spacer 6 Remove the balance shaft gear thrust plate and shaft assembly Click to enlarge To install 7 Thoroughly coat the balance shaft bearings in the block with engine oil 8 Install the balance shaft gear 9 Install the balance shaft thrust...

Page 508: ...ith the engine installed and there is sufficient working clearance take EXTREME care to assure no dirt or contamination is allowed into the cylinders during assembly and installation Before removing the pistons the top of the cylinder bore must be examined for a ridge A ridge at the top of the bore is the result of normal cylinder wear caused by the piston rings only traveling so far up the bore i...

Page 509: ...g soaked in clean oil Make sure the piston top and cylinder bore are absolutely clean before moving the piston For more details refer to the ridge removal and honing procedures later in this section 1 Remove cylinder head or heads 2 Remove the oil pan 3 If necessary remove the oil pump assembly Removing the ridge from the cylinder bore using a ridge cutter Match connecting rods to their caps using...

Page 510: ...ft journals and cylinder walls when the piston is removed 6 Squirt some clean engine oil onto the cylinder wall from above until the wall is coated Carefully push the piston and rod assembly up and out of the cylinder by tapping on the bottom of the connecting rod with a wooden hammer handle 7 Place the rod bearing and cap back on the connecting rod and install the nut temporarily Using a number s...

Page 511: ... Clean and inspect the engine block the crankshaft the pistons and the connecting rods Cut lengths of rubber hose for connecting rod bolt guides Carefully tap the piston and rod assembly out using a wooden hammer handle Стр 181 из 211 18 11 2005 file C DOCUME 1 SILENT 1 LOCALS 1 Temp trsHIPBC htm ...

Page 512: ...piston grooves using an appropriate ring groove cleaning tool using care not to cut too deeply Thoroughly clean all carbon and varnish from the piston with solvent WARNING Do NOT use a wire brush or caustic solvent acids etc on pistons Inspectthe pistons for scuffing scoring cracks pitting or excessive ring groovewear If these are evident the piston must be replaced Use a ring expander tool to rem...

Page 513: ...the top of the piston Replace the pistons that are damaged or show signs of excessive wear Inspect the grooves for nicks of burrs that might cause the rings to hang up Measure the piston in relation to cylinder diameter Refer to the cylinder bore cleaning and inspection procedures later in this section Clean the piston grooves using a ring groove cleaner A telescoping gauge may be used to measure ...

Page 514: ...Measure the piston s outer diameter using a micrometer The cylinder bore may also be measured using a dial gauge Стр 184 из 211 18 11 2005 file C DOCUME 1 SILENT 1 LOCALS 1 Temp trsHIPBC htm ...

Page 515: ...inish honing is all that is necessary If the clearance is excessive try to obtain a slightly larger piston to bring the clearance within specifications If this is not possible obtain the first oversize piston and hone the cylinder or if necessary bore the cylinder to size Generally if the cylinder bore is tapered more than 0 005 in 0 127mm or is out of round more than 0 003 in 0 0762mm it is advis...

Page 516: ... it with a rag Cut the ridge away with the ridge reamer using extreme care to avoid cutting too deeply Remove the rag and remove the cuttings that remain on the piston with a magnet and a rag soaked in clean oil Make sure the piston top and cylinder bore are absolutely clean before moving the piston 4 After the piston and connecting rod assembly have been removed check the clearances as explained ...

Page 517: ...l to provide a finish on which the new piston rings will seat A rigid hone will remove more material than the flexible hone and requires more operator skill 7 Regardless of which type of hone you use carefully follow the manufacturers instructions for operation 8 The hone should be moved up and down the bore at sufficient speed to obtain a Removing cylinder glazing using a flexible hone Cylinder b...

Page 518: ...1 After the bores are cleaned wipe them down with a clean cloth coated with light engine oil to keep them from rusting To install 12 Lubricate each piston rod bearing and cylinder wall with heavy weight engine oil 13 Take the bearing nuts and cap off connecting rod Install rubber hoses over the connecting rod bolts to protect the block and crankshaft journal 14 Install a ring compressor over the p...

Page 519: ...erlap and install the bottom rail scraper with the end about 25mm away from the butted end of the control ring Install the top rail about 25mm away from the butted end of the control but on the opposite side from the lower rail Be careful not to scrap the piston when installing oil control rings 7 Install the two compression rings The lower ring first 8 Consult the illustration for ring positionin...

Page 520: ...Oversize plugs are identified by the OS stamped in the flat on the cup side of the plug To install 5 Lightly coat the plug and or bore with an oil resistant Stud and Bearing Mount E0AZ 19554 BA or Threadlock 262 E2FZ 19554 B or equivalent 6 Cup type core plugs are installed with the flanged edge outward The maximum diameter of this plug is located at the outer edge of the flange The flange on cup ...

Page 521: ...11 Fill the cooling system and check for leaks Block Heater REMOVAL INSTALLATION 1 Disconnect the negative battery cable Drain the cooling system 2 Remove the necessary components to gain access to the engine block heater 3 As required raise and support the vehicle safely 4 Carefully remove the engine block heater from its mounting on the engine block 5 Installation is the reverse of the removal p...

Page 522: ...ar oil seal metal surface between the seal lip and the cylinder block 6 On all engines except the SHO engines screw in the threaded end of Jet Plug Remover T77L 9533 B or equivalent then use the tool to remove the seal 7 For the SHO engines Locknut Pin Remover T78P 3504 N into the crankshaft rear oil seal then remove the seal from the retainer Use caution to avoid damaging the oil seal surface Cli...

Page 523: ...e Rear main bearing installation 3 0L engine except SHO Removing the rear main oil seal using the specified tool 3 0L and 3 2L SHO engines Стр 193 из 211 18 11 2005 file C DOCUME 1 SILENT 1 LOCALS 1 Temp trsHIPBC htm ...

Page 524: ...Crankshaft rear main oil seal cover 3 0L and 3 2L SHO engines Стр 194 из 211 18 11 2005 file C DOCUME 1 SILENT 1 LOCALS 1 Temp trsHIPBC htm ...

Page 525: ...Click to enlarge Installing the rear main oil seal on the SHO engines using the required tools Стр 195 из 211 18 11 2005 file C DOCUME 1 SILENT 1 LOCALS 1 Temp trsHIPBC htm ...

Page 526: ... the seal to leak If damage is evident service or replace the crankshaft as necessary For the 3 8L engine you have to remove the flywheel to access the rear main oil seal Exploded view of installing the rear main oil seal 3 8L engine Стр 196 из 211 18 11 2005 file C DOCUME 1 SILENT 1 LOCALS 1 Temp trsHIPBC htm ...

Page 527: ...ove the crankshaft pulley attaching bolts and washer 4 Remove the cylinder front cover and the air conditioning idler pulley assembly if so equipped Remove cover assembly 5 Check the timing chain deflection Remove the timing chain and sprockets 6 Invert the engine on the work stand Remove the flywheel and the rear seal cover Remove the oil pan and gasket Remove the oil pump inlet and the oil pump ...

Page 528: ...rfaces Click to enlarge To install If the bearings are to be reused they should be identified to ensure that they are installed in their original position 10 Remove the main bearing inserts from the block and bearing caps Remove the main bearing caps by removing the retaining bolts Exploded view of the crankshaft and the related components 2 5L engine Стр 198 из 211 18 11 2005 file C DOCUME 1 SILE...

Page 529: ...n in the bores with the tang fitted in the slot provided Lubricate the bearing surfaces with Oil Conditioner part No D9AZ 19579 CF or equivalent Conditioner is needed for lubrication at initial start up 16 Install the lower main bearing inserts in the bearing caps 17 Carefully lower the crankshaft into place 18 Check the clearance of each main bearing Select fit the bearings for proper clearance 1...

Page 530: ...h Teflon D8AZ 19554 A ESG M4G194 A and ESR M18P7 A or equivalent oil resistant sealer to the flywheel attaching bolts using a cross tightening sequence Torque the bolts to 54 64 ft lbs 73 87 Nm On the flywheel if equipped with manual transmission locate clutch disc and install pressure plate 32 Turn the engine on the work stand so the engine is in the normal upright position Install the oil level ...

Page 531: ...connecting rods and caps 11 Inspect all the machined surfaces on the crankshaft for nicks scratches scores etc which could cause premature bearing wear 12 If the crankshaft main bearing journals have been refinished to a definite undersize install the correct undersize bearings Ensure that the bearing inserts and the bearing bores are clean Foreign material under the inserts will distort the beari...

Page 532: ...etain the forward pressure on the crankshaft Tighten the cap bolts to 55 63 ft lbs 75 85 Nm Click to enlarge 19 Check the crankshaft end play with a dial indicator mounted on the front of the engine 20 If the end play exceeds specification replace the upper and lower thrust bearings If the end play is less than specification inspect the thrust bearing faces for damage dirt or improper alignment In...

Page 533: ... the oil pan and oil pickup tube 5 Remove the front cover and water pump as an assembly 6 Remove the distributor drive gear 7 Remove the camshaft and crankshaft sprockets and the timing chain To do this pull back on the ratcheting mechanism of the timing chain vibration damper then install the pin through the hole to relieve the tension against the chain 8 Remove the flywheel and the engine rear c...

Page 534: ...g cap to cylinder block parting line 18 Lubricate the bearing surfaces and journals with Oil Conditioner part No D9AZ 19579 CF or equivalent heavy engine oil 50 SAE weight 19 Install the main bearing caps in the proper direction Tighten the retaining bolts as follows 1 Do NOT jam the pry bar into position Carefully tap on the pry bar until it holds the crankshaft toward the front of the engine Wed...

Page 535: ...ver and flywheel and spark plugs 25 Install the distributor cap then connect the ignition wires as tagged during removal 26 Install the engine in the vehicle Connect the negative battery cable then fill the crankcase with the correct amount and type of engine oil CLEANING INSPECTION 1 Clean the crankshaft with solvent and a brush Clean the oil passages with a suitable brush then blow them out with...

Page 536: ...ils any inspection for wear or damage it must be reground or replaced BEARING REPLACEMENT The following procedure requires the use of Plastigage or a micrometer set consisting of inside and outside micrometers and a dial indicator 1 Inspect the bearings for scoring chipping or other wear Checking the main bearing journal using a micrometer Checking main bearing bore diameter with the bearings inst...

Page 537: ...crankshaft bearing journals for diameter and out of round conditions if necessary regrind the bearing journals 3 Install the bearings and caps then torque the nuts bolts to specifications Using an inside micrometer check the bearing bores in the engine block If out of specification regrind the bearing bores to the next largest oversize 4 The difference between the two readings is the bearing clear...

Page 538: ...l to the bearing then install and tighten the cap As with the connecting rod bearings remove the cap and compare the gauging material to the provided scale Стр 208 из 211 18 11 2005 file C DOCUME 1 SILENT 1 LOCALS 1 Temp trsHIPBC htm ...

Page 539: ...clean and free of nicks or burrs Install the bearing shells in the bearing saddles making sure the shell tangs are seated in the notches NOTE Be careful when handling any plain bearings Your hands and the working area should be clean Dirt is easily embedded in the bearing surface and the bearings are easily scratched or damaged CRANKSHAFT END PLAY CONNECTING ROD SIDE PLAY 6 Place a prybar between ...

Page 540: ...e to zero Engine assembly balancing is not required Balance weights should not be installed on new flywheels 5 Install the rear cover plate if removed Flywheel mounting 3 0L engine except SHO Flywheel mounting 3 8L engine Стр 210 из 211 18 11 2005 file C DOCUME 1 SILENT 1 LOCALS 1 Temp trsHIPBC htm ...

Page 541: ...s 73 87 Nm using the standard cross tightening sequence For the SHO engines tighten the bolts in two steps 1 Step 1 29 39 ft lbs 39 53 Nm 2 Step 2 51 58 ft lbs 69 79 Nm 7 If removed install the transaxle Chilton Automotive Information Systems 2004 Thomson Delmar Learning Стр 211 из 211 18 11 2005 file C DOCUME 1 SILENT 1 LOCALS 1 Temp trsHIPBC htm ...

Page 542: ...AUST SYSTEM Introduction Location of the muffler Early model 2 5L shown Location of the catalytic converter early model 2 5L shown Стр 1 из 9 18 11 2005 file C DOCUME 1 SILENT 1 LOCALS 1 Temp trsIHDLA htm ...

Page 543: ...to enlarge Exploded view of the exhaust system 2 5L engine Exploded view of the exhaust system 3 0L engine expect SHO equipped with the AX4S transaxle Стр 2 из 9 18 11 2005 file C DOCUME 1 SILENT 1 LOCALS 1 Temp trsIHDLA htm ...

Page 544: ...oded view of the exhaust system 3 0L engine expect SHO equipped with the AX4N transaxle Exploded view of the exhaust system 3 8L engine Police sedan Стр 3 из 9 18 11 2005 file C DOCUME 1 SILENT 1 LOCALS 1 Temp trsIHDLA htm ...

Page 545: ...Click to enlarge Click to enlarge Exploded view of the exhaust system 3 0L SHO engine Стр 4 из 9 18 11 2005 file C DOCUME 1 SILENT 1 LOCALS 1 Temp trsIHDLA htm ...

Page 546: ...ent of the exhaust system but do not allow the transfer of noise and vibration into the passenger compartment Any noise vibrations or rattles in the exhaust system are usually caused be damage or misalignment of the parts As with many areas of service on your car the exhaust system presents its own Exploded view of the exhaust system 3 2L SHO engine CAUTION Before performing any operations on the ...

Page 547: ...let pipes outlet pipes and mufflers for cracked joints broken welds and corrosion damage that would result in a leaking exhaust system It is normal for a certain amount of moisture and staining to be present around the muffler seams The presence of soot light surface rust or moisture does not indicate a faulty muffler Inspect the clamps brackets and insulators for cracks and stripped or badly corr...

Page 548: ...A number of special exhaust system tools can be rented from auto supply houses or local stores that rent special equipment A common one is a tailpipe expander designed to enable you to join pipes of identical diameter It may also be quite helpful to use solvents designed to loosen rusted bolts or flanges Soaking rusted parts the night before you do the job can speed the work Location of the muffle...

Page 549: ...y and rubber insulators from the hanger brackets then remove the muffler assembly Slide the muffler rearward to disconnect it from the resonator or flexible pipe as applicable 3 Replace any damaged parts To install 4 Position the muffler assembly and slide it onto the resonator outlet pipe Check the make sure the slot in the muffler and the tab on the resonator are fully engaged 5 Install the rubb...

Page 550: ...p from the tailpipe to the frame if equipped 2 Remove the retaining clamp holding the tailpipe to the muffler or resonator 3 Using the proper tool separate the tailpipe from the muffler or resonator 4 Carefully remove the tailpipe from the vehicle 5 Installation is the reverse of the removal procedure Be sure to use new retaining clamps 6 Lower the vehicle Start the engine and check for leaks Chil...

Page 551: ...ne When the engine power output is below normal check for the following as necessary z Overheating of the cooling system z Leaks in the vacuum system z Leaking of the fuel pump or hoses z Unadjusted valve timing z A blown head gasket z A slipping clutch disc or unadjusted pedal z Excessive piston to bore clearance z Worn piston rings z A worn camshaft z Sticking valve s or weak valve spring s z A ...

Page 552: ...e following as necessary z Incorrect ignition timing z Defective Exhaust Gas Recirculation EGR valve z A very lean air fuel mixture carburetor equipped z Fault with the computerized engine control system Backfire Exhaust Manifold When the engine backfires through the exhaust manifold check for the following as necessary z Leaks in the vacuum hose system z Leaks in the exhaust system z Faulty vacuu...

Page 553: ...d oil pan gasket or bent oil pan z Improperly seated oil pan drain plug z Broken timing chain cover gasket z Blocked camshaft bearing drain hole Heavy Oil Consumption When the engine is burning large amounts of oil check for the following as necessary z Engine oil level that is too high z Engine oil that is too thin z Wrong size of piston rings z Clogged piston ring grooves or oil return slots z I...

Page 554: ...w Oil Pressure When the engine presents low oil pressure check for the following as necessary z Low oil level in the crankcase z Blocked oil pickup screen or tube z Malfunctioning or excessive clearance of the oil pump z Sticking oil pressure relief valve z Very thin engine oil z Worn loose main rod or camshaft bearings High Oil Pressure When the engine presents high oil pressure check for the fol...

Page 555: ...noise check for the following as necessary z Misaligned connecting rods z Out of round or tapered cylinder bore z Loose or tight ring side clearance z Build up of carbon on the piston s z Piston to cylinder bore clearance is excessive z Broken piston rings z Loose or seized piston pin s Knocking Valve Train When the valve train is constantly making noise check for the following as necessary z Loos...

Page 556: ...valves are constantly noisy check for the following as necessary z Unadjusted valve lash z Broken valve springs z Bent pushrods z Excessively worn camshaft lobes z Dirty or worn valve lifters z Worn valve guides z Excessive valve seat or face run out z Loose rocker arm studs Chilton Automotive Information Systems 2004 Thomson Delmar Learning Стр 6 из 6 BASIC MECHANICAL TROUBLESHOOTING 18 11 2005 h...

Page 557: ...SPECIFICATION CHARTS Click to enlarge Click to enlarge Valve Specifications Camshaft Specifications Стр 1 из 7 SPECIFICATION CHARTS 18 11 2005 http www chiltondiy com content 8687 8687_3_5 html ...

Page 558: ...ck to enlarge Click to enlarge Crankshaft and Connecting Rod Specifications Piston and Ring Specifications Torque Specifications Стр 2 из 7 SPECIFICATION CHARTS 18 11 2005 http www chiltondiy com content 8687 8687_3_5 html ...

Page 559: ...Click to enlarge Click to enlarge Torque Specifications Torque Specifications Стр 3 из 7 SPECIFICATION CHARTS 18 11 2005 http www chiltondiy com content 8687 8687_3_5 html ...

Page 560: ...Click to enlarge Engine Rebuilding Specifications Стр 4 из 7 SPECIFICATION CHARTS 18 11 2005 http www chiltondiy com content 8687 8687_3_5 html ...

Page 561: ...Click to enlarge Engine Rebuilding Specifications Стр 5 из 7 SPECIFICATION CHARTS 18 11 2005 http www chiltondiy com content 8687 8687_3_5 html ...

Page 562: ...Click to enlarge Engine Rebuilding Specifications Стр 6 из 7 SPECIFICATION CHARTS 18 11 2005 http www chiltondiy com content 8687 8687_3_5 html ...

Page 563: ... to enlarge Chilton Automotive Information Systems 2004 Thomson Delmar Learning Engine Rebuilding Specifications Стр 7 из 7 SPECIFICATION CHARTS 18 11 2005 http www chiltondiy com content 8687 8687_3_5 html ...

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Page 729: ... born smoke and particulates from such natural events as plains and forest fires ignited by heat or lightning volcanic ash sand and dust which can spread over a large area of the countryside Such a phenomenon of natural pollution has been recent volcanic eruptions with the resulting plume of smoke steam and volcanic ash blotting out the sun s rays as it spreads and rises higher into the atmosphere...

Page 730: ...rea returning at the end of the day to their homes in the suburbs It was noted that a fog and smoke type haze was being formed and at times remained in suspension over the cities and did not quickly dissipate At first this smog derived from the words smoke and fog was thought to result from industrial pollution but it was determined that the automobile emissions shared the blame It was discovered ...

Page 731: ...with which we must concern ourselves Heat Transfer The heat from the combustion process can rise to over 4000 F 2204 C The dissipation of this heat is controlled by a ram air effect the use of cooling fans to cause air flow and having a liquid coolant solution surrounding the combustion area and transferring the heat of combustion through the cylinder walls and into the coolant The coolant is then...

Page 732: ...Chilton Automotive Information Systems 2004 Thomson Delmar Learning Стр 4 из 4 AIR POLLUTION 18 11 2005 http www chiltondiy com content 8687 8687_4_1 html ...

Page 733: ...culates HYDROCARBONS Hydrocarbons HC are essentially unburned fuel that have not been successfully burned during the combustion process or have escaped into the atmosphere through fuel evaporation The main sources of incomplete combustion are rich air fuel mixtures low engine temperatures and improper spark timing The main sources of hydrocarbon emission through fuel evaporation come from the vehi...

Page 734: ...itrogen dioxide then combines with chemically active hydrocarbons HC and when in the presence of sunlight causes the formation of photo chemical smog OZONE To further complicate matters some of the nitrogen dioxide NO2 is broken apart by the sunlight to form nitric oxide and oxygen NO2 sunlight NO O This single atom of oxygen then combines with diatomic meaning 2 atoms oxygen O2 to form ozone O3 O...

Page 735: ...ers are operating in an area this acid mist will rise and be distributed over a large ground area causing land plant crop paints and building damage PARTICULATE MATTER A certain amount of particulate matter is present in the burning of any fuel with carbon constituting the largest percentage of the particulates In gasoline the remaining percentage of particulates is the burned remains of the vario...

Page 736: ... help to form the remaining crankcase emissions Since the first engines crankcase emissions were allowed to go into the air through a road draft tube mounted on the lower side of the engine block Fresh air came in through an open oil filler cap or breather The air passed through the crankcase mixing with blow by gases The motion of the vehicle and the air blowing past the open end of the road draf...

Page 737: ...tion and creating a severe fire hazard To correct this condition the vehicle manufacturers added overflow plumbing and or gasoline tanks with built in expansion areas or domes However this did not control the fuel vapor emission from the fuel tank and the carburetor bowl It was determined that most of the fuel evaporation occurred when the vehicle was stationary and the engine not operating Most v...

Page 738: ...the engine air intake for burning with the fuel and air mixture The PCV system maximizes oil cleanliness by venting moisture and corrosive fumes from the crankcase All of the vehicles covered by this manual except for the 3 0L and the 3 2L SHO engines utilize a PCV valve The PCV valve limits the fresh air intake to suit the engine demand and also serves to prevent combustion backfiring into the cr...

Page 739: ...ied from another port on the throttle body to the cylinder head cover Under various throttle conditions the air and crankcase gases flow differently through the ports in the throttle body Positive Crankcase Ventilation PCV system schematic except SHO vehicles Positive Crankcase Ventilation PCV system schematic 3 0L and 3 2L SHO vehicles Стр 2 из 51 EMISSION CONTROLS 18 11 2005 http www chiltondiy ...

Page 740: ...t fuel economy and engine ventilation with resultant shortening of engine life The components used in the PCV valve system consist of the PCV valve or tube as in SHO applications the rubber mounting grommet in the valve cover the nipple in the air intake system and the necessary connecting hoses Стр 3 из 51 EMISSION CONTROLS 18 11 2005 http www chiltondiy com content 8687 8687_4_3 html ...

Page 741: ...INSPECTION 1 Visually inspect the components of the PCV system Check for rough idle slow PCV system components 3 0L shown 2 5L similar Стр 4 из 51 EMISSION CONTROLS 18 11 2005 http www chiltondiy com content 8687 8687_4_3 html ...

Page 742: ...s not rattle it is sticking and should be replaced 2 Start the engine and bring to normal operating temperature 3 On the 2 5L engine remove the corrugated hose from the oil separator nipple On all other engines disconnect the hose from the remote air cleaner or air outlet tube 4 Place a stiff piece of paper over the nipple or hose end and wait 1 minute If vacuum holds the paper in place the system...

Page 743: ...valve cover 2 Disconnect the valve from the PCV hose and remove the valve from the vehicle 3 Installation is the reverse of the removal procedure Evaporative Emission Control EEC System OPERATION The evaporative emission control system prevents the escape of fuel vapors to the atmosphere under hot soak and engine off conditions by storing the vapors in a carbon canister Then with the engine warm a...

Page 744: ...e vapor valve is located on or near the fuel tank Its function is to prevent fuel from flooding the carbon canister The vapor valve incorporates the rollover valve In the event of a vehicle rollover the valve blocks the vapor line automatically to prevent fuel leakage The check valve is located in the fuel filler cap or on the underside of the vehicle Its function is to protect the fuel tank from ...

Page 745: ...um lines and connections for looseness pinching leakage damage or other obvious cause for malfunction 4 If fuel line vacuum line or orifice blockage is suspected as the obvious cause of an observed malfunction correct the cause before proceeding further Click to enlarge ADJUSTMENT Carbon Canister There are no moving parts and nothing to wear in the canister Check for loose missing cracked or broke...

Page 746: ...Click to enlarge EEC system for the 3 0L Flexible Fuel FF engine Стр 9 из 51 EMISSION CONTROLS 18 11 2005 http www chiltondiy com content 8687 8687_4_3 html ...

Page 747: ...nnect the negative battery cable 2 Detach the vapor hoses from the carbon canister The 3 0L Flexible Fuel vehicles utilize four canisters mounted under the rear floor pan Стр 10 из 51 EMISSION CONTROLS 18 11 2005 http www chiltondiy com content 8687 8687_4_3 html ...

Page 748: ...aps then remove the canister The 3 0L Flexible Fuel engine uses four canisters mounted under the rear floor pan 4 Installation is the reverse of the removal procedure Стр 11 из 51 EMISSION CONTROLS 18 11 2005 http www chiltondiy com content 8687 8687_4_3 html ...

Page 749: ...Стр 12 из 51 EMISSION CONTROLS 18 11 2005 http www chiltondiy com content 8687 8687_4_3 html ...

Page 750: ...Click to enlarge EEC system for the 3 0L SHO engine Стр 13 из 51 EMISSION CONTROLS 18 11 2005 http www chiltondiy com content 8687 8687_4_3 html ...

Page 751: ...Стр 14 из 51 EMISSION CONTROLS 18 11 2005 http www chiltondiy com content 8687 8687_4_3 html ...

Page 752: ...ick to enlarge Click to enlarge Purge Valves EEC system for the 3 2L SHO engine EEC system for the 3 8L engine Стр 15 из 51 EMISSION CONTROLS 18 11 2005 http www chiltondiy com content 8687 8687_4_3 html ...

Page 753: ...old below the throttle plate The exhaust gas mixes with the incoming air charge and displaces a portion of the oxygen in the air fuel mixture entering the combustion chamber The exhaust gas does not support combustion of the air fuel mixture but it takes up volume the net effect of which is to lower the temperature of the combustion chamber There are a few different EGR systems used on front wheel...

Page 754: ...nic vacuum regulator which actuates the valve diaphragm As supply vacuum overcomes the spring load the diaphragm is actuated This lifts the pintle off of its seat allowing exhaust gas to recirculate The amount of flow is proportional to the pintle position The EVP sensor mounted on the valve sends an electrical signal of its position to the ECU Pressure Feedback Electronic PFE EGR system schematic...

Page 755: ...the EVP sensor which is mounted on top of the electronic EGR valve The electronic EGR valve assembly is not serviceable The EVP sensor and the EGR valve must be serviced separately The Pressure Feedback Electronic PFE EGR Transducer converts a varying exhaust pressure signal into a proportional analog voltage which is digitized by the ECU The ECU uses the signal received from the PFE transducer to...

Page 756: ...oil induces a magnetic field in the armature The magnetic field pulls the disk back closing the vent and increasing the vacuum level The vacuum source is either manifold or vacuum As the duty cycle is increased an increased vacuum signal goes to the EGR valve Back pressure Variable Transduced BVT EGR system schematic Стр 19 из 51 EMISSION CONTROLS 18 11 2005 http www chiltondiy com content 8687 86...

Page 757: ...Click to enlarge EGR system and related components for the 3 0L engine except SHO Стр 20 из 51 EMISSION CONTROLS 18 11 2005 http www chiltondiy com content 8687 8687_4_3 html ...

Page 758: ...Click to enlarge Exploded view of the EGR valve and related components 3 0L and 3 2L SHO engines Стр 21 из 51 EMISSION CONTROLS 18 11 2005 http www chiltondiy com content 8687 8687_4_3 html ...

Page 759: ... 3 Connect a suitable tachometer 4 Detach the idle air bypass valve electrical connector 5 Remove the vacuum supply hose from the EGR valve nipple and plug the hose 6 Start the engine and let it idle with the transaxle selector lever in Neutral Check the engine idle speed and adjust to the proper specification if necessary View of the EGR system components late model 3 8L engine shown Стр 22 из 51...

Page 760: ...he EGR vacuum supply hose 11 Disconnect the vacuum connection at the BVT 12 Gently blow into the hose to port C until the relief valve closes and at the same time apply 5 10 in Hg 17 34 kPa of vacuum to port E with the hand vacuum pump Port E should hold vacuum as long as there is pressure on port C 13 Apply a minimum of 5 10 in Hg 17 34 kPa of vacuum to ports B and C using the hand vacuum pump Po...

Page 761: ...olts 5 Attach any vacuum lines or electrical connectors disengaged during removal 6 Connect the negative battery cable Electronic EGR EEGR Valve Cross sectional view of a ported EGR valve assembly Стр 24 из 51 EMISSION CONTROLS 18 11 2005 http www chiltondiy com content 8687 8687_4_3 html ...

Page 762: ...ect the vacuum line from the EGR valve Cross sectional view of a base entry type electronic EGR valve Cross sectional view of a side external entry type electronic EGR valve Disengage the electrical connector from the EVP sensor early model 2 5L engine Стр 25 из 51 EMISSION CONTROLS 18 11 2005 http www chiltondiy com content 8687 8687_4_3 html ...

Page 763: ... EGR valve Disconnect the vacuum line from the EGR valve Disconnect the mounting bolts from the EGR valve Remove the mounting bolts from the EGR valve Стр 26 из 51 EMISSION CONTROLS 18 11 2005 http www chiltondiy com content 8687 8687_4_3 html ...

Page 764: ...ectrical connector 10 Connect the negative battery cable Pressure Feedback Electronic PFE EGR Transducer 1 Disconnect the negative battery cable 2 Separate the electrical connector and the exhaust pressure line from the transducer 3 Remove the transducer from the vehicle Remove the EGR valve from the vehicle early model engine shown When installing the EGR valve be sure to remove the old gasket an...

Page 765: ...t the exhaust pressure line to the transducer 5 Connect the negative battery cable EGR Valve Position EVP Sensor Click to enlarge EGR sensor late model 3 0L except SHO and Flexible Fuel shown Стр 28 из 51 EMISSION CONTROLS 18 11 2005 http www chiltondiy com content 8687 8687_4_3 html ...

Page 766: ...or on the EGR valve then secure using the mounting nuts 5 Engage the electrical connector to the sensor then connect the negative battery cable Back pressure Variable Transducer BVT 1 Disconnect the negative battery cable 2 Disconnect the vacuum lines from the BVT EGR sensor location 3 0L Flexible Fuel engines EGR sensor late model 3 8L shown Стр 29 из 51 EMISSION CONTROLS 18 11 2005 http www chil...

Page 767: ...le EGR Vacuum Regulator EVR 1 Disconnect the negative battery cable 2 Disengage the electrical connector and the vacuum lines from the regulator 3 Remove the regulator mounting bolts then remove the regulator from the vehicle To install Cross sectional view of a Back Pressure Variable Transducer BVT EGR vacuum regulator assembly Стр 30 из 51 EMISSION CONTROLS 18 11 2005 http www chiltondiy com con...

Page 768: ... source as well as heated air from a heat shroud which is mounted on the exhaust manifold The system consists of the following components duct and valve assembly heat shroud bimetal sensor cold weather modulator vacuum delay valve and the necessary vacuum lines and air ducts All vehicles do not share all components Click to enlarge Duct and Valve Assembly The duct and valve assembly which regulate...

Page 769: ...Click to enlarge Click to enlarge Duct assembly 3 0L engine except SHO Duct assembly 3 0L 3 2L SHO engines Стр 32 из 51 EMISSION CONTROLS 18 11 2005 http www chiltondiy com content 8687 8687_4_3 html ...

Page 770: ...uum drops during acceleration The cold weather modulator only works when the outside air is cold Vacuum Delay Valve The vacuum delay valve is used for the gradual release of vacuum to the vacuum motor TESTING Duct and Valve Assembly 1 If the duct door is in the closed to fresh air position remove the hose from the air cleaner vacuum motor 2 The door should go to the open to fresh air position If i...

Page 771: ... 4 C z Yellow holds above 65 F 18 3 C and leaks below 50 F 10 C Vacuum Delay Valve 1 Connect a hand vacuum pump to the vacuum delay valve 2 Valves with 1 side black or white and the other side colored are good if vacuum can be built up in 1 direction but not the other direction and if that built up vacuum can be seen to slowly decrease 3 Valves with both sides the same color are good if vacuum can...

Page 772: ...cuum hoses to the modulator then install the air cleaner housing lid 7 Connect the negative battery cable Vacuum Delay Valve 1 Disconnect the negative battery cable 2 Disconnect the vacuum hoses from the delay valve 3 Remove the valve from the vehicle To install 4 Install the valve in the vehicle then connect the vacuum hoses 5 Connect the negative battery cable Thermactor Air Injection System OPE...

Page 773: ... air supply pump is a belt driven positive displacement vane type pump that provides air for the thermactor system It is available in 19 and 22 cu in 311 35 and 360 5cc sizes either of which may be driven with different pulley ratios for different applications The pump receives air from a remote silencer filter on the rear side of the engine air cleaner attached to the pump s air inlet nipple or t...

Page 774: ...hrough the silencer ports of the valve or through the dump port Click to enlarge Air Check Valve The air check valve is a one way valve that allows thermactor air to pass into the exhaust system while preventing exhaust gases from passing in the opposite direction Air supply pump assembly Cross sectional view of an air bypass valve Стр 37 из 51 EMISSION CONTROLS 18 11 2005 http www chiltondiy com ...

Page 775: ...r to the air cleaner or dump silencer Combination Air Bypass Air Control Valve The combination air control bypass valve combines the secondary air bypass and air control functions The valve is located in the air supply line between the air pump and the upstream downstream air supply check valves Air check valve Air supply control valve Стр 38 из 51 EMISSION CONTROLS 18 11 2005 http www chiltondiy ...

Page 776: ... with an atmospheric vent The valve assembly can be with or without control bleed The outlet port of the valve is opened to atmospheric vent and closed to the inlet port when de energized When energized the outlet port is opened to the inlet port and closed to atmospheric vent The control bleed is provided to prevent contamination entering the solenoid valve assembly from the intake manifold Therm...

Page 777: ...Remove the vacuum line to check that a vacuum signal is present at the vacuum nipple There must be vacuum present at the nipple before proceeding 3 With the engine at 1500 rpm and the vacuum line connected to the vacuum nipple air pump supply air should be heard and felt at the air bypass valve outlet 4 With the engine at 1500 rpm disconnect the vacuum line Air at the outlet should be significantl...

Page 778: ...he valve is okay Reinstall the clamps and hoses If the valve does not pass Step 4 and or 5 replace the valve Combination Air Bypass Air Control Valve 1 Disconnect the hoses from outlets A and B 2 Disconnect and plug the vacuum line to port D 3 With the engine operating at 1500 rpm airflow should be noted coming out of the bypass vents 4 Reconnect the vacuum line to port D then disconnect and plug ...

Page 779: ...e manifold vacuum and the TIV valve large nipple from the test vacuum Reconnect the TIV valve to the original hoses or connectors REMOVAL INSTALLATION Air Supply Pump 1 Disconnect the negative battery cable 2 Remove the drive belt from the air pump pulley 3 Disconnect the air hose s from the air pump 4 Remove the mounting bolts and if necessary the mounting brackets 5 Remove the air pump from the ...

Page 780: ...ble Combination Air Bypass Air Control Valve 1 Disconnect the negative battery cable 2 Disconnect the air hoses and vacuum lines from the valve 3 Remove the valve from the vehicle To install 4 Install the valve in the vehicle 5 Connect the vacuum lines and the air hoses to the valve 6 Connect the negative battery cable Solenoid Vacuum Valve Assembly 1 Disconnect the negative battery cable 2 Detach...

Page 781: ...th the 2 5L engine The pulse air injection system does not use an air pump Instead the system uses natural pulses present in the exhaust system to pull air into the catalyst through a pulse air valve The pulse air valve is connected to the catalyst with a long tube and to the air cleaner and silencer with hoses Click to enlarge Pulse Air Valve The pulse air control valve is normally closed Without...

Page 782: ...ntrol bleed is provided to prevent contamination entering the solenoid valve assembly from the intake manifold TESTING Pulse Air Valve 1 Visually inspect the system hoses tubes control valve s and check valve s for leaks that may be due to backflow of exhaust gas If holes are found and or traces of exhaust gas products are evident the check valve may be suspect 2 The valve should allow free flow o...

Page 783: ...oles are found and or traces of exhaust gas products are evident the check valve may be suspect 2 Check valves should allow free flow of air in the incoming direction only The valves should check or block the free flow of exhaust gas in the opposite direction 3 Replace the valve if air does not flow as indicated or if exhaust gas backflows in the opposite direction Solenoid Vacuum Valve Assembly 1...

Page 784: ...noid Vacuum Valve Assembly 1 Disconnect the negative battery cable 2 Disengage the electrical connector then disconnect the vacuum lines from the solenoid valve 3 Remove the mounting bolts then remove the solenoid vacuum valve To install 4 Install the solenoid valve then fasten using the mounting bolts 5 Connect the vacuum lines then engage the electrical connector to the solenoid valve 6 Connect ...

Page 785: ...of HC and CO but it also catalyzes the reduction of NOx Click to enlarge The catalytic converter assembly consists of a structured shell containing a monolithic substrate a ceramic honeycomb construction In order to maintain the converter s exhaust oxygen content at a high level to obtain the maximum oxidation for producing the heated chemical reaction the oxidation catalyst usually requires the u...

Page 786: ...Click to enlarge Service Interval Reminder Lights RESETTING Catalyst and exhaust system diagnostic data Стр 49 из 51 EMISSION CONTROLS 18 11 2005 http www chiltondiy com content 8687 8687_4_3 html ...

Page 787: ... SOON Malfunction Indicator Light MIL An illuminated MIL likely indicates the presence of a self diagnostic trouble code Information on reading such trouble codes appears later in this section Oxygen Sensor The oxygen sensor or Heated Exhaust Gas Oxygen HEGO sensor supplies the ECU with a signal which indicates a rich or lean condition during engine operation This input information assists the ECU...

Page 788: ...1 Disconnect the negative battery cable 2 Disengage the oxygen heated exhaust gas oxygen sensor electrical connector 3 Remove the sensor from the exhaust manifold or exhaust pipes as applicable To install 4 Install the sensor in the exhaust manifold or pipe 5 Engage the sensor electrical connector 6 Connect the negative battery cable Chilton Automotive Information Systems 2004 Thomson Delmar Learn...

Page 789: ...m Worn or deteriorated hoses and damaged or corroded wires may well make a good component appear faulty When troubleshooting the system always check the electrical and vacuum connectors which may cause the problem before testing or replacing a component Computer Control Module The heart of the electronic control system which is found on vehicles covered by this manual is a computer control module ...

Page 790: ...olt Remove the wiring connector from the module 4 Loosen the module bracket support screw located forward of the glove compartment Remove the bracket then remove the computer control module View of the computer control module Powertrain Control Module PCM shown other modules are basically identical CAUTION To prevent the possibility of permanent control module damage the ignition switch MUST alway...

Page 791: ... used by the ECU to calculate the injector pulse width The sensing element is a thin platinum wire wound on a ceramic bobbin and coated with glass This hot wire is maintained at 11 F 200 C above the ambient temperature as measured by a constant cold wire The MAF sensor is located in the outlet side of the air cleaner lid assembly TESTING 1 Make sure the ignition key is OFF 2 Connect Breakout Box T...

Page 792: ...ir cleaner lid or the MAF sensor gasket surfaces 4 Installation is the reverse of the removal procedure Idle Air Bypass Valve The idle air bypass valve is used to control engine idle speed and is operated by the computer control module or in response to engine coolant temperature change depending upon vehicle application The valve allows air to flow into the intake air stream to control cold engin...

Page 793: ... retaining screws tightening them to 84 inch lbs 9 5 Nm 5 Engage the idle air bypass valve electrical connector to the wiring harness then connect the negative battery cable Idle Speed Control ISC Motor The Idle Speed Control ISC motor which is used in the CFI system controls idle speed by moving the throttle lever It regulates airflow to maintain the desired engine rpm for both warm and cold engi...

Page 794: ...sed to supply a voltage output change proportional to the change in the throttle position The TP sensor is used by the ECU to determine engine operation mode closed throttle part throttle and wide open throttle The proper fuel mixture spark and EGR will be output only when the operation mode has been determined correctly REMOVAL INSTALLATION 1 Disconnect the negative battery cable 2 Detach the ele...

Page 795: ...hrottle body Click to enlarge TESTING Without Vane Air Flow Meter 1 Disconnect the temperature sensor 2 Connect an ohmmeter between the sensor terminals and set the ohmmeter scale on 200 000 ohms 3 Measure the resistance with the engine off and cool Then measure the resistance with the engine running and warmed up Compare the resistance values obtained with the accompanying chart 4 Replace the sen...

Page 796: ...ng chart If the readings are incorrect replace the sensor REMOVAL INSTALLATION Without Vane Air Flow Meter 1 Disconnect the negative battery cable 2 Disengage the electrical connector from the air temperature sensor 3 Remove the sensor 4 Installation is the reverse of the removal procedure With Vane Air Flow Meter The air charge temperature sensor is an integral component of the vane air flow mete...

Page 797: ...r scale on 200 000 ohms 3 Measure the resistance with the engine off and cool Then measure with the engine running and warmed up Compare the resistance values obtained with the chart 4 Replace the sensor if the readings are incorrect REMOVAL INSTALLATION 5 Disconnect the negative battery cable 6 Drain the cooling system to a level below the sensor 7 Disengage the electrical connector from the ECT ...

Page 798: ...from the MAP sensor 2 Connect a suitable vacuum pump to the MAP sensor and apply 18 in Hg 61 kPa of vacuum 3 If the MAP sensor does not hold vacuum it must be replaced REMOVAL INSTALLATION 1 Disconnect the negative battery cable 2 Disengage the electrical connector and the vacuum line from the sensor 3 Unfasten the sensor mounting bolts then remove the sensor 4 Installation is the reverse of the r...

Page 799: ...git or 3 digit numbers representing the results of the Self Test The service codes are transmitted on the Self Test output line found in the vehicle Self Test connector They are in the form of timed pulses and can be read on a voltmeter STAR or SUPER STAR II tester and the malfunction indicator light Reading Codes VEHICLE PREPARATION 1 Apply the parking brake place the transaxle shift lever firmly...

Page 800: ...ows 1 Turn the ignition OFF 2 Connect the color coded adapter cable to the STAR tester 3 Connect the adapter cable leads to the proper Self Test connectors 4 Ground the adapter cable for vehicles using the SUPER STAR II tester 5 Slide the SUPER STAR II tester switch to the MECS or EEC IV position according to the vehicle system STAR tester hook up STAR tester output code format Стр 2 из 5 SELF DIA...

Page 801: ...ce code is represented by a 2 digit or 3 digit number such as 23 As a result the Self Test service code of 23 will appear on the voltmeter as 2 needle sweeps then after a 2 second pause the needle will sweep 3 times Connect the analog voltmeter as follows 1 Turn the ignition OFF Click to enlarge Voltmeter hook up Analog voltmeter output code format Стр 3 из 5 SELF DIAGNOSTIC SYSTEMS 18 11 2005 htt...

Page 802: ...own position 2 Place the ignition key in the ON position 3 Record all service codes displayed 2 If using the SUPER STAR II tester proceed as follows 1 Latch the center button in the TEST position 2 Turn the ignition key ON 3 Turn the tester ON the tester will sound and 888 will be displayed for 2 seconds 4 Unlatch and relatch the center test button After all codes are received unlatch the center b...

Page 803: ...d MIL remove the jumper wire from between the Self Test Input STI connector and the signal return pin of the Self Test connector 3 The continuous memory codes will be erased from the ECU memory KEEP ALIVE MEMORY KAM The computer control module stores information regarding vehicle operating conditions and uses this information to compensate for component tolerances Whenever an emission related comp...

Page 804: ...to the faulty circuit NOT necessarily to a faulty component Loose damaged or corroded connections may contribute to a fault code on a circuit when the sensor or component it operating properly Be sure that components are faulty before replacing them especially the expensive ones Click to enlarge Diagnostic Trouble Codes Стр 1 из 8 DIAGNOSTIC TROUBLE CODES 18 11 2005 http www chiltondiy com content...

Page 805: ...Click to enlarge Click to enlarge Diagnostic Trouble Codes Diagnostic Trouble Codes Стр 2 из 8 DIAGNOSTIC TROUBLE CODES 18 11 2005 http www chiltondiy com content 8687 8687_4_6 html ...

Page 806: ...Click to enlarge Diagnostic Trouble Codes Стр 3 из 8 DIAGNOSTIC TROUBLE CODES 18 11 2005 http www chiltondiy com content 8687 8687_4_6 html ...

Page 807: ...Click to enlarge Diagnostic Trouble Codes Стр 4 из 8 DIAGNOSTIC TROUBLE CODES 18 11 2005 http www chiltondiy com content 8687 8687_4_6 html ...

Page 808: ...Click to enlarge Diagnostic Trouble Codes Стр 5 из 8 DIAGNOSTIC TROUBLE CODES 18 11 2005 http www chiltondiy com content 8687 8687_4_6 html ...

Page 809: ...Click to enlarge Click to enlarge Diagnostic Trouble Codes Diagnostic Trouble Codes Стр 6 из 8 DIAGNOSTIC TROUBLE CODES 18 11 2005 http www chiltondiy com content 8687 8687_4_6 html ...

Page 810: ...Click to enlarge Diagnostic Trouble Codes Стр 7 из 8 DIAGNOSTIC TROUBLE CODES 18 11 2005 http www chiltondiy com content 8687 8687_4_6 html ...

Page 811: ...o enlarge Chilton Automotive Information Systems 2004 Thomson Delmar Learning Diagnostic Trouble Codes Diagnostic Trouble Codes Стр 8 из 8 DIAGNOSTIC TROUBLE CODES 18 11 2005 http www chiltondiy com content 8687 8687_4_6 html ...

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Page 871: ...ent injector fuel rail pressure regulator etc fitting or fuel line connection Exercise extreme caution whenever relieving fuel system pressure to avoid exposing skin face and eyes to fuel spray Please be advised that fuel under pressure may penetrate the skin or any part of the body that it contacts z Always place a shop towel or cloth around the fitting or connection prior to loosening to absorb ...

Page 872: ...ottle shaft and valves control engine air flow based on driver demand The throttle body attaches to the intake manifold mounting pad A throttle position sensor is attached to the throttle shaft It includes a potentiometer or rheostat that electrically senses throttle opening A throttle kicker solenoid fastens opposite the throttle position sensor During air conditioning operation the solenoid exte...

Page 873: ...k position sensor operates each injector solenoid two times per engine revolution When the injector metering valve unseats fuel is sprayed in a fine mist into the intake manifold The computer varies fuel enrichment based on voltage inputs from the exhaust gas oxygen sensor barometric pressure sensor manifold absolute pressure sensor etc by calculating how long to hold the injectors open The longer...

Page 874: ... system pressure For details please refer to the procedure located earlier in this section 2 Disconnect the negative battery cable 3 Remove the fuel from the fuel tank by pumping it out through the filler neck using Rotunda Fuel Storage Tanker 034 00002 and Adapter Hose 034 00011 or equivalent Inertia switch location Стр 3 из 9 CENTRAL FUEL INJECTION CFI 18 11 2005 http www chiltondiy com content ...

Page 875: ...lace it on a work bench Remove any dirt around the fuel pump attaching flange so it will not get into the fuel tank 6 Using Fuel Tank Sender Wrench D84P 9275 A or equivalent turn the fuel pump locking ring counterclockwise then remove the lock ring 7 Remove the fuel pump and bracket assembly from the fuel tank then remove and discard the flange gasket Click to enlarge Fuel pump assembly 2 5L CFI e...

Page 876: ...gauge Turn the ignition switch to the ON position 5 10 times leaving it on for 3 seconds at a time until the pressure gauge reads at least 30 psi 270 kPa Check for leaks at the fittings 19 Remove the pressure gauge start the engine and recheck for leaks TESTING 1 Ground the fuel pump lead of the self test connector through a jumper wire at the FP lead 2 Connect a suitable fuel pressure tester to t...

Page 877: ...stallation Click to enlarge To install 10 Clean the mounting surfaces then position a new gasket on the intake manifold 11 Position the throttle body fuel charging assembly on the intake manifold then secure with the two retaining nuts Tighten the nuts to 15 25 ft lbs 20 34 Nm 12 Engage the ISC TP sensor and fuel injector electrical connectors 13 Fasten the fuel inlet and outlet connections then c...

Page 878: ...h clean engine oil Do NOT use transmission oil 4 Install the lower O ring on the injector 5 Lubricate the upper O ring then clean and lubricate the throttle body O ring seat 6 Install the injector by centering and applying a steady downward pressure with a slight rotational force 7 Install the injector and the injector retaining screw Tighten the retaining screw to 18 22 inch lbs 2 0 2 5 Nm TESTIN...

Page 879: ...Remove the four fuel pressure regulator retaining screws 3 Remove the cover assembly cup spring and diaphragm assembly then remove the regulator valve seat To install 4 Install the fuel pressure regulator valve seat 5 Install the fuel pressure regulator diaphragm assembly spring and spring cover 6 While applying downward pressure to the cover install the four retaining screws then tighten them to ...

Page 880: ...during installation 4 Unfasten the retaining screws then remove the TP sensor To install 5 Position the TP sensor according to the marks made during removal then install the retaining screws Tighten the the screws to 11 16 inch lbs 1 2 1 8 Nm 6 Connect the negative battery cable Chilton Automotive Information Systems 2004 Thomson Delmar Learning Стр 9 из 9 CENTRAL FUEL INJECTION CFI 18 11 2005 htt...

Page 881: ...ter the appropriate quantity of fuel Click to enlarge The fuel pressure regulator maintains a constant pressure drop across the injector nozzles The regulator is referenced to intake manifold vacuum and is connected parallel to the fuel injectors and positioned on the far end of the fuel rail Any excess fuel supplied by the pump passes through the regulator and is returned to the fuel tank via a r...

Page 882: ...alves The injector body consists of a solenoid actuated pintle and needle valve assembly The control unit sends an electrical impulse that activates the solenoid causing the pintle to move inward off the seat and allow the fuel to flow The amount of fuel delivered is controlled by the length of time the injector is energized pulse width since the fuel flow orifice is fixed and the fuel pressure dr...

Page 883: ...Стр 3 из 31 ELECTRONIC FUEL INJECTION EFI 18 11 2005 http www chiltondiy com content 8687 8687_5_3 html ...

Page 884: ...ly The throttle body regulates the air flow to the engine through a single butterfly type throttle plate controlled by conventional accelerator linkage The throttle body has an idle adjustment screw throttle air bypass valve to set the throttle plate position a PCV fresh air source upstream of the throttle plate individual vacuum taps for PCV and control signals and a throttle position sensor that...

Page 885: ...e at 100 maximum current during the crank to provide maximum air flow allowing no touch starting at any time engine cold or hot Relieving Fuel System Pressure 1 Remove the fuel tank cap 2 Remove the cap from the pressure relief Schrader valve on the fuel rail 3 Attach pressure gauge tool T80L 9974 A or equivalent to the fuel pressure relief valve 4 Release the pressure from the system into a suita...

Page 886: ...Clean the fuel pump mounting flange as well as the fuel tank mounting surface and seal ring groove 9 Put a light coating of grease on the new seal gasket to hold it in place during assembly then install the gasket in the fuel ring groove 10 Carefully install the fuel pump and sender assembly making sure that the filter is Electric fuel pump assembly EFI system Стр 6 из 31 ELECTRONIC FUEL INJECTION...

Page 887: ... wire at the FP lead 2 Connect a suitable fuel pressure tester to the fuel pump outlet 3 Turn the ignition key to the RUN position to operate the fuel pump 4 The fuel pressure should be 35 45 psi 241 310 kPa for the 3 0L and 3 8L engines For the 2 5L engine the fuel pressure should be 45 60 psi 310 414 kPa A safety inertia switch is installed to shut off the electric fuel pump in case of collision...

Page 888: ...e intake manifold with the attaching bolts Tighten the bolts to 12 15 ft lbs 16 20 Nm 12 Install the throttle bracket then secure using the two retaining nuts Tighten the nuts to 12 15 ft lbs 16 20 Nm 13 Engage the TPS electrical connector and the air bypass hose 14 If the fuel charging assembly is still mounted to the engine connect the engine air cleaner outlet tube to the throttle body intake s...

Page 889: ... the EGR valve and exhaust manifold fitting Remove the tube or rotate it out of the way 7 Disengage the Air Charge Temperature ACT Idle Speed Control ISC and Throttle Position TP sensor electrical connectors 8 Remove the retaining nuts from the alternator brace then remove the brace 9 Note the location of the six throttle body retaining bolts then loosen and remove the retaining bolts Accelerator ...

Page 890: ...the intake manifold then discard the old gasket To install Tag and remove the six throttle body retaining bolts then lift the throttle body from the intake manifold Стр 10 из 31 ELECTRONIC FUEL INJECTION EFI 18 11 2005 http www chiltondiy com content 8687 8687_5_3 html ...

Page 891: ...he negative battery cable 23 Start the engine and check for vacuum leaks Check the engine idle The Throttle Valve TV cable must be adjusted if the throttle body is removed for any reason and or the throttle plate idle adjustment screw position is changed 24 Adjust the TV cable as follows 1 Connect the TV cable eye to the transaxle throttle control lever link then attach the cable boot to the chain...

Page 892: ... the cables out of the way 4 Disengage the upper intake manifold vacuum fitting connections by disconnecting all of the vacuum lines to the vacuum tree EGR valve and fuel pressure regulator 5 Disconnect the PCV system by removing the hose from the fitting on the rear of the upper manifold 6 Remove the nut retaining the EGR transducer to the upper intake manifold Loosen the EGR tube at the exhaust ...

Page 893: ...2 Step 2 24 ft lbs 32 Nm 17 Install the two bolts retaining the manifold support brackets to the upper manifold then tighten to 19 ft lbs 25 Nm 18 Position the alternator bracket then install the two retaining bolts to the water pump and alternator Install the alternator bracket to the upper intake manifold retaining nut then tighten to 19 ft lbs 26 Nm 19 Connect the EGR valve to the EGR tube maki...

Page 894: ...f the lower intake manifold was removed fill and bleed the cooling system AIR INTAKE THROTTLE BODY 1 Disconnect the negative battery cable 2 Disengage the TP sensor and air bypass valve electrical connectors 3 Remove the four throttle body retaining bolts Remove the throttle body assembly then remove and discard the gasket between the throttle body and the upper intake manifold 4 If scraping is ne...

Page 895: ...e air bypass valve 7 Connect the negative battery cable Fuel Charging Assembly REMOVAL INSTALLATION 2 5L Engine 1 Disconnect the negative battery cable Properly relieve fuel system pressure Disconnect the air bypass connector from the EEC IV harness Disconnect the Throttle body and related components 3 8L engine Стр 15 из 31 ELECTRONIC FUEL INJECTION EFI 18 11 2005 http www chiltondiy com content ...

Page 896: ...old assembly and finger tighten the retaining bolts 13 Install the fuel return line Tighten the manifold retaining bolts to 15 22 ft lbs 20 30 Nm 14 Connect the upper and lower manifold support brackets Tighten the retaining bolts to 15 22 ft lbs 20 30 Nm 15 Install the EGR tube and connect the PCV system hoses Fasten the rear manifold connections 16 Connect the accelerator and speed control linka...

Page 897: ...t lbs 20 30 Nm in sequence as shown in the fuel charging assembly diagram in this section 16 Engage the A C line retainer cup and tighten the bolt to specification 17 Tighten the EGR tube and flare fitting Tighten the lower retainer nut at the exhaust manifold 18 Install the canister purge line to the fitting 19 Connect the PCV vacuum hose to the bottom of the upper manifold and the PCV closure ho...

Page 898: ...are not used make sure the gasket stays in place 13 Install the six manifold retaining bolts and tighten to 20 28 ft lbs 27 38 Nm 14 Install the canister purge lines PCV hose and vacuum lines to the vacuum tree 15 Install the throttle and speed control if so equipped to the upper intake manifold Connect the TV cable to the throttle body 16 The transaxle TV linkage has to be readjusted after the fu...

Page 899: ...ectrical connectors from the fuel injectors 5 Disengage the electrical connectors from the main wiring harness and throttle position sensor ACT sensor and the air bypass valve 6 Remove the wiring assembly Click to enlarge To install View of the 3 0L EFI injector wiring harness Стр 19 из 31 ELECTRONIC FUEL INJECTION EFI 18 11 2005 http www chiltondiy com content 8687 8687_5_3 html ...

Page 900: ...alent 2 Remove the spring lock coupling For details please refer to the procedure later in this section 3 Disconnect the fuel supply and return lines 4 Disconnect the wiring harness from the fuel injectors 5 Remove the upper intake manifold 6 Remove the two fuel injector manifold retaining bolts 7 Carefully disengage the manifold from the fuel injectors 8 Disconnect the vacuum line from the fuel p...

Page 901: ...tor wiring harness 14 Run the vehicle at idle for two minutes then turn the engine OFF and check for fuel leaks 3 0L Engine Except SHO 1 Disconnect the negative battery cable 2 Relieve the fuel system pressure Remove the air intake throttle body 3 On the 1992 engine the distributor must be raised to allow the crossover tube to clear the distributor housing and lower intake manifold assembly 4 Disc...

Page 902: ...Click to enlarge View of the 3 0L EFI injector wiring harness Стр 22 из 31 ELECTRONIC FUEL INJECTION EFI 18 11 2005 http www chiltondiy com content 8687 8687_5_3 html ...

Page 903: ...ifting while gently rocking from side to side Place removed components in a clean container to keep clean and free of contamination Fuel injector manifold mounting 3 0L engine WARNING Be very careful when handling the fuel injectors and fuel rail to Стр 23 из 31 ELECTRONIC FUEL INJECTION EFI 18 11 2005 http www chiltondiy com content 8687 8687_5_3 html ...

Page 904: ... idle for 2 minutes 21 Using a clean paper towel check for leaks where the injector is installed into the intake manifold 3 8L Engine 1 Disconnect the negative battery cable 2 Remove the fuel cap and release tank pressure Release the fuel system pressure For details please refer to the procedure earlier in this section 3 Remove the upper intake manifold assembly For details please refer to the pro...

Page 905: ... 10 Nm 11 Install the spring lock coupling For details please refer to the procedure later in this section 12 With the injector wiring still disconnected turn the ignition to the RUN position to allow the fuel pump to pressurize the system Using a clean towel check for fuel leaks 13 Connect the fuel injector wiring harness 14 Run the vehicle at idle for two minutes then turn the engine OFF and che...

Page 906: ... lower intake manifold retaining bolts Carefully lift the fuel rail regulator side only off of the injectors to gain access to the regulator retaining screws 6 Remove the three Allen retaining screws from the regulator housing then discard the screws 7 Remove the pressure regulator assembly gasket and O ring Discard the gasket and the O ring If scraping is necessary be careful not to damage the fu...

Page 907: ... rail cups Push the regulator side of the fuel rail down on the injectors then tighten the retaining bolts to 7 ft lbs 10 Nm while holding down the fuel rail 13 Install the vacuum line s to the regulator 14 For the 2 5L engine install the fuel supply manifold shield then tighten the retaining bolts to 15 22 ft lbs 20 30 Nm 15 Connect the negative battery cable Pressure Relief Valve REMOVAL INSTALL...

Page 908: ...e cap to 5 5 inch lbs 0 6 Nm Throttle Position TP Sensor REMOVAL INSTALLATION 1 Disconnect the negative battery cable 2 Disconnect the Throttle Position TP sensor from the wiring harness 3 Unfasten the two retaining screws then remove the throttle position sensor Fuel pressure valve and related components Fuel pressure relief valve location 2 5L EFI engine Стр 28 из 31 ELECTRONIC FUEL INJECTION EF...

Page 909: ...or in this manner may result in excessive idle speeds 5 Secure the sensor to the throttle body using the two retaining screws Tighten the screws to 14 inch lbs 1 5 Nm The Throttle Position TP sensor is NOT adjustable 6 Engage the sensor electrical connector to the wiring harness 7 Connect the negative battery cable Location of the throttle position sensor 3 0L EFI engine Throttle position sensor a...

Page 910: ... idle air bypass valve and gasket If scraping is necessary to clean the mating surfaces be careful not to damage the idle air bypass valve or throttle body gasket surfaces or drop any gasket material or debris into the throttle body Click to enlarge Idle air bypass valve 3 0L except SHO EFI engine Idle air bypass valve location 2 5L EFI engine Стр 30 из 31 ELECTRONIC FUEL INJECTION EFI 18 11 2005 ...

Page 911: ...screws to secure it Tighten the screws to 84 inch lbs 9 5 Nm Click to enlarge 6 Engage the electrical connector to the idle air bypass valve 7 Connect the negative battery cable Chilton Automotive Information Systems 2004 Thomson Delmar Learning Idle air bypass valve mounting and electrical connector location Стр 31 из 31 ELECTRONIC FUEL INJECTION EFI 18 11 2005 http www chiltondiy com content 868...

Page 912: ...stablished by a spring preload applied to the diaphragm Control of the fuel system is maintained through the EEC IV power relay and the EEC IV control unit although electrical power is routed through the fuel pump relay and an inertia switch The fuel pump relay is normally located on a bracket somewhere above the Electronic Control Assembly ECA and the inertia switch is located in the storage comp...

Page 913: ...y bypassing a regulated amount of air around the throttle plate the higher the voltage signal from the control unit the more air is bypassed through the valve In this manner additional air can be added to the fuel mixture without moving the throttle plate At curb idle the valve provides smooth idle for various engine coolant temperatures adjusts for A C load and compensates for transaxle load and ...

Page 914: ...y are fully engaged 6 Tighten the worm gear mounting clamp to 15 25 inch lbs 1 7 2 8 Nm 7 Start the engine and check for leaks Electric Fuel Pump REMOVAL INSTALLATION Except 3 0L Flexible Fuel FF Vehicles 1 Disconnect the negative battery cable 2 Relieve the fuel system pressure For details please refer to the procedure earlier in this section 3 Drain the fuel from the fuel tank by inserting Rotun...

Page 915: ...quivalent then remove the lock ring 8 Remove the fuel pump from the fuel tank and discard the flange gasket Click to enlarge View of the SEFI system fuel pump except 3 0L FF vehicles Стр 4 из 44 SEQUENTIAL ELECTRONIC FUEL INJECTION SEFI 18 11 2005 http www chiltondiy com content 8687 8687_5_4 html ...

Page 916: ...aps 14 Lower the vehicle 15 Install the fuel tank filler pipe 1 Position the fuel tank filler pipe in the body location 2 Connect the hoses with clamps to the fuel tank filler pipe 3 Install the underbody fuel tank filler pipe assembly bolt then tighten the bolt to 36 53 inch lbs 4 6 Nm then lower the vehicle 4 Install the fuel tank filler cap to the tether location then install the three retainin...

Page 917: ...Exploded view of the fuel pump and related components 3 0L Flexible Fuel FF engine Стр 6 из 44 SEQUENTIAL ELECTRONIC FUEL INJECTION SEFI 18 11 2005 http www chiltondiy com content 8687 8687_5_4 html ...

Page 918: ... pipe 1 Open the filler door to remove the three screws securing the fuel tank filler pipe to the pocket Mark the fuel tank filler cap tether location 2 If not done already raise and safely support the vehicle 3 Loosen the filler and vent hose on the fuel tank filler pipe 4 Remove the bolt securing the fuel tank filler pipe assembly to the underbody of the vehicle then remove the fuel tank filler ...

Page 919: ...n line into the fuel tank location slots 11 Apply light pressure to remove the fuel pump Fuel pump locking retainer ring Lift fuel pump upward rotating left while aligning the float wiper arm retainer and return line into the fuel tank location slots Стр 8 из 44 SEQUENTIAL ELECTRONIC FUEL INJECTION SEFI 18 11 2005 http www chiltondiy com content 8687 8687_5_4 html ...

Page 920: ...el tank slot Lift the fuel pump inlet filter then sender arm float through the fuel tank opening Apply slight pressure to remove the fuel pump Lift the float wiper arm through the left hand fuel tank slot and pass the pump motor retaining bracket through the right hand fuel tank slot Стр 9 из 44 SEQUENTIAL ELECTRONIC FUEL INJECTION SEFI 18 11 2005 http www chiltondiy com content 8687 8687_5_4 html...

Page 921: ... connecting the fuel vapor and vent lines electrical connectors and the fuel lines 20 Install the fuel tank in the vehicle then connect the support straps 21 Install the fuel filler pipe 1 Position the fuel tank filler pipe in the body location 2 Connect the hoses with clamps to the fuel tank filler pipe 3 Install the underbody fuel tank filler pipe assembly bolt then tighten the bolt to 36 53 inc...

Page 922: ...connect the negative battery cable Loosen the air cleaner tube retaining clamps 2 Disconnect the crankcase ventilation tube and aspirator hoses from the air cleaner outlet tube then remove the air cleaner outlet tube 3 Remove the idle speed control solenoid shield 4 Remove the accelerator cable retaining bolt then disconnect the accelerator cable from the throttle body lever 5 Remove the two accel...

Page 923: ...pper gasket Click to enlarge To install 13 Clean and inspect all gasket surfaces When cleaning aluminum parts be careful Throttle body assembly 3 0L SEFI engine except SHO and FF Стр 12 из 44 SEQUENTIAL ELECTRONIC FUEL INJECTION SEFI 18 11 2005 http www chiltondiy com content 8687 8687_5_4 html ...

Page 924: ...amp to 12 22 inch lbs 1 4 2 5 Nm Connect the crankcase tube and the aspirator hose 24 Connect the negative battery cable Start the engine and check for vacuum leaks The Throttle Valve TV cable must be adjusted if the throttle body is removed for any reason and if the throttle plate idle adjustment screw position is changed 25 Adjust the TV cable as follows 1 Connect the TV cable eye to the transax...

Page 925: ...the idle air control valve 6 Remove the accelerator cable retaining bolts then disconnect the accelerator cable from the throttle body 7 Remove the two accelerator cable bracket retaining bolts from the side of the throttle body then remove the bracket 8 Tag and disconnect the vacuum hoses attached to the intake manifold vacuum outlet fitting and cap and the EGR valve 9 Disconnect the differential...

Page 926: ...ottle body with a new one reuse the original intake manifold vacuum outlet fitting and cap EGR valve and EGR pressure sensor with the new throttle body Throttle body assembly 3 0L Flexible Fuel FF engine Стр 15 из 44 SEQUENTIAL ELECTRONIC FUEL INJECTION SEFI 18 11 2005 http www chiltondiy com content 8687 8687_5_4 html ...

Page 927: ...the throttle position sensor EGR pressure sensor and intake air temperature sensor 25 Install the crankcase ventilation tube to the throttle body 26 Install the accelerator cable bracket to the side of the throttle body then tighten the retaining bolts to 13 ft lbs 17 Nm 27 Connect the accelerator cable to the throttle body lever Install the accelerator cable retaining bolt and tighten to 13 inch ...

Page 928: ... and accelerator cables 4 Disconnect the fuel charging wiring connectors at the throttle position TP sensor and the idle air control valve 5 Carefully relieve the cooling system pressure by releasing the pressure at the radiator cap then remove the water bypass hoses 6 Disconnect the crankcase ventilation tubes 7 Remove the throttle body retaining bolts and nuts then remove the throttle body from ...

Page 929: ...FF several times without starting the engine to pressurize the fuel system 17 Start the engine and run it until the engine reaches normal operating temperatures then check for coolant leaks Check the coolant level and add if necessary 3 8L Engine 1 Disconnect the negative battery cable 2 Remove the fuel tank filler cap to relieve the fuel tank pressure then properly relieve the fuel system pressur...

Page 930: ... tank filler cap at the fuel tank 11 Connect the negative battery cable then check all of the connections at the fuel injection supply manifold fuel injectors push connect fittings etc to make sure they are all connected fastened securely 12 Turn the ignition switch ON and OFF several times without starting the engine to pressurize the fuel system Fuel Charging Assembly REMOVAL INSTALLATION The fu...

Page 931: ...hrottle body assembly To install 12 Clean and inspect the manifold mounting surfaces 13 Position new intake manifold gaskets and install the manifold assembly onto the cylinder heads 14 Install the 12 intake to head attaching bolts and tighten to 11 17 ft lbs 15 23 Nm 15 Install the intake manifold support brackets and coolant hose bracket 16 Connect all the coolant and vacuum hoses 17 Connect the...

Page 932: ...ing the fuel injector from side to side 6 Inspect the fuel injector O rings there are two per injector for signs of damage and or deterioration and replace as necessary 7 Inspect the fuel injector end cap body and washer for signs of dirt and or deterioration and replace as necessary CAUTION The fuel system is under high pressure Use care when servicing the fuel system or personal injury may occur...

Page 933: ...eve the fuel system pressure 3 Remove the intake manifold as follows 1 Properly drain the cooling system into a suitable container 2 Remove the intake air tube from the throttle body and MAP sensor Disconnect the throttle cables 3 Disengage the electrical connectors at the TP sensor air bypass valve vacuum switching valve and DIS module 4 Disconnect the coolant bypass hoses and vacuum lines 5 Disc...

Page 934: ...injectors into position 10 Install the fuel injection supply manifold rail making sure the injectors seat properly in the cylinder head 11 Install the fuel injection supply manifold rail retaining bolts then tighten the bolts to 11 17 ft lbs 15 23 Nm 12 Engage the electrical connectors at the fuel injectors 13 Install the intake manifold by reversing the removal procedure 14 Install the fuel tank ...

Page 935: ...valve to the upper intake manifold then remove the EGR valve and EGR transducer as an assembly 7 Remove the 2 canister purge lines from the fittings on the throttle body then remove the 6 upper intake manifold retaining bolts 8 Remove 2 retaining bolts on the front and rear edges of the upper intake manifold where the manifold support brackets are located 9 Remove the nut retaining the alternator ...

Page 936: ...gnment mark on the base of the distributor and the intake manifold 2 Remove the hold down clamp then lift the distributor enough to allow the fuel injection supply manifold to clear the distributor and intake manifold 4 Disconnect the fuel supply and return lines 5 Carefully disconnect the fuel charging wiring from the fuel injectors 6 Disconnect the fuel charging wiring from the fuel pressure reg...

Page 937: ... swollen Allow them to dry out first 11 Using clean engine oil lubricate the O rings then install two on each injector 12 Make sure that the cups are clean and do not have any dirt or contamination 13 Install the fuel injectors in the fuel injection supply manifold using a light twisting pushing motion Fuel injection supply manifold 3 0L SEFI engine except SHO Стр 26 из 44 SEQUENTIAL ELECTRONIC FU...

Page 938: ...the fuel charging wiring to the fuel injectors 21 Connect the vacuum line to the fuel injectors 22 Install the throttle body For details please refer to the procedure located earlier in this section 23 Start the engine and allow it to idle then check for fuel leaks and service as necessary 3 0L and 3 2L SHO Engines 1 Disconnect the negative battery cable 2 Remove the fuel tank filler cap to releas...

Page 939: ...is section 10 Install the intake manifold For details regarding this procedure please refer to the intake manifold installation in Section 3 of this manual 11 Connect the vacuum lines then fasten the remaining fuel charging wiring connectors 12 Install the cap on the fuel tank Fuel injection supply manifold 3 0 3 2L SHO engines WARNING ALWAYS use new gaskets when assembling the fuel injection supp...

Page 940: ...ection 3 of this manual 4 Remove the spring lock coupling fittings from the fuel inlet and return fittings For details please refer to the procedure located later in this section 5 Using Spring Lock Coupling Disconnect Tool D87L 9280 A 3 8 in or D87L 9280 B 1 2 in or equivalent disconnect the inlet and outlet fuel lines from the fuel injection supply manifold 6 Remove the four fuel injection suppl...

Page 941: ...jection supply manifold down install the retaining bolts Tighten the fuel injection supply manifold retaining bolts to the lower intake manifold to 6 8 inch lbs 8 11 Nm Tighten the fuel pressure regulator bracket retaining bolt to cylinder head to 15 22 ft lbs 20 30 Nm 10 Install the spring lock coupling as described later in this section Fuel injection supply manifold and related components 3 8L ...

Page 942: ...on supply manifold for this purpose For more details please refer to the fuel system relief procedure located earlier in this section 4 Remove the vacuum line at the fuel pressure regulator 5 Remove the two fuel injection supply manifold to intake manifold retaining bolts Carefully lift the fuel injection supply manifold off of the fuel injectors to get to the fuel pressure regulator retaining scr...

Page 943: ...ssary be careful not to damage the fuel pressure regulator or fuel injection supply manifold sealing surfaces 9 Install the new fuel pressure regulator return seal and O rings on the fuel pressure regulator Cross sectional view of a fuel pressure regulator 3 0L SEFI engine except SHO Стр 32 из 44 SEQUENTIAL ELECTRONIC FUEL INJECTION SEFI 18 11 2005 http www chiltondiy com content 8687 8687_5_4 htm...

Page 944: ... system pressure There is a pressure relieve valve located on the fuel injection supply manifold for this purpose For details please refer to the procedure located earlier in this section 3 Disconnect the vacuum hose at the pressure regulator 4 Remove the fuel pressure regulator from the fuel return lines and fuel injection supply manifold then discard the sealing gaskets To install 5 Install the ...

Page 945: ...ting surfaces of the fuel pressure regulator and the fuel injection supply manifold are clean If scraping is necessary be careful not to damage the regulator or manifold Cross sectional view of a fuel pressure regulator 3 8L SEFI engine Стр 34 из 44 SEQUENTIAL ELECTRONIC FUEL INJECTION SEFI 18 11 2005 http www chiltondiy com content 8687 8687_5_4 html ...

Page 946: ...ned connected securely 12 Turn the ignition switch ON and OFF without starting the engine and check for fuel leaks Idle Air Control IAC Bypass Valve REMOVAL INSTALLATION 3 0L Except SHO and 3 8L Engine 1 Disconnect the negative battery cable Properly relieve the fuel system pressure as required Click to enlarge 2 Disengage the idle air control bypass valve assembly electrical connector from the wi...

Page 947: ...e using the retaining screws Tighten the screws to 84 inch lbs 9 5 Nm Click to enlarge 6 Engage the air bypass valve electrical connector to the wiring harness 7 Connect the negative battery cable 3 0L and 3 2L SHO Engines 1 Disconnect the negative battery cable Properly relieve the fuel system pressure as required Idle Air Control IAC valve 3 0L engine except SHO Idle Air Control IAC valve 3 8L e...

Page 948: ...f scraping is necessary be careful not to damage the IAC valve or throttle body gasket surfaces Also do not allow gasket material to drop into the throttle body 5 Install the gasket on the throttle body surface Mount the air bypass valve to its mounting 6 Tighten the retaining bolts to 63 97 inch lbs 7 11 Nm 7 Engage the IAC valve electrical connector to the wiring harness 8 Connect the negative b...

Page 949: ...se the fuel system pressure at the fuel pressure relief valve on the fuel injection supply manifold using EFI CFI Fuel Pressure Gauge T80L 9974 B or equivalent 3 Using an open end wrench or a suitable deep well socket remove the fuel pressure relief valve Click to enlarge Fuel pressure relief valve location 3 0L SEFI engine except SHO Стр 38 из 44 SEQUENTIAL ELECTRONIC FUEL INJECTION SEFI 18 11 20...

Page 950: ...Click to enlarge Location of the fuel pressure relief valve 3 0L and 3 2L SHO engines Стр 39 из 44 SEQUENTIAL ELECTRONIC FUEL INJECTION SEFI 18 11 2005 http www chiltondiy com content 8687 8687_5_4 html ...

Page 951: ... TP Sensor REMOVAL INSTALLATION 3 0L 3 0L SHO and 3 2L SHO Engines 1 Disconnect the negative battery cable 2 Disconnect the throttle position TP sensor from the fuel charging wiring 3 Remove the two throttle position TP sensor retaining screw then remove the sensor Fuel pressure relief valve location 3 8L SEFI engine Стр 40 из 44 SEQUENTIAL ELECTRONIC FUEL INJECTION SEFI 18 11 2005 http www chilto...

Page 952: ...sor clockwise to the installed position only Failure to install the TP sensor in this way may result in excessive idle speeds Throttle position sensor 3 0L SEFI engine except SHO Throttle position sensor 3 0L and 3 2L SHO SEFI engines Стр 41 из 44 SEQUENTIAL ELECTRONIC FUEL INJECTION SEFI 18 11 2005 http www chiltondiy com content 8687 8687_5_4 html ...

Page 953: ...the negative battery cable 3 8L Engine 1 Disconnect the negative battery cable 2 Disconnect the TP sensor from the engine control sensor wiring 3 Remove the two throttle position sensor retaining screws then remove sensor To install Click to enlarge 4 Install the TP sensor then secure using the two retaining screws Tighten the screws to 25 34 inch lbs 2 8 3 8 Nm 5 Connect the TP sensor to the engi...

Page 954: ...the vehicle 10 Loosen the fuel mixer retainer clamp and disconnect the fuel mixer outlet tube from the flexible fuel sensor using Fuel Line Disconnect Tool 3 8 T90T 9550 C 11 Remove the flexible fuel sensor retaining bolts then remove the sensor from the bracket Click to enlarge To install 12 Install the flexible fuel sensor to the bracket then secure using the retaining bolts Tighten the bolts to...

Page 955: ...n supply manifold fuel injectors push connect fittings etc to make sure they are all properly connected fastened 21 Turn the ignition switch ON and OFF several times without starting the engine to pressurize the fuel system then check for fuel leaks Chilton Automotive Information Systems 2004 Thomson Delmar Learning Стр 44 из 44 SEQUENTIAL ELECTRONIC FUEL INJECTION SEFI 18 11 2005 http www chilton...

Page 956: ...the fuel system pressure For details please refer to the procedure covered in the appropriate fuel system in this section 2 Using your hand only remove the retaining clip from the spring lock coupling Do NOT use any sharp tool or screwdriver because it may damage the coupling 3 Twist the fitting to free it from any adhesion at the O ring seals 4 Fit Spring Lock Coupling Disconnect Tool D87L 9280 A...

Page 957: ...l vehicles except flexible fuel vehicles lubricate the male fitting O rings and the inside of the female fitting with clean engine oil For flexible fuel vehicles lubricate with oil that has an API designation of Multi Fuel Vehicles MFV Use only the specified brown O rings because they are made of a special material The use of other types of O rings may cause the connection to leak during engine op...

Page 958: ...l clip Each type of fitting requires different procedures for service Push connect fitting disassembly must be accomplished prior to fuel component removal filter pump etc except for the fuel tank where removal is necessary for access to the push connect fittings REMOVAL INSTALLATION Hairpin Clip Fittings 5 16 in 1 Inspect the internal portion of the fitting for dirt accumulation If more than a li...

Page 959: ...ard Pull on the fitting to ensure it is fully engaged Duck Bill Clip Fittings The fitting consists of a body spacers O rings and a duck bill retaining clip The clip maintains the fitting to the steel tube juncture When disassembly is required for service be sure to use the appropriate following method 1 4 IN FITTINGS To disengage the tube from the fitting align the slot on the Push Connect Disasse...

Page 960: ...ften one side of the clip will disengage before the other It is necessary to disengage the clip from both openings Pull the fitting off the tube Only moderate effort is required if the retaining clip has been properly disengaged Use hands only The retaining clip will remain on the tube Disengage the clip from the tube bead and remove Replace the retaining clip if it appears to be damaged The clip ...

Page 961: ...ining clip serrated edges on the duck bill portion into one of the window openings Push on the other side until the clip snaps into place Lubricate the O rings with clean engine oil and slide the fuel line back into the clip Chilton Automotive Information Systems 2004 Thomson Delmar Learning Стр 6 из 6 FUEL LINE FITTINGS 18 11 2005 http www chiltondiy com content 8687 8687_5_5 html ...

Page 962: ... different hose orientations can overcome this situation 4 Raise and safely support the vehicle 5 Loosen the filler pipe and vent hose clamps at the tank and remove the hoses from the tank 6 Place a safety support under the fuel tank and remove the bolts from the rear of the fuel tank straps The straps are hinged at the front and will swing aside 7 Partially remove the tank Remove the hairpin clip...

Page 963: ...ompletely on the fuel tank top 3 Make all of the required fuel line fuel return line vapor vent and electrical connections which will be inaccessible after the fuel tank is installed Route lines through the clip on the fuel tank 10 Raise the fuel tank into proper position in the vehicle 11 Bring the fuel tank straps around the tank and start the retaining bolt Align the Common fuel tank location a...

Page 964: ...0012 or equivalent into the fuel tank through the fuel tank filler pipe then remove the fuel tank with Rotunda Fuel Storage Tanker 034 00002 or equivalent 4 Remove the fuel tank filler pipe 1 Open the filler door to remove the three screws securing the fuel tank filler pipe to the pocket Mark the fuel tank filler cap tether location 2 Raise and safely support the vehicle 3 Loosen the filler and ve...

Page 965: ...nding unit pump mounting flange and fuel tank mating surfaces and seal ring groove View of the fuel tank sending unit and pump assembly except 3 0L FF vehicles Стр 4 из 11 FUEL TANK 18 11 2005 http www chiltondiy com content 8687 8687_5_6 html ...

Page 966: ...tall the fuel tank filler pipe 1 Position the fuel tank filler pipe in the body location 2 Connect the hoses with clamps to the fuel tank filler pipe 3 Install the underbody fuel tank filler pipe assembly bolt then tighten the bolt to 36 53 inch lbs 4 6 Nm then lower the vehicle 4 Install the fuel tank filler cap to the tether location then install the three retaining screws 16 Fill the tank with ...

Page 967: ...Exploded view of the fuel tank sending unit pump and related components 3 0L Flexible Стр 6 из 11 FUEL TANK 18 11 2005 http www chiltondiy com content 8687 8687_5_6 html ...

Page 968: ...l filler pipe 1 Open the filler door to remove the three screws securing the fuel tank filler pipe to the pocket Mark the fuel tank filler cap tether location 2 If not done already raise and safely support the vehicle 3 Loosen the filler and vent hose on the fuel tank filler pipe 4 Remove the bolt securing the fuel tank filler pipe assembly to the underbody of the vehicle then remove the fuel tank...

Page 969: ... and return line into the fuel tank location slots 11 Apply light pressure to remove the fuel pump Fuel pump locking retainer ring Lift the fuel pump upward and rotate to the left while aligning the float wiper arm retainer and return line with the fuel tank location slots Стр 8 из 11 FUEL TANK 18 11 2005 http www chiltondiy com content 8687 8687_5_6 html ...

Page 970: ...n line in the fuel tank slot Lift the fuel pump inlet filter then sender arm float through the fuel tank opening Apply slight pressure to remove the fuel pump Lift the float wiper arm through the left hand fuel tank slot and pass the pump motor retaining bracket through the right hand fuel tank slot Стр 9 из 11 FUEL TANK 18 11 2005 http www chiltondiy com content 8687 8687_5_6 html ...

Page 971: ...m the bench to the vehicle then support the fuel tank while connecting the fuel vapor and vent lines electrical connectors and the fuel lines 20 Install the fuel tank in the vehicle then connect the support straps 21 Install the fuel filler pipe 1 Position the fuel tank filler pipe in the body location 2 Connect the hoses with clamps to the fuel tank filler pipe 3 Install the underbody fuel tank f...

Page 972: ...nto the fuel tank through the fuel tank filler pipe 23 Transfer the fuel from the Rotunda Fuel Storage Tanker 034 00002 or equivalent to the fuel tank 24 Connect the negative battery cable then check for fuel leaks Chilton Automotive Information Systems 2004 Thomson Delmar Learning Стр 11 из 11 FUEL TANK 18 11 2005 http www chiltondiy com content 8687 8687_5_6 html ...

Page 973: ...SPECIFICATION CHARTS Click to enlarge Click to enlarge Torque Specifications Torque Specifications Стр 1 из 2 SPECIFICATION CHARTS 18 11 2005 http www chiltondiy com content 8687 8687_5_7 html ...

Page 974: ...Chilton Automotive Information Systems 2004 Thomson Delmar Learning Стр 2 из 2 SPECIFICATION CHARTS 18 11 2005 http www chiltondiy com content 8687 8687_5_7 html ...

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Page 1033: ...ing with computerized automotive control systems Along with a general explanation of the various types of test equipment available to aid in servicing modern electronic automotive systems basic repair techniques for wiring harnesses and connectors are given Read the basic information before attempting any repairs or testing any computerized system to provide the background of information necessary...

Page 1034: ...ust The complexity of a modern vehicle demands that you approach any problem in a logical organized manner There are certain troubleshooting techniques that are standard 1 Establish when the problem occurs Does the problem appear only under certain conditions Were there any noises odors or other unusual symptoms 2 Isolate the problem area To do this make some simple tests and observations then eli...

Page 1035: ...hard to reach areas it is advisable to have insulated boots over the jumper wire terminals in order to prevent accidental grounding sparks and possible fire especially when testing fuel system components Jumper wires are used primarily to locate open electrical circuits on either the ground side of the circuit or on the hot side If an electrical component fails to operate connect the jumper wire b...

Page 1036: ...ct that 12 volts or any particular amount ofvoltage is present it only detects that some voltage is present It isadvisable before using the test light to touch its terminals across the batteryposts to make sure the light is operating properly Self Powered Test Light The self powered test light usually contains a 1 5 volt penlight battery One type of self powered test light is similar in design to ...

Page 1037: ...ery is strong enough for testing Never use a self poweredtest light to perform checks for opens or shorts when power is applied to theelectrical system under test The 12 volt vehicle power will quickly burn outthe 1 5 volt light bulb in the test light Voltmeter A voltmeter is used to measure voltage at any point in a circuit or to measure the voltage drop across any part of a circuit It can also b...

Page 1038: ...y s available voltage under load will decrease more severely For this reason it is important that the battery be fully charged during all testing procedures to avoid errors in diagnosis and incorrect test results Voltage Drop When current flows through a resistance the voltage beyond the resistance is reduced the larger the current the greater the reduction in voltage When no current is flowing th...

Page 1039: ...e maximum allowable voltage drops are FUSE PANEL 0 7 volts IGNITION SWITCH 0 5 volts HEADLIGHT SWITCH 0 7 volts IGNITION COIL 0 5 volts ANY OTHER LOAD 1 3 volts Voltage drops are all measured while a load is operating without currentflow there will be no voltage drop Ohmmeter The ohmmeter is designed to read resistance ohms in a circuit or component Although there are several different styles of o...

Page 1040: ...n its lowest range and touch the two ohmmeter leads together Turn the calibration knob until the meter needle is exactly on zero All analog needle type ohmmeters must be zeroed before use but mostdigital ohmmeter models are automatically calibrated when the switch is turnedon Self calibrating digital ohmmeters do not have an adjusting knob but it sa good idea to check for a zero readout before use...

Page 1041: ... reading Multimeters Different combinations of test meters can be built into a single unit designed for specific tests Some of the more common combination test devices are known as Volt Amp testers Tach Dwell meters or Digital Multimeters The Volt Amp tester is used for charging system starting system or battery tests and consists of a voltmeter an ammeter and a variable resistance carbon pile The...

Page 1042: ...sted to make sure the problem has been corrected The biggest advantage these special testers have is their relatively easy hookups that minimize or eliminate the chances of making the wrong connections and getting false voltage readings or damaging the computer accidentally It should be remembered that these testers check voltage levels incircuits they don t detect mechanical problems or failed co...

Page 1043: ...imited such as behind instrument panels WIRE GAUGE Since computer controlled automotive electrical systems are very sensitive to changes in resistance the selection of properly sized wires is critical when systems are repaired The wire gauge number is an expression of the cross section area of the conductor The most common system for expressing wire size is the American Wire Gauge AWG system Wire ...

Page 1044: ...her The most popular and preferred method of soldering is with an electric soldering gun or iron Soldering irons are available in many sizes and wattage ratings Irons with higher wattage ratings deliver higher temperatures and recover lost heat faster A small soldering iron rated for no more than 50 watts is recommended especially on electrical systems where excess heat can damage the components b...

Page 1045: ...ts because these require more heat to melt the solder If the soldering tip overheats the solder coating on the face of the tip burns up it should be retinned Once the soldering is completed let the soldered joint stand until cool Tape and seal all soldered wire splices after the repair has cooled Wire Harness and Connectors The on board computer wire harness electrically connects the control unit ...

Page 1046: ... with replacement connector and terminal packages Some wire harnesses have mounting indicators usually pieces of colored tape to mark where the harness is to be secured In making wiring repairs it s important that you always replace damaged wires with wires that are the same gauge as the wire being replaced The heavier the wire the smaller the gauge number Wires are color coded to aid in identific...

Page 1047: ... 18 and 22 in Hg 60 78 74 29 kPa at sea level To test engine vacuum the gauge must be connected to a source of manifold vacuum Many engines have a plug in the intake manifold which can be removed and replaced with an adapter fitting Connect the vacuum gauge to the fitting with a suitable rubber hose or if no manifold plug is available connect the vacuum gauge to any device using manifold vacuum su...

Page 1048: ...Chilton Automotive Information Systems 2004 Thomson Delmar Learning Стр 16 из 16 UNDERSTANDING AND TROUBLESHOOTING ELECTRICAL SYSTEMS 18 11 2005 http www chiltondiy com content 8687 8687_6_1 html ...

Page 1049: ...carry the inflator module by the wires or connector on the underside of the module In case of accidental deployment the bag will then deploy with minimal chance of injury z When placing a live inflator on a bench or other surface always face the bag and trim cover up away from the surface DISARMING THE SYSTEM 1990 91 Vehicles 1 Disconnect the negative battery cable 2 Open the glove compartment the...

Page 1050: ...ble 1992 95 Vehicles For this procedure you will need Rotunda Air Bag Simulator 105 00008 or equivalent for 1992 vehicles 105 00010 or equivalent for 1993 95 vehicles Air bag module mounting 1990 91 vehicles Connecting a jumper wire to the air bag terminals on the clockspring 1990 91 vehicles Стр 2 из 7 SUPPLEMENTAL RESTRAINT SYSTEM AIR BAG 18 11 2005 http www chiltondiy com content 8687 8687_6_2 ...

Page 1051: ...to the steering wheel Click to enlarge 4 Disengage the driver air bag electrical connector then attach Air Bag Simulator Tool 105 00008 105 00010 or equivalent to the vehicle harness connector Rotunda Air Bag Simulator 105 00010 shown 105 00008 similar Driver air bag module mounting 1995 vehicle shown Стр 3 из 7 SUPPLEMENTAL RESTRAINT SYSTEM AIR BAG 18 11 2005 http www chiltondiy com content 8687 ...

Page 1052: ...the side of the air bag cover 6 Disengage the electrical connector from the left side of the air bag then remove the air bag module 7 Attach Air Bag Simulator Tool 105 00008 105 00010 or equivalent to the vehicle harness connector Connecting the air bag simulator tool CAUTION When carrying a live air bag make sure the bag and trim cover are pointed away from the body In the unlikely event of an ac...

Page 1053: ...Passenger air bag mounting 1995 vehicle shown Стр 5 из 7 SUPPLEMENTAL RESTRAINT SYSTEM AIR BAG 18 11 2005 http www chiltondiy com content 8687 8687_6_2 html ...

Page 1054: ...en secure with the fasteners Tighten to 8 10 ft lbs 10 2 13 8 Nm 5 If equipped with a passenger side air bag remove the air bag simulator from the harness the proceed as follows 1 Engage the electrical connector to the passenger side air bag module then position the passenger side air bag module in the instrument panel 2 Install the four upper retaining screws then tighten the screws to 11 16 inch...

Page 1055: ...Chilton Automotive Information Systems 2004 Thomson Delmar Learning Стр 7 из 7 SUPPLEMENTAL RESTRAINT SYSTEM AIR BAG 18 11 2005 http www chiltondiy com content 8687 8687_6_2 html ...

Page 1056: ... screw attaching the recirculation duct support bracket to the instrument panel cowl 4 Remove the vacuum connection to the recirculation door vacuum motor Remove the screws attaching the recirculation duct to the heater assembly Release the glove compartment door retainers then lower the door Стр 1 из 19 HEATER 18 11 2005 http www chiltondiy com content 8687 8687_6_3 html ...

Page 1057: ...se 6 Disconnect the blower motor electrical lead Remove the blower motor wheel clip and remove the blower motor wheel Remove the screws attaching the recirculation duct to the heater assembly then remove the duct Remove the blower motor wheel clip Стр 2 из 19 HEATER 18 11 2005 http www chiltondiy com content 8687 8687_6_3 html ...

Page 1058: ...tor mounting plate screws and remove the blower motor from the evaporator case Remove the blower motor wheel Disengage the electrical connector Стр 3 из 19 HEATER 18 11 2005 http www chiltondiy com content 8687 8687_6_3 html ...

Page 1059: ...Remove the blower motor retaining screws Remove the blower motor assembly from the vehicle Стр 4 из 19 HEATER 18 11 2005 http www chiltondiy com content 8687 8687_6_3 html ...

Page 1060: ... Connect the blower motor electrical lead to the wiring harness 13 Install the recirculation duct using the retaining screws 14 Install the glove compartment door to its original closed position then connect the negative battery cable Blower Motor Resistor REMOVAL INSTALLATION 1 Disconnect the negative battery cable 2 Open the glove compartment door and release the glove compartment retainers so t...

Page 1061: ...edure which requires servicing the air conditioning system In some states it is illegal to perform repairs involving refrigerant unless the work is done by a certified technician Blower motor resistor assembly 1995 vehicle shown CAUTION When draining the coolant keep in mind that cats and dogs are attracted by the ethylene glycol antifreeze and are quite likely to drink any that is left in an unco...

Page 1062: ...he driver 7 Disconnect the speedometer cable by reaching up under the instrument panel and pressing on the flat surface of the plastic connector The panel can be removed with the cluster installed 8 Release the glove compartment assembly by depressing the side of the glove compartment bin and swinging the door bin down 9 Using the steering column cluster and glove compartment openings and by reach...

Page 1063: ...anel brace retaining bolt from under the radio area 9 Remove the sound insulator under the glove compartment by removing the two push nuts that secure the insulator to the studs on the climate control case 10 Disconnect the wires of the main wire loom in the engine compartment Disengage the rubber grommet from the dash panel then feed the wiring through the hole in the dash panel into the passenge...

Page 1064: ...e heater case Lift the heater core and seals from the heater case To install 11 Transfer the three foam core seals to the new heater core Install the heater core and seals into the heater case 12 Position the heater case access cover on the case then install the four retaining screws 13 Install the seal on the heater core tubes then install the vacuum source line through the seal 14 Position the h...

Page 1065: ...Click to enlarge Location of the vacuum source line Стр 10 из 19 HEATER 18 11 2005 http www chiltondiy com content 8687 8687_6_3 html ...

Page 1066: ...on CFC chlorofluorocarbon refrigerant R 134a This new refrigerant is not available commercially in most areas as it is usually illegal for do it yourselfers to service a vehicle with this refrigerant If you have a Taurus or Sable that uses the new refrigerant R 134a the vehicle should be taken to a qualified technician for any repair requiring A C system service Стр 11 из 19 HEATER 18 11 2005 http...

Page 1067: ...ment panel and pressing on the flat surface of the plastic connector The panel can be removed with the cluster installed 8 Release the glove compartment assembly by depressing the side of the glove compartment bin and swinging the door bin down 9 Using the steering column cluster and glove compartment openings and by reaching under the instrument panel tag and disconnect all electrical connections...

Page 1068: ...nnect the wires of the main wire loom in the engine compartment Disengage the rubber grommet from the dash panel then feed the wiring through the hole in the dash panel into the passenger compartment 10 Remove the right and left cowl side trim panels Disconnect the wires from the instrument panel at the right and left cowl sides 11 Remove one screw from each the left and right side retaining the i...

Page 1069: ...end door actuator to the evaporator case and remove the actuator 13 Remove the four heater core access cover attaching screws and remove the access cover and seal from the evaporator case Lift the heater core and seals from the evaporator case To install 14 Transfer the seal to the new heater core then install the heater core into the evaporator case 15 Position the heater core access cover on the...

Page 1070: ...d to compressor failure refrigerant oil sludge and or poor air conditioning system performance 24 Check the system for proper operation Control Cables REMOVAL INSTALLATION 1 Disconnect the negative battery cable 2 Remove the instrument cluster opening finish panel 3 Rotate the temperature control knob to the COOL position 4 Disconnect the temperature control knob cable housing end retainer from th...

Page 1071: ...rument panel 7 Disconnect the cable housing end retainer from the control assembly and the cable wire from the temperature control lever arm 8 Remove the cable assembly from the vehicle through the control assembly opening in the instrument panel being careful not to hook or damage the wiring or other cables Removing the cable using the specified tool Стр 16 из 19 HEATER 18 11 2005 http www chilto...

Page 1072: ...nect the cable and retainer to the control assembly 13 Position the control assembly to the instrument panel opening then install the retaining screws 14 Slide the cable housing and retainer into the heater case cable bracket then push to secure the cable housing to the bracket 15 Connect the self adjusting clip at the temperature cable to the temperature door crank arm 16 Connect the negative bat...

Page 1073: ...l assembly by depressing the latches at the top of the connectors and pulling 6 Disconnect the vacuum harness and temperature control cable from the control assembly Discard the used pushnut from the vacuum harness Click to enlarge To install 7 Connect the temperature cable to the control assembly 8 Connect the wire connectors and vacuum harness to the control assembly using new pushnuts Push on t...

Page 1074: ...ent panel For details please refer to the procedure located earlier in this section 10 Connect the negative battery cable then check the switch for proper operation Vacuum Selector Switch REMOVAL INSTALLATION 1 Disconnect the negative battery cable 2 Remove the control assembly from the instrument panel For details please refer to the procedure located earlier in this section 3 Remove the knob fro...

Page 1075: ...10 oz 300 ml of refrigerant oil Before replacement compressor installation drain 4 oz 120 ml of refrigerant oil from the compressor This will maintain the total system oil charge within the specified limits New service replacement 10P15F compressors contain 8 oz 240 ml of refrigerant oil and new service replacement FX15 compressors contain 7 oz 207 ml of refrigerant oil Prior to installing either ...

Page 1076: ...mpressor 8 Install the compressor and manifold and tube assembly on the air conditioning mounting bracket 9 Using new O rings lubricated with clean refrigerant oil connect the suction line to the compressor manifold and tube assembly Attach the discharge line to the air conditioning condenser 10 Connect the clutch wires to the field coil connector 11 Install the drive belt 12 Leak test evacuate an...

Page 1077: ...netic clutch wire at the field coil connector on the compressor 7 Remove the top two compressor mounting bolts 8 Raise and safely support the vehicle 9 Loosen and remove the compressor drive belt 10 Disconnect the HEGO sensor wire connector and remove the air conditioning muffler supporting strap bolt from the sub frame 11 Disconnect the air conditioning system hose from the condenser and suction ...

Page 1078: ...he sub frame and connect the HEGO sensor wire connector 21 Install the compressor drive belt and lower the vehicle 22 Install the radiator and connect the radiator hoses 23 Install the fan and shroud assembly and connect the integrated relay connector 24 Connect the negative battery cable and fill the radiator with the coolant that was saved 25 Leak test evacuate and charge the system according to...

Page 1079: ... screws and washers 6 Connect the refrigerant lines to the condenser assembly using new O rings Perform the spring lock coupling connection procedure 7 Leak test evacuate and charge the refrigerant system following the proper procedures Observe all safety precautions A C condenser core assembly 1995 vehicle shown Стр 5 из 35 AIR CONDITIONER 18 11 2005 http www chiltondiy com content 8687 8687_6_4 ...

Page 1080: ... the refrigerant from the air conditioning system 4 Disconnect the heater hoses from the heater core Plug the heater core tubes 5 Disconnect the vacuum supply hose from the in line vacuum check valve in the engine compartment 6 Disconnect the liquid line and the accumulator from the evaporator core at the dash panel Cap the refrigerant lines and evaporator core to prevent entrance of Exploded view...

Page 1081: ...nnections and aspirator hose from the evaporator case 11 Remove the three nuts attaching the evaporator case to the dash panel in the engine compartment Remove the two screws attaching the support brackets to the cowl top panel 12 Carefully pull the evaporator assembly away from the dash panel and remove the evaporator case from the vehicle Click to enlarge 13 Disconnect and remove the vacuum harn...

Page 1082: ... control remove the screws holding the electronic connector bracket to the recirculation duct 18 For 1995 vehicles if equipped with automatic temperature control remove the After unfastening the six retaining screws remove the recirculation duct from the evaporator case Unfasten the two screws securing the air inlet duct then remove the duct from the case Стр 8 из 35 AIR CONDITIONER 18 11 2005 htt...

Page 1083: ...onnect the aspirator duct Click to enlarge 19 If equipped with automatic temperature control remove the blend door actuator and cold engine lock out switch which is held on by spring tension at the outermost heater core tube For 1995 vehicles equipped with automatic temperature control disengage the blower speed control electrical connector Стр 9 из 35 AIR CONDITIONER 18 11 2005 http www chiltondi...

Page 1084: ... both upright tabs on top of the evaporator case Removing the A C door actuator assembly vehicles equipped with automatic temperature control Drill a 3 16 in hole in both of the upright tabs on top of the evaporator case Стр 10 из 35 AIR CONDITIONER 18 11 2005 http www chiltondiy com content 8687 8687_6_4 html ...

Page 1085: ...cutout cover back from the opening and lift the evaporator core from the case Click to enlarge Using a hot knife small saw blade or other suitable tool carefully cut the top of the evaporator case between the raised outline Стр 11 из 35 AIR CONDITIONER 18 11 2005 http www chiltondiy com content 8687 8687_6_4 html ...

Page 1086: ...stall a spring nut on each of the two upright tabs with two holes drilled in the front flange Make sure the holes in the spring nuts are aligned with the 3 16 in 4 75mm holes drilled in the tab and flange Install and tighten the screw in each spring nut to secure the cutout cover in the closed position After cutting the evaporator case fold the cutout cover back from the opening then lift out the ...

Page 1087: ... against leakage along the cut line After installing and aligning a spring nut on each of the two tabs with the holes drilled into them tighten the screw in each spring nut to secure the cutout cover closed Стр 13 из 35 AIR CONDITIONER 18 11 2005 http www chiltondiy com content 8687 8687_6_4 html ...

Page 1088: ... bracket to the evaporator case 30 Position the evaporator case assembly to the dash panel and cowl top panel at the air inlet opening Install the two screws attaching the support brackets to the top cowl panel 31 Install the three nuts in the engine compartment attaching the evaporator case to the dash panel 32 Connect the vacuum line electrical connections and aspirator hose at the evaporator ca...

Page 1089: ...Control Head 1 Disconnect the negative battery cable 2 Remove the instrument panel finish applique 3 Remove the four screws attaching the control assembly to the instrument panel Pull the control head away from the instrument panel into a position which provides access to the rear connectors 4 Disengage the two harness connectors from the control assembly by depressing the latches at the top of th...

Page 1090: ...s retaining the upper finish panel 2 Pull the lower edge of the upper finish panel away from the instrument panel It is best to grasp the finish panel from the lower left corner and pull the panel away by walking the hands around the panel in a clockwise direction 3 Remove the four Torx head screws retaining the control assembly Pull the control assembly away from the instrument panel into a posit...

Page 1091: ...Disconnect the negative battery cable Remove the control assembly from the instrument panel 2 Remove the fan switch knob from the fan switch Remove the screws attaching the control switch to the instrument panel 3 Disconnect the electrical connector Remove the switch retaining screw Remove the switch 4 Installation is the reverse of the removal procedure Accumulator Drier Refer to Section 1 for ai...

Page 1092: ...ion the accumulator drier on the vehicle and route the suction hose to the compressor 8 Using a new O ring lubricated with clean refrigerant oil connect the accumulator drier inlet tube to the evaporator core outlet 9 Install the screw in the accumulator drier bracket 10 Using a new O ring lubricated with clean refrigerant oil connect the suction hose to the compressor 11 Connect the negative batt...

Page 1093: ... enlarge To install 4 Route the new condenser to evaporator rube and integral A C evaporator core orifice with the protective caps installed Make sure that the correct green O ring seals are installed on the spring lock coupling A C fittings 5 Remove the protective caps then connect the new condenser to evaporator tube into the system using new O ring seals lubricated with clean refrigerant oil Co...

Page 1094: ...ter spring and release the female fitting 4 After the garter spring is expanded pull the fitting apart then remove the tool from the disconnected coupling Click to enlarge To install 5 Check to make sure the garter spring is in the cage of the male fitting If the garter spring is missing install a new spring by pushing it into the cage opening If the garter spring is damaged remove it from the cag...

Page 1095: ... any O ring seal other than the specified type may allow the connection to leak intermittently during operation 9 Lubricate the male fitting green O ring seals and the inside of the female fitting with clean refrigerant oil 10 Install a plastic indicator ring into the cage opening if the indicator ring is to be used 11 Fit the female fitting to the male fitting then push into the garter spring sna...

Page 1096: ...e control assembly 3 Disconnect the temperature cable from the plenum temperature blend door crank arm and cable mounting bracket Click to enlarge To install Removing and installing the control cable end attachment Стр 22 из 35 AIR CONDITIONER 18 11 2005 http www chiltondiy com content 8687 8687_6_4 html ...

Page 1097: ... adjusting clip down the control wire away from the loop approximately 1 in 25 4mm 3 Install the cable assembly 4 Rotate the temperature selector knob to the clockwise red position marked on the control assembly face to position the self adjusting clip 5 Check for proper control operation After Cable Installation 1 Move the selector knob clockwise to the COOL position 2 Hold the crank arm firmly i...

Page 1098: ...ALLATION 1 Disconnect the negative battery cable 2 Disconnect the wire harness connector from the pressure switch Unscrew the A C cycling switch from the top of the suction accumulator drier A C cycling clutch switch Стр 24 из 35 AIR CONDITIONER 18 11 2005 http www chiltondiy com content 8687 8687_6_4 html ...

Page 1099: ... located in the condenser to evaporator tube cannot be serviced as a component of the line If replacement is necessary use the procedure for refrigerant line removal and installation located earlier in this section An orifice tube replacement service kit may be used for an optional service procedure The procedure for installation and removal of the service it are as follows REMOVAL INSTALLATION Fi...

Page 1100: ...emble the orifice tube kit with the orifice tube installed to the liquid line Make sure the flow direction arrow is pointing toward the evaporator end of the liquid line and the taper of each compressor ring is toward the compressor nut The inlet tube will be positioned against the orifice tube tabs when correctly assembled Locating the orifice tube Cut a 21 2 in section from the tube at the orifi...

Page 1101: ...le the liquid line to the vehicle using new O rings lubricated with clean refrigerant oil Use only the specified O rings at the spring lock coupling Exploded view of the A C evaporator orifice tube kit With the nut in a vise tighten each compression nut to the specified torque Стр 27 из 35 AIR CONDITIONER 18 11 2005 http www chiltondiy com content 8687 8687_6_4 html ...

Page 1102: ...olant from the radiator 4 Unscrew the switch body from the fitting in the heater inlet tube Click to enlarge To install 5 Apply sealer to the switch threads and install it into the fitting in the heater tube Tighten to 8 14 ft lbs 11 19 Nm 6 Attach the electrical connector to the top of the switch 7 Refill the radiator with the removed coolant to the proper level 8 Connect the negative battery cab...

Page 1103: ...stem for proper operation In Vehicle Temperature Sensor OPERATION The in vehicle temperature sensor is used in the automatic temperature control systems It contains a thermistor which measures the temperature of the air inside the passenger compartment The sensor is located behind the instrument panel above the glove compartment REMOVAL INSTALLATION 1 Disconnect the negative battery cable 2 Diseng...

Page 1104: ...peaker grille assembly except on 1992 95 vehicles where it is located on the right side upper outer finish panel REMOVAL INSTALLATION 1 Disconnect the negative battery cable 2 Remove the left hand speaker grille assembly except 1992 95 vehicles On 1992 95 vehicles remove the right side upper outer finish panel 3 Remove the sunload sensor assembly from the two mounting studs and disconnect the elec...

Page 1105: ...or stops and allow the door to hang by the hinge 3 Working through the glove compartment opening unfasten the electrical snap lock connector and aspirator hose at the blower motor controller Also disengage the snap lock connector from it s mounting bracket 4 Remove the two screws attaching the blower controller to the evaporator case and remove the controller Do not touch the fins of the controlle...

Page 1106: ...bracket remains in place on the evaporator case To install 5 Insert the blend door actuator horizontally over the actuator bracket on the evaporator case 6 Insert the actuator shaft into the blend door Manually moving the door will help engage the shaft 7 Attach the actuator bracket with the three attaching screws 8 Attach the actuator electrical connector and plastic clamp to the bracket on the e...

Page 1107: ...nction control actuator motor is used on vehicles equipped with automatic temperature control The motor controls the door which directs the flow of air to the defroster ducts instrument panel ducts or floor ducts Two motors are used to perform the control function and they are both located on the plenum REMOVAL INSTALLATION Panel Floor Door Vacuum Motor 1 Disconnect the negative battery cable 2 Re...

Page 1108: ...the Functional Test SELF DIAGNOSTIC TEST The control assembly will detect electrical malfunctions occurring during the self test 4 Make sure the coolant temperature is at least 120 F 49 C 5 To display error codes push the OFF and FLOOR buttons simultaneously and then the AUTOMATIC button within 2 seconds The test may run as long as 20 seconds during which time the display will be blank If the disp...

Page 1109: ... the function buttons through each position with the blower on HI and check the location s of the discharge air The airflow schematic and vacuum control chart shows the vacuum motors applied for each function selection along with an airflow diagram of the system The airflow diagram shows the position of each door when vacuum is applied and their no vacuum position With this chart airflow for each ...

Page 1110: ...tch is depressed To decrease the set speed the vehicle speed may by reduced by applying the brake or clutch pedal and then resetting the speed using the foregoing method or by depressing the COAST switch When the vehicle has slowed to the desired speed the COAST switch is released and the new speed is set automatically If the vehicle speed is reduced below approximately 25 35 mph 40 60 km h depend...

Page 1111: ...OVAL INSTALLATION Except 2L SHO 1 Disconnect the negative battery cable 2 Remove the servo assembly For details please refer to the procedure located later in this section 3 Attach the new actuator cable assembly to the servo Click to enlarge Cruise control actuator cable assembly 2 5L engine Стр 2 из 33 CRUISE CONTROL 18 11 2005 http www chiltondiy com content 8687 8687_6_5 html ...

Page 1112: ...Click to enlarge Cruise control actuator cable assembly 3 0L engine except SHO Стр 3 из 33 CRUISE CONTROL 18 11 2005 http www chiltondiy com content 8687 8687_6_5 html ...

Page 1113: ...Click to enlarge Cruise control actuator cable assembly 3 8L engine Стр 4 из 33 CRUISE CONTROL 18 11 2005 http www chiltondiy com content 8687 8687_6_5 html ...

Page 1114: ...vo assembly For details please refer to the servo procedure located later in this section 5 Connect the negative battery cable Cruise control actuator cable assembly 3 0L SHO engine Стр 5 из 33 CRUISE CONTROL 18 11 2005 http www chiltondiy com content 8687 8687_6_5 html ...

Page 1115: ... by depressing the cap locking arm and rotating the cap counterclockwise 5 Remove the cable slug from the servo pulley Gently pry up the arm slightly with a suitable small prytool and at the same time push the cable slug out of the pulley slot Excessive bending of the arm will cause it to break DO NOT USE servos with damaged or missing locking arms Actuator assembly and related components 3 2L SHO...

Page 1116: ...onto the servo pulley 9 Align the cable cap tabs with slots in the servo housing Insert the cap into the speed control servo and rotate it clockwise until the locking arm engages When removing the slug from the servo pulley gently pry the arm up SLIGHTLY using a suitable tool while pushing the cable slug out of the pulley slot 3 2L SHO Стр 7 из 33 CRUISE CONTROL 18 11 2005 http www chiltondiy com ...

Page 1117: ... that the throttle lever is at idle position after cable installation and adjustment 13 Connect the negative battery cable ADJUSTMENT Except 3 2L SHO 1 Remove speed control cable retaining clip 2 Push speed control cable through adjuster until a slight tension is felt 3 Insert the cable retaining clip and snap into place 3 2L SHO Align the cable cap tabs with the slots in the servo housing then in...

Page 1118: ...age the electrical wiring connector from the slip ring terminal 4 Remove the speed control switch assembly from the horn pad cover by removing the two attaching screws from each switch Click to enlarge To install 5 Install the control switches into the horn pad cover Attach each switch with the two retaining screws 6 Attach the control switch connector to the terminal on the slip ring 7 Install th...

Page 1119: ...large 5 Remove the horn buttons from the steering wheel by using a suitable small prytool 6 Disengage the horn wiring electrical connector s 7 Remove the screws from the speed control switch assemblies wiring Failure to follow safety and disabling procedures could result in possible air bag deployment personal injury or unnecessary air bag system repairs Remove the air bag module assembly from the...

Page 1120: ...arge To install Remove the screws from the speed control switch assemblies there are usually two on each side 1990 93 vehicles Disconnect the speed control switches from the wiring harness then remove the switches 1990 93 vehicles Стр 11 из 33 CRUISE CONTROL 18 11 2005 http www chiltondiy com content 8687 8687_6_5 html ...

Page 1121: ...ble Before any air bag component is serviced the positive battery cable MUST be disconnected for one minute to de engergize the backup power supply 2 Disconnect the positive battery cable then wait one minute for the backup power supply to deplete its stored energy 3 Remove the two back cover plugs Remove the two screw and washer assemblies securing the driver side air bag module to the steering w...

Page 1122: ...away the right hand side of the steering wheel back cover to provide enough clearance to remove the right hand speed control switch wiring from the steering wheel Repeat on the left hand side then remove the speed control actuator switch Disengage the air bag module electrical connector 1994 95 vehicles Remove the air bag module from the steering wheel then place it on a work bench with the trim c...

Page 1123: ...ioned so that no interference is encountered when installing the air bag module 11 Engage all of the harness connectors and route the wiring in the steering wheel cavity then install the wire organizer 12 Position the driver side air bag module on the steering wheel then connect the air Carefully pry the right side of the steering wheel back cover for clearance to remove the right hand speed contr...

Page 1124: ...ng of 0 1 ohms 2 Depress SET ACCEL button and check for a reading pf 714 646 ohms 3 Depress COAST button and check for a reading of 126 114 ohms 4 Depress RESUME button and check for a reading of 2090 2310 ohms 5 If the resistance values are not as indicated but the ohmmeter fluctuates remove the steering wheel and clean the brushes and slip ring surface Apply slip ring grease E1AZ 19590 A or equi...

Page 1125: ...he three retaining screws 12 Install the ignition lock cylinder and tilt lever if equipped 13 Position the steering wheel on the end of the steering wheel shaft Align the index mark on the wheel with the index mark on the shaft 14 Install a new steering wheel bolt Tighten to 23 33 ft lbs 31 45 Nm 15 Install the steering wheel horn pad 1990 95 Vehicles 1 Set the steering wheel in the straight ahead...

Page 1126: ...e contact assembly wiring harness 12 Apply two pieces of tape across the contact assembly stator and rotor to prevent accidental rotation 13 Remove the three contact assembly retaining screws then lift the contact assembly off the steering column shaft Place the air bag module on the bench with the trim cover facing upward to prevent personal injury in the event of accidental deployment of the air...

Page 1127: ...wire on the upper steering column and install the retaining screw Tighten to 18 26 inch lbs 2 3 Nm 17 Install the wiring harness retainer into the steering column and connect the harness to the main wiring Apply two pieces of tape across the contact assembly stator and rotor to prevent accidental rotation then remove the three contact assembly retaining screws After unfastening the retaining screw...

Page 1128: ... clockspring contact connector can be connected to the air bag module 27 Install the air bag module on the steering wheel and install the four nut and washer assemblies 28 Connect negative battery cable Vehicle Speed Sensor VSS REMOVAL INSTALLATION 1 Disconnect the negative battery cable 2 Raise and safely support the vehicle Remove the mounting clip 3 On 1992 95 vehicles equipped with an automati...

Page 1129: ...ctrical connector 10 Make sure the internal O ring is properly seated in the sensor housing Snap the Vehicle speed sensor assembly vehicles equipped with automatic transaxles Vehicle speed sensor assembly vehicles equipped with manual transaxles Стр 20 из 33 CRUISE CONTROL 18 11 2005 http www chiltondiy com content 8687 8687_6_5 html ...

Page 1130: ...d sensor is probably functioning properly 3 If available a known good quality speed sensor can also be substituted in place of existing sensor to check for proper operation With Electronic Instrument Cluster Because AC and DC voltage measurements are required in the diagnosis of the speed control system on vehicles equipped with an electronic instrument cluster a special diagnostic tool Fluke 8022...

Page 1131: ...hen tighten to 45 61 inch lbs 5 7 Nm 8 Engage the two amplifier electrical connectors 9 Connect the negative battery cable TESTING Do not use a test lamp to perform the amplifier tests as excessive current draw will damage electronic components inside the amplifier Use a voltmeter of 5000 ohm volt rating or higher ON Circuit 1 With the ignition in the RUN position connect a voltmeter between the w...

Page 1132: ...er and recheck OFF circuit SET ACCEL Circuit 1 With ignition in RUN connect voltmeter between light blue black of 6 way amplifier connector and black wire ground Depress and hold SET ACCEL button on steering wheel Voltmeter should read about 4 5 volts 2 Rotate steering wheel back and forth and watch voltmeter for fluctuations 3 If voltage varies more than 0 5 volts perform control switch test COAS...

Page 1133: ...oses and electrical connector from the servo assembly 5 Remove the two nuts attaching the servo to its mounting bracket 6 Carefully remove the servo and cable assembly 7 Remove the two nuts securing the cable cover to the servo 8 Pull off the cover then remove the cable assembly Click to enlarge Servo assembly and related components 2 5L engine Servo assembly and related components 3 0L engine exc...

Page 1134: ...o 62 80 inch lbs 7 9 Nm 11 Attach the servo to the mounting bracket For vehicles through 1993 tighten the retaining nuts to 45 61 inch lbs 5 7 Nm For 1994 95 vehicles tighten the retaining nuts to 62 80 inch lbs 7 9 Nm 12 Feed the actuator cable under the air cleaner air duct Servo assembly and related components 3 8L engine Servo assembly and related components 3 0L SHO engine Стр 25 из 33 CRUISE...

Page 1135: ... Install the two vacuum hoses and electrical connector at the servo 16 Connect negative battery cable 3 2L SHO 1 Disconnect the negative battery cable Click to enlarge 2 Remove the retaining clip from the actuator cable adjuster fitting Speed control servo assembly and related components 3 2L SHO engine Стр 26 из 33 CRUISE CONTROL 18 11 2005 http www chiltondiy com content 8687 8687_6_5 html ...

Page 1136: ...he bracket from the speed control servo Retain the bracket and three screws for reinstallation on the speed control servo To install 9 Attach the bracket to the speed control servo with the three screws Tighten the screw to 6 8 ft lbs 8 11 Nm 10 Make sure that the rubber seal is fully seated on the actuator cap 11 Lock the cable ball slug into the servo pulley slot 12 Pull on the throttle attachme...

Page 1137: ... adjustment 17 Connect the negative battery cable TESTING 1 Disconnect 8 way amplifier connector At connector connect an ohmmeter between orange yellow wire and grey black wire Resistance should be 40 125 ohms 2 Connect an ohmmeter between orange yellow wire and white pink wire Resistance should be 60 190 ohms 3 Connect an ohmmeter between pink light blue wire and brown light green wire Resistance...

Page 1138: ...ed when brake pedal application will not disconnect the speed control system 1 Check the brake light operation with maximum brake pedal effort of about 6 lbs If more than about 6 lbs is required check brake actuation of brake light switch Repair and or replace as necessary 2 If brake lights do not work check fuse bulbs and switch Repair and or replace as necessary 3 If brake lights are working pro...

Page 1139: ...he servo assembly whenever the brake pedal is depressed and thus acts as a redundant safety feature The vacuum dump valve should be checked whenever brake application does not disconnect the speed control system 1 Disconnect vacuum hose with the white stripe from the dump valve Connect a vacuum pump to hose and apply vacuum 2 If a vacuum cannot be obtained hose or dump valve is leaking Replace or ...

Page 1140: ...t negative battery cable 1995 3 0L SHO 1 Disconnect the negative battery cable 2 Disengage the harness connector from the clutch pedal position switch 3 Remove the clutch switch retaining screw and clip then remove the switch To install 4 Install the clutch switch on the clutch pushrod then secure with the retaining screw and clip An audible click will be heard when the clutch switch is mountedpro...

Page 1141: ...then test drive the vehicle to ensure that the clutch switch cancellation of cruise control operates properly 1995 3 0L SHO The clutch pedal position switch is self adjusting To adjust press the clutch pedal to the floor to reset the clutch switch TESTING Manual Transaxle Adjusting the clutch switch except 1995 3 0L SHO vehicles Стр 32 из 33 CRUISE CONTROL 18 11 2005 http www chiltondiy com conten...

Page 1142: ...lutch switch test as the lightcannot properly indicate the condition of the switch Do not use a strongmagnet near the clutch switch as it can be affected by magnetic fields 1 Disconnect clutch pigtail connector from speed control harness connector Connect an ohmmeter to the two switch connector terminals 2 With the clutch pedal in full up position resistance should be less than 5 ohms 3 With the c...

Page 1143: ...s 1 Disconnect the negative battery cable 2 Remove the trim panel to center instrument panel 3 Remove the radio bracket to instrument panel retaining screws Remove the center instrument panel Стр 1 из 10 ENTERTAINMENT SYSTEMS 18 11 2005 http www chiltondiy com content 8687 8687_6_6 html ...

Page 1144: ...Slowly pull the radio from the instrument panel 5 Disengage the electrical connectors and the antenna cable from the radio Remove the four screws retaining the radio and mounting bracket to the instrument panel Disconnect the antenna cable from the radio Стр 2 из 10 ENTERTAINMENT SYSTEMS 18 11 2005 http www chiltondiy com content 8687 8687_6_6 html ...

Page 1145: ...NSTALLATION 1990 95 Vehicles 1 Disconnect the negative battery cable 2 Install Radio Removal Tool T87P 19061 A into the radio or CD player face plate Push the tool in about 1 in 25mm in order to release the retaining clips Do not use excessive force when installing the special tool because this will cause damage to the retaining clips 3 Apply a light spreading force to the tool then pull the assem...

Page 1146: ...Click to enlarge Common radio assembly and mounting Стр 4 из 10 ENTERTAINMENT SYSTEMS 18 11 2005 http www chiltondiy com content 8687 8687_6_6 html ...

Page 1147: ...g sure that the rear radio or CD player assembly support is engaged on the upper support rail 7 Push the radio or CD player assembly inward until the retaining clips are fully engaged 8 Connect the negative battery cable Test the radio and or CD player for operation Compact disc player mounting Стр 5 из 10 ENTERTAINMENT SYSTEMS 18 11 2005 http www chiltondiy com content 8687 8687_6_6 html ...

Page 1148: ... the speaker to the mounting bracket using the retaining screws 7 Install the front door trim panel 8 Connect the negative battery cable Rear Seat Mounted STANDARD SPEAKER 1 Disconnect the negative battery cable 2 From the inside of the trunk disconnect the speaker wiring harness from the speaker 3 Remove the speaker cover 4 Pull one end of the speaker rubber retaining strap to disengage it from t...

Page 1149: ...egative battery cable and check speaker operation 7 Connect the negative battery cable OPTIONAL SPEAKER 1 Disconnect the negative battery cable 2 Remove the speaker grille from the package tray panel 3 Remove the speaker retaining screws 4 Pull the speaker forward then disconnect the speaker electrical wiring Remove the speaker from the vehicle Standard rear speaker mounting Sedan Стр 7 из 10 ENTE...

Page 1150: ...ck to enlarge Earlier model optional rear speaker mounting Taurus only Earlier model optional rear speaker mounting Sable only Стр 8 из 10 ENTERTAINMENT SYSTEMS 18 11 2005 http www chiltondiy com content 8687 8687_6_6 html ...

Page 1151: ...ker in the vehicle Secure using the retaining screws 6 Install the speaker grille to the package tray panel 7 Connect the negative battery cable Late model speaker mounting Taurus and Sable shown Стр 9 из 10 ENTERTAINMENT SYSTEMS 18 11 2005 http www chiltondiy com content 8687 8687_6_6 html ...

Page 1152: ... the vehicle Click to enlarge To install 5 Position the speaker then slide the speaker mounting bracket edge under the headlining and connect the speaker electrical wiring 6 Install the speaker and mounting bracket retaining screws 7 Install the inner rear corner of the upper finish panel 8 Connect the negative battery cable Chilton Automotive Information Systems 2004 Thomson Delmar Learning Rear ...

Page 1153: ...pivot shafts 3 or 4 cycles then turn off the switch This operation will place the pivot shafts in the PARK position Turn the ignition switch to the OFF position 2 Disconnect the negative battery cable Click to enlarge Windshield wiper blade and arm assembly Vehicles through 1994 Стр 1 из 16 WINDSHIELD WIPERS AND WASHERS 18 11 2005 http www chiltondiy com content 8687 8687_6_7 html ...

Page 1154: ...ng finger pressure only grasp the slide latch tab and slide the latch out from under the arm head Remove the arm and blade assembly Windshield wiper blade and arm assembly 1995 vehicles Using finger pressure only grasp the slide latch tab and slide the latch out from under the arm head then Стр 2 из 16 WINDSHIELD WIPERS AND WASHERS 18 11 2005 http www chiltondiy com content 8687 8687_6_7 html ...

Page 1155: ...e blade assembly from the wiper arm pin 5 To remove the blade assembly for 1995 vehicles depress the locking tab on the windshield wiper blade then slide the blade downward away from the windshield wiper pivot arm and remove the blade remove the arm and blade assembly Стр 3 из 16 WINDSHIELD WIPERS AND WASHERS 18 11 2005 http www chiltondiy com content 8687 8687_6_7 html ...

Page 1156: ... outward position 8 While applying downward pressure on the arm head to ensure full seating raise the other end of the arm enough to allow the latch to slide under the pivot assembly to the latched position 9 Lift the latched wiper arm and blade assembly away from the top surface of the cowl screen louvers and position the arm only on the rearward surface of the wiper arm stop Removing the windshi...

Page 1157: ...e park position 2 Install the arm and blade assemblies on the pivot shafts to the correct distance between the windshield lower molding or weatherstrip and the blade saddle centerline Rear Window Wiper Blade and Arm REMOVAL INSTALLATION To avoid scratching the glass and or paint do not pry the wiper mounting arm and pivot shaft from the pivot arm with a metal or sharp tool 1 Raise the arm away fro...

Page 1158: ...top stud and bottom saddle are securely latched 6 Push the main arm head over the pivot shaft Be sure that the pivot shaft is in the park position 7 Hold the main arm head on the pivot shaft while raising the blade end of the wiper arm and remove the 0 062 in 1 6mm pin 8 Lower the blade to the glass Rear wiper blade and arm assembly Removing the rear wiper arm blade from the pivot arm Стр 6 из 16 ...

Page 1159: ...senger side 5 On 1986 90 vehicles remove the left cowl screen 6 Remove the windshield wiper mounting arm and pivot shaft retaining clip from the operating arm on the motor by lifting the locking tab up then pulling the clip away from the pin Click to enlarge Disconnect the power lead from the windshield wiper motor Location of the windshield wiper adapter and connector arm clip Стр 7 из 16 WINDSHI...

Page 1160: ...n the windshield wiper mounting arm 11 Install the windshield wiper mounting arm and pivot shaft on the windshield wiper motor Make sure that the mounting arm and pivot shaft is securely attached to the windshield wiper motor Install the mounting arm and pivot shaft by pulling until the clip snaps in place Remove the retaining bolts from the motor then remove the windshield wiper motor assembly fr...

Page 1161: ...t the wires disengage the wiper motor electrical connector 5 Remove the nut retaining the rear wiper motor to the handle then remove the motor Click to enlarge To install 6 Install the motor to the handle then secure using the retaining nut 7 Engage the wiper motor electrical connector 8 Install the rear wiper pivot arm retaining nut and spacers 9 Install the rear wiper arm and blade 10 Connect th...

Page 1162: ...ge REMOVAL INSTALLATION 1 Disconnect the negative battery cable 2 Remove the wiper pivot arm and blade assembly from the wiper mounting arm and pivot shafts 3 Remove both the right and left cowl vent screens 4 Disconnect the linkage drive arm windshield wiper mounting arm and pivot shaft from the motor crank pin after removing the clip 5 Remove the screws bolts retaining the windshield wiper mount...

Page 1163: ... wiper arm mounting arm and pivot shafts 10 Connect the negative battery cable Windshield Washer Fluid Reservoir REMOVAL INSTALLATION Except Taurus SHO 1 Disconnect the negative battery cable 2 Remove the assembly retaining screw 3 Disengage the electrical connectors The reservoir will drain with the washer hose s disconnected 4 Disconnect the windshield washer hose s then remove the assembly from...

Page 1164: ...r reservoir with fluid Taurus SHO 1 Disconnect the negative battery cable 2 Remove the two assembly retaining screws 3 Remove the right side inner splash shield 4 Disengage the electrical connectors 5 Disconnect the hoses then remove the windshield washer reservoir assembly from the vehicle Windshield washer fluid reservoir location and mounting except SHO vehicles Стр 12 из 16 WINDSHIELD WIPERS A...

Page 1165: ...e negative battery cable 2 Remove the reservoir from the vehicle then disengage the electrical connector and hoses 3 Using a small suitable prytool pry out the windshield washer pump being careful not to damage the plastic housing 4 Remove the one piece seal and filter then inspect for damage and replace if necessary Flush out the reservoir and clean any foreign material from the wiper motor cavit...

Page 1166: ...e battery cable 2 Remove the right hand quarter trim panel 3 Disengage the reservoir electrical connector supply window washer hose and the windshield washer nozzle jet and bracket 4 Remove the reservoir retaining screws then remove the reservoir assembly from the vehicle 5 Using a small suitable prytool pry out the windshield washer pump being careful not to damage the plastic housing 6 Remove th...

Page 1167: ...nlarge Rear window washer pump and fluid reservoir Rear window washer pump mounting in the fluid reservoir Стр 15 из 16 WINDSHIELD WIPERS AND WASHERS 18 11 2005 http www chiltondiy com content 8687 8687_6_7 html ...

Page 1168: ...er hose then install the reservoir in the vehicle and secure using the retaining screws Do not operate the pump until fluid has been added to the reservoir 9 Connect the negative battery cable then add fluid to the windshield washer reservoir 10 Install the quarter trim panel Chilton Automotive Information Systems 2004 Thomson Delmar Learning Стр 16 из 16 WINDSHIELD WIPERS AND WASHERS 18 11 2005 h...

Page 1169: ... panels then remove the panels by snapping them out Click to enlarge 5 On the Taurus only remove the clock assembly or clock cover to gain access to the finish panel screw behind the clock 6 Remove the seven cluster opening finish panel retaining screws and the jam nut behind the headlight switch Remove the finish panel by rocking the upper edge toward the driver Early model instrument cluster Bas...

Page 1170: ...rew and cable loop 8 Disconnect the upper speedometer cable from the lower speedometer cable in the engine compartment Click to enlarge Late model instrument cluster Base Taurus model Late model instrument cluster Taurus SHO and Sable Стр 2 из 17 INSTRUMENTS AND SWITCHES 18 11 2005 http www chiltondiy com content 8687 8687_6_8 html ...

Page 1171: ...er in front of the cluster opening Click to enlarge 12 Connect the speedometer cable then engage the electrical connectors 13 Install the cluster then secure using the four cluster to instrument panel retaining screws 14 Connect the upper speedometer cable to the lower speedometer cable in the engine compartment 15 On column shift vehicles connect the transaxle selector indicator Exploded view of ...

Page 1172: ...ds 3 Remove the steering column cover then disconnect the shift indicator cable from the cluster by removing the two retaining screws 4 Disconnect the cluster message center switch module then remove the cluster trim finish panel 5 Remove the cluster mounting screws then pull the bottom of the instrument cluster toward the steering wheel 6 Reaching behind and underneath the instrument cluster dise...

Page 1173: ...then check the instrument cluster for proper operation 12 Connect the shift indicator assembly to the cluster and secure with the retaining screw Install the steering column cover 13 Connect the cluster message center switch module to the cluster then install the cluster trim finish panel 14 Install the lower and upper steering column shrouds Speedometer REMOVAL INSTALLATION Except Electronic Clus...

Page 1174: ...ounting screws and carefully pull the speedometer away from the dial making sure to guide the pointer through the slot 7 If necessary remove the odometer assembly by pulling the reset knob from the lever To install 8 Position the odometer on the mounting bosses then install the retaining screws Tighten the screws to 7 12 inch lbs 0 8 1 4 Nm 9 If removed install the trip odometer reset knob 10 Care...

Page 1175: ...tails please refer to the procedure located earlier in this section 11 Connect the negative battery cable then check for proper operation of the speedometer Electronic Cluster 1988 89 VEHICLES 1 Disconnect the negative battery cable 2 Remove the instrument cluster assembly For details please refer to the procedure located earlier in this section 3 Using a clean cloth to protect the lens place the ...

Page 1176: ...egative battery cable 1990 95 VEHICLES The speedometer is part of a single electronic instrument cluster module and cannot be removed separately Tachometer REMOVAL INSTALLATION Except Electronic Cluster 1 Disconnect the negative battery cable 2 Remove the instrument cluster 3 Remove the cluster main lens and mask retaining screws then remove the mask and lens 4 Remove the tachometer from the gauge...

Page 1177: ...ical terminals from the clips 6 Lift the main dial assembly from the instrument cluster assembly back plate 7 On column shift vehicles only remove the two screws retaining the transmission range indicator to the main dial them remove the transmission range indicator from the cluster 8 Manually rotate the fuel gauge pointer to align it with the slot in the dial Remove the mounting screws and carefu...

Page 1178: ...ose pliers Squeeze both ends of the clip equally so that the locking ears will slide through the clip opening in the instrument cluster back plate then push the clips through the opening 6 After the clips are removed remove the printer circuit from its mounting To install 7 Position the instrument cluster printed circuit on the back plate and install the clips by bending the taps on the clips with...

Page 1179: ...o the cluster finish panel until it snaps into place On Sable install the two retaining screws 6 Engage the electrical wiring connector 7 Install the cluster opening finish panel then secure using the four retaining screws 8 Connect the negative battery cable 1990 95 Vehicles 1 Disconnect the negative battery cable 2 Remove the cluster opening finish panel as follows 1 Disconnect the positive batt...

Page 1180: ...nnector to the rear wiper washer switch 7 Install the cluster finish panel as follows 1 Engage the electrical wiring to the switches clock and warning lights then install the finish panel by snapping it into place 2 Install the cluster opening finish panel retaining screws 3 Place the gear shift lever to its original position 4 Install the multi function switch by engaging the electrical connector...

Page 1181: ...two screws retaining the headlight switch then pull the switch out of the instrument panel disengage the electrical connector then remove the switch Click to enlarge To install 6 Position the switch engage the electrical connector then install the switch securing with the two retaining screws 7 Install the instrument cluster finish panel 8 Install the bezel then secure using the retaining nut 9 Fa...

Page 1182: ...Remove the ignition lock cylinder 4 If equipped with a tilt column tilt the column to the most downward position then remove the tilt lever 5 Remove the four bolts and opening cover from under the steering column 6 Remove the steering column trim shrouds Disengage all electrical connections from the steering column multi function switch 7 Remove the two screws retaining the multi function switch t...

Page 1183: ...lti function switch by engaging the electrical connectors then secure using the retaining screws 5 Install the steering column shrouds 6 Install the opening cover from under the steering column and secure using the retaining bolts 7 If removed install the tilt lever then return the column to its original position 8 Install the ignition lock cylinder 9 Disengage the parking brake then connect the p...

Page 1184: ... cable 1993 95 Vehicles 1 Disconnect the negative battery cable 2 Remove the instrument panel upper finish panel 3 Disengage the clock electrical connector 4 Remove the two retaining screws holding the clock in the instrument panel upper finish panel There is one screw on each clock mounting tab 5 Remove the clock from the instrument panel upper finish panel Using a scriber to remove the clock veh...

Page 1185: ...ch side 7 Engage the clock electrical connector 8 Install the instrument panel upper finish panel 9 Connect the negative battery cable Chilton Automotive Information Systems 2004 Thomson Delmar Learning Electric clock location 1993 95 vehicles Стр 17 из 17 INSTRUMENTS AND SWITCHES 18 11 2005 http www chiltondiy com content 8687 8687_6_8 html ...

Page 1186: ... snapping the connector rearward CAUTION The replaceable Halogen headlamp bulb contains gas under pressure The bulb may shatter if the glass envelope is scratched or the bulb is dropped Handle the bulb carefully Grasp the bulb ONLY by its plastic base Avoid touching the glass envelope because the oils in your hand may cause the bulb to burst when turned on Keep the bulb out of the reach of childre...

Page 1187: ...e socket DO NOT rotate the bulb during removal To install 7 With the flat side of the plastic base of the bulb facing upward insert the glass envelope of the bulb into the socket Turn the base slightly to the left or right if On some vehicles such as this early model Taurus it it possible to remove the headlight bulb and electrical connector as an assembly After removing the bulb connector assembl...

Page 1188: ...trical connector into the rear of the plastic until it snaps and locks into position 10 Turn the headlights on and check for proper operation 11 Connect the negative battery cable Headlight Assembly 1986 88 VEHICLES The headlamps on these vehicles do not need replacement when the bulb burns out Refer to bulb replacement for removal and installation procedures for when the bulb burns out 1 Disconne...

Page 1189: ...lighted grille 5 Remove the lamp just outboard of the headlight the side marker lamp on the Taurus or the combination park turn side marker lamp on the Sable On Taurus detach the grille retainers then remove the grille Once the grille is removed you can access the headlight assembly retaining bolts and screws Стр 4 из 29 LIGHTING 18 11 2005 http www chiltondiy com content 8687 8687_6_9 html ...

Page 1190: ...he fender 8 Remove the three bolts Taurus or four bolts Sable attaching the headlight housing to the brackets Unfasten the retainers then remove the side marker lamp Taurus only Remove the two bolts attaching the headlight housing to the fender Стр 5 из 29 LIGHTING 18 11 2005 http www chiltondiy com content 8687 8687_6_9 html ...

Page 1191: ...ing the retaining bolts be careful not to drop any into the engine compartment Remove the headlight assembly retaining bolts then Стр 6 из 29 LIGHTING 18 11 2005 http www chiltondiy com content 8687 8687_6_9 html ...

Page 1192: ...tor 16 Connect the negative battery cable then turn on the headlights to check for proper operation and aim if necessary 1989 95 VEHICLES 1 Disconnect the negative battery cable 2 Make sure the headlight switch and the headlight time delay switch if equipped are in the OFF position Use snapring pliers to spread the retainer 3 Remove the headlight electrical connector from the headlight bulb and re...

Page 1193: ...nector by pushing the connector until it snaps into position 9 Connect the negative battery cable then turn on the headlights to check for proper operation and aim if necessary AIMING Exploded view of the headlight assembly 1989 95 Taurus except SHO Exploded view of the headlight assembly 1989 95 Sable and Taurus SHO Стр 8 из 29 LIGHTING 18 11 2005 http www chiltondiy com content 8687 8687_6_9 htm...

Page 1194: ...e spare tire and jack and the correct tire pressures The equipment in the aiming kit can be calibrated to accommodate a slight floor slope but the floor should be reasonably flat Set up and use the equipment as described in the instructions included in the headlight aiming kit Signal and Marker Lights REMOVAL INSTALLATION Parking Front Turn Signal Light Combination The parking and turn signal ligh...

Page 1195: ...e bulb To install 4 Install the bulb in the socket then install the socket in the lamp assembly by twisting 5 Position the parking lamp in place then install the retaining screws 6 Connect the negative battery cable Side Marker Lights TAURUS 1 Disconnect the negative battery cable Using the access hole in the radiator support rotate the bulb socket counterclockwise to disengage it from the light h...

Page 1196: ...red the slot in the housing 4 Lift the lamp to clear the two lower tabs on the headlamp from the headlamp housing Exploded view of the side marker light and related components 1989 Taurus shown Remove the nut and washer from the attaching stud at the top of the lamp assembly Стр 11 из 29 LIGHTING 18 11 2005 http www chiltondiy com content 8687 8687_6_9 html ...

Page 1197: ...terclockwise then pull the bulb from the socket Remove the lamp to clear the tab s on the headlamp housing Remove the socket by twisting it counterclockwise Стр 12 из 29 LIGHTING 18 11 2005 http www chiltondiy com content 8687 8687_6_9 html ...

Page 1198: ...ining nuts screws then lift the cornering lamp from its mounting 3 Remove the bulb and socket assembly by twisting counterclockwise then remove the cornering lamp from the vehicle 4 If necessary remove the miniature bulb from the socket by pulling it out To install 5 If necessary install a new bulb in the socket 6 Install the bulb and socket assembly into the cornering lamp by twisting clockwise 7...

Page 1199: ...rning it clockwise 5 Position the cornering light back in place and install the two screws 6 Connect the negative battery cable Auxiliary Headlight Assembly TAURUS SHO 1 Disconnect the negative battery cable 2 Remove the headlight assembly 3 Remove the two screws attaching the auxiliary headlight to the headlight assembly Cornering lamp assembly earlier model Sable shown Стр 14 из 29 LIGHTING 18 1...

Page 1200: ...ect the battery cable Rear Turn Signal Brake Lights SEDAN Bulbs can be serviced from the inside of the luggage compartment by removing the luggage compartment rear trim panel if so equipped 1 Disconnect the negative battery cable Headlight assembly Taurus SHO Стр 15 из 29 LIGHTING 18 11 2005 http www chiltondiy com content 8687 8687_6_9 html ...

Page 1201: ...Click to enlarge Brake light mounting 1995 Taurus shown Стр 16 из 29 LIGHTING 18 11 2005 http www chiltondiy com content 8687 8687_6_9 html ...

Page 1202: ...Click to enlarge 2 From inside the trunk remove the lower back panel trim cover Brake light mounting 1995 Sable shown Стр 17 из 29 LIGHTING 18 11 2005 http www chiltondiy com content 8687 8687_6_9 html ...

Page 1203: ... if necessary then install the socket s in the lamp body 6 Install the lamp and use the retaining screws to secure it 7 Install the trim cover then connect the negative battery cable STATION WAGON To access the rear lights the lower back panel trim cover must be removed Pull the bulb straight out to remove it from the socket assembly Стр 18 из 29 LIGHTING 18 11 2005 http www chiltondiy com content...

Page 1204: ...e Click to enlarge 4 If necessary replace the bulb To install 5 Install the lamp socket and wiring to the rear lamp 6 Position the rear lamp to the quarter panel then secure using the two retaining screws 7 Connect the negative battery cable High Mount Brake Light Station wagon brake light turn signal mounting Стр 19 из 29 LIGHTING 18 11 2005 http www chiltondiy com content 8687 8687_6_9 html ...

Page 1205: ...gage the electrical connector Click to enlarge 3 On the wagon remove the lamp assembly trim cover at the top of the liftgate frame Remove the two plugs then remove the four retaining nuts retaining the lamp trim cover Sedan high mount brake light Taurus shown Sable similar Стр 20 из 29 LIGHTING 18 11 2005 http www chiltondiy com content 8687 8687_6_9 html ...

Page 1206: ...gage compartment disengage the wiring connector then remove the five nuts retaining the spoiler to the trunk lid 3 Lower the trunk lid and carefully lift up the spoiler and pull the wiring grommet out of the luggage compartment door then remove the spoiler from the trunk lid 4 Turn the spoiler over then lay it on a protective surface to avoid scratching it Station wagon high mount brake light Стр ...

Page 1207: ...g the rear high mount brake light to the spoiler then remove the light from the spoiler Click to enlarge To install Taurus SHO high mount brake light Стр 22 из 29 LIGHTING 18 11 2005 http www chiltondiy com content 8687 8687_6_9 html ...

Page 1208: ... then depress the brake pedal to make sure the rear hi mount lamp is functioning properly Dome Light WITHOUT MOONROOF 1 Disconnect the negative battery cable 2 Carefully squeeze the lens inward to release the locking tabs Click to enlarge 3 Remove the lens from the lamp body If necessary replace the defective bulb 4 Installation is the reverse of the removal procedure WITH MOONROOF 1 Disconnect th...

Page 1209: ...dure License Plate Lights 1 Disconnect the negative battery cable 2 Remove the two lamp body plastic retaining rivets 3 Remove the lamp assembly Dome lamp assembly vehicle with moonroof Стр 24 из 29 LIGHTING 18 11 2005 http www chiltondiy com content 8687 8687_6_9 html ...

Page 1210: ... Remove the socket and bulb assembly from the rear of the lamp assembly If necessary replace the defective bulb License plate lamp sedan Стр 25 из 29 LIGHTING 18 11 2005 http www chiltondiy com content 8687 8687_6_9 html ...

Page 1211: ...t the negative battery cable Fog Driving Lights The Taurus SHO is the only vehicle covered by this manual which is equipped with fog lamps REMOVAL INSTALLATION Fog Lamp Bulb If you are only replacing the bulb you don t have to remove the fog lamp License plate lamp station wagon Стр 26 из 29 LIGHTING 18 11 2005 http www chiltondiy com content 8687 8687_6_9 html ...

Page 1212: ...c base only rotate the miniature bulb and socket then remove the bulb from the fog lamp To install 4 Install the bulb to the socket assembly The socket assembly is indexed and can only be installed in one way 5 Engage the electrical wiring connector to the fog lamp miniature bulb 6 Connect the negative battery cable Fog Lamp Assembly 1 Disconnect the negative battery cable Fog lamp bulb and socket...

Page 1213: ...bly then remove the lamp from the vehicle 5 If replacing the fog lamp mounting bracket remove the screw retaining the mounting bracket to the front bumper then keep the mounting bracket and screw for the transfer of parts Cross sectional view of the fog lamp assembly Taurus SHO only Disengage the electrical wiring connector from the rear of the fog lamp assembly Стр 28 из 29 LIGHTING 18 11 2005 ht...

Page 1214: ...mbly into the mounting bracket assembly then install the nut s retaining the fog lamp to the mounting bracket 8 Engage the fog lamp electrical wiring connector 9 Connect the negative battery cable Chilton Automotive Information Systems 2004 Thomson Delmar Learning Стр 29 из 29 LIGHTING 18 11 2005 http www chiltondiy com content 8687 8687_6_9 html ...

Page 1215: ... manufacturer s instructions The color coding of the wires is standard throughout the industry One point to note some domestic vehicles and most imported vehicles have separate turn signals On most vehicles the brake lights and rear turn signals operate with the same bulb For those vehicles with separate turn signals you can purchase an isolation unit so that the brake lights won t blink whenever ...

Page 1216: ...panel down with the left hand then remove the cover Fuses are a one time circuit protection If a circuit is overloaded or shorts the fuse will blow thus protecting the circuit A fuse will continue to blow until the circuit is repaired Click to enlarge On most vehicles covered by this manual the fuse panel is located to the left of the steering column attached to the instrument panel Стр 1 из 7 CIR...

Page 1217: ...identification Be sure to only replace a fuel with the proper amperage rated substitute A blown fuse can easily be checked by visual inspection or by continuity checking REPLACEMENT To remove a cartridge fuse grip the fuse and pull it straight out of the fuse junction panel block If the fuse cannot be gripped you can use a non metallic tool to pull the fuse out of the block To install the fuse ali...

Page 1218: ...e link is of a fixed value for a specific electrical load and should a fusible link fail the cause of the failure must be determined and repaired prior to installing a new fusible link of the same value Please be advised that the color coding of replacement fusible links may vary from the production color coding that is outlined in the text that follows Location of fuses and the circuits they prot...

Page 1219: ... panel circuits z Black 16 Gauge Wire located on the left shock tower used to protect the battery feed to ignition switch and fuse panel circuits z Black 16 Gauge Wire located in left side of engine compartment at starter relay used to protect rear window defrost circuit on 1986 90 vehicles and 1991 2 5L engine vehicles z Brown 18 Gauge Wire located in left side of engine compartment at starter re...

Page 1220: ...s Power Locks and Power Seats One 20 amp circuit breaker located near the starter relay on 1986 89 vehicles z Power Windows Power Locks and Power Seats One 20 amp circuit breaker located on the fuse panel on 1990 92 vehicles z Headlights One 22 amp circuit breaker incorporated in the headlight switch Relays REPLACEMENT Various relays are used in conjunction with the vehicle s electrical components...

Page 1221: ...ol Module located on the passenger side of the firewall z Anti lock Brake Control Module located at the front of the engine compartment next to the passenger side fender except on Taurus SHO where it is located at the front of the engine compartment on the driver s side z Automatic Temperature Control Module located behind the center of the instrument panel z Heated Windshield Control Module locat...

Page 1222: ...by pressing the plastic retaining clip and pulling straight rearward One phillips head or regular screw has to be removed from the retaining bracket Chilton Automotive Information Systems 2004 Thomson Delmar Learning Location of the indicator flasher assembly Стр 7 из 7 CIRCUIT PROTECTION 18 11 2005 http www chiltondiy com content 8687 8687_6_11 html ...

Page 1223: ...ring diagram 1988 vehicles 3 0L and 3 8L engine control wiring diagram 1988 vehicles Body wiring diagram 1988 vehicles Body wiring diagram continued 1988 vehicles Instrument cluster wiring diagram 1988 vehicles Starting and charging system wiring diagram 1988 vehicles 2 engine control wiring diagram 1989 90 vehicles 3 0L engine control wiring diagram 1989 90 vehicles 3 8L engine control wiring dia...

Page 1224: ...vehicles 3 0L engine control wiring diagram 1993 vehicles 3 0L flexible fuel engine control wiring diagram 1993 vehicles 3 8L engine control wiring diagram 1993 vehicles 3 0L SHO engine control wiring diagram 1993 vehicles 3 2L SHO engine control wiring diagram 1993 vehicles Starting charging and windshield wiper washer system wiring diagram 1993 vehicles 3 0L engine control wiring diagram 1994 95...

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Page 1398: ...racket 4 Pull the cable sealing grommets loose from the floorpan and dash panel 5 Raise and support the vehicle safely 6 Remove the two retaining screws that retain the cables to the bracket assembly 7 Pry the cable sockets off the clamp assembly pivot balls and slide the cable insulators out of the bracket slots 8 Loosen the two bolts retaining the bracket assembly to the transaxle case Remove th...

Page 1399: ...h connect the boot to the top of the console 4 Remove the console to expose the shifter assembly Remove the four bolts retaining the shifter to the floorpan 5 Pry the two clips holding the shift cables to control assembly and pry the cable sockets off the control assembly pivot balls 6 Do not bend or kink the cable core rods To install 7 Feed the loose ends of the cables into the control assembly ...

Page 1400: ...12 15 ft lbs 16 20 Nm 5 Engage the electrical connector 6 Connect the negative battery cable Transaxle REMOVAL INSTALLATION 1986 88 Vehicles 1 Disconnect the negative battery cable 2 Wedge a wood block about 7 in 178mm long under the clutch pedal to hold the pedal up slightly beyond its normal position Common back up light switch manual transaxle Стр 3 из 39 MANUAL TRANSAXLE 18 11 2005 http www ch...

Page 1401: ... Raise and safely support the vehicle 6 Using a 15mm socket remove the nut and bolt that secures the lower control arm ball joint to the steering knuckle assembly Discard the nut and bolt Repeat this Wedge a wood block about 7 in 178mm long under the clutch pedal to hold the pedal up slightly beyond its normal position Remove the clutch cable casing from the rib on the top surface of the transaxle...

Page 1402: ...arge 8 Using a large prybar pry the left inboard CV joint assembly from the transaxle Remove the nut and bolt that retain the lower control arm ball joint to the steering knuckle assembly Using the specified tool pry the lower control arm away from the steering knuckle Be careful not to damage or cut the ball joint boot The tool must not contact the lower arm Стр 5 из 39 MANUAL TRANSAXLE 18 11 200...

Page 1403: ...ential rotator tool T81P 4026 A or equivalent through the left side and tap the joint out The tool can be used from either side of transaxle Click to enlarge Using a large prybar carefully pry the left inboard CV joint assembly from the transaxle If the CV joint assembly cannot be pried from the transaxle insert Differential Rotator tool T81P 4026 A or equivalent through the left side and tap the ...

Page 1404: ...ight switch connector from the transaxle backup light switch Click to enlarge 12 Using a deep well socket remove the starter stud bolts Wire the halfshaft assembly in a near level position to prevent damage to the assembly during the remainder of the procedure Detach the back up lamp switch connector from the transaxle back up lamp switch located on top of the transaxle Стр 7 из 39 MANUAL TRANSAXL...

Page 1405: ...ly to the transaxle 15 Using a crowfoot wrench remove the speedometer cable from the transaxle Click to enlarge 16 Remove the stiffener brace attaching bolts from the lower position of the clutch housing Remove the starter stud bolts there are usually three Using a crowfoot wrench remove the speedometer cable from the transaxle Стр 8 из 39 MANUAL TRANSAXLE 18 11 2005 http www chiltondiy com conten...

Page 1406: ...o the clutch disc and work the transaxle onto the dowel sleeves Make sure the transaxle assembly is flush with the rear face of the engine prior to installation of the attaching bolts 23 Install the lower engine to transaxle attaching bolts and tighten them to 28 31 ft lbs 38 42 Nm 24 Install the speedometer cable Be careful when threading the cable nut onto the retainer to avoid crossthreading Po...

Page 1407: ...sm to shift shaft and tighten to 7 10 ft lbs 9 14 Nm 27 Install the 2 bolts that attach the stiffener brace to the lower portion of the clutch housing and tighten to 15 21 ft lbs 21 28 Nm 28 Install the starter stud bolts then tighten to 30 40 ft lbs 41 54 Nm When threading the speedometer cable nut onto the retainer be careful to avoid crossthreading Стр 10 из 39 MANUAL TRANSAXLE 18 11 2005 http ...

Page 1408: ...ve the seal plugs then install the inner CV joints into the transaxle Using a deep well socket install the starter stud bolt then tighten to specification Attach the back up lamp switch connector to the transaxle switch Стр 11 из 39 MANUAL TRANSAXLE 18 11 2005 http www chiltondiy com content 8687 8687_7_1 html ...

Page 1409: ...th CV joints are seated in the transaxle Click to enlarge 32 Attach the subframe and the lower ball joint to the steering knuckle Insert a new After removing the plugs install the inner CV joints into the transaxle Before installing the inner CV joint be sure to position new circlips Стр 12 из 39 MANUAL TRANSAXLE 18 11 2005 http www chiltondiy com content 8687 8687_7_1 html ...

Page 1410: ...Install the top transaxle to engine mounting bolts and tighten to 28 31 ft lbs 38 42 Nm 35 Connect the clutch cable to the clutch release shaft assembly Attach the subframe and the lower ball joint to the steering knuckle then insert a new service pinch bolt and a new nut Fill the transaxle to the bottom of the fill plug hole Стр 13 из 39 MANUAL TRANSAXLE 18 11 2005 http www chiltondiy com content...

Page 1411: ...nt 1989 95 Vehicles 1 Disconnect the negative battery cable 2 Wedge a 7 in 178mm block of wood under the clutch pedal to hold the pedal up beyond it s normal position Attach the clutch cable to the clutch release lever Wedge a block of wood about 7 in under the clutch pedal to hold the pedal up beyond Стр 14 из 39 MANUAL TRANSAXLE 18 11 2005 http www chiltondiy com content 8687 8687_7_1 html ...

Page 1412: ...dometer cable and speed sensor wire 9 Support the engine using a suitable engine support fixture 10 Raise the vehicle and support it safely Remove the wheel and tire assemblies 11 Remove the nut and bolt retaining the lower control arm ball joint to the steering knuckle assembly Discard the removed nut and bolt Repeat the procedure on the opposite side its normal position Grasp the clutch cable an...

Page 1413: ...ove the nut and bolt retaining the lower control arm ball joint to the steering knuckle assembly Be sure to discard the nut and bolt since new ones must be used for installation Using Halfshaft Remover D83P 4026 A or equivalent pry the front suspension lower arm away from the knuckle Стр 16 из 39 MANUAL TRANSAXLE 18 11 2005 http www chiltondiy com content 8687 8687_7_1 html ...

Page 1414: ...le Install a plug into the seal to prevent fluid leakage Remove the CV joint from the transaxle by grasping the left steering knuckle and swinging the knuckle and halfshaft outward from the transaxle Repeat the procedure on the right side If the CV joint assembly cannot be pried from the transaxle insert a suitable tool through the left side and tap the joint out The tool can be used from either s...

Page 1415: ...upport the steering gear by wiring up the tie rod ends to the coil springs 23 Remove the transaxle to engine retaining bolts 24 Unfasten the shift mechanism stabilizer bar to transaxle retaining bolt Remove If the CV joint assembly cannot be pried from the transaxle insert Differential Rotator T81P 4026 A or equivalent through the left side and tap the joint out Support the halfshaft assembly with...

Page 1416: ...emove the 4 bolts lower the subframe and position it aside 27 Remove the starter mounting bolts then remove the starter motor assembly Unfasten the shift mechanism stabilizer bar to transaxle retaining bolt Remove the shift rod to shift shaft retaining nut and bolt then remove the rods from the transaxle Стр 19 из 39 MANUAL TRANSAXLE 18 11 2005 http www chiltondiy com content 8687 8687_7_1 html ...

Page 1417: ...ransaxle backup light switch located on top of the transaxle Unfasten the starter mounting bolts then remove the starter motor assembly from the vehicle Remove the back up light switch connector from the transaxle back up light switch located on top of the transaxle Стр 20 из 39 MANUAL TRANSAXLE 18 11 2005 http www chiltondiy com content 8687 8687_7_1 html ...

Page 1418: ... the dowel sleeves Make sure the transaxle assembly is flush with the rear face of the engine before installation of the retaining bolts 33 Install the engine to transaxle retaining bolts Tighten to 28 31 ft lbs 38 42 Nm 34 Engage the backup light switch electrical connector Position a suitable jack such as Rotunda Hi Lift Jack 014 00210 and Rotunda Transmission Adapter 014 00225 or equivalent und...

Page 1419: ...0 40 ft lbs 41 54 Nm Click to enlarge Engage the back up light switch electrical connector making sure that the locking tabs are secured Install the starter motor using the mounting bolts Стр 22 из 39 MANUAL TRANSAXLE 18 11 2005 http www chiltondiy com content 8687 8687_7_1 html ...

Page 1420: ...ansaxle 44 Install the left inboard CV joint assembly into the transaxle 45 Connect the battery cable bracket to the subframe 46 Connect the power steering cooler to the subframe 47 Position the catalytic converter then install retaining bolts and tighten to 25 34 ft lbs 34 47 Nm 48 Connect the heated oxygen sensor 49 Install the tie rod end in the knuckle and the tie rod retaining nut Tighten to ...

Page 1421: ...he transaxle fluid level Add the correct type of fluid Motorcraft MERCON Multi Purpose Automatic Transmission Fluid or equivalent to the bottom of the fill plug hole then install the fill plug Install the lower control arm ball joint to the steering knuckle assembly using a new retaining nut and bolt Стр 24 из 39 MANUAL TRANSAXLE 18 11 2005 http www chiltondiy com content 8687 8687_7_1 html ...

Page 1422: ... Using a crows foot wrench install the speedometer cable Connect the speedometer cable and speed sensor wire Fill the transaxle with the correct type of fluid to the bottom of the fill plug hole Стр 25 из 39 MANUAL TRANSAXLE 18 11 2005 http www chiltondiy com content 8687 8687_7_1 html ...

Page 1423: ...he engine lifting eyes 58 Connect the clutch cable to the clutch release lever Using a crow s foot wrench to install the speedometer cable Стр 26 из 39 MANUAL TRANSAXLE 18 11 2005 http www chiltondiy com content 8687 8687_7_1 html ...

Page 1424: ...ss you have the following parts a newfront axle wheel hub retainer a new lower control arm to steering knuckleretaining retaining bolt and nut a new driveshaft bearing retainer circlip anda new interconnecting shaft driveshaft bearing retainer circlip Once theseparts are removed they CANNOT be reused Their torque holding ability orretention capability is reduced during removal REMOVAL INSTALLATION...

Page 1425: ... still on the ground remove the wheel cover from the wheel and tire assembly then loosen the lug nuts After the vehicle is safely raised remove the wheel and tire assembly then remove the axle wheel hub retainer it is helpful to use a steel rod in the brake rotor to keep it from turning Стр 28 из 39 MANUAL TRANSAXLE 18 11 2005 http www chiltondiy com content 8687 8687_7_1 html ...

Page 1426: ...sition aside If equipped with air suspension remove the height sensor bracket retaining bolt and wire sensor bracket to inner fender Position the sensor link aside After removing the front axle wheel hub retainer discard and replace it with a new one during installation After removing the ball joint retaining bolt and nut discard them since they lose their torque retaining quality and cannot be re...

Page 1427: ...ar link at the stabilizer bar Click to enlarge If your vehicle is equipped with anti lock brakes remove the anti lock brake sensor then position it aside Using a suitable prybar separate the ball joint from the steering knuckle Position the end of the prybar outside of the bushing pocket to avoid damage to the bushing being careful not to damage the ball joint boot Стр 30 из 39 MANUAL TRANSAXLE 18...

Page 1428: ...b using front hub remover tool T81P 1104 C or equivalent and metric adapter tools T83 P 1104 BH T86P 1104 Al and T81P 104 A or equivalent NEVER use a hammer to separate the outboard CV joint stubshaft from the hub Damage to the CV joint threads and internal components mayresult The right side link shaft and halfshaft assembly is removed as acomplete unit These tools are required to remove the fron...

Page 1429: ...suspending it from a convenient underbody component with a piece of wire Do not allow the shaft to hang unsupported damage to the outboard CV joint may occur 4 Separate the outboard CV joint from the hub using front hub remover tool T81P 1104 C or equivalent and metric adapter tools T83P 1104 BH T86P 1104 Al and T81P 1104 A or equivalent convenient underbody component with a piece of wire Do NOT a...

Page 1430: ...ng the left side front wheel driveshaft and joint from the transaxle using the specified tools Support the end of the left side shaft by suspending it from a convenient underbody component with wire Стр 33 из 39 MANUAL TRANSAXLE 18 11 2005 http www chiltondiy com content 8687 8687_7_1 html ...

Page 1431: ... or link shaft The outboard CV joint does not have a circlip When installing the circlip start one end Separating the outboard CV joint from the hub using the specified tools Exploded view of the halfshaft assemblies Стр 34 из 39 MANUAL TRANSAXLE 18 11 2005 http www chiltondiy com content 8687 8687_7_1 html ...

Page 1432: ...orce push the CV joint into the differential until the circlip is felt to seat in the differential side gear Use care to prevent damage to the differential oil seal If equipped tighten the link shaft bearing to 16 23 ft lbs 22 31 Nm A non metallic mallet may be used to aid in seating thecirclip into the differential side gear groove If a mallet is necessary taponly on the outboard CV joint stub sh...

Page 1433: ...t installation 13 Install the hub nut washer and a new hub nut Manually thread the retainer onto the CV joint as far as possible Click to enlarge 14 Connect the lower control arm to the steering knuckle using a new nut and bolt Tighten the nut to 40 55 ft lbs 54 74 Nm Carefully align the splines of the inboard CV joint stub shaft with the splines in the differential Install the hub nut washer and ...

Page 1434: ... Connect the stabilizer link to the stabilizer bar Tighten to 35 48 ft lbs 47 65 Nm Connect the lower control arm to the steering wheel knuckle using a new nut and bolt If your vehicle is so equipped install the anti lock brake sensor Стр 37 из 39 MANUAL TRANSAXLE 18 11 2005 http www chiltondiy com content 8687 8687_7_1 html ...

Page 1435: ...hicle Tighten the wheel lug nuts to 80 105 ft lbs 108 144 Nm Fill the transaxle to the proper level with the specified fluid Connect the stabilizer link to the stabilizer bar Do NOT use power tools or an impact gun to tighten the hub nut and make sure to tighten it to specification Стр 38 из 39 MANUAL TRANSAXLE 18 11 2005 http www chiltondiy com content 8687 8687_7_1 html ...

Page 1436: ...e Chilton Automotive Information Systems 2004 Thomson Delmar Learning Make sure to tighten the lug nuts to the proper torque Стр 39 из 39 MANUAL TRANSAXLE 18 11 2005 http www chiltondiy com content 8687 8687_7_1 html ...

Page 1437: ...he pedal until it stops Very little effort is required about 10 lbs During the application of upward pressure a click may be heard which means an adjustment was necessary and has been accomplished Clutch Pedal REMOVAL INSTALLATION 1986 92 Vehicles 1 Disconnect the negative battery cable CAUTION The clutch driven disc may contain asbestos which has been determined to be a cancer causing agent Never...

Page 1438: ...re strand portion of the inner cable because the strands may be damaged causing cable failure Do NOT grasp the wire strand portion of the inner cable because this may cut the wires causing cable failure Click to enlarge 5 Unlatch the fuse panel View of the clutch pedal and related components 1986 2 5L Taurus shown Using a pair of pliers grasp the extended tip of the clutch cable and unlock the cab...

Page 1439: ...s from the brake booster studs and two screws from the pedal support 11 Disconnect the retaining nuts securing the clutch pedal stop bracket to the clutch pedal mounting plate then remove the pedal 12 If pawl removal is necessary disconnect the quadrant tension spring from the pedal Remove the spacer nut and pivot bolt from the clutch pedal and pivot sleeve Remove the spring washer two bushings pi...

Page 1440: ...le the gear quadrant spring to the gear quadrant noting the direction of the hook on the free end of the spring clip Note the proper position of the pawl spring and pawl Стр 4 из 20 18 11 2005 file C DOCUME 1 SILENT 1 LOCALS 1 Temp trsPDIPH htm ...

Page 1441: ...e the pawl on the gear quadrant face 17 Install the two bushings and pivot sleeve into the clutch pedal Assemble the gear quadrant spring to the gear quadrant making sure to note the direction of the hook on the free end of the spring Стр 5 из 20 18 11 2005 file C DOCUME 1 SILENT 1 LOCALS 1 Temp trsPDIPH htm ...

Page 1442: ...e the clutch pedal assembly and mounting plate to the brake booster studs and brake pedal support 22 Pull the clutch cable through the insulator clutch pedal stop bracket and the recess between the pedal and the gear quadrant Rotate the gear quadrant forward by lifting up on the clutch pedal to release the pawl then hook the cable into the gear quadrant 23 Secure the clutch shield to the clutch mo...

Page 1443: ... retaining screw located near the toe board then rotate the shield out of the way Secure by snugging up the front screw the rear retaining screw is closest to the instrument panel 4 Prop up the clutch pedal to lift the clutch pedal quadrant adjuster pawl free of the clutch pedal adjuster quadrant which is part of the self adjuster mechanism Do NOT allow the quadrant to snap back 5 Lift up on the c...

Page 1444: ...rake booster studs and two screws from the pedal support 12 Disconnect the retaining nuts securing the clutch pedal bumper bracket to the clutch pedal release plate then remove the clutch pedal 13 If pawl removal is necessary disconnect the clutch pedal lever assist spring from the pedal Remove the spacer nut and pivot bolt from the clutch pedal and pivot sleeve Remove the clutch and brake pedal s...

Page 1445: ...wl spring and pawl Note the proper position of the clutch pedal pawl spring and clutch pedal quadrant adjuster pawl Click to enlarge 16 Connect the clutch pedal lever assist spring to the quadrant noting the direction of the hook on the free end of the spring Insert the pawl spring and the pivot pin into the clutch pedal then secure the retaining clip Note the proper position of the pawl spring an...

Page 1446: ...place the pawl on the quadrant face 18 Install the two clutch release idler level rod bushings and pivot sleeve into the clutch pedal Connect the clutch pedal lever assist spring to the quadrant noting the direction of the hook on the free end of the spring Стр 10 из 20 18 11 2005 file C DOCUME 1 SILENT 1 LOCALS 1 Temp trsPDIPH htm ...

Page 1447: ... in the clutch pedal Make sure the spring washer is functional and is not trapped under the pivot sleeve Install the two clutch release idler level rod bushings and pivot sleeve into the clutch pedal Стр 11 из 20 18 11 2005 file C DOCUME 1 SILENT 1 LOCALS 1 Temp trsPDIPH htm ...

Page 1448: ... and hook the cable into the quadrant 24 Secure the clutch pedal shield to the clutch release plate then tighten to 71 106 inch lbs 8 12 Nm 25 Install the clutch pedal position switch then adjust by pressing the clutch pedal to the floor 26 Using a piece of wire cord or tape secure the clutch pedal in its upmost position to make sure the clutch pedal quadrant adjuster pawl is disengaged from the q...

Page 1449: ...arbor alignment tool this can be done before removal or during installation Once the transaxle is removed the clutch pressure plate cover is visible Стр 13 из 20 18 11 2005 file C DOCUME 1 SILENT 1 LOCALS 1 Temp trsPDIPH htm ...

Page 1450: ...the cover and the flywheel so the pressure plate can be installed in its original position 4 Remove the pressure plate and clutch disc from the flywheel If the pressure plate cover is dirty or dusty clean it with a commercially available spray cleaner Loosen the six pressure plate retaining bolts evenly to release the tension gradually Стр 14 из 20 18 11 2005 file C DOCUME 1 SILENT 1 LOCALS 1 Temp...

Page 1451: ...s any signs of overheating blue discoloration or if it is badly grooved or scored it should be refaced or replaced After all of the retaining bolts are removed you can remove the pressure plate and clutch disc from the flywheel View of a common clutch disc and pressure plate mounting Стр 15 из 20 18 11 2005 file C DOCUME 1 SILENT 1 LOCALS 1 Temp trsPDIPH htm ...

Page 1452: ...pressure plate on the flywheel then insert the cover retaining bolts but do not tighten them at this time 9 Align the clutch disc using Clutch Arbor Aligner Tool T81P 7550 A or equivalent inserted in the crankshaft To avoid clutch pressure plate cover distortion alternately tighten the cover bolts until the cover is fully seated then tighten to 24 ft lbs 33 Nm for 1993 95 vehicles For 1986 92 vehi...

Page 1453: ... panel 3 Prop up the clutch pedal to lift the pawl free of the quadrant which is part of the self adjuster mechanism Do NOT allow the clutch pedal adjuster quadrant to snap back 4 With the clutch pedal lifted up to release the clutch pedal quadrant adjuster pawl rotate the clutch pedal adjuster quadrant forward Unhook the clutch cable from the quadrant Allow the quadrant to swing rearward 5 Remove...

Page 1454: ...nstall the cable into the quadrant 10 Insert the clutch cable assembly from the engine or passenger compartment if the clutch pedal was removed through the dash panel and dash panel grommet Make sure the cable is routed inboard of the brake lines and not trapped at the spring tower by the brake lines 11 With the quadrant at the window stop position push the clutch cable through the insulator on th...

Page 1455: ... was used to temporarily secure the pedal against its stop 18 Adjust the clutch by pressing the clutch pedal down several times 19 Install the air cleaner then connect the negative battery cable Clutch Interlock Pedal Position Switch REMOVAL INSTALLATION 1 Disconnect the negative battery cable 2 Disengage the switch electrical connector 3 Remove the retaining screw and hairpin clip then remove the...

Page 1456: ...e retaining clip 5 Align the mounting boss with the corresponding hole in the bracket then install the screw Tighten the screw to 80 115 inch lbs 9 13 Nm 6 Reset the switch by pressing the clutch pedal to the floor 7 Engage the switch electrical connector then connect the negative battery cable Chilton Automotive Information Systems 2004 Thomson Delmar Learning Common clutch interlock pedal positi...

Page 1457: ...also used Only one band is used in the ATX In service fluid additions or fluid changes may be made with Motorcraft Type H automatic transmission fluid The AXOD AXOD E AX4S and AX4N automatic transaxles are 4 speed units They all have two planetary gear sets and a combination planetary differential gear set Four multiple plate clutches two band assemblies and two one way clutches act together for p...

Page 1458: ...FT LINKAGE AXOD and AXOD E Transaxle 1 Position the selector lever in the OD position against the rearward stop The shift lever must be held in the rearward position using a constant force of 3 lbs 1 4 Kg while the linkage is being adjusted 2 Loosen the manual lever to control cable retaining nut 3 Move the transaxle manual lever to the OD position second detent from the most rearward position 4 T...

Page 1459: ...er 2 If equipped with the 3 0L engine with the TV cable mounted in the engine bracket make sure the threaded shank is fully retracted To retract the shank pull up on the spring rest with the index fingers and wiggle the top of the thread shank while pressing the shank through the spring with the thumbs 3 If equipped with the 3 8L engine the TV cable must be unclipped from the right intake manifold...

Page 1460: ...The threaded shank must show movement or ratchet out of the grip jaws If there is no movement inspect the TV cable system for broken or disconnected components then repeat the procedure Click to enlarge While the spring is compressed push the threaded shank toward the spring with the index and middle fingers of the left hand Do not pull on the cable sheath The threaded shank must show movement or ...

Page 1461: ...1 shift in D range Delayed upshift at light acceleration z Cause Interference due to hoses wires etc prevents return of TV control rod or TV linkage shaft Excessive friction caused by binding grommets prevents the TV control linkage to return to its proper location z Remedy Correct the interference area check for bent or twisted rods levers or damaged grommets Repair or replace whatever is necessa...

Page 1462: ...AXOD and AXOD E Transaxles 1 Position the selector lever in the OVERDRIVE position against the rearward stop 2 If the vehicle is equipped with a floor shift selector the shift lever must be held in the rearward position using a constant force of about 3 lbs as the linkage is being adjusted 3 Loosen the manual lever to control cable retaining nut Be sure that the transaxle lever is in the OVERDRIVE...

Page 1463: ...ntrol lever on top of the switch 4 Remove the two neutral switch attaching bolts then remove the switch Click to enlarge Neutral safety switch location vehicles equipped with automatic transaxle Adjusting the neutral safety switch Стр 7 из 70 AUTOMATIC TRANSAXLE 18 11 2005 http www chiltondiy com content 8687 8687_7_3 html ...

Page 1464: ...lever housing and install the spring clip 8 Install the bushing and control cable assembly on the selector lever and housing assembly shaft and secure it with the retaining pin 9 Install the bezel assembly console locknut and shift knob 10 Position the selector lever in the Drive position The selector lever must be held in this position while attaching the other end of the control cable 11 Positio...

Page 1465: ...e 5 Disengage the electrical connector from the neutral safety switch 6 Detach the electrical bulkhead connector from the rear of the transaxle Click to enlarge 7 Remove the oil dipstick 8 For 3 8L engines remove the throttle valve cable cover Unsnap the throttle valve cable from the throttle body lever Remove the throttle valve cable from the transaxle case Detach the connectors from the neutral ...

Page 1466: ...V link Pulling too hard on the throttle valve may bend the internal TV bracket Click to enlarge 10 Install engine lifting brackets Location of the throttle valve cable cover 3 8L engines only Removing the accelerator cable Стр 10 из 70 AUTOMATIC TRANSAXLE 18 11 2005 http www chiltondiy com content 8687 8687_7_3 html ...

Page 1467: ...large 13 Install a suitable engine support fixture 14 Raise the and safely support the vehicle 15 Remove both front wheels Remove the left side outer tie rod end Installing engine lifting brackets Remove the four torque converter housing bolts from the top of the transaxle Стр 11 из 70 AUTOMATIC TRANSAXLE 18 11 2005 http www chiltondiy com content 8687 8687_7_3 html ...

Page 1468: ...nsor electrical connection then remove the exhaust pipe converter assembly and mounting bracket Click to enlarge 19 Remove the two 15mm bolts from the transaxle mount Remove the four 15mm bolts from the left engine support then remove the bracket Remove the nut securing the steering rack to the subframe On the 3 8L engine remove the front exhaust pipe converter assembly and mounting bracket Стр 12...

Page 1469: ... of the way Remove the dust cover 23 Rotate the engine by the crankshaft pulley bolt to align the torque converter bolts with the starter drive hole Remove the torque converter to flywheel retaining nuts 24 Remove the transaxle cooler line fitting retaining clips Using Cooler Line Disconnect Tool T86P 77265 AH or equivalent disconnect the transaxle cooler lines Remove the bolts from the left engin...

Page 1470: ...ition a suitable transaxle jack 29 Remove the halfshafts as follows 1 Screw Extension T86P 3514 A2 into CV Joint Puller T86P 3514 A1 and insert Slide Hammer D79P 100 A or equivalent into the extension 2 Position the puller behind the CV joint then remove the joint 3 Install shipping plugs Transaxle cooler line locations Remove the vehicle speed sensor from the transaxle Стр 14 из 70 AUTOMATIC TRAN...

Page 1471: ...observe the following 1 Clean the transaxle oil cooler lines 2 Install new circlips on the CV joint seals 3 Carefully install the halfshafts in the transaxle by aligning the splines of the CV joint with the splines of the differential 4 Attach the lower ball joint to the steering knuckle Tools necessary to remove the halfshafts Position the puller behind the CV joint then remove the joint Стр 15 и...

Page 1472: ... 5L ENGINE 1 Disconnect the negative battery cable 2 Remove the air cleaner assembly 3 Position the engine control wiring harness away from the transaxle converter housing area 4 Disconnect the TV linkage and manual lever cable at the respective levers Failure to disconnect the linkage during transaxle removal and allowing the transaxle to hang will fracture the throttle valve cam shaft joint loca...

Page 1473: ...t support insulator and position the left front splash shield aside 19 Position a workbench or shop table to support the subframe after it is disconnected Lower the vehicle to the bench table surface Position blocks or support for the subframe as required Remove the subframe retaining bolts then remove the subframe Disconnect the neutral start switch wire assembly 20 Raise the vehicle after the su...

Page 1474: ...orque specifications listed Transaxle to engine bolts 25 33 ft lbs 34 45 Nm Control arm to knuckle bolts 36 44 ft lbs 50 60 Nm Stabilizer U clamp to bracket bolts 60 70 ft lbs 81 95 Nm Tie rod to knuckle nut 23 35 ft lbs 31 47 Nm Starter to transaxle bolts 30 40 ft lbs 41 54 Nm Converter to flywheel bolts 23 39 ft lbs 31 53 Nm Insulator to bracket bolts 55 70 ft lbs 75 90 Nm 1991 95 Vehicles 1 Dis...

Page 1475: ...t on the back of the engine that retains the wiring harness and coolant line and attach Engine Lifting Eyes to the alternator bracket On the 3 8L engine install engine lifting eyes to the left front exhaust manifold stud and right rear exhaust manifold stud Click to enlarge On the 3 0L engine install engine lifting eye to the left rear cylinder Стр 19 из 70 AUTOMATIC TRANSAXLE 18 11 2005 http www ...

Page 1476: ...pension turn the air suspension switch located in the luggage compartment to the OFF position 12 Remove the oil level dipstick and disconnect the power steering pump pressure and return line bracket 13 Remove the four torque converter housing bolts from the top of the transaxle Installing lifting equipment on the 3 2L SHO engine Стр 20 из 70 AUTOMATIC TRANSAXLE 18 11 2005 http www chiltondiy com c...

Page 1477: ...move the retaining bolts from the front stabilizer bar assembly Disconnect the right and left lower arm assemblies 17 Remove the steering gear retaining nuts from the subframe Remove the front heated oxygen sensor exhaust pipe converter assembly and mounting bracket Remove the four torque converter housing bolts from the top of the transaxle Стр 21 из 70 AUTOMATIC TRANSAXLE 18 11 2005 http www chi...

Page 1478: ... from the engine mount and the four bolts from the left engine support then remove the support Remove the steering gear to subframe retaining nuts Стр 22 из 70 AUTOMATIC TRANSAXLE 18 11 2005 http www chiltondiy com content 8687 8687_7_3 html ...

Page 1479: ...Click to enlarge Remove the two retaining bolts from the engine mount then remove the mount Стр 23 из 70 AUTOMATIC TRANSAXLE 18 11 2005 http www chiltondiy com content 8687 8687_7_3 html ...

Page 1480: ... torque converter bolts with the starter drive hole Remove the four torque converter to flywheel retaining nuts 23 Remove the transaxle cooler line fitting retaining clips Using Cooler Line Disconnect Tool T86P 77265 AH or equivalent disconnect the transaxle cooler lines 24 Remove the engine to transaxle retaining bolts 25 Remove the speedometer sensor heat shield Remove the vehicle speed sensor f...

Page 1481: ...100 A or equivalent into the extension 2 Position the puller behind the CV joint then remove the joint 3 Install shipping plugs Remove the vehicle speed sensor from the transaxle WARNING Make sure the puller does not contact the speed sensor or damage will occur Do NOT pry against the case Стр 25 из 70 AUTOMATIC TRANSAXLE 18 11 2005 http www chiltondiy com content 8687 8687_7_3 html ...

Page 1482: ...o install 29 Place the transaxle assembly on the jack and raise to the engine 30 Position the transaxle to the engine then align the torque converter bolts to the flywheel Tools required to remove the halfshafts Position the puller behind the CV joint then remove the joint Стр 26 из 70 AUTOMATIC TRANSAXLE 18 11 2005 http www chiltondiy com content 8687 8687_7_3 html ...

Page 1483: ... tighten to 18 23 ft lbs 24 31 Nm At the oil cooler tighten to 8 12 ft lbs 11 16 Nm 37 Install the dust cover then tighten to 7 9 ft lbs 9 12 Nm 38 Install the starter then tighten the mounting bolts to 30 40 ft lbs 41 50 Nm 39 Raise the subframe and install the retaining bolts then tighten the bolts to 55 75 ft lbs 75 102 Nm Remove the subframe removal kit 40 Install the left engine support Tight...

Page 1484: ...onnect the heated oxygen sensor 43 Install the power steering gear assembly and retaining nuts then tighten the nuts to 85 100 ft lbs 115 135 Nm Install the engine mount then tighten to specification Стр 28 из 70 AUTOMATIC TRANSAXLE 18 11 2005 http www chiltondiy com content 8687 8687_7_3 html ...

Page 1485: ...wer the vehicle 49 Install the power steering pump pressure and return bracket then tighten to 40 50 inch lbs 4 5 5 7 Nm 50 Remove the Three Bar Engine Support Install the radiator sight shield 51 Remove all of the engine support equipment 52 Install the shift lever 53 Fasten the main wiring harness bracket then engage the electrical connectors to the engine 54 Install the battery tray and battery...

Page 1486: ...y the left halfshaft assembly is to be removed forservice remove only the right halfshaft assembly from the transaxle Afterremoval support it with a length of wire Then drive the left halfshaftassembly from the transaxle REMOVAL INSTALLATION 1 Disconnect the negative battery cable 2 Remove the wheel cover hub cover from the wheel and tire assembly then loosen the lug nuts 3 Raise and safely suppor...

Page 1487: ...hammer Discard this bolt and nut after removal Before removing the hub nut and washer insert a steel rod in the rotor to prevent it from turning Remove the hub nut and washer then discard the nut and replace with a new one during installation Стр 31 из 70 AUTOMATIC TRANSAXLE 18 11 2005 http www chiltondiy com content 8687 8687_7_3 html ...

Page 1488: ...ge 7 Separate the ball joint from the steering knuckle using a suitable prybar Position the end of the prybar outside of the bushing pocket to avoid damage to the Drive the bolt out of the front wheel knuckle using a punch and hammer then discard the nut and bolt and replace with new ones during installation If so equipped remove the anti lock brake sensor and position it aside Стр 32 из 70 AUTOMA...

Page 1489: ...BH T86P 1104 Al and T81P 1104 A or equivalent NEVER use a hammer to separate the outboard CV joint stubshaft from the hub Damage to the CV joint threads and internal components mayresult The right side link shaft and halfshaft assembly is removed as acomplete unit 9 The following removal procedure applies to the right and left side halfshafts of the automatic transaxle except for 1986 90 Tauruses ...

Page 1490: ...he hub using front hub remover tool T81P 1104 C or equivalent and metric adapter tools T83P 1104 BH T86P 1104 Al and T81P 1104 A or equivalent 5 Remove the halfshaft assembly from the vehicle Click to enlarge These tools are necessary for halfshaft removal Installing the specified tools to remove the halfshaft assembly from the vehicle Стр 34 из 70 AUTOMATIC TRANSAXLE 18 11 2005 http www chiltondi...

Page 1491: ...h a piece of wire Do not allow the shaft to hang unsupported since damage to the outboard CV joint may occur Separate the outboard CV joint from the hub using front hub remover tool T81P 1104 C or equivalent and metric adapter tools T83P 1104 BH T86P 1104 Al and T81P 1104 A or equivalent then remove the halfshaft assembly from the vehicle Стр 35 из 70 AUTOMATIC TRANSAXLE 18 11 2005 http www chilto...

Page 1492: ...may occur 2 Separate the outboard CV joint from the hub front hub remover tool T81P 1104 C or equivalent and metric adapter tools T83P 1104 BH T86P 1104 Al and T81P 1104 A or equivalent 3 Remove the halfshaft assembly from the vehicle Click to enlarge To install 11 Install a new circlip on the inboard CV joint stub shaft and or link shaft The outboard CV joint does not have a circlip When installi...

Page 1493: ...r groove If a mallet is necessary taponly on the outboard CV joint stub shaft 13 Carefully align the splines of the outboard CV joint stub shaft with the splines in the hub and push the shaft into the hub as far as possible Always use a new circlip on the inboard CV joint stub shaft and or link shaft When installing the new circlip start one end in the groove and work the circlip over the stub sha...

Page 1494: ... hub nut washer and a new hub nut Manually thread the retainer onto the CV joint as far as possible Click to enlarge 16 Connect the control arm to the steering knuckle then install a new nut and bolt Tighten the nut to 40 55 ft lbs 54 74 Nm differential Install the hub washer and a new hub nut then thread the retainer by hand on the threads as far as possible Стр 38 из 70 AUTOMATIC TRANSAXLE 18 11...

Page 1495: ...ct the stabilizer link to the stabilizer bar Tighten to 35 48 ft lbs 47 65 Nm Connect the control arm to the steering knuckle and install a new nut and bolt Tighten to 40 55 ft lbs 54 74 Nm If equipped install the anti lock brake sensor Стр 39 из 70 AUTOMATIC TRANSAXLE 18 11 2005 http www chiltondiy com content 8687 8687_7_3 html ...

Page 1496: ...ghten the wheel lug nuts to 80 105 ft lbs 108 142 Nm Fill the transaxle to the proper level with the specified fluid Connect the stabilizer link to the stabilizer bar Tighten to 35 48 ft lbs 47 65 Nm Install a new hub retainer nut then tighten to specification using a torque wrench Do NOT use an air gun or impact tools to tighten the nut Стр 40 из 70 AUTOMATIC TRANSAXLE 18 11 2005 http www chilton...

Page 1497: ...e battery cable Raise and safely support the vehicle After the vehicle is lowered tighten the lug nuts to 80 105 ft lbs 108 142 Nm Exploded view of the outboard CV joint assembly Стр 41 из 70 AUTOMATIC TRANSAXLE 18 11 2005 http www chiltondiy com content 8687 8687_7_3 html ...

Page 1498: ...aft in a vise that is equipped with soft jaw covers Do not allow the vise jaws to contact the boot or boot clamp Before removal check the CV boot for wear or damage Clean the CV joint prior to removing the boot but be careful not to damage anything Стр 42 из 70 AUTOMATIC TRANSAXLE 18 11 2005 http www chiltondiy com content 8687 8687_7_3 html ...

Page 1499: ...lamp has been removed Click to enlarge Clamp the halfshaft in a vise with soft jaw covers but do not allow the vise jaws to contact the boot or boot clamp Cut the boot clamp with a pair of side cutters then pull the clamp away from the boot Стр 43 из 70 AUTOMATIC TRANSAXLE 18 11 2005 http www chiltondiy com content 8687 8687_7_3 html ...

Page 1500: ... tap to the inner bearing race to dislodge the internal driveshaft bearing retainer circlip and separate the CV joint from the interconnecting shaft Make sure to secure the CV joint so it does not drop after separation Slide the boot back over the shaft once the clamp has been removed Стр 44 из 70 AUTOMATIC TRANSAXLE 18 11 2005 http www chiltondiy com content 8687 8687_7_3 html ...

Page 1501: ...internal driveshaft bearing retainer circlip and separate the CV joint from the interconnecting shaft Make sure to secure the CV joint so it does not drop after separation The boot cannot be removed from the shaft Стр 45 из 70 AUTOMATIC TRANSAXLE 18 11 2005 http www chiltondiy com content 8687 8687_7_3 html ...

Page 1502: ...y Do NOT reuse the circlip Replace the used circlip with a new one before assembly 10 Remove and discard the circlip located near the end of the interconnecting shaft The stop ring located just below the circlip should be removed and replaced only if damaged or worn Check the CV joint grease for contamination or foreign debris by visually inspecting it and rubbing it with fingers Any grittiness in...

Page 1503: ... circlip should be removed and replaced only if damaged or worn Clamp the CV joint in a vise with soft jaw covers with the outer face facing up Be careful not to damage the dust shield Vise jaw caps are made of copper brass wood or other soft material They are slipped over the steel jaws of the vise so the finished surfaces of the component won t get scratched or nicked Стр 47 из 70 AUTOMATIC TRAN...

Page 1504: ...epeat this until all of the balls are removed If the balls are tight in the cage use a blunt edged prytool to pry the balls from the cage Press down on the inner race until it tilts enough to permit removal of the ball A tight assembly can be tilted by tapping the inner race with a wooden dowel and hammer but do not hit the cage WARNING Be careful not to scratch or damage the inner race or cage sp...

Page 1505: ...outer race lands while pivoting the bearing cage With the cage sufficiently tilted remove a ball from the cage Repeat this until all of the balls are removed If the balls are tight in the cage use a blunt edged prytool to pry the balls from the cage Стр 49 из 70 AUTOMATIC TRANSAXLE 18 11 2005 http www chiltondiy com content 8687 8687_7_3 html ...

Page 1506: ...alent on the inner and outer ball races 17 Install the inner race in the bearing cage Pivot the cage and inner race assembly until it is straight up and down in the outer race Align the cage windows with the outer race lands while pivoting the bearing cage With the cage pivoted and aligned lift the assembly from the outer race Rotate the inner race up and out of the cage Стр 50 из 70 AUTOMATIC TRA...

Page 1507: ...ge and inner race with the outer race Tilt the inner race and cage then install a ball Repeat until all balls are installed Install the inner race in the bearing cage Install the inner race and cage assembly in the outer race Install the assembly vertically then pivot 90 into position Стр 51 из 70 AUTOMATIC TRANSAXLE 18 11 2005 http www chiltondiy com content 8687 8687_7_3 html ...

Page 1508: ...n using Boot Clamp Installer T95P 3514 A or equivalent Tighten the tool through the bolt until it s in a closed position then remove the tool Align the bearing cage and inner race with the outer race Tilt the inner race and cage then install a ball Repeat until all balls are installed On some vehicles the left and right interconnecting shafts are different depending on year and vehicle application...

Page 1509: ...Make sure the CV boot is seated in its groove and the clamp is in position using Boot Стр 53 из 70 AUTOMATIC TRANSAXLE 18 11 2005 http www chiltondiy com content 8687 8687_7_3 html ...

Page 1510: ...This will avoid overexpanding the circlip Clamp Installer T95P 3514 A or equivalent Tighten the tool through the bolt until it s in a closed position then remove the tool If removed install the stop ring If not removed make sure the ring is properly seated in its groove Install a new circlip in the groove nearest the end of the shaft by starting one end in the groove then work the circlip over the...

Page 1511: ... evenly inside of the boot Click to enlarge 25 With the front wheel driveshaft joint boot held back position the CV joint on the shaft and tap into position using a plastic tipped hammer end and into the groove This will avoid overexpanding the circlip Pack the CV joint with grease Any leftover grease in the tube should be spread evenly inside of the boot Стр 55 из 70 AUTOMATIC TRANSAXLE 18 11 200...

Page 1512: ...29 Position the boot over the joint then make sure the boot is seated in its groove and the clamp is in position using Boot Clamp Installer T95P 3514 A or equivalent Position the tool on the clamp ear then tighten the tool through the bolt until it is in the closed position Remove the tool Click to enlarge With the front wheel driveshaft joint boot held back position the CV joint on the shaft and ...

Page 1513: ... slide the boot back on the shaft Remove the clamp by engaging the pincer jaws of boot clamp pliers D87P 1090 A or equivalent in the closing hooks on the clamp and draw together Disengage the windows and locking hooks then remove the clamp 5 Mark the position of the outer race in relation to the shaft then remove the outer race from the tripod Position the tool on the clamp ear and tighten the too...

Page 1514: ...he tripod assembly Remove the boot 8 Check the CV joint grease for contamination If the CV joints are operating properly and the grease is not contaminated add grease and replace the boot If the grease appears contaminated disassemble the CV joint and clean or replace Slide the outer race off of the tripod Move the stop ring back on the shaft using snapring pliers then move the tripod assembly bac...

Page 1515: ...l procedure Click to enlarge 11 Install a new circlip Compress the circlip and slide the tripod assembly forward over the circlip to expose the stop ring groove 12 Move the stop ring into the groove using snapring pliers making sure it is fully seated in the groove 13 Fill the CV joint outer race and CV boot with grease Install the outer race over the tripod assembly aligning the marks made during...

Page 1516: ...right halfshaft 1986 90 Taurus with 2 5L engine 20 09 in 510mm Manual transaxle left halfshaft 21 24 in 539 5mm Manual transaxle right halfshaft 21 63 in 549 5mm 15 Before installing the boot clamp make sure any air pressure that may have built up in the boot is relieved Insert a small prybar between the boot and outer race to allow the trapped air to escape Release the air only after adjusting th...

Page 1517: ...t if CV joint boots or boot clamps are needed they are available separately 1 Disconnect the negative battery cable Raise and safely support the vehicle 2 Remove the halfshaft assembly from the vehicle Click to enlarge 3 Clamp the halfshaft in a vise that is equipped with soft jaw covers Do not allow the vise jaws to contact the boot or boot clamp 4 Cut and remove both boot clamps then slide the b...

Page 1518: ...on 7 If further disassembly is required remove the outboard CV joint and boot as described earlier in this section 8 Remove the driveshaft joint stop ring and bearing retainer circlip 9 Slide the inboard boot off of the interconnecting shaft 10 Remove the trilobe insert from the CV joint stub Remove the grease from the outer race then inspect the outer race and tripod assembly Removing the clamp u...

Page 1519: ...e groove on the outer race 13 Fill the CV joint housing with Ford High Temperature Constant Velocity Grease E43Z 19590 A or equivalent and spread remaining grease evenly inside of the joint boot The total fill amount is 9 oz 250 grams Remove the trilobe insert from the CV joint stub Filling the housing with CV joint grease Стр 63 из 70 AUTOMATIC TRANSAXLE 18 11 2005 http www chiltondiy com content...

Page 1520: ...to adjust the length to the specifications in the accompanying figure Click to enlarge All vehicles except SHO vehicles require a reusable low profile large front CV joint boot clamp on the right hand side inboard CV joint 17 Seat the boot in the grooves then clamp in position using Boot Clamp Installer T94P 3514 A or equivalent on the left CV joint housing 18 Install the large low profile right h...

Page 1521: ...l at various angles The joint should flex extend and compress smoothly 22 Install the halfshaft assembly then carefully lower the vehicle 23 Connect the negative battery cable 3 2L SHO The inboard CV joint assembly on these vehicles is permanently retained to the interconnecting shaft The service CV joint includes the shaft and CV joint boot The boot or driveshaft and joint replacement will necess...

Page 1522: ...disassembly and inspection 7 If further disassembly is required remove the driveshaft and CV joint and the boot 8 Remove the driveshaft stop ring and bearing retainer circlip the slide the joint boot off of the interconnecting shaft To install 9 Install the CV joint boot on the interconnecting shaft Position the boot to allow for inboard CV joint housing installation Removing the boot clamps using...

Page 1523: ...erature Constant Velocity Grease E43Z 19590 A or equivalent fill the inboard CV joint with grease then spread the remaining grease evenly inside of the boot Installing the CV joint boot on the interconnecting shaft make sure to position the boot to allow for CV joint housing installation Using the boot clamp installer to fasten the small boot clamp Стр 67 из 70 AUTOMATIC TRANSAXLE 18 11 2005 http ...

Page 1524: ... and boot sealing surfaces Slide the CV joint boot into position on the inboard CV joint housing Move the CV joint in and out as necessary to adjust to the specified length shown in the accompanying figure 14 Locate the clamp tabs in the slots then make the clamps as tight as possible by hand Click to enlarge Filling the CV joint and boot with grease After positioning the clamp tabs in the slots m...

Page 1525: ...ng installation ALWAYS replace the circlip with a new one during installation 17 Install a new circlip in the groove nearest the end of the shaft by starting one end in the groove then working the circlip over the stub shaft and into the groove Position the Boot Clamp Replacer T95T 3514 A or equivalent on the clamp ear then tighten the tool through the bolt until the tool is in a closed position W...

Page 1526: ...ative battery cable Chilton Automotive Information Systems 2004 Thomson Delmar Learning Do not overexpand or twist the circlip during installation ALWAYS replace the circlip with a new one during installation Стр 70 из 70 AUTOMATIC TRANSAXLE 18 11 2005 http www chiltondiy com content 8687 8687_7_3 html ...

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Page 1670: ...ver is gear 4 Using the tapered end of the lug nut wrench remove the hub cap from the wheel and tire assembly Aluminum wheels require a special bulge type lug nut with an enlarged chamfer to prevent distortion of the wheel hub bolt nut seat 5 Using the proper size lug nut wrench loosen but do not remove the lug nuts from the wheel and tire assembly 6 Raise and properly support the vehicle 7 Finish...

Page 1671: ...the way around INSPECTION Replace wheels if they are bent dented heavily rusted have air leaks elongated bolt holes or excessive lateral and radial run out Also inspect wheel lug nuts and be sure that they are tightened to specification Wheel Lug Studs Hub Bolts REPLACEMENT 1 Raise and safely support the vehicle 2 Remove the wheel and tire assembly 3 Remove the caliper and rotor For details please...

Page 1672: ... stud into the wheel hub 8 Install the caliper and rotor 9 Install the wheel and tire assembly then carefully lower the vehicle Chilton Automotive Information Systems 2004 Thomson Delmar Learning Стр 3 из 3 WHEELS 18 11 2005 http www chiltondiy com content 8687 8687_8_1 html ...

Page 1673: ...LATION 1 Place the ignition switch in the OFF position and the steering column in the UNLOCKED position Click to enlarge View of the front suspension components Стр 1 из 31 FRONT SUSPENSION 18 11 2005 http www chiltondiy com content 8687 8687_8_2 html ...

Page 1674: ...Стр 2 из 31 FRONT SUSPENSION 18 11 2005 http www chiltondiy com content 8687 8687_8_2 html ...

Page 1675: ...d the castle nut Discard the cotter pin and nut and replace with new ones during installation 8 Using tie rod end remover tool 3290 D and the tie rod remover adapter tool T81P 3504 W or equivalents separate the tie rod from the steering knuckle 9 Unfasten the stabilizer bar link nut then remove the stabilizer bar link from the strut Exploded view of a MacPherson strut assembly Loosen but do not re...

Page 1676: ...lt and replace with a new one during installation 11 Remove the halfshaft from the hub and support it with a wire to maintain a level position When removing the halfshaft do not allow it to move outward as theinternal parts of the tripod CV joint could separate causing failure of the joint Remove the stabilizer bar link nut then remove the stabilizer bar link from the strut Стр 4 из 31 FRONT SUSPE...

Page 1677: ...oil spring assembly from the vehicle To install 14 Install the strut and coil spring assembly and the 3 top mount to shock tower nuts 15 Install the steering knuckle and hub assembly to the strut Remove the halfshaft from the hub and support it on a wire to maintain a level position After removing the 3 top mount to shock tower nuts remove the strut and spring assembly from the vehicle Стр 5 из 31...

Page 1678: ... stabilizer bar link nut Tighten to 57 75 ft lbs 77 102 Nm Click to enlarge 20 Using a new castle slotted nut install the tie rod end onto the knuckle Tighten the nut to 23 35 ft lbs 31 47 Nm for vehicles through 1994 For 1995 vehicles tighten the nut to 35 46 ft lbs 47 63 Nm Retain the castle slotted nut with a new cotter pin 21 Install the disc brake rotor caliper and tire wheel assembly Tighten...

Page 1679: ... 7178 A or equivalent isrequired 1 Compress the spring with the coil spring compressor part No D85P 7178 A or equivalent Tighten the 3 top mount to shock tower nuts to 23 29 ft lbs 31 40 Nm CAUTION NEVER attempt to disassemble the spring or top mount without firstcompressing the spring using Strut Compressor Tool No D85P 7178 A RotundaSpring Compressor 086 00029B or equivalent Failure to properly ...

Page 1680: ...rned and the rod held still toprevent fracture of the rod at the base of the hex Carefully compress the spring using a suitable spring compressor tool Place a 10mm box wrench on top of the shock strut shaft and hold while loosening the top shaft mounting nut with a 21mm 6 point crow s foot wrench and ratchet then Стр 8 из 31 FRONT SUSPENSION 18 11 2005 http www chiltondiy com content 8687 8687_8_2...

Page 1681: ... the top mounting bracket assembly bearing plate assembly and spring remove the mounting nut After loosening the spring compressor tool remove the washer then Стр 9 из 31 FRONT SUSPENSION 18 11 2005 http www chiltondiy com content 8687 8687_8_2 html ...

Page 1682: ...t be installed with thecorrect orientation 4 Install the spring compressor tool part No D85P 7178 A or equivalent 5 Install the spring bearing plate assembly lower washer and top mount bracket assembly 6 Compress the spring with the coil spring compressor tool remove the mounting bracket and bearing plate assembly Стр 10 из 31 FRONT SUSPENSION 18 11 2005 http www chiltondiy com content 8687 8687_8...

Page 1683: ... the top of the shock strut shaft and hold while tightening the top shaft mounting nut with a 21mm 6 point crow s foot wrench and a ratchet Tighten to 40 53 ft lbs 53 72 Nm Compress the coil spring using the proper tool Стр 11 из 31 FRONT SUSPENSION 18 11 2005 http www chiltondiy com content 8687 8687_8_2 html ...

Page 1684: ...ement install a new lower control arm assembly 6 Lower the vehicle then connect the negative battery cable REMOVAL INSTALLATION Ball joints are integral parts of the lower control arms If inspection reveals an unsatisfactory ball joint the entire lower control arm assembly must be replaced Stabilizer Bar REMOVAL INSTALLATION 1 Raise and safely support the vehicle Support the vehicle with jackstand...

Page 1685: ...rame nuts then move the gear from the subframe 4 Position another set of jackstands under the front subframe then remove the rear subframe to frame bolts Lower the rear or the subframe to access the stabilizer bar brackets Remove the stabilizer bar link to stabilizer bar nut the stabilizer bar link to strut nut and the link from the vehicle with an 8mm closed end wrench and an 18mm open end wrench...

Page 1686: ... bar link 35 48 ft lbs 47 65 Nm Stabilizer bar to strut 55 75 ft lbs 75 101 Nm 8 Prior to assembly coat the inside diameter of the new insulators with No E25Y 19553 A or equivalent lubricant Do not use any mineral or petroleum base lubricants as they will cause deterioration of the rubber insulators Lower Control Arm REMOVAL INSTALLATION 1 Disconnect the negative battery cable 2 Raise and safely s...

Page 1687: ...ing knuckle A drift punch may be used to remove the bolt but be very careful not to damage the ball joint boot seal Do not allow the halfshaft to move outward or the tripod CV joint internal parts could separate causing failure of the joint 6 Remove and discard the lower control arm inner pivot bolt and nut 7 Remove the lower control arm from the frame and the tension strut Click to enlarge To ins...

Page 1688: ...to 85 105 ft lbs 115 142 Nm then carefully lower the vehicle BUSHING REPLACEMENT Inner Pivot Bushing 1 Remove the lower control arm from the vehicle 2 Using bushing removal tools T86P 5493 A3 and T86P 5493 A2 or equivalents and a C clamp assembly remove the old bushings from the control arm assembly To install 3 Use the bushing removal tool and press new bushings in place on the lower control arm ...

Page 1689: ...e Insulators 1 Remove the lower control arm from the vehicle 2 Remove and discard the nut washer and insulator from the front of the tension strut Pull the strut rearward to remove it from the subframe 3 Remove and discard the insulator from the tension strut To install 4 Install a new insulator on the tension strut end and insert it into the subframe 5 Install a new front insulator Clean the tens...

Page 1690: ...ng clearance Remove the brake rotor 8 Loosen but do not remove the three top retaining nuts from the top of the shock tower Click to enlarge 9 Remove and discard the lower arm to steering knuckle pinch bolt and nut A drift may be used to remove the bolt Using a small prybar spread the knuckle to lower arm pinch joint Remove the lower arm from the steering knuckle Be sure that the steering column i...

Page 1691: ...en remove the hub retainer ring and front wheel bearing To install 15 If equipped install the rotor splash shield using new rivets and Heavy Duty Riveter D80L 23200 A or equivalent 16 Install the front wheel bearing retainer ring and hub If necessary replace the seal on the outboard CV joint 17 Install the steering knuckle onto the shock absorber strut then loosely install a new pinch bolt in the ...

Page 1692: ...l a cotter pin Tighten the nut to 23 35 ft lbs 31 47 Nm for vehicles through 1994 For 1995 vehicles tighten the nut to 35 46 ft lbs 47 63 Nm 22 Install the stabilizer link bar assembly to the front shock absorber assembly Tighten to 57 75 ft lbs 77 103 Nm 23 Install the tire and wheel assembly tightening the lug nuts to 85 105 ft lbs 115 142 Nm 24 Carefully lower the vehicle 25 Install the three t...

Page 1693: ...gth of wire Do not allow the caliper to hang from the brake hose 5 Remove the rotor from the hub by pulling it off of the hub bolts If the rotor is difficult to remove strike it sharply between the studs with a rubber or plastic hammer If the rotor will not pull off apply a suitable rust penetrator to the inboard and outboard rotor hub mating surfaces Install a suitable 3 jaw puller and remove the...

Page 1694: ...nch 11 Install 2 3 Jaw Puller D80L 1002 L and Shaft Protector D80L 625 1 or equivalent with the jaws of the puller on the knuckle bosses Make sure the shaft protector is centered clears the bearing inside diameter and rests on the end face of the hub journal Remove the hub Installing the required tools to remove the wheel hub Стр 22 из 31 FRONT SUSPENSION 18 11 2005 http www chiltondiy com content...

Page 1695: ...side facing up then position the knuckle with the outboard side up on the spacer Install Front Bearing Remover Replacer T83P 1104 AH2 or equivalent centered on the bearing inner race then press the bearing out of the knuckle and discard Click to enlarge To install Installation of the 2 3 Jaw Puller and Shaft Protector Removing the bearing using the specified tools Стр 23 из 31 FRONT SUSPENSION 18 ...

Page 1696: ...ace Front Bearing Spacer T86P 1104 A2 or equivalent with the step side down on the hydraulic press plate then position the knuckle with the outboard side down on the spacer Position a new bearing in the inboard side of the knuckle Install Bearing Installer T86P 1104 A3 or equivalent with the undercut side facing the bearing on the bearing outer race then press the bearing into the knuckle Make sur...

Page 1697: ...he outboard side down on the hub barrel Place Bearing Remover T83P 1104 AH2 or equivalent with its flat side down centered on the inner race of the bearing then press down on the tool until the bearing is fully seated onto the hub Make sure the hub rotates freely in the knuckle after installation To prevent damage to the bearing during installation the replacer tool must be positioned as shown Стр...

Page 1698: ...nt with a new seal from the bearing kit Make sure the seal flange faces outboard toward the bearing Use Drive Tube T83T 3132 A1 and Front Bearing Dust Seal Installer T86P 1104 A4 or equivalent Seating the bearing in the hub Стр 26 из 31 FRONT SUSPENSION 18 11 2005 http www chiltondiy com content 8687 8687_8_2 html ...

Page 1699: ...Removing the bearing dust seal on the outboard CV joint Стр 27 из 31 FRONT SUSPENSION 18 11 2005 http www chiltondiy com content 8687 8687_8_2 html ...

Page 1700: ...nuts Insert a steel rod into the rotor diameter then rotate clockwise to contact the knuckle 21 Install the hub nut washer and a new hub nut retainer Rotate the nut clockwise to seat the CV joint Tighten the nut to 170 203 ft lbs 230 275 Nm Remove the steel rod washers and lug nuts Do not use power or impact tools to tighten the hub nut 22 Install the remainder of the front suspension components 2...

Page 1701: ...ation 6 Using Tie Rod End Remover tool No 3290 C and the Tie Rod Remover Adapter tool No T81P 3504 W or equivalent separate the tie rod from the steering knuckle 7 Remove the stabilizer bar link nut and the link from the strut 8 Remove the lower arm to steering knuckle pinch bolt and nut it may be necessary to use a drift punch to remove the bolt Using a small prybar slightly spread the knuckle to...

Page 1702: ...straight ahead position Stated another way it is the tilting of the front steering axis either forward or backward from the vertical A backward tilt is said to be positive and a forward tilt is said to be negative Although it is measured using a special instrument it can usually be seen by observing the location of the upper and lower control arm ball joints A line drawn through the center of thes...

Page 1703: ...ead direction When the front of the wheel is turned in the toe is positive When the front of the wheel is turned out toe is negative An incorrect toe setting can affect steering feel and cause excessive tire wear Stated another way toe in is the amount that the front of the wheels are closer together than the backs of the same wheels The actual amount of toe in is normally only a fraction of a deg...

Page 1704: ...nd raise the lower arm to normal curb height 2 Remove the wheel and tire assembly 3 Locate the bracket retaining the flexible brake hose to the body Remove the bracket retaining bolt and bracket from the body Click to enlarge 4 Remove the stabilizer bar U bracket from the lower suspension arm and bushing Remove the bolt retaining the rear brake hose Стр 1 из 39 REAR SUSPENSION 18 11 2005 http www ...

Page 1705: ... nuts attaching the shock absorber to the lower suspension arm and bushing Remove the stabilizer bar U bracket from the lower suspension arm and bushing Стр 2 из 39 REAR SUSPENSION 18 11 2005 http www chiltondiy com content 8687 8687_8_3 html ...

Page 1706: ... bolt and nut attaching the tension strut and bushing to the lower suspension arm 9 Suspend the spindle and upper suspension arms from the body with a piece of wire to prevent them from dropping down After removing the nuts attaching the shock absorber to the lower suspension arm and bushing discard them and replace with new ones during installation Стр 3 из 39 REAR SUSPENSION 18 11 2005 http www ...

Page 1707: ...ion then set the cam aside 11 With the floor jack slowly lower the suspension arm until the spring lower and upper insulators can be removed Replace the spring and insulators as required Suspend the spindle and upper suspension arms from the body with a piece of wire to prevent them from dropping down Стр 4 из 39 REAR SUSPENSION 18 11 2005 http www chiltondiy com content 8687 8687_8_3 html ...

Page 1708: ... downward into place Make certain the insulator is properly seated With the floor jack slowly lower the suspension arm until the spring lower and upper insulators can be removed Replace the spring and insulators as required Стр 5 из 39 REAR SUSPENSION 18 11 2005 http www chiltondiy com content 8687 8687_8_3 html ...

Page 1709: ... certain the spring is properly seated 14 With the floor jack slowly raise the suspension arm Guide the upper spring insulator onto the upper spring underbody seat Installing the center mounting insulator on the lower suspension arm Стр 6 из 39 REAR SUSPENSION 18 11 2005 http www chiltondiy com content 8687 8687_8_3 html ...

Page 1710: ...existing cam Install the bolt with its head toward the front of the vehicle but do NOT tighten the bolt at this time With the floor jack slowly raise the suspension arm Guide the upper spring insulator onto the upper spring underbody seat Стр 7 из 39 REAR SUSPENSION 18 11 2005 http www chiltondiy com content 8687 8687_8_3 html ...

Page 1711: ...the lower suspension arm 19 If equipped with rear disc brakes install the ABS cable into the clips on the lower suspension arm Position the rear wheel spindle in the lower suspension arm and bushing using a new bolt nut washer and the existing cam Install the bolt with the head of the bolt toward the front of the vehicle but do NOT tighten the bolt at this time Стр 8 из 39 REAR SUSPENSION 18 11 20...

Page 1712: ...hten the nuts to 15 19 ft lbs 20 26 Nm If equipped with rear disc brakes install the ABS cable into the clips on the lower suspension arm When installing the shock absorber on the lower arm install new retaining nuts Стр 9 из 39 REAR SUSPENSION 18 11 2005 http www chiltondiy com content 8687 8687_8_3 html ...

Page 1713: ...m Click to enlarge 22 Attach the flexible brake hose bracket to the body then tighten the retaining bolt to 8 12 ft lbs 11 16 Nm Attach the stabilizer U bracket to the lower suspension arm using a new bolt Tighten the bolt to 23 30 ft lbs 31 40 Nm Стр 10 из 39 REAR SUSPENSION 18 11 2005 http www chiltondiy com content 8687 8687_8_3 html ...

Page 1714: ...rbers REMOVAL INSTALLATION Station Wagon Only 1 Raise and safely support the vehicle 2 Remove the wheel and tire assembly 3 Position a jackstand under the lower suspension arm 4 Slightly lower the vehicle to put the suspension at the normal position then remove the two nuts retaining the shock absorber to the lower suspension arm Attach the flexible brake hose bracket to the body then tighten the ...

Page 1715: ...will damage the shaft surface finish and will result in severe oil leakage 6 Remove and discard the top shock absorber attaching nut using a crow s foot wrench and ratchet while holding the shock absorber shaft stationary with an open end wrench Removing the two shock absorber to lower suspension arm retaining nuts Стр 12 из 39 REAR SUSPENSION 18 11 2005 http www chiltondiy com content 8687 8687_8...

Page 1716: ...lower part of the shock absorber until the mounting studs are aligned with the mounting holes in the lower suspension arm 10 Install new lower attaching nuts but do not tighten at this time 11 Install a new shock absorber bushing repair kit washer and nut on top of the shock absorber Tighten the nut to 19 25 ft lbs 26 34 Nm Remove and discard the top shock absorber attaching nut using a crow s foo...

Page 1717: ...he wheel and tire assembly Remove the safety stand supporting the lower Install a new shock absorber bushing repair kit washer and nut on top of the shock absorber Tighten the nut to 19 25 ft lbs 26 34 Nm Tighten the two lower attaching nuts to 15 19 ft lbs 19 30 Nm Стр 14 из 39 REAR SUSPENSION 18 11 2005 http www chiltondiy com content 8687 8687_8_3 html ...

Page 1718: ... remove the three nuts retaining the shock absorber bracket to the car s body 3 Raise and safely support the vehicle Remove the wheel and tire assembly Do not raise or support the vehicle using the tensionstruts 4 Remove the bolt retaining the brake differential control valve brake load sensor proportioning valve to the control arm Using a wire secure the control arm to the body to ensure proper s...

Page 1719: ...e shock strut from the spindle 11 Remove the nut washer and lower suspension arm stabilizer bar insulator attaching the link to the rear shock absorber then remove the stabilizer bar link 12 From inside the trunk remove and discard the three upper mount to body nuts Be careful that the shock absorber does not drop when removing the three nuts then remove the shock absorber from the vehicle To inst...

Page 1720: ...ut on the tension strut Tighten the nut to 35 46 ft lbs 47 63 Nm 18 Position the link into the stabilizer bar Install the insulator washer and nut on the link Tighten to 5 7 ft lbs 7 9 5 Nm Move the spindle rearward then install the tension strut and bushing into the spindle Install the insulator washer and nut on the tension strut Position the link into the stabilizer bar then install the insulat...

Page 1721: ...bly of the strut use a cage type tool such as the No D85P 7181 A Rotunda Spring Compressor 086 0029B or equivalent is required Before compressing the spring mark the location of the insulator to thetop mount using a grease pencil 1 Remove the rear shock and spring assembly as outlined in the procedure located earlier in this section 2 Compress the spring with the coil spring compressor D85P 7178 A...

Page 1722: ...g nut with a 21mm 6 point crow s foot wrench and ratchet It is important that the mounting nut be turned and therod held still to prevent fracture of the rod at the base of the hex Compressing the spring using the appropriate tool Стр 19 из 39 REAR SUSPENSION 18 11 2005 http www chiltondiy com content 8687 8687_8_3 html ...

Page 1723: ...and seat assembly ispress fit onto the upper mount The mount washers must be installed with theproper orientation 5 Inspect the spring to ensure that the dampers sleeves and clips are properly positioned Place a 10mm box wrench on top of the shock strut shaft and hold while removing the top shaft mounting nut with a 21mm 6 point crow s foot wrench and ratchet Стр 20 из 39 REAR SUSPENSION 18 11 200...

Page 1724: ...nstall the spring insulator bottom washer if equipped top mount bracket assembly upper washer and nut Before installation check the spring to make sure the dampers sleeves and clips are positioned correctly Стр 21 из 39 REAR SUSPENSION 18 11 2005 http www chiltondiy com content 8687 8687_8_3 html ...

Page 1725: ... Be certain that the spring is properly located in the upper and lower spring seats and that the mount washers are oriented correctly Exploded view of the rear shock and spring assembly Стр 22 из 39 REAR SUSPENSION 18 11 2005 http www chiltondiy com content 8687 8687_8_3 html ...

Page 1726: ...ake load sensor proportioning valve s from the rear arm and bushing 3 Disconnect the parking brake cable from the front control arms on vehicles through 1993 For 1994 95 vehicles disconnect the parking brake cable from the rear arm and bushings 4 Remove and discard the arm to spindle bolt washer and nut 5 Remove and discard the arm to body bolt and nut 6 Remove the lower control arm from the vehic...

Page 1727: ... do not tighten at this time 8 Move the arm end up to the spindle then insert a new bolt washer and nut Tighten the nut to 44 59 ft lbs 59 81 Nm 9 Tighten the arm to body nut to 50 68 ft lbs 68 92 Nm 10 Attach the parking brake cable to the front arms or rear arm as applicable 11 Connect the brake load sensor proportioning valve to the left side front arm or rear arm as applicable 12 Carefully low...

Page 1728: ...is at normal curb height as shown in the accompanying figure Click to enlarge 2 Remove the wheel and tire assembly 3 Remove the brake line flexible hose bracket from the body Supporting the vehicle under the lower control arm so the suspension is at normal curb height Стр 25 из 39 REAR SUSPENSION 18 11 2005 http www chiltondiy com content 8687 8687_8_3 html ...

Page 1729: ...s 5 Loosen but do not remove the nut attaching the rear wheel spindle to the rear lower control arm Removing the rear brake hose support from the body Loosen but do not remove the nut attaching the rear wheel spindle to the rear lower Стр 26 из 39 REAR SUSPENSION 18 11 2005 http www chiltondiy com content 8687 8687_8_3 html ...

Page 1730: ... wire in this position 8 Remove and discard the nut attaching the rear suspension front and rear upper suspension arms to the spindle then remove the arm from the vehicle Click to enlarge To install 9 Install the rear suspension front and rear upper control arms on the spindle then install a new nut but do not tighten the nut yet control arm Remove and discard the nut attaching the front and rear ...

Page 1731: ... the rear wheel spindle 11 Tighten the nut attaching the upper suspension arms to the spindle to 150 190 ft lbs 203 258 Nm 12 Tighten the nut attaching the lower suspension arm to the spindle to 40 52 ft lbs 54 71 Nm Installing the rear upper control arm station wagon only Стр 28 из 39 REAR SUSPENSION 18 11 2005 http www chiltondiy com content 8687 8687_8_3 html ...

Page 1732: ... 12 ft lbs 11 16 Nm Tighten the nut attaching the lower suspension arm to the spindle to 40 52 ft lbs 54 71 Nm Install the rear brake hose support bracket to the body then tighten to 8 12 ft lbs 11 16 Nm Стр 29 из 39 REAR SUSPENSION 18 11 2005 http www chiltondiy com content 8687 8687_8_3 html ...

Page 1733: ...bly Click to enlarge To install 5 Position the rear lower control arm and bushing to the center body bracket then install a new bolt and nut Install the bolt with the bolt head toward the front of the vehicle but do not tighten the bolt at this time 6 Install the rear spring assembly For details please refer to the procedure located earlier in this section 7 Support the control arm and bushing in ...

Page 1734: ...eing careful not to drop the outer bearing assembly pull the hub and drum assembly off of the spindle Remove the outer bearing assembly 4 Using Seal Remover tool 1175 AC or equivalent remove and discard the grease seal Remove the inner bearing assembly from the hub 5 Wipe all lubricant from the spindle and inside of the hub Cover the spindle with a clean cloth and vacuum all loose dust and dirt fr...

Page 1735: ...uivalents Support the drum hub on a block of wood to prevent damage Make sure the cups are properly seated in the hub Do NOT use the cone and roller assembly to install thecups This will result in damage to the bearing cup and the cone and roller assembly Removing the cups if necessary with the correct tools Стр 32 из 39 REAR SUSPENSION 18 11 2005 http www chiltondiy com content 8687 8687_8_3 html...

Page 1736: ... Life Lubricant C1AZ 19590 BA or equivalent suitable wheel bearing grease If a packer is not available work in as much grease as possible between the rollers and cages Grease the cup surfaces 11 Position the inner bearing cone and roller assembly in the inner cup Apply a light Installing the inner and outer bearing cups 1986 89 vehicles equipped with drum brakes Стр 33 из 39 REAR SUSPENSION 18 11 ...

Page 1737: ...on the inner surfaces of the cap 15 Place the wheel and tire assembly on the drum Install the lug nuts then hand tighten alternately to seal the wheel evenly against the hub and drum 16 Carefully lower the vehicle then tighten the lug nuts to 85 105 ft lbs 115 142 Nm using a torque wrench 1990 95 VEHICLES 1 Raise and safely support the vehicle 2 Remove the wheel and tire assembly 3 Remove the two ...

Page 1738: ...e hub bolts If the rotor is difficult to remove strike the rotor sharply between the studs with a rubber or plastic hammer 4 Remove the grease cap from the hub Remove the cotter pin nut retainer adjusting nut and keyed flat washer from the spindle Discard the cotter pin 5 Pull the hub assembly off of the spindle Remove the outer bearing assembly 6 Using Seal Remover Tool 1175 AC or equivalent remo...

Page 1739: ... to dry before repackingthe bearings Do not spin dry the bearings with air pressure 13 Place the inner bearing cone and roller assembly in the inner cup Apply a light film of grease to the lips of a new grease seal and install the seal with Rear Hub Seal Replacer Tool T56T 4676 B or equivalent Make sure the retainer flange is seated all around 14 Apply a light film of grease on the spindle shaft b...

Page 1740: ...hub assembly from the spindle Click to enlarge To install 7 Position the hub on the wheel spindle 8 Install a new wheel hub retainer then tighten to 188 254 ft lbs 255 345 Nm 9 Using Coil Remover T89P 19623 FH or equivalent install a new grease seal Tap on the tool until the grease seal is completely seated 10 Install the rotor on the hub Install the two retaining push on nuts that hold the rotor ...

Page 1741: ...d nut cover Remove the hub grease cap being careful not the damage the cap If the vehicle is equipped with styled steel or aluminumwheels the wheel tire assembly must be removed to access the dust cover 3 Remove the cotter pin and the nut retainer Discard the cotter pin 4 Back off the adjusting nut one full turn 5 While rotating the hub drum assembly to seat the bearings tighten the adjusting nut ...

Page 1742: ...ed in degrees from the vertical and this measurement is called the camber angle Camber is not adjustable on the Sedan On the Wagon camber is adjustable but requires special equipment and procedures If you suspect an alignment problem have it checked by a qualified repair shop TOE IN Toe is a measurement of how far a wheel is turned in or out from the straight ahead direction When the front of the ...

Page 1743: ... the slip ring terminal CAUTION If equipped with an air bag the negative battery cable must be disconnected before working on the system On 1990 95 vehicles the backup power supply must also be disconnected Failure to do so may result in deployment of the air bag and possible personal injury Always wear safety glasses when servicing an air bag vehicle and when handling an air bag Steering wheel as...

Page 1744: ...move the two steering wheel horn pad cover retaining screws from the back of the steering wheel then disengage the electrical connector and remove the steering wheel horn pad cover Стр 2 из 47 STEERING 18 11 2005 http www chiltondiy com content 8687 8687_8_4 html ...

Page 1745: ...m of the steering wheel and pulling it off A steering wheel puller is not required Unfasten the wheel retaining nut then remove the steering wheel by grasping the rim and pulling it off Стр 3 из 47 STEERING 18 11 2005 http www chiltondiy com content 8687 8687_8_4 html ...

Page 1746: ...he straight ahead position of the front wheels The combination switch lever must be in the middle neutral position before installing the steering wheel or damage to the switch cam may result 6 Install a new steering wheel retaining bolt then tighten it to 23 33 ft lbs 31 45 Nm Exploded view of the steering wheel assembly 1986 89 vehicles Стр 4 из 47 STEERING 18 11 2005 http www chiltondiy com cont...

Page 1747: ... steering wheel Click to enlarge 4 For 1994 95 vehicles and SHO vehicles only remove the two steering wheel back cover plugs Remove the two air bag module retaining bolts then lift the module off of the steering wheel Disconnect the air bag wire harness from the air bag module then remove the module from the steering wheel Disengaging the air bag module electrical connector 1992 vehicles shown CAU...

Page 1748: ...l retaining bolt then tighten to 23 33 ft lbs 31 45 Nm Be sure the wiring does not get trapped between the steering wheel and the contact assembly 10 Connect the cruise control wire harness to the wheel then snap the connector assembly into the steering wheel clip 11 Connect the air bag wire harness to the air bag module then install the module to the steering wheel For 1990 93 vehicles except SHO...

Page 1749: ...iner then disengage the three electrical connectors 6 Remove the self tapping screws attaching the switch to the steering column then disengage the switch from the steering column casting 7 For 1990 95 vehicles disengage the two or three electrical connectors depending upon vehicle application Click to enlarge To install 8 For 1990 95 vehicles engage the electrical connectors 9 Align the turn sign...

Page 1750: ...mn for proper operation Ignition Switch REMOVAL INSTALLATION 1986 89 Vehicles 1 Disconnect the negative battery cable 2 Turn the ignition lock cylinder to the RUN position Depress the lock cylinder retaining pin through the access hole in the shroud with a 1 8 diameter punch then remove the lock cylinder 3 If equipped with tilt columns remove the tilt release lever after unfastening the retaining ...

Page 1751: ... retaining screws Click to enlarge Click to enlarge Unfasten the four retaining screws then remove the instrument panel lower cover Unfasten the three self tapping screws then remove the steering column shroud Стр 9 из 47 STEERING 18 11 2005 http www chiltondiy com content 8687 8687_8_4 html ...

Page 1752: ...rge 6 Disengage the ignition switch electrical connector Click to enlarge Lower the steering column by removing the four nuts attaching the column to the support bracket Disengage the electrical connector from the ignition switch Стр 10 из 47 STEERING 18 11 2005 http www chiltondiy com content 8687 8687_8_4 html ...

Page 1753: ... to enlarge 8 Remove the ignition switch and cover after unfastening the two bolts with Torx Driver D83L 2100 A or equivalent Remove the lock actuator cover plate by removing the Torx head bolt The lock actuator assembly will slide freely out of the lock cylinder housing when the ignition switch is removed Стр 11 из 47 STEERING 18 11 2005 http www chiltondiy com content 8687 8687_8_4 html ...

Page 1754: ...2 in 11 75 13 25mm from the bottom of the actuator assembly to the bottom of the lock cylinder housing Remove the ignition switch and cover by removing the two bolts with Torx Driver D83L 2100 A or equivalent Make sure the ignition switch is in the RUN position by rotating the driveshaft fully clockwise to the START position and releasing Стр 12 из 47 STEERING 18 11 2005 http www chiltondiy com co...

Page 1755: ...Installing and measuring the depth of the lock actuator assembly Стр 13 из 47 STEERING 18 11 2005 http www chiltondiy com content 8687 8687_8_4 html ...

Page 1756: ...pth of the actuator assembly as in Step 10 The actuator assembly must be 0 92 1 00 in 23 5 25 5mm inside the lock cylinder housing If the depth measured does not meet specification the actuator assembly must be removed and installed again 13 Install the lock actuator cover plate then tighten the bolt to 30 48 inch lbs 3 4 5 4 Nm Hold the actuator assembly in place then install the ignition switch ...

Page 1757: ...se button fully extended and rotate the cylinder lock to the RUN position Continue to rotate the cylinder toward the LOCK position until it stops In this position make certain the engine and all electrical accessories are OFF and that the steering shaft does not lock 3 Turn the radio power button ON Rotate the cylinder counterclockwise to the ACC position to verify that the radio is energized 4 Pl...

Page 1758: ...rim shrouds and the instrument panel lower cover Install the tilt release lever if equipped Click to enlarge Align the steering column mounting holes with the support bracket center the steering column in the instrument panel opening then install the four retaining nuts Install the instrument panel lower cover then secure using the four retaining screws Стр 16 из 47 STEERING 18 11 2005 http www ch...

Page 1759: ...e ignition switch into the actuator pin It may be necessary to move the switch slightly back and forth to align the switch mounting holes with the column lock housing threaded holes 11 Install the attaching screws and tighten to 50 69 inch lbs 5 6 7 9 Nm 12 Engage the ignition switch electrical connector 13 Connect the negative battery cable 14 Check the ignition switch for proper function includi...

Page 1760: ...LES 1 Disconnect the negative battery cable 2 Remove the steering wheel For details please refer to the procedure located earlier in this section 3 Remove the two trim shroud halves after removing the three attaching screws 4 Disengage the electrical connector from the key warning switch 5 Using a 1 8 in 3mm diameter drill carefully drill out the retaining pin being careful not to drill deeper tha...

Page 1761: ...ntil the lock cylinder releases from its breakaway base Remove the lock cylinder and drill shavings from the lock cylinder housing 5 Remove the retainer washer ignition switch and actuator Thoroughly clean all drill shavings and other foreign materials from the casting 6 Inspect the lock cylinder housing for damage from the removal operation If the housing is damaged it must be replaced To install...

Page 1762: ...erform the following 1 Disconnect the shift position indicator cable from the lock cylinder housing by removing the retaining screw 2 Disconnect the shift position indicator cable from the shift socket 3 Remove the shift position indicator cable from the retaining hook on the bottom of the lock cylinder housing Remove the four self tapping screws then remove the steering column cover from the lowe...

Page 1763: ...iner from the lock cylinder housing by squeezing the end of the retainer and pushing out Disengage the multi function combination switch connector then unfasten the two self tapping retaining screws and remove the multi function combination switch If equipped with column shift disconnect the shift position indicator cable from the lock cylinder housing by removing the retaining screw Стр 21 из 47 ...

Page 1764: ...wiring harness retainer from the lock cylinder housing by squeezing the end of the retainer and pushing out Disengage the multi function combination switch connector remove the two self tapping retaining screws then remove the multi function combination switch Стр 22 из 47 STEERING 18 11 2005 http www chiltondiy com content 8687 8687_8_4 html ...

Page 1765: ... steering wheel is attached to the column 12 If equipped with column shift perform the following 1 Remove the shift cable plastic terminal from the column selector lever pivot ball using a small prybar and prying between the plastic terminal and the selector lever Be careful not to damage the cable during or after assembly 2 Remove the shift cable bracket with shift cable still attached from the l...

Page 1766: ...Use a downward force to disengage the column assembly push on clips from the rear attachments then remove the two remaining nuts When forcing downward be careful to avoid damaging the safety slip clips on the steering column Remove the shift cable plastic terminal from the column selector lever pivot ball using a small prybar between the plastic terminal and the selector lever Be careful not to da...

Page 1767: ...e terminal to the selector lever pivot ball on the steering column 21 Apply a generous amount of grease to the V shaped steering shaft yoke Connect the steering shaft to the intermediate shaft with the U clamp and the two hex nuts When installing the steering column to the intermediate shaft connect the intermediate shaft to the steering column with the retainer assembly and two nuts Make sure the...

Page 1768: ... cable to the shift socket and loosely install the cable onto the lock cylinder housing with the screw Adjust the shift position indicator cable as follows 1 Place the shift lever in D on Taurus equipped with the 2 5L engine On all others place the shift lever in OD A weight of 8 lbs 4 kg should be hung on the shift selector lever to make sure the lever is firmly against the D or OD drive detent 2...

Page 1769: ...is no interference between the column and instrument panel 4 Cycle the combination switch through all of its functions 1990 95 Vehicles 1 Disconnect the negative battery cable Lower the glove compartment past its stops and disconnect the air bag backup power supply 2 Make sure the vehicle s front wheels are in the straight ahead position Remove the steering wheel 3 Remove the left and right lower ...

Page 1770: ...nt Click to enlarge Remove the four retaining screws from the lower steering column shroud then remove the lower and upper steering column shrouds Unfasten the two retaining bolts then remove the instrument panel reinforcement brace Стр 28 из 47 STEERING 18 11 2005 http www chiltondiy com content 8687 8687_8_4 html ...

Page 1771: ...terlock cable retaining screws then remove the cable Click to enlarge 11 Remove the two multi function combination switch retaining screws then set the switch aside If equipped with column shift disconnect the shift position indicator cable from the actuator housing by removing the screw then disconnect the cable loop from the shift tube hook Стр 29 из 47 STEERING 18 11 2005 http www chiltondiy co...

Page 1772: ...Disconnect the shift cable and bracket from the transmission column shift selector tube lever pivot 17 For vehicles equipped with console shift remove the two shift lock actuator cable retaining screws then remove the actuator 18 Remove the column from the vehicle Click to enlarge To install 19 Place the steering column in the vehicle then align the column lower yoke to the Remove the two multi fu...

Page 1773: ...shrouds 29 Install the ignition switch lock cylinder 30 Connect the tilt steering column lock lever onto the steering column flange tube 31 Attach the air bag sliding contact with the three retaining screws then tighten the screws to 18 26 inch lbs 2 3 Nm If a new contact assembly is being installed remove the plastic lock mechanism after the contact assembly is secured to the column 32 Install th...

Page 1774: ...ones 3 Drain the power steering fluid by rotating the input shaft lock to lock twice using a suitable tool Cover the ports on the valve housing with a shop cloth while draining the gear to avoid possible oil spray 4 Insert an inch pound torque wrench with a maximum capacity of 60 inch lbs 6 77 Nm into the Pinion Shaft Torque Adapter T74P 3504 R or equivalent Position the adapter and wrench on the ...

Page 1775: ... Raise the vehicle and support safely Click to enlarge 4 Remove the left front wheel and tire assembly Remove the steering shaft U joint heat shield Cut the bundling strap retaining the lines to the gear Click to enlarge 5 Remove the tie rod ends from the spindles Place a drain pan under the vehicle Exploded view of the integral power rack and pinion steering gear except SHO vehicles Exploded view...

Page 1776: ...caught on anything To install 9 Install new plastic seals on the hydraulic line fittings 10 Insert the steering gear through the left fender apron Rotate the input shaft forward to completely clear the fender apron opening 11 To allow the gear to pass between the brake booster and the floorpan rotate the input shaft rearward Align the steering gear bolts to the bolt holes Install the mounting nuts...

Page 1777: ...diate shaft to the steering column shaft Fill the power steering system 17 Connect the negative battery cable Check the system for leaks and proper operation Adjust the toe setting as necessary 1990 92 Taurus LX and Sable with 3 8L Engine 1993 95 Taurus GL high series only LX and SHO models and Sables The Variable Assist Power Steering VAPS system used on these vehicles consists of a micro process...

Page 1778: ...ide Remove the pinch bolt at the power steering gear shaft and yoke assembly then remove the steering column gear input shaft coupling 5 Raise the vehicle and support safely Remove the front wheel and tire assemblies Support the vehicle under the rear edge of the subframe with jack stands View of the Variable Assist Power Steering VAPS system components Exploded view of the Variable Assist Power S...

Page 1779: ...7 Mark the position of the jam nut to maintain the alignment then remove the tie rod ends from the spindle tie rod 8 Remove the nuts from the gear to subframe attaching bolts Support the vehicle under the rear edge of the subframe with jack stands Стр 37 из 47 STEERING 18 11 2005 http www chiltondiy com content 8687 8687_8_4 html ...

Page 1780: ...e subframe separates from the body approximately 4 in 102mm 12 Remove the heat shield band then fold the shield down 13 Disengage the VAPS electrical connectors from the actuator assembly Remove the nuts from the gear to subframe attaching bolts Remove the exhaust pipe to catalytic converter attachment Стр 38 из 47 STEERING 18 11 2005 http www chiltondiy com content 8687 8687_8_4 html ...

Page 1781: ...ain pan under the vehicle then remove the line fittings Remove the O rings from the fitting connections then replace with new ones during installation 16 Remove the left hand side sway stabilizer bar link Disengage the VAPS electrical connectors from the actuator assembly Стр 39 из 47 STEERING 18 11 2005 http www chiltondiy com content 8687 8687_8_4 html ...

Page 1782: ...lts in the gear housing 20 Install the steering gear assembly through the left wheel well 21 Connect and tighten the line fittings to the steering gear assembly 22 Engage the VAPS electrical connectors 23 Position the steering gear into the subframe Remove the left side sway stabilizer bar link Стр 40 из 47 STEERING 18 11 2005 http www chiltondiy com content 8687 8687_8_4 html ...

Page 1783: ...to the power steering gear shaft and yoke assembly Tighten the bolt to 30 38 ft lbs 41 51 Nm 34 Install the inner steering column tube boot to the cowl panel 35 Install the input shaft coupling to the steering gear shaft and yoke assembly 36 Fill the power steering system with Premium Power Steering Fluid E6AZ 19582 AA or equivalent 37 Bleed the power steering system For details please refer to th...

Page 1784: ...all the power steering pump pulley use steering pump pulley replacer T65P 3A733 C or equivalent When using this tool the small diameter threads must be fully engaged in the pump shaft before pressing on the pulley Hold the screw head and turn the nut to install the pulley Install the pulley face flush with the pump shaft or within 0 100 in 0 25mm 7 Install the pulley on the pump shaft using Steeri...

Page 1785: ...n order to gain access to the 3 screws bolts attaching the pulleys to the pulley hub 2 Matchmark both pulley to hub positions with a grease pencil or dot of paint for installation purposes 3 Remove the bolts and pulleys from the pulley hub 4 For 1994 95 vehicles remove the pulley from the hub using Steering Pump Pulley Remover T69L 10300 B or equivalent 5 Position a drain pan under the pump then r...

Page 1786: ...or proper operation 3 0L and 3 2L SHO Engines 1 Disconnect the negative battery cable 2 Remove the engine damper strut 3 Remove the power steering belt 4 Raise and safely support the vehicle 5 Remove the front right side wheel and tire assembly 6 Position a suitable jack under the engine then remove the right rear engine mount 7 Remove the power steering pump pulley as follows 1 Loosen the idler p...

Page 1787: ...Nm 15 Install the drive belt to the power steering pump pulley 16 Install the engine damper strut 17 Connect the negative battery cable then check the fluid and fill to the proper level 3 8L Engine 1 Disconnect the negative battery cable 2 Remove the engine damper mounting body bracket 3 Remove the power steering drive belt 4 Raise and safely support the vehicle 5 Remove the right side wheel and t...

Page 1788: ...able then fill the power steering reservoir to the proper level with the correct type of fluid BLEEDING If air bubbles are present in the power steering fluid bleed the system by performing the following 1 Fill the reservoir to the proper level 2 Operate the engine until the fluid reaches normal operating temperature of 165 175 F 74 79 C 3 Turn the steering wheel all the way to the left then all t...

Page 1789: ...9 With the engine idling reapply 15 in Hg 51 kPa vacuum source to the reservoir Slowly cycle the steering wheel to lock to lock stops for approximately 5 minutes Do not hold the steering wheel at the stops during cycling Maintain the vacuum as required 10 Release the vacuum and disconnect the vacuum source Add fluid as required 11 Start the engine and cycle the wheel slowly then check for leaks at...

Page 1790: ...SPECIFICATION CHARTS Click to enlarge Wheel Alignment Specifications Стр 1 из 2 SPECIFICATION CHARTS 18 11 2005 http www chiltondiy com content 8687 8687_8_5 html ...

Page 1791: ...k to enlarge Chilton Automotive Information Systems 2004 Thomson Delmar Learning Wheel Alignment Specifications Стр 2 из 2 SPECIFICATION CHARTS 18 11 2005 http www chiltondiy com content 8687 8687_8_5 html ...

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Page 1890: ...king an accurate adjustment after installing new brake shoes The special gauge measures both the drum diameter and the brake shoe setting Since no adjustment is necessary except when service is performed on the rear brakes this procedure begins with the car safely supported by jackstands and the rear drums removed 1 Apply a small amount of Disc Brake Caliper Slide Grease D7AZ 19590 A or equivalent...

Page 1891: ...heel assembly Install the wheel cover and nut covers if applicable 7 Finish the adjustment by pressing the brake pedal down several times with a minimum of 25 lbs 111 N of force 8 After adjustment check the brake operation by making several stops from various forward speeds DISC BRAKES Front disc brakes require no adjustment Hydraulic pressure maintains the proper pad to disc contact at all times ...

Page 1892: ...switch assembly is installed on the pin of the brake pedal arm so it straddles the master cylinder pushrod Click to enlarge 1 Disconnect the negative battery cable 2 Disengage the wire harness at the connector from the switch The locking tab must be lifted before the connector can be removed 3 Remove the hairpin retainer and white nylon washer Slide the stop light switch and the pushrod away from ...

Page 1893: ...sher to the pin then install the hairpin retainer to trap the whole assembly Do not substitute another type of pin retainer Replace only with a production hairpin retainer 6 Attach the wire harness connector to the switch 7 Check the stop light switch for proper operation Stop lights should illuminate with less than 6 lbs 27 N of force applied to the brake pedal at the pad The stop light switch wi...

Page 1894: ...en to 10 20 ft lbs 14 27 Nm The head of the brake master cylinder pushrod bushing must be on the side of the booster pushrod away from the brake pedal 9 Install the inner brake master cylinder pushrod spacer or if equipped the speed control adapter the master cylinder pushrod and the pushrod bushing on the brake pedal pin 10 Do NOT oil the brake light switch Position the brake light switch so that...

Page 1895: ... at the master cylinder then secure in a position to prevent the loss of brake fluid 6 Remove the nuts attaching the master cylinder to the brake booster assembly Disengage the electrical connector from the brake warning indicator Disconnect the brake lines from the primary and secondary outlet ports of the master cylinder Стр 6 из 25 BRAKE OPERATING SYSTEM 18 11 2005 http www chiltondiy com conte...

Page 1896: ...ot to damage the master cylinder housing 2 Fill the master cylinder with brake fluid 3 Place a suitable container under the master cylinder to catch the fluid being expelled from the outlet Remove the retaining nuts attaching the master cylinder to the brake booster assembly then slide the master cylinder assembly forward and upward from the vehicle Стр 7 из 25 BRAKE OPERATING SYSTEM 18 11 2005 ht...

Page 1897: ...lamp 14 Connect the brake warning light wire 15 Fill the brake master cylinder with DOT 3 brake fluid to 0 16 in 4 0mm below the MAX lines on the side of the reservoir 16 Connect the negative battery cable then bleed the brake system For details please refer to the procedure located later in this section 17 Operate the brakes several times then check for external hydraulic leaks OVERHAUL Brake mas...

Page 1898: ...e secondary piston does not come out readily use low pressure compressed air to aid in removal Depress the primary piston then remove the snapring from the retaining groove at the open end of the bore Removing the primary piston from the master cylinder Стр 9 из 25 BRAKE OPERATING SYSTEM 18 11 2005 http www chiltondiy com content 8687 8687_9_1 html ...

Page 1899: ...e out readily lightly tap the open end of the master cylinder on the bench then the piston should slide out Remove the secondary piston then Стр 10 из 25 BRAKE OPERATING SYSTEM 18 11 2005 http www chiltondiy com content 8687 8687_9_1 html ...

Page 1900: ... and replace as required Inspect the master cylinder body and replace if defective Dip all parts in clean brake fluid before installation remove the secondary piston spring Inspect all seals on the primary and secondary pistons and replace if necessary Стр 11 из 25 BRAKE OPERATING SYSTEM 18 11 2005 http www chiltondiy com content 8687 8687_9_1 html ...

Page 1901: ...ap the reservoir Connect the negative battery cable Power Brake Booster REMOVAL INSTALLATION 1 Disconnect the negative battery cable then remove the brake lines from the primary and secondary ports of the master cylinder 2 Disconnect the manifold vacuum hose from the power brake booster check valve For vehicles equipped with ABS depress the brake pedal several times to Replacing a seal on the seco...

Page 1902: ...ugh for the outer hole to clear the pin 6 Remove the switch by sliding it upward Remove the booster to dash panel retaining nuts Slide the booster pushrod and pushrod bushing off the brake pedal pin 7 Working inside the engine compartment remove the screws from the vacuum outlet manifold fitting at the dash panel then position the vacuum fitting aside 8 Position the wire harness aside Remove the t...

Page 1903: ...the master cylinder assembly on the booster assembly studs 17 Install the brake tube fittings into the master cylinder ports Tighten to 10 17 ft lbs 14 24 Nm Tighten the master cylinder nuts to 16 21 ft lbs 21 29 Nm 18 Engage the fluid level warning indicator electrical connector 19 Bleed the brake system For details please refer to the procedure later in this section 20 Adjust the manual shift li...

Page 1904: ...the pushrod length so that is it 0 230 0 245 in 5 84 6 22mm as indicated by the gauge shown A force of approximately 5 lbs 22 N applied to the pushrod with the gauge will confirm that the pushrod is seated within the power booster If adjustment is necessary grip the rod only by the knurled area Power brake booster pushrod adjustment gauge dimensions Стр 15 из 25 BRAKE OPERATING SYSTEM 18 11 2005 h...

Page 1905: ...ehicle 2 Note the position of the four brake tubes connected to the valve then disconnect them from the valve assembly 3 Remove the screw retaining the valve bracket to the lower suspension arm 4 Remove the two screws retaining the valve bracket to the underbody then remove the assembly The service replacement valve will have a red plastic gauge clip on the valve which must not be removed until th...

Page 1906: ... screw is loose 7 Position the valve assembly to the underbody then install the two retaining screws 8 Position the valve bracket to the lower suspension arm then install one retaining screw Tighten the screw to 4 6 ft lbs 6 8 Nm Make sure the brake pressure View of a common proportioning valve sedan only Стр 17 из 25 BRAKE OPERATING SYSTEM 18 11 2005 http www chiltondiy com content 8687 8687_9_1 ...

Page 1907: ...Install the brake pressure control valve s in the brake master cylinder housing port then tighten to 10 16 ft lbs 13 22 Nm 4 Install the brake tube then tighten to 12 15 ft lbs 16 20 Nm 5 Fill and bleed the brake system For details please refer to Brake System Bleeding Brake Hoses and Pipes REMOVAL INSTALLATION Flexible Hoses Flexible hoses are usually installed between the frame to front calipers...

Page 1908: ...luid distributor tube then remove the brake hose clip and the brake hose To install 5 Connect the front brake hose to the fluid distributor tube then install the hose clip 6 Remove the plugs then install the brake hose on the caliper using a new copper washer on each side of the fitting outlet Insert a retaining bolt through the washers and fittings then tighten the bolts to 30 40 ft lbs 41 54 Nm ...

Page 1909: ... the rear shock absorber 5 Remove the brake hose clip from the bracket then remove the rear hose from the brake fluid distribution tube Click to enlarge To install 6 Seat the brake hose into the bracket then install the hose clip Schematic of brake lines and related components station wagon Common rear brake hose assembly Стр 20 из 25 BRAKE OPERATING SYSTEM 18 11 2005 http www chiltondiy com conte...

Page 1910: ...lare can leak with a resultant loss of stopping power If you have never formed a double flare take time to familiarize yourself with the flaring kit practice forming double flares on scrap tubing until you are satisfied with the results 1 Obtain the recommended bulk 3 16 in double wall steel brake tubing and the correct standard tube nuts for 3 16 in tubing The outside diameter of the line is used...

Page 1911: ...e is installed maintain adequate clearance to metal edges and moving or vibrating parts 5 Clean the brake tube by flushing with clean brake fluid Install the brake tube then Commonly used types of brake line flared connections Стр 22 из 25 BRAKE OPERATING SYSTEM 18 11 2005 http www chiltondiy com content 8687 8687_9_1 html ...

Page 1912: ...t cap from the wheel cylinder bleeder fitting or caliper fitting at the right rear side of the vehicle Check to make sure the wheel cylinder bleeder screw is positioned at the upper half of the front caliper If not the caliper is located on the wrong side Place a suitable box wrench on the bleeder fitting then attach a rubber drain tube to the fitting The end of the tube should fit snugly around t...

Page 1913: ...the pressure bleeder adapter tool to the master cylinder reservoir then attach the bleeder tank hose to the fitting on the adapter 3 If all wheel cylinders are to be bled start with the right hand rear brake wheel cylinder Remove the dust cap from the right rear caliper bleeder fitting Attach a rubber drain tube to the fitting making sure the tube fits snugly 4 Open the valve on the bleeder tank t...

Page 1914: ...p the brake pedal several times to complete the bleeding procedure 6 Adjust the fluid level in the reservoir to the MAX mark with a fully charged accumulator If the pump motor is allowed to run continuously for approximately 20 minutes an internal thermal safety switch may shut the motor off to prevent it from overheating If that happens a 2 10 minute cool down period is typically required before ...

Page 1915: ...e or interfere with the caliper rotor shield or the steering knuckle Click to enlarge CAUTION Brake shoes may contain asbestos which has been determined to be a cancer causing agent Never clean the brake surfaces with compressed air Avoid inhaling any dust from any brake surface When cleaning brake surfaces use a commercially available brake cleaning solvent Exploded view of the brake shoes and li...

Page 1916: ...per assembly from the integral knuckle anchor plate and rotor using a rotating motion Suspend the caliper inside the fender housing with wire Do not allow the caliper to hang from the brake hose View of an early model front disc brake assembly Lift the caliper assembly from the integral knuckle anchor plate and rotor using a rotating motion Стр 2 из 13 FRONT DISC BRAKES 18 11 2005 http www chilton...

Page 1917: ... rotor thickness specification when machining If machining is not necessary hand sand the glaze from the braking surfaces with medium grit sandpaper Suspend the caliper inside the fender housing with wire Do NOT let the caliper hang from the brake hose Remove the outer brake pad from the caliper assembly then Стр 3 из 13 FRONT DISC BRAKES 18 11 2005 http www chiltondiy com content 8687 8687_9_2 ht...

Page 1918: ... Make sure the clips are properly seated 8 Install the caliper over the rotor as outlined later in this section Install the caliper locating pins or rear brake pin retainer as applicable Tighten the rear brake pin retainer to 25 ft lbs 34 Nm 9 Install the wheel and tire assembly Lower the vehicle then using a torque wrench tighten the lug nuts to 85 105 ft lbs 115 142 Nm 10 Pump the brake pedal pr...

Page 1919: ...g to the caliper or rotor Remove then plug the hose assembly from the caliper or rotor 4 For vehicles through 1993 remove the caliper locating pins using Torx Drive Bit D79P 2100 T40 or equivalent For 1994 95 vehicles remove the two rear brake pin retainers 5 Lift the caliper off of the rotor integral knuckle and anchor plate using a rotating motion Using a Torx head tool to disconnect the caliper...

Page 1920: ...the caliper over the rotor with a rotating motion Make sure the inner and outer shoes are properly positioned and the outer anti rattle spring is properly positioned Make sure the clip on insulators are attached to the brake shoe plate Click to enlarge Lift the caliper off of the rotor using a rotating motion Exploded view of a common caliper and related components Стр 6 из 13 FRONT DISC BRAKES 18...

Page 1921: ...he rubber bleed screw cap after bleeding 11 Install the wheel and tire assembly then lower the vehicle Final tighten the lug nuts in a star pattern to 85 105 ft lbs 115 142 Nm using a torque wrench not an impact tool Pump the brake pedal prior to moving the vehicle to position the brake shoes and linings OVERHAUL 1 Remove the caliper assembly from the knuckle and rotor Do not use a screwdriver or ...

Page 1922: ...when blowing it out of the bore by placingrags or a block of wood between the piston and the caliper bridge 2 Remove the dust seal from the caliper then discard it and replace with a new one during assembly Blow the piston out of the caliper using air pressure but be sure to put a piece of wood or rags between the piston and the caliper bridge first Remove the piston from the caliper Стр 8 из 13 F...

Page 1923: ...he caliper Always install a new seal and dust boot 5 When installing the piston back into its bore use a wood block or another flat stock like an old shoe lining assembly between the C clamp and piston Do not apply the C clamp directly to the piston surface This can result in damage to the piston Be sure the piston is not cocked Remove the dust seal from the caliper then discard it and replace wit...

Page 1924: ...ntamination of the rotor 3 Remove the caliper anchor plate bolt then remove the caliper assembly from the rotor Position the caliper aside and support it with a length of wire Do NOT allow the caliper to hang by the brake hose 4 Remove the rotor from the hub assembly by pulling it off the hub studs If additional force is required to remove the rotor apply rust penetrator on the front and rear roto...

Page 1925: ...s necessary If machining observe the minimum thickness specification Remove the rotor from the hub assembly by pulling it off the hub studs View of the hub assembly with the rotor removed Стр 11 из 13 FRONT DISC BRAKES 18 11 2005 http www chiltondiy com content 8687 8687_9_2 html ...

Page 1926: ...e caliper and caliper anchor bolts on the rotor then tighten the bolts to 85 ft lbs 115 Nm 10 Install the wheel and tire assembly then hand tighten the lug nuts 11 Lower the vehicle then final tighten the lug nuts to 85 105 ft lbs 115 142 Nm Pump the brake pedal before moving the car to position the brake shoes and linings INSPECTION Check the disc brake rotor for scoring cracks or other damage Ro...

Page 1927: ...caliper micrometer Chilton Automotive Information Systems 2004 Thomson Delmar Learning Стр 13 из 13 FRONT DISC BRAKES 18 11 2005 http www chiltondiy com content 8687 8687_9_2 html ...

Page 1928: ...uter bearing and discard the cotter pin CAUTION Brake shoes may contain asbestos which has been determined to be a cancer causing agent Never clean the brake surfaces with compressed air Avoid inhaling any dust from any brake surface When cleaning brake surfaces use a commercially available brake cleaning solvent After removing the wheel and tire assembly pry the grease cap from the hub Be careful...

Page 1929: ...in Grasp the cotter pin with needle nose pliers and pull or pry it free of the spindle Discard the cotter pin and replace it with a new one during installation Стр 2 из 16 REAR DRUM BRAKES 18 11 2005 http www chiltondiy com content 8687 8687_9_3 html ...

Page 1930: ...Remove the adjusting nut from the spindle Remove the keyed washer from the spindle Стр 3 из 16 REAR DRUM BRAKES 18 11 2005 http www chiltondiy com content 8687 8687_9_3 html ...

Page 1931: ...chining observe the maximum permissible drum diameter specification To install 6 Inspect and lubricate the bearings as necessary Replace the grease seal if any damage is visible 7 Clean the spindle stem then apply a thin coat of wheel bearing grease Remove the outer bearing assembly Note that this can be done with the hub and drum on or off the vehicle Remove the hub and drum assembly from the spi...

Page 1932: ... a new cotter pin Install the grease cap tapping lightly around the flange to seat the cap 12 Install the wheel and tire assembly Install the wheel cover or nut covers as required then carefully lower the vehicle 1990 95 Vehicles 1 Raise and safely support the vehicle 2 Remove the wheel cover or nut covers as required 3 Remove the rear wheel and tire assembly Exploded view of the rear brake drum a...

Page 1933: ...ction hole Remove the brake line to axle retention bracket This will allow sufficient room to insert suitable brake tools through the inspection hole to disengage the adjusting lever and back off the adjuster Exploded view of the brake drum and related components Стр 6 из 16 REAR DRUM BRAKES 18 11 2005 http www chiltondiy com content 8687 8687_9_3 html ...

Page 1934: ...ing specification the drum must be replaced For additional information on brake drum diameter please refer to the specification chart later in this section Brake Shoes INSPECTION Inspect the brake shoes for excessive lining wear or shoe damage If the lining is worn below 1 32 in 0 8mm replace both shoes Replace any lining that has become contaminated with brake fluid oil or grease Replace the brak...

Page 1935: ... then remove the brake drum 3 For 1993 95 vehicles remove the parking brake cable and conduit from the parking brake lever For vehicles though 1992 it may be easier to remove the parking brake cable after lifting the assembly off the backing plate 4 Using a suitable tool depress and twist the two hold down spring retainers one Remove the rear hub and drum assembly from the spindle Use an evaporati...

Page 1936: ... springs and adjuster assembly off the backing plate When removing the assembly be careful not to bend the adjusting lever Use the brake tool to compress the hold down spring and twist the plate to free the pin Once the pin is released you can withdraw the spring from the backing plate Стр 9 из 16 REAR DRUM BRAKES 18 11 2005 http www chiltondiy com content 8687 8687_9_3 html ...

Page 1937: ...arking brake lever pin retainer and spring washer then slide the lever off the parking brake lever pin on the trailing shoe To install 8 Apply a light coating of Disc Brake Caliper Slide Grease D7AZ 19590 A or An alternate method of removing the brake shoes is to disengage then remove the adjuster screw retracting spring Стр 10 из 16 REAR DRUM BRAKES 18 11 2005 http www chiltondiy com content 8687...

Page 1938: ...arking brake lever pin and into the slot of the adjuster socket that fits into the trailing shoe web The adjuster socket blade is marked R for the right hand or L for the left hand brake assemblies The R or L adjuster blade must be installed with the letter R or L in the upright position facing the wheel cylinder on the correct side to ensure that the deeper of the 2 slots in the adjuster socket f...

Page 1939: ...e brake backing plate then finger tighten the brake line to the wheel cylinder Although you can clamp the brake lines to prevent fluid leakage during wheel cylinder removal do NOT use locking pliers There are special tools available for this purpose After removing the retaining bolts remove the wheel cylinder from the backing plate WARNING Стр 12 из 16 REAR DRUM BRAKES 18 11 2005 http www chiltond...

Page 1940: ... backing mounting plate to rebuild the cylinder however removal makes the job easier 1 Disengage and remove the rubber boots from both ends of the wheel cylinder The piston should come out with the boot If not remove the piston by applying finger pressure inward on one piston the piston on the opposite end should come out Take care not to splash brake fluid all over yourself when the piston pops f...

Page 1941: ...assembly into the cylinder bore Put the cups facing inward and the pistons into the cylinder Install the boots and fit the outer lips into the retaining grooves on the outer edges of the wheel cylinder 9 If removed install the wheel cylinder onto the backing plate then connect the brake line Be sure that the inlet port where the brake hose connects is toward the rear of the car 10 Install the brak...

Page 1942: ...rd them 6 Remove the backing plate and foam gasket Click to enlarge To install 7 Install a new foam gasket on the rear wheel spindle 8 Install the brake backing plate with new adhesive coated retaining bolts 9 Install the wheel cylinder then connect the brake line 10 Install the brake shoe lining and adjuster assemblies Insert the parking brake lever through the backing plate The prongs must be se...

Page 1943: ... drive socket 13 Install the brake drum then adjust the brakes as previously outlined 14 Bleed the brake system Check the parking brake cable adjustment 15 Install the tire and wheel assembly then carefully lower the vehicle Chilton Automotive Information Systems 2004 Thomson Delmar Learning Стр 16 из 16 REAR DRUM BRAKES 18 11 2005 http www chiltondiy com content 8687 8687_9_3 html ...

Page 1944: ...alf full Discard the removed fluid CAUTION Brake shoes may contain asbestos which has been determined to be a cancer causing agent Never clean the brake surfaces with compressed air Avoid inhaling dust from any brake surface When cleaning brake surfaces use a commercially available brake cleaning solvent Стр 1 из 10 REAR DISC BRAKES 18 11 2005 http www chiltondiy com content 8687 8687_9_4 html ...

Page 1945: ...iper Remove the cable end from the parking brake lever 5 Hold the slider pin hex head with an open end wrench Remove the upper rear brake pin retainer pinch bolt Rotate the caliper away from the rotor Exploded view of the rear disc brake components late model sedan with ABS shown Exploded view of the rear disc brake components late model station wagon with ABS shown Стр 2 из 10 REAR DISC BRAKES 18...

Page 1946: ...rotate the piston and adjuster clockwise until it is fully seated Make sure one of the two slots in the piston face is positioned so it will engage the nib on the brake pad After removing the upper rear brake pin retainers or pinch bolt as applicable rotate the caliper away from the rotor Стр 3 из 10 REAR DISC BRAKES 18 11 2005 http www chiltondiy com content 8687 8687_9_4 html ...

Page 1947: ...lider pins with an open end wrench 10 Attach the cable end to the parking brake lever Install the cable retaining clip on the caliper assembly Position the flexible brake hose and bracket assembly to the shock absorber bracket then install the retaining screw Tighten the screw to 8 11 ft lbs 11 16 Nm 11 Install the wheel and tire assembly then carefully lower the vehicle Pump the brake pedal prior...

Page 1948: ...s should be replaced Brake Caliper REMOVAL INSTALLATION 1 Raise and safely support the vehicle 2 Remove the wheel and tire assembly 3 Remove the brake hose from the caliper assembly Click to enlarge 4 Remove the retaining clip from the parking brake cable at the caliper Disengage the parking brake cable end from the lever arm Removing the brake hose from the caliper assembly Стр 5 из 10 REAR DISC ...

Page 1949: ...away from the anchor plate Remove the locating slider pins and boots from the anchor plate support bracket To install 6 Apply Silicone Dielectric Compound or equivalent to the inside of the locating slider pin boots and to the pins Disengage the parking brake cable end from the lever arm Remove the rear brake pin retainers Стр 6 из 10 REAR DISC BRAKES 18 11 2005 http www chiltondiy com content 868...

Page 1950: ...s 11 16 Nm For 1993 95 vehicles tighten the retaining bolt to 30 40 ft lbs 41 54 Nm 11 Bleed the brake system filling the master cylinder as required 12 Install the wheel and tire assembly then lower the vehicle Pump the brake pedal prior to moving the vehicle to position the brake pads OVERHAUL 1 Remove the caliper assembly from the vehicle following the procedure earlier in this section 2 Mount ...

Page 1951: ...Inspect the caliper bores for damage or excessive wear If the piston is pitted scratched or scored replace the piston Click to enlarge To assemble 8 Lightly grease the parking brake lever bore and the lever shaft seal with Silicone Dielectric Compound or equivalent Press the parking brake lever shaft seal into CAUTION The snapring and spring cover are under tension caused by spring load Be careful...

Page 1952: ...er shaft Install the pushrod into the bore Make sure the pin is positioned correctly between the shaft recess Install the flat washer pushrod spring and spring cover in that order Brake Rotor REMOVAL INSTALLATION 1 Raise and safely support the vehicle 2 Remove the wheel and tire assembly 3 Remove the caliper assembly from the rotor then support it with a length of wire Do NOT let the caliper hang ...

Page 1953: ...4 88 ft lbs 87 117 Nm 10 Install the brake shoes and linings then install the caliper assembly as outlined earlier in this section 11 Install the wheel and tire assembly then carefully lower the vehicle Pump the brake pedal prior to moving the vehicle to position the brake pads INSPECTION Check the disc brake rotor for scoring cracks or other damage Rotor run out should be measured while the rotor...

Page 1954: ...n 13mm box end wrench to press the conduit retaining prongs then remove the cable end pronged fitting from the parking brake control 5 Remove the left hand cowl side trim panel then pull the carpet back to expose the cable and conduit Click to enlarge 6 Raise and safely support the vehicle Remove the left hand cowl side trim panel then pull the carpet back to expose the cable and conduit Стр 1 из ...

Page 1955: ... retainer from the cable bracket using a 1 2 in 13mm box end wrench to depress the retaining prongs Click to enlarge 9 Pull the cable assembly down through the floorpan hole Front parking brake cable and related components Стр 2 из 9 PARKING BRAKE 18 11 2005 http www chiltondiy com content 8687 8687_9_5 html ...

Page 1956: ...le 14 Push the prong retainer into the parking brake control housing until the prongs are secure then connect the front parking brake cable and conduit to the parking brake control clevis 15 Reinstall the carpet and the left hand cowl side trim panel 16 Raise and safely support the vehicle 17 Adjust the parking brake following the procedure located in this section then lower the vehicle and check ...

Page 1957: ...iper then remove the cable from the caliper 6 Push the plastic snap in grommet rearward to disconnect it from the inner floor side rail bracket 7 Remove the pronged connector from the parking park adjuster bracket then remove the cable assembly Click to enlarge To install 8 Insert the cable through the inner fIoor side rail bracket and cable adjuster Make sure the pronged connector is securely att...

Page 1958: ... drum assembly 5 Disconnect the brake cable from the parking brake actuating lever On drum brake vehicles use a 1 2 in 13mm box end wrench to depress the conduit retaining prongs then remove the cable end pronged fitting from the backing plate On disc brake vehicles remove the E clip from the conduit end of the fitting at the caliper then remove the cable and conduit from the caliper 6 On Taurus S...

Page 1959: ...ol arm 18 If equipped with drum brakes install the rear wheel and drum assembly 19 Install the parking brake cable adjuster nut 20 Adjust the parking brake following the procedure later in this section Carefully lower the vehicle then check the parking brake for proper operation ADJUSTMENT Vehicles With Drum Brakes 1 Make sure the parking brake is fully released Place the transaxle in the N positi...

Page 1960: ...ing brake with about 100 lbs 445 Nm of pedal effort several times then release the control and repeat Step 3 5 Lower the vehicle then check operation of the parking brake Brake Pedal REMOVAL INSTALLATION 1 Fully release the parking brake Raise and safely support the vehicle 2 Remove all tension from the rear cables by backing off the adjusting nut from the equalizer or adjuster 3 Lower the vehicle...

Page 1961: ...tion the control assembly in the vehicle Fit the cable through its mounting hole then press the pronged retainer in place Make sure the prongs are locked securely into place 10 Connect the cable to the control assembly Install the retaining bolts and push pin Tighten the retaining bolts to 17 26 ft lbs 23 35 Nm 11 If equipped connect the vacuum hose to the parking brake release control motor 12 Co...

Page 1962: ...e vehicle then check the parking brake assembly for proper operation Chilton Automotive Information Systems 2004 Thomson Delmar Learning Стр 9 из 9 PARKING BRAKE 18 11 2005 http www chiltondiy com content 8687 8687_9_5 html ...

Page 1963: ...er cylinder The primary rear circuit feeds the right hand front and left hand rear brakes The secondary front circuit feeds the left hand front and right hand rear brakes The master cylinder is serviced as a complete assembly HYDRAULIC CONTROL UNIT The anti lock brake Hydraulic Control Unit HCU is located in the front of the engine compartment on the left hand side of the vehicle If consists of th...

Page 1964: ...avel again exceeds the anti lock brake pedal sensor switch setting Most malfunctions to the anti lock braking system will be stored as a Diagnostic Trouble Code DTC in the keep alive memory of the ABS control module ANTI LOCK BRAKE SENSOR Four sets of variable reluctance brake anti lock sensors and sensor indicators which determine the rotational speed of each wheel are used in the ABS system The ...

Page 1965: ...mp the brake pedal a minimum of 20 times until an increase in pedal force is clearly felt Hydraulic Control Unit HCU The anti lock brake Hydraulic Control Unit HCU is located in the front of the engine compartment on the left hand side of the vehicle It attaches to a bracket that is mounted to the left hand front inside rail inside the engine compartment The battery and battery tray sit atop the h...

Page 1966: ...assembly to the mounting bracket then remove the assembly from the vehicle Click to enlarge HCU location and related components except SHO vehicles Стр 4 из 16 ANTI LOCK BRAKE SYSTEM 18 11 2005 http www chiltondiy com content 8687 8687_9_6 html ...

Page 1967: ...n to 10 18 ft lbs 14 24 Nm 8 Fasten the 19 pin connector to the harness then attach the 4 pin connector to the pump motor relay 9 On all vehicles except SHO install the acid shield and the three plastic push pins holding the acid shield to the HCU bracket Install the battery tray then install the battery and connect the cables 10 On the SHO install the anti lock brake control module to the top of ...

Page 1968: ...the height sensor bracket and from the retainer clip on the shock strut just above the spindle 7 Loosen the sensor retaining screw then remove the sensor assembly from the front knuckle Click to enlarge To install 8 Align the sensor with its mounting holes on the front wheel spindle Tighten the retaining screws to 40 60 inch lbs 4 5 6 8 Nm 9 Install the grommets at the height sensor bracket then i...

Page 1969: ...apters and remove the sensor from the vehicle To install 8 Insert the sensor into the hole in the right or left hand rear disc brake adapter then install the retaining bolt Tighten to 40 60 inch lbs 4 6 6 8 Nm 9 Install the sensor wire routing clips to the suspension arms 10 Attach string or wire to the new sensor connector then pull the sensor connector through the hole in the floor pan using the...

Page 1970: ... install the clips 8 Engage the sensor electrical connector to the wiring harness then push the grommet through the hole in the floorpan and into position 9 Lower the vehicle then connect the negative battery cable Rear Speed Indicator Ring REMOVAL INSTALLATION 1 Raise and safely support the vehicle Remove the tire and wheel assembly 2 Remove the caliper rotor and rear hub assemblies 3 Position th...

Page 1971: ...e vehicle 2 Remove the outboard CV joint For details please refer to the procedure in Section 7 of this manual 3 Position Front Sensor Ring Remover Replacer T88P 20202 A or equivalent in a press Position the CV joint on the tool 4 With the CV joint positioned on the tool use the press ram to apply pressure to the joint then remove the speed indicator ring Position Front Sensor Ring Remover Replace...

Page 1972: ...over Replacer then allow the joint to rest on the ring With the CV joint positioned on the tool use the press ram to apply pressure to the joint then remove the speed indicator ring With Front Sensor Ring Remover Replacer T88P 20202 A or equivalent positioned on the press place the sensor ring on the tool Стр 10 из 16 ANTI LOCK BRAKE SYSTEM 18 11 2005 http www chiltondiy com content 8687 8687_9_6 ...

Page 1973: ...t installed in the tool place a steel plate across the CV joint back face Press the CV joint until the joint bottoms out in the tool the ring will then be properly installed Position the CV joint in the Front Sensor Remover Replacer then allow the joint to rest on the ring Стр 11 из 16 ANTI LOCK BRAKE SYSTEM 18 11 2005 http www chiltondiy com content 8687 8687_9_6 html ...

Page 1974: ...edlenose pliers squeeze the tabs on the switch mounting clip then push the clip through the hole in the pedal support bracket 6 Remove the switch by feeding the switch harness through the hole in the top of the pedal support bracket Click to enlarge To install Make sure the wiring from the harness is restricted from coming in With the CV joint installed in the tool place a steel plate across the C...

Page 1975: ... Adjust the switch as follows 1 Push the switch plunger fully into the switch housing as shown in the accompanying figure This zeroes out the switch adjustment so that it can be automatically reset to the correct dimension during the following steps 2 Slowly pull the arm back out of the switch housing past the detent point At this point it should be impossible to reattach the arm to the pin unless...

Page 1976: ...ylinder and hydraulic control unit reservoir must be bled using Rotunda Anti Lock Brake Breakout Box Bleeding Adapter tool No T90P 50 ALA or equivalent If this procedure is not followed air will be trapped in the hydraulic control unit and will eventually lead to a spongy brake pedal 1 Disconnect the 55 pin plug from the electronic control unit ABS control module then install Anti Lock Brake Break...

Page 1977: ...nd the electrical connector from the master cylinder reservoir cap 3 Remove the brake lines from the primary and secondary outlet ports of the master cylinder then remove the Hydraulic Control Unit HCU supply hose Plug the ports and reservoir feed to prevent brake fluid from leaking onto paint and wiring 4 Under the instrument panel remove the stop light switch wiring connector from the switch Dis...

Page 1978: ...n 13 Connect the brake lines to the master cylinder then tighten to 10 18 ft lbs 14 24 Nm Attach the HCU supply hose to the reservoir 14 Connect the manifold vacuum hose to the booster check valve then engage the electrical connector to the master cylinder reservoir cap 15 Connect the negative battery cable then bleed the brake system Chilton Automotive Information Systems 2004 Thomson Delmar Lear...

Page 1979: ...SPECIFICATION CHARTS Click to enlarge Brake Specifications Стр 1 из 2 SPECIFICATION CHARTS 18 11 2005 http www chiltondiy com content 8687 8687_9_7 html ...

Page 1980: ...Click to enlarge Chilton Automotive Information Systems 2004 Thomson Delmar Learning Brake Specifications Стр 2 из 2 SPECIFICATION CHARTS 18 11 2005 http www chiltondiy com content 8687 8687_9_7 html ...

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Page 2028: ...n remove the door Click to enlarge Click to enlarge 3 If equipped disengage the window regulator wiring harness connector from the door by removing the trim cap loosening the screw then separating the connector halves Front door hinges and related components Rear door hinges and related components Стр 1 из 35 EXTERIOR 18 11 2005 http www chiltondiy com content 8687 8687_10_1 html ...

Page 2029: ... of the hinge and or the hinge attaching points are enlarged or elongated to provide for hinge and door alignment Do not cover up a poor door alignment with a door latch striker plate adjustment 1 Determine which hinge bolts and nuts must be loosened to move the door in the desired direction 2 Loosen the hinge bolts and nuts just enough to permit movement of the door with a padded pry bar 3 Move t...

Page 2030: ...striker should be shimmed to attain the clearance shown between the striker and the latch To check this clearance Click to enlarge 1 Clean the latch jaws and striker area then apply a thin layer of dark grease to the striker 2 Open and close the door to produce a measurable pattern on the latch striker 3 Using Torx Drive Bit Set D79P 2100 T or equivalent reposition the striker as required to ensur...

Page 2031: ... Open and support the hood in the fully open position 2 Mark the hood hinge locations on the hood for installation purposes Tighten the striker assembly to 25 32 ft lbs 35 45 Nm CAUTION Do not heat or try to disassemble the hood gas supports The supports are gas charged and will explode if heated or disassembled Стр 4 из 35 EXTERIOR 18 11 2005 http www chiltondiy com content 8687 8687_10_1 html ...

Page 2032: ...op extension 3 Slide the retaining clip from the bracket at the cowl top extension then remove the hood lift 4 Release the lock clip by prying with a suitable prybar enough to remove the lift Scribe the hood hinge locations on the hood for installation purposes Remove the lock clip on the end of the retaining pin at the cowl top extension then Стр 5 из 35 EXTERIOR 18 11 2005 http www chiltondiy co...

Page 2033: ... remove the end of the hood lift Using a suitable pry bar release the lock clip on the other end of the hood lift then Стр 6 из 35 EXTERIOR 18 11 2005 http www chiltondiy com content 8687 8687_10_1 html ...

Page 2034: ...moved then remove the hood from the vehicle remove the hood lift gas cylinder from the hood Unfasten the two hinge to hood bolts being careful not to let the hood slip when the bolts are removed then remove the hood from the vehicle Стр 7 из 35 EXTERIOR 18 11 2005 http www chiltondiy com content 8687 8687_10_1 html ...

Page 2035: ...ers 9 Install the gas cylinder hood lifts to the hood as follows 1 Position the hole at the end of the hood lift in the retaining bracket on the cowl top extension 2 Insert the retaining pin then install the lock clip on the end of the pin 3 Make sure the lock clip is in place on the hood lift Connect the opposite end of the hood lift to the ball stud on the hood 10 Adjust the hood latch if necess...

Page 2036: ...an be moved from side to side to align with the opening in the hood inner panel Adjust the latch up and down to obtain a flush fit with the front fenders 1 Loosen the hood latch attaching bolts in the radiator support until they are just loose enough to move the hood latch from side to side 2 Move the latch from side to side to align it with the opening in the hood 3 Loosen the locknuts on the two...

Page 2037: ...ge the cable by rotating it out of the latch return spring 5 To ease installation of the cable fasten a length of fishing line about 8 ft 2 4m long to the end of the cable 6 From inside the vehicle unseat the sealing grommet from the cowl side remove the cable mounting bracket attaching screws and carefully pull the cable assembly out Do not pull the fishing line out View of the hood latch control...

Page 2038: ...tall the cable mounting bracket attaching screws 8 Thread the terminal end of cable into the hood latch return spring From inside the vehicle unseat the sealing grommet from the cowl side remove the cable mounting bracket attaching screws and carefully pull the cable assembly out Стр 11 из 35 EXTERIOR 18 11 2005 http www chiltondiy com content 8687 8687_10_1 html ...

Page 2039: ...h to the upper radiator support Tighten to 7 10 ft lbs 9 14 Nm 11 Check the hood latch cable release operation before closing the hood Adjust if necessary then close the hood Hood Latch REMOVAL INSTALLATION Thread the terminal end of cable into the hood latch return spring Стр 12 из 35 EXTERIOR 18 11 2005 http www chiltondiy com content 8687 8687_10_1 html ...

Page 2040: ...the hood latch then tighten the attaching bolts to 7 10 ft lbs 9 14 Nm Liftgate REMOVAL INSTALLATION The liftgate removal and installation is a two person operation and should not be attempted alone 1 Scribe the location of each hinge s roof frame and bolt locations then remove the hinge to roof frame attachments at both hinges 2 Remove the gas lifts support cylinders following the procedure later...

Page 2041: ...chieved upon closing To check it use the following procedure LATCH FUNCTION TEST 1 Close the liftgate to an assumed primary condition 2 Insert the key into the key cylinder Place your left hand on the liftgate glass above and left of the key cylinder Press firmly on the glass with your left hand and slowly turn the key until the latch is released Return the key and release your left hand pressure ...

Page 2042: ... into place 6 Close the liftgate Check the support cylinder operation Trunk Lid REMOVAL INSTALLATION The trunk lid removal and installation procedure is a two person operation and should not be attempted alone 1 Matchmark the trunk lid to hinge locations 2 Unfasten the four hinge to trunk lid screws then remove the trunk lid from the vehicle Стр 15 из 35 EXTERIOR 18 11 2005 http www chiltondiy com...

Page 2043: ...it as outlined later in this section ALIGNMENT The trunk lid door can be shifted fore and aft and from side to side on all models The trunk lid should be adjusted for an even and parallel fit with the opening The Remove the four hinge to trunk lid screws then remove the trunk lid from the vehicle Стр 16 из 35 EXTERIOR 18 11 2005 http www chiltondiy com content 8687 8687_10_1 html ...

Page 2044: ...ng 2 One 1 4 in 6mm cable clamp 3 A water pipe 1 2 in 12 7mm diameter by 2 in 51mm long 4 A piece of heater hose 5 8 in 16mm diameter and 6 in 153mm long 2 Properly assemble the materials as shown in the accompanying figure Safety glasses MUST be worn when performing this operation Click to enlarge 3 Install the torsion bar by inserting one end into the hole provided in the luggage compartment doo...

Page 2045: ...to the top notch then release Trunk Lid Latch and Lock REMOVAL INSTALLATION 1 Open the trunk lid 2 Remove the lever assembly and clip If the clip breaks replace with a new lever and clip assembly 3 Remove the three latch attaching screws then disconnect the electric latch wire if so equipped 4 Remove the luggage compartment latch and rod from the vehicle with the retainer and seal 5 Remove the scr...

Page 2046: ... light electrical connectors If equipped disconnect and remove the fog lamps 3 Slide the front bumper off the right and left front bumper guide brackets mounted on the front fender Click to enlarge WARNING NEVER apply heat to the bumper energy absorbers The heat may cause thematerial inside to expand and flow out of the absorbers or crack the metal Front bumper for 1986 91 vehicles Taurus shown Sa...

Page 2047: ...umper cover to the top of the radiator grille opening panel reinforcement 2 Remove the four push pins securing the front bumper cover to the bottom of the bumper Remove the two push pins there is one on each side holding the bumper cover to the front fender wheel opening flange 3 Remove the four nuts two on each side securing the bumper cover to the front fenders Pull the ends of the bumper cover ...

Page 2048: ...ted on the front fender Click to enlarge 7 If the front bumper is to be replaced assemble the front valance panel for the front bumper 8 To install reverse the removal procedures Tighten the front bumper or bumper isolator and bracket to front bumper bolts to 17 25 ft lbs 22 34 Nm Rear Bumper Removing the front bumper cover SHO vehicles only Removing the front bumper SHO vehicles only Стр 21 из 35...

Page 2049: ...aining the rear bumper to the rear bumper isolator and bracket 2 With an assistant slide the rear bumper off the right and left rear bumper isolator and brackets 3 On the station wagon remove the step pad and rear bumper stone deflector Click to enlarge Rear bumper mounting late model Taurus sedan shown Стр 22 из 35 EXTERIOR 18 11 2005 http www chiltondiy com content 8687 8687_10_1 html ...

Page 2050: ...Click to enlarge Rear bumper mounting late model Sable sedan shown Стр 23 из 35 EXTERIOR 18 11 2005 http www chiltondiy com content 8687 8687_10_1 html ...

Page 2051: ...bumper then use a rubber mallet to impact the pad surface 6 With an assistant slide the rear bumper onto the rear bumper guide bracket mounted on the quarter panel 7 Position the bumper to the bumper isolator and brackets then install the retaining bolts Tighten the bolts to 16 25 ft lbs 22 34 Nm Grille Rear bumper mounting Station wagon shown Стр 24 из 35 EXTERIOR 18 11 2005 http www chiltondiy c...

Page 2052: ...ine up with the holes in the grille opening 6 Install the two plastic retainers through the holes in the grille and grille opening The retainers can be tapped in 1993 95 Taurus The conventional grille is not used on the 1993 95 Taurus The grille is part of the front stone deflector 1 Remove the four push pins securing the front bumper stone deflector to the radiator grille opening panel reinforcem...

Page 2053: ...e the front bumper stone deflector 6 To install reverse the removal procedure 1992 95 Sable View of the 1993 95 Taurus grille which is integral with the front stone deflector View of the 1993 95 Taurus SHO grille which is integral with the front stone deflector Стр 26 из 35 EXTERIOR 18 11 2005 http www chiltondiy com content 8687 8687_10_1 html ...

Page 2054: ...andard Manual Type Right Hand Only 1 Remove the inside sail cover 2 Unfasten the retaining nuts and washers then lift the mirror off the door To install 3 Position the mirror on the door 4 Install then tighten the retaining nuts and washers 5 Install the inside sail cover Left Hand Remote Control 1 Pull the knob assembly to remove it from the control shaft 2 Unfasten the interior sail cover retain...

Page 2055: ...ss 1 Disconnect the negative battery cable 2 Remove the screw retaining the mirror mounting hole cover then remove the cover 3 Remove the front door trim panel 4 Disengage the mirror assembly wiring connector Remove the necessary wiring guides 5 Remove the mirror retaining nuts on the sail mirrors three on sail mirrors two on door mirrors Remove the mirror while guiding the wiring and connector th...

Page 2056: ...eater or A C cable retaining clips Click to enlarge 3 Remove the right front fender liner splash shield Unplug the coaxial cable from the power antenna assembly or the manual antenna base assembly If so equipped unplug the power lead from the power antenna The manual antenna mast is detachable from the base and cable assembly 4 Under the right front fender pull the antenna cable through the hole i...

Page 2057: ...he hole in the door hinge pillar Attach the antenna cable lead to the right hand rear of the radio 10 Attach the cable to the heater or A C housing Install the front fender liner splash shield 11 Return the glove compartment door to its normal position Fenders Manual antenna assembly and related components Power antenna assembly and related components Стр 30 из 35 EXTERIOR 18 11 2005 http www chil...

Page 2058: ...to the fender 7 Position the splash shield and fender to the body of the vehicle Secure with the retaining screws and pushpins 1989 95 Vehicles 1 Remove the front bumper assembly 2 Unfasten the two screws retaining the grille opening reinforcement panel to the fender 3 Disconnect the screw retaining the upper front fender mounting bracket to the fender 4 Remove the screw retaining the front fender...

Page 2059: ...e the outer glass panel remove the roof sliding panel opening shield three front retaining screws Click to enlarge 3 Position the roof sliding panel opening shield sunshade fully rearward to expose the six glass retaining screws There are three screws on each side 4 To remove the sunshade unfasten the glass s six retaining screws or bolts and washers Fender assembly mounting 1989 95 vehicles Locat...

Page 2060: ...roof sliding panel headlining fully forward 7 Lift the front of the roof sliding panel headlining slide it forward then rotate 90 to remove To remove the sunshade remove the glass s six retaining screws or bolts and washers Push the glass upward from inside the vehicle then remove it being careful not to scratch the glass or roof paint Be sure to lift the roof sliding panel opening shield to clear...

Page 2061: ... rail or the roof panel will not work correctly 11 Slide the roof sliding panel headlining and roof sliding panel opening shield fully rearward 12 Install the roof sliding outer glass panel Align with the holes for the bolts Be careful not to push the lifter arm slide out of the track 13 Install the glass retaining screws or bolts and washers then tighten to 7 13 inch lbs 0 8 1 5 Nm 14 Position th...

Page 2062: ...Chilton Automotive Information Systems 2004 Thomson Delmar Learning Стр 35 из 35 EXTERIOR 18 11 2005 http www chiltondiy com content 8687 8687_10_1 html ...

Page 2063: ...ove the trim panel by rocking the upper edge toward the driver 7 Disconnect the speedometer cable by reaching up under the instrument panel and pressing on the flat surface of the plastic connector The cluster can be removed along with the panel 8 Release the glove compartment assembly by depressing the side of the glove compartment bin and allow the compartment to hang open 9 Using all openings t...

Page 2064: ...es the radio antenna cable and anything else that may have been removed 18 Swing the glove compartment assembly back into place then install by depressing the side tabs on the bin 19 Install the instrument cluster finish panel in position then install the retaining screws Tighten the screws to 18 26 inch lbs 2 0 2 9 Nm Install the clock or cover plate 20 Snap the lower left hand and radio finish p...

Page 2065: ...sure that the steering column shaft does not turn Remove the one bolt at the steering column opening attaching the instrument panel brace retaining bolt under the radio 7 Remove the sound insulator from under the glove compartment by removing the two push nuts that secure the insulator to the studs on the climate control case assembly 8 Disconnect the wires of the main wire loom inside the engine ...

Page 2066: ...h air bags Before attempting to service air bag equipped vehicles be sure that the system is properly disarmed and that all safety precautions are taken Serious personal injury and vehicle damage could result if this note is disregarded 1 Position the wheels in the straight ahead position Disconnect the negative and then the positive battery cables 2 Remove the radio chassis and the instrument pan...

Page 2067: ...ery and battery tray 15 Disengage the wires of the main wire loom inside the engine compartment Disconnect the rubber grommet from the dash panel then feed the wiring through the hole in the dash panel into the passenger compartment 16 Remove the retaining screws then remove the right and left hand cowl side trim panels Disconnect the wires from the instrument panel at the right and left hand cowl...

Page 2068: ...able 2 Remove the two plug buttons located at the base of the console assembly in order to expose the console mounting screws Remove the mounting screws 3 Remove the gearshift opening panel by snapping it out then remove the console floor bracket retaining screw s Manual transaxle equipped vehicles with a floor shifter as well as automatic transaxle equipped models with a column shifter have one s...

Page 2069: ...le 1993 95 Vehicles 1 Disconnect the negative battery cable 2 Remove the console finish panel retaining screw 3 Move the transaxle selector lever arm and support it rearward 4 Remove the transaxle gear shift opening seal it snaps out 5 Remove the eight console panel to console panel bracket retaining screws The two rear screws are under the the console glove compartment mat in the rear storage bin...

Page 2070: ... INSTALLATION 1986 88 Vehicles 1 Remove the window regulator handle by unsnapping the handle cover from the base to expose the attaching screw Remove the screw handle and wearplate Click to enlarge 2 Remove the door pull handle retaining screws and cover Remove the handle 3 Unfasten the upper trim panel retaining screws and remove the panel Console assembly mounting 1993 95 vehicles Remove the win...

Page 2071: ...t door panel removing tool pry the trim panel retaining push pins from the door inner panel 7 If the trim panel is to be replaced transfer all the push pins to the new panel Replace any bent broken or missing push pins Click to enlarge Click to enlarge To install Exploded view of a front door panel on 1986 88 vehicles Taurus shown Sable similar Exploded view of a rear door panel on 1986 88 vehicle...

Page 2072: ...egulator handle by unsnapping the handle cover from the base to expose the attaching screw Remove the screw handle and the wearplate Click to enlarge 2 On the front door panel remove the outside rear view mirror mounting hole cover retaining screw and cover 3 If equipped with power windows remove the housing and switch assembly If equipped with power door locks remove the housing and switch assemb...

Page 2073: ...k to enlarge Click to enlarge To install 8 Connect all door wiring then install the trim panel into position ensuring that the upper ridge is seated properly in the door channel 9 Using your hand snap the push pins into place Start at the top and move down Late model front door panel vehicle equipped with power windows Late model rear door panel vehicle equipped with power windows Стр 11 из 54 INT...

Page 2074: ... in the handle cover Interior Trim Panels REMOVAL INSTALLATION Roof Side Rear Upper Quarter Trim Panel 1986 91 SEDANS 1 Remove the coat hooks and interior roof side mouldings 2 For 1989 and later vehicles remove the rear seat back assembly Click to enlarge 3 Remove the roof side rear trim panel retaining screws then remove the panel 4 To install reverse the removal procedure 1992 95 SEDANS 1 Remov...

Page 2075: ...val procedure Lower Rear Corner Left hand Trim Panel STATION WAGON ONLY 1 Unfasten the screws then remove the the roof side inner rear moulding 2 Unfasten the screws then remove the liftgate header rail garnish moulding 3 Unfasten the screws then remove the rear corner upper finish panel 4 Unfasten the retaining screws then remove the spare wheel cover Location of the upper quarter trim panel 1995...

Page 2076: ...ate window garnish moulding retaining crews and moulding 3 Remove the liftgate assist handle retaining screws then remove the handle Click to enlarge 4 Using the Trim Pad Removing Tool from Rotunda Moulding Trim Kit 107 00401 or equivalent pry out the push pins retaining the liftgate trim panel Remove the panel 5 To install reverse the removal procedure Replace any bent or damaged push pins Cowl S...

Page 2077: ... cowl side trim panel retaining screws then remove the panel Click to enlarge 5 To install reverse the removal procedure 1992 95 VEHICLES 1 Remove the retaining screws at the front scuff plate to loosen the panel 2 Remove the cowl side trim panel retaining screw and panel Removing the coat hook retaining screw Location of the cowl side trim panel vehicles through 1991 Стр 15 из 54 INTERIOR 18 11 2...

Page 2078: ... inside finish panel 3 Remove the scuff plate lower center pillar trim panel retaining screws and panel 4 Remove the safety belt anchor bolt then slide the safety belt through the lower center pillar trim panel slot 5 To install reverse the removal procedure Position the safety belt anchor tab in its original position while feeding in the lower center pillar trim Quarter Trim Panels 1986 91 SEDANS...

Page 2079: ...the safety belt anchor tab then slide the belt through the access slot in the quarter trim panel 5 To install reverse the removal procedure Position the safety belt anchor tab in its original position while feeding in the quarter trim panel STATION WAGON 1 Remove the rear seat For details please refer to the procedure later in this section 2 Remove the roof side inner rear moulding retaining screw...

Page 2080: ...dliner REMOVAL INSTALLATION 1 Disconnect the negative battery cable 2 For 1986 91 vehicles remove the front and rear seats For details please refer to the procedure later in this section 3 Remove the left and right side visor retaining screws then remove the sun visors If equipped with a lighted vanity mirror disconnect the electrical wires Unfasten the sun visor arm clip retaining screws then rem...

Page 2081: ... moulding the liftgate header rail garnish moulding and the upper rear corner pillar finish panel 12 Remove the quarter trim panel 13 Remove the rear push pins then remove the headliner from the vehicle To install The weatherstrip must overlap at the headlining and mouldings above the belt line 14 Position the headliner assembly in the vehicle by aligning it at the front of the vehicle over the vi...

Page 2082: ...k to enlarge Installing the headliner vehicles without the roof sliding panel Installing the headliner sedans with the roof sliding panel Стр 20 из 54 INTERIOR 18 11 2005 http www chiltondiy com content 8687 8687_10_2 html ...

Page 2083: ...l the front and rear seats 21 Connect the negative battery cable Power Door Lock Actuator REMOVAL INSTALLATION 1 Remove the door trim panel and watershield 2 Using a letter X and 1 4 in 6mm diameter drill bit drill out the pop rivet attaching the actuator motor to the door Disengage the wiring at the connector and the actuator rod at the latch assembly Installing the headliner station wagons with ...

Page 2084: ... Remove the remote control assembly and the link clip 5 Remove the clip attaching the control assembly and the link clip 6 If so equipped remove the clip from the actuator motor 7 Remove the clip attaching the push button rod to the latch 8 Remove the clip attaching the outside door handle rod to the latch assembly 9 Remove the three screws attaching the latch assembly to the door 10 Remove the la...

Page 2085: ...ip 15 If equipped remove the clip from the actuator motor 16 Attach the lock cylinder rod to the lock cylinder with its clip 17 Install the remote control assembly and the link clip 18 Open and close the door to check the latch assembly operation 19 Install the watershield and the door trim panel Connect the negative battery cable Rear Door Latch REMOVAL INSTALLATION 1 Remove the door trim panel a...

Page 2086: ...tric latch actuator and rear door latch control rod to the new latch Click to enlarge To install 10 If so equipped install the clip on the actuator motor 11 Install the remote control slide links onto the latch assembly Install the latch with the links in the door cavity 12 Position the latch assembly to the door aligning the screw holes in the latch and door Install the three screws and tighten t...

Page 2087: ... Click to enlarge To install 4 Work the lock cylinder assembly into the outer door panel 5 Install the cylinder retainer into the slot and push the retainer onto the lock cylinder 6 Connect the lock cylinder rod to the lock cylinder and install the clip Lock and unlock the door to check for proper operation 7 Install the watershield and door trim panel Liftgate Lock REMOVAL INSTALLATION View of th...

Page 2088: ...e latch lever Click to enlarge 3 Remove the latch assembly from the liftgate 4 Installation is the reverse of the removal procedure Trunk Lid Luggage Compartment Lock REMOVAL INSTALLATION 1 Open the trunk lid 2 Unfasten the latch retaining screws then remove the latch Removing the lock cylinder from the liftgate Стр 26 из 54 INTERIOR 18 11 2005 http www chiltondiy com content 8687 8687_10_2 html ...

Page 2089: ...e watershield 3 Remove the inside door belt weatherstrip and the glass stabilizer 4 Remove the door glass For details please refer to the procedure later in this section 5 Remove the two nuts and washers attaching the equalizer bracket 6 Remove the three rivets manual windows or the four rivets power windows attaching the regulator base plate to the door inner panel 7 For vehicles equipped with po...

Page 2090: ...2 Install the window channel bracket onto the front door window regulator 13 For power windows install the window regulator electric drive to the front door window regulator 14 Install the regulator with the pre assembled glass bracket into the vehicle Set the regulator base plate to the door inner panel using the base plate locator tab as a guide 15 Install the new pop rivets 385189 S100 or equiv...

Page 2091: ...ith power windows disengage the wiring connector Remove the electrical window regulator from the rear door 8 For power windows remove the bolts retaining the regulator electric drive to the regulator then remove the electric drive Click to enlarge To install 9 For power windows install the electric drive to the regulator 10 Install the window regulator through the access hole in the rear door and ...

Page 2092: ...a fixed position to prevent dangerous counterbalance spring unwinding 4 Remove the two forward regulator mounting plate attaching rivets Use a 1 4 in 6mm drill bit then carefully drill out the attaching rivets 5 Remove the three window motor mounting screws 6 Push the regulator mounting plate outboard sufficiently to remove the power window motor Click to enlarge To install 7 Position the motor an...

Page 2093: ...rror by pulling it upward to remove it from the windshield glass retainer 4 If using the Music Wire method of removing the windshield 1 Using a three foot length of single strand music wire with the smallest available diameter cut the urethane seal and rubber seal around the entire edge of the windshield 2 Force the music wire through the seal at the bottom of the windshield With someone holding t...

Page 2094: ...he new urethane can be applied over it but at no time should the thickness of the material be above 0 10 in 2 5mm View of one of the tools that can be used to cut the windshield sealer When using special tools be sure to follow all of the manufacturer s instructions Use a suitable suction tool to remove the windshield glass from the vehicle Стр 32 из 54 INTERIOR 18 11 2005 http www chiltondiy com ...

Page 2095: ...ediately after application since this material will flash dry 13 Install the windshield moulding Position the glass on top of the lower glass stops Center it top and bottom and side to side Adjust the lower glass stops as required 14 Using crayon make alignment marks at points on four sides of both the glass and the window opening 15 Remove the window glass and the moulding assemblies from the veh...

Page 2096: ...e glass to the glass channel bracket Prior to removing the center pins from the rivets it is recommended that a suitable block support be inserted between the door outer panel and glass bracket to stabilize the glass during rivet removal Remove the center pin from each rivet using a drift punch Using a 1 4 in 6mm diameter drill remove the remaining rivets Use care when drilling out the rivets to p...

Page 2097: ...bolts and two 1 4 20 nuts and washers may be used as alternates for glass retention However their torque must not exceed 36 61 inch lbs 4 7 Nm Equivalent metric retainers may be used 10 Install the inside door belt weatherstrip assembly 11 Raise the glass to within 3 in 75mm of the full up position then adjust glass as described in the following procedure 12 Install the door trim panel and watersh...

Page 2098: ...hten the nut and washer A then apply a downward pressure on the equalizer bracket and tighten the nut washer B to 5 8 ft lbs 7 11 Nm 7 Set the door glass stabilizer so that it is slightly touching the glass then tighten the nut and washer assembly to 5 8 ft lbs 8 Cycle the door glass to ensure proper function and door fit 9 Install the door trim panel and the watershield Rear Door Glass REMOVAL IN...

Page 2099: ...er bracket retaining screw washer and bracket 5 Lift the glass up between the door belt molding opening then remove it from the door Click to enlarge To install 6 Fasten the plastic spacer and retainers to the main glass Install the main glass into the door 7 Secure the glass to glass bracket using Heavy Duty Riveter D80L 23200 A or equivalent to install two rivets Two 1 4 20 x 1 in bolts along wi...

Page 2100: ...ing the tube run upper screw and washer assembly as well as the lower nut and washer assembly attaching the rear door run and bracket assembly to the inner door panel then adjusting the glass fore or aft as required Click to enlarge When setting the glass to the window opening lower the glass approximately 2 in 50mm from the full up position with the four retention points loosely installed Set the...

Page 2101: ...rops of adhesive Rear View Mirror Repair Kit D9AZ 19554 B or equivalent to the mounting surface of the bracket Using a clean toothpick or wooden match quickly spread the adhesive evenly over the mounting surface of the bracket 9 Quickly position the mounting bracket on the windshield The 3 8 in 10mm circular depression in the bracket must be toward the inside of the passenger compartment Press the...

Page 2102: ... the bracket 11 Quickly position the mounting bracket on the windshield The 3 8 in 10mm circular depression in the bracket must be toward the inside of the passenger compartment Press the bracket firmly against the windshield for one minute 12 Allow the bond to set for five minutes Remove any excess bonding material from the windshield with an alcohol dampened cloth 13 Position the mirror assembly...

Page 2103: ...9 Install the seat track to seat cushion retaining screws Tighten the screws to 13 17 ft lbs 17 23 Nm 10 Move both seat track pedestals to the full rearward position then install the assist spring on the outboard side Manual front bucket seat assembly Manual front bench seat assembly Стр 41 из 54 INTERIOR 18 11 2005 http www chiltondiy com content 8687 8687_10_2 html ...

Page 2104: ... track assembly to the floorpan 3 Lift the seat and track assembly high enough to disconnect the wire harness Remove the seat and track assembly from the vehicle 4 Place the seat upside down on a clean bench If so equipped remove the center occupant seat belt 5 If so equipped disconnect the power seat switch to motor wire harness 6 Remove the cushion side from the seat track assembly 7 Remove the ...

Page 2105: ...r seat switch to the motor wire harness 17 If applicable install the center occupant seat belt to the seat track 18 Position the seat and track assembly in the vehicle 19 Lift the seat and track assembly high enough to permit connection of the wire harness then connect the wires 20 Install the seat track to floorpan attaching nuts bolts and washer Tighten the fasteners 21 Install the heat shield c...

Page 2106: ...shion assembly into the vehicle 3 Place the seat belts on top of the cushion 4 Apply knee pressure to the lower portion of the seat cushion assembly Push rearward and down to lock the seat cushion into position 5 Pull the rear seat cushion forward to be certain it is secured into its floor retainer Stationary Seat Back 1 Remove the rear seat cushion View of a late model sedan rear seat cushion Vie...

Page 2107: ...ll the rear seat cushion Split Folding Rear Seat Back 1 Remove the rear seat cushion 2 Remove the seat back side pads by unfastening the attaching screws one each Slide the pad upward while twisting it inboard slightly to disengage the plastic push pins securing the seat back side pad to the quarter trim panel 3 Remove the bolts two for each seat back retaining the seat back assembly to the floorp...

Page 2108: ...ghten the bolt and nut to 29 38 ft lbs 39 51 Nm Check the seat backs for proper operation after alignment 8 Install the seat back side pads and the attaching screws Power Seat Motor REMOVAL INSTALLATION 1986 89 Vehicles 1 Disconnect the negative battery cable 2 Remove the seat and track assembly from the vehicle 3 Remove the seat recliner mechanism and seat back from the seat track 4 Remove the se...

Page 2109: ...stall the screw used to retain the motor bracket to the seat track Tighten the screw to 54 70 inch lbs 6 8 Nm 16 Install the seat track assembly to the seat cushion 17 Install the seat recliner and the seat back to the seat track 18 Install the seat belts 19 Install the seat and track assembly in the vehicle 20 Connect the negative battery cable 1990 95 Vehicles 1 While the seat is still in the ca...

Page 2110: ...ned in the proper position 10 Install the assist springs 11 Install the seat track and motor assembly to the seat then install the seat back Install the seat into the vehicle 12 Position the seat to allow the rear Torx head screw installation then install the screw 13 Check for proper motor operation Seat Belt Systems REMOVAL INSTALLATION Front 1 Remove the D ring cover Unfasten the belt bolt then...

Page 2111: ...belt anchor to sill bolt and rubber washer Remove the belt retractor bolt Remove the web guide retaining screw then slide the guide rearward to remove it from the B pillar Click to enlarge Outboard front safety belt system and related components Стр 49 из 54 INTERIOR 18 11 2005 http www chiltondiy com content 8687 8687_10_2 html ...

Page 2112: ...the buckle upward then remove it from the seat 6 Installation is the reverse of the removal procedure Rear 1 Remove the rear seat back and cushion 2 Remove the angel wing trim and package tray trim 3 Remove the buckle end anchor nuts Remove the buckle end belts Inboard front safety belt system and related components Стр 50 из 54 INTERIOR 18 11 2005 http www chiltondiy com content 8687 8687_10_2 ht...

Page 2113: ...Rear safety belts and related components Taurus Стр 51 из 54 INTERIOR 18 11 2005 http www chiltondiy com content 8687 8687_10_2 html ...

Page 2114: ...Click to enlarge Стр 52 из 54 INTERIOR 18 11 2005 http www chiltondiy com content 8687 8687_10_2 html ...

Page 2115: ...Стр 53 из 54 INTERIOR 18 11 2005 http www chiltondiy com content 8687 8687_10_2 html ...

Page 2116: ...of the safety belt assembly or the buckle end anchor of the outboard safety belt must be pried open and discarded in order to slide the belt anchor out of the assembly 5 Installation is the reverse of the removal procedure Chilton Automotive Information Systems 2004 Thomson Delmar Learning Rear safety belts and related components Sable Стр 54 из 54 INTERIOR 18 11 2005 http www chiltondiy com conte...

Page 2117: ...SPECIFICATION CHARTS Click to enlarge Hood Trunk Lid Hatch Lid Glass and Doors Стр 1 из 2 SPECIFICATION CHARTS 18 11 2005 http www chiltondiy com content 8687 8687_10_3 html ...

Page 2118: ...nlarge Chilton Automotive Information Systems 2004 Thomson Delmar Learning How to Remove Stains from Fabric Interior Стр 2 из 2 SPECIFICATION CHARTS 18 11 2005 http www chiltondiy com content 8687 8687_10_3 html ...

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