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Pontiac Fiero 1988, Service Manual

The Pontiac Fiero 1988 Service Manual is a comprehensive manual that covers all aspects of maintenance and repair for this iconic sports car. It can be easily downloaded for free from our website, providing users with valuable information and guidance to keep their Fiero in top-notch condition.

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Summary of Contents for Fiero 1988

Page 1: ...P O N T I A C Service N avua ...

Page 2: ...FRAME AND BUMPERS 2A Frame Cradle and Mounts 2B Bumpers 2C Chassis Sheet Metal 2 STEERING SUSPENSION WHEELS AND TIRES 3 Diagnosis 3A Wheel Alignment 3B2 Manual Rack and Pinion 3B4 Steering Wheels Columns 3C Front Suspension 3D Rear Suspension 3E Tires and Wheels 3 FINAL DRIVE 4D Drive Axle 4 BRAKES 5 Brakes 5A3 Composite Master Cylinder 5B4 48H Front Caliper 5B10 48H Rear Caliper 5D2 Tandem Diaphr...

Page 3: ...esigned for the purpose Accordingly anyone who intends to use a replacement part service procedure or tool which is not recommended by the vehicle manufacturer must first determine that neither his safety nor the safe operation of the vehicle will be jeopardized by the re placement part service procedure or tool selected It is important to note that this manual contains various cautions and notice...

Page 4: ...FICATION NUMBER The Vehicle Identification Number VIN Plate is located on top of the instrument panel at the lower left of the windshield see Figure 2 Refer to Figure 3 for detailed VIN code information For Engine V I N Location refer to Figure 4 METRIC FASTENERS Pontiac models are primarily dimensioned in the metric system Most fasteners are metric and are very close in dimension to well known cu...

Page 5: ... other than the United States These fasteners may be of a lower strength different thread pitch and may not have the numbered head marking system The metric fasteners used on GM products are designed to new international standards that may not be used by some nondomestic bolt and nut suppliers In general except for special applications the common sizes and pitches are M 6 0 X 1 M 8 x 1 25 M 10 X 1...

Page 6: ...RIPTION 2 08 Sedan 2 Door P l a i n Back Hatchback 5 19 Sedan 4 Door 6 Window Notehback 1 27 Coupe 2 Door Notehback 8 35 S t a t i o n Wagon 4 Door 1 37 Coupe 2 Door Notehback S p e c i a l 3 67 Coupe 2 Door C o n v e r t i b l e 6 68 Sedan 4 Door 6 Window P l a i n Back 5 69 Sedan Door 4 Window Notehback 2 77 Coupe 2 Door P l a i n Back Hatchback 2 87 Coupe 2 Door P l a i n Back Special 1 97 Coup...

Page 7: ...FORMATION 2 5L L 4 C O VIEW A 2 8L V 6 tCODES W S 9 1 V I N NUMBER LOCATION 2 OPTIONAL V I N NUMBER LOCATION Fig 4 Engine V I N Identification Location 5 SPEED MANUAL MG1 MG2 H Fig 5 Transaxle Identification Location ...

Page 8: ...L L M E T A L B O L T S _ N L SL 4 0 7 o 12 18 25 35 57 A D H E S I V E OR N Y L O N N 0 4 0 6 1 2 1 6 2 4 3 4 5 6 C O A T E D B O L T S IN LBS 4 0 5 0 10 14 20 28 46 IWCM S I Z E S 250 312 375 437 500 562 625 750 N U T S A N D mmm 04 06 1 4 1 8 2 4 3 2 4 2 6 2 A L L M E T A L B O L T S IN L B S 4 0 S O 12 15 20 27 35 51 A D H E S I V E OR N Y L O N N m 0 4 0 6 1 o 1 4 1 8 2 6 3 4 5 2 C O A T E D ...

Page 9: ... s as well as standard and mandatory options The label will be af fixed to the inside of each passenger car vehicle at the assembly plant For additional information on the Service Parts Identifi cation Label see a GM Parts Catalog KJ o o 3 39 A9 GOG S09 33 ilv2 L S3 C 3 D Q DCJ 000 00 PQ W H O rao a 09S So SOS MSG P U A 3 Wm 9m F 3 i f f HI MAS JU 1 AS2 1 3 3 C i DtC C 4 C A 4 M A S 3 9 8 til VCd ...

Page 10: ...GENERAL INFORMATION OA 7 T l LABEL LOCATION Fig 12 Service Parts Label Location ...

Page 11: ...3125 17 85937 7 32 21875 5 55625 23 32 71875 18 25625 15 64 234375 5 95312 47 64 734375 18 65312 1 4 250 6 35000 3 4 750 19 05000 17 64 265625 6 74687 49 64 765625 19 44687 9 32 28125 7 14375 25 32 78125 19 84375 19 64 296875 7 54062 51 64 796875 20 24062 5 16 3125 7 93750 13 16 8125 20 63750 21 64 328125 8 33437 53 64 828125 21 03437 11 32 34375 8 73125 27 32 84375 21 43125 23 64 359375 9 12812 5...

Page 12: ...level Control I M F Electromotive Force EMR Electronic Module Retard EOS Exhaust Oxygen Sensor ESC Electronic Spark Control EST Electronic Spark Timing ETC Electronic Temperature Control ETCC Electronic Touch Comfort Control ETR Electronically Tuned Receiver Exh Exhaust FMVSS Federal Motor Vehicle Safety Standards Ft l b Foot Pounds Torque FWD Front Wheel Drive Four Wheel Drive 4 x 4 Four Wheel Dr...

Page 13: ...OA 10 GENERAL INFORMATION WHEN USING A FLOOR JACK LIFT ON THE CENTER OF THE FRONT CROSSMEMBER SET PARKING BRAKE AND BLOCK REAR WHEELS Fig 15 Vehicle Lifting Points P Model ...

Page 14: ...GENERAL INFORMATION OA 11 520032 OA Fig 16 Vehicle Lifting Points Model ...

Page 15: ...TACT HOIST REARWARD OF THE FRONT WHEEL SUSPENSION CONTACT HOIST UNDER THE FRONT LOWER CONTROL ARM FRAME CONTACT HOIST FORWARD OF REAR WHEEL 1 3 SUSPENSION CONTACT HOIST LIFTING ON REAR TIRES 520034 OA Fig 17 Vehicle Lifting Points Model ...

Page 16: ...w When the following maintenance services are performed make sure all parts are replaced and all necessary repairs are done before driving your car ITEM 1 Engine Oil and Oil Filter Change ALWAYS USE SF CC OR SF CD ENERGY CONSERVING OILS OF PROPER VISCOSITY Also always change oil and filter as soon as possible after driving in a dust storm See your Owner s Manual for further details ITEM 2 Chassis ...

Page 17: ... m i 50 000 km m 7 Spark Plug Wire Inspection 0 Every 30 000 m i 50 000 km 8 PCV Valve Inspection 0 Every 15 000 m i 25 000 km 24 m o s 9 EGR System Inspection 0 Every 30 000 m i 50 000 km 36 m o s 10 Air Cleaner Element Replacement Every 15 000 m i 25 000 km 24 m o s t m 11 Engine T i m i n g Check Every 30 000 m i 50 000 km m 12 Fuel Tank Cap Lines Inspection 0 Every 30 000 m i 50 000 km m 13 Th...

Page 18: ...needed ITEM 8 Positive Crankcase Ventilation PCV Valve Inspection Inspect valve for proper function Replace valve if necessary as well as any worn plugged or collapsed hoses ITEM 9 EGR System Service Conduct EGR System Service as referenced in the EGR System Chart shown in Section 6E ITEM 10 Air Cleaner Element Replacement Replace every 24 months or 15 000 miles 25 000 km Replace more often under ...

Page 19: ...and washer if so equipped Defroster operation Periodically check the air flow from the ducts at the inside base of the windshield Do this with the heater control set for defrost and fan set for high Horn operation Blow the horn occasionally to make sure it works Check all button locations B r a k e s y s t e m operation Be alert to abnormal sounds increased brake pedal travel or repeated pulling t...

Page 20: ...c h e c k Check power steering pump fluid level in accordance with Owner s Manual instructions and keep at proper level N O T I C E A large loss in this system may indicate a problem Have it inspected and repaired at once B r a k e m a s t e r cylinder reservoir fluid level c h e c k Check fluid level in accordance with Owner s Manual and keep at proper level Note A low fluid level can indicate wo...

Page 21: ...on While parked try to turn key to Lock in each gear range The key should turn to Lock only when gear is in Park on automatic or Reverse on manual transmission transaxle On cars with key release lever try to turn key to Lock without depressing the lever The key should turn to Lock only with the key lever depressed On all vehicles the key should come out only in Lock Parking brake and transmission ...

Page 22: ...vette overdrive unit and Pontiac Firebird 4 speed manual DEXRON II All others SAE 80W gear lubricant GM Part No 1052271 Manual Transmission Transaxle Shift Linkage Chassis grease meeting requirements of GM 6031M GM Part No 1052497 Key Lock Cylinders Light oil or general purpose silicone lubricant GM Part No 1052276 Automatic Transmission Transaxle Shift Linkage Engine Oil Clutch Linkage Pivot Poin...

Page 23: ...008 0B Fig 801 Typical Lubrication Points MODEL TIRE SIZE TIRE INFLATION PRESS PSI FRONT REAR EXCEPTION S TIRE INFLATION PRESS PSI TIRE SIZE FRONT REAR 6000 35 35 P195 70R14 30 30 S a f a r i 30 35 F i r e b i r d 30 30 Grand P r i x 35 35 P215 65R15 30 30 Bonneville P205 75R14 35 35 P215 65R15 30 30 Sunbird 35 35 P215 60R14 30 30 Grand Am 30 30 P185 80R13 35 35 Fiero 30 30 P185 75R14 35 35 1000 3...

Page 24: ... Cylinder with fluid meeting SAE J1703A DOT 3 specifications AUTOMATIC TRAN SMISSION CAPACITIES Type RPO Refill Overhaul 125C MD9 Metric U S Measure Metric U S Measure 3 8L 8 0 Pts 4 7L 10 Pts MANUAL TRANSrMISSION CAPACITIES Type RPO Manufacturer Liters U S Measure 5 Speed 5 Speed MG2 MT2 Muncie 1 9L 4 1 Pts Isuzu 2 5L 5 3 Pts COOLING SYSTEM FLUID CAPACITIES Models Engine Trans VIN Metric U S Meas...

Page 25: ......

Page 26: ...m engine coolant to inlet air thus heating the inlet air 3 Temperature Valve Regulates the amount of air passing through the heater core thus controlling the temperature and mix of heated and ambient air 4 Mode Defroster Heater Valve Regulates the flow and distribution of processed air to the distribution heater or defroster ducts 5 Vent Valve Regulates the flow of non processed outside air into t...

Page 27: ...e whether in Heater mode or Defrost mode Air flow is varied with blower speed Varying the mode selector between Heater and Vent position likewise varies the proportion of air coming out the heater and the center and outboard vent outlets With the selector in some midway posi tion air coming out the center and outboard vent out lets will be ambient temperature while air out the heater outlet will b...

Page 28: ...HEATING AND VENTILATION 1A 3 Figure 3 Module Air Flow ...

Page 29: ... I O N T E S T S T E P C O N T R O L S S Y S T E M R E S P O N S E MODE L E V E R T E M P E R A T U R E L E V E R F A N SWITCH F A N S P E E D l P A I R O U T L E T S F L O O R AIR O U T L E T D E F R O S T E R O U T L E T S S E E R E M A R K S 1 V E N T C O L D O F F O F F NO A I R FLOW NO AIR FLOW NO AIR FLOW 2 V E N T C O L D O F F T O H I G H O F F TO H I G H AIR F L O W NO AIR FLOW NO AIR FLO...

Page 30: ...CK AIRFLOW READJUST CONTROLS TO HIGH BLOWER SPEED HEATER MODE FULL HOT TEMPERATURE LEVER WITH THE ENGINE SUFFICIENTLY COOL REMOVE THE RADIATOR CAP CAUTION COOLANT SYSTEM IS PRES SURIZED WHEN HOT START THE VEHICLE AND IDLE UNTIL COOLANT FLOW IN THE RADATOR IS VISIBLE INSTALL THE RADIATOR CAR WITH ENGINE WARM DRIVE THE VEHICLE AT 48 KPHpOMPH WITH A THER MOMETER CHECK THE AMBIENT AIR TEMPERATURE THE ...

Page 31: ...BE AT LEAST 85 F HOT INLET WARM OUTLET WITH THE BLOWER ON HIGH MOVE THE TEMP ERATURE LEVER FROM FULL HOT TO FULL COLD AND LISTEN FOR AIRFLOW CHANGE NO AIRFLOW CHANGE BOTH WARM CHECK THE THERMOSTAT FOR PROPER INSTALLATION AND PROPERLY SEATED L REMOVE THE HOSES AT THE HEATER C O R E CHECK FOR PROPER INSTALLATION REFER TO MANUAL FOR HOSE ROUTING AIRFLOW CHANGE CHECK THE TEMPER ATURE DOOR AD JUSTMENT ...

Page 32: ...DOES NOT LIGHT ON ALL TERMINALS POOR OR NO GROUND GROUND OK REPAIR GROUND TEST LIGHT LIGHTS ON ALL TERMINALS REPLACE RESISTOR CHECK MOTOR CONNECTOR WITH A 12 VOLT TEST LIGHT TEST LAMP DOES NOT LIGHT TEST LAMP LIGHTS USE THE 12 VOLT TEST LIGHT TO CHECK THE POWER FEED TERMINAL ON THE BLOWER SPEED SWITCH REPAIR OPEN IN F E E D WIRE FROM RESISTOR TO BLOWER MOTOR WITH IGNITION OFF DISCON NECT CONNECTOR...

Page 33: ...OT HIGH HIGH N O AIRFL OW COLD TO HOT AIRFLOW MINIMUM C0LDT0H0T AIRFLOW MINIMUM COLDTOHOT AIRFLOW DEFROSTER COLD TO HOT HIGH HIGH N O AIRFL_0W MINIMUM COLD TO HOT AIRFLOW COLD TO HOT AIRFLOW MINIMUM COLD TO HOT AIRFLOW CHECK DOOR E F F E C T E D AT U MIT FOR CABLE CONNECTED CABLE SHEATTH RETAINED OK DISCONNECT CABLE AT DOOR CHECK DOOR TRAVEL EFFORT 1 NOT OK REPAIR AS NECESSARY NOT OK REPAIR AS N E...

Page 34: ...OLD LISTEN FOR DOOR SLAM PRIOR TO CONTROL END OF TRAVEL SPEED CHANGE OK NO SPEED CHANGE S SPEED CHANGE OK CHECK THE TEM PERATURE DOOR ADJUSTMENT CA BLES LINKAGE ADJUST TO FULL COLD CHECK FOR FULL HOT ADJUST THE HEATER DE FROSTER AND OR VENT DOOR TO HEATER MODE DOOR SLAM OK NO DOOR SLAM N O DOOR SLAM DOOR SLAM OK CHECK THE TEMPERATURE DOOR ADJUSTMENT CABLES LINKAGE ADJUST TO FULL COLD CHECK FOR FUL...

Page 35: ... BINDS R E P L A C E CON TROL PROBLEM FOUND REPLACE BOWDEN CABLE WITH A LONGER CABLE AND ADD A LOOP TO THE CABLE ROUTING TO INCREASE CONTROL EFFORT CHECK INSTRUMENT PANEL INTERFERENCES WITH NEW CABLE ROUTING TO INSURE PROPER OPERATION REPAIR AS NECESSARY DOOR BINDS CHECK DOOR SEAL TO INSURE PROPER SEAL INSTALLATION 1 NO CONTROL BIND SEAL OK REINSTALL AND RECHECK CLEAR ANCES TO DASH COMPONENTS SEAL...

Page 36: ...SUALLY DEFROSTER MAY BE WORSE THAN OTHERS CHECK ANOTHER VEHICLE IF POSSIBLE SAME MODEL TO DETERMINE IF THE NOISE IS TYPICAL OF THE SYSTEM AS DESIGNED INDICATE THE TYPE OF NOISE AND WHERE IT OCCURS VENT HEATER DEFROST FULL COLD FULL HOT FULL COLD FULL HOT FULL COLD FULL HOT LOW BLOWER M2 M3 HIGH BLOWER A WHINE B CLICK TICK C SQUEAL SCREECH D FLUTTER E F SCRAPING G AIR RUSH H OTHER DESCRIBE RUMBLE 1...

Page 37: ...CK REPLACE MOTOR AND FAN ASSEMBLY AND RECHECK PROBLEM STILL EXISTS IF NOISE IS A CLICK TICK OR WHINE TRY A SECOND NEW MOTOR THEN PROCEED REINSTALL ORIGINAL MOTOR AND PROCEED TO ABOVE NOISE IS CONSTANT NOISE IN HEATER MODE ONLY NOISE IN VENT MODE ONLY I NOISE IN ALL MODES BUT NOT ALL TEMPERATURE POSITIONS NOISE IN ALL MODES AND IN ALL TEMPERATURE POSITIONS CHECK DUCTS FOR OBSTRUCTIONS OR FOREIGN MA...

Page 38: ...BRACKET CBL MT 9 16 x 1 4 15 TUBE MTR CLG 9 218 26 BRACKET CBL MT 6 BRACKET CBL MTG 15 TUBE MTR CLG 9 218 27 CASE AIR INL DISTR BRACKET CBL MTG 16 WASHER FAN SUPT 9 216 27 CASE AIR INL DISTR 7 SEAL HTR BLO CASE 16 WASHER FAN SUPT 9 216 28 BRACKET CBL MT SEAL HTR BLO CASE 17 NUT BLO FAN 28 BRACKET CBL MT 8 CASE HTR 17 NUT BLO FAN 29 SHAFT W LVR DEFR VLV 8 CASE HTR 18 COVER BLO 29 SHAFT W LVR DEFR V...

Page 39: ...ll or Connect Cage on motor shaft Heater motor Cooling tube Wires at Heater blower switch console Heater ground connection Negative battery cable TEMPERATURE CONTROL POWER WENT HEATER DEFROST CABLE Remove or Disconnect 1 R H grille and speaker 2 Front console trim plate 3 Three controller retaining screws 4 Controller 5 Controller cable at control 6 Cable at heater module Install or Connect 1 Cabl...

Page 40: ... 17 Heater Module Wiring 6 Heater case cover 7 Heater core retainer 8 Heater core I Install or Connect 1 Heater core 2 Heater core retainer 3 Heater case cover 4 Heater core grommets 5 Wires at a Heater relay connection b Resistor heater blower c Heater blower switch connection d Heater ground connection e Forward courtesy lamp socket if equipped 6 Heater core inlet and outlet hoses 7 Refill cooli...

Page 41: ...tuator Actuator Install or Connect Actuator Linkages to actuator Retaining clip from actuator shaft Retaining clip form left hand rod Electrical connection at actuator Lower heater outlet Wires and radio assembly Screws and bezel at radio Negative battery cable 1 HEATER FAN CONNECTION 2 HEATER CONT ILLUMINATION CONNECTION 3 RADiO ILLUMINATION CONNECTION 4 MAIN l P HARNESS 5 l P ASM 6 HEATER CONTRO...

Page 42: ...HEATING AND VENTILATION 1A 17 Figure 21 Heater Module ...

Page 43: ...1A 18 HEATING AND VENTILATION Figure 22 Heater Hoses and Pipes Engine Code 9 ...

Page 44: ...HEATING AND VENTILATION 1A 19 Figure 23 Heater Hoses and Pipes ...

Page 45: ......

Page 46: ...ESCRIPTION Currently there are two different air condition ing systems are available 1 4 Cylinder 2 5 Liter LR8 V LN Code R V 5 2 6 Cylinder 2 8 Liter L44 V LN Code 9 HR 6 All air conditioning systems that use the fixed displacement R 4 or HR 6 compressor are referred to as C C O T Cycling Clutch Orifice Tube type sys tems This is the same system that has been used on all General Motors vehicles i...

Page 47: ... Pressure Cut Off Switch under SYSTEM COMPONENTS CONTROL V 5 Compressor Removal The V 5 Compressor is equipped with a crank case drain plug located in the body of the compressor When removing the V 5 and draining oil from the compressor the crankcase plug must be removed and oil drained from the fitting It is also necessary to drain the oil from the suction and discharge ports to assure complete o...

Page 48: ...r before it enters the car Engine coolant is circulated through the core to heat the outside air passing over the fins of the core The core is functional at all times no water valve and may be used to temper conditioned air in A C mode as well as heat or vent mode SYSTEM COMPONENTS CONTROL Controller The operation of the A C system is controlled by the switches and the lever on the control head Th...

Page 49: ...essor cut off during cold weather Additional compressor protection results from the operating characteristics of the low side pressure cycling system If a massive discharge occurs or the orifice tube becomes plugged low side pressures could be insufficient to close the contacts of the pres sure switch In the event of a low charge insufficient cooling accompanied by rapid compressor clutch cycling ...

Page 50: ...ondenser core hoses tubes etc 3 Blower fan operation see Section 8A 4 Check all air ducts for leaks or restrictions Low air flow rate may indicate a restricted evaporator core 5 Compressor clutch slippage 6 Improper drive belt tension 7 For R 4 or HR 6 compressors see C C O T A C system diagnostic procedures 8 For V 5 compressors see V 5 A C system diagnostic procedures Insufficient Cooling Quick ...

Page 51: ...URE RELIEF VALVE LOW PRESSURE LIQUID LOW PRESSURE VAPOR HIGH PRESSURE LIQUID HIGH PRESSURE VAPOR Figure 3 A C System Typical HEATER DEFROSTER DOOR MODE POSITION INDICATED BY SIDE WINDOW DEFOGGER TEMPERATURE DOOR UPPER MODE DOOR EVAPORATOR CORE BLOWER MOTOR OUTSIDE AIR RECIRCULATED INSIDE AIR DEFROSTER OUTLETS A C DUCTS LOWER MODE DOOR AIR INLET DOOR Figure 4 A C Air Flow Typical ...

Page 52: ...B L E O P E R A T I O N O F T H E H E A T E R C O R E T E M P E R A T U R E D O O R 9 V A C U U M O P E R A T E D S Y S T E M S E L E C T O R MODE L E V E R 1 0 F A N C O N T R O L D E S I G N V A R I E S WITH M O D E L 520252 1 B Figure 5 A C Controller Typical REFRIGERANT 12 PRESSURE TEMPERATURE RELATIONSHIP The table below indicates the pressure of Refri gerant 12 at various temperatures For in...

Page 53: ...ACE ORIFICE EVA CUATE AND CHARGE NO SEIZURE REPLACE OR TIGHTEN BELT AS REQUIRED OK AMBIENT TEMPERTURE MUST BE ABOVE 10 C 50 F FOR FOLLOWING DIAGNOSTIC PROCEDURE CLUTCH DOES NOT ENGAGE CHECK FOR COMPRESSOR CLUTCH ENGAGEMENT AS FOLLOWS 1 ENGINE RUNNING APPROX 1000 rpm 2 SET A C CONTROL TO NORM AND HIGH BLOWER 3 PUT AUXILI ARY FAN IN FRONT OF VEHICLE 4 OBSERVE CLUTCH OPERATION FOR 5 MIN WITH ENGINE N...

Page 54: ...ID LINE BEFORE EXPANSION TUBE IMPORTANT VEHICLES ARE EQUIPPED WITH AN ORIFICE TUBE LOCATED IN THE LIQUID LINE SEE ILLUSTRATIONS FOR SPECIFIC LOCATION WARM LEAK CHECK SYSTEM NO LEAK FOUND LEAK F DISCHARG OUND E SYSTEM REPAIR ANY LEAK FOUND DISCHARGE SYSTEM REMOVE ORIFICE AND EXAMINE NO ORIFICE ZZZUZZ HEAVILY RESTRICTED INSTALL NEW ORIFICE EVACUATE AND CHARGE REPLACE COMPRESSOR PUMP ASSEMBLY INSTALL...

Page 55: ...ECONNECT ENGINE COOLING FAN S E T A C CONTROL TO NORM AND HIGH BLOWER AND IDLE ENGINE FOR 5 MIN UTES SHUT ENGINE OFF DISCHARGE SYSTEM AND REMOVE AND DRAIN OIL FROM BOTH THE COMPRESSOR AND THE ACCUMLATOR REINSTALL THE ACCUMULATOR AND ADD 90 ml 3 0 OZ OF OIL TO THE CRANK CASE OF THE COMPRESSOR REINSTALL THE COMPRESSOR RECONNECT ENGINE COOLING FAN AND S E E CHART B EVACUATE AND CHARGE OK V 5 S Y S T ...

Page 56: ...TIVE COIL CLUTCH ENGAGES CONNECTORS OK REPLACE COMPRESSOR CLUTCH COIL ASSEMBLY EVACUATE AND CHARGE OK CONNECTOR PROBLEM CHECK FOR 12 VOLTS AT THE FEED WIRE TO THE A C LOW PRESSURE SWITCH S E E ILLUSTRATIONS REPAIR OR REPLACE AS REQUIRED X OPEN CIRCUIT 12 VOLTS CHECK ELECTRICAL SYSTEM AND REPAIR AS REQUIRED S E E SECTION 8A 64 OF SERVICE MANUAL OK OK CHECK FOR ELECTRICAL CONTINUITY ACROSS THE SWITC...

Page 57: ...VA CUATE AND CHARGE OK CLUTCH DOES ENGAGE OR CYCLES REPLACE OR TIGHTEN BELT AS REQUIRED AMBIENT TEMPERATURE MUST BE ABOVE 10 C 50 F FOR FOLLOWING DIAGNOSTIC PROCEDURE CHECK FOR COMPRESSOR CLUTCH ENGAGEMENT AS FOLLOWS 1 ENGINE RUNNING APPROX 1000 rpm 2 SET A C CONTROL TO NORM AND HIGH BLOWER 3 PUT AUXILIARY FAN IN FRONT OF VEHICLE 4 OBSERVE CLUTCH OPERATION FOR 5 MIN FEEL LIQUID LINE BEFORE EXPANSI...

Page 58: ...TION REPAIR AS REQUIRED EVACUATE AND CHARGE OK LOST CHARGE LEAK TEST REPAIR AS REQUIRED EVACUATE AND CHARGE I OK C C O T SYSTEM AIR CONDITIONING DIAGNOSIS INSUFFICIENT COOLING C H A R T C X ADD 45 kg ONE LB OF REFRIGERANT 12 AND THEN CHECK CLUTCH CYCLE RATE i MORE THAN 8 CLUTCH CYCLES PER MINUTE 8 OR LESS CLUTCH CYCLES PER MINUTE DISCHARGE SYSTEM AND CHECK FOR PLUGGED ORIFICE FEEL INLET AND OUTLET...

Page 59: ...RE INOPERATIVE P R E S S U R E CYCLING SWITCH REPLACE DO NOT DISCHARGE SYSTEM OK RECONNECT BLOWER MOTOR WIRE OK 1 SET A C CONTROL TO MAX FULL COLD AND HIGH BLOWER 2 C L O S E DOORS AND WINDOWS OF VEHICLE 3 RUN ENGINE AT 2000 RPM FOR 5 MINUTES 4 USE AUXIL IARY FAR IN FRONT OF VEHICLE INSTALL THERMOMETER IN A C OUTLET AND CHECK SYSTEM PERFORMANCE SEE SYSTEM PERFORMANCE CHART BELOW AND REFER TO CHART...

Page 60: ...R MISSING ORIFICE MISSING CYCLES ON AND OFF OR REMAINS OFF FOR A LONG PERIOD OF TIME DISCHARGE SYS FOR PLUGG TEM AND CHECK ED ORIFICE INPLACE INSTALL ORIFICE EVACUATE AND CHARGE OK REPLACE ORIFICE EVACUATE AND CHARGE OK CHECK FOR RESTRICTED SUCTION LINE RESTRICTED CLEAN REPAIR AS REQUIRED EVACUATE AND CHARGE SYSTEM OVERCHARGED EVACUATE AND CHARGE OK OK Figure 14 C C O T A C System Insufficient Coo...

Page 61: ...n operation and maintenance Battery condition is especially impor tant to the accuracy of the portable battery powered model J 29547 and is monitored by a low battery indicator SERVICE PROCEDURES Before attempting any service which requires opening of refrigerant lines or components the person doing the work should be thoroughly familiar with the information under HANDLING REFRIGERANT 12 HANDLING ...

Page 62: ...o not soak the new color coated O ring seals In refrigerant oil it can cause refrigerant leakage due to improper joint assem bly Prolonged exposure such as soaking may swell them large enough to prohibit joint assem bly ALWAYS SLIP THE O RING ONTO THE FLANGE TUBE TO ENSURE PROPER LOCATING AND SEALING Also prior to installation verify that both O rings and fittings have not been nicked or deformed ...

Page 63: ... the refrigeration system When foreign materials such as dirt air or moisture contaminate the refrigeration system they will change the stability of the Refrigerant 12 and 525 viscosity compressor oil They will also effect pressure temperature rela tionship reduce efficient operation and possibly cause interior corrosion and abnormal wear of moving parts The following general practices should be o...

Page 64: ...e hose to low side service fitting on accumulator and discharging into oil bottle Figure 18 As hose is slowly tightened down onto Schrader valve Refrigerant 12 will begin to discharge from the system into the container If no discharge occurs check for missing or defective Schrader depressor in hose fitting 2 With the low side of system fully discharged check high side system fitting on liquid line...

Page 65: ... if possible If the oil cannot easily be added to the replaced part add the oil to the accumulator Evacuating and Charging the A C System If the system has been opened for any repair or the Refrigerant 12 charge lost the system must be evacuated prior to charging Evacuation and charging is a combined proce dure and all gage lines must be purged with R 12 prior to charging There are three evacuate ...

Page 66: ...nd low side gage valves and begin vacuum pump opera tion Pump the system until the low side gage reaches 711 2 736 6mm 28 29 vacuum Note that in all evacuation procedures the spec ification of 711 2 736 6mm 28 29 vacuum is used This specification can only be reached at or near sea level For each 304 8m 1 000 feet above sea level specification should be lowered by one inch vacuum At 1524m 5 000 fee...

Page 67: ... E L O W S I D E FITTING A N D M A Y C A U S E P E R S O N A L I N J U R Y D U E T O E S C A P I N G R E F R I G E R A N T 1 2 6 Replace protective cap on accumulator fitting 7 Turn engine off 8 Leak check system with electronic leak detector J 29547 or equivalent see Diagnosis 9 Start engine 10 With system fully charged and leak checked continue to operate system performance IN LINE AIR CONDITION...

Page 68: ...INT DIST 21 4 SEAL CASE 22 5 VALVE W FITTING 6 NUT PUSH ON M3 6 x 23 11 23 24 7 SEAL OPG LINK 8 LINK ADJ SPR DEFR 25 9 COVER CASE AL 26 DEFR 27 10 SEAL 28 11 VALVE MODE 29 12 SPRING EXT 30 13 LINK ADJ SPR MODE 31 14 RETAINER 32 15 CASE BLOWER 33 16 VALVE TEMR 17 BAFFLE AIR 34 18 NUT 35 FAN WASHER FAN SUPT MOTOR ELEC TERMINAL BLO MTR GRD TUBE MOTOR COOLING SWITCH LOW PRESS ELEC GASKET O RING ACCUM ...

Page 69: ...AXIMUM AIR FLOW CROSS CAR VENTILATION CROSS CAR VENTILATION CROSS CAR VENTILATION MODE MAX NORM VENT BI LEVEL HEATER HEATER HEATER MODE DEFROST SIDE WINDOW DEFOG HEA _ AIR BLEED DEFROST HEATER AIR BLEED r DEFROST MODE SIDE WINDOW DEFOG CROSS CAR VENTILATION DEFROST AIR BLEED SIDE WINDOW DEFOG CROSS CAR VENTILATION HEATER V Figure 23 A C Module Air Flow ...

Page 70: ... FAN SWITCH BLOWER SPEED HEATER O U T L E T S A C O U T L E T S D E F O U T L E T S SEE REMARKS 1 OFF COLD LO OFF NO AIR FLOW NO AIR FLOW NO AIR FLOW 2 MAX COLD LO LOW NO AIR FLOW AIR FLOW NO AIR FLOW A 3 MAX COLD LO TO HI LO TO HI NO AIR FLOW AIR FLOW NO AIR FLOW B 4 NORM COLD HI HIGH NO AIR FLOW AIR FLOW NO AIR FLOW A C 5 B I L E V E L COLD HI HIGH AIR FLOW AIR FLOW NO AIR FLOW A 6 VENT COLD HI ...

Page 71: ...ide the accumulator The accumulator assembly should only be replaced when a physical perforation to the accumulator is found resulting in a leak the system is open to air for an extended period of time due to a front end collision removed parts ect The desiccant bag will be saturated with moisture DO NOT Replace the accumulator assembly when merely a dent is found in the outer shell of the accumul...

Page 72: ...y cable 2 Electrical connection 3 Two screws 4 Blower resistor Install or Connect 1 Blower resistor 2 Two screws 3 Electrical connection 4 Negative battery cable inspect Blower motor for proper operation in all speeds 1 A C POWER SWITCHING RELAY 2 BOLT SCREW 3 RELAY BRACKET 4 A C HIGH BLOWER RELAY 5 RESISTER ASM 6 A C HEATER MODULE ASM 520241 1B Figure 26 A C Power Switching High Blower Relay and ...

Page 73: ...s encountered during the removal of a plugged or restricted expansion tube use the follow ing procedure 1 Remove or Disconnect 1 Impacted residue 2 Pressure switch T Important Carefully apply heat with heat gun or equivalent approximately 1 4 inch from dimples on inlet pipe Do not over heat F Remove or Disconnect 1 Orifice tube while applying heat Clean B i 3 4 5 A C 1 2 3 4 B 1 2 3 4 Swab inside ...

Page 74: ...ections at controller 3 Controller 4 Three bolts at controller 5 Trim plate assembly 6 Four bolts at plate assembly 7 Negative battery cable yl Inspect Controller for mode selection operation fan operation and temperature lever oper ation FAN BLOWER SWITCH Remove or Disconnect 1 Negative battery cable 2 Four bolts at trim plate assembly 3 Trim plate assembly 4 Three bolts at controller 5 Controlle...

Page 75: ...le at controller Right speaker grill Four bolts at speaker Electrical connection at speaker Speaker Temperature control cable at heater A C module Install or Connect Temperature control cable at heater A C module Electrical connection at speaker Speaker Four bolts at speaker Right speaker grill Temperature cable at controller Controller Three bolts at controller Trim plate Four bolts at trim plate...

Page 76: ...ectrical connector One bolt Clutch relay assembly Install or Connect Clutch relay assembly One bolt Electrical connector Negative battery cable H I Inspect A C clutch for proper engagement 1 2 3 4 1 1 5 N m 13 ft lbs 2 FUEL PUMP RELAY 3 A C RELAY J10254 1B P Figure 31 Floor Heat Outlet Figure 32 Compressor Relay A C RECIRCULATING ACTUATOR F j Remove or Disconnect 1 Negative battery cable 2 A C mod...

Page 77: ...ollow the procedure may result in permanent damage to the engine COUPLED HOSE ASSEMBLY Remove or Disconnect Discharge system 1 2 3 4 5 6 B 1 2 3 4 5 Coupled hose assembly at compressor Coupled hose assembly at outlet tube assembly Coupled hose assembly at inlet tube assembly Bolt at coupled hose assembly clamp Coupled hose assembly Install or Connect Coupled hose assembly at compressor New O ring ...

Page 78: ...mbly 11 Inlet tube at accumulator Q Tighten Torque to 41 N m 30 ft lbs 12 Negative battery cable 13 Evacuate and charge system A C O U T L E T T U B E A S S E M B L Y Remove or Disconnect 1 Negative battery cable 2 Discharge system 3 Spare tire assembly 4 Jack assembly 5 Spare tire storage panel 6 Rear compressor outlet tube at front compressor outlet tube 7 Open deck lid 8 Compressor outlet tube ...

Page 79: ... hose assembly X Tighten Torque to 24 Nnn 17 ft lbs Spare tire storage panel Jack assembly Spare tire assembly Negative battery cable Evacuate and charge system EVAPORATOR CORE I4 Remove or Disconnect 1 Discharge system VIEW A VIEW B 1 CLAMPS 2 ACCUMULATOR ASM 3 FRONT COMPARTMENT PANEL SEAL 4 PIPE ASM HEATER 5 HOSE OUTLET HEATER 6 HOSE INLET HEATER 7 LOW SIDE FITTING 8 CYCLING PRESSURE SWITCH 9 TU...

Page 80: ...uid reservoir 1 Inspect The following for correct operation 1 Control assembly 2 Fan blower switch 3 Compressor clutch cycling 4 Proper cooling CONDENSER F l Remove or Disconnect Discharge system 1 2 3 4 5 6 7 Upper condenser attaching bolts Raise vehicle Grille Both condenser lines Lower condenser attaching bolts Condenser assembly 1 CONDENSER ASSY 2 NUT 3 BOLT 4 LOWER RADIATOR SUPPORT 5 S E A L ...

Page 81: ...s to 50 Nnn 37 lb ft 1 1 Adjust Belt tension to 350 newtons 80 lbs 4 Lower vehicle 5 Negative battery cable 6 Evacuate and charge system 1 WATER PUMP 2 27 N m 20 LB FT 3 STARTER MOTOR 4 BRACKET 5 COMPRESSOR ASM 6 50 N m 37 LB FT 7 CRANKSHAFT 8 BRACKET 9 SPACER H20025 1B Figure 37 A C Compressor Mounting VIN Code R 1 COMPRESSOR ASM 2 BRACKET 3 40 60 N m 30 44LB FT 4 20 34 N m 15 25LB FT 5 BRACKET A...

Page 82: ...BACKGROUND GLASS J 22555 POCKET THERMOMETER 50 TO 120 F YELLOW BACKGROUND GLASS J 23640 THERMOMETER DIAL TYPE 0 TO 220 F J 6742 03 THERMOMETER DIAL TYPE 25 TO 125 F 5 J 23600 B BELT TENSION GAUGE 6 J 5420 7 16 20 STRAIGHT ADAPTER J 25498 3 8 24 STRAIGHT ADAPTER 7 J 9459 7 16 20 90 ELBOW ADAPTER J 25499 3 8 24 90 ELBOW ADAPTER 8 J 7605 03 COMPRESSOR OIL INJECTOR 9 J 26549 C ORIFICE TUBE REMOVER 10 ...

Page 83: ......

Page 84: ...ont Head Head Gasket Front Valve Plate Suction Reed Plate and Cylinder to Front Head O Ring 13 Compressor Cylinder Shaft 16 Compressor Center Cylinder Seal 18 Compressor Leak Testing External and Internal 19 HR 6 Compressor Special Tools 20 When servicing the compressor keep dirt or foreign material from getting on or into the compressor parts and system Clean tools and a clean work area are impor...

Page 85: ...cing the compressor remove only the parts that preliminary diagnosis shows are in need of service Refer to Figures 4 and 5 for information relative to part names and location Removal and installation of external compressor parts and disassembly and assembly of internal parts must be performed on a clean workbench The work area tools and parts must be kept clean at all times COMPRESSOR CLUTCH PLATE...

Page 86: ...UGH BOLTS 6 FRONT HEAD HEAD GASKET VALVE PLATE SUCTION REED CYLINDER O RING FRONT CYLINDER SHAFT AND AXIAL PLATE PISTON BALL 6 PISTON 3 SHOE 6 THRUST BEARING AND RACES MAIN BEARING REAR CYLINDER REAR CYLINDER REAR HEAD SWITCH RING SYSTEM CONTROL SWITCH HIGH PRESSURE RELIEF VALVE RETAINER RING SWITCH Fig 4 HR 6 Compressor Components Exploded View ...

Page 87: ...crew must be flat or the end of the shaft axial plate assembly will be damaged Install the clutch plate and hub installer remover J 33013 B with bearing as shown in Figure 9 The body of theJ 3 3013 B installer remover should be backed off sufficiently to allow the center screw to be threaded onto the end of the compressor shaft 6 Hold the center screw with a wrench Tighten the hex portion of the i...

Page 88: ...ously Remove rotor and bearing assembly retaining ring using snap ring pliers J 6083 Fig 10 Install pulley rotor and bearing puller guide J 33023 A to the front head Fig 11 and install J 33020 pulley rotor and bearing puller down into the inner circle 1 CLUTCH PLATE AND HUB ASSY Tj CLUTCH PULLEY ROTOR SHAFT KEYWAY j JH SHAFT KEY G60080 1P2 EK Fig 8 Shaft Key Clutch Plate Hub Installation j T j AIR...

Page 89: ...tion or the rotor face will be bent T1 J 33023 A PULLEY i J 33020 PULLER ROTOR AND ENGAGES IN INNER BEARING PULLER CIRCLE OF SLOTS GUIDE IN ROTHR G8Q110 1P2 C Fig 11 Installing Pulley Rotor Bearing Puller Guide J 33020 PULLEY ROTOR AND BEARING PULLER G60120 1P2EK Fig 12 Removing Pulley Rotor and Bearing Assembly 2 Align the new bearing squarely with the hub bore and using puller and bearing instal...

Page 90: ...e compressor front head Fig 17 Should the J 33017 pulley rotor and bearing installer slip off direct in line contact with the inner race of the bearing loosen theJ 8433 1 center forcing screw and realign the installer and pilot so that the J 33017 installer will properly clear the front head 9 Install rotor and bearing assembly retainer ring using snap ring pliers J 6083 Fig 10 10 Reinstall clutch...

Page 91: ...w of the J 8433 1 puller crossbar to force the clutch coil onto the front head Be sure clutch coil and J 33024 installer stay in line during installation STAKE THREE 3 LOCATIONS 120 APART 520016 1D2 Fig 16 Bearing Staked in Place TJ J 8433 3 SCREW ff J 33023 A PULLER PILOT J J 33026 2 THRU BOLTS 0 PULLEY ROTOR fj J 33017 PULLEY ROTOR AND BEARING INSTALLER JJ J 8433 1 CROSS BAR G60170 1D2C Fig 17 I...

Page 92: ... front head or cylinder and shaft assembly is to be serviced or replaced the oil in the compressor must be drained measured recorded and replaced 1 STEELSHELL 2 LIPSEAL 520033 1 P I Fig 22 Compressor Shaft Seal A clean workbench covered with a sheet of clean paper and a place clean trays etc for all parts being removed and replaced is important as is the use of proper clean service tools N O T I C...

Page 93: ...Rotate the installer to seat the O ring and remove the installer Dip the new seal in clean 525 viscosity refrigerant oil and assemble seal to Seal Installer J 23 128 A by turning handle clockwise The stamped steel case side of the lip seal must be engaged with knurled tangs of installer so that flared out side of lip seal is facing and installed towards the compressor Install seal protector J 3461...

Page 94: ...in cavity 3 UsingJ 9533 1 snap ring pliers install switch retaining ring with high point of curved sides adjacent to switch housing Be sure retaining ring is properly seated in switch cavity retaining groove Leak test according to bench test procedure C O M P R E S S O R R E A R H E A D H E A D GASKET REAR VALVE PLATE SUCTION REED PLATE AND CYLINDER TO REAR HEAD O RING 4 fr Remove or Disconnect 1 ...

Page 95: ...ubricate a new cylinder to rear head O ring with clean 525 viscosity refrigerant oil and install O ring in rear cylinder O ring groove The O ring may be positioned on cylinder as shown in Figure 29 and then rolled into the O ring groove but cylinder surface must be clean Preferably cleaned with recommended solvent and blown dry with air 3 Install suction reed plate over the J 33016 and guide pins ...

Page 96: ...n progressive torque until a torque of 8 10 N m 72 84 in lbs is achieved on all six 6 bolts Install test plate J 9625 A on rear head of compressor and leak test complete compressor assembly according to Bench Check leak testing procedure Remove test plate add amount of new 525 viscosity refrigerant oil to be added as determined in Step 1 of Remove Process Install clutch parts on compressor accordi...

Page 97: ...ligned Position 6 Using a plastic headed hammer tap the front head at the mounting locations to disengage the head from the compressor cylinder Remove the front head head gasket front valve plate suction reed plate and cylinder to front head O ring Discard the head gasket and the O ring 7 Inspect the front valve plate suction reed plate and visible portion of compressor cylinder and replace as nec...

Page 98: ...ore removing the guide pins Alternately tighten the through bolts in progressive torque until a torque of 8 10 N m 72 84 in lbs is achieved on all six 6 bolts 9 Install new shaft seal kit per previous procedure 10 Add amount of new 525 viscosity refrigerant oil as determined in step 1 of Remove Install test plate J 9625 A Place shaft nut on shaft and rotate compressor shaft several turns 11 Leak t...

Page 99: ...ront Head Remove the shaft seal parts per previous procedure and discard the old seal parts Mark the location and note the alignment of the front and rear heads in relation to the compressor cylinder Fig 27 This is important for reassembly Depending on application mounting the front head may be rotated 120 clockwise or 120 counterclockwise from the standard position Fig 2 Remove the six 6 compress...

Page 100: ... using the hole locations shown in Figure 38 Using both hands press the cylinder and shaft assembly down into the rear head Lubricate a new cylinder to front head O ring with clean 525 viscosity refrigerant oil and install O ring in front cylinder O ring groove Fig 38 Assemble the suction reed plate over the guide pins and position as shown Fig 39 Be sure tips of all three suction reeds locate abo...

Page 101: ...A Place shaft nut on shaft and rotate compressor shaft several times Leak test complete compressor assembly according to Bench Check Leak Testing procedure 1 12 O CLOCK REFERENCE POSITION 2 0 RING IN PLACE ON REAR OF CYLINDER 3 DISCHARGE CROSSOVER FRONT TO REAR 4 SHAFT KEYWAY 5 OILHOLE FOR SHAFT LUBRICATION 520050 1P2 Fig 48 Front View and Detail of HR 6 Cylinder and Shaft Assembly 1 1 4 DIAMETER ...

Page 102: ...e hose connections to the gage adapters J 5420 connected to the low and high sides and allow the vapor pressure to release from the compressor If valve depressor type hoses are used loosen hose connections at gage manifold to release vapor pressure from compressor 8 Disconnect both gage adapters J 5420 or hoses from the test plate J 9625 A 9 Add 3 oz new 525 viscosity refrigerant oil to the compre...

Page 103: ...STALLER HUB DRIVE PLATE REMOVER INSTALLER CYLINDER ALIGNMENT RODS J 33017 PULLEY 8t BEARING ASSEMBLY INSTALLER l i l J 33019 BEARING STAKING TOOL p 7 J 33020 PULLEY PULLER w J 34614 SHAFT SEAL PROTECTOR pFj J 33022 SHAFT NUT SOCKET f20 J 33023 A PULLER PILOT F J 33024 CLUTCH COIL INSTALLER ADAPTER i i J 33025 CLUTCH COIL PULLER LEGS id J 33026 COMPRESSOR HOLDING FIXTURE 24 J 25030 CLUTCH HUB HOLDI...

Page 104: ...r keep dirt and foreign material from getting on or into the compressor parts and system Clean tools and a clean work area are important for proper service The compressor connections and the outside of the compressor should be cleaned before any on car repairs or before removal of the compressor The parts must be kept clean at all times and any parts to be reassembled should be cleaned with Trichl...

Page 105: ...as into the crankcase and close off a passage from the crankcase to the suction plenum The angle of the wobble plate is controlled by a force balance on the five pistons A slight elevation of the crankcase suction pressure differential creates total force on the pistons resulting in a movement about the wobble plate pivot pin that reduces the plate angle The compressor has a unique lubrication sys...

Page 106: ...SHAFT SEAL PARTS 8 THROUGH BOLTS 9 FRONT HEAD 10 FRONT HEAD TO CYLINDER O RING 11 CYLINDER SHAFT AND GUIDE PIN ASM 12 REAR HEAD TO CYLINDER O RING 13 SUCTION REED 14 VALVEPLATE 15 HEAD GASKET 16 REAR HEAD 17 COMPRESSOR CONTROL VALVE ASM 18 SYSTEM CONTROL SWITCHES 19 HIGH PRESSURE RELIEF VALVE Fig 4 V5 Compressor Components Disassembled View 520004 1D3 ...

Page 107: ... into the hub Hold the body of the remover with a wrench and turn the center screw into the remover body to remove the clutch plate and hub assembly T CLUTCH PLATE AND HUB ASSEMBLY T1 J 33013 B HUB AND CLUTCH DRIVE PLATE ASSEMBLY REMOVER PH J 34992 1 THUMB SCREW 7 J 34992 HOLDING FIXTURE G60070 1D3 J Fig 6 Clutch Plate and Hub Assembly Removal Install or Connect 1 Install the shaft key into the hu...

Page 108: ...ded fully onto the end of the compressor shaft or if the body of the installer is held and the center screw is rotated the key will wedge and break the clutch hub 7 Remove installer J 33013 check for proper positioning of the shaft key even or slightly above the clutch hub Install the shaft nut Hold the clutch plate and hub assembly with clutch hub holding tool J 33027 and using shaft nut socket J...

Page 109: ...er tangs still engaged in the rotor slots invert the assembly onto a solid flat surface or blocks 6 Drive the bearing out of the rotor hub with rotor bearing remover J 9398 A and J 29886 universal handle It is not n e c e s s a r y to r e m o v e t h e s t a k i n g in front of t h e hearing to r e m o v e t h e bearing h o w e v e r it w i l l be n e c e s s a r y to file a w a y t h e old s t a ...

Page 110: ...uter race of the bearing to prevent the possibility of distorting the outer race Stake three 3 places 120 apart 5 With the compressor mounted to the J 34992 holding fixture position the rotor and bearing assembly on the front head 6 Position the J 33017 pulley rotor and bearing installer and J 33023 puller pilot directly over the inner race of the bearing 1 J 8433 3 SCREW 2 J 8433 1 PULLER CROSS B...

Page 111: ...nk center hole ofthe J 33024 clutch coil installer Install the J 34992 2 through bolts and washers through the crossbar slots and thread them into the holding fixture J 34992 to full fixture thickness Turn the center forcing screw of the J 8433 1 puller crossbar to force the clutch coil onto the J 8433 3 SCREW TJ J 8433 1 PULLER CROSS BAR J J 33025 PULLER LEG TJ J 33023 A PULLER PILOT fHl CLUTCH C...

Page 112: ...T 4 CONTROL SWITCHES 5 MOUNTING BOSS 520017 1D3 Fig 21 Compressor and Clutch Assembly Rear View removed and replaced is important as is the use of the proper clean service tools N O T I C E Any attempt to use makeshift or inadequate service tools or equipment may result in damage and or improper compressor operation 1 STEELSHELL 2 LIPSEAL 520033 1D1 Fig 22 Compressor Shaft Seal SHAFT SEAL REPLACEM...

Page 113: ...f seal remover installer J 23128 A into the recessed portion of the seal by turning the handle clockwise Remove the seal from the compressor with a rotary pulling motion Discard the seal The handle should be hand tightened securely Do not use a wrench or pliers 7 Remove and discard the seal O ring from the compressor neck using O ring remover J 9553 01 ffl Clean m Thoroughly clean seal O ring groo...

Page 114: ...and connect gage charging lines Pressurize suction and high side of compressor with Refrigerant 12 vapor to drum pressure Temporarily install the shaft nut and with the compressor in horizontal position rotate the compressor shaft in normal direction of rotation several turns by hand Leak test the seal area and correct any leak found Remove shaft nut 6 Remove any excess oil resulting from installi...

Page 115: ...r to rear head O ring Discard the head gasket and the O ring Install or Connect 1 3 Place rear head on clean flat surface Position head with control valve at 6 o clock position Guide pins in mounting holes at 11 and 5 o clock positions Head gasket over guide pins with elongated hole at upper left pin 11 o clock Rear valve plate over guide pins with elongated hole at upper left pin Lower into place...

Page 116: ... Install test plate J 9625 A 8 Leak test complete compressor 9 Remove shaft nut and install clutch parts on compressor 10 Install compressor assembly on car 11 Evacuate and charge A C system 1 THROUGH BOLT GASKET 6 REQUIRED 2 J 35372 520023 1D3 Fig 29 Front Head Installed Thru Bolts and Gaskets In Place L E A K T E S T I N G EXTERNAL Bench Check Procedure 1 Install test plate J 9625 A on rear head...

Page 117: ...VER INSTALLER 12 J 35372 SUPPORT BLOCK 13 J 33011 O RING INSTALLER 14 J 33013 HUB DRIVE PLATE REMOVER AND INSTALLER 15 J 34993 CYLINDER ALIGNMENT RODS 16 J 33017 PULLEY BEARING ASSEMBLY INSTALLER 18 J 33019 BEARING STAKING TOOL 19 J 33020 PULLEY PULLER 2 0 J 34614 SHAFT SEAL PROTECTOR 21 J 33022 SHAFT NUT SOCKET 2 2 J 33023 PULLER PILOT 2 3 J 33024 CLUTCH COIL INSTALLER ADAPTER 2 4 J 33025 CLUTCH ...

Page 118: ...y information at end of this manual for servicing unitized construction bodies Body mount provisions are located at each end of the cradle Figure 2 The body mounts eliminate the motion of the cradle in relation to the body ON VEHICLE SERVICE UNDERBODY INSPECTION 1 Raise car 2 Check for obvious floor pan deterioration 3 Check for loose dirt and dust around the inside of the floor pan reinforcement ...

Page 119: ... wheel and tire assemblies 5 J Tighten Torque the following as indicated 1 Front cradle bolts 90 Nnn 67 lbs ft 2 Rear cradle nut 103 Nnn 76 lbs ft 10 11 12 13 Engine mount assembly 54 N m 38 lbs ft Rear Mount assembly 48 Nnn 36 lbs ft Front mount assembly 48 N m 36 lbs ft Rear lateral control arm at knuckle 50 Nnn 37 lbs ft 90 Rear lateral control arm at cradle 55 Nnn 41 lbs ft 105 Fixed adjusting...

Page 120: ...FRAME CRADLE AND MOUNTS 2A 3 1055 95 Figure 1 Cradle Alignment Specifications ...

Page 121: ...2A 4 FRAME CRADLE AND MOUNTS 1 CAGE NUT 2 RAIL 3 FRAME ASM 4 103 N m 76 LB FT 5 90 N m 66 LB FT 6 TRAILING ARM 7 FIXED ADJUSTABLE LINK 8 LATERAL CONTROL ARM J10252 2A P Figure 2 Cradle Mountings ...

Page 122: ...E CRADLE AND MOUNTS 2A 5 1 BATTERY 2 ENGINE 3 ENGINE SUPPORT FIXTURE J28467 A 4 LEFT STRUT MOUNTING Figure 3 Engine Support Fixture Mounting J10254 2A P Figure 4 Engine Support Fixture Mounting 2 8L and GT ...

Page 123: ...r ...

Page 124: ...ility for both front and rear bumper systems is achieved through honeycombed energy absorbing devices in each bumper These units convert the energy of an impact into heat and restoration 1 Damage If there is obvious damage to the unit it should be replaced 2 Inspection After Collision If the collision was so severe that the bumper did not return to its original position replace the energy absorber...

Page 125: ...lean and readable may result in liability for violation of Federal Vehicle Theft Prevention Standard and subject the vehicle owner to possi ble suspicion that the part was stolen The parts involved Front and rear bumper assemblies Hood Right and left front doors Right and left rear doors Right and left quarter panel assemblies Rear compartment lid hatch Right and left front fenders Certification l...

Page 126: ...FRONT REAR BUMPERS 2B 3 J10252 2B P Figure 2 Front Impact Bar Asm To Frame ...

Page 127: ...2B 4 FRONT REAR BUMPERS J10253 2B P Figure 3 Front Bumper Asm Non GT 1 RETAINER CLIP 2 RETAINER 3 BOLT SCREW 4 F A S C I A 5 RETAINER 6 REINFORCEMENT Figure 4 Front Facia Mounting GT ...

Page 128: ...FRONT REAR BUMPERS 2B 5 Figure 5 Rear Fascia Bracket Impact Bar Asm to Frame ...

Page 129: ...2B 6 FRONT REAR BUMPERS Figure 6 Rear Fascia Bumper Impact Bar Asm to Body Non GT Figure 7 Rear Fascia Mounting GT ...

Page 130: ...FRONT REAR BUMPERS 2 B 7 1 THEFT DETERRENT LABEL 2 FRONT FASCIA 3 REAR FASCIA H20036 2B Figure 8 Theft Deterent Label Placement ...

Page 131: ......

Page 132: ...terials 05900 or equivalent With a paddling motion mix the two components until a uniform color and con sistency is achieved 6 Apply a layer of the mixture approximately 3mm 1 8 thick on the backside of the panel overlapping the break at least 40mm 1 1 2 7 Apply one piece of the pre cut fiberglass cloth to the applied adhesive and cover the cloth with additional adhesive Apply the second piece of ...

Page 133: ...inal finish The best way of checking the viscosity of a reduced paint mate rial is with a Zahn 2 paint viscosity cup or its equivalent The temperature influences viscos ity directly If a cold can of paint is brought into an average temperature room 65 70 degrees it will be thicker and more viscous Adding sol vent to make the paint sprayable is not always the best action The paint should be allowed...

Page 134: ...uble contaminants then clean with a wax and grease removing solvent to remove any tar silicone or other road film not removed with the detergent wash 4 5 6 Sand the complete panel s with 400 grit or finer wet or dry sandpaper Repair and feather edge damaged areas as required Treat all bare metal with recommended metal conditioner and conversion coating Follow manufacturer s label directions Apply ...

Page 135: ...rer s label recommendations for paint viscosity cup reading c Spray two medium coats of activated clear coat material at 50 lbs air pressure at the gun over entire area s to be refinished For panel repair allow 15 20 minutes dry time between coats For overall refinish ing apply first coat allow to flash then apply second coat Spraying medium wet coats of clear coat material to reduce sur face text...

Page 136: ... before applying the clear coat Important If sanding of the base coat is necessary to remove imperfections such as dirt or sags sand with 400 grit or finer sand paper reclean the area s Apply one additional coat of base material and let dry Clear Coat Application 1 Mix and reduce clear coat lacquer or enamel material per label instructions use flex additive if recommended by paint source 2 Strain ...

Page 137: ...revention label SPOT REPAIR WITH L A C Q U E R C L E A R COAT ADHESION PROMOTER 1 WET SAND AREA TO BE PRIMED AND COLOR COATED WITH 400 GRITOR FINER 2 WET SAND AREA TO BE CLEAR COATED ONLY WITH 600 GRIT OR FINER 3 APPLY ADHESION PROMOTER OVER AND BEYOND SANDED AREAS 4 APPLY BASE COLOR COAT AS PER LABEL DIRECTION 5 APPLY LACQUER CLEAR COAT BEYOND BASE COLOR COAT BUT WITHIN ADHESION PROMOTER ALLOW TO...

Page 138: ...R FINER 2 WET SAND ENTIRE AREA TO BE CLEAR COATED WITH 600 GRIT OR FINER 3 APPLY AN ADHESION PROMOTER OVER ENTIRE AREA TO BE COLOR COATED AND CLEAR COATED 4 APPLY BASE COLOR COAT OVER REPAIR AREA ONLY AS PER LABEL DIRECTIONS 5 APPLY ENAMEL CLEAR COAT OVER ENTIRE PANEL AS PER LABEL DIRECTIONS G 2 0 0 1 3 2 C Figure 2 Panel Repair With Enamel Clear Coat ...

Page 139: ...2 C B BODY PANEL REPAIR H 2 0 0 3 1 2 C Figure 3 Theft Deterent Labels Body Panels and Doors ...

Page 140: ...BODY PANEL REPAIR 2C 9 J10251 2C P Figure 4 Theft Deterent Labels Hood and Deck Lid ...

Page 141: ......

Page 142: ...teering fluid level and the pump drive belt tension GENERAL DIAGNOSIS Car Pulls Leads Abnormal or Excessive Tire Wear 13 n s P e c t Front wheel or rear wheel alignment Sagging or broken springs Tire out of balance Worn strut dampener or shock absorber Tires 3 9 Vibrations 3 10 Sealed Wheel Bearings 3 15 Trim Height 3 16 r Hard driving Overloaded car Not rotating tires Scuffed Tires Inspect Toe in...

Page 143: ...ent Erratic Steering When Braking Inspect If Wheel bearings worn m Broken or sagging springs Leaking wheel cylinder or caliper Warped rotors Incorrect or uneven caster Low Or Uneven Trim Height f9 Inspect m Broken or sagging springs Overloaded car m Incorrect or weak springs Ride Too Soft Inspect Worn strut dampeners or shock absorbers m Incorrect or sagging springs Ride Too Harsh if Inspect Incor...

Page 144: ... In Start Inspect m Actuator rod deformed m Check items under High Lock Effort Key Cannot Be Removed in Off Lock y Inspect Damaged lock cylinder Linkage mis adjusted Lock Cylinder Can Be Removed 15lnspect Lock cylinder retaining screw missing High Effort In Lock Cylinder Between Off and Off Lock Inspect Distorted rack Lock Bolt Hits Shaft Lock In Off Position and Park Inspect Ignition switch is no...

Page 145: ... fit between shoe and shoe pivot pin Shoe not free in slot Steering Column Not Locking In Any Tilt Position Inspect Shoe seized on its pivot pin Shoe grooves may have burrs or dirt Shoe lock spring weak or broken Steering Wheel Fails To Return To Top Tilt Position 13inspect Pivot pins are bound up Wheel tilt spring is broken or weak m Turn signal switch wires too tight Noise When Tilting Column jf...

Page 146: ...lashing turn signal switch is inoperative B If car lights do not operate refer to page 8A 111 0 for electrical diagnosis Burned out bulbs or opens grounds in the wiring harness from the front turn signal bulb socket to the indicator lights Refer to page 8A 110 0 for electrical diagnosis Stop Light Not On When Turn Indicated V Inspect Loose column to chassis connection Disconnect the column to chas...

Page 147: ...he pads on the signal switch Bend the probes if needed then replace the turn signal switch and tighten the three screws Check the function as in Step A Short or fault in the turn signal switch wiring Connect male E and F contacts of column connector with jumper Check key reminder switch pads on turn signal switch with continuity meter If there is continuity the function is normal If not replace th...

Page 148: ...to the actuator pad If contact is not made decrease the switch contact gap until positive contact is made Use a continuity meter light G33917 3 AN Fig 6 Lock Cylinder Actuator Key in Place ACTUATOR PAD G33918 3 AN Fig 7 Checking Key Reminder Switch Continuity G33920 3 AN Fig 8 Checking Contact Gap 9 With positive contact at 0 8 mm 030 use a 0 6 mm 025 plug gap wire beneath the flat stock No contac...

Page 149: ... It green and at the tan switch terminals by pushing in the plunger all the way A click should be heard If there is no continuity replace the dimmer switch If there is continuity refer to page 8A 100 0 or 8A 101 0 for electrical diagnosis PIVOT AND SWITCH ASSEMBLY Switch Inoperative No Low High and or Wash L Inspect Loose body to switch connector Broken or damaged switch Internally damaged or worn...

Page 150: ...led cell in the fluid reservoir Aeration or foaming of the fluid is eliminated as the gas and the fluid cannot mix Proceed with the actual bench check as follows 1 Clamp the strut dampener shock UPSIDE DOWN in the vise Do not clamp on the reservoir tube or the mounting threads If a lag is noticed when it is stroked it means the gas filled cell has ruptured and replacement is necessary 2 Pump strut...

Page 151: ... be moving back and forth It feels as if the driver s seat is the pivot point in the car Another more time consuming method of determining the faulty tire is substituting tire and wheel assemblies that are known to be good Follow these steps 1 Drive the car to determine ifthe waddle is coming from the front or rear 2 Install tire and wheel assemblies known to be good from a similar car in place of...

Page 152: ...X I M U M S P E C I F I C A T I O N S E T L E F T C A S T E R 1 L E S S 1 I R O A D T E S T OK R O A D T E S T OK S T I L L L E A D S L E F T I S T I L L L E A D S R I G H T C O N T I N U E D E C R E A S I N G R I G H T C A S T E R U N T I L P U L L IS E L I M I N A T E D C O N T I N U E D E C R E A S I N G L E F T C A S T E R U N T I L P U L L IS E L I M I N A T E D SWAP L E F T F R O N T T I R E...

Page 153: ... TIRE S T I F F N E S S VARIATION RIM B E N T O R O U T O F R O U N D G33830 3 AN Fig 16 Causes of Vibrations SEALED WHEEL BEARING DIAGNOSIS See Fig 19 for Sealed Wheel Bearing Diagnosis TAPERED ROLLER BEARING DIAGNOSIS See Figs 20 and 21 for Tapered Roller Bearing Diagnosis TRIM HEIGHT DIAGNOSIS See Fig 22 for Trim Height Diagnosis ...

Page 154: ...PLACE TIRE OK I VISUAL INSPECTION X OK INDEX ASSEMBLY ON WHEEL STUDS NOT OK HIGH SPEED ABOVE 40 MPH OFF CAR OK DYNAMIC BALANCE NOT OK I ON CAR FINISH BALANCE NOT OK I OK MEASURE AND REPLACE WHEEL MEASURE AXLE OR HUB FLANGE RUNOUT OK _ L I NOT OK _ J _ REPLACE HUB OR AXLE SHAFT T OK OFF CAR DYNAMIC BALANCE I NOT OK OK STOP OK ON CAR OK FINISH BALANCE NOT OK _ i _ CHECK FOR ENGINE DRIVE LINE IMBALAN...

Page 155: ...el radial or lateral runout exceeds 050 at the tire tread proceed to Step C C If the off car tire and wheel radial or lateral runout measured in Step B exceeds 050 match mount the high radial runout point of tire to low radial runout point of wheel Reinflate mount on the dynamic balance machine and again measure and record the radial and lateral runout and its location as done in Step B In many ca...

Page 156: ...indicator as shown below Grasp disc and use a push puM movement If looseness exceeds 1270 mm 005 Replace hub and bearing assembly Hoist Car and Support Lower Control end Spin Wheal with Engine CAUT80N On front wheel drive cars drive wheel spin should be limited to 35 MPH as indicated on the speedometer This limit is necessary because the speedometer only indicates one half on the actual wheel spee...

Page 157: ...APPROXIMATELY 38 0 GENTLY REMOVE HANDS AND LET VEHICLE SETTLE REPEAT TWICE FOR A TOTAL OF 3 TIMES MEASURE Z J DIMENSIONS PUSH FRONT OF VEHICLE DOWN APPROXIATELY 38 0 GENTLY REMOVE HANDS AND LET VEHICLE RISE ON ITS OWN REPEAT TWICE FOR A TOTAL OF 3 TIMES MEASURE Z J DIMENSIONS TRUE HEIGHTS ARE THE AVERAGE OF THE HIGH LOW MEASUREMENTS D K D I M E N S I O N S LIFT REAR OF VEHICLE UP APPROXIMATELY 38 ...

Page 158: ...ions the specifications stated in column 2 of the aforesaid applicable chart are given and these are well within the range of safe vehicle operation In the event the actual settings are beyond the specifications set forth in column 2 or whenever for other reasons the alignment is being reset it is recommended that the specifications given in column 3 of the applicable chart be used ALIGNMENT PRELI...

Page 159: ... rear of the car When the wheels tilt outward at the top the camber is said to be positive When the wheels tilt inward at the top the camber is said to be negative The amount of tilt is measured in degrees from the vertical and this measurement is called the camber angle CASTER ANGLE Figure 1 Caster is the forward or rearward tilting of the wheel axis at the top from vertical A rearward tilt at th...

Page 160: ...WHEEL ALIGNMENT 3A 3 TO INCREASE CASTER AND CAMBER TO DECREASE CASTER AND CAMBER 1 UPPER CONTROL ARM 2 U C A SHAFT 3 FRONT BOLT 4 REAR BOLT Figure 2 Adjusting Front Caster and Camber ...

Page 161: ...ls 3 Grasp the top of the tire firmly and move it inboard or outboard until the correct camber is obtained 4 Again reach around the tire as in Step 2 and tighten both bolts to 190 Nnn 140 lb ft 5 If the accessibility to the bolts prevents applying complete torque it will be necessary to apply only PARTIAL torque just enough to hold the correct camber position then to remove the wheel and tire in o...

Page 162: ...5 0 CAMBER REAR 1 0 5 10 5 TOE REAR DEG PER WHEEL 15 1 15 1 Vehicle must be jounced three times before checking alignment to eliminate false geometry readings Front toe adjustment to be set separately per wheel with steering wheel held in straight ahead position within 5 0 Front rear cross car camber must be within 0 75 Front cross car caster must be within 0 75 Tie rod boot must not be twisted an...

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Page 164: ...The manual rack and pinion steering system consists of two main components the rack and the pinion The motion of the pinion is transferred through the pinion teeth which mesh with teeth on the rack which moves the rack The force is then transmitted through the steering knuckles on the control arms which turn the wheels ON CAR S E R V I C E RACK AND PINION ASSEMBLY Figure 1 Remove or Disconnect 1 2...

Page 165: ...D ASM INNER TIE CLAMP BOOT BOOT RACK PINION 13 CLAMP TIE ROD END 14 NUT HEX 15 ROD ASM OUTER TIE 16 NUT HEX SLOTTED 17 PIN COTTER 18 FITTING LUBRICATION 19 SEAL TIE ROD 20 BEARING RACK 21 SPRING ADJUSTER 22 PLUG ADJUSTER 23 NUT ADJUSTER PLUG LOCK 24 GROMMET MOUNTING RT HD 25 RING RETAINING 26 GROMMET MOUNTING LT HD 27 BUSHING RACK 28 RING RETAINING 29 RACK STEERING Fig 1 Rack and Pinion Steering A...

Page 166: ...ACK PINION BOOT A CUT BOOT CLAMP BOOT CLAMP I B SECURE BOOT CLAMP X SIDE CUTTERS J 22610 TIE ROD END CLAMP To prevent boot damage slide tie rod end of boot toward center of gear enough to expose boot groove on the tie rod Place a rubber band in groove This fills the groove and allows removal of boot from gear without damage Remove rubber band Slide boot on tie rod until boot snaps into groove THE ...

Page 167: ...ments and pinion flat location after installation STEERING PINION BALL BEARING ASSEMBLY RETAINING RING DUST COVER HEX LOCK NUT CAUTION WITH STEERING PINION REMOVED STEERING RACK CAN SLIDE FROM HOUSING AND BE DAMAGED 54 3 mm 54 3 mm Start approx 4 30 Pinch bolt notch 3 00 Finished position of Pinch bolt notch INSTALL RACK PINION 6 R E M O V E A N D INSTALL PINION SEAL REMOVE Remove seal as shown IN...

Page 168: ...own RACK BUSHING RETAINING RING RACK BUSHING RETAINING RING ACCESS HOLE BUSHING RETAINING RING ACCESS HOLE DRIFT VIEW A ON SOME MODELS J L 9 REMOVE AND INSTALL GROMMET REMOVE 1 Separate grommets from housing INSTALL 1 Install grommets on housing RETAINING RING MOUNTING GROMMET Fig 4 Rack and Pinion Assembly Service Chart C ...

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Page 170: ...specified screws bolts and nuts be used as designated and that they are tightened to the specified torque Apply a thin coat of lithium grease to all friction points when reassembling When the column assembly is removed from the car take special care in handling it The plastic fasteners which maintain column rigidity can be sheared or loosened by using a steering wheel puller other than the one rec...

Page 171: ...I G N A L L E V E R 2 I N S U L A T O R 3 HOUSING 4 S W I T C H N O T C H 5 T A N G 6 C R U I S E C O N T R O L W I R I N G Fig 2 Multifunction Turn Signal Lever L O C K C Y L I N D E R 3S3HS1CI47 Fig 3 Mechanical Neutral Start System 1 P O S I T I O N O F L O C K I N G PIN A N D C A M WITH S H I F T L E V E R IN P A R K 2 C A M 3 L O C K I N G PIN Fig 4 Park Lock System S T E E R I N G W H E E L ...

Page 172: ...t lock knob bolt positioning screws 180 apart 4 Steering shaft lock knob bolt 5 Horn lead to steering wheel pad 6 Two 2 screws retaining wheel pad 7 Negative battery cable Steering Wheel Nut 41 N m 30 Lbs Ft Steering Wheel Nut Retainer Telescoping Adjuster Lever Steering Shaft Lock Knob Bolt Steering Shaft Lock Knob Bolt Positioning Screw 12 Steering Wheel Pad Horn Contact Spring Horn Lead Fully D...

Page 173: ...ft connection Column bracket support bolts and column bracket support nut Shift indicator cable Electrical connectors Shift cable at actuator and housing holder 1 2 3 4 5 6 7 8 9 10 11 Install or Connect Column Assembly Shift cable and housing Electrical connectors Shift indicator cable Support bolts and nut Intermediate shaft upper shaft bolt Tighten m Shift Indicator See Shift Indicator Adjustme...

Page 174: ...lower attaching bolt This can be done by moving the steering column jacket assembly up and down or side to side until the steering shaft is centered 5 Tighten two 2 upper attaching bolts to specifications 6 Tighten two 2 lower attaching bolts to specifications 7 Tighten bolt 9 at flex joint to 47 N m 35 ft lbs 8 Install steering column cover 9 Connect negative battery cable 1 STEERING COLUMN SUPPO...

Page 175: ...Y 25 R A C K P R E L O A D S P R I N G 26 S W I T C H A C T U A T O R R A C K 27 S W I T C H A C T U A T O R R O D 28 S P R I N G T H R U S T W A S H E R 29 S W I T C H A C T U A T O R P I V O T PIN 30 W A V E W A S H E R 31 32 33 34 35 36 37 38 39 4 0 41 4 2 4 3 44 4 5 46 47 48 K E Y R E L E A S E L E V E R K E Y R E L E A S E S P R I N G W I R I N G P R O T E C T O R D I M M E R A N D I G N I T ...

Page 176: ... o x Q D UJ C O Q a2 r art ft J z 2 5 5 z tee 5 2 5 2 C 0 r 0 0 C O r N C 0 U C D r C 0 Q O r C N C 0 U C D f C X J 0 5 O H D 2 x z UJ Q S a h X UJ UJ X X X UJ o O 2 X u a o 2 t i H co X 2 C O u o 2 v J O 5 J 2 UJ O o f 5 s5 5 UJ X u C O CO co 2 UJ UJ w X w c o Q C O O UJ X x oo Q LU x UJ C O 2 C O 2 C O 2 x Z f x X J o 5 UJ X a C O a 2 a Q 2 oc L U C O X UJ O 2 O o 2 C O r UJ z X UJ X UJ L U L U ...

Page 177: ...ll lock cylinder Turn lock to R U N position and install key warning buzzer switch KEY W A R N I N G B U Z Z E R S W I T C H C L I P K E Y W A R N I N G B U Z Z E R S W I T C H H O U S I N G R E M O V E K E Y W A R N I N G B U Z Z E R S W I T C H REMOVE AND INSTALL HOUSING AND WIPER SWITCH R E M O V E Remove ignition and diminer switch Refer io step 5 Remove parts as shown For K E Y R E L E A S E ...

Page 178: ...s to the right off unlock INSTALL IGNITION SWITCH T DIMMER SWITCH 3 32 Drill SPRING AND BOLT ASSEMBLY DIMMER SWITCH ACTUATOR ROD ADJUST DIMMER SWITCH 6 REMOVE AND INSTALL STEERING SHAFT AND SHIFT TUBE R E M O V E Remove parts as shown ADAPTER AND BEARING ASSEMBLY BEARING RETAINER SCREWS I N S T A L L 1 Install parts as shown 2 Refer to inset for manual transmission lever adjustment OPTIONAL rB A C...

Page 179: ... S Y 35 I G N I T I O N S W I T C H A C T U A T O R A S S Y 36 S W I T C H A C T U A T O R R A C K 3 7 R A C K P R E L O A D S P R I N G 38 S T E E R I N G C O L U M N H O U S I N G 39 S W I T C H A C T U A T O R S E C T O R 40 H E X W A S H E R H E A D S C R E W 4 1 42 43 44 4 5 46 4 7 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 6 5 66 67 6 8 69 S P R I N G G U I D E W H E E L T I L T S P ...

Page 180: ...SWITCH ACTUATOR RACK 36 RACK PRELOAD SPRING 37 STEERING COLUMN HOUSING 38 SWITCH ACTUATOR SECTOR 39 HEX WASHER HEAD SCREW 40 SPRING GUIDE 4 1 W H E E L T I L T SPRING 42 SPRING RETAINER 43 COLUMN HOUSING COVER END CAP 44 SWITCH ACTUATOR PIVOT PIN 45 PIVOT SWITCH ASM 46 PIN PRELOAD SPRING 47 WIRING PROTECTOR 48 RACE UPPER SHAFT ASM 49 CENTERING SPHERE 50 JOINT PRELOAD SPRING 51 LOWER STEERING SHAFT...

Page 181: ...n SIGNAL SWITCH A R M S C R E W W I R E P R O T E C T O R 3 REMOVE AND INSTALL IGNITION LOCK AND K E Y WARNING BUZZER R E M O V E 1 Turn lock to R U N position and remove key warning buzzer 2 Remove parts as shown To assemble rotate to stop while holding cylinder I N S T A L L 1 I n s t a l l lock cylinder 2 T u r n lock to R U N position and install key warning buzzer switch TKEY WARNING BUZZER S...

Page 182: ...until rack engages pin on actuator rod Push housing down until pivot pin holes are in alignment UPPER BEARING INNER RACE SEAT L O C K B O L T RELEASE LEVER SPRING SCREW SWITCH ACTUATOR RACK I G N I T I O N SWITCH A C T U A T O R R O D r Punch Screwdriver REMOVE DRIVE SHAFT AND SECTOR R E M C V F T I L T SPRING R E T A I N E R SWITCH p ACTUATOR H R A C K P I V O T PIN J 21854 01 R E M O V E P I V O...

Page 183: ... install shift lever IGNITION SWITCH ACTUATOR ASSEMBLY L DIMMER SWITCH ROD SHIFT TUBE ASSEMBLY COLUMN SHIFT ONLY DIMMER SWITCH ASSEMBLY RETAINER RETAINER CLIP LOWER BEARING AND ADAPTER STEERING COLUMN HOLDING FIXTURE MOVE SWITCH SLIDER TO EXTREME RIGHT POSITION K E Y R E L E A S E Leave slider at extreme right PARK LOCK M o v e sliaer o n e detent to the left off lock ALL O T H E R C O L U M N S M...

Page 184: ...ed plastic in the shift tube View D and the steenng shaft View E If either one or both are sheared replace with NEW parts 5 Check for broken plastic bearing adapter at lower end of steering shaft If adapter is cracked or broken it must be replaced 6 Any vehicle damage that could cause a bent steering shaft must have steering shaft runout checked in the following mariner Remove intermediate shaft H...

Page 185: ...ng Screws 11 F T L B S 30 IN LBS 35 35 50 35 100 SPECIAL TOOLS i f W _ 7 J 23073 3 J 23073 1 J 23653 4 J 23653 J 21854 01 BT 61 9 J 23072 J 22635 BT 61 9 STEERING WHEEL P U L L E R J 21854 01 P I V O T PIN REMOVER J 22635 LOCK SHOE RELEASE LEVER J 23072 S H I F T T U B E R E M O V E R J 23073 1 2 3 J 23131 J 23653 J 23653 4 S H I F T T U B E INSTAI L E R L O C K P L A T E C O M P R E S S O R L O C...

Page 186: ... The front suspension system uses conventional long and short arm design and coil springs The control arms attach to the vehicle with bolts and bushings at the inner pivot points and to the steering knuckle hub and bearing assembly at the outer pivot points Lower balljoints use the wear indicator feature FRONT WHEEL BEARINGS NOTICE Sealed hub andbearing assemblies are used on all series vehicles y...

Page 187: ...5 Inspect Whenever the brake rotor has been separated from the wheel bearing remove any rust or other foreign material from the mating surfaces of the wheel bearing flange and rotor Failure to do so may result in lateral runout of the rotor causing brake pedal pulsation 2 Rotor and caliper refer to Section 5 for torque specifications 3 Bolt attaching brake line clip to upper control arm 4 Wheel an...

Page 188: ...or 8 o clock 8 Stud using tool J 6627 A 4 1 2 4 5 6 7 J 6627 A R E M O V E W H E E L S T U D 4 WASHERS NUT INSTALL W H E E L S T U D Figure 3 Wheel Stud Remove Install Install or Connect Insert stud in wheel hub Install four washers and a nut on the stud and tighten until stud is fully seated Rotor and caliper Refer to Section 5 for torque specifications Bolt attaching brake line clip to upper con...

Page 189: ... turn to align cotter pin 6 Left side rotor caliper and splash shield Refer to section 5 for torque specs 7 Bolt attaching brake line clip to upper control arm 8 Wheel and tire assemblies 9 Lower vehicle to the ground STEERING KNUCKLE Figure 5 Tools Required J 6627 A J 26407 4 2 3 4 5 Figure 4 Stabilizer Bar Assembly 8 9 10 Remove or Disconnect Raise vehicle on a hoist and support the lower contro...

Page 190: ... steering knuckle Tighten 20 Nnn 15 lb ft 1 2 turn 180 Maximum 1 6 turn to align cotter pin 5 Three bolts attaching hub and bearing assembly Torque to 260 N m 220 lb ft 6 Rotor and brake caliper refer to Section 5 for torque specifications 7 Tire and wheel assembly 8 Remove jack under lower control arm and lower vehicle to the ground UPPER BALL JOINT Figures 5 and 6 Tools Required J 26407 Drill bi...

Page 191: ...wheel assembly Bolt attaching brake line clip to upper control arm Tie rod end from steering knuckle and swing knuckle outboard Upper balljoint from steering knuckle using tool J 26407 Two bolts and paddle nut assembly attaching U C A shaft to crossmember and remove control arm from vehicle Install or Connect U C A shaft bolts to crossmember with a new paddle nut assembly Do not apply final torque...

Page 192: ...igure 8 Press balljoint out of lower control arm Install or Connect A s s e m b l e Clamp J 9519 10 and bolt J 9519 18 with instal lation adapters J 37161 2 and J 37161 4 on lower control arm as shown in Figure 8 1 Press ball joint into lower control arm 2 Position ball stud into steering knuckle boss and install ball stud nut Torque 35 Nnn 26 lb ft 1 2 turn 180 Maximum 1 6 turn to align and insta...

Page 193: ...o the crossmem ber and install pivot bolts Tighten slightly but do not apply final torque Remove the safety chain Shock absorber Stabilizer bar Torque bolt to 17 N m 12 lb ft Remove jack supporting lower control arm and lower vehicle to the ground With suspension system at its normal standing height torque lower control arm pivot bolts jp Tighten Torque to 50 N m 37 lb ft 3 4 turn 270 1 4 5 6 7 8 ...

Page 194: ...5 with small end toward L C A b Install bearing and J 21474 18 on bolt c Place spacer J 37162 2 over L C A bushing 2 Tighten the bolt until bushing is driven out of lower control arm 3 Remove bushing tool assembly 4 5 R REMOVE LOWER CONTROL ARM BUSHING 4 1 2 3 4 5 9 3 INSTALL LOWER CONTROL ARM BUSHING J 21474 6 J 21474 23 BEARING 7 J 21474 19 j 2 1 4 7 4 5 8 J 37162 2 LOWER CONTROL ARM 9 J 37162 1...

Page 195: ...ossmember 27 Nnn 20 lb ft Nut Tie Rod At Knuckle 20 Nnn 15 lb ft 1 2 turn 180 Note Maximum 1 6 turn to align cotter pin Bolt Hub and Bearing To Knuckle 260 Nnn 220 lb ft Nut Upper Shock 11 Nnn 8 lb ft Bolt Shock to L C A 27 N m 20 lb ft Bolt Stabilizer Bar Bushing Clamp 27 Nnn 20 lb ft Nut Stabilizer Bar Link 17 Nnn 12 lb ft SPECIAL TOOLS J 6627 A J 26407 J 21474 5 J 21474 18 J 21474 191 J 21474 2...

Page 196: ...rson Strut design This combination strut and spring adapts to the rear wheel drive The lower control arms pivot from the engine cradle The cradle has isolation mounts to the body and conventional rubber bushings are used for the lower control arm pivots The upper end of the strut is insulated by a rubber mount N O T I C E Boot protector J 28712 should be installed whenever servicing rear suspensio...

Page 197: ...RIGINAL CAMBER SETTING IT WILL BE NECESSARY HOWEVER TO CHECK ADJUST THE TOE IN SETTING 3 WHEN SERVICING ITEMS IN BOX II DO NOT SCRIBE THE MARKS AFTER REINSTALLING THESE ITEMS YOU MUST CHECK ADJUST BOTH CAMBER AND TOE IN STRUT MOUNT JOUNCE BUMPER STRUT SHIELD SPRING SEAT SPRING INSULATOR DRIVE AXLE REMOVAL BOX I REAR RIDE SPRING STRUT DAMPER KNUCKLE BOX II SCRIBING PROCEDURE 1 USING A SHARP TOOL SC...

Page 198: ...ud remover J 28733 A Hub spindle remover 1 Raise vehicle 2 Tire and wheel assembly 3 Brake caliper do not allow caliper to hang by the brake hose 4 Rotor 5 Hub nut discard nut 6 Three hub and bearing bolts 7 Install Tool J 28733 A and remove hub and REMOVE WHEEL STUD 4 WASHERS INSTALL WHEEL STUD J10253 3D P Figure 3 Removing Installing Wheel Stud 8 Install Tool J 6627 A and remove stud F Install o...

Page 199: ...r vehicle REAR KNUCKLE r Remove or Disconnect 1 Raise vehicle 2 Support front of vehicle with suitable jack stands 3 Install drive axle boot protector 4 Wheel and tire 5 Hub nut discard 6 Caliper and rotor 7 Trailing arm at knuckle 8 Fixed adjusting link lateral control arm through bolt 9 Strut mounting bolts 10 Hub knuckle assembly from drive axle r 1 I 4 Install or Connect 1 Hub knuckle assembly...

Page 200: ...BLY 6 WASHER SEAT 7 UPPER SPRING INSULATOR 8 SHIELD 9 LOWER SPRING INSULATOR 10 LOWER SPRING SEAT 11 SPRING 12 BUMPER 13 SEAT ASSEMBLY 14 UPPER MOUNT WASHER 15 INSTALL IN DIRECTION SHOWN 16 FRAME 17 KNUCKLE AND HUB ASSEMBLY 18 BRACKET 19 190 N m 140 LBS FT J10254 3D P Figure 4 Remove And Install Strut Damper ...

Page 201: ...g out directly opposite the compressor forcing screw 4 Position spring and components on strut as shown below Make sure spring is properly seated on bottom spring plate 5 Install strut spring seat assembly on top of spring The long stud must be 180 from strut mounting flange 6 Place J 26584 450 top adapter over spring seat as sembly 7 Turn compressor forcing screw until compressor top support just...

Page 202: ...d without hub nut installed to proper torque 14 Aluminum Wheel 1 Set parking brake 2 Raise vehicle 3 Remove wheel and tire assembly 4 Remove hub nut 5 Refer to steel wheel removal step 4 through step 9 USE J 33162 FOR TRI POT JOINT INSTALL DRIVE AXLE BOOT PROTECTOR INSTALL See Notice on page 1 of this section 1 Clean and inspect bearing mating surfaces and knuckle bore for dirt nicks and burrs 2 I...

Page 203: ...0 N m 140 LBS FT 2 STRUT ASSEMBLY 3 INSTALL IN DIRECTION SHOWN 4 KNUCKLE 5 50 N m 37 LBS FT 90 6 LATERAL CONTROL A R M 7 60 N m 44 LBS FT 8 FIXED ADJUSTING LINK 9 TRAILING ARM 10 FRAME J10257 3D P Figure 7 Rear Knuckle Assembly ...

Page 204: ... sidewall near the tire size of all original equipment tires This specification number assures that the tire meets GM s performance standards for traction endurance dimensions noise handling rolling resistance and others Usually a specific TPC number is assigned to each tire size When replacing tires only the size load range and construction as originally on the car are recommended This can best b...

Page 205: ...eric to P metric sizes within their own tire lines The metric term for tire inflation pressure is the kilopascal kPa Tire pressure may be printed in both kPa and psi One psi equals 6 9 kPa See the tire placard or Section OB for tire inflation specifications TIRE PLACARD Fig 4 The tire placard is permanently located on the rear face of the driver s door and should be referred to for tire informatio...

Page 206: ...al high speed tires available from many tire dealers 2 Tire pressures may increase as much as 6 psi when hot 3 Higher than recommended pressure can cause m Hard ride Tire bruising or carcass damage m Rapid tread wear at center of tire 4 Lower than recommended pressure can cause Tire squeal on turns m Hard steering o Rapid and uneven wear on the edges of the tread Tire rim bruises and rupture Tire ...

Page 207: ... removed without damage as follows 1 Tighten all wheel nuts on the affected wheel then loosen each wheel nut two turns 2 Lower car onto floor 3 Rock the car from side to side as hard as possible using one or more person s body weight to loosen the wheel and or rock the car from Drive to Reverse allowing car to move several feet in TYPE PL 1100 SERIES SAE CLASS S TYPE P 1200 SERIES SAE CLASS U TYPE...

Page 208: ...9 Tire Locating Ring TIRE REPAIR There are many different materials and techniques on the market to repair tires Tire manufacturers have published detailed instructions on how and when to repair their tires These instructions can be obtained from the tire manufacturer Due to the thin 3 2 mm 4 32 tread depth on temporary spare tires tire repair is not recommended WADDLE Waddle is side to side movem...

Page 209: ... e d 2 7 5 k P a 40 psi p r e s s u r e w h e n inflating a n y tire if b e a d s a r e not s e a t e d If 2 7 5 k P a 4 0 psi p r e s s u r e will not s e a t b e a d s deflate relubricate t h e b e a d s a n d reinflate Overinflation m a y c a u s e t h e bead to b r e a k a n d c a u s e s e r i o u s p e r s o n a l injury COMPACT S P A R E Temporary Use Only Inflate to 60 PSI G33961 3E AN Fig...

Page 210: ...correct for drum or rotor unbalance as does on car spin balancing this is overcome by their accuracy usually to within 1 8 i CL OF SPINDLE HEAVY SPOT 5 WHEEL SHIMMY ADD BALANCE WEIGHTS HERE CORRECTIVE WEIGHTS G33964 3E AN Fig 14 Dynamic Unbalance Correction ounce When balancing off car the wheel should locate on the balancer with a cone through the back side of the center pilot hole not by the whe...

Page 211: ...brasive cleaners as they could damage the protective coating ALUMINUM WHEEL HUB CAP 1 2 4 Remove or Disconnect Tire and wheel assembly Place a block of wood approximately 2 in diameter with a squared off end against the back surface of the cap A sharp hammer blow on the block of wood will remove the cap Install or Connect 1 Place cap into position at wheel opening and place a block of wood at leas...

Page 212: ...torque Accent Color Preparation 1 Sand over painted areas that will not require recoloring with 400 grit wet or dry to promote adhesion of clear coat Aluminum Damage on Wheel Surface 1 Mount tire and wheel on brake lathe and spin slowly 2 Sand wheel with backing block or pad by holding abrasive flat to surface of wheel and moving slowly back and forth from center to outer edge to remove damage Use...

Page 213: ... D E L TIRE SIZE F R O N T R E A R E X C E P T I O N S TIRE INFLATION PSI PSI TIRE SIZE F R O N T R E A R Fiero 30 30 FP205 RP215 60R15 30 35 Please refer to this listing during Pre delivery Inspection and otherwise Fig 16 Tire Pressure Specifications ...

Page 214: ...tic transaxles incorporate a male spline and interlocks with the transaxle gears through the use of barrel type snap rings The L H inboard shaft attach ment on the automatic transaxle utilizes a female spline which installs over a stub shaft protruding from the transaxle The drive axle shaft spline end mating with the steering knuckle and hub assembly will incorporate a slight helix to assure a ti...

Page 215: ...NCH 2 6 POINT DEEP WELL SOCKET if mi S 8K 1 L f J r J v f IQ S m Ik J G34752 4D AN Figure 1 Removing Installing Hub Nut 7 Fixed adjusting link lateral control arm through bolt 8 Scribe strut and knuckle assembly as outlined in section 3D 9 Strut mounting bolts 10 Hub from drive axle 11 Install J 28468 or J 33008 with J 29794 and J 2619 01 slide and remove drive axle from transaxle Install or Conne...

Page 216: ...DRIVE AXLE 4D 3 J 28712 OR J 33162 G34055 4D AN Figure 3 Drive Axle Removal ...

Page 217: ...mps This proce dure will prevent ballooning of the seal Assemble 1 Crimp clamp at drive axle shaft 2 Compress joint and seal to specified dimension 3 Crimp clamp at joint end 1 INBOARD THERMOPLASTIC SEAL 2 T R I L O B A L TRIPOT JOINT 3 A X L E SHAFT 4 130 MM 5 1 16 JOINT A N D SEAL A R E TO BE COMPRESSED TO THIS DIMENSION BEFORE CRIMPING CLAMPS G34642 4D AN Figure 5 Inboard Thermoplastic Seal ...

Page 218: ... y j a c o f f 5 d o 1 1 1 C O c c I I I K m m UJ D S W UJ a S 1 u c 1 1 d ui fc SE m liJ S CO U K a x m m m 1 1 1 1 1 1 m m m in z I 11 Q U O i g d 5 acgEuj 6 u J x u a o u i Z C U C C B O U I A I A I O B I D S I I I I I I I I I I I I I I 2 o _ h H Z G34058 4D AN Figure 6 Tri Pot Axle ...

Page 219: ...E INSTALL 1 Cut seal retaining clamps 2 Remove parts as shown Seal groove AXLE SHAFT SEAL RETAINING CLAMP 1 Flush grease from joint and repack joint with approx half of grease provided 2 Put remainder of grease in seal 3 Install parts as shown Use tool J 35910 to secure seal retaining clamp Torque to specifications SEAL RETAINING CLAMP DEFLECTOR RING RACE RETAINING RING SEAL RETAINING CLAMP REMOVE...

Page 220: ... cage window DISASSEMBLE AND ASSEMBLE INNER RACE AND CAGE 4 R E M O V E AND INSTALL I N N E R TRI POT SEAL R E M O V E INSTALL Cut seal retaining clamps Remove parts as shown TRI POT HOUSING DESIGN TYPE A SHAFT RETAINING RING SPIDER ASSEMBLY 1 Flush grease from housing and repack housing with approx half of grease furnished with new seal 2 Put remainder of grease in seal Install parts as shown Use...

Page 221: ...Tool J 8059 Snap Ring Pliers J 2619 01 Slide Hammer Assembly J 29794 Extension J 28468 or J 33008 Axle Shaft Remover J 34826 36 mm Hub Nut Socket J 28733 A Front Hub Spindle Remover J 28712 or J33162 Drive Joint Boot Protector J10254 4D P Figure 9 Special Tools ...

Page 222: ... Combination Valve 5 2 Brake Pressure Differential Warning Switch 5 2 Diagnosis and Inspection 5 2 Brake System Testing 5 2 External Conditions That Affect Brake Performance 5 5 Warning Lamp Operation 5 5 Brake Fluid Leaks 5 5 Master Cylinder Check 5 5 Substandard or Contaminated Brake Fluid 5 5 On Car Service 5 5 Pedal Travel 5 5 Stoplamp Switch Adjustment 5 6 Filling Master Cylinder Reservoirs 5...

Page 223: ... system failure Similarly full front pressure is retained in the event of a rear brake pressure failure BRAKE PRESSURE DIFFERENTIAL WARNING SWITCH The brake pressure differential warning switch con stantly compares brake pressure in both parts of the sys tem The switch will activate the BRAKE warning lamp on the instrument panel in case of a failure in either part The combination valve is designed...

Page 224: ...d Brake Lining XX X X X X X Incorrect Lining Material Replace X X X X X X X Contaminated Brake Lining Replace XX X XX XX X X X Linings Damaged by Abusive Use Replace X XX X X X X X X Heat Spotted or Scored Discs X X X X X XX X Improper Thickness Variation X XX Excessive Lateral Run out X X Automatic Adjuster Problem X X X X X Brake Assembly Attachments Missing or Loose X X X X X X X X Restricted B...

Page 225: ...stricted air filter element Replace Worn or distorted reaction plate or levers Replace plate or levers Cracked or broken power pistons or retainer Replace power pistons and piston rod retainer CRABBY BRAKES Apparent Off On Condition CAUSE CORRECTION Broken or damaged hydraulic brake lines Inspect and replace as necessary Insufficient fluid in master cylinder Fill reservoirs with approved brake flu...

Page 226: ...stem may appear to pass this test but still have slight leakage If fluid levels are normal check the vacuum booster pushrod length If an incorrect length pushrod is found adjust or replace the pushrod Check the service brake pedal travel and the parking brake adjustment When checking the fluid levels the master cylinder reser voir may be as low as one inch from the top if the linings are worn This...

Page 227: ...ular clip providing adjust ment 4 Release brake pedal and then repeat step 3 to assure that no clicking sounds remain FILLING MASTER CYLINDER RESERVOIRS The master cylinder must be kept properly filled to insure adequate reserve and to prevent air from entering the hydraulic system However because of expansion due to heat absorbed from brakes and from engine master cylin der must not be overfilled...

Page 228: ...ng located between master cylinder and brakes then the brake system served by the disconnected pipe must be bled Manual Bleeding Figure 7 Tool Required J 21472 Bleeder Wrench The time required to bleed the hydraulic system can be reduced if the master cylinder is filled with fluid and as much air as possible is expelled before the cylinder is installed on the vehicle Power brakes require removing ...

Page 229: ...to cor rect either of these two conditions Pressure Bleeding Figures 7 and 8 Tools Required J 29532 Bleeder J 29567 Bleeder Adapter J 21472 Bleeder Wrench NOTICE Pressure bleeding equipment must be the diaphragm type and must have a rubber dia phragm between the air supply and the brake fluid to prevent air moisture oil and other contaminants from entering the hydraulic system 1 Install the bleede...

Page 230: ...sure from the steel brake lines on the body to the calipers should be inspected at least twice a year when the car is on a lift for lubrication The brake hoses should be checked for road hazard damage for cracks and chafing of the outer cover and for leaks and blisters A light and mirror may be needed for an adequate inspection If any of the above conditions are observed on a brake hose it will be...

Page 231: ...e fluid Fitting flange must engage caliper orientation ledge Tighten Bolt to 45 N m 33 lbs ft 2 Hose into bracket There should be no kinks in hose 3 Bolt attaching hose clip to upper control arm Tighten Bolt to 6 N m 54 lbs in 4 Spring clip at hose mounting bracket 5 Brake pipe to hose Use backup wrench on hose fitting Make sure that hose does not make contact with any part of suspension Check in ...

Page 232: ...E PARKING BRAKE This vehicle is equipped with coated parking brake cable assemblies The wire strand is coated with a clear plastic material which slides over plastic seals inside the conduit end fittings This is for corrosion protection and reduced parking brake effort Handling of these cables during servicing of the parking brake system requires extra care Damage to the plastic coating will reduc...

Page 233: ... finish molding Raise vehicle See Section OA 7 Cable casing to cable Push through hole in cradle Seat clip on casing 8 Cable to equalizer and clip Lower vehicle See Section OA Adjust Parking brake See Section 5B10 Parking Brake Rear Cable 4 1 2 3 4 Remove or Disconnect Figure 12 Raise vehicle See Section OA Cable from clip and equalizer Cable and casing from caliper Casing clip at cradle Cable and...

Page 234: ...EMBLY 5 CLIP 9 CLIP 13 LEVER 2 FRONT CABLE 6 FLOOR PAN 10 FRAME 14 BOLT 3 GROMMET 7 CLIP 11 INSULATOR 15 WELD NUT 4 LEFT REAR CABLE 8 RIGHT REAR CABLE 12 EQUALIZER J10012 5 P Figure 12 Parking Brake Control Assembly and Cables ...

Page 235: ...ter surface finish The optimum speed for refinishing braking surfaces is a spindle speed of 200 rpm Crossfeed for rough cutting should range from 0 254 0 152 mm 0 010 0 006 inch per revolution Finish cuts should be made at crossfeeds no greater than 0 051 mm 0 002 inch per revolution TO RELEASE TABS B J 1 0 0 1 3 5 P Figure 13 Removing Brake Switch Connector electrical circuit is faulty Replace bu...

Page 236: ...ve switch terminal 4 Hydraulic pipes at combination valve Bleed brakes See Bleeding Brake Hydraulic Sys tem in this section CAUTION Do not move the car until a firm brake pedal is obtained Air in the brake system can cause loss of brakes 1 BOOSTER 2 PIPE 3 VALVE 4 BOLT 5 BRAKE PIPE RR 6 PIPE R H 7 PIPE L H 8 BRACKET J 1 0 0 1 4 5 P Figure 14 Combination Valve to Master Cylinder Mounting ...

Page 237: ......

Page 238: ... R E P A I R 5A3 2 Master Cylinder Overhaul 5A3 2 Master Cylinder Reservoir 5A3 3 1 2 3 4 5 6 7 8 9 10 11 12 RESERVOIR COVER RESERVOIR DIAPHRAGM RESERVOIR RESERVOIR GROMMET LOCK RING PRIMARY PISTON ASSEMBLY SECONDARY SEAL SPRING RETAINER PRIMARY SEAL SECONDARY PISTON SPRING CYLINDER BODY QUICK TAKE UP V A L V E NOT S E R V I C E A B L E HM0Q015A3 BG Figure 5A3 1 Composite Master Cylinder ...

Page 239: ...Y h j Remove or Disconnect Figure 5A3 2 1 Tube nuts 14 and hydraulic lines Plug open lines to prevent fluid loss and contamination 2 Two attaching nuts 15 3 Master cylinder 13 See NOTICE on page 5 1 Install or Connect Figure 5A3 2 1 Master cylinder 13 with attaching nuts 15 to 27N m 201b ft 2 Hydraulic lines and tube nuts 14 to 23 N m 17 lb ft 3 Fill master cylinder to proper level with clean brak...

Page 240: ...moving Reservoir 1 2 i v 3 j 3 RESERVOIR 4 GROMMET 12 CYLINDER BODY HM0005 5A3 BG Figure 5A3 4 Installing Reservoir MASTER C Y L I N D E R RESERVOIR j j Disassemble Figures 5A3 3 5A3 4 1 Remove and disassemble master cylinder as previously described 2 Clamp flange ofmaster cylinder body 12 in vise Important Do not clamp on master cylinder body 12 Do not remove quick take up valve from body Valve i...

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Page 242: ...aliper Assembly 5B4 3 Unit Repair Caliper Overhaul 5B4 6 5B4 6 SPRING PIN OUTBOARD SHOE LINING INBOARD SHOE LINING WEAR SENSOR SPRING MOUNTING BOLT SLEEVE BOOT SLEEVE PISTON BOOT PISTON SEAL BLEEDER VALVE CAP BLEEDER VALVE BRIDGE BOLT BRIDGE CALIPER HOUSING J 1 000 1 5 B 4 P Figure 1 48H Front Caliper Assembly Components ...

Page 243: ...between linings and rotor Position 12 inch adjustable pliers over caliper housing 16 and flange of the inboard brake shoe 3 Squeeze pliers to compress piston back into caliper bore Inboard shoe and lining 3 Lift through caliper opening If necessary push on bridge 15 moving cali per housing 16 inboard to provide clearance for removing inboard shoe and lining 3 Install or Connect Figures 1 through 8...

Page 244: ...ed and inboard spring 5 being installed Complete pin installation by tapping as in step 3 above 1 SPRING PIN J 6 1 2 5 1 B J 1 0 0 0 4 5 B 4 P Figure 4 Attaching Impact Tool 1 SPRING PIN J 6125 1B J 36620 J 1 0 0 0 5 5 B 4 P Figure 5 Removing Spring Pins Make sure springs 5 are centered on shoe flanges with each spring end projecting under pins 1 an equal amount Wheels and tires aligning previous ...

Page 245: ... PIN 2 OUTBOARD SHOE LINING 3 INBOARD SHOE LINING 5 SPRING J 1 0 0 0 8 5 B 4 P Figure 6 Moving Caliper Inboard Figure 8 Installing Springs 1 SPRING PIN J 1 0 0 0 7 5 B 4 P 6 MOUNTING BOLT 7 SLEEVE BOOT 8 SLEEVE 16 CALIPER HOUSING J 1 0 0 0 9 5 B 4 P Figure 7 Installing Spring Pins Figure 9 Front Caliper Assembly ...

Page 246: ...es 8 for corrosion Sleeve boots 7 for cuts nicks or deterioration If corrosion is found use new parts including sleeve boots 7 when installing caliper housing 16 NOTICE Make sure sleeves are installed with large holes facing inboard If sleeves are installed backwards damage to threads in mounting bracket can result 1 Sleeve 8 and sleeve boots 7 in caliper housing 16 Lubricate sleeve 8 OD and mount...

Page 247: ... Sleeve Boots UNIT REPAIR CALIPER OVERHAUL Remove or Disconnect Caliper as previously described Inspect Figure 13 Bridge 15 for cracks Disassemble Figures 13 through 15 1 Bridge bolts 14 and bridge 15 only if bridge 15 is suspected of being cracked or damaged Caliper housing 16 can be overhauled without removing bridge 15 CAUTION Do not place fingers in front of the piston in an attempt to catch o...

Page 248: ...wood or plastic tool Inspect Figure 13 Caliper bore and piston seal groove 24 for scoring nicks corrosion and wear Use crocus cloth to polish out light corro sion Replace caliper housing 16 if corrosion in and around seal groove 24 will not clean up with crocus cloth 5 Bleeder valve cap 12 and bleeder valve 13 from caliper housing 16 Clean Figure 13 All parts in clean denatured alcohol Dry with un...

Page 249: ...hten Bridge bolts 14 to 100 N m 74 lbs ft 2 Bleeder valve 13 and valve cap 12 Tighten Bleeder valve 13 to 13 N m 116 lbs in 3 Lubricated new piston seal 11 into piston seal groove 24 Make sure seal 11 is not twisted 4 Lubricated boot 10 onto piston 9 5 Piston 9 with boot 10 into bore of caliper housing 16 and push to bottom of bore Use J 36623 to bottom piston 9 6 Boot 10 to counterbore in caliper...

Page 250: ...RONT CALIPER 5B4 9 1 SPRING PIN 2 OUTBOARD SHOE LINING 3 INBOARD SHOE LINING 5 SPRING 7 SLEEVE BOOT 8 SLEEVE 9 PISTON 10 BOOT 11 PISTON SEAL 15 BRIDGE 16 CALIPER HOUSING 7 Figure 18 48H Front Caliper Assembly Cutaway View J10018 5B4 P ...

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Page 252: ...B O A R D S H O E LINING W E A R S E N S O R S P R I N G M O U N T I N G B O L T S L E E V E B O O T S L E E V E N U T L E V E R R E T U R N S P R I N G L E V E R S E A L P I S T O N A S S E M B L Y T W O W A Y C H E C K V A L V E B O O T P I S T O N S E A L A C T U A T O R S C R E W B A L A N C E S P R I N G THRUST W A S H E R 21 22 23 24 25 26 27 S H A F T SEAL B L E E D E R VALVE C A P B L E E ...

Page 253: ... only The torque values specified are for dry unlubricated fasteners Perform service operations on a clean bench free from all mineral oil materials ON CAR SERVICE SHOE AND LINING ASSEMBLIES Remove or Disconnect Figures 1 through 9 Tools Required J 6125 1B Slide Hammer J 36620 Spring Pin Remover J 36621 Piston Rotator Wrench Two thirds of brake fluid from master cylinder assem bly Release parking ...

Page 254: ... 15 is removed overhaul caliper as speci fied Bottom piston assembly 14 in caliper 27 bore Use J 36621 to turn piston assembly J 36621 has pins to engage holes in piston assembly 14 Turn left caliper piston assembly counterclock wise and turn right caliper piston assembly clockwise to move piston assembly 14 back into caliper bore 3 INBOARD SHOE LINING 26 BRIDGE J10005 5B10 P Figure 5 Moving Calip...

Page 255: ...ssembly 14 2 Inboard shoe and lining 3 with wear sensor 4 at leading edge of shoe during forward wheel rotation Make sure shoe pins 33 on back of inboard shoe engage holes 34 in end of piston assem bly 14 Use J 36621 to align piston holes if necessary 3 Outboard shoe and lining 2 NOTICE See Notice on page 5 1 NOTICE In the following steps do not use a steel drift to install pins This will damage e...

Page 256: ...ree times to seat linings CALIPER ASSEMBLY Remove or Disconnect Figures 10 through 14 1 Shoes and linings as previously described 6 MOUNTING BOLT 7 SLEEVE BOOT 8 SLEEVE 27 CALIPER HOUSING J 1 0 0 1 0 5 B 1 0 P 2 3 5 Parking brake cable 35 and return spring 11 from parking brake lever 10 Loosen cable adjustment if necessary Bolt attaching inlet fitting 36 only if caliper is to be removed from vehic...

Page 257: ...D in caliper housing 27 with silicone grease Lubricate both ID and OD sealing beads on sleeve boots 7 with silicone grease Install one sleeve boot 7 OD into groove in mounting bolt hole of caliper housing 27 Push sleeve 8 into mounting bolt hole past ID of installed sleeve boot 7 to approximate posi tion shown in figure 13 view A Install second sleeve boot 7 OD in groove at other end of mounting b...

Page 258: ...release parking brake three times 3 Check parking brake lever for full release Turn ignition on B R A K E warning lamp should be off If BRAKE warning lamp is still on and the hand lever is completely released pull downward on the front parking brake cable to remove slack from lever assembly 4 Raise car and suitably support See Section OA 5 Check that parking brake levers 10 on both calipers are ag...

Page 259: ... piston assembly 14 out of caliper housing 27 I Inspect Piston assembly 14 for scoring nicks corro sion and worn or damaged chrome plating Replace piston assembly 14 if any of the above are found Actuator screw 18 by pressing on thread end Inspect Actuator screw 18 for cracks and thread dam age 5 Balance spring 19 6 Shaft seal 21 and thrust washer 20 from actuator screw 18 7 Boot 16 Be careful not...

Page 260: ...20 towards the piston assembly 14 and the grayish surface towards caliper housing 27 Lubricated shaft seal 21 on actuator screw 18 Lubricated boot 16 onto piston assembly 14 Important Make sure outside diameter of piston assembly 14 is well lubricated before installation Lubricated piston assembly 14 and boot 15 into lubricated bore of caliper housing 27 Push piston assembly 14 toward bottom of ca...

Page 261: ... 36623 install or Connect Caliper as previously described 1 SPRING PIN 2 OUTBOARD SHOE LINING 3 INBOARD SHOE LINING 5 SPRING 7 SLEEVE BOOT 8 SLEEVE 9 NUT 10 LEVER 11 RETURN SPRING 12 LEVER SEAL 14 PISTON ASSEMBLY 15 TWO WAY CHECK VALVE 16 BOOT 17 PISTON SEAL 18 ACTUATOR SCREW 19 BALANCE SPRING 20 THRUST WASHER 21 SHAFT SEAL 25 BRACKET 26 BRIDGE 27 CALIPER HOUSING J 1 0 0 1 9 5 B 1 0 P Figure 19 48...

Page 262: ...ODELS 6 GROMMET 7 FRONT HOUSING S E A L 8 PRIMARY PISTON BEARING 9 REAR HOUSING 10 FRONT HOUSING 11 RETURN SPRING 12 PISTON ROD GAGED 13 REACTION RETAINER 14 POWER HEAD SILENCER 15 DIAPHRAGM RETAINER 16 PRIMARY DIAPHRAGM 17 PRIMARY SUPPORT PLATE 18 SECONDARY PISTON BEARING 19 HOUSING DIVIDER 20 SECONDARY DIAPHRAGM 21 SECONDARY SUPPORT PLATE 22 REACTION DISC 23 REACTION PISTON 24 REACTION BODY RETA...

Page 263: ...taching nuts 36 and booster 35 See NOTICE on page 5 1 34 v 32 PUSHROD 34 MASTER CYLINDER 35 BOOSTER 36 NUT 35 37 NUT HM0002 5D2 AB Figure 2 Removing Booster Assembly 1 Booster 35 and attaching nuts 36 to 21 N m 15 lb ft 2 Booster pushrod 32 to brake pedal 3 Master cylinder 34 to booster 35 and attaching nuts 37 to 27 N m 20 lb ft EXTERIOR COMPONENTS Figure 3 jTj Important 1 2 3 4 The vacuum check ...

Page 264: ...earing 8 with silicone grease P N 1052863 or equivalent Primary piston bearing 8 into rear housing 9 Power piston group 38 into rear housing 9 Return spring 11 Align scribe marks on housings 9 and 10 Using tool J 23456 39 apply force in a clockwise direction to lock front and rear housings 10 and 9 Figure 4 Unlocking and Locking Booster 8 PRIMARY PISTON BEARING REAR HOUSING FRONT HOUSING RETURN SP...

Page 265: ...ith an alcohol dampened cloth Dry with unlubricated compressed air Assemble Lubricate inside diameter of secondary diaphragm 20 lip inside diameter of primary diaphragm 16 lip and secondary piston bearing 18 with a thin layer of silicone grease Secondary diaphragm 20 into secondary support plate 21 Secondary diaphragm 20 and support plate 21 over power piston assembly 41 and pushrod 32 Use J 28458...

Page 266: ...AGM 21 SECONDARY SUPPORT PLATE 32 PUSHROD 41 POWER PISTON ASSEMBLY HM0007 5P2 AB DIAPHRAGM LIP 20 SECONDARY DIAPHRAGM 21 SECONDARY SUPPORT PLATE 41 POWER PISTON ASSEMBLY 42 TOOL J28458 HM0008 5P2 AB Figure 8 Assembling Secondary Diaphram Support 18 SECONDARY PISTON BEARING 19 HOUSING DIVIDER 20 SECONDARY DIAPHRAGM 41 POWER PISTON ASSEMBLY 42 TOOL J28458 HM00Q9 5P2 AB Figure 9 Assembling Housing Di...

Page 267: ...ssembly 32 m m Inspect Power piston for cracks Rubber parts for cuts or nicks Air valve pushrod assembly for corrosion Replace part s if any of the preceding are found Clean All parts in clean denatured alcohol Dry with unlubricated compressed air 22 REACTION DISC 23 REACTION PISTON 24 REACTION BODY RETAINER 25 REACTION BODY 26 AIR VALVE SPRING 27 REACTION BUMPER 28 RETAINING RING 29 FILTER 30 RET...

Page 268: ...e Figure 15 Measure After assembly of booster position J 22647 Gage 43 over piston rod 12 If piston rod 12 height is not within GO NO GO limits of gage 43 use a service adjustable piston rod to obtain correct height HM0013 5D2 AB Figure 13 Retainer Assembly 12 PISTON ROD 43 GAGE J22647 a 12 HM0Q15 5D2 AB Figure 15 Gaging Piston Rod Figure 14 Installing Retainer Into Piston ...

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Page 270: ... have a discard dimension cast into them This is a wear dimension and not a refinish dimension Any rotor which does not meet the specification should be replaced TORQUE SPECIFICATIONS Component Lbs Ft Lbs In Booster to Pedal Bracket Nuts 27 20 Brake Hose Bracket Bolts 4 36 6 54 45 33 Brake Pedal Bracket to Dash Nut 27 20 Brake Pipes from Combination Valve to Brake Hoses 15 11 Brake Pipes from Mast...

Page 271: ...3456 Power Brake Booster Disassembly and Assembly Tool J 28458 Power Piston Seal Protector J 28662 Brake Pedal Effort Gage J 29282 Control Valve Installer J 29532 Power Brake Bleeder J 29567 Brake Bleeder Adapter J 29803 I S O Flaring Tool J 36620 Spring Pin Remover J 36621 Piston Rotator Wrench J 36622 Boot Seal Installer J 36623 Piston Installer ...

Page 272: ... Service Manual supplement DESCRIPTION OF SECTION 6 S E C T I O N 6A ENGINE M E C H A N I C A L This section general contains information on the mechanical parts of the engine such as block crankshaft pistons valve train and camshaft that are common to most engines Overhaul procedures removal and replacement procedures and specifications are also covered Subsections furnish detailed information on...

Page 273: ...n all cases but because these terms have been used SECTION 6 F EXHAUST SYSTEM This section has information on all exhaust system parts such as tailpipes mufflers and the catalytic converter ORMATION PREVENTING DAMAGE AND IN CONTRIBUTING TO RELIABLE ENGINE PERFORMANCE When raising or supporting the engine for any reason do not use ajack under the oil pan Due to the small clearance between the oil p...

Page 274: ...dle speed to correct specification if not ECM controlled Incorrect or malfunctioning oil pressure switch m Incorrect or malfunctioning oil pressure gage Replace with proper gage m Improper oil viscosity or diluted oil Install oil of proper viscosity for expected temperature or install new oil if diluted with moisture or unburned fuel mixtures Oil pump worn or dirty Plugged oil filter Oil pickup sc...

Page 275: ...mpts to repair should be made only if the problem is consistent Excessive crankshaft end clearance Replace crankshaft thrust bearing Excessive front main bearing clearance Replace worn parts KNOCKS AT IDLE HOT Loose or worn drive belts Tension and or replace as necessary A C Compressor or generator bearing Replace as necessary Noisy mechanical fuel pump Replace pump Valve train Replace parts as ne...

Page 276: ...tion of the engine the dipstick should be held under the black light to assure that the dye has mixed thoroughly with the engine oil Oil with dye additive will be a bright yellow when exposed to a black light Oil without dye additive will show a light purple in color It is not necessary to clean the engine prior to inspection The difference between oil leaking with the dye additive versus old oil ...

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Page 278: ... same mating surfaces as when removed Disassemble Valve mechanism refer to specific engine section Oil gallery and water jacket plugs m Threaded plugs Cup plugs if damaged or leaking Obtain a suitable self threading screw Drill a hole in the plug Install the self threading screw Pry out plug Spark plugs Inspect Cylinder head gasket and mating surfaces for leaks corrosion and blow by If the gasket ...

Page 279: ...e reconditioned or replaced 1 Assemble Tool Required J 22677 Installer Oil gallery and cooling jacket plugs Coat plugs with GM 1050026 sealer or equivalent 2 Spark plugs 3 Valve and spring mechanism refer to specific engine section N O T I C E To avoid damage install spark plugs after cylinder head has been reinstalled VALVE DISASSEMBLY Disassemble Valve and spring mechanism refer to Specific Engi...

Page 280: ...e due to packing of chips or carbon Clean the valve guides before reaming Do not push down on the reamer VALVES p p Measure Valve run out Lift the valve off its seat and apply a dab of Prussian blue on the valve face Seat the valve and carefully rotate it The Prussian blue traces transferred to the valve seat are an indication of concentricity of the valve seat m Clean all traces of Prussian blue ...

Page 281: ...face for grooving If the groove is so deep that refacing would result in a knife edge destroying the margin the valve must be replaced The valve face may be reground to specifications if it is otherwise in good condition If the valve face cannot be ground within the limits given it must be replaced Measure valve margin after grinding valves If the margin is less than the minimum recommended margin...

Page 282: ... C E If below specification Figure 11 the valve must be replaced to avoid interference of the 2 3 015 MINIMUM BETWEEN VALVE STEM AND GAGE 015 GAGE INCLUDED IN CARBURETOR KIT BT 3005 BT 6428 OR J 25289 AREA WHERE GAGE SEATS MUST BE CLEAN AND SMOOTH Figure 10 Measuring Valve Stem Height Bridge type Tool 1 BT 6428 OR J 25289 IF VALVE STEM TIP IS LESS THAN 005 ABOVE ROTATOR AFTER GRINDING STEM INSTALL...

Page 283: ...Disassemble Drain oil from pump 1 2 3 Drive shaft and drive shaft extension if any Suction pipe and screen assembly Pump cover Figure 14 Oil Pump Front Cover Gear Type T 1 1 N m 88 IN LBS Tj OIL PUMP COVER T j PUMP OUTER GEAR PUMP INNER GEAR 5 FRONT COVER G40027 6A5A Figure 15 Gerotor Oil Pump 5 Pump gears 6 Pressure regulator valve Plug or cotter pin Spring Valve If the valve is stuck soak the pu...

Page 284: ...gears to assure priming 3 Cover and gasket 4 5 N O T I C E To avoid engine damage use only original equipment gaskets Gasket thickness is critical to proper functioning of the pump Pressure regulator valve and spring Cotter pin or plug depending on model Important Plug Type Coat threads with Loctite 573 or equivalent Cotter Pin Type Make sure the pin is properly secured Tighten Pump cover bolts to...

Page 285: ...018 0 035 0 045 0 004 m a x 0 10 m a x 0 003 0 004 0 08 0 10 0 003 0 005 0 08 0 13 0 0015 0 0045 0 040 0 120 004 m a x 10 m a x Sll CLEAP I D L E R G E A R IN M M 0 004 0 007 0 11 0 19 0 004 m a x 0 10 m a x 0 003 0 004 0 08 0 10 0 003 0 005 0 08 0 13 0 0015 0 0045 0 040 0 120 E N D C L E A R A N C E IN M M 0 001 0 004 0 03 0 10 0 002 0 005 0 05 0 13 0 002 0 005 0 05 0 13 0 002 0 006 0 05 0 15 0 0...

Page 286: ...r using a new gasket Tighten Oilfilter adapterboltsto 41 N m 30 lb ft Clean Oil pump intake screen Oil pan 4 Install or Connect Oil pan m Engine oil filter Fill crankcase with clean engine oil Inspect Remove oil pressure sending unit and install an oil pressure gage Start engine and observe oil pressure N O T I C E If the oil pressure does not build up almost immediately remove the oil pan and che...

Page 287: ...ring moving and installing tool in oil hole in crankshaft journal If such a tool is not available a cotter pin may bebent as required to dothe job Rotate the crankshaft clockwise as viewed from the front of engine This will roll upper bearing out of block Oil new selected size upper bearing and insert plain unnotched end between crankshaft and indented or notched side of block Rotate the bearing i...

Page 288: ... fillets cannot be reground They must be replaced Method B L Install bearing inserts and crankshaft into block 2 Place a piece of gaging plastic across the entire bearing width 3 Seat the bearing cap carefully by tapping it lightly with a suitable tool N O T I C E To avoid cylinder block and or main bearing cap damage the main bearing caps are to be tapped into their cylinder block cavity using a ...

Page 289: ...o pull main bearing caps into their seats Failure to observe thisinformation may damage a cylinder block or bearing cap 7 Bearing cap bolts Tighten 9 Bolts evenly then back off one full turn and torque to specification 8 Seat the crankshaft thrust bearing Figure 27 1 C E N T E R MAIN B E A R I N G T H R U S T F L A N G E S 2 WOOD BLOCK BUMP S H A F T IN EACH D I R E C T I O N T O A L I G N T H R U...

Page 290: ...shaft to bottom dead center Clean Carbon from the top end of the cylinder N O T I C E If there is a pronounced ridge at the top of the piston travel this ridge must be removed with a ridge reamer before removing piston and connecting rod assembly Do not use force Avoid breaking piston rings and damaging the piston 4 Connecting rod cap 5 Connecting rod and piston assembly Push out with a suitable t...

Page 291: ... for scoring e Piston pin for 1 Scoring 2 Galling caused by improper installation 3 Fit in connecting rod and piston Piston for 1 Scoring of the skirt 2 Cracks 3 Broken ring groove lands 4 Wear Measure Piston Rings 1 FEELER GAUGE 2 PISTON RING MEASURE RING GAP CLEARANCE WITH RING POSITIONED AT BOTTOM RING TRAVEL AS SHOWN G20029 6A Figure 33 Measuring Piston Ring Gap 3 Piston ring side clearance co...

Page 292: ...er compression Manufacturers mark facing up ring N O T I C E Use a piston ring expander to install the rings Avoid expanding the rings more than necessary which may cause ring damage Important In order to provide an effective compression seal the ring gaps must bestaggered Figure 37 Install or Connect 1 Lubricate cylinder wall and piston rings with clean engine oil 2 Turn crankshaft to bottom dead...

Page 293: ...Sprocket Keyway and threads Bearing surfaces and lobes for Wear Galling Gouges Overheating Discoloration Q Important Do not attempt to repair the camshaft replace it if damaged If a new camshaft is installed all valve lifters must be replaced except roller lifters Measure Cam lobe lift Lubricate the camshaft bearings with 1051396 or equivalent Carefully insert the camshaft If the camshaft bearings...

Page 294: ... Bearing Oil Hole Alignment 2 Camshaft Rear Cover soft plug Apply a 3mm 1 8 bead of GM 1052366 RTV sealer Fel Pro Black RTV or equivalent to the cover before installing V A L V E LIFTERS Operation Oil is supplied to the lifter through a hole in the side of the lifter body which indexes with a groove and hole in the lifter plunger Oil is then metered past the oil metering valve in the lifter throug...

Page 295: ...r more of the following a Badly worn or scuffed valve tip and rocker arm pad b Excessive valve stem to guide clearance c Excessive valve seat runout d Off square valve spring e Excessive valve face runout f Valve spring damper clicking on rotator To check valve spring and guide clearance remove the valve covers a Occasionally this noise can be eliminated by rotating the valve spring and valve Cran...

Page 296: ...fluid C A U T I O N D o not b r e a t h e f u m e s a n d avoid s k i n c o n t a c t w i t h carburetor c l e a n i n g fluid 5 Ball check valve assembly Remove with a small screwdriver 6 Plunger spring Clean 2 3 4 5 Sludge Varnish jW Inspect Lifter body for Wear Scuffing Also inspect the bore in the cylinder block Flat spot on the bottom If the bottom is worn flat or grooved replace the lifter A...

Page 297: ...ill lifter with test fluid and force out air Important Lifter must be completely submerged at all times Continue pumping for several strokes after definite resistance is felt 5 Raise weight arm to allow plunger spring to expand fully lower arm onto ram and commence turning crank slowly 1 revolution every 2 seconds 6 Time indicator travel from lower line first line above set line tolinemarked 094or...

Page 298: ...ssion mounting bolt hole boss Item 1 Figure 47 and set indicator to 0 3 Record the readings obtained on the remaining transmission mounting bolt hole bosses Measurements should not vary more than 203 mm 008 4 If the readings vary more than 203 mm 008 recheck crankshaft flange run out If the run out is excessive replace the crankshaft Threaded holes If necessary clean with a tap or drill out and in...

Page 299: ... the same nominal weight and can be i intermixed without affecting engine balance If necessary used pistons may be fitted selectively to any cylinder of the engine if they are in good condition Do not cut oversized pistons down or engine balance will be affected Measure Piston If worn or damaged replace with a standard or oversized piston Cylinder bore Figure 51 refer to Cylinder Block If worn bey...

Page 300: ... clip next to the first clip If no change is noticed relocate the clip 90 from its present location Continue until vibration is reduced Fine adjustments may be made by moving the clips in small increments T H R E A D REPAIR Damaged threads may be reconditioned by drilling out rethreading and installing a suitable thread insert Tools Required General purpose thread repair kits are available commerc...

Page 301: ...6A 24 GENERAL ENGINE MECHANICAL _ _ m M G20049 6A Figure 54 Repairing Threaded Holes ...

Page 302: ... on individually threaded shoulder bolts Combustion chambers are cast to insure uniform shape for all cylinders and enhance swirl in the cylinder Spark plugs are located near intake valves for maximum power Intake valves are large to provide easy breathing for high combustion efficiency Intake and exhaust valve seat angles are 46 to assure valve to seat contact at the outer diameter of the seat Fa...

Page 303: ... 3 Exhaust Manifold Fig 4 Camshaft and Crankshaft Gears PISTONS AND CONNECTING RODS The pistons are of a lightweight cast aluminum slipper skirt type and cam ground so that the diameter across the thrust face is larger than the diameter fore and aft of the engine Two compression rings and one oil control ring are used all of which are located above the piston pin Fig 5 Fig 5 Piston and Rod Assembl...

Page 304: ...dy maintains adequate pressure for the lubrication system and bypasses any excess back to the suction side of the pump Many internal engine parts have no direct oil feed and are supplied by either gravity or splash from other direct feed components Timing gears are lubricated by oil which is supplied through a passage from the front of the camshaft to a calibrated nozzle above the crankshaft gear ...

Page 305: ...6A14 2 5L ENGINE 6 PLUG J20005 6A4 Fig 6 Engine Lubrication ...

Page 306: ...g surfaces with Molykote or its equivalent 1 Install or Connect Push rod through cylinder head and into lifter seat 2 Guide rocker arm ball and bolt Torque 32 N m 24 lb ft 3 Rocker arm cover V A L V E SPRING SHIELD AND OR SEALS Tools required J23590 Air Adapter J5892 A Spring Compressor or J5892 1 J5892 1 can be modified to replace J5892 A by grinding 1 16 from slotted end i Remove or Disconnect F...

Page 307: ...ose Retaining bolts and intake manifold Clean All gasket surfaces on cylinder head and intake manifold Install or Connect 3 4 5 6 7 9 10 11 12 13 Retaining bolts and washers Tighten to specification Heater hose Throttle linkage and bell crank Cruise control and linkage if fitted Linkage transaxle downshift To TBI assembly Wiring Throttle linkage Vacuum hoses Fuel lines Engine coolant PCV valve and...

Page 308: ...2 Engine coolant 3 Raise car 4 Exhaust pipe 5 Oxygen sensor connector 6 Lower car 7 Battery ground cable 8 Oil level indicator tube 9 Air cleaner 10 From TBI assembly Wiring Throttle linkage 1 MOUNTING SURFACES OF BLOCK ASM HEAD ASM AND BOTH SIDES OF GASKET MUST BE FREE OF OIL AND FOREIGN MATERIAL 2 LOCATING PINS NUMBERS SHOWN DESIGNATE BOLT POSITIONS AND BOLT TIGHTENING SEQUENCE 00046A4 Fig 12 Cy...

Page 309: ...el pins 3 Cylinder head retaining bolts fingertight Tighten Cylinder head bolts gradually with torque wrench to 25 N m 18 lb ft in sequence shown in Fig 12 m Repeat sequence bringing torque to 35 Nem 26 lb ft on all bolts except number 9 Retorquenumber9 to25 N m 18lb ft Repeat sequence turning all bolts 90 degrees 4 Push rods 5 Rocker arms 6 Rocker arm cover 7 Radiator hose 8 Power steering pump b...

Page 310: ...E x e r c i s e c a u t i o n w h e n u n s c r e w i n g t h e plug or removing t h e pin a s bodily injury m a y result Clean All parts of sludge oil and varnish Varnish on parts may be removed by soaking in carburetor or cleaning solvent C A U T I O N A v o i d breathing of f u m e s or e x p o s u r e of t h e s k i n to t h e c l e a n i n g solvent a s bodily injury m a y result W h e n w o ...

Page 311: ...h clean engine oil 9 Inspect Remove the oil pressure sending unit and install an oil pressure gage Start engine and observe oil pressure NOTICE If the oil pressure does not build up almost immediately remove the oil pan and examine pump If necessary disassemble the oil pump and repack all cavities with petroleumjelly Running the engine without measurable oil pressure will cause extensive damage Ch...

Page 312: ... Rod nuts 44 N m 32 lb ft Force balancer if removed Oil pan Lower car Cylinder head assembly If Inspect m For proper completion of repair CRANKSHAFT 4 Remove or Disconnect Engine Engine oil Mount engine on suitable stand Spark plugs Crankshaft pulley and hub assembly Oil pan and force balancer Timing gear cover Crankshaft timing gear Connecting rod bearing caps with bearings and identify each for ...

Page 313: ...attachments CAUTION S u p p o r t fixture J 2 8 4 6 7 m u s t be located in c e n t e r of c o w l a n d its f a s t e n e r s properly tightened before supporting engine a n d t r a n s a x l e Bodily injury could result w i t h improper u s e of t h i s support fixture Refer to Section 2 A for installation of t h i s engine support fixture J 2 8 4 6 7 Engine Mount J 4 Remove or Disconnect 1 Engi...

Page 314: ...ter reassembly Trim at sail panel below battery side panel Support engine and transaxle with J28467 Bolt engine torque strut Raise vehicle Nuts front mount to frame 7 Nuts rear mount to frame 8 Nut front mount to bracket 9 Nut rear mount to bracket 10 Mounts front and rear 4 j Install or Connect 1 Position front and rear mounts 2 Nut rear mount to bracket 48 N m 35 lb ft 3 Nut front mount tobracke...

Page 315: ...6A1 14 2 51 ENGINE G20046 6A4 Fig 803 Manual Transaxle Mounts ...

Page 316: ...rubber washer assembly and replace if either stud or washer is damaged Sealing surfaces on push rod cover and cylinder block Dry surfaces with degreaser 4 l Install or Connect Fig 8 1 Apply a continuous 3 16 5 mm diameter bead of RTV sealant No 1052915 or equivalent around sealing surface of push rod cover 2 Cover and retaining nuts 10 N m 90 lb in 3 Intake manifold y Inspect For fluid leaks OIL P...

Page 317: ...C compressor Nuts front engine mount to cradle Splash shield Starter Starter and flywheel cover Right rear wheel Lower car Generator and serpentine belt Trim at sail panel below battery side panel Engine compartment lid and side panels Engine oil Battery cables MOUNT ASM J20003 6A4 TIMING GEAR COVER FRONT SEAL Remove or Disconnect Tools Required J28467 Engine Support Fixture Fig 806 Engine Support...

Page 318: ...ngine and remove J28467 Hub and pulley Flywheel cover Starter Inner splash shield Right rear wheel and tire Lower vehicle Serpentine belt Trim at sail panel below battery side panel Engine compartment lid and side panels Negative battery cable ENGINE ASSEMBLY 1 2 3 Remove or Disconnect Tools required J28467 Engine Support Fixture J34043 Parking Brake Cable Retainer Compressor Battery cables Engine...

Page 319: ...ap 14 Transaxle cooler lines automatic only 15 Fuel pump relay and oxygen sensor connectors 16 Fuel lines at TBI and filter 17 Vacuum hoses 18 Throttle and shift cables 19 Air cleaner 20 Engine harness and ECM harness 21 Rear console 22 Engine coolant 23 Battery cables 24 Charge A C if equipped 25 Trim at sail panel below battery side panel 26 Engine compartment lid and side cover panels m For pro...

Page 320: ...VEHICLE JACKING LOCATIONS 5 4x4 s 2 SUITABLE 4 WHEEL SUPPORT DOLLY 6 WHEEL CHOCKS 3 CALIPER SUPPORTED 4 SUPPORT CONTROL ARM ON BOTH SIDES OO NOT SUPPORT ON THE ROTOR OR SHIELD 520031 6A4 Fig 809 Engine Removal and Cradle Support Points ...

Page 321: ...from camshaft Use arbor press and adapter Position thrust plate to avoid damage by interference with woodruff key as gear is removed Refer to Section 6A General Engine Mechanical Assemble 1 Support camshaft at back of front journal in arbor press using press plate adapters 2 Position spacer ring thrust plate over end of shaft and woodruff key in keyway Fig 812 Removing Camshaft Timing Gear 3 Press...

Page 322: ... 108mm 12 N m 9 lb ft 90 Turn Camshaft Thrust Plate To Block Bolt 10 N m 90 lb in Clamps Radiator Hoses All 2 N m 17 lb in Connecting Rod Nut 44 N m 32 lb ft Cylinder Head to Block Bolt see text EFI Assembly to Manifold Bolt 20 N m 15 lb ft EFI Assembly to Manifold Nut 20 N m 15 lb ft EGR Valve to Manifold Bolt 22 N m 16 lb ft Exhaust Manifold to Cyl Head Bolt see text Flywheel To Crankshaft Autom...

Page 323: ...1 78 1 440 CAMSHAFT E N 158 170 1 040 LOBE LIFT INTAKE 398 DAMPER EXHAUST 398 FREE LENGTH JOURNAL DIAMETER 1 869 APPROX NO O F COILS CLEARNACE 0007 0027 CAMSHAFT END PLAY 0015 0050 OIL PUMP GEAR POCKET DEPTH 516 MAX 514 MIN GEAR THICKNESS 512 511 CRANKSHAFT MAIN JOURNAL CRANKPIN DIAMETER 2 3 DIAMETER 2 0 TAPER 0005 i TAPER 0005 OUT OF ROUND MAX 0005 OUT OF ROUND MAX 0005 CLEARANCE 0005 0022 CLEARA...

Page 324: ...MSHAFT LOAD CLOSED 32 35 36 58 LOBE LIFT INTAKE 10 3124 MM OPEN 72 77 26 42 EXHAUST 10 3124 DAMPER JOURNAL DIAMETER 47 4726 MM FREE LENGTH CLEARNACE 01778 0685 MM APPROX NO OF COILS _ CAMSHAFT END PLAY 0381 127 OIL PUMP GEAR POCKET DEPTH 13 1 MAX 13 05 MIN GEAR THICKNESS 12 998 MM 12 973 MM CRANKSHAFT MAIN JOURNAL CRANKPIN DIAMETER 58 42 DIAMETER 50 8 TAPER 013 TAPER 013 OUT OF ROUND MAX 013 OUT O...

Page 325: ...ER INSTALLER USE WITH J 21473 1 V A L V E S E A L INSTALLER T E S T E R V A L V E GUIDE CLEANING TOOL R E A R CRANKSHAFT O I L S E A L INSTALLER J 21054 1 J 22330 J 23590 J 8056 J 5892 A J 28687 J 5790 TOOL NO NAME J3499S TIME COVER S E A L ALIGNER J3499S INSTALLER J 235S0 AIR LINE ADAPTER J 8056 V A L V E CLUTCH SPRING TESTER J 5569 PISTON RING COMPRESSOR 4 J 28467 ENGINE LIFTING FIXTURE J 5892 A...

Page 326: ...ur steel backed aluminum bearings are used with 3 bearing being the end thrust bearing C A M S H A F T DRIVE The camshaft is cast alloy iron with tapered 13 2 mm wide lobes offset from the lifters and tapered to provide positive valve lifter rotation The camshaft is supported by four journals and includes a distributor oil pump drive gear A 3 8 pitch chain drives the camshaft through a hardened si...

Page 327: ... centerline This gallery supplies the left bank hydraulic lifters with oil Oil is directed from the left gallery by means of intersecting passages to the camshaft bearings and right oil gallery The hydraulic lifters pump oil up through the push rods to the rocker arms Oil draining back from the rocker arms is directed by cast dams in the crankcase casting to supply the camshaft lobes Oil also drai...

Page 328: ...2 8 LITER V 6 ENGINE P CARLINE 6A2 3 Figure 1 Engine Lubrication 1 of 4 ...

Page 329: ...6A24 2 8 LITER V 6 ENGINE P CARLINE Figure 2 Engine Lubrication 2 of 4 ...

Page 330: ...ATION 189 DURATION OF LUBRICATION FOR CYL S 2 4 6 LUBRICATION ENDS 134 B T D C END OF LUBRICATION BEGINNING OF LUBRICATION 190 DURATION OF LUBRICATION FOR CYL S 1 3 5 VIEWS SHOWING INTERMITTENT OILING OF CONNECTING ROD BEARING THROUGH GROOVE ON UPPER HALF OF MAIN BEARINGS is 09 3 m m Z 2 z m o o 3D Z m tsj ...

Page 331: ...6A2 6 2 8 LITER V 6 ENGINE P CARLINE Figure 4 Engine Lubrication 4 of 4 ...

Page 332: ... dolly 30 Separate engine and transaxle Install or Connect 4 1 Reconnect engine transaxle and cradle 2 Lower vehicle over dolly 3 Cradle bolts 4 in sequence Install front bolts finger tight Torque rear bolts 103 N m 76 Ib ft Torque front bolts 90 N m 66 lb ft 4 Raise vehicle 5 Strut bolts align with marks 6 Parking brake cables and calipers 7 Rear wheels 8 Lower vehicle 9 Engine strut front bolt 1...

Page 333: ...RACKET 6 BRACKET ENGINE FRONT 7 BRACKET STRUT 8 SUPPORT STRUT 9 STRUT NOTE TO POSITION STRUT IN SUPPORT PUSH ENGINE REARWARD WITH A HORIZONTAL LOAD OF 200 250 NEWTONS LOAD IS APPLIED ON A LINE DIRECTLY THROUGH CENTER OF SUPPORT SLOTS TIGHTEN BOLT WITH LOAD APPLIED 520044 6 A2 Figure 5 Engine Mounts and Torque Strut ...

Page 334: ...2 8 LITER V 6 ENGINE P CARLINE 6A2 9 Figure 6 Cradle and Transaxle Mounts ...

Page 335: ...osition itself If allowed to remain out of position drive train component failure could occur ENGINE STRUT Figure 5 Remove or Disconnect 1 Bolt and nut strut to engine bracket 2 Bolt and nut strut to chassis 3 Strut Install or Connect 1 Strut bolt and nut to chassis 57 N m 42 lb ft 2 Bolt and nut strut to engine bracket 57 N m FORWARD TRANSAXLE MOUNT Figure 6 4 Remove or Disconnect 1 Engine compar...

Page 336: ...if applicable 9 Throttle and downshift cables and bracket 10 Vacuum boost line and tube 11 Engine compartment lid 2 men and both side covers 12 Negative battery cables Rear 4 H Remove or Disconnect 1 Negative battery cable 2 Bolt torque reaction rod at cylinder head bracket 3 Swing torque reaction rod up and remove bolt connecting cylinder head bracket to bracket at front of engine 4 Loosen lower ...

Page 337: ... EGR pipe Upper manifold plenum and gaskets Intermediate intake manifold and gasket Lower intake manifold and gaskets 4 All gasket surfaces on cylinder head and intake manifolds Install or Connect Lower intake manifold and gasket torque in sequence 26 N m 19 lb ft Intermediate intake manifold and gaskets torque in sequence 21 N m 15 lb ft Upper manifold plenum and gaskets torque in sequence EGR pi...

Page 338: ...2 8 LITER V 6 ENGINE P CARLINE 6A2 13 Fig 9 Intake Manifold ...

Page 339: ...e or Disconnect Rocker arm covers Rocker arm nuts Keep components in a rack so they may be reinstalled in the same location Rocker arm pivot balls Rocker arms Push rods Install or Connect Push rods Be sure they seat in lifter Rocker arms Rocker arm pivot balls 1 2 3 4 5 1 2 3 4 1 Assemble oxygen sensor EGR valve and adapter to crossover pipe 2 Crossover 3 Crossover to manifold bolts front and rear...

Page 340: ...7 SPRING 8 BOLT 20 N m 15LB FT 9 B O L T LOCKWASHER ASM 24 N m 18 LB FT 1 0 EXHAUST MANIFOLD ASM L H 11 GASKET 5 2 0 0 4 8 8 A 2 Fig 10 Exhaust Manifold ROCKER ARMS T lfFTERS Fig 11 Valve Mechanism Figure 12 Adjusting Valve Lash Intake 2 3 4 5 Rocker arm covers UJ Inspect Start engine Check timing and idle speed VALVE STEM OIL SEAL AND OR VALVE SPRING k M Remove or Disconnect ...

Page 341: ...over the valve stem and valve guide base intake only Use plastic sleeve provided Press over valve guide boss 1 With tool J5892 compress the valve spring 2 Square cut 0 ring around the valve stem in the lower groove making sure it is not twisted N O T I C E To prevent damage from twisting coat seal with engine oil 3 Valve locks If necessary hold them in place with grease 4 Release valve spring Insp...

Page 342: ...ssover pipe Generator bracket Oil level indicator tube Loosen rocker arms until able to remove push rods Cylinder head bolts Cylinder head 1 2 3 4 5 6 7 8 9 10 4 2 3 9 10 ue Sequence C 6 2 0 3Q 7Qj kQ5 1 Q 4 U 8 13 Figure 16 Cylinder Head Installation Clean Gasket surfaces on the head cylinder block and intake manifold Cylinder block bolt threads Cylinder head bolts Inspect For cylinder head overh...

Page 343: ...the inertia weight section on the hub will destroy the tuning of the torsional damper and the engine timing reference The torsional damper has 3 timing notches on the inertia ring The 1 cylinder timing reference mark will be identified by a dab of white paint in production If a new damper assembly is installed mark the new assembly in the same location for future reference 1 cylinder reference is ...

Page 344: ...ve belts Cooling system Negative battery cable Adjust Accessory drive belts Inspect Coolant level Leaks OIL S E A L FRONT COVER M Remove or Disconnect 1 2 3 4 1 Torsional damper 2 Pry out seal with a suitable tool I 1 Install or Connect Tool Required J23042 Seal Installer Lubricate seal with clean engine oil Insert in front cover with lip facing the engine Insert Tool J23042 and drive seal into pl...

Page 345: ...g chain and sprocket Rear cover Figure 21 Camshaft NOTICE All camshaft journals are the same diameter and care must be exercised in removing camshaft to avoid damage to bearings s l Inspect For inspection of camshaft replacement of camshaft bearings and overhaul of lifters refer to Section 6A General Engine Mechanical HMH Install or Connect Important 1 2 3 4 5 6 7 Whenever a new camshaft is instal...

Page 346: ...ft extension 103561 4 1 3 4 Figure 23 Oil Pump Exploded Inspect For inspection and overhaul of oil pump refer to Section 6A General Engine Mechanical Install or Connect Oil pump and drive shaft extension Engage drive shaft extension in cover end of the distributor drive gear Pump to rear bearing cap bolt and torque to specifications Oil pan Oil in crankcase g Inspect Proper oil level For oil press...

Page 347: ...h the top of the cylinder bore CRANKSHAFT The crankshaft can be removed while the engine is disassembled for overhaul or without complete disassembly Refer to Section 6A General Engine Mechanical GENERAL DATA TYPE 60 V 6 DISPLACEMENT 2 8 Liters RPO L44 BORE 89 STROKE 76 COMPRESSION RATIO 8 5 1 8 9 1 FIRING ORDER 1 2 3 4 5 6 Cylinder Bore DIAMETER 88 992 88 070 OUR of ROUND 02 Max TAPER THRUST SIDE...

Page 348: ... 084 CRANKSHAFT END PLAY 06 21 CRANK PIN Diameter 50 784 50 758 Taper 005 Max Out of Round 005 Max ROD BEARING CLEARANCE 035 095 ROD SIDE CLEARANCE 16 44 Valve System LIFTER Hydraulic ROCKER ARM RATIO 1 5 1 VALVE LASH 1 1 2 Turns From Zero Lash FACE ANGLE 45 SEAT ANGLE 46 SEAT RUNOUT 05 SEAT WIDTH Intake 1 25 1 50 Exhaust 1 60 1 90 STEM CLEARANCE 026 068 VALVE SPRING Free Length 48 5 Pressure N m ...

Page 349: ... Torque Strut Bracket M10X1 5 40 54 30 40 Rocker Arm Cover M6X1 0 8 12 6 9 Exhaust Manifold M8X1 25 30 38 22 28 Rocker Arm Stud M10X1 5 58 66 43 49 Flex Plate to Torque Converter M10X1 5 34 47 25 35 Spark Plug M14X1 25 10 20 7 15 Flex Plate to Torque Converter M10X1 5 34 47 25 35 Starter Motor M10X1 5 36 50 26 37 Flywheel M10X1 0 61 75 45 55 Strut Bracket Asm Nut Bolt M10X1 5 50 56 36 41 Front Cov...

Page 350: ...the water pump and circulated through water jackets in the engine block intake manifold and cylinder head s and then directed back to the radiator where it s cooled This system directs some coolant through hoses to the heater core to provide for heating and defrost ing A recovery bottle is connected to the radiator to recover coolant displaced by expansion from high temperatures and maintain corre...

Page 351: ...engine is stopped and the coolant cools and contracts the displaced coolant is drawn back into the radiator by vacuum Thus the radiator is kept filled with coolant to the desired level at all times resulting in increased cooling efficiency Coolant level should be between ADD and FULL marks on recovery bottle These marks are approxi mately two quarts apart so that a 50 50 mixture can be added one q...

Page 352: ...dards of General Motors Specification 1825 M This coolant solution provides freezing protection to at least 37 C 34 F It has been formulated to be used for two full calendar years or 30 000 miles whichever first occurs of normal operation without replacement provided the proper concentration of coolant is maintained 1 hermostat A pellet type thermostat is used in the coolant outlet passage to cont...

Page 353: ...gines open coolant pipe plugs 5 Close valve Reinstall drain plugs and add suf ficient water to fill system 6 Run engine drain and refill the system as described in steps 4 and 5 a sufficient number of times until the drained liquid is nearly colorless IT Important BLOCK DRIVE WHEELS place trans mission in PARK automatic transmis sion or NEUTRAL manual transmission and set the parking brake 7 Allow...

Page 354: ...CCURRING AFTER PROLONGED DRIVING IN SLOW CITY TRAFFIC TRAFFIC JAMS GARAGES ETC IF ANSWER IS YES INSTRUCT OWNER ON DRIVING TECHNIQUES THAT WOULD AVOID OVERHEATING SAME AS FOR PROLONGED IDLES NO 3 FURTHER DIAGNOSTIC CHECKS SHOULD NOT BE REQUIRED IF NONE OF THE ABOVE APPLY GO TO DIAGNOSTIC CHART TO EFFECTIVELY USE THIS CHART QUESTION THE OWNER TO DETERMINE WHICH OF THE FOLLOWING 3 CATEGORIES APPLIES ...

Page 355: ... yes SYSTEM O K SYSTEM O K yes o k CHECK ELECTRIC COOLING FAN IF EQUIPPED see pg 5 for single speed fan or pg 8 for dual speed fan under ELECTRICAL DIAGNOSIS no not equipped ANY FIXES ABOVE no If none of the above required re pair the problem is out of the ordi nary or of a major nature Listed on chart 3 are two groups of prob lem areas that should be checked in the order listed low no VISUAL SYST...

Page 356: ...KE MANIFOLD GASKET 7 PLUGGED COOLANT PASSAGES IN CYLINDER HEADS REMOVE HEADS AND CHECK VISUALLY SEE CHASSIS SERVICE MANUAL 520010 6B Figure 6 Cooling System Diagnosis Chart 3 of 3 ENGINE OVERHEAT BOILING POOR ENGINE COOLING 1 RELIEVE PRESSURE AND CAREFULLY REMOVE RADIATOR CAP 2 RUB 20C F TEMPERATURE STICK ONTO THERMOSTAT HOUSING 3 WARM UP ENGINE AT FAST IDLE WATCH FOR COOLANT FLOW BEFORE MARK BEGI...

Page 357: ... is attached to the tanks by clinched tabs on the core that can be bent back if tank or core replacement is required If the damage to a tube is too severe a tube can be blocked or plugged as explained in Tube Block ing No more than two tubes should ever be blocked on a core Also replace the core if more than three tabs are broken on one side or if two adjacent tabs are broken Tanks The tanks are a...

Page 358: ... have been used for copper and brass radia tors The flux acid and caustic cleaners remain ing in these tanks will attack the aluminum and cause radiator failure A separate test tank con taining clean water is strongly recommended for servicing aluminum plastic radiators NOTICE Never use shop air that is not regulated at 20 psi 138 kPa to pressure test radiator Pres sures over 20 psi 138 kPa will d...

Page 359: ...ailure A separate test tank containing clean water is strongly rec ommended for servicing aluminum plastic radiator 1 Install test fittings or rubber test caps in the inlet and outlet necks and seal the oil cooler fittings with metal plugs to protect the cooler and keep the fluid from running out Figure 11 2 Attach pressure tester and gradually apply air pressure until 20 psi 138 kPa is attained D...

Page 360: ... i im BEYOND D AREA mmmfa mmmiI M i B i l l l l l i l l HI nmmm MB IHIIIIIMB KM m u n i tint IIEIIIIB H20006 6B H20006 6B Figure 14 Fins Removed from Damaged Area TUBE BLOCKING If a tube is severely damaged it can be blocked off Figure 15 Figure 15 Tube Blocking NOTICE DO NOT BLOCK OFF MORE THAN TWO TUBES IN A RADIATOR BLOCKING OFF MORE THAN TWO TUBES WILL REDUCE THE COOLING CAPABILITY OF THE SYST...

Page 361: ... a pin and apply primer to the repair area only Use of the primer produces a stronger repair Do not heat the primer Figure 18 Cleaning Area With Steel Brush C A U T I O N T h e p r i m e r c o n t a i n s trichl rethanen It c o u l d be h a r m f u l or fatal if s w a l l o w e d If s w a l l o w e d g e t medical attention U s e w i t h adequate ventilation In c a s e of e y e contact flush w i t...

Page 362: ... joint gasket tighten the clinch tabs with lock ing type pliers Figure 22 If this method doesn t seal the leak remove the tank for further inspection 1 Pry open the clinch tabs except those under inlet outlet and filler necks using J 33419 1 or a screwdriver Figure 23 Lift the tabs only enough to allow removal NOTICE Care should be taken not to overbend tabs Overbending could result in breakage If...

Page 363: ... 26 Removing Oil Cooler Gasket 7 Assemble the oil cooler nut loosely 8 Replace the other gasket by following the same procedure 9 Install the oil cooler nuts and torque to 20 Nnn 15 lb ft Do not overtighten as damage to the gasket could result 10 Leak test the radiator OIL COOLER REPLACEMENT 1 Remove the outlet tank as previously outlined 2 Remove nuts from the oil cooler fittings 3 Remove oil coo...

Page 364: ...sing cap H20038 6B Figure 27 Thermostat Housing and Outlet 2 5L H20039 6B Figure 28 Thermostat Housing and Outlet 2 8L ELECTRIC COOLING FAN C A U T I O N Keep hands tools and cloth ing a w a y from engine cooling fan to help prevent personal injury This fan is electric and can come on whether or not the engine is running The fan can start automatically in response to a heat sensor with the ignitio...

Page 365: ...ley Remover or J29785 A Pulley Remover J25033 B Pulley Installer 1 Negative battery cable 2 Cooling system 3 Serpentine drive belt 4 Water pump front cover assembly attaching bolts 5 Water pump front cover assembly Disassemble Pulley from old water pump front cover assembly using J25034 B or J29785 A Clean Water pump mating surfaces Assemble Pulley to new water pump front cover assembly using J250...

Page 366: ...t 1 Negative battery cable 2 Engine coolant 3 Drive belts 4 Radiator and heater hose 5 Water pump attaching bolts 6 Water pump Clean Water pump mating surfaces E3 1 3 4 5 6 Install or Connect A 2mm 3 32 bead of sealant on the water pump sealing surface Water pump attaching bolts with sealer and torque bolts to specifications Radiator and heater hose Accessory drive belts to proper tension Engine c...

Page 367: ...nn 18 lb in Coolant recovery hose to radiator neck Hood latch to radiator support Torque bolts to 25 Nnn 18 lb ft Fan assembly making sure bottom leg of frame fits into rubber grommet at lower radiator support Fan attaching bolts torque to 10 Nnn 88 lb in 10 Fan connector and forward lamp harness to fan frame 11 Swing engine forward strut and brace forward until brace contacts radiator support Ins...

Page 368: ...ENGINE COOLING 6B 19 Figure 34 Cooling Pipe Routing ...

Page 369: ...Figure 35 Rear Radiator Hoses V6 ...

Page 370: ... 6B 21 A H20044 6B Figure 36 Rear Radiator Hoses L4 BELT GEH A C P S AIR PUMP New 650 N 145 lb 600 N 135 lb 450 N 100 lb Used 300 N 70 lb 300 N 70 lb 200 N 50 lb Previously run J10252 6B P Figure 37 Belt Tension 2 8L ...

Page 371: ......

Page 372: ... E N C Y A S C O N F O R M I N G T O T H E R E Q U I R E M E N T S O F T H E R E G U L A T I O N S F O R T H E C O N T R O L O F A I R P O L L U T I O N F R O M N E W M O T O R V E H I C L E S T H I S C E R T I F I C A T I O N I S C O N T I N G E N T O N C E R T A I N A D J U S T M E N T S B E I N G S E T T O F A C T O R Y S T A N D A R D S IN M O S T C A S E S T H E S E A D J U S T M E N T P O I ...

Page 373: ...sses through an in line fuel filter to the TBI or fuel rail To control fuel pump operation a fuel pump relay is used When the ignition switch is turned to the ON position the fuel pump relay activates the electric fuel pump for 1 5 to 2 0 seconds to prime the injector s If the ECM does not receive reference pulses from the distributor after this time the ECM signals the relay to turn the fuel pump...

Page 374: ...ump Relay blown out Check the fuel strainer on fuel gage sending unit for damage or omission The vapor pipe extends from the fuel gage sender to the canister However it does not follow the same route as the fuel feed pipe If replacement of a fuel feed pipe or vapor pipe is required use brazed seamless steel tubing meeting GM Specification 123M or its equivalent Under no conditions use copper or al...

Page 375: ...her obstructions must not be placed within 13mm 33 64 in of cable or rod at any point in their travel EVAPORATIVE EMISSION CONTROL SYSTEM EECS An Evaporative Emission Control System EEC is used to reduce emission of fuel vapors from the vehicle fuel system See Section 6E Emission Control System The system allows evaporating fuel vapors to be stored for burning during combustion rather than being v...

Page 376: ...FUEL SYSTEM 6C 5 Fig 5 Accelerator Cable Routing Fig 6 Accelerator Cable to Engine ...

Page 377: ...on a warm day so it will act on the lower side of the diaphragm and open the valve when pressure rises high enough The higher pressure on the tank slows the evaporation of the fuel while allowing some vapor through orifice to the canister See Section 6E Emission Control System DIAGNOSIS All diagnosis related to the fuel system not found in the diagnosis section can be found in the Engine Performan...

Page 378: ...o vacuum is present perform EGR system functional test Section 6E 2 Apply external vacuum source such as hand operated vacuum pressure pump J 23738 in combination with manometer J 23951 to the purge valve control diaphragm A good valve will hold vacuum 3 If the valve will not hold vacuum replace canister 4 If the valve holds vacuum remove purge line and check for vacuum with engine operating If no...

Page 379: ...ver drain or store gasoline in an open container due to the possibility of fire or explosion 4 Reinstall any removed hoses lines and cap FUEL SYSTEM CLEANING PROCEDURE CAUTION This procedure will NOT remove all fuel vapor Do not attempt any repair on tank or filler neck where heat or flame is required as an explosion resulting in personal injury could occur If trouble is due to contaminated fuel o...

Page 380: ... clean by blowing out with compressed air Reinstall in correct orientation on pump 5 Remove fuel pump from sending unit by pulling fuel pump assembly into rubber connector and sliding pump away from bottom support Care should be taken to prevent damage to rubber insulator and fuel strainer during removal After pump assembly is clear of bottom support pull pump assembly out of rubber connector for ...

Page 381: ...ATOR CONTROLS Check for correct opening and closing positions by operating accelerator pedal Make sure that the EFI unit reaches wide open throttle position If it does not inspect for damaged or bent brackets levers or other components or for poor carpet fit under the accelerator pedal If any binding is present in the linkage check for 1 Proper routing of cable 2 Kinked or damaged cable 3 Free mov...

Page 382: ...s available including the CS 130 and CS 144 The number 130 or 144 denotes the OD in mm of the stator laminations CS generators use a new type regulator and a diode trio is not used A delta stator rectifier bridge and rotor with slip rings and brushes are electrically similar to earlier generators A conventional pulley and fan is used and on the CS 130 an internal fan cools the slip ring end frame ...

Page 383: ...rter Motor Wound field starter motors have pole pieces arranged around the armature that are energized by wound field coils Solenoid Enclosed shift lever cranking motors have the shift lever mechanism and the solenoid plunger enclosed in the drive housing protecting them from exposure to dirt icing conditions and splash GENERAL ELECTRICAL SYSTEM DIAGNOSIS Diagnosis and repair procedures for engine...

Page 384: ...TE CARS WITH AUTO TRANS CARS WITH MANUAL TRANS CHECK VOLTAGE AT CLUTCH SWITCH TERMINAL CLUTCH DEPRESSED KEY IN START t CHECK BULKHEAD CONNECTOR FUSIBLE LINK AND IGNITION SWITCH CONNECTIONS MORE THAN 7 VOLTS ON BOTH TERMINALS H I LESS THAN 7 VOLTS ON BOTH TERMINALS CHECK CONNECTIONS AND VOLTAGE AT SOLENOID S TERM 9 VOLTS OR MORE CLEAN AND TIGHTEN POS BATTERY CABLE TERMINALS AND OR REPLACE CABLE CHE...

Page 385: ...AL TO ENGINE BLOCK POS LEAD ON BLOCK X LESS THAN 9 6 VOLTS 5 VOLT OR MORE REPAIR GROUND CABLE AND CONNECTIONS CHARGE AND LOAD TEST BATTERY LESS THAN 9 VOLT OK MEASURE VOLTAGE AT SOLEN08D B TERMINAL C L E A N AND T I G H T E N CONNECTIONS AT STARTER DEFECTIVE REPAIR STARTER REPLACE BATTERY 9 VOLTS OR MORE LESS THAN 9 VOLTS REPAIR STARTER CLEAN AND TIGHTEN POSITIVE CABLE CONNECTIONS G F Oli REPLACE ...

Page 386: ...ime 4 More power available in a lighter and smaller case The battery has three major functions in the electrical system First it provides a source of energy for cranking the engine Second it acts as a voltage stabilizer for the electrical system And third it can for a limited time provide energy when the electrical load used exceeds the output of the generator Ratings A battery has two ratings 1 a...

Page 387: ...Diagnosis section The charging and electrical system should also be checked at this time Occasionally a third condition may appear 3 CLEAR OR LIGHT YELLOW This means the fluid level is below the bottom of the hydrometer This may have been caused by excessive or prolonged charging a broken case excessive tipping or normal battery wearout Finding a battery in this condition may indicate high chargin...

Page 388: ...quire a much longer period of charging than a charger that can supply 30 amperes or more State Of Charge A completely discharged battery requires more than twice as much charge as a one half charged battery Because the electrolyte is nearly pure water and a poor conductor in a completely discharged battery the current accepted by the battery is very low at first Later as the charging current cause...

Page 389: ...er expose battery to open flame or electric spark batteries generate a gas which is flammable and explosive Remove rings watches and other jewelry Wear approved eye protection Do not allow battery fluid to contact eyes skin fabrics or painted surfaces fluid is a corrosive acid Flush any contacted area with water immediately and thoroughly Be careful that metal tools or jumper cables do not contact...

Page 390: ...ry 1 2 3 4 5 Battery cover Battery heat shield Negative cable Positive cable Retainer screw and retainer 1 2 3 4 5 6 Install or Connect Battery Retainer and retainer screw Positive cable 17 N m 13 lb ft Negative cable 17 N m 13 lb ft Battery head shield Battery cover ...

Page 391: ...6D1 6 BATTERY 520187 6D Fig 801 Battery Cables LR8 L44 ...

Page 392: ...SPECIFICATIONS ENGINE BATTERY FUNCTION REPLACEMENT LR8 1981601 STD 601 CCA 630 RC MIN 90 Load Test 310 Amps L44 1981730 STD 730 CCA 525 RC MIN 90 Load Test 260 AMPS 1981731 HD 731 CCA 570 RC MIN 90 Load Test 280 AMPS ...

Page 393: ......

Page 394: ...STEM Before removing anyunit in a cranking circuit for repair the following checks should be made Electrical System General Diagnosis Follow the procedures shown in Section 6D to isolate problem Battery To determine the condition of the battery follow the testing procedure outlined in the Battery section 6D1 Wiring Inspect the wiring for damage Inspect all connections to the cranking motor solenoi...

Page 395: ...OWN TO A STOP AFTER STARTING THE ENGINE CAUSE DISTANCE TOO GREAT BETWEEN STARTER PINION AND FLYWHEEL DISTANCE TOO SMALL BETWEEN STARTER PINION AND FLYWHEEL FLYWHEEL RUNOUT CONTRIBUTES TO THE INTERMITTENT NATURE MOST PROBABLE CAUSE IS A DEFECTIVE CLUTCH A NEW CLUTCH WILL OFTEN CORRECT THIS PROBLEM MOST PROBABLE CAUSE IS A BENT OR UNBALANCED STARTER ARMATURE A NEW ARMATURE WILL OFTEN CORRECT THIS PR...

Page 396: ... FIELD COIL 10 ARMATURE 11 BRUSH 12 TERMINALS 5MT and 10 Ml Starters 1 The roll type overrunning clutch requires no lubrication however the drive assembly should be wiped clean Do Not clean in any degreasing tank or with grease dissolving solvents this will dissolve the lubricant in the clutch mechanism Use silicon grease General Electric CG321 Dow Corning 33 Medium or equivalent on the shaft unde...

Page 397: ... 6 PLUNGER PIN 8 ARMATURE 17 SCREW SWITCH ATTACHING 2 7 PINION STOP RETAINER RING 9 D R I V E ASM 18 WASHER BRAKE 2 8 L E V E R SHAFT RETAINING RING 520041 6P Fig 4A 5MT Starting Motor Disassembled View ON CAR S E R V I C E STARTER J4 Remove or Disconnect 1 Negative battery cable 2 Wiring to solenoid 3 Raise car 4 Remove heat shield 5 Bolt starter rear bracket LR8 only 6 Starter to engine bolts 2 ...

Page 398: ...CRANKING SYSTEM 6D2 5 LR8 1 STARTER 2 BRACKET 3 SHIM 520186 6D Fig 801 Starter Motor Mounting ...

Page 399: ...gh current draw indicates Too much friction tight dirty or worn bearings bent armature shaft allowing armature to drag Shorted armature This can be further checked on a growler after disassembly Grounded armature or fields Check further after disas sembly 3 Failure to operate with high current draw indicates A direct ground in the terminal or fields Frozen bearings this should have been determined...

Page 400: ...NGER DRIVE GEAR HOUSING Steps 10 and 11 are required only on diesel starters 10 Remove shift lever pivot bolt 11 Remove drive gear housing from armature shaft Shift lever and plunger assembly will now fall away from starter clutch I R E M O V E D R I V E ASSEMBLY FROM SHAFT BEARING ASSEMBLY 12 If necessary to remove overrunning clutch from armature shaft proceed as follows a Remove thrust washer o...

Page 401: ...bushings over running clutch pinion brushes and springs for discoloration damage or wear Replace as required 17 Check fit of armature shaft in bushing in drive housing Shaft should fit snugly in the bushing If the bushing is worn it should be replaced 18 Inspect armature commutator If commutator is rough it should be turned down Do not undercut or turn to less than 1 650 O D Do not turn out of rou...

Page 402: ...ed from starting motor the connec tor strap terminals must be removed from the terminal on the solenoid before making these tests Complete tests in a minimum of time to prevent overheating of the solenoid To check hold in winding connect an ammeter in series with 12 volt battery and the switch terminal on the solenoid Connect a voltmeter to the switch terminal and to ground Connect carbon pile acr...

Page 403: ...t 21 Lubricate drive gear housing bushing with lubricant 1960954 or equivalent 22 Engage shift lever yoke with clutch and slide complete assembly into drive gear housing On non diesel starters the shift lever may be installed in drive gear housing first 23 Install the shift lever pivot bolt Tighten secure ly 24 Install solenoid assembly 25 Apply sealer No 1050026 or equivalent to solenoid flange w...

Page 404: ... jumper lead momentarily from the solenoid motor terminal to the starter frame This will shift the pinion into cranking position and it will remain so until the battery is dis connected 34 Push the pinion back as far as possible to take up any movement and check the clearance with a feeler gage The clearance should be 010 to 140 Means for adjusting pinion clearance is not provided on the starter m...

Page 405: ......

Page 406: ...ndicator will glow at full brilliance not half lit Also the charge indicator will be on with the engine running if system voltage is too high or too low The regulator voltage setting varies with temperature and limits system voltage by controlling rotor field current This regulator switches rotor field current on and off at a fixed frequency of about 400 cycles per second By varying the on off tim...

Page 407: ...enter of generator never against either end frame G20193 6P Fig 1G CS Charging System Wiring Diagram GENERATOR BENCH CHECK CS To check generator in a test stand remove as specified in On Car Service and proceed as follows 1 Make connections as shown in Figure 1H except leave the carbon pile disconnected The ground polarity of generator and battery must be the same The battery must be fully charged...

Page 408: ...N m 37 lb ft Negative battery cable pivot GENERATOR L44 Remove or Disconnect 1 Negative battery cable C A U T I O N Failure to o b s e r v e t h i s s t e p m a y result in a n injury from hot battery lead at generator 2 Loosen top generator bracket to engine bolt 3 Upper generator bracket to engine bolts 2 4 Raise car 5 Right rear wheel 6 Splash guards 7 Toe link rod outer end swing up and left 8...

Page 409: ...lt 27 N m 20 lb ft 13 Toe link rod outer end do not change adjustment 14 Splash guards 15 Right rear wheel 16 Lower car 17 Upper generator to bracket bolt torque to 50 N m 37 lb ft 18 Negative battery cable Fig 801 Generator Mounting SPECIFICATIONS ENGINE EQUIPMENT GEN MOD AMP 2 5L H H HBL A A HBL 1101149 CS13Q 100A 2 8L H H HBL A A HBL 1101465 CS130 100A ...

Page 410: ...n rectifier bridge NOTICE If stator leads are welded in place of soldered cut stator leads about half way back on rectifier bridge terminals Remove stator Drive out three baffle pins and remove baffle from inside of slip ring end frame TESTING STATOR OHMMETER CHECK FOR GROUNDS 7 Check stator for grounds with ohmmeter If reading is low replace stator TESTING ROTOR BEARING OHMMETER CHECK FOR SHORTS ...

Page 411: ... I E R B R I D G E D R I V E END B E A R I N G END F R A M E P U L L E Y S E A L E D BEARING C O L L A R C O L L A R NUT C O L L A R CROSS SECTION DE FRAME CS 130 14 Note stack up of parts for drive end bearing assem bly Hold rotor with hex wrench to remove or tighten shaft nut Torque to 54 108 N m 40 80 lb ft OHMMETER OHMMETER 12 To check rectifier bridge connect ohmmeter using low scale to one t...

Page 412: ...brush holder 19 Install regulator crimp and solder connection be tween regulator and bridge 20 Install new baffle Use punch to drive pins down flush with baffle 21 Install stator solder and crimp to three connectors on bridge Avoid excessive heat which could dam age diodes in rectifier bridge 22 Install outside cover using punch to drive pins down flush with cover 23 To assemble drive end frame an...

Page 413: ......

Page 414: ...ltage is directed through the rotor and secondary leads to fire the spark plugs The capacitor in the distributor is for radio noise suppression All spark timing changes in the HEI EST distributor are done electronically by an Electronic Control Module ECM which monitors information from various engine sensors computes the desired spark timing and signals the distributor to change the timing accord...

Page 415: ...he spark plug cable has been broken voltage willjump to the nearest ground and the spark plug will not fire properly A l w a y s follow t h e tune up label p r o c e d u r e s w h e n a d j u s t i n g timing Some engines will incorporate a magnetic timing probe hole for use with special electronic timing equipment Fig 1A shows a typical magnetic probe hole Consult manufacturer s instructions for ...

Page 416: ...e assembly is separate from the key and lock cylinder However both are synchronized and work in conjunction with each other through the action of the actuator rod assembly For a complete explanation of the key and lock cylinder and the actuator rod assembly see STEERING Section 31 See Section 8 for electrical switching DIAGNOSIS IGNITION SYSTEM Spark Plugs Worn or dirty plugs may give satisfactory...

Page 417: ...on the spark plug and pull on the boot to remove the wire or use a special tool designed to remove spark plug boots W Remove or Disconnect 1 Ignition switch battery feed wire and tachometer lead if equipped from distributor cap Also release the coil connectors from the cap DO NOT use a screwdriver or tool to release the locking tabs 2 Distributor cap by turning four screws counterclockwise Move ca...

Page 418: ...onnect the timing light power leads according to manufacturer s instructions 3 Start the engine and aim the timing light at the timing mark The line on the balancer or pulley will line up at the timing mark If a change is necessary loosen the distributor hold down clamp bolt at the base of the distributor While observing the mark with the timing light slighty rotate the distributor until the line ...

Page 419: ...ttery cable 1 4 1 7 2 3 4 5 SENSOR Remove or Disconnect 1 Ignition module 2 Unplug sensor H H H Install or Connect 1 Replug sensor 2 Ignition module IGNITION SYSTEM 2 8L Distributor 1 2 3 4 5 6 7 s 1 2 3 5 6 Remove or Disconnect Battery ground cable Distributor wiring harness at coil Distributor cap and position out of way Coil assembly see Ignition Coil Removal Scribe a mark on the engine in line...

Page 420: ...IGNITION SYSTEM 6D4 7 Fig 801 Ignition Module Coils and Wiring ...

Page 421: ...STEP 3 USE HIGH SCALE SHOULD NOT READ INFINITE IF IT DOES REPLACE COIL TESTING PICKUP COIL PICKUP OHMMETER 3 REMOVE ROTOR AND PICKUP COIL LEADS FROM MODULE 4 CONNECT OHMMETER PART 1 AND PART 2 5 OBSERVE OHMMETER FLEX LEADS BY HAND TO CHECK FOR INTERMITTENT OPENS STEP 1 SHOULD READ INFINITE AT ALL TIMES IF NOT PICKUP COIL IS DEFECTIVE STEP 2 SHOULD READ ONE STEADY VALUE BETWEEN 500 1500 OHMS AS LEA...

Page 422: ...MOVE TWO SCREWS TO REMOVE MODULE TEST MODULE WITH AN APPROVED MODULE TESTER REASSEMBLY 10 WIPE DISTRIBUTOR BASE AND MODULE CLEAN APPLY SILICONE LUBRICANT BETWEEN MODULE AND BASE FOR HEAT DISSIPATION 11 ATTACH MODULE TO BASE ATTACH PICKUP CONNECTOR TO MODULE 12 ASSEMBLE PICKUP POLE PIECE AND RETAINER 13 ASSEMBLE SHAFT GEAR PARTS AND ROLL PIN 14 SPIN SHAFT TO INSURE THAT TEETH DO NOT TOUCH 15 INSTAL...

Page 423: ......

Page 424: ...mponent refer to that components section of the service manual ON CAR S E R V I C E 1 ENGINE WIRING HARNESS 2 POSITIVE BATTERY CABLE 3 TRANSMISSION CLUTCH CONN 4 SYSTEM GROUND 5 COOLING FAN TEMP SW 6 TO POSITIVE BATTERY TERMINAL 7 02 SENSOR CONN 8 A C COMPRESSOR CONN 9 HIGH PRESSURE SWITCH CONN 10 COOLING FAN SWITCH CONN 11 TEMP SWITCH LEAD 12 TACH FILTER 13 COIL LEAD 14 DISTRIBUTOR CONN 15 SPEED ...

Page 425: ...R CONN 2 COOLING TEMP SENSOR CONN 3 EMI GROUND 4 REDUNDANT 02 GROUND 5 PARK NEUTRAL SWITCH LEAD S BACK UP LAMP CONN 7 SPEED SENSOR LEAD 8 ENGINE HARNESS S TO THROTTLE BODY 10 TO A C COMPRESSOR 11 ENGINE TO NEUTRAL START OONN VIEW A MD9 Fig 802 Engine Wiring Rear LR8 ...

Page 426: ...ENGINE WIRING 6D5 3 Fig 803 Engine Wiring Front L44 ...

Page 427: ...GRD 9 ELECTRIC SPARK TIMING CONN 10 SYSTEM GROUND 11 IDLE AIR CONTROL CONN 12 THROTTLE POSITION SENSOR CONN 13 CONDUIT HARNESS ASM 14 TACH FILTER ASM 15 VEHICLE SPEED SENSOR CONN M17 MT2 16 ALTERNATOR TERMINAL 17 ALTERNATOR CONN 18 NEUTRAL START SW CONN 19 TRANS CLUTCH CONTROL CONN 20 VEHICLE SPEED SENSOR CONN MD9 DE m in L44 REAR 5 2 0 1 9 2 6 0 Fig 804 Engine Wiring Rear L44 ...

Page 428: ...lectronic Spark Timing EST Electronic Spark Control ESC Air Injection Reaction A I R Early Fuel Evaporation EFE Exhaust Gas Recirculation EGR Transmission Converter Clutch TCC Shift Light Control o A C Clutch Control Electric Cooling Fan Control Positive Crankcase Ventilation PCV or Crankcase Ventilation CV Thermostatic Air Cleaner THERMAC ABBREVIATIONS GLOSSARY OF TERMS WIRING HARNESS SERVICE O C...

Page 429: ...LWAYS REFER TO THE VEHICLE EMISSION CONTROL INFORMATION LABEL FOR THE CORRECT AND MOST CURRENT SPECIFICATIONS EVAPORATIVE E M I S S I O N SYSTEM EXHAUST EMISSION SYSTEM H 1 6 4 3 T 5 T M 6 9 7S3395 6E Figur 1 hicle Emission Control Information Label ...

Page 430: ...system Cold Oxygen Sensor On some engines the oxygen sensor will cool off after only a short period of operation at idle This will put the system into Open Loop To restore Closed Loop operation run the engine at part throttle and accelerate from idle to part throttle a few times until the system goes Closed Loop VISUAL PHYSICAL UNDERHOOD INSPECTION One of the most important checks that must be don...

Page 431: ... intermittent or hard An intermittent code is one which does not always reset when the code setting parameters are met or is not present while you are working on the vehicle This is often caused by a loose connection The facing page will contain diagnostic aids to help in detecting intermittents A hard code is one which is present when you are working on the vehicle and the condition still exists ...

Page 432: ...em is too rich While the system is in Field Service Mode the ECM will be in the following mode 1 New trouble codes cannot be stored in the ECM 2 The Closed Loop timer is bypassed Clearing Trouble Codes When the ECM sets a trouble code the Service Engine Soon light will come ON and a trouble code will be stored in memory If the problem is intermittent the light will go out 10 seconds after the faul...

Page 433: ...al tools on the market for reading this information Scan tools do not make the use of diagnostic charts unnecessary They do not tell exactly where a problem is in a given circuit However with an understanding of what each position on the equipment measures and knowledge of the circuit involved the tools can be very useful in getting information which would be more time consuming to get with other ...

Page 434: ...d on the Scan tool then those are the positions that should be checked while driving the vehicle If there does not seem to be any correlation between the problem and any specific circuit the Scan tool can be checked on each position watching for a period of time to see if there is any change in the readings that indicates intermittent operation The Scan tool is also a useful and quick way of compa...

Page 435: ...grees After the engine is started temperature should rise steadily to about 85 95 C then stabilize when the thermostat opens Manifold Air Temperature MAT Sensor This displays temperature of the intake manifold air It should read close to ambient air temperature when the engine is cold and rise as underhood and engine temperatures increase Manifold Absolute Pressure MAP The MAP sensor produces a lo...

Page 436: ...od of time Block Learn Multiplier BLM Cell or Block Learn Memory BLM There are up to sixteen different cells corresponding to ranges of rpm and engine load indicated by MAF or MAP signals and other conditions such as A C or P N switch ON or OFF etc The ECM learns how much adjustment is needed in each cell and retains it in memory so that the adjustment will immediately be made when the engine oper...

Page 437: ... under diagnosis will explain how the Scan tool can be used for diagnosis as well as what the normal readings wouldbe for the ECM sensors Electronic Control Module ECM This section describes the ECM and the information sensors in the system Figure 4 shows the operating conditions which the ECM may sense and the systems that the ECM may control See specific engines to determine which are applicable...

Page 438: ... Transmission Converter Clutch TCC The TCC Is ECM controlled and Is used on all engines with an automatic transmission This system reduces slippage losses in the torque converter by coupling the engine flywheel to the output shaft of the transmission Shift Light Control The ECM controls the shift light on some manual transmission vehicles to indicate the best shift point for maximum fuel economy T...

Page 439: ...ne of the pollutants found in engine exhaust CV CRANKCASE VENTILATION Prevents fumes in crankcase from passing into the atmosphere by drawing them into the intake manifold and burning them in the the combustion process DIAGNOSTIC CODE Pair of numbers obtained from flashing Service Engine Soon light or displaying on a Scan tool This code can be used to determine the system malfunction DIAGNOSTIC TE...

Page 440: ...he ECM that indicate how the systems are performing INTERMITTENT Occurs now and then not continuously In electrical circuits refers to occasional open short or ground LP INSTRUMENT PANEL ISC IDLE SPEED CONTROL Regulates throttle valve position to control idle speed Idle speed is controlled by the ECM and is not adjustable KM HR KILOMETER PER HOUR A metric unit measuring speed needed to travel dist...

Page 441: ...CONVERTER CLUTCH ECM controlled solenoid in transmission which positively couples the transmission to the engine THERM AC THERMOSTATIC AIR CLEANER provides preheated air to intake manifold to provide better driveability when engine is cold TPS THROTTLE POSITION SENSOR Device that tells the ECM the throttle position TVS THERMAL VACUUM SWITCH Used to control vacuum in relationship toengine temperatu...

Page 442: ...ay result in eventual water intrusion corrosion and orcomponent orcircuit failure When diagnosing open circuits are often difficult to locate by sight because oxidation or terminal misalignment are hidden by the connectors Merely wiggling a connector on a sensor or in the wiring harness may correct the open circuit condition This should always be considered when an open circuit or failed sensor is...

Page 443: ...terminal Do not use the Weather pack terminal toolJ 28742 Metri Pack Series 150 Terminal Removal Some connectors used to connect various sensors to the ECM harness use terminals called Metri Pack Figure 7 These may be used at the Coolant Sensors as well as at ignition modules They are also called Pull To Seat terminals because to install a terminal ona wire the wire is first inserted through the s...

Page 444: ...TERMINAL INTO CONNECTOR CAVITY UNTIL LOCKING TANG HAS SNAPPED INTO POSITION SS 1418 6E Figure 8 Micro Pack Terminal Replacement TOOLS NEEDED TO SERVICE THE SYSTEM The system requires an ALDL read out Scan tool tachometer test light ohmmeter digital voltmeter with 10 megohms impedance J 29125A J 34029A or equivalent vacuum gage and jumper wires for diagnosis A test light or voltmeter must be used w...

Page 445: ...or both function and range DC is used for most automotive measurements OHMMETER Measures resistance of circuit directly in ohms Refer to meter for more information OL Display in all ranges indicates open circuit Zero display in all ranges indicates a short circuit Intermittent connection in circuit may be indicated by digital r e a d i n g that will not stabilize on circuit e Range Switch r 200n R...

Page 446: ... injector Injector Tester to energize each fuel injector for a precise amount of time to perform injector balance test in CHART C 2A by checking each injector s pressure drop using pressure gage J 34730 1 FUEL PRESSURE GAGE Used to check and monitor fuel line pressure of port fuel system Part of Diagnostic Kit J34730 A INJECTOR TEST LIGHT Used to check electrical circuit to a port fuel injector Pa...

Page 447: ... m t o a n e w ECM Measures t h e circuit resistance and indicates pass or fail via green or red LED A m b e r LED indicates current polarity Can also be used as a n o n p o w e r e d continuity checker J28687 A BT8220 OIL PRESSURE TRANSDUCER WRENCH Used t o remove or install oil pressure transducer o n engine J35689 METRI PACK TERMINAL REMOVER Used t o remove 150 series Metri Pack pull to seat te...

Page 448: ...or E2SE carburetor J34935 BT8420A FLOAT LEVEL GAGE Used t o check f l o a t level or M C Solenoid travel on E2ME or E4ME carburetor J29030 B BT7610B IDLE MIXTURE SOCKET Used t o adjust idle mixture needle o n an E2SE carburetor J28696 B BT7928 MIXTURE ADJUSTMENT TOOL Used t o adjust lean mixture and rich mixture stop screws o n E2SE E2ME and E4ME carburetors J22646 02 CARBURETOR ADJUSTMENT WRENCH ...

Page 449: ...nect or connect fuel lines at Throttle Body Unit by holding fuel nut at throttle body J33179 20 MINIMUM AIR RATE ADJUSTING WRENCH Used to adjust throttle stop screw on TBI unit J29658 BT8205 FUEL PRESSURE GAGE Used to check and monitor fuel line pressure of port fuel system J33815 2 BT8253 A AIR BLEED VALVE GAGING TOOL Used to adjust Idle Air Bleed Valve on E2ME and E4ME carburetors J25322 BT7523 ...

Page 450: ...ngine Timing Vehicle Emission Control information label Idle Speed ECM Controlled Not adjustable ECM controls idle Spark Plug Type See Owner s Manual Section 7 Spark Plug Gap Vehicle Emission Control Information Label Engine Code 8th digit of VIN number See Section OA Also Owner s Manual Section 7 Engine Family Vehicle Emission Control Information label Filter Part Numbers See Owner s Manual Secti...

Page 451: ......

Page 452: ...ge Low Code 35 ldle Speed Error C o d e 4 2 E S T Code 44 Oxygen Sensor Circuit Lean Code 45 Oxygen Sensor Circuit Rich Code 51 Faulty PROM Code 53 System Over Voltage o e A 1 A 2 A 3 A 6 A 10 A 12 A 14 A 20 A 22 A 26 A 28 A 30 A 32 A 34 A 36 A 38 A 40 A 42 A 44 A 46 A 48 A 50 A 52 A 54 A 54 SECTION B SYMPTOMS Table of Contents Before Starting Intermittents Hard Start Surges and or Chuggle Lack of...

Page 453: ... C1 9 C1 9 CI 10 CI 12 9 1 o e e s m SECTION C2 FUEL CONTROL SYSTEM PURPOSE MODES OF OPERATION Starting Mode Clear Flood Mode Run Mode Open Loop Closed Loop Acceleration Mode Deceleration Mode Battery Voltage Correction Mode Fuel Cutoff Mode FUEL CONTROL SYSTEM COMPONENTS BASIC SYSTEM OPERATION THROTTLE BODY INJECTION TBI UNIT Fuel Injector Pressure Regulator Idle Air Control IAC Valve Throttle Po...

Page 454: ...SULTS OF INCORRECT OPERATION C7 2 ON CAR SERVICE C7 2 EGR VALVE C7 2 PARTS INFORMATION C7 3 Exhaust Gas Recirculation EGR Check Non ECM Controlled Chart C 7A C7 4 SECTION C8 TRANSMISSION CONVERTER CLUTCH SYSTEM GENERAL DESCRIPTION C8 1 PURPOSE C8 1 OPERATION C8 1 CIRCUIT DESCRIPTION C8 1 DIAGNOSIS C8 1 ON CAR SERVICE C8 2 SHIFT LIGHT C8 2 DESCRIPTION C8 2 DIAGNOSIS C8 2 ON CAR SERVICE C8 2 PARTS I...

Page 455: ...peration and the various systems it controls Details of basic operation diagnosis functional checks and on vehicle service are covered in Section C Component Systems The ECM has the ability to do some diagnosis of itself and ofother parts ofthe system When it finds a problem it lights a Service Engine Soon light on the instrument panel and a trouble code will be stored in the ECM memory This does ...

Page 456: ...ervice Engine Soon L i g h t C h a r t A 1 Page A 10 No ALDL Data or Won t Flash Code 12 Service Engine Soon Light On Steady Chart A 2 Page A 12 Engine Cranks But Won t Run 1 of 3 Chart A 3 e Page A 14 Fuel Pump Relay Circuit Chart A 5 o Page A 20 Fuel System Diagnosis 1 of 2 Chart A 7 Page A 22 Code 13 Oxygen Sensor Circuit Page A 26 Code 14 Coolant Sensor Circuit High Temp Indicated Page A 28 Co...

Page 457: ... T E C M C O N N E C T E D N1 Crankcase vent valve PCV N17 Fuel vapor canister 0 CONTROLLED DEVICES 1 Fuel injector 2 Idle air control valve 3 Fuel pump relay 8 Engine fan relay located under left front headlight 13 A C compressor relay 14 Direct ignition system assembly Exhaust gas recirculation valve O INFORMATION SENSORS A Manifold absolute pressure located on air cleaner B Exhaust oxygen C Thr...

Page 458: ...0 BLK452 DK BLU417 GRY416 LT GRN 432 BLK469 TAN 472 p m n r _ D C G u u u u B A LT BLU WHT 441 LT BLU BLK 442 LT GRN WHT443 LT GRN BLK 444 B1 B15 W12 W13 B23 B2 ECM SERIAL DATA DIAGNOSTIC TEST SYSTEM GND SYSTEM GND OXYGEN SENSOR GROUND OXYGEN SENSOR SIGNAL W23 B8 B12 B19 W11 B20 W14 B5 VEHICLE SPEED SIGNAL COOLANT TEMP SIGNAL SENSOR GROUND TPS SIGNAL 5VREF MAP SIGNAL SENSOR GROUND MAT SIGNAL IAC C...

Page 459: ... 4 1 9 B 2 2 T A N B L K 4 2 2 K N K B L K 4 3 9 B L U 4 6 7 B L K R E D 4 5 3 P P L W H T 4 3 0 T A N B L K 4 2 4 W H T 4 2 3 W H T 1 2 1 S E C O N D A R Y P R I M A R Y W I N D I N G T O I P O R T A C H E C M W 1 8 P A R K N E U T R A L S W I T C H A T B 7 W1 B 1 6 B 9 W19 W6 S E R V I C E E N G I N E S O O N L I G H T C O N T R O L T C C O R S H I F T L I T E W 1 6 I G N I N J E C T O R D R I V...

Page 460: ...R LT GRN BLK 901 A C CONTROL SWITCH 66 LT GRN W m A C FUSE IGN 12V A C COMPRESSOR CLUTCH DKGRN59 COOLING FAN CONTROL RELAY COOLING FAN v BATTERY FUSIBLE LINK DK GRN WHT 335 B21 532 BLK RED W10 W15 W24 W12 12V BATT 12V BATT FUEL PUMP RELAY DRIVE 12V SYSTEM GND B24 W2 B3 A C SIGNAL FOR FAN WHITE wiy 3 W12 j I W13 24 PIN CONNECTOR BLACK i B r A C REQUEST A C RELAY CONTROL H12I B24 B13 3 COOLING FAN 2...

Page 461: ... ZD PNK BLK W16 12 V IGN 0 B B 12V BATT W10 ORN W12 W13 ZD ORN W15 12V BATT B B 0 5 0 5 0 5 VOLT REFERENCE W11 GRY OA PIN ZD W14 MAP MAT GND 0 Q 0 0 3 ECM GROUND W12 BLK WHT CONNECTOR BLK WHT W13 ECM GROUND 0 0 0 BLACK r i B 000 2 5 v o l t s varina SERIAL DATA B1 ORN B 1 824 1 ZD LT BLU BLK B24 A C SIGNAL FOR FAN 0 0 000 33 5 1 9 OXYGEN SENSOR SIGNAL B2 PPL B 1 824 1 ZD TAN B23 OXYGEN SENSOR GROU...

Page 462: ...DRIVEABILITY AND EMISSIONS FUEL INJECTION TBI 6E2 A 7 BLANK ...

Page 463: ...eters the values are not recommended by General Motors for use in diagnosis For more description on the values and use of the Scan to diagnosis ECM inputs refer to the applicable diagnosis section in Section C If all values are within the range illustrated refer to symptoms in Section B SCAN DATA Idle Upper Radiator Hose Hot Closed Throttle Park or Neutral Closed Loop Acc o f f SCAN Position Units...

Page 464: ...OR GROUNDED CKT451 SEE WIRING DIAGRAM CHART A 1 YES NO DOES SCAN DISPLAY ECM DATA SEE CHART A 2 YES x DOES ENGINE START YES ARE ANY CODES DISPLAYED YES NO SEE CHART A 2 1 NO X SEE CHART A 3 NO KEFER TO APPLICABLE CODE CHART START WITH LOWEST CODE COMPARE SCAN DATA WITH TYPICAL VALUES SHOWN ON FACING PAGE ARE VALUES NORMAL OR WITHIN TYPICAL RANGES YES IL REFER TO SYMPTOMS IN SECTION B NO I I REFER ...

Page 465: ...d directly to the light bulb The electronic control module ECM will control the light and turn it ON by providing a ground path through CKT 419 to the ECM Test Description Numbers below refer to circled numbers on the diagnostic chart 1 Battery feed CKT 240 is protected by a fusible link at the battery 2 Using a test light connected to 12 volts probe each of the system ground circuits to be sure a...

Page 466: ...USE FAULTY BULB OPEN CKT419 CKT419 SHORTED TO VOLTAGE OPEN IGN FEED TO BULB NO I IS ECM BATTERY FEED CKT 240 AND ECM FUSE OK YES IGNITION OFF DISCONNECT ECM CONNECTORS IGNITION ON PROBE CKT 240 439 WITH TEST LIGHT TO GROUND IS THE LIGHT ON ON BOTH CKTS YES FAULTY ECM GROUNDS OR ECM NO LOCATE AND CORRECT SHORT TO GROUND IN CKTTHAT HADA BLOWN FUSE NO RLPAIR OPEN IN CKT THAT DID NOT LIGHT THE TEST LI...

Page 467: ... terminal grounded the light should flash a Code 12 followed by any trouble code s stored in memory A steady light suggests a short to ground in the light control CKT 419 or an open in diagnostic CKT 451 Test Description Numbers below refer to circled numbers on the diagnostic chart 1 If there is a problem with the ECM that causes a Scan tool to not read Serial data then the ECM should not flash a...

Page 468: ...GNOSTIC TERMINAL NOT GROUNDED BACK PROBE ECM CKT 451 WITH TEST LIGHT TO GROUND NOCODE 12 CHECK PROM FOR PROPER INSTALLATION IF OK REPLACE ECM USING ORIGINAL PROM RECHECK FOR CODE 12 NO CODE 12 REPLACE PROM YES IF PROBLEM WAS NO ALDL DATA CHECK SERIAL DATA CKT461 FOR OPEN OR SHORT TO GND BETWEEN ECM AND ALDL CONNECTOR IF OK IT IS A FAULTY ECM OR PROM 1 LIGHT ON J REPAIR SHORT TO GROUND IN CKT419 CO...

Page 469: ...ch coil the opposite spark plug wire should be left connected If rpm was indicated during crank the ignition module is receiving a crank signal but No Spark at this test indicates the ignition module is not triggering the coil 3 While cranking engine there should be no fuel spray with injector disconnected Replace the injector if it sprays fuel or drips like a leaking water faucet The test light s...

Page 470: ...E OTHER WIRES CONNECTED TO THE SPARK PLUGS DURING CRANKING IS THERE SPARK ON BOTH WIRES YES DISCONNECT INJECTOR CONNECTOR CRANK ENGINE IS THERE FUEL SPRAY FROM INJECTOR NO CONNECT INJECTOR TEST LIGHT TO HARNESS CONNECTOR CRANK ENGINE DOES TEST LIGHT BLINK YES H Z FAULTY INJECTOR OR O RING YES H Z RECONNECT INJECTOR CONNECTOR CRANK ENG IS THERE FUEL SPRAY FROM INJECTOR NO SEE FUEL PUMP RELAY i CIRC...

Page 471: ... lies in the Direct Ignition System or the power and ground supplies to the module Test Description Numbers below refer to circled numbers on the diagnostic chart 1 Because the Direct Ignition System uses two plugs and wires to complete the circuit of each coil the opposite spark plug wire should be left connected 2 This test will determine if the 12 volt supply and a good ground is available at t...

Page 472: ... PLUG WIRE NO SPARK SPARK ON BOTH WIRES DISCONNECT 2 WIRE CONNECTOR AT IGN MODULE IGN ON PROBE IGN CKT WITH A TEST LIGHT TO GND IS THE TEST LIGHT ON E IGN OFF DISCONNECT 6 WAY CONN AT IGN MODULE IGN ON REPEATEDLY TOUCH CKT 430 WITH A TEST LIGHT TO 12V WHILE OBSERVING CRANK RPM IS RPM INDICATED YES 1 PROBE GND CKT 450 WITH A TEST LIGHT TO 12V IS TEST LIGHT ON NO IE YES 1 OPEN IGN CKT FAULTY IGN MOD...

Page 473: ...WON T RUN 2 5L P SERIES TBI Circuit Description Ignition voltage is supplied to the fuel injector on CKT 439 The injector will be pulsed turned ON and OFF when the ECM opens and grounds injector drive CKT 467 Test Description Numbers below refer to circled numbers onthe diagnostic chart 1 No blinking light indicates no ECM control of the injector or a wiring problem 2 There is a remote possibility...

Page 474: ...ISCONNECT WHITE ECM CON ECTOR IGN ON PROBE CONNECTOR TERM W1 WITH A TEST LIGHT TO GROUND 0 REPAIR OPEN IGNITION CKT 439 REPAIR SHORT TO VOLTAGE CKT 467 LIGHT ON I LIGHT OFF FAULTY ECM CONNECTOR W1 OR FAULTY ECM FAULTY CONNECTION OR OPEN CIRCUIT 467 STEADY LIGHT I CHECK FOR SHORT TO GROUND INJECTOR CIRCUIT 467 IF CIRCUIT 467 IS NOT GROUNDED CHECK RESISTANCE ACROSS TERMINALS INJECTOR SHOULD BE OVER ...

Page 475: ... pump relay and run the in tank fuel pump The fuel pump will operate as long as the engine is cranking or running and the ECM is receiving ignition reference pulses Ifthere are no reference pulses the ECM will shut OFF the fuel pump within 2 seconds after key ON Should the fuel pump relay or the 12 volt relay drive from the ECM fail the fuel pump will be run through an oil pressure switch back up ...

Page 476: ... ORIGINAL SYMPTOM WAS ENGINE CRANKS BUT WILL NOT RUN CONTINUE TESTING OF OIL PRESSURE SWITCH ENGINE AT NORMAL OPERATING TEMPERATURE OIL PRESSURE NORMAL DISCONNECT FUEL PUMP RELAY ENGINE SHOULD CONTINUE TO RUN DOES IT YES XRECONNECT FUEL PUMP RELAY IGNITION OFF PROBE FUEL PUMP TEST TERMINAL WITH A TEST LIGHT TO GROUND LIGHT OFF _ NO TROUBLE FOUND CHART A 5 FUEL PUMP RELAY CIRCUIT 2 5L P SERIES TBI ...

Page 477: ...n reference pulses Ifthere are no reference pulses the ECM will shut OFF the fuel pump within 2 seconds after key ON The pump will deliver fuel to the TBI unit where the system pressure is controlled to 62 to 90 kPa 9 to 13 psi Excessfuel is then returned to the fuel tank The fuel pump test terminal is located in the left side of the engine compartment When the engine is stopped the pump can be tu...

Page 478: ...URE SHOULD BE 62 90 kPa 9 13psi NO PRESSURE LISTEN FOR PUMP RUNNING AT FUELTANK PRESSURE BUT LESS THAN 62 kPa 9 PSI 1 ABOVE 90 kPa 13 PSI CHART A 7 PAGE 2 OF 2 PUMP RUNS PUMP NOT RUNNING BLOCK FUEL RETURN LINE BY PINCHING FLEXIBLE HOSE AND NOTE PRESSURE CHfcCK FOR OPEN WIRE IN CKT 120 OPEN PUMP GROUND WIRE CKT 150 NO PRESSURE PRESSURE ABOVE 62 kPa 9 PSI IF OK CHECK FOR PLUGGED IN LINE FILTER PLUGG...

Page 479: ...icted flow causing pressure drop Normally a vehicle with a fuel pressure of less than 62 kPa 9 psi at idle will not be driveable However if the pressure drop occurs only while driving the engine will normally surge then stop as pressure begins to drop rapidly to zero 2 Restricting the fuel return line allows the fuel pump to develop its maximum pressure dead head pressure When battery voltage is a...

Page 480: ...BOVE 13 PSI 89 63 kPa 1 DISCONNECT INJECTOR CONNECTOR DISCONNECT FUEL RETURN LINE FLEXIBLE HOSE ATTACH 5 16 I D FLEX HOSE TO THROTTLE BODY SIDE OF RETURN LINE INSERT THE OTHER END IN AN APPROVED GASOLINE CONTAINER NOTE FUEL PRESSURE WITHIN 2 SECONDS AFTER IGNITION ON ABOVE 13 PSI 89 63 kPa 9 13 PSI 62 kPa 89 63 kPa IF LINES ARE OK REPLACE PRESSURE REGULATOR FAULTY IN TANK FUEL PUMP COUPLING HOSE P...

Page 481: ...diagnostic chart 1 Code 13 will set Engine at normal operating temperature At least 2 minutes engine time after start O2 signal voltage steady between 35 and 55 volts Throttle angle above 7 All conditions must be met for about 60 seconds If the conditions for a Code 13 exist the system will not go Closed Loop 2 This test determines if the O2 sensor is the problem or if the ECM and wiring are at fa...

Page 482: ...E RUNNING DOES IT YES x _ CODE 13 IS INTERMITTENT IF NO ADDITIONAL CODES WERE STORED REFER TO DIAGNOSTIC AIDS ON FACING PAGE NO I IGNITION ON ENGINE OFF CHECK VOLTAGE OF CKT 412 AT 0 2 SENSOR HARNESS CONNECTOR USING A DVM IT SHOULD BE 3 6 VOLTS 300 600 mV 1 YES X _ FAULTY 0 2 SENSOR CONNECTION OR SENSOR 3 6 VOLTS 300 600 mV OVER 6 VOLT 600 mV LESS THAN 3 VOLT 300 mV FAULTY ECM OPEN CKT 413 FAULTY ...

Page 483: ...vertor Clutch TCC Electronic Spark Timing EST Idle IAC Cooling Fan Test Description Numbers below refer to circled numbers on the diagnostic chart 1 Checks to see if code was set as result of hard failure or intermittent condition Code 14 will set if Signal voltage indicates a coolant temperature above 135 C 275 F for 3 seconds 2 This test simulates conditions for a Code 15 If the ECM recognizes t...

Page 484: ...ITTENT IF NO ADDITIONAL CODES WERE STORED REFER TO DIAGNOSTIC AIDS ON FACING PAGE YES NO FAULTY SENSOR CKT 410 SHORTED TO GROUND OR CKT 410 SHORTED TO SENSOR GROUND CIRCUIT OR FAULTY ECM DIAGNOSTIC AID COOLANT SENSOR TEMPERATURE TO RESISTANCE VALUES APPROXIMATE F C OHMS 210 100 185 160 70 450 100 38 1 800 70 20 3 400 40 4 7 500 20 7 13 500 0 18 25 000 40 40 100 700 CLEAR CODES AND CONFIRM CLOSED L...

Page 485: ...g Fan Test Description Numbers below refer to circled numbers on the diagnostic chart 1 Checks to see if code was set as result of hard failure or intermittent condition Code 15 will set if Signal Voltage indicates a coolant temperature below 30 C 22 F for 60 seconds 2 This test simulates conditions for a Code 14 If the ECM recognizes the grounded circuit low voltage and displays a high temperatur...

Page 486: ...RED REFER TO DIAGNOSTIC AIDS ON FACING PAGE YES FAULTY CONNECTION OR SENSOR DIAGNOSTIC AID COOLANT SENSOR TEMPERATURE TO RESISTANCE VALUES APPROXIMATE F C OHMS 210 100 185 160 70 450 100 38 1 800 70 20 3 400 40 4 7 500 20 7 13 500 0 18 25 000 40 40 100 700 NO I JUMPER CKT 410 TO GROUND SCAN SHOULD DISPLAY OVER 130 C DOES IT YES H OPEN SENSOR GROUND CIRCUIT FAULTY CONNECTION OR FAULTY ECM NO X OPEN...

Page 487: ...s Test Description Numbers below refer to circled numbers on the diagnostic chart 1 This step checks to see if Code 21 is the result of a hard failure or an intermittent condition A Code 21 will set if TPS reading above 2 5 volts Engine speed less than 1800 rpm MAP reading below 60 kPa All of the above conditions present for 2 seconds 2 This step simulates conditions for a Code 22 If the ECM recog...

Page 488: ...AY TPS BELOW 2 VOLTS 200mV DOES IT YES CODE 21 IS INTERMITTENT IF NO ADDITIONAL CODES WERE STORED REFER TO DIAGNOSTIC AIDS ON FACING PAGE NO PROBE SENSOR GROUND CIRCUIT WITH A TEST LIGHT CONNECTED TO 12 VOLTS CKT417 SHORTED TO VOLTAGE OR FAULTY ECM LIGHT ON FAULTY CONNECTION OR SENSOR LIGHT OFF OPEN SENSOR GROUND CIRCUIT OR FAULTY ECM 2 24 87 CLEAR CODES AND CONFIRM CLOSED LOOP OPERATION AND NO SE...

Page 489: ...cription Numbers below refer to circled numbers on the diagnostic chart 1 This step checks to see if Code 22 is the result of a hard failure or an intermittent condition A Code 22 will set if The engine is running TPS voltage is below 2 volts 200 mv 2 This step simulates conditions for a Code 21 If a Code 21 is set or the Scan tool displays over 4 volts the ECM and wiring are OK 3 The Scan tool ma...

Page 490: ...0 V DOES IT NO PROBE CIRCUIT 417 WITH A TEST LIGHT CONNECTED TO 12 VOLTS SCAN TOOL SHOULD DISPLAY TPS OVER 4 0 V DOES IT YES NO CODE 22 IS INTERMITTENT IF NO ADDITIONAL CODES WERE STORED REFER TO DIAGNOSTIC AIDS ON FACING PAGE YES REPLACE SENSOR NO CIRCUIT 416 OPEN SHORTED TO GROUND FAULTY CONNECTION OR FAULTY ECM CIRCUIT 417 OPEN SHORTED TO GROUND FAULTY CONNECTION OR FAULTY ECM CLEAR CODES AND C...

Page 491: ... becomes less and the voltage drops Test Description Numbers below refer to circled numbers on the diagnostic chart 1 This step checks to see if Code 23 is the result of a hard failure or an intermittent condition A Code 23 will set if Signal voltage indicates a MAT temperature less than 30 C Engine is running for longer than 58 seconds 2 This test simulates conditions for a Code 25 If the Scan to...

Page 492: ...STIC AID MAT SENSOR TEMPERATURE TO RESISTANCE VALUES APPROXIMATE F c i OHMS 210 100 185 160 70 450 100 38 1 800 70 20 3 400 40 4 7 500 20 7 13 500 0 18 25 000 40 40 100 700 CODE 23 IS INTERMITTENT IF NO ADDITIONAL CODES WERE STORED REFER TO DIAGNOSTIC AIDS ON FACING PAGE NO JUMPER CIRCUIT 472 TO GROUND SCAN SHOULD DISPLAY TEMP OVER 130 C DOES IT OPEN CIRCUIT 469 FAULTY CONNECTION OR FAULTY ECM NO ...

Page 493: ...ode 24 set when drive wheels are not turning Test Description Numbers below refer to circled numbers on the diagnostic chart 1 Code 24 will set if vehicle speed equals 0 mph when Engine speed is between 1400 and 3600 rpm TPS is less than 2 Low load condition Not in park or neutral All conditions met for 5 seconds These conditions are met during a road load deceleration Disregard Code 24 that sets ...

Page 494: ... MAY DAMAGE THE DRIVE AXLES WITH ENGINE IDLING IN GEAR SCAN SHOULD DISPLAY MPH ABOVE 0 DOES IT NO o IGNITION OFF DISCONNECT 15 WAY I P CONNECTOR IGNITION ON PROBE ECM SIDE OF 15 WAY LP CONNECTOR TERMINAL H WITH VOLTMETER TO GROUND SHOULD DISPLAY 10 VOLTS OR MORE DOES IT YES CIRCUIT 437 OPEN OR SHORTED TO GROUND BETWEEN I P CONNECTOR AND VSS BUFFER OR FAULTY BUFFER YES CODE 24 IS INTERMITTENT IF NO...

Page 495: ...tage As the air warms the sensor resistance becomes less and the voltage drops Test Description Numbers below refer to circled numbers on the diagnostic chart 1 This check determines if the Code 25 is the result ofa hard failure or an intermittent condition A Code 25 will set if A MAT temperature greater than 1 3 5 C is detected for a time longer than 2 seconds Diagnostic Aids If the engine has be...

Page 496: ...AULTY SENSOR DIAGNOSTIC AID MAT SENSOR TEMPERATURE TO RESISTANCE VALUES APPROXIMATE F C OHMS 210 100 185 160 70 450 100 38 1 800 70 20 3 400 40 4 7 500 20 7 13 500 0 18 25 000 40 40 100 700 NO CODE 25 IS INTERMITTENT IF NO ADDITIONAL CODES WERE STORED REFER TO DIAGNOSTIC AIDS ON FACING PAGE NO CKT 472 SHORTED TO GROUND OR CKT 472 SHORTED TO SENSOR GROUND CIRCUIT OR fAULTY ECM CLEAR CODES AND CONFI...

Page 497: ...on Numbers below refer to circled numbers on the diagnostic chart 1 This step will determine if Code 33 is the result of a hard failure or an intermittent condition A Code 33 will set if MAP signal voltage is too high low vacuum TPS less than 4 These conditions for a time longer than 48 seconds 2 This step simulates conditions for a Code 34 If the ECM recognizes the change the ECM and CKTs 416 and...

Page 498: ... TEST LIGHT SHOULD LIGHT DOES IT YES NO CODE 33 IS INTERMITTENT IF NO ADDITIONAL CODES WERE STORED REFER TO DIAGNOSTIC AIDS ON FACING PAGE 1 NO CKT 432 SHORTED TO VOLTAGE SHORTED TO CKT 416 OR FAULTY ECM NO PLUGGED OR LEAKING SENSOR VACUUM HOSE OR FAULTY MAP SENSOR OPEN CIRCUIT 469 IGNITION ON ENGINE STOPPED VOLTAGES Meters Below 305 305 610 610 914 914 1219 1219 1524 1524 1829 1829 2133 2133 2438...

Page 499: ... step determines if Code 34 is the result of a hardfailure or an intermittent condition A Code 34 will set when MAP signal voltage is too low The ignition is ON 2 Jumpering harness terminals B to C 5 volt to signal will determine if the sensor is at fault or if there is a problem with the ECM or wiring 3 The Scan tool may not display 12 volts The important thing is that the ECM recognizes the volt...

Page 500: ...GNITION OFF REMOVE JUMPER WIRE 9 PROBE TERMINAL B CKT 432 WITH A TEST LIGHT TO 12 VOLTS IGNITION ON SCAN SHOULD READ OVER 4 VOLTS DOES IT FAULTY CONNECTION OR SENSOR CKT 416 OPEN OR SHORTED TO GROUND OR FAULTY ECM CIRCUIT 432 OPEN OR SHORTtD TO GROUND OR FAULTY ECM IGNITION ON ENGINE STOPPED VOLTAGES ALTITUDE VOLTAGE RANGE Meters Feet Below 305 Below 1 000 3 8 5 5V 305 610 1 000 2 000 3 6 5 3V 610...

Page 501: ...light Disconnect ECM and turn the ignition ON and probe terminals to check for this condition Diagnostic Aids A slow unstable idle may be caused by a system problem that cannot be overcome by the IAC Scan counts will be above 60 counts if idle is too low and 0 counts if idle is too high If idle is too high stop engine Ignition ON Ground diagnostic terminal Wait 45 seconds for IAC to seat then disc...

Page 502: ...OUND IDLE RPM INCREASE IDLE ENGINE FOR 1 MINUTE AND NOTE RPM RETURNS TO IDLE RPM RECORDED ABOVE I IDLE AIR CONTROL CIRCUIT OK SEE FACING PAGE DIAGNOSTIC AIDS NO LIGHTS ONE OR MORE CIRCUITS CHECK FOR OPEN OR SHORT TO GROUND IN CIRCUIT WITH NO LIGHT ARE ALL CIRCUITS OK YES CHECK RESISTANCE ACROSS IAC COILS SHOULD BE MORE THAN 20 OHMS BETWEEN IAC TERMINALS OPPOSITE HARNESS CONNECTOR TERMS A TO B AND ...

Page 503: ...ule so the EST voltage should be varying If the bypass line is open or grounded the ignition module will not switch to EST mode so the EST voltage will be low and Code 42 will be set If the EST line is grounded the ignition module will switch to EST but because the line is grounded there will be no EST signal A Code 42 will be set Test Description Numbers below refer to circled numbers on the diag...

Page 504: ...HARNESS CKT 424 WITH THE TEST LIGHT CONNECTED TO 12 VOLTS AS TEST LIGHT CONTACTS CKT 424 RESISTANCE SHOULD SWITCH FROM UNDER 500 TO OVER 5 000 OHMS DOES IT NO DISCONNECT DIS 6 WAY CONNECTOR NOTE OHMMETER THAT IS STILL CONNECTED TO CKT 423 AND GROUND RESISTANCE SHOULD HAVE GONE HIGH OPEN CIRCUIT DOES IT YES NO CKT 424 OPEN FAULTY CONNECTIONS OR FAULTY IGNITION MODULE CKT 423 SHORTED TO GROUND NO OP...

Page 505: ...more And the system is operating in Closed Loop Diagnostic Aids Using the Scan observe the block learn value at different rpms The Scan also displays the block cells so the block learn values can be checked in each of the cells to determine when the Code 44 may have been set If the conditions for Code 44 exists the block learn values will be around 150 or higher 0 2 Sensor Wire Sensor pigtail may ...

Page 506: ...0 mV YES NO DISCONNECT 0 2 SENSOR WITH ENGINE IDLING SCAN SHOULD DISPLAY 0 2 BETWEEN 35 VOLTS AND 55 VOLTS 350 mV AND 550 mV DOES IT CODE 44 IS INTERMITTENT IF NO ADDITIONAL CODES WERE STORED REFER TO DIAGNOSTIC AIDS ON FACING PAGE YES REFER TO DIAGNOSTIC AIDS ON FACING PAGE NO CKT 412 SHORTED TO GROUND OR FAULTY ECM 2 24 87 CLEAR CODES AND CONFIRM CLOSED LOOP OPERATION AND NO SERVICE ENGINE SOON ...

Page 507: ...ding An open ground CKT 453 may result in EMI or induced electrical noise The ECM looks at this noise as reference pulses The additional pulses result in a higher than actual engine speed signal The ECM then delivers too much fuel causing system to go rich Engine tachometer will also show higher than actual engine speed which can help in diagnosing this problem Canister Purge Check for fuel satura...

Page 508: ...IXED ABOVE 75 VOLTS 750 mV YES DISCONNECT 0 2 SENSOR AND JUMPER HARNESS CKT 412 TO GROUND SCAN SHOULD DISPLAY 0 2 BELOW 35 VOLTS 350 mV DOES IT NO ICODE 45 IS INTERMITTENT IF NO ADDITIONAL CODES WERE STORED REFER TO DIAGNOSTIC AIDS ON FACING PAGE REFER TO DIAGNOSTIC AIDS ON FACING PAGE NO FAULTY ECM CLEAR CODES AND CONFIRM CLOSED LOOP OPERATION AND NO SERVICE ENGINE SOON LIGHT 2 18 87 7S3192 6E ...

Page 509: ...CHECK IF CODE 51 REAPPEARS REPLACE ECM CLEAR CODES AND CONFIRM CLOSED LOOP OPERATION AND NO SERVICE ENGINE SOON LIGHT C O D E 53 SYSTEM OVERVOLTAGE THIS CODE INDICATES THERE IS A BASIC GENERATOR PROBLEM CODE 53 WILL SET IF VOLTAGE AT ECM TERMINAL B2 IS GREATER THAN 17 1 VOLTS FOR 10 SECONDS CHECK AND REPAIR CHARGING SYSTEM SEE SECTION 6 D CLEAR CODES AND CONFIRM CLOSED LOOP OPERATION AND NO SERVIC...

Page 510: ... the DIAGNOSTIC CIRCUIT CHECK Verify the customer complaint and locate the correct SYMPTOM below Check the items indicated under that symptom If the ENGINE CRANKS BUT WILL NOT RUN see CHART A 3 Several of the following symptom procedures call for a careful visual physical check The importance of this step cannot be stressed too strongly it can lead to correcting a problem without further checks an...

Page 511: ...faulty An intermittent Service Engine Soon light and No Trouble Codes may be caused by Electrical system interference caused by a defective relay ECM driven solenoid or switch They can cause a sharp electrical surge Normally the problem will occur when the faulty component is operated Improper installation of electrical options such as lights 2 way radios etc EST wires should be routed away from s...

Page 512: ...r Little or no increase in speed when accelerator pedal is pushed down part way Compare customer s car to similar unit Make sure the customer s car has an actual problem Remove air cleaner and check air filter for dirt or for being plugged Replace as necessary CHECK For restricted fuel filter contaminated fuel or improper fuel pressure See CHART A 7 ECM Grounds EGR operation for being open or part...

Page 513: ...Usually most severe when first trying to make the car move as from a stop sign May cause the engine to stall if severe enough Perform careful visual physical check as Generator output voltage Repair if less than 9 or described at start of Section B more than 16 volts CHECK For open Ignition System ground CKT 453 Fuel pressure See CHART A 7 Canister purge system for proper operation See Water conta...

Page 514: ...or splits kinks and proper connections as shown on Vehicle Emission Control Information label P N switch circuit See CHART C 1A For injector leaking Check Fuel Pressure CHART A 7 IAC See Code 35 If a sticking throttle shaft or binding linkage causes a high TPS Voltage open throttle indication the ECM will not control idle Monitor TPS voltage Scan and or Voltmeter should read less than 1 2 volts wi...

Page 515: ...XCESSIVE NOx Check items which cause car to run LEAN or to run too hot EGR valve for not opening See CHART C 7 Vacuum leaks Coolant system and coolant fan for proper operation See CHART C 12 Remove carbon with top engine cleaner Follow instructions on can If the system is running lean block learn greater than 138 refer to Diagnostic Aids on facing page ofCode 44 DIESELING RUN ON Definition Engine ...

Page 516: ...observe the exhaust system backpressure reading on the gauge Reading should not exceed 1 j psi 8 6 kPa 2 Accelerate engine to 2000 rpm and observe gauge Reading should not exceed 3 psi 20 7 kPa 3 Ifthe backpressure at either rpm exceeds specification a restricted exhaust system is indicated 4 Inspect the entire exhaust system for a collapsed pipe heat distress or possible internal muffler failure ...

Page 517: ...ISVEST 2 5L Page C4 1 C7 Exhaust Gas Recirculation EGR System Page C7 1 C8 Transmission Converter Clutch TCC System Page C8 1 C10 ECM Controlled Air Conditioning P a g e d 0 1 C12 Electric Cooling Fan Page C12 1 C13 Positive Crankcase Ventilation PCV P a g e d 3 1 DIAGNOSTIC CHARTS The Diagnostic Charts for each system are found after the on car service and parts information at the back of each se...

Page 518: ... ECM For 1988 the ECM used in 2 5L equipped vehicles will be a type called GMP4 For service this ECM consists of only two parts a controller the ECM without a PROM and a calibrator called a PROM Programmable Read Only Memory PROM The PROM is programmed with information relative to a certain vehicle vehicle weight engine type transmission type axle ratio etc This allows the PROM to calibrate the EC...

Page 519: ...cuit so proper use of the chart will lead to either repairing a wiring problem or replacing the sensor to properly repair a problem 4 2 85 ENGINE COOLANT TEMPERATURE SENSOR HARNESS CONNECTOR TO ECM LOCKING TAB r r 5S 1640 6EA T SENSOR 2 ELECTRICAL CONNECTOR 3 MANIFOLD VACUUM TUBE 4 3 85 6S 2648 6 Figure C1 3 MAP Sensor MAP Sensor Figure C1 3 The manifold absolute pressure MAP sensor measures the c...

Page 520: ...ensor circuit if open should set a Code 13 A constant low voltage in the sensor circuit should EXHAUST OXYGEN 02 SENSOR 10 2 86 4S 0078 6E Figure C1 5 Exhaust Oxygen O2 Sensor set a Code 44 while a constant high voltage in the circuit should set a Code 45 Codes 44 and 45 could also be set as a result of fuel system problems See Code Charts Throttle Position Sensor TPS Figure C1 6 The throttle posi...

Page 521: ...f a diagnostic chart Indicates that the ECM connections or ECM is the cause of a problem and the ECM is replaced but does not correct the problem one of the following may be the reason 9 There is a problem with the ECM terminal i onnections The diagnostic chart will say ECM connections or ECM The terminals may have to be removed from the connector in order to check them properly The ECM or PROM is...

Page 522: ...e to each other A failure in the MAT sensor circuit should set a Code 23 or 25 The code charts also contain a chart to check for sensor resistance values relative to temperature Oxygen O2 Sensor The Scan has several positions that will indicate the state of the exhaust gases O2 voltage integrator and block learn See Scan position information in Introduction Section BE A problem in the O9 sensor ci...

Page 523: ... and production ECM number to the service ECM label This will allow positive identification of ECM parts throughout the service life of the vehicle Important To prevent internal ECM damage the ignition must be OFF when disconnecting or reconnecting power to ECM for example battery cable ECM pigtail ECM fuse jumper cables etc ECM AND COMPONENTS REPLACEMENT Remove or Disconnect 1 Negative battery ca...

Page 524: ...s old Important Do Not remove PROM from carrier to check PROM number 2 For correct reference of PROM in carrier see Figure Cl 10 Install or Connect 1 New PROM carrier in PROM socket fT Important Small notch of carrier should be aligned with small notch in socket Press on PROM carrier until it is firmly seated in the socket Do not press on PROM only the carrier 2 Access cover on ECM 1 u u o u ax ye...

Page 525: ...of the pigtail or connector could affect proper operation of the oxygen sensor Take care when handling the oxygen sensor The in line electrical connector and louvered end must be kept free of grease dirt or other contaminants Also avoid using cleaning solvents of any type Do not drop or roughly handle the oxygen sensor The oxygen sensor may be difficult to remove when engine temperature is below 4...

Page 526: ...losed install TPS on throttle shaft Rotate counter clockwise to align mounting holes 2 TwoTPS attaching screw assemblies 3 Air cleaner and new gasket T1 THROTTLE BODY ASSEMBLY T1 THROTTLE POSITION SENSOR G O SCREW ASSEMBLY 7S 3415 6E PARK NEUTRAL SWITCH See Section 8A for location of park neutral switch On car service and adjustment procedures are listed in Section 3B4 PARTS INFORMATION PART NAME ...

Page 527: ...neutral and open in drive ranges The ECM supplies ignition voltage through a current limiting resistor to CKT 434 and senses a closed switch when the voltage on CKT 434drops to less than one volt The ECM uses the P N signal as one ofthe inputs to control Idle Air Control VSS Diagnostics Test Description Numbers below refer to circled 3 Be sure Scan indicates drive even while numbers on the diagnos...

Page 528: ...ITCH CONNECTOR 9 JUMPER TERMINALS A TO B CKT 434 TO 450 SCAN SHOULD INDICATE PARK OR NEUTRAL DOES IT YES NO NO TROUBLE FOUND P N CIRCUIT OK DISCONNECT P N SWITCH THIS SHOULD CAUSE SCAN TO DISPLAY DRIVE RANGE DOES IT YES ZEZ P N SWITCH READJUSTED Oft FAULTY 3_ NO HZ JUMPER TERMINAL A CKT 434 TO ENGINE GROUND SCAN SHOULD INDICATE PARK OR NEUTRAL DOES IT YES P N SWITCH MISADJUSTED OR FAULTY NO CKT 43...

Page 529: ...nsor is also used to determine barometric pressure Test Description Numbers below refer to circled numbers on the diagnostic chart 1 Checks MAP sensor output voltage to the ECM This voltage without engine running represents a barometer reading to the ECM Comparison of this BARO reading with a known good vehicle with the same sensor is a good way to check accuracy ofa suspect sensor Readings should...

Page 530: ...S THAN STEP 1 REPLACE SENSOR OK NOT OK NO TROUBLE FOUND CHECK MAP HOSE FOR LEAKAGE OR RESTRICTION BE SURE THIS HOSE SUPPLIES VACUUM TO MAP SENSOR ONLY REPLACE SENSOR ALTITUDE VOLTAGE RANGE Meters Feet Below 305 Below 1 000 3 8 5 5V 305 610 1 000 2 000 3 6 5 3V 610 914 2 000 3 000 3 5 5 1V 914 1219 3 000 4 000 3 3 5 0V 1219 1524 4 000 5 000 3 2 4 8V 1524 1829 5 000 6 000 3 0 4 6V 1829 2133 6 000 7 ...

Page 531: ...6E2 C1 14 DRIVEABILITY AND EMISSIONS FUEL INJECTION TBI BLANK ...

Page 532: ...Line Repair C2 14 C2 5 FUEL PUMP OIL PRESSURE SWITCH C 2 1 4 C2 5 FUEL PUMP RELAY C2 14 C2 5 PARTS INFORMATION C 2 1 4 GENERAL DESCRIPTION PURPOSE The basic function of the fuel control system is to control fuel delivery to the engine Fuel is delivered to the engine by a throttle body injection TBI unit The main control sensor is the oxygen O2 sensor which is located in the exhaust manifold The O2...

Page 533: ...operate properly This depends on temperature 2 The coolant temperature sensor is above a specified temperature 3 A specific amount of time has elapsed after starting the engine Closed Loop The specific values for the above conditions vary with different engines and are stored in the PROM When these conditions are met the system goes into Closed Loop operation In Closed Loop the ECM calculates the ...

Page 534: ...EGR valve MAP sensor and the canister purge system Fuel Injector The fuel injector Figure C2 4 is a solenoid operated device controlled by the ECM The ECM turns on the solenoid which lifts a normally closed ball valve off a seat The fuel under pressure is injected in a conical spray pattern at the walls of the throttle body bore above the throttle valve The fuel which is not needed by the injector...

Page 535: ...em Figure C2 6 Idle Air Control IAC Valve The IAC valve moves in small steps called Counts which can be monitored by a Scan tool which plugs into the ALDL connector During idle the proper position of the IAC valve is calculated by the ECM based on battery voltage coolant temperature engine load and engine rpm If the rpm drops below a specified rpm the throttle valve closes and the ECM senses a nea...

Page 536: ...el System Pressure Test procedure FUEL PUMP ELECTRICAL CIRCUIT When the key is first turned ON without the engine running the ECM turns the fuel pump relay ON for two seconds This builds up the fuel pressure quickly If the engine is not started within two seconds the ECM shuts the fuel pump OFF and waits until the engine starts As soon as the engine is cranked the ECM turns the relay ON and runs t...

Page 537: ... lack of fuel 4 Engage starter for three seconds to dissipate fuel pressure in lines Fuel connections are now safe for servicing 5 When pressure is relieved and servicing is complete return fuse to fuse block A fuel system pressure test is part of several of the Diagnostic Charts and Symptom checks To perform this test follow this procedure 1 Turn engine OFF and relieve fuel pressure following ins...

Page 538: ...ssembly Idle Stop 25 Gasket Fuel Meter Body to Throttle Body 208 Spring idle Stop Screw 35 Screw Injector Retainer 230 Sensor Throttle Position TPS 36 Retainer Injector 232 Screw Washer Assembly TPS Attaching 40 Fuel Injector 250 Idle Air Control IAC Valve 42 O Ring Fuel Injector Upper 251 Screw IAC Valve Attaching 43 O Ring Fuel Injector Lower 255 O Ring IAC Valve 60 Pressure Regulator Cover Asse...

Page 539: ... 91 Important Be sure to replace the injector with an identical part Injectors from other models can fit in the Model 700 TBI but are calibrated for different flow rates See Figure C2 11 for part number location Install or Connect Lubricate new upper and lower o rings with automatic transmission fluid and place them on injector Make sure upper o ring is in groove and lower one is flush up against ...

Page 540: ...ry If any of above is present the whole fuel body casting must be replaced HHH Install or Connect 1 New pressure regulator diaphragm assembly making sure it is seated in groove in fuel meter body 2 Regulator spring seat and spring into cover assembly 3 Cover assembly over diaphram while aligning mounting holes NOTICE Use care while installing the pressure regulator to prevent misalignment of diaph...

Page 541: ... 1 Electrical connector from TPS 2 Screw assemblies and TPS T FUEL HI ETER A S S E M B L Y THROTTLE BODY A S S E M B L Y THROTTLE POSITION SENSOR PS TPS ATTACHING SCREW WASHER ASSEMBLY 8P 0916 AS 1 15 87 Figure C2 14 Throttle Position Sensor TPS NOTICE The throttle position sensor is an electrical component and should not be immersed in any type of liquid solvent or cleaner as damage may result In...

Page 542: ...ired after installation The IAC valve is reset by the ECM When the vehicle is operated at normal engine temperature at approximately 30 mph 48 km hr the ECM causes the valve pintle to seat in the throttle body The ECM then has a reset procedure to set the correct pintle position Proper idle regulation should result 1 2 Install or Connect Lubricate new o ring with transmission fluid and install on ...

Page 543: ...sembly according to previous instructions PHIDLE STOP SCREW A S S E M B L Y PH I D L E S T O P S C R E W P L U G 8P 0920 AS Figure C2 18 Removing Idle Stop Screw Plug Install or Connect 1 New fuel meter body to throttle body gasket 2 Fuel meter assembly on throttle body assembly 3 Fuel meter body to throttle body attaching screw and washer assemblies Tighten Screws to 6 0 N m 53 lb in 4 TBI unit o...

Page 544: ...ifold sealing surface for cleanliness Install or Connect 1 New TBI flange manifold mounting gasket 2 TBI with mounting hardware Tighten Mounting hardware to 17N m 12 lb ft 3 New o ringsonfuel line nuts 4 Fuel line inlet and outlet nuts by hand Tighten Inlet and outlet nuts to 27 N m 20 lb ft Use back up wrench to keep TBI nuts from turning 5 Vacuum hoses 6 Throttle linkage return spring s transmis...

Page 545: ...e and push hose 2 inches 51 mm onto each portion of the fuel pipe Tighten clamp on each side of repair 4 Secure fuel line to the frame FUEL PUMP OIL PRESSURE SWITCH Figure C2 20 The oil pressure switch is mounted on the Bulkhead Side of the engine as shown in figure 31 This switch is a parallel power supply with the fuel pump relay If the fuel pump relay should fail the oil pressure switch will pr...

Page 546: ...iaphragm operated purge valve The fuel vapors vent from the fuel tank to the canister When the engine is running manifold vacuum is supplied to the top tube of the purge valve Control Vacuum Signal which lifts the valve diaphragm and opens the valve The lower tube on the purge valve PCV Tube is connected to a timed port above the TBI throttle valve The rate of purge is controlled through this port...

Page 547: ... tube The diaphragm should hold vacuum for at least 20 seconds If it does not hold vacuum the canister must be replaced Ifthe diaphragm holds vacuum again try to blow through the hose connected to the lower tube while vacuum is still being applied An increased flow of air should be observed If not the canister must be replaced ON CAR SERWICE FUEL VAPOR CANISTER Remove or Disconnect 1 Hoses from ca...

Page 548: ...ll fire from the center electrode to the side electrode while the other will fire from side electrode to center electrode These systems utilize the EST signal from the ECM as do distributor type ignition systems equipped with EST to control spark timing Under 400 rpm the DIS module controls spark timing module Code 12 Code 42 Setting Timing ON CAR SERVICE D I S A S S E M B L Y CRANKSHAFT SENSOR IG...

Page 549: ...m 20 LBS FT fin IGN MODULE 7S 3194 6E Figure C4 2 Ignition Coils Module and Sensor 2 5L The DIS module is not repairable When a module is replaced the remaining DIS components must be transferred to the new module See Figure C4 2 Electronic Spark Timing EST This system uses the same EST to ECM circuits that distributor type systems use Following is a brief description for each ofthe EST circuits D...

Page 550: ... diagnosis Code 12 Code 12 is used during the Diagnostic Circuit Check procedure to test the diagnostic and code display ability of the ECM This code indicates that the ECM is not receiving the engine rpm REFERENCE signal This occurs with the ignition key ON and the engine not running SETTING TIMING Because the reluctor wheel is an integral part of the crankshaft and the crankshaft sensor is mount...

Page 551: ...0 lbs In IGNITION MODULE Figure C4 3 Remove or Disconnect 1 Negative battery cable 2 DIS Assembly from engine See previous procedure 3 Coils from assembly See previous procedure 4 Module from assembly plate 4 Install or Connect 1 Module to assembly plate Carefully engage sensor to module terminals 2 Coils See previous procedure 3 DIS Assembly to engine See previous procedure 4 Negative battery cab...

Page 552: ...DRIVEABILITY AND EMISSIONS FUEL INJECTION TBI 6E2 C4 5 BLANK ...

Page 553: ...he reluctor is a machined portion of the crankshaft and the crank sensor is mounted in a fixed position on the block timing adjustments are not possible or necessary Test Description Numbers below refer to circled numbers on the diagnostic chart 1 If the Misfire complaint exists under load only the diagnostic chart on page 2 must be used Engine rpm should drop approximately equally on all plug lea...

Page 554: ...S THAN 30 000 OHMS EACH AND WIRES SHOULD NOT BE GROUNDED ARE WIRES OK YES HZ REMOVE COIL RETAINING NUTS AND REMOVE COILS COILS SHOULD BE FREE OF CARBON TRACKING ARE THEY YES x SWITCH A NORMALLY OPERATING COIL WITH THE COIL FROM PROBLEM CYLINDER SPARK SHOULD JUMP TESTER GAP AT PROBLEM CYLINDER WHILE CRANKING ENGINE DID IT YES ORIGINAL IGNITION COIL IS FAULTY YES JL CHECK FOR FAULTY WORN OR CRACKED ...

Page 555: ...e reluctor is a machined portion of the crankshaft and the crank sensor is mounted in a fixed position on the block timing adjustments are not possible or necessary Test Description Numbers below refer to circled numbers on the diagnostic chart 1 If the Misfire complaint exists at idle only the diagnostic chart on page 1 must be used A spark tester such as a ST 125 must be used because it is essen...

Page 556: ...E OF CARBON TRACKING ARE THEY YES ZZ SWITCH A NORMALLY OPERATING COIL WITH THE COIL FROM PROBLEM CYLINDER SPARK SHOULD JUMP TESTER GAP WITH ENGINE IDLING DID IT YES XI ORIGINAL IGNITION COIL IS FAULTY CHART C 4D 2 DIS MISFIRE UNDER LOAD 2 5L P SERIES Til YES HZ CHECK FOR FAULTY WORN OR CRACKED SPARK PLUG S PLUG FOULING DUE TO ENGINE MECHANICAL FAULT IF SPARK PLUGS CHECK OUT OK SEE CUTS OUT MISSES ...

Page 557: ...6E2 C4 10 DRIVEABILITY AND EMISSIONS FUEL INJECTION TBI BLANK ...

Page 558: ...st gas then moves with the air fuel mixture into the combustion chamber If too much exhaust gas enters combustion will not occur For this reason very little exhaust gas is allowed to pass through the valve and none at idle The EGR valve is usually open under the engine is above idle speed T EGR VALVE T INTAKE AIR I D EXHAUST GAS T EGR VACUUM PORT 4S 0001 6E 5 j D I A P H R A G M 4S 0113 6E Figure ...

Page 559: ...ld causes Spark knock detonation Engine overheating Emission test failure DIAGNOSIS Because the EGR on 2 5L equipped vehicles is not ECM controlled a Scan tool cannot be used for diagnosis Diagnosis of the EGR system on the 2 5L is covered in CHART C 7 at the end of this section GM V A L V E R e m o v e or Disconnect 1 Air cleaner 2 EGR valve vacuum hose at valve 3 Bolts 4 EGR valve from manifold ...

Page 560: ...DRIVEABILITY AND EMISSIONS FUEL INJECTION TBI 6E2 C7 3 PARTS INFORMATION PART NAME GROUP Valve EGR 3 670 Gasket EGR Valve 3 680 ...

Page 561: ...PHRAGM RPM SHOULD DROP REPLACE VALVE RPM DROPS NO RPM CHANGE CHECK FOR MOVEMENT OF EGR VALVE DIAPHRAGM AS RPM IS CHANGED FROM APPROX 2000 TO IDLE E DOESN T MOVE CHECK VACUUM AT EGR VALVE AS ENGINE RPM IS CHANGED FROM APPROXIMATELY 2000 RPM TO IDLE UNDER 20 KPA 6 INCHES CHECK VACUUM HOSES FOR RESTRICTIONS LEAKS AND CONNECTIONS OK NO TROUBLE FOUND CLEAN EGR VALVE OR PASSAGES OR REPLACE VALVE AS NEED...

Page 562: ...om the TPS to release the clutch when the car is accelerating or decelerating at a certain rate CIRCUIT DESCRIPTION The 12 volt power supply for the solenoid in the transmission is provided through a normally closed switch located on the brake pedal linkage When the brake pedal is depressed switch open the power supply to the TCC solenoid is interrupted and the TCC is disengaged regardless ofany o...

Page 563: ...onomy point for up shifting the manual transmission based on engine speed and load The display is a lamp on the instrument panel Activation ofthe ECM driver turns the lamp on DIAGNOSIS The shift light circuit can be checked using CHART C 8B ON CAR SERVICE 9 See Section 8C if the shift light bulb needs replacement 9 See Section 6E Introduction to repair wiring problem See Section 6E C1 ifECM is to ...

Page 564: ...DRIVEABILITY AND EMISSIONS FUEL INJECTION TBS 6E2 C8 3 BLANK ...

Page 565: ...cle speed above 30 mph 48 km h Engine at normal operating temperature above 70 C 156 F Throttle position sensor output not changing indicating a steady road speed Transmission third gear switch closed Brake switch closed Test Description Numbers below refer to circled 3 numbers on the diagnostic chart 4 1 Light OFF confirms transmission third gear apply switch is open 2 At 48 km h 30 mph the trans...

Page 566: ...RANSMISSION CONVERTER CLUTCH TCC ELECTRICAL DIAGNOSIS 2 5L P SERIES TBI LIGHT ON Z Z I M FAULTY TRANSMISSION THIRD GEAR APPLY SWITCH LIGHT OFF CHECK FOR BLOWN FUSE IF OK DISCONNECT CONNECTOR AT TRANS CONNECT TEST LIGHT FROM HARNESS CONNECTOR A TO D IGNITION ON ENGINE STOPPED LIGHT OFF LIGHT ON IGNITION ON ENGINE STOPPED INSTEAD OF GROUND CONNECT TEST LIGHT TO 12 VOLTS AND PROBE ALDL TERMINAL F GRO...

Page 567: ...rol the shift light Coolant temperature TPS VSS RPM The ECM uses the measured rpm and the vehicle speed to calculate what gear the vehicle is in It is this calculation that determines when the shift light should be turned ON Test Description Numbers below refer to circled numbers on the diagnostic chart 1 This should not turn ON the shift light If the light is ON there is a short to ground in CKT ...

Page 568: ...CTORS IGNITION ON JUMPER CKT 456 TO GROUND AND NOTE SHIFT LIGHT LIGHT OFF 1_ LIGHT ON CHECKFOR CODE 24 CHART NO VSS THERMOSTAT FAULTY OR INCORRECT HEAT RANGE IF OK REVIEW SYMPTOMS IN SECTION B 1 LIGHT ON LIGHT ON IGNITION OFF DISCONNECT ECM CONNECTORS IGN ON AND NOTE SHIFT LIGHT LIGHT ON 1 LIGHT OFF REPAIR SHORT TO GROUND IN CKT 456 FAULTY ECM CHECK AND REPAIR OPEN IGNITION CKT 39 OPEN CKT 456 FAU...

Page 569: ...6E2 C8 8 DRIVEABILITY AND EMISSIONS FUEL INJECTION TBI BLANK ...

Page 570: ...ng on refrigerant charge and ambient temp When A C control switch is ON and low pressure switch is closed a signal is sent to the ECM which then turns ON the cooling fan A C RELAY AND CONNECTOR FUEL PUMP RELAY AND CONNECTOR 8S 4376 The high pressure cut out switch normally closed opens when the head pressure gets too high This disables the A C clutch before damage can occur to the system The A C c...

Page 571: ...hown by the Scan tool as A C request ON voltage present OFF no voltage When a request for A C is seen by the ECM the ECM will ground CKT 458 of the A C clutch control relay the relay contact will close and current will flow from CKT 922 to CKT 59 and engage the A C compressor clutch A Scan tool will show the grounding ofCKT 458 as A C clutch ON If voltage is seen by the ECM on CKT 901 the coolingf...

Page 572: ...OBE HARNESS TERMINAL A D WITH TEST LIGHT TO GROUND NO I T IGNITION ON ENGINE OFF DISCONNECT LOW PRESSURE SWITCH PROBE CKT 66 WITH A TEST LIGHT TO GROUND LIGHT ON BOTH NO LIGHT ONE OR BOTH LIGHT ON JUMPER CKT 922 TO CKT 59 DOES A C CLUTCH ENGAGE REPAIR OPEN IN CKT THAT DID NOT LIGHT JUMPER HARNESS TERMINALS TOGETHER SCAN SHOULD DISPLAY A C REQUEST ON DOES IT LIGHT OFF x z z z z OPEN OR SHORT TO GND...

Page 573: ...6E2 C10 4 DRIVEABILITY AND EMISSIONS FUEL INJECTION TBI ...

Page 574: ...engine cools down to about 101 C the ECM de energizes the fan relay and the fan stops If the coolant sensor fails Code 14 or 15 set the ECM will command constant fan A C equipped vehicles have a separate signal line to the J2CM for fen switch is on and the low pressure switch closed the ECM receives a signal on this line and turns on the fan The A C clutch does not have to engage for the ECM to tu...

Page 575: ...ngine is running the ECM will turn the coolingfan ON if A C is ON and vehicle speed is less than 30 mph 48 Km h Coolant temperature greater than 1 0 8 C 230 F Code 14 or 15 coolant sensor failure Diagnostic Aids If the owner complained of an overheating problem it must be determined if the complaint was due to an actual boil over or the hot light or temp gage indicated over heating If the gage or ...

Page 576: ...MINAL F WITH A TEST LIGHTTO 12 VOLTS DOES LIGHT COME ON REPAIR OPEN IN CIRCUIT THAT DID NOT LIGHT NO TROUBLE FOUND SEE FACING PAGE YES NO CHART C 12 ENGINE COOLING FAN 2 5L P SERIES TBI 1 YES m DISCONNECT FAN CONTROL RELAY JUMPER HARNESS CONNECTOR TERMINALS D TO F WITH A TEST LIGHT LIGHT ON LIGHT OFF CHECK FOR SHORT TO GROUND IN CKT 335 IF NOT GROUNDED IT IS A FAULTY ECM FAULTY FAN CONTROL RELAY N...

Page 577: ...6E2 C12 4 DRIVEABILITY AND EMISSIONS FUEL INJECTION TBI ...

Page 578: ...ve or hose may cause Rough idle Stalling or slow idle speed Oil leaks Oil in air cleaner Sludge in engine o A leaking valve or hose would cause Rough idle Stalling High idle speed FUNCTIONAL CHECK OF P C V V A L V E If an engine is idling rough check for a clogged PCV valve or plugged hose Replace as required Use the following procedure 1 Remove PCV valve from rocker arm cover 2 Run the engine at ...

Page 579: ...onents An engine which is operated without any crankcase ventilation can be damaged Therefore it is important to replace the PCV valve and air inlet filter separator where used at intervals shown in Section OB Periodically inspect the hoses and clamps and replace any showing signsof deterioration PARTS INFORMATION PART NAME Air Cleaner Valve Asm Cr Case Vent Tube Cr Case Vent GROUP e 3 402 1 745 1...

Page 580: ...l Voltage Low Code 35 ldle Speed Error Code 42 Electronic Spark Timing EST Code 44 Oxygen Sensor Circuit Lean Code 45 Oxygen Sensor Circuit Rich Code 51 PROM Error Code 52 CALPAK Error Code 53 System Over Voltage Code 55 ECM Error A 1 A 2 A 3 A 5 A 6 A 8 A 10 A 12 A 16 A 24 A 26 A 28 A 30 A 32 A 34 A 36 A 38 A 40 A 42 A 44 A 46 A 48 A 50 A 52 A 54 A 56 A 56 A 56 A 56 SECTION B SYMPTOMS Table of Co...

Page 581: ...TION C2 1 PURPOSE C2 1 MODES OF OPERATION C2 1 Starting Mode C2 1 Clear Flood Mode C2 2 Run Mode C2 2 Acceleration Mode C2 2 Deceleration Mode C2 3 Battery Voltage Correction Mode C2 3 Fuel Cutoff Mode C2 3 FUEL CONTROL SYSTEM COMPONENTS C2 3 BASIC SYSTEM OPERATION C2 3 FUEL RAIL ASSEMBLY C2 4 Fuel Injector Assembly C2 4 Pressure Regulator Assembly C2 4 THROTTLE BODY ASSEMBLY C2 5 Idle Air Control...

Page 582: ...haust Gas Recirculation EGR Check Chart C 7 C7 4 SECTION C8 TRANSMISSION TRANSAXLE CONVERTER CLUTCH AND MANUALTRANSMISSION SHIFT LIGHT GENERAL DESCRIPTION C8 1 PU RPOS E o 9 o o v o o o e a e o CS 1 OPERATION e o o o o o C8 1 Results of Incorrect Operation e C8 1 DIAGNOSIS C8 2 ON CAR SERVICE C8 2 SHIFT LIGHT e C8 2 DIAGNOSIS o C8 2 ON CAR SERVICE C8 2 PARTS INFORMATION C8 2 125C Transmission Conv...

Page 583: ...etails of basic operation diagnosis functional checks and on vehicle service are covered in Section C Component Systems The ECM has the ability to do some diagnosis of itself and ofother parts of the system When it finds a problem it lights a Service Engine Soon Light on the instrument panel and a trouble code will be stored in the ECM memory This does not mean that the engine should be stopped ri...

Page 584: ...on t Flash Code 12 Service Engine Soon Light On Steady Chart A 2 Page A 10 Engine Cranks But Won t Run Chart A 3 1 of 2 Page A 12 Fuel System Diagnosis Chart A 7 1 of 4 Page A 16 Cold Start Valve Test Chart A 9 o Page A 24 Code 13 Oxygen Sensor Circuit Open Circuit Page A 26 Code 14 Coolant Temperature Sensor Circuit High Temperature Indicated Page A 28 Code 15 Coolant Temperature Sensor Circuit L...

Page 585: ...ol valve 3 Fuel pump relay 5 Trans Converter Clutch connector 12 Exh Gas Recirc vacuum solenoid 13 A C compressor relay Exhaust Gas Recirculation valve CONFORMATION SENSORS A Manifold pressure M A P B Exhaust oxygen C Throttle position D Coolant temperature F Vehicle speed M P N switch T Manifold Air Temperature NOT ECM CONNECTED N1 Crankcase vent valve PCV N8 Oil press switch fuel pump N10 Cold s...

Page 586: ...8 A9 A4 D8 D7 D6 A11 D13 C11 C12 C14 C13 D12 461 ORN 451 WHT BLK 901 GRY RED 997 DK GRN 412 PPL 413 TAN 472 TAN 469 BLK RED 432 416 LTGRN GRY CIO A12 B3 05 B5 B4 C5 C6 C4 C3 A10 B10 D1 417 DK BLU 452 BLK 410 YEL 450 BLK WHT 453 BLK RED 424 TAN BLK 430 PPL WHT 423 WHT 441 LT BLU7WHT 442 LT BLU BLK 443 LT GRN WHT 444 LT GRN BLK 437 BRN 434 ORN BLK 450 BLK WHT ALDL CONNECTOR ALDL CONNECTOR INJ2 wT J ...

Page 587: ...A7 C2 B8 ENGINE 0 GROUND S I 1 2 0 J TAN WHT BATTERY 12V TO FUEL PUMP ALDLCONN 240 ORN 240 ORN FUSIBLE LINK ORN J 2 V BATTERY FEED PNK BLK439 467 A LT BLU 467 B LT BLU 468 A LT GRN 468 B LT GRN ECM IGN IGN 1 AAA INJECTORS PNK639 I P CONN TO GAUGE OR IND LIGHT IGN 1 NJ 1 V v V V PNK WHT 839 419 BRN WHT 422 TAN BLK TO A C POWER RELAY SEE CHART C 10 459 DK BLU 67 LT BLU TAN BLK V r SHIFT LIGHT M T ON...

Page 588: ...6 NOT USED C7 NOTUSED C8 NOTUSED C9 A3 1 7 COOLANT SIGNAL C10 4 8 MAP SIGNAL C11 4 8 MAP SIGNAL C12 TPS SIGNAL C13 5 5 5 VOLT REFERENCE C14 B B INJ 2 4 6 B C15 B B BATT 12 VOLTS C16 BACK VIEW OF C O N N E C T O R B l ra 24 PIN A B CONNECTOR BACK VIEW OF 32 PIN C D CONNECTOR PIM C I R C U I T VOLTJ K E Y ON ENG RUN B1 BATT 12 VOLTS B B R NOTIKFR m EST REF LOW n Q R4 EST CONTROI n 13 B5 DIST REFEREN...

Page 589: ...ow are used in this manual for diagnosis If a Scan reads other parameters the values are not recommended by General Motors for use in diagnosis For more description on the values and use of the Scan to diagnosis ECM inputs refer to the applicable diagnosis section in Section C If all values are within the range illustrated refer to Symptoms in Section B SCAN DATA Idle Upper Radiator Hose Hot Close...

Page 590: ...GROUNDED CKT 451 SEE WIRING DIAGRAM CHART A 1 YES DOES SCAN DISPLAY ECM DATA7 NO nr SEE CHART A 2 YES DOES ENGINE START YES X ARE ANY CODES DISPLAYED NO SEE CHART A 2 l NO I SEE CHART A 3 YES REFER TO APPLICABLE CODE CHART START WITH LOWEST CODE NO COMPARE SCAN DATA WITH TYPICAL VALUES SHOWN ON FACING PAGE ARE VALUES NORMAL OR WITHIN TYPICAL RANGES YES 3 _ REFER TO SYMPTOMS IN SECTION B NO _ REFER...

Page 591: ...ntrol module ECM will control the light and turn it ON by providing a ground path through CKT 419 to the ECM Test Description Numbers below refer to circled numbers on the diagnostic chart 1 Battery feed CKT 240 Is protected by a fusible link at the battery 2 Using a test light connected to 12 volts probe each of the system ground circuits to be sure a good ground Is present See ECM terminal end v...

Page 592: ... CKT419 SHORTED TO VOLTAGE OPEN IGN FEED TO BULB NO IS ECM BATTERY FEED CKT 240 AND ECM FUSE OK YES IGNITION OFF DISCONNECT ECM CONNECTORS IGNITION ON PROBE CKT 240 8t 439 WITH TEST LIGHT TO GROUND IS THE LIGHT ON ON BOTH CIRCUITS YES FAULTY ECM GROUNDS ORECM REFER TO ECM QUAD DRIVER CHECK CHART C1 1 NO LOCATE AND CORRECT SHORT TO GROUND IN CIRCUIT THAT HAD A BLOWN FUSE 1 NO X REPAIR OPEN IN CIRCU...

Page 593: ... followed by any trouble code s stored in memory A steady light suggests a short to ground in the light control CKT 419 or an open in diagnostic CKT 451 Test Description Numbers below refer to circled numbers on the diagnostic chart 1 If there is a problem with the ECM that causes a Scan tool to not read serial data the ECM should not flash a Code 12 If Code 12 is flashing check for CKT 451 short ...

Page 594: ... STOPPED DIAGNOSTIC TERMINAL NOT GROUNDED BACK PROBE ECM CKT 451 WITH TEST LIGHT TO GROUND NO CODE 12 CHECK PROM FOR PROPER INSTALLATION IF OK REPLACE ECM USING ORIGINAL PROM RECHECK FOR CODE 12 NO CODE 12 REPLACE PROM YES SF PROBLEM WAS NO ALDL DATA CHECK SERIAL DATA CKT 461 FOR OPEN OR SHORT TO GND BETWEEN ECM AND ALDL CONNECTOR IF OK IT IS A FAULTY ECM OR PROM LIGHT ON REPAIR SHORT TO GROUND IN...

Page 595: ...not start without reference pulses and therefore the Scan should read rpm reference during crank 2 No spark may be caused by one of several components related to the ignition system CHART C 4 will address all problems related to the causes ofa no spark condition 3 The test light should blink indicating the ECM is controlling the injectors OK How bright the light blinks is not important However the...

Page 596: ...TERMINALS CHECK FOR BLINKING LIGHT WHILE CRANKING RECONNECT INJECTOR REPEAT TEST ON ANOTHER INJECTOR ON THE SAME BANK LIGHT SHOULD BLINK ON BOTH j BASIC HEI PROBLEM REFER TO CHART C 4 BLINKING LIGHT BOTH I IGNITION OFF INSTALL FUEL PRESSURE GAGE AND NOTE PRESSURE AFTER IGNITION ON SHOULD BE 32 47 psi 220 325 kPa OK Z E SEE DIAGNOSTIC AIDS ON FACING PAGE FOR ADDITIONAL ITEMS TO CHECK IF ALL OK FUEL...

Page 597: ...ly to injectors Due to the injectors wired in parallel there should be a light ON on both terminals 2 Checks continuity ofCKT 467 and 468 3 All checks made to this point would indicate that the ECM is at fault However there is a possibility of CKT 467 or 468 being shorted to a voltage source either in the engine harness or in the injector harness To test for this condition Disconnect the injector ...

Page 598: ...NECT ECM IGNITION ON PROBE TERMINALS D15 AND D16 IN ECM CONNECTOR WITH A TEST LIGHT TO GROUND LIGHT ON 1REFER TO FACING PAGE STEADY LIGHT CHECK INJECTOR DRIVER CIRCUIT WITH STEADY LIGHT FOR SHORT TO GROUND IF CIRCUIT IS NOT SHORTED CHECK RESISTANCE ACROSS EACH INJECTOR IN THE CIRCUIT RESISTANCE SHOULD BE GREATER THAN 10 OHMS OK x z FAULTY ECM NOT OK T REPAIR SHORT TO GROUND OR REPLACE ANY INJECTOR...

Page 599: ...within the regulator assembly 2 When the engine is idling the manifold pressure is low high vacuum and is applied to the fuel regulator diaphragm This will offset the spring and result in a lower fuel pressure This idle pressure will vary somewhat depending on barometric pressure however the pressure idling should be less indicating pressure regulator control 3 Pressure that continues to fall is c...

Page 600: ... 1 1of2 START AT I THIS POINT ON CHART OK START AND IDLE ENGINE AT NORMAL OPERATING TEMP PRESSURE SHOULD BE LOWER BY 21 69 KPA 3 10 PSI OK m NO TROUBLE FOUND REVIEW SYMPTOMS SECTION B OK H REPAIR VACUUM SOURCE TO REGULATOR NOT OK APPLY 10 INCHES OF VACUUM TO PRESSURE REGULATOR FUEL PRESSURE SHOULD DROP 21 69 KPa 3 10 PSI NOT OK REPLACE REGULATOR ASSEMBLY NOT OK PRESSURE BUT NOT HOLDING PRESSURE BU...

Page 601: ... PORT Test Description Numbers below refer to circled numbers on the diagnostic chart 1 If the fuse is blown this test will confirm a short to ground on CKT 120 To prevent misdiagnosis be sure fuel pump is disconnected before test 2 Determines if the pump circuit is ECM controlled The ECM will turn ON the pump relay Engine is not cranking or running so the ECM will turn OFF the relay within 2 seco...

Page 602: ...L O C K F U E L R E T U R N L I N E B Y P I N C H I N G F L E X I B L E H O S E A N D N O T E P R E S S U R E NOT OK X D I S C O N N E C T FUEL P U M P A T R E A R B O D Y C O N N E C T O R I G N I T I O N O F F P R O B E A L D L F U E L P U M P T E S T T E R M I N A L G C K T 1 2 0 W I T H A T E S T L I G H T T O 1 2 V O L T S L I G H T OFF zrzzi 3L LIGHT OH R E C O N N E C T FUEL J M P REPLACE F...

Page 603: ... pressure and provides a second battery feed path to the fuel pump If the relay fails the pump will continue to run using the battery feed supplied by the closed oil pressure switch A failed pump relay may result in extended engine crank time because of the time required to build enough oil pressure to close the oil pressure switch and turn ON the fuel pump There may be instances when the relay ha...

Page 604: ... PRESSURE SWITCH NO LIGHT LIGHT NO TROUBLE FOUND CHAIT A 7 Page 3 of 4 FUEL SYSTEM DIAGNOSIS 2 8L P SERIES PORT LIGHT OFF zx REPAIR OPEN GROUND CKT 450 LIGHT OFF I DISCONNECT ECM A B CONNECTOR AND CHECK FOR OPEN OR SHORT TO GROUND IN CKT 465 CKT465 OK I CKT 465 NOT OK CHECK RESISTANCE ACROSS PUMP RELAY PINS OPPOSITE HARNESS CONN TERMS A AND C SHOULD MEASURE 20 OHMS OR MORE I LEPAIR CKT 465 IF CKT ...

Page 605: ...Code 44 Also hard starting cold and overall poor performance Restricted flow causing pressure drop Normally a vehicle with a fuel pressure of less than 165 kPa 24 psi at idle will not be driveable However if the pressure drop occurs only while driving the engine will normally surge then stop as pressure begins to drop rapidly 2 Restricting the the fuel return line allows the fuel pump to develop i...

Page 606: ... G U L A T O R A S S E M B L Y F A U L T Y I N T A N K F U E L P U M P C O U P L I N G H O S E O R P U L S A T O R I N L E T F I L T E R W R O N G F U E L P U M P 1 A B O V E 3 2 5 K P A 4 7 P S I D I S C O N N E C T F U E L R E T U R N L I N E F L E X I B L E H O S E A T T A C H 5 1 6 D F L E X H O S E T O P R E S S U R E R E G U L A T O R S I D E O F R E T U R N L I N E I N S E R T T H E O T H E...

Page 607: ... starter solenoid and is controlled by a cold start switch which provides a ground path for the valve during cranking when engine coolant is below 95 F 35 C The cold start fuel injection switch contains a bimetal switch which opens at a specified coolant temperature This bimetal is also heated by the winding in the cold start fuel injection switch which allows the valve to stay ON for 8 seconds at...

Page 608: ...CT COLD START FUEL INJECTION SWITCH REPEAT TEST JL LIGHT NO LIGHT REPEAT TEST ON CKT 832 TAN WIRE REPAIR OPEN CKT 806 TO STARTER SOLENOID NO DROP I DROPS REPLACE COLD START FUEL INJECTION SWITCH CHECK FOR SHORTTO GND IN CKT 832 IF NOT SHORTED REPLACE COLD START VALVE LIGHT 3L NO LIGHT CONNECT OHMMETER BETWEEN 832 TERMINAL OF SWITCH AND GROUND CHECK RESISTANCE RESISTANCE GREATER THAN 200 OHMS RESIS...

Page 609: ...ne at normal operating temperature At least 2 minutes engine time after start O2 signal voltage steady between 35 and 55 volts RPM above 1600 Throttle position sensor signal above 12 about 5 volts above closed throttle voltage All conditions must be met for about 20 seconds If the conditions for a Code 13 exist the system will not go Closed Loop 2 This will determine if the sensor is at fault or t...

Page 610: ...UNNING DOES IT NO IGNITION ON ENGINE OFF CHECK VOLTAGE OF CKT 412 ECM SIDE AT 0 2 SENSOR HARNESS CONNECTOR USING A DVM IT SHOULD BE 3 6 VOLTS 300 600 mV 3 6 VOLTS 300 600 mV i OVER 6 VOLT 600 mV FAULTY ECM OPEN CKT413 FAULTY CONNECTION OR FAULTY ECM l YES r CODE 13 IS INTERMITTENT IF NO ADDITIONAL CODES WERE STORED REFER TO DIAGNOSTIC AIDS ON FACING PAGE 1 YES X FAULTY 0 2 SENSOR CONNECTION OR SEN...

Page 611: ...s the sensor resistance becomes less and the voltage drops At normal engine operating temperature 8 5 C to 9 5 C the voltage will measure about 1 5 to 2 0 volts Test D e s c r i p t i o n Numbers below refer to circled numbers on the diagnostic chart 1 Code 14 will set if Signal voltage indicates a coolant temperature above 1 3 5 C 275 F for 3 seconds Engine running longer than 20 seconds 2 This t...

Page 612: ...MITTENT IF NO ADDITIONAL CODES WERE STORED REFER TO DIAGNOSTIC AIDS ON FACING PAGE YES NO FAULTY SENSOR DIAGNOSTIC AID COOLANT SENSOR TEMPERATURE TO RESISTANCE VALUES APPROXIMATE F C OHMS 210 100 185 160 70 450 100 38 1 800 70 20 3 400 40 4 7 500 20 7 13 500 0 18 25 000 40 40 100 700 CKT 410 SHORTED TO GROUND OR CKT 410 SHORTED TO SENSOR GROUND CIRCUIT OR FAULTY ECM CLEAR CODES AND CONFIRM CLOSED ...

Page 613: ...ption Numbers below refer to circled numbers on the diagnostic chart 1 Code 15 will set if Ignition ON engine not running Coolant temperature less than 3 0 C 22 F for 3 seconds No Code 23 MAT temperature indicated above 2 5 C 13 F or Engine running longer than 1 min Signal voltage indicates a coolant temp less than 3 0 C 22 F for 3 seconds 2 This test simulates a Code 14 If the ECM recognizes the ...

Page 614: ...T IF NO ADDITIONAL CODES WERE STORED REFER TO DIAGNOSTIC AIDS ON FACING PAGE NO JUMPER CKT 410 TO GROUND SCAN SHOULD DISPLAY OVER 130 C DOES IT DIAGNOSTIC AID COOLANT SENSOR TEMP RATURE TO RESISTANCE VALUES APPROXIMATE F C OHMS 210 100 185 160 70 450 100 38 1 800 70 20 3 400 40 4 7 500 20 7 13 500 0 18 25 000 40 40 100 700 YES OPEN SENSOR GROUND CIRCUIT FAULTY CONNECTION OR FAULTY ECM NO X OPEN CK...

Page 615: ...the most important inputs used by the ECM for fuel control and for most of the ECM control outputs Test Description Numbers below refer to circled numbers on the diagnostic chart 1 Code 21 will set if Engine running less than 1600 TPS signal voltage is greater than 2 5 volts All conditions met for 2 seconds MAP less than 70 kPa With throttle closed the TPS should read less than 1 25 volts Ifit doe...

Page 616: ... TPS BELOW 2 VOLTS 200mV DOES IT YES NO CODE 21 IS INTERMITTENT IF NO ADDITIONAL CODES WERE STORED REFER TO DIAGNOSTIC AIDS ON FACING PAGE NO PROBE SENSOR GROUND CIRCUIT WITH A TEST LIGHT CONNECTED TO 12 VOLTS LIGHT ON LIGHT OFF FAULTY CONNECTION OR SENSOR OPEN SENSOR GROUND CIRCUIT OR FAULTY ECM CKT417 SHORTED TO VOLTAGE OR FAULTY ECM CLEAR CODES AND CONFIRM CLOSED LOOP OPERATION AND NO SERVICE E...

Page 617: ...y the ECM for fuel control and for most of the ECM control outputs Test Description Numbers below refer to circled numbers on the diagnostic chart 1 Code 22 will set if Engine running TPS signal voltage is less than about 2 volt for 2 seconds 2 Simulates Code 21 high voltage If the ECM recognizes the high signal voltage the ECM and wiring are OK 3 This simulates a high signal voltage to check for ...

Page 618: ...TPS OVER 4 0 V DOES IT NO NO CODE 22 IS IN rERMITTENT IF NO ADDITIONAL CODES WERE STORED REFER TO DIAGNOSTIC AIDS ON FACING PAGE YES PROBE CKT417 WITH A TEST LIGHT CONNECTED TO 12 VOLTS SCAN TOOL SHOULD DISPLAY TPS OVER 4 0 V DOES IT YES REPLACE SENSOR NO CKT 416 OPEN SHORTED TO GROUND FAULTY CONNECTION OR FAULTY ECM CKT417 OPEN SHORTED TO GROUND FAULTY CONNECTION OR FAULTY ECM CLEAR CODES AND CON...

Page 619: ... the diagnostic chart 1 Code 23 will set if A signal voltage indicates a manifold air temperature below 25 C 13 F for 3 seconds o Time since engine start is 1 minute or Engine not running MAT temperature less than 2 5 C 13 F No Code 15 Coolant temperature reading greater than 2 6 C 15 F 2 A Code 23 will set due to an open sensor wire or connection This test will determine if the wiring and ECM are...

Page 620: ... AID MAT SENSOR TEMPERATURE TO RESISTANCE VALUES APPROXIMATE F C OHMS 210 100 185 160 70 450 100 38 1 800 70 20 3 400 40 4 7 500 20 7 13 500 0 18 25 000 40 40 100 700 CODE 23 IS INTERMITTENT IF NO ADDITIONAL CODES WERE STORED REFER TO DIAGNOSTIC AIDS ON FACING PAGE NO JUMPER CKT 472 TO GROUND SCAN SHOULD DISPLAY TEMP OVER130 C DOES IT YES NO OPEN SENSOR GROUND CIRCUIT FAULTY CONNECTION OR FAULTY E...

Page 621: ...fer to circled numbers on the diagnostic chart 1 Code 24 will set if vehicle speed equals 0 mph when Engine speed is between 2000 and 4400 rpm TPS is less than 2 closed throttle Low load condition high vacuum Not in park or neutral All conditions met for 5 seconds These conditions are met during a road load deceleration Disregard Code 24 that sets when drive wheels are not turning 2 8 12 volts at ...

Page 622: ...VEL MAY DAMAGE THE DRIVE AXLES WITH ENGINE IDLING IN GEAR SCAN SHOULD DISPLAY MPH ABOVE 0 DOES IT NO IGNITION OFF DISCONNECT 15 WAY I P CONNECTOR IGNITION ON PROBE ECM SIDE OF 15 WAY LP CONNECTOR TERMINAL H WITH VOLTMETER TO GROUND SHOULD DISPLAY 10 VOLTS OR MORE DOES IT YES CODE 24 IS INTERMITTENT IF NO ADDITIONAL CODES WERE STORED REFER TO DIAGNOSTIC AIDS ON FACING PAGE YES IE CIRCUIT 437 OPEN O...

Page 623: ... ECM will see a high signal voltage As the air warms the sensor resistance becomes less and the voltage drops Test Description Numbers below refer to circled numbers on the diagnostic chart 1 Code 25 will set if Signal voltage indicates a manifold air temperature greater than 1 3 5 C 275 F for 2 seconds Time since engine start is 1 minute or longer Diagnostic Aids A Scan tool reads temperature of ...

Page 624: ...STIC AIDS ON FACING PAGE 1 NO CKT 472 SHORTED TO GROUND OR CKT 472 SHORTED TO SENSOR GROUND CIRCUIT OR FAULTY ECM YES DISCONNECT SENSOR SCAN SHOULD DISPLAY TEMPERATURE BELOW 30 C DOES IT YES FAULTY SENSOR DIAGNOSTIC AID MAT SENSOR TEMPERATURE TO RESISTANCE VALUES APPROXIMATE F C OHMS 210 100 185 160 70 450 100 38 1 800 70 20 3 400 40 4 7 500 20 7 13 500 0 18 25 000 40 40 100 700 CLEAR CODES AND CO...

Page 625: ...itch was not detected closed under the following conditions Coolant temperature greater than specified amount EGE duty cycle commanded by the ECM is greater than 50 Manifold pressure less than 25 kPa 7 vacuum All conditions above must be met for about 8 seconds Test Description Numbers below refer to circled numbers on the diagnostic chart 1 With the ignition on the solenoid should not be energize...

Page 626: ... CONNECT TEST LIGHT BETWEEN HARNESS TERMINALS A B FAULTY EGR SOLENOID CKT 901 SHORTED TO GROUND OR FAULTY ECM SEE ECM QUAD DRIVER CHECK CHART C 1 LIGHT ON CONNECT VACUUM PUMP TO EGR VALVE APPLY VACUUM AND OBSERVE VALVE LIGHT OFF CONNECT TEST LIGHT BETWEEN TERMINAL A A N D GROUND VALVE MOVES i FAULTY HOSE OR CONNECTION BETWEEN EGR SOLENOID AND EGR VALVE OR FAULTY EGR SOLENOID VALVE DOES NOT MOVE RE...

Page 627: ...r fails the ECM will substitute a fixed MAP value and use the throttle position sensor TPS to control fuel delivery Test Description Numbers below refer to circled numbers on the diagnostic chart 1 Code 33 will set when Signal is too high kPa greater than 69 kPa with A C OFF or greater than 75 kPa with A C ON for a time greater than 5 seconds TPS less than 1 6 Engine misfire or a low unstable idle...

Page 628: ...L CODES WERE STORED REFER TO DIAGNOSTIC AIDS ON FACING PAGE NO PROBE CKT 469 WITH A TEST LIGHT TO 12 VOLTS TEST LIGHT SHOULD LIGHT DOES IT CKT 432 SHORTED TO VOLTAGE SHORTED TO CKT 416 OR FAULTY ECM YES NO PLUGGED OR LEAKING SENSOR VACUUM HOSE OR FAULTY MAP SENSOR OPEN CKT 469 IGNITION ON ENGINE STOPPED VOLTAGES ALTITUDE VOLTAGE RANGE Meters Feet Below 305 Below 1 000 3 8 5 5V 305 610 1 000 2 000 ...

Page 629: ...ls the ECM will substitute a fixed MAP value and use the throttle position sensor TPS to control fuel delivery Test Description Numbers below refer to circled numbers on the diagnostic chart 1 Code 34 will set when signal voltage is too low kPa less than 13 and ignition is turned ON or Engine running greater than 1200 rpm and throttle open greater than 25 2 If the ECM recognizes the high MAP signa...

Page 630: ...VE JUMPER WIRE PROBE TERMINAL B CKT 432 WITH A TEST LIGHTTO 12 VOLTS IGNITION ON SCAN SHOULD READ OVER 4 VOLTS DOES IT YES FAULTY CONNECTION OR SENSOR NO CKT 416 OPEN OR SHORTED TO GROUND OR FAULTY ECM CKT 432 OPEN OR SHORTED TO GROUND OR FAULTY ECM IGNITION ON ENGINE STOPPED VOLTAGES ALTITUDE Meters Feet VOLTAGE RANGE Below 305 Below 1 000 3 8 5 5V 305 610 1 000 2 000 3 6 5 3V 610 914 2 000 3 000...

Page 631: ...dy light Disconnect ECM and turn the ignition ON and probe terminals to check for this condition Diagnostic Aids A slow unstable idle may be caused by a system problem that cannot be corrected by the IAC Scan counts will be above 60 counts if too low and 0 counts if too high If idle is too high stop engine Ignition ON Ground diagnostic terminal Wait a few seconds for IAC to seat then disconnect IA...

Page 632: ...ROUND IDLE RPM INCREASE I IDLE ENGINE FOR 1 MINUTE AND NOTE RPM RETURNS TO IDLE RPM RECORDED ABOVE IDLE AIR CONTROL CIRCUIT OK SEE FACING PAGE DIAGNOSTIC AIDS NO LIGHTS ONE OR MORE CIRCUITS CHECK FOR OPEN OR SHORT TO GROUND IN CIRCUIT WITH NO LIGHT I ARE ALL CIRCUITS O K 3 YES I CHECK RESISTANCE ACROSS IAC COILS SHOULD BE MORE THAN 20 OHMS BETWEEN IAC TERMINALS OPPOSITE HARNESS CONNECTOR TERMS A T...

Page 633: ...module will switch to EST but because the line is grounded there will be no EST signal A Code 42 will be set Test Description Numbers below refer to circled numbers on the diagnostic chart 1 Code 42 means the ECM has seen an open or short to ground in the EST or by pass circuits This test confirms Code 42 and that the fault causing the code is present 2 Checks for a normal EST ground path through ...

Page 634: ...R STILL CONNECTED TO ECM HARNESS CKT 423 AND GROUND AGAIN PROBE ECM HARNESS CKT 424 WITH THE TEST LIGHT CONNECTED TO 12 VOLTS AS TEST LIGHT CONTACTS CKT 424 RESISTANCE SHOULD SWITCH FROM UNDER 500 TO OVER 5 000 OHMS DOES IT NO LIGHT ON DISCONNECT DIST 4 WAY CONNECTOR NOTE OHMMETER THAT IS STILL CONNECTED TO CKT 423 AND GROUND RESISTANCE SHOULD HAVE GONE HIGH OPEN CIRCUIT DOES IT YES CKT 424 OPEN F...

Page 635: ...r Code 44 exists the block learn values will be around 150 Check O2 sensor wire Sensor pigtail may be mispositioned and contacting the exhaust manifold For intermittent ground in wire between connector and sensor MAP sensor A MAP sensor output that causes the ECM to sense a higher than normal vacuum will cause the system to go lean Disconnect the MAP sensor and if the lean condition is gone check ...

Page 636: ...TS 350 mV YES DISCONNECT 0 2 SENSOR WITH ENGINE IDLING SCAN SHOULD DISPLAY 02 SENSOR BETWEEN 35 VOLTS AND 55 VOLTS 350 mV AND 550 mV DOES IT YES REFER TO DIAGNOSTIC AIDS ON FACING PAGE NO CODE 44 IS INTERMITTENT IF NO ADDITIONAL CODES WERE STORED REFER TO DIAGNOSTIC AIDS ON FACING PAGE NO CKT 412 SHORTED TO GROUND OR FAULTY ECM CLEAR CODES AND CONFIRM CLOSED LOOP OPERATION AND NO SERVICE ENGINE SO...

Page 637: ...sts The block learn values will be around 115 Check Fuel pressure System will go rich if pressure is too high The ECM can compensate for some increase However if it gets too high a Code 45 may be set See fuel system diagnosis CHART A 7 For rich injector Perform injector balance test CHART C 2A For leaking injector See CHART A 7 For fuel contaminated oil HEI shielding An open ground CKT 453 ignitio...

Page 638: ...ED ABOVE 75 VOLTS 750 mV YES x DISCONNECT 0 2 SENSOR AND JUMPER HARNESS CKT 412 TO GROUND SCAN SHOULD DISPLAY 0 2 BELOW 35 VOLTS 350 mV DOES IT NO ICODE 45 IS INTERMITTENT IF NO ADDITIONAL CODES WERE STORED REFER TO DIAGNOSTIC AIDS ON FACING PAGE YES H_ REFER TO DIAGNOSTIC AIDS ON FACING PAGE NO r FAULTY ECM CLEAR CODES AND CONFIRM CLOSED LOOP OPERATION AND NO SERVICE ENGINE SOON LIGHT 5 27 87 7S3...

Page 639: ...K REPLACE CALPAK CLEAR MEMORY AND RECHECK IF CODE 52 REAPPEARS REPLACE ECM CLEAR CODES AND CONFIRM CLOSED LOOP OPERATION AND NO SERVICE ENGINE SOON LIGHT CODE 53 SYSTEM OVER VOLTAGE THIS CODE INDICATES THERE IS A BASIC GENERATOR PROBLEM CODE 53 WILL SET IF VOLTAGE AT ECM TERMINAL B2 IS GREATER THAN 17 1 VOLTS FOR 2 SECONDS CHECK AND REPAIR CHARGING SYSTEM SEE SECTION 6D CLEAR CODES AND CONFIRM CLO...

Page 640: ...oon light are operating 2 There are no trouble codes stored or there is a trouble code but no Service Engine Soon light 3 The fuel control system is operating OK by performing Field Service Mode Check Verify the customer complaint and locate the correct SYMPTOM below Check the items indicated under that symptom If the ENGINE CRANKS BUT WILL NOT RUN see CHART A 3 Several of the symptom procedures b...

Page 641: ...s 44 and 45 substitute a known good sensor and recheck A Scan tool can also be used by selecting the position of the suspected problem circuit and moving related wiring and connectors See Introduction to this section on how each Scan tool position can be used An intermittent Service Engine Soon light with no stored code may be caused by Ignition coil shorted to ground and arcing at spark plug wire...

Page 642: ...k for this condition Perform Fuel System Diagnosis CHART A 7 Remove spark plugs Check for wet plugs cracks wear improper gap burned electrodes or heavy deposits Repair or replace as necessary If engine starts but then immediately stalls open distributor by pass line If engine then starts and runs OK replace pickup coil HESITATION SAG STUMBLE Definition Momentary lack of response as the accelerator...

Page 643: ...nd result in a high but false signal voltage rich exhaust indication The electronic control module ECM will then reduce the amount of fuel delivered to the engine causing a severe driveability problem Remove spark plugs Check for cracks wear improper gap burned electrodes or heavy deposits Alsocheck condition ofdistributor cap rotor and spark plug wires LACK OF POWER SLUGGISH OR SPONGY Definition ...

Page 644: ...an RPM drop on all cylinders equal to within 50 rpm go to ROUGH UNSTABLE OR INCORRECT IDLE STALLING symptom Reconnect IAC motor 3 If there is no RPM drop on one or more cylinders or excessive variation in drop check for spark on the suspected cylinder s with J 26792 ST 125 Spark Gap Tool or equivalent If no spark see Section 6D for Intermittent Operation or Miss If there is spark remove spark plug...

Page 645: ...d recheck fuel economy Suggest driver read Important Facts on Fuel Economy in Owner s Manual Check for proper calibration of speedometer Visually physically Check Vacuum hoses for splits kinks and proper connections as shown on Vehicle Emission Control Information label Ignition wires for cracking hardness and proper connections Air cleaner element filter for dirt or being plugged o Remove spark p...

Page 646: ...lator assembly Ignition system wires plugs rotor etc Run a cylinder compression check See Section 6 Inspect Oxygen sensor for silicon contamination from fuel or use of improper room temperature vulcanizing RTV sealant The sensor will have a white powdery coating and will result in a high but false signal voltage rich exhaust indication The electronic control module ECM will then reduce the amount ...

Page 647: ...er completing test described below be sure to coat threads of O2 sensor with anti seize compound P N 5613695 or equivalent prior to re installation 2 3 rn GAGE m HOSE A N D NIPPLE ADAPTER m A I R PIPE EXHAUST PORT fTI CHECK VALVE 7S 3363 6E j E G EXHAUST MANIFOLD fTI OXYGEN 02 SENSOR fT BACK PRESSURE GAGE 7S 3338 6E DIAGNOSIS 1 With the engine idling at normal operating temperature observe the exh...

Page 648: ...DRIVEABILITY AND EMISSIONS FUEL INJECTION PORT 6E3 B 9 BLANK ...

Page 649: ...C3 1 C4 Ignition System EST Page C4 1 C7 Exhaust Gas Recirculation EGR System Page C7 1 C8 Transmission Transaxle Converter Clutch TCC Page C8 1 C10 ECM Controlled Air Conditioning Page C10 1 C13 Positive Crankcase Ventilation PCV Paged3 1 DIAGNOSTIC CHARTS The Diagnostic Charts for each system are found after the on car service and parts information at the back of each section Following are the c...

Page 650: ...c C1 5 ELECTRONIC CON TvOL MODULE ECM C1 5 PROM CALPAK CI 6 Functional Check c o C1 7 COOLANT S E N S O R CI 7 MAP SENSOR CI 7 MATSENSCR 1 7 OXYGEN SENSOR Cl 8 THROTTLE POSITION SEMSOR TPS C1 B PARK NEUTRAL SWITCHe c C1 9 PARTS INFORMATION CI 9 ECM Function The ECM supplies either 5 or 12 volts to power various sensors or switches This is done through resistances in the ECM which are so high in va...

Page 651: ... properly repair a problem M a n i f o l d Air Temperature MAT Sensor The manifold air temperature MAT sensor is a thermistor a resistor which changes value based On temperature mounted in the Air Cleaner Assy Low temperature produces a high resistance 100 000 ohms at 40 C 40 F while high temperature causes low resistance 70 ohms at 130 C 266 F The ECM supplies a 5 volt signal to the sensor thru a...

Page 652: ... valve opens the output increases so that at wide open throttle the output voltage should be approximately 5 volts By monitoring the output voltage from the TPS the ECM can determine fuel delivery based on throttle valve angle driver demand Failure in the TPS circuit will set a Code 22 low voltage or Code 21 voltage too high 17 N m 12 5 FT LBS fTI T H R O T T L E BODY 4 AIR PLENUM T1 T P S j f COL...

Page 653: ...elays controlled by the ECM See ECM wiring diagram for the solenoid s and relay s and the coil terminal identification J34636 or BT 8405 testers or equivalent provide a fast accurate means ofchecking for a shorted coil or a short to battery voltage The PROM may be faulty Although the PROM rarely fails it operates as part of the ECM Therefore it could be the cause ofthe problem The replacement ECM ...

Page 654: ...tools Refer to CHART C 1A for P N switch diagnosis A C Request Signal If the pressure cycling switch is closed and A C is ON the Scan tool should indicate A C ON See Section CIO for electrical system diagnosis Reference Signal A Scan tool will read this signal and is displayed in RPM See Section C4 for more information on the Ignition System ON CAR SERVICE ELECTRONIC CONTROL MODULE ECM Service of ...

Page 655: ...nt Using the rocker type PROM removal tool engage one end of the PROM carrier with the hook end of the tool see Figure Cl 9 Press on the vertical bar end of the tool and rock the engaged end of the PROM carrier up as far as possible Engage the opposite end of the PROM carrier in the same manner and rock this end up as far as possible Repeat this process until the PROM carrier and PROM are free of ...

Page 656: ...ecessary to remove the PROM follow instructions If installed backwards REPLACE THE PROM The CALPAK may be removed and reinstalled correctly If pins bend remove PROM or CALPAK straighten pins and reinstall If bent pins break or crack during straightening discard PROM OR CALPAK and replace it GRASP CALPAK CARRIER AT NARROW ENDS ONLY fTI CALPAK IT1REMOVALTOOL 5S1526 6E Figure C 1 1 1 Removing CALPAK ...

Page 657: ... special anti seize compound is used on the oxygen sensor threads The compound consists of a liquid graphite and glass beads The graphite will burn away but the glass beads will remain making the sensor easier to remove 1 0 2 SENSOR 5S1916 6E Figure C1 13 Oxygen Sensor New or service sensors will already have the compound applied to the threads If a sensor is removed from an engine and if for any ...

Page 658: ...3B 4 or 7A Also Section 8A contains information onthe P N switch PARTS INFORMATION PART NAME GROUP Controller ECM 3 670 Calibrator PROM 3 670 CALPAK 3 670 Sensor Coolant Temp 3 682 Sensor Exhaust Oxygen 3 682 Sensor Manifold Absolute Sensor MAP 3 682 Sensor Manifold Air Temp MAT 3 682 Sensor Throttle Position Part of Sensor Kit Throttle Position 3 440 Sensor Vehicle Speed 3 682 ...

Page 659: ...ur different circuits ECM service part number 1227170 used with this engine does not have fault protection therefore a single faulty circuit many times causes all four QDR outputs to be inoperative or ON all the time A failed QDR usually results in either a shorted or open ECM output Because of the increased current flow two QDR outputs are used to drive the TCC solenoid Refer to the ECM QDR check...

Page 660: ... WAS CONNECTED TO THE VEHICLE CIRCUIT MOST LIKELY TO HAVE CAUSED THE QDR FAILURE DISCONNECT THE COMPONENT IN THAT VEHICLE CIRCUIT AND CHECK FOR A SHORT TO VOLTAGE IF THE CIRCUIT IS NOT SHORTED TO VOLTAGE REPLACE THE COMPONENT IN THAT CIRCUIT AND THE ECM ECM 1227170 QDR NUMBER ECM OUTPUT TERMINAL CIRCUIT 1 A2 NOTUSED 1 A4 EGR CONTROL 1 A5 SES LIGHT 2 A3 NOTUSED 2 D2 NOT USED 3 A7 SHIFT LIGHT M T TC...

Page 661: ... closed switch when the voltage on CKT 434 drops to less than one volt The ECM uses the P N signal as one ofthe inputs to control Idle Air Control Vehicle Speed Sensor Diagnostics Exhaust Gas Recirculation If CKT 434 indicates P N grounded while in drive range the EGR would be inoperative resulting in possible detonation If CKT 434 indicates drive open a dip in the idle may exist when the gear sel...

Page 662: ...T P N SWITCH THIS SHOULD CAUSE SCAN TO DISPLAY DRIVE RANGE DOES IT NO DISCONNECT PARK NEUTRAL SWITCH CONNECTOR JUMPER TERMINALS A TO B CKT 434 TO 450 SCAN SHOULD INDICATE PARK OR NEUTRAL DOES IT YES HZ FAULTY P N SWITCH CONNECTION OR P N SWITCH MISADJUSTED OR FAULTY NO uz JUMPER TERMINAL A CKT 434 TO ENGINE GROUND SCAN SHOULD INDICATE PARK OR NEUTRAL DOES IT YES l P N SWITCH MISADJUSTED OR FAULTY ...

Page 663: ...arometric pressure and to help calculate fuel delivery Test Description Numbers below refer to circled numbers on the diagnostic chart 1 Checks MAP sensor output voltage to the ECM This voltage without engine running represents a barometer reading to the ECM 2 Applying 34 kPa 10 inches Hg vacuum to the MAP sensor should cause the voltage to be 1 2 volts less than the voltage at Step 1 Upon applyng...

Page 664: ...ND CHECK MAP HOSE FOR LEAKAGE OR RESTRICTION BE SURE THIS HOSE S U P P L I E S V A C U U M T O MAP S E N S O R O N L Y l N O T O K CHECK SENSOR CONNECTION IF OK REPLACE SENSOR ALTITUDE VOLTAGE RANGE Meters Feet Below 305 Below 1 000 3 8 5 5V 305 610 1 000 2 000 3 6 5 3V 610 914 2 000 3 000 3 5 5 1V 914 1219 3 000 4 000 3 3 5 0V 1219 1524 4 000 5 000 3 2 4 8V 1524 1829 5 000 6 000 3 0 4 6V 1829 213...

Page 665: ...6E3 C1 16 DRIVABIUTY AND EMISSIONS FUEL INJECTION PORT BLANK ...

Page 666: ...erate most efficiently Because of the constant measuring and adjusting of the air fuel ratio the fuel injection system is called a Closed Loop System shown in Figure C2 1 MODES OF OPERATION The ECM looks at voltages from several sensors to determine how much fuel to give the engine The fuel is delivered under one of several conditions called modes All the modes are controlled by the ECM and are de...

Page 667: ... the maximum time the switch stays closed is proportional to the coolant temperature In other words as the coolant temperature goes up the maximum cold start valve ON time goes down Clear Flood Mode If the engine floods clear it by pushing the accelerator pedal down all the way The ECM then pulses the injectors at an air fuel ratio of 20 1 T1 COLD START FUEL INJECTION SWITCH P H COOLING FAN SWITCH...

Page 668: ...s Pressure regulator Throttle body assembly including Idle air control IAC valve Throttle position sensor TPS Fuel pump Fuel pump relay 2 3 4 BASIC SYSTEM OPERATION The fuel control system Figure C2 4 starts with the fuel in the fuel tank An electric fuel pump located in the fuel tank with the gage sending unit pumps fuel to the fuel rail through an in line fuel filter The pump is designed to prov...

Page 669: ...ctronic control module ECM that meters pressurized fuel to a single cylinder see Figure C2 7 The ECM energizes the solenoid which opens a valve to allow fuel delivery The fuel under pressure is injected in a conical spray pattern at the opening of the intake valve The fuel which is not used by the injectors passes through the pressure regulator before being returned to the fuel tank An injector th...

Page 670: ...ss air is bypassed around the throttle valve to decrease rpm IDLE AIR CONTROL IAC VALVE A S S E M B L Y IAC VALVE PINTLE PH IDLE AIR HOUSING T H R O T T L E VALVE THROTTLE BODY A S S E M B L Y E L E C T R I C A L INPUT S I G N A L flTI AIR INLET 8PQ331 SY Figure C2 10 IAC Valve Air Flow Diagram Typical The IAC valve moves in small steps called counts which can be measured by some test equipment wh...

Page 671: ...nds the ECM will shut the fuel pump OFF and wait until the engine starts As soon as the engine is cranked the ECM will turn the relay ON and run the fuel pump As a backup system to the fuel pump relay the fuel pump can also be turned ON by the oil pressure switch The oil pressure switch is a normally open switch which closes when oil pressure reaches about 28 kPa 4 psi If the fuel pump relay fails...

Page 672: ... accidental start disconnect and reconnect the negative battery cable before and after service is performed Where Delco Loc tm radio is installed on Pontiac cars refer to NOTICE in beginning of Section 9A to reactivate radio CAUTION To minimize the risk of fire and personal injury relieve the fuel system pressure before servicing the fuel rail or any of its fuel handling components See Fuel Pressu...

Page 673: ...rocedure 2 Cold start valve line at fuel rail fitting 3 Cold start tube o ring seal and discard 4 Fuel lines at rail 5 Fuel inlet and return line o rings and discard 6 Vacuum line at pressure regulator 7 Injector electrical connectors 8 Rail retaining bolts 9 Fuel rail assembly NOTICE Use care In removing the fuel rail assembly to prevent damage to the injector electrical connector terminals and t...

Page 674: ... Assembly 27 Seal Fuel Pressure Connection Assembly 28 Cap Fuel Pressure Connection 55 Fuel Block 56 Seal Fuel Block 57 Screw Assembly Fuel Block Attaching 85 Injector Port 86 O ring Seal Injector 87 Clip Injector Retainer 100 Valve Cold Start 101 Tube and Body Assembly 102 O ring Seal Valve 103 O ring Seal Body 104 O ring Seal Tube 8P0132 XV Figure C2 14 Model R610 F6A Fuel Rail Assembly ...

Page 675: ...e new o ring seals and install on tube and body assembly cold start valve and fuel rail fitting 2 Cold start valve onto tube and body assembly Screw in valve until it bottoms then back off until hole in valve mounting lug will be aligned with hole in intake manifold when assembly is mounted Bend tab over cold start valve to lock it in position j Install or Connect 1 Cold start valve into port in i...

Page 676: ...emblies T i g h t e n 5 Attaching screw assemblies to 5 0 N m 44 0 lb in Fuel inlet and return lines T i g h t e n Fittings to 23 7 N m 17 5 lb ft Use back up wrench on inlet and outlet fittings to prevent them from turning FUEL RAIL PORT INJECTOR INJECTOR RETAINER CLIP CLIP 8N LOCKED POSITION CLIP IN RELEASED POSITION 8PU950 AS Figure C2 18 Port Fuel Injector MANUFACTURE DATE CODE MANUFACTURERS O...

Page 677: ...tch Install or Connect 4 1 Coat threads with pipe sealant 2 Cold start fuel injection switch 3 Electrical connector 17 N m 12 5 FT LBS T THROTTLE BODY fT AIR PLENUM f T T P S jT COLD START V A L V E AIR TUBE T G A S K E T f 6 L A C V A L V E 5 S1919 6E Figure C2 20 Throttle Body Assembly Removal THROTTLE BODY ASSEMBLY Replacement Figure C2 20 The throttle body assembly repair procedures cover comp...

Page 678: ...o J 37027 or BT 8256K However if the valve pintle is extended electrically it must also be retracted electrically Under no circumstances should the valve pintle be tampered with by hand screwed or pushed in or pulled out as damage could occur Clean Gasket mounting surface of throttle body assembly to ensure a good seal NOTICE The IAC valve assembly is an electrical component and must not be soaked...

Page 679: ...icle is operated FUEL PUMP RELAY The fuel pump relay is mounted in the engine compartment in front of the air cleaner assembly Other than checking for loose connectors the only service possible is replacement PARTS INFORMATION PART NAME GROUP Injector fuel 3 330 Pump Fuel In Tank 3 900 Relay Fuel Pump 3 900 Switch Oil Pressure 1 800 Valve Asm Idle Air Control Part OfControl Kit Idle Air Valve 3 82...

Page 680: ...DRIVEABIIITY AND EMISSIONS FUEL INJECTION PORT 6E3 C2 15 BLANK V I ...

Page 681: ...ition must be OFF at least 10 seconds to complete ECM shutdown cycle Fuel pump should run about 2 seconds after ignition is turned ON At this point insert clear tubing attached to vent valve into a suitable container and bleed air from gauge and hose to insure accurate gauge operation Repeat this step until all air is bled from gauge STEP 2 Turn ignition OFF for 10 seconds and then ON again to get...

Page 682: ...is bled from gauge Step 2 Run test 1 Ignition OFF for 10 seconds 2 Ignition ON Record gauge pressure Pressure must hold steady if not see the Fuel System diagnosis Chart A 7 in Section A 3 Turn injector on by depressing button on injector tester and note pressure at the instant the gauge needle stops Step 3 1 Repeat step 2 on all injectors and record pressure drop on each Retest injectors that app...

Page 683: ...6E3 C2 18 DRIVEABILITY AND EMISSIONS FUEL INJECTION PORT BLANK ...

Page 684: ...which lifts the valve diaphragm and opens the valve The lower Tube on the purge valve PCV Tube is connected to a timed port above the throttle valve The rate of purge is controlled through this port by throttle location To increase the capacity of the fuel tank there is a vapor storage tank located near the fuel tank RESULTS OF INCORRECT OPERATION Evidence of fuel loss or fuel vapor odor can be ca...

Page 685: ...he canister has a constant purge hole With hand vacuum pump apply vacuum 15 Hg or 51 kPa through the control valve tube upper tube The diaphragm should hold vacuum for at least 20 seconds If it does not hold vacuum the canister must be replaced If the diaphragm holds vacuum again try to blow through the hose connected to the lower tube while vacuum is still being applied An increased flow of air s...

Page 686: ...en or grounded bypsss circuit will set a Code 42 and the engine will run at base timing plus a small amount of advance built into the HEI module EST CKT 423 This circuit triggers the HEI module The ECM does not know what the actual timing is but it does know when it gets the reference signal CC DE 1 2 e e 9 e e o e o o o C4 ON CAR SERVICE 9 C4 2 SETTING TlfVJING o e e c e C4 2 PARTS INFORMATION C4...

Page 687: ...INJECTION PORT ON CAR SERVICE S E T T I N G T I M I N G The timing is set by following the procedures on the Vehicle Emission Control Information label PARTS INFORMATION PART NAME GROUP Module Distr 2 383 Coil D l S t r e 0 a o a o e o e 2 1V0 ...

Page 688: ...DRIVEABILITY AND EMISSIONS FUEL INJECTION PORT 6E3 C4 3 BLANK ...

Page 689: ... normal voltage should be about 12 volts Ifthe module is turned ON the voltage would be low but above 1 volt This could cause the ignition coil to fail from excessive heat With an open ignition coil primary winding a small amount of voltage will leak through the module from the Bat to the tach terminal 4 5 Applying a voltage 1 5 to 8 volts to module terminal P should turn the module ON and the tac...

Page 690: ... C term to ign coil If Ckt is OK fault is ign coil or conn Over 10 w i t s 1 3E Connect test light from tach term to ground Crank engine and observe light Under 1 volt z z z z 1 to 10 volts Repair open tach lead or conn and repeat test 4 Replace module and check for spark from coil as in Step 6 Light on steady i _ Disconnect distributor 4 term connector Remove dist cap Disconnect pick up coil conn...

Page 691: ...6E3 C4 6 DRIVEABILITY AND EMISSIONS FUEL INJECTION PORT BLANK J ...

Page 692: ...VE The electronic vacuum regulator valve EVRV uses pulse width modulation to control EGR flow This means the electronic control module ECM turns the solenoid ON and OFF many times a second and varies the amount of ON time pulse width to vary the amount of EGR The ECM uses information from the following sensors to enable the EVRV Throttle position sensor TPS P N Switch Manifold absolute temperature...

Page 693: ...ausing the engine to run roughly or stop and any of the following could happen Engine stops after cold start Engine stops at idle after deceleration Car surges during cruise Rough idle If the EGR valve should stay open all of the time the engine may not idle Too little or no EGR flow allows combustion temperatures to get too high during acceleration and load conditions This could cause Spark knock...

Page 694: ...uild up with a screwdriver 3 Clean mounting surfaces of intake manifold and valve assembly Install or Connect 1 EGR valve using new gasket 2 Bolts and tighten to 18 N m 14 lb ft 3 Vacuum line to valve ELECTRONIC VACUUM REGULATOR VALVE Remove or Disconnect 1 Negative battery cable 2 Electrical connector at regulator valve 3 Vacuum hoses 4 Nut and regulator valve Install or Connect 1 Regulator valve...

Page 695: ...s vacuum to the EGR with the EGR diagnostic switch Code 32 will detect a faulty solenoid vacuum switch or vacuum supply CHART C 7 checks for plugged EGR passages a sticking EGR valve or a stuck open solenoid Test Description Numbers below refer to circled numbers on the diagnostic chart 1 With the ignition ON engine stopped the solenoid should not be energized and vacuum should not pass to the EGR...

Page 696: ... EGR VALVE ENGINE AT NORMAL OPERATING TEMP IN DRIVE AUTOMATIC TRANS HOLD BRAKES AND ACCELERATE MOMENTARILY UP TO ABOUT 1800 RPM OBSERVE GAGE SHOULD HAVE OVER 2 VACUUM BUT LESS THAN 10 OK IE NOT OK NO TROUBLE FOUND EGR SYSTEM OK CHART C 7 EXHAUST GAS RECIRCULATION EGR CHECK 2 8L P SERIES PORT VALVE MOVES ri DISCONNECT EGR SOLENOID ELECTRICAL CONNECTOR REPEAT TEST VALVE MOVES I VALVE DOES NOT MOVE R...

Page 697: ...6E3 C7 6 DRIVEABILITY AND EMISSIONS FUEL INJECTION PORT BLANK ...

Page 698: ... clutch can apply Coolant Temperature Sensor Engine must be warmed up before clutch can apply Throttle Position Sensor TPS After the converter clutch applies the ECM uses the information from the TPS to release the clutch when the car is accelerating or decelerating at a certain rate Another switch used in the TCC circuit is a brake switch which opens the 12 volt supply to the TCC solenoid when th...

Page 699: ...ON CAR SERVICE See Section 7 for TCC Solenoid See Section 8B for VSS IP mounted and brake system SHIFT LIGHT DIAGNOSIS The shift light circuit can be checked using CHART C 8B ON CAR SERVICE See Section 6E to repair wiring problem See Section 6E3 C1 5 ifECM is to be replaced PARTS INFORMATION PART NAME GROUP Sensor Vehicle Speed 9 761 Solenoid TCC 4 122 Description The purpose of the shift light is...

Page 700: ...DRIVEABILITY AND EMISSIONS FUEL INJECTION PORT 6E3 C8 3 ...

Page 701: ...hrottle position sensor output not changing indicating a steady road speed Transmission third gear switch closed Brake switch closed Test Description Numbers below refer to circled numbers on the diagnostic chart Diagnostic Aids i 2 Light OFF confirms transmission third gear apply switch is open At 25 mph the transmission third gear apply switch should close Test light will come on and confirm bat...

Page 702: ...RAKE PEDAL IS DEPRESSED DOES IT YES HZ IGNITION ON ENGINE STOPPED INSTEAD OF GROUND CONNECT TEST LIGHT TO 12 VOLTS AND PROBE ALDL TERMINAL F GROUND DIAGNOSTIC TERMINAL AND NOTE LIGHT NO Z 3 Z FAULTY BRAKE SWITCH OR ADJUSTMENT LIGHT ON CHECK FOR CORRECT PROM IF OK TCC ELECTRICAL CONTROL IS OK LIGHT OFF CHECK FOR OPEN CKT 422 FROM ALDL TO ECM CONNECTOR TERMINAL IF OK ST IS FAULTY ECM REFER TO ECM QU...

Page 703: ... control the shift light Coolant temperature TPS VSS RPM The ECM uses the measured rpm and the vehicle speed to calculate what gear the vehicle is in It s this calculation that determines when the shift light should be turned ON Test Description Numbers below refer to circled numbers on the diagnostic chart 1 This should not turn ON the shift light If the light is ON there is a short to ground in ...

Page 704: ...O GROUND AND NOTE SHIFT LIGHT LIGHT OFF LIGHT ON 1 CHECK FOR CODE 24 CHART NO VSS THERMOSTAT FAULTY OR INCORRECT HEAT RANGE IF OK REVIEW SYMPTOMS IN SECTION B LIGHT ON LIGHT ON I IGNITION OFF DISCONNECT ECM CONNECTORS IGN ON AND NOTE SHIFT LIGHT LIGHT ON REPAIR SHORT TO GROUND IN CKT 456 1 LIGHT OFF FAULTY ECM SEE ECM QUAD DRIVER CHECK CHART C 1 CHECK AND REPAIR OPEN IGNITION CKT 39 OPEN CKT 456 F...

Page 705: ...6E3 C8 8 DRIVEABILITY AND EMISSIONS FUEL INJECTION PORT BLANK ...

Page 706: ...increase idle speed before turning onA C to improve the quality The low pressure switch mounted in the compressor is closed when the system contains a sufficient refrigerant charge This switch opens when pressure is less than about 40 psi 276 kPa The high pressure cut out switch normally closed opens when head pressure gets too high This disables the A C clutch before damage can occur to the syste...

Page 707: ... pressure cycling switch This same voltage is supplied as a signal to ECM pin B8 After a time delay ofabout 1 2 second the ECM will ground terminal C2 CKT 458 and close the A C relay contacts When relay is energized battery voltage from CKT 50 is supplied to the A C clutch through the relay and CKT 59 Test Description Numbers below refer to circled numbers on the diagnostic chart 1 The ECM will on...

Page 708: ... 2 8L P SERIES PORT YES ZZH DISCONNECT A C RELAY PROBE CKT 459 WITH A TEST LIGHT TO 12 VOLTS YES H Z LIGHT ON A C CIRCUIT OK REFER TO DIAGNOSTIC AIDS ON FACNG PAGE NO CKT 459 SHORTED TO GROUND OR FAULTY ECM SEE ECM QUAD DRIVER CHECK CHART C 1 LIGHT OFF ZIZZ FAULTY RELAY DISCONNECT PRESS CYCLING SWITCH PROBE CKT 66 WITH A TEST LIGHT TO GROUND LIGHT ON LIGHT OFF JUMPER HARNESS TERMINALS TOGETHER SCA...

Page 709: ...6E3 C10 4 DRIVEABILITY AND EMISSIONS FUEL INJECTION PORT BLANK ...

Page 710: ...ombustion RESULTS OF INCORRECT OPERATION Aplugged valve or hose may cause Rough idle Stalling or slow idle speed Oil leaks Oil in air cleaner Sludge in engine A leaking valve or hose would cause Rough idle Stalling High idle speed DIAGNOSIS FUNCTIONAL CHECK OF PCV VALVE If an engine is idling rough check for a clogged PCV valve or plugged hose Replace as required Use the following procedure 1 Remo...

Page 711: ...ble cause and correct to ensure that system will function as intended ON CAR SERVICE An engine which is operated without any crankcase ventilation can be damaged Therefore it is important to replace the PCV valve and air cleaner breather at intervals shown in Section OB Periodically inspect the hoses and clamps and replace any showing signs of deterioration PARTS INFORMATION PART NAME GROUP Air Cl...

Page 712: ...type and requires a graphoil seal MUFFLER The muffler is a tri flow design located at the rear of the vehicle mounted transversely The com plete exhaust system is a one piece design constructed of stainless steel HANGER Spring type hangers are used to support the complete exhaust system The installation of exhaust system supports is very important as improperly installed supports can cause annoyin...

Page 713: ... SHELL 2 O U T L E T 7 1NSULAT10W 3 OXIDATION C A T A L Y S T 8 FILL PLUG 4 I N L E T 9 INSULATION _ A R m L E J FILL PS UG 5 RETAINER 1 0 AIR PLENUM A 8 R MANAGEMENT SYSTEM 5200046F Figure 4 Dual Bed Pellet 2 Catalyst Types Oxidation Catalyst Three Way Reduction Catalyst The oxidation catalyst is coated with a catalytic material containing platinum and palladium which lowersw levels of hydrocarbo...

Page 714: ...NVERTER J10001 6F P MUFFLER ASM 520021 6F Figure 5 Exhaust System LR8 Figure 6 Exhaust System L44 1 CONVERTER 2 BRACKET 3 SPRING MUST BE INSTALLED AS SHOWN 4 FRAME 5 MUFFLER 6 8 N m 71 LBS IN Figure 7 Exhaust System Spring Installation ...

Page 715: ... EXHAUST SYSTEM 1 MUFFLER ASSEMBLY 2 HANGER 3 CLAMP 4 FRAME ASSEMBLY J10003 6F P Figure 8 Muffler and Tailpipe L44 1 MUFFLER ASSEMBLY 2 FRAME ASSEMBLY 3 HANGER J10006 6F P Figure 9 Muffler and Tailpipe LR8 ...

Page 716: ...N 5 EXHAUST MANIFOLD FRONT 6 EXHAUST MANIFOLD REAR Figure 10 Exhaust Crossover Pipe 1 BRACKETS 3 HEAT SHIELD 2 BODY ASSEMBLY 4 2 N m 18 LBS IN J10004 6F P 1 BRACKETS 3 HEAT SHIELD 2 TORQUE BAR 4 1 5 N m 13 LBS IN J10005 6F P Figure 1 1 Muffler Heat Shield Figure 12 Converter Heat Shield ...

Page 717: ...1 ...

Page 718: ... the inside of each vehicle at the assembly plant Refer to Section OA of this Service Manual for label location and information TRANSAXLE DEFINITIONS The following definitions are being provided to establish a common language and assist the user in describing transaxle related conditions Some of these terms or conditions are used in the transaxle sections of this Service Manual Throttle Positions ...

Page 719: ...theshift occurs before the vehicle has reached a proper speed and tends to labor the engine after the upshift E n d B u m p a firmer feel at the endofa shift as compared to the feel at the start of the shift Also defined as END FEEL or SLIP BUMP F i r m a noticeable quick apply of a clutch or band that is considered n o r m a l with a medium to heavy throttle shift Should not be confused with HARS...

Page 720: ... AND VIBRATION ANALYSIS A noise or vibration that is noticeable when the vehicle is in motion MAY NOT be the result of the transaxle If noise or vibration is noticeable in Park P and Neutral N with engine at idle but is less noticeable as RPM increases the cause may be from poor engine performance nspect Tires for Uneven wear Imbalance Mixed sizes Mixed radial and bias ply Refer to Section 3E Susp...

Page 721: ...rk vehicle on level ground 2 Apply parking brake and block wheels 3 Start engine and operate vehicle for 15 minutes or until a normal operating temperature is reached 4 Move gear selector through all gear positions 5 Move gear selector to Park P 6 Check fluid level color and condition ...

Page 722: ...OR EXTERNAL LEAKS REFER TO SECTION 7A1 ADD FLUID TO OBTAIN PROPER LEVEL HIGH REMOVE E X C E S S FLUID FOAMS REMOVE E X C E S S FLUID BROWN LOCATE SOURCE OF CONTAMINATION REFER TO SECTION 6B TRANSAXLE OVERHAUL REQUIRED REFER TO UNIT REPAIR SECTION RECHECK COLOR AND LEVEL CHECK FOR CONTAMINATION REFER TO SECTION 7A1 PERFORM ROAD TEST REFER TO HYDRAULIC DIAGNOSIS SECTION UNUSUAL REFER TO SECTION 7A1 ...

Page 723: ...t ...

Page 724: ... Lo and Reverse Pipes 7A1 13 Parking Pawl Shaft 7A1 13 Intermediate Servo and or Accumulator Check Valve 7A1 14 Governor 7A1 14 Filler Tube 7A1 14 Valve Body Cover 7A1 14 Auxiliary Valve Body Valve Body and Oil Pump 7A1 14 Transaxle Side Case Cover 7A1 15 Drive Link Assembly Chain 7A1 15 Oil Cooler Lines and or Fitting 7A1 16 Drive Axle Seals 7A1 16 Transmission Assembly 7A1 16 MAINTENANCE AND ADJ...

Page 725: ...E F I L L CHECK FOR WATER IN FLUID OR HIGH F L U I D L E V E L DRAIN EXCESS FLUID CHECK FOR COOLANT CONTAMINATION MAKE FUNCTIONAL CHECK CHECK FOR COOLANT OR BURNED CLUTCHES CHECK TV C A B L E MANUAL LINKAGE ADJUSTMENT PERFORM ROAD TEST R E F E R TO DIAGNOSTIC CHARTS AND PRESSURE TESTS G20027 7A Figure 1 Preliminary Checking Procedure ROAD TEST PROCEDURE Important Perform the road test in an organi...

Page 726: ...taminated or lost viscosity 6 Control valve spring weak 7 Control valve and pump bolts loose 8 Control valve assembly Check ball missing or off location Stuck or damaged valves T V valve and plunger Shift T V valve Pressure regulator valve T V valve loose Pressure relief valve 1 2 accumulator piston and or seal leaking or missing Internal leaks 9 Low only Low blow off valve damaged check ball miss...

Page 727: ... as a brightly colored path leading to the source See kit directions for the color of the fluid and dye mix REPAIRING THE LEAK Once the leak has been pinpointed and traced back to its source the cause of the leak must be deter mined in order for it to be repaired properly If a gasket is replaced but the sealing flange is bent the new gasket will not repair the leak The bent flange must be repaired...

Page 728: ...cal problems from internal electrical or mechanical ones Refer to General Service Procedures for individual compo nent test procedures U Important Use only a scale type ohmmeter High impediance type ohmmeters and those with a digital readout will not work An ALCL scanner may be used to verify the ground path Remember a completed ground does not indicate that a circuit carries current Do not bench ...

Page 729: ...ANGING FLUID AND FILTER 1 Raise vehicle and suitably support See Section OA 2 Place drain pan under transaxle oil pan 3 Oil pan bolts front and sides 4 Loose rear oil pan bolts approximately 4 turns 5 Pry oil pan loose with a screwdriver and allow fluid to drain 6 Remaining oil pan bolts pan and gasket 7 Screen filter and seal Tl Important Oil pan and screen for foreign material Metal particles Cl...

Page 730: ...t Impact type tools must not be used 1 5 1 Tighten Nut to 20 34 N m 15 25 lb ft PARK LOCK CONTROL CABLE Remove or Disconnect Figures 4 and 5 Remove console covers hush panel and lower steering column as necessary for access to park lock cable 1 Negative battery cable 2 Shift lever in park position 3 Ignition key to run position 4 Cable from inhibitor NOTICE To release cable from inhibitor insert s...

Page 731: ...7A1 8 ON VEHSCLE SERVICE 5 2 0 1 1 6 7 A Figure 4 Park Lock Cable Routing 5 2 0 1 1 7 7 A Figure 5 Park Lock Cable Adjustment Illustration ...

Page 732: ... a 3 32 inch drill bit into service adjust ment hole Rotate the switch until the gage pin drops to a depth of 9mm 5 Tighten attaching bolts to recommended torque 6 Remove gage pin OIL C O O L E R AND PIPE FLUSHING Tools Required J 35944 Cooler Flushing Tool J 35944 20 Flushing Solution Water Supply Air Supply with water and oil filter Oil Drain Container 5 Gallon Pail 1 Remove the fill cap on J 35...

Page 733: ...create a surging action to ensure complete cleaning 11 Release the trigger and turn the water valve off 12 Disconnect both hoses from the oil cooler pipes 13 Reconnect the hoses to the pipes opposite the initial flush to perform a backflush 14 Repeat Steps 9 and 10 15 Release the trigger and allow water to rinse for one minute 16 Turn the water valve off 17 Attach the air supply to the air valve a...

Page 734: ...ssembly of each unit all internal parts must be lubricated with oil ON CAR SERVICE SERVICEABLE COMPONENTS The following parts can be serviced with the transaxle in the car For part removal and installation procedures not listed in this section refer to the disas sembly and reassembly sections 1 Throttle valve control cable and or sleeve seal 2 Filler pipe and or sleeve seal 3 Governor assembly and...

Page 735: ...ometer drive gear Speedometer thrust washer O ring Governor cover 5 Governor cover screws 6 Sensor assembly and gear 7 Sensor assembly retainer 8 Electrical connection at sensor 9 Negative battery cable y Inspect Speedometer for proper operation T V CABLE E 1 2 3 B E 1 2 3 Remove or Disconnect Air cleaner assembly T V cable at injector Bolt securing T V cable at transaxle Important Pull up on cabl...

Page 736: ...ft lever 4 Clip cable in place at fuel line 5 Cable to shifter bracket 6 Cable end to shift lever pin 7 Carrier assembly console 8 Radio 9 Heater control 10 Carpet clips and rivets at console 11 Carrier reinforcements 12 E C M 13 E C M Electrical connections 14 Front pad assembly 15 Front pad trim plate 16 Rear console pad assembly 17 Shift trim plate and shift knob 18 Negative battery cable LO AN...

Page 737: ...ER T U B E Figure 10 F l Remove or Disconnect 1 Fluid level indicator and nut or bolt retaining tube mounting bracket 2 Raise vehicle and suitably support see 4 Lower vehicle 5 Pull tube and seal out of vehicle from the top Install or Connect 1 Filler tube and seal 2 Raise vehicle and suitably support see Section OA 3 Locate filler and seal tube on transaxle 4 Lower vehicle 5 Filler tube mounting ...

Page 738: ... V cable at injection linkage 4 T V cable from transaxle rod Install J 28467 A Raise engine enough to take pressure from motor mounts CAUTION Bodily injury could result with improper use of support fixture Engine support must be located in cen ter of cowl and fasteners must be torqued before supporting engine Fix ture is not intended to support entire weight of engine and transaxle 5 Transaxle eng...

Page 739: ...ints with silicone boots Failure to observe this can result in seal damage and possi blejoint failure Refer to Section 4D for informa tion on tool J 3362 and for proper drive axle removal and handling procedures 5 Drive axle see Section 4D 6 Pry out seal with a screwdriver or other suitable tool Do not damage seal bore H Install or Connect 1 New seal using tool J 34115 Lubricate seal lip with a li...

Page 740: ... cables at calipers 24 Brake control cable at frame 25 Exhaust at manifold 26 Engine mounts to cradle nuts 2 27 Transmission mounts to cradle nuts 2 28 Front cradle retaining bolts 2 29 Rear cradle retaining bolts 2 30 Cradle from vehicle 31 Starter flexplate shield 32 Flexplate bolts 33 Cooler lines 34 Plug cooler lines 35 Install transmission support jack 36 Transmission support bracket at back ...

Page 741: ...ol arm through bolt to 50 N m 37 lbs ft 90 22 Remove rear axle boot protector 23 Rear wheels 24 Remove jack stands and lower vehicle 25 Remove engine fixture tool J 28467 A 26 Neutral start switch harness and shift cable bracket 27 Transmission to engine retaining bolts 28 Transmission cooler line support bracket 29 Wire harness at transmission to engine retaining bolts 30 Speedometer pick up elec...

Page 742: ... TORQUE CONVERTER CASE C O V E R DRIVE S P R O C K E T THROTTLE LEVER AND BRACKET ASM X AUXILIARY VALVE BODY S P E E D O M E T E F D R I V E G E A R OIL PUMP SHAFT CONTROL VALVE AND PUMP ASM DRIVE LINK ASM OUTPUT SHAFT DRIVEN SPROCKET DRIVEN SPROCKET SUPPORT P A R K I N G L O C K A C T U A T O R A S M L O A N D R E V E R S E C L U T C H INTERMEDIATE BAND J H 0 0 3 3 1 2 5 C Figure 1 THM 125C Trans...

Page 743: ...ffic and road conditions permit Observe all traffic safety regulations Garage Shift Check 1 Start engine 2 Depress brake pedal 3 Move gear selector Park P to Reserve55 R Reverse55 R to Neutral55 N to Drive55 D Gear selections should be immediate and not harsh Upshifts and Torque Converter Clutch TCC Apply Figure 2 With gear selector in Drive55 D 1 Accelerate using a steady increasing throttle pres...

Page 744: ...IRST 1 1 With vehicle stopped place gear selector in First 1 and accelerate to 15 MPH 24 KPH and observe That no upshift occurs That TCC does not engage R E V E R S E 1 With vehicle stopped place gear selector in Reverse R and slowly accelerate to observe reverse gear operation All possible throttle positions and corresponding MPH shift point information has not been provided TRANSAXLE PRESSURE CH...

Page 745: ...5 8 10 J M C 3 33 7 9 15 16 33 38 12 14 5 8 JNC 3 33 7 9 12 13 24 28 8 9 5 8 J P C 3 06 10 12 18 19 32 37 15 17 8 11 J U C 3 33 10 12 18 19 30 37 15 17 8 11 JWC 3 06 7 9 12 13 27 31 7 9 5 8 J X C 3 33 9 11 18 20 39 45 13 16 5 9 KDC 2 84 9 12 17 19 51 55 15 17 6 10 KHC 3 33 9 12 20 21 43 51 17 19 5 10 LSC 2 84 10 14 22 24 45 54 20 22 6 11 PDC PNC PSC PZC 2 84 10 13 20 21 39 45 18 20 7 11 PKC TRC 2 ...

Page 746: ...HZC 760 837 110 121 1810 2021 263 293 8TNC8PVC 805 886 117 129 1524 1696 221 246 8JXC 805 886 117 129 1601 1779 232 258 8HLC 805 886 117 129 1636 1825 237 265 8HRC 8PKC 8PNC 8TRC 805 886 117 129 1643 1831 238 266 8CJC8CUC 805 886 117 129 1714 1907 249 277 8CTC 8KDC8LSC 805 886 117 129 1763 1966 256 285 8KHC 805 886 117 129 1784 2052 259 298 8JNC 396 436 57 63 679 749 98 109 8JPC 8HFC 8HHC 396 436 ...

Page 747: ...ND FORWARD CLUTCH ROLLER CLUTCH LO REVERSE CLUTCH PARK NEUT DRIVE FIRST SECOND THIRD APPLIED APPLIED APPLIED APPLIED APPLIED HOLDING INTERMEDIATE FIRST SECOND APPLIED APPLIED APPLIED HOLDING LO FIRST APPLIED HOLDING APPLIED REVERSE APPLIED APPLIED H 125C 33 2 Figure 4 Range Reference Chart ...

Page 748: ...rong Damaged or leaking Direct Clutch Burned plates Lo Reverse Clutch Burned plates Low Line Pressure Check causes of low line pressure NO UPSHIFTS DELAYED UPSHIFTS OR FULL THROTTLE UPSHIFTS Manual Linkage T V Cable Oil Level Misadjusted Misadjusted unhooked bound or broken Low Governor Cover worn Thrust washer missing Governor seal worn or cut Governor spring not seated Governor weights binding o...

Page 749: ...nd apply pin Bent or wrong link T V plunger binding Shift T V valve binding 1 2 accumulator valve binding Binding 1 2 accumulator piston Broken 1 2 accumulator spring Piston seal or groove damaged 1 2 accumulator bore damaged Incorrect spacer plate or gasket Gasket incorrectly installed 2nd oil passage leaking 2nd oil passage leaking 2 3 SHIFT ROUGH OR DELAYED Oil Level T V Valve Manual Linkage Oi...

Page 750: ...leeve loose or out of position Check ball leaking Check ball capsule damaged Damaged missing seals Cracked damaged housing or piston Missing or incorrect apply ring Wrong number of clutch plates NO 2 3 SHIFT OR 2 3 SHIFT DELAYED Oil Level T V Valve Manual Linkage Governor Intermediate Servo Accumulator Exhaust Check Valve Case Incorrect level Misadjusted unhooked bound or broken Misadjusted Cover ...

Page 751: ...or incorrectly installed Damaged or missing Check ball leaking Check ball capsule damaged Seals damaged missing Cracked damaged housing or piston Backing plate snap ring out of groove Clutch plates damaged missing DELAY IN DRIVE AND REVERSE Oil Level Oil Pressure Converter Drive Sprocket Support Bushings Turbine Shaft Incorrect level Check cause of low oil pressure Converter drainback Scarf seals ...

Page 752: ...orward Clutch Control Valve Assembly See causes of low oil pressure Not moving manual valve Drive oil passage blocked in driven s p r o c k e t support or gasket Sleeve loose or mislocated Drive oil passage leak Burned or damaged plates Valve body pipe leaking or missing SECOND SPEED START Misses 1st At Times Governor Control Valve Assembly Springs distorted or out of place Governor weights bindin...

Page 753: ...ipped Intermediate servo sticking Restriction in orifice Piston missing Seal leaking NO FULL THROTTLE DETENT DOWNSHIFT T V Cable Throttle Cable Assembly Control Valve Assembly Spacer Plate Misadjusted unhooked bound or broken Not opening throttle sufficiently Shift T V valve binding T V valve binding Spacer plate holes plugged Gasket mispositioned or damaged NO OVERRUN BRAKING IN LO L1 Reverse OK ...

Page 754: ...HYDRAULIC DIAGNOSIS 125C 13 ...

Page 755: ...125C14 HYDRAULIC DIAGNOSIS Figure 11 Park Engine Running ...

Page 756: ... to the converter feed passage to fill the converter Converter return oil is directed to the transmission cooler Oil from the cooler is directed to the transmission lubrication system Oil is also directed from the pressure regulator valve to the pump slide to decrease pump output to the pressure of the regulator valve spring force or 482 kPa 70 psi Line pressure acts on the pressure relief valve w...

Page 757: ...125C 16 HYDRAULIC DIAGNOSIS NEUTRAL ENGINE RUNNING HH0002 125C Figure 13 Neutral Engine Running ...

Page 758: ... regulated to a variable pressure called throttle valve T V pressure T V pressure increases with carburetor opening and is directed to the shift throttle valve This valve limits shift T V oil pressure from going above 620 kPa 90 psi Shift T V oil is then directed to the 1 2 and 2 3 throttle valves T V boost valve T V plunger and the 1 2 accumulator valve Shift T V oil acting on the T V boost valve...

Page 759: ...125C 18 HYDRAULIC DIAGNOSIS DRIVE RANGE FIRST GEAR ...

Page 760: ...apply the forward clutch Drive oil is directed to the 1 2 shift valve Drive oil is directed to the 1 2 accumulator valve and is regulated to a pressure called 1 2 accumulator pressure this pressure is directed to the 1 2 accumulator piston to act as a cushion for the band apply on a 1 2 shift Drive oil at the governor assembly is regulated to another variable pressure called governor pressure Gove...

Page 761: ...125C 20 HYDRAULIC DIAGNOSIS DRIVE RANGE SECOND GEAR HH0004 125C Figure 17 Drive Range Second Gear ...

Page 762: ...l from the 1 2 shift valve is directed to the following 1 Intermediate Servo 2 1 2 Accumulator Piston BASIC CONTROL Second oil from the 1 2 shift valve is directed to the intermediate servo to apply the intermediate band At the same time 2nd oil moves the 1 2 accumulator piston against 1 2 accumulator pressure and the accumulator spring to maintain a controlled build up of pressure on the intermed...

Page 763: ...125C 22 HYDRAULIC DIAGNOSIS DRIVE RANGE THIRD GEAR Converter Clutch Released HH0012 125C Figure 13 Drive Range Third Gear Converter Clutch Released ...

Page 764: ... past the 3rd clutch pressure switch to the direct clutch and reverse checkball 5 seating it in the reverse passage and to the inner area of the direct clutch piston applying the direct clutch At the same time direct clutch oil is directed past the direct clutch accumulator checkball 2 into the direct clutch accumulator passage where it is called direct clutch accumulator oil to the direct clutch ...

Page 765: ...125C 24 HYDRAULIC DIAGNOSIS DRIVE RANGE THIRD GEAR Converter Clutch Applied HH0011 125C Figure 21 Drive Range Third Gear Converter Clutch Applied ...

Page 766: ...the apply side of the converter clutch The regulated line oil from the converter clutch regulator valve controls the apply feel of the pressure plate As the pressure plate begins to move to its applied position release oil on the front side of the pressure plate is redirected back between the turbine shaft and pump drive shaft and exhausted at the converter clutch control valve through an orifice ...

Page 767: ...S PART THROTTLE 3 2 DOWNSHIFT CONVERTER CLUTCH CONTROL VALVE PRESSURES T g I INTAKE DECREASE CONVERTER LUBE MAINLINE 3 T V GOVERNOR 1 2 ACCUMULATOR HH0006 125C Figure 23 Part Throttle 3 2 Downshift Valves in Second Gear Position ...

Page 768: ...tle oil and the 2 3 spring force will close the 2 3 shift valve against governor oil shutting off RND oil to the direct clutch passage Exhausting direct clutch oil opens the 3rd clutch pressure switch releasing the torque converter clutch seats the direct clutch exhaust checkball 1 flows through the two orifices and is exhausted at the 2 3 shift valve At the same time direct clutch accumulator oil...

Page 769: ...CONVERTER CLUTCH CONTROL VALVE PRESSURES f H INTAKE DECREASE I I CONVERTER LUBE MAINLINE LINE PRESSURE TAP PRESSURE RELIEF VALVE STRAINER SUMP LINE BOOST PART THROTTLE H H 0 0 0 7 1 2 5 C Figure 25 Detent Downshifts Valves in Second Gear Position ...

Page 770: ...st governor oil and allow direct clutch oil through two orifices to exhaust at the 2 3 shift valve At high vehicle speeds above approximately 50 mph 80 km h governor oil acting on the 3 2 control valve will close it Now the exhausting direct clutch accumulator oil from the intermediate servo will seat the direct clutch accumulator checkball 2 and flow through another orifice controlling the interm...

Page 771: ...125C 30 HYDRAULIC DIAGNOSIS Figure 27 Manual Second ...

Page 772: ...mediate oil acting on the reverse boost valve plus the pressure regulator spring force will boost line pressure to 827 kPa 120 psi which is required to hold the intermediate band and forward clutch on Because RND oil is exhausted the transmission will shift to 2nd gear regardless of vehicle speed RND oil is the feed for direct clutch oil in 3rd gear With the transmission in 2nd gear manual Second ...

Page 773: ...125C 32 HYDRAULIC DIAGNOSIS MANUAL FIRST HH0009 125C Figure 29 Manual First ...

Page 774: ...2 throttle valve Lo oil pressure and the 1 2 T V spring force will close the 1 2 shift valve at speeds below approximately 40 mph 64 km h This allows lo oil to enter the lo 1st passage where it seats the lo 1st checkball 3 and passes through an orifice to the lo blow off valve which exhausts lo 1st oil down to 241 kPa 35 psi The lo 1st oil is then directed to seat the lo and reverse checkball 4 an...

Page 775: ...125C 34 HYDRAULIC DIAGNOSIS ...

Page 776: ...ll 4 in the lo 1st passage and applies the lo and reverse clutch Reverse oil flows to the reverse boost valve and will boost reverse line pressure to about 827 kPa 120 psi SECOND RNDI oil from the manual valve flows to the throttle valve and is regulated to T V pressure T V oil flows through the shift T V valve and is limited by it to approximately 620 kPa 90 psi Oil from the shift T V valve is di...

Page 777: ...i TERMINAL D 12V THRU EGR SOL RED__ BLK WHITE f T C C SOL 12V TO PORTED LO VAC TERMINAL A TO 12V TERMINAL B NOT USED SWITCH ASM 3RD CL PRESSURE N O LINE D COLOR ID WHITE LINE X COLOR ID BLACK SOLENOID AND CONDUIT ASM 1988 MODELS JDC JMC JNC J W C JH0031 125C Figure 34 Wiring Diagram ...

Page 778: ...C BHC BJC BPC CBC CJC CMC CPC CRC CTC CUC HRC JXC KDC LSC PDC PKC PNC POC PPC PSC PTC PUC PZC TNC TRC JH0O3O 125C Figure 35 Wiring Diagram 1 VALVE LINE BOOST 2 LINE 3 CONVERTER FEED 4 APPLY 5 SHIFT TV EXHAUST 6 SHIFTTV ORIFICE CUP PLUG 7 VALVE BODY PIPE DRIVE 8 SLIDE COVER SEAL SEAL SUPPORT 9 LO BLOW OFF 10 GOVERNOR 11 3RD CLUTCH 12 SLIDE SEAL SEAL SUPPORT 13 VANE RING 14 SPRING PRIMING 15 ROTOR 1...

Page 779: ...T DRIVE SPROCKET BUSHING RING OIL SEAL YELLOW H 1 2 5 C 3 5 4 Figure 37 Converter Oil Passages Parts Cut Away View 1 1 CHECK BALL 2 GOVERNOR 3 RND 4 DRIVE 5 2ND 6 LO 1ST 7 DIRECT CLUTCH 3RD 8 LO 9 DETENT 10 SHIFT TV 11 PART THROTTLE 12 LUBE 13 1 2 ACCUMULATOR 14 EXHAUST 15 APPLY 16 CONVERTER FEED 17 TV 18 TV EXHAUST 19 DECREASE 20 RNDI 21 REVERSE 22 VOID 23 INTERMEDIATE 24 LINE 25 RELEASE 26 TO CO...

Page 780: ...NOR 9 SHIFT TV 10 TO COOLER 11 3RD CLUTCH 1 2 DRILLED TAPPED HOLE NON C3 ONLY 13 LINE ORIFICE LINE 14 LINE CONVERTER FEED 15 LINE SOLENOID CIRCUIT H 125C 2 5 Figure 39 Auxiliary Valve Body and Cover Gasket 1 APPLY 2 LINE 3 EXHAUST 4 RELEASE 5 TO COOLER 6 DIRECT CLUTCH 3RD 7 VOID 2ND GOVERNOR 8 DRILLED TAPPED HOLE NON C3 ONLY 9 CONVERTER FEED H 125C 1 1 Figure 40 Auxiliary Valve Body Pump Side ...

Page 781: ...E 13 LO R E V E R S E 34 D E T E N T 14 LO 1ST 35 LO 15 2ND 36 I N T E R M E D I A T E 16 V O I D 37 D R I V E 17 LO 1ST 38 VOID 18 D R I V E 39 LINE 19 G O V E R N O R 40 RNDI 20 D R I V E 41 RND 21 2ND 42 VOID 22 D I R E C T C L U T C H C H E C K B A L L S 2 2 2ngsadi eyt Figure 41 Case Cover Valve Body Side A INTAKE B A C C U M U L A T O R D I R E C T C L U T C H C 2ND D VOID E LO R E V E R S E...

Page 782: ...HYDRAULIC DIAGNOSIS 125C 41 124 ACCUMULATOR DIRECT CLUTCH CUP PLUG 139 PIPE LO REVERSE 602 SUPPORT DRIVEN SPROCKET Figure 43 Case Case Cover Side H 125C 181 3 Figure 44 Case Oil Pan Side ...

Page 783: ... Axle End 631 A LUBE B FEED FORWARD CLUTCH C S L E E V E S T E E L D SHAFT INPUT 622 RING OIL SEAL 623 BUSHING INPUT SHAFT 624 HOUSING ASSEMBLY FORWARD CLUTCH 626 SEAL FORWARD CLUTCH PISTON OUTER 627 SEAL FORWARD CLUTCH PISTON INNER 628 INSERT 629 PISTON FORWARD CLUTCH 630 GUIDE RELEASE SPRING 631 RETAINER SPRING ASM FWD CL 632 RING SNAP SPRING RETAINER 629 H 125 294 Figure 46 Forward Clutch Assem...

Page 784: ...S 125C43 1 1 D R I V E N S P R O C K E T SUPPORT 2 D I R E C T C L U T C H 3 L U B E 4 D R I V E 5 R E V E R S E 6 D I R E C T C L U T C H 7 D R A I N B A C K H 125 2 9 2 1 Figure 47 Driven Sprocket Support Cut Away View ...

Page 785: ...DIATE 8 S T V 9 T C C EXHAUST 10 DRIVE 11 T C C APPLY 12 RND 13 S T V EXH 14 1 2 ACCUM 15 LUBE 16 P T V 17 LO 18 2ND 19 LO 1ST OR REV 20 3RD CL DIRECT OR REV 21 3RD CL DIRECT 22 GOVERNOR 23 3RD CL DIRECT ACCUM 24 SUCTION 25 TO COOLER H 125C 36 3 Figure 48 Typical Valve Body Spacer Plate ...

Page 786: ...0 or low voltage is found refer to Sections 6E and 8A for electrical diagnosis If 12 volts are present at the connector refer to the TCC hydraulic diagnosis TORQUE CONVERTER EVALUATION Torque Converter Stator The Torque Converter Stator roller clutch can have one of two different type malfunctions A S t a t o r A s s e m b l y f r e e w h e e l s in both directions B S t a t o r A s s e m b l y r ...

Page 787: ......

Page 788: ... Spacer End Play 125C 25 Input Unit Parts 125C 26 Forward Clutch Assembly 125C 27 Direct Clutch Assembly 125C 28 Check Ball Capsule Replacement Procedure 125C 29 Forward and Direct Clutch 125C 29 Intermediate Band Assembly 125C 30 Driven Sprocket Support 125C 30 Bearing Replacement Procedure 125C 30 Manual Shaft 125C 31 Drive Link Assembly 125C 31 Turbine Shaft Seal and Drive Sprocket Replacement ...

Page 789: ...IL PUMP DRIVE GASKET SPACER PLATE 20 21 22 23 24 25 26 27 28 29 30 31 32 33 35 36 37 40 PLATE VALVE BODY SPACER 3 6 CONTROL VALVE OIL PUMP ASSEMBLY LINK THROTTLE LEVER TO CABLE LEVER BRACKET ASSEMBLY THROTTLE BOLT VALVE BODY CASE GASKET VALVE BODY COVER COVER VALVE BODY SCREW VALVE BODY COVER RING RETAINING AXLE JOINT SHAFT OUTPUT RING SNAP SEAL ASSEMBLY AXLE OIL SEAL STRAINER ASSEMBLY TRANSMISSIO...

Page 790: ...Remove or Disconnect Figure 3A 1 Screws 10 2 Housing 688 and oil seal 8 3 Bearing 7 4 Rotor 687 5 Governor assembly 5 3 RING OIL SEAL 4 GOVERNOR ASSEMBLY 5 GEAR SPEEDOMETER DRIVE 6 THRUST BEARING ASM GEAR COVER 7 SEAL O RING 8 SCREW GOVERNOR COVER TO CASE 9 COVER GOVERNOR 10 SPEEDO DRIVEN GEAR 11 SEAL O RING 12 SLEEVE SPEEDO DRIVEN GEAR 13 RETAINER SPEEDO GEAR 14 BOLT SPEEDO GEAR RETAINING _ H Fig...

Page 791: ...UG GOVERNOR PRESSURE PICKUP SEAL REVERSE OIL CASE TO HOUSING BEARING ASM DRIVEN SPROCKET THRUST SPROCKET DRIVEN WASHER DRIVE SKT SUPPORT THRUST PLUG CUP 3RD OIL SPRING ACCUMULATOR EXHAUST VALVE ACCUMULATOR EXHAUST RING OIL SEAL INTER BAND APPLY PIN PIN INTERMEDIATE BAND APPLY RETAINER INTERMEDIATE SERVO SPRING SPRING INTERMEDIATE SERVO CUSHION RING OIL SEAL OUTER INTER SERVO PISTON INTERMEDIATE SE...

Page 792: ...hite line appears in the window the pin length is correct If the white line does not appear select another length pin Figure 6 Repeat procedure 4 Remove pin gage Remove or Disconnect Figures 9 and 10 1 2 3 1 Bolt 712 2 Stop bracket 711 3 Bracket 710 4 Bolts 146 5 Weir 147 6 Check valve 126 and spring 125 141 125 SPRING ACCUMULATOR EXHAUST 126 VALVE ACCUMULATOR EXHAUST 128 RING OIL SEAL INTER BAND ...

Page 793: ...No 4 screw extractor 1 Lo and reverse cup plug 120 125 SPRING 3RD ACCUMULATOR EXHAUST 126 VALVE 3RD ACCUMULATOR EXHAUST x 1 H12S 134 4 Figure 10 3rd Accumulator Exhaust Valve and Spring Use a modified No 4 screw extractor 2 Output shaft C ring 30 with J 34757 Push ring with remover rotate shaft 29 pull the ring with needle nose pliers 3 Output shaft 29 from case 1 MODIFIED 4 SCREW EXTRACTOR 120 CU...

Page 794: ...dial indicator set and lifter 3 Push the lifter down then zero the dial indicator 4 Pull the lifter up 5 Reading should be 0 10 0 84 mm 004 0 33 See Figure 15 For choice of selective snap rings for proper end play ranges record the reading 6 Remove the dial indicator set and the lifter 15 CASE ASSEMBLY 16 B A L L 6 3 DIA 18 SHAFT OIL PUMP DRIVE 19 G A S K E T SPACER PLATE 20 PLATE V A L V E BODY S...

Page 795: ...y 26958 J 26958 11 H125 14 Figure 16 Output Shaft Loading Tool INPUT SHAFT SELECTIVE SNAP RSNG 621 T H S C K 1 E S S 1 83 1 93mm 2 03 2 31mm 2 23 2 33mm 2 43 2 53mm 2 83 2 73mm 0 071 0 076 0 078 0 084 0 088 0 082 0 095 0 099 0 103 0 107 IDENTIFICATION COLOR WHITE BLUE RED YELLOW GREEN H125 3181 Figure 1 8 Selective Snap Ring Chart ...

Page 796: ...T 412 THERMO ELEMENT 413 414 415 416 417 418 419 420 421 422 430 431 432 WASHER THERMO ELEMENT WASHER THRUST CASE COVER TO DRIVE SOCKET GASKET CASE TO CASE COVER CENTER GASKET CASE TO CASE COVER SPRING ROLLER ASM MANUAL DETENT BOLT MANUAL DETENT SPRING CASE COVER SPRING 1 2 ACCUMULATOR PISTON RING OIL SEAL 1 2 ACCUMULATOR PISTON PISTON 1 2 ACCUMULATOR PIN 1 2 ACCUMULATOR SCREW SOCKET MODIFIED PAN ...

Page 797: ...rbine shaft O ring Figure 21 Link assembly 101 drive and driven sprockets 103 122 Drive sprocket support thrust washer 104 Driven sprocket support thrust washer 123 l i P U T UNIT PARTS 1 2 4 5 Remove or Disconnect Figures 23 24 25 26 26L 27 and 28 Pin 702 nail 713 Detent lever 703 manual shaft 704 and actuator rod 705 Driven sprocket support 602 and thrust washer 605 on direct clutch side Plug 60...

Page 798: ... ASM DRIVEN SPROCKET THRUST 103 SPROCKET DRIVE 122 SPROCKET DRIVEN 104 WASHER CASE COVER TO DR SKT THRUST 123 WASHER DR SKT SUPPORT THRUST 106 SHAFT TURBINE 108 BEARING ASSEMBLY 109 SUPPORT DRIVE SPROCKET 112 CASETRANSMISSION H125C 76 Figure 22 Drive Link Assembly ...

Page 799: ... PAWL SHAFT 709 SHAFT PARKING LOCK PAWL 710 BRACKET PARKING LOCK 711 BRACKET DIPSTICK STOP 712 BOLT PARKING LOCK BRACKET CASE 713 PIN MANUAL SHAFT CASE RETAINING H125C 17 1 Figure 24 Retaining Pin Removal 602 SUPPORT DRIVEN SPROCKET 605 WASHER THRUST DRIVEN SPROCKET SUPPORT TO DIRECT CLUTCH HOUSING 701 ROD AND LEVER ASSEMBLY 703 LEVER ASSEMBLY DETENT 704 SHAFT MANUAL 713 PIN MANUAL SHAFT CASE RETA...

Page 800: ...AUTOMATIC TRANSAXLE 125C 13 ...

Page 801: ...UST 642 GEAR INPUT SUN 643 DRUM INPUT 644 RING SNAP INPUT DRUM SUN GR SELECTIVE ILL NO DESCRIPTION 645 BUSHING REACTION SUN GEAR 646 GEAR REACTION SUN 647 RING SNAP 648 BUSHING LO REVERSE CLUTCH HSG 649 HOUSING ASM LO REVERSE CLUTCH 650 RING SNAP 651 SEAL LO REVERSE PISTON OUTER 652 SEAL LO REVERSE PISTON INNER 653 PISTON LO REVERSE CLUTCH 655 SPRING LO REVERSE CLUTCH RELEASE 656 RETAINER LO REVER...

Page 802: ...oned 3 Swing the gage under the extension shoulder 4 Zero the dial indicator 5 Position the snap ring 644 under the extension 6 Remove the gage from under the shoulder 7 The dial indicator should read 0 33 to 0 13 mm 0 013 to 0 005 record the reading For correct snap ring selection see Figure 31 Measure washer thickness new or old with a micrometer Figure 30 Selective Snap Ring End Play Sun Gear I...

Page 803: ...bly 665 Internal gear 668 Figure 34 Removing the Lo Reverse Clutch Housing 660 SPACER S E L E C T I V E 665 CARRIER REACTION 668 GEAR REACTION INTERNAL 669 SHAFT FINAL DRIVE SUN GEAR H125 81 Figure 35 Removing Reaction Components FINAL DRIVE ASSEMBLY Measure Figures 37 38 39 and 40 1 2 3 4 Tools Required J 26958 10 Adapter J 25025 7 Post J 26900 12 or J 8001M Dial indiactor J 28585 Snap ring remov...

Page 804: ... End Play Selective Thrust Washer 680 Measurement F I N A L D R I V E TO C A S E END P L A Y SELECTIVE THRUST WASHER 680 T u i r t f M C Q C IDENTIFICATION THICKNESS N0 C0L0R 1 40 1 50mm 0 055 0 059 0 0range 1 50 1 60mm 0 059 0 062 1 White 1 60 1 70mm 0 062 0 066 2 Blue 1 70 1 80mm 0 066 0 070 3 Pmk 1 80 1 90mm 0 070 0 074 4 Brown 1 90 2 00mm 0 074 0 078 5 Green 2 00 2 10mm 0 078 0 082 6 Black 2 1...

Page 805: ...l 115 with J 28540 Seal 117 with J 26938 or J 29130 Inspect Figure 41 Drive sprocket support bearing 108 If new bearing is required be sure to inspect drive 112 108 B E A R I N G ASSEMBLY 109 SUPPORT DRIVE SPROCKET 112 CASE TRANSMISSION 115 S E A L ASSEMBLY CONVERTER 117 S E A L ASSEMBLY AXLE Hi2sc 78 Figure 41 Axle Seals Sprocket Bearing Figure 4 Converter Seal and Axle Seal Installation Bearing ...

Page 806: ...ghten Tools Required J 25259 4 0 Torx bit or equivalent Screws 114 to 24 N m 18 ft lbs with J 25359 5 Inspect Figure 46 Parking pawl 706 for damage 108 BEARING ASSEMBLY 109 SUPPORT D R I V E SPROCKET 112 CASE TRANSMISSION 114 SCREW S O C K E T BUTTON HEAD 115 S E A L ASSEMBLY CONVERTER H 1 2 5 C 77 Figure 4b Sprocket Support Replacement 706 PAWL P A R K I N G 707 S P R I N G P A R K I N G PAWL 708...

Page 807: ... case 112 tap gently with a soft mallet 3 Retainer 143 and bolt 142 torque to 24 N m 18 ft lbs r8l Inspect 3rd oil cup plug 127 for cracks or loose fit Jrd Oil Cup Plug Replacement Procedure Remove or Disconnect Figure 48 Cup Plug 2 use 3 screw extractor with 13 mm 1 2 ground off j H j Install or Connect Cup Plug 2 tap until seated in case use a 6 mm 1 4 rod 1 EXTRACTOR 3 MODIFIED 2 PLUG CUP DIREC...

Page 808: ... H 125C 73 1 Figure 4 9 Final Drive Assembly DIFFERENTIAL AND FINAL DRIVE 1 2 3 4 Disassemble Figure 4 9 Internal gear 673 Thrust bearing 674 Sun gear 675 Thrust bearing 676 1 F E E L E R GAGE 2 PINION F I N A L D R I V E 678 DIFFERENTIAL CARRIER 678 HI 25 61 Figure 5 0 Final Drive Pinion End Play l Inspect Figures 49 and 50 Final drive pinions 678 for damage Excessive end play with a feeler gage ...

Page 809: ...g 676 into carrier Sun gear 675 stepped side facing up Thrust bearing 674 outside race to internal gear Internal gear 673 onto carrier Install or Connect Figures 49 and 53 Tool Required J 33381 Final Drive Remover and Installer 1 Thrust washer 680 onto carrier assembly retain with petrolatum 2 Thrust bearing 681 onto carrier assembly inner race toward carrier retain with petrolatum 3 Carrier assem...

Page 810: ...and the adapter Leave the adapter in place 5 Install J 26958 and J 26958 11 it bottoms REACTION CARRIER ASSEMBLY turn knob until Inspect Figures 56 and 26 Sun gear shaft 669 for damage or wear m Internal gear 668 for damage or wear Thrust bearing 667 for damage or wear Assemble 1 Internal gear 668 onto sun gear shaft 669 2 Thrust bearing 667 inner race against internal 647 RING SNAP 649 H O U S I ...

Page 811: ...erse clutch composition and steel plates 658 for wear or burning Install or Connect Figures 56 and 70 Backing plate 659 stepped side down into case Steel waved plate 688 Lubricant on composition plates 658 before installation Alternate composition plate first then steel plate See Figure 70 Steel waved 688 plate Spacer ring 650 ring is 1 07 mm 0 042 thick 64a 6 5 2 6 5 3 649 HOUSING ASM LO REVERSE ...

Page 812: ...acks splits damaged splines worn gear or journal and plugged lubrication holes p Install or Connect Sun gear 646 and selective snap ring 644 Selective Snap Ring End Play Measure Figures 61 and 62 Tools Required J 26958 Loading tool J 26958 11 Bracket J 26958 10 Adapter plug J 28588 Gage J 25025 7 Post J 26900 12 or J 8001M Dial indicator 1 Install the tools as shown The loading tool should still b...

Page 813: ...ve the dial indicator set and J 28588 REVERSE CLUTCH HOUSING TO LO RACE SELECTIVE SPACER 660 THICKNESS IDENTIFICATION 1 00 1 10mm 0 039 0 043 1 1 42 1 52mm 0 056 0 060 2 1 84 1 94mm 0 072 0 076 3 2 26 2 36mm 0 089 0 093 4 2 68 2 78mm 0 105 0 109 5 3 10 3 20mm 0 122 0 126 6 H125 320 1 Figure 64 Lo Race Selective Spacer Chart 636 WASHER INPUT SHAFT THRUST 637 GEAR INPUT INTERNAL 639 WASHER INPUT CAR...

Page 814: ...turn and slot must line up with input shaft hole Seal rings 622 for damage do not remove unless replacing Piston 629 for damage or cracks Snap ring 621 for damage Insert 628 for damage Spring guide 630 for damage or distortion Retainer and spring assembly 631 for collapsed springs or bent retainer Composition and steel plates for wear or burning Waved plates 625 for wear or burning flatness Backin...

Page 815: ...SNAP BACKING PLATE THICKNESS IDENTIFICATION CODE Inches Powdered MM Inches Steel Metal 5 0 4 9 197 191 A 6 4 5 4 3 175 170 B 7 3 9 3 8 154 148 C 8 3 3 3 2 132 126 D 9 H 125C 49 5 Figure 69 Forward Clutch Backing Plate Selection 125C C L U T C H PLATE AND APPLY RING U S A G E C H A R T C L U T C H FLAT STEEL PLATE COUP FACED PLATE WAVED PLATE APPLY RING DIRECT CJC CPC CTC CUCCXCHLC HRCPMCPPC No Thi...

Page 816: ...cks or burning Snap rings 620 617 for damage Check ball capsule for free operation Check Ball Capsule Replacement Procedure Remove or Disconnect Use a 9 5 mm 3 8 drift to drive out the ball capsule assembly Install or Connect H 125 146 4 1 2 3 4 5 6 7 8 9 10 Seat the new capsule with the 9 5 mm 3 8 drift Assemble Figures 70 and 71 Center seal 613 lips facing away from capsule Inner seal 614 lips f...

Page 817: ...E 607 PLUG BAND ANCHOR HOLE H125C 52 1 Figure 75 Intermediate Band Anchor Hole Plug Install or Connect Figure 75 1 Band 606 must engage the case lug 2 Plug 607 DRIVEN SPROCKET SUPPORT m m Inspect Figure 76 and 26 Support 602 for cracks burrs or damage passage surface must be flat and smooth Bushing 603 for damage Thrust washer 605 for damage Oil seal rings 604 for nicks cuts or damage oil J 2619 0...

Page 818: ... 104 for damage or wear m Link assembly 101 for damage or loose links m Thrust bearing 121 for damage or wear m Driven support thrust washer 123 for damage or wear Turbine Shaft Seal and Drive Sprocket Replacement Procedure J 4 Remove or Disconnect Figure 79 Seals 105 from turbine shaft cut with a knife Snap ring 102 from turbine shaft Drive sprocket 103 from turbine shaft JHHHJ Install or Connect...

Page 819: ...H125C 76 Figure 78 Drive Link Assembly 148 lllilllHl ip fpl m T f l l 1 y 106 H J 29569 2 105 RING SOLID S E A L TURBINE S H A F T GREEN 106 SHAFT TURBINE 148 RING SOLID S E A L TURBINE S H A F T YELLOW R E Q U I R E S USE OF J 29829 H125 324B 109 D R I V E S P R O C K E T S U P P O R T S T A T O R S H A F T 115 S E A L C O N V E R T E R O I L 107 S E A L 0 RING 1 1 5 106 S H A F T T U R B I N E X...

Page 820: ...ect Case cover 401 see Section 7A for case cover repair Casting porosity Oil passage damage 1 2 accumulator bore damage 1 2 accumulator piston 421 seal 420 and spring 419 Cracked or damaged piston Cut or nicked seal Distorted spring Vent assembly 404 for damage Vent Assembly Replacement Procedure Remove or Disconnect Vent assembly with pliers Install or Connect 0 Apply thread sealant to the vent 4...

Page 821: ... set the washer height Seal 1 2 3 4 5 6 Inspect Figure 84 Left hand axle seal 31 for damage Replacement Procedure 0Remove or Disconnect Seal 31 j 4 Install or Connect Seal 31 use 3 26938 or J 29130 Assemble Figure 81 Case cover Thrust washer 414 use petrolatum to hold in place Pin 422 chamfered end first Piston 421 Spring 419 Gasket 415 use petrolatum to hold in place Install or Connect Figures 81...

Page 822: ...6 Input Shaft to Case Cover End Play INPUT SHAFT SELECTIVE SNAP RING 621 THICKNESS IDENTIFICATION COLOR 1 83 1 93mm 0 071 0 076 WHITE 2 03 2 31mm 0 078 0 084 BLUE 2 23 2 33mm 0 088 0 092 RED 2 43 2 53mm 0 095 0 099 YELLOW 2 63 2 73mm 0 103 0 107 GREEN H 125C 318 1 Figure 87 Selective Snap Ring Chart Important Valves and springs are not interchangeable Keep them in the order shown Position as shown...

Page 823: ...THROTTLE VALVE BUSHING 2 3 THROTTLE VALVE VALVE 1 2 SHIFT VALVE 1 2 THROTTLE SPRING 1 2 THROTTLE VALVE BUSHING 1 2 THROTTLE VALVE 324 325 Q 3 2 6 324 BALL LO BLOW OFF 325 SPRING PLUG ASSEMBLY LO BLOW OFF 326 PLUG LO BLOW OFF VALVE 355 SPRING 3 2 VALVE 356 VALVE 3 2 CONTROL 360 BUSHING T V REVERSE BOOST VALVE 361 VALVE T V BOOST 363 VALVE REVERSE BOOST 364 SPRING PRESSURE REGULATOR 365 VALVE PRESSU...

Page 824: ...AUTOMATIC TRANSAXLE 125C 37 H 125C 21 5 Figure 89 Control Valve and Oil Pump Assembly ...

Page 825: ...OOST BUSHING 328 RETAINER VALVE BODY PIPE 372 PLUG BORE PRESSURE REGULATOR 329 BOLT AUXILIARY VALVE BODY TO CASE 373 RETAINER PRESSURE REGULATOR 330 COVER AUXILIARY VALVE BODY 374 SPRING PRESSURE REGULATOR ISOLATOR 331 GASKET AUXILIARY VALVE BODY COVER 375 PLUG VALVE BORE ISOLATOR 332 VALVE CONVERTER CLUTCH CONTROL 376 RING VALVE RETAINING 333 SOLENOID ASSEMBLY 377 RETAINER THROTTLE VALVE 334 BOLT...

Page 826: ...6 17 969 0 7069 0 7074 17 969 17 982 0 7074 0 7080 H 125C 96 1 H125C 96 1 Figure 91 Oil Pump Rotor and Slide Selection Oil Pump Rotor and Slide Replacement Measure Figure 91 Tool Required One Inch Micrometer Oil Pump Rotor 353 Thickness Measurement of rotor must be made on undamaged surface Use the original rotor measurement Figure 91 to order the proper service package which includes both the rot...

Page 827: ...mp slide 348 into pump pocket 2 Slide seal support 349 and seal 350 into slide 348 3 Align side with pivot hole then install pin 345 4 Vane ring 351 into pump pocket 1 of 2 rings 6 Vane ring 351 on top of rotor 7 O ring seal 347 on top of rotor 8 O ring seal 346 slide to cover Auxiliary valve body Control valve 332 and plug 310 Switches 335 and 338 Solenoid 333 with oil seal 337 and bolt 334 attac...

Page 828: ...ten Torque the screws 27 to 11 N m 8 ft lbs M J Install or Connect Figure 101 1 Shaft 29 into case 2 C ring 30 position with needle nose pliers 3 With J 28583 push on C ring 30 9 M6 X 1 0 X 45 2 M 6 X 1 0X65 4 We X 1 0X25 1 M 8 X 1 25X65 1 M8X 1 25X85 1 M8 X 1 25 X 130 3 M 6 X 1 0X90 1 M 6 X 1 0X16 1 PIPE RETAINER TORQUE ALL 16 BOLTS TO 11 i m 8 FT LBS TORQUE ALL M8 BOLTS TO 24 N m 18 FT LBS B C D...

Page 829: ...SSEMBLY WHITE 343 BODY AUXILIARY VALVE 408 ELECTRICAL CONNECTOR Hi25c 98 2 Figure 100 TCC Wiring Diagram 29 SHAFT OUTPUT 30 RING SNAP H125C 86 Figure 101 Output Shaft C Ring 712 711 705 705 ACTUATOR ASSEMBLY 710 BRACKET PARKING LOCK 711 BRACKET DIPSTICK STOP 712 BOLT PARKING LOCK BRACKET CASE H125C 80 2 Figure 102 Dipstick Stop Parking Lock Inspect Actuator Assembly 705 for proper action t 4 Insta...

Page 830: ...cking for Proper Apply Pin yj Inspect Pin 129 for damage and seal 128 for cuts or nicks Seals 134 and 132 for cuts or nicks proper scarf cut alignment Do not remove seals 132 and 134 unless replacement is necessary Spring 131 for damage Retainer 130 for damage Cover 137 for damage cracks porosity Piston 133 for cracks seal groove damage 1 ROD 9 5mm 3 8 120 CUP PLUG LO AND R E V E R S E I v x H125C...

Page 831: ... 3 Gasket 34 4 Pan 35 onto the case 5 Bolts 36 Tighten Torque the pan bolts 36 to 11 N m 8 ft lbs 32 SEAL 33 STRAINER ASM TRANSMISSION OIL 34 GASKET OIL PAN 35 PAN TRANSMISSION OIL 36 SCREW TRANSMISSION OIL PAN 37 MAGNET CHIP COLLECTOR H125C 65 3 Figure 108 Bottom Pan and Oil Strainer GOVERNOR AND SPEEDOMETER GEAR ASSEMBLY I2 Clean Governor assembly 4 Inspect Figure 109 Governor Oil passage blocke...

Page 832: ...re 109 O ring 11 onto sleeve 12 Gear 10 into sleeve 12 4 1 Install or Connect 1 Sleeve 12 into cover 9 2 Retainer 13 3 Bolt 14 j J Tighten Torque the screw 14 to 9 N m 75 inch pounds Governor Assembly ITSS Some Models Inspect Figure 109A Governor 4 for blocked oil passage damaged springs or binding weights damaged seal replace as required Rotor 687 for cracks damaged or missing teeth Damaged beari...

Page 833: ...or damaged Internal failure to stator m Contamination from engine coolant Excess end play Measure Figure 110 Tool Required J 35I38 Torque Converter End Play Checking Tool Install J 35138 and measure end play 0mm 5mm 020 for 245mm Torque Converters 0mm 6mm 024 for 298mm Torque Converters The Torque Converter Should Not Be Replaced If J 8001 J 26900 13 J 35138 HH0001 HD Figure 1 10 Checking Torque C...

Page 834: ...And Reverse Clutch Housing Bushing Group 4 159 31 15 Reaction Carrier To Int Gear Thrust Washer Group 4 180 32 16 Sun Gear To Internal Gear Thrust Bearing Group 4 178 33 17 Case Bushing Group 4 319 Driven Sprocket Thrust Bearing Assembly Group 4 131 Bearing Assembly Group 4 131 Selective Snap Ring Group 4 169 Direct Clutch Bushing Group 4 169 Input Shaft Thrust Washer Group 4 158 Selective Snap Ri...

Page 835: ...er to Case 1 M8 x 1 25 x 40 0 24 N m 18 ft lbs Case Cover to Case 7 M8 x 1 25 x 25 0 24 N m 18 ft lbs Case Cover to Case 2 M8 x 1 25 x 25 0 24 N m 18 ft lbs Case to Drive Sprocket Support 4 M8 x 1 25 x 23 5 24 N m 18 ft lbs Oil Pan and Valve Body Cover 27 MS x 1 25 x 16 0 11 N m 8 ft lbs Manual Detent Spring Assembly to Case 1 M6 x 1 0x 10 0 11 N m 8 ft lbs Cooler Connector 2 1 4 18 NPSF 38 N m 23...

Page 836: ...r Available Converter Seal Installer J25018 A J 34008 J 28540 Adapter Plug J 26958 10 Adapter Bracket Intermediate Band Apply Pin Gauge Converter End Play Check Tool J 26958 11 J 28535 J 29830 Output Shaft Aligning and Loading Tool J 26958 Clutch Piston Seal Installer 015 and 0 3 1 wire ends Input Shaft Lifter J 26744 A J 28544 Final Drive Unit Remover Installer C Ring Remover Installer Output Sha...

Page 837: ... ...

Page 838: ...per strut mount When installing the motor and transmission mounts be certain the mounts are aligned to the center of the mounts Alignment of mounts will keep the driveline centered in installation MAINTENANCE AND ADJUSTMENT Checking Transaxle Mounts Raise the vehicle on a hoist Push up and pull down on the case while observing the mounts If the rubber separates from the metal plate of the mount or...

Page 839: ...F l Remove or Disconnect Figures 2 and 3 Negative battery cable 1 2 Place shifter in first gear 3 Shift knob 4 Front trim plate see Section 8C 5 Shifter trim plate 6 Rear console pad assembly 7 E C M see Section 6E2 8 E C M electrical connections 9 Front carrier to I P reinforcement 10 Carrier reinforcement see Section 8C 11 Carpet clips and rivets at console 12 Heater control 13 Radio see Section...

Page 840: ...ents as outlined in shift cable and select cable installation procedure SHIFT CABLE AND SELECT CABLE LEVER ASSEMBLY Remote m Disconnect 1 Cables from shift lever at transaxle 2 Bolt from mount at transaxle 3 Cotter pin from crosshaft through rod at shift shaft 4 Transaxle shift lever assembly Install or Connect 1 Shift lever assembly to shifter shaft 2 Crosshaft through rod into shift lever assemb...

Page 841: ...7B2 4 S SPEEi flSUZyf MMM MArJtJAl TRANSAXLE CABLE A H20003 7B Figure 4 Cable Adjustment ...

Page 842: ... see Section 3D 10 Axle shafts from transmission See Section 4D 11 Rubber skirts from splash shield cradle retainers 12 Rear transmission bracket mount bolts 13 Motor mount nuts from cradle and front engine mount shock 14 Bolts from crossover pipe to converter see Sec tion 6A2 15 Cradle bolts and cradle from engine and support cradle on adjustable stand 16 Oxygen sensor wire 17 Crossover pipe heat...

Page 843: ...ugh to take the pressure off the mount Figure 5 4 Four bolts attaching rear transaxle mount to transaxle 5 Nut from stud connecting upper and lower halfs of mount B Install or Connect 1 Nut 48 N m 35 lb ft connecting upper and lower mount halfs 2 Four bolts attaching rear transaxle mount 55 Nnn 41 lb ft 3 Lower engine and remove tools J 28467 A and J 35563 4 Two nuts and wire harness 48 Nnn 35 lb ...

Page 844: ...5 SPEED ISUZU 76MM MANUAL TRANSAXLE 7B2 7 J10251 7B2 P Figure 6 Transaxle Mounting ...

Page 845: ......

Page 846: ... axle Noise which originates in other places cannot be corrected by adjustment or replacement of parts in the transaxle It should also be remembered that transaxle gears like any mechanical device are not absolutely quiet and will exhibit some normal operating noise The following is a suggested approach to verify suspected transaxle noises 1 Select a smooth level asphalt road to reduce tire and re...

Page 847: ... speed constant mesh gears b Damaged or worn 1 2 synchronizer Noisy in Second Only a Damaged or worn second speed constant mesh gears b Damaged or worn 12 synchronizer Noisy in Third Only a Damaged or worn third speed constant mesh gears b Damaged or worn 3 4 synchronizer Noisy in Fourth Gear Only a Damaged or worn 3 4 synchronizer b Damaged or worn 4th speed constant mesh gears Noisy in Fifth Gea...

Page 848: ...his area can easily be confused with wheel bearing noise Inspect and replace as required A rough wheel bearing produces a vibration or growl which continues with the car coasting and transaxle in Neutral Since wheel bearings are not preloaded noise should diminish if run with the wheels off ground A brinnelled bearing causes a knock or click approximately every two revolu tions of the wheels as th...

Page 849: ...the bearing retainer Remove the bearing retainer and shims from the input and output shafts Figure 9 8 Remove the bolt used to retain the reverse idler shaft at the transaxle case Figure 10 9 Remove the collar and thrust washer from the output shaft using J 22888 and J 22888 30 Figure 11 10 Remove 14 bolts retaining the transaxle case and separate the transaxle case from the clutch housing and rem...

Page 850: ...rse Idler Shaft Bolt J22888 J22888 30 G34010 7B2 AN r 5TH G34011 7B2 AN Figure 12 5th and Reverse Shift Shafts REVERSE I D L E S H A F T REVERSE I D L E G E A R ir G34012 7B2 AN Figure 13 Reverse Idler Shaft and Gear R O L L mm nr G34013 7B2 AN Figure 11 Cellar and Thrust Washer Figure 14 1st 2nd Shift Fork Roll Pin ...

Page 851: ...race Use J 33370 with driver handle J 8092forthe output shaft race Figure 16 Remove the outer races for the input shaft front bearing output shaft front and differential side bearings Use J 26941 with J 33367 for remov ing the input and output races in the housing and the differential race in the case Use J 26941 with a slide hammer to remove the differential race in the housing Figure 17 18 and 1...

Page 852: ...gear 3rd 4th syn chronizer assembly and 3rd gear all together using J 22912 01 and a press Figure 22 3 Remove other parts from the input shaft G34019 7B2 AN Figure 20 Clutch Shaft Bushing G34021 7B2 AN Figure 22 Rear Input Bearing Output Shaft 1 Remove the front bearing using J 22227 A with J 33369 and a press Figure 23 2 Remove the rear bearing and 3rd 4th gear simul taneously using J 22912 1 and...

Page 853: ...r damage and check all gear splines for burrs nicks wear or damage Remove minor nicks or scratches with an oil stone Replace any part exhibiting exces sive wear or damage Inspect all thrust washers for evidence of exces sive wear distortion or damage Replace any of these parts if they exhibit these conditions Inspect the two case halves for cracks porosity damaged mating surfaces stripped bolt thr...

Page 854: ... the 4th gear and thrust washer next Install the thrust washer with the recessed area facing 4th gear 4 Install the front and rear bearings using J 33374 and a press Figure 28 and 29 Before install ing apply oil to the bearing interior and race surface Output Shaft Before assembling apply oil to the thrust sur faces on all gears Apply oil to all the bearing interiors and race surfaces 1 Install th...

Page 855: ... turning the side gear 2 Insert the cross pin and make sure the backlash is within the rated range 0 03 to 0 08mm 0 0012 to 0 0031 in 3 Install the lock pin and stake it 4 Heat the speedometer drive gear to about 95 C 200 F using a hot air dryer do not use hot water and then install it on the differential 5 Apply oil on the inside diameter of the ring gear then position the ring gear on the differ...

Page 856: ...Figure 36 3 Apply grease to three interlock pins and install them on the clutch housing Figure 37 4 Install the reverse shift bracket on the clutch housing Use 3rd 4th shift shaft to align bracket to housing Install retaining bolts and tighten to specification Make sure shaft operates smoothly after installation Figure 38 G34033 7B2 AN Figure 34 Front Input Shaft Bearing Race Figure 35 Front Outpu...

Page 857: ...he bearing races as shown in Figure 39 The 3 gages are identified Input Output and Differential B Place seven spacers provided with J 33373 evenly around the perimeter of the clutch housing Figure 40 C Install bearing and shim retainer on trans axle case Tighten screws to 17 N m 13 lbs ft After final torque on screws stake screws to the retaining plate D Carefully position the transaxle case over ...

Page 858: ... J 8092 and a press Apply oil to the bearing race before installation Press bearing until seated in its bore 15 Apply a 1 8 bead of Loctite No 518 or equiva lent to the mating surfaces of the clutch housing and clutch housing 16 Be sure magnet is installed in clutch housing 17 Install the transaxle case on the clutch housing Install the reverse idle shaft bolt into the trans axle case Tighten the ...

Page 859: ...sembly 25 Install a new gasket with the control box assem bly on the transaxle case and tighten four bolts to 17 N m 13 lbs ft Make sure transaxle shifts properly before installing rear cover 26 Install a new gasket with the rear cover Install seven bolts and tighten the bolts to 17 N m 13 lbs ft 27 Install the clutch fork assembly if it has been removed Install the bushing into the upper hole usi...

Page 860: ... 21 29 N m 15 21 Ft Lbs Input Output Shaft Retaining Nuts 118 137 N m 87 101 Ft Lbs Control Box to Case Bolts 15 22 N m 1116 Ft Lbs Rear Cover Bolts 15 22 N m 1116 Ft Lbs Clutch Master Cyl Retaining Nuts 20 34 N m 15 25 Ft Lbs Slave Cyl Retaining Nuts 18 26 N m 14 20 Ft Lbs Clutch Shaft Release Lever Bolt 40 60 N m 3045 Ft Lbs LUBE CAPACITY 2 55 LITERS 2 7 QT LUBE RECOMMENDED MANUAL TRANSAXLE OIL ...

Page 861: ...22912 01 J 22227 A J33366 J 33370 J 8611 01 J 7817 9 J 28412 10 J 8092 11 J 23598 12 J 22888 AND J 22888 30 13 J 33371 14 J 24256 A 15 J 22919 16 J 8853 01 16 24 17 J26540 18 J 33374 19 J 33368 20 J33369 21 J 29130 OR J 26938 22 J 2619 01 23 J 3289 20 24 J33373 25 J35274 J10252 7B2A P Figure 50 Special Tools ...

Page 862: ...t shaft m Individual sliding shift rails for each shift fork The differential is a conventional arrangement of gears that is supported by tapered roller bearings The final output gear an integral part of the output shaft turns the ring gear and differential assembly thereby turning the drive axle shafts The shifter cables are called select and shift cables When one cable moves the other cable shou...

Page 863: ...7B3 2 MUNCIE 282 5 SPEED MANUAL TRANSAXLE Figure 1 Disassembled View Gear and Case Group ...

Page 864: ... BLOCKER 1ST GEAR 49 GEAR 1ST OUTPUT 50 BEARING 1ST OUTPUT 51 BEARING THRUST 52 WASHER THRUST 53 SHAFT OUTPUT 54 BEARING OUTPUT SHAFT SUPPORT 55 BEARING OUTPUT 56 RACE BEARING OUTPUT 57 GEAR AND DIFFERENTIAL ASSEMBLY 58 BEARING ASSEMBLY DIFFERENTIAL 59 RACE BEARING DIFFERENTIAL 60 BEARING DIFFERENTIAL 61 CASE DIFFERENTIAL ASSEMBLY 62 CASE DIFFERENTIAL 63 PIN CROSS DIFFERENTIAL 64 WASHER THRUST PIN...

Page 865: ...7B3 4 MUNCIE 282 5 SPEED MANUAL TRANSAXLE ...

Page 866: ...NER 194 FORK 1ST 2ND SHIFT 195 SHAFT 1ST 2ND SHIFT 196 PIN LOCK 197 RAIL 5TH SHIFT ASSEMBLY 198 FORK 5TH SHIFT 199 PIN FORK RETAINER 200 LEVER 5TH SHIFT 201 PIN LEVER RETAINER 202 SHAFT 5TH SHIFT 203 MAGNET CHIP COLLECTOR 204 PLUG SHIFT RAIL THREE 205 BOLT SCREW M2 X 1 5 206 SPRING SLIDING SLEEVE 207 SLEEVE SLIDING 208 SEAL SHIFT SHAFT 209 PLUG 210 SNAP RING 211 STUD 212 SPEEDO SIGNAL ASSEMBLY RET...

Page 867: ...NPUT 3 4 SYNCHRONIZER THIRD GEAR INPUT INPUT SHAFT GEAR ASSEMBLY CLUTCH R E L E A S E BEARING ASSEMBLY R E V E R S E GEAR OUTPUT FIFTH GEAR SYNCHRONIZER ASSEMBLY FIFTH GEAR OUTPUT THIRD FOURTH GEAR OUTPUT SECOND GEAR OUTPUT 1 2 SYNCHRONIZER FIRST GEAR OUTPUT OUTPUT SHAFT GEAR ASSEMBLY DIFFERENTIAL GEAR ASSEMBLY S P E E D O M E T E R DRIVE GEAR R E V E R S E IDLER GEAR GX1005 7B3 Figure 3 Cross Sec...

Page 868: ...rings which are worn loose but remain smooth without spalling or pitting are the result of dirty oil Locking Locking ofbearings is caused by large particles of foreign material becoming wedged between rollers and race usually causing one of the races to turn Pre loading ofregular type taper roller bearings higher than specified can also cause locking of bearings Pitting Pitting is a result of norm...

Page 869: ...t vent plug b Worn axle shaft seals c Excessive amount of lubricant in transaxle d Loose or broken input gear shaft bearing retainer e Worn input gear bearing and or lip seal damaged f Worn shift lever seal leaks g Lack of sealant between case and clutch cover or loose clutch cover MAINTENANCE AND ADJUSTMENT CHECKING TRANSAXLE MOUNTS Raise the vehicle on a hoist Push up and pull down on the transa...

Page 870: ... Screw and shift knob 3 Front trim plate see Section 8C 4 Shifter trim plate 5 Rear console pad assembly 6 E C M see Section 6E2 7 E C M electrical connections 8 Front carrier to I P reinforcement see Section 8C 0 1 2 3 4 5 6 17 18 2 3 4 5 6 7 8 9 10 Carpet clips and rivets at console Heater control Radio see Section 9A Carrier assembly see Section 8C Shift and select cable nuts from cable ball st...

Page 871: ... transaxle 3 Retainer from select cable 4 Shift and select cables nuts from cable ball studs at transaxle brackets 5 Remove rubber grommet on cables from body Install or Connect Cables from passenger side through body into engine compartment 2 Rubber grommet on cables to body 3 Shift and select cable nuts 25 Nnn 18 lb ft on cable studs through transaxle brackets Retainer on select cable Bolt 25 N ...

Page 872: ...SAXLE Remove or Disconnect 1 Drain plug and drain transaxle 2 Select and shift cables nuts securing cables to transaxle brackets 3 Back up light switch wire and switch 4 Shift cables and nut on stud securing bracket to transaxle 5 Two bolts securing select cable mount 6 Two bolts attaching clutch slave cylinder bracket 7 Exhaust crossover pipe see Section 6A2 8 Nut clip and wire from center stud 9...

Page 873: ...rance removal F l Install or Connect 1 Transaxle through bottom and attach engine to transaxle with two studs Do not torque studs 2 Raise frame see Section 2A and install axle shafts see Section 4D 3 Clutch inspection plate and four screws 13 Nnn 10 lb ft 4 Front and rear transaxle mounts 5 Lower car 6 Lower engine and remove J 28467 A and J 35563 7 Three upper bolts and one stud 75 Nnn 55 lb ft A...

Page 874: ... wire harness from studs attaching lower half of transaxle mount to frame 3 Install J 28467 A J 35563 engine support fix ture Attach fixture hook to engine lift ring and raise engine enough to take the pressure off the mount Figure 7 4 Four bolts attaching rear transaxle mount to transaxle 5 Nut from stud connecting upper andlower halves of mount Install or Connect 1 Nut 48 Nnn 35 lb ft connecting...

Page 875: ...f transaxle mount with stud 54 Nnn 40 lb ft and coolant pipe over stud 3 Two bolts and one nut on stud 54 Nnn 40 lb ft attaching upper half of transaxle mount to transaxle 4 Lower engine and remove tools J 28467 A and J 35563 5 Two nuts on studs 48 Nnn 35 lb ft attaching lower half of transaxle mount to frame 6 Negative battery cable AXLE SHAFT SEALS Remove or Disconnect 1 Axle shaft and inner joi...

Page 876: ...MUNCIE 282 5 SPEED MANUAL TRANSAXLE 7B3 15 Figure 11 Transaxle Mountings ...

Page 877: ...AND OR BUSHINGS T l J36037 fTI UPPER BUSHING H20024 7B3 Figure 13 Upper Bushing Removal Remove or Disconnect 1 Transaxle 2 Clutch Release Lever 3 Pry out seal 4 Using J 36037 and a hammer drive the upper clutch shaft bushing into the housing 5 Clutch shaft and bushing by sliding shaft out of the case at a slight angle 6 Lower clutch shaft bushing by using J 36032 in bushing engaging the second ste...

Page 878: ...the line on J 36037 Is flush with housing surface 5 Dust seal 6 Clutch release lever 7 Transaxle Figure 16 Upper Bushing Installation SPECIAL TOOLS SPECIAL TOOLS J 28467 A Engine Support Fixture J 35563 Engine Support Fixture J 35823 Clutch Seal Installer J 36037 Upper Bushing Installer and Remover J 36032 Lower Bushing Remover J 36033 J 36190 Lower Bushing Installer J10255 7B3 P Special Tools ...

Page 879: ......

Page 880: ...utch and Differential Housing 7B3A 18 Output Shaft Support Bearing Selective Shim Procedure 7B3A 18 Transmission Case End Plate 7B3A 21 Shift Rail Detent Clutch and Differential Housing 7B3A 21 Shift Shaft Detent Transmission Housing 7B3A 22 External Transaxle Mounted Linkage Installation 7B3A 23 SPECIFICATIONS 7B3A 24 Bolt Torques 7B3A 24 Lubricants for Transaxle 7B3A 25 SPECIAL TOOLS 7B3A 26 UNI...

Page 881: ...Remove or Disconnect Figure 3 1 Snap ring 139 2 Cover 140 3 Screw 141 and outer spring seat 142 4 Fifth Rev bias spring 143 and inner spring seat 1 4 4 TRANSMISSION CASE AND CLUTCH HOUSING SEPARATION 1 2 3 4 5 Remove or Disconnect Figure 4 Bolts 81 Clutch housing 20 Transaxle must be in neutral Differential gear assembly 57 Magnet 203 Bearing 55 Remove or Disconnect Figures 5 and 6 1 Pin 158 pin m...

Page 882: ...ch and Differential Housing Figure 3 Shift Shaft Detent Components Transmission Housing 20 CASE CLUTCH AND DIFFERENTIAL 55 BEARING OUTPUT 57 DIFFERENTIAL ASSEMBLY 81 BOLT 15 21 N m 15 lb ft 203 MAGNET G X 1 2 5 3 M N 5 T X Figure 4 Clutch and Transmission Housing Components A A LOCATION O F PIN 1 58 G X 1 2 6 2 M N 5 T X _ Figure 5 Shift Lever Pin Removal 2 Cover 90 3 Shim selective 87 4 Retainer ...

Page 883: ...HIM SELECTIVE 88 RETAINER CLOCKWISE ROTATION 90 PLATE END 91 BOLT NINE 21 N m 15 lb ft 92 RETAINER COUNTERCLOCKWISE ROTATION JH1254 MN5TX Figure 8 Gear Cluster Support Components 2 Position transmission case gear cluster assembly A on J 36182 1 and 2 Align shift rail and shaft pilots to the fixture 3 Position J 36185 on shaft support bearings and pilots Using a hydraulic press separate the shaft a...

Page 884: ...mble Figure 11 Tool Required Hydraulic Press J 36183 Input Output Shaft Gears Press Tube J 36184 Input Output Shaft Press Tube Reducer T Important Figure 11 Identify blocker ring 14 for third gear and blocker ring 7 for fourth gear DO NOT MIX A G E A R C L U S T E R AND S H I F T RAIL A S S E M B L Y 180 R E V E R S E RAIL 181 S H I F T G A T E 182 R O L L E R 184 3 R D 4 T H RAIL 190 1 S T 2 N D ...

Page 885: ...t stone or crocus cloth replace the component H Assemble Figure 12 Tools Required Oven Hydraulic Press J 22912 01 Input Output Shaft Gears Remover Installer J 36183 Input Output Shaft Gears Press Tube J 36184 Input Output Shaft Press Tube Reducer Lubricate all components as assembly progresses Use lubricant P N 12345349 or equivalent Bearing race 6 and fifth gear 3 require heating in oven at 1 2 0...

Page 886: ...rst gear 49 bearing 50 caged thrust bearing 51 and thrust washer 52 using J 36183 and 15 ton press MINIMUM second gear 38 bearing 39 race 40 1 2 synchronizer 42 blocker rings 41 and 48 and 3 4 gear cluster 37 will press off with first gear Inspect Figure 13 Clean with solvent air dry m Output shaft components shaft 53 for spline wear or cracks replace if these conditions exist gear teeth 53 49 38 ...

Page 887: ...utput Shaft Components Removal Important Figure 14 m When pressing the 1 2 synchronizer assembly 42 start press operation STOP before tangs engage lift and rotate gears 49 and 48 to engage blocker ring tangs continue to press until seated be sure all shavings are removed 1 2 synchronizer 42 using J 36183 J 36184 and hydraulic press side marked 1ST and small O D groove on sleeve toward first gear 4...

Page 888: ...NG B L O C K E R RING TANGS 31 USING PROBE PUSH UP GEAR 32 THRUST WASHER 35 MUST STAY DOWN CONTINUE P R E S S OPERATION 25 GEAR R E V E R S E 5 T H SYNCHRONIZER A S S E M B L Y 31 RING B L O C K E R 5TH GEAR 32 GEAR 5TH S P E E D 33 BEARING 5TH G E A R 34 BALL THRUST WASHER POSITIONER 35 WASHER THRUST 36 SNAP RING 37 G E A R 3RD 4TH GEAR C L U S T E R 38 GEAR 2ND S P E E D 39 BEARING 2ND S P E E D...

Page 889: ...g Sleeve Bushing Remover Installer J 36039 Shift Detent Lever Bushing Remover Installer J 36190 Universal Driver Handle 1 2 3 4 Remove or Disconnect Figure 16 Remove bearings and bushings only if there is evidence of damage or a mating part is being replaced Snap ring 210 Plug 209 Screw 205 spring 206 and sliding sleeve 207 Bushing 95 sliding sleeve using J 36034 and J 36190 VIEW A 109 1 0 2 102 1...

Page 890: ...ING S L E E V E 96 BUSHING DETENT LEVER 97 BEARING SHIFT SHAFT 98 BUSHING R E V E R S E SHIFT RAIL 99 BUSHINGS THREE SHIFT RAILS 145 LEVER DETENT 204 PLUGS THREE SHIFT RAILS 205 SCREW SLIDING S L E E V E 44 N m 32 lb ft 206 SPRING SLIDING S L E E V E 207 SLIDING S L E E V E 208 SEAL SHIFT SHAFT 209 PLUG 210 SNAP RING 211 STUD 21 N m 15 lb ft INSTALL J36190 REMOVE INSTALL VIEWC SPECIAL TOOL USAGE J...

Page 891: ...flat side up 13 Stud 211 chamfer end out 21 N m 15 lb ft CLUTCH AND DIFFERENTIAL HOUSING ffij Disassemble Figure 17 Tools Required J 6125 1B Slide Hammer J 8092 Universal Driver Handle J 23907 Slide Hammer and Adapter Set J 35824 Input Bearing Assembly Remover Installer J 36029 Shift Rail Bushing Installer Remover J 36032 Clutch Shaft Inner Bushing Reverse Shift Rail Remover J 36037 Clutch Shaft U...

Page 892: ...SPACER THREE 162 PLATE INTERLOCK 163 BUSHING OUTER CLUTCH SHAFT 164 SEAL CLUTCH SHAFT 165 CLUTCH SHAFT 166 BREATHER ASSEMBLY 176 BUSHING SHIFT RAIL THREE 177 BUSHING INNER CLUTCH SHAFT 178 RETAINER 179 BOLT TWO 21 N m 15 lb ft 217 BEARING CLUTCH SHAFT TWO J36037 REMOVE 163 REMOVE INSTALL J35824 P R E S S REMOVE OIL S E E P A G E HOLE INSTALLED DOWN IN CLUTCH HOUSING VIEWB SPECIAL TOOL USAGE REMOVE...

Page 893: ...lic press VIEW B 4 Bushing 177 inner using J 36033 and J 36190 VIEW C External clutch release models only Bearing 217 inner using J 36720 1 and J 36720 2 VIEW C Internal clutch release models only 5 Clutch shaft 165 or 216 6 Bushing 163 upper using J 36037 VIEW B outer end of bushing flush to bottom of seal bore External clutch release models only Bearing 217 upper using J 36720 1 VIEW B Internal ...

Page 894: ...TX V I E W C V I E W D 9 S L E E V E 3 R D 4 T H S Y N C H R O N I Z E R 10 K E Y 3 R D 4 T H S Y N C H R O N I Z E R T H R E E 11 B A L L 3 R D 4 T H S Y N C H R O N I Z E R T H R E E 1 2 S P R I N G 3 R D 4 T H S Y N C H R O N I Z E R T H R E E 13 H U B C L U T C H 3 R D 4 T H S Y N C H R O N I Z E R 3 R D 4 T H A S S E M B L Y PROCEDURES E3 r sta 1 1 Sleeve 9 small O D groove up onto hub 13 sid...

Page 895: ...keys and balls View F Balls will click into position GX1276 MN5TX 202 180 181 182 183 184 185 186 187 188 189 190 191 192 193 194 195 196 197 198 199 200 201 202 RAIL REVERSE SHIFT ASSEMBLY SHIFT GATE 5TH REVERSE ROLLER GEAR DISENGAGE SHAFT REVERSE SHIFT RAIL 3RD 4TH SHIFT ASSEMBLY FORK 3RD 4TH SHIFT SHIFT PIN FORK RETAINER LEVER 3RD 4TH S E L E C T PIN LEVER RETAINER SHAFT 3RD 4TH SHIFT RAIL 1 ST...

Page 896: ...ese conditions exist Thrust washers 64 and 65 for wear scuffed nicked or burred condition If scuffed nicked burred or scoring conditions cannot be removed with a soft stone or crocus cloth replace the component Assemble Figure 22 Tools Required Hydraulic Press J 22919 Differential Inner Bearing Installer Heat mechanical configuration nylon speedo drive gear 71 in hot tap water for five minutes pri...

Page 897: ...6 Tools Required Hydraulic Press J 35824 Output Input Shaft Bearing Installer J 36031 Retainer Bolt Hex Socket J 36182 1 Gear Cluster and Transmission Case Assembly Disassembly Pallet 1 Position gear cluster shift rail assembly A on J 36182 1 align shift rail and shaft pilots to the fixture 2 Transmission case 85 align bearing bores in case with shaft pilots 3 NEW bearing 86 output shaft using J 3...

Page 898: ...4 j 14082140 0 70 0 028 WHITE 1 14082141 0 75 0 030 WHITE 2 1 4 0 8 2 1 4 2 0 80 0 031 WHITE 3 14082143 Q BS 0 033 WHITE 4 14082 4 0 90 0 035 GREEN 1 14082145 0 95 0 03 GREEN 2 14082146 1 00 0 039 GREEN 3 14082147 1 05 0 041 G R E E H 1 14082148 1 10 0 043 BLUE 1 14082149 1 1 5 0 045 BLUE 2 14082150 1 20 0 047 BLUE 3 14082151 1 25 0 049 BLUE 4 14082152 1 30 0 051 RED 1 13 N m 10 lb ft SEVEN A BEAR...

Page 899: ...82 ROLLER 184 3RD 4TH RAIL 190 196 19 PRESS PRESS BED 1 ST 2ND RAIL INTERLOCK PIN STH RAIL GX1264 MN5TX R1 A GEAR CLUSTER SHIFT RAIL ASSEMBLY 85 TRANSMISSION CASE 86 BEARING OUTPUT SHAFT 3 BEARING INPUT SHAFT GX1267 MN5TX R2 Figure 24 Gear and Shift Rail Assemblies Figure 25 Gear Cluster and Shift Rail Assembly Installation ...

Page 900: ...5TX Figure 28 Clutch and Transmission Housing Components Selected shim can be 0 03 mm 0 001 in above or 1 12 mm 0 004 in below the end plate mounting surface S 3 M e a s u r e Fi9ure 29 1 Distance between end plate mounting surface and outer race of output shaft bearing 86 2 Select shim from Chart Figure 29 TRANSMISSION CASE END PLATE Install or Connect Figure 30 Apply sealant P N 1052943 or equiv...

Page 901: ...ift rail 183 Figure 32 4 Detent balls 171 using a small screwdriver VIEW B m Install the detent balls for the shift rails in the following order 1 2 shift rail 190 3 4 shift rail 184 5th gear shift rail 197 5 Position holder 169 using pry to align bolt holes with threads 6 Bolts 175 9 0 N m 84 lb in BE SURE shift rails are in the correct detent positions 7 Protective cover 174 Tap until seated in ...

Page 902: ...P RING 140 COVER 141 SCREW 9 0 N m 84 lb 142 SPRING SEAT OUTER 143 SPRING 144 SPRING SEAT INNER GX1255 MN5TX n Figure 32 Detent Holder Installation use small amount of threat sealant GM P N 1052624 or equivalent 9 0 N m 84 lbin 5 Protective cover 140 position to below snap ring groove 6 Snap ring 139 Figure 33 Shift Shaft Detent Components Transmission Housing EXTERNAL TRANSAXLE MOUNTED LINKAGE IN...

Page 903: ...ASSEMBLY RETAINER 213 BOLT JH125Q MN5TX Figure 34 External Transaxle Mounted Linkage TORQUE SPECIFICATIONS P N DESCRIPTION OF USAGE TORQUE 18 Reverse shift rail guide 21 N m 15 lb ft 68 Differential pin 9 N m 84 lb in 77 Differential gear 83 N m 61 lb ft 79 Fluid drain plug 24 N m 18 lb ft 81 Clutch housing to gear housing 21 N m 15 lb ft 83 Alternate oil level 24 N m 18 lb ft check fill plug 88 O...

Page 904: ...lb ft 205 Sliding sleeve detent 44 N m 32 lb ft 211 Stud 21 N m 15 lb ft 212 Electronic speed sensor retainer 9 N m 84 lb in 219 Back up light switch assembly 9 N m 84 lb in Disassembled Parts Illustration Section 7B3 Figures 1 and 2 LUBRICANT SPECIFICATIONS Lube Capacity Approximate A N with 2 5L or 2 3L engine and P Carline 1 9 Liters 2 Quarts J L N with 2 0L Turbo and W Carline 2 1 Liters 5 Pin...

Page 905: ...7B3A 26 UNIT REPAIR MUNCIE 282 5 SPEED TRANSAXLE JH1272 M1M5TX Figure 35 Special Tools Muncie 282 5 Speed Transaxle ...

Page 906: ... O C K E T 33 J36032 CLUTCH SHAFT INNER R E V E R S E SHIFT RAIL BUSHING REMOVER 2 J36033 CLUTCH SHAFT INNER BUSHING INSTALLER 31 J36034 SLIDING S L E E V E BUSHING REMOVER INSTALLER 29 J36037 CLUTCH SHAFT UPPER BUSHING REMOVER INSTALLER 19 J36038 OUTPUT SHAFT BEARING CUP REMOVER 1 J36039 SHIFT DETENT L E V E R BUSHING REMOVER INSTALLER 30 J36182 INPUT OUTPUT SHAFT REMOVER INSTALLER ASSEMBLY S E T...

Page 907: ......

Page 908: ...the clutch system are the driving members the driven members and the operat ing members Figure 1 shows an exploded view of the clutch system The clutch housing is part of the man ual transaxle assembly Driving Members The driving members consist of two flat sur faces machined to a smooth finish One of these is the rear face of the engine flywheel and the other is the pressure plate The pressure pl...

Page 909: ...the pedal the push rod contacts the plunger and pushes it up the bore of the cylinder In the first 1 32 in of movement the center valve seal closes the port to the fluid tank and as the plunger continues to move up the bore of the cylinder the fluid is forced through the outlet line to the slave cylinder mounted on the clutch housing On the return stroke the plunger moves back as a result of the r...

Page 910: ...linder will occur if the clutch pedal is depressed while the slave cylinder is disconnected CLUTCH MASTER CYLINDER F l Remove or Disconnect Figure 5 1 Cylinder push rod at clutch pedal 2 2 Hydraulic line at master cylinder 3 Nuts attaching cylinder to cowl remove cylinder install or Connect Position cylinder push rod through cowl and loosely install cylinder to cowl nuts Cylinder push rod to clutc...

Page 911: ...tall or Connect 1 Slave cylinder bracket to transaxle Illl Tighten Torque bolt to 50 Nnn 32 lb ft L Slave cylinder bracket to shift cable bracket Tighten Torque bolt to 50 Nnn 32 lb ft Install or Connect 1 Position slave cylinder to mounting bracket and pilot slave cylinder push rod into clutch lever 2 Slave cylinder to bracket nuts 13 Tighten Torque nuts to 22 Nnn 16 lb ft C L U T C H R E L E A S...

Page 912: ...ng gears Clutch or gearbox mechanism faulty Wear in clevis linkages Check and replace faulty or worn components 520024 7C Figure 7 Clutch Hydraulic Diagnosis CLUTCH PEDAL PUSH ROD jy Inspect Figure 9 T Important Apply clutch and verify the clutch push rod remains parallel to bracket The clutch pedal lever and pivot pin must be square to pedal The clutch pedal pivot pin needs a snug fit to the clut...

Page 913: ...Burned or glazed facings b Worn splines on input shaft c Loose engine mountings d Warped pressure plate or flywheel e Burned or smeared resin on flywheel or pressure plate a Install new disc and correct U ak to engine or transaxle b Replace input shaft c Tighten or replace mountings d Replace pressure plate or flywheel e Sand off if superficial replaced burned or heat checked parts Rattling Transm...

Page 914: ...full the I D recess of the release bearing as shown in Figure 12 with P N 1051344 or equivalent 4 Transaxle as outlined in Section 7B2 or 7B3 C L U T C H R E L E A S E B E A R I N G p j Remove or Disconnect Figure 1 1 Transaxle assembly as outlined in Sections 7B2 or 7B3 2 Clutch release bearing from clutch fork shaft assembly P S n Clean Clean and inspect the release bearing NOTICE Do not place b...

Page 915: ...c assembly as previ ously outlined in this section LUBRICATE HERE 520020 7C Figure 12 Release Bearing Lubrication 3 Flywheel attaching bolts and flywheel assembly E3 Install or Connect 1 Flywheel and attaching bolts 1 U Tighten Torque bolts to 70 Nnn 50 lb ft Install or Connect 1 Pressure plate clutch disc assembly and release bearing as previously outlined in this section 2 Transaxle assembly as ...

Page 916: ... engages in center 5 Fit spring immediately to plunger and press home leaf of spring retainer to secure 7 9 10 11 N O T I C E Liberally lubricate the seal and the plunger bore with unused Delco Supreme No 11 Brake and Clutch Fluid or a fluid conforming to DOT 3 Insert plunger assembly valve end leading into cylinder body easing the entrance of the plunger seal Position push rod and retaining washe...

Page 917: ...the pipe line and cylinders is known as bleeding and isnecessary whenever any part of the system has been discon nected or the level of fluid in the supply tank has been allowed to fall so low that air has been drawn xnio the master cylinder When seals are worn it is possible for air to enter the cylinders without any sign of leaking fluid andcause a spongy pedal whichistheusualindica tion of air ...

Page 918: ...e assembly see Section 7B2 or 7B3 2 Clutch release lever 3 Clutch dust seal 4 Drive upper bushing with J36037 into housing 5 Clutch shaft and upper bushing Slide shaft out of case at a slight angle 6 Lower bushing using J36032 with J23907 Engage second step on J36032 below bushing and tighten screw to expand legs F l Install or Connect 1 Lower bushing using J36033 with J36190 2 Clutch shaft 3 Uppe...

Page 919: ...g Installation SPECIFICATIONS SPECIFICATIONS N M LB FT Clutch Flywheel To Crankshaft 70 50 Clutch Pressure Plate To Flywheel 20 15 m Clutch Pedal As sembly To Cowl 17 13 Hydraulic Pipe To Clutch Master Cylinder 17 13 Hydraulic Pipe To Clutch Slave Cylinder 17 13 Clutch Lever To Clutch Fork 27 20 Clutch Slave Cyl inder To Slave Cylinder Bracket 22 16 Slave Cylinder Bracket To Trans axle 50 32 J1025...

Page 920: ...tion 112 Back Up Lights ElectronicFuel Injection L4 VIN R 114 InteriorLights Multi port Fuel Injection V6 VIN 9 117 InteriorLights Dimming Starter and Charging System 120 PowerWindows Coolant Fan 130 Power Door Locks Vehicle Speed Sensor 134 Trunk Release Cruise Control 141 Power Remote Mirrors Horns 145 Lumbar Support BrakeWarningSystem 150 Radio Electric Steering Assist 201 Component Location Vi...

Page 921: ...gViews 203 0 Heater 60 0 Horns 40 0 Indicators Indicators Cluster 80 0 AJAR 80 2 BRAKE 80 0 CHARGE 80 3 COOLANTTEMP 80 0 FASTEN BELTS 80 1 HiBeam 80 1 SERVICE ENGINE SOON 80 1 UPSHIFT Indicator 80 0 Turn 80 1 VOLTMETER 80 3 OIL PRESSURE 80 3 Instrument Panel Indicators Cluster 80 0 InteriorLights Dimming 117 0 Introduction 2 0 Lights Exterior BackUp H2 0 Front Marker 110 0 Front Park 110 0 Hazard ...

Page 922: ......

Page 923: ...our own knowledge of the system and the Troubleshooting Hints havenot produced a quick fix follow the System Diagnosis Allpro cedures arebased on symptoms to assist you in locating the condition as fast as possible The Circuit Operation will help you under stand the circuit It describes the components and how the circuit works The Component Location List helps you find where the parts of the circu...

Page 924: ... each connector islisted in the Com ponent Location List Similarly switches and other components are shown as simply as pos sible with regard to function only The following example shows how to read a Horn schematic see figure 1 Locate the Horn schematic using the Index The circuit sche matic will look somewhat like the one to the right The schematic is read from top to bot tom Voltage is applied ...

Page 925: ...on the car Grounds are listed next in the table The location description for G101 reads LH front of engine compartment behind headlights panel You aredirected topage 201 8 figure D Nearly every component connector ground or splice shown on a schematic can be pin pointed visually byusing the Component Loca tion Views figures COMPONENT LOCATION Page Figure COMPONENTS Convenience Center Under LH side...

Page 926: ... if you need to backprobe a connector while it is on the component the order of the terminals must be mentally reversed The wire color is a help in this situation If there is more than one wire of the same color you may need tolocate a test point from its terminal number A useful trick is toimagine that you areprobing a termi nal from behind the page you are looking at Thenmentallylocatethat termi...

Page 927: ...ce and parts personnel in identi fying options and parts originally installed a Service Parts Identification Label has been placed in the car See the General Information Section OA of the Chassis Service Manual for the location of the label and the definition of the option codes Abbreviations A C Air Conditioning BCM Body Computer Module ECM Electronic Control Module or Engine Control Module I P I...

Page 928: ...hows howvoltage is applied from the positive Battery terminal to the various cir cuits on the car For example Battery voltage is applied to the Starter Solenoid Fusible Link D the BED wire and connector C100 to Fuse 1 and Fuse 2 in the Fuse Block and the Light SwitchintheLH Pod Thesefuses aresaid to be Hot At All Times since Battery voltage is always applied to them Notice that Battery voltage is ...

Page 929: ... In certain instances where space permits this detail is shown on the Power Distribution schematic The Fuse Block Details schematic is extremely helpful in locating a short circuit that causes a fuse to open F U S E BLOCK DETAILS FUSE 1 AND FUSE 2 H O T AT A L L T I M E S DOOR COURESTY LIGHTS PAGE 110 0 Figure 8 Typical Fuse Block Details Schematic o m O H o g Q Z O S2 w ...

Page 930: ...causes the fuse ahead of the Light Switch to open m O H o o 3 O 2 O C O So LIGHT SWITCH DETAILS I L I G H T I SWITCH SID 0 F F W 0 F F i PARK PARK i 8 BRN I 9 cSc401 8 BRN 19 S204 C204 9 8 BRN 8 BRN 8 BRN 8 BRN 1 9 LIGHT PAGE 111 0 LH TAIL LIGHTS PAGE 111 0 J I LIGHT PAGE 111 I LIGHTS PAGE 111 0 LIGHT PAGE 111 0 8 BRN 8 BRN 8 BRN E 1 g C 2 0 5 U V LH FRONT MARKER LIGHT PAGE 111 0 1 I LHFRONT PARK ...

Page 931: ...lights works you know that the ground and the wire up to the splice are good You have learned this just by inspecting the schematic and knowing the vehicle s symptoms No actual work on the lighting system was needed G R O U N D DISTRIBUTION G101 AND G102 FRONT LIGHTS GROUNDS l h F R O N T p a r k t u r n L I G H T l h H I G H beam H E A D L I G H T LH d u a l beam h e a d l i g h t r h D U A L bea...

Page 932: ...ALS POSSIBLE C103 6 CAVITIES 5 CAVITY CONNECTOR 5 OUT OF 5 CAVITIES ARE USED 5 CAVITY CONNECTOR 4 OUT OF 5 CAVITIES ARE USED 5 RED 1 2 S200 5 RED 12 CONNECTOR ATTACHED TO COMPONENT CONNECTOR ON COMPONENT LEAD PIGTAIL 5 RED 2 FUSIBLE LINK 1 RED INSULATION COLOR IS BOTH SHOWN AND L A B E L E D SPLICES A R E SHOWN AND NUMBERED CIRCUIT NUMBER IS SHOWN TO HELP IN TRACING CIRCUITS A WAVY LINE MEANS A WI...

Page 933: ...LE AS ELECTRONIC SIMPLIFIED COMPONENTS WITHIN THE MODULE SHOW HOW EACH CIRCUIT IS COMPLETED DO NOT MEASURE RESISTANCE OF CIRCUITS INSIDE SOLID STATE MODULES fT LL BRAKE RED 150 G200 INDICATES THAT THE C I R C U I T R Y IS NOT SHOWN IN COMPLETE DETAIL BUT IS COMPLETE IN THE INDICATED C E L L SEE GROUND DISTRIBUTION 1 ORN i 40 NO G A G E S i GAGES IC309 40 INDICATES THAT POWER IS SUPPLIED WITH IGNIT...

Page 934: ...ike electrical sole noids mechanically pushing or pulling a shaft between two fixed positions When vacuum is applied the shaft is pulled in When no vac uum is applied the shaft is pushed all the way out by a spring NO VACUUM Double diaphragm motors can be operated by vacuum in two directions When there is no vacuum the motor is in the center at rest position SERVO MOTOR PARTIAL VACUUM Some vacuum ...

Page 935: ...en the shared wiring is OK The cause must be within the wiring used only by the problem circuit If several circuits fail at the same time chances are the power fuse or ground circuit is faulty Step 3 Find the Cause and Repair Narrow down the possible causes Use the Troubleshooting Hints Make the necessary measurements as given in the System Diagnosis Before you replace a component check power sign...

Page 936: ...ly that the high beam filaments have burned out in both headlights or that both headlight connections are bad The cause must be abad connection at C100 or a break in the LT GRN wire between C100 and the RH Headlight You have quickly narrowed the possible causes down to one specific area and have done absolutely no work on the car itself Step 3 Find the cause and repair it Using the Component Locat...

Page 937: ...see Avoid using paper clips and other substitutes since they can damage terminals and cause incorrect measurements SELF POWERED TEST LIGHT Use a self powered test light J 21008 or equivalent to check for continuity This tool is made up of alight bulb battery and two leads If the leads are touched together the bulb will go on A self powered test light is used only on an unpowered circuit First disc...

Page 938: ...ontactthefuse The probes are either placed into the slots of a flat fuse or to the metal ends of a glass fuse With power on a red LED in the tester lights if the fuseisopen Thehandleofthetesterisatoolfor removingeithertype of fuse TROUBLESHOOTING TESTS TESTING FOR VOLTAGE 1 Connect one lead of a test light to a known good ground If you are using a voltmeter be sure it is the voltmeter s negative l...

Page 939: ...ess from side to side Continue this at convenient points about 6 inches apart while watching the test light or voltmeter 4 When the test light glows or the voltmeter registers there is a short to ground in the wiring near that point HOT AT ALL TIMES FUSE BLOCK FUSE REMOVED SHORT TO IF GROUND ARED SWITCH BLU LOAD DISCONNECTED SOLENOID T e s t i n g For Short With Test Light or Voltmeter With a SeSf...

Page 940: ...rt is in Connect test lamp meter or short finder at the connector to the suspect circuit dis connected rather than at the fuse termi nals H O T A T A L L T I M E S _ _ F U S E BLOCK N E E D L E STOPS MOVING HERE Finding Short With Short Finder PROPER J U M P S T A R T I N G P R O C E D U R E S With the use of electronic components such as solid state radios electronic control mod ules and others b...

Page 941: ...re 2 For service replacement non color coded fuses of the same respective current rating can be used The current rating of each fuse is molded into its head To determine whether or not an auto fuse is blown remove the suspect fuse and examine the element in the fuse for a break see Figure 1 If the element is broken replace the fuse with one of equal current rating There are however additional spec...

Page 942: ... S I B L E L I N K A F T E R S H O R T C I R C U I T Fusible links are available with two types of insulation Hypalon and Silicone GXL SIL GXL Service fusible links made with SIL GXL may be used to replace either Hypalon or SIL GXL fusible links Service fusible links made with Hypalon may only be used to replace Hypalon fusible links To determine the fusible link type nick the insulation of the bl...

Page 943: ...se of the wire insulation damage For minor damage tape over the wire If damage is more extensive replace the faulty segment of the wire Refer to the splicing instructions for copper alumi num or shielded cable for the correct splicing procedure S P L I C I N G C O P P E R W I R E Step One Open the Harness If the harness is taped remove the tape To avoid wire insulation damage use a sewing seam rip...

Page 944: ...p the Wires Select the proper clip to secure the splice To determine the proper clip size for the wire being spliced follow the directions included with your clips Select the correct anvil on the crimper On most crimpers your choice is lim ited to either a small or large anvil Overlap the two stripped wire ends and hold them between your thumb and forefinger as shown in Figure 7 Then center the sp...

Page 945: ...ith the other wires in the harness see Figure 11 If the wire does not belong in a conduit or other harness covering tape the wire again Use a winding motion tocover the first pieceof tape see Figure 12 SPLICING A L U M I N U M W I R E General Motors cars have a front body wir ing harness made of 2 0 metric and 1 0 metric 14 and 16 gauge insulated solid cable alumi num wires These wires areenclosed...

Page 946: ... splices harness branches or connectors Step Three Strip the Insulation When replacing a wire or lead use a wire of the same size as the original wire or larger Look up the metric wire size on the schematic and select the proper sized leads from the spe cial repair kit Remember that the wires in this harness can only be one of two sizes 2 0 metric or 1 0 metric 14 or 16 gauge Use wire strippers of...

Page 947: ...d to rewrap the twisted conductors after the splices have been made Step Three Prepare the Splice Untwist the conductors Then prepare the splice by following the splicing instructions for copper wirepresented earlier Remember to stagger splices to avoid shorts see Figure 17 Figure 14 Crimping The First Half Of The Splice Clip Aluminum Wire Step Four Re Assemble the Cable After you have spliced and...

Page 948: ...of the connector body Ease the lead back enough to release the locking tang Pull the pick out Gently pull the lead out of the back of the connector body Step Two Re Form the Locking Tang If the lead and terminal are in good condi tion reform the locking tang Hold the lead firmly to prevent the splice between the terminal and the wire from flexing Use the pick to bend the locking tang back intoits ...

Page 949: ...Step Two Re Form the Locking Tang Before mating the connector halves replace any terminal covers or retainers that were removed and apply grease to prevent corro sion WIDE PICK LOCKING TANG ACCESS HOLE TERMINAL RETAINERS REMOVING TERMINAL RETAINERS NARROW PICK1 DEPRESSING THE LOCKING TANG RE FORMING THE LOCKING TANG Figure 20 High Density Connectors ...

Page 950: ...TWIST WIDE PICK TO RE FORM TANG Figure 21 Bulkhead Type Connectors ...

Page 951: ...E TERMINALS PUSH UP WITH WIDE PICK LOCKING NIB REMOVING TERMINAL RETAINERS FEMALE TERMINALS LOCKING TANG LOCKING TANG LOCKING RE FORMING THE LOCKING TANG MALE TERMINAL NOTCH SMALL PICK LOCKING TANG RE FORMING THE LOCKING TANG FEMALE TERMINAL Figure 22 Metri pack Type Connectors Push To Seat Type ...

Page 952: ...lastic terminal retainers on large Weather P a c k connectors If a Weather P a c k connector requires repair donot replacetheWeather P a c k parts with other types of connectors and terminals Also do not omit either the large seal or the cable seals when making a repair Instruction in the disassemly repair and assembly of both small and large Weather Pack connectors follows The instruction is divi...

Page 953: ...g tangs using a Weather Pack pick J28742 A or the equiv alent Push the hollow cylinder of the pick into the terminal cavity from the front until it stops see Figures 26 and 27 The pick should surround the terminal see Figure 28 for drawings of locking tangs Pull the pick out Gently pull the lead out of the back of the connector body Note that the male connector body half con tains female terminals...

Page 954: ... and crimp and solder on the Weather P a c k lead assembly see Figure 29 using rosin core solder Follow the instructions for splicing wire outlined ear lier in this section for a review of splicing pro cedures If Weather P a c k lead assemblies are not available splice a new terminal and cable seal onto the existing wire Cut the wire immediately behind the cable seal Slip the new cable seal onto t...

Page 955: ... about halfway through the connector body Gently push back and forth on the lead to be sure the terminal is held in place in both directions If the terminal easily pushes or pulls out review Step Four k Re Form the Locking Tang Becareful toinsert leadsin their proper loca tions Step Seven Replace the Terminal Retainer s Large Connectorsl Secondary Locks Small Connectors Replace the terminal retain...

Page 956: ...disassembly and terminal removal and connector assembly and termi nal insertion Refer to figures 38 to 36 Step One Connector Disassembly and Terminal Removal Insert toolBT 8446orJ35689intothe con nector Figure 33 Pull back on the wire slightly pry up the locking tang and then push the wire through the front of the con nector If theterminal willbereused reshape the locking tang Step 2 Connector Ass...

Page 957: ...E LINK E V S t f i l 1 ORN j 240 ELECTRONIC C f i JLSI CONTROL 1 MODULE ECM S Q U D STATE i i t W T i i A S t t f t E L4 V l i R 3 DfifiE 102 0 G510 J L G 5 1 1 ENGINE BODY I COWTBOt I B t l i E ECM SOLID STATE J DO NOT MEASURE RESISTANCE FUSE 203 ...

Page 958: ...HOT AT ALL TIMES ...

Page 959: ...rtment near battery 201 4 A Cold Start Injector Top of engine onthrottle body Cold Start Switch TopRH side of engine onIntakemanifold 201 3 C Coolant Fan Relay LH front corner of front compartment 201 3 D CruiseBrake Switch Onbrakepedal support 201 11 A Direct Ignition System DIS Toprear of engine 201 2 B Electro Hydraulic Power Steering EHPS Controller Lower LH sideof front compartment 201 3 D El...

Page 960: ...rear bulkhead 201 5 A Behind dash near steeringcolumn 201 8 F Middle of steeringcolumn 201 8 E Beneath center console Engine compartment near battery 201 4 A RH side of engine near Battery Junction Block Top RH side of engine 201 4 B RH front of engine near dipstick 201 3 E RH side of engine belowoil fill cap 201 1 B Engine compartment on battery tray 201 2 C On trunk lid RH hinge brace 201 4 E En...

Page 961: ...I I N J 1 STOP HAZ 10 20 GAUGES TBI I N J 2 BAT 10 IGN P N S T L P W I P E R R A D 1 1 25 8 8 34 r no1 J 0 3 BAT P IGN INST LP RADIO BAT HTR A C 25 WDO 30 AMP LZT PWR ACC 30 AMP 1 25 CTSY LID FRONT VIEW OF FUSE BLOCK IGN Brown Connector LP Brown Connector REAR VIEW OF FUSE BLOCK Connector Cavity Locations 3 m O ...

Page 962: ...40 3 ORN BLK DOOR LOCK I RELAY A S S E M B L Y J PAGE 130 0 r 1 DEFOGGER 1 TIMER 5 RELAY 1 PAGE 61 0 2 P N K I 1 L H F R O N T I I POWER 8 ORN BLK I 60 I j WINDOW 1 SWITCH A A f 1 LIGHT PAGE 120 0 I I SWITCH I PAGE 12 0 1 PAGE 120 0 8 ORN BLK LUMBAR PUMP MOTOR RELAY PAGE 148 1 _ J DRIVER LUMBAR CONTROL SWITCH PAGE 145 0 1 1 I J PASSENGER LUMBAR CONTROL SWITCH PAGE 145 0 8 ORN 40 C308 40 PAGE 141 0...

Page 963: ...NJECTION H439 8 PNK BLK S507 Hi 8 PNK BLK 1 439 16AC2 r i 8 RED A I4 3 9 I SOLID j I STATE I l_J ELECTRONIC CONTROL MODULE ECM PAGE 20 3 PAGE 20 3 1 I LJ F U E L INJECTOR 839 1 PNK BLK I 639 FUSE BLOCK INSTRUMENT CLUSTER PAGES 80 0 80 1 80 2 AND 80 3 BRAKE SWITCH I g I I I 1 R A L L Y GAGE PANEL PAGE 80 3 PAGES 20 2 21 2 IfPOtilE J C O N V E N I E N C E CENTER PAGE 77 0 F U E L INJECTORS PAGE 21 3...

Page 964: ... ORN 1 ORN J POWER J 1 INPUT J L RADIO PAGE 150 0 ORN mm 140 140 8 BRN I 250 S204 BAE LJ BRAKE SWITCH PAGE 110 0 8 ORN I ORN 140 H A Z A R D I FLASHER 1 Aipt0 I ALARM MODULE 1 1 5 5 8 BRN WHT p 8 8 BRN 8 BRN 8 BRN WHT 140 PAGE 31 0 CONVENIENCE CENTER PAGE 110 0 CONVENIENCE CENTER PAGE 77 0 PAGE 114 0 8 BRN C O N T R O L L E R MOTOR 250 I GENERATOR J PAGE 30 0 I G8 A 500 8 BRN WHT 6TM0D61SV PAGE 40...

Page 965: ...AILS 7 HOT AT A L L T I M E S HOT AT A L L T I M E S FUSIBLE LINK B 3 BED 1 RED SSI mmn i STR IU Ti i I FUSE TAIL 3 BLOCK FUSE 1 20 AM 1 R K E R IHT SE 110 0 PARK LIGHT PAGE 110 0 PARK LIGHT PAGE 110 0 LIGHT PAGE 110 0 ...

Page 966: ... 8 G R Y 8 35 GRY PAGE 117 1 PRNDL ILLUMINATION LIGHT AUTOMATIC TRANSAXLEONLY PAGE 117 1 ...

Page 967: ...IGHT PAGE 110 3 8 BRN 8 BRN LICENSE LIGHTS PAGE 110 3 FROM C5Q0 PAGE 12 0 RH TAIL LIGHT PAGE 110 3 RH TAIL STOP TURN LIGHTS PAGE 110 3 RH REAR MARKER LIGHT PAGE 1103 I BRN O LH REAR MARKER LIGHT PAGE 1 1 0 4 GT MODELS 8 BRN LH TAIL STOP LIGHTS PAGE 110 4 K J RH TAIL STOP LIGHTS PAGE 1104 A j O R H R E A R MARKER LIGHT PAGE 1104 ...

Page 968: ...FIERO 8A 12 3 ...

Page 969: ... DISTRIBUTION G101 G102 FRONT LIGHTS GROUNDS 00 o BRAKE F L U I D LEVEL ELECTRO HYDRAULIC POWER STEERING CONTROLLER MOTOR HEADLIGHT DOOR MODULE 3 BLK RH DUAL BEAM R H F R O N T PARK TURN 6101 0 6102 2 m 30 O ...

Page 970: ...1 C O N T R O L I SERVO 8 BLK I 150 REAR PONTIAC E M B L E M RHTAIL 1 LIGHTS 8 BLK 8 BLK 150 150 RH TAIL STOP J LIGHTS 8 BLK 8 BLK 150 no LH TAIL I J LIGHTS J 8 BLK 8 BLK 1 150 150 1 8 T U R N V LIGHT 8 BLK I 150 f T R H B A C K U P LIGHT LICENSE I I PLATE LIGHTS C I 8 BLK 150 8 BLK 150 TURN LIGHT R H REAR t 1 M A R K E R X LIGHT 8 BLK I 150 8 BLK 150 ...

Page 971: ... GROUND DISTRIBUTION SE MODELS REAR LIGHTS GROUNDS LICENSE PLATE 8 BLK TO C500 PAGE 14 3 ...

Page 972: ...S106 JLJ3202 ENGINE JL BODY ...

Page 973: ...ATE J DO NOT MEASURE RESISTANCE I SEE POWER DISTRIBUTION 5 WHT C2 423 INSTRUMENT PANEL GAGES CLUSTER IGNITION COIL 7 SECOND ARY fc T H 4h PICKUP COIL IGNITION MODULE A M P L I F I E R SWITCH A SWITCH 8 V DIRECT IGNITION SYSTEM DIS SECOND ARY T TO S P A R K P L U G S A V C 2 8 BLK WHT I 450 E 6RMMQ G504 a IGNITION COIL n TO S P A R K P L U G S i MODULE ECM RESISTANCE ...

Page 974: ... ELECTRONIC FUEL INJECTION L4 VIN R A arA JTSL 7laVl J TZsriK K7Z 3k7 z sr xrxzM si i a FUEL CONTROL HOT AT ALL TIMES 00 ro o ...

Page 975: ...ON L4VIN R ENGINE DATA SENSORS TRANSAXLE CONVERTED CLUTCH UPSHIFT AND SERVICE ENGINE BOOM INOIICATC HOT IN RUN BULB TEST OR START 8 PNK BLK AIR A A A A V W V V ABSOLUTE TEMPERATURE A A A A V W V V PRESSURE S E N S O R SENSOR ...

Page 976: ...ELECTRONIC FUEL INJECTION L4 VIN R IDLE AIR CONTROL AND FUEL CONTROL HOT IN RUN BULB TEST OR START DO NOT MEASURE SEE ELECTRONIC FUEL INJECTION ENGINE DATA SENSORS ...

Page 977: ...d 201 5 B Top of engine top of throttle body 201 1 C Engine compartment LH side of rear bulkhead 201 5 B Top of fuel tank Behind LH side of I P 201 6 D RH front of engine compartment at Battery Junction Block 201 4 A Rear of engine LH side of throttle body 201 1 C At base of steeringcolumn 201 8 F On LH side of air cleaner 201 2 B Top of engine in front of air cleaner 201 1 A Rear of engine center...

Page 978: ...ngine 201 5 A 1 A 2 B C1 CHART Wire Color Circuit lrr t ill E i mf t lnn Cavity Socket Half Number v iri uii uiiouuii 1 BLU 467 Fuel Injector Control 2 LT BLU 67 A C On Input 3 _ _ Not Used 4 BLK 87 Resume Accelerate Input 5 _ Not Used 6 WHT 423 Spark Timing Output 7 LT BLU WHT 441 Idle Air Control A HI 8 LTGRN BLK 444 Idle Air Control B LO 9 LT GRN WHT 443 Idle Air Control B HI 10 ORN 240 Battery...

Page 979: ...ic Only Upshift Indicator Control Manual Only Coolant Temperature Sensor Input 9 10 11 12 PPL WHT LTGRN DK BLU WHT BLK 430 402 403 452 Reference Pulse Input HI Vacuum Valve Feed Vent Valve Feed Reference Ground 13 14 15 16 BRN WHT BLK BLK RED 86 451 453 Not Used Brake Input Diagnostic T e s t Input Reference Pulse Input LO 17 18 19 20 DK BLU LTGRN 417 432 Not Used Not Used Throttle Position Sensor...

Page 980: ......

Page 981: ... 9 IGNITION AND S E R V I C E ENGINE SOON LIGHT HOT AT A L L T I M E S j MXT J j s t A R r j J jr I w jmr TEST 1 I OFF Turn I i As J HOT IN RUN BULB TEST OR START ELECTRONIC CONTROL J MODULE ECM SOLID STATE j DO NOT MEASURE RESISTANCE ...

Page 982: ...RUN BULB TEST OR START HOT IN ACCY OR RUN F PUMP FUSE AMP Hj FUSE 1 BLOCK 1 ORN 440 B S C 2 0 3 1 ORN BLK 1 440 ASSEMBLY LINE DIAGNOSTIC LINK ALDL CONNECTOR G 1 TAN 120 WHT 1 TAN WHT 1 509 g F U E L PUMP 4 i R E L A Y 3 BLK WHT S E E GROUND DISTRIBUTION S E E GROUND DISTRIBUTION ...

Page 983: ...MULTI PORT FUEL INJECTION V 6 VIN 9 mm m Mmmmm mmmmm mmmmm I ENGINE DATA SENSORS TRANSAXLE CONVERTOR CLUTCH AND START I I HOT IN RUN BULB TEST OR START HOT AT ALL TIMES SENSOR ...

Page 984: ...ART HOT AT ALL TIMES F U S I B L E I LINK F 5 R U S T 1 ORN 240 E C M IGN F U S E 10 AMP 8 P N K B L K M 439 1 P N K B L K 639 K r I TBI INJ 2 F U S E 1 5 A M P J 6 3 9 F U S E B L O C K D E T A I L S JPNK 8 PNK 639 8 PNK 639 S516 639 C520 SPNK WHTW8 39 1 F U S E I B L O C K I ...

Page 985: ...e manifold 201 3 C Top RH side of engine 201 4 B Between seats on front of rear bulkhead 201 5 B Top LH side of engine 201 3 A RH front of engine on air intake duct 201 4 B Top of engine at eachintake port Engine compartment LH side of rear bulkhead 201 5 D Topof fuel tank Behind LH side of I P 201 6 D RH front of engine compartment at Battery Junction Block 201 4 A Lower LH front of engine at Sta...

Page 986: ... 5212 Mainharness behindcenter ofdash 201 6 C 5213 Mainharness behindrearbulkheadgrommet 201 15 A S216 Main harness behindcenter I P 201 15 A S504 Engineharness underrearconsole 201 5 A S508 VIN9 Engineharness lowerRH frontofengine 201 3 B S509 Engineharness underrearconsole 201 5 A S510 Engineharness underrearconsole 201 5 A S511 VIN9 Engineharness lowerRH front ofengine 201 3 B S513 Engineharnes...

Page 987: ...re MAP Sensor Input C12 LTGRN 432 Manifold Absolute Pressure MAP Sensor Input C13 DK BLU 417 Throttle Position Sensor Input C14 GRY 416 5 Volt Reference C15 LTGRN 468 Fuel Injector Control C16 ORN 240 Battery C1 CHART Cavity Wire Color Circuit Circuit Function Cavity Socket Half Number Circuit Function D1 BLK WHT 450 Ground D2 _ Not Used D3 _ _ Not Used D4 Not Used D5 TAN BLK 4 2 4 Ignition Module...

Page 988: ...ol Ignition TCC Control Auto Serial Data Link A 9 A 1 0 A11 A12 WHT BLK BRN TAN BLK 451 437 472 450 Diagnostic T e s t Input Vehicle Speed Sensor Input Manifold Air Temperature Sensor Input Ground C2 CHART Cavity Wire Color Circuit Circuit Function Cavity Socket Half Number Circuit Function B1 B2 B3 ORN BLK RED 240 453 Battery Not Used Distributor Reference Pulse Input LOW B4 WHT 423 Spark Timing ...

Page 989: ...STARTER AND CHARGING SYSTEM m m mms m 00 5 RED HOT N RUN HOT IN RUN BULB TEST OR START 5 YEL liJfljTlifi lfl IIATA i O 3 m 33 o ...

Page 990: ...erator Engine harness near generator 201 1 A STARTER AND CHARGING SYSTEM 6 VIN 9 AND L4 VIN R TROUBLESHOOTING HINTS STARTER Try the following checks before doing the System Diagnosis 1 Check the hydrometer eye that isbuilt into the vehicle Battery before troubleshooting the Starter System Green eye Battery is charged Dark eye Battery is discharged Recharge Battery _ Clear or yellow eye Battery flu...

Page 991: ...asure VOLTAGE At TRANSAXLE POSITIONS SWITCH CON NECTOR Disconnected Condition Ignition Switch START Measure Between Correct Voltage For Diagnosis F YEL Ground Battery See 1 If voltage is correct go to Table 4 1 Go to Table 6 A STARTER SOLENOID D 3ES NOT CLICK AND ENGINE DOES NOT CRANK TABLE 3 MANUALTRANSAXLE Measure VOLTAGE At CLUTCH START SWITCH CONNECTOR Disconnected Condition Ignition Switch ST...

Page 992: ...rect goto Table 2 1 Refer to Section 6D for Battery Load Test If Battery is OK remove Starter Assembly for repairs B STARTER SOLENOID CLICKS BUT ENGINE DOES NOT CRANK OR CRANKS SLOWLY TABLE 2 Measure VOLTAGE At BATTERY CABLES Conditions Battery FULLY CHARGED ECM IGN Fuse REMOVED Ignition Switch START Engine BEING CRANKED Continuedonnext column Continued from previous column Measure Between Correct...

Page 993: ...RGED OR OVERCHARGED TABLE 1 Measure VOLTAGE At GENERATOR CONNECTOR Disconnected and GENERATOR BATTERY TERMINAL Condition Ignition Switch RUN Measure Between L BRN L4 VINR Ground F BRN WHT Ground S RED Ground Battery terminal Ground Correct Voltage Battery Battery Battery Battery For Diagnosis S e e l See 2 See 3 See 3 If all voltages are correct reconnect con nector and go to Table 2 1 Check repai...

Page 994: ...to the direction current flowed when the Winding was first energized The magnetic fields of the Pull In and Hold In Windings now oppose one another This helps to quickly release the spring loaded drive mechanism and disengage the Starter As soon as the Motor Contacts open the entire circuit is turned off C I R C U I T O P E R A T I O N CHARGING SYSTEM The Generator provides voltage to operate the ...

Page 995: ...50 8 BRN WHT 250 S E E F U S E BLOCK D E T A I L S E L E C T R I C STEERING A S S I S T D A C O O L A N T FAN R E L A Y WITH AW CONDITIONING I DK GRN WHT 335 F9 JLC100 WITHOUT AIR CONDITIONING 3 B L K R E D 1 532 COOLANT FAN M MOTOR 3 BLK 151 SEE GROUND DISTRIBUTION L _ f I 3 BLK I 150 6 1 01 G201 8 DK GRN WHT 335 8 BLK D1 M C500 8 DK GRN WHT I 335 COOLANT TEMPERATURE SWITCH CLOSED ABOVE 113 C 235...

Page 996: ...illti AIR CONDITIONING COMPRESSOR CONTROLS 8 DK GRN WHT 8 GRY RED 901 _ J l A j L _ A i A i L i f V V 151 I I I iiWci ft It DO NOT MEASURE RESISTANCE 8 WHT BLK JLGIOI 451 ASSEMBLY LINE DIAGNOSTIC L NK ALDL CONNECTOR ELECTRONIC FUEL INJECTION ENGINE DATA SENSORS INSTRUMENT PANEL S212 3 B L K 1 150 G201 i i 1 CONTROL mmm HEAD H T R s WL SE GROUND DISTRIBUTION ...

Page 997: ...C Pressure Switch RH front of engine onrear of A C compressor 201 4 D Coolant Fan Relay LH front corner of front compartment 201 3 D Coolant Temperature Sensor VIN R Top LH rear of engine 201 2 B Coolant Temperature Switch VIN 9 Top RH side of engine onintake manifold 201 3 C Electronic Control Module ECM Between seats on front of rear bulkhead 201 5 B Fuse Block Behind LH side of I P 201 6 D Fusi...

Page 998: ...ition Ignition Switch RUN Jumper Between Correct Result For Diagnosis Terminal B Ground Coolant Fan runs Seel If the Coolant Fanruns refer to Section 6E for ECM diagnosis 1 Go to Table 2 A COOLANT FAN DOES NOT RUN TABLE 2 Connect FUSED JUMPER At ELECTRONIC CONTROL MODULE ECM CONNECTOR Connected Conditions Ignition Switch RUN A C Function Selector OFF Jumper Between Correct Result For Diagnosis 21 ...

Page 999: ... 335 wire for an open see schematic 2 Check BLK 150 wire for an open C COOLANT FAN RUNS CONTINUOUSLY 1 With the Ignition Switch in RUN discon nect the Coolant Fan Relay connector and connect a Test Lamp between D BRN WHT and F DK GRN WHT If the Test Lamp lights goto step 2 If the Test Lamp does not light replace the Coolant Fan Relay 2 Disconnect the A C Control Head connector If the Coolant Fan r...

Page 1000: ... TABLE 2 Connect TEST LAMP At COOLANT FAN RELAY CONNECTOR Disconnected Condition Ignition Switch RUN Connect Between Correct Result For Diagnosis D BRN WHT Ground Test Lamp lights Seel A RED Ground Test Lamp lights See 2 If the results arecorrect goto Table 3 1 Check the FAN E Fuse and BRN WHT 250 wire for an open 2 Check Fusible Link A and RED 2 wire for an open C COOLANT FAN DOES NOT RUN AT Conn...

Page 1001: ...olant Fan Relay The ECM energizes the Coolant Fan Relay by grounding circuit 335 The Relay energizes and battery voltage is applied to the Coolant Fan See Section 6E for specific conditions of the Coolant Fan operation The A C Control Head also energizes the Coolant Fan Relay by grounding circuit 335 whenever the A C Function Selector is in MAX NORM or B L Vi VIN 3 The Coolant Fan is operated by t...

Page 1002: ......

Page 1003: ...O M E T E R AND O D O M E T E R S T O T A L O D O M E T E R S T E P P E R M O T O R C O N T R O L 1 4 r 2 000 P U L S E S PER M I L E TRIP O D O M E T E R S T E P P E R M O T O R C O N T R O L TOTAL ODOMETER foioioa TRIP ODOMETER ASSEMBLY LINE A DIAGNOSTIC LINK ALDL CONNECTOR SEE GROUND DISTRIBUTION JC PYC1 8 BLK WHT I 450 M w C203 8 BLK WHT 8 BLK WHT 450 S504 450 450 450 1 BLK I 2 m 33 O ...

Page 1004: ...een seats on front ofrear bulkhead Fuse Block Behind LH side of I P Vehicle Speed Sensor RH end of transaxle C100 34 cavities LH side of front bulkhead right of brake master cylinder C203 15 cavities Between seats in front of rear bulkhead C245 8 cavities Beneath center console G504 VIN 9 LH top of engine below throttle body G504 VIN R TopLH front of engine above Starter Solenoid S201 Main harness...

Page 1005: ...RN WHT Ground Battery See 2 If allvoltages are correct go to Table 2 Check the DK GRN WHT 389 wire and BRN 437 wirefor anopen andcheck that connector C203 is mated correctly If all are good replace the Electronic Control Module Check the DK GRN WHT 389 wire for an open and check that connector C245 is mated correctly If both are OK and Cruise Control diagnostics in Section 8A 34 have been complete...

Page 1006: ...or generates a signal that indicates the speed of the vehicle The sig nal produced is a sine wave which is processed into a square waveby the Vehicle Speed Sensor Buffer to supply inputs to the Speedometer Electronic Control Module Cruise Control Module if equipped and Electro Hydraulic Power Steering Module The Vehicle Speed Sensor is mounted in t b Transaxle A magnet rotates near a coil pro duci...

Page 1007: ...CRUISE CONTROL K34 V6 VIN 9 HOT IN ACCY OR RUN CO INSTRUMEMT m JO O ...

Page 1008: ...CRUISE CONTROL VACUUM V6 VIN CRUISE CONTROL MODULE G202 ...

Page 1009: ...CRUISE CONTROL K34 L4 VIN R HOT IN A C C Y OR RUN 5 GRY ...

Page 1010: ...CONTROL 21 GROUND A W R K NEUTRAl Sr INPUT 8 D K B L U W H T TlY l 11VQ2 191T JT I 8 I 5 D K B L U I 4 j4 0 3 G R Y 1416 C J M4C255 I 5 GRvAr f 4 1 6 4 1 6 j 1 9 12Y 1 5 D K BLU I 4 1 7 T H R O T T L E POSITION 416 c j SENSOR 8 B L f 4 5 2 5 GRY A T J B 5 B L K 2 i L 4 V I N R 8 B L K E L E C T R O N I C F U E L I N J E C T I O N E N G I N E D A T A S E N S O R S ir LCSFO I I 8 B L K C V A C U U M...

Page 1011: ... 8 E Throttle Position Sensor VIN 9 LH top of engine on throttle body 201 3 A Throttle Position Sensor VIN R Top of engine right of throttle body 201 1 A Transaxle Position Switch LH rear of engine top of transaxle 201 2 B Vacuum Release Solenoid Engine compartment on LH shock tower 201 14 A Vehicle Speed Sensor RH end of transaxle 201 1 A C203 15 cavities Between seats in front of rear bulkhead 2...

Page 1012: ...Test Condition With Quick Checker Correct Response Without Quick Checker Using a Digital Meter For Different Response do Test Test Condition With Quick Checker Correct Response Meter Range Connector Terminals Correct Response For Different Response do Test 1 Cruise Switch Off 200 ohms J Ground 0 ohms B 1 Cruise Switch Off All Lights Off 20 V D C A J 0 volts A 1 Cruise Switch Off All Lights Off 20 ...

Page 1013: ...i Func tion Lever 5 Check for an open in GRY 397 wire be tween terminal B of connector C235 and terminal A of the Cruise Control Module connector C BRK C I R C U I T O P E N T E S T 1 Check for an open Brake Switch or Cruise Control Clutch Switch see schematic 2 Check for an open in the BRN 86 wire GRY 397 wire orYEL 918 wire D V E N T C I R C U I T O P E N T E S T If you are testing with a digita...

Page 1014: ...87 wire between terminal C of connector C235 and terminal M of the Cruise Control Module J VENT CIRCUIT SHORT T E S T Remove the connector from the Cruise Control Servo and measure the resistance between ter minals A and C of the Servo If it is less than 30 ohms replace the servo If it is 30 ohms or more check for a short to ground in the wire from terminal C of the Cruise Control Module to termin...

Page 1015: ...ruise Control Servo O CRUISE MODULE TEST 1 Check the resistance between G202 and G504 If it is more than 0 1 ohm clean and tighten both grounds and the negative battery cable In cases where the ground circuit is suspect add a ground strap between the engine block and the bulkhead If it is less than 0 1 ohm connect a new Cruise Control Module and check for normal operation SYSTEM DIAGNOSIS L4V1NR N...

Page 1016: ...TCH SCAN TOOL DISPLAYS ON DEPRESS BRAKE PEDAL CAN TOOL DISPLAYS OFih SCAN TOOL DISPLAYS ON REPLACE MULTI FUNCTION LEVER SCAN TOOL DISPLAYS OFF CHECK RADIO FUSE CRUISE SWITCH AND THE YEL 43 AND GRY 397 WIRES FOR AND OPEN SEE SCHEMATIC SCAN TOOL DISPLAYS OFF CHECK THE BRAKE SWITCH THE CRUISE CONTROL SWITCH WITH MANUAL TRANSAXLE THE GRY 397 WIRES AND THE BRN 86 OR YEL 918 WIRES FOR AN OPEN SEE SCHEMA...

Page 1017: ... ON SET SCAN TOOL FOR CRUISE RESUME ACCEL SWITCH SCAN TOOL DISPLAYS OFF PUT CRUISE SWITCH IN R A Continued on next page SCAN TOOL DISPLAYS ON CHECK THE SWITCH FOR A SHORT SCAN TOOL DISPLAYS OFF CHECK THE SET SWITCH AND DK BLU 84 WIRE FOR AN OPEN SEE SCHEMATIC SCAN TOOL DISPLAYS ON CHECK THE CRUISE SWITCH FOR A SHORT SEE SCHEMATIC ...

Page 1018: ...OL DISPLAYS ON I CHECK TRANSAXLE POSITION SWITCH AND ORN BLK 434 WIRE FOR A SHORT TO GROUND SCAN TOOL DISPLAYS SPEED OF CAR IN MPH SCAN TOOL DISPLAYS OFF CHECK THE CRUISE SWITCH AND GRY BLK AND BLK 87 WIRES FOR AN OPEN SEE SCHEMATIC MANUAL SET SCAN TOOL FOR MPH DRIVE THE CAR SCAN TOOL DOES NOT DISPLAY SPEED OF CAR IN MPH REFER TO SECTION 8A 33 Continued on next page ...

Page 1019: ... C2 AND GROUND 30 TO 55 OHMS _ LESS THAN 30 OHMS MORE THAN 55 0NMS CHECK FOR A SHORT TO GROUND IN THE LT GRN 402 WIRE OR THE CRUISE CONTROL SERVO SEE SCHEMATIC CHECK FOR AN OPEN IN THE CRUISE CONTROL SERVO LT GRN 402 WIRE OR BLK 150 WIRE SEE SCHEMATIC MEASURE RESISTANCE BETWEEN TERMINAL 11 DK BLU WHT OF CONNECTOR C2 AND GROUND Continued on next page ...

Page 1020: ... OR IN THE CRUISE CONTROL SERVO SEE SCHEMATIC CHECK FOR AN OPEN IN THE CRUISE CONTROL SERVO OR DK BLU WHT AND DK BLU 403 WIRES SEE SCHEMATIC VACUUM PULLS SERVO ALL THE WAY IN REMOVE JUMPER FROM TERMINAL E OF SERVO V A C U U M D O E S N O T P U L L S E R V O IM CHECK FOR BLOCKED OR L E A K I N G V A C U U M S O U R C E V A C U U M H O L D S S E R V O A L L T H E WAY IN VACUUM DOES NOT H O L D SERVO...

Page 1021: ... REMOVE JUMPER FROM TERMINAL E OF SERVO VACUUM DOES NOT PULL SERVO IN R E P L A C COJISE CONTROL SERVO VACUUM HOLDS SERVO ALL THE WAY IN DISCONNECT VACUUM RELEASE SOLENOID TURN THE IGNITION SWITCH TO RUN MEASURE THE VOLTAGE BETWEEN A PPL OF CONNECTOR AND GROUND VACUUM DOES NOT HOLD SERVO ALL THE WAY IN REPLACE CRUISE CONTROL SERVO Continued on next page ...

Page 1022: ... BETWEEN A PPL AND B BLK OF THE CONNECTOR CHECK ADJUST CRUISE BRAKE SWITCH AND CHECK YEL BLK LT GRN BLK AND PPL 943 WIRES FOR AN OPEN BATTERY 0 VOLTS REPLACE Ok REPAIR THE VACUUM RELEASE SOLENOID OR THE HOSE TO IT CHECK REPAIR BLK 150 WIRE FOR AN OPEN 00 OI ...

Page 1023: ...OUND BATTERY REPLACE MULTI FUNCTION LEVER BATTERY 0 VOLTS MEASURE VOLTAGE AT C2 TERMINAL 14 BRN TO GROUND BATTERY CHECK RADIO FUSE THE CRUISE SWITCH YEL 43 AND GRY 397 WIRES FOR AN OPEN SEE SCHEMATIC 0 VOLTS DEPRESS THE BRAKE PEDAL WHILE MEASURING VOLTAGE AT 2 TERMINAL 14 BRN TO GROUND CHECK THE BRAKE SWITCH CRUISE CONTROL CLUTCH SWITCH WITH MANUAL TRANSAXLE GRY 397 AND BRN 86 OR YEL 918 WIRES FOR...

Page 1024: ... DK BLU TO GROUND CHECK THE SET SWITCH FOR A SHORT BATTERY 0 VOLTS MEASURE VOLTAGE AT CI TERMINAL 4 TO GROUND SEE SCHEMATIC CHECK THE SET SWITCH AND DK BLU 84 WIRE FOR AN OPEN 0 VOLTS BATTERY I HOLD THE CRUISE SWITCH IN R A WHILE MEASURING VOLTAGE AT C1 TERMINAL 4 TO GROUND SEE SCHEMATIC CHECK THE CRUISE SWITCH FOR A SHORT SEE SCHEMATIC Continued on next page 00 1 W ...

Page 1025: ...RES FOR AN OPEN SEE SCHEMATIC MANUAL PUT GEAR SHIFT IN DRIVE MEASURE CONTINUITY TO GROUND AT C1 TERMINAL 18 ORN BLK SHORT OPEN CHECK TRANSAXLI POSITION SWITCH AND ORN BLK 434 WIRE FOR A SHORT TO GROUND MEASURE RESISTANCE BETWEEN TERMINAL 10 LT GRN OF CONNECTOR C2 AND GROUND Continued on next page ...

Page 1026: ...RN IT OFF JUMPER TERMINAL E OF SERVO TO BATTERY MORE THAN 55 OHMS CHECK FOR A SHORT TO GROUND IN THE LT GRN 402 WIRE OR THE CRUISE CONTROL SERVO SEE SCHEMATIC CHECK FOR AN OPEN IN THE CRUISE CONTROL SERVO LT GRN 402 WIRE OR BLK 150 WIRE SEE SCHEMATIC LESS THAN 30 OHMS MORE THAN 55 OHMS CHECK FOR A SHORT TO GROUND IN THE DK BLU WHT AND WHT 403 WIRES OR IN THE CRUISE CONTROL StRVO SEE SCHEMATIC CHEC...

Page 1027: ...WAY HOLDS SERVO ALL IN REPLACE ECM SEE SECTION 6E2 AND 8C VACUUM DOES NOT HOLD SERVO ALL THE WAY IN Continued on next page VACUUM DOES NOT PULL SERVO IN CHECK FOR BLOCKED OR LEAKING VACUUM SOURCE VACUUM SOURCE OK REMOVE JUMPER FROM TERMINAL EOF SERVO VACUUM SOURCE BLOCKED OR LEAKING REPAIR Continued on next page ...

Page 1028: ...L THE WAY IN REMOVE JUMPER FROM TERMINAL t OF SERVO VACUUM HOLDS SERVO ALL THE WAY IN DISCONNECT VACUUM RELEASE SOLENOID TURN THE IGNITION SWITCH TO RUN MEASURE VOLTAGE BETWEEN A PPL OF CONNECTOR AND GROUND m VACUUM DO ES NOT PULL SERVO IN REPLACE CRUISE CONTROL SERVO VACUUM DOES NC WAY IN T HOLD SERVO ALL THE REPLACE CRUISE CONTROL SERVO Continued on next page ...

Page 1029: ... BETWEEN A PPL AND B BLK OF THE CONNECTOR CHECK ADJUST CRUISE BRAKE SWITCH AND CHECK YEL BLK LT GRN BLK AND vvl 943 WIRES FOR AN OPEN BATTERY REPLACE OR REPAIR THE VACUUM RELEASE SOLENOID OR THE HOSE TO IT 0 VOLTS CHECK REPAIR BLK 150 WIRE FOR AN OPfcN 3 m 3D O ...

Page 1030: ...ule operate the coils of the Vacuum Valve and the Vent Valve Both valves are located in the Cruise Control Servo These valves move the throttle by means of the Vacuum Motor With V6 VIN 9 engine the Servo Position Sensor coil senses the position and motion of the Vacuum Motor It feeds this information back to the module to provide smooth acceler ation while the vehicle is in Cruise Control With the...

Page 1031: ... e Eg fW 1 r ii lit AtUJ G C210 1 D 8 6 R W HORN BLK 28 BRUSH STEERING WHEEL Mr RING B L K 28 HORN HORN WITCH 4 H6 f OR C100 TERMINAL 1 D K GRN VIEW SEE BULKHEAD CONNECTOR PAGE 202 0 29 1 OK GRN I 29 I _ A 1 LO PITCH yj HI PITCH HORN ...

Page 1032: ... O COMPONENT LOCATION Convenience Center Behind RH sideof I P Fuse Block Behind LH side of I P Horn Brush Top of steering column Horn Brush Slip Ring Top of steering column below steering wheel C210 11 cavities Lower RH side of steering column S210 Page Figure 201 9 A 201 6 D 201 8 B Main harness behind RH side of I P 201 6 C B NONE OF THE HORNS SOUND Connect TEST LAMP At CONVENIENCE CENTER Condit...

Page 1033: ...LtCt INSTRUMENT PANEL PRINTED CIRCUIT AUDIO ALARM SYSTEM BRAKE FLUID L E V E L SWITCH I CLOSED WITH LOW BRAKE FLUID 8 FPL I mm U l d t ntOi G2jLci 8 PPL IGNITION I SWITCH mSTARTJ rsuis j 209 B g C305 209 t 4 TEST OFF RUN z PARK BRAKE SWITCH CLOSED WITH PARK B R A K E APPLIED 23 m o ...

Page 1034: ...ideof I P Ignition Switch At base of steering column In Line Diode Behind I P near LH shroud Parking Brake Switch Onparking brake support C100 34 cavities LH sideof front bulkhead right of brake master cylinder C201 8 cavities LH shroud above center access hole C305 4 cavities Behind dash near LH shroud G101 On LH fender below headlamp S103 Forward lamp harness near bulkhead connector S203 Main ha...

Page 1035: ...N WITH THE IGNITION SWITCH IN RUN AND THE PARK BRAKE O F F TABLE 3 Measure RESISTANCE At IGNITION SWITCH CONNECTOR Condition Ignition Switch RUN Connect Between Correct Result For Diagnosis G2 terminal ground Infinite Ohms Seel Ifresult is correct check repair TAN WHT 33 wires and Instrument Cluster Printed Circuit for shorts to ground 1 Replace the Ignition Switch B BRAKE WARNING INDICATOR D O E ...

Page 1036: ...tch is in RUN BULB TEST or START Three switches are connected to the BRAKE Warning Indicator When any one ofthese Switches closes ground is provided and the Indicator lights The Ignition Switch provides a ground when it is in the BULB TEST and START positions The BRAKE Warning Indicator lights The Park Brake Switch provides a ground when the Park Brake is applied The BRAKE Warning Indicator lights...

Page 1037: ... RED I 2 C2 ELECTRO HYDRAULIC POWER STEERING EHPS CONTROLLER ELECTRO HYDRAULIC POWER STEERING EHPS PUMP MOTOR R E L A Y C O N T R O L SOLID STATE 5v iiar 7 8 BRN 8 BRN 437 G 7 g C 1 0 0 SEE GROUND DISTRIBUTION C E L L 14 437 MJUI INSTRUMENT V E H I C L E t J S P E E D ff S E N S O R J B U F F E R CLUSTER 1 BLK 3 B L K COOLANT 1 4 F A N 1 5 1 MOTOR 1 BLK 150 G102 A 1 5 BLK 8 BLK C2 150 A C I DIAGNO...

Page 1038: ...teering EHPS Controller Lower LH side of front compartment 201 3 D Electro Hydraulic Power Steering EHPS Pump Motor Lower LH side of front compartment 201 3 D Fuse Block Behind LH side of I P 201 6 D Fusible Link X RH front of engine compartment at Battery Junction Block 201 4 A C100 34 cavities LH side of front bulkhead right of brake master cylinder 201 13 A G101 On LH fender below headlamp 201 ...

Page 1039: ...HOT IN RUN HOT AT A L L T I M E S 1 FUSE SEE GROUND DISTRIBUTOR FUSIBLE LINK A 1 RUST I C V D V B 1 Y E L I 51 8 ORN 52 I 1 LT BLU 72 B 3 j 2_1 E l l 5 RED G201 ...

Page 1040: ... LH side of I P 201 6 D Fusible Link A RH front of engine compartment at Battery Junction Block 201 4 A High Speed Blower Relay On RH side of heater A C plenum 201 13 A C100 34 cavities LH side of front bulkhead right of brake master cylinder 201 13 A G201 Behind center of I P 201 6 C S106 Heater A C harness center of front bulkhead 201 13 A S107 Heater A C harness RH side of front bulkhead 201 13...

Page 1041: ... Battery See 2 Blower Switch HI B PPL Ground Battery See 3 If all voltages are correct replace the Blower Resistors 1 Check YEL 51 wire for schematic an open see 2 Check LT BLU 72 wire for an open see schematic 3 Check PPL 65 wire for an open see sche matic C BLOWER MOTOR TEST Measure VOLTAGE At BLOWER MOTOR CONNECTOR Disconnected Conditions Ignition Switch RUN BlowerSwitch Hi Measure Between Corr...

Page 1042: ...Speed Blower Relay is energized The relay contacts close and battery voltage is applied directly to the Blower Motor The Blower Motor runs at its fastest speed D HIGH SPEED BLOWER RELAY TEST TABLE 2 Connect FUSED JUMPER At HIGH SPEED BLOWER RELAY CONNECTOR Disconnected Jumper Between Correct Result For Diagnosis D RED B PPL Blower Motor runs Seel If the result is correct replace the High Speed Blo...

Page 1043: ...A S E S FUSE J BLOCK 5 10 AMP MANUAL j I SEE FUSE J BLOCK DETAILS FOR FIRST OPERATION TIMER CONTACT CLOSES FOR 10 MINUTES FOR FURTHER OPERATIONS TIMER CONTACT CLOSES FOR 5 MINUTES INTERIOR LIGHTS DIMMING 0 I o 8 GRY pm 7JT 1 DEFOGGER CONTROL PANEL LIGHT BRAIDED G303 G203 33 O ...

Page 1044: ... 201 6 E Fuse Block Behind LH side of I P 201 6 D C200 16 cavities LH shroud aheadof center access hole 201 6 D C302 1 cavity Near LH side ofrearwindow 201 13 B G203 On RH steering column support 201 6 F G303 On RH B pillar SYSTEM CHECK TABLE ACTION NORMAL RESULT FOR DIAGNOSIS OF OTHER RESULTS 1 Turn the Ignition Switch to RUN and depress the Defogger Control Switch The switch button returns to th...

Page 1045: ...ee 2 A PPL WHT Ground Lamp lights See 1 Defogger Switch OFF B LT BLU Ground Lamp does not light See 4 D BLK B LT BLU Lamp does not light See 4 A PPL WHT Ground Lamp does not light See 1 If all the results are correct do Test D 1 Replace the Defogger Timer Relay 2 Check the BLK 150 wire for an open see schematic Check that ground G203 is clean and tight 3 Check the LT BLU 292 wire for an open see s...

Page 1046: ... 2 If all the results are correct refer to the GM Body Service Manual Section 2 for gridlinerepair 1 Do Test B 2 Check the braided wire for an open Check that ground G303 is clean and tight see schematic Continued in next column CIRCUIT OPERATION With the Ignition Switch in RUN voltage is applied to the Defogger Control WhentheDefogger ControlSwitchis pressed ON voltage is then applied to the Defo...

Page 1047: ...8A 65 Air Delivery 4 MoveFan Switch from JL 0 to H I Increased airflowat each step 8A S3 Blower Controls 5 DEF Warm air flows from windshield and side window outlets Slight air flow at floor outlets Compressor turns on 8A 65 Air Delivery 8A 64 Compressor Controls 6 VINT TemperatureLeveratCOLD Air at outside temperature flows from Instrument Panel outlets Compressor does not run 8A 65 Air Delivery ...

Page 1048: ...FIERO 8A 62 1 p I ...

Page 1049: ...AIR CONDITIONING BLOWER CONTROLS C60 MANUAL A A Jk A A HOT AT ALL TIMES HOT IN RUN 1 FUSE 1 RUST 5 RED S206 m I RED 3 RED S 3 BLK ...

Page 1050: ...age Figure A C Power Relay Front compartment on RH side of heater A C module Blower Motor Center of front bulkhead Blower Resistors Front compartment lower RH side of heater A C module Fuse Block Behind LH side of I P Fusible Link A RH front of engine compartment at Battery Junction Block High Speed Blower Relay On RH sideof heater A C plenum C100 34 cavities LH side of front bulkhead right of bra...

Page 1051: ... PPL Ground Correct Resistance 0 ohms Less than 3 ohms For Diagnosis Seel See 2 If voltages in Table 1 and resistances in Table2 arecorrect but Blower Relay does not operate replace the Blower Relay 1 Check the BLK 150 wire for an open 2 Check the PPL 65 wire for an open If wire is good recheck measurements made in Test A C BLOWER RESISTORS TEST Measure RESISTANCE At BLOWER RESISTORS Disconnected ...

Page 1052: ...present check ORN 52 wire for a wire to wire short to voltage If wire is good replace Blower Switch 2 Check ORN 52 wire for an open If wire is good replace Blower Switch E A C POWER RELAY TEST Measure VOLTAGE At A C POWER RELAY CONNECTOR Disconnected Conditions Ignition Switch RUN A C Mode VENT Blower Switch LO Ml or M2 Measure Between Correct Voltage For Diagnosis D BRN Ground Battery S e e l A B...

Page 1053: ...ough the HTR A CFuse With the Mode Selector in the OFF position no volt age is supplied to the A C Power Relay coil and its contactsremain open In anyother mode the relay is energized and its contacts close provid ingvoltage to the Blower Switch With the Blower Switch in the LO position voltage is applied through all three Blower Re sistors to the Blower Motor The blower runs at low speed As the B...

Page 1054: ...8A 63 5 FOEKO ...

Page 1055: ... N R T M I 6 8 L T G R N I 66 A2 JlC100 VI VIN 9 8 LTGRN 66 A3 3 C 1 0 0 8 LT BLU 1 6 7 D S C203 8 L T G R N 8 L T G R N 8 G R Y R E D 9 0 1 S 5 3 0 8 G R Y R E D J 9 0 I PRESSURE CYCLING SWITCH OPENS BELOW 165 kPa 24 PSI r CLOSES ABOVE 330 kPa 48 PSI 8 L T BLU 67 A _ C 1 0 0 8 LT B L U A C HIGH f PRESSURE C U T O U T 7 SWITCH 8 LT BLU I 67 OPENS ABOVE 2930 kPa 425 PSI T 8 L T BLU I 67 8 LT BLU 67...

Page 1056: ...Cut Out Switch RH front ofengine LH end of A C compressor A C Low Pressure Switch RH front ofengine LH end ofA C compressor Electronic ControlModule ECM Between seats onfront ofrearbulkhead FuseBlock BehindLH sideof I P Pressure CyclingSwitch Frontcompartment on accumulator C100 34 cavities LH sideoffrontbulkhead rightofbrakemaster cylinder C203 15 cavities Between seats in front ofrearbulkhead G5...

Page 1057: ...IN 9 1 B L K L 4 V I N R 1 BLK WHT I 450 I 4 5 0 K ft G504 sis l i S T i l f i T t i i CONTINUED FROM PAGE 63 0 1 BLK WHT 1 922 N C 2 0 3 1 B L K W H T I 922 1 A C COMPRESSOR CONTROL R E L A Y 1 BLK 1 BLK A C CLUTCH 01ODE IS TAPED INSIDE COMPRESSOR CONNECTOR U VHt R 150 V 6 V I N 9 153 L4 VIN R mmm 1 BLK GROUND DISTRIBUTION 1 BLK 152 153 G503 1 B L K J I 5 0 A C HIGH PRESSURE C U T O U T SWITCH OP...

Page 1058: ...ee Section IB for Refrigerant and Compressor diagnostics 4 Turn off Ignition Switch and check refrigerant pressure at the low side service fitting If pressure is less than 207 kPa 30 psi refer to Section IB for refrigerant diagnostics If refrigerant pressure is higher than 207 kPa 30 psi isolatetrouble conditionsusingprocedures in System Diagnosis SYSTEM DIAGNOSIS L4V1NR Use the Isolation Tests be...

Page 1059: ...e 2 Check for an open in the LT BLU 67 wire 3 Check for an open in the DK BLU 458 wire If wire is good replace the A C Compressor Control Relay A E C M C O M P R E S S O R C O N T R O L T E S T TABLE 2 Connect FUSED JUMPER At ECM CONNECTOR C2 Disconnected Conditions Ignition Switch RUN Engine not running A C Mode NORM Temperature Outside Car ABOVE 60 F 16 C Continued in next column Continued from ...

Page 1060: ...C Compressor Control Relay with a fused jumper connected across the terminals of the A C High Pressure Cut Out Switch connector disconnected If battery voltage is present replace the A C High Pressure Cut Out Switch If battery voltage is not present check the wiring between the switches back to the A C Control Head see schematic SYSTEM DIAGNOSIS V6 VIN 9 Use the Isolation Tests below to choose the...

Page 1061: ...perature Outside Car ABOVE 60 F 16 C Jumper Between Correct Result For Diagnosis C1 C2 DK BLU Ground A C Compressor Control Relay operates and A C Compressor Clutch engages Seel If the result is correct but A C System does not operate normally condition is due to the ECM Refer to Section 6E for ECM diagnostic procedures 1 Replace the A C Compressor Control Relay B A C COMPRESSOR CLUTCH TEST Measur...

Page 1062: ...essure Cut Out Switch which are both normally closed The A C Low Pressure Switch opens if the refrigerant charge is too low to operate the A C Compressor with out possible damage to it The A C High Pres sure Cut Out Switch opens when refrigerant pressure is too high for normal operation The A C Compressor Control Relay is oper ated by the ECM When the ECM receives the A C On signal at terminal 2 i...

Page 1063: ...AIR CONDITIONING AIR DELIVERY MZXl C60 MANUAL 1A C j C O N T R O L HEAT PARTIALLY O P E N DEFROST BY DESIGN D O O R OUTSIDE RECIRCULATING D O O R ...

Page 1064: ...NENT LOCATION Page Figure Fuse Block Behind LH side of I P 201 6 D Mode Door Actuator Rear of heater A C module 201 8 C Recirculating Door Actuator Rear of heater A C module 201 8 C G201 Behind center of I P 201 6 C S212 Main harness behind center of dash 201 6 C Continued from previous column NORM A A A Fresh Air from Instru ment Panel Outlets and Floor BI LEV A B A Fresh Air from Instru ment Pan...

Page 1065: ...R F RED A BLK Test Lamp lights See 3 A C Mode B L D PPL A BLK Test Lamp lights See 4 A C Mode MAX C LT BLU A BLK Test Lamp lights See 5 A C Mode NORM C LT BLU A BLK Test Lamp lights See 5 A C Mode VENT C LT BLU A BLK Test Lamp lights See 5 Continued from previous column 5 If all results are correct but the Mode Door Actuator does not operate replace the Actuator If none ofthe results are correct o...

Page 1066: ...ny of the Mode Switch buttons is pushed the motor is en ergized through the contact assembly The motor will then run until the contact assembly opens the motor circuit and the motor stops at the se lected position The actuator motion is trans ferred to the Mode Door and Heat Defrost Door by two spring loaded telescopic links The Outside Recirculating Door has two posi tions allowing either outside...

Page 1067: ...5 AMP SEE LIGHT SWITCH DETAILS I JlllWTOTlllfiT LIGHTS H O T A T A L L T I M E S H O T IN R U N B U L B T E S T O R S T A R T STOP HAZ FUSE 20 AMP SEE FUSE B L O C KDETAILS GAGES FUSE 10 AMP SEE FUSE BLOCK DETAILS FUSE BLOCK ORN 140 S204 1 8 ORN I ORN 140 140 1 PNK BLK 39 FUSE BLOCK DETAILS S203 8 PNK BLK 39 LIGNTS QN INPUT POWER INPUT I G N I T I O NI N P U T S E E FUSE BLOCK DETAILS CONVENIENCE ...

Page 1068: ...T PULSED CHIME LIGHTS O N F A S T C H I M E KEY W A R N I N G S L O W CHIME SEATBELT W A R N I N G KEY IGNITION I N P U T FASTEN BELTS I N P U T P A R K I N G B R A K E I N P U T FASTEN BELTS O U T P U T Sc OUKD iL HY 1 Y F Y 5 s AUDIO ALARM MODULE SOLID STATE 00 N O T M E A S U R E RESISTANCE 00 1 VI ...

Page 1069: ...f steering column 201 9 B In Line Diode Behind I P near LH shroud 201 8 A Parking Brake Switch Onparking brake support 201 9 C Remote Dimmer Below center of I P near steering column support 201 8 D Seatbelt Switch Behind LH seat 201 13 B C201 8 cavities LH shroud above center access hole 201 12 C C210 11 cavities Lower RH sideof steering column 201 8 B C305 4 cavities Behind dash near LH shroud 20...

Page 1070: ...Reminder does not operate E Lights On Input Test Only the Lights On Chime Reminder operates when it should not E Lights On Input Test Onlythe Parking Brake Warning does not operate F Parking Brake Input Test Only the Parking Brake Warning operates when it should not F Parking Brake Input Test A AUDIO ALARM MODULE TEST Connect TEST LAMP At CONVENIENCE CENTER Condition Audio Alarm Module REMOVED Con...

Page 1071: ...ten Belts Indicator lights Seel Remove Jumper Fasten Belts Indicator does not light See2 If the indicator response was correct replace the Audio Alarm Module 1 Check repair thebulb theYEL 237 wire the BLK 150 wire and the Instrument Cluster Printed Circuit for opens 2 Checkthe Instrument Cluster Printed Cir cuit for a short to Battery E LIGHTS ON INPUT T E S T Measure VOLTAGE At CONVENIENCE CENTER...

Page 1072: ...ition Input and 2 a ground at the Fasten Belts Input This occurs when the Seat belt Switch is closed and because the LH front seatbelt is not buckled While the slow chime sounds the module also supplies steady bat tery voltage tothe Fasten Belts Output to light the Fasten Belts Indicator To sound the Key In Ignition Warning both the Ignition Key Warning Switch and the LH Front Door Jamb Switch mus...

Page 1073: ...R 18 8 WHT C3 121 C500 VS VIN 9 5 DK GRN 5 LT GRN 5 BLK WHT 1121 I 8 WHT 150 IGNITION SWITCH G 1 J J C 1 r r 135 1 C 2 A AA 1 I DIRECT I IGNITION I i SYSTEM WHT 121 I 5 BLK p 1 5 0 I M FUEL TANK MM 1 RESISTANCE 5 PNK C3 30 1 PNK B W C502 30 B V C511 121 fun GAGE 90 OHMS AT F U L L j SENDER 0 OHMS A T EMPTY L kf J j TACHOMETER FILTER T JLS2S1 ACCY I ASTARTj j i f f RUN J 8 DK GRN 135 m X D 3 O C 5 ...

Page 1074: ...INSTRUMENT PANEL INDICATORS CLUSTER INDICATORS WARNINGS AND ALARMS HEADLIGHTS ...

Page 1075: ... AJAR I J T INDICATOR 10 V C2 35 DK GRN 146 35 DK GRN 03 8 DK GRN 146 CI 00 146 8 BLK ORN C201 158 S312 8 BLK ORN 1158 A C 3 1 5 8 BLK ORN 8 158 A i p BLK ORN I 158 A S C 3 J 6 8 BLK ORN JQ 158 A l BLK ORN 1 158 LH RH 00 00 0 1 DOOR AJAR A DOOR AJAR SWITCH A SWITCH CLOSED WITH DOOR OPEN CLOSED WITH DOOR OPEN A SWITCH CLOSED WITH DOOR OPEN SEE GROUND DISTRIBUTION 8 BLK S212 HOOD 1 AJAR 3 BLK 1 1 SW...

Page 1076: ...4VINR SEE FUSE SLOCK D E T A I L S SEE GROUND DISTRIBUTION 3 BLK r AT MAXIMUM PRESSURE STARTER f t l CHARGING SYSTEM V 6 V I N 9 HOT IN RUN B U L B T E S T O R S T A R T NOT USED I SENDER 90 OHMS K AT MAXIMUM PRESSURE B33ggC500 SEE STARTER AND CHARGING SYSTEM ...

Page 1077: ...I DO NOT MEASURE 1 RESISTANCE 1 ELECTRO HYDRAULIC 5 DK GRN WHT V6 VIN S NOT USED L4 VIN R C245 5 DK GRN WHT 389 8 BRN G7 SI CI 00 437 1 1 4 1R 0 PULSES PER MILE r 1 INSTRUMENT SPEEDOMETER VEHICLE E BUFFER TOTAL ODOMETER TRIP OMWHET6B 8 BLK WHT M i CLUSTER PRINTED CIRCUIT ASSEMBLY LINE DIAGNOSTIC LINK ALDL CONNECTOR SEEGROUND DISTRIBUTION CI 450 C203 450 S504 8 BLK WHT 8 BLK WHT 450 1 BLK I 450 050...

Page 1078: ...Used NotUsed NotUsed NotUsed NotUsed NotUsed NotUsed NotUsed NotUsed NotUsed NotUsed Speed Signalto Electro Hydraulic Power Steer ingModule NotUsed Ground Vehicle SpeedSensorLo Vehicle SpeedSensorHigh Ignition Speed Signal To ECM and Cruise Control Mod ule BULB LOCATIONS 1 NotUsed A Illumination 2 NotUsed B Illumination 3 NotUsed C UPSHIFT Indicator 4 Ground D RHTurn Indicator 5 NotUsed E Charge I...

Page 1079: ...100 34 cavities C201 8 cavities C203 15 cavities C211 8 cavities C245 8 cavities C250 4 cavities C315 2 cavities C316 2 cavities C500 34 cavities C502 3 cavities C511 2 cavities G201 G202 Page Figure In console near rear of shifter 201 5 B Top LH of engine above exhaust manifold 201 3 A LH top of engine 201 2 A Under console near radio 201 9 D Toprear of engine 201 2 B Lower LH sideof front compar...

Page 1080: ...s LH side of I P 201 12 C S504 Engine harness under rear console 201 5 A SYSTEM CHECK TABLE ACTION NORMAL RESULT FOR DIAGNOSIS Turn Ignition Switchto RUN SERVICE ENGINE SOON Indicator is on Fasten Belts Indicator will come on for 4 to 5 seconds The Audio Alarm will sound if the Passenger s seatbelt is unbuckled Fuel Gage shows current fuel level Voltmeter showsbattery voltage OilPressure Gage show...

Page 1081: ...indicates F orbeyond at all times DoTest F also see TestCterminal7 Fuel Gageis inaccurate DoTestE also see TestCterminal7 Continuedinnextcolumn Continuedfromprevious column Coolant Temperature Gage indicates hot with enginecool and Ignition Switchin RUN Do Test G also see Test B terminal 11 Coolant Temperature Gage indicates cold at all times DoTest H also see TestB terminal 11 Coolant Temperature...

Page 1082: ...ection 6E HiBeam Indicator doesnot operate properly See Headlights Section8A 100 Fasten Belts Indicatordoes not operafeproperly SeeWarnings and Alarms Section 8A 76 BRAKE Indicator doesnutoperate property SeeBrakeWarning System Section 8A 41 TurnIndicator does not operateproperly SeeExteriorLights Section8A 110 also see TestC terminals land 4 Charge Indicator doesnotoperate properly See Starter an...

Page 1083: ...ERMINALS DOES NOT OPERATE CHECK BULBS AND PRINTED CIRCUIT IF OK REPLACE THE INSTRUMENT CLUSTER SEE SECTION SC SF THE CORRECT VOLTAGE OR RESISTANCE IS NOT FOUND AT A TERMINAL DO THE TEST GIVEN OR GO TO THE PAGE REFERRED NOT USED NOT USED NOT USED E NOT USED F NOT USED G NOTUSED H NOTUSED J NOT USED NOT USED C N V NOT USED NOT USED A I L Eld3 J V E H I C L E S P E E D S I G N A L T O E L E C TROHYDR...

Page 1084: ...MENT CLUSTER SEE SECTION 8C IF THE CORRECT VOLTAGE OR RESISTANCE IS NOT FOUND AT A TERMINAL DO THE TEST GIVEN OR GO TO THE PAGE REFERRED HOOD TRUNK DOOR AJAR INDICATOR GROUNDED WITH HOOD TRUNK OR DOOR OPEN DO TESTS Q AND R DK GRN 146 TEMPERATURE GAGE FROM COOLANT TEMPERATURE SENDER SWITCH 55 OHMS AT 260 F 127 C 1365 OHMS AT 100 F 38 C DO TESTS G HAND I LTGRN 135 PANEL ILLUMINATION INPUT VARIABLE V...

Page 1085: ... WITH LIGHTS ON AND DIMMER CONTROL ADJUSTED SEE SECTION 8A 117 GRY 8 3 RH TURN INDICATOR FLASHING BATTERY VOLTAGE WITH RH TURN SIGNAL ON SEE SECTION 8A 110 DK BLU 15 IGNITION POWER TO THE CHARGE INDICATOR SEE SECTION 8A 11 PNK BLK 39 CHARGE INDICATOR SEE SECTION 8A 30 BRN 25 6 FUEL GAGE INPUT 0 OHMS EMPTY TO 90 OHMS FULL DO TESTS D F AND E PNK 30 7 FASTEN BELTS INDICATOR BATTERY VOLTAGE FOR ABOUT ...

Page 1086: ...correctly repair replace the Fuel Gage Sender and its wires 1 Check repair PNK 30 wires for opens Check Printed Circuit for flaws and for clean and tight Fuel Gage connections ReplaceFuelGageifthe above checks are OK see Section SC 2 Check repair the BLK 150 wire for an open see schematic G COOLANT TEMPERATURE GAGE SHORT TEST Disconnect the Coolant Temperature Sender Switch connector and put the I...

Page 1087: ...e Seel If the result is correct replace the Oil Pressure Sender 1 Check TAN 31 wire see schematic for for a short to ground Replace the Oil Pressure Gage if the wire is OK see Sec tion 8C M OIL PRESSURE GAGE OPEN TEST Connect FUSED JUMPER At OIL PRESSURE SENDER CONNECTOR Disconnected Condition Ignition Switch RUN Jumper Between Correct Result For Diagnosis A TAN Ground Oil Pressure Gage shows low ...

Page 1088: ...put the Ignition Switch in RUN If the Indicator lights check the BLK 150 wire for an open except Hood Ajar Switch connector If OK replace the suspect Switch If the Indicator does not light check the suspect wireforanopen see schematic S UPSHIFT INDICATOR WIRE TEST Disconnect ECM connector C2 Put the Igni tion SwitchinRUN andmeasurethevoltage at terminal 7 Electronic Fuel Injection terminal A7 Mult...

Page 1089: ... Buffer is processed to drive the Odometers They are operated by a stepper motor that responds to pulses from the Speedometer cir cuit Tachometer The Tachometer displays engine speed in rpm Voltagepulsesaretakenfromthe Ignition System and sent to the Tachometer The Tachometer responds to the frequency of the voltage pulses which increases with engine speed Incoilequippedvehicles VIN 9 there is a T...

Page 1090: ...FIERO 8A 80 17 ...

Page 1091: ...WIPER WASHER I HOT IN ACCY OR RUN FOR C100 TERMINAL VIEW S E E B U L K H E A D CONNECTOR PAGE 2020 SEE GROUND DISTRIBUTION 8 BLK I L_ 3 BLK 3 BLK m S2i 3 B L K 1150 J L G 2 0 1 FUSE BLOCK C100 ...

Page 1092: ... front bulkhead C100 34 cavities LH side of front bulkhead right of brake master cylinder C207 7 cavities Behind dash near steeringcolumn G201 Behind center of I P S106 Heater A C harness center of front bulkhead S212 Main harness behind center of dash Page Figure 201 6 D 201 9 F 201 10 B 201 13 A 201 8 F 201 6 C 201 13 A 201 6 C Continued from previous column With Wiper Switch in HI hold the Wash...

Page 1093: ...ostic procedures Check GRY 91 wire for an open Check that connectors C207 and C100 are cor rectly mated If wire and connectors are OK replace theWiper Washer Control Check PPL 92 wire for an open Check that connectors C207 and C100 are prop erly mated If wire and connectors are OK replace the Wiper Washer Control Check ORN 98 wire for an open Check that connectors C207 and C100 are prop erly mated...

Page 1094: ...y The wipers remain in the PARK position When the Wiper Switch is in HI Battery voltage is applied directly to the Wiper Motor through the PPL wire to the High speed brushes The wipers run continuously at High speed When turned off the wipers make the last sweepinLowspeed andpark similar to LO speed operation The Wiper Motor is protected by a Circuit Breaker The Circuit Breaker opens if the wipers...

Page 1095: ...WIPER WASHER PULSE 0 HOT IN ACCY OR RUN 1 WHT 1 WHT SMUTCH OFF fO i F S C207 7K WASHER PUMP fmj PUMP WIPER WASHER SWITCH SEE GROUND DISTRIBUTION m 39 O ...

Page 1096: ...fluid reservoir WiperMotorModule Front compartment center of front bulkhead C100 34 cavities LH side of front bulkhead right of brake master cylinder C207 7 cavities Behind dash near steering column G201 Behind center of I P S106 Heater A C harness center of front bulkhead S212 Mainharness behindcenterof dash Page Figure 201 6 D 201 9 F 201 10 B 201 13 A 201 8 F 201 6 C 201 13 A 201 6 C SYSTEM CHE...

Page 1097: ...per Washer Battery Voltage Tfest B Wiper Motor Module Input Voltage Test No delay in pulse mode C Wiper Washer Pulse Control Resistance Tfest Wipers will not shut off Wipers run at high speed only low speed inoperative B Wiper Motor Module Input Voltage Test Washer will not operate B Wiper Motor Module Input Voltage Test D Washer Pump Test Wipers run at low speed only high speed inoperative B Wipe...

Page 1098: ... WHT 93 and GRY 91 wires for opens If the wires are good replace the Wiper Washer Switch D WASHER PUMP TEST fTABLE 1 Measure VOLTAGE At WIPER MOTOR MODULE Connected Conditions Ignition Switch ACCY Washer Switch ON Measure Correct For Diagnosis Between Voltage For Diagnosis C GRY Ground Battery Seel B ORN Ground Battery See 2 If the voltages are correct go to Table 2 1 Check the GRY 91 wire for an ...

Page 1099: ...er Switch in PULSE voltage is applied to the Solid State Pulse Speed Wash Control through the GRY 91 wire This voltage signals the Solid State Pulse Speed Wash Control to momentarily ground the coil of the Park Run Relay With the Park Run Relay ener gized voltage is applied through the contacts of the relay to the Wiper Motor After the Wipers have started the Park Run Switch supplies battery volta...

Page 1100: ...FIERO 8 A 9 1 5 f m ...

Page 1101: ......

Page 1102: ... side of front bulkhead right ofbrake master cylinder 201 13 A G101 On LH fender belowheadlamp 201 11 C G102 On RH fender belowheadlamp 201 11 C G201 Behindcenter of I P 201 6 C S103 Forwardlamp harness near bulkheadconnector 201 10 C S202 Main harness behind I P 201 7 A S212 Main harness behind center of dash 201 6 C A ALL HEADLIGHTS ARE INOPERATIVE OR INTERMITTENT TABLE 1 Connect TEST LAMP At LI...

Page 1103: ... check wiring to lights for an open 1 Check YEL 10 wire for an open 2 Replace Headlight Dimmer Switch CIRCUIT OPERATION Voltage is applied to the Light Switch at all times The Light Switch includes a self reset tingCircuit Breaker TheCircuit Breaker opens when the Headlight circuit draws toomuch cur rent When the Circuit Breaker opens it inter rupts the current flow With no current flow the Circui...

Page 1104: ...FIERO 8 A 100 3 j i ...

Page 1105: ...AV SOtl 1 B L K HOT AT ALL TIMES ftti TMt r m CLOSE i K 4 CLOSE 4 CLOSE K 1 BLK G101 8 G R Y B L K I 903 8 LT GRN BLK I 904 8 DK GRN 150 G102 iv 2 902 8 G R Y 901 LH HEADLIGHT DOOR MOTOR RH HEADLIGHT DOOR MOTOR HEADLIGHT DOOR MODULE 23 m 9 O ...

Page 1106: ...ment at Battery 201 6 D 201 4 A Fusible Link C In forward lamp harness right of brake master 201 10 C Fusible Link D r r In foward lamp harness right of brake master 201 10 C Headlight Dimmer Switch Lower LH sideof steering column 201 8 B Lower LH side of front compartment 201 11 C n Front compartment in each headlight assembly 201 11 C C100 34 cavities LH sideof front bulkhead right of brake mast...

Page 1107: ...ve CI connected Con nect fused jumpers from terminal C DK GRN of connector C2 to terminal A of the Module and from terminal D GRY of the connectortoterminalB oftheModule Oper ate the Headlights If RH Headlight Door works replace the Headlight DoorModule If RH Headlight Door does not work check wiring to the motor Replace the motorif thewiringis OK CIRCUIT OPERATION Voltage to open the Headlight Do...

Page 1108: ...FIERO 8 A 102 3 ...

Page 1109: ...R LIGHTS TURN HAZARD PARK FRONT MARKER STOP HIGH LEVEL STOP CO H O T A T A L L T I M E S H O T I N R U N B U L B T E S T O R S T A R T H O T A T A L L T I M E S FUSE BLOCK HOT AT ALL TIMES 0 1 O 3 BLK 3 m 30 O ...

Page 1110: ...F10 A 500 V 150 150 2 BLK S213 3 B L K J 1 5 0 JL G202 1 S E E GROUND DISTRIBUTION 1 Y E L 18 C401 1 BLK 150 CONTINUED FROM C210 PAGE 110 0 Y 8 Y E L 1 8 8 DK GRN I J8 J C500 1 DK GRN 1 DK GRN n RH T A I L Z r 3 s t q p t u r n p EZJ LIGHT X jES 19 19 RH T A I L STOP TURN LIGHT TAIL I STOP TURN T A I L STOP TURN 8 B L K 150 8 BLK m 110 S403 S E E GROUND DISTRIBUTION ...

Page 1111: ... 8 WHT 17 8 WHT LH T A I L ISTOP LIGHT Jp O S T O P L I G H T TAIL STOP TAIL STOP RH T A I L 1 STOP LIGHT 1 DK GRN 0 1 RH T A I L 1 S T O P L I G H T 8 BLK 150 8 BLK T A I L I STOP TAIL I STuP 150 8 BLK 150 8 BLK 1 BLK S401 150 SEE GROUND DISTRIBUTION i S407 1 BLK 150 i BLK 150 ro S403 2 BLK 150 F10 C500 2 BLK 150 S213 i 3 BLK 150 L 6202 I SEE GROUND DISTRIBUTION 1 D K G R N RH TURN LIGHTS 8 BLKH1...

Page 1112: ...HERO 8 A 110 3 UJ W Z LU O Q C LU Q C Q C LU Q C z Q C D Q T O 00 2 CO X c Q C o LU 2 Q Q C O UJ UJ X to UJ ...

Page 1113: ...EXTERIOR LIGHTS TAIL STOP TURN REAR MARKER LICENSE GT MODELS BRN 8 BRN LH REAR MARKER LIGHT BLK 150 LH T A I L STOP LIGHTS HOT AT ALL TIMES 1 FUSE BLOCK S213 3 BLK I150 JfiL 202 ...

Page 1114: ...EXTERIOR LIGHTS REAR PONTIAC EMBLEM GT MODELS J 2 BLK I 11 j 2 BLK I I S407 150 S403 2 BLK 1 1 5 0 C500 2 BLK I 150 GROUND DISTRIBUTION 3 BLK 1150 G202 ...

Page 1115: ...ylinder 201 13 A C201 8 cavities LH shroud above center access hole 201 12 C C210 11 cavities Lower RH side of steeringcolumn 201 8 B C305 4 cavities Behinddash nearLH shroud 201 13 B C401 2 cavities Tapedtorearlights harness toright of license platelamps 201 14 A C500 34 cavities Engine compartment nearbattery 201 4 A G101 OnLH fender belowheadlamp 201 11 C G102 On RH fender belowheadlamp 201 11 ...

Page 1116: ...use Check that ground G202 is clean and tight C I R C U I T OPERATION Stop Lights Voltage is applied to the Stop Lights through the Stop HAZ Fuse Brake Switch and the Turn HazardSwitchAssembly Whenthebrake pedal is depressed the Brake Switch will close andthe Stop Lights will operate Turn Lights Battery voltage is applied to the LH Stop Turn Light through the Turn B U Fuse Turn Flasher Hazard Swit...

Page 1117: ...geisapplied through the LT BLU wires to the Marker Lights They glowsincetheyaregroundedthroughtheentire Park Lights System As before the small markerbulbslight up butnot allparkbulbs If both the Park Lights and either the LH or RH Turn Lights are on at the same time the markerbulb forthat sidewillnotlightup With batteryvoltageonbothsidesofabulb itwillnot glow With the Turn Lights off however the m...

Page 1118: ...FIERO 8 A 1 1 0 9 ...

Page 1119: ...LIGHTS TURN M A N U A L TRANSAXLE 8 LTGRN 24 E13C500 8 LT GRN 24 8 L T G R N I 2 4 MANUAL tftAMStoLI 8 LTGRN 24 LH BACK UP 8 LTGRN 24 1 I 1 5 0 1 BLK 2 2 1 1 BLK 8 B L K 1 5 0 g w t t M W i S403 g k 150 B 150 M 4 S E GROUND j 1 C A DISTRIBUTION 4 P K I M I m I BLK f 150 S401 LIGHT RH BACK UP LIGHT 8 BLK 1 BLK 3 BLK F 1 0 S C 5 Q 0 2 BLK 1150 S213 3 BLK 1150 G202 I J I m I I 1 BLK I I S E E GROUND ...

Page 1120: ...Back Up Light Switch Fuse Block Behind LH side of I P 201 6 D Transaxle Position Switch LH rear of engine top of transaxle 201 2 B C401 2 cavities Taped to rear lights harness to right of license plate lamps 201 14 A C500 34 cavities Engine compartment near battery 201 4 A G202 Between seats near rear bulkhead 201 6 A S213 Main harness behind rear bulkhead grommet 201 15 A S401 Rear lights harness...

Page 1121: ...ts Switch for manual If Back Up Lights remain on check the bulbs sockets and LT GRN 24 wire for a short to Battery CIRCUIT OPERATION With the Ignition Switch in RUN BULB TEST or START voltage is applied through the TURN B U Fuse to the Gear Selector Switch with automatic transaxle or to the Back Up Lights Switch with manual trans axle Whenever the Gear Selector Lever is shifted toREVERSE the Gear ...

Page 1122: ...F I E R O 8 A 1 1 2 3 ...

Page 1123: ...A T A L L T I M E S HOT AT ALL TIMES I FUSE CTSV LIO 1 BLOCK FUSE 1 25 AMP J 340 1 OKN 150 3 BLK 150 M_ G202 A G 2 0 1 SWITCH i4 SWITCH 8 BLK 150 4g S E E GROUND CLOSED 1 M CLOSED S213 i 4g S E E GROUND WITH WITH DISTRIBUTION DOOR DOOR 3 BLK 150 OPEN OPEN i G202 ...

Page 1124: ...MES 8 BRN CIGAR 5 0 I LIGHTER LIGHT 5 BLK I t m FUSE 28 AMP L 1 FUSE BLOCK BORN 240 CtftClfT I BREAKER iST iilft i LIGHT SWITCH SEE LIGHT SWITCH DETAILS 8 BRN C2SC100 8 BRN o I CONSOLE V ASHTRAY LIGHT F UNDERHOOD 35 BLK 8 BLK WHT i 156 H O O D AJAR G202 ...

Page 1125: ...ter of front bulkhead 201 10 B Trunk Ajar Switch LH sideof engine compartment C100 34 cavities LH sideof front bulkhead right ofbrake master cylinder 201 13 A C200 16 cavities LH shroud ahead of center access hole 201 6 D C201 8 cavities LH shroud above center access hole 201 12 C C208 2 cavities Center of dash behind radio C209 2 cavities Behind LH sideof I P near shroud 201 8 A C247 12 cavities ...

Page 1126: ...FIERO 8A 114 3 I i ...

Page 1127: ...INTERIOR LIGHTS DIMMING HOT AT ALL TIMES ...

Page 1128: ......

Page 1129: ...ht of steering column S211 Main harness behind RH side of I P S212 o Main harness behind center of dash S213 Main harness behind rear bulkhead grommet Page Figure 201 6 E 201 6 D 201 8 D 201 10 A 201 6 C 201 6 A 201 6 F 201 6 C 201 6 C 201 6 C 201 15 A A INTERIOR LIGHTS D I M M I N G TEST TABLE 1 A INTERIOR LIGHTS D I M M I N G TEST TABLE 2 Connect A TEST LAMP AT FUSE BLOCK HOT SIDE OF INST LPS FU...

Page 1130: ...N 9 wire for anopen see sche matic 2 Check DK GRN WHT 944 wire for an open see schematic 3 Replace Remote Dimmer CIRCUIT OPERATION Battery voltage is applied at all times through the TAIL Fuse to the Light Switch When the Light Switch is in PARK or HEAD battery voltage is applied to the dimming con trolin the Panel Interior Lights Control and to the Remote Dimmer Adjusting the dinuning controlchan...

Page 1131: ...N 3 PNK 1 7 8 B L U A R C I R C U I T B R E A K E R it SF 1 1 FUSE BLOCK IC200 2 PNK A 76 U P Jot 2 DK BLU 2 DK BLU 2 B L K 164 2 BRIM G O 164 2 BRN 150 165 POWER R E M O T E MIRRORS 307 V 2 B L K 5 B L K l l 5 0 165 L H F R O N T R H F R O N T ...

Page 1132: ... each door 201 12 A C200 16 cavities LH shroud ahead of center access hole 201 6 D C307 8 cavities Near center of LH shroud 201 12 C C308 8 cavities Near center of RH shroud 201 12 D G301 Onupper RH shroud 201 12 D S301 Crosscar harness under console 201 12 B S314 Crosscar harness under console 201 12 B SYSTEM DIAGNOSIS Do the tests listed for your symptom in the Symptom Table below or when direct...

Page 1133: ...NDOW MOTOR CONNECTOR Disconnected Conditions Ignition Switch RUN Operate associated Power Window Switch UP and DN Connect Between Correct Result For Diagnosis A BRN or DK BLU B DK BLU or TAN Test Lamp Lights Seel If the result is correct replace the Win dow Motor Refer to the Body Section 5 for replacement procedures 1 Check the wiring to that Power Window Switch for an open see schematic CIRCUIT ...

Page 1134: ...FIERO 8A 120 3 ...

Page 1135: ... E E FUSE BLOCK DETAILS 8 ORN 8 ORN 40 S303 40 40 8 ORN B 1 C308 8 ORN I 40 1 2 ORN BLK 60 POWER REMOTE MIRRORS INTERIOR LIGHTS LOCK UNLOCK L k RH DOOR LOCK SWITCH 8 L T BLU 1 1 8 L T BLU D j j t C1 195 c A 3 194 C308 8 BLK I 194 _ LOCK _ L O C K DOOR LOCK R E L A Y ASSEMBLY 2 G R Y LH DOOR M LOCK MOTOR PERMANENT MAGNET EACH MOTOR CONTAINS A S E L F R E S E T T I N G CIRCUIT B R E A K E R ...

Page 1136: ... I P 201 6 D C200 16 cavities LH shroud ahead of center access hole 201 6 D C201 8 cavities LH shroud abovecenter access hole 201 12 C C307 8 cavities Near center of LH shroud 201 12 C C308 8 cavities Near center of RH shroud 201 12 D S125 Main harness behind LH sideof I P near Fuse Block 201 6 D S303 Crosscar harness above steering column 201 12 B SYSTEM CHECK TABLE ACTION NORMAL OPERATION Operat...

Page 1137: ... UNLOCK and hold BLK Ground Battery See 2 If all the voltages are correct check the LT BLU 195 wire and BLK 194 wire for an open see schematic 1 Check the CTSY LID Fuse Check the ORN 40 and ORN DK BLU 340 wires for opens see schematic 2 Replace the suspect Door Lock Switch C DOOR LOCK RELAY A S S E M B L Y T E S T TABLE 1 Connect TEST LAMP At DOOR LOCK RELAY ASSEMBLY CON NECTOR CI Connect Between ...

Page 1138: ... circuit to the coil of the Door Lock Relay Assembly The lock relay is energized The contact for the lock relay closes and is connected to battery voltage through the ORN BLK wire Voltage is then ap plied to the GRY wire and the Door Lock Motors The motors are grounded by the TAN wire from the other terminal of the motor through the contact for the unlock relay The motor in each door runs to opera...

Page 1139: ... W H T I 1 4 2 ft G E A R SELECTOR S W I T C H G 2 0 1 T R U N K i l l RELEASE I S O L E N O I D I AfSTEfl INTERIOR LIGHTS I D I M M I N G HOT AT ALL TIMES CTSY LID FUSE k 2 5 AMP MAMUAL v TRANSAXLE 1 FUSE B L O C K 35 GRY 8 cj 1 ORN DK BLUfi 340 S125 1 ORN DK BLUl 340 SEE FUSE B L O C K DETAILS I i PANEL LIGHT ON _ OFF I 35 BLK SEE G R O U N D DISTRIBUTION I A 8 GRY BLK 1 942 j l T R U N K RELEAS...

Page 1140: ...H side of I P 201 At base of steering column 201 In Line Diode Behind I P near LH shroud 201 Parking Brake Switch Onparking brake support 201 Starter Solenoid VIN 9 Lower LH front of engine 201 Starter Solenoid VIN R Lower LH front of engine 201 Transaxle Position Switch LH rear of engine top of transaxle 201 Trunk Release Relay Behind I P on RH side of steering column support 201 7 B Trunk Releas...

Page 1141: ... Diagnosis Seel See 2 Ifbothvoltages arecorrect gotoTable4 1 Check repair GRY BLK 942 wire for an open 2 Check repair YEL 5 Automatic Trans axle or TAN WHT 33 Manual Trans axle wires TRUNK RELEASE TEST TABLE 4 Connect FUSED JUMPER At TRUNK RELEASE RELAY CONNECTOR Disconnected Condition Trunk Release Switch DEPRESSED Jumper Between Correct Result For Diagnosis B GRY BLK C BLK WHT Trunk unlatches Se...

Page 1142: ......

Page 1143: ...POWER REMOTE MIRRORS HOT AT ALL TIMES FOR C2Q0 TERMINAL VIEW SEE JUNCTION BLOCK PAGE 202 2 ...

Page 1144: ...hole 201 12 C C304 4 cavities RH shroud near center access hole 201 12 D C310 4 cavities In LH door below mirror 201 7 A C311 4 cavities In RH door below mirror 201 12 A G301 Onupper RH shroud 201 12 D S125 Main harness behind LH side of I P near Fuse Block 201 6 D S223 Power mirror harness 201 12 B S303 Crosscar harness above steering column 201 12 B S306 Power mirror harness behind center of I P...

Page 1145: ... replace the RH Outside Mirror Drive Unit after checking connector C311 YEL 88 LT GRN 89 WHT 81 and LT BLU 82 wires Replace Outside Mirror Switch CIRCUIT OPERATION Each Outside Mirror has two reversible motors one motor adjusts the mirror view up and down the other motor adjusts the mirror view right and left The driver operates four switches that controlthepolarity ofthe voltage to the motors The...

Page 1146: ...FIERO 8 A 141 3 ...

Page 1147: ...I M E S I T FUSE W B ACC BLOCK I CIRCUIT 0 E T A l s 1 FUSE BLOCK I BREAKER 1 3 ORN BLK 60 01 GRY O W C2Q0 BLK B 1 ORN 340 AP5C340 PASSENGER S LUMBAR CONTROL SWITCH J BRN 763 8 PPL 765 8 G R Y 714 8 WHT 766 8 WHT 766 8 G R Y 764 8 PPL 76r J BRN 763 m 30 O ...

Page 1148: ......

Page 1149: ...bar Pump Motor Relay Passenger s Lumbar Control Switch Passenger s Lumbar Valve Assembly Under driver s seat Under driver s seat Behind LH side of I P Under RH sideof driver s seat Under driver s seat Under driver s seat Under passenger s seat Page Figure 201 6 D C200 16 cavities C201 8 cavities C305 4 cavities C340 C341 C342 G201 S212 S311 S313 5315 5316 S317 S318 Under passenger s seat LH shroud...

Page 1150: ... in the Symptom Table below Tests follow the Symptom Table SYMPTOM TABLE SYMPTOM DO TEST Both Lumbar Controls do not inflate and or deflate the Supports A Lumbar Pump Motor Relay Test Lumbar and or Bolster Supports do not operate in the driver s seat only B Lumbar Control Switch Test C Lumbar Valve Assembly Test Lumbar and or Bolster Supports do not operate in the passenger s seat only B Lumbar Co...

Page 1151: ...BAR INFLATE Measure Between Correct Voltage For Diagnosis F ORN BLK Ground Battery See 1 B BRN Ground Battery See 2 E WHT Ground Battery See 2 Lumbar Control Switch BOLSTER DEFLATE A PPL Ground Battery See 2 C GRY Ground Battery See 2 If voltages are correct do Test C 1 Check In Line Fuse and ORN BLK 60 wire for an open 2 Check attached wire for a short to ground Replace Lumbar Control Switch if w...

Page 1152: ...Control Switch is moved to LUMBAR and INFLATE the Lumbar Pump Motor starts to operatetopumpuptheLumbarSupport When the Lumbar Control Switch is moved to DEFLATE the Lumbar Control Pump Motor reverses to pull the air from the Lumbar Sup port A similar action occurs when the Lumbar Control Switchis operated forthe Bolster Sup port ...

Page 1153: ... 35 Y E L ANTENNA F O C 2 4 7 43 i I 9 COAXIAL CABLE 8 BRN I 9 S211 1 8 BRN B j BRN SEE LIGHT SWITCH DETAILS INTERIOR LIGHTS DIMMING 1 ORN S210 j i 1 ORN A M 40 ORN SEE FUSE BLOCK OETAILS 40 C208 40 5 GRY m o 5 YEL file BLK X RADIO CLOCK DISPLAY IJF EQUIPPED ANTEMWA INPUT DISPLAY DIM SIGNAL BATTERY POWER INPUT IF EQUIPPED WITH DIGITAL CLOCK AND OR DIGITAL DISPLAY 5 BRN 199 5 L T BLU 115 5 DK BLU P...

Page 1154: ......

Page 1155: ... S210 1 ORN A A 40 ORN SEE FUSE BLOCK DETAILS 40 C208 5 GRY 40 MA DISPLAY WliUlPPIBl tIPiT DISPLAY OIM SIGNAL BATTERY POWE I imm IF EQUIPPED WITH DIGITAL CLOCK AND QR DIGITAL DISPLAY GROUND PANEL LIGHT 1 RADIO I ll v 5 tf SLU 199 f YEL ftjAft SPEAKElt 116 i T STEREO 115 5 TAN 201 5 DK GRN 5 DK BRN 117 1 5 LT GGN 1 200 5 BLK G 150 C247 117 8 BLK SEE GROUND OlSTitliTIi RH I P SPEAKER T I mvmmm 150 O...

Page 1156: ...ws clean of any paint or varnish Go to System Check for a guide to normal operation Go to System Diagnosis for diagnostic tests S Y S T E M CHECK Use the System Check Table as a guide to normal operation Refer to System Diagnosis for a list of symp toms and diagnostics steps Dome Light Module Fuse Block Sub Woofer Amplifier C208 2 cavities C247 12 cavities C248 2 cavities G201 S201 5210 5211 5212 ...

Page 1157: ... Correct Voltage For Diagnosis A ORN Ground Battery Seel If voltage is correct remove Radio for service 1 CheckORN 40 wirefor anopen see sche matic B PANEL LIGHT TEST Measure VOLTAGE At RADIO CONNECTOR Disconnected Conditions Light Switch PARK Dimming Switch BRIGHT Measure Between Correct Voltage For Diagnosis M GRY Ground Battery Seel If voltage is correct remove Radio for service 1 Check GRY 8 w...

Page 1158: ...NK Ground Battery See 1 13 PNK Ground Battery Seel 13 PNK 14 BLK Battery See 2 o If voltages are correct go to Table 2 1 Check repair PNK 143 wires see sche matic If PNK 143 wires are good remove Radio for service 2 Check repair BLK 150 wire see sche matic E SUBWOOFER AMPLIFIER TEST TABLE 2 Measure AC VOLTAGE At SUBWOOFER AMPLIFIER CONNECTOR Connected Conditions Ignition Switch RUN Radio ON High V...

Page 1159: ...CONNECTOR Connected Conditions Ignition Switch RUN Radio ON Measure Between Correct Voltage For Diagnosis B WHT BLK Ground Approximately 8 volts Seel Performance sound control at minimum A YEL Ground 3 5 to 4 5 volts See 2 Performance sound control at maximum A YEL Ground Approximately 8 volts See 2 If all voltages are correct check repair YEL 303 wire see schematic 1 Check repair WHT BLK or WHT 3...

Page 1160: ...g BLK 12 around 1 volt Seel DK BLU AC WHT If the voltage is correct check repair wires between the Subwoofer Amplifier and the Subwoofer Speaker 1 Remove Subwoofer Amplifier for service H NOISE DIAGNOSIS TEST Unplug Antenna at the back of the Radio If noise disappears it was being picked up by the Antenna Consult the Delco Sound Service Guide for Antenna noise diagnosis If noise persists it is com...

Page 1161: ...itorandpowerleadtothat accessory Consult Delco Sound Service Guide AE stations weak noisy both A M and FM DefectiveAntennaorlead inwire TemporarilyreplacetheAntennawithanotherone Repair replacethedefective oneiftheRadioreceptionimproves Check attheAntennaCoaxlead inandtheconnector A M only weak noisy AM alignment RemoveRadioforrepair FM only weak noisy FM alignment RemoveRadioforrepair Noisepresen...

Page 1162: ...PUT LEAD 2 1 0MFD 100W CAPACITOR Figure 3 Install a 250 MFD 100V capacitor on the alternator output lead to ground IGNiTOM NOISE Try the following fixes in the given order 1 Check for loose or defective spark plug wire 2 Check for defective spark plug 3 Move all wiring away from HEI and spark plug wires 4 Reroute sparkplugwireslayingagainst any thing that could possibly transmit noise to the Radio...

Page 1163: ...olled by the Radio itself by means ofthe Dim Display Input Signal The ETR model s clock memory and Radio memory functions are powered at all times through the BAT Fuse If power to the ETR model is cut off by disconnecting the Battery for example the operator must reset the memory functions when power is restored The Subwoofer Speaker System consists of a Subwoofer Amplifier Subwoofer Speaker and a...

Page 1164: ...FIERO 8 A 150 11 ...

Page 1165: ......

Page 1166: ...Figure A R H R e a r O fVIN R E n g i n e Figure C R e a r O fT h r o t t l e B o d y ...

Page 1167: ...URE SWITCH SENDER OXYGEN SENSOR STARTER SOLENOID 12H27 1 MANIFOLD ABSOLUTE PRESSURE MAP SENSOR COOLANT TEMPERATURE SENSOR BACK UP LIGHT SWITCH CONNECTOR TRANSAXLE POSITION SWITCH DIRECT IGNITION SYSTEM 12H26 1 Figure B LH Rear Of VIN R Engine Figure A Front Of VIN R Engine Figure C RH Front Of Engine Compartment ...

Page 1168: ... COIL 12H35 1 FRONT OF CAB W COOLANT FAN RELAY 12H4 6 Figure A LH Top Of VIN 9 Engine Figure D LH Side Of Front Compartment S 5 1 g S508 FUSIBLE LINK G S516 S5D2 S511 PRESSURE SENSOR CONNECTOR STARTER SOLENOID 12H36 1 COOLANT TEMPERATURE SWITCH COLD START SWITCH Figure B Lower RH Front Of VIN 9 Engine Figure C RH Front Of VIN 9 Engine Figure E RH Front Of VIN 9 Engine Near Dipstick oo ...

Page 1169: ... LOCATION VIEWS Figure A RH Front Of Engine Compartment Figure D Lower Front Of 11 9 Engine Figure B RH Top Of VIN 8 Engine Figure C LH Front Corner Of Engine Compartment Figure E RH Front Of Engine Compartment ...

Page 1170: ...COMPONENT LOCATION VIEWS L Figure A Between Seats Rear Bulkhead Vf N R Figure B Top LH Rear Of VIN 9 Engine Figure B Between Seats Rear Bulkhead VIN 8 Figure D LH Front Of Engine Compartment ...

Page 1171: ...OMPONENT LOCATION VIEWS Figure A Under Rear Of Console Figure C Behind Cluster Figure E Above Brake Pedal Figure B Under Front Of Console Figure D Behind LH Side Of I P Figure F Right Of Steering Column ...

Page 1172: ...ON VIEWS L 12H8 1 RH STEERING COLUMN BRACKET Figure B Below LH Side Of I P TURN FLASHER fV Y f SSr T S x LH STEERING C O L U M N B R A C K E T 1 2 H 1 0 3 Figure A Behind LH Side Of l p Figure C Left Of Steering Column ...

Page 1173: ... LOCATION VIEWS Figure A Behind LH Side Of I P Figure C Behind Center Of I P Figure E Top LH Of Steering Column Figure B Center Of Steering Column Figure 0 Below Center Of S P Figure F RH Side Of Steering Column ...

Page 1174: ...e C At Base Of Parking Brake Figure E LH Rear Corner Of Front Compartment TURN HAZARD IGNITION KEY SWITCH WARNING SWITCH ASSEMBLY IN COLUMN HAZARD BUTTON ASSEMBLY 12C9 1 CRUISE CONTROL MODULE 1 2 H 1 9 4 WASHER PUMP 12H5 4 Figure B Top RH Side Of Steering Column Figure D Behind Carpet Support Between Seats Figure F RH Side Of Front Bulkhead ...

Page 1175: ...COMPONENT LOCATION VIEWS HOOD AJAR WIPER MOTOR Figure A Center Of Figure C LH Corner Of Front Compartment ...

Page 1176: ...Figure A Below LH Side Of I P Figure C LH Front Of Car ...

Page 1177: ...R C303 LH C304 RH 12H43 1 US 03 I o Figure A LH Door RH Door Similar Figure C LH Shroud POWER WINDOWS SWITCH CONNECTOR MIRRORS CONTRO SWITCH CONNECTOR S301 S314 12H42 1 DOOR LOCK RELAY ASSEMBLY Figure P Front Of Passenger Compartment Behind Figure D RH Shrour ...

Page 1178: ... COMPONENT LOCATION VIEWS Figure B LH Side Of Passenger Compartment ...

Page 1179: ...COMPONENT LOCATION VIEWS VACUUM RELEASE SOLENOID S401 Figure A Rear Of Car 12H47 1 ...

Page 1180: ......

Page 1181: ...GRN Instrument Panel Indicators Cluster Hood Trunk Door Ajar Indicator 80 2 E1 ORN ORN Air Conditioning Blower Controls 63 0 E2 LT BLU LT BLU Air Conditioning Blower Controls 63 0 WIRE COLOR CAVITY PIN SOCKET SCHEMATIC PAGE HALF HALF E3 TAN TAN Air Conditioning Blower Controls 63 0 E4 RED RED Air Conditioning Blower Controls 63 0 F6 TAN WHT TAN WHT Brake Warning System 41 0 7 Not Used F8 BRN WHT B...

Page 1182: ...T V6VIN 9 LTGRN PPL PNK PNK Backup Lights 1 1 2 0 Starter and Charging System 30 0 Electronic Fuel Injection Ignition 20 0 Multi port Fuel Injection Ignition 21 0 23 K BLK WIRE COLOR CAVITY PIN SOCKET SCHEMATIC PAGE HALF HALF E4 _ _ Not Used F6 TAN TAN Cruise Control Vacuum 34 1 F7 BRN BRN Exterior Lights Tail Rear Marker License 110 3 F8 WHT ORN WHT Instrument Panel Indicators Cluster Hood Trunk ...

Page 1183: ...C200 V18004 0 ...

Page 1184: ... C201 LTJCDEDE3EHE3E3 3 BLK J E E3 JE E LZ3E5 x WHT E3E3II1E3E LZ1E E 1 T A j BLK C203 GRY C210 V0O2110 BLK BLK C211 V08O06 0 c L H 3 a F E E E r BLK C245 BLK V08000 t I M a I F n LJ n n G I I c cr rir n 1 K or n r L a G R Y BLK C247 ...

Page 1185: ... i 3 s U LXTJ BLK WHT C248 BLK 0 0 BLK C250 C255 L4 VIN R ONLY SEE C245 LZEO nm nm BLK BLK C303 C304 SEE C303 D C B A BLK BLK C305 8E3E3LI E3E E3E3E3 W H T t rp _T rp n M M M M J 7 BLK C307 V08005 0 C308 SEE C307 BLK BLK C4G1 ...

Page 1186: ...Y 12020015 A B C 0 E F G H J K L M M BLK A C CONTROL HEAD 12015130 BLK A C H I G H P R E S S U R E S W I T C H 12041139 A C POWER RELAY SEE A C COMPRESSOR CONTROL RELAY T O j M L K J H G O T O j A B C I D J E F I O BLK ASSEMBLY LINE DIAGNOSTIC LINK ALDL CONNECTOR 12010043 B f A BLK B A C K U P L I G H T S W I T C H ...

Page 1187: ...WITCH SEE CRUISE CLUTCH SWITCH m m LZ3 WW lOffili C1 BLK C2BLU BRAKE SWITCH V00269 0 B BLK CLOCK C208 8900444 a BLK CLUTCH START SWITCH 1 2 0 1 5 0 3 4 COLD START INJECTOR SEE COLD START SWITCH fmmmmm JSLn o DCZ I ex BLK COLD STA1T SWITCH 12048039 H I rams A I B U Z Z E R o BLK CONVENIENCE CENTER 12015999 Ii ...

Page 1188: ... 0 GRY COOLANTFAN RELAY BLK COOLANT TEMPERATURE SENSOR BLK COOLANT TEMPERATURE SWITCH SENDER 12033709 T l L A I T GRY CRUISE BRAKE SWITCH 2977373 WHT CRUISE CLUTCH SWITCH 12010649 A M U d 3 U WHT CRUISE CONTROL MODULE GRY CRUISE CONTROL SERVO 12020646 3 C ...

Page 1189: ...3 C1 BLK C2 BLK DIRECT IGNITION MODULE DOME READING LIGHTS SEE CLOCK C208 ID BLK DOME READING LIGHTS WITH AMPLIFIER SWITCH V00122 3 B A BLK DOOR LOCK MOTORS 12004140 Hi C1 BLK C2 GRY DOOR LOCK RELAY ASSEMBLY V00213 0 o o o A B C BLK DOOR LOCK SWITCH LH 12015683 00 O N oo DOOR LOCK SWITCH RH SEE DOOR LOCK SWITCH LH 2 m 30 O ...

Page 1190: ... L4 VINR V00212 0 n a 1 6 1 5 1 4 1 3 1 2 1 1 1 0 9 8 7 6 5 4 3 2 1 L T n n 12 11 10 9 8 7 6 S 4 3 2 1 ID CI BLK C2 BLK ELECTRONIC CONTROL MODULE ECM V6 VIN 9 A B C D BLK ELECTRONIC SPARK TIMING EST DISTRIBUTOR C506 He BLK ELECTRONIC VACUUM REGULATOR VALVE EVRV 1 2 0 1 5 7 9 7 ...

Page 1191: ...R LOCK MOTORS BLK FUEL INJECTOR L4 VIN R FUEL PUMP RELAY SEE A C COMPRESSOR CONTROL RELAY HI A BLK FUEL TANK AND SENDER C502 12020827 r i r c i r p i E H F J G i L 1 I BLK GEAR SELECTOR SWITCH 12034169 BLK GENERATOR WHT HEADLIGHT LH 6288471 HEADLIGHT RH SEE HEADLIGHT LH IE u BLK HEADLIGHT DIMMER SWITCH 8917643 ...

Page 1192: ... V00207 0 BLK HEATER CONTROL HEAD LIGHT 2977647 GRY BLK HIGH LEVEL STOP LIGHT HIGH SPEED BLOWER RELAY SEE A C COMPRESSOR CLUTCH RELAY B C m i i BLK IDLE AIR CONTROL MOTOR L4 VIN R 12040754 it BLK IDLE AIR CONTROL MOTOR V6 VIN 9 12015798 C2 BLK J E L b I M F C1 GRY IGNITION COIL V6 VIN 9 ...

Page 1193: ... i 14 j h i 113 i II I I 12 I h i I 11 1 h i F l C1 BLK C3 BLK INSTRUMENT PANEL fl A B C j D P WHT LIGHT SWITCH 12034061 GRN MANIFOLD ABSOLUTE PRESSURE MAP SENSOR V00222 0 A B GRY MANIFOLD AIR TEMPERATURE MAT SENSOR 12041411 B WHT MODE DOOR ACTUATOR 8900443 BLK MULTI FUNCTION LEVER C235 12020651 GRY OIL PRESSURE SWITCH ...

Page 1194: ... MIRROR LH C310 OUTSIDE MIRROR RH C311 SEE OUTSIDE MIRROR LH C310 A B C D WHT PANEL INTERIOR LIGHTS CONTROL 12034060 BLK POWER STEERING B A JLJLJD WHT POWER WINDOW SWITCH RH 12004101 BLK PRESSURE CYCLING SWITCH a MJQ CZ GRY RADIO RADIO SPEAKERS SEE CLOCK C208 JLLii1 LLJJLJ BLK RALLY GAGE PANEL V00337 1 0 2A B C D WHT REMOTE DIMMER 12034060 ...

Page 1195: ...TER C511 BLK THROTTLE POSITION SENSOR L4 VIN R V00041 0 BLK THROTTLE POSITION SENSOR TPS V00041 0 m BLK THROTTLE POSITION SENSOR V6 VIN 9 12015793 D C BLU TRANSAXLE CONVERTER CLUTCH SOLENOID 12015390 xiJL BLK TRUNK AJAR SWITCH V00127 6 ram LTD BLK TRUNK RELEASE RELAY mrZlLZliJ GRY TRUNK RELEASE SWITCH V00490 0 ...

Page 1196: ...HARNESS CONNECTOR FACES r t Z E CB A BLK UNDERHOOD LIGHT BLK VEHICLE SPEED SENSOR BLK WIPER MOTOR TA B C U n D E F G M r J GRY WINDSHIELD WIPER SWITCH C207 12010430 ...

Page 1197: ...NVENIENCE CENTER CI 00 BULKHEAD CONNECTOR CONNECTOR GROMMET HARNESS NUMBER HARNESS NAME DETAIL VIEW PAGE FIGURE 1 MAIN HARNESS INSTRUMENT PANEL 201 15 A 2 ENGINE 201 2 B 3 AIR CONDITIONING 201 13 A 4 FORWARD LAMP 201 11 C 5 BODY REAR 201 14 A ...

Page 1198: ...VENIENCE CENTER SYMBOLS CONNECTOR GROMMET HARNESS NUMBER HARNESS NAME DETAIL VIEW PAGE FIGURE 1 MAIN HARNESS INSTRUMENT PANEL 201 15 A 2 ENGINE 201 3 A 3 AIR CONDITIONING 201 13 A 4 FORWARD LAMP 201 11 C 5 BODY REAR 201 14 A rn 30 O CO ...

Page 1199: ......

Page 1200: ...te Dimmer Switch 8B 8 Sidemarker Lights 8B 9 Turn Signal Flasher 8B 9 Horns 8B 9 REPLACEMENT BULB SPECIFICATIONS 8B 11 The following information previously shown in this section has been moved to the section s shown Cooling Fan Relay 6B Fuse Block 8A Ignition Switch 3B4 Instrument Panel Bulb Replacement 8C Multifunction Switch 3B4 Neutral Start Switch 3B4 7 Overhead Light Body Service Manual 8J Pa...

Page 1201: ...st be aimed for proper illumination of the road Headlight aim should be checked at least once a year when a new headlight bulb is installed or if service or repairs in the front end area have or may have disturbed the headlights or their mountings The headlight bezels do not need to be removed to aim the headlights Headlight focus is set when the sealed beam unit is made no adjustment for focus is...

Page 1202: ...mation is given in Section 8A Information on properly repairing wiring harnesses connectors etc is on 8A 5 Most lighting problems are caused by loose connectors open or shorted wiring burned out bulbs bad switches inadequate ground or blown fuses Many of these require only replacement of a defective part When replacing a part that requires a special procedure such as a lens and housing assembly se...

Page 1203: ...Light assembly 3 Bulb socket from light assembly 4 Bulb from socket 1 2 3 4 Install or Connect Bulb into socket Bulb socket in light assembly Light assembly Two screws into light assembly HAZARD FLASHER The hazard flasher is in the convenience center on the right side of the heater or A C module under the instrument panel To remove it release the tab lock on the side and pull it straight out HEADL...

Page 1204: ...LIGHTING SYSTEMS AND HORNS 8B 5 H20067 8B Fig 8B 3 Headlight and Retractor System Components ...

Page 1205: ...ct 1 Switch and harness assembly 2 Rubber slot filler 3 Switch cover plate 4 Headlight mounting bracket align marks on bracket 5 Electrical connections at mounting bracket 6 Four attaching bolts at mounting bracket P P Tighten 9 10 1 1 12 Four bolts at headlight mounting bracket to 9 N m 80 lbs in Light light assembly and bezel One bolt at link assembly Two bolts one at each side of light assembly...

Page 1206: ...ALL COMPONENTS ON VEHICLE 2 PLACE VEHICLE ON LEVEL PAD 3 STOP ALL OTHER OPERATIONS OR WORK ON VEHICLE 4 CLOSE DOORS 5 ATTACH AIMERS TO HEADLAMPS 6 ROCK VEHICLE SIDEWAYS III TO CHECK OR S E T AIM PER SAE J599 USE THE FOLLOWING LIMITS VERTICAL AIM HORIZONTAL AIM 2 UP TO 2 5 DOWN 4 R TO 4 L FUEL LOAD TO BE 1 2 TANK OR LESS VERTICAL ADJ SCREW HORIZONTAL ADJ SCREW 520115 8B Fig 8B 5 Headlight Aiming 12...

Page 1207: ...nly Trade No 1156 32 Candlepower The taillight lens is two pieces To remove a bulb remove the appropriate piece Each piece is attached to the body by three screws which are recessed under rectangular black tabs Remove or Disconnect 1 Open rear compartment lid 1 2 3 4 5 6 Three black tabs covering screws by prying carefully with a screwdriver One screw under each tab Tailight lens Bulb socket from ...

Page 1208: ...r Flasher from clip 4 Install or Connect 1 Flasher into clip 2 Electrical connector HORNS If the horns do not blow or blow constantly follow the diagnostic procedures in Section 8A Horn Tone Poor 1 Horn Tone Poor Tighten bolts in mounting area 2 Low Pitched Moan Sounds like mooing Caused by current too high Adjust current see the following 3 Weak Tone Current too low Correct poor connections or gr...

Page 1209: ...ew Current adjustments should be made 1 4 turn 90 at a time Horn Assembly Fig 8B 8 The horns are mounted behind the front fascia on the front compartment rail Remove or Disconnect 1 2 Electrical connector Bolt Install or Connect 1 Bolt 2 Electrical connector Horn Relay The horn relay is located in the convenience center on the right side of the heater or A C module under the instrument panel To re...

Page 1210: ...057 Taillights Only GT Models 194 Turn Signals Only GT Models 1156 Sidemarker Lights Front and Rear 194 INTERIOR LIGHTS T r a d e No Air Conditioner Heater Controls 37 Ashtray 194 Cigarette Lighter 168 Cluster Lighting 194 Gage Pod V 6 Engines 161 Console Ashtray 70 Dome Reading 906 Gear Selector Indicator 70 Headlight High Beam Indicator 194 Indicator Lights AJAR Deck or Door 194 BRAKE 194 Chargi...

Page 1211: ......

Page 1212: ...Support Assy 8C 12 Lighter Trimplate 8C 13 IP Pad 8C 13 Lower Heater Outlet Duct 8C 13 Defroster Ductwork 8C 13 IP Duct Assy 8C 14 GENERAL DESCRIPTION INSTRUMENT PANEL AND GAGES The instrument panel on most cars is a single unit design and all parts attach to the main instrument panel with clips and screws To service the instrument panel and components see On Car Service information PRINTED CIRCUI...

Page 1213: ...Electronic speedometers include instruments that use a dial indicator and those using bar graph LCD s Liquid Crystal Displays or VTF Vacuum Tube Fluorescent displays Mechanical Speedometers A mechanical speedometer uses a cable driven through a pinion gear by the transmission output shaft The cable connects to a magnetic drag cup inside the speedometer which rotates the speedometer needle The end ...

Page 1214: ...eater After the engine is running the oil pressure light should go out when the oil pressure reaches the correct specification If not an oil pressure problem a faulty oil pressure switch or an open circuit from the choke heater fuse to the oil pressure switch is indicated SERVICE ENGINE SOON LIGHT All cars have a SERVICE ENGINE SOON light mounted in the instrument cluster The SERVICE ENGINE SOON l...

Page 1215: ...m the speedometer circuitry This signal controls the rate at which the motor turns the odometer gears Trip Odometer The trip odometer can be reset by twice fully depressing the push button located on the right side of the speedometer cluster The first depression shows all zeroes and the second locks them in position Both depressions must be done to avoid possible half cycling of the trip odometer ...

Page 1216: ... E SHIFT INDICATOR LIGHT RIGHT TURN INDICATOR LIGHT Q G E N E R A T O R LIGHT S E A T B E L T REMINDER LIGHT S E R V I C E ENGINE SOON REMINDER LIGHT T A C H O M E T E R OIL PRESSURE G A G E OIL P R E S S U R E G A G E Q V O L T M E T E R I D HEADLIGHT SWITCH p PARKING LIGHTS SWITCH INSTRUMENT PANEL LIGHTS SWITCH INSIDE FRONT COMPARTMENT LID HOOD R E L E A S E mS E L E C T R I C TRUNK R E L E A S ...

Page 1217: ...URE GAGE 10 FUEL GAGE 1 1 SHIFT INDICATOR MANUAL TRANS ONLY 1 2 RIGHT TURN INDICATOR LIGHT 13 CHECK COOLANT LIGHT 14 SEAT BELT REMINDER LIGHT 15 CHECK ENGINE LIGHT 16 TACHOMETE R 17 VOLT GAGE 1 8 OIL PRESSURE GAGE G 2 0 0 4 0 8 C Fig 2 Instrumentation 5 SPEED MANUAL AUTO TRANS 1 RETAINER 2 5 N m 4 5 LBS FT 3 SENSOR 4 SEAL 5 GEAR 6 RETAINER MUST BE SEATED ON SENSOR ASSEMBLY NOT ON TRANS GOVERNOR CO...

Page 1218: ...ay be required See Section 6E and 8A for complete diagnosis and wiring diagrams of the CHECK ENGINE light circuit ON CAR SERVICE INSTRUMENT PANEL WIRE HARNESS Instrument panel wire harness procedures are in Section 8B INSTRUMENT PANEL PAD ASSEMBLY Figure 815 removal 1 2 3 4 5 6 7 8 9 10 Remove or Disconnect Hood release Steering column cover Speaker grills and speakers I P attaching screws I P ser...

Page 1219: ...late Shifter trim plate Shifter knob Inspect For rattles 4 1 2 3 4 5 Remove or Disconnect Console shift plate Console pad Carpet from retainers 4 button fasteners Remove carpet and console side cover Screw from amplifier bracket Disconnect amplifier connector 44 Install or Connect Reverse above steps INSTRUMENT PANEL CLUSTER Figures 804 and 806 1 2 3 4 5 6 7 44 1 2 3 4 5 6 Remove or Disconnect Neg...

Page 1220: ...TALL THESE BOLT SCREWS FIRST B INSTALL THESE BOLT SCREWS SECOND C INSTALL THESE BOLT SCREWS LAST H20071 8C Fig 804 IP Trimplates WITH A C NO A C 1 A C WIRE ASSEMBLY 2 LAMP SOCKET 3 BULB 4 T O A C RELAYS 5 FORWARD COURTESY LAMP HOUSING 6 HEATER WIRE ASSEMBLY 7 TO HEATER RELAY 8 T O HEATER BLOWER RESISTOR H2Q077 8C Fig 805 Courtesy Lamps ...

Page 1221: ... D INSTALL FOURTH H20076 8C Fig 806 IP Cover Housing Cluster 1 1 6 N m 14 LBS IN 2 TRIM PLATE 3 CLUSTER HOUSING ASSEMBLY 4 SUPPORT BRACKET 5 GAGE CONNECTOR 6 SUPPORT ASSEMBLY H20075 8C L X H 1 TRIM PLATE 2 1 6 N m 14 LBS IN INSTALL FIRST 3 1 6 N m 14 LBS IN INSTALL SECOND 4 SUPPORT ASSEMBLY 5 1 6 N m 14 LBS IN 6 CONNECTOR 7 POWER MIRROR SWITCH H20072 8C Fig 807 Gage Cluster Housing Trimplate V6 Fi...

Page 1222: ...ON OF ARROW BEFORE TIGHTENING BOLT SCREWS H20068 8C Fig 809 Shift Plate 1 1 6 N m 14 LBS IN INSTALL FIRST 2 NUT 3 ECM BRACKET 4 SUPPORT ASSEMBLY 5 1 6 N m 14 LBS IN INSTALL SECOND 6 1 6 N m 14 LBS IN INSTALL LAST 7 REAR CONSOLE PAD H20073 8C 1 FLASHER 2 CLIP 3 LH STEERING COLUMN SUPPORT BRACKET H2QQ78 8C Fig 810 Rear Console Pad to Support Fig 811 Turn Signal Flasher ...

Page 1223: ...EW V 3E INSTALLED 2 SHIFTER BKT FOURTH 3 UPR FLR PAN THESE BOLT SCREWS TO BE INSTALLED FIFTH T THESE BOLT SCREWS TO BE INSTALLED FIRST Y THESE BOLT SCREWS TO BE INSTALLED SIXTH U THESE BOLT SCREWS TO BE INSTALLED SECOND Z THIS BOLT SCREW TO BE INSTALLED LAST V THIS BOLT SCREW TO BE INSTALLED THIRD H20070 8C Fig 813 Console Support Assembly ...

Page 1224: ...8C Fig 814 Lighter Trimplate 1 VENT DUCT PANEL 2 INSTRUMENT PANEL PAD H20067 8C 1 HEATER MODULE ASM 2 SCREW 3 HEATER OUTLET 4 EE 520221 I B Fig 815 IP Pad Fig 816 Lower Floor Heater Outlet 1 SEAL 2 DUST PANEL ASSY 3 MODULE ASSY 4 DEFROSTER DISTRIBUTOR ASSY 5 BOLT 4 REQUIRED 6 BOLT SCREW 3 Fig 817 Defroster Ductwork ...

Page 1225: ...8C 14 INSTRUMENT PANEL GAGES CONSOLE 3 H E A T E R A C MODULE S INSTRUMENT PANEL ASM 520071 1A Fig 818 IP Duct Assembly ...

Page 1226: ...or is located in the terminal connector on the wiper motor A strap attached to one of the motor bolt hole grommets provides a ground for the suppressor An automatic reset type circuit breaker located on the motor brush holder assembly protects the motor A fuse in the fuse block protects the vehicle wiring Referring to Fig 3 note that there are four terminals which are lettered for illustrative pur...

Page 1227: ...IPER SYSTEMS 4 v fVIEVy A DO 10 VIEW B 3 VIEW C VIEW D 1 CONTAINER 5 C H E C K VALVE 9 N U T 2 NOZZLE 6 PUMP 10 BOLT SCREW 3 CONNECTOR 7 G R O M M E T 4 HOSE 8 S T U D H20007 8E Fig 2 Windshield Washer System Components ...

Page 1228: ...in order to have the blades stop in their normal park position and the wiper motor shut off properly the motor operates in low speed This is accomplished as follows with the multi function lever in the off position the low speed brush circuit is completed to 12 volts DC at the multi function lever through a park switch located on the brush assembly terminals A and B The park switch contacts are no...

Page 1229: ...r then returns to park positic and shuts off T C H P O P U L S E Wiper runs one low speed wipe Blades stop at inner wipe position next wipe is delayed for period of 18 to 1 25 seconds depending upon rheostat setting then cycle repeats PULSE function is overridden followed by wash and dry cycle above Blades then return to inner wipe position and PULSE function resumes K J s I T 1 L 0 W Wiper runs i...

Page 1230: ... Fig 7 WIPER WASHER MULTI FUNCTION LEVER TEST Disconnect wiring harnesses from wiper motor and perform the following multi function lever tests using a digital voltmeter with ignition switch on All voltage readings taken with respect to vehicle ground To use Wiper Washer Multi function Lever Check Chart Fig 11 probe terminals 1 through 4 with digital voltmeter and multi function lever in various p...

Page 1231: ...tor Mechanical Diagnostic Chart Make sure the wiring harness has been checked before starting Wiper On Car diagnostic procedures Figs 12 through 17 ON CAR OFF CAR SERVICE WIPER ARM 2 Remove or Disconnect 1 Using Tool J 8966 or equivalent lift arm off transmission spindle shaft Fig 18 Fig 9 Washer Pump On car Check To install reverse removal procedures and check operation of wipers The tool used to...

Page 1232: ...blades 1 One element uses a spring type retainer on the end of the blade Fig 21 To remove element insert and rotate a screwdriver as shown 2 The second element Fig 20 is retained by tabs on the blade housing To remove element bend housing tip downward and pull element upward and twist outward when housing tab and element slot align Slide element downward until all tabs are removed through slot 3 T...

Page 1233: ...EXT STEP LAMP ON LAMF OFF CHECK FUSE FUSE I3LOWN REPLAC E FUSE FUSE OK REPAIR OPEN IN FEED CIRCUIT BETWEEN FUSE BLOCK AND WIPER MOTOR FUSE BLOWS FUSE OK CHECK FOR SHORT IN WIRE OR MOTOR FOR HIGH AMPERAGE DRAW PROBLEM IS IN MOTOR REFER TO SERVICE PROCE DURE WITH WIPER SWITCH IN LOW LEAVE WIRING CONNECTED TO WIPER MOTOR CONNECT JUMPER WIRE FROM MOTOR TO GROUND WIPER RUNS WIPfcR D O t S NOT RUN REPAI...

Page 1234: ...IR WIPER MOTOR LOOK FOR HIGH SPEED HUNG OR GROUNDED BRUSH LAMP ON REPLACE COLUMN SWITCH CONDITION NO 3 WIPER HAS HIGH SPEED ONLY INOPERATIVE IN LOW SPEED PULSE WIPER ONLY REMOVE MODULE CONNECT FRONT AND REAR MODULE CONNECTORS CHECK WIPER SYSTEM IF OK REPLACE MODULE IF NOT OK GO TO NEXT STEP REMOVE CONNECTOR FROM WIPER TERMINAL CONNECT 12 VOLT SOURCE TO TERMINAL NO C WIPER RUNS IN LOW WIPER INOPERA...

Page 1235: ... SWITCH CONDITION NO 5 WIPER SHUTS OFF BUT BLADES DO NOT RETURN TO PARK POSITION PULSE WIPER ONLY REMOVE MODULE CONNECT FRONT AND REAR MODULE CONNECTORS CHECK WIPER SYSTEM IF OK REPLACE MODULE IF NOT OK GO TO NEXT STEP REMOVE CONNECTOR FROM WIPER TERMINAL CONNECT JUMPER FROM TERMINAL NO C TO NO BAND 12 VOLT SOURCE TO TERMINAL NO A WIPER INOPERATIVE OR DOES NOT PARK WIPER RUNS AND PARKS REPLACE WIP...

Page 1236: ...437 mm 11 64 drill bit 3 Remove cover HHH Install or Connect To install attach cover to housing with seven 4x10 mm 5 32 x3 8 thread forming self tapping screws Circuit Board Replacement Fig 27 Disassemble Screw Circuit board cover 1 2 3 Printed circuit board by lifting carefully at outboard end to disconnect terminal clips at inboard end Assemble When assembling printed circuit board make sure ter...

Page 1237: ...ERATE WIPERS IN HIGH SPEED WITH WINDSHIELD DRY CURRENT DRAW WILL FLUCTUATE CURRENT DRAW BELOW 5 0 AMPS CURRENT DRAW CEEDS 5 0 AMPS EX REPLACE WIPER MOTOR REMOVE WIPER ARMS AND BLADES AND REPEAT TEST CURRENT DRAW STILL EXCEEDS 5 0 AMPS CURRENT DRAW O K DISCONNECT WIPER LINKAGE FROM MOTOR CRANK ARM AND REPEAT TEST REPLACE WIPER BLADE ELEMENTS AND REPEAT TEST CURRENT DRAW STILL EXCEEDS 5 0 AMPS CURRE...

Page 1238: ...HECK S Y S T E M CONDITION NO 9 WIPER MOTOR PARKS BUT ABOVE NOR MAL POSITION DYNAMIC BRAKE CHECK WITH IGNITION SWITCH ON W REMOVE CONNECTOR FROM Wl BETWEEN TERMINAL NO B TO PER SWITCH IN PARK POSITION PER TERMINAL CHECK FOR OPEN GROUND LIGHT ON REPAIR OPEN IN MOTOR OR REPLACE HOLDER AS SEMBLY LIGHT OFF C H E C K ARM AND BLADE LOCATION AND OR TRANSMISSION LINKAGE G400U 8E2J Fig 17 Windshield Wiper ...

Page 1239: ...8E2 14 WINDSHIELD WIPER SYSTEMS Fig 20 Blade Assembly Type 1 ...

Page 1240: ... E L E M E N T D O W N W A R D T O D I S E N G A G E F R O M T O P T A B S 3 S L I D E E L E M E N T U P W A R D T O R E M O V E F R O M H O U S I N G T A B S V I E W A I N S E R T S C R E W D R I V E R A H E R E A N D P U S H D O W N W A R D T O R A I S E S P R I N G H O U S I N G 2 0 4 5 Fig 22 Blade Assembly Type 3 Fig 24 Wiper Motor Installation T R A N S M I S S I O N A S S E M B L Y T R A N ...

Page 1241: ... Rotation CCW Looking at Arm PARK When motor is off the car the motor housing must be grounded TERMINAL LETTERS ON HARNESS CONNECTOR D C B A o g Hi SPEED 12V D c B A CP D a a 12V LO SPEED 0 C B A a cp o o 12V 2775 Fig 26 Operating Wiper Motor Independent of Vehicle Wiring E N G A G E ALL 5 T E R M I N A L S 3 3 5 3 Fig 27 Pulse Wiper Circuit Board Installation ...

Page 1242: ...IPER SYSTEMS 8E2 17 HEATER A C HARNESS DUCT VENT P A N E L WIPER MOTOR ASM WIPER MOTOR CONNECTOR CONTAINER ASM WINDSHIELD WASHER PUMP CONNECTOR WINDSHIELD WASHER PUMP H20010 8E Fig 28 Windshield Wiper Washer Wiring ...

Page 1243: ......

Page 1244: ... radio problems are normally repaired at authorized warranty repair stations the tendency is to removethe set when aproblem is reported without any preliminary diagnosis This results in a large number of radios being No Trouble Found units when received by the warranty repair stations Often the trouble can be corrected without radio removal ETR radios require clock and button reset if the battery ...

Page 1245: ...cheon from fender 4 Attach alligator clip to upper end of antenna to act as antenna Leave other end of clip unattached 5 Tune radio for weak AM station or signal which is dependent on clip i e clip attached station is present clip removed no station 6 Remove clip 7 Ground upper end of antenna to fender preferably with knife blade very short jumper wire etc 8 If radio station is not received then t...

Page 1246: ... in the tip This results in a resistance reading of approximately 100 000 ohms G 3 5 2 0 9 9 E Fig 2 Lead in Cable Diagnosis SERVICE PROCEDURES RADIO AND SPEAKERS N O T I C E All radios are the bridge audio type using two wires to each speaker It is very important when changing speakers or performing any radio work to avoid pinching the wires A short circuit to ground from either wire will cause d...

Page 1247: ... M F M Stereo Radio Operation Power Button PWR press to turn radio on Press again to turn radio off m Upper Knob rotate knob to control volume listening to the radio with ignition on or to display time of day with ignition off m Balance Control located behind upper knob turn to adjust left right speaker balance Lower Knob rotate knob to tune radio stations manually Frequency will be displayed duri...

Page 1248: ...day will be displayed when you press the SCAN or SEEK button ETR STEREO CASSETTE UMS Figure 802 ETR AM FM Stereo Radio Operation Power Button PWR press to turn radio on Press again to turn radio off Upper Knob rotate knob to control volume Press knob to recall station frequency when listening to the radio with the ignition on or to display time of day with ignition off Press knob to select the oth...

Page 1249: ...se Reduction DNR button to reduce high frequency background hiss on AM FM FM stereo and tape For best results 120 minute tapes are not recommended ETR STEREO CASSETTE EQUALIZER UX 1 Figure 803 ETR AM Stereo FM Stereo Radio Operation Power Button PWR press to turn radio on Press again to turn radio off VOL V bAL 60 250 IK 3 5K 5 OK EJECT SEARCH H20012 9A Fig 803 U X 1 Radio Upper Knob rotate knob t...

Page 1250: ...e displayed The time of day will be displayed when you press the SCAN or SEEK button To Operate Tape Player Insert the cassette squarely through the door This automatically switches the unit from radio to tape operation If the sound is garbled or there is no sound eject the tape and reinsert it squarely To advance the tape press the forward FWD button To listen to the earlier portion of the tape p...

Page 1251: ...9A 8 RADIO SYSTEMS AND ANTENNAS G20019 9A Fig 804 Sub Woofer Amplifier Wiring ...

Page 1252: ...ofer Switch Wiring 1 GRILLE 2 SPEAKER A S M 3 TO CONVENIENCE CTR WIRING 4 INSTRUMENT PANEL 5 2 0 2 5 6 9 V I E W A L4 V I E W B 1 24 Nm 18 LBS FT 2 GROUND STRAP 3 OIL DIPSTICK 4 STARTER 5 A C COMPRESSOR 6 BATTERY C A B L E 7 ENGINE HARNESS 8 DECK LID HINGE 9 STATIC SHIELD 10 28 Nm 21 LBS FT 11 50 Nm 37 LBS FT 12 BATTERY CABLE H 2 0 0 2 6 9 A Fig 8 0 6 Front Speaker Grille Fig 807 Rear Speaker Wiri...

Page 1253: ... FEED 3 MAIN BODY WIRING HARNESS 4 FRONT S P E A K E R S 5 CLOCK LEAD H 2 0 0 3 0 9 A 1 CONSOLE SUPPORT 2 AMPLIFIER 3 1 6 N m 14 LBS IN 4 CARPET SUPPORT AMPLIFIER MUST BE ASSEMBLED TO CARPET SUPPORT PRIOR TO ASSEM BLY TO CONSOLE SUPPORT H 2 0 0 3 2 9 A Fig 809 Radio Wiring Fig 8 10 Amplifier to Carpet Support ...

Page 1254: ...STEMS AND ANTENNAS 9A 11 1 DOME LAMP CONN 2 DOME READING LAMP SUBWOOFER CONTROL ASSEMBLY 3 CONDUIT 4 FASTENER 5 STEERING COLUMN SUPPORT 6 CROSS CAR HARNESS H20031 9A Fig 811 Dome Reading Lamp Sub Woofer Harness ...

Page 1255: ......

Page 1256: ...ontrol switches located in the end of the directional signal lever To disengage the system two release switches are provided An electrical release switch mounted on the brake pedal bracket brake and clutch pedal bracket on cars equipped with manual transmission disengages the system electrically when the brake pedal or clutch pedal is depressed A vacuum release valve mounted on the brake pedal bra...

Page 1257: ...nd releasing the Set Coast Button or tapping the button Do not hold the button in the depressed position or the system will go into the coast mode Tap down is a function in which cruise speed can be decreased by 1 mph increments one tap 1 mph decrease The accelerator may he depressed at any time t o override the cruise system Release of the accelerator will return the car to the previous set cruis...

Page 1258: ...en the controller senses an over or underspeed condition it will pulse the opening of the vent or vacuum valve The pulse will be repeated as required until the speed correction necessary brings the car to the set speed From any set speed under normal road load conditions the vacuum valve will remain in a completely open position when vehicle speed has dropped 5 mph below set speed Likewise when ve...

Page 1259: ...m is either vacuum mechanical or electrical the technician should perform a few initial checks before turning to Section 8A This can be done by first eliminating a vacuum or mechanical problem by starting the engine and using finger to feel for source vacuum at the servo and by visual inspection of vacuum release valve throttle linkage vacuum hoses etc If preliminary inspection reveals no solution...

Page 1260: ...INER 1 C A B L E ASM 2 CLIP 3 ENGINE 4 C A B L E ASM 5 C A B L E I N S T A L L E D IN DIRECTION SHOWN 6 B R A C K E T REINF MOTOR COMPT 7 S E R V O ASM 8 L E V E R ASM 9 B R A C K E T 10 RETAINER 1 1 TAB SERVO ASM 4 IF A TAB HOLE DOES NOT LINE UP WITH THE PIN MOVE THE C A B L E AWAY FROM THE S E R V O ASM UNTIL THE NEXT C L O S E S T TAB HOLE LINES UP AND CONNECT PIN TO TAB WITH RETAINER CAUTiOM D...

Page 1261: ...LE AND CONNECT PIN TO TAB WITH RETAINER 9 6 IF A TAB HOLE DOES NOT LINE UP WITH THE PIN MOVE THE CABLE AWAY FROM THE SERVO ASM UNTIL THE NEXT CLOSEST TAB HOLE LINES UP AND CONNECT PIN TO TAB WITH RETAINER J CAUTION DO NOT STRETCH CABLE SO AS TO MAKE A PARTICULAR TAB HOLE CONNECT TO PIN THIS COULD PREVENT ENGINE FROM RETURNING TO IDLE 1 CRUISE SERVO 2 CRUISE CABLE MUST BE INSTALLED IN DIRECTION SHO...

Page 1262: ...CONTROL 9B 7 H20025 9B Fig 803 Vacuum Tank Servo Brackets Hoses tl GD T V I E W A 1 SUPPORT ASM 2 UPPER FLOOR PAN 3 C A R P E T SUPT 4 M O D U L E A S M 5 HARNESS ASM G20011 9B Fig 804 Cruise Control Module V6 ...

Page 1263: ...TION O F SWITCH IS PUSHED THROUGH THE RETAINER TOWARD THE BRAKE P E D A L 3 P U L L B R A K E PEDAL F U L L Y REARWARD AGAINST PEDAL STOP UNTIL AUDIBLE C L I C K SOUNDS CAN NO LONGER BE HEARD SWITCH ASM WILL BE MOVED IN RETAINER PROVIDING ADJUST MENT 4 R E L E A S E B R A K E PEDAL AND REPEAT STEP 3 TO ASSURE THAT NO AUDIBLE C L I C K SOUNDS REMAIN 5 REPEAT STEPS 1 THRU 4 FOR CLUTCH PEDAL G20009 9...

Page 1264: ...ER JACKET SUPPORT PLUG CAREFULLY CAUTION DO NOT SCORE MACHINED SURFACE OF HOLE 2 THOROUGHLY CLEAN PLUG HOLE REMOVING ANY BURRS COMPOUND PAINT OR ROUGH SPOTS 3 APPLY A COATING OF LUBRICANT TO THE 0 RING AND MACHINED SURFACE OF HOLE 4 INSERT THE HAIRPIN END OF THE HEATING COIL INTO THE OPENING TO THE INSIDE FACE OF ENGINE BLOCK TO INSERT SUPPORT INTO ENGINE BLOCK MERELY CEN TER THE AXIS OF THE HEATE...

Page 1265: ...TMENT 2 CANISTER A S M 3 CORD A S M 4 PIPE A S M VACUUM 5 PIPE A S M PURGE 6 HEATER A S M 7 ENGINE A S M 8 TERMINAL GUARD 9 GROUND RING 10 SUPPORT 11 BOLT SCREW 12 ENGINE BLOCK OUTSIDE 13 G A S K E T S 0 RING G20015 9E Fig 802 Block Heater L4 ...

Page 1266: ...R 9E 3 VIEW A 1 HEATER HOSE 2 BLOCK HEATER 3 HEATER CORD 4 C O R E HOLE ENGINE 5 GENERATOR 6 ENGINE HARNESS 7 STRAP E X C E S S CORD TO PIPES AS SHOWN 8 E N G I N E BLOCK INNER WALL 9 GROUND LEVEL Fig 803 Block Heater V6 ...

Page 1267: ......

Page 1268: ...w band are normal with the engine idling or for short periods after long engine cranking However continuous readings in the low band can indicate faulty operation TACHOMETER Figure 2 The tachometer indicates speed of the engine in revolutions per minute RPM The engine can safely be operated up to a maximum RPM as indicated by the start of the red bar Engine operation with tachometer readings in th...

Page 1269: ...trol that allows the mirrors to be adjusted from the driver s seat See Section 8C On Car Service for specific location and service procedures DIAGNOSIS RALLY GAGES TACHOMETER Diagnosis of individual rally gages is found in Section 8A 81 or 82 depending on the type of instrument cluster ELECTRIC REAR WINDOW DEFOGGER Figure 3 Use the chart in Figure 3 to aid in diagnosis of problems with the rear de...

Page 1270: ...per ground Check for relay pull in click when 12 volts is applied to the light blue wire terminal of timer assembly If no pull in replace timer assembly Defective control switch With switch held in ON position and connector installed on switch connect a test light to the light blue wire terminal with connector on rear of switch to ground Test light should glow brightly if not replace switch System...

Page 1271: ......

Page 1272: ... for servicing P body styles This information is current at time of publi cation approval TABLE OF CONTENTS TITLE SECTION GENERAL INFORMATION u STATIONARY GLASS 2J UNDERBODY 3J FRONT END 4 J DOORS 5J REAR QUARTERS 6J REAR END 7J ROOF 8 J SEATS 9J ELECTRICAL Wiring Harness Illustrations 10J INDEX ...

Page 1273: ......

Page 1274: ...Two noninterchangeable keys are used Square headed key is used in the ignition lock cylinder Oval headed key is used in all other lock cylinders Key identification is obtained from the four character key code stamped on the knockout portion of the key head and an identification letter stamped on the key shank After the code number has been recorded by the owner the plugs should be knocked out of t...

Page 1275: ...e cylinder metal over retainer Lubricate cylinder with a light oil 9 10 Mechanical parts having contacting surfaces in relative motion with other body parts are lubricated during assembly To maintain ease of operation it is recommended that these parts be lubricated at the basic service intervals shown in the Maintenance Schedule with the following lubricants Door hinge engine oil 30 weight prefer...

Page 1276: ...nt area leak use a brushable seam sealer or equivalent which can be painted Sealed components such as ventilation ducts use 3M Auto Bedding and Glazing Compound or equivalent Important Water entry through the high level ventilation ducts may be due to a damaged duct shroud vent screen or a blockage in the shroud drain j Windshield pillar drip molding use 3M Auto Bedding and Glazing Compound or equ...

Page 1277: ...g and control the general noise level inside the passenger area of the car When deadeners are disturbed because of damage removed during repair operations or a new replacement panel is installed the deadener material must be replaced by a service equivalent material The application pattern and location of deadener materials can be determined by observing the original production installation Antico...

Page 1278: ...shield Pillar G 9 3 0 8 0 1 B G Fig 8 Pressure Test of Wheelhouse Fig 6 Watertest Stand Fig 9 Air Hose and Bubble Solution Test of Windshield Glass Sealant interior surfaces One or more ofthe following methods will remove the residue CAUTION Standard shop practices particularly eye protection should be followed during these operations to avoid personal injury Where access is possible scraping can ...

Page 1279: ... Since epoxy resin has superior adhesive properties all repair work done on the back side of the part should be done with fiberglass cloth and structural adhesive Then cosmetic repair on the face side of the part may be completed with polyester body filler Preparation of the back and face sides of the part and the use of structural adhesive will be the same as the procedure for RIM and RRIM R E A ...

Page 1280: ...strate Surrounding Damage Fig 14 Tape Support for Repair Material until a uniform color and consistency is achieved Fig 15 Apply the mixed repair material with a squeegee or plastic spreader Apply a light coat over the entire area then continue application to a level slightly above the surrounding contour Allow the mixture to cure 20 to 30 minutes at 16 C to 2 7 C 60 F to 80 F If low areas or pits...

Page 1281: ...sander with a 320 disc Fig 17 Establishing Rough Contour with Body File If G93704 1 BG Fig 18 Block Sanding for Accurate Contour 2 Structural type repair When a piece of attaching surface of a part is cracked or broken away as in Figure 19 structural strength may be restored as follows a Align and secure the piece on the face side with body tape and clamp Fig 20 G93705 1 BG Fig 19 Damaged Attachin...

Page 1282: ...ately cover the cloth with additional adhesive in sufficient quantity to fill the weave Figs 24 and 25 f Allow 20 30 minutes cure time at 16 C to 2 7 C 60 F to 80 F Trim excess repair material at edge if necessary g Repair the face side of the area following steps la through le PAINTING OF EXTERIOR PANELS The original factory applied paint finish consists ofabasecoat clear coatenamel paint Forpain...

Page 1283: ... with a readily visible black smoke residue which hangs temporarily in the air Test for Vinyl Plastic To determine ifa part to bepainted is vinyl plastic polyvinyl chloride a copper wire test should be performed as follows 1 Heat a copper wire in a suitable flame such as provided by a propane or equivalent torch until the wire glows turns red 2 Touch the heated wire to the backside or hidden surfa...

Page 1284: ...nts The clear coat is necessary to control the gloss requirement and to prevent crocking rubbing off of the color coat after drying 4 Allow to dry according to label directions before installing part AVAILABILITY OF COLORS FOR PAINTING INTERIOR PLASTIC PARTS Interior colors are color keyed to trim code combination numbers located on the body number plate or service parts identification label Conve...

Page 1285: ......

Page 1286: ...ting elements in the glass because the heating elements will be damaged 1 Mix two parts of polishing compound No 14 Rareox or equivalent with one part water to obtain a creamy mixture 2 Stir mixture now and then to maintain a creamy texture Powdered cerium oxide is hard to mix with water and tends to separate 3 Draw a circle around scratches on opposite side of glass with a wax marking pencil or c...

Page 1287: ...o keep reveal molding flush with body 7 Flood molding with warm water S T A T I O N A R Y G L A S S The short method can be used where original adhesive left on window opening pinch weld flanges after glassremoval can serve as abase for the new glass 1 WINDSHIELD REVEAL MOLDING 2 URETHANE ADHESIVE 3 WINDSHIELD G94186 Fig 3 Installing Windshield Reveal Molding This method would apply in cases of cr...

Page 1288: ...en pinch weld flanges 6 and glass edge Remove glass 3 Refer to applicable installation method Position glass 3 and apply hand pressure to wet out and set adhesive Remove suction cups Paddle adhesive around edgeofglass with a brush or flat bladed tool to ensure a watertight seal Important Watertest immediately use a soft spray of warm or hot water Do not direct a stream of water at wet adhesive Wor...

Page 1289: ...tool to ensure a watertight seal as 7 8 9 10 11 12 Watertest immediately use a soft spray of warm or hot water Do not direct a stream of water at wet adhesive Work in additional adhesive needed Reveal molding Seatback to motor compartment panel Rear console pad to shifter plate Headlining Rear quarter trim panels Upper seat belt anchor assemblies 3t Tighten 13 14 15 16 17 18 19 20 Upper seat belt ...

Page 1290: ...yl tape or other installations of unknown material must be replaced using the extended method Prep and Sealing Figure 9 1 Clean around edge and inside surface of glass with alcohol Allow to air dry 2 Apply clear primer to perimeter of glass edge and 7 mm 9 32 inboard on inner surface 3 Apply black primer over clear primer on glass Allow five minutes to dry 4 Apply smooth continuous bead of adhesiv...

Page 1291: ... primer over clear primer on glass Allow five minutes to dry 7 Apply a smooth continuous bead of adhesive 10 mm 3 8 high by 5 mm 3 16 wide completely around inside edge of glass Fig 9 Tip bead of adhesive slightly inboard WATERLEAK CORRECTION Where accessible waterleaks can be corrected without removing and reinstalling the glass This method applies only to urethane installed glass and the use of ...

Page 1292: ...e or terminal is soldered to the bus bar on the side The ground wire or terminal is soldered to the bus bar on the right side The system operates on 12 volts Under some conditions heat from the glass may not be detected by finger touch The length of time required to remove interior fog from the back glass will vary with such conditions as car speed outside glass temperature and atmospheric pressur...

Page 1293: ...er and silver plastic thoroughly If hardener has crystalized immerse packet in hot water until the hardener reliquifies 3 At room temperature apply grid repair material to repair area using a small wood stick or spatula 4 Carefully remove the decal or tape NOTICE The grid line repair material mustbe cured with heat To avoid heat damage to interior trim protect the trim near the repair area where h...

Page 1294: ... area should be buffed with fine steel wool This removes the oxide coating formed during glass manufacture Applythepaste type rosinfluxin small quantities to the wire lead and bus bar repair area using a brush The soldering iron tip should be coated with solder beforehand Use only enough heat to melt the solder and only enough solder to ensure a complete repair Do not overheat the wire when resold...

Page 1295: ......

Page 1296: ...d quality type of air dry primer be used such as corrosion resistant chromate or equivalent material It is not advisable to use combination type primer surfacers There are many tools that may be used to correct the average collision damage situation including frame straightening machines lighter external pulling equipment and standard body jacks ALIGNMENT CHECKING An accurate method of determining...

Page 1297: ...ng 8 1 2 3 Install or Connect Figure 2 Lower garnish molding 5 Five garnish molding screws 6 Five garnish molding plugs 7 FLOOR CARPETS The floor carpet consists of molded right and left side carpet assemblies Floor pan insulators are attached to the floor carpet assemblies The right and left side floor carpets may be serviced separately 1 2 3 4 5 6 1 2 3 4 5 6 Remove or Disconnect Figures 1 2 and...

Page 1298: ...UNDERBODY 3J 3 G94080 3J P Fig 1 Seatback to Motor Compartment Panel Fig 2 Installing Lower Garnish Molding ...

Page 1299: ...3J4 UNDERBODY ...

Page 1300: ...UNDERBODY 3J 5 MEASURE WITH BOLT INSTALLED H93810 3J P Fig 4 Underbody Reference Point Locations ...

Page 1301: ...LL CONTROL POINTS ARE SYMMETRICAL SIDE TO SIDE 5 TRAM BAR SHOULD BE HORIZONTAL FOR TOP MEASUREMENTS r 65 B C E F H I J K J93807 Fig 5 Horizontal and Vertical Dimensions TOP VIEW Q c c V i n c c CM O CM A 9 4 2 4 i u M G93808 3J P Fig 6 Front Compartment Upper Side Rail Dimensions TOP VIEW J93809 3J P Fig 7 Rear Compartment Upper Side Rail and Suspension Strut Tower Dimensions ...

Page 1302: ... cradle attaching bolt Center of front outboard cradle attaching bolt Motor compartment front cradle mounting bracket G Inboard side of front cradle mounting bracket outboard flange where bend begins NONE Motor compartment front cradle mounting bracket H Center of rear cradle attach ing bolt bolt installed Center of rear cradle attach ing bolt bolt installed Rear engine cradle attach ing location ...

Page 1303: ... E to J 1 257 49 1 2 F to H 867 34 1 8 G toG 1 056 41 9 16 H toH 917 36 1 8 H to 0 251 9 7 8 J to J 1 005 39 9 16 J to E 1 625 64 K toK 1 422 56 L to L 1 348 53 1 16 L to M 942 37 1 16 Mto M 1 202 47 5 16 Mto L 1 580 62 3 16 N to N 1 413 55 5 8 N to 0 354 13 15 16 0 to 0 1 030 40 1 2 0 to N 1 259 49 9 16 VERTICAL A 456 17 15 16 A 268 10 9 16 B 228 9 C 98 3 7 8 D 65 2 9 16 E 68 2 11 16 F 165 6 1 2 ...

Page 1304: ...o the passenger compartment and is expelled through the pressure relief valve located in the body lock pillar under the quarter applique panel Shroud Vent Top Screen 1 2 3 4 5 6 7 M 1 2 3 4 5 6 7 Remove or Disconnect Figure 1 Windshield wiper arm assemblies Attaching screws 2 Fasteners 3 two required Rivet 4 using a 6 3 mm 1 4 drill bit Spring 5 Windshield washer hoses as required Screen 1 by lift...

Page 1305: ...ge 9 Install or Connect Figure 2 Hinge 9 Bolts 10 Door assembly 8 Bolts 11 Front and Rear Gap Adjustment 1 Loosen four bolts 10 2 Align as necessary 3 Tighten four bolts 10 Side to Side Gap Adjustment 1 Loosen two bolts 11 2 Align as necessary 3 Tighten two bolts 11 HOOD ASSEMBLY The hood is composed of a single outer panel and an inner reinforcement Both panels are composed of fiberglass 1 2 3 4 ...

Page 1306: ...ound hinge on hood inner panel and front panel to indicate original hinge position Block hood and prop open on side to be removed Nuts 23 Bolts 22 Hinge 21 Hood too High or Low at Front Corners Loosen nuts 23 Reposition hood assembly Tights nuts 23 Hood too High or Low at Rear Corners Determine amount and direction of adjustment needed Adjust hood bumper accordingly Hood too Far Fore or Aft Loosen...

Page 1307: ...triker 27 Install or Connect Figure 4 1 Striker 27 2 Nuts 28 Hood Ajar Switch A hood ajar switch is located in the front compartment area This switch indicates if the hood is not fully closed by sending electrical current to an indicator light located in the instrument panel 4 Remove or Disconnect 1 Loosen switch from body 2 Electrical connector from switch Install or Connect 1 Electrical connecto...

Page 1308: ...FRONT END 4J 5 24 HOOD LATCH 25 HOOD LATCH BOLT 2 28 HOOD RELEASE CABLE 17 HOOD 27 STRIKER 28 STRIKER NUT 2 29 CABLE CONNECTOR Qg40 2 4J Fig 4 Hood Latch and Striker ...

Page 1309: ...33 Rivet front fender to fascia at marker light 37 3 Side marker lamp assembly 34 4 Rocker panel Inspect For proper alignment of panel at hood door wheelhousing and fascia Theclearancebetween fender and door and fender and front compartment hood should be 4 mm 5 32 FRONT WHEELHOUSE PANEL J4 Remove or Disconnect Figure 8 1 Attachments at Fender panel 36 m Chassis 39 m Fascia 40 2 Wheelhousing panel...

Page 1310: ...R LAMP 35 MARKER LAMP SCREW 2 36 BOLTS FENDER PANEL TO INNER PANEL 4 37 RIVET 1 J 9 4 0 9 3 4 J P Fig 7 Front Fender Panel Attachment 38 INNER WHEELHOUSE PANEL 39 FASTENERS 8 40 BOLTS INNER PANEL TO FASCIA 3 J 9 4 0 9 4 4 J P 46 MOLDING 47 NUTS 2 G 9 4 0 9 7 Fig 8 Wheelhousing Panel Attachment Fig 9 Front Fender Molding ...

Page 1311: ......

Page 1312: ...Switch 5J 11 Outside Mirrors 5J 11 Outside Mirror Manual 5J 11 Mirror Glass Manual 5J 12 Remote Control Mirror Manual 5J 12 Remote Control Mirror Glass Manual 5J 12 Remote Control Mirror Glass Power 5J 12 Power Mirror Drive Unit 5J 13 Door Glass Assembly 5J 14 Door Glass Adjustment 5J 14 Window Regulator Cam Assembly 5J 14 Regulator Assembly Manual 5J 15 Regulator Assembly Power 5J 15 Rear Cam 5J ...

Page 1313: ... 2 Handle 11 3 Plate 13 Install or Connect Figures 2 and 3 L Plate 13 2 Clip 12 on handle 3 Handle 11 m Position handle at same angle as opposite side handle Press handle onto regulator spindle to engage clip DOOR LOCK KNOB AND REMOTE HANDLE BEZEL Remove or Disconnect Figure 4 1 Covers 17 2 Screws 16 3 Lock knob 19 Use a small flat bladed tool such as a screwdriver Insert blade between end of knob...

Page 1314: ...rimeter of door 8 use J 9886 between panel and door Panel 7 pull outward to disengage from retainer at beltline Remote control mirror cable end if equipped Screw 6 Cable Wire harness if equipped T O O L J 9 8 8 6 R E T A I N I N G S P R I N G D I S E N G A G E D PUSH TOOL IN D I R E C T I O N O F A R R O W I N S I D E H A N D L E G94816 5B BG 15 BEZEL 16 BEZEL ATTACHING SCREWS 2 17 SCREW COVERS 2 ...

Page 1315: ...ts with J 23554 Door trim panel EXTERIOR MOLDINGS 1 2 3 CENTER MOLDING ASSEMBLY p Remove or Disconnect Figure 5 1 Door trim panel 2 Water deflector 3 Nut 24 from rear clip 25 put window in full up position to allow access to nut from inside of door panel 4 Plastic retainer 23 at outside door handle 5 Molding assembly 22 Install or Connect Figure 5 1 Molding assembly 22 2 Plastic retainer 23 3 Nut ...

Page 1316: ...s Inspect 1 2 3 4 For holes or tears in deflector Apply waterproof tape to both sides if necessary Replace deflector if it cannot be properly repaired Install or Connect Figures 1 7 and 8 Waterdeflector 34 Apply additional strip caulk and tape as required Stiffener 10 Armrest hanger plates 4 Door trim panel Inner Panel Water Deflector The water deflector is secured by a string loaded sealing mater...

Page 1317: ...ure 9 1 Lower garnish molding Refer to Section 3J 2 Loosen quarter trim panel 3 Screws 39 4 Door opening weatherstrip 38 Break bond between channel and weatherstrip with a putty knife or flat bladed tool and a release agent Fig 8 Door Inner Panel Water Deflector Tape Locations o Start at any convenient location grasp the weatherstrip and pull from the pinch weld flange and channel continue around ...

Page 1318: ...a two part material applied to the hardware attachment as a liquid Upon installation and tightening the adhesive cures to bond the attachment and prevent loosening or back out The adhesive bond does not prevent future removal if required Loctite 75 or equivalent can be used on any threaded fastener SPRING CLIPS Spring clips are used to secure remote control connecting rods and inside locking rods ...

Page 1319: ...anel away from inner door to disengage retainers at top Pull panel straight back as ifit werehinged at the back of the inner door All attaching rods Fig 10 Removing Spring Clip 2 Water deflector 34 3 Nine screws 59 from front and rear of inner panel assembly 4 Nut from rear clip 24 Put window in full up position to allow access to nut from inside of door panel 5 Outside door handle 4 Install or Co...

Page 1320: ...It must bereplaced with one ofthe same part number or with an equivalent part if replacement becomes necessary Do not use a replacement part of lesser quality or substitute design Torque values must be used as specified during reassembly to assure proper retention of this part yj Inspect Figures 15 17 Check for proper door alignment Apply modeling clay or body caulking to lock bolt opening m Close...

Page 1321: ..._ _ _ G94108 Fig 13 Door Locking Mechanism 60 RIVETS 1 4 DIA x 5 8 PLASTIC G94109 Fig 14 Outer Door Panel ...

Page 1322: ...s They are installed in the front door hinge pillars When the door of the vehicle is closed the plunger is depressed which creates an open in the ground circuit When the door is opened the plunger is released and completes the circuit to ground Fig 18 When a newjamb switch is installed and the door is closed the first time the plunger is forced into the sleeve and automatically adjusts the jamb sw...

Page 1323: ...Front filler weatherstrip Remote control cable end Door trim panel Remote Control Mirror Glass Manual Remove or Disconnect Figure 20 1 Mirror 68 2 Upper screws by putting mirror glass 69 in full down position for access 3 4 4 1 2 3 4 63 MIRROR GLASS ASSEMBLY 64 MIRROR HOUSING 65 MOUNTING STUDS 2 66 GASKET 67 NUTS 2 G 9 4 1 1 1 Fig 19 Outside Mirror Manual Lower screws by putting mirror glass 69 in...

Page 1324: ...Electrical connector 76 Screws 73 Drive unit Install or Connect Figure 21 Drive unit Screws 73 Electrical connector 76 Mirror housing 72 Nuts 67 Mirror glass 71 Battery negative cable Inspect 1 For proper operation Front filler weatherstrip Door trim panel 67 MIRROR ATTACHING NUTS 2 71 GLASS ASSEMBLY 72 MIRROR HOUSING 73 DRIVE UNIT ATTACHING SCREWS 3 74 PIVOT 75 DRIVE GEARS 2 76 ELECTRICAL CONNECT...

Page 1325: ...taching screws Window too far forward or rearward Loosen front run channel bolts 88 and 89 m Loosen rear cam guide assembly 90 and 91 m Align glass in correct up position Tighten upper bolt on front run channel 88 Tighten upper bolts on rear cam guide 91 e Lower glass m Tighten lower bolt on front run channel 89 Tighten lower bolts on rear cam guide 90 Window too high or low in up position Adjust ...

Page 1326: ...01 4 Bell crank and bracket assembly 5 Window regulator cam assembly 6 Remove block from glass and check operation Regulator Assembly Power Regulator Assembly Manual 1 2 3 4 5 6 Remove or Disconnect Figure 24 Put glass in full up position and block into place Window regulator cam assembly Cam assembly front door inner panel 101 Bell crank and bracket assembly Rivets 9 from regulator Regulator 100 ...

Page 1327: ...R DOOR REAR UP STOP TO SUPPORT REAR STABILIZER TO INNER DOOR FRONT STABILIZER TO INNER DOOR FRONT UP STOP TO INNER DOOR REAR INNER PANEL CAM TO INNER DOOR FRONT INNER PANEL CAM TO INNER DOOR 694115 Fig 23 Door Hardware Attaching Bolts 9 RIVETS 1 4 DIA x 1 2 ALUMINUM 100 REGULATOR MANUAL 101 CAM ASSEMBLY FRONT DOOR INNER PANEL G94116 Fig 24 Window Regulator Assembly Manual 4 Install or Connect Figu...

Page 1328: ...igure 23 1 Front glass run channel 2 Front glass run channel bolt 89 Retainer support bolts 87 and 88 Adjust Run channel and tighten bolts Inspect For proper operation of glass 4 Water deflector 5 Trim panel Cam Assembly Front Door Inner Panel 4 4 1 2 3 4 1 2 Remove or Disconnect Figure 23 Trim panel Water deflector Inner panel cam assembly bolts 98 and 99 Inner panel cam assembly Install or Conne...

Page 1329: ...Lock cylinder assembly 51 4 Install or Connect Figure 27 1 Lock cylinder assembly 51 2 Cylinder assembly retainer 53 3 Top portion of outer door panel 4 Water deflector 5 Trim panel 5 4 A DOOR AJAR S W I T C H 54B S C R E W 54C C O N N E C T O R G 9 4 4 9 7 5 J P Fig 26 Installing Door Ajar Switch POWER DOOR LOCK SYSTEMS The power door lock system has a motor actuator in each door A rod connects t...

Page 1330: ...l up position Rivets at bell crank plate assembly 44 All rod assemblies Bell crank and plate assembly 103 4 4 i Install or Connect 1 Bell crank and plate assembly 103 2 All rod assemblies 3 Rivets at bell crank plate assembly 44 Inspect For proper operation 4 Water deflector 5 Trim panel DOOR HINGE SYSTEM NOTICE The door hinge components are important attaching parts in that they could affect the ...

Page 1331: ...agement at striker and correct door panel clearance with fender panel The clearance betweeen door panel and fender panel should be no more than 4 mm 5 32 131l9htin Hinge bolts from 20 to 28 N m 14to20 ft lb inspect Door assembly for proper engagement o All electrical door devices for proper operation 6 Front run channel 7 Water deflector 8 Door trim panel DOOR HINGE I Hlj Remove or Disconnect Figu...

Page 1332: ...or 107 or 110 Important Align hinge with marks previously made on body and door g p y j Tighten 8 mm bolts from 20 to 28 N m 15 to 20 ft lb 10 mm bolt from 40 to 55 N m 30 to 40 ft lb 4 Outer door panel assembly 13 nspect Door assembly engagement at striker adjust where necessary m Clearance between door panel and fender panel no more than 4 mm 5 32 5 Noise control adhesive patch 6 Lower garnish m...

Page 1333: ......

Page 1334: ...r and Pocket Assembly 6J 7 Fuel Filler Door Remote Latch and Cable Assembly 6J 7 Exterior Panels and Moldings 6J 7 Rear Wheelhouse Panel 6J 7 Rear Fender Finish Molding 6J 7 Rear Fender Panel Assembly 6J 9 Rear Roof Panel Assembly 6J 9 QUARTER TRIM ROCKER PANEL COVER Remove or Disconnect Figure 1 1 Two wheelhousing screws 1 2 Cover plates 2 3 Three rivets 3 under cover plates 2 4 Seven rivets 3 fr...

Page 1335: ...44 Remove or Disconnect Figure 4 Rear compartment side panel cover Two screws 10 Rear compartment side panel cover hinge 11 Cover extension 12 Install or Connect Figure 4 Cover extension 12 2 Rear compartment side panel cover hinge 11 and screw 3 Two screws 10 4 Rear compartment side panel cover BACK WINDOW SIDE FILLER PANEL 37 STYLE 4 1 2 3 4 5 Remove or Disconnect Figure 5 Rear compartment side ...

Page 1336: ... Cloth tape from body REAR Q U A R T E R TRIM PANEL The rear quarter trim panel is a one piece plastic assembly The panel fits into the seatback to motor compartment panel Remove or Disconnect Figure 7 1 Upper shoulder belt anchor assembly 2 Screw 13 3 Panel 14 Unseat retainer clip by grasping panel with hands and pulling inward 4 Seat belt webbing from slots 15 on panel 14 Install or Connect Figu...

Page 1337: ...PER S C R E W S 9 LOWER S C R E W S G93797 Fig 5 Back Window Side Filler Panel 37 Style 2 Speaker assembly 14A 3 Screws 12A 4 Rear quarter trim panel SPEAKER GRILLE Fig 4 Rear Compartment Cover Extension 37 Style 4 W Remove or Disconnect 1 Rear quarter trim panel 2 Speaker grille by placing trim panel face down on protected surface and disengaging grille retainers from trim panel ...

Page 1338: ... panel Upper shoulder belt anchor assembly Q Tighten Anchor bolt 35 to 48 N m 26 to 35 ft lb APPLIQUE PANEL ASSEMBLY Remove or Disconnect Figure 10 Upper shoulder belt anchor assembly Rear quarter trim panel Hex nut 19 Grasp panel at front and pull outboard Do not pull out more than one inch while sliding it rearward to dislodge the spring clip from the panel Install or Connect Figure 10 Two retai...

Page 1339: ...panel assembly 4 Screw 23 5 Valve 24 4 4 4 install or Connect Figure 11 Valve 24 Screw 23 Applique panel assembly Rear quarter trim panel Upper shoulder belt anchor assembly Tighten 13A S C R E W S 14A S P E A K E R A S S E M B L Y 15A C O N N E C T O R 16A C O N N E C T O R G945Q2 6J P Fig 8 Installing Quarter Speaker Assembly 17 SCREW 4 18 LOWER VALVE G94 126 Fig 9 Lower Pressure Relief Valve An...

Page 1340: ...pper shoulder belt anchor assembly Rear quarter trim panel Latch release screw and handle 30 Applique panel assembly Screw and bracket 31 Cable 28 from handle 30 j M Install or Connect Figures 12 and 13 2 3 4 5 6 7 Cable 28 in body Bracket 31 and screw Cable 28 to handle 30 Applique panel assembly Latch release handle 30 and screw Rear quarter trim panel Upper shoulder belt anchor assembly Q Tight...

Page 1341: ...ing Fuel Door and Pocket Assembly 29 POCKET 30 RELEASE HANDLE ASSEMBLY 31 BRACKET 32 PUSH PULL RETAINER 6 33 SCREW 8 34 PANEL G9413Q I I G94131 Fig 13 Fuel Filler Door Remote Latch and Cable Assembly Fig 14 lnstalling Rear Wheelhouse Panel ...

Page 1342: ...nder panel 42 Fender panel 42 Fender to wheelhouse panel screws 41 Seven rivets 40 NOTICE Care must be taken when fasteners are installed to plastic or fiberglass components To prevent damage align all parts before installation of fasteners 7 Rear fender finish molding 8 Rocker panel cover REAR ROOF PANEL ASSEMBLY It is not necessary to remove rear quarter windows when removing rear roof panel ass...

Page 1343: ...ct Figure 17 Rear roof panel 52 Align rear roof panel to rear roof fastener holes Eight front roof panel to front roof nuts and bolts 51 Jill Tighten Front roof panel fasteners to 10 N m 7 ft lb Three rear roof panel to rear roof nuts 50 jlptj Tighten Rear roof panel nuts to 10 N m 7 ft lb Roof drip molding Headlining assembly refer to Section 83 Upper garnish moldings refer to Section 8J Two rear...

Page 1344: ...REAR QUARTERS 6J 11 Fig 17 Rear Roof Panel Assembly ...

Page 1345: ......

Page 1346: ...e could result Electrical connector remote control deck lid release at left hinge if equipped Bolts 1 Lid Install or Connect Figure 1 Lid align with scribe marks Screws 1 Electrical connector Inspect 1 Close lid carefully and check for proper alignment REAR COMPARTMENT HINGE U Remove or Disconnect Figure 2 Rear Compartment Lid Adjustment 7J 4 Rear Compartment Weatherstrip 7J 6 Rear Compartment Lin...

Page 1347: ... compartment lid 8 Partially lower lid and remove wood blocks 1 Hinge 4 Fig 2 2 Screw 13 3 Pin 9 with end of torque rod resting against plywood grasp U end of rod 8 and pull rearward to release pin 4 Rod 3 from hook 7 5 Rod 3 pM j Install or Connect Figures 3 and 6 Rod 3 Rod 3 in hook 7 Pin 9 With torque rod resting against plywood grasp U end of rod 8 and pull rearward to insert pin Release U end...

Page 1348: ... 1 3 3 Fig 4 Attaching Rear Compartment Lid Torque Rod REAR COMPARTMENT STRIKER Fig 5 lnstalling Rear Compartment Lid Hinge REAR COMPARTMENT LID LOCK ASSEMBLY Remove or Disconnect Figure 7 Remove or Disconnect Figure 8 1 Bolts 16 i Bolts 18 2 Striker 15 2 Lock Assembly 17 Install or Connect Figure 7 Install or Connect Figure 8 1 Striker 15 1 Lock assembly 17 2 Bolts 16 hand tighten bolts Carefully...

Page 1349: ...nector Solenoid 23 Slide solenoid from latch to disengage tab Install or Connect Figure 11 Solenoid 23 Engage tab on latch Screw 24 Electrical connector REAR COMPARTMENT AJAR SWITCH The rear compartment ajar switch is located at the top left corner of the stowage compartment This switch indicates ifthe rear compartment lid is not fully closed by sending electrical current to an indicator light loc...

Page 1350: ... 15 left or right as required Tighten bolts 16 Leading edge too high or low either side Loosen nuts 5 both hinges Move both hinges left or right as required Tighten nuts 5 19A LOCK CYLINDER 20A COVER 21A RETAINER 22A SCREWS 23A SUPPORT G94503 7J P Fig 10 Installing Lock Cylinder 97 Style Lid too far left or right e Loosen nuts 5 both hinges Move both hinges left or right as required Tighten nuts 5...

Page 1351: ... in weatherstrip over flange and push on securely Continue around weatherstrip being sure it is fully seated on flange REAR COMPARTMENT LINER 4 Remove or Disconnect Figure 13 1 Rear compartment weatherstrip 28 2 Rear compartment lamp 3 Rear compartment liner 30 4 Install or Connect Figure 13 1 Rear compartment liner 30 2 Rear compartment lamp 3 Rear compartment weatherstrip 28 TAIL LAMP ASSEMBLY 2...

Page 1352: ...s 48 5 Bolt 42 6 Eleven nuts 40 4 H J Remove or Disconnect Fig 16 1 Nuts 2 four required 2 Spoiler 4 Install or Connect 1 Gasket 3 to spoiler 4 2 Studs 1 on spoiler through holes in lid 3 Nuts 2 tighten to 5 7 N m 48 60 in lb REAR FASCIA 4 Install or Connect Figure 15 Eleven nuts 40 9 Inspect 2 3 4 5 Rubber caged nuts to ensure rubber is not cut or torn to allow proper sealing Bolt 42 Eleven screw...

Page 1353: ...RETAINER CLIP 37 TENSION CLIP 38 SCREW 3 G94148 Fig 14 Tail Lamp Assembly 37 Style Shown 97 Style Similar b REAR D E C K LID 39 STRIP 5 40 NUT 11 41 NUT 2 42 BOLT 43 BOLT 2 44 RAIL L H 45 RAIL C E N T E R 46 RAIL R H 47 RAIL INTERMEDIATE 48 S C R E W S 11 G94143 Fig 15 Luggage Carrier Assembly ...

Page 1354: ...ounted stop lamp is attached to the roof at the centerline of the back window 4 Remove or Disconnect Fig 18 1 Screws 54 2 Cover 55 3 Screws 56 4 Connector 57 5 Center high mounted stop lamp 58 1 2 3 4 5 Install or Connect Center high mounted stop lamp 58 Connector 57 Screws 56 Cover 55 Screws 54 Fig 16 Installing Spoiler FASCIA 4 RETAINERS m so BOLT m 6 1 SOLT 2 2 B O L T SS RETAINERS Cf Q94S08 Fi...

Page 1355: ...7J 10 REAR END f 4 64 SCREWS 66 CO ER 6 6 SCREWS 6 7 C O N N E C T O R 6 8 C E N T E R H I G H M O U N T E D S T O P L A M P G94504 7J P Fig 18 Center High Mounted Stop Lamp ...

Page 1356: ...mbly Refer to Section 2J Vista vent assembly if equipped First three fender to side rail attaching bolts from windshield on right and left fenders Release fenders at top for adequate clearance with roof cover panel Roof drip moldings Interior upper garnish moldings Dome lamp assembly Sunshade assemblies Headlining assembly Two roof panel attaching screws 2 at cowl panel 3 Two nuts and six screws 4...

Page 1357: ...of roof to rearmost rib 8 and turn toward center of roof Overlap 9 with the right side sealing strip 25 mm 1 L1 5 6 7 Inspect For good contact with surface Rear roof sealing strip 10 over right arid left side roof sealing strips Overlap right and left roof sealing strips 11 by 9 mm 3 8 at inner edge f I Important Ensure gap between quarter panel and roof is sealed at right and left sides Fig 4 Cut...

Page 1358: ...ener retainers 15 Dome lamp wiring harness through dome lamp opening Headlining 13 to roof and secure fasteners Rear quarter trim panels Upper seat belt anchor assemblies Tighten Anchor bolts to 35 N m 26 ft lb Right and left side upper garnish moldings Dome lamp connector to wiring harness Dome lamp assembly Coat hooks Sunshade assembly DOME LAMP ASSEMBLY The dome lamp operates in conjunction wit...

Page 1359: ...vent assembly is manually operated and consists of a vent glass two hinges molding headlining escutcheon and a latch mechanism The two piece detachable vent latch assembly operates on the over center principle and doubles as a hold open device The latch assembly is attached to the glass with screws which pass through the glass and into special shoulder nuts The screws and nuts are insulated from t...

Page 1360: ...ROOF 8J 5 G 9 4 1 5 8 Fig 8 Upper Garnish Molding FCU G94159 Fig 9 Roof Drip Molding ...

Page 1361: ...t at rear center Apply pressure to force lace over retainer from front to rear Button assembly 37 Escutcheon 36 Vent glass VENT GLASS WEATHERSTRIP 1 2 Remove or Disconnect Figure 14 Vent glass Weatherstrip 35 a hot air gun or adhesive removing solvent can be used to help break the bond and clean out any remaining adhesive Install or Connect Figure 14 Adhesive to gutter 40 Adhesive to weatherstrip ...

Page 1362: ...ROOF 8J 7 Fig 1 2 Vista Vent Assembly 13 HEADLINING 38 FINISHING TRIM LACE 39 HEADLINING RETAINER 13 G94163 Fig 1 3 lnstaMing Vista Vent Headlining Retainer ...

Page 1363: ...8J 8 ROOF ...

Page 1364: ...or quarter inner The emergency locking feature of the retractor remains unlocked to allow free movement of the occupant s upper body while the vehicle is being operated When the vehicle decelerates or changes direction abruptly the single loop belt s is locked in position by a pendulum that causes a locking bar to engage a cog of the retractor mechanism The retractor has a comfort lock feature tha...

Page 1365: ...O U S L Y BUT UCCa C B1L WILL YUBW P F ALARM REPLACE T I M E R REMINDER L I O H T M L A R M N E V E R ON 1 C H E C K FUSE 2 C O N N E C T SHORT T E S T E R T O T I M E R F E E D C I R C U I T P I N K A T I M E R C O N N E C T O R All TO B O D Y G R O U N D R E M I N D E R LI ALARM Wf 8MT NORMAL i C H E C K ALARM IF BEFICYBVi TEST L I G H T O F F C i 8 T LIGHT ON R E P A I R P I N K WIRE e nwee mmi...

Page 1366: ...ngle formed by battery bracket 1 and stiffener bead 2 4 Drill a 9 mm 11 32 hole as marked in step 3 through engine compartment forward panel CAUTION Any holes penetrating to the exterior of the vehicle must be sealed to prevent carbon monoxide from entering the vehicle Suitable sealers include silicone butyl or acrylic type caulking In the event that the child seat anchor bracket is removed the bo...

Page 1367: ...ition IS 2 Recliner control mechanism 10 3 Recliner mechanism cover 9 4 Recliner mechanism cover bolts 8 w SEATBACK ASSEMBLY m 4 Remove or Disconnect Figure 5 1 Seat assembly 2 Recliner mechanism cover 9 and attaching bolt Inner hinge arm attaching bolt 11 Seatback Install or Connect Figure 5 Seatback Inner hinge arm attaching bolt 11 Recliner mechanism cover bolts 8 and cover 9 Seat assembly Insp...

Page 1368: ...tions Hard or slow operation due to adjusters not being parallel with each other Seat assembly slightly too far to right or left SEAT ADJUSTER CONTROL ARM KNOB Manual seat adjuster control arm knobs are a press fit on the adjuster control arm If removing or installing a control knob or a trimmed seat assembly place a protective cover over trim material in area of knob 4 Remove or Disconnect Figure...

Page 1369: ...roper operation of seat assembly SEAT ADJUSTER ASSEMBLY 2 Adjuster to seat bottom frame front and rear attaching bolts 18 3 Seat adjuster 19 from seat 4 Install or Connect Figure 8 1 Seat adjuster 19 to seat 2 Adjuster to seat bottom frame front and rear attaching bolts 18 Remove or Disconnect Figure 8 Q Tighten 1 Seat assembly with adjuster attached and place upside down on a clean surface Adjust...

Page 1370: ... 35 BOLT 2 M12 1 75 25 35 48 26 35 BOLT 3 M12 1 75 30 35 48 26 35 BOLT 4 M8 1 25 20 20 24 15 17 BOLT 5 M12 1 75 39 35 48 26 35 BOLT 6 Ml 2 1 75 35 35 48 26 35 BOLT 7 Ml 2 1 75 43 35 48 26 35 BOLT 8 M12 1 75 31 35 48 26 35 BOLT 9 M12 1 75 49 35 48 26 35 Gh STUD 10 M6 1 00 15 N A N A BOLT 11 M12 1 75 53 35 48 26 35 NUT 12 M12 1 75 35 48 26 35 a NUT 13 M10 1 50 30 40 22 29 4 NUT 14 M6 1 00 10 14 7 10...

Page 1371: ...ck bar in locking slots of adjuster lower channel 2 Adjuster lock bar 2 Connect spring or in spring disconnected or stall new spring broken 3 Adjuster lock bar 3 Lubricate lock bar sticking or binding pivot If bar is binding eliminate cause of binding or replace adjuster 2 Adjuster will not 1 Locking wire too 1 Tighten locking wire unlock loose or disconnected enough to allow lock bar to disengage...

Page 1372: ...g screws and slide cover 9 downward and rearward of the seat Unzip underside of backseat trim cover and remove hog rings from bottom corners of seatback cover Hog rings from trim curtain on underside of seat cushion Work tube harness connector 3 out from under inboard edge of foam on bottomside of seat cushion and disconnect Raise corner of seatback trim over upper portion of recliner Mechanism to...

Page 1373: ...itch and tube harness 2 from underside of seat cushion foam 4 1 Install or Connect Install reverse of removal procedure When cementing edges of trim cover around opening for switch in foam brush on cement using a nitrile nonstaining adhesive such as Hughes HC 4183 3M 08046 or equivalent P U M P AND BRACKET ASSEMBLY 1 2 3 4 5 Remove or Disconnect Fig 9 Seat assembly from vehicle Hog rings from curt...

Page 1374: ...4 Passenger Compartment Right Side 10J 5 Passenger Compartment Left Side 10J 6 Front Door Wiring Left Side 10J 7 Shroud Wiring Right Side 10J 8 Shroud Wiring Left Side 10J 9 Motor Compartment Wiring 10J 10 Rear End Wiring 10J 11 Compartment Lid Wiring 10J 12 Circuit Abbreviations 10J 13 See Section 8A in the chassis portion of this manual for detailed diagnostics ...

Page 1375: ...o ...

Page 1376: ...o o o ...

Page 1377: ......

Page 1378: ......

Page 1379: ...cp CJ1 1 TJ m m m C D 3 CQ C D a a 3 o 3 C D CQ ...

Page 1380: ...ELECTRICAL 10J 7 Fig 6 Front Door Wiring Left ...

Page 1381: ......

Page 1382: ...ELECTRICAL 10J 9 ...

Page 1383: ...o t 2 o ...

Page 1384: ......

Page 1385: ...10J 12 ELECTRICAL _ _ _ _ GS41S3 Fig 11 Compartment Lid Wiring ...

Page 1386: ...RK Brake CTR Center DN Down DR Door E L E C T Electric GRD Ground HTD Heated J Block Junction Block LGTG Lighting LK Lock LP Lamp LT Left MIR Mirror MTR Motor PWR Power RDG Reading REM Remote RLY Relay RT Right RTN Return S S P K R Stereo Speaker SW Switch WDO Window WRNG Warning G93801 Fig 12 Glossary of Circuit Abbreviations ...

Page 1387: ......

Page 1388: ...ubrication 5J 7 Hinge System 5J 19 Inside Remote Handle 5J 7 Jamb Switch 53 11 Lock Assembly 5J 17 Lock Knob and Remote Handle Bezel 5J 2 Lock Striker 53 9 Map Pocket 5J 4 Outer Door Panel Assembly 5J 7 Outside Handle 53 7 Outside Mirrors 5J 11 Power Door Lock Systems 5J 18 Sealing 5J 4 Spring Clips 53 7 Trim Panel 53 2 Weatherstrips and Channels 53 5 Window Regulator Handle 53 2 E Extension Rocke...

Page 1389: ...Outside Mirrors 5J 11 p Painting of Exterior Panels 1J 9 Painting Polyproplene Plastic Parts 1J 10 Painting Rigid or Hard ABS Plastic Parts 1J 10 Painting Vinyl and Flexible soft ABS Plastic Parts 1J 11 Power Door Lock System 5J 18 Mirror Drive Unit 5J 13 Window Regulator 5J 15 Pressure Relief Valve Lower 6J 5 Upper 6J 6 Q Quarter Trim 6J 1 Quarter Window 2J 4 R Reaction Injection Molded and Reinf...

Page 1390: ...ds Rear Compartment 7J 2 Trim Applique Panel 61 5 Door Trim Panel 5J 2 Seatback to Motor Compartment 3J 1 u Underbody Alignment Checking 3J 1 Underbody Reference Point Locations 3J 5 Upper Pressure Relief Valve 6J 6 V Valve Pressure Relief Lower 6J 5 Upper 6J 6 Ventilation 4J 1 Vertical Underbody Dimensions 3J 6 Vinyl Reveal Molding Stationary Glass 2J 2 Vista Vent 8J 4 w Water Deflector Door Inne...

Page 1391: ......

Page 1392: ...Service hAamd ...

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