Westward THE INTERCEPTOR BT-57 Shop Manual Download

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Summary of Contents for THE INTERCEPTOR BT-57

Page 1: ...WESTWARD INDUSTRIES LTD liTHE INTERCEPTOR 2501 Hwy 1A West Portage Ia Prairie MB CANADA R1N 3L5 SHOP MANUAL PART NO 938000 ...

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Page 3: ...ou to be very careful in those areas where carelessness can cause personal injury The following general WARNINGS should be followed when you work on a vehicle Always wear safety glasses for eye protection Do not smoke when working on a vehicle Remove rings watches loose hanging jewelry and loose clothing before beginning to work on a vehicle Use safety stands whenever a procedure requires you to b...

Page 4: ...his service manual are 2 1 Vehicle Identification General Information 2 Maintenance and Lubrication 3 Wheels and Tires 4 Brake System 5 Steering 6 Suspension 7 Axles and Driveshafts 8 Automatic Transaxle 9 Emission Control Systems 10 Noise Vibration and Harshness 11 Engine 12 Ignition System 13 Fuel System 14 Exhaust System 15 Cooling System 16 Starting System 17 Battery and Charging System 18 Lig...

Page 5: ...ion how to remove and reinstall components or systems Disassembly and Assembly how to take apart the part or system and put it back together Adjustments how to perform in vehicle adjustments Specifications provides a summary of all specifications used in the Section Service Tools Equipment lists all the Service Tools used in the Section Additional headings such as Service Procedures and Cleaning a...

Page 6: ...Westward lndustriefi limited G0 4 Interceptor Service M mnal 4 ...

Page 7: ...arshness 10 1 11 Engine 11 1 12 Ignition System 12 1 13 Fuel System 13 1 14 Exhaust System 14 1 15 Cooling System 15 1 16 Starting System 16 1 17 Battery and Charging System 17 1 18 Lighting Systems 18 1 19 Instruments Clusters Controls and Warning Systems 19 1 20 Wiring Harness Connectors and Circuit Protection System 20 1 21 Auxiliary Equipment 21 1 22 Heating and Air Conditioning 22 1 23 Seat a...

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Page 9: ...IN Vehicle Identification Number The official Vehicle Identification Number VIN for title and registration is stamped on a decal Use this number for warranty identification of the vehicle it indicates manufacturer body type engine model and product serial number The last three 3 digits of the Vehicle Identification Number indicates the serial number of the unit Engine Model and Serial Number It is...

Page 10: ... for reuse parts that are to be reused should be carefully and thoroughly cleaned by the appropriate method Reassembly Standard values such as torques and certain adjustments must be strictly observed in the reassembly of parts If removed these parts should be replaced with new ones 1 Oil Seals 2 Gaskets 3 0 rings 4 Lockwashers 5 Cotterpins lock pins 6 Nylon nuts 1 2 Depending on where they are 1 ...

Page 11: ...le or chain straight away from the hook and do not apply any sideways force to it To further help prevent damage do not take up slack too quickly in the cable or chain c Rear towing should be used only in emergency situations e g to pull the vehicle from a ditch a snowbank or mud WARNING PLEASE MAKE SURE THE TRANSMISSION IS IN N Neutral AND EMERGENCY BRAKE IS OFF FAILURE TO DO SO CAN CAUSE SEVERE ...

Page 12: ...OFF Switch off ON Switch on PCV Valve Positive crankcase ventilation valve PTC Positive temperature coefficient RH Right hand ST Start SW Switch TDC Top dead center 1 4 ...

Page 13: ... 2 Vehicle Emission Control Information 2 1 DESCRIPTION AND OPERATION Vehicle Emission Control Information Decal The Vehicle Emission Control Information Decal is located on the engine electrical panel right above the coolant recovery bottle SUBJECT PAGE DESCRIPTION AND OPERATION continued Severe Maintenance Schedule 2 4 MAINTENANCE 2 2 Maintenance Information 2 3 Normal Maintenance Schedule 2 7 L...

Page 14: ...t Environmental Protection Agency Follow the procedures to perform the required emission system maintenance items listed on the maintenance schedules Maintenance service must conform to the specifications contained in this section or to those listed on the Vehicle Emission Control Information Decal or the emission systems may become inoperative Gasoline Octane Rating The G0 4 Interceptor is design...

Page 15: ...n extremely humid climates 6 Driving in severe dust conditions 7 Driving in area where road salt or other corrosives are used 8 Driving on rough and or muddy roads Owner Maintenance Checks The following list of vehicle checks and inspections should be performed at the intervals indicated Whenever You Stop for Fuel 1 Check the engine oil level 2 Look for under inflated tires At Least Monthly 1 Chec...

Page 16: ...isc brake pads and rotors 2 4 Inspect bolts and nuts on chassis and body Rotate tires and adjust air pressure 18 000 miles 30 000 km 1 200 hours Change engine oil and replace oil filter 4 21 000 miles 35 000 km 1 400 hours Change engine oil and replace oil filter 4 Change automatic transmission fluid 2 24 000 miles 40 000 km 1 600 hours Change engine oil and replace oil filter 4 Rotate tires and a...

Page 17: ...connections Inspect bolts and nuts on chassis and body Inspect front fork assembly Inspect steering operation and linkage Repack front and rear wheel bearings Rotate tires and adjust air pressure Replace timing chain belt Failure to replace timing chain belt may result in damage to the engine 3 4 Inspect timing chain belt 3 4 63 000 miles 105 000 km 4 200 hours Change engine oil and replace oil fi...

Page 18: ...00 hours Change engine oil and replace oil filter 4 Rotate tires and adjust air pressure 2 6 117 000 miles 195 000 km 7 800 hours Change engine oil and replace oil filter 4 120 000 miles 200 000 km 8 000 hours Change engine oil and replace oil filter 4 Replace spark plugs 4 Inspect alternator and A C compressor drive belts 4 Replace air cleaner element 4 Check idle speed 4 Inspect ignition timing ...

Page 19: ...ons Inspect front steering system Inspect steering operation and linkage Change automatic transmission fluid 35 000 miles 42 000 km 2 325 hours Change engine oil and replace oil filter 4 Rotate tires and adjust air pressure 40 000 miles 48 000 km 2 650 hours Change engine oil and replace oil filter 4 45 000 miles 54 000 km 3 000 hours Change engine oil and replace oil filter 4 Rotate tires and adj...

Page 20: ...100 000 miles 6 650 hours Change engine oil and replace oil filter 4 2 8 105 000 miles 7 000 hours Change engine oil and replace oil filter 4 Replace timing chain belt 4 Inspect fuel hoses 4 Rotate tires and adjust air pressure 110 000 miles 7 325 hours Change engine oil and replace oil filter 4 115 000 miles 7 650 hours o Change engine oil and replace oil filter 4 Rotate tires and adjust air pres...

Page 21: ...use Junction Panel 5 Radiator Coolant Recovery Reservoir 6 Radiator Cap 7 Spark Plugs 8 Engine Oil Level Dipstick 9 Oil Filter 10 Positive Crankcase Ventilation Valve 11 Battery 12 Fuel Pump Shut off Switch Service Points Body Lubricate periodically the following points with Multi Purpose Grease Door latches Door tracks rollers Window tracks rollers Cargo Box Hinges 2 9 ...

Page 22: ...imilar Engine Oil SAE 5W30 recommended SAE 5W20 temperatures below 20 F 10 C SAE 1OW30 temperatures above 100 F 38 C Engine Coolant 50 50 mixture compatible with aluminum Fuel Canister Part No 133017 Fuel Filter Part No 423016 FG871 Positive Crankcase Ventilation Valve Part No 104041 Rear Wheel Bearings Wheel Bearing Grease Rear Wheel Driveshaft and Joint inboard side Constant Velocity Joint Greas...

Page 23: ...es and objects imbedded in the tread Inspect more frequently in times of rapid or extreme temperature changes and after driving on rough road surfaces that are littered with road debris SUBJECT PAGE DIAGNOSIS AND TESTING continued Tire Wear Troubleshooting 3 3 Torque Sensitivity 3 5 Vehicle Speed Sensitivity 3 5 Wheel Balance 3 7 Wheel Rim Condition 3 2 Wheel Tire Vibration Troubleshooting Chart 3...

Page 24: ...ngs Be certain the new tires match recommended sizes and offsets WARNING DO NOT MIX DIFFERENT TYPES OF TIRES ON THE SAME VEHICLE SUCH AS RADIAL BIAS AND BIAS BELTED TIRES EXCEPT IN EMERGENCIES BECAUSE VEHICLE HANDLING MAY BE SERIOUSLY AFFECTED ANY MAY RESULT IN LOSS OF CONTROL Wheel Rim Condition Check the condition of the wheel rims Replace rims that are bent cracked heavily rusted air leaks or w...

Page 25: ...pecification suspension components y Bent Brace Replace Brace Loose wheel plate adjustment bolts Add or remove washers to till IIi I adjust wheel plate FEATHER EDGE Toe out of adjustment Adjust to specifications Bent or Worn Brace Replace brace Damaged front axle Replace front axle BALD SPOTS OR Unbalanced wheel BALANCE the tire and wheel TIRE CUPPING CHECK the runout and replace tire if necessary...

Page 26: ...ow 20 mph Speed required to cause vibration increases as runout decreases Vehicle speed sensitive vibration Chart cont d POSSIBLE CAUSE REMEDY Wheel hop Not a cause of vibration below 20 mph Produces up down movement in steering wheel and instrument panel along with mechanical vibration Most noticeable between 20 40 mph Caused by tires having radial runout of more than 0 045 inch Do not attempt to...

Page 27: ...w changes in vehicle speed engine speed and engine torque affect the vibration The type of vibration sensitivity torque sensitive engine speed sensitive or vehicle speed sensitive Torque Sensitivity When the vibration is torque sensitive the condition can be improved or worsened by accelerating decelerating coasting maintaining a constant vehicle speed and applying more or less engine torque Vehic...

Page 28: ...lipping into the tire tread block grooves Measure the lateral runout just above the letters identifying the tire size Measure wheel radial runout at the tire rim along the inside edge of the flange Use the following Wheel Tire Runout Troubleshooting Chart to determine whether the wheel or runout is the source of the vibration problem check Tire Radial and lateral runout I 3 6 Lateral runout is gre...

Page 29: ...ance Before balancing wheels clean deposits of dirt mud and ice from the wheel and tire as well as from the inside and outside of the rims Remove existing balance weights Remove all stones and other any objects wedged between tire beads to avoid operator injury and obtain a good balance Inspect the tire for damage Check and if necessary correct tire inflation pressure then balance the tire and whe...

Page 30: ...uld be two inches or slightly more off the floor Before spinning the wheels check for loose suspension joints worn wheel bearings and brake grab Start the engine select drive and accelerate slowly Make certain that the speedometer does not exceed an equivalent road speed of 35 mph 3 8 56km h Remember that wheel speed when engine driven will be twice speedometer speed WARNING WHEN BALANCING REAR WH...

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Page 32: ...ystem is a feeling through the 4 2 pedal The brake warning indicator in the instrument panel and the brake fluid level in the brake master cylinder reservoir are also indicators of a malfunction in the brake system NOTE Prior to performing any diagnosis make certain that the brake system warning indicator is functional Refer to Section 19 for the procedure Road Test Perform a road test to compare ...

Page 33: ...um booster hose Improper power brake booster to brake master cylinder push rod clearance adjustment Brake master cylinder malfunction Pedal is Low or Low fluid level Go to Pinpoint Test F1 Feels Spongy Air in system Brake master cylinder malfunction Brake Lockup Brake pads and disc contaminated by grease or brake Go to Pinpoint Test G1 During Light Brake fluid Pedal Force Brake pads bent distorted...

Page 34: ...r cylinder return port clogged Pinpoint Tests Brake System PINPOINT TEST A BRAKES PULL OR DRIFT TEST STEP RESULT ACTION TO TAKE A1 I VERIFY CONDITION Road Test the vehicle at a speed of 25 40 mph 40 70 km h Yes Refer to Section 6 without applying the brakes No Go to A2 Does the vehicle pull or drift to one side A2 I INSPECT TIRE PRESSURE Measure the air pressure in all three tires Yes Go to A3 Are...

Page 35: ...eral times and hold the Replace the brake brake pedal down master cylinder Does the brake pedal slowly go to the floor Refer to Section 19 to diagnose the brake system warning indicator circuit PINPOINT TEST C VIBRATION WHEN BRAKES ARE APPLIED TEST STEP RESULT ACTION TO TAKE C1 I ROAD TEST NOTE Allow one mile 1 6 km between each application to Yes Refer to C2 allow the brakes to cool No Refer to S...

Page 36: ...power brake Is the power brake booster to brake master cylinder push booster to brake master rod adjustment within specification cylinder push rod E3 I INSPECT BRAKE HYDRAULIC SYSTEM Inspect the brake master cylinder disc brake caliper and Yes Perform the By pass brake hoses for hydraulic fluid leaks condition test in this Is the hydraulic system OK section No Service as required PINPOINT TEST F P...

Page 37: ...H EXCESSIVE AND OR ERRATIC PEDAL TRAVEL TEST STEP RESULT ACTION TO TAKE H1 I CHECK BRAKE PEDAL PRESSURE Perform the brake pedal reserve check Yes Go to H2 Is the brake pedal travel OK No Service as required H2 I INSPECT PUSH ROD ADJUSTMENT Inspect power brake booster to brake master cylinder push Yes Go to H3 rod adjustment Refer to this section No Adjust the power brake Is the power brake booster...

Page 38: ...the Brake Master brake hoses for hydraulic fluid leaks Cylinder Compensator Is the hydraulic system OK Port Check in this No section Repair leaks as necessary PINPOINT TEST K BRAKE SHUDDER TEST STEP RESULT ACTION TO TAKE K1 I ROAD TEST NOTE Allow one mile 1 6 km between each application to Yes Go to K2 allow the brakes to cool No Refer to Section 2 When safe to do so apply the brakes The shudder c...

Page 39: ... cylinder reservoir N2 I INSPECT BRAKE HYDRAULIC SYSTEM Perform the Brake System Test Procedure in this section Yes Perform the Brake Is the hydraulic system OK Component Test Brake Booster Functional Check Inspect all vacuum hoses and connections All unused vacuum connectors should be capped Hoses and their connections should be properly secured and in good condition with no holes or collapsed ar...

Page 40: ... the engine operating If the brake pedal feels hard no power assist repeat 4 10 test and listen for air leaks Air leaks can occur at the vacuum booster hose connections vacuum hose check valve the hose itself and in the power brake booster Repair or replace the defective component Brake Master Cylinder Normal Conditions The following conditions are considered normal and are not indications that th...

Page 41: ...red and in good condition with no holes or collapsed areas Inspect the hose containing the check valve for damage Check the power brake booster system operation as follows 1 Check the hydraulic brake system for leaks or insufficient fluid 2 With the transaxle in Park P or Neutral N stop the engine and apply the parking brake Depress the brake pedal several times to exhaust all vacuum in the system...

Page 42: ...age and proper routing Check the brake hoses connecting the brake lines to the disc brake calipers for any signs of damage cracking of softening The hose fittings must be tight without signs of leakage 4 12 5 If signs of leakage are not present but the brake master cylinder is definitely low it is possible that evidence of fluid leakage may have been washed off by rain or snow because brake fluid ...

Page 43: ...ke tube bundles are serviced as complete assemblies If a certain brake tube is not serviced refer to the following procedure 1 Obtain the recommended bulk 0 1875 inch 3 16 inch 4 76mm double wall steel brake tubing and correct standard tube nuts for 0 1875 inch 3 16 inch 4 76mm tubing 2 Cut the tubing to the length required Clean the burrs after cutting The correct length may be obtained by measur...

Page 44: ...are tightened to the specific torque Check the brake hoses and fittings for leaks or damage Thoroughly check the disc brake caliper for damp areas that might indicate a leaking disc 4 14 brake caliper seal Check for brake fluid contamination which might also indicate a leaking disc brake caliper seal If a leaking seal is indicated disassemble and inspect the disc brake caliper Refer to disassembly...

Page 45: ...xible brake hoses at the front wheel and rear wheels Always bleed the applicable primary or secondary brake system after primary or secondary brake system hose or brake tube replacement When connecting a tube to a hose tube connector or the brake master cylinder tighten the brake tube flare nut to specification Inspect the brake lines under the vehicle for damage and proper routing Inspect the bra...

Page 46: ...o exhaust any vacuum that may exist in the power brake booster 2 Carefully move the brake pedal back and forth and measure the amount of free play 4 16 If the brake pedal free play is 0 16 0 28 inch 4 7mm then the brake pedal free is within specification If the brake pedal free play is not within specification continue with the procedure 3 Loosen the power brake booster to brake master cylinder pu...

Page 47: ...ism Parallelism is the variation in the thickness of the disc brake rotor If the two rubbing surfaces of the disc brake rotor are not parallel the disc brake rotor may cause excessive brake pedal travel a pulsating brake pedal or noise Two methods can be used to check if the two faces of a disc brake rotor are parallel They are a A micrometer can be used to measure the disc brai e rotor thickness ...

Page 48: ...x 0 86 inch Dimensions outer 235x22mm diameter x thickness Disc Brake Rotor 0 86 inch Standard Thickness 22mm Disc Brake Rotor 0 78 inch Minimum Thickness 20mm Power Brake Booster Type Vacuum Multiplier Diameter 9inches 228 6 mm Item Description Parking Brake Type Mechanical two rear wheel control Operation System Center lever Torque Specifications rube Nuts 144 180 lb in 16 20 N m SERVICE TOOLS A...

Page 49: ...n either side of the hydraulic fitting Rotor The cast iron disc brake rotor attaches to the wheel hub The braking surfaces of the ventilated disc brake rotor are separated by non directional cooling fins Wheel Hubs and Bearings Refer to Section 6 Suspension for the description and operation of the wheel hub and bearings Caliper The disc brake caliper consists of a pin slider type disc brake calipe...

Page 50: ...iscard them 5 Remove the two brake calipers bolts and the disc brake caliper from the wheel hub assembly 6 Remove the anti squeak caps Installation 1 Install the anti squeak caps 2 Position the disc caliper on the wheel hub assembly and install the brake disc bolts Tighten the disc brake bolts to 29 36 ft lbs 39 49 N m 4 20 _ 3 Connect the flexible brake hose with new W copper washers a d the banj...

Page 51: ... spring from the brake pads Part Item Number Description 8 430759 Wheel Cylinder Bolts 2 required brake 9 Banjo Bolt 10 430936 Brake Hose one at the front and two at the rear Brake Pad Shims 11 Brake Pad 12 Tighten to 29 36 ft lbs A 39 49 N m Tighten to 16 22 ft lbs B 22 29 N m M SHAPED ANTI RATTLE SPRING BRAKE SHOES AND LININGS 6 Remove the two disc brake caliper locating pins and the M shaped an...

Page 52: ...pins 4 22 5 6 8 9 Install the M shaped anti rattle spring Install the disc brake pad anti rattle clip Install the wheel and tire assembly Tighten the wheel hub bolts to 65 87 ft lbs 88 1 18 N m Lower the vehicle Check the brake fluid level Add brake fluid as necessary Rotor Removal 1 Remove the disc brake caliper Refer to the procedure in this section 2 Remove the four disc brake rotor bolts and p...

Page 53: ...d out of the disc brake caliper 2 Remove the retaining ring 3 Position a block of wood or a roll of shop towels between the caliper piston and the disc brake caliper 4 WARNING DO NOT USE AN EXCESSIVE AMOUNT OF AIR PRESSURE TO REMOVE THE PISTON EXCESSIVE PRESSURE CAN FORCE THE PISTON OUT OF THE CALIPER BORE WITH ENOUGH FORCE TO CAUSE PERSONAL INJURY NEVER ATTEMPT TO CATCH THE PISTON BY HAND AS IT C...

Page 54: ...to remove the seal PISTON SEAL 7 Remove the bleeder screw 8 Remove the caliper sleeves and the boots 4 24 BOOTS CALIPER SLEEVE 9 CAUTION Do not use petroleum based solvent kerosene or gasoline for cleaning caliper parts Their use as a cleaning agent can leave residues which can damage the rubber seals Wash the parts in clean denatured alcohol and dry with compressed air Assembly 1 Lubricate the pi...

Page 55: ...nstall a new retaining ring 6 Install the bleeder screw 7 Install the caliper sleeves and new boots 8 Lubricate the inside surface of the boots and the outer surface of the caliper sleeves with the pink grease contained in the overhaul kit Do not allow the grease to enter the bushing bore SERVICE PROCEDURES Rotor Service Rotor Minimum Thickness Disc brake rotor minimum thickness is the thickness a...

Page 56: ...out is checked by mounting a Dial Indicator Magnetic Base or equivalent on good mounting point of the vehicle and measuring the disc brake rotor with a dial indicator Disc brake rotor runout cannot be more than 0 004 inch 0 1mm 4 26 CLEANING AND INSPECTION WARNING BREATHING ASBESTOS DUST IS HAZARDOUS TO YOUR HEALTH DUST AND DIRT PRESENT ON THE DISC BRAKE ASSEMBLY MAY CONTAIN ASBESTOS FIBERS THAT A...

Page 57: ...brake rotor must be visually inspected to check for any abnormal wear and checked with a micrometer to make sure the thickness is within the specifications Minimum thickness for disc brake rotor is 0 78 inch 20 mm ventilated disc and 0 43 inch 11 mm solid disc This applies to the front and rear disc brake rotors used on the G0 4 vehicle There must be no wheel bearing free play when checking for di...

Page 58: ...tor Thickness Vented Solid Disc Brake Rotor Scoring Disc Brake Rotor Machining Limit Disc Brake Rotor Thickness Variation Fluid Specifications DOT 3 Brake Fluid Minimum 0 08 inch 2 0mm 0 78 inch 20 mm 0 43 inch 11 mm Maximum 0 39 inch 10 mm 0 86 inch 22 mm 0 51inch 13mm 0 009 in 0 22mm 0 817 in 20 762 mm Must not vary more than 0 001inch 0 025mm Torque Specification Description Lb ft N m Brake Cal...

Page 59: ...icator in the instrument panel is illuminated when the parking brake is applied Operation of the brake system warning indicator depends on the ignition switch and the parking brake signal switch and bracket mounted on the parking brake control If the ignition is ON and parking signal switch is closed by the SUBJECT PAGE Pivot and Rod Assembly 4 34 Parking Brake Caliper Pad System Diagram 4 35 Park...

Page 60: ...8 Washer 6 444024 Bushina Park Brake Lever 7 771459 3 8 X 3 Hexhead Gr 5 Bolt 8 444055 Caliper lever Bracket LH 9 770818 5 16 X 3 4 NC FlanQe Lock Bolt 10 770819 5 16 FlanQe Locknut 11 444054 Caliper Lever Bracket RH 12 774142 1 4 X 1 Clevis Pin 13 771699 3 32 X 1 2 Cotter Pin 14 442605 Park Brake Calioer 15 774141 1 4 28 X 2 Clevis 16 774142 1 4 X 1 Clevis Pin 17 444052 Rod Extension Park Brake 4...

Page 61: ...INPOINT TEST A PARKING BRAKE WILL NOT APPLY TEST STEP RESULT ACTION TO TAKE A1 ICHECK FOR MISADJUSTED FRONT PARKING BRAKE CABLE AND CONDUIT Perform the Cable Actuated Rear Wneel Parking Brake Yes Vehicle OK adjustment procedure in this section Go to A2 Does the oarkina brake now enaaae orooerlv No A2 I CHECK FOR WORN BRAKE PADS Inspect the brake pads for excessive wear Refer to this Yes Go to A3 s...

Page 62: ... Screw 13 Flange Nuts on other side of cab A Tighten to 14 19 ft lbs 19 26 N m not shown 4 32 Removal 1 Remove the si slotted head bolts and flange nuts which holds the access cover console to the cab 2 Remove the access cover console 3 Remove the adjustment nut 4 Disconnect the parking brake signal switch elec trical connector from the parking brake signal switch and bracket 5 Remove the two park...

Page 63: ...p from the pivot bracket 6 Pull the control lever end of the cable through the body opening and remove it from the vehicle Installation 1 Attach the clevis on the park brake cable to the right caliper lever bracket using the clevis pin and cotter pin 2 Lock the retaining clip on the cable to the pivot bracket 3 Push the control lever end through the body opening into the vehicle cab 4 Install the ...

Page 64: ...he nuts and bolts on the left caliper lever bracket and remove the bracket 6 Remove the nuts and bolts on the right caliper lever bracket and remove the bracket 3 Disengage the other end of the park brake rod from the pivot arm 4 Remove the pivot bracket and bushing from the center control arm mount 4 34 Installation 1 Attach the left and right caliper lever brackets using the appropriate nuts and...

Page 65: ...ntrol rod through the appropriate hole on the pivot bracket as shown Parking Brake Caliper Pad System ITEM DESCRIPTION OTY 1 Hex Cao Screw 2 2 Rib Plate w Brake Pad 1 3 Sorina 2 4 Bushina 2 5 Flat Plate w Brake Pad 1 6 Cam 1 7 Cam Actuator Bracket 1 8 Hex Nut 2 4 Tum the clevis until there is no free play in the cable system and attach the clevis pin and cotter pin 4 35 I ...

Page 66: ...centered on a hoist to avoid bending or damaging the disc brake rotors 5 Do attempt to clean or restore oil or grease soaked brake pads When contaminated brake pads are found they must be replaced in complete sets and the disc rotor braking surfaces wiped clean Removal 1 Raise and support the vehicle 2 Remove the rear wheel and tire assemblies 3 Unscrew the parking brake bolts and remove the parki...

Page 67: ...s Rear Apply the brake pedal a few times and verify that the rear brakes do not drag when the wheel rotates Control Stroke Parking Brake Verify that the parking brake control stroke is 11 16 notches when applying the parking brake control 5 Unscrew the parking brake bolts and remove the parking brake pads from the brake disc Installation 1 Install the parking brake calipers in the reverse order of...

Page 68: ...lbs N m Parking Brake Control Bolts 14 19 19 26 Wheel Hub Bolts 65 87 88 118 4 38 4 5 With the parking brake engaged the resistance should be less than 5 ohms With the parking brake disengaged the resistance should be greater that 10 000 ohms If the parking brake signal switch is not within specification replace the parking brake signal switch and bracket Refer to the procedure in this section If ...

Page 69: ...r assembly moves forward within a power piston until a vacuum port is closed At this point vacuum is still applied to both sides of the diaphragm As the valve rod and plunger assembly continues to move forward an atmospheric port is opened Atmospheric pressure then enters the rear half of the power brake booster Engine vacuum on the front half of the diaphragm and atmospheric pressure on the rear ...

Page 70: ...draulic pressure is produced in the brake master cylinder is converted into motion The brake caliper pistons move inward against the brake pads and contact the metal braking surface of the disc brake rotor When the brake pedal is released the pressure in the system is relieved and the brake pads and pistons return to their neutral or unapplied position Brake Master Cylinder The brake master cylind...

Page 71: ... Pad The brake system warning light comes on when the brake master cylinder float in the in the brake master cylinder drops too low and completes the circuit Once the circuit is closed the brake system warning light will come on and remain on whenever the ignition switch is in the ON or START position The same brake system warning light indicates when the parking brake is applied If the brake syst...

Page 72: ...levis pin Discard the cotter pin J Remove the clevis pin from the clevis I Have a second technician support the power brake booster at the front of the vehicle Remove the four power brake booster nuts securing the power brake booster to the bulkhead I 1 Remove the power brake booster 4 42 Ji 2 Apply suction and pressure to the vacuum y hose from the engine side Make sure air only flows toward the ...

Page 73: ...o the brake pedal 4 6 ff Disconnect the clevis end of the valve rod from the brake pedal Remove one 3 8 nylon lock nut and 3 8 X 5 bolt Remove the brake pedal and plastic bushings Brake Master Cylinder Removal See diagram on next page Disconnect the battery ground cable Disconnect the brake master cylinder fluid level sensor electrical connector Disconnect the brake tubes Cap the tubes and plug th...

Page 74: ...from the brake master cylinder reservoir Remove the brake master cylinder reservoir screw Carefully remove the brake master cylinder reservoir from the brake master cylinder by prying upward with a screwdriver Remove and discard the reservoir seals from the brake master cylinder Part Item Number Description 1 Brake Master Cylinder Fluid Level Sensor Electrical Connector 2 Power Brake Booster 3 Bra...

Page 75: ... Replacement Removal and Installation FRONT DISC BRAKE CALIPER Double wall steel tubing is used throughout the brake system with the exception of the flexible brake hoses for the front and rear disc brakes Installation To install reverse the removal procedure 6 Remove the brake hose from the routing brackets and remove the brake hose from the vehicle Installation 1 Position the brake hose in the r...

Page 76: ... 46 BIW MASTER C VUNOER BRAKE MASTER CYLINDER cRESER OIR Item Description 1 2 3 4 5 6 Washer 7 Seal 8 Retainer 9 Spring 10 Brake Master C Iinder Reservoir Screw 11 Secondary Piston Stop Screw 12 0 ring 13 Reservoir Seals 14 Brake Master C Iinder Reservoir 15 Brake Master C Iinder Float 16 Cap Seal 17 Brake Master Cylinder Filler Cap 4 Remove the brake master cylinder reservoir seals from the brake...

Page 77: ...bore while slowly rotating and pushing Install the primary piston 5 Install the primary piston snap ring Push the primary piston into the bore to ease primary piston snap ring installation 6 Install new brake master cylinder reservoir seals Brake Booster Check Valve The brake booster check valve is integral with the vacuum booster hose If the brake booster check valve requires service replace the ...

Page 78: ... enter the system and cause spongy pedal action Bleeding is a simple procedure used to remove air from the hydraulic circuits When bleeding the brake hydraulic circuit bleed the rear wheel first and then the front wheel WARNING BRAKE FLUID CONTAINS POLYGLYCOL ETHERS AND POLY GLYCOLS AVOID CONTACT WITH EYES WASH HANDS THOROUGHLY AFTER HANDLING IF BRAKE FLUID CONTACTS EYES FLUSH EYES WITH RUNNING WA...

Page 79: ...rake master with a shop towel cylinder reservoir run dry c Tighten the two rear bleeder screws 5 CAUTION Brake fluid is harmful to painted d Loosen the front bleeder screw Leave and plastic surface immediately wash it the bleeder screw open until clear with water brake fluid flows out Be sure to check the brake fluid level often and do not Pump the brakes until clear bubble free let the brake mast...

Page 80: ...rake fluid is separated from the air by a rubber diaphragm 8 Loosen the bleeder screw approximately 3 4 tum ofa tum The bleeder tank must contain enough brake fluid to complete the bleeding operation and should be 9 When the brake fluid entering the bottle is charged with 10 30 pounds of air pressure Never completely free of bubbles tighten the exceed 50 pounds of pressure bleeder screw remove the...

Page 81: ...ed adjusting unless the brake master cylinder has been changed If the push rod is too long it will cause dragging brakes If the push rod is too short it will cause a low brake pedal Adjustment of the brake booster to master cylinder push rod is usually made during replacement of the brake master cylinder Proper using crocus cloth Never use emery paper or sandpaper Make sure the brake line ports ar...

Page 82: ...eder Master Cylinder Gauge 4 52 3 While holding the gauge in position tighten the set screw 4 Invert Master Cylinder Gauge and place it over the brake booster to master cylinder push rod 5 Check the clearance between the end of the gauge and the brake booster to master cylinder push rod 6 If the clearance is not zero loosen the brake booster to master cylinder push rod lock nut and adjust the brak...

Page 83: ...nents Excessive friction in the steering which is caused by a Improper or lack of lubrication b Damaged seals allowing contaminants such as moisture and dirt to enter SUBJECT PAGE REMOVAL AND INSTALLATION Steering Box Bracket 5 1 0 Steering Column Base 5 10 Steering Gearbox 5 5 Disassembly Assembly 5 6 Inspection 5 7 Steering Support 5 1 0 Steering Support Weldment 5 9 Trunion Tube 5 7 Disassembly...

Page 84: ...ection 6 Suspension Steering Wheel Incorrect tire pressure Adjust tire pressure Refer to Section 3 Vibration Wheels and Tires Front tire wears unevenly worn or Replace tires Check alignment mismatched Wheel alignment incorrect Adjust wheel alignment Refer to Section 6 Suspension Unbalanced or distorted wheels Repair or replace wheels Steering gearbox is loose or worn Check steering gearbox mountin...

Page 85: ...or looseness of fork support when the Play or looseness of steering steering wheel gearbox is turned Steering wheel rubbing on steering column covers Service Procedures Turning Effort Check 1 Raise the front wheel clear off the hard level surface Position the jack stands so they do not interfere with steering travel 2 Turn the steering wheel until the front wheel is in a straight position 3 NOTE F...

Page 86: ...n the ground If the housing moves more than 0 06 inch 1 5mm the steering gearbox base and brackets may be loose Tighten bolts 30 ft lbs 40 N m Tighten the bolts securing the steering gearbox to the steering box bracket to 30 ft lbs 40 N m Use Loctite when tightening If the housing movement is still excessive after tightening the steering box bracket check the mounting brackets for wear or damage 1...

Page 87: ...Column Refer to Inspection and Verification Steering System and the Troubleshooting Charts in this section CLEANING AND INSPECTION 1 Clean all parts 2 Inspect the bearings steering shaft trunion tube for unusual wear or damage If any defects are found replace the bearings steering shaft trunion tube Check the trunion tube for cracks dents or abnormal wear Replace if necessary REMOVAL AND INSTALLAT...

Page 88: ...sassembly Assembly 1 Remove four 1 4 x 3 4 sockethead bolts from the gearbox 5 6 2 Remove the eccentric housing and steering hub from the steering gearbox 3 Remove steering bracket 4 Remove eight nuts and socket head bolts which secures gearbox case together 5 Split the gearbox case into its two halves 6 Separate the steering rack from the plate mount by removing five 5 16 x 3 4 flange bolts 7 Rem...

Page 89: ... when assembling it 6 Apply a lithium grease to the steering rack teeth and pinion gear Trunion Tube The trunion tube is mounted to the vehicle frame with six 6 bolts It supports the forks shocks and front wheel assembly Removal and Installation 1 Apply park brake 2 Put transmission in PARK 3 Block rear wheels 4 Disconnect the battery ground cable 5 Remove dash top 6 Remove cotter key and castella...

Page 90: ...19 Trunion Tube 5 342246 Lower Fork Support 6 323816 Steering Shaft 7 342247 Upper Fork Support 8 771140 3 8 x 2 Socket Head 9 770223 3 8 Stover Locknut 10 770324 5 16 Flatwasher 11 772363 3 8 x 1 4 Bolt NC 5 8 4 Pull the tapered bearings and tapered cut from the trunion tube If necessary use a bearing puller 5 Remove bearing s from the steering shaft CAUTION Do not damage bearings and steering sh...

Page 91: ...m Upper Steering Shaft Removal 1 Remove the screws and two 5 16 bolts with flatwashers which secure the upper steering cover and lower steering panel 2 Separate the upper steering cover and lower steering panel and remove from the steering column 3 Remove the multi function switch Refer to Section 19 for removal procedures 4 Remove the steering support weldment from the instrument panel 5 Remove u...

Page 92: ...n replace the part SPECIFICATIONS Torque Specifications Tighten two socket bolts to secure steering box to steering box bracket 30 ft lbs 40 N m Tighten two upper steering bolts on u joint to 17 ft lbs 23 N m Tighten castellated nut to 80 ft lbs and check for drag on steering wheel Tighten flange locking bolts holding steering rack to plate to 40 ft lbs 55 N m Tighten bolts the steering hub to ste...

Page 93: ...sc brake and rear wheel hub may be replaced individually The front wheel bearings inner and outer races and rollers are replaced as a set SUBJECT PAGE DIAGNOSIS AND TESTING continued Wheel Bearings 6 4 ADJUSTMENTS Alignment Front 6 9 Alignment Rear 6 12 Bearing Front Wheel 6 11 Bearing Rear Wheel 6 11 Equipment Installation 6 9 Ride Height Correction 6 11 Suspension Rear 6 12 Tire Lead 6 10 Tire W...

Page 94: ...immediately suspect the tires or wheels when attempting to diagnose a vibration problem Other sources of vibration include Loose or worn wheel bearings Loose or worn suspension or steering components Worn or damaged rear wheel driveshaft joints Disc brake rotor runout Loose engine or transaxle supports Engine driven accessories Road Test Always begin a suspension diagnostic procedure with a road t...

Page 95: ...olated by increasing or decreasing engine rpm with the transaxle in NEUTRAL N or by stall testing with the transaxle in gear If the vibration is linked to engine speed the problem is probably not a wheel or tire condition If the road test indicates that the vibration is related to the tires and wheels refer to the Troubleshooting Chart in this section If the vehicle leads to one side during the ro...

Page 96: ... the suspension and replace worn or damaged parts as necessary Refer to this section for procedures for the front suspension and rear suspension 6 4 Cycle the shock absorber piston up and down to check for proper fluid resistance Bounce test the vehicle at each wheel to check shock absorber function Damping action should be positive and uniform all around Inspect the shock absorber for evidence of...

Page 97: ...ide caster Go to Pinpoint Test C1 Rear suspension damage Rough Ride Weak rear spring or front shock s Go to Pinpoint Test D1 Malfunctioning spring shock assembly Excessive Noise Wear of lower or upper control arm joint Go to Pinpoint Test E1 Damaged or worn axle torsion beam Looseness of suspension connection Malfunctioning spring shock assembly Improper Tire Wear Incorrect tire pressure Go to Pin...

Page 98: ...ecessary Improper wheel alignment refer to Section 6 Torsion Rod Sway bar out of adjustment Adjust the wheel Damaged or worn front suspension alignment component Refer to Trailing Arm Adjustment Section 6 25 Replace the worn front suspension component Front I Rear Suspension Loose broken shock absorber mount bolts Tighten Replace the shock Noises absorber mounts Refer to this section for informati...

Page 99: ...CHECK ALIGNMENT Check the vehicle alignment Refer to the procedure Yes Go to A2 in this section No Adjust alignment to specifications Is the alignment within specification Inspect suspension components for looseness or deformation and repair or replace as necessary A2 I EXAMINE SUSPENSION COMPONENTS Inspect the front and rear suspension components Yes Repair or replace as necessary for looseness o...

Page 100: ...E1 I INSPECT FRONT END Inspect the front end Refer to the procedure in this Yes Perform Pinpoint Test D to inspect the section shocks Is the front end OK No Service as necessary PINPOINT TEST F IMPROPER TIRE WEAR F1 I CHECK TIRE PRESSURE Check the tire pressure Yes Go to F2 Is the cold tire pressure 28 psi front 30 psi rear No Inflate tires to proper pressure Go to F2 F2 I CHECK ALIGNMENT Place th...

Page 101: ...llon of gasoline missing from the fuel tank Yes Go to G2 No Check the suspension components for looseness or damage Repair replace components as necessary Yes Go to G3 No Balance the tires and wheels as necessary Yes Go to G4 No Repair replace components as necessary Yes Repair as necessary No Inspect the steering system for a loose steering gearbox mounting bracket or loose or damaged steering co...

Page 102: ...or incorrect tire inflation pressure Faulty tire construction The way in which a tire is constructed can produce a lead Off center belts on a radial tire cause the tire to develop a side force while rolling straight down the road If one side of the tire is slightly larger in diameter that the other the tire will have a tendency to roll to one side This will develop a side force which can produce l...

Page 103: ...vehicle 8 Remove the rear wheels 9 Place a level on the wheel hub and adjust the upper control arms until the camber is near zero 0 degrees 10 Install the rear wheels Recheck tow in 11 Lower the vehicle REMEDY ACTION BALANCE the tire and wheel CHECK the runout and replace tire if necessary REPLACE the shock absorber rear wheels and recharge the front absorber s ADJUST the toe to specifications CHE...

Page 104: ...the rear suspension installation and seldom requires service attention D viations from the specification for rear wheel camber and toe can only result from distortion of the axle torsion beam structure by improper hoisting road impact or collision damage Alignment Rear Camber and toe in adjustment are provided The lower control arms are for toe in The upper control arms are for camber Toe in out o...

Page 105: ...may be disassembled in order to replace any of the SUBJECT PAGE DISASSEMBLY AND ASSEMBLY Con t Preparation Pre Assembly 6 22 Wheel Hub and Wheel Bearings 6 21 CLEANING AND INSPECTION Axle Shaft 6 26 Compression Spring Front Shock 6 26 Front Shock Tube 6 26 Wheel Hub and Bearing Inspection Chart 6 27 ADJUSTMENTS Balance Weights 6 24 Bearing End Play 6 24 Bearing Pre load 6 24 Bearing Spacer 6 24 Wh...

Page 106: ... signs of leakage as described but not if it falls under the description of weepage Wheel Bearing and Hub The wheel hub is supported by the front axle and the hub assembly for the rear wheels on opposed outer and inner wheel bearings A press fit secures the bearing inner races into the hub The rear wheel driveshaft and joint which is splined to the wheel hub is secured to the wheel hub with a stak...

Page 107: ...port The top of the shock should bottom out in upper support NOTE Use a heavy rubber mallet on the shock to prevent damage 2 Tighten the 3 8 x 2 socket head bolt to 18 20 lb ft 25 28 N m 3 Install fender in reverse order of removal 4 Push axle and wheel assembly up into the ends of the shock 5 Install the front axle supports Tighten the flange nuts to 50 lb ft 164 N m 6 Install disc brake caliper ...

Page 108: ...moval 1 Raise the vehicle and support the front of the vehicle on the cross tube Make sure that the wheel just clears the floor 2 Remove two brake caliper bolts and slide the disc brake caliper off the brake disc 6 16 Note On large brake Disc Rim axle and caliper must be removed as an asssembly with wheel bolts loose CAUTION Do not allow the brake disc to hang from the brake hose This can cause sp...

Page 109: ...rear axle wheel hub retainer 4 NOTE Have an assistant apply the brakes during procedure to prevent the wheel hub assembly from turning Remove the rear axle wheel hub retainer and discard 5 Remove the brake hose clip that secures the rear brake hose to the frame 6 Remove the two rear disc brake caliper bolts 7 Lift the rear disc brake caliper off the rear disc brake rotor 8 CAUTION Do not allow the...

Page 110: ...large flatwasher When the nut is loosened it must be replaced with a new nut Front Removal Installation Refer to the Front Shock removal installation procedure in this section Wheel Bearing Hub Rear Removal 1 Raise the vehicle 2 Unbolt and remove the rear wheel from the hub assembly 3 Straighten the staked edge of the halfshaft attaching nut flange using a small cape chisel 6 18 Caution Use care n...

Page 111: ...to the halfshaft use either a two jaw puller or a hub puller to achieve separation Installation Rear Wheel 1 Slide wheel plate bolts into wheel plate and fasten to the rear suspension yoke 2 Bolt mechanical brake caliper to wheel plate 3 Position the hydraulic caliper to the wheel plate and install the attaching bolts Tighten the caliper attaching bolts to 29 36 ft lb 39 49 N m 4 Position the cali...

Page 112: ...r spring and shock absorber bolt from the vehicle frame and the suspension arm 8 Remove the 3 8 bolts and nuts securing the suspension arm s to the outer brackets on the axle torsion bar 9 Remove the axle torsion bar bolts from the torsion bar brackets and remove the axle torsion bar Axle Torsion Beam and Suspension Arms Exploded View 4 5 11 Part Part Item Number Description Item Number Descriptio...

Page 113: ... 69 86 lb ft 93 117 N m 10 Tighten the suspension arm nuts to 40 50 lb ft 54 68 N m 11 Check the wheel alignment Refer to the Wheel Alignment procedure 12 Bleed the rear brakes Operate the park brakes and adjust if necessary Refer to Section 4 for the procedure Control Arms Rear Upper and Lower The procedure applies to the upper and or lower control arms 1 Raise and support the rear end of the veh...

Page 114: ...the inspection charts in this section Hub cracks or damage to the casting Wear pattern at the oil seal contact surface Scoring or rusting of the bearing bore Assembly 1 Pack the bearing with lubricant Pack the hub area as shown in the installed view below INNER WHEEL BEARING OIL SEAL INNER WHEEL BEARING OIL SEAL OUTER AND INNER WHEEL BEARINGS 2 Place the inner bearing into the bore so that it rest...

Page 115: ...hock Damper Washer 7 343594 Piston Uni ring 8 344004 Damper Piston 9 344011 Damper Tube 10 344001 Front Shock Strut 11 344017 Snap Ring 12 343630 Star Washer 10 Position the rotor on the hub observing the original aligning marks and install the attaching bolts Tighten the attaching bolts to 33 40 ft lb 44 54 N m Install the wheel hub and wheel bearing assembly Refer to the procedure in this sectio...

Page 116: ... amount of torque required to rotate the spacer selection tool using an inch pound torque wrench 6 24 9 Take the torque wrench reading just as the tool starts to rotate IMPORTANT If the torque wrench indicai es 2 2 10 4 lb in 0 25 1 8 N m the spacer is the correct thickness If the torque wrench indicates less than 2 2 lb in 0 25 N m a thinner spacer must be installed If the torque wrench indicates...

Page 117: ...wheel hub in place 8 NOTE The torque wrench reading must be taken just as the tool starts to rotate Measure the amount of torque required to rotate the Spacer Selection Tool using an inch pound torque wrench If the torque wrench indicates 2 2 10 4 lb in 0 25 1 8 N m the outer wheel bearing retainer washer is the correct thickness If the torque wrench indicates less than 2 2 lb in 0 25 N m a thinne...

Page 118: ...ch tire tread using a toe in gauge 4 Lower the vehicle and measure the distance between the marked lines at the front and rear of the wheels The difference between 6 26 the front and rear should be no more than 1 8 inch toe in Adjustments can be done by increasing or decreasing the length of the lower control arms 5 When finished adjusting toe in raise the rear of the vehicle and remove the rear w...

Page 119: ...proper handling or tool usage Overheating Lubricant failure Incorrect lubricant Fine abrasives mixed with lubricant Incorrect lubricant Lubricant failure Outer and inner bearing cup misaligned in spindle bore due to burr nick or dirt on cup seal Contaminated lubricant CORRECTION Replace bearings Replace bearings Use only specified lubricant Replace bearings Replace bearings Use only specified lubr...

Page 120: ...place inner and outer wheel indentations in raceway bearing is not rotating bearings if rough or noisy rl ll Insufficient lubricant I lUJ I CAGE WEAR Fine abrasives mixed with lubricant Replace inner and outer wheel uI Insufficient lubricant bearings Use only specified lubricant ABRASIVE ROLLER WEAR Fine abrasives mixed with lubricant Replace inner and outer wheel Jl 1 bearings if rough or noisy r...

Page 121: ...osion set up by small relative movement between bearing rollers races and cups without adequate lubrication Excessive loading Incorrect lubricant Insufficient lubricant Improper fit Excessive preload Incorrect lubricant Moisture contamination CORRECTION Replace bearings Use correct bearings Use only specified lubricant Replace inner and outer wheel bearings Replace bearings Use only specified lubr...

Page 122: ...0 Material Steel Tires Size P155 80R13 Air Pressure front psi kPa 30 200 Air Pressure rear psi kPa 28 180 Wheel Rim Runout and or Balance Specifications Description inches mm Wheel radial runout 0 04 1 0 Wheel Lateral runout 0 04 1 0 Tire Runout Specifications Description Specification Tire Lateral Runout 0 010 in 2 5 mm Tire Radial Runout 0 06 in 1 5 mm Torque Specifications Lb ft N m 65 87 88 11...

Page 123: ...heel hub retainer Backlash between the wheel hubs and rear wheel driveshaft and joints is eliminated by the splines The rear wheel hub splines are machined straight while the rear wheel driveshaft and joint splines are machined with a slight helical cut The difference in splines provides a tight SUBJECT PAGE DIAGNOSIS AND TESTING Continued Troubleshooting Chart Halfshafts Rear Wheel 7 4 REMOVAL AN...

Page 124: ...r In both types of rear wheel driveshaft joints the outer race is machined into the rear wheel driveshaft joint housing 7 2 The inboard tripod type rear wheel driveshaft joints can be disassembled and serviced Other than the rear wheel driveshaft joint boot the outboard Birfield type rear wheel driveshaft joint is serviced only as an assembly with the right hand rear wheel driveshaft and joint or ...

Page 125: ...haft joint boots from the inside without external evidence of damage The rear wheel driveshaft and joint is not to be used as a lever arm to position other rear end components Always support the Part Item Number Description 10 11 12 13 14 A 250747 Driveshaft Bearing Retainer Circlip 250745 Rear Wheel Driveshaft and Joint LH Rear Wheel Driveshaft Join Part of 3B436 7 Birfield Type Differential Side...

Page 126: ...Improper Operation of Rear Wheel Worn or seized rear wheel Driveshaft and Joint driveshaft joint Abnormal Noise from Rear Wheel Insufficient grease in rear wheel Driveshaft and Joint driveshaft joint or spline Excessive backlash on spline Worn rear wheel driveshaft joint Loose dynamic damper Steering Wheel Pulls Toward either Incorrect rear wheel bearing th Right or Left Side while Driving preload...

Page 127: ...he left hand or right hand rear wheel driveshaft a nd joints 1 Raise and support the vehicle 2 Drain the transmission fluid from the transaxle Refer to Section 8 for automatic transaxles 3 Remove the wheel hub bolts and the rear wheel and tire assembly REMEDY Adjust rear wheel bearing preload or Replace bearing Refer to Section 6 Refer to Section 6 Refer to Section 6 Refer to Section 6 Adjust toe ...

Page 128: ...ce if necessary Refer to Sections 6 8 for the procedures 2 NOTE The original driveshaft bearing retainer circlip must not be reused Install a new driveshaft bearing retainer circlip on the front wheel driveshaft joint 3 Lubricate the end of the rear wheel driveshaft joint with grease 7 6 DRIVESHAFT BEARING RETAINER CIRCLIP 4 Remove the Differential Plugs 5 CAUTION Insert the front wheel driveshaft...

Page 129: ...MBLY Halfshaft Assembly Inboard Disassembly 1 Clamp the front wheel driveshaft and joint in a vise equipped with protective jaw caps to prevent damage to any machined parts 2 NOTE Peel the rear wheel driveshaft joint boot clamp away from the rear wheel driveshaft joint boot as shown Remove the large rear wheel driveshaft joint boot clamp and discard Side cutters can be used to cut the rear wheel d...

Page 130: ...for assembly reference TRIPOD BEARING AUGNMENT MARKS 6 Remove the outer race 7 8 OUTER RACE TRIPOD BEARING 7 Remove the snap ring TRIPOD BEARING SNAP RING 8 Use a brass drift and hammer to gently tap the tripod bearing from the rear wheel driveshaft 9 If the rear wheel driveshaft joint boot is to be reused wrap the rear wheel driveshaft splines with tape before removing the boot from the rear whee...

Page 131: ... in the rear wheel driveshaft and outer race 8 Extend or compress the rear wheel driveshaft joint as necessary until the distance between the rear wheel driveshaft joint boot clamp grooves measures 4 11 inches 1 04 3mm components must be lubricated with a Constant 104 3 mm Velocity Joint Grease High Temperature prior to 4 111NCH assembly 1 If necessary cover the rear wheel driveshaft splines with ...

Page 132: ... flex extend and compress smoothly CLEANING AND INSPECTION CV Joint Boot Indentation Inspection Indentations or dimples in the inboard and or outboard rear wheel driveshaft joint boots may occur due to improper handling during storage or service of the rear wheel driveshaft and joints If during inspection a rear wheel driveshaft joint boot is observed to be dimpled proceed as follows 1 Inspect the...

Page 133: ...priate rear wheel driveshaft joint boot installation steps within assembly of the halfshaft SPECIFICATIONS Half shaft Assembled Lengths LEFT DRIVESHAFT AND JOINTS 617 4mm 24 31 INCHES assembly inboard in this section for the necessary procedure PULL DRIVESHAFT JOINT BOOT OUTWARD TO REMOVE DIMPLE Extreme care should be taken not to allow the rear wheel driveshaft joint boots to come in forceful con...

Page 134: ...oint Boot inches Clamps 104 3mm 4 11 inches LUBRICANT SPECIFICATIONS Specification Quantity High Temp Constant Velocity Joint 100g 3 5 oz Grease E43Z 19590 A ESP M1 C207 A TORQUE SPECIFICATIONS Description N m Lb Ft Rear Suspension Lower Arm 43 54 32 40 Ball Joint Nut Rear Axle Wheel Hub 157 235 116 174 Retainer Wheel Hub Bolts 88 118 65 87 SERVICE TOOLS EQUIPMENT Differential Plugs 7 12 ...

Page 135: ...Pinpoint Tests Transaxle 8 20 Troubleshooting Charts Transaxle 8 17 IN VEHICLE SERVICE Backup Lamp Switch 8 35 Differential Seals 8 31 Intermediate Servo 8 31 SUBJECT PAGE IN VEHICLE SERVICE cont d Main Control Valve Body 8 29 Switch Kickdown 8 35 Transmission Fluid Check 8 29 Transmission Fluid Drain 8 29 Transmission Fluid Fill 8 29 Vacuum Throttle Valve Diaphragm 8 33 REMOVAL Transaxle 8 35 DIS...

Page 136: ...View Part Item Number Description 1 One Way Clutch 2 One Way Clutch Race 3 Drum Hub Assembly 4 Bearing Housing 5 Output Gear 6 Turbine Shaft Continued 8 2 SUBJECT PAGE ADJUSTMENTS Intermediate Band 8 1 09 Kickdown Switch 8 1 09 Throttle Control Valve Rod 8 1 08 SPECIFICATIONS 8 109 SERVICE TOOLS EQUIPMENT 8 111 hydraulically controlled unit and uses a torque converter equipped with a centrifugal t...

Page 137: ...ial Pinion Shaft 29 Direct Clutch 18 Differential Gear Case 30 Forward Clutch 19 Differential Ring Gear 31 Sun Shell 20 Side Bearing Housing 32 Rear Clutch Hub 21 Differential Oil Seal 33 Front Planet 22 Main Control Valve Body 34 Rear Planet Carrier Thrust Bearing Washer Locations DIMENSION C DIMENSION DIMENSION n 0 DIMENSION D Selective D MENS ON C THRUST BEARING WASHER LOCATION Dimension Compon...

Page 138: ...Park Neutral Position Switch 4 Fluid Level Indicator PNP Switch 5 Oil Filler Tube Bolt 17 Main Control Valve Body 6 Oil Filler Tube 18 Vacuum Throttle Valve 7 Oil Pump Diaphragm 8 Oil Pump to Transaxle Bolts 8 19 Turbine Shaft 9 Check Ball 20 194001 Torque Converter 10 Case Detent Spring 21 Oil Pump Shaft 11 Main Control Valve Body A Tighten to 71 97 lb in 8 11 N m Bolts 9 Req d B Tighten to 61 87...

Page 139: ...Section 8 Automatic Transaxle Internal Linkages Rear Planetary Gearset and Low Reverse Clutch 8 5 ...

Page 140: ...n Parking Lever Actuating Rod Governor Inlet Tube Governor Outlet Part Item Number Description 29 Support 30 Support Retaining Bolt 31 Manual Control Lever 32 Manual Control Lever Arm 33 Parking Pawl 34 Parking Pawl Return Spring 35 Parking Pawl Shaft 36 Low Reverse Clutch Dished Plate 37 Low Reverse Clutch External Spline Clutch Plate 38 Low Reverse Clutch Internal Spline Clutch Plate 39 1 Low Re...

Page 141: ... Assembly 2 Servo Piston 12 Forward Clutch Drum 3 Intermediate Band Servo 13 Band Adjusting Stop Retainer 14 Band Adjusting Stop Nut 4 Sun Shell 15 Governor Cover Bolt 3 Req d 5 Sun Gear Spacer 16 Governor Cover 6 Sun Gear 17 Governor Valve 7 Front Planet Carrier A Tighten to 41 59 Lb Ft 8 Front Ring Gear 55 80 N m 9 Band Strut B Tighten to 71 97 Lb in 10 Intermediate Band 8 11 N m Contmued 8 7 ...

Page 142: ...tion 1 Differential 7 Torque Converter Stator 2 Idler Gear and Idler Gear Support Bolt 6 Req d Shaft 8 Torque Converter Stator 3 Idler Gear Shaft Roll Pin Support 4 Bearing Housing Bolt 8 9 Differential Oil Seal Req d A Tighten to 19 26 N m 5 Bearing Housing 14 19 Lb Ft 6 Output Shaft B Tighten to 11 14 N m Continued 95 122 Lb in 8 8 ...

Page 143: ...ds the rear carrier causing the rear planet pinion gears to rotate counterclockwise This rotates the rear internal ring gear counterclockwise driving the output gear counterclockwise These actions provide a gear ratio of 2 4 1 at the output gear Neutral The NEUTRAL N position allows no powerflow through the transaxle and allows the wheels to rotate freely Drive In the DRIVE D position the automati...

Page 144: ...ngine s flywheel and encloses the other torque converter components Turbine The turbine splines to the turbine shaft Fluid motion from the impeller causes the turbine to rotate Allowing the transfer of power from the engine to the transaxle At engine idle fluid motion is not great enough to overcome vehicle weight so the engine can idle without having to place the transaxle in NEUTRAL N 8 10 Impel...

Page 145: ...ankshaft Idler Gear Planetary Carriers Contmued Geartrain The control of the planetary geartrain provides the transaxle with three forward gears and reverse The geartrain is a Simpson Compound planetary gearset which consists of two planet carriers front and rear two ring gears front and rear and a common sun gear The gearset is controlled using three multi disc clutches direct forward and low rev...

Page 146: ...either the one way clutch or the low reverse clutch 8 12 Low Reverse Clutch The low reverse clutch holds the rear planet carrier stationary to the transaxle case It is the holding device for reverse and provides for engine braking in MANUAL LOW 1 position first gear Park Gear and Parking Pawl The park gear attaches to the output gear and locks the output gear to the transaxle case This is accompli...

Page 147: ... the transaxle and torque converter Part Item Number Description 8 Differential Pinion Gears 9 Differential Side Gears 10 Differential Side Gear Thrust Washers 11 Ring Gear Part of 4026 12 Differential Bearing Speedometer Drive Gear End A Tighten to 69 83 N m 51 62 Lb Ft Main Control Valve Body Fluid is directed to the various components at the correct pressures through the main control valve body...

Page 148: ...ts 18 Main Control Valve Body Bolt 9 2 Req d Req d 4 Sub Body 19 Upper to Lower Valve Body 5 Pressure Regulator Valve A bolts 6 Spring 20 Upper to Lower Valve Body 7 Spring Set B bolts 8 Pressure Regulator 21 Orifice Check Valve and Spring 9 Side Plate Bolt 22 Check Ball and Spring 10 Pressure Regulator Sleeve 23 Side Plate 11 Side Plate 24 2 3 Shift Valve 12 Spring 25 Spring 13 3 2 Timing Valve 2...

Page 149: ...ype and is driven by the governor drive gear located on the drum hub assembly The governor sends road speed il formation to the main control valve body for use in determining shift strategy Intermediate Servo The servo piston is a hydraulic piston connected to a rod When the servo piston is actuated it forces the rod against the end of the intermediate band causing the intermediate band to hold th...

Page 150: ...rst to avoid incorrect or unnecessary repairs Always make certain proper safety precautions are used when performing any test or repair The diagnosis and testing should be performed in the following sequence 1 Inspection and Verification provide easy inspection to detect obvious problems with the transaxle 2 Transaxle Fluid Level Check is important in detecting problems with the transaxle Refer to...

Page 151: ...utch es Main control valve body Intermediate band Clutch es Kickdown circuit Clutch es Intermediate band ACTION GO to Pinpoint Test B1 GO to Pinpoint Test AI GO to Stall Test in this section GO to Governor Check in this section GO to Stall Test in this section GO to Stall Test in this section GO to Stall Test in this section GO to In Shop Test in this section GO to Pinpoint Test B1 GO to Stall Tes...

Page 152: ...gear Oil pump GO to Stall Test in this section Torque converter GO to Stall Test in this section Clutch es GO to Stall Test in this section Hydraulic circuit GO to In Shop Test in this section Engine Braking Inadequate Main control valve body GO to Stall Test in this section Intermediate band GO to Stall Test in this section Hydraulic circuit GO to In Shop Test in this section Excessive Creep Torq...

Page 153: ...s Differential INSPECT REPLACE the differential Gear s INSPECT REPLACE the gears Vehicle Moves in PARK P Parking pawl INSPECT the parking pawl Gearshift lever out of CHECK gearshift lever adjustment adjustment No Start Park Neutral Position Switch REFER to Section 7 Overheating NOTE Excessive Cooler and lines INSPECT REPLACE the cooler overheating may cause and or lines damage to internal 0 Interm...

Page 154: ...e Key ON engine running Engine at idle Read the vacuum on the gauge Is the manifold vacuum 15 22 in Hg 381 559 mm H present and held by the hose A3 CHECK THROTTLE VALVE DIAPHRAGM FUNCTION Key OFF Remove the vacuum throttle valve diaphragm Connect a Vacuum Tester or equivalent to the vacuum throttle valve diaphragm as shown below Apply 16 20 in Hg 406 4 508 mm Hg vacuum Check that vacuum is held Ch...

Page 155: ...mm 26 9mm or over Are the measurements within specifications Component Tests Transmission Fluid Level Check 1 Apply the parking brake and ensure that the vehicle is in a level position 2 Run the engine at normal idle speed If the Automatic Transmission Fluid ATF is cold run the engine at fast idle speed about 1200 rpm for several minutes When the ATF is warm slow the engine down to normal idle spe...

Page 156: ...be red not brown or black Odor can sometimes indicate an overheating condition clutch disc or band failure 3 Use an absorbent white facial tissue to wipe the transmission oil level indicator Examine the stain for evidence of solids specks of any kind and for antifreeze signs gum or varnish on the transmission oil level indicator If specks are present in the ATF or there is evidence of engine coola...

Page 157: ...nt of the transaxle as evidenced by ATF around the torque converter housing may have several sources By careful observation it is possible in many instances to pinpoint the source of the leak before removing the transaxle from the vehicle The paths which the ATF can take to reach the bottom of the torque converter housing are as follows Possible Converter Area Leak Points CONVERTER CRANKSHAFT LEAK...

Page 158: ...ree minutes and then return the engine to idle 4 Connect a Digital Multimeter or equivalent to the vehicle to monitor engine speed 5 Ground the engine self test STI TEN terminal in the data link connector 6 The idle speed should be within 750 50 rpms Refer to Section 11 for the idle speed adjustment procedures if the idle speed is not within specification Stall Test 1 Check the engine coolant leve...

Page 159: ...in transaxle all normal Lower than specification One way clutch in torque converter slipping Governor Check SPECIAL SERVICE TOOL S REQUIRED Engine Oil Pressure Gauge 1 Warm the engine until the Automatic Transmission Fluid ATF reaches normal operating temperature 122 176 F 50 80 C 2 Connect an Engine Oil Pressure Gauge to the governor pressure outlet 1 Specified stall speed 2300 2500 rpm Action to...

Page 160: ...ure outlet 6 Disconnect and plug the vacuum throttle valve diaphragm hose s 7 Connect a Vacuum Tester or equivalent to the vacuum throttle valve diaphragm Control Pressure Within specifications Out of specifications 8 26 CONTROL PRESSURE OUTPUT PORT 8 Drive the vehicle 9 Gradually increase the engine rpm and apply vacuum slowly to the vacuum throttle valve diaphragm 10 Record the governor pressure...

Page 161: ...ase 10 Repeat steps 7 and 8 If the flow is not within specification flush the system If specified flow is not yet obtained replace the cooler lines Shift Point Checks Road Test 1 Warm the engine until the Automatic Transmission Fluid ATF reaches normal operating temperature 122 176 F 500 8000C 2 Place the gearshift lever in DRIVE D 3 Drive the vehicle 4 Accelerate the vehicle at minimum throttle 5...

Page 162: ... and then release the accelerator pedal 9 Repeat these steps for the 1 2 and R range CONTROL PRESSURE SPECIFICATIONS CHART Control Pressure D and 1 2 R When 46 54 psi 150 166 psi 76 95 psi idling 314 373 kPa 1030 1148 520 657 kPa kPa At 141 157 psi 150 166 psi 251 262 psi stall 971 1089 1030 1148 1727 1813 s_peed kPa kPa kPa CONTROL PRESSURE TEST EVALUATION CHART Control Pressure Possible Location...

Page 163: ...sket on the transmission oil pan and instal the transmission oil pan on the transaxle Install the transmission oil pan bolts and tighten to 43 69 lb in 5 8 N m 8 Install a new washer on the transmission fluid drainplug Install the transmission fluid drainplug and tighten the transmission fluid drainplug to 29 40 lb ft 39 54 N m 9 Lower the vehicle Transmission Fluid Fill If the automatic transaxle...

Page 164: ...rted first then the detent spring is installed Use petroleum jelly if necessary to retain the detent spring and check ball 8 30 Install the throttle control valve rod into its hole in the transaxle case Install the check ball and detent spring into the slotted hole in the transaxle case DETeNT SPRING SHIFT ROD DRIVING PIN CHECK BAll 2 CAUTION Do not overtighten the main control valve body bolts Ov...

Page 165: ...upport the vehicle 2 Remove the rear wheel driveshaft and joint Refer to Section 7 for the removal procedure 3 Use a flat blade screwdriver to remove the differential oi seal Installation 1 Use Differential Seal Replacer to install the differential oil seal 2 Install the rear wheel driveshaft and joint Refer to Section 7 for the installation procedure 3 Lower the vehicle 4 Check the transmission f...

Page 166: ... retaining snap ring 10 Remove the servo retainer servo piston and servo piston spring by slowly loosening the C clamp 8 32 11 Remove the servo piston spring and the servo piston large seal Installation SERVO PISTON LARGE SEAL SERVO PISTON SPRING 1 Lubricate the servo piston with the specified transmission fluid Assemble the servo retainer servo piston servo piston large seal and servo piston spri...

Page 167: ...while tightening the band adjusting stop nut 7 Install the rear wheel driveshaft and joint Refer to Section 7 for the installation procedure 8 Install the main control valve body Refer to the procedure in this section SERVICE TOOL S REQUIRED Vacuum Diaphragm Rod Gauge Removal 1 Drain the transmission fluid Refer to the procedure in this section 2 Disconnect the vacuum hose from the vacuum throttle...

Page 168: ...auge to measure the distance from the flat surface of the Vacuum Diaphragm Rod to the end of the Rod 8 34 VACUUM DIAPHRAGM ROD GAUGE 9 Use this measurement to select the correct size throttle control valve rod from the following chart THROTTLE CONTROL VALVE ROD SELECTION Throttle Control Depth Measurement Valve Rod Length inch mm inch mm Under 1 000 25 4 1 161 29 5 1 000 1 020 25 4 25 9 1 181 30 0...

Page 169: ...h Installation To install reverse the removal procedure Adjust the kickdown switch Refer to the procedure in this section REMOVAL Transaxle SPECIAL SERVICE TOOL S REQUIRED Differential Plugs Disconnect the battery ground cable 2 Remove the manual control lever nut and the manual control lever arm 3 Remove the shift cable and bracket from the transaxle 4 Disconnect the speedometer cable from the tr...

Page 170: ...support bracket bolts and the front transaxle support bracket 23 Remove the two rear transaxle support bracket bolts and the rear transaxle support bracket and insulator 24 Remove the intake manifold support 25 Remove the three transaxle to engine bolts and remove the case rear bracket 26 Remove the three transaxle to engine bolts from the transaxle case to cylinder block 8 36 front bracket Remove...

Page 171: ...e fabric particles on components as this can block passages and cause valves to stick Clean the disassembled parts and clean the oil passages with compressed air and check to be sure they are not clogged NOTE The casings allow separate repairs to be carried out on either the automatic transaxle or the final drive section When a problem exists that only requires work on one section separate the tra...

Page 172: ...t out of the turbine shaft 3 Pull the turbine shaft out of the torque converter stator support 4 Separate the kickdown solenoid wire from the wiring harness and remove the kickdown solenoid 8 38 Part Item Number Description 14 194000 Oil Pan to Case Gasket 15 Main Control Valve Body 16 Park Neutral Position Switch PNP Switch 17 Kickdown Solenoid 18 Vacuum Throttle Valve Diaphragm 19 Turbine Shaft ...

Page 173: ...eter cable sleeve and speedometer gear assembly to the transaxle and remove the speedometer cable sleeve and speedometer gear assembly 9 Remove the 16 transmission oil pan bolts and remove the transmission oil pan from the transaxle Discard the oil pan to case gasket 10 NOTE Be careful not to lose the check ball and detent spring located in the slotted hole Remove the nine main control valve body ...

Page 174: ...he front clutch drum Do this several times as you rotate the assembly two complete revolutions 8 40 12 Measure the direct clutch drum end play by checking the clearance of the small slot between the direct clutch drum tabs and the sun shell slots Record this measurement for reference upon reassembly The standard end play is 0 020 0 031 inch 0 5 0 Bmm 13 Remove the oil cooler hose fittings from the...

Page 175: ... Apply Devices Governor Assembly and Front Planetary Gearset Part Part Item Number Description Item Number Description 1 Servo Piston Spring 9 Band Strut 2 Servo Piston 10 Intermediate Band 3 intermediate Band Servo 11 Direct Clutch Assembly Retainer 12 Forward Clutch Drum 4 Sun Shell 13 Band Adjusting Stop 5 Sun Gear Spacer 14 Band Adjusting Stop Nut 6 Sun Gear 15 Governor Cover Bolt 3 7 Front Pl...

Page 176: ...p opening 19 Remove the direct clutch assembly 8 42 DIRECT CLUTCH ASSEMBLY 20 Remove the forward clutch drum needle bearing located on the forward clutch drum Part Item Number Description 1 Direct Clutch Drum 2 Intermediate Band Strut 3 Intermediate Band 4 Forward Clutch Drum Needle Bearing 5 Forward Clutch Drum 21 Remove the front ring gear 22 Remove the oil pump thrust washer if the thrust washe...

Page 177: ...Front Ring Gear Needle Bearing 5 Front Planet Carrier Thrust Washer 6 Front Planet Carrier 7 Sun Gear Spacer 8 Sun Gear 26 Remove the front planet carrier FRONT PlANET CARRIER 27 Remove the sun gear 28 Remove the sun gear spacer 29 Remove the sun shell 30 Remove the sun shell thrust washer and thrust bearing 8 43 ...

Page 178: ...vo retainer servo piston and servo piston spring by slowly loosening the C clamp 34 Disassemble the band apply servo by removing the servo piston spring Remove the servo piston large seal Discard the servo piston large seal SERVO PISTON LARGE SEAL SERVO PISTON SPRING 35 Remove the governor cover bolts governor cover and governor gasket Discard the governor gasket 36 Remove the governor from the tr...

Page 179: ...Section 8 Automatic Transaxle 39 Position the converter housing to remove the differential Internal Linkages Rear Planetary Gearset and Low Reverse Clutch 8 45 ...

Page 180: ...ription 26 Parking Lever Actuating Rod 27 Governor Inlet Tube 28 Governor Outlet Tube 29 Support 30 Support Retaining Bolt 31 Manual Control Lever 32 Manual Control Lever Arm 33 Parking Pawl 34 Parking Pawl Return Spring 35 Parking Pawl Shaft 36 Low Reverse Clutch Dished Plate 37 Low Reverse Clutch External Spline Clutch Plate 38 Low Reverse Clutch Internal Spline Clutch Plate 39 2 Low Reverse Clu...

Page 181: ...earing and rear planet carrier to ring gear thrust washer from the rear planet carrier Part Item Number Description 1 One Way Clutch Race 2 Rear Planet Carrier 3 Snap Ring 4 Rear Carrier to Ring Gear Thrust Washer 5 Drum Hub Assembly 6 Rear Carrier to Ring Gear Needle Bearing 47 Before removing the one way clutch use a feeler gauge to measure the clearance of the one way clutch retaining plate and...

Page 182: ...NING TO AVOID PERSONAL INJURY WEAR EYE PROTECTION DURING THE FOLLOWING PROCEDURE 8 48 Use a flat blade screwdriver to pry the low reverse snap ring from the snap ring groove 52 Remove Clutch Compressor 53 Remove the low reverse clutch hub 54 Remove the return springs from the low reverse clutch piston 55 WARNING WHEN PERFORMING THE FOLLOWING PROCEDURE USE CARE TO PROTECT YOURSELF FROM THE FORCE OF...

Page 183: ...nual control lever support and slide the manual control lever out of the transaxle case MANUAL CONTROL LEVER SUPPORT BOLTS 2 61 Remove the parking lever actuating rod and ferrule as an assembly from the transaxle case 62 Position the transaxle with the oil pan opening facing up Remove the roll pin securing the manual control lever shaft to the transaxle case by lightly tapping the roll pin with a ...

Page 184: ...Section 8 Automatic Transaxle 65 Use a small flat blade screwdriver to remove the case detent spring 8 50 CASE DETENT SPRING ...

Page 185: ...m Number 1 Differential 8 Torque Converter Stator 2 Idler Gear and Idler Gear Shaft Support 3 Idler Gear Shaft Roll Pin 9 Differential Oil Seal 4 Bearing Housing Bolt 8 Req d A Tighten to 14 19 lb ft 19 26 5 Bearing Housing N m 6 Output Shaft B Tighten to 95 122 lb in 11 14 7 Torque Converter Stator N m Support Bolt 6 Req d 8 51 ...

Page 186: ...r 70 Use a brass drift and hammer and tap lightly on the idler gear shaft to remove the idler gear and output gear assembly from the bearing housing 71 NOTE Separate or mark each output shaft bearing selective shim upon removal for installation reference Use Stator Driven Sprocket Bearing Remover Puller and Impact Slide Hammer to remove the bearing race from the bearing housing Remove the output s...

Page 187: ...verter impeller hub seal from the torque converter stator support IMPACT SliDE HAMMER SEAL REMOVER TOOl 75 Use Puller and impact Slide Hammer to remove the output shaft bearing race from the torque converter stator support still mounted in the converter housing 76 Remove the six torque converter stator support bolts 77 CAUTION Have an assistant hold the torque converter stator support to prevent i...

Page 188: ...disassembling the differential measure and record the backlash of the differential pinion gears as follows Differential Exploded View 8 54 1 Install the left and right front wheel driveshaft and joints on the differential 2 3 Support the front wheel driveshaft and joints on V blocks Measure and record the backlash of both differential pinion gears using Dial Indicator with Bracketry or equivalent ...

Page 189: ...the gearcase in a vise equipped with soft jaws 6 Use a 5 32 inch 4mm pin punch at least 3 5 inches 90mm long and a hammer to remove the differential pinion shaft lock pin Drive the differential pinion shaft lock pin free of the gearcase Item 8 9 10 11 12 A Part Number Description Differential Pinion Gears Differential Side Gears Differential Side Gear Thrust Washers Ring Gear Differential Bearing ...

Page 190: ... should be kept with their respective gears for possible reinstallation 8 56 Rotate the differential pinion gears and differential pinion thrust washers out of the gearcase 12 Remove the differential side gears and differential side gear thrust washer from the gearcase DIFFERENTIAL SIDE GEAR 13 Refer to cleaning and inspection for differential inspection Assembly Before differential assembly clean...

Page 191: ...ission fluid and install the differential side gear thrust washers to the differential side gears Install the side gear assemblies to the DIFFERENTIAL gearcase BEARING 3 Use Driver Handle Bearing Cone Replacer or a press to install the rear differential bearing to the gearcase DIFFERENTIAL BEARING 4 Locate and record the identification number on each differential side gear thrust washer The follow...

Page 192: ...emove the differential pinion gears and install them into the gearcase again DIFFERENTIAL PINION GEAR 8 Install the differential pinion shaft into the gearcase with the flat on the shaft up and the differential pinion shaft lock pin hole entering the case last 8 58 9 Use a suitable drift and hammer to install the differential pinion shaft lock pin through the gearcase and into the differential pir...

Page 193: ...b Support the front wheel driveshaft and joints on V blocks DIAL INDICATOR WITH BRACKETRY TOOL c Use Dial Indicator with Bracket or equivalent to measure the backlash of both differential pinion gears The standard backlash is 0 000 0 004 inch 0 0 1 mm d If the backlash is more than allowed adjust it by selecting a differential side gear thrust washer from the following table Differential side gear...

Page 194: ...t used in the automatic transaxle It should be handled very carefully Since many parts look alike they should be kept in a well arranged order If the clutches have been overheated or the intermediate band has been burned be sure to disassemble clean and inspect the main control valve body Main Control Valve Body Exploded View 8 60 ...

Page 195: ...ll and Spring Contmued 1 Remove the manual valve from the upper valve body 2 Remove the bolts attaching the oil filter to the valve body and remove the oil filter 3 With the lower half facing you remove the nuts and bolts attaching the upper and lower valve bodies noting the position of each bolt for installation reference Item 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 A B c D Part Number...

Page 196: ... Turn the assembly over and carefully remove the separator plate the check ball and spring and the orifice check valves and spring from the lower valve body ORIFICE AND SPRING Upper Valve Body Valve Location 8 62 6 Remove the orifice check valve from the upper valve body with a magnet as shown 7 The following illustration shows the position and components for each of the valve assemblies in the up...

Page 197: ...4 0 2 3 Shift 0 272 6 9 1 61 41 0 20 0 1 2 Shift 0 258 6 55 1 26 32 0 18 0 Second Lock 0 219 5 55 1 32 33 5 18 0 Pressure Regulator 0 461 11 7 1 69 43 0 15 0 Throttle Relief 0 276 7 0 0 44 11 2 6 0 Orifice Check 0 197 5 0 0 61 15 5 12 0 Description Manual Valve 1 2 Shift Valve 2 3 Shift Plug 2 3 Shift Valve Modifier Valve Downshift Valve Wire Dia inch mm 0 031 0 8 0 022 0 55 0 028 0 7 0 022 0 55 0...

Page 198: ...de Plate 3 Pressure Regulator Sleeve 4 Pressure Regulator Plug 5 Spring Seat 6 Pressure Regulator Valve 1 2 Shift Valve 2 3 Shift Valve and Modifier Valve Part Item Number Description 1 Shift Plug 2 Modifier Valve 3 2 3 Shift Valve 4 Side Plate 5 Separator Plate 6 1 2 Shift Valve 8 64 ...

Page 199: ... 6 Install the one check ball and spring and the orifice check valve and spring to their correct position in the lower valve body as shown ORIACEANO SPRING 7 Place the separator plate over the lower valve body half Hold the separator plate and lower valve body together and turn the assembly over and place it on the upper valve body 8 Align the upper and lower valve bodies and install the valve bod...

Page 200: ...nd outer gears 6 Before assembly inspect the oil pump as follows a Place Gauge Bar over the machined surface of the pump housing Measure the clearance between the inner gear and the straightedge with a feeler gauge Repeat this procedure and measure the clearance between the outer gear and the gauge bar Standard clearance for both measurements is 0 001 0 002 inch 0 02 0 04mm The maximum allowable c...

Page 201: ...06 0 008 inch 0 010 inch 0 25mm 0 14 0 21 mm OUTER GEAR HOUSING 0 002 0 008 inch 0 010 inch 0 25mm 0 05 0 20mm SEAL RING SEAL RING GROOVE 0 002 0 006 inch 0 016 inch 0 40mm 0 04 0 16mm 7 Check for a worn pump housing bushing as follows b Measure the pump cover bushing inside diameter The bushing diameter limit is 1 499 inches 38 075mm Replace the oil pump if the bushing is worn beyond this limit a...

Page 202: ...to the pump housing Install the seven pump cover bolts Tighten the pump cover bolts to 95 122 Ib in 11 14 N m 4 After assembly install the oil pump shaft to the oil pump and ensure the gears turn easily 8 68 OIL PUMP Direct Clutch SPECIAL SERVICE TOOL S REQUIRED Clutch Spring Compressor Disassembly Measure the clearance between the snap ring and the pressure plate of the direct clutch using a feel...

Page 203: ...rect Clutch Outer Piston Seal Contmued 1 Use snap ring pliers or a flat blade screwdriver to remove the direct clutch snap ring Part Item Number Description 7 Direct Clutch Drum 8 Direct Clutch Dished Plate 9 Direct Clutch Internal Spline Clutch Plates 10 Direct Clutch External Spline Clutch Plates 11 Direct Clutch Pressure Plate 12 Direct Clutch SnaQ Ring 2 Remove the direct clutch pressure plate...

Page 204: ...ying compressed air not to exceed 60 psi 400 kPa into the fluid hole of the direct clutch drum and remove the piston 8 Remove the inner and outer piston seal rings and discard 9 Refer to cleaning and inspection for clutch inspection 8 70 Assembly 1 Clean and blow dry all parts 2 Coat the new inner and outer piston seal rings with the petroleum jelly and install the seals to the direct clutch pisto...

Page 205: ...1 8mm adjust it by selecting a proper pressure plate using the following chart DIRECT CLUTCH PRESSURE PLATE SIZE Part Number Thickness of Pressure Plate 0 205 inch 5 2mm 0 213 inch 5 4mm 0 221 inch 5 6mm 0 228 inch 5 8mm 0 236 inch 6 0mm 0 244 inch 6 2mm b WARNING TO AVOID PERSONAL INJURY WEAR EYE PROTECTION DURING THE FOLLOWING PROCEDURE Assemble the direct clutch assembly on the oil pump as show...

Page 206: ...RE USE CARE TO PROTECT YOURSELF FROM THE FORCE OF THE PISTON KEEP FINGERS FROM BETWEEN THE WOOD BLOCK AND PISTON EYE PROTECTION SHOULD ALSO BE USED WHEN PERFORMING THIS PROCEDURE Place a wood block over the forward clutch drum Remove the forward clutch piston by applying a short burst of compressed air not to exceed 60 psi 400 kPa into the fluid hole of the pump housing with the direct clutch and ...

Page 207: ...es to soak in the specified transaxle fluid for a minimum of two hours Install the clutch plates starting with an external splined clutch plate then an internal splined clutch plate and alternating until all the clutch plates are installed Install the forward clutch pressure plate and the forward clutch snap ring 10 Check and adjust the forward clutch clearance as follows a Install the forward clu...

Page 208: ... flat blade screwdriver to remove the park gear spring from the park gear 8 74 11 WARNING TO AVOID PERSONAl INJURY WEAR EYE PROTECTION DURING THE FOllOWING PROCEDURE Item 4 5 6 Assemble the direct clutch drum and the forward clutch drum on the oil pump as shown Check the operation of the forward clutch piston by applying a short burst of air pressure not to exceed 400 kPa 60 psi to the opening in ...

Page 209: ...o the ring gear and make sure the snap ring is fully seated in the snap ring groove 4 Install the park gear onto the ring gear 5 Insert the two pins that secure the park gear to the ring gear 6 Install the park gear spring into the ring gear making sure that the ends of the clip are inserted into the holes of the pins Forward Clutch Hub Disassembly 1 Use a flat blade screwdriver to remove the forw...

Page 210: ...oded View Part Item Number Description 1 Governor Oil Screen Clamp 2 Governor Oil Screen 3 Governor valve Contmued 8 76 2 Remove the servo piston from the servo retainer by pulling straight out on the stem 3 Replace the seals and sealing rings 4 Refer to cleaning and inspection for band apply servo inspection Assembly 1 Install the servo piston into the servo retainer by pressing straight in on th...

Page 211: ...REQUIRED Bearing Cone Replacer Axle Bearing Seal Plate Disassembly Output Shaft Exploded View OUTPUT SHAFT 1 NOTE Label the output shaft bearings for proper installation Use an arbor press Bearing Pulling Attachment or equivalent and Step Plate Adapter or equivalent to remove both output shaft bearings 2 Refer to cleaning and inspection for output shaft and gear inspection Assembly 1 Prior to inst...

Page 212: ...Item Number Description 1 Idler Gear 2 Idler Gear Spacer 3 Bearing Race 4 Idler Gear Shaft Nut 5 Idler Gear Bearing Contmued 1 Insert the hex of Torque Adapter into the end of the idler gear shaft and place the assembly into a vise as shown 8 78 Item 6 7 8 9 10 Part Number Description Adjustment Shim Bearing Race Idler Gear Shaft Seal Idler Gear Shaft Idler Gear Bearing TORQUE ADAPTER ...

Page 213: ... idler gear IMPACT SLIDE INTERNAL PULLER 6 Press the remaining bearing race from the idler gear using Step Plate Adapter or equivalent as shown STEP PLATE ADAPTER 7 Inspect the bearing races for scoring If worn or damaged replace the bearing races and idler gear bearings as matched sets Assembly 1 Use a hydraulic press Driver Handle and the appropriate step plate adapter from Step Plate Adapter Se...

Page 214: ... inch 0 12mm 0 006 inch 0 14mm 0 007 inch 0 16mm 0 008 inch 0 20mm 0 020 inch 0 50mm 7 When the correct preload is reached position the idler shaft end in Torque Adapter and support both in a vise Tighten the idler gear shaft nut to 94 130 lb ft 128 177 N m ASSEMBlY Transaxle SPECIAl SERVICE TOOl S REQUIRED Description Tool Number Differential Seal Reolacer Driver Handle Bearing Cup Replacer Valve...

Page 215: ...cations DIMENSION DIMENSION C o OIMENSIO DIMENSION C A B THRUST BEARING WASHER LOCATION Dimension Component A B c D Thrust Bearin_g 1 65 in 41 9mm 1 85 in 46 9mm 2 08 in 52 9mm 2 75 in 69 9mm Thrust Washer 1 61 in 41 0mm 2 03 in 51 5mm 2 74 in 70 0mm 8 81 ...

Page 216: ... in the converter housing and drive into place with a bras_s hammer Install the six torque converter stator support bolts and tighten to 95 122 lb in 11 14 N m 8 82 Qf TORQUE CONVERTER STATOR SUPPORT VALVEBODY I GUIDE PINS 4 Use Driver Handle and the appropriate step plate from Step Plate Adapter Set or equivalent to press the outer race for the output shaft into the torque converter stator suppor...

Page 217: ... Planetary Gearset and Low Reverse Clutch Part Part Item Number Description Item Number Description 1 Drum Hub Assembly 4 Low One Way Clutch Inner 2 Needle Bearing Race 3 Thrust Washer 5 Rear Carrier Contmued 6 Retaining Ring Continued on next page 8 83 ...

Page 218: ...e case detent spring and detent ball Part Item Number Description 31 Manual Control Lever 32 Manual Control Lever Arm 33 Parking Pawl 34 Parking Pawl Return Spring 35 Parking Pawl Shaft 36 Low Reverse Clutch Dished Plate 37 Low Reverse Clutch External Spline Clutch Plate 38 Low Reverse Clutch Internal Spline Clutch Plate 39 3 Low Reverse Clutch Pressure Plate Retainer Snap Ring 40 Low and Reverse ...

Page 219: ...actuator support bolts and tighten to 106 142 Ib in 12 16 N m 10 Install the parking lever actuating rod and ferrule assembly PARKING LEVEF ACTUATING ROI AND FERRULE ASSEMBLY 0 11 Install the park actuator support to the ferrule on the parking fever actuating rod and install the circlips 12 Install a new manual control lever seal to the manual control lever 8 85 ...

Page 220: ...cleaning and inspection for low reverse clutch inspection Install new seals into the low reverse piston Lubricate the low reverse piston and seals with petroleum jelly and install the low reverse piston to its bore in the transaxle case 18 Place the return springs and low and reverse clutch hub on top of the low reverse piston Install Clutch Compressor and compress the assembly far enough to permi...

Page 221: ...e bushing against the one way clutch retaining plate Compress the clutch assembly enough to install the low reverse snap ring Install the low reverse snap ring BUSHING ONE WAY CLUTCH 23 Use a feeler gauge to measure the clearance between the one way clutch and the one way clutch retaining plate 24 If the clearance is not within specifications of 0 032 0 041 inch 0 8 1 05mm use a one way clutch ret...

Page 222: ...ollars on the converter housing as shown 8 88 29 Insert the output shaft outer bearing race into the recessed end of the shim selection gauge and place the shim selection over the output shaft Thread the two halves of the shim selection gauge together so that no clearance exists between the two halves as shown below 30 Use spacer collars and bolts shim selection gauge to assemble the converter hou...

Page 223: ...ELOAD 4 42 7 97 lb in 0 5 0 9 N m ASSEMBLED PRELOAD 0 26 7 96 lb in 0 03 0 9 N m OUTPUT SHAFT BEARING SELECTIVE SHIM CHART Part Number Thickness of Shim 0 0039 inch 0 1Omm 0 0047 inch 0 12mm 0 0055 inch 0 14mm 0 0063 inch 0 16mm 0 0071 inch 0 18mm 0 0197 inch 0 50mm Measure the clearance around the entire circumference and select output shaft bearing selective shims equivalent to the maximum clear...

Page 224: ...ng Ensure the alignment groove in the idler gear shaft lines up with the support ridges in the bearing housing 39 Install a new idler gear shaft roll pin 40 Install the bearing housing onto the transaxle case 8 90 BEARING HOUSING 41 Install the eight bearing housing bolts Tighten the bearing housing bolts to 14 19 lb ft 19 26 N m 42 Install the differential into the converter housing 43 Position t...

Page 225: ...ber of shims is three SHIM SELECTION GAUGE DIFFERENTIAL SHIM SIZE Part Number Thickness inch Thickness mm 0 0039 0 10 0 0047 0 12 0 0055 0 14 0 0059 0 15 0 0063 0 16 0 0079 0 20 0 0098 0 25 0 0118 0 30 0 0138 0 35 0 0157 0 40 0 0177 0 45 0 0197 0 50 0 0217 0 55 0 0236 0 60 0 0256 0 65 0 0276 0 70 0 0295 0 75 0 0315 0 80 0 0335 0 85 0 0354 0 90 48 Disassemble shim selection gauge Install the select...

Page 226: ...e a plastic or rubber mallet to install the governor outlet tube and governor inlet tube into the transaxle case 56 Install the governor with a new governor gasket so that the sleeve projection is aligned with the alignment mark on the transaxle case 57 Install the governor cover and tighten the governor cover bolts to 71 97 lb in 8 11 N m 58 Apply a 1 16 inch 1 5mm wide continuous bead of Gasket ...

Page 227: ...er ensure that all rotating parts rotate without resistance 63 Install the thrust bearing dimension D to the rear planet carrier as shown THRUST BEARING 64 Install the sun gear spacer over the small end of the sun gear and insert the sun gear into the sun shell SUN GEAR SUN GEAR SPACER SUN SHELL SUN SHELL THRUST WASHER 65 Place the sun shell thrust washer over the end of sun gear protruding from t...

Page 228: ...ching thrust washer with petroleum jelly Match the tangs on the thrust washer with the mating holes in the rear clutch assembly and install the thrust washer 73 Install the forward clutch assembly to th e front ring gear Gentle rotation of the forward clutch with side to side movement will align the clutch discs 74 Install the needle bearing in the forward clutch drum with the rollers up The compa...

Page 229: ...hinist straightedge over the pump cover in the transaxle case being careful not to place the straightedge on the bolt holes in the transaxle case e Use a feeler gauge to measure the clearance at either of two locations f 1 Between the straightedge and the pump cover if the pump cover is lower than the transaxle case 2 Between the gauge bar ends and the transaxle case if the pump cover is higher th...

Page 230: ...IL PUMP 78 Each time the transaxle is disassembled measure and adjust the direct clutch end play as follows a Use petroleum jelly to install the oil pump gasket to the oil pump b Install the plastic selective thrust washer to the pump cover Use petroleum jelly to keep it in place k PLASTlC SELECTIVE THRUST WASHER c Install the thrust washer onto the end of the pump cover Use petroleum jelly to kee...

Page 231: ...0 020 0 031 inch 0 5 0 Smm replace the plastic selective thrust washer on the pump cover with the appropriate washer from the chart PlASTIC SElECTIVE THRUST WASHER CHART Part Number Thickness Of Shim 0 075 inch 1 9mm 0 083 inch 2 1 mm 0 091 inch 2 3mm 0 098 inch 2 5mm 0 106 inch 2 7mm 0 059 inch 1 5mm 0 067 inch 1 7mm 0 051 inch 1 3mm h Reassemble the oil pump as previously outlined Install the oi...

Page 232: ... the specified transmission fluid and install it on the vacuum throttle valve diaphragm Install the vacuum throttle valve diaphragm into the transaxle case and tighten using pliers on the crimped portion of the vacuum throttle valve diaphragm 85 Lube a new throttle valve diaphragm gasket with the specified transmission fluid and install the throttle valve diaphragm gasket to the kickdown solenoid ...

Page 233: ...ator or equivalent to the threads of the Park Neutral Position Switch PNP switch 92 Install the PNP switch onto the transaxle case Tighten the PNP switch to 14 19 lb ft 19 26 N m 93 NOTE Install a new clip on the turbine shaft Install the turbine shaft and oil pump shaft 94 Lubricate the inside of the torque converter with no more than 0 5 quart 0 5L of the specified transmission fluid 95 Install ...

Page 234: ...ne bolts Tighten the transaxle to engine bolts to 27 38 lb ft 37 52 N m CASE REAR BRACKET TRANSAXLE TO ENGINE BOLTS 3 REQ D FRONT TRANSAXLE T j ENGINE SUPPORT TRANSAXLE TO ENGINE BOLTS 3 REQ D 9 Install the intake manifold support Tighten the intake manifold support bolts to 27 38 lb ft 37 52 N m 10 Install the case rear bracket and the three transaxle to engine bolts Tighten the transaxle to engi...

Page 235: ...saxle may result Install the manual control lever arm on the manual control lever and tighten the manual control lever nut to 33 47 lb ft 44 64 N m 27 Install coolant pipe retaining bracket located below the distributor 28 Connect the transaxle vacuum hose 29 Connect the transaxle electrical connectors 30 Connect the ground strap to the transaxle Tighten the ground strap bolt to 65 95 lb in 8 10 N...

Page 236: ...ty parts 1 Worn scored or heat damaged clutch plates If one clutch plate is to be replaced replace all the clutch plates 2 Broken or worn snap rings 3 Deformed clutch piston spring retainer 4 Weakened or damaged direct clutch piston spring Free length of the direct clutch piston spring should measure 1 031 inches 26 2mm If one or more springs is not in specification replace all of the springs 8 10...

Page 237: ...h plate is to be replaced replace all of the clutch plates 2 Broken or worn snap ring 3 Deformed clutch piston spring retainer 4 Weakened or damaged clutch piston return springs Free length of the return springs Item 7 8 9 10 11 Part Number Descri ltion Low and Reverse Clutch Hub Low Reverse Pressure Plate Retainer Snap Ring Low Reverse Clutch Dished Plate Low Reverse Clutch External Spline Clutch...

Page 238: ...r worn snap ring or park gear spring 2 Broken or worn gears or direct clutch piston spring Forward Clutch Hub Check for the following and replace any worn or damaged parts 1 Broken or worn snap ring 2 Damaged or worn ring gear or rear clutch hub Oil Pump Check for the following and replace any faulty parts 1 Damaged or worn inner or outer gear tooth surfaces 2 Seal rings 3 Damaged or worn inner ge...

Page 239: ...omponent removal clean the case with cleaning solvent or use a high pressure steam cleaner to remove any internal or external grease oil or dirt 2 Inspect all press fit bearing races for pitting scoring or other types of damage If any races must be replaced the mating bearing must be replaced as well 3 Check the threads of any threaded bolt holes All damaged threads must be repaired prior to reass...

Page 240: ...t the gear case for damage at the thrust areas where the gears ride Look for grooves pitting or scoring 3 Check the gear case for damage at the differential pinion shaft bore Ensure that it has not become oblong Check to see that the differential pinion shaft fits snugly in the bore without any lateral movement 4 Check the differential pinion shaft for grooves and ensure that the roll pin bore has...

Page 241: ...ameter of the boss bushing If it exceeds 2 0896 inches 53 075mm replace the torque converter When internal wear or damage has occurred in the transaxle contaminants such as metal particles clutch plate material or band material may have been carried into the torque converter and oil cooler These contaminants can be a major cause of recurring transaxle troubles and must be removed from the system b...

Page 242: ...hose from the cooler return line 5 Use compressed air to blow out the transmission oil cooler and hoses blow air into the cooler return hose until all solvent is removed 8 108 6 Remove the rubber hose from the remaining transmission cooler hose ADJUSTMENTS Throttle Control Valve Rod SPECIAL SERVICE TOOL S REQUIRED Vacuum Diaphragm Rod Gauge NOTE The throttle control valve rod is a selective compon...

Page 243: ...top out exactly three turns 3 Hold the band adjusting stop to prevent it from turning install and tighten the band adjusting stop nut to 41 59 lb ft 55 80 N m Kickdown Switch 1 Disconnect the kickdown switch electrical connector 2 Using a Digital Multimeter or equivalent measure the resistance between the two kickdown switch terminals as follows a With the accelerator pedal in the fully released p...

Page 244: ...er Max 0 031 inch 0 8mm Standard Backlash Differential Pinion Gears 0 0 004 inch 0 01 mm DIFFERENTIAl SHIM SIZE TORQUE SPECIFICATIONS Part Number Thickness Thickness mm Description lb Ft lb ln N m inch Transaxle Fluid Drain 29 40 39 54 0 0039 0 10 Plug 0 0047 0 12 Main Control Valve 71 97 8 11 0 0055 0 14 Body Bolts 0 0059 0 15 Transmission Oil Pan 43 69 5 8 0 0063 0 16 Bolts 0 0079 0 20 0 0098 0 ...

Page 245: ... Torque Converter to 26 36 34 49 Flywheel Nuts Engine Oil Pressure Transmission Housing 71 97 8 11 Gauge Cover Bolts Transaxle to Engine 27 38 37 52 Bolts Intake Manifold Support 27 38 37 52 Axle Bearing Seal Plate Bolts Front Transaxle Support 28 37 38 51 Insulator Bracket Bolts Bearing Cup Replacer Rear Engine Support 47 66 64 89 Rebound Insulator Bolts Front Transaxle Support 69 83 93 113 Insul...

Page 246: ...tial Rotator Support Housing Bearing Cup Replacer Description of Other Service Tools Step Plate Adapter Set Internal Puller Bearing Pulling Attachment Three Bar Engine Support Seal Remover Dial Indicator with Bracketry Hi Lift Jack Transmission Jack Pressure Test Fittings Vacuum Tester Torque Converter Leak Test Kit LOCK LEVER Torque Converter Oil Cooler Cleaner Digital Multimeter Oil Leak Detecto...

Page 247: ...350 y 350C y 350 y SWITCH 13480 350C y 52E BK Section 8 Automatic Traosaxle HOT IN START OR ON 160 BK1Y 160E BKIY INTERIOR FUSE JUNCTION PANEL 14A06B 160E BKI I 160J BKI I 8 113 ...

Page 248: ...8 114 Section 8 Automatic Transaxle TRANSMISSION CONTROL SELECTOR DIAL BEZEL 0 6mm 0 0241NCH ...

Page 249: ...Section 8 Automatic Transaxle TRANSMISSION SHIFT CABLE AND BRACKET LOCKNUT 8 115 ...

Page 250: ......

Page 251: ...y occur in four areas tires engine accessories suspension and driveline It is important therefore that an NVH problem be isolated into its specific area as soon as possible The easiest and quickest way to do this is to perform a road SUBJECT PAGE DIAGNOSTIC PROCEDURES Can t Know the History of the System 10 2 Know the System 10 2 Road Test 10 2 Neutralize Transaxle Mount and Exhaust System 10 4 Ne...

Page 252: ...ormal vibration can be caused by a component such as engine transaxle mount which is acting in a rigid manner because of a distorted or twisted mounting position As a result the mount does not absorb vibrations as it should Grounded or abnormally strained exhaust system and hangers will also lead to this condition The exhaust system must be neutralized while it is hot because the thermal expansion...

Page 253: ...akes Drivetrain Includes all power transmitting components from the engine to the wheels including transaxle and transaxle halfshafts Engine Run up Test Operation of engine through normal rpm range with vehicle sitting still transaxle in NEUTRAL Used for engine and accessory vibration check Engine Misfire One or more cylinders in the engine fail to fire at the proper time Engine Imbalance A percep...

Page 254: ...Operation of vehicle under conditions designed to recreate the problem condition Runout Out of round or wobble Shake Low frequency vibration usually results in visual movement of components Tire Force Vibration Tire vibration caused by variations in tire construction resulting in a vibration when the tire rotates against the pavement this condition may even present on perfectly round tires Two pla...

Page 255: ...1 3 Tensioner Spring 11 13 Valve Train Analysis Dynamic 11 12 Valve Train Analysis Static Engine Off 11 11 Camshaft Overhead Camshaft Engines 11 12 Hydraulic Lash Adjusters HLA Overhead Camshaft 11 12 SUBJECT PAGE Rocker Arm 11 11 Troubleshooting Chart HLA 11 12 Valve Cover Removed 11 11 Valve Spring Retainer and Valve Spring Retainer Keys 11 12 Valve Springs 11 12 Valves and Cylinder Head 11 1 2 ...

Page 256: ...ID THE POSSIBILITY OF PERSONAL INJURY OR DAMAGE TO THE VEHICLE DO NOT OPERATE THE ENGINE WITH THE HOOD OPEN UNTIL THE FAN HAS FIRST BEEN EXAMINED FOR POSSIBLE CRACKS AND SEPARATION Engine Identification The U S Motor Vehicle Theft Law Enforcement Act of 1984 requires identification of certain high theft vehicles to reduce the National Auto Theft Rate This federal law requires Westward Industries L...

Page 257: ... damaged INSPECT head gasket Hydraulic lash adjuster INSPECT hydraulic lash malfunctioning adjuster Burnt valve INSPECT valve Improper valve to valve seat INSPECT valve and or contact valve seat Restricted exhaust system REFER to Section 9 Excessive or Insufficient Carbon accumulation in INSPECT for carbon combustion Combustion chamber buildup Valve spring weak or broken INSPECT valve spring Valve...

Page 258: ...nnecting rod damage bearing Excessive crankshaft end play INSPECT crankshaft end play Crankshaft main bearing seized INSPECT crankshaft main or heat damage bearing Cooling system malfunctioning REFER to Section 15 i e water pump vibration of radiator etc Fuel system malfunctioning REFER to Section 13 Loose torque converter nuts REFER to Section 8 Loose flywheel to crankshaft REFER to Section 11 bo...

Page 259: ...op the engine and inspect all seal and gasket areas for leaks using Oil Leak Detector A clear bright yellow or orange area will identify the leak For extremely small leaks several hours of running the engine may be required for the leak to appear 4 Service all leaks as required Pressure Method Use a Pressurization Kit to test for engine oil leakage Testing Procedure 1 Plug all crankcase openings e...

Page 260: ...require at least four or five compression strokes Record the highest reading Test Results Repeat steps 5 7 above for each cylinder and compare the readings with the following specifications Compression should be 204 psi 141 2 kPa with a minimum of 149 psi 1030 kPa Remember that the engine must be at normal operating temperature and the throttle valve must be fully open Compression Readings Interpr...

Page 261: ...leakage detector is inserted in the spark plug hole the piston is brought up to top dead center on the compression stroke and compressed air is admitted through the leakage detector Once the combustion chamber is pressurized a special gauge will read the percentage of leakage Leakage exceeding 20 percent is considered excessive While the air pressure is retained in the cylinder listen for the hiss...

Page 262: ...ESSURE TESTER The following are potential gauge readings Some should be considered as normal others should be investigated further 11 8 09 0 I 2 l 4 0 0 1 2 s 7 S ffi 10 1l 12 800 u IS NORMAL READING Needle greater than 17 7 inches 60 kPa and holding steady NORMAL READING DURING RAPID ACCELERATION AND DECELERATION When the engine is rapidly accelerated dotted needle the needle will drop to a low n...

Page 263: ...ted search out and correct the condition Excess air leaking into the system will upset the fuel mixture and cause conditions such as rough idle missing on acceleration or burned valves If the leak exists in an accessory unit the unit will not function correctly ALWAYS FIX VACUUM LEAKS Engine Oil Consumption Excessive NOTE Use the following information to assist in explaining normal oil consumption...

Page 264: ...ed driving towing high ambient temperature etc may result in greater oil usage 2 Verify engine has no external oil leak Refer to Engine Oil Leaks in this section 3 Verify engine has correct oil level dipstick 11 10 4 Verify that the engine is NOT being run in an overfilled condition Check the oil level at least 5 minutes after a hot shutdown with the vehicle parked on a level surface In no case sh...

Page 265: ...cle and place it on an engine work stand Remove the intake manifolds cylinder heads oil pan and oil pump Refer to Section 11 01 for the removal and installation procedures b Check the piston ring clearance ring gap and ring orientation Service as required c Check for excessive main bearing clearance Service as required 11 Repeat the test to verify the concern has been repaired Oil Pressure Test Se...

Page 266: ... rocker arms so that the valve tips and rocker arms are well oiled If insufficient oiling is still suspected check engine oil level check oil passages for blockage and check for proper engine oil pressure TROUBLESHOOTING CHART HYDRAULIC LASH ADJUSTER HLA CONDITION POSSIBLE SOURCE ACTION Tappet Noise When Engine is First Insufficient oil in system RUN engine at 2000 3000 rpm Started After Oil is Ch...

Page 267: ...r extended service while the engine is disassembled Cylinder Block Cleaning and Inspection The cylinder block may be cleaned by immersing it in a cleaning vat using a commercial cleaning solution The cylinder block may also be cleaned with automotive parts cleaning solvents and brushes or by steam cleaning Be sure to clean all oil passages and remove all gasket material cements and sealers from th...

Page 268: ...pward 11 14 from the oil pan rail to the cylinder water jacket and the lower rear face of the cylinder block NOTE Openings larger than 1 4 inch 6 35mm should not be serviced using metallic plastic Openings in excess of 1 4 inch 6 35mm can be drilled tapped and plugged using common tools The following procedure should be used to service porous areas or sand holes in cast iron smaller than 1 4 inch ...

Page 269: ...tions with an oil stone Cylinder Bore Taper Measure the cylinder bore diameter at points A and C as shown 1 I I I I I I I CYUNDER BORE TAPER r A I I I I I I I I c I CYUNDER WALLS CAUTION The boring size should be based on the size of an oversized piston If the difference between measurements A and C exceeds the maximum taper value of 0 0006 inch 0 015mm rebore the cylinder to oversize Cylinder Out...

Page 270: ...surement To finish the procedure you will need to incrementally increase the diameter of the non flexible hone until a uniform diameter is obtained at the cylinder walls When the cylinder is sized and prepared for the piston wash it thoroughly with detergent and hot water until a light colored lint free cloth wiped through the bore comes out clean Then apply engine oil to the cylinder walls 11 16 ...

Page 271: ... be installed using a tool that contacts the crowned portion of the engine block plug This method will expand the engine block plug prior to installation and may damage the engine block plug and or machined bore When installed the maximum diameter must be set in the tapered edge of the bore to effectively seal the plugged bore If the engine block plug replacing tool has a depth seating surface do ...

Page 272: ...ropriate main bearing cap 6 Install the main bearing cap and tighten the main bearing cap bolts to 40 43 lb ft 54 59 N m in the order shown 11 18 7 Remove the main bearing cap and measure the crankshaft main bearing to journal clearance The clearance should be 0 0007 0 0014 inch 0 018 0 036mm The limit is 0 0039 inch 0 1 Omm If the clearance is over the limit grind the crankshaft and install overs...

Page 273: ...rk the crankshaft at its high or low reading position Then support the crankshaft on the center and on one end journal Repeat the above procedure taking the reading on the unsupported end journal Record this reading Repeat the last set up on the opposite end journal Study the above readings and marks to know if where and how much the crankshaft is bent Most automotive machine shops are equipped to...

Page 274: ...ch 0 05 mm Journals Refinishing Crankshaft grinding is necessary to straighten and restore journals to a round condition Crankshaft grinding should be done only by experienced professionals CAUTION Failure to maintain the original fillet radius at the line where the journal meets the counterweight of the crankshaft can result in crankshaft damage FILLET RADIUS m I CRACK AT CRANKSHAFT JOURNAL The g...

Page 275: ...emature ignition A shiny thrust surface offset from the centerline between the piston pin holes can be caused by a bent connecting rod Replace pistons showing signs of excessive wear irregular or fractured ring lands or damage from detonation and premature ignition Inspect the outer circumferences of all pistons for seizure or scoring Replace the piston if necessary Pistons Fitting Service Tool De...

Page 276: ...n and insert it between the piston and Piston Pin Remover Replacer Use an arbor press and press the piston pin into the piston If the press pressure is lower than specifications replace the piston pin or connecting rod Piston to Cylinder Clearance The piston to cylinder wall clearance limit is 0 006 inch 0 15mm Oversize pistons and piston rings are available in 0 10 inch 0 25mm and 0 020 inch 0 50...

Page 277: ...piston ring to the bottom of the piston ring travel area Use a feeler gauge to measure the ring opening clearance end gap PISTON l l RING I I I I I The minimum and maximum limits are as follows Top Ring 0 006 0 012 inch 0 15 0 30 mm Second Ring 0 006 0 12 inch 0 15 0 30 mm Oil Ring 0 08 0 028 inch 0 20 0 70mm The oil ring clearance maximum limit is 0 039 inch 1 0 mm Piston and Piston Pin Fit The p...

Page 278: ...eter 00 and the connecting rod inner diameter 10 Cleaning Connecting rods may be cleaned in hot or cold commercial tank type cleaners They may also be cleaned with automotive parts cleaning solvents or steam cleaned Inspection The connecting rod and related parts should be carefully inspected for conformance to specifications Various forms of engine wear caused by these parts can be readily identi...

Page 279: ... bore Assemble the piston piston pin and connecting rod following the procedures outlined Connecting Rod Bending Clearance The connecting rods should be inspected for proper piston pin bore diameter crankshaft bearing bore diameter length bend and twist Use a bending fixture and a feeler gauge to inspect the connecting rod bending clearance The bend limit is 0 0016 inch 0 04mm per 3 94 inches 100m...

Page 280: ...4135 inches 5 904 mm Camshaft Journal Oil Clearance 1 Measure the camshaft bores in the cylinder head 11 26 2 The front and rear camshaft bore diameter should be 1 7124 1 7135 inch 43 495 43 525 mm The center camshaft bore diameter should be 1 7126 1 7135 inch 43 500 43 525 mm Measure the journal diameters Refer to the procedure in this section 3 Subtract the camshaft bearing journal outer diamete...

Page 281: ... end play exceeds the limit replace the camshaft thrust plate or the camshaft Camshaft Sprocket Inspect the camshaft sprocket for warping or abnormal wear Inspect the sprocket teeth for wear deformation chipping or other damage If necessary replace the sprocket Refer to Section 11 01 for the removal and installation procedure Hydraulic Lash Adjusters Cleaning Thoroughly clean all the parts in clea...

Page 282: ...the relief valve and check for scores burrs or sticking Repair as necessary Outer Rotor Side Clearance Use a feeler gauge and Straight Edge to measure the outer rotor side clearance STRAIGHT EDGE The limit is 0 0055 inch 0 14 mm If the above clearance is out of limits replace the gears or body Clean the relief valve and check for scores burrs or sticking Repair as necessary Oil Pan Cleaning Scrape...

Page 283: ...n the intake and exhaust ports with a small wire wheel and a drill motor Be careful not to allow the drill chuck to contact the valve seats Remove all gasket material from the valve cover gasket surface head gasket surface the exhaust and intake manifold surfaces and the water outlet connection surface Use a valve guide cleaning tool and a small bristle brush to clean the valve guide bores Clean t...

Page 284: ...e cylinder these chips can damage the cylinder wall when the engine is started Thoroughly clean the spark plug counterbore seat and threads of all dirt or other foreign material 2 Start the tap into the spark plug hole being careful to keep it properly aligned As the tap begins cutting the new threads apply aluminum cutting oil to the tap 11 30 Continue cutting threads and applying oil until the s...

Page 285: ... dial indicator shaft Divide the measurement by two to determine the actual guide clearance The intake clearance is 0 0010 0 0024 inches 0 025 0 060 mm The exhaust clearance is 0 0012 0 0026 inches 0 030 0 065 mm The maximum stem to valve guide clearance is 0 008 inch 0 20 mm If the clearance exceeds specification replace the valve and or valve guide Valve Seats Refacing Cylinder head valve seats ...

Page 286: ... or bent stems a rough or damaged face and damaged or unevenly worn stem tips Valves Refacing If necessary reface the valves to a 45 degree angle following the valve grinding equipment manufacturer s recommendations Remove as much stock from the end of the valve stem as the total removed from the seat and valve face Bevel the edge of the valve stem end after grinding the end of the stem 11 32 Valv...

Page 287: ...meters The intake valve stems are 0 27244 0 2750 inch 6 970 6 985mm and the exhaust stems are 0 2742 0 2748 inch 6 965 6 980 mm If the clearance is greater than specified replace the valve or valve guide or both depending on the dimension that is causing the excess clearance Valve Head Margin Thickness Inspect the valve head margin thickness of each valve STEM TIP The exhaust valve head margin thi...

Page 288: ...make them unfit for further service Replace all studs that are stripped or otherwise damaged Clean the Exhaust Gas Recirculation EGR exhaust passages Check the intake manifold for flatness Place a straightedge across the manifold Use a feeler gauge between the straightedge and the intake manifold to measure the flatness Exhaust Manifold Cleaning Remove all gasket or foreign material from all outle...

Page 289: ...ting rod journal Diameter 1 5724 to 1 5731 inch 39 940 to 39 956 mm Out of round limit 0 0020 inch 0 05mm Crankshaft to journal 0 0007 to 0 0014 inch clearance 0 018 to 0 036mm Limit 0 0039 inch 0 1 Omm Crankshaft free End play limit 0 0031 to 0 0111 inch 0 08 to 0 282 inch Service limit 0 012 inch 0 30mm TORQUE SPECIFICATIONS Description Lb ft Main Bearing Cap Bolts 3 40 43 Connecting Rod Nuts 11...

Page 290: ...e intake air flows through the throttle body into the intake manifold To enhance 11 36 SUBJECT PAGE Oil Level Indicator Tube 11 72 Oil Pan 11 61 Oil Pump 11 63 Oil Pump Screen Cover and Tube 11 61 Pilot Bearings 11 70 Pistons and Connecting Rods 11 65 Rocker Arms and Rocker Arm Shafts 11 42 Sensors 11 72 Timing Chain Belt 11 48 Timing Sprockets 11 49 Timing Chain Belt Tensioner 11 51 Valve Cover a...

Page 291: ...ion supply manifold is returned by the fuel pressure regulator to the fuel tank through the fuel tube hose Crankshaft The crankshaft is positioned on the bottom of the cylinder block The crankshaft is supported by five two bolt main bearing caps the crankshaft main bearings and the crankshaft thrust bearings The crankshaft thrust bearings are located with the No 4 crankshaft main bearings The cran...

Page 292: ...cylinder block Engine oil is pulled up from the oil pan through the oil pump screen cover and tube and delivered to the oil pump where it is 11 38 Section 11 Engine then circulated through the other various engine components Engine Cooling System Engine cooling is provided by a water pump mounted on the front end of the cylinder block A water thermostat controls coolant temperature and is located ...

Page 293: ...010 Water Pump Pulley 2 613493 Drive Belt Idler Pulley A C Compressor Belt If Equipped 3 613893 Drive Belt A C Compressor 4 A C Clutch Pulley for A C Compressor if Equipped BLADE WILL ALSO OPERATE IF THE ENGINE COOLANT TEMPERATURE ECT SENSOR IS DISCONNECTED Drive Belt System The alternator is driven by a drive belt that also drives the water pump If the vehicle is equipped with air conditioning th...

Page 294: ...Internal Component Location Part Item Number Description 1 Camshaft Sprocket 2 Rocker Arm Shaft 3 Hydraulic Lash Adjuster 4 Rocker Arm 6 Camshaft 7 Oil Pump Screen Cover and Tube 11 40 Item 8 9 10 11 12 13 14 Part Number Description Oil Pump 114000 Connecting Rod Crankshaft Sprocket Timing Chain Belt Piston Exhaust Valve Valve Spring ...

Page 295: ...six valve cover bolts to 44 80 lb in 5 9 N m 4 Install the upper engine front cover Refer to the installation procedure in this section 5 Install the distributor to spark plug wires into the spark plug wire separators 6 Install the oil separator hose onto the valve cover 7 Install the PCV valve into the valve cover 8 Install the accelerator cable 9 Install the air cleaner to intake manifold 7 Remo...

Page 296: ...val 1 Remove the valve cover Refer to the removal procedure in this section Section 11 Engine 2 Remove the 10 rocker arm bolts and rocker arm seats in the sequence shown 3 Remove the rocker arm and shaft assemblies 11 42 ROCKER ARM SEATS 10 ...

Page 297: ...rrangement for the rocker arm shaft assemblies See the illustration NUMBER 1 CYLINDER I I NUMBER1 CYLINDER b A l I EXHAUST 2 Install the 10 rocker arm bolts and rocker arm seats Tighten the rocker arm bolts to 16 21 lb ft 22 28 N m in the sequence shown Hydraulic lash Adjuster Removal 1 Remove the valve cover Refer to the removal procedure in this section 2 Remove the rocker arm shaft assemblies R...

Page 298: ...hold the valve shut the valve is damaged or burnt and the cylinder head must be removed and serviced SERVICE TOOL S REQUIRED Valve Seal Replacer Valve Spring Compressor Valve Spring Compressor Set Removal 1 Remove the valve cover Refer to the removal procedure in this section 2 Remove the rocker arm shafts Refer to the removal procedure in this section 11 44 3 NOTE The appropriate piston must be a...

Page 299: ...retainers 3 Use Valve Spring Compressor and Valve Spring Compressor Set to compress the valve spring and install the valve spring retainer key 4 Turn off the compressed air Remove the air line and adapter 5 Repeat steps 1 through 3 as required 6 Install the rocker arm shafts Refer to the installation procedure in this section 7 Install the valve cover Refer to the installation procedure in this se...

Page 300: ...nd the inner crankshaft pulley 11 46 Installation To install reverse the removal procedure Tighten the four crankshaft pulley retaining washer bolts to 109 152 lb in 12 17 N m Crankshaft Front Oil Seal SERVICE TOOL S REQUIRED Front Seal Replacer Seal Remover Removal 1 Remove the timing chain belt Refer to the removal procedure in this section 2 Remove the crankshaft sprocket 3 Using Seal Remover r...

Page 301: ...ion procedure in this section Engine Front Covers Removal 1 Remove the accessory drive belts Refer to this section for the removal and installation NKSHAFT procedure 4 Install the crankshaft pulley hub 5 NOTE Before installing the crankshaft pulley bolt coat the bolt threads with Black Silicone Rubber or equivalent 2 Remove the three water pump pulley retaining bolts and the water pump pulley 3 Re...

Page 302: ...e wheel and tire assembly Refer to the removal procedure in Section 3 2 Remove the timing chain belt tensioner spring spring cover and timing belt tensioner bolt 11 48 TIMING BELl TENSIONER SPRING f J TIMING CHAIN TENSIONER I SPRING COVER 3 Mark the direction of rotation on the timing chain belt 4 Remove the timing chain belt Installation 1 Align the camshaft sprocket and crankshaft sprocket with ...

Page 303: ...ER 4 Position the timing chain tensioner and timing belt tensioner spring assembly on the engine and install the timing belt tensioner bolt Do not tighten the timing belt tensioner bolt 5 Install the timing chain belt tensioner spring on the anchor 6 Rotate the crankshaft two turns in the direction of normal rotation and align the timing marks Ensure all marks are still correctly aligned 7 Tighten...

Page 304: ...sprocket bolt to 36 45 lb ft 49 61 N m Crankshaft Removal The following illustration is an exploded view of the crankshaft sprocket 11 50 Part Item Number Description 1 104014 Cylinder Block 2 114004 Crankshaft Sprocket 3 114003 Crankshaft Key 4 Crankshaft Pulley Hub 5 114008 Crankshaft Pulley Bolt A Tighten to 80 85 lb ft 108 118 N m 1 Remove the timing chain belt Refer to the removal procedure i...

Page 305: ...and install the timing chain belt tensioner spring on the timing chain belt tensioner 2 Position the timing chain belt tensioner and the timing chain belt tensioner spring assembly on the engine Install the timing belt tensioner bolt 3 Install the timing chain belt tensioner spring on its anchor 4 Rotate the crankshaft clockwise and align the timing marks Ensure that all timing marks are still cor...

Page 306: ...ssemblies 8 Remove the camshaft thrust plate bolt Remove the camshaft thrust plate 9 Gently pull the camshaft out of the LH side of the cylinder head 11 52 Installation ROCKER ARM SEATS 10 CYUNDER HEAD 1 Clean the camshaft and cylinder head surface ...

Page 307: ...equence shown TORQUE SEQUENCE 6 Install the distributor Refer to Section 12 for the installation procedure 9 Install the timing chain belt Refer to the installation procedure in this section 10 Adjust the camshaft timing Refer to the adjustment procedure in this section 11 Install the battery Refer to Section 17 for the installation procedure Camshaft Front Seal SPECIAL SERVICE TOOL S REQUIRED Dus...

Page 308: ... seal using Dust Boot Replacer 11 54 3 Install the distributor Refer to Section 12 for the installation procedure 4 Install the camshaft sprocket Refer to the installation procedure in this section 5 Install the valve cover Refer to the installation procedure in this section 6 Install the timing chain belt Refer to the installation procedure in this section 7 Connect the battery ground cable ...

Page 309: ...ction 11 1 for the draining procedure 3 Remove the distributor to spark plug wires and spark plugs Refer to Section 12 for the removal procedure Item 7 8 9 A B 4 5 6 Part Number Description 153347 Upper Radiator Hose 104038 Head Gasket 104028 Cylinder Head Bolts 1 0 Req d Tighten to 14 22 lb ft 19 30 N m Tighten to 56 60 lb ft 75 81 N m Remove the distributor Refer to Section 12 for the removal pr...

Page 310: ...nder head bolts to 56 60 lb ft 75 81 N m 11 56 4 Install the water bypass tube or hose and bracket 5 Install the upper radiator hose 6 Install the wiring harness connectors 7 Install the front and rear engine lift hangers and the engine ground wire 8 Install the distributor Refer to Section 12 for the installation procedure 9 Install the intake manifold Refer to the installation procedure in this ...

Page 311: ...ck 2 Coat a new water pump housing gasket and water pump inlet gasket with Perfect Seal Sealing Compound or equivalent 3 Position the water pump housing gasket on the cylinder block and the water pump inlet gasket on the water pump inlet connector 4 Carefully position the water pump on the cylinder block using care to align the bolt holes and not to shift the position of the water pump housing gas...

Page 312: ...ses to the upper intake manifold 5 Connect the vacuum hoses and wiring as tagged during removal 11 58 6 Install the air cleaner to intake manifold tube 7 Connect the accelerator cable to the throttle control lever 8 Install the intake manifold support bolts Tighten the intake manifold support bolts to 22 34 lb ft 31 46 N m 9 Fill the cooling system Refer to Section 15 for the filling procedure 10 ...

Page 313: ... as tagged during removal 5 Connect the coolant hoses to the intake manifold 6 Install the air cleaner to intake manifold tube Refer to this section for the installation procedure 7 Connect the accelerator cable to the throttle control lever 8 Install the intake manifold support and intake manifold support bolts Tighten the intake manifold support bolts to 22 34 lb ft 31 46 N m 9 Fill the cooling ...

Page 314: ...ust manifold is in position 5 6 7 Use Oxygen Sensor 02S Wrench EGO Sensor Wrench to install the Oxygen Sensor 02S Position the exhaust manifold shield and install the exhaust manifold shield bolts Tighten the exhaust manifold shield bolts to 12 171b ft 12 17 lb ft Connect the 02S electrical connector and install the connector in the routing bracket Install the air cleaner to intake manifold tube 8...

Page 315: ...n 5 Install the oil pan drain plug Tighten the oil pan drain plug to 22 30 lb ft 29 41 N m 6 Add specified type and amount of engine oil Refer to the procedure in this section 7 Install the exhaust inlet pipe Refer to Section 14 for the installation procedure 8 Connect the battery ground cable Oil Pump Screen Cover and Tube Removal 1 Disconnect the battery ground cable 2 Drain the engine oil 3 Rem...

Page 316: ...e oil pump 4 Install the oil pump screen cover and tube 5 Install the two oil pump screen cover and tube bolts Tighten the two oil pump screen cover and tube bolts to 71 97 lb in 8 11 N m 11 62 6 Apply oil resistant sealer across the joint line of the cylinder block and the oil pump and the crankshaft rear oil seal retainer SEALER LOCATIONS 7 Install the oil pan gasket and oil pan 8 Tighten the oi...

Page 317: ...Number Description 6 Oil Pump Bolt 6 Req d 7 104020 Oil Level Dipstick 8 104017 Oil Level Indicator Tube A Tighten to 71 97 lb in 8 11 N m B Tighten to 14 19 lb ft 19 25 N m 1 Remove the crankshaft sprocket Refer to the removal procedure in this section 2 Remove the oil pan Refer to the removal procedure in this section 3 Remove the six oil pump bolts 4 5 OIL PUMP Remove the oil pump and oil pump ...

Page 318: ...o crankshaft main bearing caps tight while servicing the others Remove the crankshaft main bearing cap bolts CRANKSHAFT MAIN BEARING CAP BOLTS CRANKSHAFT MAIN BEARING CAP 3 Remove the crankshaft main bearing caps and the lower crankshaft main bearings 11 64 CRANKSHAFT MAIN BEARING CAP 4 CAUTION Always turn the crankshaft clockwise The timing chain belt is designed to turn in its original direction...

Page 319: ...each crankshaft main bearing cap bolt is tightened be sure that the crankshaft can be rotated clockwise by hand If not remove that crankshaft main bearing cap and investigate for the source of interference Tighten all crankshaft main bearing cap bolts and check again for proper crankshaft rotation 6 Install the oil pan Refer to the installation procedure in this section Pistons and Connecting Rods...

Page 320: ...ing rod studs 11 66 8 Use a hammer handle or piece of wood to tap the connecting rod and piston upward until the piston rings clear the top of the cylinder block 9 NOTE If removing more that one piston and connecting rod mark each with the applicable cylinder number to aid in installation Remove the connecting rod and piston assembly from the top of the cylinder bore PISTON AND CONNECllNG ROD RUBB...

Page 321: ...the engine Start the connecting rod piston assembly into the cylinder bore keeping the F mark on the piston toward the front of the engine Be sure the connecting rod number and the cylinder bore number match 5 Use a hammer handle or piece of wood to tap the piston rod assembly into the cylinder bore Guide the connecting rod studs over the crankshaft journal Remove the rubber hose from the connecti...

Page 322: ...inch 0 30mm 11 Install the oil pan Refer to the installation procedure in this section 12 Install the cylinder head Refer to the installation procedure in this section Connecting Rod Bearings Removal 1 Remove the oil pan Refer to the removal procedure in this section 2 Turn the crankshaft clockwise until the connecting rod and the piston assembly to be removed are at Bottom Dead Center BDC 3 Remov...

Page 323: ...ecting rod nuts Tighten the connecting rod nuts to 11 13 lb ft 15 1 7 N m Tighten the connecting rod nuts a second time to 22025 lb ft 29 34 N m 6 Check the connecting rod side clearance The clearance is 0 0043 0 0103 inch 0 11 0 0 262mm with a limit of 0 012 inch 0 30mm 7 Install the oil pan Refer to the installation procedure in this section Flywheel Service Tool s Required Flywheel Holding Tool...

Page 324: ... this section 2 Remove the flywheel reinforcing plate bolt and the flywheel reinforcing plate 3 Remove the crankshaft rear oil seal using Seal Remover 11 70 Crankshaft Rear Cover and Oil Seal SPECIAl SERVICE TOOl S REQUIRED Seal Remover Seat Replacer Removal 1 Remove the flywheel Refer to the removal procedure in this section 2 Remove the flywheel reinforcing plate bolt and the flywheel reinforcin...

Page 325: ...L WASHERS FLYWHEEL ATTACHING BOLT Section 11 Engine 4 Install the flywheel reinforcing plate Tighten the flywheel reinforcing plate bolt to 71 97 lb in 8 11 N m 5 Install the flywheel Refer to the installation procedure in this section 11 71 ...

Page 326: ...evel dipstick 2 Remove the oil level indicator tube bracket bolt and then pull the oil level indicator tube from the engine Discard the 0 ring Installation 1 Install a new 0 ring then install the oil level indicator tube 2 Install the oil level indicator tube bolt 3 Install the oil level dipstick Sensors Oil Pressure Sensor Removal The oil pressure sensor is located on the rear of the engine near ...

Page 327: ...ts Pull the rear the removal procedure suspension lower arms downward separating the rear suspension lower arms 6 Disconnect the accelerator cable from the from the rear wheel knuckles throttle body Remove the two accelerator shaft bracket bolts from the valve cover 23 Remove the RH rear wheel driveshaft and Remove the accelerator cable bracket joint and LH rear wheel driveshaft and joint and inst...

Page 328: ...r and install engine and transaxle assembly into vehicle 7 Install the engine support insulator through bolt and nut into the engine support insulator Tighten the engine support insulator through bolt to 39 47 lb ft 53 64 N m 8 Remove the lifting cables from the engine lifting eyes 9 Connect the vacuum lines to the intake manifold vacuum outlet fitting and cap and the evaporative emission canister...

Page 329: ...onnect the shift cable and bracket from the transaxle Refer to Section 8 for the Crankshaft installation procedure Removal 27 Connect the PNP switch kickdown solenoid 1 Remove the engine Refer to the removal electrical connector and transaxle ground procedure in this section 28 Connect all engine harness electrical 2 Remove the cylinder head Refer to the connectors and grounds removal procedure in...

Page 330: ...not remove that bearing cap and determine the source of interference Be sure the crankshaft main bearings are in their proper position Install the crankshaft main bearing caps Tighten the crankshaft main bearing cap bolts to 40 43 lb ft 54 59 N m in the order shown 4 Measure the crankshaft bearing to journal clearance Refer to Section 11 for the procedure 5 NOTE The end play is adjustable through ...

Page 331: ... section 2 Use Oil Filter Wrench to remove the oil filter 3 Remove the adjustment bolt and the alternator bolt t GENERA BOLT ITOR GENERATOR 4 Remove the alternator 5 Use Strap Wrench or equivalent to remove the three water pump pulley bolts 6 Remove the water pump pulley 7 Remove the four crankshaft pulley retaining washer bolts and the crankshaft pulley retaining washer CRANKSHAFT PUu EY RETAININ...

Page 332: ... cover and the timing belt tensioner bolt 12 Mark the direction of the rotation on the timing chain belt 11 78 13 Remove the timing chain belt 14 Remove the four water pump bolts and remove the water pump and water pump inlet connector 15 Remove the water pump housing gasket ...

Page 333: ...e the six 6 valve cover bolts ENGINE FRONT COVER VALVE COVER BOLTS 6 REO D IGNITION WIRE SEPARATOR 17 Remove the valve cover and valve cover gasket 18 Remove the crankshaft pulley bolt 19 Remove the crankshaft sprocket crankshaft pulley hub and crankshaft key Part Item Number Description 1 104014 Cylinder Block 2 114004 Crankshaft Sprocket 3 114003 Crankshaft Key 4 Timing Chain Belt Guide 5 114008...

Page 334: ...lts and three exhaust manifold nuts EXHAUST MANIFOLD BOLTS 4 25 Remove the exhaust manifold and exhaust manifold gasket 26 Remove the cylinder head bolts 27 Remove the cylinder head and head gasket 28 Remove the oil pressure sensor 11 80 29 Remove the three engine support insulator mounting bracket bolts and the engine support insulator mounting bracket 30 Remove the oil pan bolts and nuts 31 Remo...

Page 335: ...7 lb in 8 11 N m B Tighten to 14 1 9 lb ft 19 25 N m 34 NOTE Repeat the following five steps for each of the connecting rod and piston assemblies Mark each connecting rod and piston assembly with its applicable cylinder number to aid in installation Remove the connecting rod nuts 35 Remove the connecting rod caps and the lower connecting rod bearings 36 To prevent scratching of the crank shaft jou...

Page 336: ... MAIN BEARING PISTON AND CDNNEC IlNG ROD RUBBER HOSE 39 Remove the 10 ten crankshaft main bearing cap bolts 40 Remove the crankshaft main bearing caps and the lower crankshaft main bearings 41 CAUTION Use care not to damage the bearing journals while removing the crankshaft Remove the crankshaft from the cylinder block 42 Remove the upper crankshaft main bearings from the cylinder block ...

Page 337: ...the crankshaft Install the crankshaft into the cylinder block 3 Install the lower crankshaft main bearings and the crankshaft main bearing caps 4 Measure the crankshaft main bearing to crankshaft journal clearance with Plastigage or equivalent Refer to this section for the procedure 5 Tighten the crankshaft main bearing cap bolts to 40 43 lb ft 54 59 N m in the order shown 6 NOTE The end play is a...

Page 338: ...rt the connecting rod bearing into the connecting rod cap 13 Measure the connecting rod bearing to crankshaft journal clearance with Plastigage or equivalent Refer to this section for the procedure 14 CAUTION Ensure that the number on the connecting rod and the connecting rod cap are on the same side and that they match Install the connecting rod cap 15 Install the connecting rod nuts Tighten the ...

Page 339: ... pump bolts Tighten the oil pump bolts to 14 19 lb ft 19 25 N m OIL PUMP 21 Apply oil resistant sealer across the joint line of the cylinder block and the oil pump and crankshaft rear oil seal retainer SEALER LOCATIONS 22 Install the oil pan and oil pan gasket 23 Install the oil pan bolts and nuts Tighten the oil pan bolts and nuts to 69 78 lb in 8 9 N m 24 Install the engine support insulator mou...

Page 340: ...fold and the seven exhaust manifold bolts and nuts Tighten the exhaust manifold bolts and nuts to 12 17 lb ft 16 23 N m 30 Position the exhaust manifold shield and install the exhaust manifold shield bolts Tighten the exhaust manifold shield bolts to 12 17 lb ft 16 23 N m 31 Clean all traces of intake manifold gasket material from the intake manifold and the cylinder head 32 Position the intake ma...

Page 341: ...g surface and install a new valve cover gasket as shown VALVE COVER GASKET 38 Install the valve cover 39 Install the six 6 valve cover bolts Tighten the six 6 valve cover bolts to 44 80 lb in 5 9 N m 40 Clean the gasket surfaces of the water pump and the cylinder block Coat a new water pump housing gasket with Perfect Seal Sealing Compound or equivalent 41 Position the water pump and water pump ho...

Page 342: ...Tighten the timing belt tensioner bolt to 14 191b ft 19 26 N m 50 Install the lower engine front cover and two lower engine front cover bolts Tighten the lower engine front cover bolts to 71 97 lb in 8 11 N m 11 88 51 Install the upper engine front cover and four upper engine front cover bolts Tighten the upper engine front cover bolts to 71 97 lb in 8 11 N m 52 Install the inner crankshaft pulley...

Page 343: ...1 Remove the cylinder head Refer to the removal procedure in this section 2 Support the cylinder head assembly with the head gasket surface facing upward on a table or bench Use blocks or pins to prevent valve or camshaft parts from contacting the table or bench 3 Clean the combustion chamber deposits with a wire wheel and a drill motor Leave the valves in place to prevent damage to the valves or ...

Page 344: ... with a suitable tool 11 90 ROCKER ARM SEATS 10 7 NOTE Mark the valves or keep the valves matched to their original locations Compress the valve springs using Valve Spring Compressor and Valve Spring Compressor Set to remove the valve spring retainer keys upper valve spring retainer valve springs lower valve spring retainer valves and valve stem seals ...

Page 345: ...VALVE SEAL REPLACER 3 Assemble the valves lower valve spring retainer shims if used valve springs 4 5 upper valve spring retainer and valve spring retainer keys in their original locations Install the camshaft and camshaft thrust plate Install the front camshaft seal with Dust Boot Replacer 6 Install the two rocker arm and shaft assemblies NO 1 CYUNDER NO 4 CYUNDER INTAKE a a a I EXHAUST 7 Bolt th...

Page 346: ...rocedure in this section 2 Remove the oil pump body cover screws from the oil pump body cover 3 Remove the oil pump body cover inner gear and outer gear 4 Drive or pry the crankshaft front seal from the body Discard the crankshaft front seal 11 92 5 Remove the cotter pin retainer spring and relief valve from the oil pump body Discard the cotter pin Oil Pump Exploded View Part Item Number Descripti...

Page 347: ...ore replacing a cylinder block determine if it is serviceable If so perform the necessary service Refer to this section for the procedure Disassembly 1 Completely disassemble the engine following the procedures in disassembly and assembly 2 Remember to ridge ream the cylinder bores before removing the piston assemblies Assembly 1 Clean the gasket and seal surfaces of all serviceable parts and asse...

Page 348: ...front cover 11 94 UPPER ENGINE FRONT COVER 8 Ensure that the timing mark on the camshaft sprocket aligns with the pointer on the cylinder head 9 If the camshaft mark is not in sight turn the crankshaft one complete revolution and check the camshaft timing mark alignment If the timing marks are aligned the camshaft is properly timed to the crankshaft If the timing marks are not aligned continue thi...

Page 349: ... Displacement 1 3L 80 8 cu in Horsepower 63 5 at 5000 rpm Number of cylinders 4 Bore and stroke 71 x 83 6mm 2 78 x 3 29 inch Firing order 1 3 4 2 Oil pressures Hot 50 64 psi 3 5 4 5 kg cm2 3000 rpm 393 411 kPa GENERAL SPECIFICATIONS CYLINDER HEAD AND VALVE TRAIN Cylinder head and valve 9 7 1 train compression ratio Compression is 199 psi at 300 rpm Valve guide bore diameter 7 01 to 7 03mm 0 2760 t...

Page 350: ...598 to 0 0604 inch Oil 4 020 to 4 040mm Head gasket surface 0 15mm 0 006 inch 0 1583 to 0 1591 inch flatness overall Piston Pin Cylinder bore Diameter 19 974 to 19 980mm Diameter 71 00 to 71 019 mm 0 7864 to 0 7866 inch 2 7953 to 2 7960 inch Limit 71 17mm 2 8020 inch Piston to pin 0 0 to 0 026mm interference 0 0 to 0 00102 inch Out of round service limit 0 019mm 0 0007 inch Taper service limit 0 0...

Page 351: ... 31 46 22 34 Support Bolts Cylinder Head Bolts 75 81 56 60 Oil Pan Bolts and Nuts 8 9 69 78 Engine Rear Plate 7 10 61 87 Bolts Oil Pump Bolts 19 25 14 19 Flywheel to Torque 34 49 25 36 Converter Nuts Flywheel Reinforcing 8 11 71 97 Plate Bolts Torque Specifications Continued Description N m Lb ft Oil Pump Screen 8 11 Cover and Tube Bolts Flywheel Attaching 96 103 71 76 Bolt Connecting Rod Nuts 2 2...

Page 352: ...l result in slippage which may cause a noise condition or improper accessory operation alternator will not charge etc Over tightened drive belts will place an unnecessary load on the accessory bearings 11 98 SUBJECT ADJUSTMENTS PAGE Drive Belt Tension Adjustment 11 102 Drive Belt A C Compressor 11 1 02 Deflection Adjustment 11 1 03 Tension Adjustment 11 1 02 Drive Belt Alternator 11 1 04 Deflectio...

Page 353: ...adjusted Part Item Number Description 5 Crankshaft Pulley 6 Generator Pulley 7 Drive Belt Drive Belt Cracking Chunking Wear Under severe operating conditions high temperatures low humidity drive belt rib cracking can occur at less than 30 000 miles 48 000 km Drive belt rib cracking is not a reason for concern and has no detrimental effect on drive belt performance The drive belt is still perfectly...

Page 354: ...belt seating REPLACE correctly if necessary Severely misaligned Use a straightedge to CHECK for severe pulley angular misalignment between adjacent Drive belt too tight pulleys CORRECT as necessary Drive belt worn out CHECK drive belt tension REPLACE if necessary CHECK drive belt tension REPLACE drive belt if necessary Severely Glazed Drive Seized accessory CHECK all accessories for free rotation ...

Page 355: ...e Belt Replacement A C Compressor Removal 1 Loosen the drive belt idler pulley nut 2 Loosen the fan belt idler pulley bolt until there is enough slack to remove the A C compressor drive belt 3 Remove the A C compressor drive belt from the drive belt idler pulley A C clutch pulley and the crankshaft pulley 4 Remove the A C compressor drive belt from the vehicle Installation 1 Route the A C compress...

Page 356: ...sion Refer to the procedure in this section 3 Tighten the alternator adjustment bolt to 14 19 lb ft 19 25 N m 4 Raise and support the vehicle 5 Tighten the alternator lower bolt to 27 38 lb ft 37 52 N m 6 Lower the vehicle 7 On vehicles equipped with air conditioning install the A C compressor drive belt Refer to the procedure in this section ADJUSTMENTS Drive Belt Tension Adjustment CAUTION Prope...

Page 357: ...g 3 Tighten the drive belt idler pulley nut to 27 38 lb ft 37 52 N m 3 Tighten the drive belt idler pulley nut to 27 38 lb ft 37 52 N m Deflection Adjustment NOTE If the drive belt has been in service for some time it should be inspected for adjustment A drive belt that is severely glazed frayed cracked or contaminated with oil must be replaced Minor cracks in the back of the drive belt are accept...

Page 358: ... glazed frayed cracked or contaminated with oil must be replaced Minor cracks in the back of the alternator drive belt are acceptable as long as no large pieces are missing 1 Loosen the alternator adjustment bolt 2 Raise and support the vehicle 3 Loosen the alternator lower bolt 4 Lower the vehicle 5 CAUTION Do not pry on the alternator rear housing and bearing Position the pry bar against a stron...

Page 359: ...th oil must be replaced Minor cracks in the back of the drive belt are acceptable as long as no large pieces are missing 1 Apply 22 lb 98 N of pressure to the drive belt at a point midway between the alternator pulley and the crankshaft pulley 2 NOTE Always check the drive belt deflection when the engine is cold or has been stopped for at least 30 minutes A drive belt is considered new if it has b...

Page 360: ...m 9 10mm A C 0 31 0 35 in 0 35 0 39 in Compressor 8 9 mm 9 10mm Drive Belt TENSION A C 110 132 lb 95 110 lb Compressor 50 60 kg 43 50 kg Drive Belt Alternator Drive 86 103 lb 68 86 lb Belt 39 47 kg 31 39 kg TORQUE SPECIFICATIONS Description Lb ft N m Alternator Adjustment Bolt 14 19 19 25 Alternator Lower Bolt 27 38 37 52 Drive Belt Idler Pulley Nut 27 38 37 52 SERVICE TOOLS EQUIPMENT Offset Belt ...

Page 361: ...ner to intake manifold tube Engine air intake resonator Throttle body Air Induction System Components SUBJECT PAGE REMOVAL AND INSTALLATION Cont d Engine Air Cleaner 11 1 08 Engine Air Intake Resonator 11 11 0 CLEANING AND INSPECTION Air Cleaner Element 11 11 0 Engine Air Cleaner 11 11 0 Engine Air Intake Resonator 11 110 The air induction system contains electronic sensors which are common with o...

Page 362: ...nt Removal 1 Remove air intake panel with 2 screws and nuts 2 Release the air cleaner hold down clamps 3 Lift the air cleaner housing cover and the air cleaner element ACL element 4 Remove the air cleaner element Installation To install reverse the removal procedure Engine Air Cleaner Removal 1 Disconnect the battery ground cable 2 Disconnect the Mass Airflow MAF sensor electrical connector 11 108...

Page 363: ...e the air cleaner housing bolt and nut 10 Remove the air cleaner housing Installation To install reverse the removal procedure Air Cleaner to Intake Manifold Tube Removal 1 Loosen the clamp securing the air cleaner to intake manifold tube onto the Mass Air Flow Sensor MAF sensor 2 Disconnect the air cleaner to intake manifold tube at the MAF sensor 3 Remove the wing nut at the core support 4 Remov...

Page 364: ...tion 2 for the recommended ACL elen maintenance mileage interval The ACL element sl be replaced at the specified mileage intervals Hoi ACL element in front of a light and carefully inspe for any splits or cracks If the ACL element is spli1 cracked replace it Engine Air Cleaner Clean the air cleaner housing and cover with a s or compressed air Wipe them dry if a solvent is Inspect the air cleaner h...

Page 365: ...wing sources Section 9 Emission Control System The applicable section of this group SUBJECT PAGE REMOVAL AND INSTALLATION Cont d Crankshaft Position CKP Sensor 11 119 Engine Coolant Temperature ECT Sensor 11 1 17 Idle Air Control Bypass Air lAC BPA Valve 11 116 Idle Switch 11 114 Intake Air Temperature lAT Sensor 11 11 6 Mass Airflow MAF Sensor 11 114 Oxygen Sensor 02S 11 118 Powertrain Control Mo...

Page 366: ... 0 Data Link Connector DLC Self Test 0 0 0 0 Input TEN Terminal Park Neutral Position PNP Switch 0 0 0 0 0 E L Load 0 0 Vehicle Speed Sensor VSS 0 0 E L Load Blower fan control switch second position or higher headlamps on Throttle Position TP Sensor The Throttle Position Sensor TP sensor is a variable resistor type sensor It is mounted on the left hand side of the throttle body The TP sensor dete...

Page 367: ... and senses the oxygen concentration in the exhaust gas It sends this information to the Powertrain Control Module PCM which uses the information to determine fuel injection amounts The sensing element is made of zirconia ceramic with a platinum coating Camshaft Position CMP Sensor The Camshaft Position CMP sensor detects the number 1 cylinder when it reaches Top Dead Center TDC and signals the Po...

Page 368: ...ensor Removal 1 Remove the Throttle Position TP sensor electrical connector THROTTLE POSITION TP SENSOR ELECTRICAL CONNECTOR 2 Remove the two TP sensor screws 11 114 3 Remove the TP sensor Installation To install reverse the removal procedure Tighten the TP sensor screws to 14 2 20 3 lb in 1 6 2 3 N m Refer to the TP sensor adjustment procedure in this section Idle Switch Removal and Installation ...

Page 369: ...e manifold tube to the MAF sensor and remove the air cleaner to intake manifold tube from the MAF sensor 5 Disconnect the vacuum hose 6 Remove the upper engine air cleaner ACL 7 Remove the two MAF sensor bolts and the MAF sensor Installation To install reverse the removal procedure Tighten the MAF sensor bolts to 71 88 lb in 8 10 N m 11 115 ...

Page 370: ...NGINE AIR _ CLEANER Installation To install reverse the removal procedure Tighten the IAT sensor to 71 97 Ib in 8 11 N m Idle Air Control Bypass Air lAC BPA Valve Removal 1 Disconnect the battery ground cable 2 Drain the cooling system below the level of the Idle Air Control Bypass Air lAC BPA valve 3 NOTE The lower coolant line should be disconnected after the lAC BPA valve is separated from the ...

Page 371: ...nstall reverse the removal procedure Install a new gasket Tighten the lAC BPA nuts and bolts to 71 88 lb in 8 10 N m Refer to Section 15 for the cooling system filling procedure Engine Coolant Temperature ECT Sensor Removal 1 Disconnect the battery ground cable 2 Drain the cooling system below the level of the Engine Coolant Temperature Sensor ECT sensor 3 Remove the two upper intake manifold brac...

Page 372: ... 118 Oxygen Sensor 02S Removal 1 Disconnect the battery ground cable 2 Remove the air cleaner intake tube Refer to Section 11 for the removal and installation procedure 3 Disconnect the Oxygen Sensor 02S electrical connector 4 Remove the 02S wire from the hanger 5 Remove the exhaust manifold heat shield bolts and the exhaust manifold heat shield 6 Remove the 02S from the exhaust manifold EXHAUST M...

Page 373: ...TMENTS Throttle Position TP Sensor 1 Disconnect the Throttle Position TP sensor electrical connector THROlTLE POSmON TP SENSOR ELECTRICAL CONNECTOR 2 Connect a Digital Multimeter or equivalent between terminals A and B THROTTLE POSITION TP SENSOR 3 Turn the throttle lever to the Wide Open Throttle WOT position and check the resistance reading on the multimeter The reading should be approximately 5...

Page 374: ...tor SPECIFICATIONS TORQUE SPECIFICATIONS Description Ib in Mass Airflow MAF 71 88 Sensor Intake Air Temperature 71 97 lAT Sensor Idle Air Control Bypass 71 88 Air lAC BPA Bolts Engine Coolant Temperature ECT Sensor Upper Intake Manifold Bracket Bolts Oxygen Sensor 02S Exhaust Manifold Heat Shield Bolts Throttle Position TP 14 2 Sensor Screws 20 3 SERVICE TOOLS EQUIPMENT Digital Multimeter 11 120 l...

Page 375: ...ming procedures are included in this section The distributor is mounted on the rear flywheel end of the cylinder head and is direct driven by the camshaft at one half the crankshaft speed Two offset drive tangs pinned to the distributor shaft engage with the camshaft in only one position Rotation is counterclockwise as seen from the left of the vehicle The firing order is 1 3 4 2 SUBJECT PAGE REMO...

Page 376: ... device a magnetic flux field is completed from the magnet through the Hall effect device and back to the magnet 12 2 As the vane passes through this opening the flux lines are shunted through the vane and back to the magnet During this time a voltage is produced as the vane passes through the opening When the vane clears the opening the window edge causes the signal to drop to almost zero volts T...

Page 377: ...lse of about 28 000 volts is induced in the coil secondary winding This pulse is transmitted to the central terminal in the distributor cap through the distributor rotor to the distributor cap terminal and through the distributor to spark plug wire to the appropriate spark plug At the spark plug electrodes in the combustion chamber the high voltage arcs to ground and ignites the compressed air fue...

Page 378: ...uit to fire the spark plugs Distributor The distributor is mounted on the rear flywheel end of the cylinder head and is direct driven by the camshaft at one half the crankshaft speed Two offset drive tangs pinned to the distributor shaft engage with the camshaft in only one position Rotation is counterclockwise as seen from the left of the vehicle 12 4 The distributor houses the Camshaft Position ...

Page 379: ... cable 2 Remove the two distributor cap screws 3 Pull the distributor cap off and position it aside 4 Remove the distributor rotor I DISTRIBUTOR Installation To install reverse the removal procedure Check for proper operation Distributor Removal 1 Disconnect the battery ground cable 2 Remove the two distributor cap screws 3 Pull the distributor cap off and position it aside 4 Disconnect the two di...

Page 380: ... 7 Remove and discard the distributor 0 ring from the distributor 12 6 Installation 1 Install a new distributor 0 ring on the distributor 2 NOTE When installing the distributor ensure that the offset drive tangs engage with the camshaft slots NOTE The rotor position should be the same as when removed Position the distributor and install the two distributor bolts If a replacement distributor is bei...

Page 381: ...tor to spark plug wire boots not the distributor to spark plug wires until the distributor to spark plug wires are free 3 NOTE Plug wires are numbered for each cylinder Note the differing lengths and the numbering of distributor to spark plug wires with Number 1 being the longest wire This should help prevent confusion when determining the correct wire to plug connection 4 Disengage the distributo...

Page 382: ...der 1 3 4 2 reading counterclockwise 12 8 Whenever a distributor to spark plug wire is removed for any reason from the spark plug or distributor cap or a new distributor to spark plug wire is installed Silicone Dielectric Compound or equivalent must be applied to the distributor to spark plug wire boot before the distributor to spark plug wire is connected Using a small clean tool coat entire inte...

Page 383: ...istributor rotor and replace it if any of the following conditions exist Cracks Carbon tracks Burns Damaged points Damaged spring Replace the distributor rotor if it is damaged Refer to the replacement procedure in this section Ignition Coil Note The ignition coil is integral with the distributor If the ignition coil requires service the distributor must be replaced Spark Plugs Note Before cleanin...

Page 384: ...ARK PLUGI LOW FUEL PUMP PRESSURE OR INCORRECT IGNITION TIMING REPLACE THE SPARK PLUG 12 10 Section 12 Ignition System NORMAL IDENTIFIED BY LIGHT TAN OR GRAY DEPOSITS ON THE FIRING TIP OIL FOULED IDENTIFIED BY WET BLACK DEPOSITS ON THE INSULATOR SHEU BORE ELECTRODES CAUSED BY EXCESSIVE OIL ENTERING COMBUSTION CHAMBS THROUGH WORN RINGS AND PISTONS EXCESSIVE CLEARANCE BETWEEN VALVE GUIDES AND STEMS O...

Page 385: ... Timing Check and adjust the ignition timing using the following procedure 1 Start the engine and allow it to warm up to normal operating temperature 2 Shut off all of the accessories 3 Connect Timing Analyzer or equivalent 4 Using a jumper ground the Self Test Input STI terminal at the Data Link Connector DLC SELF TEST INPUT STI DATA UNK CONNECTOR DLC 5 Check the base ignition timing The yellow i...

Page 386: ... STI terminal at the DLC 12 Remove the Timing Analyzer or equivalent SPECIFICATIONS IGNITION SYSTEM SPECIFICATIONS Description Specification Spark Plug Type AGS32C Spark Plug Gap 0 039 0 043 inches 1 0 1 1mm Firing Order 1 3 4 2 Ignition Timing 10 degrees BTDC TORQUE SPECIFICATIONS Description Lb ft Distributor Bolts 14 19 Spark Plugs 15 22 SERVICE TOOLS EQUIPMENT SERVICE TOOLS Spark Plug Boot Pul...

Page 387: ...l related component Highly flammable mixtures are always present and may be ignited resulting in possible personal injury SUBJECT PAGE REMOVAL AND INSTALLATION cont dl Bracket Accelerator Cable 13 7 Fuel Draining 13 7 Fuel Filling 13 8 Fuel Filter 13 1 0 In Line 13 11 In Tank 13 1 0 Fuel Pressure Regulator 13 13 Fuel Pump 13 13 Fuel Return System 13 1 3 Fuel Tank 13 8 Fuel Tank Filler Pipe 13 9 Fu...

Page 388: ...e the throttle body replace the throttle body with the throttle position sensor and idle switch attached Refer to Section 11 for the removal and installation procedure 13 2 Fuel Pump Electric For inspection of the fuel pump refer to the Powertrain Control Emissions Diagnosis Manual Specifications FUEL PRESSURE SPECIFICATIONS Description Specification Fuel Pressure at Idle 21 0 260 kPa 30 38 psi Fu...

Page 389: ...r 6 Fuel Injectors 7 Fuel Injection Manifold 8 Fuel Pressure Regulator Fuel Tank Filler Cap WARNING THE FUEL TANK FILLER CAP MAY BE PRESSURIZED TO REMOVE ROTATE CAP OVER 1 2 TURN COUNTERCLOCKWISE FUEL TANK FILLER CAP IS VENTING FUEL OR A HISSING SOUND IS HEARD WAIT UNTIL THE CONDITION STOPS BEFORE REMOVING THE FUEL TANK FILLER CAP IF THESE PRECAUTIONS ARE NOT FOLLOWED FUEL MAY SPRAY AND CAUSE PERS...

Page 390: ...e located at the fuel pump outlet The function of this valve is to maintain pressure in the system after the vehicle is shut down The pressure retention helps prevent hot starting problems A pressure relief 13 4 valve is provided to regulate the maximum fuel pump outlet pressure The fuel tank sender filter protects the fuel pump at its inlet This fuel tank sender filter strains dirt and contaminan...

Page 391: ...under the electrical component rail in the engine compartment Push the red button to reset INERTIA FUEL SHUTOFF O l WITCH RESET SUlTON Fuel Tank Filters lines and Electric Fuel Pump Refer to the Powertrain Control Emissions Diagnosis Manual Section 98 Fuel Delivery Turbocharger Systems for diagnosis of the 1 3L fuel system DIAGNOSIS AND TESTING Inspection and Verification Accelerator Pedal and lin...

Page 392: ... lock tabs and remove the accelerator cable from the accelerator pedal 1 Remove the accelerator cable from the throttle control lever 4 Squeezethelocktabssecuringthe accelerator cable housing to the bulkhead 2 Loosen the locknuts at the accelerator cable bracket located near the throttle body 13 6 5 Remove the accelerator cable from the accelerator cable clip on the cylinder head 6 Remove the acce...

Page 393: ...ghten the accelerator mount bolts to 22 lb ft jo N ml Bracket Accelerator Cable Removal 1 Remove the accelerator cable from the throttle control lever 2 Loosen the locknuts at the accelerator cable bracket located near the throttle body 3 Remove the two accelerator cable bracket bolts and the accelerator cable bracket from the valve cover Installation ACCELERATOR CABLE BRACKET ACCELERATOR I CABLE ...

Page 394: ...OR NEAR ANY FUEL RELATED COMPONENT HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY BE IGNITED RESULTING IN PERSONAL INJURY R moval 1 Remove the cargo box from its position over the engine compartment 2 Remove four bolts holding lower trunk to the door slide rails 3 Remove the lower trunk assembly from vehicle frame 4 Disconnect the battery ground cable 5 Remove the gas straps 6 Remove the gas...

Page 395: ...ure to the door slide rails using four bolts lockwashers and nuts 16 Install the cargo box into position over the engine compartment and secure to lower trunk assembly using the retainer and wing nut Fuel Tank Support Straps WARNING DO NOT SMOKE OR CARRY LIT TOBACCO OR AN OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENT HIGHLY FLAMMABLE MIXTURES ARE ALWAYS PRESENT AND MAY ...

Page 396: ... trunk assembly onto the frame of the vehicle Make sure the lower trunk assembly is between the door slides 8 Secure the lower trunk assembly to the door slides with four bolts lock washers and nuts Tighten bolts to 30 lb ft 40 N m Fuel Tank to Filler Pipe Hose Removal WARNING DO NOT SMOKE OR CARRY LIT TOBACCO OR AN OPEN FLAME OF ANY TYPE WHEN WORKING ON OR NEAR ANY FUEL RELATED COMPONENT HIGHLY F...

Page 397: ...ARE ALWAYS PRESENT AND MAY BE IGNITED RESULTING IN PERSONAL INJURY 1 Remove the cargo box from the lower trunk assembly 2 Relieve the fuel pressure as follows Start the engine Disconnect the fuel pump relay electrical connector After the engine stalls turn the ignition to the off position Connect the fuel pump relay electrical connector 3 Loosen the clamp and disconnect the fuel supply line at the...

Page 398: ...stem pressure Refer to the procedure in this section 13 12 2 Open the cargo box lid by unlocking the rear latch 3 Unscrew the fastener and remove bracket which holds the cargo box to the frame 4 You and another person lift the cargo box slightly and slide the cargo box back and remove from the vehicle 5 Remove four bolts which hold the lower trunk assembly to the door slides 6 Remove the lower tru...

Page 399: ... slide the cargo box back and remove 2 Disconnect the Inertia Fuel Shutoff switch electrical connector which is under the electrical component rail in the engine compartment 3 Remove the two inertia fuel shutoff screws and the inertial fuel shutoff switch Installation Inertia Fuel Shutoff Switch To install reverse the removal procedure Fuel Return System Removal and Installation The fuel return sy...

Page 400: ...elay electrical connector 2 Disconnect the vacuum supply hose from the top of the fuel pressure regulator 3 Disconnect and plug the fuel line 13 14 4 Remove the two fuel pressure regulator bolts 5 Remove the fuel pressure regulator 6 Remove the 0 ring from the fuel pressure regulator Discard the 0 ring Installation To install reverse the removal procedure Install a new 0 ring and then tighten the ...

Page 401: ... as assemblies All replacement hoses must be serviced as assemblies Bulk fuel hose must not be used to service tubing in high pressure fuel systems Fuel Lines and Return Lines WARNING FUEL SUPPLY LINES WILL REMAIN PRESSURIZED FOR LONG PERIODS OF TIME AFTER ENGINE IS SHUTDOWN THIS PRESSURE MUST BE RELIEVED BEFORE SERVICING OF THE FUEL SYSTEM IS BEGUN CAUTION The use of copper tubing is not recommen...

Page 402: ...s section Wide Open Throttle Position 1 Adjust the accelerator cable deflection Refer to the accelerator cable deflection adjustment procedure in this section 2 Depress the accelerator pedal to the floor 13 16 3 Confirm that the throttle plate is in the wide open position in the throttle body SPECIFICATIONS Fuel System Specifications Fuel Capacity 7 0 US gals 26 5 liters Fuel Pressure Fuel Pressur...

Page 403: ...eases or cuts off fuel delivery to the fuel injector based on engine demands and driving conditions The fuel delivery sub system consists of High pressure electric fuel pump SUBJECT PAGE REMOVAL AND INSTALLATION Fuel Charging System 13 22 Fuel Pressure Relief 13 22 Fuel Charging Wiring 13 28 Fuel Pump Relay 13 28 Fuel Injection Supply Manifold 13 26 Fuel Injector 13 23 Fuel Pressure Regulator 13 2...

Page 404: ...de of the fuel injection supply manifold Fuel is metered and injected into the intake ports according to the fuel injector signals received from the PCM When these injection signals are applied to the coil of the fuel injector the needle 13 18 valve is pulled off its seat Fuel is then injected around the back face of the intake valve The amount of fuel supplied to the engine depends on the length ...

Page 405: ... signal to the PCM The PCM uses the signal to measure throttle valve angle and adjust the air fuel mixture Intake Manifold The intake manifold is a two piece upper and lower intake manifold aluminum casting Runner lengths are tuned to optimize engine torque and Part Item Number Description 5 Throttle Position TP Sensor 6 133348 Mass Air Flow Sensor 7 134037 Air Cleaner Element power output Vacuum ...

Page 406: ...ature 6 Electrical Connector Fuel Injection Supply Manifold The fuel injection supply manifold delivers high pressure fuel from the fuel supply line to the fuel injectors The fuel injection supply manifold consists of a tubular rail fuel injector connectors a mounting flange for the fuel pressure regulator and mounting attachments which hold the fuel injection supply manifold and fuel injector Fue...

Page 407: ... to fuel remaining in the fuel supply line Once the fuel in the supply line has been used the engine will stall CAUTION Do not reset the Inertia Fuel Shutoff Switch IFS switch IFS until the entire fuel system has been inspected for leaks To reset the IFS switch depress the reset button on the switch located in the center and under the electrical component rail in the engine compartment INERTIA FUE...

Page 408: ...gine 4 Disconnect the fuel pump relay electrical connector and wait for the engine to stall 5 Turn the ignition switch to the OFF position The fuel pressure is now relieved 13 22 6 Connect the fuel pump relay electrical connector 7 Disconnect the battery ground cable Post service Procedures After the service is complete and the fuel charging system is installed on the engine the following steps mu...

Page 409: ...9 NOTE Mark the coolant hoses prior to removal to ease installation Tilt the throttle body back and disconnect the two coolant hoses 10 Remove the throttle body and throttle body gasket TB gasket Discard the throttle body gasket Installation To install reverse the removal procedure Install a new throttle body gasket Tighten the throttle body nut and three throttle body bolts to 14 191b ft 19 25 N ...

Page 410: ... the fuel system to reduce the possibility of injury or fire 1 WARNING FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING Relieve the fuel pressure Refer to the procedure in this section 2 Remove the upper intake manifold Refer to Section 11 for the removal procedure 3 Disconnect and plug the fuel lines 13 24 Item 7 8 9 10 A B Part Number Description Fuel lniec...

Page 411: ...upply manifold the insulators do not get lost Remove the fuel injection supply manifold and insulators FUEL INJECTION SUPPLY MANIFOLD 7 Remove the fuel injector from the fuel injection supply manifold FUEL INJECTOR 8 Remove and discard the fuel injector insulators and 0 rings from the fuel injectors Installation To install reverse the removal procedure Install new fuel injector 0 rings and insulat...

Page 412: ...ne release the fuel pressure from the fuel system to reduce the possibility of injury or fire 1 Relieve the fuel pressure Refer to the procedure in this section 2 Remove the upper intake manifold Refer to Section 11 for the removal procedure 3 Disconnect and plug the fuel lines 4 Disconnect the fuel injector electrical connectors 13 26 FUEL INJECTOR ELECTRICAL CONNECTORS 4 l 5 Remove the two fuel ...

Page 413: ...1 97 N m 8 11 N m WARNING FUEL IN THE FUEL SYSTEM REMAINS UNDER HIGH PRESSURE EVEN WHEN THE ENGINE IS NOT RUNNING Before disconnecting any fuel line release the fuel pressure from the fuel system to reduce the possibility of injury or fire 1 Relieve the fuel pressure Refer to the procedure in this section 2 Disconnect the vacuum supply hose from the top of the fuel pressure regulator 3 Disconnect ...

Page 414: ...ON SENSOR ELECTRICAL FUEL CHARGING WIRING ELECTRICAL CONNECTOR TO R ENGINE COOLANT TEMPERATURE EC1 SENSOR ELECTRICAL CONNECTOR 4 Disconnect the Engine Coolant Temperature ECT sensor electrical connector 5 Disconnect the fuel charging wiring electrical connector Installation To install reverse the removal procedure Fuel Pump Relay Removal and Installation Refer to Section 20 for the removal and ins...

Page 415: ...e speed adjustment screw for the correct idle speed The idle speed specifications should be as 700 800 rpm automatic transaxle in PARK P position 6 Turn the engine off and allow the engine to cool 7 Remove the ground from the PCM STI TEN pin at the DLC 8 After the engine has cooled start and run the engine until it reaches operating temperature and ensure the idle speed is to specification Idle Mi...

Page 416: ......

Page 417: ...Precautions WARNING EXHAUST GASES CONTAIN CARBON MONOXIDE WHICH CAN BE HARMFUL TO HEALTH AND ARE POTENTIAllY LETHAL EXHAUST SYSTEM LEAKS SHOULD BE REPAIRED IMMEDIATELY NEVER OPERATE THE ENGINE IN ENCLOSED AREAS CAUTION leaded gas must not be used in a vehicle with a catalytic converter the lead will poison the catalyst The following precautions must be observed when operating a vehicle equipped wi...

Page 418: ...nical Electrical Exhaust pipe Misrouted pinched crushed damaged wiring Damage loose Corroded loose vacuum hoses connectors Incorrect idle speed Dirty air cleaner element Damaged catalytic converter 3 Exercise the wiring and connectors for the solenoids and other components for obvious problems due to looseness corrosion or other damage The engine must be running at operating temperature when perfo...

Page 419: ...utral and the parking Go to A2 brake set Is the manifold vacuum above 406 4 mm Hg 16 in Hg A2 I PERFORM VACUUM TEST EXHAUST DISCONNECTED Turn the engine oft Yes Go to A3 Disconnect the exhaust system at the exhaust manifold No Go to A4 Repeat test step A 1 Is the manifold vacuum above 406 4mm Hg 16 in Hg A 3 I PERFORM VACUUM TEST CATALYTIC CONVERTER ON MUFFLER OFF Turn the engine off Yes Replace t...

Page 420: ...Lower the vehicle 4 Start the engine and inspect for exhaust leaks 14 4 Exhaust Down Pipe Removal 1 Raise and support the vehicle 2 Remove the three exhaust down pipe nuts from the exhaust manifold Exhaust Down Pipe 3 Remove and discard the exhaust gasket between the down pipe and manifold 4 Remove the three 3 8 x 2 1 2 bolts flatwashers locknuts and exhaust hold down springs 5 Remove the exhaust ...

Page 421: ...mponents Often the associated noise is hard to distinguish from other chassis noises Look for broken of loose hangers and tabs Replace or tighten as necessary It is important that exhaust clearances and alignment be maintained Perform the following procedure to align the system 1 Loosen the attaching hardware hangers and tabs 2 Align the exhaust system beginning at the front of the vehicle to esta...

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Page 423: ...5 20 DESCRIPTION AND OPERATION Cooling System The cooling system consists of Radiator Water pump Water thermostat SUBJECT PAGE REMOVAL AND INSTALLATION Cont d Radiator 15 1 5 Aluminum Core Downflow 15 1 5 Radiator Coolant Recovery Reservoir 15 18 Radiator Draincock 15 21 Radiator Hoses 15 1 3 Lower 15 13 Upper 15 13 Thermostat Water 15 11 Transmission Oil Cooler 15 21 Water Bypass Hose 15 14 Water...

Page 424: ...re than 50 percent antifreeze except in areas where 15 2 antifreeze protection below 40 F 40 C is required In this case refer to the coolant mixture chart on the Cooling System Fluid container but in no case exceed 60 percent antifreeze water mixture A standard ethylene glycol hydrometer or Battery Anti Freeze Tester or equivalent can be used to check the protection level of the coolant To prevent...

Page 425: ...ont of the cylinder block The water pump is driven by a drive belt that is driven by the crankshaft coolant flow is restricted to the cylinder block cylinder head intake manifold and heater core As the coolant temperature increases the water thermostat opens allowing a portion of the coolant to pass into the radiator The coolant flows through the radiator tubes and is cooled by air passing over th...

Page 426: ...ours will not damage the engine so you can DIAGNOSIS AND TESTING Electrical Schematic Engine Cooling System 1 plug it in at night to start your vehicle the following morning Use a timer to conserve energy To operate the block heater simply plug it into a grounded 11 0 volt outlet It is recommended that you use a Ground Fault Interrupter on your 11 0 volt outlet WARNING Do not use the block heater ...

Page 427: ...sually inspect the following components of the engine cooling fan motor system 5 If fault is not visually evident proceed to the Troubleshooting Chart VISUAL INSPECTION CHART Troubleshooting Chart Engine Cooling System NOTE Use a Digital Multimeter or equivalent to perform electrical Pinpoint Tests ENGINE COOLING SYSTEM CONDITION POSSIBLE SOURCE REMEDYIACTION Loss of Coolant External leaks GO to P...

Page 428: ...sion oil cooler Is there evidence of coolant leakage PINPOINT TEST 8 ENGINE OVERHEATS TEST STEP RESULT ACTION TO TAKE 81 I CHECK COOLANT LEVEL Verify the coolant level is at the FULL mark Yes GO to 82 on the radiator coolant recovery reservoir No GO to Pinpoint Test A 1 Verify the coolant level is at the top of the filler tube after removing the radiator cap Is the coolant level OK 82 I CHECK COOL...

Page 429: ...es the engine cooling fan motor operate 87 ICHECK ENGINE COOLING FAN MOTOR GROUND Key OFF Yes GO to 88 Disconnect the engine cooling fan motor connector No SERVICE the BK wire for open Use Rotunda 73 Digital Multimeter 106 00051 or equivalent to measure the resistance of the BK wire between the engine cooling tan motor connector and ground Is the resistance lose than 5 ohms 88 I CHECK FAN CONTROL ...

Page 430: ... positive terminal Does the engine cooling fan motor operate PINPOINT TEST C COOLING FAN OPERATES CONTINUOUSLY TEST STEP RESULT ACTION TO TAKE C1 I CHECK FAN CONTROL RELAY Key OFF Yes REFER to the PC ED Disconnect the fan control relay connector Manual 3 Section 68 to Jumper the 8K W wire terminal and the W diagnose the fan control 8K wire terminal on the fan control relay to relay circuit the bat...

Page 431: ... 8 If the system does not hold pressure service the system for leaks If no external leaks are present refer to Section 11 for engine disassembly and inspection procedures Radiator Cap Pressure Test Inspect both sides of the radiator cap rubber seal and the vacuum valve seat Check for particles of rust or dirt that could impair sealing Flush away any foreign material with warm tap water Also check ...

Page 432: ...lease the pressure by depressing the relief valve on the underside of the tester 9 Repeat the test at least twice to verify that the pressure reading is acceptable and consistent If the radiator cap pressure is 15 10 less than or greater than the specified value replace the radiator cap Thermostat Water Overheating or failure to reach normal operating temperature can indicate improper water thermo...

Page 433: ...ect the aluminum A separate clean test tank is necessary if possible for aluminum radiators If conditions do not allow for a separate test tank clean the test tank thoroughly each time before testing an aluminum radiator Clean the radiator before leak testing it to prevent contamination of the test tank Leak test the radiator in clean water with 20 psi 137 pa of air pressure REMOVAL AND INSTALLATI...

Page 434: ...r head with the bolt holes correctly aligned 5 Position the water hose connection on the cylinder head using care to align the bolt 15 12 holes and not to shift the position of the water hose connection gasket 6 NOTE Ensure that the thermostat flange is properly seated into the recess in the water hose connection before tightening the bolts Install the water hose connection bolt and nut Tighten th...

Page 435: ...ling system to the specified level with the recommended antifreeze water mixture Refer to the procedure in this section Lower Removal 1 Drain the cooling system Refer to the procedure in this section 2 Remove upper trunk box 3 Squeeze and slide the lower radiator hose clamp away from the outlet fitting LOWER RADIATOR HOSE CLAMP 4 Disconnect the lower radiator hose from the radiator 5 Disconnect th...

Page 436: ... an exploded view of the water pump inlet connector WATER PUMP INLET CONNECTOR 1 Remove upper box and right hand fender 2 Drain the cooling system Refer to the procedure in this section 15 14 3 On vehicles with air conditioning remove the A C compressor Refer to Section 22 for the removal procedure 4 Disconnect the lower radiator hose at the water pump inlet connector 5 Remove the water pump inlet...

Page 437: ...tifreeze water mixture Refer to the procedure in this section 7 Assemble fender and box 8 Check for leaks at the water pump inlet connector Radiator Aluminum Core Downflow Removal 1 WARNING NEVER REMOVE THE RADIATOR CAP UNDER ANY CIRCUMSTANCES WHILE THE ENGINE IS RUNNING FAILURE TO FOLLOW THIS INSTRUCTION COULD RESULT IN PERSONAL INJURY AS WELL AS DAMAGE TO THE COOLING SYSTEM AND ENGINE TO PREVENT...

Page 438: ...r radiator hose clamp and slide the clamp down the upper radiator hose 7 Disconnect the upper radiator hose from the radiator 15 16 RADIATOR 7 Disconnect the upper radiator hose from the radiator 8 Disengage the wiring harness from the routing clamps on the fan shroud 9 Squeeze and slide the lower radiator hose clamp away from the radiator 10 Take bolts out of engine wiring panel ...

Page 439: ...saxle remove three fan shroud assembly bolts For vehicles with a manual transaxle remove four fan shroud assembly bolts Installation 1 If necessary install the fan shroud assembly with three fan shroud assembly bolts 2 NOTE When installing the radiator ensure the radiator support upper brackets are fully engaged on the radiator and that the mounting pins located on the lower tank ot the radiator a...

Page 440: ... in this section 13 Install the radiator cap on the radiator filler neck 14 Warm up the engine and check for leaks Radiator Coolant Recovery Reservoir Removal 1 Remove the overflow hose from the radiator coolant recovery reservoir 2 Slide the radiator coolant recovery reservoir up and out of its mounting bracket 15 18 RADIATOR COOLANT RECOYeRY RESERVOIR Installation To install reverse the removal ...

Page 441: ...D ASSEMBLY BOLTS 4 8 Loosen the two fan shroud assembly bolts securing the bottom of the fan shroud to the radiator 9 Remove the engine cooling fan motor fan blade and fan shroud assembly from the vehicle Installation 1 NOTE When installing the engine cooling fan motor fan blade and fan shroud assembly ensure the bottom of the fan shroud engages the fan shroud lower bolts Position the engine cooli...

Page 442: ...s Fan Shroud Removal and Installation Refer to the engine cooling fan motor procedure in this section for removal and installation of the fan shroud Engine Cooling Fan Motor Removal The following illustration is an exploded view of the engine cooling fan motor and fan shroud assembly FAN BLADE NUT ENGINE COOLING FAN MOTOR 1 Remove the fan blade and shroud assembly Refer to the procedure in this se...

Page 443: ...the cooling system to the specified level with the recommended antifreeze water mixture Refer to the procedure in this section Water Temperature Indicator Sender Unit Removal 1 NOTE The water temperature indicator sender unit is threaded into the front side of the cylinder block Drain the engine coolant to a level below the water temperature indicator sender unit Refer to the procedure in this sec...

Page 444: ...oval 1 NOTE The block heater wiring is available as option If equipped then proceed as follows Disconnect the battery ground cable 2 Remove the air cleaner element ACL element Refer to this section for the removal procedure 3 Raise and support the vehicle 4 Remove the two intake manifold support bolts and remove the intake manifold support 5 Remove the support bracket bolt 15 22 SUPPORT BRACKET BO...

Page 445: ...s far enough from the tanks solder it in the usual manner 3 If the exact location of the leak cannot be pinpointed treat a larger area to assure the effectiveness of the repair Radiator Tank The radiator tanks are plastic and unlike the core fins cannot be soldered To seal minor leaks in the radiator tanks use self leveling single component silicone such as Dow Corning 1200 Clear Prime Coat and Si...

Page 446: ...G SYSTEM PRESSURE IS RELEASED AFTER ALL OF THE PRESSURE HAS BEEN RELEASED USING THE THICK CLOTH PRESS DOWN ON THE RADIATOR CAP TURN IT AND THEN REMOVE IT With the radiator cap off examine the coolant in the upper tank Draw a sample with a hydro 15 24 meter or Battery Antifreeze Tester or equivalent Check for rust dirt or oil Also check the freezing point It should be approximately 35 F 3JOC if the...

Page 447: ...from the heater core and plug or cap both nipple and hose Position a drain pan under the radiator and open the radiator draincock and drain the system Clean the cooling system by flushing with clear water If it is excessively rusty or dirty reverse pressure flush or use an approved flushing system Refer to the flushing procedures in this section Refill the system with equal parts of water and anti...

Page 448: ...onnecting the cooling system hoses the heater loop must be back flushed separately to remove sediment in the heater core Refer to the procedure in this section 15 26 9 Install the water thermostat in the water hose connection Refer to the procedure in this section TO HEATER CORE _ 11 Jlllll FROM HEATER CORE ...

Page 449: ...everal times Allow full flow for approximately five 5 minutes 3 Shut off the flushing water supply and remove the adapters installed for the flushing operation Reconnect all cooling system connections tightening all hose clamps to 22 31 lb in 2 5 3 5 N m 4 Refill the cooling system with approved antifreeze coolant mixture Refer to the coolant replacement procedure in this section 5 With the coolin...

Page 450: ...40 C WATER THERMOSTAT OPENING TEMPERATURE Position Temperature Starts to open 86 5 89 5 C 188 193 F Full open 100 C 212 F Closed 83 C 181 F 15 28 COOLING FAN CONTROL RESISTANCE Coolant Temperature Resistance ohms 1 68 F 20 C 2200 2700 104 F 40 C 1000 1300 176 F 80 C 290 350 196 F 91 C 230 240 20JOF 9JOC 190 200 228 F 1 08 C 146 152 1 Tho resistance specifications shown refer to the Engine Coolant ...

Page 451: ... while it is cranking the engine The amount of resistance in the starting circuit must be kept to an absolute minimum to provide maximum current for starter operation A discharged battery loose or corroded DISASSEMBLY AND ASSEMBLY Cont d Drive End Housing 16 27 Starter Drive Replacement 16 1 7 Starter Motor 16 1 3 SERVICE PROCEDURES Jump Starting 16 31 Road Service 16 31 CLEANING AND INSPECTION Ar...

Page 452: ...ge drop is 0 5 volt Part Number Item 1 2 3 4 184012 5 184021 STARTER SOLENOID Description Starter Solenoid Starter Drive Drive Lever and Pin Starter Motor Armature Brush Set The starter motor can be considered as having two electrical circuits a low current circuit and a high current circuit 16 2 L L The low current circuit is the control circuit and includes the ignition switch starter solenoid P...

Page 453: ...itch contacts are closed battery current is applied to the S terminal on the starter solenoid The PNP switch is mounted on the transaxle Starter motor system components and wiring Item Part Number Description 1 B terminal 2 Pull in Coil 3 Hold in Coil 4 Drive Lever and Pin 5 Starter Drive 6 Starter Field Coil 7 184012 Starter Motor Armature Item 8 9 10 11 12 13 Part Number Description 184021 Brush...

Page 454: ...ized creating a magnetic field in the solenoid coil 3 The iron plunger core is drawn into the solenoid coil 4 A drive lever and pin connected to drive assembly engages the starter drive to the flywheel ring gear 5 When the iron plunger core is all the way into the coil its contact disc closes the circuit between the battery and the starter motor terminals 16 4 6 The current flows to the starter mo...

Page 455: ...n switch Unusual starter noise Starter motor improperly mounted GO to Pinpoint Test Malfunctioning starter motor C1 PINPOINT TEST A Engine Cranks Slowly TEST STEP RESULT ACTION A1 I CHECK BATTERY CONNECTIONS Inspect the battery terminals for loose or corroded Yes GO to A2 connections No Clean and tighten Are the battery terminals clean and tight battery cable connections A2 I CHECK BATTERY Check b...

Page 456: ...s 84 I CHECK STARTER MOTOR GROUND CIRCUIT Perform the starter motor ground circuit test in Yes Remove the starter this section motor and perform Is the voltage greater than 10 volts the motor pinion test No Repair and or replace the battery ground cable and or engine ground cable as required PINPOINT TEST C Unusual Starter Noise TEST STEP RESULT ACTION C1 I CHECK STARTER MOTOR MOUNTING Inspect the...

Page 457: ...gative lead to starter motor housing START B TERMINAL DIGITAL MULTlMETER 3 Turn the ignition switch to the START position while watching the voltage reading If the voltage at the S terminal is eight 8 volts or more there is a starter motor or high current circuit malfunction Perform the starter motor circuit checks explained later in this section If there is no voltage there is a malfunction in th...

Page 458: ...epeat steps 1 one through to 6 six If the voltage reading is still higher than 0 5 16 8 volt at the M terminal and 0 5 volt or lower at the 8 terminal the problem is in the starter solenoid contacts Remove the starter solenqid for repair 8 If the voltage reading taken at the starter solenoid B terminal is still higher than 0 5 volt after cleaning the cables and connections at the starter solenoid ...

Page 459: ... procedure found in this section Individual Cables 1 Connect the positive lead of the Digital Multimeter to the battery positive post Connect the negative lead to the B terminal of the starter solenoid 2 Locate the excessive voltage drop in the cable by moving the voltmeter negative lead toward the battery Check each mechanical connection point When the reading disappears the last mechanical conne...

Page 460: ...the Starter motor does not run smoothly Voltmeter reads below 11 5 volts 16 10 5 Install the inductive pickup of the test to the wire between the battery positive post and starter solenoid B terminal 6 Connect a heavy ground wire between the battery negative post and a good clean ground on the starter motor housing 7 Press the remote starter switch and observe the starter ammeter gauge and voltmet...

Page 461: ...aft If there is continuity replace the starter motor armature DIGITAL MULTIMETER COMMUTATOR Starter Solenoid Solenoid S terminal Circuit Resistance Use the digital multimeter to check for continuity between the M terminal and S terminal Replace the starter solenoid if there is no continuity DIGITAL MULTIMETER Solenoid M terminal 1 Check for continuity between M terminal and the starter solenoid bo...

Page 462: ...pport bracket 7 Remove the two starter motor support nuts and washers 8 Remove the starter motor support 9 Disconnect the S terminal connector at the starter solenoid 10 Remove the 8 terminal washer and nut 11 Remove the 8 terminal connector from the starter solenoid 12 Remove the lower starter motor bolt 13 Remove the starter motor Installation NOTE Do not tighten the support bracket bolts until ...

Page 463: ... Drive End Housing 10 184006 Starter Solenoid Screws 2 11 184011 Drive Lever and Pin Drive Lever and Pin Plate 12 184008 Drive Lever and Pin Seal 13 Shim 14 Tighten to 55 75 lb in 6 8 15 N m A 1 Remove the starter motor Refer to the Starter Removal in this section 2 Remove the M terminal nut from the M terminal 3 Remove the field wire from the M terminal Starter Solenoid and Shim location Part Ite...

Page 464: ...ru bolts and the brush end plate and bushing THRU BOLT 2 BRUSH END PLATE AND BUSHING 8 NOTE Note the position of the drive lever and pin at time of removal to ensure the proper installation Remove the drive lever and pin from the starter drive STARTER DRIVE 9 Remove the drive lever and pin seal and drive lever and pin plate from the drive plate and pin 10 Using a deep socket or similar tool drive ...

Page 465: ...on 1 Field Wire Grommet 2 Starter Field Coil 3 Field Wire Connector 4 184015 Brush End Plate and Bushing 5 184019 Brush End Plate Screws 2 14 Remove the starter motor armature from the starter field coil 15 Remove the armature washers from the end of the starter motor armature shaft 16 Use a suitable tool pull back on the brush spring while pulling the brush set downward through the brush holder A...

Page 466: ...tension brush springs are properly positioned in the brush holder and against the brush set 4 Install the armature washers to the starter motor armature shaft 16 16 BRUSH HOLDER ARMATURE WASHERS 5 Install the two brush end plate screws and the brush end plate and bushing 6 Install the starter drive and the retaining collar 7 Install the starter drive stop ring 8 Compress the starter drive stop rin...

Page 467: ...r solenoid screws 16 Connect the field wire to the M terminal 17 Install the nut to the M terminal Tighten theM terminal nut to 71 106 lb in 8 12 N m 18 Install the starter motor Refer to the installation procedure in this section Starter Drive Replacement Disassembly 1 Remove the starter motor Refer to the removal procedure found in this section 2 Remove theM terminal nut from theM terminal 3 Rem...

Page 468: ...he starter drive 16 18 STARTER DRIVE 8 Remove the drive lever and pin seal and drive lever and pin plate from the drive lever and pin 9 Use a deep socket or similar tool to drive the retaining collar from the starter drive stop ring 11 222 STARTER DRIVE 10 Remove the starter drive stop ring from the groove in the starter motor armature shaft 11 Remove the retaining collar and starter drive from th...

Page 469: ...lever and pin seal and drive end housing with a thin film of contact cement DRIVE LEVER AND PIN 7 Install the drive lever and pin plate and drive lever and pin seal in the drive end housing against the starter field coil DRIVE END HOUSING 8 Install the thru bolts Tighten the thru bolts 55 75 lb in 6 8 N m 9 Install the plunger and spring 10 NOTE If the shims were removed during disassembly make su...

Page 470: ...r Description 1 184006 Drive End Housing 2 Plunger 3 Shims 4 Starter Solenoid 5 M Terminal 4 NOTE Shims are found between the starter solenoid and the drive end housing remove them and set aside Remove the starter solenoid screws and the starter solenoid 16 20 STARTER SOLENOID SCREWS 5 Disengage the plunger from the drive lever and pin and remove the plunger DRIVE LEVER AND PIN 6 Remove the thru b...

Page 471: ...4019 Brush End Plate Screws 2 10 Remove the starter motor armature from the starter field coil 11 Remove the armature washers from the end of the starter motor armature shaft 12 Use a suitable tool to pull back on the brush spring while pulling the brush set downward through the brush holder Assembly BRUSH SPRING 1 NOTE When the brush set extends past the brush spring release the brush spring The ...

Page 472: ... AND PIN 7 Install the yoke plate and yoke seal in the drive end housing Seat the drive end housing against the starter field coil 16 22 8 9 10 11 12 13 DRIVE END HOUSING Install the thru bolts Tighten the thru bolts to 55 75 lb in 6 8 N m Install the plunger NOTE If the shims were removed during disassembly make sure they are installed with the starter solenoid Connect the field wire to the M ter...

Page 473: ...ve the starter solenoid screws and the starter solenoid STARTER SOLENOID SCREWS 5 Disengage the plunger from the drive lever and pin and remove the plunger DRIVE LEVER AND PIN 6 Remove the two thru bolts and the brush end plate and bushing THRU BOLT 2 BRUSH END PLATE AND BUSHING 7 NOTE Note the position of the drive lever and pin at removal to ensure proper installation Remove the drive lever and ...

Page 474: ...e two brush end plate screws and the brush end plate and bushing 16 24 Part Item Number Description 1 Field Wire Grommet 2 Starter Field Coil 3 184014 Field Wire Connector 4 184015 Brush End Plate and Bushing 5 184019 Brush End Plate Screws 2 13 Remove the starter motor armature from the starter field coil 14 Remove the armature washers from the end of the starter motor armature shaft 15 Use a sui...

Page 475: ...springs are properly positioned in the brush holder and against the brush set 4 Install the starter motor armature washers onto the starter motor armature shaft BRUSH HOLDER ARMATURE WASHERS 5 Install the two brush end plate screws and the brush end plate and bushing 6 Install the starter drive and the retaining collar 7 Install the starter drive stop ring 8 Compress the starter drive stop ring an...

Page 476: ...thru bolts to 55 75 lb in 6 8 N m 14 Install the solenoid plunger 15 NOTE If shims were removed during disassembly make sure they are installed with the starter solenoid Position the starter solenoid and install the starter solenoid screws 16 Connect the field wire to the starter solenoid M terminal 17 Install the nut on the M terminal Tighten the M terminal nut to 71 1 06 Ib in 8 12 N m 18 Instal...

Page 477: ...rive End Housing 2 Plunger 3 Shims 4 Starter Solenoid 5 M terminal 4 NOTE If shims are found between the starter solenoid and the drive end housing remove them and set aside Remove the starter solenoid screws and the starter solenoid STARTER SOLENOID SCREWS 5 Disengage the plunger from the drive lever and pin and remove the plunger DRIVE LEVER AND PIN 6 Remove the two thru bolts and the brush end ...

Page 478: ... and spring 5 NOTE If shims were removed during disassembly make sure they are installed with the starter solenoid Position the starter solenoid and install the starter solenoid screws 6 Connect the field wire to the M terminal 7 Install the nut on the M terminal Tighten the M terminal nut to 71 1 06 Ib in 8 1 2 N m 8 Install the starter motor Refer to the installation procedure in this section 16...

Page 479: ...e drive lever and pin at removal to ensure proper installation Remove the drive lever and pin from the starter drive STARTER DRIVE 8 Remove the drive lever and pin seal and drive lever and pin plate from the drive lever and pin 9 Remove the two brush end plate screws and the brush end plate and bushing Part Item Number Description 1 Field Wire Grommet 2 Starter Field Coil 3 184014 Field Wire Conne...

Page 480: ...ature shaft BRUSH HOLDER ARMATURE WASHERS 4 Install the two brush end plate screws and the brush end plate and bushing 5 Coat the drive lever and pin plate drive lever and pin seal and drive end housing with a thin film of contact cement 16 30 DRIVE LEVER AND PIN 6 Install the yoke plate and yoke seal in the drive end housing Seat the drive end housing against the starter field coil DRIVE END HOUS...

Page 481: ...tions in the numerical order shown Disconnect the connections in the reverse order shown CAUTION Do not allow the vehicles to touch CAUTION Do not disconnect the battery of the vehicle to be started Doing so could damage the operational vehicle s electrical system while jump starting NOTE Make connections in numerical order disconnect in reverse order 4 3 2 1 DISCHARGED BATTERY BOOSTER BATTERY 1 P...

Page 482: ...ature coil windings for broken or burned insulation and unwelded or open connections 2 Check starter motor armature for open circuits shorts and grounds Check for pole rub or rub on magnetic shunts 3 Place the starter motor armature on V blocks 4 Rotate the starter motor armature and use a Dial Indicator With Bracket Tool to measure the runout of the commutator 16 32 V BLOCKS 5 If the runout is 0 ...

Page 483: ...ng bushings are worn and or the starter motor armature shaft ends are worn Replace the bushings 17 Check the condition of the starter motor armature shaft ends If the starter motor armature shaft ends are worn or damaged replace the starter motor armature Bushings Check the condition of the brush end plate bushing and the drive end housing bushing BRUSH END DRIVE END DRIVE END PLATE BUSHING HOUSIN...

Page 484: ...he brush set 3 If the positive brush is near or beyond the wear limit replace the starter field coil WEAR LIMIT LINE 17 mm 0 671n 4 Use Digital Multimeter to check for continuity between the insulated brush holders and the brush set 16 34 If continuity exists between either insulated brush holder and the brush set repair or replace the brush set DIGITAL MULTIMETER 5 Check the sliding action of the...

Page 485: ...in both directions 6 If the starter drive gear does not turn freely in one direction and lock up in the opposite direction replace the starter drive ADJUSTMENTS Starter Drive Pinion Depth Adjustment NOTE This procedure is performed with the starter motor removed from the vehicle To remove the starter motor refer to the removal procedure in this section MILLED CONDITION EXCESSIVE WEAR ON 2 OR 3 TEE...

Page 486: ... the field wire connector to the M terminal of the starter solenoid 16 36 11 Install the M terminal nut to the M terminal Tighten the M terminal nut to 71 106 lb in 8 12N m SPECIFICATIONS Starter Specifications Description Specifications Commutator Runout 0 002 inch 0 05 mm Commutator Outer 1 22 inch 31 mm Diameter Commutator Segment 0 020 0 30 inch 0 5 Depth 0 8 mm Brush Wear Limit 0 453 inch 11 ...

Page 487: ...harging system is a negative ground system consisting of a alternator with an internal electronic voltage regulator a battery a volt gauge battery ground cable battery to starter relay cable and the necessary electrical wiring Refer to the Electrical and Vacuum Troubleshooting Chart in this section IGR Alternator with Integral Regulator Internal Fan and Regulator Type The alternator is mounted on ...

Page 488: ... a charging system malfunction DIAGNOSIS AND TESTING Electrical Schematic Charging System A 12 volt battery is used to start the vehicle and supplies extra electrical power at times of high system current demand HOT IN START OR ON HOT AT ALL Tl iiE HOT Al ALL TtMES iOA J ___ ___ JlB 20 Alternator 95 95 17 2 ...

Page 489: ...arting system tests on the vehicle note the complaint such as slow cranking battery discharged top of battery wet voltmeter gauge showing discharge and proceed to the Troubleshooting Chart NOTE Use Digital Multimeter or equivalent to perform electrical Pinpoint Tests CONDITION POSSIBLE SOURCE SOLUTION REMEDY System Does Not Charge Loose or worn drive belt GO to Pinpoint Test A 1 Corroded battery c...

Page 490: ...TAYS ON ENGINE RUNNING TEST STEP RESULT ACTION TO TAKE C1 I CHECK DRIVE BELT TENSION Perform the drive belt adjustment procedure in YES Go to C2 Section 11 Adjust or Replace the drive Is the drive belt adjusted properly NO belt C2 I CHECK ALTERNATOR Perform the alternator component tests in this YES Refer to Section 19 to section diagnose the charging Is the alternator OK NO system Repair or Repla...

Page 491: ...leads to the negative battery post The multimeter clips must contact the battery posts and not the tester clips Unless this is done the actual battery terminal voltage will not be indicated 4 Turn the load control knob in a clockwise direction until the ammeter reads approximately half the cold cranking amps 5 When the ammeter has read the required load for 15 seconds note the multimeter RESULT AC...

Page 492: ...ately 2000 rpm The voltage should increase a minimum of 0 5 volts above the base voltage Refer to the Bench Test procedures 17 6 to check the alternator if the voltage does not increase as specified If the voltage increased as specified the charging system is operating normally Proceed to the battery capacity testing Drain Testing With Clamp On DC Ammeter Test Procedure 1 Turn the ignition off and...

Page 493: ...ess than 0 05 amps If it exceeds 0 05 amps after a few minutes and if this drain did not show in previous tests the drain is most likely caused by a malfunctioning electronic component As in previous tests remove the fuses in the junction panel one at a time to located the problem circuit Alternator On Vehicle Tests Load Test 1 Connect the leads of the Starting and Charging Tester to the vehicle a...

Page 494: ... OFF Engine at Idle B approximately 14 1 14 7 volts 12 volts L approximately 13 0 14 0 volts one 1 volt s approximately 14 1 14 7 volts 12 volts 4 If the voltages are as specified check the wiring harness between the battery and the B terminal It the voltages are below specification check the wiring harness If the wiring harness is in good condition refer to Alternator Bench Tests in this section ...

Page 495: ... continuity between each slip ring and the rotor core ROTOR CORE SUP RINGS 4 If there is continuity replace the alternator rotor 5 Check the color and condition of the slip rings 6 If the slip rings are dark clean them with fine sandpaper 7 If the slip rings are grooved refinish them in a lathe Brushes 1 Inspect the alternator brushes for wear Alternator Brush 21 5mm 0 851N Wear Limit Line l_o 2 I...

Page 496: ...continuity between the following terminals of the rectifier 17 10 Item Part Description Number 1 E Terminal 2 8 Terminal 3 P3 Terminal 4 P2 Terminal 5 P1 Terminal 6 L Terminal Diode Specification Negative Black Positive Red Continuity E P1 P2 P3 No 8 P1 P2 P3 Yes L P1 P2 P3 Yes P1 P2 P3 E Yes P1 P2 P3 8 No P1 P2 P3 L No E L 1 If the rectifier fails any of the above continuity checks replace the re...

Page 497: ...y Refer to this section for diagnosing the battery REMOVAL AND INSTALLATION Environmental Protection Help Us Protect Our Environment It is strongly recommended that lead acid batteries be returned to an authorized recycling facility for disposal SUBJECT PAGE SERVICE PROCEDURES Battery Charging 17 1 3 Environmental Protection 17 11 Jump Starting 17 13 Maintenance Free Batteries 17 13 CLEANING AND I...

Page 498: ...not over tighten 6 Apply petroleum jelly to the terminals Battery Tray Removal 1 Remove the battery Refer to the removal procedure in this section 17 12 2 Lift the battery tray from the engine compartment Installation 1 Position the battery tray in the engine compartment 2 Install the battery Refer to the installation procedure in this section SERVICE PROCEDURES WARNING HYDROGEN AND OXYGEN GASES A...

Page 499: ... with charger still on measure battery voltage It shows 12 volts or higher the battery is accepting a charge and is capable of being recharged However it may require up to two hours of charging with batteries colder than 41 F 5 C before the charge rate is high enough to show on the charger ammeter It has been found that all non damaged batteries can be charged by this procedure If a battery cannot...

Page 500: ...HE END WALLS BECAUSE THE SIDE WALLS HAVE ADDITIONAL STRENGTH DUE TO INNER CELL PARTITIONS THIS IS PARTICULARLY IMPORTANT WITH POLYPROPYLENE CASE BATTERIES WHICH HAVE FLEXIBLE END WALLS GRIPPING THE END WALLS ON THIS TYPE OF BATTERY COULD CAUSE THE ELECTROLYTE TO SPEW FROM SOME OF THE CELLS AND POSSIBLY CAUSE PERSONAL INJURY AND DAMAGE TO THE VEHICLE Use a suitable battery carrier for lifting and t...

Page 501: ...relay cable Refer to the Electrical and Vacuum Troubleshooting Manual for schematics and locations of components and wiring Integral Alternator Regulator The alternator produces an output current and has an internal electronic voltage regulator The alternator is mounted on the front of the engine and is driven by the alternator water pump drive belt Alternator Circuit Circuit Description Battery P...

Page 502: ...l Nut 6 B Terminal Lead 1 Disconnect the battery ground cable 2 Remove the B terminal nut 3 Remove the B terminal lead 4 Disconnect the alternator electrical connector 5 Remove the adjustment bolt 6 Raise the vehicle 7 Remove the alternator bolt 8 Disconnect the alternator water pump drive belt from the alternator pulley 9 Remove the alternator from the vehicle Installation To install reverse the ...

Page 503: ...r and Coil 12 184025 Alternator Front Housing Capscrews 4 req d 1 Make an alignment mark on the alternator front housing and alternator rear housing and bearing and stator frame for proper assembly alignment Part Item Number 13 184027 14 184023 15 16 184024 17 184026 18 184028 19 20 A B Description Bearing Retainer Screws 4 req d Alternator Pulley Nut Lockwasher Alternator Pulley Alternator Front ...

Page 504: ...ing to temperatures higher than 122 140 F 50 600C Use a 200 watt soldering iron to heat the alternator rear housing and bearing area to allow the alternator rear bearing to be removed from the alternator rear housing 4 Use a flat blade screwdriver to separate the alternator front housing from the stator and coil 17 18 Alternator Rear Housing and Bearing 5 NOTE Be careful not to lose the stopper sp...

Page 505: ... the alternator rear bearing from the alternator rotor assembly 13 Remove the B terminal nut and insulator 14 Remove the rectifier screw 15 Remove the two alternator regulator screws 16 Use a flat blade screwdriver to separate the stator and coil from the alternator rear housing 17 Remove the stator and coil along with the brush holders and rectifier from the alternator rear housing 18 Remove the ...

Page 506: ...ectifier and brush holder to the alternator rear housing 6 Position the stator and coil in the alternator rear housing so that one of the shallow ridges in the lamination lines up with the case bolt holes 17 20 7 Install the rectifier screw 8 Install the two alternator regulator screws 9 Install the insulator and the B terminal nut 10 Use a suitable socket or bearing installer to fit the outer bea...

Page 507: ...he alternator front housing 14 Install alternator pulley and lockwasher 15 Secure the alternator rotor in a soft jawed vise and install the alternator pulley nut Tighten the alternator pulley nut to 43 58 lb ft 59 78 N m 16 Use a stiff wire or straightened paper clip to retain the brushes in their holders 21 If the alternator rotor drags or does not turn easily disassemble the alternator to determ...

Page 508: ...sing and bearing to temperatures higher than 122 140 F 50 60 C Use a 200 watt soldering iron to heat the alternator rear housing and bearing area to allow the alternator rear bearing to be removed from the alternator rear housing 4 Use a flat blade screwdriver to separate the alternator front housing from the stator and coil 17 22 5 NOTE Be careful not to lose the stopper spring that fits in the g...

Page 509: ...regulator and rectifier from the alternator rear housing 11 Remove the shield from the voltage regulator assembly 12 CAUTION To avoid overheating and damage to the rectifier work quickly while soldering Do not apply the soldering iron for more than five seconds at a time Unsolder the stator and coil leads from the alternator rear housing 13 Unsolder the alternator regulator assembly leads 14 Separ...

Page 510: ... pliers which will act as a heat sink to protect the diodes Solder the alternator regulator assembly leads 4 Solder the stator and coil leads 17 24 5 Install the shield onto the voltage regulator assembly 6 Install the stator and coil assembly along with the rectifier and voltage regulator to the alternator rear housing 7 Position the stator and coil in the alternator rear housing so that one of t...

Page 511: ...r to this section for the diagnosis and testing procedures Front Bearing Replacement Disassembly 1 Make an alignment mark on the alternator front housing and alternator rear housing and bearing and stator and coil frame for proper assembly alignment 2 Remove the four alternator front housing capscrews FRONT HOUSING 3 CAUTION Do not apply direct heat to the alternator rear housing and bearing Exces...

Page 512: ...ING 6 Secure the alternator rotor in a soft jawed vise and remove the alternator pulley nut 7 Remove the lockwasher and alternator pulley 8 Remove the alternator rotor from the alternator rear housing 9 Remove the four bearing retainer screws 10 Remove the bearing retainer 11 Use an appropriate socket or driver that fits the outer bearing race to press the alternator front bearing out of the alter...

Page 513: ...ring is located on the inner side toward the slip rings Use a suitable driver on the inner bearing race to press the alternator rear bearing onto the rotor shaft I j I 4 Place the alternator rotor into the alternator front housing 5 Install alternator pulley and lockwasher 6 Secure the alternator rotor in a soft jawed vise and install the alternator pulley nut Tighten the alternator pulley nut to ...

Page 514: ...ng procedures Rear Bearing Replacement Disassembly 1 Make an alignment mark on the alternator front housing and alternator rear housing and bearing and stator and coil frame for proper assembly alignment 2 Remove the four alternator front housing capscrews 17 28 3 CAUTION Do not apply direct heat to the alternator rear housing and bearing Excessive heat could cause the alternator rear bearing grea...

Page 515: ...ing Attachment or equivalent and a suitable socket to press the alternator rear bearing from the alternator rotor assembly Assembly 1 NOTE Install the alternator rear bearing so that the stopper spring is located on the inner side toward the slip rings Use a suitable driver on the inner bearing race to press the alternator rear bearing onto the rotor shaft 2 Use a stiff wire or straightened paper ...

Page 516: ...lternator to determine the cause Refer to this section for the diagnosis and testing procedures Alternator Regulator Disassembly 1 Make an alignment mark on the alternator front housing and alternator rear housing and bearing and stator and coil frame for proper assembly alignment 2 Remove the four alternator front housing capscrews 17 30 FRONT HOUSING 3 CAUTION Do not apply direct heat to the alt...

Page 517: ...ate the alternator front housing from the stator and coil 5 NOTE Be careful not to lose the stopper spring that fits in the groove of the alternator rotor shaft STOPPER SPRING Remove the alternator front housing and alternator rotor from the alternator rear housing and bearing 6 Remove the B terminal nut and insulator 7 Remove the rectifier screw 8 Remove the two alternator regulator screws 17 31 ...

Page 518: ...il and voltage regulator 15 Remove the two shields from the voltage regulator 17 32 16 Remove the solder from the voltage regulator and remove the alternator brush REMOVE SOLDER 17 Refer to this section for the diagnosis and testing procedures Assembly 1 Solder the alternator brush into the voltage regulator 2 Assemble the rectifier stator and coil and voltage regulator 3 CAUTION Use only rosin co...

Page 519: ...t one of the shallow ridges in the lamination lines up with the case bolt holes CASEBOLT I 1I 8 Install the rectifier screw 9 Install the two alternator regulator screws 10 Install the insulator and the B terminal nut 11 Use a stiff wire or straightened paper clip to retain the brushes in their holders 17 33 ...

Page 520: ... rotor if the alternator rotor shaft is not smooth Check all wire leads on the alternator rotor for poor solder connections or burned insulation Resolder poor connections and replace the alternator rotor if signs of burned insulation exist 17 34 Stator and Coil Wipe the stator and coil with a clean cloth Do not clean with solvent Check all wire leads on the stator and coil for poor solder connecti...

Page 521: ...tor Refer to Section 03 05 for the drive belt adjustment procedure SPECIFICATIONS TORQUE SPECIFICATIONS Description N m Lb Ft Alternator Pulley Nut 59 78N 43 58 Alternator Front Housing 4 5 Capscrews SERVICE TOOLS AND EQUIPMENT Bearing Puller Attachment Lb ln 35 48 17 35 ...

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Page 523: ...ted on the steering column The head lamp switch is on the left side of the steering column and is serviced with the multi function switch as an assembly The headlamps turn on when the rotary switch at SUBJECT PAGE DIAGNOSIS AND TESTING continued Troubleshooting Chart Dome Light 18 18 Troubleshooting Chart Headlamps 18 3 Troubleshooting Chart Turn Signals Hazard Flasher 18 8 Troubleshooting Chart P...

Page 524: ...tivated current is directed to the backup lamps The backup lamps will indicate the vehicle is engaged in the reverse gear When the transaxle is shifted to any other gear position the backup lamps are turned off 18 2 Turn Signals and Hazard Lamps To operate the turn signals the ignition switch must be in the ON position Move the turn signal switch stalk in the desired direction down for left and up...

Page 525: ...AKE I CHECK FUSE Check the fuse located in the main fuse panel Yes Go to A4 Is the fuse OK No Go to A2 I CHECK THE HEADLAMP SYSTEM Key OFF Yes Go to A3 Replace the Fuse Inspect the fuse No Go to A4 Does the fuse fail again I CHECK FOR SHORT GROUND Key OFF Yes Replace the fuse Go to A4 Remove the fuse No Service the wire Locate and disconnect the multi function switch connector Locate and disconnec...

Page 526: ...nce less than 5 ohms between the headlamp relay and the multi function switch and greater than 10 000 ohms between the headlamp relay connector and ground PINPOINT TEST B Headlamps on Continuously TEST STEP RESULT ACTION TO TAKE 81 I CHECK HEADLAMP RELAY Perform the Headlamp Relay component test in the Yes Go to 82 section No Replace the headlamp relay Is the headlamp relay OK B 2 I CHECK THE HEAD...

Page 527: ...e the resistance between the terminals on the multi function switch with the headlamp switch in the following positions Headlamp Switch Terminals Resistance Flash to Pass less than 5 ohms All Others Greater than 10 000 ohms Low Beam Greater than 10 000 ohms Less than 5 ohms High Beam Less than 5 ohms Greater than 10 000 ohms 3 Measure the resistance between terminals on the multi function switch w...

Page 528: ...ally inspect the components of the brake light system 3 Check the wiring harness for obvious signs of shorts opens bad connections or damage 4 If fault is not visually evident determine the symptom and proceed to the following Troubleshooting Chart Visual Inspection Chart Mechanical Electrical None Blown fuse Damaged brake light bulb s Damaged wiring harness Loose or corroded connections NOTE Use ...

Page 529: ...lts panel F5 I CHECK BRAKE ON OFF SWITCH Key OFF Yes Service the wire s between the Disconnect the brake on off switch connector brake on off switch and the Measure the resistance between the terminals of brake lights the brake on off switch with the brake pedal Replace the brake on off switch depressed and released No Does the resistance switch between less than 5 ohms with the brake pedal depres...

Page 530: ...rness Loose or corroded connections NOTE Use a digital multimeter or equivalent to perform electrical Pinpoint Tests Turn Signal I Hazard Flashers Condition Possible Source Action Turn Signal Lamps I Fuse Go to Pinpoint Test H1 Hazard Flasher Lamps Multi function switch Inoperative Circuit Indicator Flasher Bulbs Turn Signal Lamps Multi function switch Go to Pinpoint Test J1 Inoperative in One Cir...

Page 531: ...e the resistances greater than 10 000 ohms H4 I CHECK TURN SIGNAL SWITCH Perform the Turn Signal Switch component test in this Yes Go to H5 section No Replace the multi function Is the turn signal switch OK switch H5 I CHECK POWER SUPPLY TO TURN SIGNAL SWITCH Key OFF Yes Go to H6 Disconnect the multi function switch connector No Service the wire between the Key ON multi function switch and Measure...

Page 532: ...es Replace the indicator flasher Disconnect the indicator flasher connector No Service the wire s in Using a jumper connect the battery positive terminal question to the LH turn signal inoperative wire or the RH turn signal inoperative at the indicator flasher connector Do the turn signal lamps illuminate PINPOINT TEST K TURN SIGNALS ON CONTINUOUSLY TEST STEP RESULT ACTION TO TAKE K1 I CHECK TURN ...

Page 533: ...ctor No Service the wire Disconnect the multi function switch connector Measure the resistance of the wire between multi function switch connector and indicator flasher connector Is the resistance less than 5 ohms PINPOINT TEST N HAZARD FLASHER ON CONTINUOUSLY TEST STEP RESULT ACTION TO TAKE N1 I CHECK HAZARD FLASHER SWITCH Key OFF Yes Go to N2 Disconnect the multi function switch connector No Rep...

Page 534: ...d accessories 5 If fault is not visually evident determine the symptom and proceed to the following Troubleshooting Chart Troubleshooting Chart Parking Lamps Side Marker Lamps License Lamp NOTE Use a digital multimeter or equivalent to perform electrical Pinpoint Tests Refer to Troubleshooting Chart below TROUBLE SHOOTING CHART PARKING LAMPS SIDE MARKER LAMPS LICENSE LAMP CONDITION POSSIBLE SOURCE...

Page 535: ...ing lamp Is the parking lamp relay OK relay P5 I CHECK POWER SUPPLY TO RELAY Key OFF Yes Go to P6 Remove the parking lamp relay No Service the wire s Measure the voltage on the wires at the parking lamp between the Stop Light relay connector fuse and the parking lamp Are the voltages greater than 10 volts relay P6 I CHECK HEADLAMP SWITCH Perform the Headlamp Switch component test in this Yes Go to...

Page 536: ...p connector s and ground Is the resistance less than 5 ohms PINPOINT TEST R PARKING LAMPS ON CONTINUOUSLY TEST STEP RESULT ACTION TO TAKE R1 I CHECK THE HEADLAMP SWITCH Perform the Headlamp Switch component test in the Yes Go to R2 headlamp diagnosis portion of this section No Replace the multi function Is the headlamp switch OK switch R2 I CHECK PARKING LAMP RELAY Perform the Parking Lamp Relay c...

Page 537: ...place the tail lamp Measure the resistance of the wire between the rear socket in question lamp connector s and ground No Service the wire s Is the resistance less than 5 ohms PINPOINT TEST U LICENSE LAMP INOPERATIVE TEST STEP RESULT ACTION TO TAKE U1 I CHECK LICENSE LAMP BULB Remove inoperative license lamp bulb Yes Go to U2 Check the continuity between the terminals of bulb No Replace the bulb s...

Page 538: ...E ACTION Backup Lamps Inoperative Fuse Go to Pinpoint Test U1 Circuit Park neutral position switch Individual Backup Lamp Circuit Go to Pinpoint Test V1 Inoperative Backup lamp bulb s Backup Lamps on Circuit Check for short to power on the Continuously Park Neutral Position wire Service as necessary Switch Otherwise replace the park neutral position switch Pinpoint Tests Backup Lamps PINPOINT TEST...

Page 539: ...e backup lamp backup lamp bulb bulb Does the continuity exist V2 I CHECK POWER TO BACKUP LAMP Disconnect the rear lamp connector s Yes Go to V3 Key ON No Service the wire Transaxle in REVERSE R Measure the voltage on the wire at the rear of the lamp connector s V3 I CHECK BACKUP LAMP GROUND Disconnect the rear lamp connector Yes Replace the backup lamp Measure the resistance of the wire between th...

Page 540: ... dome lamp bulb Measure the resistance the wire between the terminal of the fuse holder and ground Is the resistance greater than 10 000 ohms W4 I CHECK DOME LAMP BULB Key OFF Yes Go to W5 Remove the dome lamp bulb No Replace the dome light bulb Check the continuity between the terminals of the dome lamp bulb Does continuity exist W5 I CHECK POWER SUPPLY TO LAMP Key OFF Yes Go to W6 Locate and dis...

Page 541: ...he bulb Refer to the appropriate procedure in this section b Remove the bulb from the lamp socket This can be done one of two ways depending on the type of bulb used for each application Refer to the following illustrations Press in and Rotate to Remove DOUBLE ELEMENT MINIATURE BULB LAMP SOCKET SINGLE ELEMENT MINIATURE BULB Switch Headlamp Removal and Installation The headlamp switch is incorporat...

Page 542: ...IF THE BULB IS DROPPED KEEP THE HEADLAMP BULB OUT OF REACH OF CHILDREN NOTE A correctly aimed headlamp should not require reaming after replacement of the headlamp Never turn on the headlamps with the headlamp removed 1 Remove the hood panel 2 Remove the four screws and the headlamp trim ring securing the headlamp to the headlamp housing 3 Remove headlamp from the headlamp housing 4 Disconnect the...

Page 543: ...s bulb socket and remove it from the front side marker lamp housing Front Signal Turn Light Removal 1 Remove two screws securing the amber lens to the housing 2 Remove the amber lens from its housing 3 Rotate the front signal bulb in its socket and remove it from the front signal lamp housing Installation To install reverse the removal procedure Rear Tail Light The rear tail light assembly consist...

Page 544: ...e the license plate bulb in its socket and remove it from the licensee plate lamp housing Installation To install reverse the removal procedure Clearance Lights Removal 1 Remove two screws securing the red lens to the housing 2 Remove the red lens from its housing 3 Rotate the clearance light bulb in its socket and remove it from the clearance lamp housing Installation To install reverse the remov...

Page 545: ...e recommended inflation pressure Brake On Off BOO Switch 1 Disconnect the Brake On Off BOO switch electrical connector 2 Loosen the BOO switch nuts 3 Connect the digital multimeter across the BOO switch terminals 4 Position the BOO switch until multimeter indicates continuity 5 Carefully move the BOO switch toward brake pedal until the multimeter indicates the BOO switch is open infinite resistanc...

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Page 547: ...d gear and shaft are contained in a sleeve that is bolted to the transaxle Electrical connections from the gear and shaft are made to the speedometer SUBJECT PAGE REMOVAL AND INSTALLATION Auxiliary Switches 19 12 Bulbs Gauges 19 11 Gauge Removal and Installation 19 11 Indicator Warning Lights 19 11 Speedometer Sender Drive 19 12 Speedometer Sleeve Seal 19 14 SERVICE PROCEDURES Drive and Driven Gea...

Page 548: ...he engine is started Release the parking brake and the light will go off Brake Fluid Level Warning Light It indicates low brake fluid level in the reservoir The brake master cylinder fluid level sensor is located in the master cylinder reservoir When the brake fluid drops to a predetermined level the contact on the float completes the ground for the indicator circuit The parking brake signal switc...

Page 549: ...Turn Signals Hazards If the systems are not working properly refer to the appropriate section of this service manual to diagnose the system in question 4 Check the wiring harness for obvious signs of shorts opens bad connections or damage 5 If the fault is not visually evident determine the symptom and proceed to the following Troubleshooting Chart NOTE Use a digital multimeter to perform electric...

Page 550: ...rtrain Control I Emissions module Diagnosis Manual Circuit Pinpoint Tests Instrument Panel PINPOINT TEST A FUEL LEVEL ALWAYS READS EMPTY TEST STEP RESULT ACTION TO TAKE A1 I CHECK FUEL LEVEL SENSOR Perform the Fuel Level Sensor component test in this Yes Go to A2 section No Replace the fuel level Is the fuel level sensor OK sensor A2 I CHECK FUEL GAUGE Perform the Fuel Gauge component test in this...

Page 551: ...UEL GAUGE Perform the Fuel Gauge component test in this section Yes Service the wire between Is the fuel gauge OK the gauge and ground No Replace the fuel gauge PINPOINT TEST C FUEL LEVEL ALWAYS READS FULL TEST STEP RESULT ACTION TO TAKE C1 I CHECK FUEL LEVEL SENSOR Perform the Fuel Level Sensor component test in this Yes Go to C2 section No Replace the fuel level Is the fuel level sensor OK senso...

Page 552: ...rform a calibration test to check speedometer wire for shorts operation Does the speedometer operate freely F2 I CHECK SPEEDOMETER GEAR ASSEMBLY Remove the speedometer gear assembly from the Yes Replace the speedometer transaxle gear assembly Inspect the speedometer gear No Replace the speedometer Are there any broken teeth on the speedometer gear PINPOINT TEST G SPEEDOMETER ODOMETER INOPERATIVE T...

Page 553: ...he connector Is the voltage greater than 10 volts H5 I CHECK WARNING INDICATORS GROUND Key OFF Yes Replace the warning Disconnect warning indicator connector indicator at the instrument Measure the resistance of the wire s between the panel warning indicator s and ground No Service the wire s for Are the resistances less than 5 ohms open PINPOINT TEST J BRAKE WARNING NEVER I ALWAYS ON TEST STEP RE...

Page 554: ...istance less than 5 ohms J5 CHECK PARKING BRAKE SIGNAL SWITCH Key OFF Yes Go to J6 Locate and disconnect the parking brake signal switch No Replace the parking brake connector signal switch and bracket Measure the resistance of the wire between the parking brake signal switch and ground under the following conditions Parking Brake Resistance Engaged Less than 5 ohms Released Greater than 10 000 oh...

Page 555: ...r connector Measure the resistance of the wire between the voltmeter and ground PINPOINT TEST L LOW OIL PRESSURE WARNING NEVER ALWAYS ON TEST STEP RESULT ACTION TO TAKE L1 I CHECK ENGINE OIL PRESSURE Check the engine oil pressure If necessary refer to Yes Go to L2 Section 11 Engine No Refer to Section 11 Is the engine oil pressure within specification Engine to service the engine L2 I CHECK LOW OI...

Page 556: ...or RH turn signal operate properly turn indicator assembly M2 I CHECK LH AND OR RH INDICATOR BULB Key OFF Yes Go to M3 Remove the LH and RH turn indicator lamp assembly No Replace the LH and or RH Check the continuity between the terminals of the LH turn indicator assembly and or RH turn indicator lamp assembly Does continuity exist M3 ICHECK THE LH AND OR RH SIGNAL INPUT TO THE INSTRUMENT PANEL K...

Page 557: ...he instrument panel 4 Remove the gauge through the front part of the instrument panel Install the replacement gauge into the instrument panel in the reverse order of removal Test the gauge for continuity If the gauge does not operate as specified replace the gauge Instrument Panel Retaining Bracket Gauge Yes No Bulbs Gauges Removal Replace the high beam indicator lamp assembly Service the wire 1 R...

Page 558: ... back of the auxiliary switch 4 Compress the two tabs on each side of the auxiliary switch 5 Push out the auxiliary switch through the front of the instrument panel 19 12 Installation To install reverse the removal procedure Speedometer Sender Drive The speedometer sender drive is located at the transaxle where the driven gear meshes with drive gear mounted on the differential The driven gear and ...

Page 559: ...ttaching bolt 4 Pull the speedometer sleeve and driven gear as an assembly out of the transaxle 5 Remove the 0 ring from the speedometer gear sleeve 6 Remove the roll pin using a pin punch 7 Remove the speedometer gear and shaft as an assembly ROLL PIN Installation GEAR SHAFT ASSEMBLY 1 Install the speedometer gear and shaft in the sleeve 2 Install the roll pin 3 Install a new 0 ring on the speedo...

Page 560: ... procedure in this section SERVICE PROCEDURES Drive and Driven Gears Damaged 1 A speedometer gear in the speedometer sender drive with two or three adjoining teeth badly scored is indicative of improperly assembly procedure The gear should be inserted in the transaxle while twisting the speedometer gear assembly back and forth This will ensure initial gear engagement and prevent gear damage Never ...

Page 561: ...curacy problem Odometer accuracy can be checked by using roads established at mile increments or a known local course If roads with mile markers are used a five mile stretch is recommended to allow for inaccuracies If an error is greater than 3 75 percent a change to the speedometer drive driven gear selection tire size or tire inflation may need attention The odometer should be checked again to v...

Page 562: ...D TESTING continued Troubleshooting Chart Ignition Switch 19 1 8 REMOVAL AND INSTALLATION Flasher Indicator 19 20 High Beam Flash to Pass Switch 19 20 Ignition Switch 19 20 Multi Function Switch 19 19 SPECIFICATIONS SERVICE TOOLS EQUIPMENT 19 21 The windshield wipers are controlled by the wiper control lever which is integral with the multi function switch The wiper control lever is located on the...

Page 563: ...er switch then releasing it The hazard flasher switch remains in or toward the steering column while it is in the off position NOTE The turn signal is system deactivated when the hazard flasher system is on Turn signal and windshield wiper switch motion does not affect the hazard flasher system Flasher Indicator The indicator flasher allows the turn signal and hazard flasher switch to complete the...

Page 564: ...ld Wiper Switch Fuse Refer to this section to diagnose Inoperative Circuit the wiper system Windshield wiper switch Pinpoint Tests Ignition Switch PINPOINT TEST A IGNITION SWITCH INOPERATIVE TEST STEP RESULT ACTION TO TAKE A1 I CHECK POWER SUPPLY TO IGNITION SWITCH Key OFF Yes Go to A5 Disconnect the ignition switch connector No Service the wire s Measure the voltage on the wire at the ignition sw...

Page 565: ...ch Continuity Test in this Yes Service the wire between the section ignition switch and fuse panel Is the ignition switch OK No Replace the ignition switch PINPOINT TEST D NO POWER IN START POSITION TEST STEP 01 I CHECK IGNITION SWITCH Perform the Ignition Switch Continuity Test in this section Is the ignition switch OK Component Tests Ignition Switch Ignition Switch Continuity Test Use a digital ...

Page 566: ... off the steering column 19 20 Installation To install reverse the removal procedure Tighten the sliding contact screws to 18 26 lb in 2 3 N m Ignition Switch Removal 1 Disconnect the battery ground cable 2 Remove the instrument top panel from the instrument panel 3 Mark and then disconnect the electrical connectors at the back of the ignition switch 4 Remove the ignition retaining nut 5 Remove th...

Page 567: ...Section 19 Instrument Panel Controls and Warning Lights SPECIFICATIONS SERVICE TOOLS EQUIPMENT Digital Multimeter 19 21 ...

Page 568: ...f the wind shield wiper pivot shafts are serrated and cone shaped to prevent the windshield pivot arm from slipping in the windshield wiper pivot shaft The windshield wiper pivot arm is installed in the windshield pivot shaft and windshield parallel arm is installed on the windshield pivot shaft They are held in position with windshield wiper pivot arm nuts A retaining clip attaches the windshield...

Page 569: ...nected to windshield wiper motor 2 Visually inspect the components of the wiper system 3 Check windshield wiper pivot arms for proper adjustment and proper connection to the motor shaft 5 If the fault is not visually evident determine the symptom and proceed to the Troubleshooting Chart Troubleshooting Chart Wiper System NOTE Use a digital multimeter to perform electrical Pinpoint Tests CONDITION ...

Page 570: ...he wire at the windshield wiper motor connector and the multi function switch connector Are the voltages greater than 10 volts A5 I CHECK WINDSHIELD WIPER MOTOR Perform the windshield wiper motor component test Yes Go to A6 in this section No Replace the windshield Is the windshield wiper motor OK wiper motor A6 I CHECK WINDSHIELD WIPER SWITCH Perform the windshield wiper switch test component Yes...

Page 571: ...sconnect the multi function switch switch connector No Service the wire s Disconnect the windshield wiper motor connector Measure the resistance of the wire between the multi function switch connector and the windshield wiper motor connector Is the resistance less than 5 ohms PINPOINT TEST E WINDSHIELD WIPERS CONTINUE TO RUN WHEN SWITCH IS TURNED OFF TEST STEP E1 I CHECK WINDSHIELD WIPER SWITCH Pe...

Page 572: ...gage it from the tapered splines on the windshield wiper parallel arm shaft and wiper motor 3 Remove the wiper assembly including the windshield parallel arm and parallel wiper arm Installation 1 Turn the ignition switch to the ON position 2 NOTE The on off cycling of the windshield motor will locate the windshield wiper mounting arm and parallel arm in the park position 19 26 Turn the windshield ...

Page 573: ...ument panel 4 Remove rivets and top plate covering the wiper motor pivot arm assembly NOTE Some models may not have the top plate 5 Remove the wiper arm and parallel arm assembly from the wiper arm and parallel arm base 6 Pry and remove retaining clip connecting the pivot arm of the wiper to the wiper arm and parallel arm base 7 Separate the pivot arms from the wiper motor and the wiper arm and pa...

Page 574: ...he front window weatherstrip 5 NOTE Ensure the windshield wiper mounting arm and parallel arm is aligned with the windshield wiper mounting arm shaft and parallel arm shaft so that the windshield wiper mounting arm and parallel arm shaft splines are fully seated Tighten the windshield wiper parallel arm nut to 8 1 0 lb ft 12 14 N m and windshield wiper mounting nut to 12 14 lb ft 16 20 N m SPECIFI...

Page 575: ...rupt system the PNP switch is a safety device preventing the engine from starting while the AT is in a forward or reverse gear The PNP switch closes when the gearshift lever is in the PARK P or NEUTRAL N positions only allowing the starter motor to operate with the ignition switch in the START ppsition The PNP switch is not adjustable The PNP switch is located on the transaxle case SUBJECT DIAGNOS...

Page 576: ...utral position switch PNP switch Starter motor Engine Cranks With Gearshift Circuit REPLACE the PNP switch Lever in Ranges Other Than PNP switch PARK or NEUTRAL Starter motor Pinpoint Test Starting Interrupt System PINPOINT TEST A ENGINE WILL NOT CRANK TEST STEP RESULT ACTION TO TAKE A1 CHECK BATTERY Check the battery Refer to Section 17 Yes GO to A2 Is the battery OK No CHARGE or REPLACE the batt...

Page 577: ...Removal 1 Disconnect the battery ground cable 2 Disconnect the Park Neutral Position PNP switch electrical connector PARK NEUTRAL POSITION PNP SWITCH 3 Use an extension and a crow s foot wrench to remove the PNP switch from the front LH side of the transaxle case motor and the PNP switch Installation 1 Apply Gasket Eliminator or equivalent to the threads of the PNP switch 2 Install the PNP switch ...

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Page 579: ... to the horn the ground circuit is provided through its mounting bracket Troubleshooting Chart Horn System SUBJECT PAGE DIAGNOSIS AND TESTING continued Troubleshooting Chart Horn System 19 33 REMOVAL AND INSTALLATION Horn Assembly 19 35 Horn Switch 19 35 SERVICE TOOLS EQUIPMENT 19 36 DIAGNOSIS AND TESTING Inspection and Verification Horn System 1 Verify customer concern by operating the horn 2 Vis...

Page 580: ...ECK POWER SUPPLY TO HORN Key Off Yes Go to 88 Locate and disconnect the horn connector No Go to 83 Depress the horn switch Measure the voltage on the wire at the horn connector Is the voltage greater than 10 volts with the horn switch depressed 83 I CHECK HORN SWITCH Key OFF Yes Replace the horn switch Reconnect the horn Go to 84 Disconnect the horn switch No Ground the wire at the horn switch con...

Page 581: ...connect the battery ground cable 2 NOTE The horn is located on the RH side of the firewall Disconnect the horn electrical connector HORN BRACKET BOLT HORN BRACKET HORN 3 Remove the bracket bolt 4 Remove the horn Installation To install reverse the removal procedure Horn Switch Removal 1 Disconnect the battery ground cable 2 Disconnect the horn switch electrical connector 3 Remove the horn button N...

Page 582: ...9 771417 10 323532 19 36 jsheering I haft fliiiii E ll Description Horn Button Assembly Horn Cup Pucks 2 Horn Cup Plate Nuts 3 Upper Steering Plate Compression Springs 3 Steering Wheel Machine Screw Insert for the Machine Screw Washer Plate Assembly Upper Steering Bushing Installation To install reverse the removal procedure SERVICE TOOLS EQUIPMENT Digital Multimeter ...

Page 583: ... Fan Hazard I Heater Option Beacon Lights Stop Lights Turn Signal Front Wiper Horn Dome Running Lights Dash Lights All fuses are 15 amp unless otherwise indicated in the above chart Indicator Flasher location The indicator flasher is located in the instrument panel Engine and Instrument Panel Wiring The engine and instrument panel wiring connects electrical components to their respective relays fu...

Page 584: ...allation To install reverse the removal procedure Wiring Harnesses The vehicle consists of the following wiring harnesses Main harness Rear harness Removal 1 Disconnect the battery ground cable 2 Remove any body panels or trim panels to access the harness 3 NOTE Tag all wires before removing to ensure proper installation Disconnect all wiring harness electrical connector 4 Disengage the wiring har...

Page 585: ... Bottom Trunk Assembly 9 Fuse Panel 10 Circuit Breakers 11 Diagnostic Connector engine compartment 12 Diagnostic Connector instrument panel SERVICE PROCEDURES Wire Terminals Insert a push tool or thin metal tool such as a small screwdriver from the terminal side of the connector and then with the locking tabs pressed down pull the terminal out from the wire side of the connector Female Type Part I...

Page 586: ...ewdriver in the locking tab and twist Grasp the connector housing and pull until the locking tab is on the ramp Turn the connector over and repeat the procedure on the opposite side of the connector Grasp the connector housing and pull apart LOCKING TABS 20 4 Disconnecting electrical connectors with one locking tab Connector precautions The connector can be disconnected by pressing the lock lever ...

Page 587: ... Over a Vinyl 12 000 250 Floor Working at a Bench 6 000 100 Sliding Across a Vehicle 25 000 1 000 Seat 1 Leave the module in the original packaging until ready to install in a vehicle 2 Avoid touching the module connector pins 3 Avoid laying the module on a nonconductive surface 4 As an added safeguard uses 3M Static Protection Kit 3M part number 18293 This kit contains special wrist straps a 15 x...

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Page 589: ... utility vehicle use this section to insert the supplier instruction maintenance service installation manuals and sheets that are provided with the equipment Record the name manufacturer serial number and other information of the auxiliary equipment in the space provided This will ease reference should the need for servicing and maintenance Use the chart below Description of Equipment 21 1 ...

Page 590: ...ent Record the name manufacturer serial number and other information of the auxiliary equipment This will ease reference should the need for servicing and maintenance be required Use the chart below Description of Equipment 21 2 ...

Page 591: ...r in the passenger compartment Refrigeration is accomplished by making practical use of three laws of nature These laws are as follows SUBJECT PAGE SERVICE PROCEDURES A C Compressor 22 29 External Leak Test 22 29 Rotating Torque Check 22 29 A C Manifold Gauge Set Connection 22 32 A C Heater System Deodorizing 22 31 Inspection and Assembly Requirements 22 36 Refrigerant Oil Addition 22 35 During A ...

Page 592: ... the pressure exerted on it 22 2 In an expansion valve refrigerant system liquid refrigerant R 134a is stored in the A C condenser core under high pressure When the liquid R 134a is released into the A C evaporator core by the A C evaporator expansion valve the resulting decrease in pressure and partial boiling lowers the temperature of the R 134a to its new boiling point As the R 134a flows throu...

Page 593: ...ION Safety Precautions WARNING AVOID BREATHING A C REFRIGERANT AND LUBRICANT VAPOR OR MIST IF ACCIDENTAL SYSTEM DISCHARGE OCCURS VENTILATE THE WORK AREA BEFORE RESUMING SERVICE WARNING WEAR IMPERVIOUS GLOVES AND SAFETY GOGGLES AT ALL TIMES WHEN HANDLING LIQUID REFRIGERANT SHOULD ANY LIQUID REFRIGERANT GET INTO THE EYES OR ON THE SKIN IMMEDIATELY FLUSH EYES AND SKIN WITH PLENTY OF WATER FOR AT LEAS...

Page 594: ...as been opened for replacement of a component or which has discharged through leakage must be evacuated before charging 4 Immediately after disconnecting a component from the system seal open fittings with a cap or plug 22 4 5 Before disconnecting a component from the system clean the outside of the fittings thoroughly 6 Do not remove sealing caps from a replacement component until it is ready to ...

Page 595: ...lls in low pressure vapor and pumps out high pressure vapor to the A C condenser core The high pressure vapor entering the A C condenser core is cooled by outside air passing over the A C condenser core fooling fins This heat loss causes the high pressure vapor to become high pressure liquid This high pressure liquid passes through the suction receiver drier before entering the A C evaporator expa...

Page 596: ...r clutch field coil the A C clutch hub moves away from the A C compressor clutch pulley and the A C compressor shaft ceases to rotate 22 6 Refrigerant System Protection A C Compressor Pressure Relief Valve The A C compressor features a pressure relief valve which will discharge high pressure refrigerant to the atmosphere when the pressure exceeds its relief setting of 526 640 psi 3626 4413 kPa The...

Page 597: ... evaporator core is cooled and dehumidified then conducted to the passenger compartment Excess moisture from the dehumidification process is drained through an A C evaporator drain hose to the outside of the vehicle A C EVAPORATOR CORE A C Evaporator Expansion Valve The A C evaporator expansion valve is located in the A C evaporator inlet The A C evaporator expansion valve senses the temperature a...

Page 598: ...re of the A C evaporator core drops to 32 F 1 8 F 0 C 1 C the A C evaporator temperature control turns the A C compressor clutch off When the A C evaporator core temperature increases to 37 4 41 0 F 3 5 C the A C evaporator temperature control thermostat turns the A C compressor clutch on An A C evaporator temperature control thermostat sensing bulb inside of the A C evaporator core signals the A ...

Page 599: ...r and is mounted to the vehicle frame SIGHT GLASS SUCTION RECEIVER DRIER Special Service Equipment CAUTION Do not use R 12 service tools and equipment when servicing a R 134a system Doing so may cause damage to the R 134a A C system The refrigerant system has a high pressure discharge and a low pressure suction gauge port valve They provide access to both sides high pressure and low pressure of th...

Page 600: ...circuit breaker 30A blower Damaged or loose Blown fuse s drive belt 30A Cooling Fan Damaged A C 20A Wiper compressor Damaged A C Damaged wiring compressor clutch harness Damaged Loose or corroded refrigerant hose s connections 0 Damaged vacuum Damaged blower lines motor Damaged heater blower motor switch Damaged A C compressor clutch control relay 3 Check for damage to the A C compressor and the A...

Page 601: ...22 Heating and Air Conditioning DIAGNOSIS AND TESTING Electrical Schematics A C System 0 OJ gj I z II C 0 3 Ill Ul 0 2 _ C n 0 lll v1 i 0 I 0 C n g g m6 E tn I I 0 I r ill j r 1 0 m I m 1 g z 0 m 0 8 i _ 22 1 I ...

Page 602: ...ate Circuit Breaker Circuit Blower motor relay Blower motor Heater blower motor switch Blower Motor Runs Circuit Go To Pinpoint Test F1 Constantly Heater blower motor switch Blower Motor Does Not Circuit Go To Pinpoint Test G1 Operate Properly Heater blower motor switch A C blower motor resistor No Operation in Low Circuit Go To Pinpoint Test H1 Blower Setting A C blower motor resistor Heater blow...

Page 603: ... When A Cis Activated No Air Circulation or Air flow control door Improper Air Circulation Heater and ventilation intake Blower Motor Operates duct blocked Ducts blocked or leaking Frost Being Blown out of Evaporator box drain tube Ducts Refrigerant system ACTION REMEDY Inspect the A C drive belt tension Refer to Section 11 Adjust or replace A C drive belt if necessary Otherwise replace the A C co...

Page 604: ...o B3 Service the heater core Service the temperature control door Replace the heater cable PINPOINT TEST C INSUFFICIENT A C COOLING Test Step Result Action To Take C1 j CHECK REFRIGERANT Perform the Refrigerant System Tests in this section Yes Go to C2 Is the refrigerant system OK No Repair as necessary C2 I CHECK TEMPERATURE CONTROL CABLE Inspect the heater cable for kinks or breaks Yes Service t...

Page 605: ...e of the W GN wire between No Service the W GN wire the top terminal of the BLOWER circuit breaker holder and ground Is the resistance greater than 10 000 ohms E7 I CHECK BLOWER MOTOR Perform the Blower Motor component test in this Yes Go to E8 section No Replace the blower motor Is the blower motor OK EB j CHECK HEATER BLOWER MOTOR SWITCH Perform the Heater Blower Motor Switch component Yes Go to...

Page 606: ...wire at the blower switch motor connector No Service the R wire Is the voltage greater than 10 volts PINPOINT TEST F BLOWER MOTOR RUNS CONSTANTLY Test Step Result Action To Take F1 I CHECK HEATER BLOWER MOTOR SWITCH Key OFF Yes Service the BL W wire for Locate and disconnect the heater blower motor shorts to ground switch connector No Replace the heater blower Heater blower motor switch OFF motor ...

Page 607: ...ater blower motor switch OK and the heater blower motor switch No Replace the heater blower motor switch PINPOINT TEST K A C COMPRESSOR CLUTCH DOES NOT ENGAGE Test Step Result Action To Take K1 I CHECK REFRIGERANT SYSTEM Perform the Refrigerant System Tests in this section Yes Go to K2 Is the refrigerant pressure OK No Service the refrigerant system as necessary K2 I CHECK FUSES Key OFF Yes Go to ...

Page 608: ...oth of the thermal protection switch connectors See illustration in test step K5 Measure the resistance of the thermal protection switch between the BK wires of the terminal protection switch connectors Is the resistance less than 5 ohms K7 CHECK A C COMPRESSOR CLUTCH CONTROL RELAY Key OFF Remove the A C compressor clutch control relay Apply 12 volts to the BL wire terminal and the W BK wire termi...

Page 609: ...CH GROUND Key OFF Yes GotoK11 Disconnect the A C switch connector No Service the BUY wire for Turn the heater blower motor switch to the low open speed position Measure the resistance of the BUY wire between the A C switch connector and ground Is the resistance less than 5 ohms K11 CHECK WIRE BETWEEN A C SWITCH AND A C EVAPORATOR TEMPERATURE CONTROL THERMOSTAT Key OFF Yes Go to K12 Disconnect the ...

Page 610: ...re cut off switch No Replace the A C connector pressure cut off Measure the resistance between the terminals of the switch A C pressure cut off switch Is the resistance less than 5 ohms K15 CHECK WIRE BETWEEN A C COMPRESSOR CLUTCH CONTROL RELAY AND A C COMPRESSOR CLUTCH Key OFF Yes Refer to the PC ED Remove the A C compressor clutch control relay Manual Section 6B Disconnect the A C compressor clu...

Page 611: ... wire terminal in the A C compressor clutch control relay during the following conditions BL 0 Wire Terminal Voltage on GN W Wire Terminal Open Less than 1 one volt Grounded Greater than 10 volts Are the voltages OK L4 CHECK A C MODE SELECTOR SWITCH Key OFF Yes Go to L5 Locate and disconnect the A C switch connector No Replace the A C switch Turn the A C switch OFF Measure the resistance of the A ...

Page 612: ...cuits the A C compressor clutch control relay connector No Service the BL 0 wire for and ground short Is the resistance greater than 10 000 ohms PINPOINT TEST M A C COMPRESSOR CLUTCH CYCLES RAPIDLY Test Step Result Action To Take M1 I CHECK REFRIGERANT SYSTEM Perform the Refrigerant System Tests in this Yes Refer to the PC ED Manual section Section 6B to diagnose the A C Is the refrigerant system ...

Page 613: ...I CHECK SYSTEM Key OFF Yes Go to N4 Replace the blown fuse s No Go to N5 Key ON Do es the fuse s fail again P4 I CHECK FOR SHORT S TO GROUND Key OFF Yes Service the wire s in question Remove the Engine Fan fuse and the Wiper fuse Replace the Engine Fan fuse Locate and disconnect the condenser fan relay No and the Wiper fuse Reconnect connector the condenser fan relay Measure the resistance of the ...

Page 614: ...NUOUSLY Test Step Result Action To Take Q1 CHECK CONDENSER FAN RELAY Key OFF Yes Go to 02 Locate and disconnect the condenser fan relay No Replace the condenser fan Measure the resistance of the W BK and BL BK relay wires on the condenser fan relay Is the resistance greater than 10 000 ohms Q2 CHECK WIRE BETWEEN CONDENSER FAN RELAY AND POWERTRAIN CONTROL MODULE Yes Refer to the PC ED Manual Key OF...

Page 615: ...s could cause leakage at the heater water hose connection Yes Replace the A C switch No Service the BL wire for open Plugged Heater Core Ensure the engine coolant is at the proper level then start the engine and feel the outlet heater hose to see if it is hot If it not warm flow through the heater core is restricted Pressure Test Heater core leaks can be indicated by wet spots around hose connecti...

Page 616: ...ith the plug and adapter to the heater core tubes as indicated in the in vehicle pressure test 3 Attach the Radiator Heater Core Pressure Tester to the adapter 22 26 RADIATORIHEATER CORE PRESSURE TESTER PLUG HEATER CORE 4 Pump 30 psi 206 kPa of air pressure into heater core 5 Submerge the heater core in water 6 If a leak is observed service or replace the heater core Blower Motor 1 Locate and disc...

Page 617: ...the fittings at the gauge set Open long enough for air to escape and then tighten the fittings 2 Start the engine and turn on the A C system 3 As soon as the system is stabilized record the high and low pressures as shown by the manifold gauges The low side should be between 20 41 psi 137 284 kPa and the high side should be between 185 263 psi 1 274 1813 kPa As low pressure drops high pressure sho...

Page 618: ...rvice hoses and a manifold gauge set so system pressures can be read Always replace the A C charging valve caps on the gauge port valves after servicing the refrigerant system 22 28 Action to Take CHECK the refrigerant system for leaks CHECK the A C condenser core for damage DISCHARGE excessive coolant and VERIFY refrigerant pressure is normal DISCHARGE the system EVACUATE the system Recharge the ...

Page 619: ...inch 25 4 mm per second past the suspected area When escaping refrigerant gas is detected a ticking or beeping signal will be heard As the amount of refrigerant gas detected increases the rate of the ticking or beeping increases If the refrigerant gas is relatively concentrated the signal will become increasingly shrill Follow the instructions included with the leak detector for proper handling an...

Page 620: ...re not compatible Also R 134a systems require the use of dedicated special service tools and equipment R 134a special service tools and equipment that 22 30 come in contact with the R 134a refrigerant or refrigerant oil can only be used on R 134a A C systems R 12 special service tools and equipment cannot be used on R 1 34a A C systems and vice versa CAUTION Using R 12 components refrigerant or re...

Page 621: ... 2 ounces 44 ml of the deodorizer product into the recirculate air opening 5 Shut the A C system blower OFF 6 Spray equal amounts of the remaining 4 ounces 118 ml of the deodorizer product into each of the air outlet openings instrument panel registers and defrosters 7 Allow the vehicle to sit for about 30 minutes before returning it to the customer Refrigerant Recovery If a R 134a A C Service Cen...

Page 622: ... OF REFRIGERANTS NOTE Hoses should have shutoff devices or check valves within 12 inches 305 mm of the hose end to minimize the introduction of non 22 32 condensable gases air into the recycling station and to minimize the amount of refrigerant released when the hose s is disconnected 1 Connect the hose s of the R 134a A C Service Center or equivalent to the vehicle A C service ports and the recov...

Page 623: ...f small cans of refrigerant is not recommended If the charging cylinder method is used the center port of the manifold gauge set should have two refrigerant hoses with integral shut off valves built into the manifold gauge set The R 134a Manifold Gauge Set is equipped in this manner If the gauge set is the type that does not have shut off valves and two hoses at the center port a tee fitting and t...

Page 624: ...w A C compressor before it can be installed NOTE It will be necessary to transfer the A C compressor clutch from the old A C compressor to the new A C compressor Install the new A C compressor Refer to Section 22 3 for the installation procedure Be sure the A C compressor bolts are 22 34 tightened to the proper specifications Check the tension of the drive belt 4 Remove the suction receiver drier ...

Page 625: ...pancake filter from the liquid line It will be necessary to discharge the system first Refer to the procedure in this section 18 Discard the pancake filter It can be used ONE TIME ONLY 19 Reconnect the liquid line back into the system 20 Evacuate charge and leak test the system Refer to the procedure in this section Make any necessary adjustments 21 Check the operation of the A C system in all mod...

Page 626: ...tems and is not suitable for use in R 12 systems Never use an R 1 34a refrigerant oil in R 1 2 systems R 12 systems require the use of a mineral based refrigerant oil with special additives known as YN 9 This type of refrigerant oil was made specifically for R 12 systems and is not suitable for use in R 134a systems Never use R 12 refrigerant oil YN 9 in R 134a systems 22 36 During Component Repla...

Page 627: ...ctrical specifications SERVICE TOOLS EQUIPMENT A C Test Adaptor Kit Digital Multimeter Radiator Heater Core Pressure Tester R 1 34a A C Service Center R 134a Automatic Calibration Halogen Leak Detector R 134a Manifold Gauge Set R 134a Low Side Quick Disconnect R 134a High Side Quick Disconnect R 134a Vacuum Pump 1 5 CFM R 134a Vacuum Pump 3 0 CFM 22 37 ...

Page 628: ...termines the speed at which the blower motor operates Each position of the fan speed control switch is detented for positive engagement of fan speed Heat Cold Control Temperature is controlled by pulling control for more heat Push in to reduce heat The heat cold control controls the temperature of the heating defrosting and A C system if equipped between the cool push in and the warm pull out side...

Page 629: ...s the two blower motor speeds It is mounted above the blower motor in the blower motor housing Heater Core The heater core has fins and tubes that are positioned to extract available heat from the engine coolant and transfer that heat to the air that passes through the core To modulate the temperature of the discharged air a portion of the incoming air is bypassed around the heater core by the tem...

Page 630: ... Panel Top Removal 1 Remove four screws which secure the instrument panel top to the instrument panel assembly 2 Remove the instrument panel top from the instrument panel assembly 2 Disconnect the battery ground cable 22 40 Installation Install the instrument panel top in reverse order or removal Instrument Panel Top Climate Controls Temperature Heat Cold Control Removal and Installation 1 Remove ...

Page 631: ... cable in the reverse order of removal Tighten the nut to the back of the dash panel Fan Speed Control Removal and Installation 1 Disconnect the battery ground cable 2 Disconnect the wires which connect to the back of the fan speed control switch 3 Mark each wire connection to the connectors on the back of the fan speed control switch 4 Pull the knob off the fan speed control switch 5 Loosen and r...

Page 632: ...e the instrument panel top screws 2 Remove the instrument panel top 3 Remove the defroster vent clamp 22 42 4 Carefully pull away the heater duct from the adjustable defroster vents 5 Remove two screws on each defroster vent 6 Remove the defroster vents from the instrument panel or the instrument panel top Installation Install the adjustable defroster vent in the reverse order of removal Heater Co...

Page 633: ...se order of removal Heater Water Hoses Inlet Removal 1 Drain the cooling system Refer to Section 15 for the procedure 2 Loosen the hose clamp nuts and move the hose clamps back onto the inlet heater water hose at both ends of the inlet water hose 3 Pull the inlet heater water hose off the heater core inlet tube and off the elbow on the intake manifold 4 Remove the hose tray under the LH side of th...

Page 634: ...be 0 ring for damage Replace if necessary 22 44 Installation To install reverse the removal procedure ADJUSTMENTS Defrost Vent Control Cable 1 Move the Defrost Vent cable to the defrost position 2 While holding down the air flow door against its stop secure the Defrost Vent cable over the air flow door arm 3 Verify that the Defrost Vent control cable moves it full stroke Temperature Heat Cold Cont...

Page 635: ...s only 1 Move the Heater Valve Shutoff control cable to the full hot position 2 Connect the Heater Valve Shutoff control cable to the heat cold door arm on the valve 3 Secure the Heater Valve Shutoff control cable into place 4 Verify that the Heater Valve Shutoff control cable moves its full stroke 22 45 ...

Page 636: ...OR AT LEAST 15 MINUTES REMOVE CONTAMINATED CLOTHING AND SHOES CALL A PHYSICIAN WARNING REFRIGERANT HFC 134a IS ALWAYS UNDER PRESSURE BECAUSE THE 22 46 SUBJECT PAGE REMOVAL AND INSTALLATION Cont d A C Evaporator Temperature Control Thermostat 22 56 A C Pressure Cut off Switch 22 57 Blower Motor Resistor 22 55 Climate Control Assembly 22 54 Heater Blower Motor Assembly 22 55 Heater Case Core 22 55 H...

Page 637: ...or upside down liquid R 134a will enter the system and may damage the A C compressor CAUTION Refrigerant R 134a should not be mixed with air for leak testing or used with air for any other purpose above atmospheric pressure R 134a is combustible when mixed with high concentrations of air and high pressures Prompted by environmental concerns G0 4 vehicles are equipped with non chloroflourocarbon no...

Page 638: ... C the A C evaporator temperature control thermostat turns the A C compressor clutch on A sensing bulb inside the A C evaporator core signals the A C evaporator temperature control is wired in series with the A C compressor clutch control relay and signals the Powertrain Control Module to turn the A C compressor clutch on and off The blower motor operates constantly when the A C switch is depresse...

Page 639: ...m cooling and provides for complete evaporation of all the liquid refrigerant in the A C evaporator core The amount of refrigerant in the A C evaporator core determines the temperature and pressure at the A C evaporator case outlet inside the A C evaporator expansion valve sensing bulb and in the equalizer line These pressures act on top and bottom of the diaphragm The diaphragm along with the sup...

Page 640: ...on the RH side of the A C condenser core The condenser fan relay supplies power to the A C condenser 22 50 cooling fan and is controlled by the Powertrain Control Module Refrigerant System WARNING AVOID BREATHING AIC REFRIGERANT AND LUBRICANT VAPOR OR MIST IF ACCIDENTAL SYSTEM DISCHARGE OCCURS VENTILATE THE WORK AREA BEFORE RESUMING SERVICE WARNING WEAR IMPERVIOUS GLOVES AND SAFETY GOGGLES AT ALL ...

Page 641: ...tate and local ordinances Service Access Gauge Port Valves The refrigerant system has a high pressure discharge and a low pressure suction gauge port valve These are Schrader valves which provide access to both sides high pressure and low pressure of the system for service hoses and a manifold gauge set so system pressures can be read Always replace the A C charging valve caps on the service acces...

Page 642: ...eiver drier when The suction receiver drier is restricted plugged or perforated The refrigerant system has been left open for more than four hours or completely discharged for 24 hours or more There is evidence of moisture in the system for example internal corrosion of metal lines or dark thick refrigerant oil A component such as A C condenser core evaporator A C compressor or refrigerant line is...

Page 643: ...in series with the A C switch and the A C evaporator temperature control thermostat A C Condenser Fan Switch The A C condenser fan switch is located on the outlet manifold of the A C condenser core When manifold pressure exceeds 220 psi 1 51 9 kPa the A C condenser fan switch closes and the A C condenser cooling fan starts to operate When manifold pressure drops below 178 psi 1 225 kPa the A C con...

Page 644: ...mpensate for the amount of oil lost with the old component Clean refrigerant oil should be added to the replacement components as follows A C evaporator core Add 1 7 fluid ounces 50 ml A C condenser core Add 1 one fluid ounces 30 ml Suction receiver drier Drain the oil from the old suction receiver drier Add the same amount plus 0 34 fluid ounce 1 0 ml of clean refrigerant oil to the new suction r...

Page 645: ...and remove the A C evaporator expansion valve Discard the 0 ring 13 Remove the A C evaporator core from the A C evaporator case Installation NOTE Replacement A C evaporator cores do not come equipped with an A C evaporator core screen Transfer the evaporator core screen from the old A C evaporator core to the new A C evaporator core NOTE If installing a new A C evaporator core add the proper amoun...

Page 646: ... evaporator core outlet fitting 4 Disconnect the A C evaporator expansion valve at the A C evaporator core outlet 22 56 fitting and A C evaporator case inlet fitting Discard the 0 ring at each fitting 5 Remove the A C evaporator expansion valve Installation NOTE Apply clean refrigerant oil to the new 0 rings prior to installation To install reverse the removal procedure Test the system for proper ...

Page 647: ... from the passenger compartment Refer to Section 4 Brake System for the removal procedure 6 Remove the gearshift lever control from the passenger compartment Refer to Section 19 for the removal procedure 7 Remove the rivets and slotted bolts and flange nuts which secure the seat panel to the vehicle frame 8 Remove the slotted bolts and flange nuts which secure the passenger compartment to the vehi...

Page 648: ... to 11 18 lb ft 15 25 N m 22 58 A C Condenser Fan Switch Removal 1 Disconnect the battery ground cable 2 Discharge the A C system Refer to Section 22 Service for the procedure 3 Remove the LH and RH engine intake panels from the vehicle 4 Remove the seat from the seat panel in the passenger compartment 5 Remove the parking brake from the passenger compartment Refer to Section 4 Brake System for th...

Page 649: ...es Evaporator to Compressor Removal 1 Discharge the A C system Refer to Section 22 Service for the procedure 2 Remove the battery Refer to Section 17 for the removal procedure 3 Remove the radiator coolant recovery reservoir 4 Disconnect the evaporator to compressor suction line at the front evaporator to compressor suction line fitting 5 Disconnect the evaporator to compressor suction line at the...

Page 650: ...rings prior to installation To install reverse the removal procedure Tighten the liquid line at the suction receiver outlet fitting to 69 1 04 Ib in 8 11 N m Tighten the liquid line at the A C evaporator core inlet fitting to 87 174 Ib in 10 1 9 N m Tighten the rear liquid line to the front liquid line fitting to 94 10 41b ft 12 8 14 2 N m 22 60 Jumper Lines Removal 1 Discharge the A C system Refe...

Page 651: ...r to condenser discharge line fitting to 11 18 lb ft 15 24 N m Heater Water Hoses Removal and Installation Refer to Section 22 1 Heating for the heater water hoses for removal and installation procedure A C Compressor Removal 1 Discharge the A C system Refer to Section 22 Service for the procedure 2 Remove the A C compressor to condenser discharge line bolt Plug the A C compressor outlet fitting t...

Page 652: ... N m ADJUSTMENTS Heater Valve Shutoff Control Cable 1 Move the Heater Valve Shutoff control cable to the full hot position 2 Connect the Heater Valve Shutoff control cable to the heat cold door arm on the valve 3 Secure the Heater Valve Shutoff control cable into place 4 Verify that the Heater Valve Shutoff control cable moves its full stroke 22 62 A C Compressor Drive Belt Tension Refer to Sectio...

Page 653: ...e at the 69 104 8 11 Suction Receiver Drier Outlet Fittinq A C Compressor to 11 18 15 24 Condenser Discharge Line Fitting Jumper Line at the 87 174 10 19 A C Condenser Core Outlet Fitting Evaporator to 8 11 10 15 Compressor Suction Line Fitting Bolt Rear Liquid Line to 9 4 10 4 12 8 14 2 Front Liquid Line A C Compressor 14 19 19 25 Bracket Bolts A C Compressor to 8 11 10 15 Condenser Discharge Lin...

Page 654: ...and the A C pressure cut off switch A thermo protection switch is integrated into the A C compressor to protect the A C compressor from overheating The thermo protection switch will open the circuit to the A C compressor clutch field coil if the A C compressor gets too hot The thermo protection switch cannot be serviced separately and must be replaced with the A C compressor as an assembly 22 64 S...

Page 655: ...h Pulley Removal The following illustration on next page shows an exploded view of the A C compressor clutch and the A C compressor clutch pulley 1 Remove the A C compressor from the vehicle 2 NOTE Use a suitable tool to hold the clutch hub while removing the clutch hub bolt Place A C compressor in a vise and remove the clutch hub bolt A C Clutch and A C Compressor Clutch Pulley Exploded View Part...

Page 656: ...ghten to 10 8 lb ft 14 7 N m 4 Remove the two A C compressor clutch shims from the A C compressor belt 22 66 A C COMPRESSOR CLUTC i_St _1 REO D 5 Remove the clutch pulley snap ring CLUTCH PULLEY SNAP RING 6 Lift the A C compressor clutch pulley from the A C compressor Installation To install reverse the removal procedure Tighten the clutch hub bolt to 10 8 lb ft 14 7 N m ...

Page 657: ...l screws 4 Remove the A C compressor clutch field coil Installation To install reverse the removal procedure AJC COMPRESSOR CLUTCH RELD COIL ELECTRICAL CONNECTOR AIC COMPRESSOR CLUTCH FIELD COIL SCREWS 3 REQ D AJC COMPRESSOR CLUTCH FIELD COIL Shaft Seal and Seat Service Tools Required Compressor Shaft Seal Plate Remover Replacer Compressor Shaft Seal Remover Replacer Removal 1 Remove the A C compr...

Page 658: ...ssembly There is no disassembly and assembly of this component The A C compressor clutch pulley and A C compressor clutch field coil are the only serviceable parts on this assembly 22 68 3 Set the measuring probe of the Dial Indicator Magnetic Base or equivalent on the clutch hub surface 4 Apply 12 volts to the clutch field coil electrical connector 5 The clutch hub to A C compressor clutch pulley...

Page 659: ...ower and upper restraints The tongue and buckle attachment can be accomplished by a single continuous movement SUBJECT PAGE SERVICE PROCEDURES Continued Safety Belt Twisted at Safety Belt Guide 23 5 CLEANING AND INSPECTION General Cleaning Method A 23 6 General Cleaning Method B 23 7 General Cleaning Method C 23 7 Safety Belt Maintenance 23 6 Safety Belt Webbing 23 6 ADJUSTMENTS Safety Belt Should...

Page 660: ...nger compartment Refer to procedure in this section 2 CAUTION To avoid possible damage to seat components handle the seat with care 3 Remove the four seat mounting bolts NOTE Open compartment door under seat to gain access to flange nuts and bolts securing seat to seat panel 4 Remove the seat assembly from the passenger compartment Installation 1 NOTE Before installing the seat assembly ensure the...

Page 661: ...m passenger compartment Installation To install reverse the removal procedure NOTE Use new 3 16 x 1 1 2 cotterpins when securing head restraint tube to seat back NOTE Install head restraint guards to head restraint tube prior to installation Safety Belt Retractor and Tongue Removal 1 Remove the seat shoulder strap boot from the safety belt guide 2 Remove the safety belt guide bolt and washer from ...

Page 662: ...e vehicle 2 Install the safety belt retractor bolt and washer Tighten the safety belt retractor bolt to 28 58 lb ft 38 78 N m 3 Install the safety belt retractor screw 4 Install the anchor bracket bolt Tighten the anchor bracket bolt to 25 58 lb ft 38 78 N m 5 Install the safety belt guide bolt and washer Tighten the safety belt guide bolt to 28 58 lb ft 38 78 N m 6 Install the seat shoulder strap...

Page 663: ...rocedure in this section Functionally test the new safety belt Refer to the functional test procedure in this section Safety Belt Twisted at Safety Belt Guide 1 Grasp the belt webbing at the safety belt guide 2 Rotate and fold the belt webbing over itself as required to remove the twist 3 Feed the fold portion of the belt through the safety belt guide 4 When completed the safety belt tongue should...

Page 664: ...LUDING RETRACTOR AND ATTACHING HARDWARE SHOULD BE INSPECTED AFTER ANY COLLISION IT IS RECOMMENDED THAT ALL SAFETY BELT ASSEMBLIES BE REPLACED UNLESS THE COLLISION WAS MINOR AND A QUALIFIED TECHNICIAN FINDS THAT THE 23 6 BELTS SHOW NO DAMAGE AND CONTINUE TO OPERATE PROPERLY SAFETY BELT ASSEMBLIES NOT IN USE DURING A COLLISION SHOULD ALSO BE INSPECTED AND REPLACED IF EITHER DAMAGE OR IMPROPER OPERAT...

Page 665: ... retail upholstery cleaner with cloth or brush as directed by instructions on container 4 Rub in a circular manner until the stain is removed 5 NOTE Spot cleaning as described in Method A will be sufficient when the soiled area is not excessive In the event of severe soiling or staining clean the entire safety belt to avoid a ring condition Gradually widen the area of application to the edges of t...

Page 666: ...D INCREASE THE CHANCE AND OR SEVERITY OF INJURY IN AN ACCIDENT The shoulder restraint portion of the safety belt adjusts automatically to a snug position After unbuckling the safety belt it is recommended that care be taken during retraction to prevent it from hitting trim panels windows and painted surfaces Lap Portion Adjustment The lap portion of the safety belt adjusts automatically Pull up on...

Page 667: ...s in the fully open position Door Glass The frame mounted door glass is sealed to the frame with urethane The frame pieces around the window frame is riveted together Mirrors The outside rear view mirror is a truck mount design The mirror base is secured to the mirror bracket on the lower RH and LH front part of the vehicle frame The four screws attach the mirror to the mirror bracket The mirror b...

Page 668: ...ly remove the glass from the window frame 7 Remove the top and bottom seal 24 2 Part Item Number Description 1 584019 20 Frame Door Window Front RH LH 2 584018 17 Frame Door Window Rear RH LH 3 584024 23 Lower Window Frame RH LH 4 584022 21 Window Roller Support RH LH 5 584005 Window Handle Grip 6 589004 Latch Inside Window Assembly 7 684015 Window Frame Seal 8 583688 Pulley Roller 9 584026 Too Wi...

Page 669: ...eparate the door panels This allows access to the door latch assembly 6 Remove the door latch assembly Item Part Number Description 1 Door Handle 2 Grip 3 Inside Handle not exactly as shown 4 583812 Inside Handle Spring 5 584008 Door Latch Bushing 6 Door Latch 7 584007 Door Handle Spring Support 8 Door Latch Stiffener RH LH 9 773676 5 16 x 1 1 2 Flathead Socket Head Bolt 10 771040 5 16 Stover Lock...

Page 670: ... manner using a one piece locking rubber mount Removal NOTE Remove the windshield wiper pivot arm from the front windshield 1 Using dish soap or equivalent lightly soap window seal 2 Using a window trim tool insert tool from the outside of the vehicle into the trim s top groove and angle it so lock releases Draw the tool around the window until the lock is completely released 3 Slowly push out on ...

Page 671: ...4 Using a blunt tool gently pry a corner of the headliner away from the roof panel 5 Using your hands gently pull the headliner away from the roof panel Be careful not tear or damage the headliner Installation 1 Apply glue PL 200 or equivalent to roof panel Smooth out with a putty knife to cover the entire surface 2 Align the headliner and press onto the roof panel 3 Install roof panel to cab fram...

Page 672: ...m cable NOTE This will ease removal I installation of flooring 3 Remove the flooring Installation 1 Replace and align the flooring into the cab area 2 Insert edges of flooring by the doors into trim 3 Secure flooring to cab using the flooring retaining pins 4 Attach accelerator pedal to accelerator mount using steel pin and cotterpin Retaining Pin 25 2 ...

Page 673: ...e lower trunk assembly is secured to the frame and provides additional space for storage REMOVAL AND INSTALLATION Cargo Box Removal 1 Open the box lid by unlocking the rear latch 2 Unscrew fastener inside the rear part of box and remove bracket which holds the cargo box to the frame 3 You and another person lift the cargo box slightly and slide back and remove Installation Install the cargo box in...

Page 674: ...en flange bolts to 14 18 lb ft 19 25 N m Trunk Handle Removal 1 Loosen two screws behind the handle 2 Remove handle 3 Remove mounting bolts 26 2 4 Remove lock Installation To install reverse the removal procedure Trunk Lid Latch Removal 1 Remove the handle Refer to removal procedure in this section 2 Drill out the four rivets holding the trunk lid latch to upper trunk lid 3 Remove the latch 4 Remo...

Page 675: ...val procedure Tighten flange bolts to 14 18 lb ft 19 25 N m Striker Plate SPECIFICATIONS Striker Mounting Bolt TORQUE SPECIFICATIONS ADJUSTMENTS Upper Trunk Lid Striker Plate 1 Open the upper trunk lid 2 Loosen the two striker plate mounting bolts 3 Slide the striker plate from side to side to position 4 Tighten the two striker plate mounting bolts 5 Open and close the upper trunk lid to check for...

Page 676: ......

Page 677: ...ident the window latch striker plate and or the door pulley rollers need to be adjusted Refer to the door alignment procedure in this section Verify that the clearance between the body and window is not excessive or uneven If the clearance is excessive or uneven the window latch striker and or door pulley rollers need to be adjusted Refer to the alignment procedure in this section Door Alignment D...

Page 678: ...ON Outside rear view mirrors should not be cleaned with a dry cloth or abrasive cleaning powders Do not remove ice with a scraper The outside rear view mirrors should only be cleaned with a soft clean cloth and mild detergent and water or a glass cleaner otherwise damage to the reflective surface will result Frozen Mirrors CAUTION Thaw out mirror prior to adjusting the arm or mirror base SPECIFICA...

Page 679: ...3418 Hood Panel 2 533543 LH Upper Front Filler Panel 533544 RH Upper Front Filler Panel 3 533564 LH Lower Front Filler Panel 533565 RH Lower Front Filler Panel 4 509000 Front Bumper Assembly 5 534021 Engine Intake Front Panel 6 539001 Roof Assembly 7 533686 Rear Cab Panel 8 539005 LH Rear Fender Assembly 539004 RH Rear Fender Assembly 9 533729 LH Inner Fender Well 533730 RH Inner Fender Well 10 50...

Page 680: ...moval 1 Remove the hood panel bolts securing the hood panel to the vehicle frame 2 Remove the hood panel from the vehicle NOTE On some models it may be necessary to disconnect electrical connectors before removing the hood panel from the vehicle Installation To install reverse the order of removal Upper Front Filler Panel Removal 1 Break the caulking around the upper front filler panel 2 Remove th...

Page 681: ...r Assembly Removal 1 Remove the upper cargo box from the rear of the vehicle 2 Remove the four mounting bolts and nuts securing the upper part or flanges of the rear fender assembly to the frame 3 Remove two mounting bolts and nuts securing the fender assembly to lower door track 4 Remove one mounting bolt and nut securing the fender assembly to the lower trunk 5 Remove the fender assembly from th...

Page 682: ...le Installation To install reverse the order of removal 27 4 Bumpers Front Bumper Removal 1 Remove hood panel Refer to the procedure in this section 2 Label the wiring to head lamps parking lamps and signal lamps which are in the front bumper 3 Disconnect the wiring to the head lamps parking lamps and signal lamps 4 Remove the two carriage bolts and nuts on each side of the front bumper 5 Remove t...

Page 683: ...the rear license plate electrical connector to the rear license plate light 3 Remove the rear bumper from the rear of the vehicle Installation To install reverse the order of removal Engine and Transaxle Mounting Exploded View REAR OF VEHIC 5 c 6 27 5 ...

Page 684: ... Mount 2 Bolt Rubber Engine Mounts Bolt Bracket Engine Mount 2 Front Transaxle Support Insulator Through Bolt Nut Nut Bracket Engine Mount 2 Bolt Tighten to 39 47 ft lb 53 64 N m Tighten to 29 40 ft lb 39 54 N m Tighten to 50 68 ft lb 67 93 N m Tighten to 14 1 9 ft lb 19 26 N m Tighten to 21 34 ft lb 28 46 N m Tighten to 27 38 ft lb 37 52 N m Tighten to 28 37 ft lb 38 51 N m Front Support Insulato...

Page 685: ... insulator bolts Remove the rear engine support 5 Remove the rear transaxle support insulator through bolt and nut REAR TRANSAXLE SUPPORT INSULATOR REAR TRANSAXLE SUPPORT INSULATOR THROUGH BOLT 6 Remove the rear transaxle support insulator Installation To install reverse the removal procedure Refer to Torque Specifications in this section Support Rear Engine Removal 1 Support the engine with a thr...

Page 686: ...tor 27 8 6 If it is necessary to remove the RH engine support bracket remove the four RH engine support bracket bolts 7 Remove the RH engine support bracket Installation 1 If removed position the RH engine support bracket into place and install the four RH engine support bracket bolts Tighten the four RH engine support bracket bolts to 44 63 lb ft 59 85 N m 2 Position the RH engine support insulat...

Page 687: ...his section 3 Remove the jack from under the engine 4 Install the engine air cleaner Refer to Section 11 for the installation procedure Support Bracket Transaxle Front Removal 1 Remove the front transaxle support insulator Refer to the procedure in this section 2 Remove the four front transaxle support bracket bolts Remove the front transaxle support bracket Installation 1 Position the front trans...

Page 688: ...ne Support 44 63 Bracket Bolts RH Engine Support 48 69 Insulator Through Bolt RH Engine Support 39 47 Insulator Nuts Engine Support Bracket 29 40 Bolts Rear Engine Support 47 66 Rebound Insulator Bolts Front Transaxle Support 27 38 Insulator Nuts Rear Transaxle Support 21 34 Insulator Nuts Front Transaxle Support 28 37 Bracket Bolts Rear Transaxle Support 14 19 Bracket Bolts Front Transaxle Suppor...

Page 689: ...i squeak material that has slipped out of position Apply additional adhesive to these areas Vehicle Masking Suitable covers should be installed over the wheel and glass Mask off all upper exterior body sheet metal where painting or refinishing is not required If the vehicle has break lines in the metal use these in masking off the coating margin line Sheet Metal 1 Scuff sand with No 180 grit paper...

Page 690: ...keep the vehicle looking factory new for years to come The following cleaning and care recommendations will provide the vehicle with the necessary appearance protection Proper exterior appearance protection includes proper and frequent washing including underside areas polishing to shield paint and unpainted metal surfaces touching up nicks and scratches with proper paint Washing Use a wash and wa...

Page 691: ...rne pollen insect droppings and other organic matter especially vehicles subjected to these materials and exposed to high temperatures and sunshine should be washed as often as necessary to keep them free of organic matter Similar precautions should be taken where a vehicle may be exposed to chemical industrial fallout Failure to do so may result in damage to the exterior surfaces Glass Glass shou...

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