Mitsubishi Montero 1988 Manual Download

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Summary of Contents for Montero 1988

Page 1: ...Chapter 2 Part B 2 OL and 2 4L four cylinder engines Chapter 2 Part C 3 OL V6 engine Chapter 2 Part D General engineoverhaul procedures 2 Chapter 3 i Cooling heating and air conditioning systems Chapter 4 Fuel and exhaust systems Chapter 5 Engine electrical systems Chapter 6 Emissions control systems Chapter 7 Part A Manual transmission Chapter 7 Part B Automatic transmission Chapter 7 Part C Tran...

Page 2: ...1987 Mitsubishi pick up 1988 Mitsubishi Montero ...

Page 3: ...extremae neither the publisher nor the author can accept responsibility for anyzrrors in or omissions from the information given z Et _ A Note provides information necessary to properly complete a procedure or information which will make the procedure easier to understand CAUTION A Caution provides a special procedure or special steps which must be taken while completing the procedure where the Ca...

Page 4: ...r the vehicle near the right rear shock absorber Engine identification number The engine ID number consists of two parts a model number and a serial number On four cylinder engines it is located on the right side of the engrne In oneof two places 1 on a machined surface at the front car ner of the block just below the number one spark plug 2 6L engine or 2 at the lower right front corner of block ...

Page 5: ... tells what color and type of paint was originally applied to the vehicle Safety Certification label g The Safety Certification label is affixed to the left door pillar The plate contains the name of the manufacturer the month and year of production the Gross Vehicle Weight Rating GVWR and the certification statement I t f The paint code ID plate is usually located on the radiator support ...

Page 6: ...nual Application of these tech niques will enable the home mechanic to be more efficient better orga nized and capable of performing the various tasks properly which will ensure that the repair job is thorough and complete Fasteners Fasteners are nuts bolts studs and screws used to hold two or more parts together There are a few things to keep in mind when working with fasteners Almost all of them...

Page 7: ...ost standard bolts have slashes radiating out from the center of the head to denote the grade or strength of the bolt which is an indication of the amount of torque that can be applied to it The greater the number of slashes the greater the strength of the bolt Grades 0 through 5 are commonly used on automobiles Metric bolts have a property class grade number rather than a slash molded into their ...

Page 8: ...ightening can cause it to eventually come loose Bolts screws and studs depending on the material they are made of and their thread diameters have specific torque values many of which are noted in the Specifications at the beginning of each Chapter Be sure to follow the torque recommendations cbsely For fasteners not assigned a specif ic torque a general torque value chart is presented here as a gu...

Page 9: ...e hammer near the mating surfaces A regular hammer can be used if a block of wood is placed between the hammer and the pat t Do not hammer on cast parts or parts that could be easily damaged With any particularly stubborn part always recheck to make sure that every fasten er has been removed Avoid using a screwdriver or bar to pry apart an assembly as they can easily mar the gasket sealing surface...

Page 10: ...with spark plug hole adapter Hydraulic lifter removal tool Ridge reamer Hand operated vacuum pump Damper steering wheel puller asa _ zssA Valve spring compressor Timing light General purpose puller Valve spring compressor Piston ring groove cleaning tool Ring removai instaiiation tool ...

Page 11: ...lug gap aqusting tool Feeler gauge set Brake bleeder wrench Standard screwdriver 5 16 inch x 6 inch Phillips screwdriver No 2 x 6 inch Combination pliers 6 inch Hacksaw and assortment of blades Tire pressure gauge Grease gun Oil can Fine emery cloth Wire brush Tap and die set Battery post and cable cleaning tool Oil filter wrench Funnel medium size Safety goggles Jackstands 2 Drain pan Note If bas...

Page 12: ... those tools that will actually be used Tool stores tilloften be the only source of some of the special tools that are needed but regardless of where tools are bought try to avoid cheap ones especially when buying screwdrivers and sockets because they won t last very long The expense involved in replacing cheap tools will eventually be greater than the initial cost of quality tools Care and mainte...

Page 13: ...d lay a cloth over the vent holes Connectthe red jumper cable to the positive terminals of each bat tery Connect one end of the black jumper cable to the negative terminal of the booster battery The other end of this cable should be connected to a good ground on the vehicle to be started such as a bolt or bracket on the engine block see illustration Make sure the cable will not come into contact w...

Page 14: ...cles may be towed with all four wheels on the ground If necessary the front or rear wheels may be raised for towing On vehicles with an automatic transmission do not exceed 19 MPH ortow thevehiclefartherthan 19 miles thereare nospeedordistance limitations on vehicles with a manual transmission Equipmentspecifically designed for towing should be used and should be attached to the main structural me...

Page 15: ...he ignition switch Moiypenetranfsloosen and lubricate frozen rusted and corroded fas teners and prevent future rusting or freezing Heat sinkgreaseis a special electrically non conductive grease that is used for mounting electronic ignition modules where it is essential that heat is transferred away from the module Sealants RTVseaiantis one of the most widely used gasket compounds Made from silicon...

Page 16: ...ire Remember at all times that gasoline is highly ftammable Never smoke or have any kind of open flame around when working on a vehicle But the risk does not end there A spark caused by an electrical short circuit by two metal surfaces contacting each other or even by static electricity built upinyourbodyundercertainconditions can ignitegasolinevapors which in a confined space are highly explosive...

Page 17: ...4 696 14 5 0 145 98 1 Pounds force per square inch psi Ibf in lb in Pounds force per square inch psi Ibf in lb in Pounds force per square inch psi Ibf in lb in Pounds force per square inch psi Ibf in lb in Kilopascals kPa X 6 895 Kilopascals kPa X 0 01 Kilograms force per square centimetre kgf cm kg cm Torque moment of force Pounds force inches Ibf in lb in Pounds force inches Ibf in lb in Pounds ...

Page 18: ...43 Automatic transmission Engine will start in gears other than Park or Neutral 50 Fluidleakage 47 Symptom Section General shift mechanism problems 48 Transmission slips shifts rough is noisy or has no drive in forward or Reverse gears 51 Transmission will not downshift with the accelerator pedal pressed to the floor 49 Driveshaft Knock or clunk when transmission is under initial load just after t...

Page 19: ...ng carburetor or fuel injector Check for clogged fuel filter or lines and defective fuel pump Also make sure the tank vent lines aren t clogged Chapter 4 5 Choke not operating properly Chapter 1 6 Faulty distributor components Check the cap and rotor Chapter 1 7 Low cylinder compression Check as described in Chapter 2 8 Valve clearances not properly adjusted Chapter 1 four cylinder en gines 9 Wate...

Page 20: ... properly adjusted Chapter 1 13 Alternator light fails to come on when key is turned on 1 Faulty bulb Chapter 12 2 Defective alternator Chapter 5 3 Fault in the printed circuit dash wiring or bulb holder Chapter 12 14 Engine misses throughout driving speed range 7 Fuel filter clogged and or impurities in the fuel system Check fuel fil ter Chapter 1 or clean system Chapter 4 2 Faulty or incorrectly...

Page 21: ...ter Chapter 1 7 Loose or damaged oil pressure switch Chapter 2 8 Pistons and cylinders excessively worn Chapter 2 9 Piston rings not installed correctly on pistons Chapter 2 10 Worn or damaged piston rings Chapter 2 11 Intake and or exhaust valve oil seals worn or damaged Chapter 2 12 Worn valve stems 13 Worn or damaged valves guides Chapter 2 24 Excessive fuel consumption 1 Dirty or clogged air f...

Page 22: ...ining the oil Check the dipstick and inside the rocker arm cover for water deposits and an oil consistency like that of a milkshake 1 Leaking cylinder head gasket Have the system pressure tested or i e move the cylinder head Chapter 2 and inspect 2 Cracked cylinder bore or cylinder head Dismantle engine and inspect Chapter 2 3 Loose cylinder head bolts tighten as described in Chapter 2 31 Abnormal...

Page 23: ...n Chapter 7 unless otherwise noted 40 Noisy in Neutral with engine running 2 Damaged main drive gear bearing 3 Insufficient transmission oil Chapter 1 4 Transmission oil in poor condition Drain and fill with proper grade oil Check old oil for water and debris Chapter 1 5 Noise can be caused by variations in engine torque Change the idle speed and see if noise disappears 41 Noisy in all gears 1 Any...

Page 24: ...e to a shop check the fluid level and condition as described in Chapter 1 Add fluid if necessary or change the fluid and filter if needed If problems persist have a professional diagnose the transmission Driveshaft Note Refer to Chapter 8 unless otherwise specified for service informa tion 52 Leaks at front of driveshaft Defective transmission rear seal See Chapter 7 for replacement pro ceduye As ...

Page 25: ...ue in the transfer case mounts 4 Internal wear or incorrect adjustments 65 Noise 1 Lack of oil in transfer case 2 Noise in 4H and 4L but not in 2H indicates cause is in the front differ Zntial or front axle 3 Noise in 2H 4H and 4L indicates cause is in rear differential or rear axle 4 Noise in 2H and 4H but not in 4L or in 4Lonly indicates internal wear or damage in transfer case Brakes Note Befor...

Page 26: ...so make sure that all rotors are the same thickness 4 Out of round rear brake drums Remove the drums and have them turned or replace them with new ones 73 Brakes drag indicated by sluggish engine performance or wheels being very hot after driving 1 Output rod adjustment incorrect at the brake pedal 2 Obstructed master cylinder compensator Disassemble mastercylin der and clean 3 Master cylinder pis...

Page 27: ...t adjusted properly Chapter 1 2 Fluid level low Chapter 1 3 Hoses or pipes restricting the flow Inspect and replace parts as nec essary 4 Air in power steering system Bleed system 5 Defective power steering pump 83 Steering wheel fails to return to straight ahead position Incorrect front end alignment Tire pressures low Steering gears improperly engaged Steering column out of alignment Worn or dam...

Page 28: ...ead worn in one place 1 Incorrect tire pressure 1 Tires out of balance Have them balanced on the vehicle 2 Front end alignment incorrect toe out 2 Damaged or buckled wheel Inspect and replace if necessary 3 Loose or damaged steering components Chapter 1 3 Defective tire ...

Page 29: ...ad Center TDC for number one piston locating 3 Valve cover removal and installation 4 Valves servicing See Chapter 2D Valve springs retainers and seals replacement 6 Water pump removal and installation See Chapter 3 Specifications General Firingorder Cylinder numbers drivebelt end to transmission end Displacement 2 OL 2 4L Bore 2 OL 2 4L Stroke 2 OL _ _ _ 2 4L Camshaft Camshaftendplay Lobe height ...

Page 30: ...e vehicle gasket crankshaft oil seals and cylinder head gasket are all accessible with the engine in place Clean the engine compartment and the exterior of the engine with some type of degreaser before any work is done It will make the job easier and help keep dirt out of the internal areas of the engine Depending on the components involved it may be helpful to remove the hood to improve access to...

Page 31: ...4 3 Detach the spark plug wires and cable brackets from the valve cover see illustration 4 Clearly label and then disconnect any emission hoses and cables which connect to or cross over the valve cover 5 Remove the valve cover bolts see illustration and lift the cover off If the cover sticks to the cylinder head tap on it with a soft face hammer or place a block of wood against the cover and tap o...

Page 32: ...e the shafts When installing the rocker arms shafts and springs note the markings and the difference between the left and right side parts see illustrations Place the notches in the end of the shaft up see iiius tration and install the bolts through the cap into the shafts to keep them aligned until they are ready to be installed onto the cylinder head 9 If removed insert the hydraulic lash adjust...

Page 33: ...de each intake valve Refer to Chapter 20 for the jet valve servicing procedure This procedure is essentially the same as for the 2 6L engine covered in Chapter 2 Part A Refer to Part A Section 6 and follow the procedure outlined there but also refer to the illustrations accompanying this Sec tion t 5 7 On adjustable type rocker arms back off the adjusters until they only protrude 1 mm 0 040 in Ide...

Page 34: ...ve Qy 1 BoM 2 Crankshaft pulley 3 Flange bolt 4 Flange bolt 5 Upper front cover 6 Gaskef 7 Lower front cover 8 Access cover 8 8a Timing belt and related components exploded view 9 Gasket 18 Bolt 27 Bolt 10 Timing be t 19 Camshaft sprocket 28 Tensioner 3 ii Flange bolt 20 Nut 29 Silent Shaft belt 12 Washer 27 Oil pump sprocket 30 Flange bolt 13 Nut 22 Crankshaft sprocket bolt 31 Washer 74 Spacer 23...

Page 35: ...e the crankshaft counterclockwise Also don t turn the crankshaft after the timing belt has been removed 1 Position the number one piston at Top Dead Center see Section 3 2 Disconnect the negative cable from the battery 3 Remove the air cleaner assembly and associated hoses see Chap ter 4 4 Set the parking brake and block the rear wheels Raise the front of the vehicle and support it securely on jac...

Page 36: ... by hand and move It side to stde to detect roughness and excess play Visually inspect the sprockets for any signs of 4 Front Screwdriver 8 mm 3 in shaft 8 15 A screwdriver Is used to keep the Silent Shaft from turning as the oil pump is loosened flmmg mark punch on sprocket i Trmmg mark on cylrnder head Trmrng mark notch m fiangP Tlmlng mark notch in sprocket 8 22 Camshaft and crankshaft sprocket...

Page 37: ...ner up with one fingerto tighten the belt see illustration and tighten the tensioner bolt to the torque listed in this Chapter s Specifications Note Use the index fin gerandpress fimty on the timing be t see illustration The belt deflec tion should be 1364 to 9 32 inch 5 0 to 7 0 mm 26 Slip the timing belt onto the crankshaft sprocket While maintaining tension on the rear firewall side of the belt...

Page 38: ... into place with a hammer and socket 5 Reinstall the sprockets the timing belt the Silent Shaft belt and re lated components as described in Section 8 6 Run the engine and check for oil leaks 10 Camshaft removal inspection and instafiation Removal 1 Position the number one piston at Top Dead Center see Section 3 2 Disconnect the negative cable from the battery 3 Remove the valve cover see Section ...

Page 39: ...ications see Section 5 21 Install the camshaft sprocket and tighten the bolt to the torque listed in this Chapter s Specifications 22 Install the timing belt see Section 8 11 4 Carefully label the wires and hoses to aid in reassembly 23 Temporarily set the valve clearances prior to engine start up see Chapter 1 Note Latermodels use hydrauliclashadjusters on theintake and exhaust valves but the jet...

Page 40: ...e fuel rail see Chapter 4 14 Raise the vehicle and support It securely on jackstands 15 Remove the bolts that retain the lower intake manifold bracket to the engine see illustration 16 Unbolt the intake manifold and remove it from the engine If it sticks tap the manifold with a soft face hammer or carefully pry it from the head Caution Do not pry between gasket sealing surfaces Installation 17 Tho...

Page 41: ...d izFzz z L L 12 8 Remove the exhaust manifold mounting nuts arrows 2 OL engine shown unscrew the flare nuts on the air injection tube Remove the tube from the manifold 7 Remove the three bolts that secure the heat shield see illustration to the exhaust manifold Lift the heat shield off 8 Apply penetrating oil to the threads and remove the exhaust manifold mounting nuts see illustration brackets a...

Page 42: ... Part D It s a good idea to have the head checked for warpage even if you re just re placing the gasket 12 Remove all traces of old gasket material from the block and head see illustration Do not allow anything to fall into the engine Clean and in spect all threaded fasteners and be sure the threaded holes in the block are clean and dry Ins talla tion Refer to illustrations 13 13 and 73 14 13 Plac...

Page 43: ...the pan and tap the wood with a hammer Note If necessary for additional clearance for the oilpan remove the engine mounts andraise the engine a few inches 6 Thoroughly clean the oil pan and sealing surfaces Remove all traces of old gasket material Check the oil pan sealing surface for distortion Straighten or replace as necessary Installation 7 If the oil pan was sealed with RTV sealant only no ga...

Page 44: ...f the pressure relief spring and compare the measurement to this Chapter s Specifications Replace parts as necessary Pack the pump cavity with petroleum jelly and install the cover Xghten the bolts to the torque listed in this Chapter s Specifications Note Be sure to install the gears with the mating marks in the correctplace see illustration Installation Ii Install a new crankshaft front oil seal...

Page 45: ...ter Check that the rod on the front mount is not bent a jack under the engine oil pan Place a large block of wood between the 5 Check for relative movement between the mount plates and the en jack head and the oil pan then carefully raise the engine just enough to gine or frame use a large screwdriver or pry bar to attempt to move the take the weight off the mounts Warning DO NOTplace anypatiofyou...

Page 46: ...ative battery cable from the battery then raise the vehicle and support it securely on jackstands if not already done 8 Remove the fasteners and detach the mount from the frame and en gine see illustrations Do not disconnect more than one mount at a time except during engine removal 9 Installation is the reverse of removal Use thread locking compound on the mount bolts and be sure to tighten them ...

Page 47: ...ilent shafts chain sprockets removal inspection and installation 9 Spark plug replacement See Chapter 1 Timing chain and sprockets removal inspection and installation _ 10 Top Dead Center TDC for number one piston locating 3 Valve cover removal and installation 4 Valves servicing See Chapter 2D Valve spring retainer and seals replacement 6 Specifications General Firingqrder _ _ Cylinder numbers fr...

Page 48: ... 50 96 in lbs 96 in lbs 50 105 in lbs 120 in lbs This Part of Chapter 2 is devoted to in vehicle repair procedures for the 2 6L timing chain engines All information concerning engine removaf and installation and engine block and cylinder head overhaul can be found in Part D of this Chapter The following repair procedures are based on the assumption that the engine is installed in the vehicle If th...

Page 49: ...he timing plate then check to see if the distributor rotor is pointing to number 1 cylinder if not the camshaft is 180 degrees out of time number 4 is at TDC the crankshaft will have to be rotated 360 degrees stroke but TDC generally refers to piston position on the compression stroke 2 Positioning the piston s at TDC is an essential part of many proce duressuch ascamshaftand timing chain sprocket...

Page 50: ...carburetor that will in terfere with the removal of the valve cover 6 Wipe off the valve cover thoroughly to prevent debris fromfalling onto the exposed cylinder head or camshaft valve train assembly 7 Remove the valve cover bolts see illustrations 8 Carefully lift off the valve cover and gasket If thegasket is stuck to the cylinder head tap it with a rubber mallet to break the seaLDo not pry be t...

Page 51: ...cap bolts i 4 turn at a time until the spring pressure is relieved see illustration Do not remove the bolts 4 Lift the rocker arms and shaft assembly from the cylinder head Rein stall the bearing cap at the transmission end to hold the camshaft in place Inspection Refer to illustrations 5 5 and 5 6 5 Ifyou wish to disassemble and inspect the rocker arm assemblies a good idea as long as you have th...

Page 52: ...d check for oil leaks and proper operation 6 Valve springs retainers and seals replacement Refer to illustrations 6 4 6 9 and 6 17 Note 1 Broken valve springs and defective valve stem seals can be re FRONT OF SHAFT LEFT 12 OIL HOLES AT SHAFT BOTlO t ENGINE 5 8a Install the rocker shafts into the front bearing cap 6 4 This is what the air hose adapter that threads into the spark plug hole looks lik...

Page 53: ...slight resistance is felt 15 Lubricate the valve stem with engine oil and install a new guide seal 16 Install the spring s in position over the valve 17 Install the valve spring retainer Compress the valve spring and care fully position the keepers in the groove Apply a small dab of grease to the inside of each keeper to hold it in place see illustration 18 Remove the pressure from the spring tool...

Page 54: ...lustration and detach the exhaust manifold IO Separate the front catalytic converter from the exhaust manifold Ins talla tion 11 Discard the old gaskets and use a scraper to clean the gasket mating surfaces on the manifold and head then clean the surfaces with a rag soaked in lacquer thinner or acetone 12 Place the exhaust manifold andconverterassembly in position on the cylinder head and install ...

Page 55: ...afts s j i Inspection Z l 11 Check the sprocket teeth for wear and damage Check the spr et cushion rings and ring guides silent shaft sprockets only for wear and damage Rotate the cushion rings and check for smooth operation In spectthe chain forcracked side plates and pitted or worn rollers Replace any defective or worn parts with new ones Ins talla tion Refer to illustrations 9 16a 8 1 Sb 9 16 a...

Page 56: ... The bolt should be tightened to the specified torque on y after the cylinder head and camshaft have been installed 23 The remtinder tion is the reverse of removal 1 TO 3 5 mm PLATED LINK LO4 TO 14 IN 9 16 Push in the direction of arrow F to remove the slack from the silent shaft chain 10 Timing chain and sprockets removal inspection and installation Refer to illustrations 10 6 10 7 10 8 10 9a and...

Page 57: ...sproc up the plated linkon the chain with the marked tooth on the spro illustration Slide the crankshaft sprocket all the way onto the ft while depressing MATING MARK ING CHAIN MATING MARK I tt ie chain tensioner so the chain fits into place fitthe guides l test the cam shaft sprocket on the sprocket holder see illustration and make sure the plated links and mating marksarealigned properly Caution...

Page 58: ...cover so be sure the strap or wire hanger on the tool does not fall into the cover or it will be very difficult to remove the tool when the camshaft has been installed 5 Remove the camshaft sprocket bolt anddistributordrive gear see ii lustration Note Prevent the camshaft from turning by locking it inplace with a largepairof Vise grips oradjustablepliers Fasten the too onto the camshaft without co...

Page 59: ...l the plug to the rear of the cylinder head 16 Apply a thin coat of assembly lube ormoly base grease tottie bearing surfaces of the camshaft bearing caps 17 Install the rocker arm shaft assembly Tighten the camshaft bearing cap bolts l 4 turn at a time starting from the middle and working out to the ends until the torque listed in this Chapter s Specifications is reached 16 Install the camshaft sp...

Page 60: ...the threads in the head bolt holes Mount each head bolt in a vise and run a die down the threads to remove corrosion and restore the threads Dirt corrosion sealant and damaged threads will affect torque readings 15 Place a new gasket on the block Check to see if there are any mark ings such as TOP on the gasket that say how it is to be installed Those identification marks must face UP Also apply s...

Page 61: ...cularly around the bolt holes If necessary place the pan on aplock of wood and use a hammer to flatten and restore the gasket su c 8 lnstal e o n pan end seals then apply a i 8 inch wide bead of RTV sealant to the oil pan gasket surfaces Continue the bead across the end seals Make sure ihe sealant is applied to the inside edge of the bolt holes 9 Carefully place the oil pan in position 10 Install ...

Page 62: ...e illustra tion 16 3 and install the oil pick up tube and screen Tighten the bolts to the torque listed in this Chapter s Specifications 15 Install the oil pan see Section 15 17 3 On engines with a symmetrical bolt pattern be sure to mark the flywheel driveplate to the crankshaft 17 FlywheeVdriveplate removal and inslallation Removal Refer to illustrations 17 3 and 17 4 1 Raise the vehicle and sup...

Page 63: ...n the retainer bore or damage it during installation If you want to take the chance pry out the old seal see illustration Apply a film of clean oil to the crankshaft seal journal and the lip of the new seal and carefully tap the new seal intoplace see illustra tion The lip is stiff so carefully work it onto the seal journal of the crank shaft with a smooth object like the end of an extension as yo...

Page 64: ... remaining steps are the reverse of removal 11 Run the engine and check for oil leaks 19 Engine mounts check replacement and adjustment I Engine mounts seldom require attention but broken or deteriorated mounts should be replaced immediately or the added strain placed on the driveline components may cause damage or wear Check Refer to illustrations 19 4a and 19 4b 2 During the check the engine mus...

Page 65: ...se a large screwdriver or prybar to attempt to move the mounts If movement is noted lower the engine and tighten the mount fasteners 6 Rubber preservative should be applied to theinsulators to slow dete rioration Replacement Refer to illustrations 19 8a 19 8b and 19 8 7 Disconnect the negative battery cable from the battery then raise the vehicle and support it securely on jackstands if not alread...

Page 66: ...e roll restrictor check clearance A 0 4 inch lO O mm and clearance B 0 3 inch f7 5 mm Refer to illustrations 19 11 and 19 12 11 When installing the roll restrictor to the front insulator adjust the clear ance between the roll restrictor and the side of the insulator see illustra tion 12 Position the roll restrictor and leave the nut loose until the correct clearance see illustration has been attai...

Page 67: ... Oil pan removal and installation 17 Oil pump removal inspection and installation 18 Rear main oil seal replacement 20 Repair operations possible with the engine in the vehicle 2 1 Rocker arm components removal and installation 5 Spark plug replacement See Chapter 1 Thermostat replacement See Chapter 3 Timing belt removal installation and adjustment 10 Top Dead Center TDC for number one piston loc...

Page 68: ...by an eccentric type locknut maintains belt tension Each camshaft actuates two valves per cylinder through hydrau lic lash adjusters and shaft mounted forged aluminum rocker arms Each cast aluminum three ring piston has two compression rings and a three piece oil control ring The piston pins are pressed into forged steel connecting rods The flat topped pistons produce a 8 85 1 compression ratio Th...

Page 69: ...on rings pistons connecting rods and rod bearings is possible with the engine in the vehicle However this practice is not rec ommended because of the cleaning and preparation work that must be done to the components involved 3 Top Dead Center TDC for number one piston locating This procedure is essentially the same for all engines Refer to Chap ter 2 Part A Section 3 and follow the procedure outli...

Page 70: ...alve covergasket Right side cover 8 Remove the breather hose from the cover see illustration 9 Tag and detach the spark plug wires 10 Disconnect the electrical connectors and vacuum hoses necessary for removal Label and move the wiring and hoses aside 11 Remove the air cleaner assembly see Chapter 4 12 Remove the air intake plenum see Chapter 4 13 Remove the valve cover bolts and washers and lift ...

Page 71: ...he valve cover it is necessary to apply RTV to the edges arrows on the outside of the gasket where it mates with the camshaft seals OIL INTAKE WAR HAS EXI RA HOLE IN BOTrOM 43 2 1 5 2 An exploded view of the rocker arm assembly 5 Rocker arm components removal and installation NOTCH Refer to illustrations 5 2 5 4 and 5 5 1 Position the engine at TDC compression for the number 1 cylinder see Section...

Page 72: ...le from the negative terminal of the battery 3 Drain the cooling system don t forget to drain the cylinder block see Chapter 1 4 Remove the air cleaner to throttle body inlet hose see Chapter 4 5 Remove the spark plug wires and distributor cap Be sure to mark the spark plug wares for proper rernstallation see Chapter 1 6 Remove the throttle cable and transmission kickdown linkage see Chapter 4 and...

Page 73: ...e to remove the debris from the holes Warning Wearsafetyglassesora faceshield toproti3ctyoureyes when using compressed air 17 Position the gaskets on the cylinder heads No sealant is required however follow the instructions included with the new gaskets 18 Make sure all intake port openings coolant passage holes and bolt holes are aligned correctly 19 Carefully set the manifold in place Be careful...

Page 74: ...t material and carbon deposits from the manifold and cylinder head mating surfaces If the gas ket was leaking have the manifold checked for warpage at an automotive machine shop and resurfaced if necessary 9 Position new gaskets over the cylinder head studs Note If the new gasketis marked install thegasket with the numbers I 3 5on the top onto the right cylinder headand install thegasket with the ...

Page 75: ...ering wheel puller to the damper and slowly draw the vibration damper off Installation 7 Lightly lubricate the seal contact surfacewith engine oil and position it on the nose of the crankshaft Align the keyway in the pulley with the key in the crankshaft and push the pulley into place by hand If necessary tap lightly on the damper using a block of wood and a hammer 8 Prevent the crankshaft from tu...

Page 76: ...e illustra tion 15 Relieve tension on the timing belt by loosening the nut or bolt on the timing belt tensioner see illustration 10 14 16 Check to see that the timing belt is marked with an arrow as to which side faces out If there isn t a mark paint one on only if the same belt win be reinstalled Slide the timing belt off the sprockets Check the condition of the tensioner Installation Refer to il...

Page 77: ...disassembly refer ring to the appropriate Sections as necessary 11 Crankshaft front oil seal replacement Refertoillustrations 11 4 11 7 11 8aand 1f 8b 1 Disconnect the negative cable from the battery 2 Remove the drivebelts see Chapter l crankshaft pulley and timing belt see Sections 9 and 10 3 Wedge two screwdrivers behind the crankshaft sprocket Carefully pry the sprocket off the crankshaft Some...

Page 78: ...liter four cylinder engine Refer to Part A Section 6 and follow the procedure outlined there 14 Cylinder head s removal and installation Note Allow the engine to cool completely before beginning this proce due Removal 1 Position the engine at TDC on the compression stroke for the num ber 1 cylinder see Section 3 Drain the engine coolanf see Chapter Q 2 Remove the timing belt cover timing belt cams...

Page 79: ...ote Ifyou reonlyremovingonecamshaftand you want to save time by not removing and installing the timing belt and re timing the engine you can unfasten the camshaft sprocket and sus pend it out of the way with the belt still attached by a piece of rope Be sure the rope keeps firm tension on the be t so the be t won t become dis engaged from any of the sprockets 2 If you re removing the left driver s...

Page 80: ...damage to the sealing surfaces may result and oil leaks could develop If the pan is stuck dislodge it with a hammer and a block of wood 10 Use a gasket scraper to remove all traces of old gasket material and sealant from the block and pan Clean the mating surfaces with lacquer 3mm DIAMETER OFRTV SEALANT MUST NOT BE FORCED OUT FROM 17 14 The bead of RTV sealant should not interfere with the holes f...

Page 81: ...n i 8 Clean all components with solvent then inspect them for wear and damage 9 Remove the oil pressure relief valve plug washer spring and valve plunger Check the oil pressure relief valve sliding surface and valve spring If either the spring or the valve is damaged they must be replaced as a set 18 10b Checking rotor end clearance with a straightedge and a feeler gauge 10 Check the following cle...

Page 82: ...efer to Part A and follow the procedure outlined there 21 Engine mounts check and replacement Refer to illusffafion 27 7 This procedure is essentially the same for all engines See Part A of this Chapter and follow the procedure outlined there but use the torque values listed in this Chapter s Specifications Use the accompanying ex ploded view for reference see illustration 21 1 An exploded view of...

Page 83: ...1986 _ 1987through1989 _ __ 1990on Transmission to engine bolts 1983through1986 _ _ __ 19870n L 3 l 2 turns backed off from 52 in lbs No adjustments necessary 2 7 8 turns backed off from 72 in lbs No adjustments necessar 7 turns backed off from 43 in lbs No adjustments necessary 6 turns backed off from 30 in lbs No adjustments necessary 0 08 to 0 1 inch 0 02 to 0 06 inch Ft lbs unless otherwise in...

Page 84: ...isual inspection of the suspected component and the area immediately around it Pay particular attention to gasket mating sur faces A mirror is often helpful for finding leaks in areas that are hard to see 10 If the leak still cannot be found clean the suspected area thoroughly with a degreaser or solvent then dry it 11 Drive the vehicle for several miles at normal operating temperature and varying...

Page 85: ...nut 3 Place the shift control lever on the left side of the transmission in the neutral position Place the selector lever inside the vehicle in the neutral position also see illustration 4 At this point the control rod adjustment is made automatically Tight en the control rod to control arm adjusting locknut securely 5 Set the parking brake then apply the brakes then check to make sure the engine ...

Page 86: ...ting screw to the specified rpm see Chapter 1 Turn the engine off 3 Loosen the bolt so rods B and C can slide back and forth easily see illustration 4 Gently push rod A all the way to the rear Push rod C up so that the throttle is against the stop then tighten the bolt so that rods Band C can t move in relation to each other 5 Open the throttle valve In the carburetor completelyand qbs_erve the tr...

Page 87: ...he transmission case there should be continuity only when the transmission is in Park or Neutral 3 If the switch fails the test check the shift linkage adjustment see Sec tion 3 Replacement 4 Unplug the electrical connector and unscrew the switch from the transmission Some transmission fluid will spill out so have a container to catch it 5 Make sure the shift lever fingers ar e centered in the swi...

Page 88: ...earance at point A and B at the steering column see illustration 3 Loosen the interlock cable end nuts and align the cable end to the specifications listed in this Chapter 4 Tighten cable nuts and check for proper shift lever movement as de scribed in step I 7 5 The rear band adjusting screw is accessible after removing the transmission oil pan 7 Bands adjustment Refer to illustrations 7 I 7 5 2nd...

Page 89: ...trol linkage rod or cable 14 Disconnect the shift linkage 15 Support the engine with a jack Use a block of wood under the oil pan to spread the load 8 6 Mark the relationship of the torque converter to the driveplate 16 Support the transmission with a jack preferably a jack made for this purpose Safety chains will help steady the transmission on the jack 17 Remove the rear mount to crossmember bol...

Page 90: ...78 8 Chapter 7 Part B Automatic transmission 8 11a Transmission installation details typical 2WD model 8 11 b Transmission installation details 2 4L 4WD model shown 3 OL 4WD models similar ...

Page 91: ...al information 1 Hinges and locks maintenance 7 Hood removal installation and adjustment 9 Instrument cluster bezel and trim panels removal and installation 18 Outside mirror removal and installation 17 Radiator grille removal and installation IO Rear cargo door removal installation and adjustment 14 Upholstery and carpets maintenance 4 Vinyl trim maintenance 3 Windshield and fixed glass replaceme...

Page 92: ...g screws into the holes just enough for them to get a good grip in the metal Now the dent can be pulled out by pulling on the protruding headsof the screws with locking pliers 7 Thenext stageofrepairistheremovalof paintfromthedamagedarea and from an inch or so of the surrounding metal This is easily done with a wire brush or sanding disk in a drill motor although it can be done just as effectively...

Page 93: ...e is extensive the body must be checked for proper alignment or the vehicle s handling characteristics may be adversely af fected and other components may wear at an accelerated rate 3 Due to the fact that all of the major body components hood fenders etc are separate and replaceable units any seriously damaged compo nents should be replaced rather than repaired Sometimes the compo nents can be fo...

Page 94: ... as well as the hinges should be periodically lubricated with white lithium base grease to prevent sticking and wear 10 Radiator grille removal and Installation 9 11 Loosen the jam nuts to adjust the bumper screws early models 9 Loosen the bolts and move the hood into correct alignment Move it only a little at a time Tighten the hinge bolts and carefully lower the hood to check the alignment IO If...

Page 95: ...shion Side stay 11 Bumpers removal and installation Refer to illustrations 11 3a and 11 3b 1 Disconnect any wiring or other components that would interfere with bumper removal 2 Support the bumper with a jack or jackstand Alternatively have an assistant support the bumper as the bolts are removed 3 Remove the retaining bolts and detach the bumper see illustra tions 4 Installation is the reverse of...

Page 96: ...ler and hardener The ratio of filler to hardener is critical and if you mix it incorrectly it will either not cure properly or cure too quickly you won t have time to file and sand it into shape 2 then screw the slide hammer into the hole and operate it Tap with a hammer near the edge of the dent to help pop the metal back to its orlglnal shape When you re finished the dent area should be close to...

Page 97: ...a perfectly smooth surface 8 Use coarse grit sandpaper and a sanding board or block to work the filler down until it s smooth and even Work down to finer grits of sandpaper always using a board or block ending up with 360 or 400 grit 10 Apply several layers of primer to the area Don t spray the primer on too heavy so it sags or runs and make sure each coat is dry before you spray on the next one A...

Page 98: ... inner trim panel 2 Bracket 3 Clip 4 Regulator handle 5 Escutcheon 6 Inside handle cover 7 Arm rest 8 Lock knob 9 Door trim 10 inner weatherstrip 77 Clip 12 Trim clip 13 Plastic watershield 4 insert a putty knife between the trim panel and the door and disen gage the retaining clips see illustration Work around the outer edge un til the panel is free 5 Once all of the clips are disengaged detach t...

Page 99: ... in tors and push them through the door opening so they won t interfere with door removal stallthearmrest doorpulls Reinstall theclipandpressthe manual regula tor window crank onto the shaft until it locks 2 Place ajackorjackstand under the door or have an assistant on hand to support it when the hinge bolts are removed Note lfajack orjackstand is used place a rag between it and the door to protec...

Page 100: ...itch cap Door switch Adjustment 6 Following installation of the door check the alignment and adjust it if necessary as follows a Up and down and side to side adjustments are made by loosening the hinge to body bolts and moving the door as necessary b The door lock striker can also be adjusted both up and down and sideways to provide positive engagement with the lock mecha nism This is done by loos...

Page 101: ...ss connectors 7 Rear pillar lower trim 12 Back door 8 Coffer pin 13 Inside handle cover 9 Clevis pin I4 Back door trim 10 Washer tube 15 Watershield 16 Door upper hinge 17 Door lower hinge 18 Striker 19 Striker shim 20 Weatherstrip 14 7 Caigo door details on the 7 pick ups 1 Wire assembly 2 Rear gate yJ 3 Striker 8 4 Rear gate panel J 5 Remote control EJ L 6 Latchassembly 7 Outside handle ...

Page 102: ...oor lock Adjustment Refer to illustration 15 f 7 11 To adjust the outside door handle freeplay remove the retaining clip from the actuating rod and turn the connector up or down to remove the freeplay see illustration Cargo door Refer to illustration 15 14 Removal and installation 12 Remove the door trim panel as described in Section 12 13 Remove the plastic watershield taking care not to tear it ...

Page 103: ...ator power door lock 15 11 Adjusting the freeplay on the exterior handle I 15 21 Adjusting the freeplay on the exterior handle of the rear cargo door Montero shown but pick up similar 15 14 Cargo door lock and handle details on the Montero 1 Trim and watershield 2 Garnish bracket 3 Garnish 4 Outside harTdIe 5 Inside handle 6 Door lock assembly 7 Door lock actuator power door lock ...

Page 104: ...the outside area of the door and then sliding the glass up and out of the door 4 Remove the regulator retaining screws 5 Detach the regulator and guide it out of the opening in the door 6 Installation is the reverse of removal 17 Outside mirror removal and installation Refer to illustrations 17 1 and 17 2 1 On some mirrors use a small screwdriver to pry the screw cover off the mirror base see illu...

Page 105: ...ock Screw hole cover Center cover Instrument panel 18 1 b lnstruyrz cluster and trim panel details on thk Montero 1 2 3 4 5 6 7 8 9 10 11 12 Lap heater duct A Lap heater duct B Hood release cable bracket Demister grille left Demister grille right Glove box Instrument cluster Instrument cluster bezel Combination meter pad Combination meter case Center panel Recirculation fresh air changeover cable ...

Page 106: ...ender 20 Front fender removal and installation Refer to illustrations 20 3a and 20 3b 1 Raise the vehicle support it securely on jackstands and remove the front wheel 2 Disconnect the antenna and all light bulb wiring harness connectors and other components that would interfere with fender removal 3 Remove the fender mounting bolts see illustrations 4 Detach the fender It s a good idea to have an ...

Page 107: ...nt 12 Parking brake shoes 1992 and later models with rear disc brakes replacement _ __ _ ______ _ _ __r ____ 13 Power brake booster check removal and installation _ _ _ _ IO Wheel cylinder removal overhaul and installation _ _ 6 Stxcifications General Brakefluidtype See Chapter 1 Brake booster pushrod protrusion 1987andearlier 0 004 to 0 020 inch 1988on _ 0 028 to 0 043 inch Disc brakes Minimum br...

Page 108: ...ormal service If a problem is sus _ p ected in the brake system do not drive the vehicle until the fault is corrected d Tires load and front end alignment are factors which also affect brakingperformance 2 Disc brake pads replacement Warning Disc brake pads must be replaced on both front wheels at the s ime tfme never replace the pads on only one wheel Also the dust created by the brake system may...

Page 109: ...ces of the caliper and support plates with a thin coat of multi purpose grease Install the pad clips on the bracket see illustration 2 5b 8 Slide the caliper assembly into position over the new pads and seat it on the mounting bracket If removed install and tighten the up per caliper bracket bolt 2 9 Pry the caliper up with a screwdriver and then insert the stopper plate 9 Install the pad support ...

Page 110: ...rotate the caliper up to allow removal of the pads see illustrations 12 Remove the anti rattle springs if equipped and pull the brake pads and shims from the caliper bracket see illustration 2 13b and upper pad retaining clips from the bracket 13 Remove the retaining clips from the bracket see illustrations 14 Cleanthemountingsurfacesofthecaliperandbracket removingany dirt or corrosion Install new...

Page 111: ...ston Sleeve Dust boot k I1 Piston seal 3 8 Apply compressed air to the brake fluid hose connection in the caliper body position a wood block between the piston and the caliper to prevent damage 2 Loosen the wheel lug nuts raise the front of the vehicle and support it securely on jackstands Remove the wheels 3 Remove the brake hose inlet fitting bolt and detach the hose Have a rag handy to catch sp...

Page 112: ...ground Test the brakes carefully before piac ing the vehicle into normal operation 4 Brake disc inspection removal and installation Refer to illustrations 4 4a 4 4b 4 5 and 4 7 Note The following procedure applies to both front and rear disc brakes Inspection 1 Loosen the wheel Itug nuts raise the vehicle and support it securelyon jackstands Remove the wheel On rear disc brakes reverse and install...

Page 113: ... sembly with the drum removed and compare it to illustrations 5 4a and 5 28 1 Loosen the wheel lug nuts raise thevehicleand support it securely on jackstands Remove the wheel s 2 Pull off the brake drum if you have difficulty removing it screw an 8 mm bolt into each of the two threaded holesin the drum see illustration Tighten each bolt one half turn at a time to back the drum off the axle flange ...

Page 114: ...rfacing will eliminate the possibility of out of round drums 15 Inspect the backing plate ledges for grooves see illustration If the grooves are not too deep they can be removed by filing or sanding the backing plate If the grooves are too deep the backing plate must be re placed or the brake shoes will hang up in the grooves 16 Check the free length of the primary green and secondary grey brake s...

Page 115: ...points shown 2 5 18 Place the parking brake strut into position with the spring on the forward end left side struts are stamped L and right side R 20 Install the auto adjuster assembly and spring into position between the lowerends of the brake shoes Make sure that the auto adjuster mech anism is properly installed or it will not operate 21 Lubricate the backing plate shoe contact points with mult...

Page 116: ...tall the wheels and lower the vehicle to the ground Leading trailing type Referfoillusfrations5 28 5 29 5 30 5 3ia 5 316 5 31 5 36 5 38 5 39 5 4Oa and 5 4Ob 28 Use pliers to detach the upper return spring see illustration 5 31a Remove the trailing shoe hold down spring 29 Remove the leading brake shoe hold down spring and pin see iiius tration This is accomplished by grasping the spring cup with a...

Page 117: ...ly to the trailing shoe 38 Connect the parking brake cable to the lever and position the shoe againstthe backing plate see illustration Install the hold down pin and spring 39 Connect the leading shoe to the lower spring and rotate it up into posi tion see illustration Install the hold down pin and spring 40 Install the upper return spring see illustrations 41 Wiggle the brake shoe assembly to cen...

Page 118: ...caps or plastic bags to cover the ends of the lines once they are disconnected Caution Brake fluid will damage paint Cover all body parts andbe careful not to spill ftufd during this procedure _ 4 Loosen the tube nuts atthe end ofthebrakelines where they enter the master cylinder To prevent rounding off the flats on these nuts the use of a flare nut wrench which wraps around the nut is preferred 5...

Page 119: ...sensor float 10 Reservoir setil 11 Stop bolt 12 Gasket 13 Stopper ring 14 Primxy piston 15 Secondary piston 1 b Typical later model mask cylinder exploded view 16 Before installing the new master cylinder it should be bench bled Be cause it will be necessary to apply pressure to the master cylinder piston and at the same time control flow from the brake line outlets it is recom mended that the mas...

Page 120: ... first remove the spring clip Then using a normal wrench to hold the hose and a flare nut wrench to hold the tube make the disconnection Use the wrenches in the same manner when making a connection then install a new clip Note MaI surethe tube passes through the center of grommet 5 When disconnecting two hoses use normal wrenches on the hose fii tings When connectingtwo hoses make sure they are no...

Page 121: ...er as de scribed in Section 7 On some vehicles it is not necessary to disconnect the brake lines from the master cylinder as there is enough room to reposi tion the cylinderto allow booster removal 7 Locate the pushrod clevis connecting the booster to the brake pedal see illustration This is accessible from the interior in front of the driver s seat 8 Remove the clevis pin retaining clip with plie...

Page 122: ...the handle is applied 4 to 6 clicks on lever type parking brakes or 16 to 17 clicks on umbrella type models adjust the cable 2 Raise the vehicle and support it securely on jackstands 3 On 2WD models adjust the parking brake turnbuckle until the stroke 18 9 5 of the pull handle is as specified see illustration Make sure that the brake balancer is nearly parallel with the center line of the vehicle ...

Page 123: ...n 2 Cable end shoe ever connection 7 Split pin 10 Spacer 3 Stopper 5 Aausting nuts 8 Washer il Lever assembly 12 3 Umbrella type parking brake front cable details 1 Parking brake switch 2 Accelerator cable 3 Pedal bracket 4 Snap ring 5 Parking brake front cable end 6 Parking brake pull rod 7 Bolts 8 Clip 9 Parking brake front cable ...

Page 124: ...ecurely on jackstands 2 Disassemble the rear brakes and remove the ends of the parking brake cables from the parking brake levers Section 5 3 Remove the return spring if equipped separate the parking brake cables at the adjuster then remove the bolts and the cables see illustra tions 4 Installation is the reverse of the removal procedure 5 Following installation adjust the parking brake see Sectio...

Page 125: ...st in front of the rear axle The modulator receives a signal from the control unit it then regulates the hydraulic pressure to the rear wheels as necessary to prevent full rear wheel lock up G sensor The G sensor islocated behind the center of the dash under the ash tray The G sensorsenses the force and speed of deceleration and sends a signal to the control unit Speed sensor The speed sensor is l...

Page 126: ...hort circuit 16 nlvuulll 21 nrLn Battery voltage G sensor Voltage drop Broken wire Short circuit Failure of ON Broken wire z2 nnnl Release valve Broken wire z Short circuit nnnrur Ho G v e I Broken wire Short circuit 55 Control unit Replacement uuvuu in Normal Normal n 14 2 Anti lock codes and diagnosis table ...

Page 127: ...trical troubleshooting general Information A typical electrical circuit consists of an electrical component any switches relays motors fuses fusible links or circuit breakers related to that component and the wiring and connectors that link the component to both the battery and the chassis To help you pinpoint an electrical circuit problem wiring diagrams are included at the end of this book Befor...

Page 128: ... switch turned On the test light should come on Finding an open circuit When diagnosing for possible open circuits it is often difficult to locate them by sight because oxidation or terminal misalignment are hidden by State of fuse blown due to overcurrent State of fuse blown due to thermal fatigue 3 3 On later models miniaturized fuses are used overcurrent or thermal fatigue can cause them to fai...

Page 129: ...rmal function Some circuit breakers must be re set manually 6 Relays general infofmation Refer to illustration 6 2 1 Several electrical accessories in the vehicle use relays to transmit the electrical signal to the component If the relay is defective that component will not operate properly 2 The various relays are grouped together in several locations see illustration 6 2 This group of relays Is ...

Page 130: ...om the steering column 6 Installation is the reverse of removal 8 ignition switch and lock cylinder removal and installation Refer to illustration 8 2 1 Disconnect the negative battery cable from the battery 2 Remove the steering column cover to gain access to the ignition switch lock cylinder see illustration 3 Using wire cutters remove the cable band 4 Remove the bolts that hold the ignition swi...

Page 131: ...lywith lacquer fhinneroralcohol before installation 12 la Removing the rear light lens 12 ld To remove a side marker bulb like the one shown push it in and rotate it go degrees counterclockwise 11 Headlights adjustment Note The headlights must be aimedcorrectly If adjustedincorrectly they couldblind the driver of an oncoming vehicle and cause a serious accident or seriously reduce your ability to ...

Page 132: ...o control stud nuts 1986 and earlier models 12 Bulb replacement Refer to illusfrations 12 la 72 lb 12 Ic 12 Id 72 le and 12 If 1 The lenses of many lights are held in place by screws which makes it a simple procedure to garn access to the bulbs see illustrations 2 On some lights the lenses such as the interior dome light lens a e held in place by clips The lenses can be removed either by unsnappin...

Page 133: ...ur screws attaching the instrument cluster to the dash see illustration 8 Remove the speedometer cable fitting and remove the cable from the back of the cluster see illustration 19 4 Disconnect the electrical wire from the buzzer 9 Carefully pull out on the cluster until it is free of the dash then discon nect the two electrical connectors at the rear of the cluster 10 Installation is the reverse ...

Page 134: ...he printed circuit board by turning them counterclockwise 10 Reassembly is the reverse of disassembly a D W 15 8 Instrument cluster exploded view 1987 and later models ClearplastIc cover Instrument cluster face Oil pressure gauge Engine coolant temperature gauge Fuel gauge Voltmeter Warning indicator reset switch instrument cluster case Printed circuit board 16 Cruise control system description an...

Page 135: ...wiring for damaged or loose connections The actuator can be checked by applying battery power momentarily A discern ible click indicates that the solenoid is operating properly 19 Speedometer cable replacement Refer to illustrations 19 2 and 19 4 1 Disconnect the negative cable from the battery 2 Disconnect the speedometer cable from the transmission see illus tration 3 Detach the cable from the r...

Page 136: ...Chapter 12 Chassis electrical system m LAI ...

Page 137: ...Chapter 12 Chassis electrical system E p u I I ...

Page 138: ...12 12 Chapter 12 Chassis electrical system ...

Page 139: ...Chapter 12 Chassis electrical system 12 13 ...

Page 140: ...12 14 Chapter 12 Chassis electrical system I f a ...

Page 141: ...Chapter 12 Chassis electrical system 12 15 p o f I grs mi ...

Page 142: ...MPI CIRCUIT 2 4L ENGINE 2O lla Fuel injection circuit 2 4L engine 1 of 2 20 11 b Fuel injection circuit 2 4L engine 2 of 2 I I I ...

Page 143: ...20 12a Fuel injection circuit 3 OL engine 1 of 2 T I 0 11 I I p e sunent mnneCtor I 4 20 12b Fuel injection circuit 3 OL engine 2 of 2 ...

Page 144: ...12 18 Chapter 12 Chassis electrical system L y 4 ...

Page 145: ...ntrol relay D 28 a i L m D 28 b i L IF 11 25 BY 1 11 25 w I I F RBnRB I m 125 F Br1 IBr Brn I To engine control unit Refer to P 8 40 42 Door lock actuator Door lock actuator D 28 a b i K rn D 28 a j K D 28 a j L I I i 1 1 1 1 1 18 D 28 b i L D 28 b j K Color code for wiring B Black Br Brown L Blue Lg Light green P Pink R Red G Green Gr Gray LI Light blue 0 Orange Y Yellow W White 20 15 Power door ...

Page 146: ...and installation _ _ _ 18 Front driveaxle boot replacement and Constant Velocity CV jointoverhaul 4WDmodels __ _____ __ ____ 21 Front driveaxles 4WD models removal and installation 20 Front hub assembly 4WD models removal bearing repack installation and adjustment _ _ _ _ 19 Front wheel bearing check repack and adjustment 2WD models only _ _ See Chapter 1 General information _ _ _ _ _ _ _ _ _ 1 Pi...

Page 147: ... best to assume however that the disc will need replacement at about 40 000 miles 64 000 km 6 Because of the clutch s location between the engine and transmis sion it cannot be worked on without removing either the engine or trans mission If repairs which would require removal of the engine are n ot needed the quickest way to gain access to the clutch is by removing the transmission as described i...

Page 148: ... a clutch alignment tool through the clutch disc hub 5 Carefully inspect the flywheel and pressure plate for indexing marks The marks are usually an X an 0 or awhite letter Ifthey cannot be found apply marks yourself so the pressure plate and the flywheel will be in the same alignment during installation 6 Turning each bolt only l 2 turn at a time slowly loosen the pressure plate to flywheel bolts...

Page 149: ...te to flywheel bolts a little at a time working in a criss cross pattern to prevent distorting the cover After all of the bolts are snug tighten them to the torque listed in this Chapter s Sfjecifications Be move the alignment tool 17 Using high temperature grease lubricate the inner groove of the re lease bearing refer to Section 4 Also place grease on the fork fingers 18 Install the clutch relea...

Page 150: ...us damage A flashlight will be helpful to direct light into the recess 5 Check to make sure the pilot bearing turns smoothly and quietly If the transmission input shaft contact surface is worn or damaged replace the bearing with a new one 6 Removal can be accomplished with a special puller but an alternative method also works very well 7 Find a solid steel bar which is slightly smaller in diameter...

Page 151: ...st cov er Be sure the dust cover is secure on the cylinder housing lnsfallation 15 Installation is the reverse of the removal procedure Use new sealing washers at the banjofrtting After the cylinder has beetinstalled bleed the clutch hydraulic system as described in Section 9 8 6a With the cylinder padded to catch the piston use compressed air to force the piston out of the bore make sure your han...

Page 152: ...the shaft is provided by the rear wheel bearing The front axle on 4WD vehicles consists of a frame mounted differen tial assembly and two driveaxles The driveaxles incorporate two constant velocity CV joints each enabling them to transmit power at various sus pension angles independent from each other Because of the complexity and critical nature of the differential adjust ments as well as the spe...

Page 153: ...ansmission transfer case to prevent lubricant leakage 12 3 Typical front driveshaft installation details 13 1 Make sure to mark the relationship of the universal joints driveshaft and center bearing before beginning disassembly 12 Installation is the reverse of the removal procedure During installa tion make sure all flange marks line up When connecting the center bear ing support to the frame fir...

Page 154: ...nt the universal joint in the vise with the large socket on one side of the yoke and the small socket on the other side pushing against the bearing Carefully tighten the vise until the bearing is pushed out of the yoke and into the large socket see illustration If it can t be pushed all the way out remove the universal joint from the vise and use apairof pliers to finish removing the bearing 6 Rev...

Page 155: ...ic bags tightly around them to prevent excessive fluid loss and contamina tion 7 Support the rear axle assembly wrth a jack Leaf spring models 8 Remove the U bolt nuts from the leaf spring seats and raise the axle assembly slightly with the jack 9 Remove the rear spring shackle bolts and lower the rear of each leaf spring to the floor Coil spring models 10 Remove the stabilizer bar bolts 11 Remove...

Page 156: ...uts attaching the bearing cage and brake backing plate to the axle housing Tighten the nuts to the torque listed in this Chapter s Specifications 17 Install the right side axle into the housing without a shim or O ring in place and temporarily tighten the attaching nuts to a torque of 5 in lbs When theaxle is installed in this manner agapwill existbetween the bear ing case and the axle housing end...

Page 157: ...up the nut while holding one of the wheels to keep the shaft from turning as it is tight ened 14 Tighten the nut to the torque in the Specifications Section atthe begin ning of this Chapter This torque figure is very important because it deter mines the preload on the pinion shaft bearings 15 Connect the driveshaft and fill the differential wtth the specified lubri cant Chapter 1 Tighten the fill ...

Page 158: ...al of care are required to remove and install the hub on 4 WD models so be sure to read through the entireproce dure before beginning work It may be a good idea to leave the job to a dealer sewice department or repair shop Removal 1 Raise the front of the vehicle and support it securely on jackstands 2 Refer to Chapter 9 and remove the brake caliper pad assembly Do not disconnect the hose from the...

Page 159: ...y pulling straight out on it see illustration 5 On all models remove the screws and detach the lockwasher from the hub 6 Using the special socket available from your dealer or most auto parts stores and a breaker bar remove the locknut see illustration 7 Carefully remove the hub from the spindle don t drop the outer bear ha Bearing repack 8 Use a screwdriver to pry the grease seal out of the rear ...

Page 160: ... turn the hub as described in Step 21 it should be one to four pounds Check the axial play of the wheel hub as shown in the accompanying illustration see this Chapter s Specifica tions then install the lockwasher If the holes in the lockwasherand lock nut do not line up loosen the locknut slightly 40 degrees maximum 24 On 1984 and later models install the free wheeling hub assembly 25 On models wi...

Page 161: ...llation Refer to illustrations 20 6 and 20 12 Removal 1 Raise the front of the vehicle and support it securely with jackstands then remove the wheels and the brake caliperassemblies see Chapter9 21 6 Remove the snap ring the inner race and the circiip from the shaft Do notdisconnectthe hosesfromthecalipersanddo notallowthecalipers to hang by the hoses suspend them with pieces of stiff wire so ther...

Page 162: ... Note 2 Obtain a new rubber bootkit for each joint on the driveaxle before beginning disassembly do not disassemble the Birfield outer joints if they are worn or damaged new driveaxles are in order 1 Remove the boot bands by prying up the ends with ascrewdriveror by cutting them off new bands must be used during reassembly 2 Use a screwdriver to remove the large circlip from the DOJ outer race see...

Page 163: ...e en ww 0 4 With the solenoid valves disconnected check the resistance across the solenoid terminals The resistance should be 36 to 46 ohms at 60 de grees F If not within these specifications replace the solenoid valve as sembly 5 Turn off the engine and check the vacuum hoses and pipes from the solenoid valve assembly to the actuator for kinks cracks or other dam age 6 Disconnect the vacuum hoses...

Page 164: ...nd refilling See Chapter 1 Engine cooling fan and clutch check and replacement 5 General information 1 Heater air conditioning control assembly removal and installation 19 Heater core removal and installation _ _ 12 Heating system general information _ 10 Radiator removal and installation 4 Thermostat check and replacement 3 Waterpump check 7 Waterpump replacement 8 Specifications General Coolant ...

Page 165: ...ditioning system The air conditioning system consists of a condenser mounted in front of the radiator an evaporator mounted adjacent to the heater core a com pressor mounted on the engine a receiver drier which contains a high pressure relief valve and the plumbing connecting all of the above components A blower fan forces the warmer air of the passenger compartment through the evaporator core sor...

Page 166: ...rain the cooling system see Chapter 1 If the coolant is relatively new or in good condition see Chapter l save it and reuse it FIANCE FIANCE AIR VENT AIR VENT FLANGE IN FLANGE IN IN Gr 3 13 Thermostat installation 2 6L engine shown 7 Follow the upper radiator hose to the engine to locate the thermostat housing 8 Loosen the hose clamp then detach the hose from the fitting If it s stuck grasp it nea...

Page 167: ...th an automatic transmission disconnect the cooler hoses from the radiator see illustration Use a drip pan to catch spilled fluid 7 Plug the lines and fittings 8 Remove the radiator mounting bolts 9 Carefully lift out the radiator Don t spill coolant on the vehicle or scratch the paint 10 With the radiator removed it can be inspected for leaksand damage If it needs repair have a radiator shop or d...

Page 168: ... illustration 7 5 1 A failure in the water pump can cause serious engine damage due to overheating 2 There are three ways to check the operation of the water pump while it s installed on the engine Ifthe pump is defective it should be replaced with a new or rebuilt unit 3 With the engine running at normal operating temperature squeeze the upper radiator hose if the water pump is working properly a...

Page 169: ...er hose 9 Water pump 10 Gasket 1 9 14 6 c I 8 28 Typical water pump installation details 2 4L and 1983 and later 2 OL engines 3 Air conditioner tensioner pulley 8 Crankshaft pulley 9 Crankshaft pulley 10 Upper timing belt cover ii Lower timing be t cover 12 Timing belt tensioner 13 77ming be f 14 Lower radiator hose 15 Heater hose 16 Waterpump 17 Gasket 18 O ring ...

Page 170: ...ne side of the new gasket and to the gasket mating surface of the new pump then carefully mate the gasket and the pump Slip a couple of bolts through the pump mounting hole to hold the gasket in place 35 Carefully attach the pump and gasket to the engine and thread the bolts into the holes finger tight Be sure to install the bolts with the correct length into the corresponding water pump holes 36 ...

Page 171: ...els 4 Turbo fan 7 Side ventilator duct 10 Water valve 5 Blower motor 8 Defroster duct If Heater core 6 Heater resistor 9 Center ventilator duct 12 Heater control panel assembly 10 1 b Heater unit and related components 1988 and later models Glove box stopper Glove box frame Air selection wire connection Duct Blower assembly Blower motor Gasket Fan Resistor block 44 2 F 77 ...

Page 172: ...4a To adjust the INSIDE OUTSIDE air control cable move the cable housing in the securing clip pre 1988 models 4 Remove the center console see Chapter 11 5 Remove the center panel and the center ventilator bezel see illus tration 10 1 a 6 Disconnect the heater control cables at the heater assembly not at the control assembly 7 Disconnect the heater hoses at the heater core Use some rags near the ho...

Page 173: ...e the cable housing in the securing clip to adjust it pre 1988 models 12 14 To adjust the DEF HEAT VENT damper move the cable housing in the securing clip pre 1988 models 12 I9 Heater unit exploded view 1988 and later models 7 Heater hose connections 2 Instrument panel 3 Main duct 4 Center ventilator duct 5 Defroster duct 6 Center reinforcements 7 Heater unit 8 Grommet ...

Page 174: ...s by air outside or recirculated entering the evap orator core by the action of the blower motor where it receives cooling When the air leaves the evaporator it enters the heater air conditioner duct assembly and by means of a manually controlled deflector either passes through or bypasses the heater core in the correct proportions to provide the desired vehicle temperature Distribution of this ai...

Page 175: ...the refrigerant used in the system can cause serious injuries and respiratory irritation 3 Loosen the hose clamps and remove both hoses from the receiver drier 4 loosen the clamp and pull up on the receiver receiver to remove it from its mount 5 When installing the receiver drier lubricate the inside surfaces of the hoses and the outside of the fittings with refrigerant oil Be sure the hose clamps...

Page 176: ...enser brackets 7 Lift the condenser out of the vehicle and plug the lines to keep dirt and moisture out 8 Ifthe orfginal condenser will be reinstalled store it with the line fittings on top to prevent oil from draining out 9 Ifa new condenser is being installed pour one ounce of refrigerant oil into it prior to installation 10 Reinstall the components in the reverse order of removal Be sure the ru...

Page 177: ... vehicle fire wall 8 Removethe boltsattachingtheevaporatortothedashboardandfire wall and carefully move it down and out from the dashboard Do not mis place the plastic duct that fits between the heater assembly and the evaporator 9 Use a flat bladedscrewdriver to remove the clips from the evaporator housing and remove the evaporator see illustrations 10 Installation is the reverse of removal Be su...

Page 178: ... the clustertrim panel and lift it out of place by carefully prying out on the lower left corner see illustration 5 Disconnect the electrical connectors at the right of the cluster trim panel 6 Disconnectthe control cable from the heater not from the control as sembly see illustration 7 Removethefourscrewsattachingthecontrolassemblyandremoveit from the dashboard see illustration 8 Minor repairs su...

Page 179: ...6 Heater control assembly details 13 Heater control assembly 16 Heater fan switch 14 Heater control panel lens 17 Control illumination harness 19 7 To remove the heater control assembly from the 15 Heater control panel dashboard remove these four screws arrows ...

Page 180: ...elf diagnosis and malfunction codes fuel injected modelsonly 15 Thermostatic air cleaner check carbureted models only _ _ See Chapter 1 Throttle opener carbureted models only 12 Vacuum delay valve carbureted models only 11 Specifications Dashpot adjustment Engine set speed 2 OLengine 2 6Lengine Dashpotdroptime Throttle position sensor Output voltage 2 4Lengine 3 OLengine Resistance at closed throt...

Page 181: ...ematic 1985 and 1986 2 OL engine shown 2 6L engine similar secondary air control valve b a Vacuum switch valve JJacuum s i Hiah altttude compensator FeballCalifornla and High altitude vehicles for Federal Secondary air control solenoid valve 1 3b Vacuum schematic 1987 through 1989 all engines ...

Page 182: ...rst see illustrations This doesn t mean however that emission control systems are partic ularly difficult to maintain and repair You can quickly and easily perform many checks and do most of the regular maintenance at home with com mon tune up and hand tools Note Because ofa Federailymandatedex tended warranty which covers the emission controlsystem components check with your dealer about warranty...

Page 183: ...sists of one or twova 2 The blow by gas is led through a rubber hose Tram the Wont ot the pomriqurd separators jnoi used 011 all models an overfill limiter two way valve cover into the a7r cleaner and through anotner hose tram the rear or valve a tuel check valve a purge control valve carbureted models or the cover into the intake manirnld through tne onitce H7 narrow ihrottle purge comroi soienol...

Page 184: ... cleaner and burned tank by an increase in atmospheric temperatures are routed to the sepa 4 The purge control valve is kept closed at idle speeds to prevent vapor rator tank in which liquid gasoline formed by condensation of the vapors is ized fuel from entering the air cleaner and causing high idle carbon mon separated The remaining fuel vapor is led into a two way valve The two oxide emissions ...

Page 185: ...k 10 Duringfillingof thefuel tank theairin thetankflowsthrough the level ing pipe and out into the atmosphere venting the tank When the fuel en tering the tank has sealed off the leveling pipe opening in the tank further filling cannot be done because of the air pressure inside the tank Iffilling is confinued overflow of fuel will result come clogged over a long period of time it is recommended th...

Page 186: ...k s 28 The function of the separator tank is to temporarily accommodate an increased volume of gasoline caused by expansion at high outside air temperatures They also prevent liquid fuel from entering the vapor line during hard cornering 29 Mark each fuel vapor hose and its corresponding fitting with num bered pieces of tape 30 Refer to Chapter 4 and remove the fuel tank 31 The separator tanks are...

Page 187: ...urge control so lenoidvalve apply a vacuum and verify that the valve leaks vacuum when voltage is applied when voltage is discontinued the valve should main tain vacuum 44 Measure the resistance between the terminals of the solenoid valve and compare your reading to the range of acceptable resistance listed in this Chapter s Specifications 45 If the purge control solenoid valve fails either of the...

Page 188: ...g maycauseover heating of the catalyst which may damage the converter or other vehicle components Heat damage can also occur during diagnostic testing if spark plug wires are removed and the engine is allowed to idle for a pro longed period of time 5 Caution Vehicle operation including idling should be avoidedifen gine misfiring occurs Under these conditions the exhaust system will op erate at an ...

Page 189: ...es of nitrogen emission standards require high rates of EGR flow which adversely affects driveability of the vehicle To solve this problem it is necessary to increase EGR flow during high load vehicle operation and decrease EGR flow to improve driveability during low load operation 3 To accomplish this two different systems are in use one for vehicles sold in California and one for vehicles sold i...

Page 190: ...ow is modulated to attain effective oxides of nitrogen reduction and is sus pended at idle and wide open throttle conditions 11 The vacuum to be applied on the EGR contrdl valve is controlled by a thermal valve see illustration which senses the coolant temperature andcutsoffthevacuumwhentheengineiscoldandavacuumvalvewhich respond to vehicle load by detecting engine manifold vacuum which re sponds ...

Page 191: ...speeds remain the same the valve IS not operating properly and it should be replaced with a new one 23 Pull on the sub H valve and check tor smooth operation It the mr valve bmds it should be removed from its bore cleaned thoroughly tub 5 cated with a small amount of light 011and remstalled If itstlll does not oper ate smoothly replace it with a new one Canadian models yIL 24 Check all vacuum hose...

Page 192: ...re exceeds 104degrees F 27 Repeat the test outlined in Step 2 This time movement of the dia phragm should occur If no movement is felt the EGR control valve the thermal valve and the vacuum hoses should be checked for leaks and oth er defects i Fuel injected models EGR system inspection Refer to illustrations 7 28 and 7 31 28 Disconnect the vacuum hose with the green stripe from the EGR valve and ...

Page 193: ... up a hand operated vacuum pump to the EGR valve apply a vacuum of 10 in Hg and note whether the diaphragm leaks the valve should hold the vacuum 38 Release the vacuum applied in the previous Step Apply less than 1 2 in Hg and try to blow through the valve you shouldn t be able to now ap ply 9 5 or more in Hg and try to blow through the valve again this time you should be able to see illustration ...

Page 194: ...nscrew the valve from the manifold 63 When installing the thermal valve be sure to use thread sealing tape on the threads 8 Heated air intake system carbureted models only Description Refer to illustration 8 1 1 Carbureted models are equipped with a temperature regulated air cleaner see illustration so that the carburetor can be calibrated leaner to reducecarbon monoxideand hydrocarbon emissions I...

Page 195: ...uum directly to the motor inlet fitting see illustration The air control valve should be in the up heat on position If it is not check to be sure it is not sticking If the valve moves freely but wiIl not operate properly when a vacuum is applied the air clean er housing will have to be replaced 12 If the vacuum motor operates properly but the valve does not operate when vacuum is applied to the se...

Page 196: ... are equipped with adashpot which delays the closing of the throttle valve during vehicle deceleration and reduces the hydrocarbon emissions Dashpot adjustment Refer to ilhsfrafions 9 7 9 8a and 9 8b 6 Before adjusting thedashpot make sure the idlespeedissetcorrect ly Use a tachometer connected according to the manufacturer s instruc tions 7 Push the dashpot rod up through its entire stroke until ...

Page 197: ...e idle speed adjustment procedure see Chapter 4 4 Maintenance consists of checking the vacuum hoses and wires for damage and correct installation and making sure the linkage is not binding in any way 13 Feedback Carburetor FBC system Description Refer to illustration 13 1 1 An electronically controlled feedback carburetor FBC system see illustration is used on 1985 and later models The fuel ir mix...

Page 198: ...ailure tostart unstableidleandpoordri veability Ifaproblemoccurs besuretochecktheignitionsystemandengine mechanical condition before assuming that the FBC is at fault Throttle position system check 8 Check the sensor body and plunger for damage and cracks 9 Checkthethrottlesensormountingscrewstomakesuretheyaretight do not move the sensor or the fuel air mixture will be adversely affected 10 The se...

Page 199: ...nt temp Less than 30 86 Fj or more than 40 C j ll 13v I i i lu4 Fj I I Check meter Terminai Condition reading number when normal of computer __ Check Item ____ Jet mixture solenoid valve JSV Ignition switch OFF i Oh Idling 2000 rpm wtth A C s ltch ON Idling Idling Idhng ll 13v B l 2 1ov J 13 ISV B 3 5 ir A 10 1 __ _ I3 15V A 9 0 U hV j B 2 Idle up control solenoid valve lgnitmn pulse Power supply ...

Page 200: ...19 Start and run the engine at idle then apply a vacuum of 11 8 in Hg 300 mm Hg minimum with the pump Theenginespeedshouldincrease If it doesn t replace the throttle opener with a new one Throttle opener solenoid valve check 20 With the ignition switch off disconnect the wires from the throttle opener solenoid valve 21 Using an ohmmeter check the resistance between the solenoid valve terminals it ...

Page 201: ...perature sensor PCV ISC Positive Crankcase Ventilation Idle Speed Control 14 la Multi Point Injection MPI system 2 4L Federal and Canadian models l l Oxygen sensor 10 Barometric pressure 2 Air flow sensor sensor 3 Intake air temoerature ll EGR temperature sensor 4 Engine coolant temperature sensor 5 Throttle position sensor l 6 Idle position switch l 7 No 1 cylinder top dead center sensor 8 Crank ...

Page 202: ...35 The vacuum switch is mounted on the right side of the firewall 36 Unplug the wiring harness connector and attach the leads of an ohm meter or self powered test light to the switch terminals No continuity should be indicated 37 Disconnect the vacuum hose from the switch fitting and attach a hand held vacuum pump to the fitting with a section of hose 38 Apply a vacuum of 10 2 in Hg 60 mm Hg or mo...

Page 203: ...ion sensor Top dead center sensor Vehicle speed sensor You can locate these sensors and switches by referring to the accom panying illustrations see illustrations 4 The ECU also monitors most of its own input and output circuits If it detects a fault somewhere in the MPI system it stores this information in its memory You can often determine the location of a problem or at least yhich circuit it s...

Page 204: ...emperature sensor California models Ignition timing adjustment terminal A B C D E F G H I J K L M N 0 P Q R T u V 14 3b MPI system component locatio 3 OL models Air conditioner compressor power relay Air flow sensor Idle speed control IX servo Throttle position sensor with idle position switch Air conditioner temperature sensor Engine coolant temperature sensor ignition coil power transistor Craqk...

Page 205: ...diagnosis connector MPI pjagnosis 10 11 Ground 15 6 The self diagnosis connector is located in the console below the radio to put the ECU into malfunction code output mode simply hook up an analog voltmeter to the indicated terminals of the connector I Hames and conneefor 12 13 l em I uuuIn 1 41 Retmled l Harnessand connector EGRtemperaturesense EGRv e EGAvalvecontml s mold vake EGRvahe ccntroi va...

Page 206: ... voltmeter to the self diagnosis connector as shown see illustration 7 Turn the ignition switch to On The ECU will begin displaying the con tents of its memory immediately fjow refer to the accompanying malfunc tion code and diagnosis table see illustration If the MPI system is operating normally and there are no problems the needle on the voltmeter indicates a normal pattern of deflection in othe...

Page 207: ...he sensor Don t forget to plug in the electrical connector Engine coolant temperature sensor Refer to illustration 16 5 5 Unplug the electrical connector from the engine coolant temperature sensor remove the sensor from the intake manifold and immerse its tem perature sensing tip in a container of water Place a thermometer in the water so you can monitor the temperature and hook upan ohmmeter to t...

Page 208: ...ck wise rotation increases the output voltage counterclockwise decreases it 16 After adjustment tighten the screws securely 17 Adjust the accelerator cable see Chapter 4 18 On 3 OL engines unplug the electrical connector for the throttle posi tion sensor 19 Hookup an ohmmeter between terminals 1 and 2 with apairofjumper wires see illustration 20 Insert feeler gauges with atotal combined thickness ...

Page 209: ...pandand contract If the motor position sensor is functioning properly the indicated resistance should decrease smoothly as the idle speed control servo plunger contracts 43 If the indicated resistance doesn t behave this way or if the change isn t smooth replace the idle speed control servo assembly Oxygen sensor 2 4L engine 44 Warm up the engine to its normal operating temperature 45 Unplug the e...

Page 210: ... 1 Spark plug wire distributor cap and rotor check and replacement See Chapter 1 Starter motor in vehicle check _ 18 Starter motor removal and installation 19 Starter motor solenoid gear reduction assembly replacement 20 Starting system general information and precautions 17 Vacuum advance unit check and replacement 12 Voltage regulator alternator brushes replacement 16 Specifications Distributor ...

Page 211: ...tallation Refer to illustration 3 1 1 Caution Always disconnect the negative cable first and hook if up last or the battery may be shorted by the fool being used to loosen the cable clamps Disconnect both cables from the battery terminals see il lustration 2 Remove the battery hold down clamp 3 Lift out the battery Be careful it s heavy 4 While the battery is out inspect the carrier tray for corro...

Page 212: ...compartment I disconnect the primary wires and the high voltage lead then unbolt the bracket 1 Negative primary wire 4 Ballast resistor 2 Positive primary wire 5 High voltage lead 3 Bracket most auto parts stores Note Be sure to purchase the correct tester for either an electronic distributor or points distributon depending which sys tem the vehicle is equipped with 2 Connect the clip on the teste...

Page 213: ... not as specified replace the resistor 7 5a To check the coil secondary resistance on an earlier type coil touch one lead of the ohmmeter to one of the primary terminals and the other lead to the high tension terminal arrows then compare your reading to the coil secondary resistance listed in this Chapter s Specifications 2 4L Engine 3 OL Engine High oJ voltage terminal High voitage terminal 7 4b ...

Page 214: ...tor cap 8 8b Also paint an alignment mark on the engine and the distributor base to ensure the correct timing after the distributor is installed 14 Reattach the vacuum line s to the advance unit if equipped 15 Reattach the spark plug wires to the plugs if removed 16 Connect the cable to the negative terminal of the battery 17 Check the ignition timing see Chapter 1 and tighten the distributor hold...

Page 215: ...distributor on 1984 through 1989 models Mitsubishi type 1 Breather 7 Igniter 12 Vacuum advance unit 18 Oil seal 2 P 8 Dowel pin single diaphragm type 19 Packing 3 Contact carbon 9 Signal rotor 73 Rotor shaft 20 Housing 4 Rotor 10 Advance plate 14 Spring retainers 21 O ring 5 Cable assembly Ii Vacuum advance unit 15 Centr ugal advance springs 22 Washer 6 Groundwire dual diaphragm type 16 Centrifuga...

Page 216: ... cap 2 O ring 3 Contact carbon 4 Rotor 5 O ring 6 Distributor housing assembly Pickup coil Dust proof cover for signal generator Dust proof cover for igniter Vacuum advance unit Centrifugal advance springs Signal rotor shaft assembly Packing i 9 7e An exploded view of the distributor on 1986 through 1989 models Nippondenso type ...

Page 217: ...onnect an ohmmeter or small dry cell to the remaining terminals as shown this will apply a small signal to the igniter 9 Ifthetestlightglowswhenthesignalisappliedand oesoutwhenitis removed the igniter is apparently working properly If not it is defective Note Even if the testresults are as specified the igniter maybe defective 10 When reassembling the distributor be sure to align the mating marks ...

Page 218: ...the distributor see Section 8 23 Remove the rotor see Chapter I 24 Remove the protective cover from the distributor housing see illus tration 25 Remove the screw from the spacer see illustration and remove the spacer 26 Carefully remove the upper disk spacer the disk and the lower disk spacer see illustration Note The disk and spacers are keyed to en sure proper reassembly see illustration 27 Chec...

Page 219: ... 72 7 and 12 8 6 Remove the distributor cap and rotor see Chapter 1 7 Remove the vacuum unit mounting screws see illustration 8 Remove the vacuum unit link from the pin on the breaker base then detach the vacuum unit see illustration 9 Installation IS the reverse of removal 13 Charging system general information and precautions The charging system includes the alternator with an integral volfage r...

Page 220: ... clamp and pro ceed to the next step 2 If the test light comes on here is ashort drain in the eledtrical system of the vehicle The short must be repaired before the charging system can be checked 3 Disconnect the alternator wiring harness a If the light goes out the alternator is bad b If the light stays on pull each fuse until the light goes out this will tell you which component is shorted 2 Usi...

Page 221: ...strations 16 2 16 3 and 16 4 Note If you are replacing the brushes but not the regulator itself the fof lowing procedure requires that you unsolder the old brush leads from the regulatorand solder the new ones into place Unless you are skrKvd with a soldering gun have this procedure performed by someone who is If you overheatanddamage theregulator you couldendupspendinga lotmore money than necessa...

Page 222: ...es from the voltage regulator brush holder assembly carefully unsolder the brush leads and extract each brush and lead from the holder 16 10b Use two screwdrivers to split the alternator 8 exploded view of the Melco type alternator 1 Alternator pulley 7 Front bracket 12 Brush 2 Seal 8 Stator 13 3 Rotor assembly Brush spring 9 Terminal 14 4 Rear bearing Slinger if equipped IO Plate 15 Rectifier 5 B...

Page 223: ...arter motor the start er solenoid and the wires connecting them The solenoid is mounted dl rectly on the starter motor The solenoid starter motor assembly is installed on the transmlsslon bellhousing When the ignition key is turned to the Start position the starter sole noid is actuated through the starter control clrcult The starter solenoid then connects the battery to the starter The battery su...

Page 224: ...Run the engine until normal operating temperature is reached Dis connect the coil wire from the distributor cap and ground it on the engine 10 Connectavoltmeter positive lead to the positive battery post and con nect the negative lead to the negative post 11 Cranktheengineandtakethevoltmeterreadingsassoonasasteady figure is indicated Do not allow the starter motor to turn for more than 30 seconds ...

Page 225: ... 20 5 Direct drive starter motor components I 8 I 7 Rear bracket 12 Lever Rear bearing 13 Washer Brush holder I4 Snap ring assembly 15 Stop ring Housing 16 Over running Armature clutch I Front bracket Solenoid M terminal 20 7 Disconnect the field coil wire from terminal M 20 8a Remove the through bolts from the starter housing ...

Page 226: ...hown I Mounting screw 7 Brush 13 Packing B 18 Stop ring 2 Solenoid 8 Rear bearing 14 Plate 19 3 Screw Over running clutch 9 Armature 15 Planetary gear 20 Integral gear 4 Screw 70 Housing 16 Lever 21 5 Rear bracket Planetary gear holder 11 Ball I7 Snap ring 22 Front bracket 6 Brush holder 12 Packing A ...

Page 227: ...motor or solenoid disconnect the field coil wire from the solenoid terminal see illustration if you re replacing the gear reduction assembly skip this step and proceed to the next step 8 To detach the starter motor from the gear reduction assembly simply remove the two long through bolts and pull off the starter see illustra tions 9 To detach the solenoid from the gear reduction assembly remove th...

Page 228: ...r 1 Fuel injection system check 19 Fuel injector s check removal and installation 24 Fuel hoses and vapor separator replacement 9 Fuel pressure regulator removal and installation 25 Fuel pressure relief procedure fuel injected models 2 Fuel pump fuel pressure check 3 Fuel pump removal and installation 4 Fuel rail assembly removal and installation 23 Fuel system check See Chapter 1 Fuel tank cleani...

Page 229: ...00 rpm 850 f 50 rpm 850 f 50 rpm 750 f 100 rpm 750 lOOrpm 800 1OOrpm 750 f 50 rpm 800 f 50 rpm 750 f 100 rpm 800rtlOOrpm 750 f 50 rpm 700 f 50 rpm Idle up throttle opener engine speed carbureted air conditioned models 850 to 950 rpm Float level 1986 and earlier models 0 787 in 0 0394 in Dashpot speed 1987 through 1989 models Manual transmission Automatic transmission 2000 rpm 1500 rpm Slow Cut Sol...

Page 230: ...ing equipped with Feedback Control FBC systems which utilize sensors and solenoid actuators controlled by the engine s electron ic control module to control emissions Some 1989 and all 1990 and later models are fuel injected A multi point one injector per cylinder Electronic Fuel Injection EFI system is used on both 3 OL and 2 4L engines All fuel injected models use an in tank electric fuel pump F...

Page 231: ...ications 9 Stop the engine and observe the gauge The pressure should remain constant or return to zero slowly 10 If the pressure was higher or lower than specified or if it dropped to zero instantly when the engine was shut off the fuel pump is defective and should be replaced with a new one Fuel injected models Fuel pump check 2 4L models only Refer to illustrations 3 1 la 3 1 lb 3 Ilc and 3 lld ...

Page 232: ... or equivalent to the adapter as shown be sure to seal both hose flanges with O rings or gaskets as shown 3 18a Fuel pressure regulator vacuum hose 2 4L engine arrow 3 18b Fuel pressure regulator vacuum hose 3 OL engine arrow Symptom Fuel pressure is lower than standard value Fuel pressure is higher than standard value Fuel pressure does not vary even if the vacuum hose is conoected Probable cause...

Page 233: ...engine block Remove the spark plugs and place your thumb over the number one cylinder spark plug hole 3 Rotate the crankshaft in a clockwise direction with a wrench on the large bolt attaching the pulley to the front of the crankshaft until you can feel the compression pressure rising in the number one cylinder 4 Continue rotating the crankshaft until the notch on the crankshaft pulley lines up wi...

Page 234: ...ust systems 4 7 2 OL engine 1 2 6L engine 4 6 An exploded view of the mechanical pumps used on 2 OL upper and 2 6L lower engines I Air cleaner housing 2 Fuel hose 3 Fuelpump 4 Push rod 5 Gasket 6 Insulator 7 Gasket I 3 b 2 I ...

Page 235: ...carefully and move it out from under the vehicle 9 Check the tank interior for rust and corrosion If the tank is not ex tremely corroded it can be cleaned and reused Special solvents made especially for cleaning fuel tanks are available If you use one be sure to follow the directions on the container The inside of the tank is plated with zinc so be sure to use a cleaner that will not harm it in an...

Page 236: ...rn hose connection 6 Vapor hose connection 7 Breather hose connection 8 Fuel filler hose connection 9 Fuel tank protector 4 WDj 10 Fuel tank mounting nut 11 Fuel tank 12 Overfill limiter two way valve 13 Fuel pump assembly 14 Packing 15 Fuel gauge unit 16 Fuel filler cap 17 Filler neck cover 18 Reinforcement 19 Filler neck 20 PAeking 21 ei etainer 22 Grommet 23 Check valve br Long body and extende...

Page 237: ...rankcase breather hose if equipped from the front of the air cleaner housing see illustration 5 7b Breather hose clamp location 7 3 Pull off the crankcase breather hose carbureted engines 4 Remove the large hose leading to the secondary air supply system valve see illustration 5 Slide back the hose clamp and remove the hose that leads to the purge control valve from the air cleaner housing see ill...

Page 238: ...ed engines 7 7 Remove the two nuts lock washers and flat washers carbureted engines 7 8b Remove the vacuum hose carbureted engines 7 10a An exploded view of the air cleaner assembly 1990 fuel injected models 1 Breather hose 3 OL engine only 7 Air cleaner housing 2 Air intake hose 8 Cover 3 Air cleaner assembly 9 Grommet 4 Air duct 10 Air flow sensor assembly 5 Air cleanercover 11 Air Ilowsensorgas...

Page 239: ...le has a support bracket at the carburetor or throttle body loosen the locknut at the bracket see illustration and detach the cable from the bracket 4 Working inside the vehicle under the dash unhook the throttle return spring pull outthecotterpinanddisconnecttheacceleratorcabiefr6r i the accelerator pedal assembly see illustration 8 3 Typical accelerator cable support bracket with locknut and adj...

Page 240: ...d as far as it will go 12 Periodically apply athin coat of multi purpose grease to theaccelera tor pedal pivot points 9 Fuel h es and vapor separator replacement Warning Gasoline is extremely flammable so take extra precautions when you work on any part of the fuel system Don t smoke or allow open flames or bare light bulbs near the work area and don t work in a garage whereanaturalgas typeapplian...

Page 241: ...rts where neces sary Before dismantling the carburetor make sure you have a carburetor rebuild kit which will include all necessary gaskets and internal parts car buretor cleaning solvent and some means of blowing out all the internal 11 6 R emove and plug the three fuel hoses passages of the carburetor To do the job properly you will also need a clean place to work and plenty of time and patience...

Page 242: ... 26c 1226d 1226e 1226f 12 27a 12 27band 12 28 1 Remove the carburetor see Section 11 Remove the air cleaner hold down stud see illustration and the air cleaner gasket from the top of the carburetor Pull back the hose clamp and remove the coolant hose from the back of the carburetor see illustration 2 Remove the spring clip and carefully pry the throttle opener actuating rodoutoftheprimarythrottles...

Page 243: ...he spring clip thewasher the valve seal from the end of the plunger Slip the O ring off the body The diaphragm and plunger one piece can now be withdrawn from the valve body Lay the parts out on a clean surface in the order of disassembly see 12 4b idle mixture screw spring washer and rubber seal _ _ 12 5 Unsnap the accelerator pump linkage from the throttle shaft arm 11 Remove the enrichment syst...

Page 244: ...he carburetor 12 7a Remove the ASV body attaching screws 12 8b Remove the screws attaching the solenoid to the carburetor body _ _ _ 12 10 Vent system components i2 12a Remove the CAV housing screws 12 12b CAV components 12 7b The ASV body 12 8 The solenoid and spring 12 11 Enrichment system components 12 12 Remove the choke unloader diaphragm plate screws ...

Page 245: ...mblymount hasase rfes of lines scribed on it Note which one is lined up with the dot on the body see illustration 15 Remove the two screws holding the choke pinion gear assembly to the carburetor body and carefully pull it free see illustration 12 13b Pull the hose off the carburetor body 12 14b Note the reference lines on the upper choke pinion gear assembly mount 12 17 Remove the spring clip fro...

Page 246: ...etor Be careful not to bend or otherwise damage the float mechanism see illustration 23 Before removing the float invert the top cover and measure the dis tance from the float seam to the gasket surface of the top cover see illus tration Record the measurement for future reference 24 Carefullyslideoutthepivotpinandseparatethefloatandinletneedle from the top cover see illustration Slip the needle o...

Page 247: ...r bore 12 264 Remove the primary main jet 12 23 Measure the distance from the float seam to the gasket surface of the top cover 12 24 Remove the inlet needle seat 12 26b Anti overflow mechanism steel ball 12 26e Remove the secondary main jel 12 24a Slide out the pivot pin 12 25 Remove the top cover gasket 12 26 Accelerator pump steef che ball and weight location 12 261 Remove the idle jets ...

Page 248: ...ew one 36 Check the strainer screen for clogging and damage 37 Check the vacuum chamber Push the vacuum chamber rod in seal off the nipple and release the rod If the rod does not return the vacuum chamber is most likely in good condition Ifthe rod returns when rel j sed the diaphragm is defective The vacuum chamber should be replaced with a new one if this condition exists 38 To check the fuel cut...

Page 249: ...owever you can do the basic adjustments for the idle speed and mixture without an exhaust gas analyzer if you follow the steps outlined here Just remember that final adju_stment must be done with the proper equipment to ensure compliance with emission standards 3 Before making the idle speed and mixture adjustments check the ig nition system including the ignition timing Look for cracked or discon...

Page 250: ...uire any adjustment as long as the rack and pinion gears are properly oriented and the choke pinion gear assembly is adjusted so that the choke plate is lightly seated in the closed position when the choke linkage is installed 14 Carburetor FBC 1985 and 1986 models overhaul Warning Gasoline is extreme y flammable so take extra precautions when you work on any part of the fuel system Don t smoke or...

Page 251: ... chamber rod from the secondary throttle le vet then remove the depression chamber see illustration 12 Detach the accelerator pump rod from the throttle lever see illustra tlon 13 Remove the snap ring from the choke rod then disconnect the rod from the choke lever see illustration 14 Remove the float chamber cover screws B and remor the throttle body see illustration 15 Remove the screws A and rem...

Page 252: ...move the choke breaker cover 14 11 Remove the depression chamber 14 12 Remove the accelerator pump rod 14 14 Remove the float chamber cover 14 13 Remove the snap ring then remove the choke rod 14 16 Remove the pin and the float then remove the needle ...

Page 253: ...screws and remove the choke pinion assembjy see illustration Caution When removing the need e seat clamp area see illustration A with pliers not area 6 see illustration 21 Remove the checkweight and ball and the steel ball of the anti over 18 Using a screwdriver with the right size tip remove the main jets from fill device see illustration the jet blocks see illustration 22 Remove the accelerator ...

Page 254: ...ith compressed air before beginning reassembly 27 Reassembly is the reverse of disassembly Don t reuse any old gas kets or O rings Use the new ones in the carburetor rebuild kit 28 When replacing jets make sure the old jet and new jet are the same size a No is stamped on each jet 29 lnspectthe operation of the throttle and choke linkage and the sub EGR valve They should operate smoothly Float adju...

Page 255: ... over the heads of the B screws Choke valve setting Refer to illustrations 14 33 14 34 14 35 14 36 14 37a 14 37b 33 Fit the strangler spring to the choke lever see illustration 34 Align the inscribed line or black painted line of the choke pinion with the inscribed line on the cam lever see illustration 35 Temporarily tighten the new lock screws see illustration 36 Set the choke valve by moving th...

Page 256: ... the proce dure forthis adjustment in Chapter6 in the lnformation sensors Section 16 Carburetor FBC 1987 through 1989 models overhaul Warning Gasoline is extremely flammable so takeextra precautions when you work on any part of the fuel system Don t smoke or allow open flames or bare light bulbs near the work area and don t work in a garage whereanaturalgas typeappliance suchasa waterheaterorcloth...

Page 257: ...ert a screwdriver between the float chamber cover and the enrichment cover and pry the float chamber cover loose 9 Remove the retainer screw and retainer for the feedback solenoid Using a pin or a small screwdriver with a thin flat tip push the stopper por tion and remove the two terminals from behind the electrical connector see illustration then remove the feedback solenoid and the O rings the f...

Page 258: ... seat 23 Spring 24 Body 25 Spring 26 Diaphragm 27 Valve 28 Mixture control valve MCV assembly 29 Gasket 30 Cover 31 Spring 32 Diaphragm 33 Body 34 Spring 35 Diaphragm 36 Bracket 37 Cover 38 Spring 39 Diaphragm 40 Body 4 I Primary main air jet 42 Primary pilot jet 43 Secondary pilot jet 44 Float chamber cover 1hi5 L I a 11 12 16 8 Using a pair of flat bladed screwdrivers pry up on 16 7b To remove t...

Page 259: ...agm and check valve parts 23 through 27 Brmetal Plate assembly 16 11a To remove the bimetal assembly grind off the heads of the two rivets Canadian models have no rivets and remove the screw arrow 26 Remove the vacuum hose and detach the depression chamber dashpot parts 28 and 29 27 Remove the Throttle Position Sensor TPS part 31 28 Do NOT remove the throttle lever cam follower fast idle adjusting...

Page 260: ...liary accelerator pump cover Spring Diaphragm Check valve Vacuum hose Depression chamber dashpot Mixing body Throttle Position Sensor TPS Throttle lever Cam follower Fast idle adjustment screw Free lever Throttle linkage adjustment plate Idle speed ao stment screw SAS 2 Spring Secondary lever Idle speed adjustment screw SAS I g Concealmentplug Mixture adjustment screw MA Throttle body i 16 21 Remo...

Page 261: ...ration 16 11 b Note The bimetalas sembly on Canadian models doesn t use rivets 55 When you install the Slow Cut Solenoid Valve SCSV and the Feed back Solenoid Valve FBSV make sure you install the terminals at their correct locations in the electrical connector see illustration 56 After you ve installed the float chamber cover assembly install the three Throttle Positton Sensor TPS terminals at the...

Page 262: ...p increases the choke valve to choke bore clearance bending the lever down decreases clearance Rod L 16 64 If the clearance is out of specification adjust it by bending the throttle lever at the indicated point bending the lever open increases the choke valve to choke bore clearance hurts startability and increases the likelihood that the engine will stall bending the lever closed decreases cleara...

Page 263: ... at idle for two minutes 7 Note the idle speed and compare your reading with the idle speed listed in this Chapter s Specifications 8 If the idle speed isn t within the specified limits readjust it by turning adjusting screw No 1 SAS 1 see illustration Caution Don t touch SAS 2 see i usfretion This screw which is preset at the factory esta blishes the relationship between the throttle valve and th...

Page 264: ...ation sensors and the engine control unit refer to Chapter 6 19 Fuel injection system check Note the fool owing procedure is based on the assumption that the fuel pressure is adequatk see Section 3 1 Checkall ground wire connections for tightness Check all wiring har ness connectors related to the MPI system Loose connectors and poor grounds can cause many problems that resemble more serious malfu...

Page 265: ... battery cable and adjust the accelerator cable when you re through see Sec tion 8 Add coolant to replace the coolant lost when you disconnected the coolant hoses from the throttle body 3 OL engine Refer to illustration 20 14 13 Disconnectthe negative cable from the battery Disconnectthe accel erator cable see Section 8 14 Detach the vacuum hose s see illustration 15 Loosen the hose clamp and deta...

Page 266: ...sistant turns the ignition switch to On not to Start The servo should make an audible sound 6 If the servo is silent inspect the electrical circuit If the circuit is in good shape the likely cause is a malfunction of the servo or the engine control unit 7 Unplug the ISC servo electrical connector 21 12 Holding the ISC servo as shown power it up with a 6V DC battery by touching the terminals of the...

Page 267: ...he air intake plenum assembly and remove it and the gasket 5 Using a scraper remove all traces of old gasket material from the ple num and intake manifold mating surfaces Clean the surfaces with a rag soaked in lacquer thinner or acetone Installation is the reverse of remov al Use anew gasket and tighten the plenum mounting bolts to the torque listed in this Chapters Specifications in several stag...

Page 268: ...6 7 8 9 10 II 12 13 14 15 16 17 18 19 20 21 6 An exploded view of the air intake plenum assembly 3 OL engine Air intake hose ThrottlePosition Sensor TPS electrical connector Idle Speed Control KC servo electrical connector Accelerator cable adjusting bolt TV kickdown cable Accelerator cable Coolant hoses EGR temperature sensor electrical connector Vacuum hose Brake booster vacuum hose High tension...

Page 269: ...Fuel return hose 3 Fuel injector wiring harness 15 Bolt 4 Air intake pipe 16 Fuelpressure regulator 5 Air hose 17 O ring 6 Accelerator cab e 18 Fuel rail assembly 7 Kickdown cable 19 Insulator 8 Coolant hose 20 Fuel injector 9 Vacuum hose 27 O ring 10 Throttle body 22 Grommet 11 Gasket 23 Insulator 2 Fuel injector wiring harness electrical connector 9 Remove the bolt that attaches the metal pipe b...

Page 270: ...or bare light bulbs near the work area and don t work in a garage where a naturalgas type appliance such as a water heater or clothes dry er with a pilot light is present If you spill any fuel on your skin rinse it off immediately with soap and water When you perform any kind of work on the fuel system wear safety glasses and have a Class 6 type fire extin guisher on hand Check Refer to illustrati...

Page 271: ...k on the fuel return hose and dis connect the fuel return hose from the metal tube attached to the fuel pres sure regulator 6 On 2 4L engines remove the bolt that attaches the bracket for the metal pipe between the regulator and the fuel return hose 7 Unbolt the fuel pressure regulator and detach it from the fuel rail Dis card the old O ring 8 Installation is the reverse of removal Use a new O rin...

Page 272: ...l TBD engine U engine For California W engine For California 4 wheeldrive models U engine For Federal W engine For Federal and Canada and TBD engine W engine For California 26 la An exploded view of typical pre 1687 exhaust systems 1 Front bxhaustpipe 4 Main muffler 7 Center exhaust pipe 2 Asbestos plate 5 Gasket 8 Protector 3 Hanger 6 Suspender ...

Page 273: ...exhaust systems used on 1987 and later models 1 Gasket 2 Front exhaust pipe left 5 Oxygen sensor 9 Hanger 10 Main muffler 3 Front exhaust pipe right 6 Catalytic converter 7 11 4 Front exhaust pipe Center exhaust pipe 8 Heat cover Catalytic converter hanger 12 Tail pipe hanger ...

Page 274: ...7 Cylinder head reassembly 11 Pistons and connecting rods installation and rod bearing Cylinder honing _ _ 16 oil clearance check _ 24 Engineblock cleaning 14 Pistonsandconnectingrods removal 12 Engine block inspection 15 Pistonrings installation _ _ __ _ 21 Engine overhaul disassembly sequence 7 Rear main oil seal installation _ 23 Engine overhaul general information 2 Valves servicing _ _ _ 10 E...

Page 275: ...ng Standard Service limit Oil ring Standard Servicelimit Crankshaft and connecting rods Endplay standard Main bearing journal Diameter Taper limit 1983through1986 19870n Out of round limit 1983through1986 19870n Connecting rod journal Diameter Taper limit 1983through1986 19870n Out of round limit 1983through1986 19870n 3 5866 inches 0 002 to 0 004 inch Not available 0 001 to 0 002 inch Not availab...

Page 276: ...h Intake Standard Servicelimit Exhaust Standard Service limit 1983 through 1986 Service limit 1987 on Valve stem to guide clearance Intake Standard Servicelimit Exhaust Standard Servicelimit Valve spring free length 1983and1984 Standard Serviceiimit 1985 on Standard Servicelimit Valve spring installed height Standard _ Servicelimit Jet valves L Stem diameter Seatangle Springfreelength Springpressu...

Page 277: ...ard Servicelimit All others Intake Standard Servicelimit Exhaust Standard Service limit Valve spring Out of square limit Pressure Installed height Free length 1983 and 1984 Standard Servicelimit 1985 on Standard Servicelimit Jet valves Stem diameter 1987through1989 All others Face seat angle 1987through1989 All others Ft lbs unless otherwise indicated 14 58 34 121 9 cubic inches 143 4 cubic inches...

Page 278: ... top compression ring Standard ServiCelimit Number 2 compression ring Standard Servicelimit Oil ring Standard Servicelimit 1985 and 1986 Number 1 compression ring Standard Servicelimit Number 2 compression ring Standard Servicelimit Oil ring Standard Servicelimit _ _ 19870n Number 1 compression ring Standard Servicelimit 1 I 65 inch Not available 7 7 Ibs at 0 846 in Not available 1 7720 inch 0 000...

Page 279: ...y All others Rear bearing journal diameter Rear bearing oil clearance 1987only All others Torque specifications Mainbeanngcapbolfs Connectingrodcapnuts Jetvalves l Note Refer to Part i3 for additional torque specifications 3 OL engine General Displacement Bore Stroke Cylinder compression pressure Oiipressure Engine block Inside diameter Cylinder taper limit _ Cylinder out of round limit 0 008 to 0...

Page 280: ...rvicelimit Valve stem to guide clearance Intake Standard l Service limit Exhaust Standard Servicelimit Valve spring free length Standard Servicelimit Valve spring installed height Standard Servicelimit Valve stem diameter Intake Exhaust Torque specifications Mainbearingcapbolts Connecting rod bearing cap nuts Note Refer to Part C for additional torque specifications 3 587 inches 0 0012 to 0 0035 i...

Page 281: ...arts A B and C for additional Specifications 2 4a Remove the oil pressure sending unit switch and install a pressure gauge in its place 2 6L engine shown 2 Engine overhaul general information Refer to ksfrations 2 4 1 2 46 and 2 4 It s not always easy to determine when or if an engine should be com pletely overhauled as a number of factors mustbe considered High mileage isn t necessarily an indica...

Page 282: ...pecifi cally it can tell you if the compression is down due to leakage caused by worn piston rings defective valves and seats or a blown head gasket Note The engine must be at normal operating temperature and the bat tery must be fully charged for this check 2 Begin by cleaning theareaaround thesparkplugs before you remove them Compressed air should be used if available otherwise a small brush or ...

Page 283: ... there s any possibility of confusion make a sketch of the engine compartment and clearly label the lines hoses and wires 6 Raise the vehicle and support it securely on jackstands Drain the cooling system see Chapter 1 7 Label and detach all coolant hoses from the engine 8 Remove the coolant reservoir cooling fan shroud and radiator see Chapter 3 9 Remove the drivebelt and idler if equipped see Ch...

Page 284: ...ul disassembly sequence Refer to illustrations 7 5a 7 56 and 7 5 1 It s much easier to disassemble and work on the engine if its mounted on aportableenginestand Astandcanoften be rentedquitecheaplyfrom an equipment rental yard Before it s mounted on astand the flywheel drf veplate should be removed from the engine 2 If a stand isn t available it s possible to disassemble the engine with it blocked...

Page 285: ...ools are necessary for the disassembly and inspection procedures and replacementparts aren t a ways readily available it may be more practical and economical for the home mechanic to purchase re placement head s rather than taking the time to disassemble inspect aiid recondition the orIginal 1 Cylinder head djsassembly involves removal of the intake and ex haust valves and related components The r...

Page 286: ...nsmission 8 Oil seal case 2 Pilot bearing 9 Gasket 3 Adapter plate 10 Oil separator 4 Driveplate automatic II Rear main oil seal transmission 12 Bearing cap 5 13 Lower bearing 6 Crankshaft ad pter Rear plate 14 Crankshaft 7 Bell housing cover 15 Upper bearing UPPER BEARING GROOVED1 7 5 Exploded view of the internal engine components 3 OL engine BEARING BLOCK CAP ...

Page 287: ...ead gas ket intake manifold and exhaust manifold mating surfaces Be very care ful not to gouge the cylinder head Special gasket removal solvents that soften gaskets and make removal much easier are available at auto parts stores 3 Remove all built up scale from the coolant passages 4 Run a stiff wire brush through the various holes to remove deposits that may have formed in them 5 Run an appropria...

Page 288: ... the seat The total valve stem movement indicated by the gauge needle must be divided by two to obtain the actual clearance After this is done if there s still some doubt regarding the condition of the valve guides they should be checked by an automotive machine shop the cost should be minimal Valves 15 Carefully inspect each valve face for uneven wear deformation cracks pits and burned areas Chec...

Page 289: ...and make sure the installed spring height is correct The cylinder head gasket surface will also be resurfaced if its warped 4 Afterthevalvejobhasbeenperformedbyaprofessional theheadwill be in like new condition When the head is returned be sure to clean it again before installation on the engine to remove any metal particles and abrasive grit that may still be present from the valve service or hea...

Page 290: ...Parts A 6 or C of Chapter 2 1 Useyourfingernail to feel ifaridge hasformedattheupperlimitofring travel about i 4 inchdownfromthetopofeachcylinder lfcarbohdepos its or cylinder wear have produced ridges they must be completely re moved with a special tool see illustration Follow the manufacturer s instructions provided with the tool Failure to remove the ridges before at tempting to remove the pist...

Page 291: ...has been re moved from the vehicle It s assumed the flywheel or driveplate crank shaft balancer vibration damper timing chain or belt oilpan oil pump and piston connecting rod assemblies have already been removed The rear main oilseal housing must be unbolted and separated from the block be fore proceeding with crankshaft removal 13 3 Checking crankshaft endpiay with a feeler gauge 13 4b The main ...

Page 292: ...turned clean alloil holesandoilgalleriesone more time Brushes specifically designed for this purpose are available at most auto parts stores Flush the passages with warm water until the water runs clear dry the block thoroughly and wipe all machined surfaceS with a light rust preventive oil Ifyou have access to compressed air use it to speed the drying process and blow out all the oil holes and ga...

Page 293: ... the cylinder with the feeler gauge in place with moderate pressure 9 If it falls through or slides through easily the clearance is excessive and a new piston will be required If the piston binds at the lower end of the cylinder and is loose toward the top the cylinder is tapered If tight spots are 8nCOUnt8r8d as the piston feeler gauge is rotated in the cylinder the cylinder is out of round 10 Re...

Page 294: ... as shown here z _ 17 Pistons and connecting rods inspection Refer to illustrations 17 2 17 4a 17 4b 17 IO and 17 11 1 Before the inspection process can be carried out the piston connect ing rod assemblies must be cleaned and the original piston rings removed from the pistons Note Always use new piston rings when the engine is reassembled 2 Using a piston ring installation tool see illustration ca...

Page 295: ...resized and new pins installed 14 Ifthe pistons must be removed from the connecting rods for any rea son they should be taken to an automotive machine shop While they are there have the connecting rods checked for bend and twist since automp tive machine shops have special equipment for this purpose Note Un less new pistons and or connecting rods must be installed do not 18 2 Use a wire or stiff p...

Page 296: ...the same general position as their location in the engine This will enable you to match any bearing problems with the corre sponding crankshaft journal 4 Dirt and other foreign particles get into the engine in avariety of ways it may be left in the engine during assembly or it may pass through filters or the PCV system It may get into the oil and from there into the bearings Metal chips from machi...

Page 297: ...and tools Torque wrench l 2 inch drive Piston ring installation tool Piston ring compressor Vibration damper installation tool Short lengths of rubber or plastic hose to fit over connecting rod bolts Plastigage Feeler gauges Fine tooth file New engine oil Engine assembly lube or moly base grease Gasket sealant Thread locking compound In order to save time and avoid problems engine reassembly must ...

Page 298: ...e different cross sections be sure to install them in the correct locations with the marks facing UP 21 9b DO NOT use a piston ring installation tool when installing the oil ring side rails Again double check to make sure you have the correct rings for the en gine 7 Repeat the procedure for each ring that will be installed in the first cyl inder and for each ring in the remaining cylinders Remembe...

Page 299: ... oil clearance check Note Don t touch the faces of the new bearing inserts with your fingers Oil and acids from your skin can etch the bearings 22 11 Lay the Plastigage strips arrow on the main bearing journals parallel to the crankshaft centerline 5 Clean the back sides of the new main bearing inserts and lay one in each main bearing saddle in the block If one of the bearing inserts from each set...

Page 300: ... keginning of this Chapter to make sure it s correct 16 If the clearance is not as specified the bearing inserts may be the wrong size which means different ones will be required Before deciding differentinsertsareneeded makesurenodirtoroilwas betweenthe bear ing inserts and the caps or block when the clearance was measured If the Plastigagewaswideratoneendthan theother thejournalmay betapered see...

Page 301: ...oil to the outer edge of the new seal The seal must be pressed squarely into the housing bore so hammering it into place isn t recommended If you don t have access to a press sandwich the housing and seal between two smooth pieces f wood and press the seal into place with the jaws of a 23 3 Apply anaerobic sealer onto the upper portion of the retainer large vise If you don t have a vise big enough...

Page 302: ... 5 CYLINDERS 2 4 6 24 9b On the V6 engine the proper letter must be positioned towards the front of the engine R for cylinders 1 3 and 5 L for cylinders 2 4 and 6 24 9a On four cylinder engines the arrow on the piston must face the front of the engine guide the piston into the cylinder The rings must be compressed until they re flush with the piston 8 Rotate the crankshaft until the number one con...

Page 303: ...f the bearing inserts and the insides of the connecting rods and caps perfectly clean when assembling them b Make sure you have the correct piston rod assembly for each cylin der c The arrow or mark on the piston must face the front timing chain end of the engine 24 17 Measuring the width of the crushed Plastigage to determine the rod bearing oil clearance be sure to use the correct scale standard...

Page 304: ...ons is included in this part of Chapter 7 Information on the automatic transmission and transfer case can be found in Parts B and C of this Chapter The manual transmission used in these models is a four speed or a five speed unit with fifth gear being an overdrive Due to the complexity unavailability of replacement parts and the spe cial tools necessary internal repair by the home mechanic is not ...

Page 305: ...or transfer case Do not damage the splines on the transmission output shaft 6 If the oil seal cannot be removed with a screwdriver or pry bar a spe cial oil seal removal tool available at auto parts stores will be required see illustration 7 Using a large section of pipe or a very large deep socket as a drift install the new oil seal Drive it into the bore squarely and make sure it s_ completely s...

Page 306: ...rom the support bracket on the crossmember Lay the cable on top of the left frame rail to keep it out of the way Remove the pin attaching the rear park ing brake cable balancer to the parking brake lever 8 Unplug the electrical connector for the back up light switch just be hind the steering box Disconnect the clutch cable from the clutch control lever at the transmission bellhousing Back off the ...

Page 307: ...transmissionsmay beavailable checkwithyourdealerpartsdepattment and auto parts stores At any rate the time and money invohedin an ovi haul is almost sure to exceed the cost of a rebuilt unit Nevertheless it s not impossible for an inexperienced mechanic to re build a transmission if the special tools are available and the job is done in a deliberate step by step manner so nothing is overlooked The...

Page 308: ...r removal and installation 11 Rear stabilizer bar coil spring models removal and installation _ 16 Rear suspension coil spring removal and installation 15 Rear suspension lateral rod coil spring models removal and installation __ 14 Rear suspension trailing arms coil spring models removal and installation _ _ 13 Steering and suspension check _I _ I See Chapter 1 Steering freeplay adjustment _ 20 S...

Page 309: ...ackle pin nuts Front shackle pin nut U Boltnuts Rearshockabsorbernuts Coil spring type Trailing arm to frame nut Trailing arm to axle bolts Lateral rod nuts Stabilizerbarbracke boits Lower shock absorber bolt Upper shock absorber nut Steering Steering gear to frame bolts Flexible coupling to steering gear pinch bolt Pitman arm to steering gear nut Pitman armto relay rod nut Idler arm bracket to fr...

Page 310: ...Chapter 10 Suspension and steering systems IO 3 ...

Page 311: ...10 4 Chapter 10 Suspension and steering systems L ...

Page 312: ...uining the threads Heating the stuck fastener and surrounding area with a torch sometimes helps too but isn t recom mended because of the obvious dangers associated with fire Long break erbarsand extension or cheater pipes will increase leverage but never use an extension pipe on a ratchet the ratcheting mechanism could be damaged Sometimes turning the nut or bolt in the tightenbg clockwise direct...

Page 313: ...r arm and remove it from the vehicle 6 On 4WD models remove the two shock absorber to lower control arm bolts accessible from the upper surface of the arm then fully com press the shock absorber and lift it up and over the arm to remove it see illustration 7 Installation is the reverse of the removal procedure Make sure the washers and bushings are assembled in the proper order Tighten the bolts a...

Page 314: ...he wheel and the brake caliper as sembly see Chapter 9 2 Remove the anchor arm dust covers see illustration 3 Mark the torsion bar directly opposite the mark on the anchor arm see illustration Caution Do notpunch orscratch the torsion bar use paint to make the mark 4 Loosen the jam nut and adjusting nut at the anchor arm assembly until the torsion bar can be slipped out of the anchor arms Installa...

Page 315: ...hicle and support it securely on jackstands Apply the parking brake Remove the wheel 2 Use a special spring compressor tool to compress the spring see il lustration Warning When compressed the spring is under consider 5 10 If the distance A from the bump stop to the bracket is not as specified with the vehicle weight on the suspension the torsion bars may require further adjustment I _ 7 3 On 4WD ...

Page 316: ...r 3 Upper balljoint coffer pin 4 Upper bal ioinf nut 5 Rebound bumper 6 Alignment shims 7 Upper suspension arm 1 2 3 4 5 7 5b 4WD model upper Shock absorber Torsion bar anchor nut Brake hose clip Brakehose Coffer pin suspension arm details 6 Upper balljoint 7 Brake hose bracket 8 Rebound bumper 9 Alignment shims IO Upper suspension arm ...

Page 317: ... and other damage replacing them if necessary On later 4WD models It may be necessary to loosen the body mount nuts and raise the front of the body with a jack to provide sufficient clearance to alfow re moval of the upper arm lnsfallafion 7 Position the arm on the frame and install the bolts Install any align ment shims that were removed Tighten the bolts to the torque listed in this Chapter s Sp...

Page 318: ... to an automotive machine shop to have the old bushing pressed out and a new one pressed in 5 On 2WD models slip the pivot shaft into the crossmember and through the control arm and bushing from the rear Use a soft face ham mertotaptheshaft into place Install thelockwashersandnuts holding the rear of the shaft in place Install the washer and nut on the front of the pivot shaft Position the arm at ...

Page 319: ...ring and steering knuckle 4WD models 10 With the vehicle raised and supported position a floor jack under the lower arm it must stay there throughout the entire operation Remove the wheel Remove the balljoint cotter pin and loosen the castellated nut a couple of turns but don t remove it it will prevent the balljoint and steering knuckle from separating violently 11 Using a balljoint separating to...

Page 320: ...nsion arms from the steering knuckle see illustration There are several types of tools available but the kind that pushes the balljoint stud out of the knuckle boss works the best The wedge or pickle fork type works fairly well but it tendstodam age the balljoint seal Some two jaw puHers will do the job also Once the balljoints have been released from the tapered holes in the knuckle re movethe nu...

Page 321: ...atorassembly before removing the shock absorber 5 If the unit is defective it must be replaced with a new one Replace worn rubber bushings with new ones 6 Install the shocks in the reverseorderof removal but letthevehicle be free standing on the ground before tightening the mounting nuts 7 Bounce the rear of the vehicle a couple of times to settle the bushings into place then tighten the nuts secu...

Page 322: ...Refer to illustration 13 2 Warning Wheneveranyofthesuspensionorsteeringfastenersareloos ened or removed they must be inspected and if necessary replaced with newonesofthesamepartnumberoroforiginalequipmentqualityandde sign Torque specifications must be followed for proper reassembly and component retention 1 Raise the vehicle and support it securely on jackstands 2 Remove the parking brake cable b...

Page 323: ...bolt see illustration 4 Remove the lower left shock absorber bolt 5 Lower the axle and remove the springs and seats 6 Installation is the reverse of removal Tighten the nuts and bolts to the torques listed in the Specifications Section at the beginning of this Chapter before lowering the vehicle weight onto the suspension 16 Rear stabilizer bar coil spring models removal and installation Refer to ...

Page 324: ...mepartnumberoroforiginalequipmentqualityandde sign Torque specifications must be followed for proper reassembly and component retention Removal I Disconnect the cable from the negative battery terminal 17 6 Remove the steering wheel from the shaft with a puller DO NOT hammer on the shaft 2 Using a small screwdriver pry off the horn button or center pad and unplug the horn switch connector 3 Unscre...

Page 325: ...d and knuckle arm with a puller see illustration 12 If a tie rod end is to be replaced loosen the jam nut and mark the rela tionship of the tie rod end to the tie rod with white paint When installing the new rod end thread it onto the tie rod until it reaches the mark then turn the jam nut until it contacts the rod end Don t tighten it fully at this time 13 Turn the tie rod ends so they are at app...

Page 326: ...ecessary 5 Starttheengineandturnthesteeringwheelfullyinbothdirectionstwo or three times The engine should be running at 1000 rpm or less 6 Remove the jackstands and lower the vehicle completely 7 With the engine running at 1000 rpm or less turn the steering wheel fully in both directions two or three times 8 Return the steering wheel to the center position 9 Check that the fluid is not foamy or cl...

Page 327: ...e wheels are bent the result is a hazardous condition which must be corrected To check the wheels raise the vehicle and set it on jackstands Visually inspect the wheels for obvious signs of damage such as cracks and deformation Tire and wheel balance is very important to the overall handling brak ing and ride performance of the vehicle Whenever a tire is dismounted for repairor replacement the tir...

Page 328: ...ork is done by a specialist Four wheel drive models are equipped with a transfer case mounted on the transmission housing Drive is passed through the transmission and transfer case to the front and rear axles by the driveshafts 2 Shift lever removal and installation On these models the transfer case is combined with the transmission Refer to illustrations 2 la and 2 lb to form one unit The transfe...

Page 329: ...upport it securely on jackstands 2 The4WD indicator Bght switches are located on the night handside of I the transfer case housing see illustration 3 Unscrew the switch and remove the steel ball 4 Installation is the reverse of removal Se sure to apply Teflon tape or a small amount of RTV sealant to the threads Tighten the switch to the torque listed in this Chapter s Specifications 7 Lower the ve...

Page 330: ...k andreplacement 43 Suspension and steering check _ _ 17 Thermostatic air cleaner check carbureted models 25 Timing belt replacement V6 and 1984 and later 2 4L four cylinder models only See Chapter 2A Tireandtirepressurechecks 7 Tire rotation 14 Transfer case lubricant change 4WD models 35 Transfer case lubricant level check 4WD models 21 Tune up general infonation 3 Underhood hose check and repla...

Page 331: ...E viscosity No 49 38 27 16 0 32 12 23 29 120 loo 80 60 10 10 20 IO j z j W ai l ENGINE OIL VISCOSITY For best fuel economy and cold starting select the lowest SAE viscosity grade oil for the expected temperature range l SAE 5W 20 not recommended for sustained high speed vehicle operation 2 6L 0763H 2 0 and 2 4L 4 cylinder engine 4 cylinder engines V6 engine Cylinder location and distributor rotati...

Page 332: ...y safety and reliability in mind Included is a master maintenance schedule page l 7 followed by procedures dealing specifically with every item on the schedule Visual checks adjustments component replacementand other helpful items are included Refer to the accampanying illustrations of the engine compatt ment and the underside of the vehicle for the locations of various compo nents Servicing your ...

Page 333: ... ____ _ _I_ _ _ j c ___ 1 4 Chapter 1 Tune up and routine maintenance ...

Page 334: ...Chapter 1 Tune up and routine maintenance 1 5 ...

Page 335: ...l 6 Chapter 1 Tune up and routine maintenance ...

Page 336: ...hanism Chapter 6 Inspect the evaporative emissions system Section 32 at all times and with the vehicle s ultimate resale in mind many of the maintenance procedures may be performed more often than recom mended in the following schedule We encourage such owner initiative When the vehicle is new it should be serviced initially by a factory au thorized dealer service department to protect the factory...

Page 337: ... Check all engine related fluids Clean and check the battery Section 8 Check and adjust the drivebelts Section 26 Replace the spark plugs Section 42 Check the cylinder compression Chapter 2 Inspect the distributor cap and rotor Section 43 inspect the spark plug and coil wires Section 43 Replace the air filter Section 29 Check and adjust the idle speed Section 34 Check and adjust the ignition timin...

Page 338: ... pan coolant spills immediately Keep antifreeze containers covered and repair leaks in your cooling system immediately 8 All vehicles covered by this manual are equipped with a pressurized coolant recovery system A white plastic coolant reservoir located in the engine compartment is connected by a hose to the radiator filler neck see illustration If the engine overheats coolant escapes through ava...

Page 339: ...uring normal opera tion If the master cylinder requires repeated additions to keep it at the proper level its an indication of leakage in the brakesystem which should be corrected immediately Check all brake lines and connections see Section 23 for more information 5 6 The automatic transmlsslon fluid level must be between the two notches in the dipstick with the fluid at normal operating temperat...

Page 340: ... dipstick 6 If additional fluid is required pour the specified type directly into the reservoir using a funnel to prevent spills 7 If the reservoir requires frequent fluid additions ail power steering hoses hoseconnectionsandthepowersteeringpumpshould becarefully checked for leaks 7 Tire and tire pressure checks Refer to illustrations 7 2 7 3 7 4a 7 4b and 7 8 1 Periodic inspection of the tires ma...

Page 341: ...attery cables always detach the negative cable first and hook it up last Check and maintenance 1 Battery maintenance is an important procedure which will help ensure that you aren t stranded because of a dead battery Several tools are re quired for this procedure see illustration 2 When checking servicing the battery always turn the engine and all accessories off 7 4b If the valve core is tight ra...

Page 342: ...arger with a rate higher than two amps check the batteryregularlyduring charging to make sure it doesn t overheat If you re using a trickle charger you can safely let the battery charge overnight after you ve checked it regularly for the first couple of hours 14 if the battery has removeable cell caps measure the specific gravity with a hydrometer every hour during the last few hours of the chargi...

Page 343: ... are used at the ends of the hoses it may be a good idea ALWAYS CHECK hose for chafed or burned areas that may cause an untimely and costly failure SOFT hose indicates inside deterioration This deterioration can contaminate the cooling system and cause particles to clog the radiator HARDENED hose can fail at any time Tightening hose clamps will not seal the connection or stop leaks 9 4 Hoses like ...

Page 344: ...obe around vacuum hoses and fittings listening forthe hissing sound characteristic of a vacuum leak Warning When probing with the vacuum hose stethoscope be very careful not to come into contact with moving engine components such as the drivebelts cooling fan etc Fuel hose Warning There are certain precautions which must be taken when in specting or servicing fuel system components Work in a well ...

Page 345: ... so note how they re situated to avoid touching them when working under the vehicle 13 9 The engine oil drain plug is located at the rear of the oil pan it s usually fairly tight so use a box end wrench or six point socket to avoid rounding off the corners of the plug 13 14 The oil filter is usually on very tight and will require a special wrench for removal DO NOT use the wrench to tighten the ne...

Page 346: ...an oil change make it a point to check frequently for leaks and correct oil level 27 The old oil drained from the engine cannot be reused in its present state and should be disposed of Oil reclamation centers auto repair shops and gas stations will normally accept the oil which can be refined t Forward 4 Tires Bias Tire 5 Tires Bias belted Tire rl QD Radial Tire 14 2 The rotation diagram for these...

Page 347: ...s Specifications between the valve stem and the adjusting screw Carefully tighten the adjusting screw until you can feel a slight drag on the feeler gauge as you withdraw it from between the stem and adjusting screw see illustration 8 Since the jet valve spring is relatively weak use special care not to force the jet valve open Be particularly careful if the adjusting screw is hard to turn Hold th...

Page 348: ...ould be loose with the camshaft lobes facing away from the rocker arms 14 Adjust the valves labelled 6 as described above see illustra tion 15 5 15 Install the valve cover and the air cleaner assembly 16 Chassis lubrication Refer to illustrations 76 1 16 2a and 16 2b 1 A grease gun and cartridge filled with the recommended grease are the only items required for chassis lubrication otherthan some c...

Page 349: ...n the stands 5 If grease fittings aren t already installed the plugs wilt have to be re moved and fittings screwed into place 6 Force a little of the grease out of the gun nozzle to remove any dt then wipe it clean wtth a rag 7 Wipethegreasefitting and push the nozzlefirmlyoverit Squeezethe trigger on the grease gun to force grease into the component Bpth the balljointsand swivel joints should be ...

Page 350: ...l bushings one at each end of the center gear rod Finally check the steering gear arm balljoint and the one on the idler arm which supports the center rod on the side opposite the steering box This unit is bolted to the side of the frame member and any play calls for replacement of the bushings 9 To check the steering box first make sure the bolts holding the steer ing box to the frame are tight T...

Page 351: ...in until the washer damper rubber contacts the firewall Depress and release the clutch pedal several times Pull the cable forward again tighten theadjust ing nut then back it off to provide the specified amount of play see illus tration Tighten the locknut Hydraulic clutch 5 The freeplay is adjusted by turning the stopper bolt or adjustable clutch master cylinder pushrod see illustration Loosen th...

Page 352: ...the recommended lubricant until it just starts to run out of the opening 4 Install the plug and tighten it securely 22 2a Rear differential check fill plug location arrow use a box end wrench to remove and install the plug to avoid rounding off thehex 23 6 You ll find an inspection hole like this in each front caliper placing a steel rule across the hole should enable you to determine the thicknes...

Page 353: ...d lower the vehicle Parking brake 20 The parking brake is operated by an umbrella type handle next to the steering column or a center mounted lever and locks the rear brake sys tem The easiest and perhaps most obvious method of periodically checkingtheoperationof the parking brake assemblyistoparkthevehicle on a steep hill with the parking brake set and the transmission in Neutral If 23 15 Pry the...

Page 354: ...odicailycheckedand adjusted Check 2 The number type and routing of belts used on aparticuiarvehicle de pends on the engine model year and accessories installed see iiiustra tion 3 Various types of drivebelts are used on these models Some compo nents are driven by V belts these are the conventional type Others are driven by V ribbed belts Some models use a single V ribbed belt to drive GREASE GLAZE...

Page 355: ...nd the belt when the buckle is unlatched 4 If any of the above checks reveal problems with the seat belt system replace parts as necessary 28 Carburetor throttle body mounting nut bolt torque check 1 Nuts or bolts attach the carburetor to the intake manifold or the fuel injection systemthrottle body to the air intake plenum The bolts or nuts can sometimes work loose during normal engine operation ...

Page 356: ...overed with dirt it should be replaced 11 insert the filter element in the air cleaner housing and align the tabs the install the air flow sensor body and secure it with the clips 12 Connect the air intake hose securely making sure there are no air leaks Rectangular filter housing Refer to illustration 29 13 13 Detachthe clips pullthe coverupandliftthefilteroutofthe housing see illustration If the...

Page 357: ...securely If spring type clamps were originally installed it would be a good idea to re place them with screw type clamps Push the filter back into the clip Start the engine and check carefully for leaks at the filter hose connections Fuel injected models Refer to illustration 30 9 7 Depressurize the fuel system Chapter 4 8 The fuel filter is located under the vehicle adjacent to the fuel tank Rais...

Page 358: ...fast idle cam disen gages 7 You ll notice thatenginespeed corresponds to theplateopening With the plate closed the engine should run at a fast idle speed As the plate opens and the throttle is moved to disengage the fast idle cam the engine speed will decrease 8 With the engine off and the throttle held half way open open and close the choke several times Check the linkage to see if its hooked up ...

Page 359: ...least eight pints newspapers and clean rags f Raise the vehicle and support it securely on jackstands 5 Move the drain pan and necessary tools under the vehicle being careful not to touch any of the hot exhaust components Drain plug equipped models 6 Place the pan under the drain plug rn the transmission pan and re move the plug Be sure the drain pan is in position as fluid will come out with some...

Page 360: ...de of the bearing Place l 2 oz of grease inside the end of the grease cap 19 Place a new seal over the inner bearing and tap the seal evenly into place with a hammer and block of wood until it s flush with the hub 20 Carefully place the hub assembly onto the spindle and push the grea se packed outer bearing into position 21 Install the washer and adjusting nut Tighten the nut to about 22 ft lbs 22...

Page 361: ...ions 4 1 5 and 4 1 6 1 The Positive Crankcase Ventilation PCV system directs blowby gases from the crankcase back into the intake manifold so they can be burned in the engine 2 Rough idling or high idle speed and stalling are symptoms of faults in the PCV system 3 The system on these models consists of a hose leading from the valve cover to the intake manifold and a fresh air hose between the air ...

Page 362: ... be the same as the one specified on the Emissions Control Information label The wire should just slide between the elec trodes with a slight amount of drag If the gap is incorrect use the adjuster on the gauge body to bend the curved side electrode slightly until the prop er gap is obtained see illustration If the side electrode is not exactly over the center electrode bend it with the adjuster u...

Page 363: ...n as indicated here if in doubt about its condition buy a new one 5 Check inside the boot for corrosion which will look like a white crusty powder 6 Pushthewireandbootbackontotheendofthesparkplug Itshouldfit tightly onto the end of the plug If it doesn t remove the wire and use pliers to carefully crimp the metal connector inside the wire boot until the fit is snug 7 Using a clean rag wrpe the ent...

Page 364: ...on deposits lodge between the electrodes Heavy deposits accumulate and bridge the electrode gap The plug ceases to fire resulting in a dead cylinder Recommendation Locate the faulty plug and remove the deposits from between the electrodes I TOO HOT Symptoms Blistered white insu F____ lator eroded electrode and absence of deposits Results in shortened plug life Recommendation Check for the correct ...

Page 365: ... this manner 4 Connect a tachometer according to the manufacturer s instructions and make sure the idle speed is correct carbureted models Adjust it if necessary as described in Chapter 4 5 Allow the engine to reach normal operating temperature Be sure the air conditioner if equipped and all other accessories are off 6 With the ignition switch off connect the pick up lead of the timing light to th...

Page 366: ... If you hear engine pinging the ignition timing is too far advanced BeforeTopDeadCenter Reconnectthetiminglightandturnthedistribu torto move the mark 1 or 2 degrees in the retard direction counterclock wise Road test the vehicle again to check for proper operation 45 2 Locate the EGR valve arrow and check the hoses leading to it for damage 46 3 Solenoid valve air filter details 17 To keep pinging ...

Page 367: ...light resetting Refer to illustration 48 2 1 At certain mileage intervals an emissions maintenance reminder light on the instrument cluster will illuminate alerting the driver that it s time to check the EGR system and or replace the oxygen sensor see the Main tenance schedule at the beginnrng of this Chapter 2 After performing the required service a switch on the instrument clus ter must be moved...

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