143 105 98MB
English Pages 1454 Year 2003
THOMSON
Chilton
*
Part No. 9362
DELMAR LEARNING
1 998
- 2002
Digitized by the Internet Archive in
2015
f
https://archive.org/details/chiltonsautorepa00john_0
CHILTON AUTO REPAIR MANUAL 1998-2002 Edition
——
:
THOMSON *
DELIVIAR LEARNING
Chilton Auto Repair
Manual 1998-2002
Channel Manager:
Production Editor
Alar Elken
Beth A. Lutz
Elizabeth
Executive Director, Professional Business Unit;
Marketing Coordinator:
Custom
Greg Clayton
Bnan McGrath
Claudette Corley
Publisher, Professional Business Unit:
Production Director:
Technology Project Manager
David Koontz
Map'
David Porush
Vice President, Technology and Trades
SBU:
Ellen Black
Editorial Assistant:
Production Manager:
Kristen Shenfield
Larry
Hough
Publishing Coordinator
Editors:
Main
Rich Rivele Christine L. Sheeky
Tun Crain
Thomas A. Mellon
COPYRIGHT 2003
by Delmar Learning, a
sion of Thomson Learning, Inc.
Thomson
1
ing
is
a trademark used herein under
divi-
Learn-
license.
ALL RIGHTS RESERVED. No part of this work covered by
the copyright hereon
may
ISBN: 0-8019-9362-8 be
reproduced in any form or by any means graphic, electronic, or mechanical, including pho-
Printed in the United States of America 1
2 3 4 5
XX 05 04 03
tocopying, recording, taping,
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NOTICE TO THE READER Publisher does not warrant or guarantee any of the products described herein or perform any independent analysis in connection with any of the product information contained herein. Publisher does not assume,
expressly disclaims, any obligation to obtain and include information other than that provided to
it
and
by the
manufacturer.
warned to consider and adopt all safety precautions that might be indicated by the and to avoid all potential hazards. By following the instructions contained herein, the reader willingly assumes all risks in connection with such instructions. The reader
is
expressly
activities herein
The publisher makes no representation or warranties of any kind, including but not limited t£>, the warranties purpose or merchantability, nor are any such representations implied with respect to
oi fitness for particular
the material set forth herein,
and the publisher takes no responsibility with respect to such material. The pubnot Ee liable for any special, consequential, or exemplary damages resulting, in whole or part, u'"1ers' use of, or reliance upon, this material.
'isher s.-^H t
1111
Table of Contents Unit Repair Sections
Specifications
1
Specifications, Scheduled Maintenance Interval and Scheduled Mainte-
nance Labor Time Charts
Heater Cores
2
Heater Core Removal and Installation Procedures
Timing Belts
3
Timing
Brakes
4
Brake System Component Service Procedures
Belt
Removal and
Installation
Procedures
Table of Contents Car Sections
Chrysler Corp.
Ford Motor Co.
General Motors
5
Concorde, LHS, 300M,
6
Sebring Coupe, Avenger
7
Talon
8
Neon
9
Cirrus, Sebring Convertible, Stratus. Breeze
Intrepid, Vision
10
PT Cruiser
11
Contour, Mystique, Cougar (1999-01)
12
Taurus, Sable
13
Continental
14
Escort, Tracer
15
Focus
16
Lincoln LS
17
Mustang
18
Mark
19
Crown
20
Thunderbird
21
C-
VIII
Victoria,
Town
& H-Bodies— Le
Car,
Grand Marquis
Sabre, Park Ave., Eighty Eight, LSS, Regency,
Bonneville
& K-Bodies
—
22
E-
23
F-Body— Camaro,
Deville,
26
— J-Body — L/N-Body—
27
N-Body— Skylark,
28
V-Body— Catera
29
W-Body
24 25
G-Body
Riviera,
Concours, Eldorado, Seville
Z28, Firebird, Trans
Am
Aurora
Cavalier, Sunfire
Intrigue,
—
Malibu, Cutlass Achieva, Alero, Grand
Century, Regal, Impala, Lumina, Monte Carlo, Cutlass Supreme,
Grand Prix
—
Am
30
Y-Body
Geo/Chevrolet
31
Metro, Prizm
Saturn
32
LW,
Corvette
SC1.SC2,
SL, SL1.SL2,
SW1.SW2
Model Index Section No.
Model
5-1
14-1
F
Achieva
27-1
Alero
27-1
Aurora
24-1 6-1
21-1
Bonneville
Firebird
23-1
Focus
15-1
G Grand
Am
Grand Marquis
B
Breeze
C
31-1
PT Cruiser
10-1
R Regency
21-1
19-1
Riviera
24-1
12-1
29-1
Saturn Coupe
32-1
Saturn Sedan
32-1
Intrepid
Catera
28-1
Intrigue
29-1
L 21-1
Le Sabre
S Sable
Camaro
Century
21-1
Prizm
27-1
5-1
25-1
Park Ave.
29-1
i i
Impala
29-1
P
Regal
23-1
Cavalier
Section No.
29-1
Grand Prix
9-1
Model
22-1
Escort
A
Avenger
Section No.
Eldorado
3
300M
Model
Saturn
Wagon
32-1
Sebring Convertible
9-1
Sebring Coupe
6-1
Cirrus
9-1
LHS
Seville
22-1
Concorde
5-1
Lincoln LS
16-1
Skylark
27-1
Concours
22-1
LSS
21-1
Stratus
9-1
Continental
13-1
Lumina
29-1
Sunfire
Contour
11-1
LW
32-1
Corvette
30-1
Cougar (1999-01)
Crown
Victoria
Cutlass
Malibu
9-1
Mark
9-1
Supreme
D DeVille
M
1-1
'6-1
Cutlass
25-1
T 7-1
Talon
26-1
Taurus
12-1
18-1
Thunderbird
20-1
Metro
31-1
Town Car
19-1
Monte Carlo
29-1
Tracer
14-1
Trans
VIII
Mustang
17-1
2-1
Mystique
11-1
1-1
Neon
N
E Eighty Eight
5-1
Am
23-1
V 5-1
Vision 8-1
z
Z28
23-1
EDITORIAL POLICY Manufacturer and Model Coverage
make and model that is currently available on the market. Rather, the Chilton Editorial Staff makes makes and models warrant coverage. Those that are included herein represent Chilton’s judgement as to the make up 90% of vehicles that will be presented to the average technician for diagnosis and repair. In general, this Manual
This Manual does not seek to cover every judicious decisions as to which
makes and models
that
does not cover:
•
Dodge
Exotics (e.g. Rolls-Royce,
Romeo,
Viper; Alfa
OEM’s with no U.S. presence (e.g. Fiat) • OEM’s that have not sold enough units to be a
etc.)
•
factor in the repair market.
Model Year Information
Every
effort is
made
to
gather current data for use
in this
Manual. Data
acquired from manufacturers
is
at the
time
when each
OEM
chooses
to
choose to release their new model information at different times of the year, ndeed, the same manufacturer can be early one season with information, and then late the next season. As a result, not all models are equally curent when each edition of this Manual goes to press. You will note that the Editorial Staff has taken care to indicate the currency of coverage for each model. release
Different manufacturers
it.
Safety Notice
Proper service and repair procedures are
vital to
all motor vehicles, as well a> the personal safety of those perand repairing vehicles using safe effectivemethods. The procedures contain
the safe, reliable operation of
forming the repairs. This manual outlines procedures
for servicing
many NOTES, WARNINGS and CAUTIONS which should be followed along injury or improper service which could damage the vehicle or compromise
It
is
t*
eliminate the possibility of personal
safety.
important to note that repair procedures and techniques, tools and parts for servicing vehicles, as wel as the
individual performing the
work vary widely.
serviced, or to provide cautions as to
all
any other process
Some
that
It
not possible to anticipate
fluids,
hazards that
may
of the
all
result.
and experience
skill
conceivable ways or condtions under which vehicles
Standard and accepted
safe’/
of the
may be
precautions and equipment should
and safety goggles or other protection should be used dung
cutting, grinding, chiseling, pry-
can cause material removal or projectiles.
procedures require the use
of tools specially
completely satisfied that neither your personal
Although information
is
of the possible
be used when handling toxic or flammable ing, or
with standard safety procedures its
in this
manual
is
safety,
designed
for a specific
purpose. Before substituting aother tool or procedure, you must be
nor the performance of the vehicle will be endangered
based on industry sources and
is
as complete as possible
at the
me
of publication, the possibility
some vehicle manufacturers made later changes which could not be included here. Information o very late models may not be available in some circumstances. While striving for total accuracy, the Publisher cannot assume responsibility fr any errors, changes, or omissions that may occur in the compilation of this data. exists that
LOCATING AND USING INFORMATION Organization
The Table
of Contents, located at the front of the
book,
lists
each Unit Repair Section and Model Specif section
in this
manual.
is located in the book, you need only look in the Tablof Contents. Once you have found the where specific procedures are located in that section. Turn to the lnd< at the front of the model specific section. At the upper left-hand side is a listing of the main topics within that section and the page number onvhich they may be found. Following the main topics is an alphabetical listing of all of the procedures within the section and their page numbers.
To find where a particular model specific section
proper section, you
may wish
The Mode! Index, located any vehicle model covered
to find
just after the Table of
in this
manual.
Contents
in
the beginning of this manual,
may
also besed to locate the specific section for
Specifications
Specifications charts for
all
models covered
in this
book are located
Chapter
in
1.
They include: Vehicle and Engine
Identification, General
Engine Specifications, Engine Tune-Up Specifications, Capacities, Valve Specifications, Crankshaft & Connecting Rod Specifications, Piston & Ring Specifications, Engine Fastener Torque Specifications, Brake Specifications, Maintenance Interval Specifications, Ball Joint Specifications
Wheel
&
Tire Specifications,
and Wheel Alignment Specifications.
Unit Repair Sections
the applicable
URS
models for the specific system or component, unless specifically noted othermodel specific sections, therefore refer to the URS for the service procedures for
to cover all applicable
The three Unit Repair Sections are written wise. The procedures covered in the
are not repeated in the
systems or components. Refer
to the Table of
Contents
for
URS
coverage.
Model Specific Sections
The model specific sections are grouped by manufacturer and arranged
in alphabetical order The text anc llustrations that comprise the sermodel specific section are arranged in the following order of systems and components: Engine Repair (Gasoline, then Fuel System (Gasoline, then Diesel if applicable), Drive Train, Steering and Suspension
vice procedures in each
Diesel
if
applicable),
All illustrations
are located as close as possible to the applicable procedure. Procedures are for
all
models
in
the particular section unless
specifically noted otherwise.
Part
Part
Numbers
numbers
listed in this
book are not recommendations by the Publisher
for
any product by brand name. They are references
that
can be
used with interchanges manuals and aftermarket supplier catalogs to locate each brand supplier's discrete part number.
Special Tools
Special tools are
recommended by
the vehicle manufacturer to perform their specific job.
absolutely necessary, they are referred to priate part let.
number, from your
in
the text by the part
number
local dealer or regional distributor, or
Before substituting any tool for the one
recommended, read
Use has been kept to a minimum, but where These tools may be purchased, under the appro-
of the tool manufacturer.
an equivalent tool can be purchased locally from a tool supplier or parts out-
the previous Safety Notice.
ACKNOWLEDGMENTS
This publication contains material that distribution of the Ford
is
reproduced and distributed under a license from Ford Motor Company. No further reproduction or
Motor Company material
is
allowed without the expressed written permission from Ford Motor Company.
Portions of the material contained herein have been reprinted with permission of General Motors Corporation, Service Technology Group.
SPECIFICATIONS GENERAL MOTORS
CHRYSLER CORP. Chrysler Sebring
1-2
Avenger Chrysler Cirrus • Sebring Convertible • Stratus •
Chrysler
LHS
Dodge
300M
1-10
Eagle Vision
1-37
Concours • Eldorado •
1-53
1-61
Ford Contour • Mercury
1-70 1-83
Ford Thunderbird Ford Crown Victoria •
Town Car •
Chevrolet
1-90
ZX2 • 1-100
Mercury Tracer
1-113
LS
1-122
1-132
VIII
SHO
•
Buick Regal • 1998-01 Century •
Supreme •
Intrigue •
Pontiac Grand Prix
GENERAL MOTORS G-BODY
GENERAL MOTORS
Buick Riviera • Oldsmobile
Chevrolet Corvette
1-197
1-274
GEO/CHEVROLET Metro • Prizm
1-284
SATURN
Chevrolet Cavalier • Pontiac Sunfire
1-255
Y-BODY
GENERAL MOTORS
1-210
GENERAL MOTORS
LS • LSI • LS2 • LW1 • LW2 • SCI • SC2 • SL • SL1 • SL2 •
SW1
Chevrolet Malibu • Oldsmobile Cutlass
1-145
1-246
Cutlass
1-187
L/N-BODY
Ford Mustang • Lincoln
Cadillac Catera
Monte Carlo • Oldsmobile
J-BODY
Ford Focus
1-234
Chevrolet Impala • Lumina •
Camaro • Pontiac
Aurora
Mercury Grand Marquis
Mercury Sable
1-174
Seville
Grand Am GENERAL MOTORS V-BODY
GENERAL MOTORS W-BODY
GENERAL MOTORS
Firebird
Cougar & Mystique
Mark
&
F-BODY
Lincoln Continental
Ford Taurus • Taurus
E-
Cadillac DeVille • DeVille
FORD MOTOR CO.
Lincoln
1-158
Pontiac Bonneville
1-23
1-45
PT Cruiser
Eagle Talon
Ford Escort • Escort
Achieva • Alero • Pontiac
K-BODIES
Dodge/Plymouth Neon
Lincoln
LSS
Buick Skylark • Oldsmobile
• Regency •
GENERAL MOTORS
• Concorde •
• Dodge Intrepid •
Chrysler
GENERAL MOTORS N-BODY
&
Buick LeSabre • Park Avenue • Oldsmobile Eighty Eight • Ninety Eight •
Plymouth Breeze
C-
H-BODIES
Coupe • Dodge
1-223
•
SW2
1-297
SPECIFICATIONS
1-2
CHRYSLER CORP.
CHRYSLER CORP. Chrysler Sebring
Coupe
•
Dodge Avenger
ENGINE AND VEHICLE IDENTIFICATION Model Year
Engine
Code©
Liters (cc)
Cvl.
Fuel Sys.
Engine Type
N
2.5 (2497)
152
V6
MFI
Y H
2.0 (1996)
122
14
MFI
V6
MFI
SOHC DOHC DOHC
3.0 (2972)
Cu.
In.
181
Eng. Mfg.
Code©
Year
Mitsubishi
W
1998
Chrysler
X
1999
Chrysler
Y
2000
MFI: Multi-port Fuel Injection
1
2001
DOHC: Double Overhead Camshaft
2
2002
SOHC:
© ©
Single
Overhead Camshaft
8th position ol the Vehicle Identification
Number (VIN).
10th position of VIN. 93461 C01
GENERAL ENGINE SPECIFICATIONS measurements are given
All Engine
Engine
Displacement
Series
Fuel
Horsepower
@
rpm
Year
Model
Liters (cc)
(IDA/IN)
System
1998
Avenger
2.5 (2497)
N
MFI
155 @5500
2.0(1996)
Y
MFI
2.5 (2497)
N
MFI
2.0(1996)
Y
MFI
2.5 (2497)
N
2.0(1996)
Sebring Coupe
Avenger
1999
Sebring Coupe
2.5 (2497)
2.0(1996)
in inches. Net
Net
Torque
@ rpm
Oil
Pressure
Ratio
lbs.)
(in.)
3.29x2.99
140 @6000
130 @4800
3.44x3.27
155 @5500
161
3.29x2.99
140 @6000
@4400 130 @4800
MFI
155 @5500
161
@4400
3.29x2.99
Y N Y
MFI
140 @ 6000
130 @4800
3.44x3.27
MFI
155 @5500
161
@4400
3.29x2.99
MFI
140 @6000
130 @4800
3.44 x 3.27
@4400 @4400
3.29x2.99
9.4:1
3.29x2.99
9.4:1
@4400 @4400
3.29x2.99
9.4:1
3.29x2.99
9.4:1
3.59 x 2.99
Avenger
2.5 (2497)
N
MF!
155 @5500
161
2.5 (2497)
N
MFI
155 @5500
161
Avenger
2.5 (2497)
MFI
155 @5500
161
Sebring Coupe
2.5 (2497)
MFI
155 @5500
161
Sebring
3.0 (2972)
N N H
MFI
200 @5500
20504400
2001-02
Compression
@4400
(ft.
161
Sebring Coupe
2000
Bore x Stroke
9.4:1
©
9.6:1 9.4:1
3.44x3.27
©
9.6:1 9.4:1
d)
9.6:1 9.4:1
©
9.6:1
© © © ©
9.0:1
®
rpm
35-75 @3000 25-80 @3000 35-75 @ 3000
25-8003000 35-75 @3000 25-80 @ 3000 35-75 @ 3000
25-80 @ 3000 35-75 @3000 35-75 @3000 35-75 @3000 35-75 @ 3000
43-100© 3500
Avenger Coupe MFI: Multi-port Fuel Injection
©California -9.0:1 93461 C02
f
SPECIFICATIONS CHRYSLER CORP.
ENGINE TUNE-UP SPECIFICATIONS Idle
Engine
Spark Plug
ignition
Fuel
Speed
Valve
Gap
Timing
Pump
(rpm)
Clearance
(deg.)
Displacement
Engine
Year
Liters (cc)
IDA/IN
(in)
1998
2.0(1996)
Y
0.033-0.038
2.5 (2497)
N Y N N N H
0.039-0.043
1999
2.0(1996) 2.5 (2497)
2000
2.5 (2497)
2001-02
2.5 (2497) 3.0 (972)
NOTE: The
0.033-0.038
0.039-0.043 0.039-0.043 0.039-0.043 0.039-0.043
Vehicle Emission Control Information label often reflects specification changes
© © © © © © © made dunng
(psi)
MT
AT
In.
Ex.
47-50
800
800
HYD HYD HYD HYD HYD HYD HYD
HYD HYD HYD HYD HYD HYD HYD
47-50
—
750
47-50
800
800
— — — —
47-50 47-50 47-50 47-50 production.
The
label figures
750 750 750 750
must be used
if
they
differ
from those
m this chart.
HYD: Hydraulic
©
Basic ignition timing
is
not adjustable.
0*6100
2.5L (VIN N) Engine Firing Order:
1-2-3-4-5-6
Distributor Rotation: Clockwise
GENERATOR TENSIONER PULLEY
PULLEY
COM-
PRESSOR PULLEY 10- 20mm
CRANK SHAFT PULLEY
(0 4-0 Bin)
MB991660 (MICROPHONE) O461G01
Accessory drive belt routing 3.0L engine
For complete service labor times, order the Chilton Labor Guide
—Chrysler
SPECIFICATIONS
1-4
CHRYSLER CORP.
CAPACITIES Engine Oil with
Transmission
Fuel
Cooling
Displacement
Engine
Filter
(Pis.)
Tank
System
Liters (cc)
ID/VIN
(qts.)
Manual
2.0(1996)
Y
4.5
4.2
18.2
16.9
2.5 (2497)
N
4.5
—
18.2
16.9
7.4
2.0(1996)
Y
4.5
4.2
18.2
16.9
7.4
2.5 (2497)
N
4.5
—
18.2
16.9
7.4
2.0(1996)
Y
4.5
4.2
18.2
16.9
7.4
2.5 (2497)
N
4.5
—
18.2
16.9
7.4
2.0(1996)
Y N N N N H
4.5
4.2
18.2
16.9
7.4
18.2
16.9
7.4
18.2
16.9
7.4
18.2
16.9
7.4
18.2
16.9
7.4
8
16.3
8.5
Engine
Avenger
1998
Sebring
Coupe
Avenger
1999
Sebring Coupe
2.5 (2497)
2000
2001-02
Avenger
2.5 (2497)
Sebring Coupe
2.5 (2497)
Avenger
2.5(2497)
Sebring NOTE:
©
All
Coupe
capacities are approximate.
Overhaul
till
Add
3.0 (2972) fluid
capacity with torque converter
gradually and ensure a proper
fluid level is
4.5
— — — —
4.5
4.2
4.5 4.5
4.5
Auto.©
W
(gal.)
7.4
obtained.
empty 93461 cof
VALVE SPECIFICATIONS Engine
Seat
Face
Displacement
Engine
Angle
Angle
Year
Liters (cc)
ID/VIN
(deg.)
(deg.)
1998
2.0(1996)
Y
45-45.5
44.5-45
1999
2001-02
Stem-to-Guide
Stem
Installed
Clearance
Diameter
Pressure
Height
(lbs.
@
in.)
60® 1.496
(ia)
(in.)
(in.)
Intake
Exhaust
Intake
Exhaust
1.496
0.0009-
0.0020-
0.2336-
0.2325-
0.0026
0.0037
0.2343
0.2332
0.0016-
0.2360
0.2360
2.5 (2497)
N
44-44.5
45-45.5
6061.740
1.740
0.0008-
0.0040
0.0060
2.0(1996)
Y
45-45.5
44.5-45
6061.496
1.496
0.0009-
0.0020-
0.2336-
0.2325-
0.0026
0.0037
0.2343
0.2332
0.0008-
0.0016-
0.2360
0.2360
0.0040
0.0060
0.0008-
0.0016-
0.2360
0.2360
0.0040
0.0060
0.0008-
0.0016-
0.2360
0.2360
0.0040
0.0060
0.0008-
0.0016-
0.2400
0.2400
0.0019
0.0027
2.5 (2497)
2000
Spring
Springiest
2.5 (2497)
2.5 (2497)
3.0 (2972)
N
N
N H
44-44.5
44-44.5
44-44.5
44-44.5
45-45.5
45-45.5
45-45.5
45-45.5
6061.740 6061.740
6061.740 6061.740
1.740
1.740
1.740
1.740
93461 C05
© SPECIFICATIONS
1-5
CHRYSLER CORP.
CRANKSHAFT AND CONNECTING ROD SPECIFICATIONS measurements are given
All
in inches. Connecting Rod
Crankshaft
Engine Displacement
Engine
Main Brg.
Year
Liters (cc)
ID/VIN
Journal Dia.
1998
2.0(1996)
Y
Main Brg.
Shaft
Thrust
Journal
Oil
Side
Clearance
End-play
on No.
Diameter
Clearance
Clearance
2.0469-
0 0009-
0.0035-
3
1.8894-
0.0010-
0.0051-
2.0475
0.0024
0.0094
1.8900
0.0023
0.0150
0.0020-
3
1.9700
0.0008-
0.0039-
0.0020
0.0098
3
1.8894-
0.0010-
0.0051-
Oil
2.5 (2497)
N
2.3600
0.0008-
0.0016
0.0098
2.0(1996)
Y
2.0469-
0.0009-
0.0035-
2.0475
0.0024
0.0094
2.5 (2497)
N
2.3600
0.0008-
0.0020-
0.0016
0.0098
2000
2.5 (2497)
N
2.3600
0.0008-
0.0020-
0.0016
0.0098
2001-02
2.5 (2497)
N
2.3600
0.0008-
0.0020-
0.0016
0.0098
3.0 (2972)
H
2.00-
0.0008-
0.0020-
2.4000
0.0016
0.0098
1999
1.8900
0.0023
0.0150
3
1.9700
0.0008-
0.0039-
0.0020
0.0098
3
1.9700
0.0008-
0.0039-
0.0020
0.0098
3
1.9700
0.0008-
0.0039-
0.0020
0 0098
3
1.7709-
0.0008-
0.0012-
1.7714
0.0019
0.0270 93461C06
PISTON AND RING SPECIFICATIONS measurements are given in inches.
All
Ring Gap
Engine
Ring Side Clearance
Displacement
Engine
Piston
Top
Bottom
Oil
Year
Liters (cc)
IDA/IN
Clearance
Compression
Compression
Control
1998
2.0 (1996)
Y
2.5 (2497)
1999
2.0
(19%)
2.5 (2497)
2000
2.5 (2497)
2001-02
2.5 (2497)
3.0 (2972)
Y
N N
H
0.019-
0.009-
0.0010-
0.0010-
0.0002-
0.020
0.031
0.026
0.0026
0.0026
0.0070
0.0008-
0.010-
0.016-
0.006-
0.0012-
0.0008-
NA
0.0016
0.016
0.022
0.019
0.0028
0.0024
©
0.009-
0.019-
0.009-
0.0010-
0.0010-
0.0002-
0.0017
0 020
0.031
0.026
0.0026
0.0026
0.0070
0.0008-
0010-
0.016-
0.006-
0.0012-
0.0008-
NA
0.0016
0.016
0.022
0.019
0.0028
0.0024
0.0008-
0.010-
0.016-
0.006-
0.0012-
0.0008-
0.0016
0.016
0.022
0.019
0.0028
0.0024
0.0008-
0.010-
0.016-
0.006-
0.0012-
0.0008-
0.0016
0.016
0.022
0.019
0.0028
00024
0.0003-
0.012-
0.018-
0.008-
0 0012-
0.0018-
0.0008-
0.0090
0.017
0.023
0.019
0.0017
0.0023
0.019
NA: Not Available
© Clearance
at
1
1/16 Inch from the bottom ot the
Oil
Control
0.009-
0.0005-
N
Bottom
Compression Compression
0.0017
0.0005-
N
Top
skirt
Please
visit
our web
site at
www.chiltonsonline.com
NA NA
SPECIFICATIONS CHRYSLER CORP.
1-6
TORQUE SPECIFICATIONS All readings in Engine
Rod
Crankshaft
Head
Bearing
Bearing
Damper
Flywheel
Bolts
Bolts
Bolts
Intake
Year
Liters (cc)
ID/VIN
Bolts
Bolts
1998
2.0(1996)
Y N Y N N N H
©
55
80
69
©
55
80 80 80
2.5 (2497)
1999
2.0(1996) 2.5 (2497)
2000
2.5(2497)
2001-02
2.5 (2497)
3.0(2972)
©
Step
1
:
Faslenere
1
through 6 to 24
Fasteners 7 through 10 to 20
Step
2:
Fasteners
1
Fasteners 7 through
Step
3:
Fasteners
1
Step
4:
©Step Step
Tighten
all
ft.
ft.
lbs.
ft.
lbs.
through 6 to 48 1
0
to
20
ft.
Spark
Lug
Exhaust
Plugs
Nuts 88-103
©
105
70
17
17
20
37
134
68
16
22
18
88-103
©
105
70
17
17
20
88-103
69
37
134
68
16
22
18
88-103
69
37
134
68
16
22
18
88-103
69
37
134
68
16
22
18
88-103
69
37
125
55
17
23
18
80
©
lbs.
through 6 to 48 ft.
lbs.
fasteners 1/4 turn
side bolts to 21 ft
1:20
lbs.
80
©
Man ifold
ft lbs.
Fasteners 7 throught 10 to 20
©Tighten
ft.
lbs.
Main
Engine
Displacement
ft.
Cylinder
lbs.
lbs.
2: 1/4 turn 93461 C08
BRAKE SPECIFICATIONS All
measurements
in inches unless noted Brake Drum Diameter
Brake Disc
Bracket Bolts
Inside
Wear
Machine
Thick-
Thickness
Thickness
Run-out
Diameter
Limit
Diameter
ness
F
0.940
0.880
0.003
—
R
0.390
0.330
0.003
Sebring
F
0.940
0.880
0.003
Coupe
R
0.390
Avenger
F
0.940
0.880
0.003
— © — © —
R
0.390
0.330
0.003
©
Sebring
F
0.940
0.880
0.003
Coupe
R
0.390
Avenger
F
0.940
0.880
0.003
— © — © — © — © — — — — —
Avenger
2000-01
Lining
Maximum
1998
2000-01
Maximum
Minimum
Model
1999
Max.
Original
Year
©
©
0.330
0.330
©
©
0.003
0.003
R
0.390
0.330
0.003
Sebring
F
0.940
0.880
0.003
Coupe
R
Avenger
0.390
©
0.330
©
0.003
F
0.940
0.880
0.003
R
0.390
0.330
0.003
Sebring
F
0.940
0.880
0.003
Coupe
R
0.390
©
0.330
©
0.003
Brake Caliper
Min.
Original
—
© — — — — — — — —
© — © — © —
© — — — — — — — —
—
— —
(ft.
lbs.)
Mounting Bolts (ft lbs.)
0.080
65
54
0.039
—
38
0.080
65
54
0.039
—
38
0.080
65
54
0.039
—
38
0.080
66
54
0.039
—
38
0.080
65
54
0.039
—
38
0.080
66
54
0.039
—
38
0.080
65
54
0.039
—
38
0.080
66
54
0.039
—
38
F: Front
R:
Rear
© Minimum © Maximum
diameter: 9.00
diameter
is
in.
stamped on drum
©Vented
rear disc: 0.790
© Vented
rear disc: 0.720 93461009
6
4 7
SPECIFICATIONS
1-7
CHRYSLER CORP.
WHEEL ALIGNMENT Camber
Caster
Year
Model
1998
ALL
2002
Range
Setting
Axis Toe-in
Inclination
(Deg.)
(W-Deq.)
(Deg.)
(in.)
(Deg.)
+1.50
+4.31
+0.50
0
0+/-0.13
7.31
R
—
—
+0.50
-1.34
0.13+/- 0.13
—
F
+1.50
+4.31
+0.50
0
0+/-0.13
7.31
R
—
—
+0.50
-1.34
0.13+/- 0.13
—
F
+1.50
+4.31
+0.50
0
0+/-0.13
7.31
R
—
—
+0.50
-1.34
0.13+/- 0.13
—
F
+1.50
+4.31-
+0.50
0
0+/-0.13
7.31
R
—
—
+0.50
-1.34
0.13+/- 0.13
—
F
+1.50
+4.31
+0.50
0
0+/-0.13
7.31
R
—
—
+0.50
-1.34
0.13+/- 0.13
—
ALL
2001
Setting
(+/-Deg.)
ALL
2000
Range F
ALL
1999
Steering Preferred
Preferre
ALL
33461C10
TIRE,
WHEEL AND BALL JOINT SPECIFICATIONS OEM
Wheel
Ball Joint
Rear
Size
Inspection
32
29
5.5-J
None
32
29
6.5-JJ
P215/55R16
32
32
6-JJ
None
30
30
6-JJ
None
30
30
5.5-J
Tire Pressures (psi)
Tires
Year
Model
Standard
Optional
1998
Avenger, base
P195/70HR14
P205/55HR16
Avenger ES
P215/50HR17
Sebring JX
P205/65R15
Sebring Jxi
P215/55R16
Sebring LX
P195/70R14
2000
Avenger, base
PI 95/70HR1
Avenger ES
OEM: PSI:
32
29
6-JJ
32
29
5.5-J
P21 5/50HR1
None
32
29
6.5-JJ
Sebring JX
P205/65R15
P215/55R16
30
30
6-JJ
Sebring Jxi
P215/55R16
None
30
30
6-JJ
Sebring LX
P195/70R14
32
29
5.5-J
65-JJ
P205/55HR 1
Sebring Lxi
P215/50R17
None
32
29
Avenger, base
P195/70HR14
P205/55HR16
32
29
5.5-J
Avenger ES
P215/50HR17
None
32
29
6.5-JJ
6-JJ
Sebring JX
P205/65R15
P215/55R16
30
30
Sebring Jxi
P215/55R16
None
30
30
6-JJ
Sebring LX
P195/70R14
P205/55HR16
32
29
5.5-J
6.5-JJ
P215/50R17
None
32
29
Avenger, base
P195/70HR14
P205/55HR16
32
29
5.5-J
Avenger ES
P215/50HR17
None
32
29
6.5-JJ
6-JJ
Sebring
2001-02
None P205/55HR16
P205/55R16
Sebring Lxi
1999
Front
Lxi
Sebring JX
P205/65R15
P215/55R16
30
30
Sebring Jxi
P215/55R16
None
30
30
6-JJ
Sebring LX
P195/70R14
P205/55HR16
32
29
5.5-J
Sebring Lxi
P215/50R17
None
32
29
6.5-JJ
© © © © © © © © © © © © © © © © © © © © © © © ©
Equipment Manufacturer
Original
Pounds Per Square Inch
STD. Standard
OPT: Optional
L
Lower
U:
Upper
©
Replace
It
any measurable movement
is
found 93461 Cl 1
Timing belt service
is
covered
in
Section 3 of this manual
SPECIFICATIONS
1-8
CHRYSLER CORP.
SCHEDULED MAINTENANCE INTERVALS
—Sebring, Dodge—Avenger
Chrysler
VEHICLE MILEAGE INTERVAL TYPE OF
Enqine Coolant Rotate
&
oil
hoses & clamps
level,
tires
Automatic transaxle
30
45
37.5
y
S/I
y
82.5
90
97.5
y
/
/
y
y
y
y
y
y
y
y
y
y
y
y
S/I
y
y
y
y
y
y
y
y
y
y
y
y
y
y y
Brake hoses & disc brake S/I
(xIOOO)
75
y
S/I
fluid level
22.5
y
R
filter
15
7.5
SERVICE
SERVICED
TO BE
60
52.5
'
67.5
pads
& front
Driveshaft boots
y
S/I
suspension components Air
filter
y
S/I
V y
y y y y y
S/I
y
y
y
V y
y y y
S/I
y y y y
S/I
y
y
R
element
Enqine coolant
R
Spark plugs (DOHC)
R
Spark plugs (SOHC)
Accessory drive Ball joints
&
©
R
belts
steering linkage
y y y
y
seals
Exhaust system
S/I
Fuel hoses
S/I
Manual transaxle
PCV
S/I
oil
valve
Rear drum brake
lining
&
rear
y
wheel cylinders
Camshaft timing Ignition
belt
cables
Distributor
cap &
rotor
y y y y
S/I
Fuel system
S/I
Replace
©
y
R S/I
EVAP system
R:
R
S/I:
Service or Inspect
Spark plugs: replace every 100,000 miles.
FREQUENT OPERATION MAINTENANCE (SEVERE SERVICE) If
a vehicle
is
operated under any of the following conditions
•
Extremely dusty areas.
•
50%
•
Prolonged idling (vehicle operation
or more of the vehicle operation
is in
In
Frequent short running periods (engine does not
-
Police, taxi, delivery
&
oil filter
is
considered severe service:
32°C (90°F) or higher temperatures, or constant operation
stop and go
-
Oil
it
in
temperatures below 0°C (32°F).
traffic).
warm to normal
operating temperatures).
usage or trailer towing usage.
change: change every 3000 miles.
Disc brake pads: check every 6000 miles. Air
filter
element: change every 15.000 miles.
Automatic transaxle
Rear drum brake
fluid;
linings
change every 15,000
&
rear wheel cylinders:
miles.
check every
1
5,000 miles.
Spark plugs: change every 15,000 miles. 93461C12
SPECIFICATIONS CHRYSLER CORP.
1-9
SCHEDULED MAINTENANCE INTERVALS DAIMLERCHRYSLER CORPORATION CHRYSLER SEBRING (through DODGE AVENGER The In
following should be
estimating
how
t
used as a guide when determining the amount
work required
of
for
a particular service.
long a particular Scheduled Maintenance Service should take, please observe the following:
• • •
Labor Time is time based on field research and data supplied by the vehicle manufacturer Labor time operations are given in hours and tenths of an hour All labor operations are to be used as a guide.
Mechanic
Skill
Level Codes:
(A)
PRECISION: Highly
(B)
GENERAL: Normally skilled with certification MAINTENANCE: Semi-skilled working on certification.
(C)
7500 Mile Service (C) All Models 15000 Mile Service (C) All Models 22500 Mile Service (C) All Models 30000 Mile Service (B) All Models
2000)
skilled with multiple certification.
LABOR
LABOR
TIME
TIME
3 1.5
3 2.1
37500 Mile Service (C) All Models 45000 Mile Service (B) All Models 52500 Mile Service (C) All Models 60000 Mile Service (B) All Models 67500 Mile Service (B) All Models Replace timing belt add
3 1.5
3 2.1
LABOR TIME
75000 Mile Service All Models 82500 Mile Service All Models 90000 Mile Service All Models 97500 Mile Service All Models
(B) 1.5
(C)
3 (B) 2.1
(C)
3
1.3 1 .8 93461CO
Heater Core replacement
is
covered
in Section
2
of this
manual
SPECIFICATIONS
1-10
CHRYSLER CORP.
CHRYSLER CORP. Chrysler Cirrus • Sebring Convertible Dodge Stratus • Plymouth Breeze
•
ENGINE AND VEHICLE IDENTIFICATION Engine
Code©
Liters (cc)
C N
2.0(1996)
Model Year
Code©
Year
Chrysler
W
1998
Mitsubishi
X
1999
Chrysler
Y
2000
Chrysler
1
2001
Chrysler
2
2002
Cyl.
Fuel Sys.
Engine Type
Eng. Mfg.
122
14
MFI
2.5 (2497)
152
V6
MFI
G
2.4 (2351)
148
14
MFI
X
2.4 (2429)
143
14
MFI
U H
2.7 (2736)
167
V6
MFI
3.0 (2972)
181
V6
MFI
SOHC SOHC SOHC DOHC DOHC SOHC
Cu.
In.
Chrysler
MFI: Multi-point Fuel Injection
SOHC:
Single Overhead Camshaft
DOHC: Double Overhead Camshaft
© ®
8th position of
VIN
10th position of VIN 93461C14
SPECIFICATIONS
1.11
CHRYSLER CORP.
>
•
GENERAL ENGINE SPECIFICATIONS All
measurements are given
Engine
Engine
Displacement
Series
Fuel
Horsepower
@ rpm 132@6000
Net
@ rpm 25-80@3000
3.44x3.98
9.4:1
25-80@3000
170@4350 167@4000
3.29x2.99
9.4:1
25-80@3000
3.44x398
9.4:1
25-80@3000
170@4350 129@5000
3.29x2 99
9.4:1
25-80@3000
3.44x3 26
9.8:1
25-80@3000
167 @4000
3.44x3.98
9.4:1
25-80@3000
170@4350
3.29x2.99
9.4:1
25-80@3000
132@6000 150@5200
129@5000 167@4000
3.44x3.26
9.8:1
25-80@3000
3.44x3.98
9
4:1
25-80@3000
168@5800 150@5200 168@5800 132@6000 150@5200 168@5800 150@5200 150@5200 168@5800 168@5800 150@5200 168@5800 150@5200
170@4350 167@4000
3.29x2.99
9
4:1
25-80@3000
3.44x3.98
9.4:1
25-80@3000
170@4350 129@5000 167@4000
3.29x2.99
9.4:1
25-80@3000
3.44x3.26
9.8:1
25-80@3000
3.44x3 98
9.4:1
25'80@3000
170@4350 167@4000 167@4000 170@4350 170@4350 167@4000 170@4350
3.29x2 99
9.4:1
25-80@3000
3 44x3.98
9.4:1
25-80@3000
3 44x3 98
9.4:1
25-80@3000
3.29x2.99
25-80@3000
3 29x2 99
94:1© 94:1©
344x3.98
9.4:1
25-80@3000
167 @4000
3 44x3.98
9.4:1
167 @4000
3 44x3.98
94:1
25-80@3000
MFI
150@5200 168@5800
170@4350
3.29x2 99
9
4:1©
25-80@3000
MFI
168@5800
170@4350
3 29x2.99
94:1©
25-80@3000
MFI
150@5200
167@4000
3 44x3.98
9.4:1
25-80@3000
MFI
168@5800
170@4350
329x299
U
MFI
200@5900
192@4300
3 39x3.09
9.6:1
45-105@3000
G G
MFI
9.5:1
43-100@3500
341x3.94
9.5:1
43-100@3500
MFI
158@4000 158@4000 205@4500 205@4500
3.41x3 94
H H
142@5500 142@5500 200@5500 200@5500
359x2 99
9.0:1
43-1 00@ 3500
359x2.99
90:1
43-100@3500
Cirrus
2.4 (2429)
Cirrus
2.5(2497)
Sebring Convertible
2.4 (2429)
Sebring Convertible
2.5(2497)
Stratus
2.0(1996)
Stratus
2.4 (2429)
Stratus
2.5 (2497)
N
MFI
Breeze
2.0(1996)
MFI
Cirrus
2.4 (2429)
Cirrus
2.5 (2497)
Sebring Convertible
2.4 (2429)
Sebring Convertible
2.5 (2497)
Stratus
2.0(1996)
Stratus
2.4 (2429)
Stratus
2.5 (2497)
Breeze
2.4 (2429)
Cirrus
2.4 (2429)
Cirrus
2.5 (2497)
Sebring Convertible
2.5 (2497)
Stratus
2.4 (2429)
Stratus
2.5 (2497)
Breeze
2.4 (2429)
Cirrus
2.4 (2429)
Cirrus
2.5(2497)
Sebring Convertible
2.5(2497)
C X N X N C X N X X N N X N X X N N
Stratus
2.4 (2429)
Stratus
2.5 (2497)
X N
Sebring Sedan
2.7 (2672)
Coupe
2.4 (2351)
2.4 (2351)
Sebring
Coupe
3.0(2972)
Stratus
Coupe
3.0(2972)
MFI MFI MFI
MFI MFI MFI
MFI MFI MFI MFI MFI MFI
MFI MFI MFI MFI MFI
MFI MFI MFI MFI
MFI
MFI
150@5200 168@5800 150@5200 168@5800 132@6000 150@5200 168@5800
MFI: Multi-point Fuel Injection
®
Pressure
9.8:1
MFI
Coupe
Oil
pression Ratio
System
C X N X N C X
Stratus
Com-
Stroke (in.)
(ID/V1N)
2.0(1996)
Sebring
Borex
3.44x3.26
Liters (cc)
Breeze
2001-02
@rpm
(ft lbs.)
Model
1998
2000
Net
Torque
129@5000 167@4000
Year
1999
in inches.
California: 9.0:1
Brake service
is
covered
in Section
4 of this manual
329x2 99
9.4:1
9
4:1
©
©
25-80@3000 25-80@3000 25-80@3000
25-80@3000
SPECIFICATIONS
1-12
CHRYSLER CORP.
GASOLINE ENGINE TUNE-UP SPECIFICATIONS Idle
Ignition
Engine
Spark Plug
Timing
Fuel
Speed
Valve
Gap
(deg.)
Pump
(rpm)
Clearance
Displacement
Engine
Year
Liters (cc)
1D/VIN
(in.)
MT
AT
1998
2.0(1996)
0.035
©
2.4 (2429)
C X
2.5(2497)
N
0.038-0,043
2.0(1996)
0.035
2.4 (2429)
C X N X
© © © © © © ©
2.5(2497)
N
0.038-0.043
2.4 (2429)
X
0.050
2.4 (2351)
G
0.039-0.043
2.5 (2497)
N
0.038-0.043
2.7 (2672)
U
0.048-0.053
3.0 (2972)
H
0.039-0.043
1999
2.4 (2429) 2.5 (2497)
2000
2001-02
NOTE: The
— — © — — — — — — — © ©
0.050
0.050 0.038-0.043
0.050
Vehicle Emission Control Information label often reflects specification changes
(psi)© 48
49 49 48
49
©
49
made during
47-50
49 58 47-50 production.
© © © © © © © © © © ©
— —
49
© © © ©
AT
© — — ©
49
49
©
NIT
The
label figures
—
© © — © © must be used
© © if
they differ from those
HYD: Hydraulic
© © ©
This reading measured with Ignition timing
vacuum hose disconnected from
cannot be adjusted. Base engine timing
is
fuel
set at
pressure regulator.
TDC during
assembly.
Refer to the Vehicle Emission Control Information label for correct specifications.
r
In.
Ex.
HYD HYD HYD HYD HYD HYD HYD HYD HYD HYD HYD HYD HYD
HYD HYD HYD HYD HYD HYD HYD HYD HYD HYD HYD HYD HYD
in this
chart
SPECIFICATIONS CHRYSLER CORP.
For complete Engine Mechanical specifications, see Section
1
of this
manual
1.10 O
1-14
SPECIFICATIONS CHRYSLER CORP.
CAPACITIES Engine Engine
Oil with
Transmission
Fuel
Cooling
(pts.)
Tank
System (qts.)
Displacement
Engine
Filter
Year
Model
Liters (cc)
ID/VIN
(qts.)
5-Spd
Auto.
(gal.)
1998
Breeze
2.0(1996)
4.5
4.4
16.0
7.4
Cirrus
2.4 (2429)
C X
16.0
9.0
16.0
10.5
Cirrus
2.5 (2497)
N
4.5
Sebring Convertible
2.4 (2429)
X
5.0
Sebring Convertible
2.5 (2497)
N
4.5
— — — —
Stratus
2.0 (1996)
4.4
2.4 (2429)
5.0
Stratus
2.5 (2497)
4.5
— —
Breeze
2.0(1996)
4.5
4.4
Cirrus
2.4 (2429)
Cirrus
2.5 (2497)
C X N C X N
4.5
Stratus
Sebring Convertible
2.4(2429)
X
5.0
Sebring Convertible
2.5 (2497)
4.5
Stratus
2.0(1996)
4.5
4.4
Stratus
2.4 (2429)
Stratus
2.5 (2497)
Breeze
2.4 (2429)
N C X N X
— — — —
Cirrus
2.4 (2429)
5.0
Cirrus
2.5 (2497)
X N
4.5
Sebring Convertible
2.5 (2497)
N
4.5
— — — — — —
Stratus
2.4 (2429)
X
5.0
4.4©
8.0© 8.0© 8.0© 8.0© 8.0© 8.0© 8.0© 8.0© 8.0© 8.0© 8.0© 8.0© 8,0© 8.0© 8.0© 8.0© 8.0© 8.0© 8.0© 8.0© 8.0©
2.4 (2351)
G
4.5
3.1
2.7 (2672)
U N
5.0
4.5
1999
2000-01
Sebring/Stratus
Coupe
Sebring Sedan Sebring/Stratus NOTE:
All
© © Heavy
capacities are approximate.
Overhaul
fill
Coupe Add
fluid
3.0 (2972)
gradually and ensure a proper fluid level
capacity with torque converter empty:
1
5.0
5.0
4.5
5.0
4.5 5.0
is
16.0
9.0
16.0
10.5
16.0
7.4
16.0
9.0
16.0
10.5
16.0
7.4
16.0
9.0
16.0
10.5
16.0
9.0
16.0
10.5
16.0
7.4
16.0
9.0
16.0
10.5
16.0
9.0
16.0
9.0
16.0
10.5
16.0
10.5
16.0
9.0
6.6
16.3
7.4
—
8.0©
16.0
9.5
4.2
8.0
16.3
8.5
obtained.
8.2 pts.
Duty: 5.2 pts. 93461C17
SPECIFICATIONS
-IE
-I
CHRYSLER CORP.
VALVE SPECIFICATIONS Engine Displacement
Engine
Year
Liters (cc)
ID/VIN
1998
2.0(1996)
C
2.4 (2429)
2.5 (2497)
1999
2.0(1996)
2.4 (2429)
2.5 (2497)
2000
2.4 (2429)
2.5 (2497)
2001-02
2.4 (2429)
2.4 (2351)
2.5 (2497)
2.7 (2672)
3.0 (2972)
X N
C X N
X N X
G N U H
Seat
Face
Angle
Angle
-fisau 44.545 45 4544.5
44.545 45
4544.5 45
4544.5 45
4544.5
4544.5
44.545
44.545
1C
SPECIFICATIONS CHRYSLER CORP.
CHRYSLER CORP. Chrysler PT Cruiser ENGINE AND VEHICLE IDENTIFICATION Model Year
Engine
Code©
Liters (cc)
B
2.4 (2429)
Cu.
In.
148
cyi.
Fuel Sys.
L4
SMFI
Engine Type
DOHC
Eng. Mfg. Chrysler
DOHC: Double Overhead Camshaft
©
8th position o(
©10th
Code®
Year
1
2001
2
2002
VIN
position of
VIN 93461 CS7
GENERAL ENGINE SPECIFICATIONS Engine
Engine
Displacement
Series
Fuel
Net
Net
Horsepower Torque
@ rpm
Bore x
Com-
Oil
Stroke
pression
Pressure
Liters (cc)
(IDA/IN)
System
(in.)
Ratio
@ rpm
2001
PT
Cruiser
2.4 (2429)
B
SMFI
1
50(3)5200
164 @4000
3 44x3.98
94:1
25-80@3000
2002
PT
Cruiser
2.4 (2429)
B
SMFI
150(5)5200
164@4000
3 44x3.98
9.4:1
25-80(5)3000
Year
Model
@ rpm
(ft.
lbs.)
SMFI: Sequential Multi-port Fuel Injection
For Tune-up, Capacities and Firing orders, see Section
1
of this
manual
1-46
SPECIFICATIONS CHRYSLER CORP.
ENGINE TUNE-UP SPECIFICATIONS Spark Plug
Engine
Ignition
Fuel
Idle
Valve
Speed
Clearance
(rpm)
In.
Ex.
© ©
HYD
HYD
HYD
HYD
Displacement
Engine
Gap
Timing
Pump
Year
Liters (cc)
IDA/IN
(in.)
(deg.)
(psi)
2001
2.4 (2429)
B
0.048-0.053
49
2002
2.4 (2429)
B
0.048-0.053
© ©
NOTE: The Vehicle Emission HYD:
© ©
Control Information label often reflects specification
changes made during production
49 The
label figures
must be used
if
they differ from those
in this chart.
Hydraulic
Ignition liming is regulated
Idle
speed
is
by the Powertrain Control Module (PCM), and cannot be adjusted.
controled by the Powertrain Control Module (PCM), and cannot be adjusted. 33461C59
t
SPECIFICATIONS
1I _/|7 ** I
CHRYSLER CORP.
CAPACITIES Power
Rear
Oil with
Automatic
Transfer
Drive
Engine Engine
Fuel
Cooling
Displacement
Engine
Filter
Transaxle
Unit
Axle
Tank
System
Liters (cc)
IDA/IN
(qts.)
(qts.)
(qts.)
(pts.)
(gal.)
(qts.)
4.5
20.0
9.5
4.5
20.0
9.5
Model
Year 2001
PT
Cruiser
2.4 (2429)
B
2002
PT
Cruiser
2.4 (2429)
B
NOTE:
All
© 31TH ©
capacities are approximate.
Add
fluid
© ©
gradually and check to be sure a proper fluid level
overload
fill
capacity with torque converter empty: 8 5 qts.
41TE overhaul
fill
capacity with torque converter empty: 9.1 qts
is
© ©
1.22
1.22
obtained
Overrunning clutch: 0 75 pts 93461 CEO
VALVE SPECIFICATIONS Engine
Seat
Face
Spring
Stem-to-Guide
Stem
Spring Test
Installed
Clearance
Diameter
Pressure
Height
Displacement
Engine
Angle
Angle
Year
Liters (cc)
IDA/IN
(deg.)
(deg.)
2001
2.4 (2429)
B
45
44.5-
129-143@
45.0
1.17
44.5-
129-143@
45.0
1.17
2002
©
2.4 (2429)
B
45
(lbs.
@
in.)
(in.)
(in.)
(in.)
Intake
Exhaust
Intake
Exhaust
1.50
0 0018-
0.0029-
0.2340
0.2330
00025
0.0037
0.0018-
0.0029-
0 2340
0.2330
0.0025
0.0037
1.50
Intake valve 44 5 degrees
Exhaust valve: 45 degrees 904E1C6'
For complete service labor times, order the Chilton Labor Guide
SPECIFICATIONS
1-48
CHRYSLER CORP.
CRANKSHAFT AND CONNECTING ROD SPECIFICATIONS All
measurements are given
in inches. Connecting Rod
Crankshaft
Engine Displacement
Engine
Main Brg.
Shaft
Thrust
Journal
Oil
Side
Clearance
End-play
on No.
Diameter
Clearance
Clearance
2
1.9670-
0.0009-
0.0051-
1.9685
0.0027
0.0150
1.9670-
0.0009-
0.0051-
1.9685
0.0027
0.0150
Main Brg.
Oil
Year
Liters (cc)
IDA/IN
Journal Dia.
2001
2.4 (2429)
B
2.3610-
0.0007-
0.0035-
2.3625
0.0023
0.0094
2.3610-
0.0007-
0.0035-
2.3625
0.0023
0.0094
2002
B
2.4 (2429)
2
93461 C62
PISTON AND RING SPECIFICATIONS measurements are given in inches.
All
Ring
Engine
Gap
Ring Side Clearance
Top
Displacement
Engine
Piston
Top
Bottom
Oil
Year
Liters (cc)
IDA/IN
Clearance
Compression
Compression
Control
2001
2.4 (2429)
B
0.0009-
0.0098-
0.0090-
0.0098-
0.0011-
0.0011-
0.0022
0.0200
0.0180
0.0250
0.0031
0.0031
0.0070
0.0009-
0.0098-
0.0090-
0.0098-
0.0011-
0.0011-
0.0004-
0.0022
0.0200
0.0180
0.0250
0.0031
0.0031
0.0070
2002
®
Oil control ring
2.4 (2429)
side
rails
must be
B
free lo rotate after
Bottom
Compression Compression
Oil
Control 0.0004-
assembly 93461 C63
SPECIFICATIONS
1-49
CHRYSLER CORP.
TORQUE SPECIFICATIONS All readings in Engine
lbs.
ft.
Cylinder
Main
Rod
Crankshaft
Displacement
Engine
Head
Bearing
Bearing
Damper
Flywheel
Spark
Lug
Year
Liters (cc)
ID/VIN
Bolts
Bolts
Bolts
Bolts
Bolts
Intake
Exhaust
Plugs
Nuts
2001
2.4 (2429)
B
© ©
20
17
20
100
B
© ©
70
2.4 (2429)
© ©
100
2002
100
70
20
17
20
100
©Step Step
1:25 2:
ft
50 Jt
Step 3:50
ft.
©M8
lbs
Ml
lbs.
®
lbs.
Step 4 Plus 1/4 turn
20
bolts:
1
bolts:
Manifold
ft lbs
30 ft.
lbs plus 1/4 turn
Step
1
20 ft
Step
2:
Plus 1/4 turn
lbs
93461 C64
BRAKE SPECIFICATIONS All
measurements
in inches unless noted Brake Drum Diameter
Brake Disc
2001
2002
PT
PT
Cruiser
Cruiser
Max.
Lining
Guide
Original
Minimum
Maximum
Inside
Wear
Machine
Thick-
Thickness
Thickness
Run-out
Diameter
Limit
Diameter
ness
(ft lbs.)
F
0 902-0.909
0.803
0.005
—
—
—
0.313
26
R
0.344-0.364
0.285
0.005
863-8 65
NA
NA
©
16
F
0.902-0 909
0.803
0.005
-
—
—
0.313
26
R
0.344-0 364
0.285
0.005
8.63-8 65
NA
NA
©
16
©Rear Disc
NA: Not Available
0 350
in
F: Front
Rear Bonded Shoes 0 062
in
Rear
Rear Riveted Shoes 0 031
in.
R:
Maximum
Caliper
Pin Bolts
Model
Year
Original
Min.
Please
visit
our web
site at
www.chiltonsonline.com
6
SPECIFICATIONS
1-50
CHRYSLER CORP.
WHEEL ALIGNMENT Camber
Caster Preferred
PT
2001
PT
2002
Cruiser
Cruiser
Axis
Range
Setting
Range
Setting
Toe-in
Inclination
(+/-Deg.)
(Deg.)
(+/-Deg.)
(Deg.)
(in.)
(Deg.)
F
+1.00
+2.45
+0.40
0.00
R
—
-
+0.40
F
+1.00
R
—
Model
Year
Steering Preferred
LO
—
0.00 + 0.40
N/A
+0.20
+0.00 + 0.40
N/A
+0.40
0.00
0.00+0.40
N/A
+0.40
+0.20
+0.00+0.40
N/A
N/A: Not Available 93461 C66
TIRE,
WHEEL AND BALL JOINT SPECIFICATIONS
OEM
Tire Pressures (psi)
Tires
Wheel
Ball Joint
Inspection
Rear
Size
2001
PT Cruser
P205/55R1
None
32
32
5.5-J
2002
PT Cruser
P205/55R16
None
32
32
5.5-J
Model
Year
OEM: PSI:
Original
Standard
Optional
Front
© ©
Equipment Manufacturer
Pounds Per Square Inch
© Replace
if
any measurable movement
is
found 93461 C67
SPECIFICATIONS CHRYSLER CORP.
1
EH
SCHEDULED MAINTENANCE INTERVALS Chrysler
— PT Cruiser VEHICLE MILEAGE INTERVAL
TYPE OF SERVICE
TO BE SERVICED Engine
&
oil
lev^l,
22.5
30
45
37.5
52.5
R
filter
Brake hoses Coolant
15
7.5
S/I
hoses &
(xIOOO)
60
67.5
75
82.5
90
97.5
y y
y y
y y
y y
y
y y
S/I
y
y
y
y
y
y
y
S/I
V
y
y
y
y
y
y
y y y
y y y y
y y y
y y y y
y y y
y y y
y y y
y y y y y y y y
S/I
V
V
R
y
clamps
CV joints & front
suspension
components Exhaust system
Rotate
S/I
Brake
S/I
linings
R
Lubricate ball joints
Engine coolant
S/I
©
R
PCV valve cables
Camshaft timing R: Replace
© ®
y
R
element
Spark plugs
Ignition
y
/ y
S/I
tires
filter
y
S/I
oil
Accessory drive belts
Air
y
S/I
Manual transaxle
S/I:
belt
®
R
Service or Inspect
Engine coolant flush and replace
at
Camshaft timing
20.000 miles
belt:
replace at
1
100,000 miles.
FREQUENT OPERATION MAINTENANCE (SEVERE SERVICE) If
a vehicle I* operated under any of the following conditions
•
Extremely dusty areas.
•
50%
•
Prolonged
•
Frequent short running periods (engine does not
•
Police, taxi, delivery
Oil
&
or
oil filler
Rotate
Brake Air
more of the vehicle operation
tires
usage or
trailer
la
considered severe service:
32°C (90°F) or higher temperatures, or constant operation
Idling (vehicle operation In stop
and go
In
temperatures below 0*C (32*F).
truffle).
warm
to normal operating temperatures).
towing usage.
change: change every 3000 miles
every 6000 miles
linings: inspect
filter
is In
It
every
1
2,000 miles.
element: service or inspect every 15,000 miles
Automatic transaxle: change
Manual transaxle
fluid:
fluid
&
adjust
bands every 15.000 miles
replace every 15,000 miles
Engine coolant: replace
at
36,000 miles and every 30,000 miles thereafter
9)461 css
Timing belt service
is
covered
in
Section
3
of this
manual
1-52
SPECIFICATIONS CHRYSLER CORP.
SCHEDULED MAINTENANCE INTERVALS DAMILERCHRYSLER CORPORATION CHRYSLER PT CRUISER The In
following should
estimating
how
be used as a guide when determining the amount
• • •
work required
for
a particular service.
Labor Time is time based on field research and data supplied by the vehicle manufacturer. Labor time operations are given in hours and tenths of an hour. All labor operations are to be used as a guide.
Mechanic
Skill
Level Codes:
(A)
PRECISION: Highly
(B)
GENERAL: Normally skilled with certification. MAINTENANCE: Semi-skilled working on certification.
(C)
7500 Mile Service (C) All Models 15000 Mile Service (C) All Models 22500 Mile Service (C) All Models 30000 Mile Service (B) All Models
of
long a particular Scheduled Maintenance Service should take, please observe the following:
skilled with multiple certification.
LABOR
LABOR
TIME
TIME
37500 Mile Service 7 9 8 1.5
All
Models
45000 Mile Service All Models 52500 Mile Service All Models 60000 Mile Service All Models 67500 Mile Service All
(C)
Models
7 (C) 1.0 (C)
9 (B) 1.9
LABOR TIME
75000 Mile Service All Models 82500 Mile Service All Models 90000 Mile Service All Models 97500 Mile Service All Models ..
(C)
9 (C)
9 (B) 1.9
(C)
7
(C)
8 93461C69
SPECIFICATIONS CHRYSLER CORP.
1
EQ
vJU
CHRYSLER CORP. Eagle Talon ENGINE AND VEHICLE IDENTIFICATION Engine
Code
©
Cu.
Liters (cc)
F *
Y
In.
Model Year
Cyl.
Fuel Sys.
Engine Type
Eng. Mfg.
Code©
Year
DOHC DOHC
Mitsubsihi
W
1998
2.0(1997)
122
4
MFI Turbo
2.0(1996)
122
4
MFI
Chrysler
MFI: Multi-port Fuel Injection
DOHC: Double Overhead Camshaft
©
8th digit of the Vehicle Identification
©10th
digit of
the
Number
(VIN)
VIN 93461 C70
GENERAL ENGINE SPECIFICATIONS All
measurements are given
Engine
Engine
Displacement
Series
Year
Liters (cc)
(IDA/IN)
System
1998
2.0(1997)
F
MFI-Turbo
©
2.0(1996)
Y
MFI
140@6000
MFI
in inches. Net
Net Fuel
Torque
Horsepower
@
rpm
rpm
Bore x
Com-
Oil
Stroke
pression
Pressure
@ rpm
(in-)
Ratio
(?)
335x3 46
8.5:1
@4800
3.44x3.27
9.6:1
(ft.
131
@
lbs.)
©
Multi-port Fuel Injection
©Automatic 205® 6000
2100 6000
Manual:
©Automatic: 2200 3000
21403000
Manual:
® ©
1 1
4 psi or more at curb
40
psi or
more
at
curb
idle
idle
speed
speed 3461CM
Heater Core replacement
is
covered
in
Section
2
of this
manual
4 I
"U 4!
SPECIFICATIOMS CHRYSLER CORP
ENGINE TUNE-UP SPECIFICATIONS Idle
Ignition
Engine Displacement
Engine
Spark Plug
Timing
Fuel
Speed
Valve
Gap
(deg.)
Pump
(rpm)
Clearance
Year
Liters (cc)
ID/VIN
(in.)
MT
AT
1998
2.0(1997)
F
0.028-0.030
5B
5B
2.0(1996)
Y
0.033-0.038
©
©
NOTE: The
Vehicle Emission Control Information label often reflects specification changes
HYD: Hydraulic
© ©
Pressure
at idle with
Basic ignition timing
vacuum is
applied to fuel pressure regulator
not adjustable
made
(psi)© 33
AT 750
800
800
38 during production.
MT 750
The
label figures
must be used
if
they
differ
In.
Ex.
HYD HYD
HYD HYD
from those
in this chart.
SPECIFICATIONS
CC
1
CHRYSLER CORP.
CAPACITIES Engine
Engine
Oil with
Transmission (pts.)
Drive
Displacement
Engine
Filter
Axle
Fuel
Cooling
Year
Liters (cc)
ID/VIN
(qts.)
5-Spd
Auto.
(qts.)
Tank
System
1998
2.0(1997)
F
4.6
©
14.2
1.8
16.0
7.4
2.0(1996)
Y
4.5
4.2
182
—
16.0
7.4
NOTE:
All
©2WD 4WD:
capacities are approximate
Add
fluid
gradually and ensure a proper
fluid level is
obtained
4.6 4.8 93461 C73
VALVE SPECIFICATIONS Engine
Seat
Face
Displacement
Engine
Angle
Angle
Year
Liters (cc)
ID/VIN
(deg.)
(deg.)
1998
2.0(1997)
F
44-44 5
45-45.5
2.0(1996)
Y
45
Spring
Stem-to-Guide
Stem
Spring Test
Installed
Clearance
Diameter
Pressure
Height
(lbs.
44.5-45
@
in.)
5461.570 123-137© 1.153
(in.)
(in.)
(in.)
Intake
Exhaust
Intake
Exhaust
1.570
0.0008-
0.0020-
0.2600
0.2560
0.0040
0 0060
0.0019-
0.0029-
0.2336-
02325-
0 0030
0 0040
0.2343
0.2332
1.496
93461 C 74
Brake service
is
covered
in
Section 4 of this manual
1-56
SPECIFICATIONS CHRYSLER CORP.
CRANKSHAFT AND CONNECTING ROD SPECIFICATIONS All
measurements are given
in inches. Connecting Rods
Crankshaft
Engine
Main Brg.
Shaft
Thrust
Journal
Oil
Side
Clearance
End-play
on No.
Diameter
Clearance
Clearance
0.0008-
0.0020-
3
1.7700
0.0008-
0.0039-
0.0016
0.0071
2.0469-
0.0009-
0.0035-
2.0475
0.0024
0.0094
Displacement
Engine
Main Brg.
Year
Liters (cc)
IDA/IN
Journal Dia.
1998
2.0(1997)
F
2.2400
Y
2.0(1996)
Oil
3
0.0020
0.0098
1.8894-
0.0010-
0.0051-
1.8900
0.0023
0.0150 93461 C75
PISTON AND RING SPECIFICATIONS measurements are given
All
Ring
Engine
in inches.
Gap
Ring Side Clearance
Displacement
Engine
Piston
Top
Bottom
Oil
Year
Liters (cc)
IDA/IN
Clearance
Compression
Compression
Control
1998
2.0(1997)
F
0.0012-
0.0098-
0.0157-
0.0039-
0.0016-
0.0008-
0.0020
0.0138
0.0217
0.0157
0.0031
0.0024
0.0089
0.0005-
0.0090-
0.0190-
0.0090-
0.0010-
0.0010-
0.0002-
0.0017
0.0200
0.0310
0.0260
0.0026
0.0026
0.0070
2.0(1996)
Y
Top
Bottom
Compression Compression
Oil
Control 0.0005-
93461 C76
f
SPECIFICATIONS CHRYSLER CORP.
C7
1
*
TORQUE SPECIFICATIONS All readings in Engine
ft.
lbs.
Cylinder
Main
Rod
Crankshaft
Displacement
Engine
Head
Bearing
Bearing
Damper
Flywheel
Year
Liters (cc)
ID/VIN
Bolts
Bolts
Bolts
Bolts
Bolts
Intake
Exhaust
1998
2.0(1997)
F
© ©
94
94-101
14
Y
© ©
©
2.0(1996)
105
—
17
©Step
1:58
ft.
55
Bolts 1-6:
loosen
24
Step
3: 15*ft lbs
Step
4:
Plus 90 degrees
Step
5:
Repeat Step 4
Bolts 1-6
©Step
1:
18
Bolts 7-10: 20
Step
2:
Plus 90 degrees
14.5 ft
lbs.
20
Bolts 7-10:
Step
lbs.
plus
Nuts
18-22
18
65-80
17
20
65-80
ft lbs
2: Fully
®
Lug
Plugs
©Stepl:
lbs.
Step
ft.
Spark
Manifold
Step
© 20
90 degrees
ft lbs
2:
3:
49
ft lbs
ft.
lbs
Plus 90 degrees
ft lbs
plus
90 degrees 93461077
All
BRAKE SPECIFICATIONS measurements in inches unless noted Bake Caliper Brake Disc
Year
Model
1998
Talon
F:
Front
R:
Rear
Minimum
Bracket
Mounting
Original
Minimum
Maximum
Lining
Bolts
Bolts
Thickness
Thickness
Runout
Thickness
(fibs.)
(fibs.)
F
0940
0.882
0 003
0.080
65
54
R
0.390
0.331
0.003
0.080
—
38
93461078
For complete Engine Mechanical specifications, see Section
1
of this
manual
SPECIFICATIONS
1-58
CHRYSLER CORP.
WHEEL ALIGNMENT Camber
Caster Preferred
Year
Model
1998
Talon©®
F
Talon©© Talon©
©
Range
Setting
Range
Setting
(+/-Deg.)
(D^)
(+/-Deq.)
1.50
+4.69
0.50
Axis Toe-in
Inclination
(Deg.)
(in.)
(Deg.)
-0.08
0+/- 0.12
R
—
—
0.50
+1.30
—
F
1.50
+4.69
0.50
-0.35
0+/- 0.13
R
—
—
0.50
-1.69
0.13+/- 0.13
F
1.50
+4.69
0.50
-0.08
0+/- 0.12
R
—
—
0.50
+1.30
—
—
— — —
Front wheel drive
©With
©With
@
Steering Preferred
All
14 inch wheels
16 inch wheels
wheel drive 93461 C79
TIRE,
WHEEL AND BALL JOINT SPECIFICATIONS
OEM Year 1998
OEM: PSI:
Wheel
Ball Joint
Rear
Size
Inspection
Tire Pressures (psi)
Tires
Model
Standard
Optional
Talon ESi
Front
P195/70HR14
None
32
29
5.5-JJ
Talon TSi
2wd
P205/55VR16
None
32
29
6-JJ
Talon TSi
4wd
P215/50VR17
None
32
29
6.5-JJ
© © ©
Onginal Equipment Manufacturer
Pounds Per Square Inch
© Torque
required
in
inch lbs. to rotate ball joint
when removed from
the knuckle 93461 ceo
SPECIFICATIONS CHRYSLER CORP.
1-59
SCHEDULED MAINTENANCE INTERVALS Eagle
—Talon
VEHICLE MILEAGE INTERVAL
TO BE SERVICED Engine Coolant Rotate
&
oil
(Non-turbo)
filter
level,
TYPE OF SERVICE
7.5
15
R
y
S/I
y y y y V
S/I
y
©
hoses & clamps
Automatic fransaxle
fluid level
&
Driveshaft boots
front
y y
45
52.5
60
67.5
75
82.5
90
y
y
y y y y y y y y
y y y y y y y
S/I
y y y y y y y y
S/I
y
y
S/I
y
y y y y
suspension
y
y
97.5
y y y
y y
y
S/I
Brake hoses & disc brake pads
y y y y y
37.5
y y y
V
S/I
y
30
y y y y
S/I
tires
22.5
(xIOOO)
components Air
R
element
filter
Automatic transaxle
fluid
R
& filter©
R R
Engine coolant
Spark plugs
Accessory drive belts
&
Ball joints
S/I
steering linkage seals
S/I
Exhaust system
S/I
Fuel hoses
Manual transaxle
(including
oil
transfer)
Rear axle
oil
(AWD)
Camshaft timing
R
belt
R
cables
Ignition
EVAP & fuel system R: Replace
Service or Inspect
S/I:
(D
Engine
@
Turbo w/A/T only
oil
&
S/I
(Turbo):
filter
change every 5000 miles
FREQUENT OPERATION MAINTENANCE (SEVERE SERVICE) If
a vehicle is operated
under any of the following conditions
it
is
considered severe service:
Extremely dusty areas •
50%
-
Frequent short running periods (engine does not
or
more
of the vehicle operation
Police, taxi, delivery Oil
&
Air
filter
filter
usage or
trailer
is in
32°C (90°F) or higher temperatures, or constant operation
warm
to
in
temperatures below O'C (32*F)
normal operating temperatures).
towing usage.
change: change every 3000 miles
element: service or inspect every 7500 miles
Automatic transaxle
fluid:
change every 15,000 miles
Spark plugs: change every 15,000 miles Disc brake pads: check
more
frequently than every
7500 miles 3M6!Cai
For Accessory Drive Belt
illustrdtions,
see Section
1
of this
manual
1-60
SPECIFICATIONS CHRYSLER CORP.
SCHEDULED MAINTENANCE INTERVALS DAIMLERCHRYSLER CORPORATION EAGLE TALON The In
following should be
estimating
how
used as a guide when determining the amount
• • •
work required
for a particular service.
Labor Time is time based on field research and data supplied by the vehicle manufacturer. Labor time operations are given in hours and tenths of an hour. All labor operations are to be used as a guide.
Mechanic
Skill
Level Codes:
(A)
PRECISION: Highly
(B)
GENERAL: Normally skilled with certification. MAINTENANCE: Semi-skilled working on certification
(C)
7500 Mile Service (C) All models 15000 Mile Service (B) All models 22500 Mile Service (C) All models 30000 Mile Service (B) All models
of
long a particular Scheduled Maintenance Service should take, please observe the following:
skilled with multiple certification.
LABOR
LABOR
TIME
TIME
6 1.9
6 2.1
37500 Mile Service All models 45000 Mile Service All models 52500 Mile Service All models 60000 Mile Service All models 67500 Mile Service All models
(C)
6 (B) 1.9
(C)
6 (B) 2.4
LABOR TIME
75000 Mile Service (B) All models 82500 Mile Service (C) All models 90000 Mile Service (B) All models 97500 Mile Service (C) All models
1.9
6 2.1
6
(C) :...
.6 93461 C82
f
SPECIFICATIONS FORD MOTOR CO.
FORD MOTOR
C-f
1I
U
I
CO.
Lincoln Continental ENGINE AND VEHICLE IDENTIFICATION Model Year
Engine
Code® V
Cu.
Liters (cc)
In.
Cyl.
FuelSys.
Engine Type
Eng. Mfg.
8
SFI
DOHC
Ford
281
4.6 (4593)
Code©
Year
W
1998
OHV: Overhead Valves
X
1999
DOHC: Double Overhead Camshafts
Y
2000
SFI: Sequential Fuel Injection
1
2001
2
2002
® ©
8th digit ol the Vehicle Identification
Number
10th digit ol the Vehicle Identification
(VIN)
Number
(VIN) 93461 C$3
GENERAL ENGINE SPECIFICATIONS Fuel
Net
Displacement
Engine
System
Horsepower
Engine
Net
Torque
6 rpm
Bore x
Com-
Oil
Stroke
pression
Pressure
(in.)
Ratio
6 rpm
Year
Model
Liters (cc)
IDA/IN
Type
0 rpm
1998
Continental
4.6 (4593)
V
SFI
260@5750
27063000
3.55x3.54
9.8:1
3361500
1999
Continental
4.6 (4593)
V
SFI
27565750
275 6 4750
3.55x3.54
9.8:1
3361500
SFI
275 6 5750
275 6 4750
3.55x3.54
9.8:1
3361500
SFI
275 6 5750
27564750
3.55x3.54
9.8:1
3361500
2000
Continental
4.6 (4593)
V
2001
Continental
4.6 (4593)
V
For
Tire,
Wheel and Ball Joint
(ft.
lbs.)
specifications, see Section
1
of this
manual
SPECIFICATIONS FORD MOTOR CO.
1-62
ENGINE TUNE-UP SPECIFICATIONS Engine
Spark Plug
Ignition
Fuel
Idle
Valve
Displacement
Engine
Gap
Timing
Pump
Speed
Liters (cc)
ID/VIN
(in.)
de 9)
ARK
BRAKE
ANCHOR SPRING
ANCHOR
PLATE
SHOE 93006G13
15. 16.
Install the Install
shoe-to-shoe spring.
the retainer spring.
Kelsey Hayes rear brake assembly
(left
side
shown)— Neon
BRAKES
4-11
CHRYSLER CORP.
discoloration or distorted end coils. Replace
UPPER RETURN WHEEL CYLINDER AUTOMATIC SPRING ADJUSTER MECHANISM LEADING SPRING BRAKE SHOE TRAILING BRAKE HOLD SHOE
DOWN
parts as required.
run-out and diameter.
HOLD
must not exceed
(0.064mm)
BRAKE SUPPORT
maximum To
in
0.0025
30 degrees
surface
in.
rotation, or
360 degrees
in
rota-
brake drums are marked with the
drum diameter
allowable brake
on the face
of the
drum.
install:
Lubricate the 8 brake shoe contact
PARK BRAKE
points with high-temperature grease.
LEVER
used on the rear brakes
•The
brake shoe assemblies
trailing
are unique to the
LOWER RETURN SPRING
PLATE
drum
not to specification,
drum braking
either
(0.089mm)
in.
13.
ANCHOR
If
(0.15mm). The diameter variation
in.
(oval shape) of the
tion. All
DOWN CUP
BRAKE SHOE
for cracks or
reface the drum. Run-out should not exceed
0.006
0.0035
CLIP
drums
Inspect the brake
12.
signs of overheating. Measure the
left
of this vehicle
and
right side of
the vehicle. Care must be taken to
ensure the brake shoes are properly Varga rear wheel brake assembly
side shown)
(left
—
Cirrus, Sebring
Coupe. Stratus. Breeze
installed in their correct side of the
vehicle.
shaped prytool through the auto-
larly
matic adjuster access hole and engage
Then
the teeth on the adjuster quadrant.
When
the trailing shoes are
to the trailing
brake shoe assembly. Do
properly installed on their correct side
not attempt to
remove
of the vehicle, the
it
from the
origi-
shoe assembly or reuse the
nal brake
park brake actuating
lever will be positioned under the
rotate the quadrant so the teeth of the
original actuating lever on a replace-
brake shoe web.
quadrant are moved toward the front of
ment brake shoe assembly. All replacement brake shoe assemblies for this vehicle must have the actuating lever as part of the trailing brake shoe
onto the parking brake lever and
the vehicle. This will back off the adjust-
ment
of the rear
brake shoes.
Continue moving the quadrant
c.
toward the front of the vehicle
until
it
the
drum from
the
hub
the parking brake cable from
the parking brake lever.
the actuating spring from the
Do
not
remove the
mechanism and trailing Remove the upper return
adjuster
brake shoe spring from
Install the
assembly
Make sure
to the
rotating
it
leading shoe and
brake support plate
the leading brake shoe
is
Remove the automatic adjuster mechanism from the brake shoe by fully
squarely seated on the brake support plate
extending the adjuster and rotate the
retainer
10.
4.
Reinstall the automatic sell-adjuster
adjuster
16
install the
brake shoe and attaching pin
inward to attach.
from the brake shoe.
lever
Remove
15
Remove
assembly. 3.
Reinstall the parking brake cable
on the leading brake shoe by 9
Remove
4
trailing
assembly.
stops moving. 2.
1
shoe contact areas, and
on the
install the
brake
pm.
retainer
the brake shoes. 5.
Remove
adjuster out to release from the brake shoe. the lower return spring from
To inspect: 1 1
Remove
the brake
shoe
retainer
Thoroughly clean
.
and lining
pin attaching the leading brake
shoe assem-
should show contact across the entire
replace. Clean
Remove the leading brake shoe and adjuster mechanism as an assembly
The brake
parts
all
width and from heel to toe: otherwise,
bly to the brake support plate
and inspect the brake sup-
7.
the
from the rear brake support
port plate
and the automatic adjuster mech-
anism. Be sure the quadrant (toothed part) of the adjuster is free to rotate
adjuster
mechanism cannot be separated its
from the leading brake shoe
until the
removed from the support 8
Remove
entire tooth contact range
is
shoe
trailing
should be
brake adjuster
Remove
its
pin.
attached to the adjuster
and pin attaching the
shoe assembly
length of
Check the knurled
teeth retainer
full
plate.
the trailing brake
to the
spring are unique to the side of the vehicle they are used on. The springs
are colored for identification. The
throughout
and
is free
is
in
It
mounting
18
to
should be securely
mechanism and
good condition.
If
worn or damaged, replace
leading brake shoe
its
brake shoe.
If
the trailing brake shoe
19
the it.
the trailing brake
left
side)
on the
then on the trailing
Reinstall the self-adjuster spring first
then attach
on
it
is
serviceable, lubricate lightly
to
the adjuster.
shoe assembly.
this vehicle, the parking is
first,
brake support plate. the adjuster
actuating lever
Reinstall the upper return spring
(blue, right side, green,
slot
with high-temperature grease between the
•On
left
side springs are green and the right
brake slide the
shoe and the adjuster mechanism
upper brake shoe return spring and adjuster mechanism actuating
side springs are blue.
The
plate.
Reinstall the lower return spring
•The
the brake shoes. 6.
17.
brake
permanently attached
strut
and the quadrant. Check the brake
springs. Overheating indications are paint
For complete Engine Mechanical specifications, see Section
20.
Reinstall the rear brake
21.
Reinstall the wheel
and
the lug nuts in a star pattern
1
of this
manual
drums. tire.
Torque
sequence
to
n
BRAKES
4"i L
CHRYSLER CORP.
I
about 45
and
pattern
Nm), then repeat the
lbs. (61
ft.
final
torque to
95-100
lbs.
ft.
(129-135 Nm). the brake pedal. Brake shoe adjustment
occur the
first
0.006
through the access hole and engage the
(oval shape) of the
teeth
time the brake pedal
ground. This
will
2.
against the braking surface of the rear brake
of
will
3.
not require any type
manual adjustment.
Road
23.
test vehicle to
check
for
away from off
the
the adjustment
proper
the
the
hub
are
the adjusting lever actuating
To
Remove
14.
Thread the adjuster starwheel
which
into the adjuster,
a 2-shoe leading/trailing
self-adjuster
mechanism used on
this
the screw type adjuster.
The
all
the
remove
will
all
Remove
the upper
is
Remove
shoe assembly
is
the brake
shoe hold-down
drum brakes
mechanism do
the
8.
Gen-
the event that
in
install:
Lubricate the 6 brake shoe contact
15.
Reinstall the
wave washer on the
pivot pin of the parking brake actuating
16.
Install the trailing
brake shoe onto
ating lever. 17.
is
Remove
the automatic adjuster from
and
trail-
the brake
Remove
the retaining clip securing
ing brake shoe. 10.
adjustment time. The
down
Remove
shoe hold-
spring and pin attaching the trailing
1 1
Remove
the trailing brake
shoe from
the brake support plate
only one side of the vehicle at a time.
shoe from the parking brake actuating
automatic adjustment
feature of the parking brake system. the brake shoes are
same
the automatic adjuster will
time,
remove
all
slack from the parking brake cables,
make brake shoe
installation
difficult.
Locate and remove the rubber plug
a.
from the brake support plate (backing
lever.
Insert a brake adjuster tool or simi-
shaped prytool through the auto-
matic adjuster access hole and carefully lever out of
engagement with the adjuster starwheel. While holding the lever away from the
shoe and the parking
brake actuating 20.
lever.
Place the leading brake shoe onto
12.
Clean
and
install the
parts well.
all
21.
Reinstall the lower
The brake
lining
22.
and from heel
brake shoe.
to toe; otherwise, replace.
Clean and inspect the brake support plate
and the automatic adjuster mechanism. Be sure the adjuster
is
If
damaged, replace
free to rotate
the adjuster it.
If
is
as to interfere with the installation of the
brake drum.
the adjuster
are paint discoloration or distorted
is
or
ser-
Check end
drums
for
signs of overheating. Measure the
run-out and diameter. reface the drum.
If
24.
Reinstall the rear brake
Check and adjust
cracks or
drum
not to specification,
Run-out should not exceed
to
drums.
the brake shoes as neces-
sary.
25.
Reinstall the wheel
and
the lug nuts in a star pattern
about 45
Replace parts as required. Inspect the brake
Manually adjust the brake shoes
the furthest adjusted position but not so far
throughout
tion with high-temperature grease.
13.
23.
and spring onto the leading
worn
viceable, lightly lubricate the threaded por-
coils.
and upper return
Reinstall the automatic adjuster actu-
ating lever
entire range.
attaching pin and hold-down
spring.
springs.
the brake springs. Overheating indications
plate).
push the adjuster actuating
on
Reinstall the automatic adjuster
the trailing brake
should show contact across the entire width
its
the rear wheel assembly.
and separate the
To inspect:
If
removed from both
sides of the vehicle at the
shoe retaining
the brake support plate in proper position .
shoes, replace the brake shoes from
Remove
pin.
Reinstall the parking brake actuat-
ing lever-to-trailing brake
19.
the trailing brake
plate.
will
install
to
removing the rear brake
extremely
squarely seated on the
clip.
prior to driving the vehicle.
to the
is
shoe hold-down spring on the
hold-down 18.
brake shoe assembly to the brake support
due
brake shoe
trailing
advisable
adjustment procedure must be done
'When
Position the trailing brake shoe onto
the brake support plate and be sure the
support plate shoe contact areas and
the parking brake actuating lever to the trailit
adjustment manually
initial
shoe from
the leading brake
ing brake shoe.
not require manual brake
initial
Remove
brake support plate.
the parking brake actuating lever
shoes are replaced,
speed up the
larly
allow-
the face of the
self-
9.
b.
maximum
with a self-adjusting
shoe adjustment. Although, the brake
to the
actuated each time
the vehicle service brakes are applied.
which
the
drum diameter on
the attaching pin of the parking brake actu-
the support plate.
mechanism
adjuster
is
marked with
lever.
and lower return
spring and pin attaching the leading brake
7.
vehicle
This
in.
rotation. All brake
wheel
mechanism. The automatic
initial
360°
drum.
Remove
tension from the adjuster.
self-adjuster
1. make
30° rotation, or 0.0035
in
with high-temperature grease.
6.
to
in
(0.089mm)
expanding type with an automatic
internal
erally,
surface
in.
(0.064mm)
able brake
springs from the brake shoes. is
0.0025
the leading brake shoe.
5.
drum brake
drum braking
either
points and the brake shoe anchor points
way
rear
must not exceed
the automatic adjuster actuating lever from
4.
The Sebring Convertible’s
in.
drums
drum from
spring from the leading brake shoe.
brake operation.
Sebring Convertible
Remove
assembly.
drums. Brake shoes should now be coradjusted and
back
will
of the rear brake shoes.
is
depressed, pushing the rear brake shoes
rectly
on the adjuster wheel. Rotate the
adjuster wheel upward
Adjust the rear brakes by depressing
22.
(0.15mm). The diameter variation
starwheel, insert a second prytool
pattern
lbs. (61
ft.
and
final
tire.
Torque
sequence
to
Nm), then repeat the
torque to 100
ft.
lbs.
(135
for
proper
Nm). 26.
Road
test vehicle to
brake operation.
check
BRAKES
IQ O
>1
FORD MOTOR COMPANY
1998-01 FORD
MOTOR COMPANY
Brake Caliper
REMOVAL & INSTALLATION Ford Focus 1
.
Before servicing the vehicle, refer to
the precautions
ir^
the beginning of this sec-
tion. 2.
Remove
or disconnect the following:
•
Front wheel
•
Brake hose from the support
•
Outer brake pad retaining clip
•
Brake caliper from the steering
•
Brake pads
•
Brake hose from the caliper
bracket
knuckle
To install: 3.
Install or
connect the following:
Brake hose to the caliper. Tighten
•
the fitting to 11
lbs.
ft.
(15 Nm).
Brake pads
• •
Brake caliper to the steering knuckle. Tighten the bolts to 21 lbs.
4.
Lift
6.
Remove
from the
(28 Nm).
•
Outer brake pad retaining clip
•
Brake hose
•
Front wheel
to the
7.
support bracket
the caliper off of the brake rotor.
5. ft.
If
the inboard disc brake
caliper.
Bleed the brakes and check
for
proper
caliper
FRONT
and allow
8.
Remove
9.
If
4.
14
15
the brake caliper. is
the wheel and
Remove
tire
assembly
16
tie
prevent strain on the brake
spring
the 2 locator pin covers
and
locator pins.
Free the hose from
lbs.
If
mounting on
removed, caliper.
Reinstall the to
20
ft.
2 caliper locator pins lbs.
(28
Nm)
Reinstall the caliper locator pin cov-
Reinstall the outer disc brake
pad
clip.
Reconnect the brake hose
to the front
Bleed the brake system of
air
strut.
install the
Torque the
brake hose
fitting to
10
18
the master cylinder
ft.
(14 Nm).
1 1
its
17
onto the
clip).
Reinstall the caliper over the brake
ers.
not to be serviced,
To install: 10.
the outer disc brake pad
sure that the outboard disc positioned properly.
and position onto the caliper anchor
and torque
to drain.
the caliper
is
plate.
hose.
Remove Remove
spring clip (anti-rattle 3.
rotor
disposal. Disconnect the brake hose at the
off the caliper to
remove the
removed
from the vehicle, place a pan under the
Ford Contour, Mercury Mystique
2.
13.
the brake caliper is to be
Make
brake pad
caliper to catch the brake fluid for proper
operation.
1
12.
pad
19
Position the inboard disc brake pad
If
Top
the brake pedal feels spongy,
repeat the brake bleeding procedure
20
into the caliper.
and
Reinstall the wheel
tire
assem-
the strut.
Positioning the outboard disc brake pad Position of disc brake pad (brake shoe and lining) spring
clip— Contour, Mystique
View
ot
(brake shoe and lining)
inboard disc brake pad (brake
shoe and lining)— Contour. Mystique
For Accessory Drive Belt
illustrations,
see Section
ofl
when complete
tique
1
of this
manual
—
Contour. Mys-
BRAKES
4-14
FORD MOTOR COMPANY
Torque the lug nuts
bly.
to
62
ft.
lbs.
torque to 30
21.
Pump
to position the to
move 22.
brake pads before attempting
and check
tor
Reinstall the guide pin
and the
the wheel and
tire
assembly.
and conduit from the parking brake
lever at
the disc brake caliper, using a pair of pliers. 3. 4.
Remove Remove Lift
19.
If
the brake pedal feels spongy,
Reinstall the wheel
20.
the rear disc brake caliper off of
bly.
Torque the lug nuts
to
and allow the brake 8.
fit-
caliper.
Discard the
Remove
.
move
brake fluid
lbs.
(128
Reconnect the
Fit
rear brake
hose
brake pads before attempting
.
and check
new washers.
the rear disc brake caliper over
the rotor and position onto the anchor plate.
PARKING BRAKE REAR CABLE AND
Before servicing the vehicle, refer to
DOT
in
3.
the beginning of this sec-
or disconnect the following:
Rear wheel
•
Parking brake cable
•
Caliper mounting bolts
•
Brake
•
Brake caliper
fluid
hose
install: Install or
•
Brake
or disconnect the following:
•
Front wheel
•
Brake
•
Caliper mounting bolts
•
Brake caliper
fluid
the
3 or 4
the beginning of this sec-
connect the following:
Use new copper
fluid hose.
washers and tighten the
Remove
the
Check
necessary.
Remove
tion. 2.
Make sure
Before servicing the vehicle, refer to
•
for
Lincoln LS
in
if
the
tion. 2.
test the vehicle
the precautions
to the
rotors.
brake fluid and add
the precautions
To
T87P-2588-A.
move
the brake pedal to seat the
REAR
the vehicle.
Road
22.
1.
Retract the piston fully into the
caliper using
12.
ft.
35
assem-
FRONT
caliper using service tool 1 1
94
tire
the disc brake caliper.
To instaii:
pump
pads against the
proper brake system operation.
fluid to drain.
washers.
10.
Before attempting to
Finish removing the rear brake hose
and washers from the
9.
5.
level of the
the brake pedal several times
erly.
Crack open the rear brake hose
Bleed the -brake system.
1
Pump
21.
to position the
ting
to
and
bolt to
(47 Nm).
lbs.
4.
vehicle,
Nm).
Place a pan under the caliper to
(35 Nm).
vehicle has a firm brake pedal.
catch any lost brake fluid. Dispose of prop-
7.
when com-
the master cylinder
repeat the brake bleeding procedure.
the anchor plate. 6.
off
plete.
cover and remove the locating pin. 5.
Top
air.
Tighten the mounting lbs.
ft.
Front wheel
•
lever.
Properly bleed the brake system of
18.
the cotter pin and guide pin. the caliper locating pin
ft.
ing the parking brake control several times.
the parking brake rear cable
26
Brake fluid hose. Use new copper
•
cotter
Adjust the parking brake by operat-
17.
Remove Remove
caliper.
washers and tighten the
and conduit onto the parking brake
1.
Brake
Reinstall the parking brake rear cable
16.
REAR
connect the following:
Install or
•
pin.
proper brake system operation.
2.
install:
bolts to
15.
test the vehicle
3.
cover.
the vehicle.
Road
Nm).
Reinstall the caliper locating pin
14.
the brake pedal several times
lbs. (41
ft.
To
and
Reinstall the caliper locating pin
13.
(85
Nm).
ft.
bolt to
36
(48 Nm).
Brake caliper. Tighten the mounting
•
hose
REAR DISC BRAKE CALIPER
lbs.
bolts to
25
(33 Nm).
lbs.
ft.
•
Parking brake cable
•
Rear wheel
4.
Bleed the brake system.
5.
Before attempting to
vehicle,
pump
move
pads against the
rotors.
Make sure
level of the
brake fluid and add if
the
Check the
vehicle has a firm brake pedal.
brake fluid
the
the brake pedal to seat the
DOT
3 or 4
necessary.
Ford Taurus Lincoln Continental
Mercury Sable K
CAUTION
On Continentals, the switch, located
in
air
the
suspension
left
side of the
luggage compartment, must be turned OFF before raising the vehicle. Failure to do so in
unexpected
the air springs
may
result
inflation or deflation of tfiat
may
result in
shifting of the vehicle during service.
FRONT 1.
Remove brake
fluid
master cylinder reservoir is 1/2 full.
from the brake
until the reservoir
A HC
BRAKES
*T
FORD MOTOR COMPANY For Continentals, turn the air sus-
2.
pension switch, located
the
in
compartment,
the luggage
OFF
to the
4.
posi-
3.
Remove
4.
Mark is
it
assembly.
tire
the retaining bolt
the wheel and
assembly.
tire
reinstalled in the correct location.
the hollow bolt connecting
plug the brake hose. Discard the 2 copper
Remove
6.
6.
ing pins
rear disc
Retract the disc brake caliper piston
using an old brake
pad or block
of
wood and
a C-clamp.
bolt to
rotate the rear disc brake
piston and adjuster clockwise until fully
•Make
attached to the brake pads.
rear disc brake piston and adjuster face is
Install
the disc brake pads to the
Make sure
are correctly attached to the brake pad plate
Position the disc brake caliper and
9.
pad assembly above the rotor and with a rotating motion.
install
Make sure
it
the inner
sure one of the 2 slots
positioned so
it
will
in
Apply silicone
dielectric
to the inside of the slider pin
inside of the insulators with silicone grease
Torque the locating pins
25
to
(34
lbs.
ft.
Nm).
10.
Remove
the plug
and
install the
1 1
.
pads are
Remove
13.
Install the
torque the nuts to
wheel and
23-26
lbs.
ft.
85-104
assembly,
(115-142
lbs.
ft.
Nm).
Pump
14.
the brake pedal several times
pads prior
to
moving
the vehicle.
pension service switch
Road
16.
to the
test the vehicle
ON
position.
and check
for
proper brake system operation.
.
master cylinder reservoir is
14.
V2 2.
until the reservoir
For Continentals, turn the
the luggage
in
compartment,
the
air
left
to the
sus-
side of
OFF
tion.
posi-
hose
to the caliper
40
ft.
7.
Torque the
Install the
Tire
,
the banjo bolt securing the
the upper brake caliper
wheel and
the
85-104
Place the brake caliper on the
8
mounting bracket and tire
assembly,
lbs.
ft
mount-
and remove from the vehicle
To install:
filling
9
(115-142
slide into position
the upper brake caliper retain-
Install
ing bolt. Torque the bolt to
Nm).
33-43
ft.
lbs
(45-59 Nm).
Pump
the brake pedal several times
to position the brake
pads prior
to
10. Install the brake
moving
caliper
the vehicle. 17.
to the
test the vehicle
ON
air
Torque the banjo bolt to 16-22
sus-
bolt
and check
for
1 1
.
Connect the parking brake cable
Wheel and Ball Joint
and
tire
assembly
and
disc brake pads.
12.
Install the
13
Bleed the brake system
14
Install the
wheel and
tire ft.
assembly. lbs.
(88-118 Nm).
the disc brake pads.
specifications, see Section
to
bracket bolt.
Torque the lug nuts to 65-87 the wheel
lbs
the operating lever. Position the bracket
FRONT Remove Remove
ft.
(22-29 Nm)
position.
Ford Escort
.
to the brake
using 2 new copper sealing washers
For Continentals, turn the
Road
hose
and secure with the banjo
install the
1
the parking brake cable from
Slide the brake caliper oft the
ing bracket
(54 Nm).
lbs.
Bleed the brake system,
torque the nuts to
2.
For
rotor.
and check the
Remove the wheel and tire assembly. Remove the disc brake pads. Remove the parking brake cable
Remove
6
Mercury Tracer
pension switch, located
brake pads to the brake
test the vehicle
retaining bolt.
from the brake
full.
Road
copper sealing washers.
master cylinder as required
18.
fluid
lbs.
brake hose to the brake caliper Discard 2
proper brake system operation.
Remove brake
assembly.
the brake pedal several times
Remove
5
(31-35 Nm)
the cable retaining clip
pension service switch
REAR
Pump
Remove
4
Using new washers, connect the flex
16.
For Continentals, turn the air sus-
15.
1
13.
brake
15.
to position the brake
ft.
the operating lever
Attach the cable end to the parking lever. Install
retaining bolt to tire
tire
aside.
lock and sealer. Install the pin retainers and
on the caliper assembly.
master cylinder as required.
wheel and
bracket bolt and position the bracket
drop of thread-
1
.
3
Make sure
bracket.
and apply
retainer threads
12.
the
.
2
installed correctly.
new copper washers and torque the hollow bolt to 30-40 ft. lbs. (41-54 Nm). filling
Install the
REAR
boots and the
the residue from the pin
brake
Bleed the brake system,
Bleed the brake system.
9.
1
brake hose to the disc brake caliper. Use 2
12.
(22-29 Nm).
disc brake pads.
compound
Position the slider pins and boots in
torque to
11.
lbs.
8.
10.
slider pins.
the brake
Lubricate the locating pins and the
ft.
brake system for proper operation. 9.
the support bracket. Position the caliper
10.
banjo bolt with 2 new
Install the
on the disc brake pad.
assembly on the support
tioned.
16-22
to position the
engage the nib
the outer anti-rattle spring
properly posi-
brake hose to the brake
install the
(88-118 Nm).
the
and outer pads are properly positioned and is
and
7.
1 1
the brake pad insulators
Install the
Torque the lug nuts to 65-87
seated.
'•’Make sure the clip-on insulators are
caliper.
caliper
rear caliper piston adjuster
T87P-2588-A,
tool
(39-49
lbs.
ft.
copper sealing washers. Torque the banjo
Using
8.
fully in the piston bore,
8.
6.
sup-
To install:
install:
2 brake caliper retaining bolts.
Nm).
the disc brake caliper locat-
and boots from the
Place the brake caliper in position
install
Torque the bolts to 29-36
away
port bracket.
motion.
7.
the rear disc brake caliper
Remove
7.
and
the caliper off the rotor using a rotating
To
Lift
caliper.
install:
5.
and
from the rear disc support bracket.
*
the caliper locating pins
the caliper. Disengage the
brake caliper retaining
and remove the brake
To
the retaining clip from the
at
Remove 2
4.
parking brake cable end from the lever arm.
and
the brake hose to the disc brake caliper
sealing washers.
parking brake
the banjo bolt securing the
copper sealing washers.
bolts
Remove
J
brake hose to the brake caliper. Discard 2
ers. 5.
Remove
3.
and dis-
connect the brake hose from the caliper
the disc brake caliper to ensure
Remove
5.
lift
the wheel and
assembly. Discard the copper sealing wash-
tion.
that
Remove Remove
3.
side of
left
I
15
1
of this
Pump
the brake pedal several times
manual
BRAKES FORD MOTOR COMPANY banjo bolt and torque to 30
ting. Install the ft.
(40 Nm).
lbs.
17.
Bleed the brake system and check for
leaks.
Replace the bleeder screw rubber cap.
18.
Install the
wheel and
Torque the lug nuts
85-105
ft.
(115-142 Nm).
lbs.
Pump
19.
the brake pedal several times
pads before the vehicle
to position the brake is
assembly.
tire
a star pattern to
in
moved.
Road
20.
test the vehicle
and check
for
proper brake system operation.
REAR 1
Remove Remove
.
2.
the wheel and
tire
assembly.
the banjo bolt securing the
brake hose to the disc brake caliper. Sepabrake hose from the caliper and
rate the
plug the hose. Discard 2 copper sealing
washers.
Remove
3. 9. 7
Rear Wheel Brake Caliper
1
Rear Disc Brake Adjuster
16.
Release the tension from the parking
caliper.
Rear Brake Operating Lever
8
Snap Ring
3
Brake Adjuster Screw
9
Dust Seal
4
Rear Disc Brake Caliper
10
Piston
5
Wheel Cylinder Bleeder Screw
11
O-Ring
6
Piston Seal
12
Brake Connecting Link
brake cable and disengage the cable end
from the parking brake lever on the brake caliper.
Rear disc brake assembly
—
Hold the disc brake caliper locating
4.
and remove 2 brake pin 5.
Escort, Tracer
Lift
away from pads
brake
to the
ton(s) using a
remove
C-clamp and an old disc
Road
test the vehicle
On
and check the
brake system for proper operation.
6.
single piston calipers, engage the
To
the insulator.
1 1
Remove
.
the wheel and
tire
assem-
bly.
that
it
the disc brake caliper to ensure
be installed to the
will
same
side
Remove
the banjo bolt that connects
Remove and plug
the brake hose.
Discard 2 copper sealing washers. 4.
On
single piston calipers,
remove
the lower brake caliper locating pin. 5.
Rotate the brake caliper approxi-
mately 90 6.
away from the anchor assembly.
Slide the brake caliper
anchor assembly
until the
away from
brake caliper dis-
engages from the upper locating pin and remove from the vehicle. 7.
clip
On
dual piston calipers,
remove the
and washer with the locating pin and
remove the disc brake
To 8.
caliper.
install: If
required,
caliper.
the brake pads are prop-
the caliper pis-
If
required, use Caliper Piston
T87P-2588-A
on the anchor
8.
plate.
recommended thread locking compound on
the threads. Install the
13.
locating pin
Apply a suitable silicone
9.
10.
lower disc brake caliper to
23
ft.
and
lbs. (31
On
ing
dual piston calipers, place the
Install the
Properly
.
Apply a drop
compound
caliper onto the brake rotor.
to
pin
and
clip
by pressing the caliper down
to
locating
23-26
of suitable thread lock-
to the threads of the brake
retainers.
compress the bias springs and the
the disc brake pads
install
pin retainer bolts
disc brake caliper locating
brake caliper locating pins
the disc support bracket.
in
disc brake caliper over the brake rotor with
Install the
seated.
dielectric
to the inside of the locating pin
the brake pads installed and lower the
15.
rotate
anti-rattle clips.
1 1
Nm). 14.
is
boots and the caliper locating pins.
and boots
and torque
and
the tool clockwise until the piston
locating pins are
to the
to rotate the caliper
piston into the caliper bore. Align the tool
compound due
the brake caliper locating
tips with the slots in the piston
and
install the
brake pin
Torque the brake pin retainer bolts ft.
lbs.
(31-35 Nm) while holding
the brake caliper locating pins with an
open-end wrench. 12.
Attach the 'end of the parking brake
pin into position and secure with the washer
cable to the parking brake lever on the disc
and
brake caliper.
clip.
16.
Unplug and
install the
the disc brake caliper using 2
compress
Remove
Adjuster
Rotate the brake caliper assembly
into place
and
the disc brake caliper from the
install:
7.
properly
erly installed.
K»New
the brake hose fitting to the disc brake caliper.
is
if
both calipers are being removed. 3.
the anti-rattle
Make sure
.
12.
Mark
2.
on
installed
FRONT 1
Make sure
10.
assembly
the disc support bracket
pins and boots from support bracket.
upper disc brake caliper locating pin into
Ford Mustang
retainer bolts.
the disc brake caliper
vehicle.
brake pad or block of wood.
rotor.
open-end wrench
pin hex-heads with an 93006G22
to position the brake
disc brake
at the
Spindle
Spring 2
the retaining clip from the
parking brake rear cable
sealing washers,
1
brake hose to
new copper
on each side
of the
fit-
13.
Unplug and
install the
the disc brake caliper using 2
sealing washers on the
brake hose to
new copper
fitting. Insert
the
banjo bolt through both washers and the
A-17I
BRAKES FORD MOTOR COMPANY brake line
and torque
fitting
30
to
(40
lbs.
ft.
torque the
fitting
nut to
10-18
Torque the lug nuts to 85-105
lbs.
ft.
Properly bleed the brake system and
14.
check
Install the
15.
wheel and
Torque the lug nuts
85-105
ft.
assembly.
pads before moving
moving the
and check the
test ftie vehicle
Road
16.
and check
test the vehicle
Lincoln Mark
REAR
VIII
1
FRONT the wheel
and
tire
assem-
connects the brake hose
(if
Lincoln
the wheel
and
tire
assembly.
the brake fitting retaining
from the disc brake caliper and discon-
line fitting that
bolt
to the brake line at
nect the flexible brake hose from the caliper.
the frame bracket. Plug the brake line.
Plug the hose and the caliper
hose and
the retaining clip from the
fitting
brake cable. Disconnect the cable from the
bracket.
caliper.
Remove
the hollow bolt attaching the
brake hose to the caliper and remove
the
ing pins.
brake hose. Discard the sealing washers.
remove the
caliper
may be
To
equipped).
If
right
and
left
air
the pins
reinstalled correctly.
slots
install:
on the
Fully retract piston into caliper bore
7.
Install the caliper
over the rotor with
the outer brake pad against the rotor's brak-
8.
tool are
in the caliper.
meshed
seated
in the caliper
bore
Make sure
that the
locating pins
Install the caliper
and thread them
into the spin-
the caliper locating pins to
45-65
ft.
lbs.
9.
(if
10.
equipped).
Install
new
and
fitting outlet
install the hollow bolt
through the hose
30
and
lbs. (41
ft.
1 1
and
into the caliper.
Torque the bolt
install the retaining clip.
hose 12.
is
to
the bracket
Make sure
the
not twisted.
Remove
connect the brake line to the brake hose and
disc brake caliper guide
the inner
pad
mark the
If
may be
they
5
Lift
right
removing both
and
left
sides so
reinstalled correctly
the disc brake caliper oft of the
anchor plate
To
install:
is
6
in the pis-
Retract the disc brake caliper piston
piston bore, using an old brake
ton slot. 10.
Apply a suitable thread-locking com-
them
ing pins to .
in
7
by hand. Torque the locat-
19-26
Install the
ft.
lbs.
(26-35 Nm).
new gasket on each
and torque
13.
30-40
ft.
lbs.
pad
8
Position the disc brake caliper onto
Make
sure the inner and
and the
anti-rattle spring is properly positioned
The
to
caliper bleed
screw should be positioned on
top of the caliper
when assembled on
the
vehicle.
equipped).
9
tire
Install
2 new
caliper guide pin bolts.
Torque the bolts to 21-26
3 brake fluid from a closed container.
wheel and
C -clamp
outer pads are properly positioned
and adjust the tension
Install the
a
disc brake pads to the
sure that the brake pad insula-
the anchor plate
Bleed the brake system using clean
15.
Make
caliper
side
Connect the brake pad wear sensor (if
wood and
plate
(40-54 Nm).
Connect the parking brake cable
connector
DOT
to
of
Install the
tors are correctly attached to the brake
brake hose on the disc
brake caliper with a
12.
pad or block
to the caliper locating pin threads
start
14
the plug from the brake line,
Remove 2
4
fully in the
the caliper in
over the rotor with a
Make sure
of the fitting outlet. Insert the retaining bolt fit-
Nm).
Place the brake hose
.
rotor with the anti-rattle
Install the caliper
rotating motion.
1 1
sealing washers on each
side of the brake hose
ting
arm.
and
Connect brake pad wear sensor con-
9.
nector
bolt
caliper Plug the brake hose. Discard the
calipers, 10
Place the disc brake caliper assem-
above the brake
pound
(61-88 Nm).
tire
correct side.
properly positioned with the nub
dle/anchor plate assembly by hand. Torque
and
the front wheel
securing the brake hose from the disc brake
pads are on the
spring located on the lower adapter support
icone dielectric grease.
position before
sealing washers
bly
sil-
OFF
Loosen and remove the banjo
3.
the piston. 8.
to the
assembly
with the
ton boot between the inner brake pad and
inside of the locating pin insulators with
right-
luggage compartment,
pin bolts and discard
ing surface. This prevents pinching the pis-
Lubricate the locating pins and the
of the
Remove
2
Be sure
disc pads in the support
Install the
bracket.
suspension, the
air
raising the vehicle
until the piston is
6.
equipped with
must be turned
pads
piston. Rotate the tool clockwise
on the
If
suspension switch, located on the
hand side
plate using a rotating motion.
Adjuster T87P-2588-A
sides so
retention capability and must not be
Place the Rear Caliper Piston
7.
Once removed, these parts
caliper.
1
the disc brake
washers, per
bolt sealing
and 2 banjo
the disc brake caliper locat-
To install:
removing both
FRONT
reused.
the caliper off the brake rotor
Remove
6.
the caliper locating pins and
mark the
calipers,
they
(if
Remove
Lift
and anchor
Disconnect the brake pad wear sen-
sor connector
Remove
5.
Town Car
lose their torque holding ability or
Release the tension from the parking
bracket and disengage the hose from the
5.
for
—Before continuing with this procedure. make sure to have available. 2 new disc brake caliper guide pin bolts
equipped).
Remove
3.
Loosen the brake
4.
and check
Ford Crown Victoria
for
Disconnect brake pad wear sensor
connector
bly.
3.
test the vehicle
Mercury Grand Marquis Remove
.
2.
Remove
Remove
Road
18.
proper brake system operation.
vehicle, to position the
proper brake system operation.
2.
system
brake pads.
Road
.
Verify proper parking brake
17.
lbs.
operation.
brake system for proper operation.
1
brake pads.
assembly.
ft.
Apply the brake pedal several times
15.
4 before
the vehicle. 17.
tire
85-105
to
Apply the brake pedal several times
16.
(115-142 Nm)
the brake pedal several times
to position the brake
wheel and
Install the
14.
lbs.
before moving the vehicle, to position the
3 brake fluid from a closed container.
Torque the lug nuts
(115-142 Nm).
lbs.
Pump
16.
tire
a star pattern to
in
Bleed the brake system using clean
13.
DOT
for leaks.
ft.
(115-142 Nm).
(13-24 Nm).
Nm).
I
Unplug and
assembly
ft
lbs.
install the
the disc brake caliper using 2
For Wheel Alignment specifications, see Section
1
of this
manual
(28—26 Nm).
brake hose to
new copper
O
i
4
BRAKES FORD MOTOR COMPANY
sealing washers on the banjo bolt. Torque
30-40
the bolt to
(41-54 Nm).
lbs.
ft.
Bleed the brake system,
11.
the
filling
DOT 3 12.
brake fluid from a sealed container. Install
the wheel and
Torque the lug nuts
85-104 13
lbs.
ft.
If
tire
equipped with
ON
Pump
position.
the brake pedal several times
pads
to position the brake
prior to
moving
Road
15.
Install the
12.
test the vehicle
and check
for
wheel and
If
equipped with
air
Pump
the caliper. 1 1
ON
position
,
brake pads prior to moving
and check
for
caliper.
must not be
equipped with
air
hand side
of the
must be turned
suspension, the
OFF
position before
raising the vehicle.
Remove
and
the rear wheel
tire
Loosen and remove the banjo
•
Brake caliper
•
Inner and outer brake pads
To
install:
2.
Compress
21
Remove 2
disc brake caliper locating
brake caliper
bolts. Lift the disc
off
the rotor
ft.
using an old brake
fully in the piston bore,
pad or block
of
wood and
Install the
6.
that the
lbs.
to
Brake hose to the support bracket
•
Front wheel
3.
to
remove the parking
Remove
6.
the inner and outer disc
brake pads.
To
install: If
installing
new
disc brake pads, use
T87P-2588-A
or
the brake fluid from
tire
assembly.
room
for the
new brake
the outer disc brake pad clip).
Install the inner
8.
Remove
4.
and outer disc brake
the 2 locating pin covers
and remove the locating pins.
the locating bolts by
hand
lbs.
Unplug and
Install
only.
and
install the
lbs.
start
Torque both
back
Lift
and
tie
it
off to
prevent
damage
drop
1
of a thread locking
similar sealer.
hose.
Remove
agent or
to the brake ,
Apply a small amount
of disc brake
the outboard disc brake pad caliper slide grease to the shaft of the locat-
to
from the anchor
plate.
ing pin. 8.
Remove
the inboard disc brake pad 12.
from the brake
To
30
ft.
lbs. (41
and torque
Nm).
install: 13.
9.
Reinstall the locating pin
caliper.
to
the
Clean the locating pin threads and
the caliper off of the brake rotor
11.
(41-54 Nm).
rear disc brake caliper
into position over the disc brake pads.
the strut.
7.
new copper
filling
mounting on
10.
sealing washers on the banjo bolt. Torque ft.
its
apply
brake hose
Bleed the brake system,
Free the hose from
5.
6.
(22-27 Nm).
the disc brake caliper using 2
Swing the
9.
of the caliper
bolts. Lubricate the
compound.
30-40
and
ton. This will allow
spring clip (anti-rattle
caliper locating bolts with a suitable sili-
ft.
the wheel
pads.
bushings and locating
the bolt to
rear disc brake caliper
the brake rotor and anchor plate.
pads.
over the rotor with a
Clean the inner surface
9.
pin.
piston clockwise, retracting the caliper pis-
rotating motion.
16-20
!4> of
Remove Remove
2.
rotor with the anti-rattle
Install the caliper
bolts to
and guide
the caliper locating pin
the master cylinder reservoir.
spring located on the lower adapter support
dielectric
the cotter pin
similar tool, to rotate the rear disc brake
assembly above the
cone
for
the wheels.
no need
is
7.
Remove
.
and check
the brake fluid from
rear caliper piston adjuster 1
fluid
brake cable or brake hose.
Mercury Cougar (1999-01 model)
Position the disc brake caliper
8.
Vfe of
Swing the
5.
away from
Mercury Mystique
pads are on the
and add
cover and remove the locating pin.
(28 Nm).
FRONT
correct side.
arm.
Remove Remove Remove
4.
•
10. 7.
fluid level in the
fluid reservoir
test the vehicle
Remove
3.
a C-clamp.
disc brake pads on the
Make sure
caliper.
Road
.
There
Retract the disc brake caliper piston
Check the brake
2.
Ford Contour
install:
5.
1
connect the following:
and anchor plate using a rotating motion.
To
to
REAR
the caliper piston into the
Brake caliper. Tighten the bolts
•
Plug the brake hose and discard
both sealing washers.
the brake pedal several times
the vehicle.
20.
Inner and outer brake pads
•
securing the brake hose to the disc brake
assembly.
(85 Nm).
the master cylinder reservoir.
Install or
3.
bolt
tire
lbs.
ft.
proper brake system operation.
caliper bore.
assembly.
62
as necessary.
Outer brake pad retaining clip
•
right-
move 19.
Brake hose from the support
wheel and to
achieve a good pedal before attempting
master cylinder
bracket
luggage compartment,
to the
or disconnect the following:
Front wheel
•
•
suspension switch, located on the
caliper.
to
Remove
.
reused. If
Pump
18.
Focus
Once removed, these parts
retention capability and
Reinstall the
17.
Torque the lug nuts
1
4.
support
pad spring
Reinstall the disc brake
16.
REMOVAL & INSTALLATION
lose their torque holding ability or
3.
to its
strut.
clip.
banjo bolt sealing washers, per
2.
Secure the brake hose
15.
Disc Brake Pads
^Before continuing with this procedure, make sure to have available, 2
1.
and
(28 Nm).
lbs.
Reinstall the caliper locating pin
on the
REAR
ft.
covers.
proper brake system operation.
proper brake system operation.
air
Reinstall the 2 locating pins
13.
torque to 20 14.
test the vehicle
plate.
the rotor.
the vehicle.
Road
anchor
Position the disc brake caliper onto
12.
the brake pedal several times
to position the
Place the outboard disc brake pad
.
into position in the
suspension, turn
the air suspension switch to the 14.
assembly.
(115-142 Nm).
lbs.
ft.
tire
a star pattern to
in
new pads.
Place the inboard disc brake pad into
10.
Torque the lug nuts
push the
or similar tool to
allow room for the
Replace the rubber rear disc brake
.
15.
the vehicle.
from a sealed container.
fluid
bleeder screw cap.
13.
suspension, turn
air
caliper piston into the caliper bore. This will
3 brake
85-104
(115-142 Nm).
the air suspension switch to the 14.
assembly.
a star pattern to
in
a
DOT 1 1
master cylinder as required. Only use clean
C-clamp
master cylinder as required. Only use clean
If
installing
new
disc brake pads, use pin.
Reinstall the guide pin
and the
cotter
BRAKES
>1.1Q H 3
FORD MOTOR COMPANY
I
Adjust the parking brake by operat-
14.
ing the parking brake control several times Reinstall the wheel
15.
Torque the lug nuts
bly.
and
to
62
assem-
tire
ft.
lbs.
(85
Nm). 16. Adjust the parking brake by operating the parking brake control several
times.
Pump
1 7.
move
the brake pedal several times
good pedal before attempting
to achieve a
to
the vehicle.
Check the brake
18.
master cylinder
fluid level in the
and add
fluid reservoir
fluid
as necessary.
Road
19.
and check
test the vehicle
for
proper brake system operation.
Lincoln LS
FRONT
2
3 4
Rear Disc Brake Caliper Anchor Plate
voir.
Guide Pin
is Vfe full.
fluid level in the reser-
Remove brake
fluid until the reservoir
Discard the removed
fluid.
2.
Remove
the wheel and
3.
Remove
the disc brake caliper locat-
tire
assem-
bly.
Parking Brake Lever
ing pins.
Rear disc brake components
the master cylinder reservoir
cap and check the
Anti-Rattle Clip
5
Remove
1.
Rear Disc Brake Rotor
1
the caliper assembly from the
Lift
anchor plate and
— Contour, Mystique
rotor.
Suspend the
4
caliper inside the fender
housing with wire Do not allow the caliper to
hang from the brake hose.
Remove
5.
the inner and outer brake
pads Inspect the rotor braking surfaces
for
scoring and machine as necessary
To install:
Use
6
or block of
C-clamp and an old brake pad
a
wood
to seat the caliper piston
in its bore.
Remove any
7.
rust buildup
from the
inside of the caliper in the brake pad contact
area
8
Install the inner
pad
in
the caliper
piston.
9
outer pad onto the anchor
Install the
Make
plate
sure the clips are properly seated.
Install the
10.
disc brake caliper onto the
anchor plate 1 1
Install caliper locating
.
torque to 26 12.
2
Rear Caliper Piston Adjuster
Nm)
3
Nibs (Part of T87P-2688 A)
4
Piston Adjuster Slots (Part of
Pump
14.
2BS88) Rear Disc Brake Caliper Piston and Adjuster
brake pads to the
9300SG27
tire
85-104
lb
(115-142
the vehicle to position the
Refill the
rotor.
master cylinder reservoir as
necessary, using only clean
and the adjuster tool— Contour. Mystique
assembly and ft
the brake pedal several times
moving
prior to
15
pins and
(35 Nm).
wheel and
torque lugs nuts to
6
of rear caliper piston
Install
lbs.
Rear Disc Brake Caliper
1
Diagram
ft
DOT 3
brake fluid from a closed container.
For Maintenance Interval recommendations see Section ,
1
of this
manual
or 4
BRAKES
4-20
FORD MOTOR COMPANY
REAR 1
Remove
.
the master cylinder reservoir
cap and check the
is
fluid level in the reser-
Remove brake
voir.
Vz
full.
Remove Remove
2. 3.
fluid until the reservoir
Discard the removed the wheel
and
fluid.
tire
assembly.
the disc brake caliper locat-
ing pins at the support bracket.
5.
Remove Remove
6.
Inspect the rotor braking surfaces for
4.
the caliper. the disc brake pads.
scoring and machine as necessary.
To install: Using Rear Caliper Piston Adjuster
7.
T87P-2588-A, until
it
is fully
clockwise
rotate the piston
seated.
Make
slots in the piston face
is
sure one of the
positioned so
it
engage the nib on the brake pad.
will
Install the
8.
brake pads
bracket. Place the caliper rotor into position
Make
the support
in
assembly over the
on the support bracket.
sure the brake pads are installed cor-
rectly.
Install
9.
and torque the disc brake
caliper locating pin to 10.
25
the wheel and
Install
and torque the lug nuts
to
lbs.
(33 Nm).
tire
assembly
ft.
85-104
ft.
Front disc brake caliper, pads and related
Pump
11.
ing pins.
the brake pedal several times
moving the
prior to
brake pads to the 12.
Refill
vehicle, to position the
DOT
if
3 or 4
Road
test the vehicle
and check the
housing with wire. Do not allow the caliper to
Remove
the inner
and outer brake
install:
wood
Remove any
8.
1.
rust buildup in
side of the
left
luggage compartment, must be turned OFF before raising the
is
Vz
may
vehicle. Failure to do so in
unexpected
result
inflation or deflation of
the air springs that
may
result in
from the
pad
in
the caliper
10.
3.
outer pad onto the anchor
Install the
sure the clips are properly
'•Make sure
the master cylinder reservoir
cap and check the
is
fluid' level in
Remove brake
voir.
Vz
full.
2.
On
Discard the removed
fluid.
Continentals, turn the air suspen-
sion switch, located
in the left
luggage compartment, 3.
the reser-
fluid until the reservoir
Remove
to the
the wheel
and
side of the
OFF
position.
tire
assembly.
Remove
12.
Install
13.
the disc brake caliper onto the
23-28
Install
ft.
lbs.
wheel and
torque lugs nuts to
pins and
(31-38 Nm).
85-104
ft.
lb.
(115-142
Nm) 14. prior to
the brake pedal several times
moving the vehicle
brake pads to the 15.
Refill
position.
tire
assembly.
the screw retaining the rail.
the retaining clip from the the disc brake caliper.
at
;
Remove
the upper disc brake caliper
to position the
rotor.
the master cylinder reservoir as
away from
the rotor.
7.
Remove
8.
Inspect the rotor braking surfaces for
To 9.
the disc brake pads.
it
r
install:
Using Rear Caliper Piston Adjuster
T87P-2588-A, until
Pump
OFF
scoring and machine as necessary.
assembly and
tire
suspen-
locating pin at the support bracket. Rotate
plate.
torque to
to the
the wheel and
air
side of the
left
lever.
the insulators are
Install caliper locating
the
in
the cable end from the parking
the caliper
anchor
Remove
Remove Remove
Remove 6.
installed on the brake pads. .
fluid.
Continentals, turn the
parking brake cable
brake
seated.
1 1
1.
On
fluid until the reservoir
Discard the removed
brake hose bracket to the frame side 5.
Make
fluid level in the reser-
luggage compartment,
10.
shifting of the vehicle during service.
FRONT
full.
2.
the brake pad contact
piston.
plate.
the master cylinder reservoir
Remove brake
4.
Install the inner
9.
Remove
cap and check the
area.
switch, located in the
position.
and check the
REAR
sion switch, located
inside of the caliper
For Continentals, the air suspension
ON
test the vehicle
brake system for proper operation.
to seat the caliper piston
in its bore.
CAUTION
3 brake
Continentals, turn the air suspen-
Road
17.
voir.
Use a C-clamp and an old brake pad
or block of
Mercury Sable
On
16.
pads. Inspect the rotor braking surfaces for
7.
Lincoln Continental
DOT
from a closed container.
hang from the brake hose.
To Ford Taurus
necessary, using only clean fluid
the caliper inside the fender
scoring and machine as necessary.
brake system for proper operation.
t'
assembly from the
—Taurus, Continental, Sable
sion service switch to the
Suspend
6.
brake fluid from a closed container.
the disc brake caliper locat-
the caliper
motion. 5.
the master cylinder reservoir
Lift
anchor plate and rotor using a rotating
rotor.
necessary, using only clean
13.
Remove
4.
lbs.
(115-142 Nm).
components
is fully
rotate the piston clockwise
seated.
Make
slots in the piston face will
is
sure one of the
positioned so
it
engage the nib on the brake pad. Install the
brake pads
in
the support
bracket. Rotate the caliper
BRAKES
A
FORD MOTOR COMPANY
H-
91 L I
assembly over
the rotor into position on the support
Make sure
bracket.
pads are
the brake
installed correctly. 1 1
Remove
.
the residue from the rear
brake pin retainer bolt threads and apply
drop of a suitable threadlock sealer.
1
Install
and torque the disc brake caliper locating pin to
23-26
brake
lbs.
ft.
(31-35 Nm).
Attach the cable end to the parking
12.
the cable retaining clip
lever. Install
on the caliper assembly. Position the brake flex
hose and bracket assembly
rail,
and
toll
lbs.
ft.
(16 Nm).
wheel and
Install the
13.
to the side
screw. Torque
install the retaining
and torque lug nuts
assembly
tire
85-104
to
ft.
lbs.
(115-142 Nm).
Pump
14. prior to
the brake pedal several times
moving
the vehicle, to position the
brake pads to the 15.
Refill
rotor.
the master cylinder reservoir
necessary, using only clean fluid
DOT 3
if
Front disc brake pads
brake
—
Escort, Tracer
from a closed container.
On
16.
Continentals, turn the
sion service switch to the
Road
17.
ON
test the vehicle
air
suspen-
moving the vehicle
prior to
and check the
Check the
13.
fluid level in the
cylinder reservoir and
Ford Escort
proper brake system operation
Road
14.
Mercury Tracer
1
the master cylinder reservoir
cap and check the
fluid level in the reser-
Remove brake
voir.
is 1/2 full.
3. 4.
fluid until the reservoir
the wheel
and
tire
assembly
the W-spring.
2 disc brake pad locating
Remove
5.
replace
To 7.
the brake
pads and shims
caliper.
if
needed.
Use a suitable
push the pis-
tool to
Apply a suitable grease between the
to
the brake caliper. Install the
locating pins. Install the
M-spring.
1 1
Install the
wheel and
Torque the lug nuts
to
tire
65-87
ft.
assembly lbs.
fluid until the reservoir
3.
If
and
ft.
Pump
13.
assem-
wheel and
tire ft
assembly. lbs
the brake pedal several times
moving
the vehicle to position the
brake pads. 14.
bly.
necessary, remove the screw plug
Check the brake
fluid level in the
master cylinder reservoir and
and turn the adjustment gear counterclockwrench
screw plug and torque
(16 Nm).
lbs.
Install the
prior to
fluid tire
15.
Road
test the vehicle
fill
if
needed
and check
lor
proper brake system operation.
to pull the pis-
ton fully inward.
4
Remove
5
Using a small prybar, pivot the
on
its If
mounting bracket
to
FRONT WITH SINGLE PISTON
access the
CALIPER
the upper lock bolt requires
lubrication or service, caliper with
Remove
6.
Mustang
the lower brake caliper bolt
remove
it
mechanics
and sus-
To
2 3.
Inspect the brake rotor. Resurface or if
9.
bolts
needed.
reservoir.
Remove the wheel and tire assembly Remove 2 anchor plate mounting
and
lift
the disc brake caliper from the
anchor plate and rotor using a rotating
install:
motion Hang the disc brake caliper from
Apply an appropriate brake pad grease
Pivot the caliper
discard Vi of the brake
from the brake master cylinder
Properly dispose of the used brake fluid
spring and guides. 7.
Remove and
1
fluid
wire.
the brake pads, shims,
on
its
the
body with
caliper
mounting
4.
bracket and position the brake pads, shims,
spring and guides to the brake
the brake pedal several times
12
then loosen the gear Vi
(88-118 Nm).
fluid level in the reser-
the wheel
rotor,
Torque the lug nuts to 65-87
between the shims and the brake pads.
(88-118 Nm).
Pump
Remove
8.
10.
12.
2.
replace
W-spring and 2 brake pad
touch the
just
of a turn. Install the
Discard the removed
full.
pend the
shims and the disc brake pad guide plates
.
Vi
brake pads.
install:
and position the brake pads and shims
9.
is
caliper
ton into the brake caliper bore 8.
for
the master cylinder reservoir
Remove brake
voir
Turn the adjustment gear clockwise
1 1
12
Remove
.
10.
Inspect the brake rotor. Resurface or
6.
and check
ft.
with an Allen wrench until the brake pads
to
wise with an Allen
pins and remove the M-spring.
from the brake
test the vehicle
cap and check the
Discard the removed fluid
Remove Remove Remove
2.
master
as needed.
REAR
FRONT Remove
fill
33-43
(45-59 Nm).
lbs.
brake system for proper operation
1
caliper bolt. Tighten the bolt to
to position the
brake pads.
position.
Do
not
let
the disc brake
Remove
the outer
and inner disc
brake pads and the anti-rattle clip from the
rotor.
disc brake caliper.
Lubricate and install the lower
5.
For Tune-up, Capacities and Firing orders, see Section
wire.
hang by the brake hose
1
of this
Clean any residue from the caliper
manual
BRAKES
4-22
FORD MOTOR COMPANY
anchor plate and disc brake pad contact
pads and the
areas
brake caliper.
6 Inspect the disc brake rotor for scoring and wear. Replace or machine, as necessary.
pads over the
1 1
caliper pin boots
for
bolts to 12.
To install: Use a
large
C-clamp and a
wood
13.
Remove
the insulators
pads,
if
the protective paper from
on the back
ft.
lbs.
of the disc brake
14.
ft.
bolts.
2
Torque the
in
tire
assembly
(115-142 Nm). oppo-
the brake pedal prior to
15.
Fill
Road
and check the
test the vehicle
FRONT WITH DUAL PISTON CALIPER 1
.
Remove and
discard Vz of the brake
from the brake master cylinder reservoir.
fluid
Properly dispose of the used brake 2.
mov-
ing the vehicle to seat the brake pads.
the inner and outer disc brake
17.
a star pattern to
for the
the disc brake calipers were replaced
If
brake system for proper operation.
brake caliper assembly.
Pump
3 brake fluid from a
or repaired, be sure to bleed the system.
(130 Nm).
the wheel and
lbs.
16.
and onto the anchor
Repeat the procedure
site disc
equipped. Install
95
Install
85-105
bore. 9.
rotor
and torque the lug nuts
into block 10. to push the caliper piston back its
the disc brake caliper and
anchor plate mounting
damage. Replace as
necessary.
8.
Install
DOT
closed container.
plate using a rotating motion. Hand-start
Inspect the piston boot and the
7.
.
voir with clean
anti-rattle clip in the disc
3.
Remove Remove
the wheel and
fluid.
assembly.
tire
the clip, washer
and disc
brake caliper locating pin.
the brake master cylinder reser-
Remove
4.
the disc brake caliper from
the brake rotor and the caliper anchor plate.
Hang
the disc brake caliper from the
with wire. 1
A
} (
Do
not
let
body
the disc brake caliper
hang by the brake hose.
Remove
5.
the outer and inner disc
brake pads from the disc brake caliper.
Clean any residue from the caliper
6.
anchor plate and disc brake pad contact areas. Inspect the disc brake rotor for scoring
7.
and wear. Replace or machine, as necessary. Inspect the piston boots and the
8.
caliper pin boots for
damage. Replace as
necessary.
To install: Use a
9.
large
C-clamp and a wood
block to push the caliper pistons back into their bores.
Remove
10.
the protective paper from
the insulators on the back of the disc brake
pads, 1
1
equipped.
if
Install the
.
pads
inner and outer disc brake
Make sure
the disc brake caliper.
in
the pads are seated properly. 12.
the disc brake caliper and
Install
pads over the
rotor
and onto the anchor
plate using a rotating motion.
Make
sure that
the guiding surfaces of the disc brake pads 1
Upper Caliper Brake Bolt
2
Front Caliper Sleeve
3
Insulator
and the anchor bracket are seating
hand
correctly.
Press the disc brake caliper
13.
down by
compress the bias spring and
to
slide
the disc brake caliper locating pin into posi-
4
Caliper Housing (Part of tion.
2B119) 5
Disc Brake Pad Anti-Rattle Clip
Caliper Piston
7
Piston Seal
fated
Install
8
Dust Boot
9
Brake Shoe and Lining
85-105 16.
washer and
the wheel and
17.
ft.
lbs.
in
clip.
tire
assembly.
a star pattern to
(115-142 Nm).
Repeat the procedure for the oppo-
site disc
brake caliper assembly.
Pump
the brake pedal prior to
mov-
10
Front Disc Brake Caliper Anchor Plate
ing the vehicle to position the brake pads.
11
Disc Brake Caliper Locating
voir with clean
Pin
closed container.
18.
Tighten to 88 N-m (65 Lb-Ft)
19. 93006G30
;
Install the
15.
Torque the lug nuts
6
A
Disc brake pads
14.
components
— Mustang with single
If
the brake master cylinder reser-
DOT
3 brake
fluid
from a
the disc brake calipers were replaced
or repaired, be sure to bleed the system.
20. piston caliper
Fill
Road
test the vehicle
and check the
brake system for proper operation.
.
BRAKES
4-23
FORD MOTOR COMPANY
REAR 1
11.
Remove and
.
discard
V2 of the brake
clips
and
12.
Remove Remove
2. 3.
the wheel and
tire
install
the screw retaining the brake
brake rotor into position on the disc support
Make sure
bracket.
the disc brake
Remove
4.
the retaining clip from the
parking brake cable
at
the disc brake caliper.
Release the tension from the parking
5.
13.
pound
Apply a suitable thread-locking comto the threads of the
1.
upper brake pin
Install the
tighten to
6.
23-26
brake pin retainer and
(31-35 Nm) while
lbs.
ft.
Remove 7.
Install the
Remove
away
on the disc brake
Install the
wheel and
Torque the lug nuts
85-105 1 7.
To
ft.
lbs. (11
in
tire
assembly
10.
Repeat the procedure
site disc
18.
T87P-2588-A, clockwise
Remove and
2.
Remove
3.
rotate the caliper piston
Vfe of
the front wheel and
tire
Remove 2
4.
disc brake caliper locating
for the
oppo-
brake caliper assembly
Pump Fill
the brake pedal prior to
DOT
rotor.
Suspend
let
the caliper
5.
Remove
6.
ing
mov-
the brake master cylinder reser-
voir with clean
not
and
the caliper inside
Do
hang by the brake hose.
the disc brake pads from the
caliper.
ing the vehicle to position the brake pads 19.
until the piston is fully seated.
properly dispose
pins and remove the caliper from the anchor
a star pattern to
5-142 Nm).
install:
Using Rear Caliper Piston Adjuster
position before
plate
Inspect the disc brake rotor for scoring
and wear. Replace or machine, as necessary.
OFF
the fender housing with a length of wire.
disc support bracket. 9.
to the
brake caliper. 16.
the inner and outer disc
right-
luggage compartment,
caliper. Install the retaining clip to the disc
rotor.
brake pads and the anti-rattle clip from the
suspension, the
assembly.
the upper brake pin retainer.
Rotate the disc brake caliper
air
the brake fluid from the master cylin-der.
parking brake cable end to
the parking brake lever
from the brake 8.
with an open-end wrench. 15.
pin hex-head with an open-end wrench.
of the
must be turned
caliper.
Hold the disc brake caliper locating
equipped with
hand side
holding the disc brake caliper locating pin
on the disc brake
lever
If
suspension switch, located on the
raising the vehicle.
brake cable and disengage the parking
brake cable end from the parking brake
FRONT air
retainer.
14.
and check the
Mercury Cougar (1998 Model)
pads and
anti-rattle clips are correctly installed.
hose bracket to the shock absorber bracket.
test the vehicle
brake system for proper operation.
Rotate the disc brake caliper over the
fluid.
assembly.
Road
21
disc brake pad anti-rattle
the inner and outer disc
brake pads on the rear disc support bracket.
fluid from the brake master cylinder reservoir.
Properly dispose of the used brake
Install the
Inspect the disc brake rotor for scor-
and wear Replace or machine as neces-
sary.
Observe the minimum thickness
specification
stamped on the
machining
required.
is
rotor
if
3 brake fluid from a
closed container.
(Ensure
that
one
of the 2 slots in the
rear brake piston face it
will
is
positioned so
engage the nib on the back
ot the
20.
If
the disc brake calipers were
replaced or repaired, be sure to bleed the
system.
inner brake pad.
1
Brake Casper Bon
2
Front Casper Sleeve
3
Insulator
4
Otac Brake Caliper
6
One Brake Pad Ann
Rattle
Clp
1
7
Caliper Housing
Front Disc Brahe Caliper Anchor Plate
e
Caliper Piston
7
Ptaton Seal
a
Oval Boor
9 2
Piston Seal (2 Req'd)
3
Caliper Piston (2
4
8
10
9
Req
Clip
d)
Washer
to
Anti-Rattle Clip and Insulator
Dust Boot (2 Req d)
11
Wheel Cylinder Bleeder Screw
5
Front Brake Locating Pin
12
Cover
6
Brake Shoe and Lining
11
Brake Shoe and l rung Front Disc Brake Celper Anchor Plate
Disc Brake CaJtper Locating
pm A
Tighten toil N-m (OOLO-Ft)
Front Disc brake pads and related
Disc brake pads and related components
— Mustang with dual piston
caliper
—Cougar
nents (15 inch wheel)
For complete service labor times, order the Chilton Labor Guide
compo
BRAKES
4-24 To
the disc brake caliper off the rotor
install:
wood
block to seat the caliper piston
Do not allow metal or sharp come into direct contact with piston surface or damage will
caliper
the
Install the correct
8.
to the caliper piston
bend the
to the caliper
marked
for left-hand or
Install the
using care not
machining
to
To outer disc brake to properly
The outer pads are
right-hand installa-
disc brake caliper over the
rotor with the outer brake
pad against the
braking surface. This prevents pinch-
rotor’s
ing the piston boot
between the inner brake
worn,
It
.
2 new locating pin
install
insulators in the disc brake caliper by fabri-
cating a tool for this purpose.
inside of the locating pin insulators with silicone dielectric grease. Install the caliper locating pins
into
assembly by
Torque the caliper locating pins
1. 14.
lbs.
ft.
Install the
85-104 15.
If
ft.
to
(61-88 Nm).
lbs.
lbs.
tire
assembly.
pattern to
in a star
(115-142 Nm).
equipped with
16.
Position Caliper Piston Tool
T87P-
the rear disc brake caliper. Be
sure the pins on the tool are
meshed
If
air
suspension, turn
ON
posi-
the brake pedal prior to
in
make sure
to bleed the
hydraulic brake system. 17.
Fill
DOT
the master cylinder reservoir with
3 brake
fluid
from a closed con-
tainer.
18.
Road
test the vehicle
and check
clockwise
until the piston is
seated
in
Lincoln Mark
the
caliper.
pads
FRONT Install the inner
in
and outer disc brake
Make sure
the support bracket.
tire
1
the
2.
Position the disc brake caliper above
the rotor with the anti-rattle spring located
.
the
3. 4.
Make sure
the inner pad
is
properly posi-
Turn the
switch to the
caliper over the rotor with a rotating motion.
Install
Remove and
discard Vz of the brake
from the brake master cylinder.
fluid
pads are on the correct sides. .
VIII
air
OFF
Remove Remove
suspension service position.
the wheel
and
tire
assembly.
the disc brake caliper pin
retainers from the locating pins
and remove
the caliper from the anchor plate and disc
assembly.
(115-142 Nm).
equipped with
air
suspension, turn
ON
posi-
tion.
Pump
the brake pedal prior to
mov-
ing the vehicle to seat the brake pads. 5.
17.
If
the disc brake calipers were
replaced or repaired be sure to bleed the hydraulic brake system. 18.
clean
Fill
DOT
the master cylinder reservoir with
3 brake fluid from a closed con-
tainer.
19.
Road
test the vehicle
and check
for
proper brake system operation.
REAR If
air
equipped with
air
suspension, the
suspension switch, located on the
hand side
of the
must be turned
right-
luggage compartment,
to the
OFF
position before
1
9
Oise Brake Caliper Housing
10
2
Caliper Piston
3
Brake Piston Seal
4
Piston Boot
Remove and
properly dispose Vz of 5
Front
Wheel Disc Brake
Shoe
Insulator (2 Req'd)
6
Brake Shoe and
7
Front Disc Brake Caliper Anchor Plate
8
Brake Shoe Hold-Down
the brake fluid from the master cylin-der.
3
Remove
the rear wheel
and
tire
assembly.
4
Release the tension from the parking
Rear Brake Pin Retainer (2 Req’d) Disc Brake Caliper Locating Pin
Caliper Guide
1
raising the vehicle.
2
Pm
Excluder
12
Wheel Cylind/r Bleeder Screw
13
Bleed Screw Cap
Lining
A
Tighten to 3 1-38 N-m (23-28 Lb-Ft)
Spring
brake cable and disconnect the parking 93006G33
brake cable from the disc brake caliper.
Remove
for
proper brake system operation.
with
a star pattern to
the air suspension switch to the
16.
mov-
was repaired
the disc brake caliper
or replaced,
clean
result.
tioned.
wheel and
Torque the lug nuts
the wheel and
ing the vehicle to seat the brake pads.
bore.
2588-A on
ft.
Pump
15.
Use a C-clamp and an old brake
9.
If
by hand. Torque the
tion.
wood block to seat the caliper piston in Do not allow metal or sharp objects to come into direct contact with the plastic caliper piston surface or damage will its
85-104
in
(26-35 Nm).
the air suspension switch to the
if
required.
on the lower adapter support arm.
hand. 13.
rotor
lbs.
Torque the lug nuts
14.
pad,
1 1
and thread them
the spindle/anchor plate
45-65
stamped on the
thickness
install:
8.
10.
Lubricate the locating pins and the
12.
is
minimum
Install
ft.
the slots on the piston. Rotate the tool
pad and the piston. 1 1
and wear. Replace or machine, as nec-
specification
tion.
10.
ing
19-26
pins to 13.
inner disc brake
making sure
the anti-rattle clip.
install
and outer disc
Inspect the disc brake rotor for scor-
7.
anti-rattle clips.
Install the correct
9.
pad
the inner
essary. Observe the
result.
pad
Remove
6.
Insert 2 disc brake caliper locating
12.
pins and thread them
brake pads.
bore.
in its
objects to
and
anchor plate using a rotating motion.
Use a C-clamp and an old brake
7 pad.
FORD MOTOR COMPANY
2 caliper locating pins.
Lift
Front disc brake pads and related
components
— Mark
VIII
yf.OC
BRAKES
**
FORD MOTOR COMPANY brake
Suspend
rotor.
the caliper inside the
fender housing with a length of wire. let
not
Remove
Do
necessary.
the inner and outer disc
not exceed the
minimum
Do
necessary.
not exceed the
minimum
allowable thickness stamped on each disc
brake
brake
To
Using a C-clamp and a block
7.
wood
of
1 1
into the caliper
housing
disc brake pads to Install
8.
brake pads
to allow for the
until
Using Caliper Piston Adjuster T87Protate the disc brake caliper piston
seated
is fully
it
pads to
braking surface. This prevents pinch-
caliper piston.
retainers to the locating pins, by
Torque the caliper pin retainers
hand
to
ft.
(22-32 Nm).
lbs.
1 1
.
Install the
Torque the lug nuts
85-105 12.
lbs
ft.
Turn the
13.
Pump
assembly
14
85-105
ing the vehicle to seat the disc brake 14.
If
movpads
15.
16.
1 7.
the brake master cylinder as
needed with clean
DOT
3 brake
fluid
Road
from a
and check
for
proper brake system operation
1
fluid
.
Verify that the parking brake control
released. 3.
switch to the 4.
5.
air
OFF
Remove Remove
the brake pedal prior to
tire
assembly
the retaining clip from the at
the disc brake
Release the parking brake cable ten-
7.
Remove
test the vehicle
and check
lor
sandpa-
C-clamp and an old brake
a
Remove
all
rust buildup
from the
Make sure
8
and
that
is installed
it
Install
Make
brake pad.
not bend the pad clips
126-169
in the
disc brake caliper over the
2 new anchor bracket
bolts.
Torque the bolts to
lbs
ft
(170-230 Nm) wheel and
Torque the lug nuts
12.
If
disc
install
Install the
85-104
piston or distortion
Install the outer
sure the clips are properly
Install the
and
mounting
holding ability or retention capability and must not be reused.
Do
can occur
rattles
10.
their torque
from the lining
the inner disc brake pad to the
during installation
rotor
•Before continuing with this procedure, make sure to have available. 2 new disc brake caliper anchor bracket mounting bolts, per caliper. Once
is
side
Ford Crown Victoria
Town Car
the anti-rattle spring
seated in the caliper lining inspection open-
seated
ft
lbs.
in
tire
assembly.
a star pattern to
(115-142 Nm).
equipped with
air
suspension, turn
the air suspension switch to the
ON
posi-
tion.
13.
Pump
the brake pedal prior to
mov-
ing the vehicle to seat the brake pads. 14.
FRONT
clean If
retainers securing the caliper to the locating
equipped with
air
Fill
the master cylinder reservoir with
DOT 3
brake fluid from a closed con-
suspension, the tainer.
air
suspension switch, located on the
hand side
Please
grit
wood block to seat the caliper piston in its bore Do not allow metal or sharp objects to come into direct contact with the plastic caliper piston surface or damage will
and
the disc brake caliper pin
pins.
Use
6.
caliper piston.
sion and disengage the cable end from the caliper lever.
medium
sure to wear an approved respira-
pad,
ing
brake fluid from a
removed, these parts lose
caliper.
is
To install:
proper brake system operation.
Lincoln
machining
If
tor.
9
DOT 3
rotor thickness speci-
when machining.
Make
per.
movpads
the brake master cylinder as
Road
minimum
Refer to the fication
11.
position.
the wheel and
faces for scoring and machine as necessary.
7
the disc brake calipers were
Fill
and outer disc
the inner
inside of the caliper legs
position.
suspension service
parking brake cable
6.
If
Remove
brake pads. Inspect the rotor braking sur-
result.
Mercury Grand Marquis
Turn the
not allow the caliper to hang from the
suspension service
discard Vi of the brake
from the brake master cylinder.
2. is
air
needed with clean
19.
Remove and
(115-142 Nm).
ON
Pump
assembly
closed container.
REAR
Do
brake hose.
brake system. 18.
test the vehicle
lbs.
tire
a star pattern to
replaced or repaired, be sure to bleed the 1.
closed container. 16.
ft.
in
ing the vehicle to seat the disc brake
brake system. Fill
the wheel and
Turn the
switch to the
the disc brake calipers were
replaced or repaired, be sure to bleed the
15.
Install
Torque the lug nuts
position.
the brake pedal prior to
lbs.
(31-35 Nm).
pattern to
suspension service
air
ft.
the
rotor
using a rotating motion. Suspend the
by hand.
in
Torque the pin retainers to 23-26
(115-142 Nm)
ON
switch to the
in a star
tire
on the support bracket.
pin retainers to the caliper
and thread them
Lift
caliper inside the fender housing with wire.
braking surfaces with
Install the caliper
locating pins
wheel and
disc brake caliper anchor
not necessary, hand-sand the glaze from the
Rotate the disc brake caliper over the
rotor into position
16-23
Check
correctly installed to the slot in the
13.
tire
assembly from the disc brake
5.
on the inner disc brake pad
that the nib
pad and the piston. the disc brake caliper pin
Be sure
with the
the rear disc support bracket.
in
is
Install
the caliper.
meshed
and outer disc brake
Install the inner
ing the piston boot between the inner brake
10.
in
be sure the pads are on the correct sides,
and
the front wheel and
Remove 2
4.
on the piston.
12.
pad against the
Remove
3.
caliper
.
slots
the disc brake caliper over the
fluid.
install:
the pins on the tool are
the caliper.
rotor with the outer brake rotor's
new
the brake rotor
the inner, then outer disc
in
Install
9.
fit
the brake fluid from
bracket mounting bolts and discard.
2588-A,
press the disc brake caliper piston
Vfe of
rotor.
To
install:
position before
assembly.
allowable thickness stamped on each disc rotor.
Remove
2.
runout and wear. Replace or machine as
ing,
OFF
Properly dispose of the used brake
Inspect the disc brake rotor for scor-
10.
to the
the brake master cylinder reservoir.
bracket.
Inspect the disc brake rotor for scor-
must be turned
raising the vehicle.
Remove
9.
runout and wear. Replace or machine as
ing,
away from the disc
rotor.
brake pads from the disc brake support
the outer, then inner disc
brake pads from the caliper. 6.
Rotate the caliper
8.
brake
hang by the brake hose.
the caliper 5.
Do
visit
of the
our web
right-
15.
luggage compartment,
site at
www.chillonsonline.com
If
the disc brake calipers were
BRAKES
4-26
FORD MOTOR COMPANY necessary, hand-sand the glaze from the
braking surfaces with
Make To
medium
grit
sandpaper.
sure to wear an approved respirator. install:
Use a C-clamp and an old brake
8.
wood block to seat the caliper piston in its bore. Do not allow metal or sharp objects to come into direct contact with the pad,
plastic caliper piston surface or
damage
will
result.
Remove
9.
rust buildup
all
from the
inside of the caliper legs. 10.
Install the inner disc
caliper piston.
Do
during installation
and
brake pad to the
not bend the pad clips in
the piston or distortion
rattles
can occur.
Install the
brake pad.
Make sure
the clips are properly
outer disc
seated.
^Make
sure the insulators are
installed on the brake pads. 1 1
Install the
.
disc brake caliper over the
disc brake rotor and install 2 caliper retain-
16-20
ing bolts. Torque to
ft.
lbs.
(22-27
Nm). 12.
Install the
wheel and
Torque the lug nuts
85-104 13.
Item i
2
2.
Description
the air
Bolt (2 Req’d)
ft.
If
lbs.
in
tire
assembly.
a star pattern to
(115-142 Nm).
equipped with
air
suspension switch
suspension, turn
to the
ON
posi-
tion.
the brake pedal prior to
mov-
ing the vehicle to seat the disc brake
3
Rivet (3 Req'd)
4
Wheel Hub
5
Washer
6
Front Disc Brake Rotor
7
Wheel Hub Without ABS
with
Pump
14.
Disc Brake Caliper
pads.
ABS
15.
(2 Req'd)
Fill
DOT
clean
the master cylinder reservoir with
3 brake
fluid
from a closed con-
tainer.
16.
If
the disc brake calipers were
replaced or repaired be sure to bleed the
8
Front Disc Brake Rotor Shield
9
Front
system.
Road
1 7.
10
Wheel Spindle
test the vehicle
and check
for
proper brake system operation.
Front Disc Brake Caliper Anchor Plate Assembly
Brake Drums 93006G83
Exploded view
of the front disc
assembly— Crown
Victoria,
replaced or repaired be sure to bleed the
system. 16.
3.
Town
REMOVAL & INSTALLATION Car,
Remove
Grand Marquis
the rear wheel and
Focus
tire
assembly.
Road
1
test the vehicle
and check
for
proper brake system operation.
4.
Remove 2
Remove
.
disc brake caliper retain-
Rear wheel
•
Wheel speed sensor,
•
Brake drum, bearing and spindle
ing bolts. 5.
REAR
Lift
the disc brake caliper off the disc
brake rotor and anchor plate using a rotat1
air
If
equipped with
suspension, the
air
ing motion.
suspension switch, located on the right-
hand side
of the
must be turned
luggage compartment,
to the
OFF
7.
ing of the brake fluid
from
the brake master cylinder reservoir. Properly
dispose of the used brake
fluid.
Remove
the inner
and outer disc
brake pads.
position before
raising the vehicle.
Remove Vz
6.
Refer to the cation
install:
2.
Install or
•
faces for scoring and
minimum
rotor thickness specifi-
when machining.
If
machining
is
not
equipped
,
connect the following:
Brake drum, bearing and spindle assembly. Tighten the bolts to 49
rotor braking sur-
machine as necessary.
if
assembly.
To
Inspect the disc brake rotor for scor-
and wear. Inspect the
or disconnect the following:
•
lbs.
(66 Nm).
•
Wheel speed sensor,
•
Rear wheel
if
equipped
ft.
1
BRAKES
4-27
FORD9. MOTOR COMPANY Ford Contour
b.
A
forward motion of the tool
wheel and allow the brake shoes to 1
Remove Remove
.
2.
the wheel and the brake
tire
drum
assembly.
retainers,
c.
5.
Grasp the brake drum and remove.
4.
If
the
light force,
be backed a.
drum
will
not slide
off
with
sure the brake
drum and shoes
6.
Position the brake
drum onto
7.
the
the parking brake control sev-
times to adjust the rear brake shoes.
Pump
10.
move 1
the brake pedal several times
good pedal before attempting
to
the vehicle.
Road
.
test the vehicle
and check
for
proper brake system operation.
the
Ford Taurus
wheel hub.
as follows:
Removelhe rubber plug on
Make
eral
to assure a
are clean of any oils or protective coatings.
then the brake shoes will need to off
retract.
the brake drum.
To install:
if
installed. 3.
Remove
Work
will
separate the quadrant from the knurled
Mercury Mystique
Install
new brake drum
retainers
if
Mercury Sable
available.
backing plate and insert a screwdriver or
8.
small brake adjusting tool into the slot to
and
Reinstall the wheel
Torque the lug nuts
to
94
ft.
tire
lbs.
assembly.
(128 Nm).
contact the brake strut and quadrant.
1
Remove Remove
.
2.
and
the wheel
tire
assembly.
the brake drum.
—If the brake drum cannot be removed easily,
remove
the brake tube-to-axle
retention bracket and pry rubber plug
from rear brake backing plate inspection hole. This will allow sufficient
room
screwdriver and disengage brake shoe adjusting lever and back off the brake for insertion of a
brake tools
to
adjuster screw.
3
Inspect the
drum
Machine or
other wear
for
scoring and/or
replace, as necessary.
To install:
Measure the brake drum inside diam-
4
D81L-1 103-A brake adjustment
eter using
gauge.
5
Using the brake adjustment gauge,
adjust the brake shoes to the
sions as the brake
6
same dimen-
drum
Position the brake
drum over
the
brake shoes on the axle hub
7 Positioning a screwdriver to release the brake
Install the
wheel and
lire
Torque the lug nuts to 85-104
shoes— Contour. Mystique
assembly ft
lbs.
(115-141 Nm).
8
Pump
the brake pedal several times
to position the brake
shoes and complete
the adjustment
9
Road
test the vehicle
and check
for
proper brake system operation.
Ford Escort
Mercury Tracer 1
2
Remove the wheel and tire assembly. Remove 2 brake drum retaining
screws 3.
necessary
mum
drum from the hub drum and refinish or replace, as
Pull the brake
Inspect the
If
refinishing,
check the maxi-
inside diameter specification.
To install: 4
If
needed, adjust the brake shoes to
fit
the brake drum.
Retracting the brake shoes to allow
drum removal
5.
Place the brake
6
Install
Torque
— Taurus and Sable
7.
Timing belt service
is
covered
in
Section
3
of this
to
89-123
Install the
manual
drum on
the hub.
2 brake drum retaining screws. inch lbs. (10-14 Nm).
wheel and
tire
assembly.
BRAKES FORD MOTOR COMPANY Torque the lug nuts
to
73-100
lbs.
ft.
(100-135 Nm). 8.
the brake
Check
system
Lower
•
Parking brake cable
cylinder and anchor block
operation.
Brake shoe hold-down springs and
•
Ford Mustang
pins 3.
1
.
2.
Remove Remove
the wheel
and
tire
Brake drum, bearing and spindle
•
assembly.
assembly. Tighten the bolts the
drum
retaining nuts,
equipped, and remove the brake drum. Inspect the brake
drum
and wear. Check the drums
for
to
49
ft.
if
(66 Nm).
lbs.
3.
return spring
Brake shoe assembly to the wheel
•
proper
for
•
•
Wheel speed sensor,
•
Rear wheel
if
equipped
scoring
for conditioning
Operate the brake pedal to adjust the
and wear. Replace or machine as necessary. If
maximum diame-
machining, observe the
ter specification.
To
install:
4.
If
a
installed,
Ford Contour
new brake drum
being
remove the protective coating
1
Remove
.
drum using Brake Adjusting Gauge D81L1103-A.
Remove
2.
the brake drum.
6.
Install
7.
Install the
8.
Complete the brake adjustment by
carefully backing the vehicle
and
tire
drum
retainers,
If
the
light force,
be backed
up several
drum
not slide
then the brake shoes
off
need
lbs.
Brake Shoe Retracting
5
Parking Brake Return Spring
6
Brake Shoe Hold Down
7
Anchor Block
8
Brake Shoe Hold Down Spring Pin
Rear Brake Backing Plate
the rubber plug on the
small brake adjusting tool into the slot to
25
93006GS0
Location ot brake components
(ill N).
test the vehicle
4
9
mum
Road
Rear Brake Shoe and Lining
to
backing plate and insert a screwdriver or
force of
Rear Wheel Cylinder
3
Spring
times while applying the brakes with a mini-
9.
and
Spring
with
will
Strut
if
off:
Remove
a.
will
Rear Brake Quadrant
2
Grasp the brake drum and remove.
4.
assembly.
the brake
equipped. 3.
tire
the rear wheel
assembly.
Adjust the brake shoes to the brake
wheel and
1
Mercury Mystique is
from the drum using brake cleaner. 5.
rear brakes.
and check the
Contour/Mystique contact the brake strut and quadrant.
brake system for proper operation.
b.
A
forward motion of the-screw-
driver will separate the quadrant from the
Brake Shoes
knurled wheel and allow the brake shoes to retract.
Remove the brake drum. Remove the brake shoe hold down springs and the brake shoe hold down pins. 6. Remove the brake shoe retracting
REMOVAL & INSTALLATION
c.
5.
Focus 1
.
Remove
or disconnect the following:
Rear wheel
•
Wheel speed sensor,
•
Brake drum, bearing and spindle
if
equipped
assembly •
springs. 7.
•
Brake shoe hold-down springs and
Disengage the parking brake cable
and conduit from the parking brake 8.
Remove
9.
Disengage the
lever.
the brake shoes. rear brake strut
and
Lubricating points on backing
quadrant from the rear brake shoe.
tour/Mystique
pins •
Brake shoe assembly from the
wheel cylinder and anchor block •
Parking brake cable
•
Lower
return spring
•
Upper
return spring
•
Primary shoe from the strut and brake shoe adjuster
•
Parking brake return spring
•
Secondary shoe from the
strut
sup-
port
To 2.
install: Install or
connect the following:
•
Secondary shoe
•
Parking brake return spring
•
support
Primary shoe to the strut and brake
shoe fully •
to the strut
PLATE
adjuster. Rotate the adjuster
93006G51
clockwise.
Upper
return spring
Removal
of
parking brake cable
— Contour/Mystique
plate— Con-
— A m 9Q “ L.*J
BRAKES FORD MOTOR COMPANY rear brake strut
Engage the
14.
adjuster assembly off the backing plate and
and
wheel cylinder assembly.
quadrant.
adjusting
spring. Reinstall the brake
16.
shoe hold down
down
spring pin and the hold
shoe
into
points.
pin and hold
down
ter— Contour/Mystique
shoe
Discard the horseshoe
retracting
To
20. Adjust the brake shoes by
where
the brake shoes contact the backing
gauge.
plate.
Insert a small screwdriver or similar
.
and quadrant
quadrant
of the
to the
brake
drum by expanding
22.
Trial
of the
of the
adjusting screw and install the socket. Turn the adjusting screw into the adjusting pivot
nut to the limit of the threads and then back
the brake drum The shoes
fit
off Vfe turn.
Assemble the parking brake
10.
properly adjusted.
Make
washer over the socket end
steel
the brake strut
should just contact the drum surface when
23.
of lubricant to the
the adjusting screw. Install the stainless
to adjust the brake
same measurement
shoes
Apply a thin coat
9.
adjuster screw threads and socket end of
brake
and quadrant.
fit
coating of disc brake
with an appropriate brake adjustment
strut
Adjusting the brake shoes to
light
caliper slide grease at the points
tool into the knurled
93006G54
Apply a
8.
first
clip.
install:
measuring the inside drum diameter
21
BEAR BRAKE STRUT AND QUADRANT
slide the lever off the
parking brake lever pin on the trailing shoe.
springs.
Measuring the brake drum inner diame-
the horseshoe retaining clip
and spring washer and
shoe hold down
spring.
Reinstall the brake
19.
93006G53
Remove
7.
rant.
Reinstall the brake
the retracting springs
from the lower brake attachments and upper shoe-to-adjusting lever attachment
the slot on the rear brake strut and quad-
18.
lever.
Remove
6.
spring.
Insert the leading brake
17
When removing
the assembly, be careful not to bend the
Reinstall the parking brake rear
15.
lever to
the trailing shoe by installing the spring
drum and
sure that the brake
brake shoes are clean of any oils or protec-
washer and a new horseshoe retaining
tive coatings.
Crimp the
the
drum— Contour/Mystique
24
Reinstall the brake
25.
Reinstall
new drum
retainers,
brake cable.
rear
may be necessary
to
back
on the park-
off
Position the leading shoe on the
12
cable and conduit to the parking brake lever It
Position the trailing shoe on the
1 1
if
backing plate and attach the rear parking
Reconnect the parking brake
26.
backing plate and attach the lower brake
ing brake cable adjustment to allow for the
shoe adjusting spring
new brake shoes.
shoes.
Reinstall the wheel
27. bly.
and
Torque the lug nuts to 62
tire ft.
13
assem-
lbs.
slots
(85
Work
28
Install the adjuster
ing shoe.
the parking brake control sev-
times to complete the brake shoe
adjustment and
to
end
ted
to the brake
end must
The narrow
fits
into the
slot
fit
in the
on
slot
into the lead-
on the dual
shoe adjusting
The single slotted side
check the parking brake
assembly
on the brake shoes. The wide
the dual slotted
Nm).
eral
clip
retains the lever to the
it
shoe securely.
drum.
available.
BRAKE
clip until
slot-
lever
of the adjuster
93006GS5
assembly must
adjustment as well. Measuring the brake shoe adjustment Contour/Mystique
Pump
29
to assure a
30. 10.
Remove
the parking brake rear
test the vehicle
for
••The adjuster socket blade
proper brake system operation.
trail-
R
is
for the right or L for the left
marked brake
assemblies. The adjuster blade must be installed with the letter R or L in the
brake cable anchor on the trailing brake
Ford Taurus
shoe.
Mercury Sable
1 1
on the
bracket
and check
cable and conduit from the parking
To
into the slots
ing shoe and the rear parking brake cable
the brake pedal several times
good pedal
Road
fit
upright position, facing the wheel
install: .
Lubricate the rear brake shoe contact
points on the backing plate with an appro-
Engage the parking brake
and conduit
13.
rear cable
into the parking brake cable
anchor on the
.
trailing
Position the trailing brake shoe on
the backing plate.
the wheel and
tire
cylinder.
assem-
bly.
3.
Remove Remove
the brake drum.
Remove
the 2 brake
springs and pins. 5.
Lift
Complete the
Pump
is
installation
brake shoes and finish the
brake shoe adjustment.
covered
in
Section
2
by revers-
the brake pedal several times
to position the
the brake shoes, springs.and
Heater Core replacement
the adjuster socket
brake lever.
ing the removal procedures.
15
shoe hold-down
Make sure
into the parking
14
the parking brake cable from
the parking brake lever. 4.
brake shoe.
Remove
fits 2.
priate grease.
12.
1
of this
manual
OH 4 “Oil
BRAKES FORD MOTOR COMPANY
1
Parking Brake Lever Pin
14
Boot
(Inner)
2
Spring Expander
3
Rear Wheel Cylinder
4
Piston and Insert
5
15
Brake Shoe Adjusting Screw Socket
16
Brake Shoe Adjusting Lever
17
Parking Brake Lever Pin
18
Leading Shoe and Lining
19
Brake Shoe Adjusting Screw
Shoe Adjustment Access Hole
6
Wheel Cylinder Retaining
7
Brake Adjusting Hole Cover
8
Brake Shoe Hold-Down
Bolt (2 Req'd)
Spring
16.
20
Cup
21
Washer
Rear Brake Backing Plate
22
Brake Adjuster Screw
Shoe and
23
Washer
24
Parking Brake Lever Retainer
25
Adjusting Pivot Nut
Spring Pin 9
10 11
Trailing
Lining
Brake Shoe Hold-Down Spring
12
Brake Shoe Retracting
13
Parking Brake Lever
Spring
A
Pm
Tighten to 12- 18 N-m
(107-159 Lb-In)
93006G56
Brake shoes and related
Road
components— Taurus and Sable
test the vehicle
and check the
brake system for proper operation.
Use a suitable high temperature
7.
grease to
Ford Escort
screwdriver into the knurled quadrant of the
To install:
lightly lubricate the
contact points on the backing plate.
Mercury Tracer
Position the trailing brake shoe on
8.
and
the backing plate 1
.
Remove
brake shoe
the wheel
and
tire
assem-
install
one
of the
brake shoe hold-down springs.
rear
quad operating
shoes
to the
2.
Remove 2 brake drum
retaining
screws and remove the brake drum. 3. 4.
Remove Remove
2 brake shoe return springs. the right-hand anti-rattle
and
install the
other brake
15.
Install the
16.
Install
right-hand anti-rattle
Install the
brake drum.
2 brake drum retaining
17.
Install the
wheel and
Torque the lug nuts
to
tire
65-87
ft.
assembly. lbs.
(88-118 Nm).
shoe hold-down spring. 10.
as the
screws.
Position the leading brake shoe on
the backing plate
and adjust the
brake drum.
bly. 9.
lever
same measurement
18.
Complete the brake shoe adjust-
ment by sharply applying the brakes sev-
spring.
spring. 1 1
5.
Push and turn
to release
2 brake
shoe hold down springs and remove the
.
12.
Install
2 brake shoe return springs.
Using a brake adjusting gauge, mea-
sure the inside diameter of the brake drum.
eral
times while driving the vehicle
alternating between forward and reverse
gears.
springs. 13. 6.
Remove
the leading
and
shoes from the brake backing
trailing
ment
plate.
14.
Compare
the brake
to the brake
drum measure-
shoes.
Adjust the brake shoes by inserting a
19.
Check
the brake
system operation by
making several stops while driving forward.
BRAKES
4-31
FORD MOTOR COMPANY
Separate the brake shoes by remov-
7.
shoe
ing the brake
Remove
8.
retracting springs.
the parking brake lever pin
and spring washer, then remove the
retainer
brake shoe adjusting lever from the adapter
To
install:
Apply a
9.
light coating of caliper slide
grease to the brake backing plate brake
shoe contact areas as well as the adjuster screw threads.
Assemble the adjuster screw and
10.
the
brake shoe adjusting screw socket and washer. Turn the brake shoe adjusting screw
socket
all
way down, then back
the
trailing
turn.
off
parking brake lever to the
Install the
11.
shoe with the spring washer and a
new parking brake
lever pin retainer.
Crimp
the retainer to securely retain the parking
brake
lever.
Place the trailing shoe on the brake
12.
backing plate and attach the parking brake 1
2
Parking Brake Link Spring
Brake Shoe
HoM-Down Spring
Pin
7
Brake Shoe Hold-Down Spring
8
Brake
Drum Screw (2
9
Brake
Drum
cable.
Req'd) 13.
Install
Rear Brake Backing Plate
10
Brake Shoe Retracting Spnng
Rear Wheel Cylinder
11
Parking Brake Lever
backing plate and attach the lower brake shoe
5
Right
12
Parking Brake Return Spnng
retracting spring
6
Rear Brake Shoe and Lining
13
Brake Adjusting Hole Cover
Hand Anti-Rank Spnng
Place the leading shoe on the brake
14
Install the
down
pin, spring
16
retainers, brake
shoe hold-down springs
Install
Remove the wheel and
tire
assem-
bly.
5.
Lift
adjuster 2.
Remove
3.
Disconnect the parking brake rear
the brake drum.
the brake shoes, springs
oft of
and
the brake backing plate as an
assembly using care not to bend the brake
cable from the parking brake lever
Remove 2 brake shoe hold-down
shoe adjusting 6.
Remove
leading brake shoe hold-
and
retainers.
the brake adjuster assembly
between the brake shoes The
brake shoe adjusting screw socket end
must
and hold-down pins.
between both brake shoes.
15.
— Escort/Tracer
Mercury Cougar (1998 Model)
4.
pin,
4
to the slots
.
hold-down
3
Brake shoes and related components
1
the brake shoe
spring and retainers on the trailing brake shoe
fit
into the slot in the leading
and the adjuster nut end must slots of the trailing brake
brake
17
fit
shoe
into the
shoe and parking
lever. Install the
brake shoe adjusting lever
lever.
the brake
shoe adjusting
screw spring.
on the pin in the
of the leading
shoe and
to the slot
brake shoe adjusting screw socket
18
Install the
upper brake shoe
ing spring in the slot
and the
on the
trailing
retract-
shoe
brake shoe adjusting
slot in the
lever Verify that the brake
shoe adjusting
lever is contacting the starwheel
on the
adjuster assembly
19
Adjust the brake shoes to the brake
drum. 20.
Install the
brake drum.
21
Install the
wheel and
tire
assembly
Using a torque wrench, torque the lug nuts in
a star pattern to
85-105
ft
lbs.
(115-142
Nm).
22
Apply the brakes several times
while backing up the vehicle. After each stop, the vehicle
23.
Road
must be moved forward
test the vehicle
and check
for
proper brake system operation by making Checking the adjustment
of the
brake shoes
— Escort/Tracer
For complete Engine Mechanical specifications, see Section
several stops from varying forward speeds
1
of this
manual
BRAKES
4-32
GENERAL MOTORS
1998-01 GENERAL 7.
Brake Caliper
Remove
the caliper
MOTORS
the rubber dust boots from
mounting
heads
bolt
Road
equipped).
REMOVAL & INSTALLATION 8. 9.
GM
C-
& H-BODIES:
the caliper
Buick LeSabre, Park Avenue
10.
Oldsmobile Eighty Eight Royale,
11.
To
Ninety Eight, Regency
12.
Pontiac Bonneville
(if
the caliper
mounting
bolts.
Remove Remove
Bosch 2U ABS system cannot
for
GM
rear).
E- K-
V-BODIES:
the caliper from the vehicle.
Cadillac Catera, deVille, Eldorado,
the brake pads.
Seville
install: Install the
brake pads. Lubricate the
mounts on
FRONT
the
1
steering knuckle with silicone grease.
increase brake pressure above master
and check
test the vehicle
proper braking performance
the park brake cable from
working on the
slides where the caliper
FRONT & REAR ^The
Remove Remove
recommended
brake system using the the22. procedure.
(if
13.
Install the caliper
over the
14.
Install the caliper
mounting
Torque the mounting bolts
to
38
Remove
%
of the
brake fluid from
the master cylinder.
rotor.
bolts. lbs. (51
ft.
Disconnect the negative battery cable.
.
2.
Remove
3.
Mark
the front wheel.
relationship between the wheel
the
and the
cylinder pressure applied by during
braking. There ize the
no need
is
system prior
depressur-
to
wheel stud
Nm). 15.
Install the
park brake cable
(if
work-
Remove brake
fluid
from the master
cylinder reservoir until the reservoir
approximately 2.
is
the front wheel.
16.
Install the
rubber dust boots over
the caliper mounting bolt heads
Mark
the
17.
prior to removal, for installation reference.
the clearance
2 lug nuts to retain the rotor
once the caliper 4.
piston
is
removed.
Using a large C-clamp, bottom the in
the caliper bore by positioning the
C-clamp on the outboard pad and on the round portion piston 5.
is
of the
brake caliper where the
housed.
Remove
the banjo bolt that fastens
the gaskets. 6.
Cap
keep the rotor
the brake line to avoid excessive
contamination.
Using a large C-clamp against the
5.
is
removal. If
too tight, check the caliper
6.
Place a catch pan under the caliper.
7.
Disconnect the brake hose from the
Cap
leading and trailing edges for build up. File
caliper.
down as
fluid loss or
18.
necessary.
Connect the brake hose
caliper. Install the
to the
brake hose banjo
using new gaskets, and torque to 33
bolt, ft.
lbs.
the lug nuts used to secure
mounting bolts
for
wear and/or damage. Replace
parts as necessary.
To
Install the
the caliper
Inspect the mounting bolts; sleeves
9.
the rotor. 20.
contamination.
and remove the caliper from the vehicle.
and boots
Remove
the lina to prevent excessive
Remove
8.
(45 Nm). 19.
the brake hose to the brake caliper. Discard
fluid loss or fluid
purposes.
into the caliper to provide clearance during
Check the clearance between the
brake caliper and caliper bracket stops.
Install
to
inboard pad, compress the caliper piston
(if
position of the wheel to the wheel studs,
3.
2 wheel nuts
in place.
equipped).
full.
Remove
for re-installation
Install
to service. ing on the rear).
1.
4.
wheel, aligning the refer-
install:
Before installing the caliper,
10.
make
ence marks made during removal, and
sure the piston
torque the lug nuts to 100
and the brake pads are properly seated.
21.
Refill
ft.
lbs.
(140 Nm).
the master cylinder and bleed
1 1
is fully
seated
the bore
in
Lubricate the mounting bolt shafts
.
and inner diameter
of the
sleeves with
sili-
cone grease. 12.
Install the caliper in the caliper
mounting bracket and bolts.
to
38
ft.
Nm).
lbs. (51
13.
mounting
install the
Torque the mounting bolts
Connect the brake hose with the
and new gaskets. Torque the brake hose to
33 14.
ft.
lbs.
Refill
bolt bolt
(45 Nm). the master cylinder and bleed
the brake system. 15.
Remove
the 2 wheel nuts securing
the rotor.
wheel and
assembly.
16.
Install the
17.
Connect the negative battery cable.
18.
Road
tire
test the vehicle for
proper
brake system operation. '
REAR—DEVILLE, ELDORADO SEVILLE 93006G60
Measuring ;he
aliper clearance
Regency, Bonneville
— LeSabre, Park Avenue, Eighty
1.
Disconnect the negative battery
cable. Eight Royale, Ninety Eight, 2.
Remove
%
of the brake fluid
the master cylinder.
from
A
BRAKES
**
GENERAL MOTORS the parking brake lever and the retaining
3.
Remove
4.
Install 2 wheel nuts to keep the rotor
the rear wheel.
21
in place.
5.
Place a catch pan under the caliper.
6.
Disconnect the brake hose trom the
Cap
caliper.
the line to prevent fluid loss or
contamination.
Remove
8.
by
lever, arid
Remove
10.
Lift
the caliper up and slide the
remove the
suitable tool in the caliper pis-
Use a
11.
ton slots to turn the piston and thread
it
the caliper. After bottoming the piston, the inner
edge
Refill
air
Remove and
into
lift
Compress
must
the boot
Inspect the pin boot, bolt boot and
Remove
6.
and replace as necessary. Inspect the bolt sleeve and pin
sleeve for corrosion or damage.
Pull the
roded or damaged sleeves; do not
14.
If
not replaced,
from the caliper and
support)
boot seats
Hold
15.
the. caliper in
sleeve.
As the
it
caliper
the caliper
of the pin
groove, then push the
in
pads
16.
•
not to
damage
down, being
the piston boot
inboard disc brake pad.
17.
boot
of the
careful
18.
20
ft.
19.
1 1
Fill
lbs.
nec-
1
the bolt to
32
ft.
to
Install the
4
Camaro
Remove
%
Matchmark
completely removing the caliper for
replacement or service, bolt inlet fitting
5
of the
tire
brake fluid from
inlet fitting to
prevent system
and torque
parking brake cable onto
for
II
the caliper it
is
must be
corroded, worn or
damaged
inlet fitting bolt for
blockage,
clear or replace as necessary. 7.
8
1
if
Check the
rotor
fluid loss.
see Section
to the
Inspect the guide pins and boots and
replace
inlet fitting to
illustrations,
damage
install:
6
replacement or service,
housing and
order to prevent
in
To
and 2 gaskets from the caliper housing Plug the openings
For Accessory Drive Belt
the caliper housing from the
caliper guide pin
brake lines
bolt, inlet fitting
in the caliper
Remove
2
and mounting bracket
hook
prevent system contamination or excessive
(43 Nm).
the
suspended trom the vehicle using a wire the relationship of the
completely removing the caliper
from the vehicle
fluid loss.
Remove
not being completely removed,
assembly. If
and
bolts
wheel and hub, then remove the wheel and
remove the
parking brake cable
lbs.
.
3.
(27 Nm).
Install the
F-BODY:
2.
and torque
If
housing and
wheel(s).
the master cylinder
If
2 wheel nuts to
2 gaskets from the caliper housing 3 Plug the openings in the caliper
second retaining pin
and bleed the brake system
Install the
Install
remove the brake hose
spring retainer.
rotor
on the bracket abutments.
Install the sleeve bolt
.
Chevrolet
moves
clips.
bracket, with the cable attached,
20.
Install the
assembly.
lire
from the vehicle
Pontiac Firebird
essary, use a small prybar to reseat or enter the pad clips
one
Install the caliper
and hub, then remove the wheel
retain the rotor.
2
Install
12.
and
fit-
Nm)
caliper retaining pin.
9.
the
damage
pad
lbs (16
ft.
Brake pads
10.
After the caliper is in position,
recheck the position
12
the relationship between
Matchmark
1
the wheel
(80 Nm).
lbs.
ft.
Torque the bolts to
Brake caliper pipe Torque the
the brake pedal
contamination or excessive
on the
Compress
sleeve boot by hand as the caliper into position to prevent
caliper.
8.
GM
Pivot the caliper
Brake
vehicle, then with the
pump
REAR
connect the following
Install or
Lower the
12.
caliper
onto the pin.
earlier
Brake caliper
ting to
boot
made
assembly.
•
pin
approaches the pin
tire
slowly and firmly 3 limes to seal then brake
59
over the end of the pin
work the large end
boot,
fully
start
and
the wheel and
install
Caliper mounting bolts
•
the position as
Align the matchmarks
1 1
•
•
sliding the caliper onto the pin sleeve.
removed and
or disconnect the following
engine running
groove. This prevents cutting the pin boot
when
the master cylinder and bleed the
Fill
Brake caliper pipe
small end
in the
10.
to
(40 Nm).
lbs.
ft.
•
over the pin sleeve (installed on caliper until the
fitting,
Brake pads
remove the pin boot
install the
the inlet
Brake caliper spring retainer
7.
away corrosion.
install
brake system.
To install:
try to
removed,
If
and 2 new gaskets. Torque the bolt
•
to the sleeves for
access
to
•
inspection or replacement. Replace cor-
polish
30
to drive the caliper
outside inward.
sleeve boot for cuts, tears or deterioration
boots
bolt
retaining pins out of the caliper from the
To install:
to gain
9.
the pistons into the
punch
down
circlip.
the bleeder screw.
a
Press the caliper housing
8.
compress the bias springs. Slide a new retainer pin into position and install a new
caliper housing to provide clearance.
Use
housing over the
bracket are seated correctly.
caliper.
Open
block-
and onto the mounting bracket. Ensure the guiding surfaces on the inboard and outboard disc brake pads and mounting
Attach a hose to the bleeder screw
4.
Install the caliper
7.
the wheel(s).
3.
inlet fitting bolt for
rotor
1.
on the
Check the
age, clear or replace as necessary.
wheel.
test the vehicle for proper
Road
to the brake
install:
6.
Connect the negative battery cable.
5.
13.
To
install the
damage
lines.
the wheel nuts retaining the
2.
flat.
12.
the master cylinder and bleed
Remove
boot next to the piston
of the
and press out any trapped lay
23.
order to prevent
in
is
must be
hook
REAR—CATERA
caliper from the vehicle.
it
suspended from the vehicle using a wire
26.
caliper inboard off of the pin sleeve to
the caliper
Adjust the parking brake cable.
brake system operation.
the caliper sleeve bolt.
If
not being completely removed,
32
(43 Nm).
25.
up and disengaging the end.
lifting
9.
remove the cable end
retainer pin.
lbs.
rotor
the parking brake cable
and
and mounting bracket.
rotor
bolt
the circlip
the caliper housing from the
22.
24
brake at the equalizer.
mounting
torque the bolt to
the brake system.
Loosen the tension on the parking
7.
and new gaskets and ft.
5.
Connect the brake hose with the
.
Remove Remove
4.
onto the parking brake cable.
clip
Install the caliper
and
into the
Install
of this manual
housing over the
mounting bracket
2 caliper guide pin bolts
start-
BRAKES
4-34
GENERAL MOTORS
9. the upper pin ing with
27
to
and torque the bolts
(37 Nm).
lbs.
ft.
Attach the brake hose to the caliper
using 2 new copper gaskets. Torque the bolt to
22
lbs.
ft.
10.
If
(30 Nm).
the hose fitting
was removed,
bleed the entire brake system. 1 1
Lower the vehicle
.
sufficiently
and COAT BUSHING ASSEMBLY WITH SILICONE GREASE
cycle the parking brake.
PLACES
2
12.
Raise and safely support the vehicle.
13.
Inspect the caliper parking brake
levers
93006G89
Caliper mounting bolt and sleeve lubrica-
and ensure they are against the stops
points— Riviera, Aurora
tion
on the caliper housing. on
If
the levers are not
Compressing the
front caliper
piston— Riv-
check the parking brake
their stops,
Aurora
iera,
14.
and
15.
brake
the 2 nuts securing the
then align the matchmarks
rotor, lier
Remove
made
the wheel assembly.
install
Lower the
Check
contamination.
the piston into the caliper
Remove Remove
the hydraulic
system
8.
the caliper
mounting
9.
remove
G-BODY:
To
FRONT
%
Siphon
3.
Remove Install
the rotor
the
tire
is
Seat the caliper piston Install the
Install the caliper
38
ft.
in
the caliper
Ver-
rotor.
and disconnect the brake
1
63
lbs.
ft.
2.
Remove
3.
Install
to
tire
and wheel assembly.
when the caliper is removed. Remove the bolt securing the brake
4.
hose
to the
the
the
2 wheel nuts loosely to secure
to the caliper
hose from the
new washers. Torque
of the brake fluid out of
the rotor
(85 Nm).
Reconnect the brake hose
caliper using
%
Siphon
.
the master cylinder reservoir.
on the anchor
Nm). Torque the mounting
lbs. (51
removed.
the bolts securing the brake
to the caliper
hose from the
pads against the
pedal.
fully in its bore.
Torque the caliper mounting bolts
13.
14.
hose
brake pads
bracket and install the mounting bolts.
and wheel assembly.
the caliper
Remove
the brake pedal several times
REAR
10.
bolts to 4.
lbs.
no hydraulic leaks and a good firm brake
ify
pads from the caliper or
the brake
11.
12.
2 wheel nuts loosely to secure
when
Pump
18.
anchor bracket.
or of the brake fluid out of
the master cylinder reservoir. 2.
being replaced
install:
Oldsmobile Aurora
.
is
ft.
anchor bracket.
Buick Riviera
1
the caliper
assembly
100
the master cylinder with fluid
Refill
to seat the brake
If
tire
to
and bleed the brake system.
the caliper from the anchor
leaks.
wheel and
Install the
(140 Nm).
for
bracket.
GM
16.
17.
bolts.
the 2 lug nuts securing the
rotor.
and torque the wheel nuts
bore to provide clearance for removal.
firmly 3 times to seat then brake pads.
16.
fluid
the brake pedal slowly 7.
and
and possible
Compress
6.
vehicle, then with the
pump
engine running
Plug the hose to prevent excessive
5.
earfluid loss
Remove
15.
adjustment.
fit-
and disconnect the brake
caliper.
Plug the hose to prevent excessive
5.
fluid loss
and possible
fluid
contamination.
caliper.
ting bolt to
33
ft.
lbs.
(45 Nm).
6. 7.
Remove the park brake cable Remove upper and lower caliper
and
bolts
To
caliper from
lift
mounting bracket.
install:
8.
Seat the caliper piston
9.
Make
fully in its bore.
sure the notches
in
the caliper
piston are at 6 and 12 o’clock. 10.
Mount
Install the
bolts to 1 1
.
63
ft.
lbs.
(85
Nm)
Reconnect the brake hose
to the
new copper washers. Torque
caliper using
the
caliper onto anchor bracket.
2 mounting bolts and torque
mounting
bolt to
12.
Install the
13.
Remove
33
ft.
lbs.
(45 Nm).
park brake cable.
the wheel nuts securing the
rotor.
14.
Reinstall the tire
and wheel assembly
and torque the wheel nuts (1)
Pin Bolts
(2)
(4)
Outboard Pad Caliper Boot inboard Pad
(5)
Piston Seal
(3)
(140 Nm). (6)
Piston
(7)
Anchor bracket
15.
(9)
Caliper Housing
16.
Anchor Bracket
-Riviera, Aurora
ft.
lbs.
the master cylinder with fluid
Pump
the brake pedal several times
to seat the brake 93006G87
Front caliper and brake pad components-
100
and bleed the brake system.
(8) Bleeder Valve
(10) Caliper
Refill
to
,
ify
pads against the
rotor.
Ver-
no hydraulic leaks and a good firm brake
pedal.
BRAKES
4-35
GENERAL MOTORS
GM
J-BODY:
Chevrolet Cavalier Pontiac Sunfire 1
.
Siphon
%
of the brake fluid out of
the master cylinder. 2.
6
Remove
3.
Compress
the
and wheel assembly
tire
the caliper piston back into
the caliper bore using a large pair of pliers.
C-clamp or special piston 4.
the caliper
If
retracting tool.
be completely
to
is
removed from the vehicle
bench service,
for
disconnect and cap the brake line from the Discard the old washers.
caliper. 5.
Remove
the caliper
mounting bolts
and sleeves. 10. 7.
Remove Remove
caliper,
the caliper from the knuckle. the brake pads from the
caliper
if
is
being replaced.
To install: brake pads in the caliper.
8.
Install the
9.
Install the caliper
on the steering
knuckle. Install
the mounting bolts and
40
sleeves and torque to 1 1
If
1
2
3 4
5
6 7
8
9
sleeve
ear
OUTBOARO SHOE A LINING INBOARD SHOE A LININC PAD CLIP WEAR SENSOR PIN BOOT
PIN BOLT
11
PIN SLEEVE
13
PISTON ASSEMBLY
14
PISTON SEAL
the mounting bolt to 12.
8LEEOCR VALVE CAP BLEEOER VALVE 17 LEVER RETURN SPRING 18 BOLT ANO WASHER 19 CABLE SUPPORT BRACKET 20 CALIPER BODY ASSEMBLY 2t caliper support
35
ft.
lbs.
(44 Nm).
master cylinder and bleed
Refill the
IS
the brake system
13
—
Install
and tighten 14
GM
Rear caliper and brake pad components
to
new copper washers. Torque
the caliper using
16
BOLT BOOT SLEEVE BOLT BOLT SLEEVE
to
12
Nm).
was discon-
uncap and connect the brake hose
nected, PISTON BOOT
lbs. (51
ft.
the caliper brake line
the
tire
and wheel assembly
to specification
Verify correct brake operation
L/N and N-BODY:
Buick Skylark Riviera. Aurora
Chevrolet Malibu
Oldsmobile Achieve. Cutlass
SHOE
Sc
Am
Pontiac Grand
PISTON SLOTS MUST BE ALIGNED AS SHOWN BEFORE INSTALLING CALIPER OVER
1
LININGS
Siphon
%
of the brake fluid out of
the master cylinder
2
Remove
3
Compress
the
tire
and wheel assembly.
the caliper piston back into
the caliper bore using a large pair of pliers.
C-clamp or 4
Plug the hose to prevent excessive
fluid loss
6
and possible
Remove
and remove the PISTON BOOT
7
PISTON ASSEMBLY
Remove
caliper,
CALIPER BODY
8 in
the piston
if
fluid
the caliper
caliper from the knuckle.
the brake
the caliper
is
pads from the
being replaced
— Riviera. Aurora
Inspect the condition of the caliper
support
for rust
and corrosion
der the travel of the caliper.
For
Tire,
Wheel and Ball Joint
contamination.
mounting bolts
To install:
ASSEMBLY Aligning the notches
the brake hose from the
and discard the copper washers.
caliper
5
special piston retracting tool
Remove
specifications, see Section
1
of this
manual
that will hin-
BRAKES
4-36
GENERAL MOTORS
9.
Inspect the caliper mounting hard-
New
ware.
bolts are usually
recommended.
Lubricate the mounting bushings and
10.
sleeves with silicone grease as required.
2 wheel nuts to retain the
4.
Install
BUSHING
a large C-clamp over top of
and against the back
the caliper housing
Install
the brake pads in the caliper.
the outboard shoe. Slowly tighten the C-
12.
Install
the caliper on the steering
clamp
13.
40 14.
mounting
the
lbs. (51
bolts
and torque
Connect the brake hose
mounting
bolt to
Refill
35
ft.
5.
to the caliper
lbs.
(44 Nm).
the master cylinder
6.
7.
the
8.
and wheel assembly.
16.
Install
Verify correct brake operation.
tire
If
the caliper
93006G61
prevent brake
the caliper
Buick Century, Regal
To
Chevrolet Lumina, Monte Carlo
10.
bolts.
is
to
Intrigue
1 1
Pontiac Grand Prix If
.
remove the brake pads from the mounting bracket.
bush-
FRONT
found, replace the slide bolts installing the brake
caliper assembly. of the brake fluid
from 12.
Before installing the caliper,
make
the master cylinder assembly.
sure the piston(s) are seated 2.
Mark a
Remove
the
tire
and wheel assembly.
and
that the brake
in
the bore,
pads are correctly
relationship between the wheel and installed.
the wheel stud for re-installation purposes. 13.
]
CALIPER SLIDE BOLT
7
OUTBOARD SHOE
3
LINING INBOARD SHOE & LINING Si
7
BUSHING ASSEMBLY CALIPER BOOT
B
PISTON
»Be sure that the insulation on the EGR tube aligns with and contacts the
ing: •
Negative battery cable
•
Engine cover from the top
insulation on the
of the
vacuum harness
at
the rear of the engine. Rotate the
intake manifold •
tube. Torque the
intake manifold
Drain the cooling system.
3.
EGR
wide-open position and reconnect the speed control and
throttle lever to the
Accelerator and the speed control
Upper intake manifold loosening and
cable from the throttle lever
ening sequence
tight-
—3.2L and 3.5L engines
throttle cables.
C-| 9
CHRYSLER CORPORATION CONCORDE •
PCV
•
Air cleaner
•
Ground wire
•
valve hose
to the intake
•
plenum
Throttle
10. •
Fill
INTREPID
hous-
the engine
Inspect the manifold for
Remove
filter.
verify correct
or disconnect the following:
To
install:
•
Exhaust system
5.
Install or
•
V-band clamps and
left
New
•
catalytic
torque to 15
Remove
4.
rotate the transaxle dip-
or disconnect the following:
2.7L Engine
RIGHT MANIFOLD
•
Oxygen (O 2 S) sensor
•
Engine
oil
ft.
ft.
(15
lbs.
•
HO 2 S
•
Negative battery cable
sensor
Nm)
connector
electrical
Operate the vehicle and inspect for
6
Front Crankshaft Seal
fold
To install:
tion.
Remove
or disconnect the following:
•
Negative battery cable
•
Air intake
plenum and
Remove
5.
•
•
filter
Exhaust manifold and new gasket
Battery cable housing tube-to-
and torque the bolts (23
Ehaust Gas Recirculation (EGR)
outward
valve and tube
Oxygen (O 2 S) sensor
•
V-band clamp from the manifold
lbs.
O 2 S sensor
•
Transaxle dipstick tube
O-ring
lbs.
for the
(12
•
traces of the old manifold
engine
dipstick
•
To
install:
4.
Install or connect the following:
(10
to
new V89 inch
Nm)
Engine wiring harness support bracket to the cylinder head
Exhaust manifold and new gasket.
Torque the bolts
17
to
Nm) working from
ft.
lbs.
utilize
in this
timing
section.
•
Exhaust system
•
Negative battery cable
belt
removed from the vehicle service.
Catalytic converter with a
lbs.
procedure later
Note that the timing
oil
band clamp and torque
faces.
engines that
chains, please refer to the applicable
3.2L and 3.5L Engines
Nm)
tube and tube
Exhaust manifold
procedures
REMOVAL & INSTALLATION
•
gasket and clean both gasket mating sur-
•
ft.
Heat shields and torque the bolts to
•
all
17
•
Heat shield
Remove
to
front crankshaft seal
are tor timing belt equipped engines
working from the center
105 inch
*»Do not reuse the V-band clamps.
•
Nm)
transaxle bolt
•The
only. For
connect the following
Install or
6.
•
•
•
traces of the old manifold
all
gasket and clean both gasket mating surfaces the air
housing
3.
to 21
Nm)
Exhaust manifold bolts and mani-
•
the precautions in the beginning of this sec-
2.
(28
exhaust leaks
fold heat shield
Before servicing the vehicle, refer to
and torque the nuts
lbs
screws toll
and mani-
dipstick tube
fold
Heat shield and torque the retaining
•
Engine wiring harness support bracket from the cylinder head
Nm)
(20
lbs.
ft.
Exhaust pipe to the exhaust mani-
•
Loosen and
3.
connect the following:
manifold gasket and exhaust
manifold to the cylinder head and
not reuse the V-band clamps.
•
1.
traces of the old manifold
all
faces.
stick tube out of the way.
REMOVAL & INSTALLATION
or
required.
Negative battery cable
converter
»Do
Exhaust Manifold
if
Remove
4.
•
engine
operation.
damage
for distortion against a
gasket and clean both gasket mating sur-
Test run the engine, check for fuel
and coolant leaks and
in
Check
manifold
the beginning of this sec-
tion. 2.
and
oil
VISION
straight-edge or thickness gauge. Replace
Before servicing the vehicle, refer to
.
•
Exhaust manifold bolts and mani-
•
3.
LEFT MANIFOLD
and bleed the cooling system.
Change
9.
•
fold
the precautions
body purge tubes
Negative battery cable
•
300M
Negative battery cable
•
1
fitting
Intake manifold plenum cover
8.
•
cracks.
Brake booster hose to intake manifold
air filter
LHS
ing
manifold
plenum •
plenum and
Air inlet
plenum and plenum hose
•
Use care
marks are
all
be sure
perform this all
valve timing
carefully aligned both before
removing the
and
to
must be
to
belt
and
after belt installation
service has been completed
It
may
be good practice to set the engine to Top
Dead Center (TOC) No.
1
cylinder compres-
(23
the center out-
3.2L and 3.5L Engines
ward. •
Heat shields and torque the bolts to
105 inch •
•
•
lbs.
(12
Nm)
New V-band clamp and torque 100 inch lbs. (11.3 Nm) O 2 S sensor EGR valve and tube using new kets, then torque to
95 inch
to
Before servicing the vehicle, refer to
gas-
Remove
lbs.
•
Exhaust pipes from the exhaust manifold
Heated Oxygen (HO 2 S) sensor electrical
and
(101
or disconnect the following:
Negative battery cable
• ft.
the beginning of this sec-
•
•
torque the bolt to 75
in
tion.
lbs. (11
Battery cable tube-to-transaxle
Nm)
.
2.
Nm) •
1
the precautions
Removing
wiring
Heat shield-to-exhaust manifold
crankshaft— 3 21 and 3.5L
engines
screws
For complete Engine Mechanical specifications, see Section
the timing belt sprocket dowel
pin Irom the
1
of this
manual
CHRYSLER CORPORATION
5-14
CONCORDE
•
LHS
300M
•
sion stroke (firing position) and aligning
all
•
INTREPID
This serves as a reference for
all
sprocket onto crankshaft.
hammer on
work
Verify that
that follows.
Before servicing the vehicle, refer to
1.
VISION
at the
the precautions
DO NOT
an equivalent setup to pull the
9.
timing marks before removing the timing belt.
•
all
Do
the sprocket.
valve timing marks are
Timing
•
belt
Properly relieve the fuel system
2.
Rotate the crankshaft 2 complete
10.
3.
Drain the cooling system.
camshafts and crankshaft. The marks must
4.
Remove
align with their respective locations.
or disconnect the following:
marks do not
•
Negative battery cable
•
Radiator and cooling fan
module
When
timing has been verified,
assembly •
Accessory drive belts
•
Crankshaft damper
•
Timing
belt front
If
cover
may be
and torque the
85
ft.
be removed. Use silicone rubber adhe-
•
crankshaft
belt
and tensioner. Refer
to
the appropriate section for the
removal and installation procedure
Assemble
4.
to
the chain on the
camshafts. Ensure the plated links are fac-
the proper tension
1.
Tensioner and chain from the
To install:
•
Radiator and cooling fan assemblies
ing toward the front. Align the plated links
•
Negative battery cable
to the dots
sealer.
Timing
tensioner as an assembly
lbs.
Accessory drive belts and adjust
•
•
Camshafts, secondary chain and
•
bolt to
the reverse order of
in
Bearing caps
•
timing
(115 Nm).
reusable and should not
sive sealant to replace any missing
Slowly loosen the camshaft bearing
the tightening sequence.
shaft damper, using tool L-3281,
cover
sealer on the timing belt front
Second chain tensioner mounting
Crankshaft damper. Hold the crank-
•
•The
•
bolts
belt covers.
bolt
Primary timing chain
cap retaining bolts
correct valve
install the
or disconnect the following:
•
3.
the
align, repeat the timing belt
installation procedure.
Remove
2.
turns and recheck the timing marks on the
pressure.
locating the
and tensioner using the
recommended procedure
tion.
first
proper crankshaft position. Failure to do so will result in piston-to-valve contact.
aligned.
beginning of this sec-
turn the crankshaft or
camshaft without
not
and bleed the cooling system.
11.
Fill
12.
Start the vehicle,
repair
if
check
for leaks
and
necessary.
on the camshaft sprockets.
'•There are 2 different styles
of
camshaft (secondary) chain tensioners
The Early Build tensioners will sepasub-components, the Later Build tensioners will not. Compress the camshaft (secondary) chain as follows: .
•
Crankshaft timing belt sprocket Locate the small dowel pin
5.
rate into
the
in
Camshaft and Valve
Lifters
crankshaft. With a small punch, carefully tap
out the dowel from the end of the crankshaft.
Remove
6.
tool
6341A, taking care not
Separate the tensioner cylinder
a.
2.7L Engine
from the tensioner housing. b.
install:
Before servicing the vehicle, refer to Inspect the crankshaft seal
7.
For early build vehicles:
5.
to nick the shaft
seal surface or seal bore during removal.
To
REMOVAL & INSTALLATION
the crankshaft seal using
sur-
lip
the precautions in the beginning of this sec-
and
face for varnish
Polish the area
dirt.
internal tensioner
tion.
using 400
grit
sandpaper
to
remove varnish
WARNING
as necessary. Install or
8.
•
Rear lower timing belt cover
•
Dowel
into the crankshaft
protrudes 0.047 •
Timing
belt
in.
so that
at
the crank-
C-4685C1,
bearing, washer and
Installing the crankshaft oil
it
(1.2mm)
sprocket
shaft using tool
and 3.5L engines
When
the timing chain
is
removed
and the cylinder heads are installed,
6342
•
12mm
thrust bolt or
seal—3.2L
oil
to
from the
remove the
components.
c.
Assemble the tensioner housing.
d.
Using hand pressure, compress
and lock the tensioner using a fabricated
connect the following:
Crankshaft seal using seal installer tool
Carefully drain the
housing using care not
lockpin. 6.
For
late build vehicles:
—
EH E ^
CHRYSLER CORPORATION CONCORDE
•
LHS
•
300M
INTREPID
•
•
VISION
PLATED CHAIN LINKS
i
Exploded view
camshaft (secondary)
of the
chain tensioner, early build— 2. 7L engine
Proper camshaft (secondary) chain alignment— 2 7L engine
•
Camshaft bearing caps and torque
••Mark the timing
the bolts gradually, in sequence, to
tion tor installation. Align the timing
105 inch •
belt sprockets with
Nm)
(12
timing belt covers before removing the
torque the bolts to 105 inch lbs
timing belt.
Nm)
•
Timing
Primary timing chain
•
Negative battery cable
Remove
tion for the removal
the lockpin from the sec-
ondary chain tensioner.
compressed— 2. 7L engine
and timing
and
installation
procedure
Fabricate a lockpin, as shown, to keep the
tensioner
belt tensioner
Refer to the appropriate sec-
belt.
10
marks on the rear
Secondary chain tensioner and
(12 •
lbs.
belt rotation direc-
•
Camshaft timing
•
Intake manifold
3.2L and 3.5L Engines
belt sprockets
assembly using the
recommended procedure Place the tensioner
a.
in
a soft-jawed
1
•
Before servicing the vehicle, refer to
.
~Be
tion.
surlaces between the exhaust manifold
vise.
Slowly compress the tensioner
b.
lockpin can be
until the fabricated
Camshafts are serviced from the
rear of
the cylinder head Although the engine
Remove
the
compressed and
locked tensioner from the vise. Insert the
7.
compressed and locked
camshaft chain tensioner
in
between the
Position the camshafts so that the
8.
and dots are facing upward
Install or
9.
•
removed
the cylinder head
for
connect the following:
The
rear timing belt cover
must be
that
allows
it
to rotate
on
its
shaft
Properly relieve the fuel system
2.
pressure.
Drain the cooling system.
3.
Remove •
or disconnect the following
Negative battery cable Radiator/cooling fan assemblies
and the accessory drive
Ensure that the rocker arms are correctly seated and in proper positions.
5
must be removed from the
have a D-shaped hole
•
** WARNING
clean the gasket mating
vehicle. Note too, that the camshaft sprockets
4
Camshafts
to
and the cylinder head.
camshaft service,
several degrees in each direction
camshafts and chain.
plated links
not need to be
sure
does
installed. c.
Exhaust manifold
the precautions in the beginning of this sec-
•
belts
Rocker arm/shatt tightening sequence
Crankshaft damper and the timing 3.2L and 3.5L engines belt
For Accessory Drive Bell
covers
illustrations,
see Section
1
of this
manual
CHRYSLER CORPORATION
a
i
5
removed
Remove
to
CONCORDE
•
LHS
•
300M
•
INTREPID
remove the cylinder heads.
the rear timing belt cover-to-cylin-
Remove
der head bolts.
the rear timing belt
•
Exhaust manifold with new gasket Intake manifold
•
Timing
•
Accessory drive belts and
belt cover
to the
set
them
•
Starter heat shield
•
3 starter-to-engine/transaxle bolts
•
and
13. oil
arm assembly
Fill
and
filter
change
is
repair
if
To
recommended. check
for leaks
2.
and
arm and
shaft
the rear camshaft cover
•
•
These engines use hydraulic up the free-play
in
Inspect camshaft journals
head
for
If
wear
is
damage. Inspect the head
oil
Measure the height Measure
a micrometer.
unworn area and
in
specification
0.001
is
2 places: the
in
wear. in.
in.
(0.254mm).
if
it
is
Nuts to the catalyst support bracket
Positive battery cable and torque
89 inch
lbs.
(10
Negative battery cable to the remote
REMOVAL & INSTALLATION 3.2L and 3.5L (VIN G) Engines 2.7L Engine
1.
1.
Remove •
•
Starter-to-engine/transaxle nut and
or disconnect the following:
Battery feed
or disconnect the following:
Negative battery cable from the
remote ground post
Negative battery cable from the
remote ground post •
Remove •
bolts
and posi-lock connec•
tors
Positive battery feed wire from the
worn beyond
To install: Lubricate the camshaft journals and
.
lobes with clean engine Install or
12. • •
oil.
connect the following:
Camshaft Camshaft cover and O-ring and torque the bolts to 21
ft.
lbs.
(28
Nm) •
Rocker arm assemblies
•
Cylinder head assembly
New head
bolts are
recommended.
•
Rear timing belt covers
•
Timing
belt sprocket,
and timing
timing belt
belt tensioner. Refer to
the appropriate section for the
removal and Installation procedure.
Be sure that once they are
all
installed, the timing of the
camshaft(s)
is
accurate.
Nm)
Posi-lock connectors
this specification.
1 1
lbs.
Starter heat shield
starter
Replace the camshaft
ft.
ground post
The standard
(0.0254mm) with
the wear limit being 0.010
•
cam using
the wear zone. Subtract
cam
the figures to get
of the
starter-to-
Nm)
the nut to
holes for
clogging. Replace the camshaft as required. 10.
•
wear or
present, inspect the cylinder
and torque the 3
necessary.
Starter Motor
for
away from the
and mount
•
nick or scratch the journals.
it
the valve train
system, therefore no lash adjustments are
remove the camshaft from the rear of the head taking care not to
rotating
roller lifters •
Carefully,
Starter
(54
to take
forward
engine/transaxle bolts 40
and
WARNING
it
engine
O-ring.
damage.
Starter by sliding
between the catalyst and the engine
necessary.
ADJUSTMENT
Remove
I:
connect the following:
Install or
•
mount and
assemblies. 8.
rearward
install:
Valve Lash the rocker
it
mount
and bleed the cooling system. An
Start the vehicle,
14.
to
component locations before disas-
Remove
toward the
it
between the catalyst and the engine
sembly. 7. 9.
Starter by rotating
engine and sliding
proper tension
Negative battery cable
•
the cylinder head bolts
^•IVIark the rocker
mount
bracket and
covers and crankshaft
Radiator and cooling fan assembly
•
pump passages. Remove
Nuts from the catalyst support
for the
cylinder head.
note
belt
•
assembly
damper
*>The right-hand side timing has O-rings located behind it
6.
VISION
•
covers.
water
•
Exploded view
of the oil
pan removal and
installation
— 2.7L and 3.5L (VIN G) engines
CHRYSLER CORPORATION CONCORDE •
2.
Starter
and position
access
to the posi-lock
connector
from the
slightly relieve the pressure
3.
pan,
left
•
Remove
the 3
left
engine
to
the starter by sliding
rear-
it
To
To install: 7.
8.
Install or
•
Starter by sliding
pan and
of sealer
pump body and 79EBOO
and torque the nut
Starter
to
(12
Install
a.
starter-toft.
b.
5
Nm)
10 inch
using the
oil
remote
ft.
40
ft.
Install the dipstick
8.
9.
Fill
amount
REMOVAL & INSTALLATION
8
grades
to
and housing and
Oil
and torque the ft.
lbs.
Crankshaft sprocket
•
Timing chain
•
Timing chain cover
9
SAE 5W-30 or SAE 10Wonly. Do not mix the two
Crankshaft damper Fill
the engine with clean engine
Start the vehicle,
10. repair
connect the following:
pan
•
•
the engine with the proper
oil
Install or
•
of clean
30 engine
new pickup tube 0-
(28 Nm).
connect the negative battery cable.
Pan
bolts
(28 Nm).
pickup tube mounting bolts to 21
(55 Nm).
lbs.
over
pump mounting
lbs.
ft.
Lubricate the
7.
Nm)
and working outward. Torque the bolts
ground post
to 21
pump
into position.
ring with clean engine oil
(55 Nm).
lbs.
and
Install the oil
6.
and torque
Install the collar-to-transaxle bolts
40
Carefully, install the oil
the crankshaft
lbs. (1.1
locations— 2. 7L
bolt
Nm)
Starting with the center vertical bolt
c.
to the
(28
nuts/bolts to 105 inch
the vertical collar to the
10. and torque to
lbs.
Nm)
Negative battery cable
lbs.
ft.
pump mounting
engine
pan mounting bolts and tighten, tem-
89
porarily to
40
M6
Oil
M8
following procedure:
Nm)
and torque the
connect the following:
Install the structural collar
7.
engine mount-to-engine bolts
engine/transaxle bolts
if
check
lor leaks
oil.
and
necessary.
of oil.
Before servicing the vehicle, refer to
1.
if
gasket sur-
(3mm) bead
in.
nuts/bolts to 21
lbs.
(54
all
pan and torque the
mount
inch lbs. (10
Oil
Oil
forward
it
Positive battery feed wire to the
•
Install or •
and the
starter
•
bolts, oil
pan and
oil
Apply a Vs
6.
Slightly, lower the engine.
•
pan mounting
between the catalyst and the engine
left
cooler line clips,
oil
at the parting line of the oil
connect the following:
Posi-lock connector
3
oil
the rear seal retainer.
•
•
cooler lines from the
oil
install:
5.
the posi-lock connector.
5-17
VISION
•
faces.
mount.
Remove
INTREPID
equipped
Clean the
4.
Remove
•
gasket
ward between th£ catalyst and the engine
6.
Oil
provide
more room. 5.
300M
necessary •
Slightly, raise the
if
Transmission
engine mount-to-
engine bolts. 4.
Engine
•
engine mount.
•
pan and transmission housing
oil
Place a support under the engine and
LHS
Structural collar from the rear of the
•
to gain
it
•
Start the engine,
check
for leaks
3.2L and 3.5L Engines
and
the precautions in the beginning of this secrepair
if
necessary.
The timing
tion.
Drain the engine
2.
and remove the
oil
Oil oil filter.
Remove
3.
access the
Pump
Negative battery cable
•
Dipstick and housing
must be removed
belt
pump
to turn the crankshaft to
REMOVAL & INSTALLATION
(TDC) No.
1
It
is
good
practice
Top Dead Center
cylinder compression stroke
(firing position)
before starting disassembly
This should align
2.7L Engine
to
located behind the
crankshaft drive sprocket
or disconnect the following:
•
oil
timing marks and be a
all
Before servicing the vehicle, refer to
1
the precautions in the beginning of this sec-
A
tion.
To ensure a proper seal, apply sealer as
shown— 2. 7L
and 3.5L (VIN
F)
2.
Drain the engine
3.
Remove •
Crankshaft damper
•
Timing chain cover
•
Timing chain
•
Crankshaft sprocket
•
Oil
pan
•
Oil
pickup tube and o-ring
•
Oil
pump
4.
Fill
the
clean engine
Tire,
Prime the
because
To install:
engines
For
oil.
or disconnect the following
Wheel and
oil
pump
pump
and cause low
rotor cavity with
1
of this
before installation,
pump oil
3.5L engines
oil.
Ball Joint specifications, see Section
oil
a dry
manual
will
wear prematurely
pressure— 3. 2L and
CHRYSLER CORPORATION
5-18 good point
CONCORDE
•
LHS
work
of reference for all
300M
•
INTREPID
•
VISION
Timing
•
to fol-
•
Refer to the appropri-
belt.
ate section for the
low. 1
•
the precautions in the beginning of this section.
Drain the engine
2.
9.
Timing
belt covers, thrust bearing,
washer
plate
and vibration dampe
using tool L-4524
oil.
8.
Apply a
light
coating of engine
the entire circumference of the
installation procedure.
Before servicing the vehicle, refer to
.
removal and
in
Connect the negative battery cable.
Drain the cooling system.
•
Accessory drive belts
1 1
Remove
•
Radiator and radiator hoses
12.
Fill
•
Negative battery cable
13.
Start the vehicle,
Negative battery cable
•
Accessory drive
•
Oil filter
•
Oil
pan
•
Oil
pump
•
Windage
•
Crankshaft damper using a suitable
belts
Timing
•
Fill
16.
Fill
amount pickup tube
pan gasket
tray/oil
and bleed the cooling system.
oil
grades of
oil.
SAE 5W-30 or SAE 10WDo not mix the two
only.
Start the engine,
17.
to aid installation. Align the
oil
check
for leaks
and
necessary.
check
for leaks
and
Timing Chain, Sprockets, Front Cover and Seal
REMOVAL & INSTALLATION 2.7L Engine
Rear Main Seal
matchmarks on
marks on the
the camshaft sprockets to
rear
REMOVAL & INSTALLATION
When
aligning the timing marks,
or disconnect the following: 1.
Timing
•
if
pressure.
timing belt covers before removing the timing.
Remove
repair
the transaxle with the proper fluid.
covers
belt
Place matchmarks on the timing belt
6.
.
the engine with the correct
clean
of
30 engine
proper
puller tool
5.
15.
and
transaxle.
3.
•
to
lip.
place with a plastic mallet.
Install the flexplate/flywheel
4.
or disconnect the following:
oil
seal
Place the seal over the special tool
and tap the seal 10.
oil
Before servicing the vehicle, refer to
Refer to the appropri-
belt.
the precautions ate section for the
removal and
in
the beginning of this sec-
rotate the crankshaft, not the
camshafts.
DO NOT
rotate the
tion.
installation procedure. 2.
Drain the transaxle
3.
Remove Remove
fluid.
Crankshaft sprocket using a suit-
•
able puller tool 4.
•
Oil
pump-to-engine screws and
the transaxle, inspection
cover and flywheel/flexplate.
pump Oil pump
•
the negative battery cable.
5.
cover screws and
Using a small prytool, carefully pry
out the rear
cover Oil pump rotors Wash all parts in solvent and carefully for damage or wear.
or
damage
oil seal.
Be careful not
to nick
the crankshaft flange seal surface
•
7.
or the retainer bore.
inspect
To 6.
To
install:
Place the Seal Pilot tool C-4681 on
install:
Clean
8.
no traces
parts well. There should be
all
on any com-
of old gasket/sealer
7.
Lightly coat the oil seal outside
Removing
diameter with Loctite® Stud N’ Bearing
ponents.
Assemble the
9.
the crankshaft.
oil
pump
with
Mount®
new
the crankshaft center bolt using
the Crankshaft
or the equivalent.
Damper Holder tool— 2.7L
engine
parts as required. 10.
1 1
pump
Install the oil
fasteners to
108 inch
Prime the
.
oil
cover.
Torque the
(12 Nm).
lbs.
pump
CHAIN GUIDE
prior to installa-
tion by filling the rotor cavity with clean
engine
oil
CAMSHAFT DAMPER
oil.
12.
Install
the
oil
pump and
tighten the
pump-to-engine screws as follows:
M8 screws: 21 M10 screws: 40
a.
ft.
b.
Tighten the
13. install
a
14.
new
oil
lbs.
ft.
(28 Nm).
lbs.
(55 Nm).
CHAIN GUIDE
pan drain plug and
oil filter.
connect the following:
Install or
pump
•
Oil
•
Windage
•
Oil
pickup tube tray/oil
pan gasket
pan and torque fasteners
108
to
inch lbs. (12 Nm). Pay attention to
sealing the integral •
oil
pan gasket and
windage
its
CHAIN TENSIONER
tray.
Crankshaft sprocket using tool C-
4685C1
12mm
,
thrust bearing,
bolt to
ARM
washer and
7922BG33
draw the sprocket
onto the crankshaft
Exploded view
of the timing
chain drive
assembly— 2. 7L engine
— CHRYSLER CORPORATION CONCORDE CAMSHAFT
CAMSHAFT
TIMING
TIMING
MARK
MARK
•
LHS
•
300M
•
INTREPID
•
5-19
VISION
^
TIMING
CHAIN TENSIONER
Using the Tensioner Resetting Special tool, to
purge the
oil
from the tensioner
2.7L engine
•The
camshafts
when
will rotate clockwise,
the camshaft sprocket bolts are
removed. Right camshaft sprocket mounting
•
camshaft damper and
bolts, After the timing chain
is
installed, the timing
marks should be aligned
— 2.7L engine
sprocket •
camshafts or crankshaft with the timing chain
•
damage may
Power steering pump and position it
camshaft sprocket bolts and
Lower timing chain guide, ten-
•
removed without locating
aside without disconnecting the
sioner
the crankshaft position, piston and/or
valve
Left
sprocket
arm and primary timing
hydraulic lines
chain
occur.
•
Accessory drive
•
Timing chain cover bolts
belt tensioner pulley
To install: 1
Before servicing the vehicle, refer to
.
the precautions in the beginning of this sec-
4.
tion,
5.
Remove
2.
or disconnect the follow-
Clean and inspect the sealing sur-
•Lubricate the timing chain and guides with clean engine oil before
Align the crankshaft sprocket timing
installation.
faces.
mark with the
oil
pump housing mark
7
ing: •
Upper intake manifold and valve
60 degrees
covers
crossmember
•
Upper
•
Fan module
•
Accessory drive belts
radiator
pump housing
is
Install the
timing chain by perform-
ing the following procedure:
Top Dead Center (TDC).
a
Verify that the crankshaft sprocket
timing mark or disconnect the followoil
aligned with the mark on
is
pump housing
ing: b.
•
the center bolt.
Damper using a 3-jaw
at
oil
the
8191, hold the crankshaft and remove
•
on the
Remove
6.
Using Crankshaft Damper Holder
3.
tool
•The mark
from the •
right cylinder
aligning the timing mark on the sprocket to the c.
left
side primary timing
head
Camshaft Position (CKP) sensor
the
left
chain sprocket onto the chain, while
and timing chain access plug from puller
Place the
Primary timing chain tensioner
2 plated
links
on the chain.
Lower the chain with the
left
sprocket
cylinder head
through the
For Wheel Alignment specifications, see Section
1
of this manual
left
cylinder head opening.
CHRYSLER CORPORATION
5-20 d.
CONCORDE
Loosely position the
LHS
•
•
300M
g.
Align the right camshaft sprocket
and loosely position the
Verify that
all
Install
the
left
lower timing chain
guide and tensioner. Torque the bolts to 21 ft.
aligns with the camshaft sprocket and
damper attaching
holes. Install the sprocket
attaching bolts and torque to 21
ft.
(28
lbs.
Turn the
14.
%
in.
left
camshaft by inserting a
square drive extension with a breaker
bar into the intake camshaft drive hub.
Rotate the camshaft until the camshaft hub aligns with the camshaft sprocket and
(28 Nm).
lbs.
POSITIONING
square drive extension with a breaker
bar into the intake camshaft drive hub.
the plated links are
aligned to their proper timing marks. 8.
in.
Nm).
sprocket over the camshaft hub. h.
Piston and Rings
Rotate the camshaft until the camshaft hub
drive sprocket.
timing mark to the plated link on the timing chain
chain tensioner into the
At the right cylinder head, insert a
13.
%
Position the timing chain around
pump
VISION
Install the
12.
Align the plated link to the crank-
the water
•
right cylinder head.
shaft sprocket timing mark. f.
INTREPID
camshaft
left
sprocket over the camshaft hub. e.
•
•Inspect the timing chain guide access plug O-rings before installing. Replace
damper attaching
holes. Install the sprocket
attaching bolts and torque to 21
(28
lbs.
ft.
Nm).
damaged
Cross-sectional view of the piston rings
O-rings as necessary. 15.
necessary, rotate the engine
If
2.7L, 3.2L Engines Install the
9.
plug to the
15
lbs.
ft.
•To
left
timing chain guide access
cylinder head and torque to
(20 Nm).
need
to
be purged from the
remove any slack
in
To arm the timing chain tensioner:
16.
reset the timing chain tensioner,
oil will first
slightly clockwise to
the timing chain.
Use a flat-bladed prytool
to gently pry the
tensioner arm towards the tensioner slightly.
Then, release the tensioner arm. Verify the
tensioner.
tensioner extends.
Purge
10.
oil
from the timing chain ten-
sioner using the following procedure:
Remove
a.
the tensioner from the ten-
sioner housing. b.
oil seal.
Apply a Va
18.
in.
(3mm) bead
at the parting line of the oil
Place the check ball end of the ten-
sioner into the shallow end of the Ten-
sioner Resetting Special tool 8186.
Using hand pressure, slowly
c.
Inspect and replace the timing chain
17.
cover gasket and
depress the tensioner
until oil is
purged
of sealer
pan and engine
block.
•When
installing the timing cover,
guide the seal over the crankshaft to prevent
damage
to the seal’s lip. - SIDE RAIL
1
from the cylinder. d.
19.
Reinstall the tensioner into the ten-
sioner housing. 1 1
Install or
9306BG04
•
Timing cover and gasket and torque the
using the following procedure: a.
M10
and the
Position the cylinder plunger into
(12
40
bolts to
M6
bolts to
Crankshaft damper
8186.
•
Accessory drive
Apply a downward force
tensioner
r-
until the
is reset.
Ensure that the tensioner
is
Nm)
3.5L Engine
lbs.
UPPER
NO. 1 RING GAP
belt tensioner pul-
Power steering pump
•
Crankshaft damper
•
Crankshaft center bolt and torque the bolt to
properly
The tensioner body must be bottomed against the top edge of the
(54
ley •
WARNING
lbs.
105 inch
SIDE RAJL
•
b.
ft.
Cross-sectional view of the piston rings—
Nm)
the deeper side of the Tensioner Resetting special tool
SPACER EXPANDER
ing:
Reset the timing chain tensioner
.
2 -
connect the follow-
125
ft.
lbs.
(170
Nm)
using tool 8191
reset.
•
Accessory drive belts
Tensioner Resetting Special tool 8186. Failure to properly perform the resetting procedure may cause ten-
•
Fan module and
•
Upper
sioner jamming.
•
Negative battery cable
electrical wiring
harness radiator
GAP AND SPACER EXPANDER GAP 9306BG03
crossmember
Piston ring gap positions— 2. 7L, 3.2L,
3.5L Engines
.
CHRYSLER CORPORATION CONCORDE
•
LHS
•
300M
•
INTREPID
•
5-21
VISION
FUEL SYSTEM Fuel System Service Precautions
At the
2.
Power Distribution Center
(PDC), remove the Fuel Safety
the
is
most important
performing not only
when
factor
system maintenance
fuel
until
man-
4.
may
ner
in
a safe
result in serious personal injury or
death. Maintenance vehicle’s fuel
and
testing of the
system components can be
accomplished safely and
effectively
ing to the following rules
and guidelines:
•
To avoid the possibility of
by adher-
fire
and per-
sonal injury, always disconnect the negative battery cable unless the repair or test proce-
dure requires that battery voltage be applied. relieve the fuel
run.
OFF
Turn the ignition switch
**
engine
CAUTION
The previous steps must be performed to relieve the high pressure fuel from the fuel rail. The following steps must be performed to remove excess fuel from the fuel rail. Do not use the following steps to relieve high pressure for excessive fuel will
(injector, fuel rail,
ulator, etc.), fitting or fuel line
skin, face
and eyes
advised that
pressure regconnection.
avoid exposing
Please be
to fuel spray.
any part
of the
body
Disconnect the
5.
from any
Connect
6.
that
it
connector
electrical
injector.
an alligator
1
1
end
of a
jumper wire (with
Connect
1
end
of a
sure.
second jumper
3.
Lower the
4
Remove
wire to the other injector terminal.
contacts.
** WARNING
Always place a shop towel or cloth
•
around the loosening spillage.
(should
absorb any excess
Ensure it
fuel
due
to
that all fuel spillage
occur)
is
quickly removed from
engine surfaces. Ensure
•
Negative battery cable
•
Purge and vent
•
Fuel line from the pressure regula-
that all fuel
age the
the jumper wire to a
9.
At the
ground
for
5.
• Do come
install the fuel
pump
fuel
spark or open
•-When
the fuel
relay
Push the
it
straight
fuel filter/regulator into the
pump module and Connect the
6
pump
and pulling the
turn to lock
it
into
position.
relay.
not allow fuel spray or fuel vapors into contact with a
it
To install:
no more
Power Distribution Center
extinguisher near the work area.
(PDC),
in the
up
Momentarily, touch the other end of
Always keep a dry chemical (Class B)
by pushing
locking tab, turning the regulator to
than a few seconds.
to
Filter/regulator
injector.
unlock
soaked
cloths or towels are deposited into a suit-
•
able waste container.
fire
lines
tor
Applying power to an injector for more than a few seconds will dam-
8.
•
fuel tank.
or disconnect the following:
connection prior to
fitting or
to
Properly relieve the fuel system pres-
2.
to the positive side of the
battery. 7.
Before servicing the vehicle, refer to the
.
precautions in the beginning of this section.
clip) to either injector terminal
and the other end
under pressure may pene-
fuel
trate the skin or
to
of the fuel tilter/pressure
regulator
Exercise extreme caution whenever relieving
system pressure,
away view
Cut
system pres-
sure prior to disconnecting any fuel system
component
fuel
until the
FUEL FLOW TO FUEL INJECTORS
continue restarting the engine
no longer
will
it
INTERNAL FUEL FILTER
Relay.
be forced into a cylinder chamber.
Always
•
Operate the engine
3.
stalls; then,
but any type of maintenance. Failure to con-
duct maintenance and repairs
Pump
fuel lines
and
install the
is
tank.
flame. •
Always use a back-up wrench when
loosening and tightening
fuel line
tion fittings. This will prevent
stress •
and torsion
where
Do
7.
repair
if
check
for leaks
and
necessary.
Pump
fuel fitting Fi-
not substitute fuel hose,
REMOVAL & INSTALLATION
Fuel Filter
fuel pipe is installed.
Before servicing the vehicle, also
sure to refer to the precautions
make
The
fuel filter
mounts
front of the fuel tank. in
the begin-
ends
ning of this section as well.
ot the filter are
inlet
marked
and
rail in
The in-tank
outlet
the fuel
for installation
purposes.
Install the fuel filter
tain that
is
it
frame
to the
The
voltage
properly orientated.
RELIEVING
is
•The in
the beginning of this section.
contains
is
pump pump
supplied through the fuel
fuel pump is serviced as part of the pump module. The fuel pump module
The fuel
Before servicing the vehicle, refer to the
pump module
pressure regulator which
relay
REMOVAL & INSTALLATION
precautions
fuel
pump and
adjusts fuel system pressure. Fuel
making cer-
Fuel System Pressure
1
Start the engine,
Fuel
to clear the DTC's.
to fuel line piping.
Always replace worn
rings with new.
connec-
unnecessary
removed, 1 or more Diagnostic Trouble Codes (DTC’s) may be stored in the Powertrain Control Module (PCM) memory. A DRB scan tool must by used
fuel filter is part of the fuel pressure regulator mounted on the fuel
installed in the top of the fuel tank
contains the electric fuel pump, fuel reservoir, inlet strainer fuel
pump module.
unit, fuel
For Maintenance Interval recommendations see Section ,
1
of this
supply and return
manual
and
pump
gauge sending line
connections
CHRYSLER CORPORATION
5-22
CONCORDE
and the pressure
The
regulator.
LHS
•
pump requires pump module.
INTREPID
VISION
•
SPECIAL TOOL
Fuel Injector
#6856
level
sensor are the only serviceable items. fuel
•
inlet
pressure regulator and
strainer, fuel
300M
•
the
If
REMOVAL & INSTALLATION
service, replace the fuel
Before servicing the vehicle, refer to the
1.
Before servicing the vehicle, refer to
1.
precautions
the precautions in the beginning of this sec-
the beginning of this section.
in
Relieve the fuel system pressure.
2.
tion.
Remove
3.
Properly relieve the fuel system
2.
•
pressure.
Remove
3.
•
or disconnect the following:
Using special tool 6856, remove the fuel
Clean the top of the tank to remove
4.
any loose
pump module
locknut
quick-connect
connect
on the ledge between the tank threads
ring
thumb and forefinger pump module electrical con-
• 'Fuel
and the pump module opening.
with
fitting
pump module
Position the fuel
8.
in
the tank. Be sure the alignment tab on the nector from the top of the fuel
Using special tool 6856, remove the
pump
pump module
underside of the
pump module fuel
in
flange sits
the corresponding notch in the fuel
tank.
locknut by turning
it
counter-
While holding the
9.
fuel
pump module
CAUTION
in
place install the locking ring and torque
to
40 inch
6856
The fuel reservoir of the fuel pump module does not empty out when the tank is drained. The fuel in the reservoir
may
spill out
when
module
the
pump and
Fuel tank
•
Fuel
is
O-ring
from the tank and discard the O-ring.
To 7.
all
Wipe
parts.
the
Fuel injectors
Lubricate the injector O-rings with
Fill
the fuel
•
connect the following:
Fuel injector and secure with retaining clips
•
Fuel
rail
press
onto cylinder head and
rail
into place.
Make sure
that
the injectors are fully seated.
pump module
electrical
con-
•
Fuel rail-to-cylinder head bolts
torque bolts to 100 inch •
the fuel tank with fuel. Install
filler
oil.
Install or
6.
rail
retainer clips
5.
using special tool
Intake
fitting’s
0-rings with clean engine
ON
the connector together until the retainer
position to pressurize
Check the
fuel
system
for
leaks.
Nm)
plenum
Lubricate the quick-connect
7.
and
lbs. (11
cap. Turn the ignition
seats and a click
oil;
then,
push
heard.
is
Connect the negative battery cable.
8.
new 0-
seal area of the tank clean. Place a
•
rail
install:
Negative battery cable
the system.
Thoroughly clean
Fuel injector-to-fuel
nector
switch to the
install:
Fuel rail-to-engine bolts and fuel
•
connect the following:
•
11.
the fuel
Nm)
lbs. (5
Install or
10.
•
Remove
Fuel injector electrical connectors
•
To
or a spanner-type tool.
removed. 6.
tabs together and pull
•
clean engine
clockwise.
I'
fitting’s retainer
the fitting assembly off of the fuel tube nipple.
pump mod-
ule by squeezing the quick-connect
5.
rail’s
then, squeeze the quick-
fitting;
dirt.
Fuel lines from the fuel
•
plenum and cover
Place a shop rag under the fuel
4.
Fuel tank
•
Intake manifold
opening with a clean cloth
Negative battery cable
•
or disconnect the following:
Negative battery cable
DRIVE TRAIN ing any repair
Transaxle Assembly
on the 42LE four-speed auto-
•
shift linkage
REMOVAL & INSTALLATION
adjustment. Also, check for
free the
The 42LE four speed transaxle uses
Use
fully-adaptive controls. Adaptive controls are those which perform their functions
based on real-time feedback sensor mation. The transaxle
is
the
in
use of hydraulically applied clutches to
However,
tronics to control virtually
all
it
MOPAR
If
the differential
requires fluid, use
Hypoid gear
shift
uses elec-
Type 7176 Automatic Trans-
the precautions
in
the beginning of this sec-
other func-
Remove
2. in
the vehicle: valve
body
assembly, solenoid pack, manual valve lever position sensor, input and output speed
sensors, transfer chain and sprockets, short (right side) stub shaft seal
side) stub shaft
the factory
and
and the long
ball bearing.
recommends
(left
Note that
that before attempt-
Strut-to-steering knuckle bolts on
both sides of the vehicle and/or rod ends, •
if
•
tie
required
Antilock Brake System (ABS) wheel
speed sensor,
Before servicing the vehicle, refer to
.
The following components are
serviceable
•
lubricant.
tion.
tions.
Front wheels
sump
80W-90 petroleum based
ties.
•
mission Fluid only. Do not substitute
1
a planetary gear train.
tool.
transaxle fluid.
infor-
conventional
scan
connector from the har-
ness, remove the wire
diagnostic trouble codes with the Chrysler
DRB
Transaxle wiring connector block located on the right shock tower. To
matic transaxle, always check for proper
if
equipped
Halfshafts
^Remove
the halfshafts by inserting a
prybar between the halfshaft and the or disconnect the following:
•
Negative battery cable
•
Engine
•
Crankshaft Position (CKP) sensor
air inlet
tube
connector and remove the sensor
from the upper
transaxle case and prying the shafts
from the transaxle housing. Swing the shafts out of the way, keeping the joints straight
and suspend using wire.
Be careful not
to
right side of the
seals. transaxle bell housing
damage
the halfshaft
COO
CHRYSLER CORPORATION CONCORDE
LHS
•
•
300M
•
INTREPID
•
O CO
VISION
Be sure the reverse lamps come on when
in
reverse.
Do not
let
the halfshafts or CV-joints
hang unsupported. Internal joint damage may result if allowed to hang free. Remove
3.
When
installing the transaxle, be
careful that the fuel tubes at the rear
engine do not contact the
of the
lowing:
or disconnect the following:
10.
REMOVAL & INSTALLATION connect the following:
Install or
** WARNING
•
Engine-to-transaxle brackets
•
Transaxle wiring harness
•
Transaxle bell housing cover
•
Driveplate and torque the fastener
Mark
4.
the ijriveplate to the torque
transaxle case bolts to 75
bolts are not to be reused. Starter
housing and allow the
starter
crossmember
motor
between the engine and the
to sit
secure
frame •
Transaxle
oil
cooler lines and plug
pushing the ends, can damage boots or CV-joints. Always support both ends of the halfshaft to prevent dam-
lbs.
Rear transaxle case mount and rear
•
bell
ft.
Nm)
(101
assembly from the
Allowing the CV-joint assemblies to dangle unsupported, or pulling or
Nm)
(101
lbs.
ft.
Transaxle and torque the engine-to-
•
The driveplate-to-torque converter
•
75
to
converter and remove the torque converter bolts.
Halfshaft
fol-
all
in
age
position and
fasteners
•
Transaxle dipstick tube
•
Exhaust pipe
——
the openings
or
disengagement
of the Tri-pot
joint.
Before servicing the vehicle, refer to
1.
engine exhaust
to
the precautions in the beginning of this sec-
manifold tion. •
•
Transaxle dipstick
•
Transaxle gear selector cable
Transaxle gear selector cable and
Remove
2 oil
ing:
Exhaust pipe from the exhaust man-
•
•
Torque the bolts
Starter.
to
40
ft.
•
ifold
and position out
^lf the clearance
will not
of the
way
starter
allow for
ground strap
is
•
Front wheels
•
Front caliper assembly from steer-
installed
correctly.
ing knuckle Align torque converter matchmarks
•
system from the vehicle. Support the transaxle using a transjack.
driveplate bolts to
Front brake rotor from the
•
Speed sensor cable routing bracket
relieve the weight off the rear transaxle
•
transaxle
mount
lbs.
(81
Nm)
strut
Hub and
assembly
bearing-to-stub axle
transaxle brackets retainer nut 1 1
While pulling the top of the steering
.
3.
mount through-bolt
knuckle outward,
Rear crossmember
•
ft.
housing cover and engine-to-
Bell
•
Engine-to-transaxle brackets and
•
60
from
Raise the transaxle slightly to
hub
•
and torque new torque converter-to5.
Negative battery cable
(54 Nm). Be sure that the
lbs.
transaxle removal, remove the exhaust
mission
or disconnect the follow-
cooler lines
onto the hub and
inner CV-joint,
install the
bearing assembly and secure
new
with
Install a puller tool
it
into place
retainer clip in place, into the
using the wheel lug nuts.
r»Pry the transaxle mount rearward
to
transaxle.
ABS
•
separate the mount from the transaxle.
4
wheel sensor
(if
removed) and
Protect wheel stud threads by
installing a
wheel lug nut onto a wheel stud.
strut-to-steering knuckle bolts
Lower the
6.
rear of the transaxle to
Front wheels and torque the lug
•
gain access to the bell housing bolts.
Remove
nuts, in a star pattern to
the bell housing bolts.
95-100
hub from turning Using the hub and bearing assembly.
•
Transaxle dipstick
the transaxle to catch transaxle fluid that
•
Transaxle wiring harness connector
will
drain out of the case.
Remove
8.
on the
or disconnect the following:
•
Transaxle dipstick tube and plug hole
•
Engine-to-transaxle bolts and
and the driveplate-to-crankshaft bolts must not be reused. Install new
whenever these
If
install:
and negative
do
this, insert
a prybar
battery
Start the
engine and allow
it
to idle
2 minutes. Apply the parking brake and
for
move tion,
the selector through each gear posi-
ending if
in
N Recheck
the fluid level
necessary. Be sure the vehicle
a light coating of grease to the
is
Fluid (ATF) only.
is
if
being replaced.
the torque
Do
not substitute transaxle
sump requires fluid, 80W-90 petroleum based Hypoid gear
fluid.
use
pilot hole of the crankshaft
converter
Air inlet tube
Irom
when refilling the transaxle. Use Mopar Type 7176 Automatic Transmission
Inspect the driveplate for cracks.
^Apply
•
sensor
joint
on the
level
cracks are present, replace the driveplate.
To
Dislodge the inner Tri-pot
transaxle To
CKP
and add
bolts are
removed. 9.
shock tower
•
12.
driveplate-to-torque converter
bolts
bolts
right
5
the stub shaft retaining snapring
cable
transaxle
'The
puller tool,
force the halfshaft outer stub axle from the
(129-135 Nm)
lbs.
flat-bladed prying tool to prevent the
ft
Place a drain pan under the dipstick
7. in
Use a
If
the differential
lubricant.
13. tion
Check the transaxle
Adjust the
Removing
or proper opera-
shift linkage,
if
For Tune-up, Capacities and Firing orders, see Section
the stub axle Irom the front
hub/bearing assembly
necessary.
1
of this
manual
—
halfshaft service
CHRYSLER CORPORATION
5-24
CONCORDE
LHS
•
300M
•
•
INTREPID •VISION stub shaft-to-hub and bearing assembly
on the intercon-
time. Take care not to pull
necting shaft to remove or separation of the
install: Install the Tri-pot joint side of the
10.
When
halfshaft by performing the following proce-
dure:
retaining circlip
and 0-ring seal on the
components
transaxle stub shaft. These are not reusable
whenever the
(163 Nm).
tightening the stub shaft
retaining nut, be careful not to
the halfshaft could result.
and must be replaced
halfshaft
removed.
is
Apply an even coat
b.
lbs.
exceed the maximum torque specifi15. cation of 120 ft. lbs. (163 Nm). If this specification is exceeded, failure of
Replace the inner Tri-pot joint
a.
ft.
WARNING
I-
To
120
retainer nut to
spider assembly will occur.
Road
grease on
of
test the vehicle to
check
for
noise or vibration.
the splines of the inner Tri-pot joint,
Be careful not
to
damage
where the 0-ring seats against the Tri-pot the threads for
CV-Joints
joint.
the axle nut 6. joint
when removing
the outer CV-
from the steering knuckle
—
through the
Install the halfshaft
c.
OVERHAUL
halfshaft
hole
in
the splash shield. Grasp the inner
service joint in in
between the transaxle case and the inner Tri-pot joint
and pry on Tri-pot
hand and interconnecting
1
shaft
Inner (Tri-pot) Joint
the other. Align the inner Tri-pot joint
spline with the stub shaft spline on the
joint.
1
Use a rocking motion with
transaxle.
Before servicing the vehicle, refer to
.
the
the precautions
i»Do not
try to
remove the inner
Tri-pot
inner Tri-pot joint to get
it
the beginning of this sec-
in
past the circlip tion.
from the transaxle stub shaft
joint
this time.
on the transaxle stub
at
Only disengage the inner
Tri-
pot joint from the retainer snapring.
shaft.
Continue pushing the Tri-pot
d.
onto transaxle stub shaft
until
it
Check
from the
WARNING strut
assembly-to-steering
where they go through the strut assembly and steering knuckle. When removing the bolts, turn the
position, the joint will not
damage
8.
joint
hand and
rotate
it
to
into the
12.
tri-pot joint
rollers in place
housing, hold the
on the trunions to pre-
vent the rollers and needle bearings
from
it
out and to the
falling
away.
Carefully, slide the shaft/spider
assembly from the
hub and bearing assembly.
Install or
Remove
tri-pot
housing.
the spider assembly-to-shaft
snapring; then, slide the spider assembly
off
connect the following: the shaft.
•
Top
of the steering
knuckle into the
assembly. Align the steering
knuckle-to-strut assembly mount-
strut.
ing holes.
assembly with
•
Strut assembly-to-steering knuckle
attaching bolts. Install the nuts to the
out and to the
attaching bolts and while holding the
rear of the vehicle, until the outer CV-joint
clears the
move
separating the spider joint
6.
one hand. Grasp the steering knuckle with the other
away
»When
rear of the vehicle. Install the outer CV-joint
Separate the top of the steering
Hold the outer
the shaft
from the
5.
strut
knuckle from the lower end of the
If
shaft.
with the other and rotate
the steering knuckle will result. 7.
position
Hold the outer CV-joint assembly
11.
down
housing.
with one hand. Grasp the steering knuckle
nuts9.off the bolt; do not turn the bolts the steering knuckle or
in
on the stub
knuckle bolts are serrated (toothed)
in
in
by grasping the inner joint and pulling. locked
The
locked
tri-pot
that the
assembly. is
and retaining
Tri-
ing knuckle attaching bolts from the strut is fully installed.
the halfshaft
Slide the boot
4.
should not be visible when the inner
inner Tri-pot joint
Remove
clamps.
the strut assembly-to-steer-
pot joint
Disconnect the negative battery cable.
3.
stops
moving. The O-ring on the stub shaft
Remove
2.
joint
bolt heads, torque the nuts to
hub and bearing assembly. lbs.
125
ft.
(170 Nm). Turn the nuts on the
DO NOT turn the bolts. New hub and bearing assembly-tobolts.
•
When removing
the outer CV-joint
stub shaft retainer nut. Tighten but
from the hub and bearing assembly, do not allow the flange disc on the hub and bearing assembly to become
•
damaged.
•
happens,
do not torque the nut
and screw
and water can enter the bearing, which wili cause premature bearing failure. If
this
Remove
at this time.
Speed sensor cable routing bracket
dirt
Brake rotor and caliper assembly; then, tighten the caliper guide pin bolts to
the halfshaft inner joint from
30
ft.
lbs. (41
1
•
Front wheels and lug nuts
•
Negative battery cable
- SNAP RING
2 - SEALING
Nm)
3 - SPIDER 4
BOOT
ASSEMBLY
- SNAP RING PLIERS INTERCONNECTING SHAFT
5 -
9306BG11
the transaxle stub shaft by grasping the inner Tri-pot joint and the interconnecting shaft
and pulling both pieces
at the
same
13.
Pump
the brakes until a firm pedal
is
obtained. 14.
Apply the brakes and torque the new
View
of the halfshaft inner tri-pot joint
snapring
and
CHRYSLER CORPORATION CONCORDE 1 1
Install
.
make sure
•
LHS
•
300M
the snapring onto the shaft:
INTREPID
•
Outer CV-Joint
If
installing a
new
boot, distribute Vz
of the grease in the service
the tri-pot housing
package inside
13.
tion.
and the other Vz inside
Carefully, slide the spider
and shaft 14. - SEALING
1
3 -
-
4
BOOT
.
assembly
15.
Position the inner boot clamp evenly
5 tool
C-4975.
of the halfshaft boot, shaft
the halfshaft and the retain-
Slide the boot
down
away
the shaft
Remove
the grease to expose the
CV-joint-to-shaft retaining ring. 6.
place the tool over the clamp bridge, tighten the tool nut until the jaws are completely
View
Remove
from the CV-joint housing.
BOOT CLAMP 9306BG12
Disconnect the negative battery cable.
3.
4.
into the tri-pot housing.
Using the Crimper
2.
ing clamps.
on the sealing boot.
INTERCONNECTING SHAFT THINNEST GROOVE INTERCONNECTING SHAFT
Before servicing the vehicle, refer to
the precautions in the beginning of this sec-
the boot.
2 -
.
the groove. 12.
5-25
VISION
that the snapring is fully seated 1
in
•
Spread the snapring ears apart and
slide the CV-joint
and boot
closed (face-to-face).
clamp
assembly
off of
the shaft.
7
Slide the boot off the shaft.
8.
Throughly, clean and inspect
parts for signs of excessive wear:
if
all
neces-
sary, replace the halfshaft.
The seal must not be dimpled, stretched or out of shape.
If
neces-
sary, equalize the seal pressure
shape
it
and
••Component
parts are not service-
able and must be replaced as an
assembly.
by hand.
To install: 16.
Position the boot onto the
tri-
pot housing retaining groove and install the retaining
clamp evenly on the
9
is
3 -
tool
C-4975.
place the tool over the clamp bridge tighten
SEALING BOOT
-
1
2 - SPECIAL
Using the Crimper
TOOL C-4975
the tool nut until the jaws are completely
CLAMP BRIDGE 93O60G13
Securing the halfshaft boot clamp
closed (face-to-face). 18.
If
visible
10
Install the halfshaft into the
on the
the CV-joint
seated
11.
If
drift;
of
7.
Slide the boot
Throughly, inspect
excessive wear;
if
off
be
the shaft. all
parts for signs
necessary, replace the
halfshaft.
'•Component
parts are not serviceable
and must be replaced as an assembly. To
install:
Slide the inner tri-pot boot clamp
9.
and boot onto the
shaft; then, position the
boot so that only the thinnest (sight) groove is
visible
on the
shaft.
Install the
shaft just far
can be
spider assembly onto the
enough so
that the
snapring
installed.
* WARNING
1
INTERCONNECTING SHAFT RETAINING SNAP RING - OUTER C/V JOINT ASSEMBLY -
2 If
necessary, tap the spider assembly
onto the shaft using a brass careful not to hit
be the outer bearings.
3
drift;
View
verify that the
of the halfshaft outer CV-joint
and snapring
For complete service labor times, order the Chilton Labor Guide
snapring
is
the shaft groove.
installing a
10. careful not to hit the outer bearings.
8.
and in
new
boot, distribute
of the grease in the service
necessary, tap the spider assembly the shaft using a brass
shaft.
Slide the outer CV-joint assembly on
the shaft, spread the snapring ears, position
fully
vehicle.
off
clamp
shaft; then, position the
boot so that only the thinnest (sight) groove
boot. 17.
Slide the outer CV-joint boot
and boot onto the
package
Vfe
into the
CHRYSLER CORPORATION
5-26
CONCORDE
CV-joint housing and the other
LHS
•
300M
•
•
INTREPID
V2 inside
k
•
VISION housing retaining groove and
WARNING
retaining
the boot.
Position the outer boot clamp evenly
12.
place the tool over the clamp bridge, tighten the tool nut until
If
shape
it
Using the Crimper
15.
neces-
14. equalize the seal pressure sary,
Using the Crimper tool C-4975,
13.
The seal must not be dimpled, stretched or out of shape.
on the sealing boot.
and
install the
clamp evenly on the boot. C-4975,
tool
place the tool over the clamp bridge, tighten the tool nut until the jaws are completely
closed (face-to-face).
by hand.
16.
the jaws are completely
Install the halfshaft into the vehicle.
Position the boot onto the CV-joint
closed (face-to-face).
STEERING AND SUSPENSION in
Bag
Air
unnecessary system repairs and/or
•
Both
personal injury.
**
bell
CAUTION
1
Some
Disconnect the negative battery cable
.
and
isolate the cable using
an appropriate
vehicles are equipped with an bag system. The system must be disabled before performing service on or around system components, steering column, instrument panel components, wiring and sensors. Failure to follow safety and disabling procedures could result in accidental air bag deployment, possible personal injury and unnecessary system
Always wear safety goggles when working with or around the air bag
repairs.
system.
PRECAUTIONS Several precautions must be observed
when handling
the inflator
module
to avoid
accidental deployment and possible per-
sonal injury. •
Never carry the
inflator
module by
the
wires or connector on the underside of the
module. •
When
for
2 minutes before starting any
on any
air
ponents. This
1=
bag system or related comdisable the
will
air
bag system.
be sure the bag and trim cover are pointed away from the body. In the unlikely event of an accidental deployment, the bag will, then deploy with minimal chance of injury. When placing a live air bag on a bench or other surface, always face the bag and trim cover up, away from the surface. This will reduce the motion of the module if it is accidendeployed.
tally
bag and trim cover are pointed
the steering gear under the master cylin-
bag and trim cover
With the
•
module on
»Ht may be helpful
of
•
Before servicing the vehicle, refer to
.
on each side)
Move
6.
the steering gear and interme-
diate shaft into the engine
gain access to the
•
Roll pin
to
avail-
and separate the intermefrom the steering gear
•
Right front wheel
•
Tie rod
end from the steering arm right strut
make
(If equipped with a 2.7L engine, turn left front tire towards the left as far
tion.
as possible to provide clearance.
the event
in
Turn the front wheels to the straight-
ahead position.
the begin-
DISARMING
Remove
or disconnect the following:
•
Negative battery cable
•
Wiper arms
•
Wiper module cover and cowl cover
•
CAUTION Bag system must be
compartment
roll pin.
the
3.
Reinforcement from the
strut
towers
and wiper module •
dis-
armed before repair and/or removal of any component in its immediate area including the air bag itself. Failure to do so may cause accidental
deployment
4 steering gear mounting bolts (2
the precautions in the beginning of this sec-
ning of this section as well.
Air
order
the bench,
Before servicing the vehicle, also
The
in
the clear the air conditioning lines.
REMOVAL & INSTALLATION
2.
i?
mounting
bracket to the steering gear
diate shaft
an accidental deployment.
sure to refer to the precautions
loosen the 2
bolts attaching the right
Power Rack and Pinion Steering
1
in
to
line
^Special tools are commercially able for removing roll pins.
never place anything on or close to the
module which may be thrown
to the side without
Booster vacuum
on the inflator
it
disconnecting the fluid lines
facing up. •
Master cylinder from the booster
and position
Place the inflator module on a bench
or other surface with the
fluid lines
equipped with speed proportional
steering, disconnect the wiring from
Gear
away. •
If
the solenoid control valve on the end of
carrying a live air bag,
hold securely with both hands, and ensure that the
5.
•
carrying a live inflator module,
fluid
der.
CAUTION
When
Power steering gear
•
Allow the system capacitor to dis-
repair
housing
from the reservoir
insulator (wrap with quality electrical tape).
charge
rods from the steering gear
Siphon the power steering
•
air
2.
tie
and place them on the transaxle
of the air bag, resulting
Throttle body’s intake air duct
and
resonator
Clamp
4.
position with •
the steering wheel
some
in
the center
type of holding device.
Intermediate shaft from the steering
column coupler
The steering gear
is
removed
or installed
through the right side of the vehicle
CHRYSLER CORPORATION CONCORDE
LHS
•
•
300M
•
INTREPID
equipped with Antilock Brake Sys-
** WARNING
STEERING
GEAR BOOT
5-27
VISION
•
tem (ABS)
Be sure the spacer block is
in
Brake caliper assembly. Support the
•
the rack
centered before connecting the
frame with a strong piece of wire.
rods to the steering gear.
Do Tie rods to the steering gear with
•
assembly from the vehicle
caliper
tie
and
the washers between the rods
not allow the assembly to hang
Remove
by the brake hose.
the
front brake rotor disc
SPACER the steering gear. Torque the bolts
BLOCK 10. 9300BG05
Center the spacer block
the steering
in
gear before installing the
to
tie
60
lbs.
ft.
(82 Nm).
Remaining components
•
in
the
The
reverse order of the removal steps
rods
Negative battery cable
•
Add Mopar' power and
the reservoir
let
it
go through the strut and steering
steering fluid to
2
settle for at least
it
OFF Add
fluid
knuckle. Do not turn the bolts during
removal.
minutes. Start the engine for a few seconds
and turn
damage
until the fluid level
Be sure the
tie
cedure.
shown
more than 2 as
the fluid
is
OFF
ing the
To
end
rod attaching points
tie
'•If
the
1
equipped with a 2.7L engine, turn
•
Right
tie
straight-ahead.
•
27
to
on the
tion.
on the end
use
of the coil spring requires the
of a coil
spring compressor tool.
bly.
required that 5 coils be captured
is
to half of the
specified torque, then tighten the
nuts
in
sequence again
to
95
pin •
is
roll pin.
centered
in
ft.
lbs.
•
Bracket bolts; tighten them
ened) •
to
27
lbs.
(37
ft.
lbs.
Solenoid valve,
if
(47
socket
of the strut shaft to prevent
Remove
the upper
it
strut shaft nut.
mount assem-
Remove
the coil spring
and com-
Remove
the lower spring isolator from
The suspension arms must hang
the strut
assembly lower spring seat
Remove
2.
freely.
Inspect
f.
or disconnect the following:
mal wear,
•
Negative battery cable
•
Front wheel(s)
•
Stabilizer bar attaching link at the
components
all
leakage or
oil
strut.
abnor-
for
Replace
failure.
parts as required.
To install: (58 (if
strut
Nm) tie
7.
assembly
Loosen, but do not remove the outer
3.
loos-
Nm)
Steering gear fluid lines; torque the nuts to 35
•
ft.
L-4558A
tool
10mm
supports under the suspension arms.
Be sure the
lbs.
and a
jounce bumper and seat bearing and
e.
4 steering gear mounting bolts and ft.
Rod Socket
strut shaft nut
pressor as an assembly from the
the joint.
torque the bolts to 43
the coil
the upper strut
»»Do not support the vehicle by placing
Intermediate shaft to the steering
gear using the
is off
dust shield as an assembly
(129 Nm). •
Compress
load
It
within the jaws of the compressor tool.
sequence
indexing of the
from turning. Remove the
Nm) in
all
Install Strut
c.
the precautions in the beginning of this sec-
Right front wheel. Torque the lug
nuts
for
Position the spring compressor
d.
(37
lbs.
ft.
Before servicing the vehicle, refer to
.
^Service
rod on the steering arm
and torque the nut
mount
mount assembly.
Steering gear
left front tire
strut
assembly
spring until
connect the following:
Install or
•
by performing
mark the
paint,
tool onto the strut.
the center of the steering gear travel. 9.
Using
strut
parts at
b
Position the
strut
lower spring isolator, spring and
upper
upward.
the strut from the vehicle.
Securely mount the strut assembly
a
unit,
rod hole while rais-
tie
of the steering gear
the bolts.
assembly upper
the following procedure:
install:
8. at
left
Remove
into a vise
Slide the right end of the steering
gear out through the
off
the 3 strut
Disassemble the
6.
for
a few minutes, then repeat the procedure. 7.
Remove
5.
mount-to-shock tower mounting nuts and
extremely foamy, allow
the vehicle to stand with the engine
Hold the bolt head with a
strut removal.
washers.
If
assembly-to-steering
wrench and turn the nuts
Lower the vehicle and repeat the pro-
12.
rods and the steering gear as
not hold the
at a time. Refill the reservoir
strut
knuckle bolts must not be turned during
needed.
washers between
to position the
Do
the locked position for
in
seconds 9300BG06
off the floor
engine. Turn the steering from
lock-to-lock several times.
wheel
The
4.
Raise the front wheels
start the
knuckle will
as necessary
remains constant.
and
the bolts are turned,
If
to the steering
result.
Repeat this procedure
1 1
assembly-to-steering
strut
knuckle bolts are serrated where they
end from the steering arm using
Nm)
•
speed proportional steering
tie
puller
Please
visit
MB-
stream
of fluid
strut.
site at
A
slight
between the strut,
will
rod
Speed sensor wiring harness
our web
by performing the
Inspect the strut assembly for
and dripping
mounting bracket from the
strut
signs of leakage Actual leakage
990635.
equipped with
a.
rod end-to-strut assembly steering arm
attaching nut. Then, remove the outer
Assemble the
following procedure:
if
www.chiltonsonline.com
running
off
down
the lower
amount
strut
of
be a
the side
end
of the
seepage
rod and strut shaft seal
CHRYSLER CORPORATION
9® 5 "40 is
CONCORDE
LHS
•
•
300M
•
INTREPID
not unusual and does not affect perfor-
mance
of the strut
the lower spring isolator on
Install
b.
assembly.
compressed
the strut unit. Install the
the lug nuts, in sequence, to
'•Service of the
95-100
the use of a coil spring compressor
(129-135 Nm).
lbs.
ft.
tool.
Negative battery cable
•
Rear 1
bearing into the
installed into the seat with the notches
Before servicing the vehicle, refer to
.
bly.
made
Align the paint marks
during
removal.
assembly, lower spring
Install the
e.
The
spring until
assembly and a lower
of the strut
The
strut is attached to the spindle
strut shaft, aligning
on the
mount-to-shaft
Remove
2.
retainer nut. Inspect
alignment marks
all
strut
Compress
coil spring. all
load
is off
of the
the coil
upper
mount assembly.
by a
rear spindle with a pinch
align as
or disconnect the following:
Caliper assembly and rotor from
•
required. While holding the strut shaft
10mm
from turning with a
the hub,
equipped with
if
rear disc
socket,
brakes
torque the strut shaft nut to 70
lbs.
ft.
Brake flex hose from the support
•
(94 Nm).
bracket and wheel cylinder,
com-
Equally loosen the spring tension
until all
the spring
equipped with
rear
drum
Plug the brake
flex
hose
released.
is
compressor
tool.
the rear caliper to tower. Torque the 3 upper nuts to
25
ft.
if
brakes. to prevent
system contamination. Do not allow
Install the front strut into the strut
8.
indexing of the
for
Rear wheel
•
made during removal and
Remove
strut
spring
bolt to hold the spindle to the strut.
Install the strut
pressor tool
mount
mark the isolator,
Position a spring compressor tool
b.
mount
jounce bumper and
the paint marks.
strut
paint,
parts at reassembly.
springs
onto the
bly.
g.
coil
springs are contained between the upper
split collar
f.
and upper
assemblies support the
rear strut
spring seat on the body of the strut assem-
upper mount on the
Using
tion.
positioned around the struts. The coil
and spring assem-
Securely mount the strut assembly
into a vise.
weight of the vehicle using
Lower the seat bearing and dust
d.
shield onto the strut
a.
the precautions in the beginning of this sec-
on
down.
required that 5 coils be cap-
is
tool.
bearing seat. The bearing must be
the bearings facing
It
coil spring requires
tured within the jaws of the compressor
the paint marks made during removal. Install the strut
VISION
coil
spring onto the strut assembly aligning
c.
•
7922BG48
hang by the
lbs.
brake hose. Support the caliper
off
Separate the lateral links trom the spin-
frame with a strong piece
of
dle— rear
(33 Nm). of the
strut service
Position the steering knuckle neck
9.
wire. into the strut
assembly.
Install the strut
Speed sensor cable routing bracket
•
assembly-to-steering knuckle bolts.
Install
and tube, the nuts onto the attaching bolts
• to 125 10.
lbs.
ft.
if
equipped with
ABS
and torque Lateral links to the rear spindle
(169 Nm). Do not turn the
assembly
bolts
serrated bolt heads during installation. Turn •
Rear strut assembly-to-stabilizer
only the nuts. bar attaching link at the stabilizer bar
'•Hold the hex on the attaching
The
strut assembly-to-steering knuckle bolts are serrated (toothed)
attaching link does not have to be
where they go through the strut and steering knuckle. Do not turn the bolts during removal.
turned,
damage
If
removed from the
bolts are
3.
to the steering
Remove
in
•
Brake rotor and caliper assembly
to
14
bolts to
ft.
lbs.
(19
Nm)
removed from the 4
it
to
will
Outer
tie
lbs.
(37
to
strut.
down
trailing
arm while
the strut
is
being
From inside the trunk of the remove the 3 upper strut mountbolts and remove the strut from the
5.
vehicle,
assembly onto the
assembly and torque the
attaching nut to 70
rear strut
serviced.
27
Nm)
Stabilizer link strut
arm
—
service
the end of the strut assembly. Let the
from the rod on the steering
attaching link stud at the bar
Using a hammer, tap on the top sur-
spindle and assembled components hang
if
the nut from the stabilizer-to-strut
spread
bracket onto the front strut,
off
Remove
be
and
ft.
•
jammed. This
punch
face of the spindle, driving the spindle
and torque the attaching nut
•
punch
Front speed sensor cable routing
equipped •
center
bolt. Install a
the spindle casting allowing
the adapter and torque the caliper
•
7922BG49
the hole on the spindle and tap the
into the hole until
connect the following:
strut.
the rear spindle-to-strut
assembly pinch
knuckle will result. Install or
link
stud while breaking the nut loose. The
ft.
lbs.
(95
ing
T922BG50
vehicle.
Nm)
Front wheel and lug nuts. Torque
6.
Disassemble the
the following procedure:
strut
by performing
Loosen, then remove the rear spindle-tostrut pinch bolt
— rear
strut service
CHRYSLER CORPORATION CONCORDE c.
•
300M
•
the strut shaft nut
it
paint
Remove
assembly
off of the strut shaft.
the coil spring and 7.
4558 and
Remove
compressor
an assembly from the
Insert a center
punch
into the hole
spindle and tap until the casting
spread
— rear
on the
mal wear,
all
for
pressor tool
leakage or failure. Replace
oil
parts as required.
strut service
Remove
abnor-
is
a.
Install
the lower spring isolator on
the strut unit.
If
it
is
the original isolator,
b.
Install
Install
bottom
the jounce
bumper
Install the plate
into the
on top
of the
Install the
bumper and
spindle tap
is tightly
on the
10.
d.
hammer
spindle driving the strut
— rear
it
on the surface
down and
strut service
off
of the
the end of
Install
tension
comreleased.
is
compressor
Push or
tool.
the top plate onto the strut
the notch in the
seated against the locating
assembly.
Remove
the center
in the spindle.
or connect the following:
Strut-to-spindle pinch bolt and ft.
lbs.
(55
Nm)
Lateral link-to-spindle attaching bolt
and torque
to
105
ft.
(140
lbs.
Nm)
the coil spring
and com-
•
marks on the spring
Stabilizer bar attaching link
and
torque the stabilizer link-to-stabilizer bar attaching nut to 70
to that of
ft.
lbs.
(95
the strut unit.
Access the 3 upper through the trunk
strut
mounting nuts
—
rear strut service
During reassembly, tap the spindle onto the strut until the notch in the spindle
Allow the components to hang from the trailing arm as shown
—
Timing belt service
rear strut service
is
covered
ft.
tap the spindle
strut, until
torque to 40 •
pressor tool onto the strut unit and align the paint
strut
Install
•
an assembly.
unit as
Tap with a
dust shield, jounce
(95 Nm).
lbs.
ft.
the spindle assembly onto the
of the strut.
dust shield and into the jounce bumper. c.
the spring
punch from the hole
align the paint marks.
dust shield.
until all
assembly onto the
following procedure:
70
(28 Nm). 9.
by performing the
socket tool L-
Allen wrench to pre-
Torque the 3 upper mounting nuts to 20 lbs.
strut
strut rod
8mm
Position the strut in the vehicle.
8.
To install:
Assemble the
the
Equally loosen the spring
g
components
install the strut shaft
the strut shaft nut to
strut.
Remove the plate, dust shield and jounce bumper off of the strut unit. Inspect
mount
vent the strut shaft from turning, torque
tool as
e.
f.
Using the
f.
mount
the upper strut
marks and
strut
strut shaft. Align the
retaining nut.
strut shaft nut. d.
upper
assembly onto the
from turning. Remove the
5*29
VISION
•
Install the
e.
8mm
and an
Allen wrench on the end of the strut shaft to prevent
INTREPID
rod socket tool L-
Install the strut
4558 on
LHS
•
in Section
tightly
3
of this
manual
seated against the tab
— rear
is
strut
CHRYSLER CORPORATION
5-30
CONCORDE
•
LHS
•
300M
•
INTREPID
•
VISION
WARNING
stabilizer link
Nm), while holding the
stud at the hex with a wrench
Pulling the steering knuckle out from
Rear speed sensor cable routing tube
•
and
bracket,
Rotor and caliper assembly
•
ABS
equipped with
if
the vehicle after releasing from the ball joint
(if
equipped with rear disc brakes) and torque the bolts to 16
Rear brake
•
flex
hose
ft.
lbs.
to the
(22
ft.
drum
keep the
lbs.
Loosen the pivot if
equipped
bolt
rear
lower control arm service
REMOVAL & INSTALLATION
a metal encased pivot bushing and a solid
rubber tension strut bushing. The lower
the tension strut.
arm
is
bolted to the cradle assembly
Front Refer to the front strut removal and
procedure
for coil spring service
information.
isolator bushing.
The
the lower control
arm and
able.
If
the ball joint
The
is
however,
ball joint seal,
is
tension strut from the cradle as an assembly
the
by
replaced.
ing.
Refer to the rear strut removal and instalfor coil spring service
If
replaceable
isolator bushing. Inspect the control
is
damaged, do
bushings
To
Before servicing the vehicle, refer to in
2.
ball joints
on these vehi-
cles are not serviced separately.
The
lower ball joints operate with no freedefective, the entire lower con-
arm must be replaced.
3.
Install or
8.
the beginning of this sec-
•
the ball joint stud-to-steer-
connect the following:
into bracket
bolt.
•
Carefully insert a prybar between the
sure the
ball joint
ball joint seal
first,
then
front lower control
on the cradle
bracket attaching bolt.
is
from knuckle. Be
•
does not get dam-
Washer and new nut on
BALL JOINT
STUD
SEAL
a steel
LOWER CONTROL ARM TENSION STRUT BUSHING
TENSION STRUT
NUT
TO CRADLE ISOLATOR BUSHING
WORD
“FRONT"
STAMPED
LOWER CONTROL
washer
ARM
IN
CONTROL ARM
PIVOT BUSHING
HERE
the tension strut-to-cradle nut and
— lower
control
arm service
Inspect the control
the end of
sion strut-to-cradle bracket retainer
forging with 2 rubber bushings isolating the
Remove
not
the tension strut. Torque the ten-
BALL JOINT
7922BG56
Do
tighten the bolt at this time.
aged during separation.
arm
install
Lower control arm-to-cradle
REMOVAL & INSTALLATION The
necessary.
lower control arm pivot bushing
lower control arm and the steering knuckle
and separate
Lower Control Arm
the front wheel(s).
clamp nut and
if
Tension strut and isolator bushing into the cradle
Remove Remove
ing knuckle 4.
excessive wear or deterioration
install:
tion.
Ball Joint
for
and replace these components,
or bent lower control arm.
the precautions
trol
arm
arm and
tension strut for distortion, check the rubber
not attempt to repair or straighten a broken
1.
information.
the lower control
removing the pivot bushing from the
first
cradle, then sliding the tension strut out of the
as well as the lower control arm inner bush-
Rear
assembly pivot
Separate the lower control arm and
7.
non-service-
becomes worn,
pivot bushing-to-cradle
bolt.
ball joint is built into
arm must be
entire lower control
arm
tension strut
at the
Loosen and remove the lower control
6.
using a pivot bolt through the center of the rubber pivot bushing
’»The lower
nut must be used during
'•A new tension strut-to-cradle attaching nut must be used when installing
control
Lower
A new
lower control arm from the front cradle
Coil Springs
procedure
using an open end
at the flats
installation.
to speci-
assembly. The isolator bushings consist of
installation
the nut,
wrench. Discard the tension strut-to-cradle retainer nut.
wheel toe set
When removing
from turning by holding the
and remove it—
brakes.
Have the
strut
tension strut
Nm)
Bleed the brake system,
If
the tension strut-to-cradle
the tension strut.
95
fications.
play.
Remove
5.
if
Rear wheel(s) and torque the lug
with rear
lation
can be damaged.
it
equipped with rear drum brakes
(129
12.
joint or
attaching nut and washer from the end of
nuts, in sequence, to
11.
Nm)
can separate the inner CVnot separate the inner CV-
wheel
cylinder and support plate,
•
Do
joint.
arm and tension
strut for distortion
— lower
control
arm service
1
CHRYSLER CORPORATION CONCORDE nut to 110
9.
lbs.
ft.
•
LHS
•
300M
INTREPID
•
•
5-31
VISION
(150 Nm), while
holding the tension strut
with
flat
an open end wrench. Inspect the ball joint seal and replace it
if
damaged.
Install the
lower
ball joint
stud into the steering knuckle and install the
clamp
bolt
and
nut.
Torque the bolt
to
40
ft.
(55 Nm).
lbs.
10.
Install
the front wheel and lug nuts.
Torque the lug nuts,
95-100
ft.
lbs.
in
a star pattern, to
(129-135 Nm). Lower
vehicle so the suspension
the
supporting the
is
ARBOR PRESS RAM SPECIAL TOOL 6644TOOL MB 990 799
-
1
2 -
weight of the vehicle 1 1
.
Torque the lower control arm pivot
bushing-to-cradle bracket attaching bolt to
105
ft.
lbs.
.
PIVOT BUSHING
5 -
TENSION STRUT BUSHING
6 -
LOWER CONTROL ARM
Remove
3 - SPECIAL TOOL MB990799 4 - TENSION STRUT BuSH*lG
LOWER CONTROL ARM
5 -
the nut
the lower control
arm
s tension
bushing
strut
Position Installer tool 6644-1 on top
bushing with the pivot bushing
of the pivot
and separate the ten-
Removing
pivot
bushing
8.
Remove
arm
Installing the lower control
the lower control arm/ten-
sion strut assembly from the vehicle. 2.
ARSOR PRESS RAM SPECIAL TOOL 6644-4
2 -
(142 Nm).
CONTROL ARM BUSHING REPLACEMENT 1
4 -
-
1
3 - SPECIAL
setting in the recessed area of the installer
sions strut from the lower control arm. tool. 3.
Using an arbor press, position the 9.
lower control arm with the large end of the pivot bushing inside the Receiver tool
MB-
990799. 4.
Remover
tool
6644-2 on
pivot bushing out of the lower control
6.
install:
with the word strut,
MB-
tool
arm so
that
it
ARBOR °fl£SS root b6aaj
-
10
.
lower control arm
4 - SPEClA-
Position an open end wrench on the
keep
it
arm nut
95
to
ft.
lbs.
TOOL 0644-3 TOOL U8980TW
from turn-
Torque the tension strut-to-lower con-
ing.
Using a new pivot bushing, position
the lower control
1
5 - SPECIAL
trol in
the ten-
the control
2 - special
of the tension strut to
990799.
it
away from
s -
1 1
on the Receiver
flat
7.
FRONT, stamped on
facing
arm.
Turn the lower control arm over and it
tension strut into the
Install the
lower control arm's tension strut bushing
sion
reposition
squarely bottoms
arm. 10.
Using the arbor press, press the
arm.
To
arm 7.
until the installer tool
against the surface of the lower control
Position
top of the pivot bushing. 5.
Using the arbor press, press the
pivot bushing into the lower control
arm
Installing the lower control
(130 Nm).
strut
s tension
bushing
is
square with the bushing hole.
TENSION STRUT BUSHING REPLACEMENT To install: 1
.
Remove
Thoroughly, lubricate the new tenthe lower control arm/ten-
sion strut bushing, the lower control sion strut assembly from the vehicle. 2.
Remove
the nut and separate the ten-
and the
Installer tool
Bushing
Installation
sions strut from the lower control arm.
Lube
Press the new tension strut bushing
8 3.
arm
6644-3 with Rubber
Using an arbor press, position the by hand, into the large end ot the Installer
lower control arm with the tension strut
bushing inside the Receiver
tool
6644-3 as
tool
MB-
9
lar
as
it
will
go
Position the lower control
arm onto
990799. 4
Position
Remover
tool
on the arbor press so
6644-4 on
hole top of the tension strut bushing. 5.
is
that the tension strut
centered on the Receiver tool
MB-
990799
Using the arbor press, press the tenPosition Installer tool 6644-3. with
sion strut bushing out of the lower control the bushing installed, inside the tension
ARBOR PRESS RAM SPECIAL TOOL 6644-2
arm.
•As
4 -
SPECIAL TOOL MB990799 PIVOT BUSHING
6 -
LOWER CONTROL ARM
1
-
2 3 -
strut
bushing
the lower control
Remover
tool is press through
the tension strut bushing, 9306BG25
Removing
the
arm
pivot
it
will cut the
bushing into 2 pieces. 6.
Remove
bushing hole
1 1
.
12.
the lower control arm, both
is
covered
bushing.
Using the arbor press, press the ten-
sion strut bushing into the lower control tool.
arm.
Heater Core replacement
lower control
Position Installer tool 6644-2 on top
of the tension strut
bushing pieces and the Remover
in the
arm.
in Section
2
of this
manual
CHRYSLER CORPORATION
5-32
CONCORDE
LHS
•
300M
•
*-As the bushing is being installed, a pop will be heard and Installer tool 6644-3 will move slightly up off the
•
INTREPID
the control
arm assembly
it
New hub and
•
straight off of the wheel
the
hub and bearing-to-stub
from the arbor press and remove
6644-3 from the tension
the tension strut bushing
is
Installer
bushing;
strut
now
installed.
not torque the nut
'•This hub nut
a torque prevailing
is
retaining nut
14.
Install the
tension strut into the lower
assembling the hub.
bolts to 16
ft.
Wheel and
lug nuts. Torque the lug
nuts
Remove
7.
word FRONT, stamped on the tension facing 15.
away from
the
hub and bearing assembly
to the
arm nut
95
to
Pump
12.
keep
it
from turn-
ft.
lbs.
(130 Nm).
Wheel Bearings
•If the metal seal on the hub and bearing assembly is seized to the steering knuckle and becomes dislodged on the hub and bearing during removal, the hub and bearing must be replaced.
If
ADJUSTMENT
the flinger disc
rear wheel bearings.
lubrication or
There
is
Remove
8.
the
hub and bearing assem-
bly from the steering knuckle by sliding
no periodic
maintenance recommended
straight out of the knuckle
is
and
off
the
its
from moving. Torque the hub and bearing assembly-to-stub shaft retaining nut ft.
120
to
(163 Nm).
lbs.
WARNING
When
wheel drive vehicles are
front
the brakes until a firm pedal
14.
must be replaced. These
ft.
With the weight on the vehicle on
13.
becomes
during the removal proce-
dure, the hub and bearing assembly
equipped with permanently sealed front and
95-100
wheels, apply the brakes to keep the vehicle
I:
damaged
a star pattern to
obtained.
Position an open end wrench on the
ing. Torque the tension strut-to-lower control
mount
in
(22 Nm).
lbs.
(129-135 Nm).
lbs.
steering knuckle assembly.
of the tension strut to
flat
strut,
the 3 attaching bolts that
the control arm.
time.
at this
Torque the brake caliper guide
bly.
A MUST be used when •
control arm’s tension strut bushing with the
A NEW
be used when
Brake rotor and the caliper assem-
retaining nut and can not be reused.
NEW
MUST
assembling the hub. Tighten but do
axle retainer nut. •
tool
bearing assembly-to-
stub shaft retainer nut. retaining nut
Remove
6.
Remove
the front brake rotor from
hub by pulling
mounting stud.
control arm. 13.
Remove
5.
the
VISION
•
it
ends
tightening the hub and bearing assembly to stub shaft retaining nut, do not exceed the maximum torque of 120 ft. lbs. (163 Nm). If the maximum torque is exceeded this may result in a failure of the halfshaft.
for these units.
of the stub shaft.
REMOVAL & INSTALLATION
prybar or tap
Gently pry the assembly out with a
9.
mer,
if
out with a soft-faced
ham-
Inspect the toe setting on the vehicle
and
adjust,
if
necessary.
necessary. Be very careful not to
damage
Front
it
the
hub and bearing assembly.
Rear
To install: 1.
Before servicing the vehicle, refer to
the precautions
in
the beginning of this sec-
tion. 2. 3.
Clean the hub and bearing mounting
10.
surfaces of
Remove Remove
the front wheel. the front caliper
•
away from the knuckle and
caliper off the
of the
lifting
the
machined abutment on the
steering knuckle.
Suspend
the caliper out of the
with a piece of wire.
way
•
Before servicing the vehicle, refer to
connect the following:
2.
Remove
bearing squarely onto the
•
stub shaft and the steering knuckle
•
Hub and
and tighten equally
assembly
is
until the
•
bear-
seated squarely •
knuckle. Torque the mounting bolts
•
80
ft.
lbs.
or disconnect the follow-ing:
Rear wheel
Brake caliper and
rotor,
if
equipped
Brake drum,
if
equipped with drum
brakes
against the front of the steering
to
the beginning of this sec-
with rear disc brakes
Bearing assembly mounting bolts
ing
in
tion.
Install or
11.
assembly
guide pin bolts, then rotating the top
4.
and be sure there are no
nicks present.
from the steering knuckle by removing the 2
caliper
dirt
1.
the precautions
Bearing dust cap Cotter pin, nut retainer, nut, washer
and bearing/hub assembly from the
(110 Nm).
spindle
To 3.
install: Install or
•
connect the following:
Bearing/hub assembly, the bearing/hub assembly washer and torque the nut to 124
ft.
lbs.
(168
Nm) •
Nut retainer and a new cotter pin
•
Dust cap
•
Brake drum or rotor and caliper
assembly •
Rear wheel and torque the lug nuts, in
a star pattern, to
95-100
ft.
lbs.
(129-135 Nm) 4.
Road
test the vehicle to verify
no
excessive noise from the rear wheel bearing area. Carefully pry the front bearing/hub
assembly away from the steering knuckle
CHRYSLER CORP. 1998-02 Chrysler-Sebring Coupe
DRIVE TRAIN ENGINE REPAIR FUEL SYSTEM
6-26 6-2
F Front Crankshaft Seal
6-23
PRECAUTIONS
6-2
Removal &
Installation
Fuel Filter
STEERING AND
Removal &
SUSPENSION
6-36 6-36
Disarming
6-36
Precautions
6-36
Fuel
Installation
6-4
Removal
6-3
Pump
Removal Fuel
6-3
Alternator
Installation
Installation
System Pressure
Removal &
Lifters
Installation
6-16
Removal &
Installation
Coil Spring
Removal &
Installation
6-16
Removal &
6-28 Ignition
Timing
6-5
Intake Manifold
6-11
Cylinder Head
Removal &
6-8
Installation
D
Lower Control Arm
Installation
6-3
Removal
6-2
Removal &
&
Installation
6-5
Exhaust Manifold
6-14
Removal &
6-14
Installation
6-42
Oil
6-19
Pan
Removal & 6-5
Installation
Installation
Pump Removal &
6-19 6-21
Installation
6-21
Starter
Installation
6-22
6-39 6-18
Motor Installation
6-18 6-38
Strut
Removal
&
Installation
6-38
T Transaxle Assembly Installation
6-26 6-26
U Upper
6-41
Ball Joint
Removal & Removal &
Installation
6-41 6-41
Installation
6-41
V 6-18
Valve Lash
6-18
Adjustment
W Water
Pump
Removal &
6-7 Installation
Wheel Bearings
6-7
6-43 6-43
Adjustment
Removal &
P Piston and Ring
6-39
Shock Absorber
6-41
6-42
6-10
S
O Oil
E
Engine Assembly
Installation
Installation
Upper Control Arm 6-41
Ball Joint
Removal &
6-2
Distributor
6-11
L
Lower
Removal &
6-22
6-10
Rocker Arm/Shafts
Removal &
6-40
6-8
Installation
6-30
6-40
Installation
Removal &
Removal &
I
Removal &
6-22
Rear Main Seal
Removal &
6-30
6-36
R
6-24
6-30
Bleeding
6-31
Overhaul
Removal
Installation
Hydraulic Clutch System
6-31
CV-Joints
6-24
6-30
Halfshaft
6-28
Adjustment
6-24
6-23
Precautions
6-36 Installation
6-24
H
6-28
Clutch
Removal &
Fuel System Service
C Camshaft and Valve
Steering Gear
6-24
6-24
Relieving
Power Rack and Pinion
6-15
6-24
&
6-22
Positioning
6-15
6-24
Removal &
Bag
Installation
Fuel Injector
A Air
Dodge-Avenger
•
Installation
6-43
CHRYSLER CORP.
6-2
SEBRING COUPE
AVENGER
•
PRECAUTIONS of the following precautions,
all
which deal with personal
prevention
safety,
component damage, and important points when servicing a
of
IMMEDIATELY seek
brake fluid internally,
Before servicing any vehicle, please be sure to read
The EPA warns
•
with used engine
prolonged contact
that
may cause
oil
skin disorders, including cancer!
motor vehicle:
should make every
Never open, service or drain the radia-
system when the engine
tor or cooling
hot; serious
burns can occur from the steam
Observe
•
all
applicable safety precaufuel.
Whenever
servicing the fuel system, always work
Do
well-ventilated area. or vapors to
come
in
in
a
not allow fuel spray
contact with a spark,
open flame or excessive heat
(a hot
drop
sure to used engine
oil.
oil.
other exposed after
Soap and
expo-
water, or
waterless hand cleaner should be used. •
new
All
vehicles are
your vehicle.
If
of
becomes contaminated, completely
fluid.
Any brake
brake
the brake fluid flush the
Never reuse any brake
fluid.
fluid that is
removed from
the system should be discarded. Also,
Protective
soon as possible
fluid for
system with new
minimize your
oil.
Wash your hands and any skin areas as
when working around
effort to
used engine
to
of
You
gloves should be worn when changing
is
and hot coolant.
tions
exposure
number
a
to take into consideration
•
proper operation of the brake system. You
should always buy the correct type
medical assistance.
now equipped
come in will damage
contact with
a painted surface;
the paint.
it
Never operate the engine without the
•
proper amount and type of engine
so WILL result
Timing
•
belt
oil;
doing
severe engine damage.
in
maintenance
Many models
extremely
is
with an air bag system, often referred to as a
important!
Supplemental Restraint System (SRS) or
ence-type, non-freewheeling engine.
Supplemental
timing belt breaks, the valves
Inflatable Restraint (SIR) sys-
do not
allow any brake fluid to
utilize
an
in
interferIf
the
the cylinder
tem. The system must be disabled before
head may
extinguisher near the work area. Always
performing service on or around system
tially
keep
components, steering column, instrument
expensive) engine damage. Refer to the
light, for
example). Keep a dry chemical
fire
fuel in a container specifically
designed
for fuel storage; also,
panel components, wiring and sensors.
always
and disabling proce-
strike the pistons,
causing poten-
serious (also time-consuming and
maintenance
manual
interval charts in the front of
recommended
properly seal fuel containers to avoid the
Failure to follow safety
possibility of fire or explosion. Refer to the
dures could result
additional fuel system precautions later in
deployment, possible personal injury and
timing belt section for belt replacement and
this section.
unnecessary system repairs.
inspection.
Fuel injection systems often remain
•
in
accidental air bag
Always wear safety goggles when
•
working with, or around, the
turned OFF. The fuel system pressure must
When
be relieved before disconnecting any
sure the bag and trim cover are pointed
lines. Failure to
do so may
and/or personal
injury.
•
fuel
wash your hands thoroughly
handling brake
brake fluid
fluid.
If
you do get
with clean, running water for 15 minutes.
eye
irritation persists,
or
if
and trim cover upward, away
from the surface. This
motion
module
of the
will if
it
is
system precautions
accidentally
If
you have taken
air
bag
later in this section.
Clean, high quality brake fluid from a
•
sealed container
is
essential to the safe
for the
and
replace-
and
interval for the timing belt,
to the
Disconnecting the negative battery
cable on
some
vehicles
may
the functions of the on-board
tem^) and may
interfere with
computer sys-
require the computer to
undergo a relearning process once the negative battery cable •
When
reconnected.
is
drum
servicing
brakes, only dis-
assemble and assemble one side
reduce the
deployed. Refer to the additional
your eyes, flush your eyes
in
bag on a work surface, always
air
face the bag
ethers and polyglycols. Avoid contact with
after
carrying a non-deployed air bag, be
deployed
Brake fluid often contains polyglycol
the eyes and
bag system.
away from your body. When placing a non-
result in fire
ment
•
pressurized, even after the engine has been
air
this
at a time,
leaving the remaining side intact for refer-
ence. •
Only an MVAC-trained, EPA-certified
automotive technician should service the conditioning system or
its
air
components.
ENGINE REPAIR that serve as inputs to the
Distributor
PCM;
the
PCM
•
determines crankshaft position from these sensors, then calculates injector sequence
REMOVAL
and ignition timing, based on the 1
2.5L Engine
.
is
Disconnect the negative battery cable.
3.
Remove
or disconnect,
if
necessary
camshaft driven mechanical distributor. This engine uses a fixed ignition timing system, in
which the basic ignition timing
adjustable.
is
• 5.
The CKP sensor
is
is
mounted inside
the rotor-to-distributor
manifold bolt
•
•
Air cleaner cover to air cleaner
•
to
help with installation.
not
housing cover clamps
Rotor Distributor’s 2 electrical harness
connectors
Positive Crankcase Ventilation
•
Distributor
t
hold-down nuts and
Hall
(PCV) make-up
mounted
air
hose from the
air inlet
tube
•
Throttle
body hose clamp
•
Air cleaner cover, resonator
remotely from the distributor, while the
sensor
cap
Distributor cap
Matchmark
Air inlet resonator to the intake
•
effect devices.
Spark plug wires from the distributor
•
Crankshaft Position (CKP) sensor and
CMP
•
The Powertrain Control Module
Camshaft Position (CMP) sensor are
or disconnect the follow-
and the distributor-to-engine positioning
for access:
(PCM) determines spark advance. The
tor
Remove
the beginning of this section.
in
2.
equipped with a
4.
ing:
Before servicing the vehicle, refer to the
precautions
The 2.5L engine
data.
Exhaust Gas Recirculation (EGR) tube
washers •
Spark plug cable mounting bracket
•
Transaxle dipstick tube
•
Distributor
(if
necessary)
the distribu-
housing. Both sensors generate pulses
inlet
tube
and
CHRYSLER CORP. SEBRING COUPE TIMING DISTURBED
INSTALLATION
1
2.5L Engine
TIMING
piston
NOT DISTURBED
2.
’•Before servicing the vehicle, refer
to
the precautions in the beginning of this
.
Inspect the rotor for cracks or burned
and replace
defective. Install
it
3.
Inspect the 0-ring seal.
If
Install or
new
is
Remove •
rotor should align the No. 1 terminal of
nicked or Distributor
one. Be sure ers
the 0-ring
connect the following:
Distributor
’•'With the distributor fully seated, the
•
cracked, replace with a
hold-down nuts/wash-
and tighten the nuts
properly seated on the distriblbs.
to
108 inch
Nm)
(13
utor. •
3.
Install or
connect the following: •
•
REMOVAL 2.0L Engine
the distributor cap.
the rotor onto the distributor. 2.
of the
stroke.
Align the rotor with the distributor
•
electrodes,
Top Dead Center (TDC)
1
housing matchmark.
section. 1
is at
compression
6-3
AVENGER
Alternator
Rotate the crankshaft until the No.
.
•
or disconnect the following:
Negative battery cable
•
Right front wheel
•
Wheel
•
Auto-cruise speed control assembly
•
Alternator drive belt
well side cover
•
Alternator electrical connectors
•
Alternator bracket
•
Alternator
Spark plug cable bracket
Both distributor wiring connec-
2.5L Engine
Distributor drive with the slotted
tors
end
••When
of the
camshaft
the distributor
is
installed
properly, the rotor will be aligned with
the previously •
made mark.
Distributor
4
hold-down nuts/wash-
Distributor cap
•
Spark plug cables
•
Transaxle dipstick tube
Install or
108 inch
lbs.
EGR
Spark plug cable bracket
Both distributor wiring connec-
Throttle
Distributor cap
•
PCV hose
•
Spark plug cables
•
•
Transaxle dipstick tube
•
EGR
lbs. (11
Nm) •
Air cleaner cover, resonator
•
Throttle
•
PCV hose
•
Air cleaner
•
Air inlet resonator to intake
inlet
housing cover
Air inlet resonator to intake
mani-
fold bolt
•
and
•
A/C compressor
•
Power steering pump/alternator
Negative battery cable
Alternator bracket Intake manifold
Alternator electrical connectors
•
Alternator
housing cover clamps
mani-
Negative battery cable
5.
Generator Generator brace
Prior to installation, align the distributor
shaft with the distributor
engine
housing— 2. 5L Exploded view
ot the alternator
plenum
• •
body hose clamp
4
plenum
Intake manifold
•
tube
7922CG01
drive belt
•
fold bolt •
belt
drive belt
clamps •
tube and tighten the bolts to
95 inch
Air cleaner
Power steering pump drive cover
and
body hose clamp
•
Auto-cruise control reservoir
assembly •
tube
tors •
Wheel well side cover
if
Nm)
Air cleaner cover, resonator inlet
Right front wheel
•
•
lbs. (11
or disconnect the following:
Negative battery cable
•
tube and tighten the bolts to
95 inch •
•
connect the following,
(13
Nm) •
•
removed: •
ers and tighten to
Remove
•
and related components— 2. 0L engine
For complete service labor times, order the Chilton Labor Guide
stay
CHRYSLER CORP.
6-4
SEBRING COUPE
•
AVENGER used a
lbs.
(490-712 N)
for
belt.
k If
110-160
belt or
new
WARNING new
installing a
belt,
tension the
70 lbs. (310 N) and operate the engine for 5 minutes or more; belt to
then, apply the final tension. 3.
Torque the alternator-to-lower alterna-
tor bracket nut to
45
Nm) and
lbs. (61
ft.
alternator-to-upper bracket bolt to 40
ft.
the lbs.
(54 Nm). 4.
Install or
connect the following:
•
Auto-cruise speed control assembly
•
Wheel
•
Right front wheel
•
Negative battery cable
well side cover
2.5L Engine 1.
Pump
1.
2. 3.
4.
cover Drive belt (A/C compressor) Drive belt (Power steering oil and generator) Intake manifold plenum (Refer to GROUP 11 - Intake
5.
Generator bracket
6.
Intake manifold
Generator Generator 9. Tensioner 10. Tensioner 11. Generator
pump
7.
plenum stay
connect the following:
Alternator
•
Alternator electrical connectors
harness connector
8.
Manifold.)
Install or
•
pulley bracket pulley
Intake manifold
•
Alternator bracket. Torque the alter-
bracket
nator-to-lower alternator bracket nut to 30
Exploded view
of the alternator
and related components
—2.5L engine
16
1
.
2.
Remove • •
or disconnect the following:
Negative battery cable Drive belt
•
Alternator belt
•
Oil level
gauge
unit 2.
•
Alternator electrical connectors
•
Alternator brace
•
Install or
ft.
(22 Nm).
lbs.
plenum
•
Power steering pump/alternator
connect the following:
Attach a belt tension gauge
on the drive
Alternator
power steering pump
•
Alternator bracket
the drive belt tension to
99-121
•
Alternator electrical connectors
(440-540 N)
belt or
•
Alternator drive belt
lbs.
Attach a belt tension gauge
on the drive
belt; then,
90-110
lbs.
midway
adjust the drive belt
(400-490 N)
Alternator
for a
to
for a
(642-838 N)
3.
17 4.
pulleys; then, adjust
used
for a
new
belt.
ft.
lbs.
Install
(24 Nm). the
A/C compressor’s
Powertrain
Intermediate
Speed
module
Control switch
link
Main switch
control
assembly
Stop
light
switch
Vehicle speed
sensor |
npulspeed sensor
Reservoir assembly
Transaxle range sensor 9306CG03
View
of the auto-cruise
speed control and related components
—2.0L and 2.5L engines
lbs.
143-187
Torque the tension pulley bracket nut
belt.
control
midway
between the alternator and
belt,
•
tension to
the
drive belt 2.
1.
Nm) and
Intake manifold
2.0L Engine
tion.
lbs. (41
•
Before servicing fhe vehicle, refer to
the precautions in the beginning of this sec-
ft.
alternator-to-upper bracket bolt to
INSTALLATION
3.0L Engine
plenum stay
•
drive
CHRYSLER CORP.
6-5
SEBRING COUPE* AVENGER Attach a belt tension gauge
5.
on the drive
midway
between the crankshaft
belt,
and tension pulleys; then, adjust the drive
66-86
belt tension to
110-132
a used belt or for a
new
17
lbs.
ft.
Heater hoses
•
lbs.
•
(490-590 N)
•
Electrical
connectors from the
engine components
Brake booster vacuum hose
at the
engine
Vacuum hoses running
to the bulk-
•All wires and connectors should be labeled at the time of engine removal This will save time during assembly.
head
belt.
•
(24 Nm).
Install or
7.
Accelerator cable and bracket
•
for
Torque the tension pulley bracket nut
6.
to
(295-385 N)
lbs.
•
High pressure
fuel line
and discard
the 0-ring •
connect the following:
pump
•
Power
•
Auto-cruise control reservoir
steering
drive belt cover
ply
Right front wheel
•
Negative battery cable
belts
Do not disconnect the hoses or allow pump to hang by the hoses.
the
eidfet
•
Power steering pump move aside
rail
M Hrr
Wheel
Accessory drive
•
Fuel return hose from the fuel sup-
assembly •
•
well side cover •
Power steering pump bracket
•
A/C compressor and move aside
7.
3.0L Engine Install or
•
•
and torque the bolts
33
(44
ft.
lbs.
36
Oil level
bolt to
gauge
10
•
Alternator belt
•
Drive belt
•
unit
lbs.
ft.
(49
below the manifold and discard the
Nm)
gasket and nuts
and torque the
(15
Install the
Nm)
the engine are secure.
Exploded view
mount
ot the right-side
engine
the hoist just
— 2.0L engine
Ignition timing
is
Pow-
controlled by the
Module (PCM) and
is
86
Nm
not
adjustable.
Engine Assembly
REMOVAL & INSTALLATION 2.0L and 2.5L Engines Before servicing the vehicle, refer to
1.
the precautions in the beginning of this section.
•The
transaxle must be removed
before removing the engine. They will not
come
out as a unit.
2.
Drain the engine coolant.
3.
Drain the engine
4.
Drain the transmission
5.
Properly relieve the fuel system
oil oil.
98-118 Nm 71-85 11 lbs.
pressure. 6.
• •
Remove Hood
or disconnect the following:
Engine mount insulator mounting Engine mount bracket 3 Engine mount stopper 1.
•
Engine under cover
•
Transaxle assembly
•
Radiator by disconnecting the
hoses
at the
bolt
2.
Negative battery cable
4.
Dynamic damper
Exploded view
ol the right-side
engine mount
— 2.5L engine
engine
Please
visit
our web
site at
enough
Draw tension on to support the
engine's weight but no more.
Timing
ertrain Control
engine hoist equipment
and make certain the attaching points on
Negative battery cable
Ignition
Exhaust system joint bolts just
•
and torque the
lbs.
ft.
hoses or discharge the system.
to
Nm)
Alternator brace bolts to
•
Do not loosen or remove the A/C
connect the following;
Alternator
www.chiltonsonline.com
Do
not dis-
CHRYSLER CORP. SEBRING COUPE
AVENGER
•
turb the placement of the vehicle on the
Check the transaxle drain plug,
i.
tightening
stands.
Rear (bulkhead side)
•
roll
stopper
stopper through-
roll
•
them
Upper (right-side) engine mount-
refill
if
•
necessary,
the cooling system.
Double check
Engine Coolant Temperature (ECT)
gauge
the
and engine
radiator
drain cocks, closing
and
bolt
refill
•
Check the
j.
Front engine
needed, and
if
transaxle.
through-bolt •
it
unit
ECT sensor connector Left
bank Heated Oxygen Sensor
(H0
2 S)
•
Brake booster vacuum hose Fuel supply and return hoses
installation items,
•
to-engine nuts/bolts, through-bolt
paying particular attention to loose hoses
•
Heater hoses
and mount assembly
or
hanging wires, loosened nuts, poor
•
Starter electrical connectors
•
k.
all
•
Support bracket below the mount
routing of hoses and wires.
•
Engine
10.
Connect the negative battery cable. engine and check
Start the
Attend to
11.
Immediately place stand or support
it
on an engine
it
with
Do not allow it to rest on the pan or lie on its side. Do not leave the engine hanging from the blocks.
for leaks.
leaks immediately.
Adjust the drive belts to the correct tension.
Adjust
wooden
all
all
cables (transaxle,
and check the
selector)
the operation of
fluid levels.
Alternator wiring
•
Drive belts
•
A/C compressor
•
Check
Power steering pressure switch Power steering
pump. Do not
oil
disconnect the hose
gauges and dashboard
all
Oil
•
7. •
throttle, shift
Pressure switch
•
•
Engine mount stay and
an
install
oil
Road
12.
hoist.
To
Installation is the reverse of the
1
removal procedure. Please note the follow-
manifold, using a
33
bolts to
lbs.
ft.
and
71-85
ft.
new
gasket. Torque the
lbs.
roll
Front
d.
mount through-bolt:
stopper through-bolt: 41
(56 Nm).
lbs.
'•Allow the mounts
to
engine weight before the front
roll
support the
final tightening of
Drain the engine
4.
Drain the cooling system.
5.
Recover the A/C
Remove
6.
Hood Negative battery cable
•
Strut tower bar
•
Air cleaner
•
Radiator reservoir tank
•
Front exhaust pipe
•
Throttle cable
•
Manifold
high pressure fuel
22 inch
Check
and secure engine.
it
lbs. (2.5
the engine if
lightly lubri-
•
lbs.
ft.
refill
(35 Nm).
Power steering
oil ft.
pump and torque (42 Nm)
lbs.
Power steering pressure switch
A/C compressor
•
Drive belts
•
Alternator wiring
•
Oil
•
Starter electrical connectors
•
Heater hoses
pressure switch
•
Fuel supply and return lines
•
Brake booster vacuum hose Left
• •
ECT sensor connector ECT gauge unit
•
Ground wire
connector
Exhaust Gas Recirculation (EGR)
•
Crankshaft Position (CKP) sensor
IAC motor
•
TPS connector
•
Control wiring/injector wiring har-
Right bank Heated
Distributor connector
•
Fuel injector connector
•
Right bank
•
CKP
•
KS connector EVAP solenoid valve connector EGR valve connector
Oxygen Sensor
•
Fuel injector connector Distributor connector •
•
Control wiring/injector wiring har•
ness combination connector • •
Throttle Position
•
Idle Air
Sensor (TPS)
(HO 2 S)
sensor connector
Control wiring harness and power steering harness combination con-
nector
Control (IAC) motor con•
the
Manifold
differential
nector •
connector
ness combination connector
(HO 2 S) •
electrical
•
connector •
2 S)
•
Evaporative (EVAP) Emission purge
Knock Sensor (KS) connector
bank (HO
•
combina-
connector
drain plug
necessary, and
the engine lifting devise
pressure sen-
•
Nm).
oil
26
Remove
•
Control wiring harness and power
tion •
connect the
and torque the
line
bolts to
•
solenoid valve connector
WARNING
Make certain each terminal is clean and the connector is firmly seated. Do not route wires near hot surfaces or moving parts.
h.
differential
steering wiring harness
nectors to the engine.
oil,
Engine mount stay and torque the
the bolts to 31
valve connector
Connect the wiring harness con-
bolts to
or disconnect the follow-
•
2.5L engine.
cated with clean engine
lbs.
refrigerant.
•
Torque the power steering
Using a new Oring
ft.
sor connector
ft.
g.
60
Nm)
oil.
•
ft.
fc
(81
3.
stopper through-bolt.
pump bracket bolts to 16 lbs. (22 Nm) for 2.0L engine or to 29 lbs. (39 Nm) for f.
to
pressure.
• e.
Engine mount bracket and stopper
ing:
stopper through-bolt: 32
roll
Engine assembly
and torque the bolts
•
(86 Nm).
(44 Nm).
lbs.
Properly relieve the fuel system
2.
(44 Nm).
(98-118 Nm).
lbs.
Rear
c.
ft.
ft.
Right-side
b.
ft.
63
connect the following:
the beginning of this sec-
in
•
to the
Right-side mount-to-engine nut bolt:
Engine assembly
install: Install or
bolts as follows: a.
•
Before servicing the vehicle, refer to
.
the precautions
Torque the engine mount nuts and
9.
Engine mount bracket and stopper
tion.
Connect the exhaust system
a.
such as
•
•
ing important steps:
Lifting Tool,
MZ203827
test the vehicle.
3.0L Engine
To install: 8.
engine
lights.
sor connector
Ground wire •
Throttle cable
Pressure sen-
CHRYSLER CORP. SEBRING COUPE •
Front exhaust pipe
•
Accessory drive
•
Radiator reservoir tank
•
Properly support the engine and
•
Air cleaner
•
Strut tower bar
•
Timing
•
Negative battery cable
•
Hood and
8.
Fill
replace the 9.
Fill
remove the
for
oil
pump
by hand to
freedom of movement.
Install
8.
tensioner and camshaft
or connect the following:
•
Rear timing
•
Camshaft sprocket(s), timing
belt
cover belt
and tensioner
adjust as needed
and
filter.
the cooling system to the proper %
Recharge the A/C system with the
10.
motor mount
right
belt,
Rotate the water
7.
check
sprockets
the engine with clean
level.
belts
6-7
AVENGER
•
With the timing belt removed, DO NOT4. rotate the camshaft or crankshaft or damage to the engine may
while the sprocket bolts are being
occur.
tightened.
DO NOT
allow the camshafts to turn
proper refrigerant. 1 1
Start the vehicle,
.
repair
if
check
for leaks
and
necessary.
•
Rear timing belt cover
•
Water
WARNING
pump
To install:
Water Pump
Do not attempt
Thoroughly clean
5.
all
sealing sur-
faces.
REMOVAL & INSTALLATION
assembly
ten-
installed in the engine.
This will cause
** WARNING
compress the
to
sioner plunger with the tensioner
damage
to the ten-
sioner and other related components.
Replace the water pump if there are any cracks, signs of coolant leakage from the shaft seal, loose or rough
2.0L Engine 1
Before servicing the vehicle, refer to
.
the precautions in the beginning of this sec-
6. turning bearings,
tion.3.
or sprocket or loose or Drain the engine coolant.
2.
Timing
•
damaged impeller damaged
•
This procedure requires removing the
timing belt and auto-tensioner. The
New
Remove
9.
connect the following
water
pump
O-ring
1 1
factory specifies that the timing
marks should always be aligned before removing the timing belt. Set the engine at Top Dead Center (TDC) on the No. 1 cylinder compression
Be sure the O-ring is properly seated in the water pump groove before
•
stroke. This should align all timing
pump and
105 inch
marks on the crankshaft sprocket and both camshaft sprockets.
lbs.
torque the bolts to
(12
or disconnect the following:
psi
•
Right inner splash shield
•
Accessory drive belts
for leaks.
If
Negative battery cable
release the pressure and continue the
•
Right inner splash shield
engine assembly process
engine and check
for
proper
if
Check and top
off
the cooling sys-
necessary
Before servicing the vehicle, refer to
the precautions in the beginning of this section.
okay
•
and bleed the cooling system.
2.5L Engine 1.
pressurize the cooling system to 15
(103 kPa) and check
Refill
Start the
.
12.
Nm)
Using a cooling system pressure tester,
Remove
Water
the engine support.
operation.
tem,
tightening the screws.
covers
mount bracket and mount
Crankshaft damper
10
** WARNING
belt
Right engine
•
Install or
be compressed
in a vise.
sprocket flange.
•
MUST
The tensioner
2
Drain the engine coolant.
•This procedure requires removing the timing belt and auto-tensioner. Set the engine at Top
Dead Center (TDC) on
umm Ariw put*
'
2
1
Water
2.
O-nng
pump
Exploded view Exploded view
of the
water
pump mounting— 2. OL engine
Timing belt service
ing
is
covered
in
ot the
— 2.5L engine
Section 3 of this manual
water
pump mount-
CHRYSLER CORP.
6-8 the No.
SEBRING COUPE
•
AVENGER
cylinder compression stroke.
1
This should align
To
camshaft sprockets.
4.
belt
pump
Water
assemblies
connect the following:
Install or
with a
new O-ring and
Negative battery cable lbs.
Accessory drive belts and crank-
•
ft.
Support the engine and remove the
•
•
Timing
belt
covers
•
Timing
belt
and tensioner 5.
pump mounting Water pump Water
• •
Inspect the
Thermostat
Timing
•
Negative battery cable
pump
signs of coolant leakage
the cooling system to the proper
Start the vehicle, if
check
for leaks
and
necessary.
Any problems
5.
Cylinder Head
New
water
inlet
all
for flatness
using a
within 0.004
flat
cylin-
in.
(0.1mm).
REMOVAL & INSTALLATION
new pump.
Clean
parts.
gauge and a straight-edge. The
der head must be
Check the cylinder head
6.
for cracks or
other damage.
connect the following:
Install or •
require a
all
cylinder head sealing surface.
Check the cylinder head
excessive looseness or rough turning bearing.
aluminum feeler
vent and
Thoroughly clean
5.
sealing surfaces. Use care not to scratch the
or cracks,
at the
New
head bolts are recommended.
sealing surfaces.
damage
for
WARNING
Stretch-type bolts are used.
belt
level. 6.
all
install:
h
Nm)
bolts
repair
Thoroughly clean
(23
lbs.
•
Fill
To install: 4.
To
•
engine mount
right
Nm)
(23
head
ft.
Bracket and torque the bolts to 17
•
damper
shaft
Cylinder head bolts and cylinder
•
or disconnect the following:
gasket and torque the bolts to 17 •
cover
Rocker arm/rocker arm shaft
•
install:
•
Remove
camshaft sprocket and rear timing
discard the gasket
and O-ring
the crankshaft sprocket and both
3.
pump and
Water
•
timing marks on
all
new gasket and
Install a
7.
pipe O-ring.
the cylinder
2.0L Engine head.
:
Wet
WARNING
1
the O-ring with water to
installation easier;
the precautions
make
DO NOT use
oil
or
in
the beginning of this sec-
short bolts
Properly relieve the fuel system
2.
positions
New
water
pump
gasket
^Fit the pump inlet opening over the water pipe and press the assembly together to force the pipe into the water
pump. •
Water
pump and
torque the
to-engine bolts to 20
ft.
lbs.
Timing
belt
and timing
Remove
Negative battery cable
•
Air cleaner
•
All
and wiring
harness connections required
for
•
Fuel line
•
Throttle linkage
Accessory drive
•
Power steering pump and move
•
Right engine mount.
Remove
underneath the engine.
•
•
• •
Accessory drive
belts
and adjust
•
tension
•
Negative battery cable
•
Fill
Coil pack wiring connector
•
tem.
lbs.
(34 Nm).
ft.
lbs.
(68 Nm).
c.
Step
3:
Again
d.
Step
4:
Plus 14 (90 degree) turn.
pack unit
Ignition coil
belt cover,
timing
.
in
Cylinder head cover
Timing
•
Timing
•
Intake
Unstretched 3.
Remove
Negative battery cable
•
Timing
•
Thermostat and bracket
belt
cover
belt
and exhaust manifolds,
if
Ignition coil
•
Coil pack wiring connector and
pack
•
Power steering pump
•
Accessory drive
•
Throttle linkage
•
All ducts,
belts
hoses, fuel lines and
wiring harness connectors
12.
bolt
assembly
•
Air cleaner
•
Negative battery cable Fill
the cooling system.
7922CG08
'•A complete
or disconnect the following:
•
camshaft
spark plug wires
the beginning of this sec-
Drain the cooling system.
belt rear cover,
•
belt,
tion. 2.
for the
Rocker arm/rocker arm shaft
•
Threads are not straight on line Threads are straight on line
Before servicing the vehicle, refer to
(68 Nm).
if
3.0L Engine 1
wrench
•
operation.
the precautions
lbs.
ft.
removed
and exhaust manifolds,
Timing
50
connect the following:
Install or
Cylinder head cover Intake
to
not use a torque
Spark plug wires from the spark
engine and verify proper
Start the
ft.
50
sprocket and timing belt
necessary
and bleed the engine cooling sys-
25
2:
assemblies
plugs
Crankshaft damper
1:
Step
belt(s)
aside
the
and engine block from
~Do
Step
b.
•
•
covers
4
a.
11.
Timing
belt
in
4th step.
sioner. Set the timing belt tension
•
7.
lines
cylinder head removal
(27
belt ten-
assembly
vacuum hoses,
are to be installed in
9 and 10.
steps as follows:
ing: •
(110mm)
7, 8,
Torque the cylinder head bolts
10.
or disconnect the follow-
•
floor jack
6.
Drain the engine coolant.
4.
pump-
Nm) •
3.
oil.
cylinder head bolts, the
Install the
9.
pressure. •
threads with clean engine
tion.
grease.
Lubricate the cylinder head bolt
8.
Before servicing the vehicle, refer to
.
oil
and
filter
change
is
recommended. Checking the cylinder head bolts ing (stretching)— 2
.
OL engine
for neck-
13.
Run
Start the
engine and check
for leaks.
the engine with the radiator cap off so
— CHRYSLER CORP. SEBRING COUPE
AVENGER
•
surfaces of the head and block. Check the cylinder head for cracks,
Remove
coolant leakage.
compound and
damage
or engine
scale, sealing
carbon. Clean the
oil
sages thoroughly. Check the head
pas-
for flat-
ness. End-to-end, the head should be no
more than 0.008
(0.2mm)
in.
the service limit
out-of-true.
If
exceeded, correct to
is
meet6. specifications. Note
maximum
that the
amount from stock allowed
to be
removed
from the cylinder head and mating cylinder block
is
0.0079
(0.2mm).
made
If
in.
the cylinder head cannot be
serviceable by removing this amount,
replace
it.
Check
that the
head gaskets have the
proper identification marks for the engine.
Lay the head gasket with the identification Cylinder head bolt tightening
sequence— 2. OL engine
mark
the front top.
at
-»Do not apply sealant warms and
as the engine
the thermostat
bolt
5.
opens, coolant can be added to the radiator.
When
the cooling system
engine OFF,
is full,
install the radiator
cylinder head
shut the
•
cap and
With the engine cool, check
Add coolant and
levels.
Restart the engine
check
for
and
oil
all
fluid
Distributor
•
Ground
•
test drive vehicle to
proper operation.
•
Before servicing the vehicle, refer to
To
left
end
down onto
of
Cylinder head bolts: keep them
8.
Lubricate the bolts with clean engine
9.
Install the bolts
washers by hand and
in
one or 2 turns on the threads
Cylinder head and discard the gasket
•The washers must
install:
Properly relieve the fuel system
Drain the cooling system
4.
Remove
10
or disconnect the follow-
Negative battery cable
Timing
belt
lines that
may
inhibit cylinder
Water
Identification
pump
Nm).
Step 2 70
ft.
lbs (95
c.
Step 3 80
ft
lbs (108
Install or
• •
assembly
inlet
62
Stepl
b.
1 1
head removal Intake manifold
proper
in the
a
and camshaft sprockets
Wiring harnesses, vacuum hoses
and
Torque the head bolts
sequence as follows
ing:
•
be installed cor-
The rounded shoulder ot the washer denotes the lace in contact with the bolt. The flat side ot the washer contacts the head.
3.
•
each bolt
rectly.
pressure.
•
and the special
just start
numbered order
Thoroughly clean and dry the mating
•
cylinder head straight
the block.
oil.
Exhaust manifolds and crossover
tion.
•
Install the
7.
assembly
strap from the
pipe
2.5L Engine
2.
new
head bolts are recommended.
the front cylinder head
as required
the precautions in the beginning of this sec-
head gas-
cylinder head bolts are used. All
Valve covers and rocker arm
•
•
1.
to the
mating surfaces. Stretch-type
ket or
assemblies
allow the engine to cool. 14.
from the inner rear of the front
lbs (84
ft
Nm).
Nm).
connect the following
Valve cover and gasket
Exhaust manifolds and crossover pipe
pipe retaining
•
mark :p
o
o
Distributor
•
Intake manifold
•
All wiring
^o,/
harnesses,
hoses and
Transaxle side
^
•
12.
the oil
vacuum
lines
Negative battery cable Fill
and
the cooling system filter is
Changing
recommended
to elimi-
nate pollutants such as coolant in the oil.
Install the
tion
mark
engine
head gasket with the at the front facing
13.
HBCGM identifica-
upward
—2
51-
With the radiator cap
engine and check Cylinder head bolt tightening sequence
oil
2.5L engine
engine
Heater Core replacement
is
covered
in Section
2
of this
or coolant.
Check
electrical
manual
off, start
for leaks of fuel,
the
vacuum,
the operation of
all
systems as well as dash-
CHRYSLER CORP.
6-10
SEBRING COUPE
board gauges and
AVENGER
•
Add coolant as
lights.
the
engine warms.
Perform necessary adjustments
14.
to
the accelerator cable and drive belts. Allow the engine to cool
and once again check
and adjust the coolant
level.
3.0L Engine
•
Spark plug cables
•
PCV and blow
•
Breather hose
•
Water
10.
cable.
Properly relieve the fuel system
3.
pressure.
pipe
removing the
•
Exhaust manifold
•
Intake manifold
•
Alternator
upper intake manifold
•
Timing
which
•
Negative battery cable
Before servicing the vehicle, refer to
1.
inlet
Disconnect the negative battery
2.
by hoses
Fill
4.
If
right (firewall) side
rocker arm/shaft assembly, remove the
belt
the cooling system to the proper
is
(air intake
a 2-piece unit of
5.
Remove
6.
Identify the rocker
plenum),
aluminum
alloy.
the valve cover(s).
arm
shaft
assem-
the precautions in the beginning of this secblies before removal.
level.
tion.
11.
Start the vehicle,
check
for leaks
and
repair
if
MD
ers Special Tool
necessary.
auto lash adjuster retain-
Install the
7.
Relieve the fuel system pressure.
2.
998443
to
keep the
Drain the cooling system.
3.
auto lash adjusters from falling out of the
Remove
4.
or disconnect the following:
rocker arms
Rocker Arm/Shafts
Negative battery cable
•
is
•
Timing
•
Alternator
belt 8.
REMOVAL & INSTALLATION
when
the rocker
arm assembly
removed.
Remove
the rocker
arm
shaft
assem-
blies.
Intake manifold
•
’»The hydraulic automatic lash
•
Exhaust manifold
•
Water
•
Breather and blow by hoses
•
Positive Crankcase Ventilation
the precautions in the beginning of this sec-
arm
(PCV) hose
tion.
lash adjusters.
2.5L Engine
adjusters are precision units installed
pipe
inlet
1
Before servicing the vehicle, refer to
in
the
machined openings in the rocker Do not disassemble the auto
units.
Spark plug cables
•
Nm
•
Rocker arm cover
•
Timing
•
Cylinder head and discard the gas-
belt rear
3.5 2.5 ft.lbs.
cover
ket
To install: Clean
5.
all
mating surfaces
of
any
residual gasket material.
Lubricate the threads of the cylinder
6.
head bolts with clean engine Install or
7.
Cylinder head with a
•
Torque the
8.
oil.
connect the following:
bolts, in
new gasket
sequence, as
fol-
lows: a.
Step
1:
80
b.
Step
2:
Loosen
3:
80
ft.
lbs. all
(108 Nm). bolts in
sequence. Step
c.
Install or
9.
ft.
lbs.
(108 Nm).
connect the following:
•
Rear timing belt cover
•
Rocker arm cover
EXHAUST SIDE
^
FRONT OF ENGINE
1.
2.
Rocker cover Rocker cover gasket
10.
seal Oil seal
12.
11.
3. Oil 4. 5. 6.
EXHAUST SIDE
7.
8. 9346FG01
9.
Cylinder head boll torque sequence
engine
Rocker Rocker Rocker Rocker Rocker
arm and rocker arm arm and rocker arm
13. 14.
shaft shaft
15.
shaft spring
Rocker arm shaft Lash adjuster Rocker arm C Rocker arm shaft Lash adjuster Thrust case
16. O-ring 17. Camshaft
arm A arm B
— 3.0L Exploded view of the cylinder head valve
train
assembly
— 2.5L engine
CHRYSLER CORP.
6-11
SEBRING COUPE* AVENGER 4.
9.
To
To install: The rocker arm shafts are hollow and used as a lubrication
oil
duct. Ensure
Check
valve train parts are clean.
all
arm mounting portion
rocker
wear or damage. Replace
for
Check
all oil
install:
•
Rocker arms and shafts.
shaft cap to
necessary.
holes for clogging with a
23
lbs. (31
ft.
•
Rocker arm cover with a new gasket
•
rockers were removed, lubricate and install
• •
Breather hose
•
Negative battery cable
in their
any
original posi-
tions.
For the right cylinder head,
10.
the rocker the
FLAT
arm and
in
the rocker
toward the timing For the
11.
FLAT
12.
Install
air intake
hose
Vacuum connection
at
the
power
brake booster and the Positive
Crankcase Ventilation (PC V) valve •
remaining vacuum hoses and
All
pipes, as necessary. Tag for identi-
•
if
necessary, to save time
assembly.
at
arm shafts facing
shaft
Fuel line(s), the throttle control
cable and brackets
REMOVAL & INSTALLATION
assembly with the
arm
shaft facing toward
2.0L Engine This engine uses a 2-piece
the retainers and spring clips
original positions
on the exhaust
intake manifold.
aluminum
A non-reusable
gasket
joins the 2 halves.
•Be
sure to observe
tion that
sembly.
dure.
lbs. (31
ft.
•
fication,
Nm) working from the center, outward. Remove the valve lash retainer tools that may have been installed at disas23
Accelerator cable, breather hose
new gasket
and intake shafts Torque the retainer bolts to
•
Intake Manifold
the transaxle side of the engine.
in their
with a
or disconnect the following:
Negative battery cable
cylinder head, install the
the rocker
in
Remove •
install
assemblies with
belt side of the engine.
left
arm and
rocker
shaft
Drain the cooling system.
3.
and
Oil seals
them on the shafts
If
Relieve the fuel system pressure.
Nm)
•
PCV valve PCV hose
small wire and clean as required.
When
1.
2.
properly aligned, torque the rocker
the
of the shafts if
connect the following:
Install or
warnings
in
all
cautions and
the beginning of the sec-
may
be related
to this
proce-
Do not use conventional fuel filters, hoses or clamps when servicing fuel injection systems. They are not compatible with the injection system and could fail, causing personal injury or damage to the vehicle. Use only hoses and clamps specifically designed for fuel injection.
Inspect the spark plug tube seals
13.
located
on the ends
of
each tube. These
seals slide onto each tube to seal the cylin-
der head cover to the spark plug tube.
these seals
show signs
of
If
hardness and/or
cracks, they should be replaced. 14.
Install or
connect the following:
•
Valve cover(s)
•
Upper intake manifold (plenum),
if
necessary •
All
remaining electrical connectors
and tighten the
air
tube connec-
tions •
Negative battery cable
An
15.
oil
and
filter
change
is
recom-
mended. Start the
16.
engine and check
for leaks,
abnormal noises and vibrations.
3.0L Engine 1.
Before servicing the vehicle, refer to
the precautions in the beginning of this section. 2.
Relieve the fuel system pressure
1.
3.
•
Negative battery cable
•
Breather hose
•
Positive Crankcase Ventilation
Rocker arm cover
•
Rocker shaft cap
•
Rocker arms and shafts
hose
11
Generator wiring harness connection
12
PCV
2.
(PCV) hose and valve •
Air intake
Breather hose 3 Accelerator cable connection 4 Clip 5 MAP sensor connector 6 Intake air temperature sensor connector 7 Vacuum hose connection 8 TPS connector 9 Idle air control motor connector 10 Control winng harness
recommended procedure. Remove or disconnect the following:
using the
connection 16 EGR pipe connection 17 Fuel return hose connection 18 High-pressure fuel hose connection E3 use
new components
Intake manifold hose, cable and wire attachment identification
Brake service
is
covered
in
Section 4 of this manual
hose assembly
Vacuum hose 14 Vacuum hose connection 15 Brake booster vacuum hose
13
—
2 OL engine
CHRYSLER CORP.
«* 6-12
SEBRING COUPE
•
AVENGER
Alternator wiring harness
•
Manifold Absolute Pressure (MAP)
sensor and
•
Throttle Position (TP) sensor con-
nector and position the engine
rail bolt.
Before servicing the vehicle, refer to
.
the precautions in the beginning of this sec-
sensor connectors
(IAT)
each fuel 1
Temperature
Intake Air
>-»Use care, there are spacers under
2.5L Engine
•
tion.
Disconnect the negative battery
2.
may be necessary to remove the power steering fluid reservoir and mounting bracket to access all of the
'•Tt
lower intake manifold fasteners.
cable.
wiring harness aside
Exhaust Gas Recirculation (EGR)
•
pipe connection
Intake manifold stay
•
Properly relieve the fuel system
3.
and engine
fuel line(s)
from the
assembly. For quick-connect
To
fit-
tings,
Throttle
•
Intake manifold
•
Fuel
^Use
fitting retainer
tabs
plenum and gasket
sages
CAUTION
drop out of the fuel
as
rail
is
it
being
To prevent fuel from getting
your
in
catch any gasoline
to
0.006
Remove
or disconnect the following:
body
hose clamp
•
Throttle
cylinder head and intake manifold assembly.
•
Air cleaner cover
Check both surfaces
•
Vacuum connection from
Clean
gasket material from the
all
for cracks or other
air inlet
and
inlet
in.
(0.15mm) per 12
flat
limit is
within
(30.5cm)
in.
0.008
of
in.
(0.20mm). Properly position the
9.
hose
the
pas-
air
necessary.
if
gauge.
feeler
manifold length. The
and gasket
To install: 4.
clogging. Clean
The surfaces must be
8.
spillage. Intake manifold
cracks or other
Check upper and lower manifold
edge and
eyes, wrap shop towels around the
connection
for
gasket surfaces for flatness using a straight-
removed. •
for
7.
care since the fuel injectors can
gasket sealing surfaces.
all
damage. Check the intake manifold
assembly
rail
Clean
Check both surfaces
5. together and separate the connection.
body assembly
•
squeeze the
install:
6.
hanger Fuel injector connectors
intake manifold bolts, intake
manifold and discard the gaskets
Disconnect the
4.
fuel rail •
Lower
•
pressure.
new gaskets on
the heads and install the lower intake mani-
power
fold.
Torque the nuts as follows:
damage. Check the intake manifold water
brake booster and the Positive
a.
Front bank: 60 inch lbs. (7 Nm).
passages and
Crankcase Ventilation (PCV) valve
b.
Rear bank: 14-17
Clean
if
passages
air
clogging.
for
straight-edge and feeler gauge.
0.006
in.
(0.15mm) or
0.008
in.
(0.20mm).
New
The
pattern, starting
a crisscross
from the inside and
working outwards
17
to
ft.
lbs.
•
a
with clean engine Install or
11.
being removed or
may save time
Fuel injectors
•
Seat the injectors and torque the
Manifold Absolute Pressure (MAP) • •
injector
and pressure reg-
•
Power steering pressure switch and
Oxygen (O 2 S) sensor connectors,
assembly manifold plenum with
Plenum support bracket located the rear of the
gasket. •
body assembly
•
Throttle
•
Intake manifold stay
and engine •
MAP
Fuel injector electrical connectors Fuel line(s) to the fuel
to
sensor
Control wiring harness mounting
•
Upper
intake
plenum with new gas-
fasteners located on top of the
kets
and torque the bolts
upper plenum near the valve cover
lbs.
(18
Throttle Position (TP)
and
Idle Air
•
•
Engine control
•
Alternator wiring harness connection
•
Throttle
•
Fuel line(s)
•
Throttle cable bracket
•
Throttle control cable brackets
•
Exhaust Gas Recirculation (EGR)
•
Throttle cable bracket
•
Vacuum hose
at the
booster and the •
All
nections
valve
remaining vacuum hoses and
and •
air intake
Start the
operation.
engine and check for proper
lbs.
(18
Nm)
tube and torque the screws to
95 inch
lbs. (11
Nm)
body assembly
•
Throttle
•
TPS and
•
Plenum support bracket located
•
Control wiring harness and tighten
•
valve and transducer assembly
EGR
to
tube
7 upper intake plenum-to-lower
the •
l/^C electrical
connections
mounting fasteners
Power steering pressure switch and
manifold bolts, plenum and gasket
oxygen sensor connectors,
•
Fuel injector electrical connectors
connected.
•
4
hose
Negative battery cable
ft.
valve and transducer assembly
EGR
the rear of the
Accelerator cable, breather hose
•
EGR EGR
tube from the intake manifold
pipes •
body assembly
ft.
•
power brake
PCV
tighten to 13 •
13
Plenum support brackets and
Fuel injector connectors
Control (IAC) motor electrical con-
to
Nm)
EGR
connectors
assem-
^Exert a slight tug on the fuel line away from the fuel rail to verify positive engagement.
•
electrical
rail
bly
•
pipe connection
(12
lbs.
if
necessary •
105 inch
Nm)
(IAT) sensor connectors
rail,
oil.
connect the following:
•
sensor and Intake Air Temperature
Fuel
(20-23
lbs.
at
Lubricate fuel injector O-rings with oil
ft.
Repeat once more.
fuel rail bolts to
hanger
7.
and tag
clean engine
install the intake
new
is
14-17
Lubricate the fuel injector O-rings
10.
assembly. •
ulator
and
it
disengaged. This
Thoroughly clean the mating surfaces
6.
d.
helpful to identify
connection as
Front bank:
c.
(23
Nm) •
may be
(20-23
lbs.
Nm).
each sensor connector and vacuum
gasket and the manifold and in
necessary, to save time
if
ft.
Nm).
assembly.
at
limit is
*lt
torque the manifold
remaining vacuum hoses and
fication,
should be
connect the following:
Install or
•
less.
It
All
pipes, as necessary. Tag for identi-
manifold for flatness using a
of the intake
5.
•
necessary. Check the gasket surface
fuel rail-to-intake
and
fuel rail
manifold bolts
•
MAP
if
dis-
sensor and IAT sensor con-
nectors
CHRYSLER CORP.
6-13
SEBRING COUPE* AVENGER
19-23
Air intake
TPS
3 4 5 6
motor connector Vacuum hose connection Throttle body assembly Power steering oil pressure switch connector Heated oxygen sensor connector Intake air temperature sensor connector Injector connector Control wiring harness
10
of the
plenum and
Vacuum hose
at
booster and the •
All
connector
the
and
air inlet
hose.
Tighten the intake hose-to-throttle
1
.
repair
if
EGR EGR
check
pipe connection valve and EGR transducer
assembly 19
Intake manifold
plenum
20 Intake manifold plenum gasket
•
•
tor leaks
•
tion.
Fuel
rail,
injectors
Properly relieve the fuel system pres-
•
sure. 3.
and pressure
assembly
Insulators
Positive Crankcase Ventilation
(PCV) hose Right front upper timing belt cover
and bracket
Remove
or disconnect the following:
•
Negative battery cable
•
Intake manifold
•
Fuel injector connector
•
Fuel supply and return hoses
•
Vacuum hose
Negative battery cable Start the engine,
4.
sensor Heated oxygen sensor harness
Before servicing the vehicle, refer to
body hose clamp.
12.
MAP
3.0L Engine
2.
connectors
Air cleaner cover
•
Vacuum hose connection
the precautions in the beginning of this sec-
Remaining engine control system
•
connection 14 15 16 17 18
regulator as an
remaining vacuum hoses and
electrical
Vacuum hose connection Brake booster vacuum hose
valve
pipes •
Accelerator cable connection
manifold— 2. 5L engine
intake
power brake
PCV
11
12.
13
Idle air control
9
•
hose
1
2
7 8
Exploded view
ft.lbs.
and
necessary.
•
plenum
For complete Engine Mechanics I specifications, see Section
Intake manifold
and discard the
gasket
To install: Clean
all
mating surfaces
residual gasket material.
1
of this
manual
of
any
CHRYSLER CORP.
6-14 5.
SEBRING COUPE
Install or
•
AVENGER
•
connect the following:
new
Intake manifold with a
Nm
3.9 2.9 ft.lbs.
gasket.
Torgue the nuts as follows: a.
Right bank to 62 inch lbs. (7 Nm).
bank
16
to
b.
Left
c.
Right bank to 16
d.
Left
bank
16
to
(22 Nm).
lbs.
ft.
ft.
lbs.
(22 Nm).
(22 Nm).
lbs.
ft.
(22 Nm).
e.
Right bank to 16
•
Right front upper timing belt cover
ft.
lbs.
and bracket and torque the bolts
10
lbs.
ft.
•
PCVhose
•
Fuel
rail
bolts to •
6.
repair
assembly and torque the 102 inch
(12
lbs.
Nm)
Vacuum hose and return hoses
•
Fuel supply
•
Fuel injector electrical connector
•
Negative battery cable
Start the vehicle, if
to
Nm)
(15
check
for leaks
and
necessary.
Exhaust Manifold
REMOVAL & INSTALLATION
2.0L Engine 1
.
Before servicing the vehicle, refer to the
precautions 2.
3.
the beginning of this section.
in
Properly drain the engine coolant.
Remove
1. Air
or disconnect the following:
•
Negative battery cable
•
Air intake
hose and small
2.
intake hose
Radiator upper hose connection hose connection Control wiring harness connection Water pipe assembly
3. Air 4.
hose
air
5.
Engine oil level gauge Heat protector Engine hanger 9. Front exhaust pipe connection 10. Heat protector 11. Exhaust manifold 12. Exhaust manifold gasket 6.
connection
7.
•
Upper radiator hose from the ther-
8.
mostat housing •
Control wiring harness connection
•
Water pipe assembly and engine
oil 7922CG13
level dipstick
• •
Pulsed secondary
Heat shield and the engine hanger
•
Engine
•
Control wiring harness connection
•
Engine hanger or lower heat shield,
locknuts, separate the exhaust pipe
•
Loosen the mounting fasteners and
Clean
all
Upper radiator hose stat
To install: gasket material from the
mating surfaces and check the manifold
for
to the
thermo-
if
housing
•
hose and small
•
Air intake
•
Negative battery cable
air
hose
Fill
Start the
engine and check
Install or
•
New
•
exhaust leaks.
17
ft.
lbs.
crisscross
(23
Nm)
•
(44
if
33
Nm)
Pulsed secondary valve,
and
equipped
.
Before servicing the vehicle, refer to
the precautions in the beginning of this section.
ft.
To
install:
3.
Clean
gasket material from the
2.
4.
Install or
•
Remove
or disconnect the follow-
•
Negative battery cable
•
Cooling fan assembly
for
cracks or warpage.''
New
connect the following:
gasket, manifold and stay
(brace) and torque the fasteners, in
ing: air injection
all
mating surfaces and check the manifold 1
new gasket and new
locknuts. Torque the nuts to lbs.
exhaust manifold stay
(brace), the exhaust manifold
FRONT BANK
in a
Exhaust pipe to the exhaust manifold with a
Exhaust manifold mounting fasteners, the
for
2.5L Engine
connect the following:
torque the fasteners,
•
equipped
Exhaust pipe-to-exhaust manifold
the gasket
gasket and manifold and
pattern, to
dipstick and tube
locknuts, separate the exhaust pipe
the cooling system.
7.
8.
oil level
and discard the gasket
cracks or warpage. 6.
— 2.0L engine
air injection
equipped
remove the exhaust manifold.
5.
exhaust manifold and related components
•
if
and discard the gasket 4.
of the
Exhaust pipe-to-exhaust manifold
valve, •
Exploded view
Heat shield and engine hanger
a crisscross pattern, to
22
Nm) New gasket,
exhaust pipe
ft.
lbs.
(29 •
install the
CHE U IJ
CHRYSLER CORP. SEBRING COUPE •
AVENGER
•
Battery and tray
•
Front exhaust pipe
•
Air cleaner
•
Oil dipstick
•
Strut tower bar
•
Upper and lower heat shields
•
Exhaust Gas Recirculation (EGR) pipe,
•
left
assembly guide
side only
Exhaust manifold and discard the gasket
To install: 3.
Clean
mating surfaces of any
all
residual gasket material. 4.
connect the following:
Install or •
Exhaust manifold with a new gasket
and torque the bolts (44 •
EGR
if
13
ft.
.
6.
7.
Intake manifold
4. 5.
plenum stay Heated oxygen sensor 10. Generator 11. EGR pipe assembly 12. Exhaust manifold stay 13. Exhaust manifold 14 Exhaust manifold gasket
Condenser fan motor assembly Dipstick guide assembly connection Engine hanger Exhaust manifold Exhaust manilold stay Exhaust manifold aasket
3.
lbs.
(18
Nm)
of the
ft.
lbs.
(15
9.
plenum
5.
guide
Oil dipstick
•
Air cleaner
•
Front exhaust pipe
•
Battery
Intake manifold
8.
Strut tower bar
•
and
assembly
tray
Start the vehicle,
repair
Exploded view
lbs.
Nm) •
1
ft.
Upper and lower heat shields and torque the bolts to 10
3.
2.
33
removed. Torque the
pipe,
bolt to •
to
Nm)
if
check
for leaks
and
necessary.
components— 2. 5L engine
exhaust manifold assembly and related
Front Crankshaft Seal to the
the nuts to •
33
ft.
lbs.
(44 Nm).
(13
5.
repair
ft.
lbs.
Nm)
Clean
Engine
•
Cooling fan assembly
•
Negative battery cable
dipstick
oil level
Start the vehicle,
check
and tube
4
Install or
•
for leaks
2.
•
Before servicing the vehicle, refer to the
precautions
in
Remove
or disconnect the following:
Negative battery cable
•
Intake manifold
plenum
plenum and
gasket, the manifold
ifold
brace and torque the nuts,
and man-
ft.
lbs.
stay
Exhaust Gas Recirculation (EGR)
in
a
(30
tion. 2.
Drain the engine
3
Remove
pipe assembly
leaks
equipped
oil.
or disconnect the following
•
Negative battery cable
•
Accessory drive belts
•
Crankshaft damper/pulley
•
Timing
bell
•
Timing
bell
•
Crankshaft sprocket
EGR
•
HO 2 S
ft.
lbs.
Nm)
(44
pipe assembly
cover
WARNING
sensor
Intake manifold
plenum
5.
Before servicing the vehicle, refer to
Exhaust pipe-to-exhaust manifold
Alternator
•
Alternator
if
.
using a new gasket and torque the
•
Heated Oxygen (HO 2 S) sensor
•
Manifold heat shield,
•
•
•
•
New
nuts to 33
the beginning of this section.
•
•
1
the precautions in the beginning of this sec-
Nm)
necessary.
REAR BANK .
2.0L Engine for
connect the following:
crisscross pattern, to 22
and
•
1
gasket material from the
all
mating surfaces and check the manifold cracks or warpage.
•
if
To install:
equipped and torque the lower
heat shield fasteners to 10
REMOVAL & INSTALLATION
and the gasket
fold
Engine hanger or lower heat shield, if
manifold brace, the exhaust mani-
exhaust manifold and torque
plenum and
Be careful not
stay (brace)
of the
to nick the seal
surface
crankshaft or the seal bore.
Negative battery cable
Start the engine,
and
repair
if
check
for
exhaust
•
necessary.
Front crankshaft seal using a seal puller tool
Exhaust pipe-to-exhaust manifold locknuts, separate the exhaust pipe
WARNING
3.0L Engine
and discard the gasket 1
•
Manifold heat shield,
if
.
Before servicing the vehicle, refer to the
equipped precautions
•
Exhaust manifold bolts, the exhaust 2.
in
Remove
For Accessory Drive Belt
the beginning of this section
Be careful not
or disconnect the following:
illustrations,
see Section
to
damage
the seal
contact area of the crankshaft.
1
of this
manual
CHRYSLER CORP.
6-16
SEBRING COUPE
AVENGER
•
3.0L Engine
To install: engine oil
new
Lubricate the
4.
the
oil. Install
new
seal by using oil seal installer Tool No.
1
Before servicing the vehicle, refer to the
.
precautions
Remove
2.
6780-1. Place a
new
oil
seal into
the opening •
Timing
•
Crankshaft sprocket
with the seal spring facing the inside of the
engine. Be sure the
seal
oil
installed flush
is
or disconnect the following:
Negative battery cable
• 5.
the beginning of this section.
in
6.
Crankshaft timing belt sprocket
•
Timing
Crankshaft Position (CKP) sensor
•
Crankshaft sensing blade
•
Crankshaft spacer and key
•
Front
Timing
•
Crankshaft damper/pulley
•
Accessory drive belts
belt
cover
3.
Lubricate the
engine
Change
the
oil filter
and
refill
check
Start the engine,
repair
if
and
for leaks
1
or disconnect the following:
Camshaft bearing caps
•
Camshafts
•
Camshaft followers
•
Crankshaft key and spacer
•
Crankshaft sensing blade
•
CKP
•
Crankshaft sprocket
•
Timing
•
Negative battery cable
Any components that are to be reused must be installed in their original locations. Use care to identify and mark the positions of any removed valve train components so
with Special Tool
sensor
they
may be
reinstalled correctly.
belt
Inspect the camshaft bearing
7.
Before servicing the vehicle, refer to
.
Remove •
connect the following:
New oil seal MD998717
necessary.
2.5L Engine
they are to
The
seal lip with clean
•
the
crankcase. 8.
oil
if
for later installation.
oil.
Install or
Negative battery cable
•
seal
install:
4.
7.
oil
To
at
camshafts are not interchangeable.
belt
•
Identify the camshafts,
5.
be reused,
6.
•
in
ward. Perform this step on one camshaft
belt
•
connect the following:
camshaft bearing cap retaining fasteners
the correct sequence, inside working out-
a time.
with the front cover. Install or
first
Loosen, but do not remove, the
4.
front crankshaft
Outer camshaft bearing caps,
•
seal with clean
holes
the precautions in the beginning of this sec-
in
oil
feed
the cylinder head for clogging.
Inspect the camshaft bearing journals for
tion.
Camshaft and Valve Drain the engine
2.
Remove
3.
Lifters
10.or scoring. Check the cam surface wear
oil.
or disconnect the following:
•
Negative battery cable
•
Accessory drive belts
•
Crankshaft damper/pulley
abnormal wear and damage. A
REMOVAL & INSTALLATION
groove lobes
To
2.0L Engine
•
Front timing belt covers
Timing
•
Crankshaft sprocket and key
Before servicing the vehicle, refer to
1.
belt
the precautions
in
•
Front crankshaft seal by prying out with a
flat
Properly relieve the fuel system
pressure.
Remove
3.
WARNING Be careful not
Negative battery cable
•
Spark plug wires
•
Ignition coil
Apply a
new
light
coating of clean engine
new
the
lip of
engine
pack with spark plug
pump housing
by using
MD998717. Be
Oil Seal Installer
sure the
installed flush with the oil 5.
Install or
oil
•
Ground
•
Timing
pump
seal
of the
camshafts
cam
for
followers.
cam
followers. Be sure
the
oil
cam
and properly positioned.
followers
in their
Install
original positions
K
WARNING
strap belt covers, timing belt
and
camshaft sprockets
'The
and condition
remove the camshafts
on the hydraulic adjuster and valve stem.
front crankshaft oil seal into the oil
Tool
fit
Cylinder head cover and discard
the
oil seal. Install
the
are inside the roller
the gasket
the
camshaft and
they are clean, well lubricated with clean
wires •
To install: 4.
all
The hydraulic valve lash adjusters or disconnect the following:
•
to nick the seal surface
of the crankshaft or the seal bore.
oil to
If
installation of the
tipped prytool; be
shop towel
with a
9.
it
sure to cover the end of the prytool tip
Thoroughly clean
are acceptable,
2.
cam
for replacement.
related parts.
the beginning of this sec-
tion.
the roller path or on the
cause
for
worn
install:
8.
•
in
is
visible
camshaft bearing caps are num-
To avoid valve to piston contact, be sure
NONE
of the pistons are at
Dead Center (TDC) when
Top
installing
the camshafts.
bered for correct location during instal-
is
lation.
cover.
connect the following:
•
Crankshaft timing belt sprocket and
•
Timing
belt
•
Timing
belt
•
Crankshaft damper/pulley
•
Accessory drive belts
•
Negative battery cable
key
6.
Change
the
engine with clean 7.
repair
covers
oil filter
Start the engine, if
and
fill
the 7922CG16
oil.
necessary.
check
for leaks
and
Camshaft bearing cap identification— 2. OL
Camshaft bearing cap retaining
engine
removal sequence
bolt
— 2.0L engine
CHRYSLER CORP.
6-17
SEBRING COUPE -AVENGER •Inspect the spark plug well seals for cracking and/or swelling and replace, if necessary. 16.
and
Install
Connect the negative battery cable.
19.
20. Test run the vehicle.
the cylinder head cover
Check
for leaks
proper operation.
for
2.5L Engine
assembly. 17.
Torque the cylinder head cover fasten-
ers, in
sequence, using the following 3 steps:
7922CG17
a.
Step
1:
40 inch
lbs. (4.5
b.
Step
2:
80 inch
lbs. (9
c.
Step
3:
105 inch
18.
Camshaft bearing cap retaining ening sequence
1 1
nals
•
— 2.0L engine
Nm).
and cam followers with clean engine
Nm).
Camshafts
•
Right and
•An left
connect the following:
Ignition coil
pack and torque the
Nm)
2.
Relieve the fuel system pressure.
3.
Drain the cooling system.
•
Spark plug wires
4.
Drain the engine
•
Ground
5.
Remove
•
All
caps No. 2 through No. 5 and
right
strap
vacuum
and remaining
lines
Torque the
lbs.
(12
•
Negative battery cable
•
Timing
filter
wash
change
is
recom-
may have
Upper intake manifold plenum
•
Lower intake manifold
•
Cylinder head bolts and cylinder
fallen
head
M6
fasteners to
in correct
No.
1
and
105 inch
sequence
No. 6 bearing
left-side
caps.
Bearing caps and torque the
•
fasteners to 21
lbs.
ft.
before the seals
may be
installed.
•
Camshaft end seals
•
Camshaft sprockets,
sure
M8
Nm)
must be installed
’••The end caps
•Make
(28
all
if
removed
timing marks are prop-
erly aligned, using the
recommended
procedure. •
Timing
belt
•
Timing
belt
covers
** WARNING Verify that all timing rect.
If
marks are
cor-
the timing belt or sprockets
are incorrectly installed, engine
damage
will occur.
Clean
15.
all
sealing surfaces.
Make
cer-
1
Breather hose connection
Blow-by hose Fuel hose assembly connection 4 Vacuum pipe connection 5. Spark plug cable 6. Rocker cover
2.
tain the rails are flat.
3.
•
New
cylinder head cover gaskets
DO NOT allow
oil
or solvents to con-
7.
Distnbutor
8.
Camshaft sprocket Cylinder head assembly Rocker arm and rocker assembly Camshafl Camshaft oil seal
9.
tact the timing belt as they
can dete-
and cause tooth skipping. Apply Mopar Silicone Rubber Adhesive Sealant, at the camshaft cap corners and at the top edge of the Vi round seal.
to.
riorate the rubber
For
Tire,
Wheel and
11. 12.
Exploded view
of the rear cylinder
shaft
head and camshaft mounting
Ball Joint specifications, see Section
and
•
out any sealant or
gasket material that
belt covers, timing belt
camshaft sprockets
Apply Mopar® Gasket Maker, sealer
14. to the
Nm)
and to
oil.
or disconnect the following:
into the engine.
side No. 6 13.
oil
mended
camshaft bearing
cylinder
head must be removed.
connect the following:
•
the beginning of this sec-
• For camshaft service, the
wiring Install or
in
tion.
(12 Nm).
fasteners to 105 inch lbs. (12
oil.
12.
Before servicing the vehicle, refer to
.
bolt tight-
Lubricate the camshaft bearing jour-
.
Install or
lbs.
1
the precautions
1
of this
— 2.5L engine
manual
CHRYSLER CORP.
6-18
SEBRING COUPE
•
AVENGER located on the ends of each tube. These
seals slide onto each tube to seal the cylin-
der head cover to the spark plug tube.
show signs
these seals
of
If
hardness and/or
cracks, they should be replaced.
28 - 34 21
-25
•
Cylinder head cover
•
Spark plug wires Intake manifold
•
Throttle and speed control cables
•
Air inlet resonator, air inlet
and
Nm ft. lbs.
air
remaining electrical connectors
All
•
Tighten the
•
Negative battery cable
9.
Fill
1 1
the
2.
PCV
Start the
.
air
tube connections
and bleed the cooling system.
Change
engine with clean Blow-by hose
hose
cleaner housing cover
•
10.
1.
plenum
•
oil filter
and
the
fill
oil.
engine and check
for leaks,
abnormal noises and vibrations.
valve and hose assembly
connection 3.
88 65
Nm
4.
ft.lbs.
5.
6. 7.
8. 9.
10. 11.
12.
3.0L Engine
Spark plug cable Vacuum pipe and hose asembly Rocker cover Relay box bracket assembly Control module and bracket assembly Thrust case Camshaft sprocket Rocker arm and rocker shaft assembly Camshaft Camshaft oil seal
LEFT BANK 1
.
2.
7922CG19
Exploded view
of the front cylinder
Thrust case from the
•
left
Before servicing the vehicle, refer to the
precautions
head and camshaft mounting— 2. 5L engine
in
Remove
the beginning of this section. or disconnect the following:
•
Negative battery
•
Timing
•
Thermostat housing
•
Blow by hose
belt
head
assembly •
Left
camshaft from the rear
of the
head Distributor from the right cylinder
•
head Right camshaft from the rear of the
•
head
To
3.4 ± 0.5
6.
Lubricate the camshaft journals.
7.
Install or
connect the following:
31 * 3 23 ± 2
•
Camshaft
•
Thrust case and torque the fasteners to
into the cylinder
108 inch
lbs.
^Lubricate the camshaft with clean engine •
'The
N
m
31 * 4 in-lb
install:
head
(13
Nm)
oil
seal
Nm ft-lb
lip
oil.
Camshaft seal
13 ± 2
before installing the seal. Be sure the seal
is
installed flush with the cylinder
head surface. •
Camshaft sprocket and torque ft.
lbs.
(88
to
65
Nm)
•
Cylinder head
•
Lower intake manifold using new
88 ± 10 N m 65 * 7 ft-lb
gaskets
8.
Nm
109*21
camshaft must be installed
•
Rocker arm and shaft assemblies
•
Timing
belt
Inspect the spark plug tube seals
Exploded view of the rocker arm and camshaft assembly
—3.0L engine
in-lb
.
CHRYSLER CORP. SEBRING COUPE •
Positive Crankcase Ventilation
•
Timing
(PCV) hose
•
Negative battery cable
•
Spark plug cables
•
Rocker arm cover
•
Rocker arm and shaft
•
Camshaft sprocket
• •
3.
belt
Negative battery cable
•
Engine under cover Heated Oxygen (HO 2 ) sensor elecconnector
trical
•
Front exhaust pipe
Thrust case
•
Starter
motor
Camshaft
•
Starter
motor
ADJUSTMENT The engines
in
these vehicles do not
connect the following:
Install or
3.
•
Camshaft
•
Thrust case and torque the bolt to
109 inch
65
torque to 23 •
Rocker arm cover and torque the
•
Spark plug cables
35 inch
bolts to
lbs.
lbs. (4
•
PCV and blow
•
Thermostat housing
•
Timing
•
Negative battery cable
2.0 and 2.5L Engines
precautions
Nm)
40
ft.
starter-to-
lbs.
(54
2.0L engine or 20-25
(26-33 Nm) motor
gaskets
for
electrical
when
ft.
2.5L engine
connectors
installing the
exhaust pipe.
front
Before servicing the vehicle, refer to the
1
for
Starter
~Use new
Nm)
lbs. (31
ft.
REMOVAL & INSTALLATION •
Rocker arm and shaft assembly and
motor and torque
transaxle bolts to
Nm)
(88
lbs.
ft.
Starter
Nm)
Camshaft sprocket and torque the bolt to
Starter Motor
Nm)
(13
connec-tors
or connect the following:
Install
•
lbs.
electrical
To install:
require periodic valve lash adjustment.
•
or disconnect the following:
•
•
Valve Lash
To install:
•
Remove
2.
6-19
AVENGER
•
the beginning of this section
•
Front exhaust pipe. Torque the front
Gasket
5.
Heated oxygen sensor
Catalytic converter
6.
Front exhaust pipe
Gasket Heated oxygen sensor
7.
Gasket
8 9
Protector
in
by hoses
44 33
44 33
Nm ft.lbs.
Nm ft.lbs.
belt
RIGHT BANK 1
.
Before servicing the vehicle, refer to the
precautions 2.
in
the beginning of this section
Remove
or disconnect the following:
•
Negative battery
•
Timing
•
Intake manifold
•
Breather hose
belt
plenum
•
Blow by hose
•
Spark plug cables
•
Rocker arm cover
•
Rocker arm and shaft assembly with Tool
9.4 ftlbs.
MD998443
•
Distributor
•
Camshaft sprocket with Tool
•
Camshaft
Hanger
MB990767 and MD998715 To 3.
Exploded view
of the front
exhaust pipe and related components
Install or
•
connect the following:
Camshaft and a new
oil seal,
cDOHC>
if
removed •
4.
Nm
65
ft.
(88
lbs.
Nm)
Distributor
Rotate the camshaft until the dowel
on the 5.
54
Camshaft sprocket and torque the bolt to
•
pin
— 2 5L engine
install:
end
front
Install or
is
26 - 33 Nm 20 -25 rtibi
properly positioned
connect the following:
•
Rocker arm cover and torque the
•
Spark plug cables
•
Blow by and breather hose connec-
bolts to
35 inch
lbs. (4
Nm)
54 40
Nm ft.lbs.
Removal steps 1.
•
Intake manifold
the bolts to 13
Starter terminal
2. Starter
tions
and connector
motor
plenum and torque ft.
lbs.
(18
Nm)
View
of the starter
motor— 2. OL (DOHC) engine and 2.5L (SOHC) engine
For Wheel Alignment specifications, see Section
1
of this manual
CHRYSLER CORP.
6-20
SEBRING COUPE
AVENGER
•
exhaust pipe-to-exhaust manifold nuts to 36 front
ft.
Nm) and
(49
lbs.
CHI
PAN GASKET
Oil FILTER
the
ADAPTER
exhaust pipe-to-catalytic con-
verter bolts to
36
(49 Nm).
lbs.
ft.
connector
•
H02sensor
•
Engine under cover
•
Negative battery cable
electrical
NIPPLE
3.0L Engine 1
Before servicing the vehicle, refer to the
.
precautions
in
the beginning of this section.
Remove
2.
DRAIN PLUG
or disconnect the following:
Negative battery cable from the
•
3
O-RING
shock tower FILTER
•
Air cleaner resonator
•
Starter
motor cover
Starter electrical connectors
3.
assembly
Starter
•.
Oil
PUMP BODY
To install:
7922CG21
connect the following:
Install or
4.
Torque the
Starter assembly.
•
25
bolt to
(33
lbs.
ft.
Exploded view
Nm) and
the
•
Front exhaust pipe
•
Oil dipstick
Nm).
•
Oil drain
connectors to the starter
Electrical
•
Starter cover
•
Air cleaner resonator
15 inch
and torque the
lbs. (6
components— 2. OL engine
starter
rear bracket bolt to 8 inch lbs. (1
•
to
bolt to
Nm)
Negative battery cable to the shock
•
of
the engine lubricating
•
25
ft.
and tube
plug and torque the plug lbs.
(34
the engine with clean
Fill
9.
Start the engine, if
check
pan attaching bolts
Oil
pan
To
install:
4.
Thoroughly clean and dry the
and
necessary.
Apply a continuous /ie inch (4mm)
5.
bead
of silicone
adhesive sealant to the
pan gasket surface. Be sure
2.5L Engine
mounting
Pan
within a 1
.
pan,
oil
bolt holes.
oil.
for leaks
tower
Oil
Oil
•
cylinder block ana cylinder block bolts and
Negative battery cable
8.
repair
Nm)
•
oil
to circle all
bolt holes as well. Install the oil
10-15 minute period
pan
applying the
of
Before servicing the vehicle, refer to the
gasket material to ensure proper sealing.
precautions
REMOVAL & INSTALLATION
in
the beginning of this section. 6.
2.
Drain the engine
Install or
• 3.
2.0L Engine
Remove •
the precautions in the beginning of this sec-
Negative battery cable and lower •
•
•
Center-member Engine
oil
dipstick tube
and dipstick •
Drain the engine
2.
Remove
3.
motor
Starter
•
Front and rear plates
•
oil.
or disconnect the following:
Nm)
dipstick tube and dip-
•
Transaxle inspection cover •
Center-member and torque the
•
Front plate
•
•
Front exhaust pipe
•
•
Oil
pan bolts
torque the drain plug to 29
•
Oil
pan
(40
and tube
bolts to
•
if
damage and
replace, 5.
pan
oil
if
6.
for
damage and
7.
necessary. While the pan oil
screen for clog-
8.
cracks. Clean and/or
repair
Oil
(88
Nm)
ft.
lbs.
Nm)
Negative battery cable the engine with clean
new
oil
and
oil filter.
Start the engine, if
lbs.
pan drain plug and gasket and
check
for leaks
and
necessary.
3.0L Engine
block and the to the
oil
Install or
Oil
Groove
Hole of
pan and torque the bolts
Nm)
1
bolt 7922CG22
To ensure a leak-free seal, apply sealer as
connect the following:
inch lbs. (12
'
pan.
seams between
pan and the engine block.
•
ft.
necessary.
Apply sealant
oil
65
Front exhaust pipe
Fill
install a
Thoroughly, clean the mating surfaces
of the cylinder
7.
oil
(108
Oil dipstick
removed, inspect the
the
Engine
lbs.
•
cracks; replace, is
ft.
motor
stick
To install:
ging,
80
Starter
Negative battery cable
Inspect the
53
Front and rear plates and torque the
•
4.
to
Nm)
Transaxle inspection cover
bolts to
tion. •
pan and torque the bolts
inch lbs. (6 •
Before servicing the vehicle, refer to
.
Oil
or disconnect the following:
the front exhaust pipe 1
connect the following:
oil.
to
108
shown and
tighten the bolts following the
specified sequence
—2.5L engine
.
Before servicing the vehicle, refer to the
precautions
in
the beginning of this section.
2.
Drain the engine
3.
Remove
as follows:
oil.
the engine support
module
CHRYSLER CORP.
6-21
SEBRING COUPE* AVENGER Crankshaft sprocket
•
Pump
Oil
•
Oil
pump
pickup tube and O-ring
and torque the
REMOVAL & INSTALLATION 2.0L Engine 1
•
Timing
•
Cankshaft damper
New
•
Nm)
pan
Oil
the precautions in the beginning of this sec-
pickup (28
lbs.
ft.
•
Before servicing the vehicle, refer to
.
pump
oil
tube screw to 21
belt
and covers
oil filter
the engine with clean
16.
Fill
17.
Test run the vehicle to check for
oil.
tion.
Tighten the upper
oil
pan bolts
in
2.
Drain the engine
3.
Remove
oil.
An
leaks.
sequence
or disconnect the following:
•
Negative battery cable
•
Timing
•
Oil
•
Crankshaft sprocket
•
Oil
•
Oil
belt
may be
1
Before servicing the vehicle, refer to
.
tion. 2.
Drain the engine
3.
Drain the engine coolant.
Remove
oil
pan bolts
mounting
sequence
Negative battery cable
•
Front exhaust pipe
•
Lower
oil
Remove
5.
Check
6.
•
Starter electrical connectors
•
Starter
•
Oil dipstick
To
Cover
•
Upper
Clean
block and oil
pan and discard the gas-
mating surfaces
all
of
any
install:
5.
Install or
the inner
Upper
connect the following: oil
Torque the
53 inch •
sequence,
bolts, in
lbs. (6
10
to
1 1
inch lbs. (11
Nm)
.
Starter
•
Starter electrical connectors
•
Oil dipstick
12.
O-ring and torque the bolt to 36 lbs.
•
(48
Lower
Nm)
oil
6.
pan with a new gasket to
•
Negative battery cable
Start the vehicle,
repair
if
rotors
pump
30-33
check
necessary.
the
pump
oil.
Oil
back cover and
ft.
oil
lbs.
to
oil
oil
flats of
the
11
pump
to the
•
and inspect
plunger slides
broken spring.
Be sure the
the
pump oil
using new parts
Align the marks
the
pump
lbs.
(10 Nm).
relief valve,
and valve cap. Torque the
30-33
ft.
lbs.
pump
(41-44 Nm).
before installation by
Install the
O-ring into the counter-
pump body the pump onto
discharge passage.
Position
the crankshaft until
teners to 10
ft.
fasteners to
30
14.
front oil seal
1
oil.
bore on the
seated on the block. Torque the size
(23-28
For Maintenance Interval recommendations, see Section
pump
Apply gasket maker sealer on the
pump.
rotor
on
back cover and
the rotor cavity with clean engine
filling
connect the following:
lbs.
rotors
surfaces are clean and free
Prime the
12.
body.
engine block.
ft.
for a
Reinstall the
valve cap to
before installa-
pump
dam-
for
and outer rotors when assembling
spring, gasket
pump-to-engine block bolts and
Nm) New
pump
parts well.
all
pump
Install
13.
oil
case
torque the screws to 89 inch
body.
pump
pump
that the oil relief
Assemble
10.
(10 Nm).
relief valve,
ring into the discharge
torque to 17-21
for leaks
Clean
the inner
on the crankshaft as you
Install or •
Check
9.
oil.
flats
the
as required with clean
when assembling
pump
pump
Align the
14.
oil
of old sealer.
using new parts
the engine
of the
pump
Remove
8.
Align the marks on
oil.
(41-44 Nm).
with the
Oil
Inspect the
6.
tion by filling the rotor cavity with clean
15.
the engine with clean
and
lbs.
upper and lower covers
To install:
lbs.
install the
Front exhaust pipe
•
96 inch
Nm)
•
Fill
pump
the
and outer
Prime the
engine
and torque the bolts (11
ft.
Crankshaft sprocket
block and
Install
13.
•
7.
Apply gasket maker
passage
and guide with a new
belt
the inside of the case for excessive wear.
Be sure the
block mounting surface of the
•
and inspect
surfaces are clean and free
Reinstall the
96
belt
Timing
age and remove the rear cover.
broken spring.
for a
parts well
all
pump
valve cap to to
Timing
•
•
dam-
spring, gasket and valve cap. Torque the
Nm)
Cover and torque the bolts
•
5.
rotors
torque the screws to 88 inch
pan with a new gasket.
Crankshaft damper
smoothly and check
Install the
9.
•
for
that the oil relief plunger slides
as required with clean
residual gasket material.
To
pump
the
Assemble
8.
Clean
case
of old sealer.
ket 4.
pump
install:
7.
•
oil
smoothly and check
and guide
Drive belts and accessories
•
loca-
the inside of the case for excessive wear.
ket
•
tag the front cover
age and remove the rear cover
pan and discard the gas-
or disconnect the following:
bolts.
Inspect the
4.
•
in their original
Remove and
In
and must
oil.
Negative battery cable
•
pump mounting
different sizes
be reinstalled Tighten the lower
pressure.
the precautions in the beginning of this sec-
pump pick-up tube and O-ring pump and front crankshaft
front cover/oil
tions.
oil
2.5L Engine
4.
bolts
engine
pan
seal
The
pressure gauge should be
oil
installed to verify proper
lbs. ft.
(14
Nm) and
lbs. (41
M8
size
fas-
M10
Nm).
connect the following:
Install or
•
Timing
belt
and crankshaft sprocket
•
Timing
belt
cover
•
Crankshaft damper
•
Drive belts and accessories
of this
manual
CHRYSLER CORP.
6-22
SEBRING COUPE
•
AVENGER •
New
•
Negative battery cable
oil filter
the engine with clean
7.
Fill
8.
Start the vehicle,
repair
if
check
oil.
for leaks
and
necessary.
Rear Main Seal REMOVAL & INSTALLATION 2.0L and 3.0L Engines
**Be sure to observe all cautions and warnings in the beginning of the section that
may be
related to this proce-
dure. 1
Remove
.
or disconnect the following:
•
Transaxle
•
Flexplate/flywheel
•
Rear crankshaft
'•Pry the
oil
seal
seal from the housing
using a suitable
To
oil
flat
bladed prying
tool.
install:
"•When
installing the
new
seal there
is
no need to lubricate sealing surface. 2.
connect the following:
Install or
•
housing using a
Oil seal into
suit-
able installation tool 1. Oil
2. Oil
11. Plug 12. Relief
pressure switch pressure gauge unit
4. Oil filter
5. Oil filter
15. Oil
6. 7.
bracket bracket gasket Drain plug Drain plug gasket
18. Oil
9. Oil
screen screen gasket
19. Oil
of the oil
pan and pump assembly
pump cover pump outer pump inner
rotor
Fill
the cooling system.
16.
Fill
the engine with clean
install
a
new
Road
17.
oil
—2.5L engine
and
oil filter.
test the vehicle.
Check
for
proper operation as well as leaks.
Transaxle
68
ft.
lbs.
(92
Nm)
2.5L Engine
rotor
1
.
4.
•
Oil
•
Oil
•
Oil
•
Oil
Clean
Before servicing the vehicle, refer to the
precautions 2.
15.
•
16. O-ring
17. Oil
pan
7922CG20
Exploded view
Flexplate/flywheel and torque the bolts to
pump case
8. Oil
10. Oil
•
spnng
13. Relief plunger 14. Crankshaft oil seal
3. Oil filter
pump pump pump pump
•
case
Flexplate/flywheel
5 rear seal housing-to-engine bolts
•
Oil seal
•
Rear crankshaft
case
any
or disconnect the following:
Transaxle
•
outer and inner rotors
of
the beginning of this section.
•
cover
mating surfaces
all
in
Remove
housing oil
seal
from the
oil
residual gasket material.
3.0L Engine 1
.
3.
5.
Prime the
6.
Install or
pump
oil
Before servicing the vehicle, refer to the
precautions 2.
To install:
in
the beginning of this section.
Drain the engine
Remove
the engine support
•
Negative battery cable
•
Oil filter
•
Oil
•
Inner and outer rotors
•
Oil
module
Oil filter
pump
cover and torque the
•
lbs. (10 Nm) pump case assembly New front crankshaft oil seal
•
Relief plunger
•
Baffle plate
•
Oil
•
Baffle plate
bolts to
pressure switch
89 inch
Oil
bracket
•
Lower and upper
•
Baffle plate
oil
pan
screen and gasket
•
Baffle plate
•
Relief spring
•
case
Oil
•
•
Oil
pump
• oil.
as follows:
•
before installation.
connect the following:
oil
screen with a new gasket Fig. 1
-
pan and cover
2
-
pan
3 -
•
Upper
oil
•
Lower
oil
•
Oil filter bracket with a
and plunger
Front crankshaft
and spring
93
install
Crankshaft Rear Oil Seal
SPECIAL TOOL MD-99871 SEAL
HOUSING 9346FG05
seal
new gasket Install the
•
Oil
pressure switch
new
rear
main seal
CHRYSLER CORP. SEBRING COUPE* AVENGER seal
housing using a suitable
to the
To 3.
5.
install:
»»When
installing the seal there is no
need
Apply a
light coating of
engine
bolts to
connect the following:
Install the seal into the
housing using
and torque the (92
lbs.
Nm)
Piston and Ring
to lubricate sealing surface.
MD998718.
ft.
Transaxle
•
oil to
68
seal lip circumference.
oil
Install or •
Tool
Flexplate/flywheel
mating surface of the seal housing.
the entire 6.
•
Apply silicone rubber adhesive sealant
4.
flat
bladed prying tool
6-23
and housing and torque
Oil seal
the
mounting
(11
Nm)
bolts to
Identification
96 inch
mark
“1
lbs.
POSITIONING
R"
Chrysler engine connecting rod and cap installation
— ensure
and rod prior
to
matchmark
the cap
disassembly
to
Chrysler piston ring identification mark
Piston ring orientation
locations
2.5L (VIN N) engines
NO
SIDE RAIL
side
rail
^
-
NO
1
ring
gap
Y)
and
1
RING GAP
UPPER of
lower/^-
Gap
— 2.0L (VIN
\
ff Front of engine
J
\
No. 2 ring gap and spacer expander gap
Gap
of
upper side
The small arrows on
Piston positioning
the crown ot the pistons
Piston ring end-gap spacing
— 2.0L (VIN Y)
Piston ring end-gap
spacing— 2. 5L and
the front ol the engine
3.0L engines
engine
must point toward
— 2 OL and 2.51
engines
FUEL SYSTEM Fuel System Service Precautions Safety
is
the
most important
performing not only
nance but any type to
fuel
of
factor
maintenance. Failure
conduct maintenance and repairs
safe
manner may
injury or death.
in a
of
system components can be
accomplished safely and
effectively
to the following rules
by
and guide-
lines.
•
spillage Ensure that
applied.
(should
•
Always
relieve the fuel
fire
and per-
occur)
is
all
fuel spillage
quickly removed from
engine surfaces. Ensure
system pres-
that all fuel
soaked
cloths or towels are deposited into a suit-
component
able waste container
(injector, fuel rail,
pressure reg-
•
connection
Exercise extreme caution whenever relieving fuel
system pressure,
and eyes
to
avoid exposing
to fuel spray.
Please be
advised that fuel under pressure
may pene-
skin, face
trate the skin or
any part
of the
body
that
to
•
Always keep a dry chemical (Class B)
extinguisher near the work area.
fire
• Do not allow fuel spray or fuel vapors come into contact with a spark or open
flame. •
it
Always use a back-up wrench when
loosening and tightening
contacts.
To avoid the possibility of
it
sure before disconnecting any fuel system
ulator, etc.), fitting or fuel line
result in serious personal
Maintenance and testing
the vehicle’s fuel
adhering
when
system mainte-
dure requires that battery voltage be
Always place a shop towel or cloth
sonal injury, always disconnect the negative
around the
battery cable unless the repair or test proce-
loosening to absorb any excess fuel due to
fitting
or connection prior to
For Tune-up, Capacities and Firing orders, see Section
fuel line
tion fittings. This will prevent
stress •
1
and torsion
to fuel line piping.
Always replace worn
of this
manual
connec-
unnecessary
fuel fitting
0-
CHRYSLER CORP.
6-24
SEBRING COUPE
rings with new.
where
fuel
pipe
Do
•
AVENGER
not substitute fuel hose,
Separate the
5.
the bottom of the
is installed.
Remove
6.
fuel filter
Fuel System Pressure
connection
flare nut
at
mounting bolts and the
the
Do
not use conventional fuel
the injection system and could
from the vehicle.
CAUTION
servicing the vehicle, refer to
Before
1.
the precautions
in
the beginning of this sec-
tion.
Remove
2.
the fuel
filler
cap
to release
Do not use conventional fuel filters, hoses or clamps when servicing fuel injection systems. They are not compatible with the injection system and
3.
Remove
4.
At the fuel tank, disconnect the fuel
injury or
harness connector.
only hoses and clamps specifically
pump
Start the vehicle
5. until
the rear seat cushion.
it
to the
stalls
OFF
from lack
and allow
it
to run
To
Install
7.
pump
connector.
Tighten the
flare nut fitting
before mounting the
attachment of the
Use
27
Negative battery cable
•
Rear seat cushion
panel on the far right side
on the bracket. bracket only
its
filter
Access cover
•
Fuel
•
Return hose and high pressure fuel
•
bolt.
While holding
housing, torque the eye bolt
lbs.
(29 Nm). Torque the flare nuf fo
ft.
lbs.
(36 Nm).
Tighten the
filter
to
To
Install the intake air
11.
hose,
replaceable fuel
filter is
located
in
Start the vehicle,
13.
if
and
Pump
air intake
hose
fuel filter
housing securely
for access.
with a wrench. Cover the hoses with
shop
torque
lbs. (2.5
Nm)
High pressure hose, return hose fuel
pump
wiring
Negative battery cable
Check the
fuel
pump
Apply sealant
for
proper pres-
access cover and
to the
Install the rear seat
Pressurize the fuel system by turning
9.
pump 1
cushion.
7.
8.
the ignition key to the
Disconnect the negative battery cable
Hold the
22 inch
sure and inspect the entire system for leaks. 6.
REMOVAL & INSTALLATION
and remove the 4.
for leaks
Properly relieve the fuel system
pressure.
pump assembly and
install the cover.
Fuel
tion.
3.
check
necessary.
Before servicing the vehicle, refer to
the precautions in the beginning of this sec-
2.
5.
for leaks.
brake booster. repair
1.
Fuel
and •
system and check
pump assem-
if
the ize the fuel
pump
position projections
the nuts to
position to pressur-
engine compartment, on the bulkhead, next
nuts and
connect the following:
Install or
Connect the negative battery cable,
ON
pump
bly
removed. 12.
to the
Fuel
with the holes In the fuel
•
turn the key to the
wiring
install:
"Align the seal
4.
mounting bolts
pump
hose
ease
of the filter will
•
A
the
•
fully.
REMOVAL & INSTALLATION
is for
pump.
by hand
ft.
10.
Fuel Filter
the seat cushion by pulling
lower cushion upward. There are 2
fuel lines.
pressure hose and eye the fuel
22
or disconnect the following:
•
access covers underneath the seat. The
Using new gaskets, connect the high
9.
Always wrap shop towels around a fitting that is being disconnected to absorb residual fuel in the lines.
on
Movement
fuel filler cap.
CAUTION
filter
Install the filter
8.
finger-tight.
K
Remove
3.
install:
7.
the rear seat cushion and the
specifically
Relieve the fuel system pressure.
2.
fuel
position.
then reconnect the fuel
to the vehicle.
causing
for fuel injection.
^Remove
designed for fuel injection.
Disconnect the negative battery cable,
6.
damage
fail,
to the vehicle.
the stopper outward and lifting the
Turn the key
of fuel.
designed
the high pressures in fuel injection
systems, and could cause substandard parts to fail, causing personal
fuel tank pressure.
damage
Use only hoses and clamps
RELIEVING
fuel injec-
They are not compatible with
tion systems.
personal injury or •:
filters,
hoses or clamps when servicing
filter.
engine
Start the
ON
position.
to verify
proper fuel
performance.
Before servicing the vehicle, refer to
the precautions
in
the beginning of this sec-
Fuel Injector
tion.
towels and remove the eyebolt. Discard the
REMOVAL & INSTALLATION
gaskets.
2.0L Engine 1
.
Before servicing the vehicle, refer to
the precautions in the beginning of this section. 2.
3.
Position the fuel
Exploded view nection
of the fuel line-to-filter
con-
pump
Relieve the fuel system pressure.
Remove
or disconnect the following:
•
Battery
•
Air intake
•
High pressure
hose fuel
hose connection
and discard O-ring for installation
by •
Fuel injector harness connector
•
Fuel injector electrical connectors
aligning the seal projections (arrows) with the fuel
pump
holes
COUPE*
CHRYSLER CORP.
SEBRING
6-25
AVENGER
*
2.5L Engine Before servicing the vehicle, refer to
1.
the precautions in the beginning of this section.
Relieve the fuel system pressure.
2.
Remove
3.
•
or disconnect the following:
Power steering
oil
pressure switch
connector •
Heated Oxygen (HO 2 ) sensor connector
•
Intake Air Temperature (IAT) sensor
connector
6.
connectors
•
Injector
•
Control wiring harness
plenum
•
Intake manifold
•
Fuel injector electrical connectors
•
High pressure
•
O-ring from the high pressure fuel
fuel
hose connection
hose connection • •
Fuel
rail
and injectors as an assem-
bly •
Fuel injector-to-fuel
rail
Air intake
•
Battery
repair
rail
and injectors as an assem-
check
for leaks
and
•
Fuel injector retaining clips
•
Fuel injector(s) and discard the 0rings and
necessary.
if
Fuel bly
hose
Start the vehicle,
retaining
clips
•
grommet
Fuel injectors and discard the 0-
•
rings
To 4.
5.
install: Install or
connect the following
•
New
•
Fuel injectors
fuel injector
O-rings
Lubricate the O-rings with clean
engine fuel rail
oil;
then, install the injectors into the
by twisting them
make sure
that they turn
(left
and
right) to
smoothly
in
the
seat.
WARNING Do not allow engine the fuel •
oil to
get into
rail.
Fuel injector-to-fuel
rail
retaining
clips •
Fuel injector electrical connectors
•
Fuel
•
Fuel injector harness connector
•
New
rail
high-pressure
fuel
hose 0-
ring lubricated with clean engine oil
** WARNING Do not allow engine the fuel •
1
oil to
get into
tion
fuel
hose connec-
and torque the
fuel rail bolts to 1.8
Nm)
fuel ft.
oil
pressure switch
High-pressure 9 O-nng 8.
fuel
10 Fuel
3. Intake air
5.
temperature sensor connector Injector connectors Control wiring harness
11. Insulators
4.
12 Injector supports 13. Insulators 14 injectors
6.
Intake manilold
rail.
High pressure
Power sleenng connector
Heated oxygen sensor connector
2.
7. Injector
plenum
connectors
15.
hose connection
rail
O-nngs
16 Grommets
hose-tolbs. (2.5
swear Exploded view
ot the fuel injector, tuel rail
and related components
For complete service labor times, order the Chilton Labor Guide
— 2.5L engine
CHRYSLER CORP.
6-26
SEBRING COUPE
•
AVENGER
4.
To
install:
•
Negative battery cable
Lubricate the O-rings and grommet(s)
•
Intake manifold
•
Fuel injector electrical connector
with clean engine tors into the fuel
and
•:
in
by twisting them
rail
make sure
right) to
smoothly
then, install the injec-
oil;
•
the seat.
WARNING
the fuel
rail.
oil to
New
connect the following:
fuel injector
O-rings and
grommet(s) Fuel injectors Fuel injector-to-fuel
Vacuum hose
High pressure
fuel
hose connection
•
Fuel pressure regulator
fuel hose-to-fuel rail
•
Fuel
bolts to 1.8
lbs. (2.5
•
Insulators
•
Fuel injectors and discard the O-rings
ft.
Nm)
plenum
Intake manifold
•
Control wiring harness
To install:
•
Injector connectors
4.
•
IAT sensor connector
•
HO 2 S
•
Power steering
sensor connector oil
Start the vehicle,
retaining
rail
repair
if
Fuel
rail
and torque the
for leaks
•
Insulators
•
Fuel
and
lbs.
New
•
ft.
(10-13 Nm)
necessary.
•
.
the3.precautions
high-pressure
fuel
hose 0-
ring
oil.
of this
80 inch
Nm)
lbs. (9
Vacuum hose
•
Fuel return and supply hoses
•
Fuel injector electrical connector
•
Intake manifold
•
Negative battery cable
sec-
plenum
tion. 2.
Lubricate the O-ring with clean
the beginning
13
to
Nm)
•
Before servicing the vehicle, refer to in
oil
Fuel pressure regulator and torque the bolts to
1
new O-ring
and torque the bolts
rail
inch lbs. (12
fuel rail-to-
intake manifold bolts to 7.2— 9.4
Fuel injector with a
lubricated with clean engine
pressure switch
check
connect the following:
Install or
•
3.0L Engine •
with the injectors
rail
•
Fuel injector electrical connectors
•
engine
Fuel supply and return hoses
•
and torque the
connector
•
•
clips
6.
•
7.
get into
plenum
rail.
Install or •
the fuel
get into
oil to
that they turn
Do not allow engine
5.
(left
Do not allow engine
Properly relieve the fuel system pres-
3.
Start the vehicle,
5.
sure.
Remove
or disconnect the following:
repair
if
check
and
for leaks
necessary.
DRIVE TRAIN •
Transaxle Assembly
REMOVAL & INSTALLATION
•
Back-up
light
position
it
lower arm and lower
switch harness and
Speedometer
•
electrical connector,
from the transaxle assembly •
Manual 2.0L
•
Starter
Rear
•
Transaxle mount bracket
the precautions in the beginning of this sec-
•
Upper transaxle mounting bolts
tion.
•
Front wheels
•
Undercover
.
Before servicing the vehicle, refer to
• 2.
Drain the transaxle fluid.
Remove
or disconnect the following:
•
Battery and battery tray
•
Battery brace
•
Air cleaner
•
Select and shift cable cotter pins
•
rod end from the
and intake hoses
Stabilizer bar link
from the damper
fork •
and the cable ends from the
Damper control
Engine front
roll
stopper through-
Centermember
Support the transaxle, using a trans-
mission
jack,
and remove the transaxle
lower coupling
steering knuckle •
Bell
•
•
tie
housing cover
•
bolt
4.
Cotter pin and
Clutch release cylinder connection
necting the hydraulic line
stopper mounting bracket
•
1
and
and move aside without discon-
support the engine assembly. roll
Halfshafts from the transaxle
secure aside
Using Special Tool 7137 or C-4852,
AND 2.5L ENGINES
ball joints
from the steering knuckle
aside
bolt.
^•The coupling
bolt threads
from the
engine side, into the transaxle, and fork
from the
lateral
lower
is
located just above the halfshaft open-
arm ing.
transaxle
•
Lateral lower arm,
compression Slide the transaxle rearward and care-
5.
fully
7137
or
C-4852
lower
To 6.
it
from the vehicle.
install: Install or
•
connect the following:
Transaxle and torque the transaxle-
to-engine bolts to 70
lbs.
ft.
(95
Nm) •
Bell
housing cover and torque the
bolts to •
84 inch
mounting bolts
For transaxle removal, properly support
Also, use a transmission jack to support
the engine assembly as
the transaxle assembly
shown
Nm) and (73 Nm) •
lbs. (9
Nm)
Centermember and torque to
65
ft.
the rear bolt to
Front engine
roll
the front
lbs.
54
(88 ft.
lbs.
stopper through-
— CHRYSLER CORP. SEBRING COUPE and
bolt
Once
lightly tighten.
weight of the engine
full
mounts, torque the bolt
is
the
on the
42
to
ft.
(57 Nm).
lbs.
Battery
•
Air cleaner
•
Front exhaust pipe
•
•
Clutch release cylinder
•
Halfshafts using
new
and
•
tray
assembly
When
keep
installing the halfshaft,
avoid damaging the
to the axle, to
seal
—
ing knuckle. Torque the ball joint
48
Nm). Torque the
rod end nut to
21 a •
(28
lbs.
ft.
new
Nm) and
Damper 65
secure with
(88
•
Vehicle Speed Sensor (VSS) con-
•
Battery and tray
•
Starter
5.
Clutch release cylinder connector
•
Transaxle assembly upper coupling
•
Centermember
•
Rear
•
Transaxle
(39
lbs.
•
Undercover
•
Wheels
•
Transaxle
ft.
roll
fork
4
to the
when
light
Air cleaner
•
Battery tray
•
Battery stay
Upper
•
Bell
Battery and battery tray
•
Battery brace
•
Air cleaner
•
Shifter lever-to-transaxle nut, cable
and intake hoses
pan bolt
oil
and cable from the
housing cover
Transaxle assembly lower coupling
mounting bracket
•
Shifter cable
•
Speedometer, solenoid, neutral
Transaxle assembly safety switch (inhibitor switch), the
connect the following
Install or
•
lbs.
(48
ft.
Bell
•
Transaxle
•
Transaxle dipstick and tube
•
Starter
housing cover and torque the
cover— to—engine bolt to 80 lbs. (9 Nm) and the cover— to ft.
lbs.
•
Upper
pan
oil
or
Rear
•
Transaxle
•
Upper transaxle mounting bolts
Driveshaft connection
Clutch release bearing engagement
new
Lower arm and torque the nut ft.
lbs.
(108
mount
bracket
to
80
•
Front wheels Left side
•
Tie rod
Nm)
undercover
end from the steering
knuckle
end and torque the nut
Tie rod
21
hose
to
ft.
lbs.
Nm)
(28
Stabilizer bar link
from the damper
fork •
and battery
Mopar
roll
•
• air intake
stopper mounting bracket
•
bolt
•
•
and
and using Special Tool 7137
C-4852. support the engine
assembly
(26
•
•
cooler lines
oil
inch
Nm).
Nm)
temperature sensor
connectors
lbs.
Nm)
transaxle bolt to 19
ft.
oil
Transaxle assembly and torque the
(48
Wheel speed sensor connector,
if
•
Damper
fork from the lateral lower
equipped control is level,
and
•
refill
•
number 4773167.
and torque the nut
33
Nm)
ft.
lbs.
•
come ON
(45
Tranasxle
42
lbs.
ft.
ENGINE
Rear to
33
roll ft.
arm and compression
Lateral lower
lower arm, lower ball joints from the steering knuckle
Nm) •
Halfshafts from the transaxle
mount stopper and
torque the nut to 60
reverse.
(57
arm
to
Transaxle mount bracket and torque the nut to
the transaxle for proper operalights
Stabilizer link
•
MS9417 MTX
•
3.0L
fluid.
or disconnect the following:
electrical
switch and
Be sure the vehicle
in
Remove
Driveshaft connection
lower coupling bolts to 36
Select and shift cables and
Check
Drain the transaxle
3.
Clutch release bearing engagement
•
Nm)
Be sure the reverse
tion.
Lower arm
•
cotter pins
fluid, part
2.
switch and
speedometer connector
9.
Tie rod
•
Upper transaxle mounting bolts and
the transaxle with
equipped
end
•
stopper mounting bracket
torque them to 35
8.
Brake hose clamp
if
pulse generator, kickdown servo
mount bracket
stopper through-bolt.
•
•
•
roll
•
Before servicing the vehicle, refer to
.
the precautions in the beginning of this sec-
bolts
lbs.
Back-up
and
bracket and stopper
Wheel speed sensor,
ft.
Starter
mount
Stabilizer link
•
to
Remove the engine support Tighten mount through-bolt to 51 (69 Nm) and tighten the front engine
•
for leaks
transaxle
7.
•
check
necessary.
Automatic
•
Nm)
the transaxle
•
if
To install:
(43
lbs.
Rear
Start the vehicle,
6.
repair
retaining clip
damper
transaxle and torque the nuts to 32
•
the transaxle fluid to the proper
stopper
roll
•
•
Nm)
and torque the self-locking nut ft.
Fill
level.
•
•
the through-bolt to
Stabilizer link to the
29
assembly
Air cleaner
light
•
fork to the lower control
lbs.
ft.
Front exhaust pipe
•
up
tion.
(65
lbs.
cotter pin.
arm and torque •
tie
ft.
•
bolts
ball joints to the steer-
self-locking nuts to
up light switch connector and selection cable connec-
tions
1
and
Tie rod
Shift
switch connection
oil
rated part of the halfshaft. •
•
connector
—
Back
the transaxle, with the ser-
lip of
Back
•
nector
the inboard joint straight in relation
VSS
and selection cable connec-
Shift
tions
circlips
•
•
6-27
AVENGER
•
ft.
lbs. (81
and
secure aside
Nm)
housing cover
•
Bell
•
Engine front
stopper and torque the nut lbs.
(45
Nm)
roll
stopper through-
bolt 1
.
Before servicing the vehicle, refer to
the precautions in the beginning of this sec-
•
Centermember
•
Clutch release cylinder and torque to
tion.
13
ft.
lbs.
(18
Nm)
•
Centermember
•
Flexplate-to-torque converter bolts.
Rotate the crankshaft to bring the 2. 3.
Drain the transaxle
Remove
•
fluid.
Starter
motor and
electrical
connecbolts into a position for removal,
tors
or disconnect the following:
Please
one
visit
our web
site at
www.chiltonsonline.com
at a time.
OQ “£0
CHRYSLER CORP. SEBRING COUPE
AVENGER
•
^*To make installation easier, use
Damper
•
make matchmarks on
chalk or paint to
the torque converter and flexplate.
These marks
65
be used at assembly assembly, keeping these
29
WARNING
K
Left side
•
Wheels
•
Transaxle
removing the bolts, push the torque converter toward the •
damaging the
roll
•
Support the transaxle using a trans-
coupling
NOT
•
bolt.
Nm) and
(69
lbs.
coupling bolt
inserted from
is
(43
51
torque the front
35
ft.
lbs.
Nm)
(48
Dipstick tube and dipstick
•
Shifter cable
mounting bracket
•
Shifter lever
and torque the nut
•
Oil
(19
lbs.
ft.
a.
b.
to
carefully lower
Nm)
After the torque converter
6.
mounted on assembly
70
lbs.
ft.
10.
(95 Nm).
clutch pedal clevis pin play to agree with
pulse generator, kickdown servo
the standard value and secure the
switch and
pushrod with the locknut.
oil
temperature sensor
connectors
electrical
and
•
Air cleaner
•
Battery tray Refill the
torque the torque converter-to-flexplate bolts to
55
lbs.
ft.
Install or
8. •
Bell
’•AA/hen adjusting the clutch pedal
air intake
connect the following:
108 inch
lbs.
Nm)
(12
Centermember and torque the
Nm) and lbs.
to
65
lbs.
ft.
fluid. Start the
2 minutes.
to idle for
Recheck
fluid level
and add
if
neces-
marks
bolt full
and
ft.
for
weight of the engine
mounts, torque the bolt lbs.
•
Once is
to
proper oper-
With the pedal
Clutch
When
Pedal Height and Free-Play
WARNING
the inboard joint straight to the axle to avoid lip of
1.
keep
damaging the
lbs.
(28
tie
Torque the
Compare
cotter pin.
48
ft.
lbs.
the
measured value with
desired distance of 7.0-7.09
in.
(6-1 3mm).
disengaged, check the
the
The measurement should
(70mm)
or more.
measurements are not within
system. still
If
after
bleeding the measurements
not within specified range, there
(65
in
the system, which
is
a
must
the
be replaced.
REMOVAL & INSTALLATION
Measure the clutch pedal
clevis pin
play at the face of the pedal pad. Press the
pedal lightly until resistance
measure
this distance.
vis pin play
is
2.0L and 2.5L Engines
met, and
The clutch pedal
cle-
should be within 0.040-0.120
ft.
secure with a new
component
in.
(175-1 80mm).
ball joint
rod end nut to 21
Nm) and
If
faulty
oil
Tie rod and ball joints to the steer-
Nm), the
Measure the clutch pedal height from
are
2.
self-locking nuts to
measurement should
specification, bleed the clutch hydraulic
relation
the transaxle with the
ing knuckle.
to
the face of the pedal pad to the bulkhead. in
splined part of the halfshaft. •
in.
circlips
installing the halfshaft,
fully
of the pedal pad.
5. I-
OFF.
distance between the bulkhead and the top
be 2.760
new
to
and the pedal resting point
be between 0.240-0.510
ADJUSTMENT
Halfshafts using
ON
determine the clutch pedal free-play. The
ft.
(56 Nm).
is
the clutch pedal until the resis-
clutch pedal free-play
the
on the
42
Move
4.
this point
range on the dipstick.
Check the transaxle
lightly tighten.
the clutch pedal
the way, the interlock
all
tance begins to increase; measure between
should be between the
HOT
the
in
stopper through-
roll
when
switch switches over from
N.
(69-78 Nm).
Front engine
that
selector through each gear position, ending
ation. •
Check
d.
front
(88
51-58
the rear bolts to
play, be careful not to push the pushrod toward the master cylinder.
MOPAR®
depressed
sary. Fluid level
mounting bolts
it
height or the clutch pedal clevis pin
Apply the parking brake and move the
in
•
transaxle with
engine and allow
hose
and battery
ATF PLUS transmission
(75 Nm).
housing cover and torque the
bolts to
Turn the pushrod to adjust the
c.
safety switch (inhibitor switch), the
mounting
to the engine. Install the to
equipped with cruise control sys-
by tightening the locknut.
Align the balance matchmarks and
7.
seal
If
has been
the transaxle, install the transaxle
and tighten
so the pedal
standard clutch pedal height. Then, lock
Speedometer, solenoid, neutral
To install:
bolt
the standard value, then tighten
nector and turn the switch to obtain the
cooler lines and secure with
from the vehicle.
it
is
tem, disconnect the clutch switch con-
clamps •
not equipped with cruise control,
the locknut.
Slide the transaxle rearward and
5.
bolts
If
and adjust the stop
turn
height
•
14
standard values,
play, is not within the
adjust as follows:
Starter
located just above the halfshaft
opening.
Clutch pedal height and tree-play adjust-
ment measurements
to
stopper bolt
roll
tighten to
the engine side into the transaxle and is
mount through-bolt
9.
^The
lbs.
Upper transaxle mounting bolts and
•
at
remove the transaxle lower
the pan)', and
ft.
stopper mounting bracket
Transaxle
engine the side ot the case,
32
to
9300CG01
Rear
ft.
(at
mount bracket and torque
and remove the engine support
converter. 4.
to
Nm)
transaxle. This will prevent the converter from remaining in contact with
mission jack
fork
undercover
mounting nuts
the
Clutch pedal clevis pin play
Nm)
(39
lbs.
ft.
•
After
the engine, possibly
damper
and torque the self-locking nut
parts in balance.
Clutch pedal height
to
Nm)
(88
lbs.
ft.
Stabilizer link to the
•
will
to realign the
fork to the lower control
arm and torque the through-bolt
in.
(1-3mm). 3.
If
the clutch pedal height or clevis pin
1
.
Before servicing the vehicle, refer to
the precautions
in
the beginning of this sec-
tion. 2.
Remove
or disconnect the following:
C OQ U L.V
CHRYSLER CORP. SEBRING COUPE* AVENGER
Apply multi-purpose grease to the
8
clutch release bearing. Pack the bearing
inner surface and the groove with grease.
Do
not apply grease to the resin portion of
the bearing. Place the bearing in position
and
install
the return clip.
Apply a coating
9.
of
grease to the
clutch disc splines, then use a brush to rub it
the grooves. Using a clutch disc align-
in
ment
tool, position the clutch disc
flywheel. Install the retainer bolts tighten a
little
at a time, in
on the
and
a diagonal
sequence. Install the transaxle
10.
check the
assembly and
fluid level.
1 1
Connect the negative battery cable.
12.
Verify proper clutch operation.
3.0L Engine 1
.
Before servicing the vehicle, refer to
the precautions in the beginning of this section. 2.
Remove
Negative battery cable
•
or disconnect the following:
Negative battery cable
yUiiiltml
•
Transaxie
•
Pressure plate-to-flywheel bolts,
When
pressure plate and clutch disc
grease to each part, but be careful not to apply excessive grease. Exces-
Valve and spring
sive grease will cause clutch slip-
Clutch release cylinder
page and shudder.
Clutch cover and disc
Clutch fluid line bracket
’Hf the pressure plate loosen the bolts
one or 2 turns
in a
is to
be reused,
diagonal pattern,
time. This will pre-
at a
installing the clutch, apply
Insulator,
vent warping the clutch cover assembly.
Remove
3.
the return clip
sure plate release bearing.
Do
19 ± 3 N-m 14 ± 2 ft-fb
and the presnot use sol-
vent to clean the bearing. Inspect the clutch release fork and
4.
damage
fulcrum
for
remove
the release fork
or wear.
If
necessary,
and the fulcrum
from the transaxle. Carefully inspect the condition of the
5.
clutch
components and replace any worn
or
damaged parts. To install: Inspect the flywheel for heat
6.
damage
or cracks. Resurface or replace the flywheel
as required. Install or
7.
connect the following:
•
Flywheel using new bolts
•
Fulcrum,
•
Release fork
^Apply grease
if
removed, and tighten
a coating of multi-purpose
to the point of contact with the
fulcrum and the point of contact with the release bearing. Apply a coating of
multi-purpose grease to the end
of the
release cylinder's pushrod and the
pushrod hole
in
the release fork.
Exploded view
Timing belt service
is
ol the clutch
covered
in
assembly-3. 0L engine
Section
3
of this
washer and clutch tube
Union, union bolt and gasket
manual
CHRYSLER CORP.
6-28
SEBRING COUPE* AVENGER
**To make installation easier, use
Damper
•
make matchmarks on
chalk or paint to
the torque converter and flexplate.
These marks
will
fork to the lower control
arm and torque 65
be used at assembly
•
the through-bolt to
Nm)
(88
lbs.
ft.
damper
Stabilizer link to the
fork
to realign the assembly, keeping these
and torque the self-locking nut
parts in balance.
29
WARNING
U
•
Left side
•
Wheels
•
Transaxle
removing the bolts, push the torque converter toward the After
•
Rear
verter from remaining in contact with
damaging the
•
Support the transaxle using a transthe side of the case,
NOT
coupling
ment measurements
to 51
torque the front
stopper bolt
roll
tighten to •
bolt.
Nm) and
(69
lbs.
Clutch pedal height and tree-play adjust-
35
ft.
lbs.
standard values,
play, is not within the
adjust as follows:
Upper transaxle mounting bolts and
•
at
and remove the transaxle lower
the pan),
(43
lbs.
mount through-bolt
Transaxle ft.
(at
ft.
stopper mounting bracket
roll
engine 4.
32
to
and remove the engine support
converter.
mission' jack
mount bracket and torque
Nm)
transaxle. This will prevent the conthe engine, possibly
undercover
mounting nuts
the
to
Nm)
(39
lbs.
ft.
Nm)
(48
a.
If
height
Starter
•
Dipstick tube and dipstick
•
Shifter cable
mounting bracket
•
Shifter lever
and torque the nut
not equipped with cruise control,
and adjust the stop
turn
is
bolt
so the pedal
the standard value, then tighten
the locknut.
9.
(••The coupling bolt
inserted from
is
the engine side into the transaxle and is
14
located just above the halfshaft •
opening.
Oil
(19
lbs.
ft.
b.
to
Nm)
standard clutch pedal height. Then, lock
clamps
by tightening the locknut.
Speedometer, solenoid, neutral
•
carefully lower
After the torque converter
mounted on
safety switch (inhibitor switch), the
clutch pedal clevis pin play to agree with
pulse generator, kickdown servo
the standard value and secure the
switch and
pushrod with the locknut.
has been
the transaxle, install the transaxle
•
70
to
lbs.
ft.
temperature sensor
connectors
'When
mounting
to the engine. Install the
and tighten
oil
10. electrical
assembly
(95 Nm).
and
Air cleaner
•
Battery tray
air intake
Refill the
torque the torque converter-to-flexplate
55
bolts to
lbs.
ft.
Install or
8.
•
Bell
engine and allow
connect the following:
108 inch
lbs.
Nm)
(12
Centermember and torque the
fluid. Start the
2 minutes.
to idle for
Nm) and
to
65
lbs.
ft.
51-58
the rear bolts to
marks
if
neces-
in
bolt full
and
roll
for
proper oper-
weight of the engine
mounts, torque the bolt lbs.
•
is
to
Clutch
When
Pedal Height and Free-Play
WARNING
seal
lip of
1.
keep
the inboard joint straight in relation to the axle to avoid
lbs.
(28
tie
48
ft.
cotter pin.
lbs.
rod end nut to 21
Nm) and secure
faulty
measured value with the
(65
(6-1 3mm).
the
The measurement should
(70mm)
or more.
measurements
are not within
If
after
bleeding the measurements
not within specified range, there
component
in
the system, which
is
a
must
REMOVAL & INSTALLATION
Measure the clutch pedal
clevis pin
play at the face of the pedal pad. Press the
pedal lightly until resistance
measure
this distance.
vis pin play
new
in.
disengaged, check the
be replaced.
is
2.0L and 2.5L Engines
met, and
The clutch pedal
cle-
should be within 0.040-0.120
ft.
with a
measurement should
in.
(175-1 80mm).
ing knuckle. Torque the ball joint
still
the face of the pedal pad to the bulkhead. the
If
system. are
2.
Nm), the
the clutch pedal height from
desired distance of 7.0-7.09
Tie rod and ball joints to the steer-
to
specification, bleed the clutch hydraulic
oil
the transaxle with the
self-locking nuts to
Measure
Compare
damaging the
splined part of the halfshaft. •
in.
circlips
installing the halfshaft,
fully
of the pedal pad.
5.
C
OFF.
distance between the bulkhead and the top
be 2.760
new
to
and the pedal resting point
With the pedal
ADJUSTMENT
Halfshafts using
ON
determine the clutch pedal free-play. The
ft.
(56 Nm).
is
the clutch pedal until the resis-
be between 0.240-0.510
the
on the 42
Move
clutch pedal free-play
stopper through-
Once
4.
this point
range on the dipstick.
Check the transaxle
lightly tighten.
the clutch pedal
the way, the interlock
all
tance begins to increase; measure between
should be between the
HOT
the
ft.
(69-78 Nm).
Front engine
when
switch switches over from
N. Recheck fluid level and add
ation. •
that
selector through each gear position, ending front
(88
Check
d.
depressed
sary. Fluid level
mounting bolts
push the pushrod
Apply the parking brake and move the
in
lbs.
play, be careful not to
toward the master cylinder.
housing cover and torque the
bolts to •
it
adjusting the clutch pedal
height or the clutch pedal clevis pin
MOPAR®
transaxle with
ATF PLUS transmission
(75 Nm).
hose
and battery
Align the balance matchmarks and
7.
Turn the pushrod to adjust the
c.
from the vehicle.
it
To install: 6.
equipped with cruise control sys-
nector and turn the switch to obtain the
cooler lines and secure with
Slide the transaxle rearward and
5.
bolts
If
tem, disconnect the clutch switch con-
in.
(1-3mm). 3.
If
the clutch pedal height or clevis pin
1.
Before servicing the vehicle, refer to
the precautions
in
the beginning of this sec-
tion. 2.
Remove
or disconnect the following:
CHRYSLER CORP.
fi.OQ U LXJ
SEBRING COUPE* AVENGER
Apply multi-purpose grease to the
8.
clutch release bearing. Pack the bearing inner surface and the groove with grease.
Do
not apply grease to the resin portion of
the bearing. Place the bearing
and
install
Apply a coating
9.
in
position
the return clip. of grease to the
clutch disc splines, then use a brush to rub it
the grooves. Using a clutch disc align-
in
ment
tool, position the clutch disc
flywheel. Install the retainer bolts
tighten a
at a time, in
little
on the
and
a diagonal
sequence. 10.
Install
check the
the transaxle assembly and
fluid level.
11.
Connect the negative battery cable.
12.
Verify proper clutch operation.
3.0L Engine 1
.
Before servicing the vehicle, refer to
the precautions in the beginning of this section. 2.
•
Negative battery cable
•
Transaxle
•
Pressure plate-to-flywheel bolts,
When
pressure plate and clutch disc
grease
loosen the bolts
in a
is to
be reused,
diagonal pattern,
one or 2 turns at a time. This will prevent warping the clutch cover assem-
not to
installing the clutch, apply
each
the return clip
sure plate release bearing.
Do
Insulator,
be careful apply excessive grease. Excesto
part, but
Valve and spring
Clutch release cylinder
page and shudder.
Clutch cover and disc
19*3 N-m 14*2 ft-fb
and the presnot use sol-
vent to clean the bearing. Inspect the clutch release fork and
4.
damage
fulcrum
for
remove
the release fork
or wear.
If
necessary,
and the fulcrum
from the transaxle. Carefully inspect the condition of the
5.
clutch
components and replace any worn
or
damaged parts. To install: Inspect the flywheel tor heat
6.
damage
or cracks. Resurface or replace the flywheel
as required. Install or
7.
connect the following:
•
Flywheel using new bolts
•
Fulcrum,
•
Release fork
if
**Apply a coating grease
removed, and tighten
of
multi-purpose
to the point of contact with the
fulcrum and the point
of contact
with
the release bearing. Apply a coating of
multi-purpose grease to the end
of the
release cylinder’s pushrod and the
pushrod hole
in
the release fork.
washer and clutch tube
Union, union bolt and gasket
sive grease will cause clutch slip-
bly.
Remove
or disconnect the following:
Negative battery cable
Clutch fluid line bracket
'Hf the pressure plate
3.
Remove
Exploded view
Timing belt service
is
of the clutch
covered
assembly-3. OL engine
in Section
3 of this manual
CHRYSLER CORP.
6-30
SEBRING COUPE
AVENGER
•
•
Release fork shaft
•
Left
•
Release fork
•
Clutch release bearing
•
Release fork boot and fulcrum
•
Release fork boot and maintenance
Tighten the bleed screw, then release
4.
Cotter pin, halfshaft nut and washer
•
Loosen the bleed screw, then have the
3.
clutch pedal pressed to the floor.
support spring
•
Front wheel
•
Tie rod
Repeat the procedure
5.
MB991113
until the fluid is
free of air bubbles. i-
cover
suggested that a hose be attached to the bleed screw with the
Install or
•
connect the following:
other end
Release fork boot and maintenance
•
Release fork
(19
lbs.
ft.
Valve and spring
•
Union, bolt and gasket and torque
Insulator,
17
ft.
•
of joint
damage
lbs.
to
assembly
Check
3.
the clutch for proper operation.
•
Lateral
(23
Nm)
the
compression
Halfshaft from the hub/knuckle by
REMOVAL & INSTALLATION
setting
to 11
ft.
up a puller on the outside
wheel hub and pushing the half-
lbs.
shaft from the front
hub
Halfshaft from the transaxle by
and torque the (19
arm and
using a joint separation tool •
•
lbs.
fork lower through-bolts,
upper pinch bolt and damper fork
2.0L and 2.5L Engines
ft.
damper
arm from the steering knuckle
Nm)
Fluid line bracket
bar link from the
Damper
the reservoir with clean brake
washer and clutch tube
inserting a prybar between the
Nm)
transaxle case and the halfshaft
Negative battery cabie If
Check and top
4.
in
fork
Halfshaft
and torque the fastener
14
Refill
7.
•
the bolt to
Sway
•
fluid.
Nm)
Clutch release cylinder
bolt to
improper methods
the joint, leading to possible failure.
• 6.
•
•
of
support spring and release fork
Clutch disc and cover and torque
(15
Use
separation can result
bleeding.
the bolts to 14
•
container at
reservoir to run out of fluid during
shaft •
in a
bleeding operation. Do not allow the
Clutch release bearing
Left
immersed
least half full of brake fluid during the
cover •
•
WARNING
’»lt is
To install: 3.
end from the steering
knuckle using joint separation Tool
the clutch pedal.
off the fluid level,
if
necessary.
the vehicle
is
going to be rolled
equipped with a center bearing on
remove the center bear-
the right halfshaft,
vehicle, obtain 2 outer CV-joints or
ing bracket-to-chassis bolts; then, tap
proper equivalent tools and
Hydraulic Clutch System
If
while the halfshafts are out of the
the hubs.
the vehicle
If
is
install to
rolled with-
lightly
on the center bearing bracket
sep-
to
arate the inner shaft from the transaxle.
out the proper torque applied to the
BLEEDING
front will
1.
wheel bearings, the bearings
no longer be usable. Before servicing the vehicle, refer to
1.
the precautions in the beginning of this sec-
the precautions tion. 2.
DOT
Fill
the reservoir with clean
4 brake
DOT
Do not
pull
damages
Before servicing the vehicle, refer to in
the beginning of this sec-
on the shaft. Doing so
the inboard joint.
Do not
insert the prybar too far or the oil
seal
in
the case
may be damaged.
tion.
3 or
Remove
2.
or disconnect the following:
fluid.
•
To install:
Negative battery cable
4.
Inspect the halfshaft boot for
Check
or deterioration.
damage
the ball joints
and
splines for wear. 5.
Replace the circlips on the ends
of
the halfshaft(s). 59 - 71
6.
Nm
43-52 ft.lbs.
Insert the halfshaft into the transaxle.
Be sure 7.
If
it
is fully
seated.
equipped with a center bearing on
the right halfshaft, install the center bearing
196-255 Nm 145-188 ft.lbs.
bracket-to-chassis bolts and torque to 30 lbs.
8.
Removal steps 1.
2. 3.
Cotter pm Drive shaft nut Tie rod end connection
4. Stabilizer link 5.
Damper
and
Pull the knuckle
install the
assembly outward
other end of the halfshaft into
10 Drive shaft and inner shaft (R.H.) .
n.
the hub.
Drive shaft
9.
connection 12 Circlip .
fork
7.
arm connection Compression lower arm connection
7
8.
Harness
'
9.
Bolt
6. Lateral
lower
Install the
washer so the chamfered
edge faces outward*
Install the halfshaft
clip
Indicates parts which should be temporarily tightened, and then fully tightened with the vehicle on the ground in the unladen condition.
10.
Connect the
lateral
arm and
the
com-
pression arm to the steering knuckle.
Torque the self-locking nuts lbs.
of the left
and
right halfshaft
nut
and tighten temporarily.
Caution
Exploded view
ft.
(40 Nm).
assemblies' mounting
to
43-52
(59-71 Nm).
1 1
.
Install or
connect the following:
ft.
CHRYSLER CORP. SEBRING COUPE •
Damper
•
Halfshaft snapring
Nm)
•
Tri-pot spider
and the upper pinch lbs.
(24-33 Nm) and •
ft.
17-25
to
install a
new
Sway
Do not disassemble the spider assembly.
lbs.
ft.
cot-
The
bar link to the
damper 29
to
ft.
fork
(39
lbs.
Birfield joint assembly, located on the wheel side of the halfshaft, is not to be disassembled; repair of this
joint is only by
*
Nm)
Lockwasher and axle
replacement
** WARNING If
torque the axle nut with the Special
MB990767
from turning
to
to
the boot
145-188
ft.
lbs.
2.01 (DOHC) ENGINE
4.
(200-260 Nm) 1
^•Before securely tightening the axle
make sure
nut,
there
is
the precautions in the beginning of this sec-
no load on the
New
soft
cotter pin
•
Negative battery cable
12.
jawed
halfshaft
and place
•
in
slide the
damper from
the halfshaft.
If
removed,
install the
a
damper by performing
dynamic
the following proce-
vise.
Tri-pot boot
dure:
Tri-pot case
Slide the damper onto the halfshaft new bands. b Position the damper so the dis-
a.
bands and remove any grease
from the case
level.
necessary, remove the dynamic
damper bands and
5. it
Disassemble or remove:
•
the transaxle to the proper
Fill
Remove
3.
Front wheel
If
damage.
To install: 2.
•
be reused, wrap plas-
tion.
wheel bearings. •
Before servicing the vehicle, refer to
.
is to
tape around the shaft splines to
protect the boot from
Tri-Pot Joint
hold the hub
Tri-pot boot
of the
halfshaft.
nut; then,
•
tic
Tool
assembly
** WARNING
pin
and torque the nut
•
76
bolt to
to the steering knuckle
end
and torque the nut
ter
(88
Nm)
(103
Tie rod
lbs.
ft.
6-31
AVENGER
fork then torque the lower
through-bolt to 65
•
•
with
tance from the front of the birfield joint to Test drive the vehicle
13.
and check
for
proper operation.
3.0L Engine 1
.
Before servicing the vehicle, refer to
the precautions in the beginning of this section. 2.
Remove •
or disconnect the following:
Negative battery cable
•
Front wheel
•
Vehicle Speed Sensor (VSS) cable,
•
Brake hose
•
Driveshaft nut
if
equipped clip
and
cotter pin
•
Lower arm
•
Tie rod
•
Stabilizer link
•
Driveshaft and circlip
ball joint
connection
end
To install: 3.
Install or
connect the following:
•
Driveshaft
•
Stabilizer link
and torque the nut
33
Nm)
•
ft.
lbs.
Tie rod
21
ft.
(44
end and torque the nut
lbs.
(28
•
New
•
Lower arm
to
to
Nm)
cotter pin to the tie rod
end
ball joint
•
Driveshaft nut and torque
•
maximum of 167 New cotter pin to
ft.
lbs.
Brake hose clip
•
VSS
•
Front wheel
•
Negative battery cable
if
to a
Nm)
the driveshaft nut
•
cable,
it
(226
5.
Snap nng
10.
equipped
8
J
asscnnWy 9Q0GCG06
Exploded view
Heater Core replacement
of the halfshatt
is
covered
in
assemblies— 2. OL (DOHC) Engine
Section
2 of this manual
CHRYSLER CORP.
6-32
SEBRING COUPE
•
AVENGER Remove
2.
soft
jawed
halfshaft
and place
it
in
a
vise.
Disassemble or remove:
3.
bands
•
Tri-pot boot
•
Tri-pot case for
left
halfshaft or
tri-
pot case/inner shaft assembly for
9.
right halfshaft
^Wipe
the grease from the tri-pot
case. 10.
Distribute a portion of the 3.7 oz. Positioning the dynamic
damper on
(105 g) specified repair
the
assemblies— 2. OL (DOHC) Engine Install the tri-pot
edge
14.60-14.84
of the in.
damper assembly
(371-377mm)
is
1.
(191-1 97mm)
7.52-7.76
for the left halfshaft.
Tighten and secure the damper
Position the boots large end on the
•
WARNING
Position the large and small boot If
Adjust the boot so that the bands
are spaced at 3.03-3.27
WARNING
d.
plastic tape
in.
(77-83mm).
Tighten the band securely.
dam-
4.
2.5L (SOHC) ENGINE
age.
Before servicing the vehicle, refer to
newsmall boot clamp onto
7.
Apply the specified repair
8.
Install
the tri-pot spider
kit
is
If
working with the
necessary
right halfshaft
and
to replace the tri-pot case,
To
install:
tion. 5.
the halfshaft followed by the tri-pot boot.
between the spider axle and the
be reused, wrap plas-
press the case from the inner shaft assembly.
the precautions in the beginning of this seca
is to
tape around the shaft splines to protect the boot from damage.
it
Install
the boot
tic
around the shaft
splines to protect the boot from
6.
Tri-pot boot
clamps onto the boot. c.
Wrap
Do not disassemble the spider assembly.
tri-pot case.
bands. :
WARNING
in.
b. c.
boot by performing
assembly
the following procedure:
for the a.
right halfshaft or
Tri-pot spider
assembly and
add the remaining grease. the front
Halfshaft snapring
•
grease into the
kit
tri-pot case, insert the spider halfshaft
•
If
installing a
new
tri-pot
case onto
grease
roller.
assembly
onto the shaft from the spline beveled section direction
and secure with the snapring.
12
Lubricating the tri-pot spider assembly
5 (R H. only)
\
“
fMT
Iff T.J.
boot repair
1
kit
T.J.
2. T.J.
3. T.J. 4. T.J.
T.J. repair kit
boot band boot band
Seal plate 6 Inner shaft 7. Bracket assembly 8. Dust seal outer
9306CG11
^%> 'U
Bearing repair
dust
9.
shaft
assembly
11.
Bracket
assembly
repair kit
Dust seal inner Center bearing Center bearing bracket
12. Circlip
13
Snap nng
14.
Spider assembly
15. T.J. boot 16 B.J. assembly
Lubricating the tri-pot case assembly installed
seal f
kit
10.
case and inner case
5.
5
9306CG12
Exploded view
ot the haltshaft
assemblies— 2. 5L (SOHC) Engine
CHRYSLER CORP. SEBRING COUPE
•
AVENGER
6-33
the right halfshaft, perform the following
procedure: Lubricate the inner shaft splines
a.
with Multi-Mileage Grease No.
2525035.
Press the inner shaft assembly into
b.
tri-pot case.
Secure the
c.
tri-pot
MB991248 on
Tool
case with special
a hydraulic press
with the case facing upward. d.
Position's
new
036023
seal plate in the
Installing the inner dust seal to the center
center of the tri-pot case.
Place a 1.18
e.
the seal plate
in.
Removing
(30mm)
and press the
pipe on
seal into the
shaft
the tri-pot case from the inner
assembly
— Right
halfshaft with 2.5L
bearing bracket
— Right
halfshaft with 2.5L
(SOHC) Engine
(SOHC) Engine
tri-pot case.
T'
Wrap
WARNING
plastic tape
around the shaft
splines to protect the boot from
dam-
age. Install a
6.
new small boot clamp onto
the halfshaft followed by the tri-pot boot.
Apply the specified repair
7.
between the spider axle and the
grease
onto the shaft from the spline beveled section direction
Installing the outer dust seal to the center
Removing
spider assembly
Install the tri-pot
8.
kit
roller.
and secure with the snapring
bearing bracket the center bearing bracket from
the inner shaft assembly
— Right
— Right
halfshaft with 2.5L
(SOHC) Engine halfshaft
with 2.51 (SOHC) Engine
Distribute a portion of the 4.23 oz.
9.
(120 g) specified repair
kit
grease into the
tri-pot case, insert the spider
MB990938
assembly and
add the remaining grease. Install the tri-pot
10.
boot by performing
the following procedure:
Position the boots large end on the
a.
tri-pot case. b.
Position the large and small boot
i.*~M
clamps onto the boot. are spaced at 3.03-3.27 d.
in.
(77-83mm).
Tighten the band securely.
Removing
the center bearing Irom the
center bearing bracket— Right halfshaft
2.5L (SOHC) ENGINE
it
in
Remove
.
the right halfshaft
Installing the inner shaft into the center
bearing bracket— Right halfshaft with 2.5L
(SOHC) Engine
with 2.5L (SOHC) Engine
Center Bearing
1
MB991172
Adjust the boot so that the bands
c.
MB990938 and place
a soft-jawed vise.
Remove
2.
from the
Remove
3.
the tri-pot spider
assembly
tri-pot case.
the tri-pot case by perform-
ing the following procedure: a.
Position the inner shaft/tri-pot case
assembly on by Tool
a hydraulic press
MB991248
supported
with the tri-pot case
facing upward. b.
WJ6CG22
Position a bar inside the tri-pot
case, on the end of the inner shaft and
press the case from the inner shaft
Installing the center bearing to the center
Installing the inner shaft
bearing bracket— Right halfshaft with 2.5L
tri-pot
(SOHC) Engine
is
covered
— Right
(SOHC) Engine
assembly.
Brake service
case
in
Section 4 of this manual
assembly
into the
halfshaft with 2.5L
CHRYSLER CORP.
6-34
SEBRING COUPE
AVENGER
•
9306CG16
Positioning the birfield joint boot’s small Installing the seal plate into the tri-pot
case— Right
halfshaft with 2.5L
Measuring the small band's crimp
diameter
(SOHC)
Engine
Place the inner shaft assembly
4.
in
MB991561
a
soft-jawed vise.
Using a wheel
5. ter
puller,
press the cen-
bearing bracket from the inner shaft.
Using a hydraulic press,
6.
Adapter Tool
MB990938, press
Tool
Installer
MB990932 and Snap-in
Bar
the center bearing
and inner dust seal from the center bearing bracket.
9306CG14
9306CG17
To install: Positioning the birfield joint boot's large
Using a hydraulic press,
7.
Adapter lool
MB990938, press
Tool
Installer
MB990932 and Snap-in
View
of the
band crimper
tool
diameter 8.
Bar
the center bearing
into the center bearing bracket.
Using a hydraulic press,
8.
Adapter Tool
MB990938, press
Tool
Installer
MB990933 and Snap-in
Bar
the inner duct seal 9.
into the center bearing bracket.
Using a hydraulic press,
9.
Installer
MB990931 and Snap-in Bar MB990938, press the outer duct seal
Adapter Tool Tool
9306CG18
into the center bearing bracket.
Using a hydraulic press and Adapter
10. 1.
MB991 1 72,
Tool
press the inner shaft into
Positioning the birfield joint boot’s large
the center bearing bracket. 1 1
Install
.
band
band
the tri-pot case onto the right
halfshaft by performing the following proce-
Using a Band Crimper Tool
Disassemble or remove:
2.
dure:
Lubricate the inner shaft splines
a.
Tri-pot joint
•
Dynamic damper,
with Multi-Mileage Grease No. 2525035.
tri-pot case.
Secure the
c.
tri-pot
MB991248 on
Tool
case with special
To
Birfield joint
boot bands
•
Birfield joint
boot
new
•
seal plate in the
•
or install:
4.
boot
Birfield joint
boot small band
Place a 1.18
in.
(30mm)
pipe on
Place the halfshaft
so that the
the seal plate and press the seal into the 5.
birfield joint is
in
standing
vertically.
12
Assemble the
13.
Install the right halfshaft.
tri-pot joint
assembly. 6.
Birfield Joint
in.
Boot
soft
jawed
vise.
halfshaft
and place
it
in
a
is
exposed on the
shaft.
Adjust the Band Crimper Tool
MB991561 so
that the
jaw opening
is
until the is
grease
oz. in
is
install a
not correct,
new
one.
(155g) specified
the repair
kit,
pack the
10.
(0.1-1
Position the'boot so 0.004-0.061
.55mm)
of clearance exists
in.
between
the boots large diameter end and the birfield
0.114
Position the small band so there
joint
housing shoulder.
11. is
clearance between the boot and the bands
mating edge.
of
band crimp
birfield boot.
(2.9mm). 7.
Remove
groove
the crimp dimension
amount
Position the boots small diameter so 1
of the
(2.4-2.8mm).
Using 5.47
a soft jawed vise
tri-pot case.
that only
in.
remove the band
Birfield joint
center of the tri-pot case. e.
0.094-0.110
If
Assemble
the small
measurement
internal
install:
3.
Position a
eguipped with a
•
a hydraulic press
with the case facing upward. d.
if
2.0L (DOHC) engine
Press the inner shaft assembly into
b.
MB991561, crimp
•
Adjust the Band Crimper Tool
MB991561 so in.
(3.2mm).
that the
jaw opening
is
0.126
CHRYSLER CORP. SEBRING COUPE 12.
and position the large boot
Install
band so
that
6-35
AVENGER
•
rests against the boot(s) pro-
it
and a gap exists between the clamp
jection
and the boot. Using a Band Crimper Tool
13.
MB991 561, crimp
the small band until the
measurement
internal
0.094-0.110
of the
crimp
is
(2.4-2.8mm).
in.
3306CG13
If
the crimp dimension
remove the band 14.
If
is
not correct,
new
install a
Measuring the small band
diameter
s
crimp
equipped with a 2.0L (DOHC)
engine, install the dynamic
damper by per-
forming the following procedure: Slide the
a.
3306CG16
Positioning the birfield joint boot's small
one.
damper onto
MB991561
the halfshaft
new bands.
with b.
damper so
Position the
the dis-
tance from the front of the birfield joint to the front
assembly
(371-377mm) 7.52-7.76
edge
of the
14.60—14.84
is
in.
damper
in.
for the right halfshaft or
(191-197mm)
for the left
halfshaft. c.
Positioning the birfield joint boot s large
Tighten and secure the damper
View
of the
band crimper
tool
diameter
bands. 15.
the tri-pot joint.
Install
3.0L ENGINE Before servicing the vehicle, refer to
1.
the precautions in the beginning of this section.
Remove
2.
halfshaft
and place
it
in
a 11
soft
jawed
vise.
Disassemble or remove:
3.
•
Tri-pot joint
•
Dynamic damper
•
Birfield joint
boot bands
•
Birfield joint
boot
To
10.
install:
Assemble
4.
Positioning the birfield joint boot’s large
band
or install:
MB991561, crimp
•
Birfield joint
boot
•
Birfield joint
boot small band
5.
Positioning the birfield joint boot s small
band
Place the halfshaft
in
vise so that the birfield joint
0 094-0.110
a soft jawed is
standing ver-
the small
measurement
internal
in.
of the
(2.4-2
band crimp
MB991561 so
is
8mm)
in
Position the boots small diameter
so that only
1
groove
is
If
exposed on the
is
install a
not correct,
new
MB991561 so in.
that the
jaw opening
is
0.1
14
(2.9mm). 8.
amount
of
grease
oz.
one.
Position the boot so 0.004-0 061
is
.55mm)
mating edge.
the boots large diameter
Using a Band Crimper Tool
joint
of
end and the
0 126
rests against the boot(s) pro-
exists
between the clamp
Using a Band Crimper Tool
internal
in
birfield
housing shoulder.
For complete Engine Mechanical specifications, see Section
the small
measurement in.
(2
of the
band crimp
until the is
4-2 8mm).
** WARNING
clearance exists between
(0.1-1
is
and position the large boot it
and a gap
0094-0 110
clearance between the boot and the bands
9.
pack the
birfield boot.
Position the small band so there
that
MB991 561, crimp
(155g) specified
in the repair kit,
jaw opening
and the boot. 14.
Using 5.47
Adjust the Band Crimper Tool
Install
jection
shaft. 7.
that the
2mm).
band so
the crimp dimension
remove the band
(3
13
** WARNING
tically.
6.
Adiust the Band Crimper Tool
12
until the
If
the crimp dimension
remove
1
of this
is
the band install a
manual
not correct,
new one.
CHRYSLER CORP.
6-36
SEBRING COUPE
•
AVENGER
STEERING AND SUSPENSION 9.
ment on
Bag
Air
CAUTION
:
Some
or near
tion:
SRS Use a
vehicles are equipped with an
bag system, also known as the Supplemental Inflatable Restraint (SIR) system or Supplemental Restraint System (SRS). The system must be disabled before performing service on or around system components, steering column, instrument panel components, wiring and sensors. Failure to follow safety and disabling procedures could result in accidental air bag deployment, possible personal injury and unnecessary system repairs.
the inflator
module
multi-meter for which
2 miliamp (mA)
test current is
minimum range
measurement
for
of resistance
SRS
use with the Chrysler
Check Harness when checking the SRS
diate inspection
DRB
11.
air
III
diagnosed and serviced.
of the air
12.
Air
Bag Control Unit (SRS-ECU)
13.
Air
Bag Modules
14.
If
resulting in unnecessary system
repairs and/or personal injury.
are diag-
in
sonal injury. Along with the precautions
DISARMING
LOCK
the
The system consists
following:
ules,
Never carry the
inflator
module by
on the underside
the wires or connector
of
carrying a live inflator module,
hold securely with both hands, and ensure
Place the inflator module on a bench
or other surface with the bag
4.
and trim cover
inflator
module on the
module which may be thrown
Disconnect the negative battery
5.
Do
connectors or wires are
6.
Air
If
System bag
the clock spring
before drying or baking the vehicle after i
painting. After air
bag system service, check
SRS warning
is in
operation to be sure
system functions properly.
that the 8.
light
Make
the
OFF
when
a scan tool
connected or disconnected.
DO NOT
use any
air
bags, the
G sensor and
bag modules
electrical test
tem to
is
designed
deploy the
air
to retain
bag
air
bag sys-
enough voltage
for a short period of
time even after the battery has been dis-
connected.
SRS-ECU
the sating
to ignite
from the
REMOVAL & INSTALLATION
G sensor
2.0L and 2.5L Engines
and deploy.
CAUTION
vehicle equipped
the air bag or to the driver by rendering the air
bag system inoperative.
is
air
can provide diagnostic infor-
bag system,
it
mation. The
SRS-ECU monitors
the air bag
position, the
minate
for
is
in
the system.
turned to the
SRS
warning
When
ON
or
If
key.
the
SRS
(air bag system) clock spring under the steering wheel and render the Security Restraint System (SRS)
START 1
light
may damage
injury.
the
should
about 7 seconds, then turn
operating condition.
and pinion unit, center the front wheels and remove the ignition
inoperative, risking serious driver
system and stores data concerning any detected faults
Prior to removal of the steering rack
Failure to do so
The SRS-ECU not only controls the
That indicates that the
equip-
one minute before
Power Rack and Pinion Steering
with an air bag system, to avoid injury to
ignition key
certain that the ignition switch
position
at least
Gear
the technician by inadvertent deployment of
air
Wait
c.
working on the vehicle. The
Service technicians should use care
bag components should not be
modules themselves and
A
located
to the output signal
when working around any
Bag Control Unit (SRS-ECU), the
7.
air
faulty,
the Supplemental Restraint
is
must be ON. The SRS-ECU, then causes the
subjected to heat over 200°F (93°C).
Remove
light is
cates the status of the air bag system.
analog
not attempt to repair any of the
replace that harness.
the
console assembly monitors the system
must respond
bag system wiring harness connectors. of the
high-quality electrical tape or similar
non-conductive wrapping.
located under the
SRS warning
cable and insulate the cable end with
bag
bag Electronic
air
(SRS-ECU)
To deploy the
the
in
the key
within the steering column.
event of an accidental deployment.
Air
The
clock spring interconnection
With the
Remove
located on the instrument panel which indi-
bench, never place anything on or close to
any
inflator unit.
air
and which contains a sating G sensor and
facing up.
air
the center of the steer-
analog G sensor. An
3.
bag mod-
air
and another located above the
Control Unit floor
bag and trim cover are pointed
away.
the
in
2
of
glove box, which contains the folded
and an
When
that the
one located
ing wheel
the module. 2.
position.
from the ignition lock cylinder. b.
.
the
in
the beginning of this section, observe the
1
in
straight-ahead position and place the key
to avoid
accidental deployment and possible per-
bag system using the
Position the front wheels
a.
replaced.
air
following procedure:
they should only be
faulty,
Disarm the
1.
components
may cause
accidental deployment of the air bag,
NEVER ATTEMPT TO REPAIR THE FOLLOWING COMPONENTS:
of these
CAUTION
:
nents. Failure to do so
bag diagnostic codes.
any
bag during vehicle servicing,
Air Bag system must be disarmed before removing many compo-
and
for reading
the vehicle’s
The
and may be used.
scan tool
If
the
refer to all service precautions.
other factory special tool wiring adapters
erasing
required.
if
imme-
SRS warning light is in any of these 3 conditions, the SRS system must be inspected,
SRS Check Harness acts like a “break-out box” for checking SRS wiring. There are that are available
is
or
while driving,
To avoid injury from accidental deploy-
MB991613
Chrysler Special Tool
10.
more than 7 seconds
light illuminates
ment
electrical circuitry.
nosed as
when handling
digital
maximum
or less at the
PRECAUTIONS Several precautions must be observed
does not illuminate as described or
light
stays on for
the
air
SRS components
any
except those specified by Chrysler corpora-
.
Before servicing the vehicle, refer to the
illu-
precautions
in
the beginning of this section.
off.
SRS system is in the SRS warning
2.
Drain the power steering fluid using
the following procedure:
CHRYSLER CORP. SEBRING COUPE
1.
Joint
assembly and gear box
connecting 2. 3. 4.
bolt
5.
a.
of the
* should be temporarily tightened before they are finally tightened once the total weight of the engine has been placed on the vehicle body.
power rack and pinion steering gear mounting
Disconnect the power steering
return (low side) hose. b.
Connect a suitable container
wheels, several times, from side-to-side,
In
Disarm the SRS system.
4.
Remove
the
Both front wheels
•
Lower steering column
between the jack and the
Cotter pins and
tie
Both triangular braces near the
Support the center crossmember.
round
the through-bolt from the front
roll
stopper and remove the 3 bolts
securing the center crossmember. •
Nm) and
Center crossmember and properly
•
Rear
roll
torque
fluid lines;
ft
lbs.
secure the low side
stopper through-bolt and
torque to 32
lbs (43
ft.
Nm)
the 2 rack assembly-to-chassis bolts
and the
Rack and pinion steering assembly
(69-78 Nm)
•
its
•
rubber mounts
Front
rear bolt to
roll
the nut to
•When
removing the rack and pinion assembly, tilt the assembly to the inner side of the compression lower arm. and remove from the left side of the
Use caution
to
For Accessory Drive Belt
bolts to
•
Tie rod
20
•
1
stopper bolt and torque
32
ft.
lbs.
(43
Nm)
Stabilizer bar
ft.
50-56
ft.
lbs
(69-78 Nm)
ends and torque the nuts
lbs.
(27
to
Nm)
Solenoid's wiring harness connector,
see Section
lbs.
•
•
illustrations,
ft.
Both triangular braces and torque the
install:
Align the rack assembly so the
51-58
•
avoid damaging
the boots.
To
Nm)
Crossmember and torque the front bolts to 58-65 ft. lbs. (78-88 Nm)
and
vehicle.
(18
lbs.
Power steering
engine into position
tit-
Rack assembly clamp bolts and
•
•
equipped with Electronic
Nm)
hose with the clamp and raise the
pressure pipe
vent excessive fluid leakage
rod ends from
crossmember 5.
fluid
lbs (69
the high side fitting to 11
pan.
tings; then, plug the fittings to pre-
joint-to-
Control Power steering (EPS)
Remove
oil
and return hose from the rack
Solenoid’s wiring harness connec-
•
Power steering
•
the steering knuckles
if
ft.
•
ft.
Pinch bolt and torque the bolt to 13
(15
and washer tank
Stabilizer bar
•
Steering rack and torque the mounting bolts to 51
•
damage to the when supporting and jacking engine, place a block of wood
rack and pinion input shaft bolt •
or connect the following:
Install
•
order to prevent
or disconnect the following
•
tor,
shaft
removed.
3.
•
7.
engine,
While cranking the engine, turn the
until the fluid is
umn
slightly
6.
ignition coil. d.
splines are inserted into the steering col-
rear roll stopper through-bolt.
** WARNING
Properly disable the ignition sys-
tem by removing the connector from the
support the engine and remove the
Lower the engine
to the
hose. c.
Clamp Gear box assembly
The fasteners marked
Stay (L.H.) Stay (R.H.)
Exploded view
Center
8.
Caution
tion 6.
member assembly
7.
9.
Power steering pipe connection Cotter pin Tie rod end and knuckle connec-
6-37
AVENGER
•
if
equipped with EPS
Front wheels
of this manual
CHRYSLER CORP.
6-38 8.
Refill
ing fluid
SEBRING COUPE ‘AVENGER power
the reservoir with
steer-
and properly bleed the power
steering system. 9.
Perform a front end alignment.
3.0L Engine 1
.
Before servicing the vehicle, refer to
the precautions in the beginning of this section. 2.
Drain the power steering
3.
Remove •
fluid.
or disconnect the following:
Negative battery cable from the
left
shock tower •
Front exhaust pipe
member
•
Center
•
Steering shaft assembly
•
Tie rod
3.
end from the steering
knuckle •
Return hose and pressure tube 9346FG07
connections Exploded view
•
Cylinder clamp
•
Steering gear from the vehicle
To install: 4.
connect the following:
Install or
•
Steering gear to the vehicle
•
Cylinder clamp and torque the bolts to 51
•
(69
To
ends
Tie rod
(15
lbs.
ft.
Strut
•
Upper mounting bolts
•
Strut
to 21
ft.
•
Strut
to
33
ft.
lbs.
(44
•
Strut
assembly
to the lower control
ft.
lbs.
(300
bar link and torque the nut to
33
lbs.
ft.
(44
Nm)
Front speed sensor harness clamp,
•
Brake hose clamp
•
Front wheel
•
Negative battery cable
if
equipped
Nm) •
Stay and torque the bolts to 55 lbs.
•
(74
5.
ft.
Nm)
Steering shaft assembly and torque the bolt to 13
ft.
lbs.
(18
Center
•
Negative battery cable
Fill
Nm)
member
•
and bleed the power steering sys-
tem. 6.
repair 7.
Start the vehicle, if
check
for leaks
and
necessary.
Perform a front wheel alignment.
Strut
REMOVAL & INSTALLATION 3.0L Engine 1
.
Before servicing the vehicle, refer to
the precautions
in
the beginning of this sec-
tion. 2.
Remove
or disconnect the following:
®
Negative battery cable
•
Front wheel
•
Brake hose clamp
•
Front speed sensor harness clamp, if
•
•
equipped
Sway
2
BRAKE HOSE CLAMP FRONT SPEED SENSOR HARNESS CLAMP
1.
3.
STABILIZER LINK
4.
BOLTS
5
NUT STRUT ASSEMBLY
6.
9346FG08
bar link
Lower control arm
Exploded view
of
the front strut
assembly—3. OL
Nm)
Sway
•
assembly and torque the
Nm)
knuckle (29
•
connect the following:
upper bolts
lbs.
the bolts to 221
assembly
install:
Nm)
to the steering
and torque the nut
arm and steering knuckle. Torque
from the steering knuckle
•
Install or
Nm)
Pressure tube and return hoses and torque to 11
•
lbs.
ft.
assembly— 3. OL
gear
of the steering
— 4.
ment,
Check and adjust the
if
CHRYSLER CORP. SEBRING COUPE* AVENGER
C OQ U 03
end align-
front
needed.
Shock Absorber REMOVAL & INSTALLATION
front
2.0L 1
.
AND 2.5L ENGINES Before servicing the vehicle, refer to the
precautions 2.
3.
in
Remove
the beginning of this section. or disconnect the following:
Negative battery cable
•
Wheel
•
Sway bar link from the damper fork Damper fork lower through-bolt, upper pinch bolt and damper fork
•
98 71
•
assembly •
1
4.Stff-toctang
7 Jppsr bu*vng 6 srw t*; 6 Cup 9 Burnp rufib* 10 Oust cow*
w
nut
2
Shock absorber
3 4
Upp* bu*tvng A Upp* brack* a**krrtky Upp* spring pad
5 6 Coksr
CAUTION Do Not remove the large center
spring
12 Shock bso'twr
Exploded view
nut.
Co4
11
of the front
Msomety
shock absorber
Exploded view
To install: Install or
•
connect the following:
ft.
Shock absorber and torque
the
upper mounting nuts
ft.
(44 •
Nm) and
to
32
fork then torque the lower
through-bolt/nut to 65
ft.
lbs.
(103
•
Nm) 4
to
29
ft.
(39
lbs.
Use a
jack to raise or lower the lower
control arm, so that the top shock absorber
Nm)
plate studs align through the body. Raise
Wheel
the jack to hold the shock absorber
assem-
bly in position.
Perform a front end alignment
(88
shock absorber
ot the rear
assembly mounting
76
bar link and torque the link-
to-damper fork nut
lbs.
Nm)
Damper
lbs.
Sway
•
the upper pinch bolt to
5.
Install or
connect the following:
Rear
~The
shock absorber assembly
is a
load bearing component; therefore, the
vehicle chassis and axle weight must
be supported separately, requiring the use of 2 separate lifting devices.
The
rear
package shelf
must be removed
to
front cover(s)
access the top mount-
Most connections are
ing nuts.
plastic clips.
Use care when removing these components to
avoid unnecessary damage. 1
Remove
or disconnect the following:
•
Rear shelf speaker covers
•
Rear shelf top assembly
•
Front cover(s) to access the shock
absorber top mounting nuts 2.
Raise and support lower control arm
assembly •
slightly.
Shock absorber upper mounting nuts
7922CG31
Exploded view
of the front
shock absorber
•
Shock absorber lower mounting
•
Shock absorber
bolt
1. Self-locking
3.
5. 6.
Upper bushing B
12 Shock absorber assembly
4.
Position the shock absorber assembly
7. Collar
8 Cep 9 Dus’ cover 10 Bump rubber
3.
To install:
nut
Washer Upper bushing A Braoei Spnng pad
2.
11
Cotl
7922CGM
so that the lower mounting bolt can be
assembly mounting
installed
For
Tire,
and
Wheel and Ball Joint
Exploded view
lightly tightened.
specifications, see Section
spnng
1
of this
ot the rear
manual
shock absorber
CHRYSLER CORP. SEBRING COUPE
•
AVENGER Carefully release the spring
9.
com-
pressor, watching the spring position as seats.
When
the spring
it
properly seated,
is
release/remove the compressor tools. Reinstall the
10.
ENGINES
3.0L 1
shock absorber assembly.
.
Before servicing the vehicle, refer to
the precautions in the beginning of this section. 2.
Disassemble as follows:
3.
Remove
and place 4.
it
in
Install
the strut/shock assembly
compressor
a suitable
Special Tool
tool.
MB991 176
to
secure the strut and remove the dust cover
and jam
10. 11.
COIL SPRING
12.
SHOCK ABSORBER ASSEMBLY
JAM NUT
7.
2.
WASHER
8.
UPPER BUSHING A UPPER BRACKET ASSEMBLY UPPER SPRING PAD COLLAR
9.
3.
4. 5. 6.
5.
UPPER BUSHING B CUP ASSEMBLY BUMP RUBBER DUST COVER
1.
6. 7.
cover.
9346FG09
Exploded view
shock absorber
of the
Remove the coil spring. Remove the lower spring To assemble: 8.
9.
10. •
Top
and torque the
plate nuts
mounting nuts •
•
32
to
ft.
lbs.
Lower mounting
bolt
and torque
the bolt to 71
lbs.
(98
Interior trim
ft.
in
Compressor Tools MB991237 and
MB991238
Nm)
compress the spring
pieces
compressor
3.0L ENGINE
precautions
in
Make
certain
or disconnect the following:
absorber
been removed from
Negative battery cable
and washer from the top
•
Rear shelf trim
absorber assembly
•
Cover from the upper shock tower
•
Upper mounting nuts
release the tension on the spring compressor.
•
Shock from
Allow the spring
•
Shock assembly
If
the spring
of the
shock absorber
To install:
may remain connect the following:
Install or
3.
•
Shock absorber and torque shock ft.
•
to steering
lbs.
(98
lbs.
(45
73
Nm)
Upper shock nuts and torque ft.
to
32
Nm)
•
Upper tower cover
•
Rear shelf trim
•
Negative battery cable
in
expand
to is
the
absorber shield. ring, the spring,
to
lator
fully.
If
only the
components
6.
REMOVAL & INSTALLATION
sor.
Remove the upper insulator the bumper and lower insuto
each
8.
shield,
in
the beginning of this sec-
lbs.
Before servicing the vehicle, refer to the beginning of this sec-
in
Disassemble as follows:
3.
Remove
4.
5.
6.
7.
the rear shock from the
Install the
assembly
in
a spring
com-
Remove
the jam nut,
washer and
Remove
the upper bracket
assembly
is
correctly
or 16
ft.
lbs.
strut to
(22
rear strut. Install the dust cap.
18
Nm) on
the collar the cup,
and bushing.
bump
rubber and
9.
Remove
the coil spring
To assemble: 10.
Smoothly compress the washer and piston rod
Remove Remove
dust cover.
Install
the coil spring to the shock
absorber using Compressor Tools
MB991237 and MB991239. nut.
ft.
the
bump
Install the
dust cover and
12.
Install the
cup and bushing
13.
Install the collar,
1 1
Nm)
the strut/shock to the vehicle.
2.
8.
spring compres-
certain the spring
Install the
(25
tools.
Install
pressor tool.
mount and washer.
Torque the nut on the front Before servicing the vehicle, refer to
(64 Nm).
dust cover and remove the
tion.
lower insulator, the shock
spring.
AND 2.5L ENGINES
lbs.
ft.
Install the
and spring pad.
Install or align the
insulator rings.
Front
nut.
upper bushing.
positioned relative to the upper and lower
tion.
1.
location for proper reassembly.
Install the
Make
47
and jam
properly aligned, torque the
the precautions
absorber bumper and the uncompressed
7.
to
seat.
compress the spring and
vehicle.
install:
shock absorber
Coil Spring
the precautions
16.
compressor assembly.
spring. Install the upper spring insulator,
2.0L
15.
being replaced, the spring
from the spring. Take notice
To
When
rubber.
upper spring pad and
install the insulator
absorber bearing, washer, mount and shock
the
knuckle bolt
Carefully
to be replaced, slowly
By hand, remove the upper shock
5.
13.
14.
bump
the dust cover and
Install the
Rear is
1.
the rear steering knuckle
Install
shock
•
4.
.
12.
compressor
assembly and shock
remove the piston rod nut
plate,
lower spring pad and coil
Install the
jam nut
After tension has
3.
the shock absorber
the beginning of this section.
Remove
2.
slowly.
properly engaged before
is
tightening.
Before servicing the vehicle, refer to the
.
compressor and
pad.
spring. 1 1
spring compressor assembly or
equivalent. Tighten the
the
1
Place the shock absorber assembly
2.
Nm)
(44
nut.
Remove the strut insulator. Remove the upper spring seat and pad. Rempve the bump rubber and dust
.
rub-
ber.
and bracket assembly.
supper spring pad
CHRYSLER CORP. SEBRING COUPE 14.
the upper bushing and
Install
86
trol
Nm
When
15.
Remove
install the
the upper
properly aligned, install the
jam nut and torque 16.
arm mounting
and using the
washer.
the
17
to
(23 Nm).
lbs.
tt.
nuts.
Remove
the nuts
joint separation tool, separate
arm
shafts from the
shock
absorber tower.
compressor tools and
Remove
5.
shock absorber.
or disconnect the following:
Upper control arm assembly
•
Upper arm
•
Upper
6-41
AVENGER
•
shaft assembly-to-upper
arm nuts/bolts and
control
Ball Joint
the
shaft(s)
REMOVAL & INSTALLATION The upper
install:
6.
Install the
and bolts
2.0L and 2.5L engines, and cannot be seror
damaged
28
ball
—
Nm
/ —t-J
20 1Ub*r
Upper arm
1.
ball joint
2.
8.
Self-locking nut for
4
Upper arm
REMOVAL & INSTALLATION suspension on the 2.0L and called a Multi-Link
arms used
9. of the
suspension; a curved arm called the
called the Lateral
arms contain lower
straight
Lower Arm. Both since there
are 2 sockets in the steering knuckle. Ball joints
and lower arms are removed and
A
replaced as an assembly
ment
is
(86 Nm).
knuckle and torque
front
end align-
ft.
lbs.
(28
Nm)
Check the wheel alignment and if
necessary.
3.0L Engine c.
If
the ball joint stud
is
out of speci-
fication (turns too easily or is too
continue with the
1
.
stiff),
ball joint/control
tion.
assembly replacement.
-The
upper
ball joint boot
removed and replacement
Before servicing the vehicle, refer to
the precautions in the beginning of this sec-
arm
can be
the joint greased. ball joint boot is
A new
Remove
Rear wheel
•
Upper control arm from the
recom-
shock absorber
tower, locate the
at
steer-
ing knuckle
mended. Inside the engine compartment,
or disconnect the following:
•
•
Upper control arm assembly
•
Upper control arm bracket
•
Upper control arm
required after these procedures.
Upper Control Arm
20
mounting
2. ball joints
with
Front wheel
upper control arm
Suspenin this
Compression Lower Arm and also a
arm
lbs.
Ball joint to the
•
adjust,
front
it
or connect the following:
the locking nut to
assembly
4.
Exploded view
is
ft.
Install
• shaft
7922CG35
sion. There are 2 lower
shafts to
upper a/m
mstalation
2.5L engines
arm
and secure
3 Upper arm assembly
Ball Joint
front
(57 Nm).
mounting nuts. Torque the mounting
nuts to 62
and knucxle
connection
The
lbs.
the shock absorber tower
1
the
arm assembly.
Lower
ft.
Align the upper control
1
replacement of the upper con-
joint requires trol
A worn
to 41
for the 7.
viced separately.
upper arm shaft assemblies
upper control arm and torque the nuts
to the
an integrated part
ball joint is
upper control arm assembly
of the
To
the
upper con-
REMOVAL & INSTALLATION 2.0L and 2.5L Engines 1
.
Before servicing the vehicle, refer to the
precautions 2.
the beginning of this section
in
Remove
or disconnect the following:
•
Front wheel
•
Ball joint stud
from the steering
knuckle, using the joint separation Tool 3.
The
MB991113
ball joint
can be checked using
the following procedure: a.
An adapter (MB 990326)
able that
adapts If
to
fits
onto the
ball joint
is
avail-
stud and
an inch-pound torque wrench.
this tool is not available, a
shop-made
substitute can be fabricated. b.
Turn the
ball joint
1,
stud with the 2.
torque wrench. The factory standard for
breakaway torque (0.34-1.45 Nm).
is
3-13
UPPER ARM AND KNUCKLE CONNECTING BOLT UPPER ARM ASSEMBLY MOUNTING BOLTS
3
4 5
UPPER ARM ASSEMBLY UPPER ARM BRACKET UPPER ARM JGtl
inch lbs.
Exploded view
ol the
upper control arm assembly
For Wheel Alignment specifications, see Section
1
of this
manual
CHRYSLER CORP.
6-42
SEBRING COUPE
«
AVENGER
3.
connect the following:
Install or
•
Upper control arm and brackets and torque the bolts (57
•
to
42
ft.
torque the bolts to 29
ft.
lbs.
•
(39
Nm) •
•
Upper control arm
to the steering
knuckle and torque the bolt 73 lbs. •
(98
ft.
MB991113
50-56
fork-to-lower control arm
•
arm mounting
Lower control arm
(98-118 Nm).
install:
3.
When
6.
installing the control arm,
tem-
bolt nut to
Check the
front
71-85
ft.
lbs.
end alignment and
'adjust as required.
arm
ing the control
Compression Lower Arm
suspension
to the
the vehicle
is sitting
Install or
on
its
only after
fully
.
precautions
connect the following:
Damper
•
REMOVAL & INSTALLATION
fork
and torque the fork-to-
lower control arm through-bolt to
64
Lower Arm
•
ft.
lbs.
(88
(88-108 Nm).
Ball joint stud
from the steering
MB991113 •
Install a
new
Lower control arm-to-crossmember
cotter
To
install:
Tension rod to the control arm and
•
3.
torque the nuts to
Stay bracket from the crossmember
•
bolt
or disconnect the following:
•
Front wheel
lbs.
ft.
pin.
Front wheel
or disconnect the following:
•
knuckle and
65-80
tion.
•
the beginning of this section.
knuckle, using Joint Separator Tool
Ball joint stud to the
the precautions in the beginning of this sec-
in
Remove
Nm)
torque the nut to
Before servicing the vehicle, refer to
Before servicing the vehicle, refer to the
wheels. 2.
Remove
is
bolt
To
4.
2.
weight of the vehicle
full
on the suspension, torque the inner lower
1
.
the
Lower control arm-to-crossmember
crossmember. Tighten them
1
Front wheel
Once
5.
to
(69-78 Nm)
lbs.
ft.
porarily tighten the nuts and/or bolts secur-
Nm)
Rear wheel
Lower Control Arm
Lateral
crossmember
and torque the mounting bolts
through-bolt
Upper control arm assembly and
Stay bracket to the
knuckle, using Joint Separator Tool
Damper
•
lbs.
Nm)
•
from the steering
Ball joint stud
•
To install:
80-94
ft.
connect the following:
Install or
lbs.
•
(108-127 Nm)
Control arm to the crossmember
and torque the bolts (83 •
9871 -
to
60
lbs.
ft.
Nm)
Ball joint stud to the
knuckle and
torque the nut to 43-51
ft.
lbs.
(59-71 Nm) • 4.
front
end alignment and
adjust as required.
Nm ft.
Front wheel
Check the
lbs.
3.0L 1
.
ENGINE Before servicing the vehicle, refer to
the precautions
in
the beginning of this sec-
tion. 2.
Remove
or disconnect the following:
•
Front wheel
•
Lower control arm from the steer-
•
Lower control arm mounting
ing knuckle bolt
and clamp cover
• 3.
If
Lower control arm replacing the bushing, perform the
following:
Apply soapy water between the
a.
shaft
bushing
Grease: MOPAR Multi-mileage Lubricant Part No. 2525035 or equivalent
1.
2. 3.
and old bushing and pry the old out.
To
install:
4.
Apply soapy water
new bushing and
Compression lower arm ball joint and knuckle connection Compression lower arm mounting
4.
Stay
5.
bolt
6.
Shock absorber lower mounting bolt and nut Lateral lower arm ball joint and
•
7.
knuckle connection Lateral lower arm mounting bolt
and
•
Compression lower arm assembly
8.
nut Lateral lower
to the shaft
install the
and
new bushing,
if
removed. 5.
Install or
arm assembly
connect the following:
Lower control arm Lower control arm clamp and torque the bolts
to
60
ft.
lbs. (81
Caution Indicates parts which should be temporarily tightened, and then fully tightened with the vehicle on the ground in the unladen condition. 7922CG36
Exploded view
of the lateral
lower arm and the compression lower arm mounting
Nm) •
Lower control arm
to the steering
knuckle and torque the bolts to 80 ft.
lbs.
(108
Nm)
CHRYSLER CORP. SEBRING COUPE Front wheel
•
Check and adjust the
6.
6-43
AVENGER
•
front toe,
if
needed.
Rear 1
Before servicing the vehicle, refer to
.
the precautions in the beginning of this section.
Remove
2.
or disconnect the following:
•
Rear wheel
•
Stabilizer Jink
Wheel Speed Sensor (WSS),
•
if
equipped
Lower control arm assembly
•
to
steering knuckle
Lower control arm
•
3.
To install: Install or
3.
connect the following:
Lower control arm and torque the
•
bolt to
55
ft.
lbs.
(74
Lower control arm
•
Nm)
to the steering
knuckle and torque the bolt to 80 lbs.
• •
•
WSS,
if
SZ?CGJ7
equipped
Exploded view
Stabilizer link
and torque the
29
Nm)
lbs.
ft.
ft
Nm)
(108
(39
of the front
hub assembly mounting and related components
bolt to
Remove
knuckle and torque the self-locking
or disconnect the follow-
Rear wheel nut to 21
ing:
Wheel Bearings
•
Front wheel
•
Vehicle Speed Sensor (VSS),
couple of lug nuts and
if
Caliper and brake pads; then, sup-
•
port the caliper out of the
play,
remove the
caliper
and
rotor.
a dial indicator to bear against the
back and in.
forth.
If
(0.05mm), replace the
front
guide pins Once the caliper
•
Upper
secured, the lug nuts can be
is
rear
hub and wheel bearing assem-
designed
for the life of the vehicle
maintenance. The bearing with the wheel
is
leading to possible failure.
hub and can only be unit.
REMOVAL & INSTALLATION
VSS.
•
Front wheel
•
New
•
is
cotter pin
and bend
to
secure
(halfshaft)
hub
side
is installed
hub.
Install
outward, away from the
the washer and
hub nut Tighten
145-188
ft
lbs
(200-260 Nm).
** WARNING
bearing assembly from the
knuckle
•The
equipped
the axle nut with the brakes applied. Torque
4 hub-to-steering knuckle bolts
Hub and
if
Examine the driveshaft
the nut to •
is
washer Locate the chamfered side This
and
a sealed unit
removed and/or replaced as one
•
6
Never use wedge-type tools or the ball joint can be damaged.
requires no type of adjustment or periodic
install the
removed.
knuckle outward
of
joint,
Rear The
from the steering
improper methods of joint separation can result in damage to
bearing assembly.
bly
ball joint
** WARNING Use
in the holder. Slide the caliper
Brake rotor from the hub assembly
pull the
hub and
pads
•
knuckle using a press type tool and
end-play exceeds 0.002
Caliper holder and place the brake
over the brake pads and
hub hub
•
way
Position
flange near the center ridge. Wiggle the
lightly tighten to
using wire
Front To check hub and bearing assembly end-
Nm)
hold the rotor on the hub.
equipped
ADJUSTMENT
(28
lbs.
ft
Position the rotor on the hub. Install a
5.
Pump
the brake pedal until hard,
before attempting to
hub and wheel bearing assembly
move
the
vehicle.
not serviceable and should not be
disassembled.
Rear To install:
Front
4 1
.
Before servicing the vehicle, refer to the
precautions 2.
in
Remove
and washer.
Install or
•
the beginning of this section.
Hub
WITH
connect the following:
to the steering
knuckle and
torque the bolts to 65
ft.
lbs.
1
(88
•
Upper
Before servicing the vehicle, refer to
the precautions in the beginning of this sec-
Nm)
the cotter pin, halfshaft nut
.
DRUM BRAKES
tion. ball joint to the steering
For Maintenance Interval recommendations, see Section
2.
1
Remove
of this
or disconnect the following:
manual
CHRYSLER CORP.
6-44
SEBRING COUPE
cVehicles with
•
AVENGER
drum brakes>
74 - 88 54 - 65
ABS
•
VSS,
•
Rear wheel and lower the vehicle
if
equipped with
WITH DISC BRAKES
Nm ft.lbs.
1
Before servicing the vehicle, refer to
.
the precautions in the beginning of this section.
Remove
2.
or disconnect the follow-
ing: •
Rear wheel
•
Vehicle Speed Sensor (VSS),
if
equipped with Anti-lock Brake Sys-
tem (ABS) Caliper and brake pads; then, sup-
•
port the caliper out of the
way
using wire Brake rotor
•
Remove
3.
the parking brake shoes as
follows: a.
Upper shoe-to-anchor springs.
b.
Lower shoe-to-shoe spring.
c.
Brake shoe hold-down springs.
d.
Parking brake cable from the actu-
ating lever.
Remove Remove
4. 5.
the 4 hub-to-knuckle bolts. the
hub and bearing assem-
bly from the knuckle.
"The
hub assembly is not serviceable and should not be disassembled. 6.
Rear speed sensor cVehicles with
1.
7. 8.
ABS-rotor cVehicles with
ABS> 2.
Caliper assembly
3.
Brake drum Brake disc Clip mounting
4. 5.
Shoe and
assembly
Rear hub assembly
6.
lining
ABS>
If
Socket
Caution
Do
To
Press the wheel sensor rotor onto
the hub.
not disassemble the rear hub assembly. 8.
of the rear
hub assembly mounting
Install the
hub
Rear wheel
•
Vehicle Speed Sensor (VSS),
3. if
equipped with Anti-lock Brake Sys-
If
Socket
replacing the hub, use special
MB991248 and
To install:
•
Brake drum
4.
•
4 hub to the knuckle bolts
•
Hub and knuckle
’"The hub assembly is not serviceable and should not be disassembled.
a press, to
remove
the wheel sensor rotor from the hub.
tem (ABS)
bearing assembly from the
to the
54-65
ft.
knuckle and lbs.
(74-88
Nm) 9.
•
remove
install:
torque the bolts to Exploded view
a press, to
the wheel sensor rotor from the hub.
7.
bolt
replacing the hub, use special
MB991248 and
Install the
hold rotor on hub. Install
brake pads
the caliper holder and place
in holder.
brake pads and Install or
•
Hub
connect the following:
to the
bolts to •
knuckle and torque the
54-65
Brake drum
ft.
lbs.
(74-88 Nm)
parking brake shoes.
Position the rotor on the hub. Install
a couple of lug nuts and lightly tighten to
11.
Press the wheel sensor rotor onto the
hub. 5.
10.
caliper
is
Slide the caliper over
guide pins. Once
install
secured, lug nuts can be
removed.
VSS,
12.
Install the
13.
Install the rear
if
equipped
wheel.
CHRYSLER CORPORATION 1997 Eagle-Talon
7-17
DRIVE TRAIN ENGINE REPAIR FUEL SYSTEM
7-14
PRECAUTIONS STEERING AND SUSPENSION Air
Removal &
7-25
Installation
Pump
Removal &
Installation
Fuel System Pressure
7-25
Disarming
7-26
Precautions
7-25
Fuel
&
Installation
Removal &
Lifters
Installation
Steering Gear
7-15
Removal &
7-15
Rear Main Seal
7-15
Removal
7-14
Halfshaft
7-9
Hydraulic Clutch System
7-20
Removal &
Adjustments
7-18
Removal &
7-18
Installation
7-28
Coil Spring
Installation
7-20
Removal &
Installation
7-20
Overhaul
Ignition
Removal &
Installation
7-5
7-3
&
Removal &
Installation
Lower
Installation
Lower Control Arm
Removal & 7-25
Oil
Removal &
7-3
Installation
Oil
7-12 7-12
Removal &
Installation
7-12
7-8
Pinion Seal
7-9
Piston and Ring
Removal &
F
Removal &
Installation
7-9
Removal &
Installation
Positioning
7-25 Installation
7-27
T Transaxle Assembly
Transfer
Installation
Case Assembly
Removal &
Installation
Removal &
7-17 7-17
7-19 7-19 7-6
Turbocharger
Upper
Installation
7-6
7-29
Ball Joint
Removal &
Installation
Upper Control Arm
Removal &
7-29 7-29
Installation
7-29 7-1
Valve Lash
W Water
Pump
7-4
&
Installation
Wheel Bearings
7-25
Adjustment
7-13
Removal &
7-13
1
7-11
Adjustment
Removal
P
Removal &
7-11
7-27
Strut
V
Installation
7-8
Front Crankshaft Seal
7-30
Pump
Exhaust Manifold Installation
7-29
7-12
Pan
Removal & 7-3
Installation
U
7-30
Installation
7-6 7-11
Starter
0
E
Engine Assembly
7-7
7-29
Ball Joint
Removal &
7-13 7-6
Installation
L
7-25
Installation
7-7
Intake Manifold
D Differential Carrier
7-3
Timing
Adjustment
7-5
Cylinder Head
&
Removal &
7-20
CV-Joints
Removal
7-19
7-19
Bleeding
7-28
7-13 Installation
Rocker Arm/Shafts
Removal &
7-18
Clutch
&
S 7-14
7-2
7-26
R
7-15
H
7-9
7-26 Installation
System Service
Precautions
C Camshaft and Valve
Power Rack and Pinion
7-14
7-14
Relieving
7-2
Alternator
Removal
Installation
Fuel Injector
Fuel
Bag
Removal
Removal &
7-2
A
7-14
Fuel Filter
7-2
7-4 7-31 7-31
Installation
7-32
CHRYSLER CORP.
7-2
TALON
PRECAUTIONS
sure to read
of the following precautions,
all
which deal with personal of
to
prevention
safety,
component damage, and important points take into consideration when servicing a Never open, service or drain the radia-
•
cooling system
when
the engine
Observe
tions
applicable safety precau-
all
when working around
fuel.
Whenever
servicing the fuel system, always work
Do
well-ventilated area. or vapors to
open flame
oil
to
changing
come
in
in
a
not allow fuel spray
Soap and
exposure
to
becomes contaminated, completely
used engine
new
All
hand cleaner
so WILL result
Timing
The system must be
head may tially
keep
and sensors. Failure
fuel in a container specifically
designed
for fuel storage; also,
to follow safety
disabling procedures could result
always
an interfer-
strike the pistons,
in
If
the
the cylinder
causing poten-
serious (also time-consuming and
expensive) engine damage. Refer to the
and acci-
in
extremely
is
utilize
ence-type, non-freewheeling engine.
umn, instrument panel components, wiring
fire
maintenance
timing belt breaks, the valves
around system components, steering col-
example). Keep a dry chemical
belt
doing
oil;
severe engine damage.
in
Many models
important!
extinguisher near the work area. Always
light, for
will
it
Never operate the engine without the
•
•
now equipped
vehicles are
removed
come in condamage
fluid to
proper amount and type of engine
oil.
should be used. •
fluid that is
the paint.
soon as pos-
used engine
Any brake
fluid.
from the system should be discarded. Also,
tact with a painted surface;
disabled before performing service on or
drop
brake
flush the
Never reuse any
fluid.
do not allow any brake
oil.
worn when
water, or waterless
with an air bag system.
contact with a spark,
or excessive heat (a hot
sible after
of brake
the brake fluid
system with new
a
Wash your hands and any
oil.
If
prolonged con-
number of skin disorders, including canYou should make every effort to mini-
mize your exposure
your vehicle.
may cause
other exposed skin areas as
and hot coolant. •
that
used engine
Protective gloves should be
is
burns can occur from the steam
hot; serious
The EPA warns
•
tact with
should always buy the correct type fluid for
medical assistance.
cer!
motor vehicle:
tor or
IMMEDIATELY seek
brake fluid internally,
Before servicing any vehicle, please be
maintenance
manual
interval charts in the front of
recommended
properly seal fuel containers to avoid the
dental air bag deployment, possible per-
this
possibility of fire or explosion. Refer to the
sonal injury and unnecessary system
ment
additional fuel system precautions later in
repairs.
timing belt section for belt replacement and
Fuel injection systems often remain
•
pressurized, even
OFF. The
turned
engine has been
after the fuel
working with, or around, the
system pressure must
be relieved before disconnecting any fuel lines. Failure to
do so may
and/or personal
injury.
•
Brake
fluid often
brake fluid
in
fluid.
If
with clean, running water for 15 minutes.
eye
irritation persists, or
if
you have taken
a non-
vehicles
may
interfere with
computer sys-
require the computer to
bag on a work surface, always
undergo a relearning process once the neg-
and trim cover upward, away
ative battery cable
air
module
of the
reduce the
will if
it
is
sealed container
is
reconnected.
drum
brakes, only disat a time,
leaving the remaining side intact for refer-
bag
ence.
later in this section.
essential to the safe
is
servicing
assemble and assemble one side
accidentally air
When
•
Clean, high quality brake fluid from a
• If
some
tem^) and may
system precautions
you do get
Disconnecting the negative battery
•
cable on
away from your body. When placing
deployed. Refer to the additional
your eyes, flush your eyes
to the
inspection.
bag system.
the7.functions of the on-board
motion
replace-
and
interval for the timing belt,
sure the bag and trim cover are pointed
from the surface. This
contains polyglycol
air
carrying a non-deployed air bag, be
face the bag
and wash your hands thoroughly
handling brake
after
When
deployed
result in fire
ethers and polyglycols. Avoid contact with the eyes
Always wear safety goggles when
•
this section.
for the
and
proper operation of the brake system. You
Only an MVAC-trained, EPA-certified
•
automotive technician should service the conditioning system or
its
air
components.
ENGINE REPAIR Alternator
To
install;
4.
Install or
REMOVAL & INSTALLATION Non-Turbo .
ft.
lbs.
Nm).
(61
•
Alternator
•
Alternator bracket
•
•
Alternator electrical connector
•
Under cover side panel
•
Alternator drive belt
•
Right wheel
•
Negative battery cable
connect the following:
Install or
Adjust the alternator drive belt deflec-
5. 1
alternator-to-lower bracket nut to 45
connect the following:
Speed control assembly
Before servicing the vehicle, refer to
and tension
tion
to the following
speciTca-
the precautions in the beginning of this sec-
Turbo
tions: tion.
Used
a.
2.
Disconnect the negative battery
belt deflection:
0.35-0.47
in.
1.
(9.0—1
2.0mm)
cable. 3.
Remove •
b.
(7.5-1 Right wheel
belt deflection:
0.30-0.41
Under cover side panel
•
Speed control assembly
•
Alternator drive belt
2.
Used
belt tension:
90-110
lbs.
3.
Disconnect th# negative battery cable.
Remove •
d.
Alternator electrical connector
•
Alternator bracket
New
belt tension:
6.
110-160
ft.
lbs.
(54
Right wheel
lbs.
•
Under cover side panel
•
Alternator drive belt
•
Power steering pump
•
Power steering pump
Torque the alternator-to-upper
bracket nut to 40 Alternator
or disconnect the following:
(400-490 N) (490-712 N)
•
the beginning of this sec-
0.5mm)
-
•
in
in.
tion.
c.
•
New
or disconnect the following:
Before servicing the vehicle, refer to
the precautions
Nm) and
the
drive belt
CHRYSLER CORP.
7-3
TALON Ignition
Timing
ADJUSTMENT Ignition timing is controlled ertrain Control
ment
is
by the Pow-
Module (PCM). No
adjust-
necessary or possible.
Engine Assembly
REMOVAL & INSTALLATION The following procedure can be used on all
vehicles. Slight variations
to extra 4
etc.,
may occur due
but the basic pro-
Generator
cedure should cover
5 Generator brace
1
Exploded view
connections,
of the alternator
models.
all
Before servicing the vehicle, refer to
.
the precautions in the beginning of this sec-
and related components— Non-turbo
tion.
0 *
Nm
20-25 14 — 18
2.
Relieve the fuel system pressure.
3.
Drain the cooling system and the
crankcase.
ft.lbs.
Remove
4.
rf.
or disconnect the following:
•
Negative battery cable
•
Engine undercover,
•
Hood assembly. Matchmark hood hinges
if
prior to
equipped the
removal to
ease alignment during installation. •
Air cleaner
assembly and
air intake
ducts 1 Drive belt (Generator) 2 Generator harness connector 3 Generator 4 Drive belt (power steering) 5 Water pump pulley 6 Power steering pulley 7 Generator brace
•
of the alternator
•
6.
(12-15 Nm) and the
above the engine without disconnecting
bot to 8.7-1
the hoses.
alternator-to-lower bracket nut/bolt to
14-18
•
Alternator electrical connector
•
Alternator
7.
To 4.
5.
ft.
(20-25 Nm).
lbs.
ft.
lbs.
Adjust the power steering drive belt
deflection
and tension
•
Accelerator cable
Install or
•
Heater hoses
Brake vacuum hose
•
Connection
•
High pressure
a.
•
Alternator electrical connector
•
Alternator drive belt
Fuel return line
Oxygen (O 2 S) sensor connection
b
a.
c.
belt deflection:
0 35-0.45
New
0.30-0.35
Used
(245-490 d.
New
(490-686
55.1-110.2
New
(490-686 8.
belt tension:
0.18-0.22
•
belt tension:
• in.
55.1-1 10.2
belt tension:
belt tension:
110.2-154.3
for
thermo switch sen-
110.2-154 3
Transaxle assembly
•
lbs
Idle
•
Motor Position (MP) sensor con-
•
Throttle Position (TP) sensor con-
connect the following:
•
Under cover side panel
•
Right wheel
•
Negative battery cable
lbs
speed control connection
nector
N).
nector •
N).
N).
Connection
• lbs.
N).
Install or
Coolant Temperature Sensor (CTS)
sor
in
(7-9.0mm). c.
in
connector
belt deflection:
Used
(245-490 d.
belt deflection:
0.22-0.32
in.
(9-1 1.5mm). b.
belt deflection:
(4.5-5.5mm).
to the following specifications:
Used
New
Coolant temperature gauge connection
(5.5-8 mm).
Adjust the alternator drive belt deflection
and tension
Used
fuel line
•
•
to the following
vacuum hoses
tor
•
specifications:
connect the following:
Alternator
if
Wheel Drive
•
install:
•
All
(AWD)
Torque the alternator-to-upper bracket 1
Transaxle and transfer case,
equipped with
and related components— Turbo
^Support the power steering pump
and
intercooler
93Q60GQ?
Exploded view
Radiator, coolant reservoir
Exhaust Gas Recirculation (EGR) temperature sensor connection on
lbs
California vehicles only •
Fuel injector connectors
For complete service labor times, order the Chilton Labor Guide
CHRYSLER CORP.
7-4
TALON transistor connector
Power
• •
Ignition coil connector
•
Condenser and noise
filter
Accelerator cable
for
•
Transaxle and torque the upper
tion.
mounting bolts
connec-
Nm) and
tor •
Crankshaft Position (CKP) sensor
•
Camshaft Position (CMP) sensor
lbs.
•
Manifold
differential
pressure sen-
sor connector
and control harness
•
Distributor
•
Alternator and
pressure switch
oil
connectors Drive belt and compressor and wire
•
the
compressor aside,
DO NOT
equipped.
if
discharge the system or
lbs.
ft.
any brackets to
22
ft.
Nm)
Radiator and intercooler
•
Air cleaner
•
Control brackets
To
•
Hood
5.
•
Negative battery cable
•
Water pump, gasket and 0-ring.
Engine mount
Torque control brackets
8.
Fill
the engine with clean
9.
Fill
the cooling
system
oil.
to the
Start the engine, allow
1 1
it
and check
test the vehicle
for
all
not allow
(roll
stop-
Water pump, using a new gasket. Torque bolts
before removal.
assembly
1
.
Before servicing the vehicle, refer to in
the beginning of this sec-
2.
Drain the cooling system.
3.
Remove •
6.
or disconnect the following:
Timing
belt.
Refer to the timing belt
unit repair section in this
lbs.
ft.
(69
manual
belt rear cover,
Timing
belt
•
Remaining components
•
Negative battery cable
Fill
Start the engine,
7.
repair
if
necessary.
on the
mount. Exhaust pipe and torque the nuts to ft. lbs. (49 Nm) Vacuum hoses
•
Water hoses
•
Fuel return and high pressure hoses
36
vacuum hose
•
Brake booster
•
Wiring harness connections
•
A/C compressor
electrical
connec-
tors •
CKP
•
CMP
•
Ignition coils
sensor sensor connector
and
fuel injector
con8.7-11
It.lbs.
nectors •
Manifold
differential
pressure sen-
4
sor connector •
Capacitor
•
TP sensor connector
•
Ignition
•
ECT sensor
•
power
transistor connector
Engine coolant temperature gauge
Removal slaps 1.
Generator brace
2 Water 3.
pump
Water pump gasket
4. O-ring
connector •
Oxygen (O 2 S) sensor connection
Water pump mounting and
bolt locations
to
17
ft.
if
removed
the cooling system to the proper
Nm)
•
(13 Nm).brace.
(24 Nm).
Timing
lower mount through-bolt
is
lbs.
pump
•
nut should not be tightened until the
weight of the engine
ft.
•
Engine and torque the engine
50
10
level.
install:
connect the following:
to
Alternator-to-water
Torque the brace pivot bolt
REMOVAL & INSTALLATION
tion.
certain to note the orientation
•
other grease to
oil or
contact the O-ring. •
the precautions
full
pipe 0-ring
to reach
Do Road
.
Make
front
inlet
coolant.
bracket
bolts to
connect the following:
water
level.
i**Some engine mount pieces have arrows on them for proper assembly.
'•The
New
lbs.
mount
if
bolts
*»Coat the O-ring with water or proper
pers)
•
pump
Install or
•
•
Install or
necessary
Water
Water Pump
•
7.
to the rear cover.
belt rear cover,
functions for proper operation.
port the engine weight.
To
access
•
•
leaks.
the engine
for
Timing
Discard the gasket and 0-ring.
aside
Remove
brace
install:
Attach a hoist to the engine and sup-
6.
pump
•
assembly
normal operating temperature and check
discard the gasket 5.
Alternator-to-water
Unfasten the retainers, then remove
4.
ft.
Nm)
and torque the bolts
(30
•
(69
32
Power steering pump and wire Exhaust manifold-to-pipe nuts and
•
to 51
the lower bolts to
•
10.
disconnect the refrigerant lines •
(44
Starter lbs.
connectors •
timing belt removal and installa-
•
—2.0L (VIN
F)
engine
check
for leaks
and
CHRYSLER CORP.
7-5
TALON
—
Front of engine (Timing belt side) 1
3
1
5
10
8
2
0
0
O
0
0
0
0
0
7
9
6
4 "322DG04
Cylinder head bolt removal sequence 2 OL (VIN F
and Y) engines
V*
Front of eng me (Trning belt sde)
6
1
3
,
0
0
O
0
o
0
0
0
0
10
4
2
5
7
8
r ^10.
Cylinder Head
•
Engine center cover
•
Spark plug wires
Brake booster vacuum hose
•
Fuel lines from the fuel supply
•
Bypass hose and water hose con-
Engine
Drain the cooling system and
crankcase
Remove
•
Accelerator cable and mounting
Power steering pump
•
Cylinder head cover and semi-cir-
•
Idle Air
Knock
•
Heated Oxygen (HO 2 S) sensor
•
Engine coolant temperature gauge
(ks)
lbs. d.
Heat protector
•
Thermostat housing and O-ring
•
Intake manifold stay
(35
in
•
To
bolts to 17
•
Ignition
module (power
of the •
Throttle Position (TP) sensor
•
Condenser
•
Manifold Differential Pressure
for
(MDP) sensor •
head bolts from below the head
•
Ignition coil
•
Camshaft Position (CMP) sensor
the bolt
(99.4 •
Crankshaft Position (CKP) sensor
•
Air conditioning
•
Engine control wiring harness
to the end;
measures more than 3.91
mm),
a
new
Install the
9.
engine
oil to
retainer
together •
Power steering pump
•
Timing
install
them
our web
site at
Refer to the appropri-
www.chiltonsonline.com
and
installation procedure. •
PCV, breather and vacuum hoses
•
Water hose and bypass hose
fin-
ger-tight.
visit
belt.
ate section for the removal
cylinder head. Apply clean
and
oil seal
and the cylinder head come
in.
cylinder head gasket,
the bolts
packing
at the front of the
cylinder head where the camshaft
or disconnect the following
Please
Apply sealant
with identification mark facing upwards
compressor
Rocker arm cover and apply sealant to the semi-circular
replace the bolt.
Install
8.
Remove
the length of the cylinder
Nm)
Heat protector
12.
lbs
Nm)
•
the cylinder
warpage.
Measure
Fuel injectors if
5.
Check
ft
and torque the
(23
Radiator and water hoses
•
engine block and the sealing surface
7.
lbs.
bolts to 16ft. lbs (22
of the cylinder head.
head
ft.
•
Thoroughly, clean the deck surface
transistor)
25
Thermostat housing and torque the
Cylinder head and discard the gas-
install:
6.
new gasket
to
Nm)
Intake manifold stay
steps, using the specified
ket
sensor
15
connect the following:
and torque the bolts
•
Engine Coolant Temperature (ECT)
to
* turn (90
Turbocharger, using a
•
sender •
Tighten the bolt
Install or
1 1
sequence •
sequence
Tighten the bolt an additional V*
e
Cylinder head bolts gradually,
2-3
in
(20 Nm).
turn (90 degrees).
Turbocharger assembly from
sensor
58
degrees) from the mark.
Water and radiator hoses
•
•
ft.
exhaust manifold
Control (IAC) motor
to
bolts completely in the
Tighten the bolts
c.
•
•
sequence
belt
•
Label and disconnect the following:
4.
in
(78 Nm).
Loosen the
b.
Timing
body
sequence, using
reverse order
•
Intake air duct (hose) from the
throttle
lbs.
cular packing
bracket
•
ft.
•
or disconnect the following:
Negative battery cable
in
Tighten the bolts
a.
hoses, breather hose and
(PCV) hose
tion.
•
Tighten the bolts
the following procedure:
Positive Crankcase Ventilation
the precautions in the beginning of this sec-
3.
rail
nections
Vacuum
Before servicing the vehicle, refer to
2.
2.0L (VIN F and Y) engines
•
•
1.
3220005
Cylinder head bolt tightening sequence
REMOVAL & INSTALLATION
2.01 (Vin F)
1
CHRYSLER CORP.
7-6 •
TALON
Fuel lines to fuel supply a
new
engine
of
oil
to the
new
using
rail,
O-ring. Apply a small
•
Spark plug wires and center cover
•
All
•
Intake air hose, at the throttle
body
•
them
oil filter
and
refill
the
be stretched, replace
appears
engine and check
for fuel,
To remove the arms, the camshaft must
new head gasket and
Install a
the
be removed.
clean engine
is
It
recommended
first
that all
rocker arms and lash adjusters be replaced of the bolts with
Coat the threads
7.
Start the
a bolt
If
it.
cylinder head
crankcase. 15.
for stretching.
engines do not use rocker arm shafts; the valves are directly actuated by rocker arms.
to
6.
Replace the
REMOVAL & INSTALLATION The Dual Overhead Camshaft (DOHC)
Clean the cylinder head bolts and
inspect
the cooling system to the proper
level.
14.
Rocker Arm/Shafts
the deck and the cylinder head for
5.
Negative battery cable Fill
and
Thoroughly clean the cylinder head
4.
adjust
13.
install:
warpage.
Accelerator cable, connect and
for coolant leaks
proper operation.
and engine block sealing surfaces. Check
removed connectors
engine and check
Cylinder head
•
To
Brake booster vacuum hose
the proper
in
sequence
0-ring.
•
•
Cylinder head bolts,
•
amount
and
oil
together. Refer the camshaft procedure for
install the bolts finger-
details.
coolant and
tight in the
leaks.
oil
in
2.01 (Vin Y) Engine
engine block. The short bolts go
the corners.
Tighten the cylinder head bolts
8.
proper sequence,
the
in
in
Before servicing the vehicle, refer to
1.
the precautions
25
ft.
lbs.
Outer bolts 7 through 10: 20
ft.
lbs.
Center bolts
a. in
Turbocharger
the following steps: 1
through
6:
REMOVAL & INSTALLATION
the beginning of this sec-
(33 Nm). tion. b.
Drain the cooling system and
2.
(27 Nm).
crankcase.
•
and
d.
Air cleaner
Air conditioning
air intake
Power Steering Pump (PSP) switch Heated Oxygen (HO 2 S) sensor
Engine coolant temperature gauge g.
Engine Coolant Temperature (EOT)
lbs.
Outer bolts 7 through 10: 20
ft.
lbs.
Manifold Absolute Pressure (MAP)
1
through
6:
4.
Remove
Turn
fasteners
all
•
Throttle Position (TP) sensor
•
Idle Air
more
•
Injector harness
in
Ignition coil
•
Camshaft Position (CMP) sensor
•
Wastegate vacuum hose
•
Air outlet
•
Upper and lower heat shield
new gasket
Refer to the timing belt
belt.
for timing belt
Purge
•
•
Water hose
•
Overflow tube
•
Brake booster vacuum hose and
purge •
hose and brake booster •
Overflow tube connection
•
Upper radiator hose and water hose
belt.
rail
•
•
connectors
•
Exhaust pipe nuts and discard the
Air intake duct
Exhaust manifold Exhaust manifold-to-turbocharger through-bolts/nuts
and
air
•
cleaner
assembly •
under the turbo has a
gasket
Heater hose
necessary
timing belt removal and instal-
line
using
All electrical
•
Water cooling lines
'"The water
new gasket
Accelerator cable and adjust as
manual
feed line-to-turbo eyebolt and
threaded connection.
•
Refer to the timing belt
unit repair section in this
hose
•
connections.
Oil
gaskets •
Fuel lines-to-fuel supply a
vacuum hose connections
Timing
air
water pipe
rail
•
Triangular engine hanger bracket
•
at the
aside.
Exhaust manifold self-locking nuts
Upper
hose
pump
•
Intake manifold stay radiator
Power steering pump and bracket nected and wire the
instal-
•
engine
•
removal and
hose connections
assembly. Leave the hoses con-
•
Heater hoses from the rear of the
Fuel lines from the fuel supply
•
manual
lation.
body
and tube
Front exhaust pipe-to-exhaust
Timing
Oil return line
ket •
Oil filter
capscrews and gas-
from r/nder the turbo
Turbocharger
lation. •
Intake manifold stay
•
Intake
•
and exhaust camshafts
Exhaust pipe from the exhaust manifold
10.
Fill
the engine with clean
11.
Fill
the cooling system to the proper
oil.
^Both water
pipes and
oil
feed line
can remain attached.
level.
12.
Turn the ignition to the
and check
for fuel leaks.
Then,
ON
position
start the
if
Oxygen (O 2 S) sensor Oil dipstick
•
Accelerator cable from the throttle
•
•
Air intake bellows hose
Camshafts
solenoid valve
Condenser fan/radiator assembly,
•
•
Exhaust Gas Recirculation (EGR)
Radiator
equipped with A/C
sequence. Do
unit repair section in this
•
Negative battery cable
•
connect the following:
manifold using a
Control (IAC) motor
•
through 10: 14
1
or disconnect the follow-
•
Install or
Intake Air Temperature (IAT) sensor
air
oil.
ing:
not use a torque wrench for this step. 9.
•
for
Drain the cooling system.
•
turn (90 degrees)
sensor
•
ft.
Drain the engine
3.
(27 Nm).
sensor
•
50
2.
(67 Nm).
sender
•
lbs.
Center bolts
e.
f.
•
ft.
tion.
(27 Nm).
•
•
Outer bolts 7 through 10: 20
6:
duct
compressor
•
•
lbs.
through
(67 Nm).
Negative battery cable
•
•
ft.
1
or disconnect the following:
•
•
50
Center bolts
c.
Remove
3.
Before servicing the vehicle, refer to
1.
the precautions in the beginning of this sec-
Inspect the following items:
5.
•
Turbine (hot side) and compressor
CHRYSLER CORP.
7-7
TALON Intake Manifold
28-34 Nm 20-25 ft**.
REMOVAL & INSTALLATION 2.0L (VIN F) Engine Before servicing the vehicle, refer to
1.
the precautions in the beginning of this section.
Relieve the fuel system pressure.
2.
10-12
3.
Drain the cooling system.
4.
Remove
Nm
^^7-9ftJb.
or disconnect the following:
•
Negative battery cable
•
Accelerator cable, breather hose
and •
air intake
Upper
hose
radiator hose, heater
hose
and water bypass hose 1
Oil return
.
pipe
•
Gasket Turbocharger Eye bolt s Gasket 2
.
3. 4
Water pipe B
.
Eye bolt Gasket
7.
8
Eye bolt Gasket
.
.
13.
line
High pressure
and
fuel line
fuel
hose
Label and disconnect the following
5.
Exhaust fitting 6.
14.
Brake booster vacuum
•
the electrical connectors:
pipe
12. Oil
•
return
8-10 Nm 8-7 ft. m
Water pipe A
9
1
necessary vacuum hoses and
pipes
.
6
10
All
•
Gasket •
Oxygen (O 2 S) sensor Engine Coolant Temperature (ECT) sensor
Exploded view
assembly— 2 OL
turbocharger
of the
(cold side) wheels for cracking or
other
damage
installing the threaded
water
Turbine and compressor wheels for
•
ease of movement
inlet pipe,
leakage
Oil
•
Wastegate valve operation.
problem
is
If
Install or
any
Pressure
test the
wastegate valve by
•
actuator to
make sure
the rod moves.
Water
Water cooling lines and torque to
•
Thermostat housing,
Nm)
•
Power brake booster and Positive
if
may be damaged. >"»The wastegate actuator should main-
vacuum; fc*
if
not, replace
it.
WARNING to adjust the
waste-
gate valve.
To
(49
ft.
ft.
to
36
ft
Nm) (42
lbs.
and torque the bolts
(19
lbs.
10
ft.
(15
lbs.
vacuum •
To
Nm) bracket,
oil
Replace
sages
hose
Air outlet
•
Wastegate hose
•
Air intake bellows
•
Oil dipstick
•
O2S
•
Radiator assembly
for
il
connected
•
tube and dipstick
in
a crisscross
from the inside and
pattern, starting
working outwards,
to
11-14
10.
Fill
the cooling system to the proper
oil.
•
Fuel
rail,
check
if
for leaks
and
lightly with oil.
bolts to
necessary.
locking nuts. Before
Timing belt service
Nm).
is
covered
in Section
lbs.
with injectors and pres-
sure regulator, lubricate Start the vehicle,
ft.
(15-19 Nm).
the engine with clean
.
new gas-
Torque the manifold-to-cylin-
der head bolts
Negative battery cable
pas-
connect the following:
Intake manifold, using a ket.
sensor
air
clogging
Install or
7.
return line with clean all
lines,
Intake manifold
damage and water passages and
Heat shields
Fill
repair oil.
necessary
Inspect the intake manifold's mount-
install:
Prime the
if
install;
6
level.
engine
and heater connections
ing surfaces for cleanliness, cracks or other
removed
9.
1 1
body water hose
inlet
Crankcase ventilation (PCV) valve
to
Nm)
•
•
Do not attempt
with injectors and pres-
rail,
•
and torque the bolts
Power steering pump and
•
Fuel
Intake manifold bracket
to •
Spark plug wires
sure regulator attached
Engine hanger and torque the bolts
•
Do not apply more than 10 psi (71 kPa) for the wastegate diaphragm
•
Throttle
14
WARNING
tain
temperature sensor
connect the following
Oil feed line
applying approximately 9 psi (62 kPa) to the
speed control
•
31
deposits, clean as required
Exhaust Gas Recirculation (EGR)
•
lbs.
•
Idle
•
•
Exhaust manifold using a new gasket
for restriction or
Thermo switch
•
the inner
•
found, replace the
passages
oil to
Turbocharger
part. Oil
apply light
for the
•
7.
•
connection
pipe flange surface. 8.
•
•
(VIN F) engine
3 of this manual
all
seals
Torque the retaining
84-108
inch lbs. (10-13
CHRYSLER CORP.
7-8
TALON
Thermostat housing,
•
Intake manifold brace bracket
•
Throttle
•
All
if
•
removed
•
(34
body bracket •
hoses, cables and electrical
•
connectors •
Run
9.
opens,
check
refill
plenum using a new gasket to
25
cooling system
the radiator completely and •
for leaks.
Adjust the accelerator cable. Check
•
lbs.
Fuel
body using a new gasket and engine
(23
to
•
Nm)
rail fuel
in
EGR pipe Vacuum hoses and PCV hose
to-turbocharger nut/bolts to ft.
•
•
Engine control wiring harness and
•
•
2.
Nm)
and torque the bolts (44
•
Vacuum hose at throttle body MAP and CT sensors
•
Condenser cooling
•
Accelerator cable at the bracket and
•
Power steering pump
•
O 2 S sensor harness
•
Oil level indicator
Properly relieve the fuel system presthrottle
4.
(10
AIS motor and TP sensor
body
33
to
lbs.
ft.
Nm) fan
10.
sure. 3.
lbs.
Exhaust pipe using a new gasket
•
the beginning of this sec-
oil lines
Heat shields and torque the bolts to
•
tion.
40-47
the turbocharger
89 inch
ets/clips
ft.
(55-65 Nm).
lbs.
Engine hanger, water and at
reposition and secure with brack-
Before servicing the vehicle, refer to
18-22
(25-30 Nm) and the manifold-
lbs.
level.
in
a crisscross pattern to
rings
Alternator wiring harness
the precautions
Exhaust manifold and new gasket.
Torque the manifold-to-head nuts
new 0-
lines using
•
1.
for
connect the following:
Install or
6.
17
vehicle has cooled, recheck the coolant
2.0L (VINY) Engine
gasket material from the
all
damage.
assembly
and adjust the ignition timing. Once the
Clean
mating surfaces and check the manifold
Intake manifold stay
ft.
•
the engine until the thermostat
install:
5.
Nm)
Throttle
To
lbs.
ft.
hanger and torque the bolts
Negative battery cable Refill the
8. 10.
Intake
and torque the bolts
•
Breather and
•
Vacuum
•
Negative battery cable
Drain the cooling system.
Remove • •
air intake
reservoir,
if
hoses
and tube using a
new O-ring
equipped
or disconnect the following: •
Negative battery cable
Negative battery cable
Vacuum
6.
reservoir,
if
Fill
the cooling system to the proper
7.
Fill
the engine with clean
8.
Fill
the
oil.
equipped with level.
coding system
to the
proper
cruise control 7.
Adjust the accelerator cable.
level.
and breather hoses
•
Air intake
•
Accelerator cable from the bracket
Operate the engine
9.
Exhaust Manifold
•
Engine harness retaining clips
•
Manifold Absolute Pressure (MAP)
Coolant Temperature (CT) sensor connector
•
1
Before servicing the vehicle, refer to
1.
motor
Air Injector Service (AIS)
the precautions in the beginning of this section.
tion. 2.
Drain the cooling system.
3.
Remove
Drain the cooling system.
•
Negative battery cable
Remove
•
Air intake
•
Upper
Alternator wiring harness
Pollution Control Valve
4.
(PCV) hose
•
Vacuum hoses
•
Exhaust Gas Recirculation (EGR)
or disconnect the following:
Negative battery cable
•
Condenser cooling
•
fan,
if
equipped
A/C
Power steering pump and move
•
Intake manifold stay
rail
and engine
hanger •
Throttle
•
Intake manifold
•
Injector connectors
•
Fuel
•
Intake manifold
rail
it
Air
Engine control wiring harness from
Water pipe assembly
Dipstick tube
•
Oil dipstick
•
Exhaust pipe-to-turbocharger nuts,
•
Upper heat shield
separate the exhaust pipe and dis-
•
Engine hanger
card the gasket
•
•
•
and torque the retainers
in
rail
bolts to
ft.
lbs.
Injector connectors
and vacuum hose con-
lbs.
a criss-
(23
(10
Nm)
Heat shields
•
at
exhaust manifold
Lower heat shield
•
Exhaust manifold and discard gasket
Exhaust manifold-to-turbocharger
4.
and nut
Install or
•
Engine hanger, water and if
oil
lines
(23 •
Exhaust manifold and discard gasket
connect the following:
Exhaust manifold with a new gasket
and torque the bolts
neces-
sary •
•
To install:
from the turbocharger,
Nm)
Front exhaust pipe from the manifold
and turbocharger
bolts
assembly and torque the
89 inch
Air intake
nections
with injectors
cross pattern to 17
the rear of the engine
•
•
new gasket
hose connection
•
•
•
plenum and gasket
connect the following:
hose from water
Oxygen (O 2 S) sensor harness
body
Intake manifold using a
hose
radiator
•
install: Install or
or disconnect the following:
outlet
aside
Fuel lines from the fuel
Fuel
oil.
•
with
•
•
Before servicing the vehicle, refer to
3.
aside
•
•
.
move
it
leaks.
the precautions in the beginning of this sec-
Drain the engine
•
•
and exhaust
2.
pipe
5.
for fluid
the engine coolant.
Engine control wiring harness and
assembly
To
off
thermo-
2.0L (VINY) Engine
Throttle Position (TP) sensor con-
connector •
Top
until the
2.0L (VIN F) Engine
nector •
opens.
Check
REMOVAL & INSTALLATION
sensor •
stat
17
ft.
lbs.
Lower heat shield and torque the bolts to
•
to
Nm) 10
ft.
lbs.
(15
Nm)
Front exhaust pipe using a
new
CHRYSLER CORP.
7-9
TALON gasket and torque the bolts to 33 (44
lbs.
•
MB995022 /
Engine hanger and torque the bolts to
10
ft.
lbs.
(15
Nm)
•
Upper heat shield and torque the
•
Oil dipstick
bolts to 10
•
ft.
Nm)
ft.
lbs.
(15
Nm)
and water pipe
Engine wiring harness
to the rear of
the engine
Z)
hose and upper radiator hose
•
Air
•
Air intake Tiose
7922D619
• 5.
7922DG17
Negative battery cable
Fill
To prevent damaging the end of the crank-
the cooling system to the proper
level.
6.
repair
shaft, use the proper sprocket
tool— 2.0L (VIN Start the vehicle, if
check
for leaks
removal
To avoid damaging the front seal, use the front oil seal installer Tool
MB995022—
2.0L (VIN Y) engine
Y) engine
and
necessary.
Front Crankshaft Seal
REMOVAL & INSTALLATION 2.0L (VIN 1
.
Before servicing the vehicle, refer to the
precautions 2.
Engine
F)
the beginning of this section.
in
Remove
or disconnect the following:
•
Negative battery cable
Installing the front crankshaft sprocket
•
Timing
using the Crankshaft Sprocket Installer
belt.
Refer to the timing belt
unit repair section in this
3.
for
manual
timing belt removal and instal-
Using the special tool crankshaft
to
seal— 2.0L
remove
the front
(VIN Y) engine
Tools
MB995035 and MB995026— 2 OL
(VIN Y
|
engine
lation.
2.
•If reusing the timing belt, be sure mark the direction of rotation on the belt.
This will ensure the
same
Remove
direc-
•
Negative battery cable
•
Timing
belt.
Refer to the timing belt
unit repair section in this
life.
for timing belt •
Crankshaft pulley
•
Timing
•
sprocket
is difficult to
may
Crankshaft seal by prying
remove,
it
out
New
Crankshaft
oil
shaft oil seal
• Be
seal using Crank-
2
Removal Tool
oil
seal
bore or the crankshaft sealing surface.
tool
To
install:
Crankshaft sprocket
3.
Apply clean engine
•
Timing
4
Install or
unit repair section in this for timing belt
manual
removal and instal-
•
•
•
Accelerator cable Irom the throttle
•
oil to
the
MB995035 and MB995026 belt.
for
•
Refer to the timing belt
manual
3.
Rocker cover
•
Timing
for
•
in
Section
Dead
Refer to the timing bell
2 of this manual
manual
timing belt removal and instal-
Camshaft sprockets
tion.
covered
belt
lation.
Negative battery cable
the precautions in the beginning of this sec-
is
piston at Top
unit repair section in this
timing belt removal and instal-
Heater Core replacement
1
Center (TDC) on the compression stroke.
Before servicing the vehicle, refer to •
Valve (PCV) hose, from the
Position the No.
lation. 1
Breather hose and Pollution Con-
rocker cover
using a seal driver
unit repair section in this
2.0L (VINY) Engine
Spark plug cables
trol
Crankshaft sprocket using special
Timing
Engine center cover
• •
oil seal.
Cable bracket from intake plenum
•
connect the following:
Oil seal
Tools
lation.
Negative battery cable
or disconnect the following
Negative battery cable
•
crankshaft seal using a driver
Refer to the timing belt
Remove •
body careful not the scratch the
connect the following:
belt.
Before servicing the vehicle, reler to
tion.
•
•
1
MB995020
install:
•
2 OL (VIN F) Engine
the precautions in the beginning of this sec-
Removal Tool
MB995027
using a suitable prytool
Install or
instal-
be used. •
•
manual
removal and
Crankshaft sprocket using Crankshaft Sprocket
an appropriate puller
REMOVAL & INSTALLATION
lation.
belt crankshaft
•If the sprocket
Camshaft and Valve Liners
ing:
tion of rotation, thereby extending belt
To
or disconnect the follow-
to
CHRYSLER CORP.
7-10
TALON Remove
2.
Dowel pins
or disconnect the following:
•
Negative battery cable
•
Ignition coil
•
Pollution Control Valve (PCV) hose
pack
and breather hose from cylinder head cover Semi-circular packing from the rear
•
of the
Exhaust side
Intake side
head
•
Camshaft Position (CMP) sensor
•
Timing
Refer to the timing belt
belt.
unit repair section in this
manual
7922DG08
for
Tap the camshaft with a plastic loosen the bearing caps
hammer
—2.0L (VIN
For installation, position the camshafts
to
lation.
with the dowels facing up, as
F)
shown Camshaft sprockets
•
2.0L (VIN
engine
F)
engine
~Use 5.
Exhaust side
Intake side
bearing caps and torque
Install the
the bolts evenly,
in
2-3
steps to 14
ft.
lbs.
to
Lubricate the seal
7.
Install or
Front
lip
with engine
bracket
Outside camshaft bearing cap
•
seal using Seal Installer
Bearing caps. Gradually, loosen the
•
MB998713
camshaft bearing caps
•
Camshaft sprockets
•
Timing
unit repair section in this for timing belt
Identifying the rocker in
arm
shafts
— notice
•
8. 4. (Use
a
of the
camshaft
wrench on the hex shaped part to hold the
cam when
front
Cylinder head by applying sealant
in
2-3
steps.
^If the bearing caps are hard to remove, tap the rear of the camshaft
hammer.
with a plastic
Apply sealant
and
•
Bearing caps. Loosen the bearing
cap bolts
instal-
one camshaft
^Keep
the bearing caps in order. They must be installed in the location from which they were removed.
packing
•
Camshafts
rear bearing
caps where they meet
^The able.
Rocker cover using a new gasket
•
PCV hose and
•
Spark plug wires
•
Center cover
•
Accelerator cable and adjust
•
Negative battery cable
camshafts are not interchange-
Mark the camshafts
breather hose
To 3.
it
install: Install or
2.0L (VIN Y) Engine
Bearing caps and rocker arms must be installed
in
the
same
Camshafts, lubricate with engine
•
Bearing caps and torque the bolts
in
(28
sequence
them with oil
Loctite
seal
location
Camshaft(s) and seals
Install or
connect the following:
Camshafts, lubricate with engine
oil
and position with the dowels facing up :
If
WARNING
new camshaft(s) are being remove the rocker arms
installed,
and
camshaft(s) and bearBe sure the camshaft(s) can
install the
ing caps.
n
be turned by hand. After checking, remove the camshafts and install the rocker arms.
nij 7922DG03
Camshaft bearing cap
bolt tightening
sequence—2. OL
ft.
Camshaft
To install: •
21
•
from which they were removed. •
to
Outside camshaft bearing caps, lubricate
the beginning of this section.
in
Nm)
•
Before servicing the vehicle, refer to the
precautions
connect the following:
•
evenly and
WARNING 1
for later
identification.
lbs. '
at a time.
to the lower part of the
the cylinder head.
removing the sprockets. •
removal and
to the semi-circular
the
manual
lation.
the intake side
in
reverse of the tightening sequence,
Refer to the timing belt
belt.
bolt.
Rear timing belt cover and
oil.
connect the following:
oil
MB990767 and MB998719,
removing the sprocket mounting •
6.
•
tool
secure the camshaft sprockets when
(20 Nm).
the slits
timing belt removal and instal-
(VIN Y) engine
518®
oil
CHRYSLER CORP.
7-11
TALON •
Rear timing belt cover and bracket
•
Camshaft sprockets
•
Timing
belt.
54 40
Refer to the timing belt
unit repair section in this
manual
Nm ft. lbs.
for
timing belt removal and installation. •
Semi-circular packing, lubricate with
5699
Loctite •
CMP
Install the
4.
.
at rear of cylinder
head
sensor cylinder head cover. Torque
the bolts in the proper sequence, evenly as «
follows: a.
Step
1:
40 inch
lbs. (4.5
Nm).
b.
Step
2:
80 inch
lbs. (9.0
Nm).
c.
Step
3:
106 inch
connect the following:
Install or
5.
(12 Nm).
lbs.
breather and
PCV hoses
•
Air,
•
Coil pack
•
Negative battery cable
Valve Lash
ADJUSTMENT Valve clearance valve clearance
is
is
not adjustable. Proper
maintained by the
hydraulic lash adjusters.
Exploded view
Starter
of the starter
and related components— Non-turbo
REMOVAL & INSTALLATION
Nm ft.lbs.
Non-Turbo Before servicing the vehicle, refer to the
1.
precautions
in the
Remove
2.
beginning of this section
or disconnect the following
•
Negative battery cable
•
Starter electrical
•
Starter bolts
and
connectors starter
To install: connect the following:
Install or
3.
•
and torque the
Starter
transaxle bolts to
40
starter-tolbs.
ft.
(54
Nm)
Starter electrical
•
Negative battery cable
30 22
Turbo 1.
Nm ft.lbs.
2 A09X0122
Before servicing the vehicle, refer to the
precautions 2.
\ \
connectors
•
in
the beginning of this section
Remove
or disconnect the following:
•
Battery
•
Air
•
Starter electrical connectors
•
Starter bolts
hose "C"
Removal steps Air
1
and
starter
hose
C
2 Starter terminal and connector .
To install: 3.
Install or
•
Starter
3. Starter
motor
connect the following:
and torque the
transaxle bolts to
22
9M6DG01
starter-to-
ft.
lbs.
(30
Exploded view
of the starter
and related components— Turbo
Nm)
Brake service
is
covered
in Section
4 of this manual
CHRYSLER CORP.
7-12
TALON
•
Starter electrical
•
Air
•
Battery
•
connectors
hose “C" •
cylinder
shaft
compression
Exhaust pipe using a new gasket.
should be aligned
Torque the exhaust pipe-to-manifold 9.
Oil
flange nuts to
Pan
2.0L (VIN F) Engine
33
ft.
the precautions
the beginning of this sec-
in
at this point.
Using the proper equipment, support
Remove
or disconnect the following:
Front engine
mount bracket and
accessory drive belts
oil.
for leaks.
2.0L (VINY) Engine
•
Timing
belt
upper and lower covers
•
Timing
belt
and crankshaft sprocket
•
Oil
pressure sending unit electrical
connector
tion.
1
2.
Drain the crankcase.
3.
Remove
Before servicing the vehicle, refer to the
.
precautions
or disconnect the follow-
ing: •
Negative battery cable
•
Exhaust pipe, lower
it
Remove
on
Using the appropriate equipment,
Turbocharger return pipe from the
pan
Oil
cracks. Replace
Tap a thin prytool
faulty.
if
damage and
all
and
MD998162
pan and discard the gasket
all
oil
for
While the pan for
cracks. Replace
Install or
6.
pan so
that
Oil
Oil
80
tool,
ft.
(108
^lf necessary, the
•
Dipstick and tube assembly
come
•
Negative battery cable
Start the
Oil
oil.
engine and check
oil
pan
for leaks.
• 6.
clean
such a manner that
in
bolt holes are circled
and there
is
oil
cover
Oil
After all
pump
a con-
drive
7.
in.
•
(4mm)
•
connect the following:
48-72
inch lbs. (6-8 Nm).
Oil return pipe,
using a new gasket
and torque the retainers inchlbs. (7-10 •
•
to
72
Left
lbs.
ft.
62-88
Nm)
Crossmember and torque to
resid-
from the mating sur-
Assemble
the
oil
pump it
to
gears into
ensure smooth
movement and no looseness. Be sure
there
diameter.
in
applying sealant. Torque bolts
after
to
should
pan. Install within 15 minutes
Oil
pump, all
bead approximately
in a
Install or
8.
of sealer
oil
components and remove
the front case and rotate
be applied
and driven gears
faces.
pan.
"•The continuous bead
at the rear of the
disassembling the
ual gasket material
tinuous bead of sealer around the entire perimeter of the
pump
engine front cover.
oil.
faces of the
silent shaft can
out with the cover assembly. •
the engine with clean
8.
pump
Nm)
Front exhaust pipe
Fill
oil
assembly
•
7.
of
lbs.
proper
for
Front case cover and
•
Front plate and torque the bolts to
faulty.
removed
installation.
Nm)
(12 •
position.
lengths of the mounting
bolts as they are
lbs.
in
driven gear-to-silent shaft
Front cover mounting bolts
’•‘'Note the
connect the following:
pump
bolt
pump.
pan using a new gasket and
is
loose mate-
all
oil
torque the bolts to 107 inch
clogit
pan and engine
oil
the point where the
at
engine block meets the
damage and
screen
(8mm)
in.
traces of the old gasket or
Apply sealant around the gasket sur-
7.
Plug on the side of the engine block. Insert a suitable tool with a
•
gasket surfaces of the cylinder oil
Oil
the engine front cover,
pan bolts
Apply sealant
oil
removed. Clean sealing surfaces
rial is all dirt
Oil
•
Using a wire brush or other
block and the
Front plate
in
using special plug removal Tool
block mating surfaces.
install:
6.
Plug cap
•
pan
pan
oil
removed, inspect the
To
Dipstick and tube assembly
•
Clean
to break the seal.
Inspect the
5.
•
sealer material from the
between the engine block and pan
Front exhaust pipe
install:
5.
bolts.
screen and discard gas-
the silent shaft
•
oil
and bracket oil
shaft diameter of 0.32
To 4.
Crossmember side of the
pan,
into the plug hole. This will hold
engine.
of the
•
•
Negative battery cable
•
•
support the weight
Oil
or disconnect the following:
•
•
models 4.
•
oil.
•
Wheel Drive (AWD)
All
Oil filter
•
from the
Transfer assembly and right driveshaft,
Oil
•
ket
engine manifold •
pressure sensor
•
the beginning of this section.
in
Drain the engine
2. 3.
0.16
oil.
the weight of the engine.
Before servicing the vehicle, refer to
1.
its
4.
•
engine and check
Start the
all
to
of
The timing marks
stroke.
Drain the engine
5.
the engine with clean
Fill
clean
(60 Nm).
is at
3.
Negative battery cable
•
ging,
lbs.
ft.
Nm)
(42
lbs.
43
plug and torque
Oil drain
•
10.
REMOVAL & INSTALLATION
Top Dead Center (TDC)
Transfer assembly and right drive-
member and
the
oil
bled or the cover
pump is
gear cavity must be
leum
jelly.
is disassemremoved, the
filled
This seals the
acts like a primer so the
draws
oil
turns.
Do not use grease.
with petro-
pump and oil pump
as soon as the engine
the bolts 1
Nm)
(100
Whenever
torque the forward
.
Before servicing the vehicle, refer to
the precautions
in
the beginning of this sec7922DG21
retainer bolts to
Nm) and bolts to
72
ft.
the rearward
58
ft.
lbs.
(80
lbs.
(100
member Nm) left
tion. 2.
Using the special Tool
Disconnect the negative battery
cable. Rotate the engine so that the No.
1
tighten the plug
MD998162
cap— 2.0L
to
(VIN F) engine
CHRYSLER CORP.
7-13
TALON is
2.0L (VIN Y) Engine
no ridge wear on the contact surface
Rear Main Seal
between the front case and the gear surface of the oil
1
pump
the precautions
pump, by aligning
Oil
the
pump
oil
drive gear with the driven gear tim-
engine
Drain the engine
3.
Remove
New
oil.
1
or disconnect the following:
•
Negative battery cable
•
Rear plate
•
Oil filter
•
Oil
pan
•
Oil
pick-up tube
•
Timing
cover and torque the
bolts to 13 •
REMOVAL & INSTALLATION Before servicing the vehicle, refer to the
.
precautions
ft.
Nm)
(18
lbs.
crankshaft seal using an
New
and adapter
belt.
MD998285, on
seal guide Tool
end
for
the
•
Transaxle
•
Transfer case,
•
Drive plate,
from damage. Apply a
tect the seal
new •
new
a
25
•
Nm)
(34
lbs.
ft.
pump
drive gear onto
Secure the
oil
silent shaft
by installing and tighten-
ing the driven gear bolt to Install or
.
•
cap
lbs.
(40 Nm).
MD998162,
20
to
lbs.
ft.
oil
oil
•
Oil
•
Oil
in
the
4
5.
Install or
•
•
oil
•
pan
The width
the bolt holes.
applied
is
to
of the sealant
be about 0.16
in.
(4mm)
•
bead
wide.
•
inch lbs. (12
to
108
•
Electrical
•
Oil ft.
•
oil
•
14.
lbs.
fill
the crankcase
Negative battery cable Start the engine. Verify oil pressure
and inspect
for leaks.
Oil
belt.
If
removed, drive the
oil
case so the
separator
its oil
hole
is
6
Refer to the timing belt
manual
Install or
•
17
connect the following:
Seal case using a
new
gasket,
if
removed
7
•
Flywheel or drive plate
•
Transfer case,
•
Transaxle
•
Negative battery cable
Refill
and check
if
equipped
the crankcase Start the engine
lor leaks
Piston and Ring
pickup tube
pump meets
oil
Oil
at
the point
the engine block
pan using a new gasket and
Nm)
Oil filter adapter
lbs.
Nm)
and
pump
connect the following:
using a new 0-
and torque the assembly
harness
(45
without
in
ring. Align the roll pin with the hole
cooler and torque the bolt to 33
Oil filter
way
torque the bolts to 108 inch lbs
oil
pressure switch •
the
timing belt removal and instal-
(12
pressure gauge unit and
all
facing downward.
Apply Loctite' 18718,
pressure switch Oil
oil
5.
into the oil seal
Crankshaft sprocket using the
where the
Nm)
pressure gauge unit and
Oil
6.
connect the following
pan and torque the bolts
Oil
on the
new 0-
lation
sealant application. Install or
install a
pump and torque the bolts to ft. lbs. (23 Nm) New crankshaft oil seal in the oil pump
Timing
the seal
it.
of sealant to the sealing
pump and
unit repair section in this
pan within 15 minutes
oil
—Press
Oil
for
—Install the
MD998376
proper installation tools
flange groove, keeping towards the inside of
Oil seal in the crankshaft rear oil
seal case using Seal Installer Tool
tilting
oil
oil.
connect the following:
Install or
•
seal using crankshaft
MB995020 pump mounting bolts pump
Apply a bead
pan and cylinder block the
oil
discharge passage.
new gasket in
seal with clean engine
seal tool
surface of the
tighten the
mating surfaces. Apply sealant
•
engines have a separator that
Lubricate the inner diameter of the
3.
new
To install:
(27 Nm).
screen using a
Oil
Crankshaft
ring into the counterbore
case groove. Using the spe-
Clean the
12.
ft.
connect the following:
Tool
cial
•
29
Plug cap using a new O-ring front
•
if
oil seal.
should also be removed.
4
silent shaft in place.
•
—Some
surface or the seal bore.
side of the engine block to lock the
left
•
seal case,
oil
To install:
Insert a suitable tool into the hole in
9.
13.
Crankshaft rear
leaking: otherwise, the
bracket gasket and torque
the bolts to
ot
•
Do not nick the crankshaft sealing
Nm)
(24
lbs.
ft.
on the bracket using
Oil filter oil filter
1 1
if
equipped with a manual transaxle
Crankshaft sprocket using the
and torque
front case gasket
the bolts to 17
left
equipped
Front case assembly, through a
•
the
if
equipped with an
housing cover and flywheel,
Bell
timing belt removal and instal-
MB995027
ference of the seal pilot tool.
10.
•
crankshaft sprocket Removal tool
thin coat of oil to the outer circum-
if
automatic transaxle
manual
lation.
crankshaft to pro-
of the
•
the
or disconnect the following:
Negative battery cable
Refer to the timing belt
unit repair section in this
front case gasket. Position
front
the beginning of this section.
•
appropriate driver •
in
Remove
2.
oil.
pump
Oil
the beginning of this sec-
2.
ing marks. Lubricate the gears with
•
in
tion.
connect the following:
Install or
•
Before servicing the vehicle, refer to
front cover.
To install: 8.
.
to
40
ft.
(55 Nm).
•
New
•
Rear plate
•
Negative battery cable
oil filter
the engine with clean
7.
Fill
8.
Start the
Chrysler engine connecting rod and cap oil.
installation
engine and check
For complete Engine Mechanical specifications, see Section
1
—ensure
to
matchmark
for leaks
of this
and rod prior
manual
to
disassembly
the cap
CHRYSLER CORP.
7-14
TALON
R”
mark
identification
‘‘1
of rail
lower/^-
Gap side
.» Gap
No. 2 ring gap'
of
upper side rail
Piston ring end-gap
Piston ring orientation— 2. OL Engine
locations
gap
of engine F Front
and spacer expander gap
Chrysler piston ring identification mark
1
ring
\
(t m
No.
spacing— 2. OL
(VIN Y)
engine
NO. RING GAP
SIDE RAIL
1
UPPER
Timing
c=>
belt side
Piston positioning 7922AG06
Piston ring end-gap
spacing— 2. OL
—2.0L (VIN
Y) engine.
The small arrows on the crown
of the pis-
tons must point toward the front of the
(VIN F) Piston positioning
engine
—2.0L (VIN
F)
engine
engine
FUEL SYSTEM Fuel System Service Precautions Safety
is
an important factor when ser-
may
in
a safe
tenance and testing of the vehicle’s
Main-
fuel
effectively
by adhering to the
of fire
soaked cloths or towels
to fol-
Do
•
come
and per-
loosening and tightening
fuel line
stress
relieve the fuel
system pres-
and torsion
pipe
Do
connec-
(injector, fuel rail,
ulator, etc.), fitting or fuel line
pressure reg-
fuel
system pressure,
skin, face
and eyes
to avoid
to tuel spray.
any part
of the
Protector
•
Rear seat cushion
Fuel Filter
REMOVAL & INSTALLATION
not substitute fuel hose where fuel
On most in
vehicles, the fuel
Fuel System Pressure
On some non-turbo
fuel filter is
mounted under
filter is
located
mounted on
the engine compartment,
firewall.
the
engines, the
the vehicle near
the fuel tank.
RELIEVING
may pene-
body
that
1
Be sure
.
warnings
in
to
observe
all
cautions and
the beginning of the section
it
that
fitting
connector
•
!:
Always place a shop towel or cloth
around the
connect the following:
pump
Fuel
CAUTION
Please be
contacts. •
position.
is installed.
exposing
advised that fuel under pressure trate the skin or
Install or
•
connection.
Exercise extreme caution whenever relieving
OFF
Disconnect the negative battery cable.
fuel fitting Fi-
sure prior to disconnecting any fuel system
component
to run
unnecessary
to fuel line piping.
Always replace worn
•
rings.
Always
it
Always use a back-up wrench when
battery cable unless the repair or test proce-
•
5.
flame.
tion fittings. This will prevent
applied.
engine and allow
stops, due to lack of fuel. Turn the
After relieving fuel pressure:
spark or open
sonal injury, always disconnect the negative
dure requires that battery voltage be
4.
not allow fuel spray or fuel vapors into contact with a
Start the it
ignition switch to the
extinguisher near the work area.
•
To avoid the possibility
fuel
Always keep a dry chemical (Class B)
• fire
sys-
lowing rules and guidelines. •
all
all
are deposited into a suitable waste container.
tem components can be accomplished and
3.
until
manner
result in serious personal injury.
safely
fuel spillage is
Ensure that
vicing the fuel system. Failure to conduct
maintenance and repairs
Ensure that
quickly removed from engine surfaces.
spillage.
or connection prior to
loosening to absorb any excess fuel due to
may be related to this procedure. Remove or disconnect the following:
2.
•
Rear seat cushion
•
Protector
•
Fuel
pump
connector
Do not use conventional fuel filters, hoses or clamps when servicing fuel injection systems. They are not compatible with the injection system and could fail, causing personal injury or damage to the vehicle. Use only
CHRYSLER CORP.
7-15
TALON hoses and clamps specifically designed for fuel injection systems.
•
Main pipe
loosen
flare nut,
holding the fuel
filter
it
while
nut securely
with a back-up wrench 1
Properly relieve the fuel system pres-
.
•
sure. 2.
On non-turbo
engines, raise and
6.
safely support the vehicle to gain access to
the
filter,
filter.
3.
Flare nut connection from the
filter
and discard gaskets If
•
Before servicing the vehicle, refer to the
precautions
in
the beginning of this section.
equipped with a
fuel tank
mounted
remove or disconnect the following: Eyebolt, gasket and connector
•
Pressure regulator
•
Fuel
filter
bolts
•
Fuel
filter
bracket,
and
filter
To service the fuel
•Wrap that is
shop towels around the fitting being disconnected to absorb
residual
Pump Locking MB991480 is needed
To install: 7.
Install or •
4.
pump on AWD
Cover the hose connection with shop
Fuel
vehicles,
necessary Ring Removal tool
a Fuel
the lines.
fuel in
if
connect the following:
filter in its
bracket and finger-
Fuel
tighten at this time
Pump
towels to prevent any splash of fuel that
could be caused by residual pressure fuel
pipe
5.
•
the
or disconnect the following:
**
Negative battery cable
Eye
bolt,
by holding the
fuel filter
nut securely with a back-up wrench •
'•Movement attachment
line.
Remove •
in
High-pressure ter
fuel line
from the
of the filter will
ease
REMOVAL & INSTALLATION
of the fuel lines.
CAUTION
1
Be sure new O-rings are installed prior to assembly. •
•
Main pipe
•
Fuel
at the filter.
in the
main
filter nut.
Manually, •
pipe's flare nut.
ft.
lbs.
25 •
ft.
Fuel
Nm) and
(30
lbs.
•
filter
ft.
mount-
If
22
lbs.
(14
ON
to
for leaks
Fuel lines
•
Fuel
pump assembly from
MB991480. All
lift-
the tank
install:
5
Install or
release the fuel pres-
to
remove the locking
ring
Wheel Drive (AWD) model.
To
sure before opening the fuel system.
engine
Harness connector
•
on the
repairs of a leak are required,
remember
and
Use Fuel Pump Locking Ring Removal
Tool
position to pres-
and check
Rear seat cushion, by pulling the
•
4
Nm)
Negative battery cable
Turn the key to the
7W2DG10
to
the flare nut to
mounting bolts and
surize the fuel system
F)
or disconnect the following:
Negative battery cable
ing the cushion up
(35 Nm).
torque to 10
— 2.0L (VIN
beginning of this section.
seat stopper near the floor
Using a back-up
wrench, torque the eyebolts
ing
Remove
3.
screw
ol the fuel tilter
in the
Relieve the fuel system pressure.
2.
fil-
and discard gaskets
Exploded view
Before servicing the vehicle, refer to the
.
precautions
8.
connect the following
pump
•
Fuel
•
Fuel hoses
•
Harness connector
in the
tank
•
Rear seat cushion
•
Negative battery cable
Fuel Injector
REMOVAL & INSTALLATION 2 OL (VIN Y) Engine Before servicing the vehicle, refer to the
1
precautions in the beginning ol this section.
29 22
2
Relieve the fuel system pressure
3.
Remove
Nm ft. lbs.
or disconnect the following:
•
Battery
•
Air intake
•
High pressure fuel rail
Exploded view
of the fuel filter
mounting— 2. OL
(VIN Y) engine
For Accessory Drive Belt
illustrations,
see Section
1
of this
hose fuel
hose from the
and discard the O-ring
•
Fuel injector harness connector
•
Fuel
•
Fuel injector electrical connectors
•
Fuel injector-to-fuel
•
Fuel injectors
manual
rail
rail
relainer(s)
and discard the O-rings
CHRYSLER CORP.
7-16
TALON
To
install:
4.
Install or
connect the following:
•
New
«
Fuel injectors
fuel injector
O-rings
^Lubricate the O-rings with clean engine
oil;
then, install the injectors
by twisting them
into the fuel rail
(left
and right) to make sure that they turn smoothly in the seat.
WARNING
C
1.
High-pressure luel hose connection
2.
O-ring
3. Injector 4.
Do not allow engine the fuel
oil to
get into
6.
rail.
8. 9.
Fuel injector-to-fuel
•
Fuel injector electrical connectors Fuel ft.
harness connector
rail
connectors Retainers
7. Injectors
•
•
Fuel
5. Injector
rail
and torque the bolts
to
2
Nm)
lbs. (3
O-rings O-rings
refainer(s)
rail
Exploded view
•
Fuel injector harness connector
•
New
of the fuel injector, fuel
high-pressure fuel hose O-ring
12
Nm
8.7
ft.
lbs.
^Lubricate the O-ring with clean engine C
oil.
WARNING
Do not allow engine the fuei •
oil to
get into
rail.
hose connection
High pressure
fuel
and torque the
fuel hose-to-fuel rail
bolts to 1.8
lbs. (2.5
•
Air intake
•
Battery
ft.
Nm).
hose
2.0L (VIN F) Engine 1
.
Before servicing the vehicle, refer to
the precautions
in
the beginning of this sec-
tion. 2.
3.
Relieve the fuel system pressure.
Remove
or disconnect the following:
•
Negative battery cable
•
Spark plug cables
3.
High-pressure fuel hose connection O-ring Fuel return hose connection
4.
Vacuum hose connection
5.
6.
Fuel pressure regulator O-ring
7.
PCV
1.
2.
•
High pressure from the
•
fuel line
connection
fuel rail
O-ring and discard
it
•
Fuel return line connection
•
Vacuum hose connection
•
Fuel pressure regulator
•
O-ring and discard
•
Positive Crankcase Ventilation
it
13. O-rings 14.
of the fuel injector, fuel rail
Fuel injector connectors
PCV hose New O-ring
WARNING
•
Insulators
•
Fuel injector(s)
fuel rail.
•
O-rings and discard them
turns smoothly.
•
Grommets and
Do not allow the
oil to
Make sure
get into the
•
Do not allow the
Fuel injector(s)
•
New
insulators
•
Fuel
rail
ft.
lbs. (3
and torque the bolts
Nm)
"Lubricate the O-ring with clean engine oil.
the fuel injector
discard them
connect the following:
engine
•
rail
New grommets New O-rings
F)
•
oil.
Fuel
•
and related components— 2. OL (VIN
engine
Fuel injector connectors
Install or
Grommets
'Lubricate the O-rings with clean
•
To install:
connectors
rail
10. Insulators 11. Insulators 12. Injectors
•
*
Fuel
93060G05
Exploded view
•
•
9.
hose
(PCV) hose
4.
8. Injector
fuel rail. to 2
oil to
Make sure
get into the
the fuel pressure
regulator turns smoothly.
CHRYSLER CORP.
7-17
TALON Fuel pressure regulator and torque
•
to
7
ft.
lbs. (9
'•Lubricate the O-ring with clean
engine
Nm)
•
Vacuum hose connection
•
High pressure
(2.5
•
Fuel return line connection
•
New
0-ring
Do not allow the
oil
bolt to 1.8
ft.
lbs.
Nm)
•
Spark plug cables
•
Negative battery cable
to get into the
connection
fuel line
and torque the
oil.
fuel rail.
DRIVE TRAIN •
Transaxle Assembly To 6.
REMOVAL & INSTALLATION
mount and
Transaxle
Install or •
connect the following:
Transaxle and
Manual
Nm) and bolts to
1
.
Before servicing the vehicle, refer to the •
2.
Center
equipped.
Remove
or disconnect the following
•
Battery
•
Air intake
lbs.
ft.
•
Negative battery cable
•
Battery
•
Control actuator and bracket,
(30-34 Nm)
58
ft.
lbs.
(78
•
battery tray if
Air cleaner assembly, intercooler
and
Nm)
4
ft.
and
equipped with auto-cruise
housing cover and slave cylin-
Bell
lbs
Nm)
(12
•
assembly
the transaxle
22-25
(69
lbs.
ft.
der and torque the bolts to 9
Mark
air
hose, as required
the shift cable’s location.
•
Adjusting nut and
•
Dipstick
•
Solenoid connector
shift
cable
and tube assembly
hoses •
•
50
fluid.
or disconnect the follow-
ing:
.
member assembly and
Drain the transaxle and transfer case if
Remove
right-hand stay and torque the
• 3.
Drain the transaxle
3.
the beginning of this section.
in
bolts to fluid,
2.
mount and torque
the through-bolt to
precautions
transaxle
install:
Halfshafts
•
Neutral safety switch (inhibitor
Battery tray and support
Auto-cruise actuator and bracket,
if
-Be
sure to install the washer
switch) connector
the
in
•
proper direction.
equipped with cruise control
Pulse generator kickdown servo switch connector
•
Charcoal canister and bracket
•
Shift
•
and select cables from the
transaxle •
Back-up
•
Vehicle Speed Sensor (VSS)
• 4.
• light switch
•
•
Starter •
stopper bracket mounting
roll
•
•
Transaxle mounting bracket nuts
•
Engine undercover Transfer case assembly,
with All
if
equipped
Wheel Drive (AWD)
Do not remove
or install the axle
when the damage to
shaft nut floor or
Transfer case assembly,
vehicle
is
Slave cylinder from the
and torque
to
54
lbs.
ft
ing.
Do
line
and position
•
Bell
housing cover
•
Right-hand center
hous-
not disconnect the fluid it
aside.
Center
Tie rod
• •
ft.
(48
lbs.
VSS and back-up
•
Cruise control actuator,
•
Battery tray support
•
Charcoal canister bracket and can-
light
ends and
from
Exhaust pipe and transfer case, on
Wheel Drive (AWD) vehicles
connectors
•
Lower
removed
•
Flexplate-to-torque converter spe-
and
il
tray
bell
housing cover
cial bolts
•To remove
the bolts, turn the engine
Air duct
and
air
cleaner assembly
Refill the transaxle. fill
with gear
crankshaft with a box wrench and bring the bolts into a position appropriate for
On turbocharged
removal, one
Refill
85W
or
the transfer case with gear
GL-4
at a time.
oil ol classification
or higher,
** WARNING After
removing the
bolts,
push the
torque converter toward the transaxle
oil of
SAE 75W-
so
75W-90.
it
doesn't stay on the engine,
allowing
oil to
pour out
verter hub or cause
member
ball joints
Halfshafts
All
(support) •
Sheet metal undercover
•
Nm)
35
or higher, SAE 75W-85W or 75W-90. On non-turbocharged models, fill with Mopar MS9417 MTX Fluid P/N 4773167 9.
stay
•
the engine support fixture.
•
classification
member
Transaxle mounting bracket sup-
steering knuckle
GL-4 bell
Upper transaxle-to-engine bolts
•
Transaxle assembly mounting bolts to
Starter
porting the transaxle
(74
Starter
models, •
roll
bolts
cooler
•
stopper bracket mounting
Rear
•
•
8 Halfshafts
•
lbs
ft
oil
ister
the bearings will
•
70
to
temperature sensor connector
lines
Nm)
Remove
on the
occur.
removed
if
Transaxle mounting bracket nuts
and torque 7.
•
Speedometer cable and
Nm)
bolts
5.
Oil
•
(95
Transaxle mounting bolts
Rear
•
and torque the bolts
Attach a support fixture to the engine •
Engine undercover and lower the vehicle
Automatic
of the
damage
con-
to the
converter.
Place a transmission jack under the transaxle and support •
1
Before servicing the vehicle, refer to the
•
it.
precautions
Transaxle mounting bolt
For
Tire,
in
Wheel and Ball Jo ini
the beginning of this section.
specifications,
see Section
Lower transaxle-to-engine bolts
and transaxle
1
of this
manual
-HI 7#”80
CHRYSLER CORP. TALON
To
install:
5.
Install
•
pedal lightly until resistance
measure 5.
or connect the following:
Transaxle and torque the transaxle-
vis pin play
to-engine bolts to 35
(1-3mm).
Nm) and
lbs.
ft.
(48
the torque converter-to-
driveplate bolts to
34-38
ft.
If
housing cover and torque the
Bell
•
Transfer case and exhaust pipe,
lbs. (5
new
using a els
ft.
Nm)
AWD mod-
gasket, for
to 51
•
Circlips
and halfshafts
•
Tie rods
and
the castle nut to
25
lbs.
ft.
(34
35
ft.
lbs.
Nm)
•
Speedometer cable and
•
Solenoid connector
•
Neutral safety switch (inhibitor
Clutch release fork
•
Return clip
for
Oil
temperature sensor connector
remaining components
AWD, check
equipped with
fluid level
engine and allow
N
in
(neutral).
and add,
’»lf the vehicle
if
it
to idle
Lubricate the clutch release bearing.
6.
Lightly apply multi-purpose grease to
push the pushrod
7.
Install or
•
connect the following:
Clutch disc using a suitable guide
that
when
all
the clutch pedal
is
the way, the interlock
ON
to OFF.
on the
fly-
wheel •
Pressure plate
•
Clutch release (slave) cylinder and torque the bolts to 13
ft.
lbs.
(18
2.01 (VIN F) Engine 1
Before servicing the vehicle, refer to the
.
• •
Recheck the
ADD mark on the Do not add fluid unless the or below the ADD mark.
above the
the beginning of this section.
or disconnect the following:
Transaxle
Clutch
oil
tubes by unscrewing the
fittings
necessary.
warm and should
in
Remove
2.
has run for less than 15
considered
5.
the clutch disc splines.
REMOVAL & INSTALLATION
be
dipstick.
chamber
•
Clutch
•
Clutch release (slave) cylinder
•
Valve plate and valve plate spring
union
minutes but more than one minute, the fluid is
Check
precautions
the selector through each gear posi-
ending
to the clutch release
Mopar ATF Plus ATF automatic
2 minutes. Apply the parking brake and
move
Apply grease
Nm)
the transfer case.
Start the
tion,
adjusting the clutch pedal
switch connector
If
4.
fork boot
fork contact areas.
height or the clutch pedal clevis pin
depressed
transaxle fluid.
7.
Turn the pushrod to adjust the
to position the disc
All
with
connect the following:
•
switch changes from
with Dexron®ll,
Install or
ening the locknut.
d.
•
it
Release fork boot and fulcrum
Fulcrum and release
toward the master cylinder.
•
to
install:
•
Pulse generator kickdown servo
Refill
•
3.
play, be careful not to
type 7176, Mitsubishi Plus
cause damage
clutch pedal height. Then, lock by tight-
c.
cooler
to
other direction or removing
turn the switch to obtain the standard
*»When oil
away from
force.
equipped with cruise control,
pushrod with the locknut.
Under-guard
fill
If
the standard value and secure the
Starter
it
the clip by pushing the fork in any
To
switch) connector
and
the standard value, then tighten
clutch pedal clevis pin play to agree with
lines
6.
is
Nm) •
•
bolt so the pedal
and adjust the stop
b.
(48
•
Release fork by sliding
Be careful not
not equipped with cruise control,
detach the clutch switch connector and
Transaxle mounting bracket and
torque the bolts to
•
ing the return clip
in.
the locknut.
ft.
and torque
ball joint
Clutch release bearing by unfasten-
the fulcrum
If
height
Nm)
(69
should be within 0.04-0.12
•
cle-
the clutch pedal height or clevis pin
a.
turn
and torque the bolts
lbs.
met, and
adjust as follows:
(46-53 Nm) bolt to 4
is
The clutch pedal
play are not within the standard values,
lbs.
•
•
this distance.
•
oil fluid
bolt,
gaskets and union
Clutch release (slave) cylinder, without disconnecting the fluid line
level is at •
Pressure plate
•
Clutch disc
Clutch
ADJUSTMENTS
Clutch Pedal Free-Play 1
.
Before servicing the vehicle, refer to the
precautions 2.
in
the beginning of this section.
Measure
the clutch pedal height from
the face of the pedal pad to the firewall. 3.
Compare
the
measured value with the
proper distance of 6.93-7.17
in.
(176-1 82mm). 4.
Measure the clutch pedal
7922DG15
Slide the release fork in the direction of
clevis pin
play at the face of the pedal pad. Press the
the arrow to disengage ball
it
from the pivot
Lubrication points for the clutch release lever and bearing
CHRYSLER CORP.
7-19
TALON Hydraulic Clutch System
2.
Drain the transfer
3.
Remove •
BLEEDING
•Do
Negative battery cable
•
Front exhaust pipe
•
Transfer case assembly and torque
not allow the reservoir to run out
44
the bolts to
during bleeding, otherwise the entire procedure must be repeated.
oil.
or disconnect the following:
ft.
lbs.
(59
Nm)
of fluid
•Be
damage
careful not to
case's output housing
oil
the transfer
seal.
Do
not
Before servicing the vehicle, refer to
1
the rear driveshaft hang; suspend
let
the precautions in the beginning of this sec-
from the body with a piece
it
of wire.
tion.
Cover the opening 2.
Cross-sectional view of proper clutch disc fluid
Fill
meeting
and pressure plate alignment, showing the 3.
transfer case to keep
DOT
Attach a hose to the bleeder valve on
the slave cylinder with the other
hose submerged Valve plate spring and valve plate
•
Gasket, union, gasket and union
•
Clutch
oil fluid
to 11 •
tubes, then
oil
them and tighten the
attach
ft.
lbs.
4
chamber. Uncap or
unplug the clutch
fresh
DOT
in a
container
end
and
of the
at least half
3 brake fluid from a sealed
fittings 5.
floor,
6.
install:
oil
•
then loosen the bleed
Before servicing the vehicle, refer to
Tighten the bleed screw and have
transfer extension
Repeat the procedure
oil.
connect the following:
Transfer case assembly and torque
to
40-43
ft.
lbs.
(55-60 Nm) on
manual transaxle or 43-58
transaxle.
Transfer Case Assembly
care
when
installing the rear
driveshaft to the transfer case output shaft.
Remove
•
or disconnect the follow-
Front exhaust pipe using a
new
gasket and torque the bolts to 33
ing: 1
•
Transaxle
•
Clutch
Before servicing the vehicle, refer to the
precautions oil
in
lbs (44
Nm)
the beginning of this section
tube by unscrewing the
fitting
'•Plug or cap the ends
to
prevent con-
tamination from entering the
line.
•
Release (slave) cylinder
•
Pressure plate and clutch disc
•
Clutch release bearing
•
Clutch release lever
•
Boot
To
install:
3.
Apply a suitable grease
to the clutch
release lever. Lightly apply multi-purpose grease to
the clutch disc splines. 5.
lbs.
REMOVAL & INSTALLATION
tion.
4.
ft.
(60-80 Nm) on automatic
until the fluid is
the precautions in the beginning of this sec-
2.
on the
the transfer case-to-transaxle bolts
•Use 1.
seal lip
Install or
5.
free of air bubbles.
2.0L (Vin Y) Engine
from dripping
Lubricate the driveshaft sleeve yoke
your helper release the clutch pedal
Transaxle
oil
dirt out.
4.
screw on the slave cylinder.
(15 Nm).
keep
To and
Have an assistant press the clutch
pedal to the
to
housing with clean engine
container.
on the release cylinder
bolt,
full of
the transaxle and
3 specifications.
alignment tool
•
in
the reservoir with clean brake
Install or
Boot assembly
•
Clutch release lever
•
Clutch release bearing
•
54-59 40-44
connect the following:
•
Nm ft. lbs.
^
Clutch disc and pressure plate
assembly •
Clutch release (slave) cylinder and torque the bolt to 14
ft.
lbs.
(19
Nm) •
Clutch lbs.
•
oil
(15
tube and torque to 11
ft.
Nm)
Transaxle
Exploded view
ol the transfer
case assembly mounting— Vehicles with manual transaxle
For Wheel Alignment specifications, see Section
1
of this
manual
ft.
CHRYSLER CORP.
7-20
TALON 4.
6.
Fill
the transfer case with gear
classification
85W
GL-4
SAE 75W-
or higher,
fluid level in the
75W-90. Check the
or
•
connect the following:
Install or
oil of
Toe control arm,
Circlips
•
Halfshaft into the transaxle
arm nut
(-Be sure
seated.
is fully
it
(1
Halfshaft into the
•
Center bearing bracket,
and torque the bolts
REMOVAL & INSTALLATION
(45
to
equipped
if
Before servicing the vehicle, refer to the
2.
h
33
Nm)
lbs. (71
Halfshaft nut, temporarily tighten
•
Tie rod end
to 21
is
going to be rolled
Also,
if
proper torque
to the front
Remove
•
lbs.
the
tie
lbs.
ft.
1
or disconnect the following:
New
Cotter pin, halfshaft nut and washer
•
Speedometer drive from the extension housing
.
2.
right
removing the
if
Tie rod from the steering knuckle
•
Stabilizer link
•
Damper
from the damper fork
Lateral lower
rod
in
connect the following:
The
Rearwheel(s)
•
Wheel speed sensor,
if
with Anti-Lock Brake
System (ABS)
equipped
•
Brake caliper and rotor or brake drum
•
Parking brake shoes (disc brakes) or
•
Parking brake cable from the back-
•
Wheel cylinder brake
WARNING
•
improper methods
of joint
damage
in
•
to •
removed
•
Remaining brake components
•
ABS
wheel speed sensor,
if
•
Rear wheel
•
Brake drums,
if
equipped
Shock absorber from
All
•
equipped with an inner shaft
if
Halfshaft by pressing
•
Halfshaft/inner shaft
tapping plastic
it
from the hub
it
line,
if
1
the steering
Halfshafts by prying
transaxle on
FWD
it
•
from the
3.
WARNING it
from the transaxle; doing so damages the inboard joint. Do not insert
ma y
oil
Before servicing the vehicle, refer to the
seal in
be damaged.
it
from the
splines for wear.
Check
damage
the ball joints
and
halfshaft
and place
it
in
a soft
vise.
Disassemble or remove the following: •
Tri-pot boot
•
Tri-pot case
bands
hub assembly
install: Install or
Tri-pot spider
assembly
WARNING
Do not disassemble the spider assembly.
connect the following:
hub assembly
•
Halfshaft in the
•
New
•
Halfshaft into the differential
•
Differential
mount support
•
Washer on
the halfshaft
•
Halfshaft nut
in
the cor-
ft.
h
If
and torque lbs.
it
to
WARNING
the boot
tic
is to
be reused, wrap plas-
tape around the shaft splines to
damage.
protect the boot from
(196-255 Nm)
’If the cotter pin hole does not align, tighten the nut to 188 ft. lbs. (255 Nm) and install the cotter pin in the first hole that aligns.
Tri-pot boot
on the inner shaft
circlip
rect direction
•
Halfshaft snapring
•
h
Halfshaft from the
the grease from the tri-pot case.
•
•
Inspect the halfshaft boot for
the beginning of this section.
dif-
housing
145-188
install:
or deterioration.
in
Remove
(Wipe
mount support.
Halfshaft by prying ferential
To
vehicles
the prybar too far or the
3. 4.
Cotter pin, nut and washer from the
•
vehicles
not pull on the shaft to dislodge
2.
Toe control arm from the steering
Differential
assembly by
AWD
.
precautions
jawed
•
from the transaxle with a
hammer on
Tri-Pot Joint
halfshaft
Wheel Drive (AWD) vehicles
•
assembly, located
halfshaft.
arm and lower arm from
Trailing
Birfield joint
knuckle
Center support bearing bracket bolts,
To
if
on the wheel side of the halfshaft, is not to be disassembled; repair of this joint is only by replacement of the
the steering knuckle
the joint, leading to possible failure.
the case
line,
FRONT WHEEL DRIVE— (FWD)
ing plate
arm from the steering
3. separation can result
Do
Parking brake cable
the beginning of this section.
knuckle
[:*
Wheel cylinder brake
•
(200-260 Nm)
equipped with drum brakes
•
•
Bleed the brake system.
to
shoe/lever assembly (drum brakes)
knuckle
on
ft.
removed
(24-33 Nm)
•
fork from the lateral lower
arm
•
52
cotter pin
Install or
right halfshaft •
of
to
Nm)
Before servicing the vehicle, refer to the
precautions
•
!'
to the steering
Rear
Negative battery cable.
•
ft.
Nm)
(98
lbs.
wheel bearings, the bear-
ings will no longer be usable.
•
trail-
with the brakes applied
not applied
is
Nm) and
(28
17-25
145-188
the hubs.
in
ball joint to the
Wheel and torque the axle nut
•
with the halfshafts removed, install 2 outer CV-joints tools
and
lbs.
ft.
nut to
Use
4.
steering knuckle and torque the nut
WARNING
ft.
knuckle and torque the bolt
lbs.
ft.
•
the beginning of this section.
the vehicle
(28 Nm),
lbs.
ft.
Lower shock mount
•
outward
in
20
to
arm nut to 85-99 ft. lbs. 1 8-1 37 Nm) and lower arm nut
to 71
Washer, face the chamfered edge
•
Front
If
hub
•
Halfshaft
precautions
arm and
ing
transaxle and add, as required.
1
trailing
lower arm. Torque the toe control
on the halfshaft ends
•
Dynamic damper bands from halfshaft,
if
the
necessary
To install: If
removed,
install
the
dynamic damper
by performing the following procedure:
CHRYSLER CORP.
7-21
TALON
Lubricating the tri-pot case assembly installed
1 T.J. boot band 2 T.J boot band 3. T.J case
4
Circlip
5
Snap
10 B J
(large)
(small)
B B B
11
12 13
(105 g)
assembly
Do not disassemble the BJ assembly e*cepi replacement of the B J boot.
Dynamic damper
9
of the front halfshaft
assemblies
(120 g)
for
tri-
9
— Front wheel
Install the tri-pot
boot by performing
the following procedure:
9306GG
Exploded view
oz.
grease into the
add the remaining grease.
Caution
6 Damper band
kit
pot case, insert the spider assembly and
ring
bool
T.J
non-turbo or 4 23
turbo specified repair
J boot band (large) J boot
6 Spider assembly 7.
for
J bool band (small)
Position the boots large end on the
a.
drive
tri-pot case.
Wrap
Position the large and small boot
b
** WARNING
A
clamps onto the boot Adjust the boot so that the bands
c.
around the shaft protect the bool Irom dam-
plastic tape
splines lo
are spaced at
3.03—3 27
in.
age.
ALL WHEEL DRIVE (AWD) 5.
Install a
Apply the specified repair
between the spider axle and the 7.
Install the tri-pot
kit
front halfshaft
damper on
the
assemblies— Front wheel
tion direction
grease
tion.
roller
Remove
2.
spider assembly soft
and place
it
in
drive
bands
•
Tri-pot boot
•
Tn-pot case (right halfshaft) or
Distribute a portion ol the 3.7 oz
pot case/inner shaft assembly Slide the
a.
damper onto
halfshaft)
the halfshaft
new bands.
with b.
••Wipe
Position the
damper so
the dis-
the grease from the tri-pot
case.
tance from the front of the Birfield joint to the front
bly
edge
of the
14.60-14.84
is
in.
damper assem-
(371-377mm)
for the right halfshaft (non-turbo)/left
halfshaft (turbo) or
(191-197mm)
7.52-7.76
c.
•
Halfshaft snapring
•
Tri-pot spider
assembly
** WARNING
in.
for the left halfshaft
Do not disassemble the spider assembly.
(non-turbo, M/T). Tighten and secure the damper
bands.
•
For Maintenance Interval recommendations, see Section
1
a
Disassemble or remove the following:
3
and secure with the
halfshaft
jawed vise
snapring. 8.
Before servicing the vehicle, refer to
1
the precautions in the beginning of this sec-
onto the shaft from the spline beveled sec Positioning the dynamic
— FRONT
new small boot clamp onto
the halfshaft followed by the tri-pot boot 6.
(77-83mm).
Tighten the band securely.
d
of this
Tri-pot boot
manual
tri-
(left
CHRYSLER CORP.
7-22
TALON Install a
6.
new small boot clamp onto
the halfshaft followed by the tri-pot boot.
Apply the specified repair
7.
between the spider axle and the
grease
spider assembly
Install the tri-pot
8.
kit
roller.
onto the shaft from the spline beveled section direction
and secure with the snapring.
Distribute a portion of the 3.70 oz.
9. 10.
(105 g) specified repair
kit
grease into the
tri-pot case, insert the spider
assembly and
add the remaining grease. Install
the tri-pot boot by performing
the following procedure:
Position the boots large end on the
a.
tri-pot case.
Position the large and small boot
b.
clamps onto the boot. Adjust the boot so that the bands
c.
are spaced at 3.03-3.27
in.
(77-83mm).
Tighten the band securely.
d.
ALL WHEEL DRIVE
(AWD)—REAR
Before servicing the vehicle, refer to
1.
the precautions
in
the beginning of this sec-
tion.
Remove
2. 8 Dust seal (outer) 9. Dust seal inner) 10 Center bearing 11 Center bearing bracket 12 Circlip
Caution
Do nof disassemble the men °' lhe B J b °°''
B.J.
soft
assembly except replace-
’
If
the boot
of the front halfshaft
is to
it
—AWD
•
Tri-pot boot
bands
be reused, wrap plas-
tape around the shaft splines to
tic
damage.
protect the boot from 4. is
and place
If
working with the
left
necessary to replace the
halfshaft
tri-pot case,
and
it
press
the case from the inner shaft assembly.
To the
install: installing a
5.
If
left
halfshaft,
new
tri-pot
case onto
perform the following pro-
cedure: Lubricate the inner shaft splines
a.
with Multi-Mileage Grease No. 2525035.
Press the inner shaft assembly into
b.
tri-pot case.
Secure the
c.
tri-pot
MB991248 on
tool
case with special
the case facing upward. d.
Position a
new
e.
Place a 1.18
boot band (targe) boot band (small)
3. T.J.
case
A
in.
(30mm)
and press the
T.J.
Snap
ring
Spider assembly 6 T.J boot 7 B.J boot band (large) 8. B.J. boot band (small) 9. B.J. boot 5.
seal plate in the
center of the tri-pot case.
the seal plate
2. T.J.
1.
a hydraulic press with
pipe on
10. B.J. assembly 11. Circlip
seal into the
tri-pot case. Caution
h
Do
WARNING
not disassemble the B.J. assembly.
Wrap
plastic tape around the shaft splines to protect the boot from dam-
age.
9306DG10
Exploded view
of the rear halfshaft
assemblies
— AWD
in
a
Disassemble or remove the follow-
3.
assemblies
halfshaft
vise.
ing:
9306DG07
Exploded view
jawed
CHRYSLER CORP. TALON c.
Adjust the boot so that the bands
are spaced
MB990938
at:
Conventional: 2.99—3.23
•
7I 09 tw
in.
(76-82mm) Limited
•
(81 d.
slip:
3.19—3.43
in.
-87mm)
Tighten the band securely.
Center Bearing Positioning the tri-pot boot bands halfshaft
assemblies with t
Tri-pot case
•
— Rear
AWO
ALL WHEEL DRIVE (AWD) 1
and clean the case
Before servicing the vehicle, refer to the
.
precautions
thoroughly •
Halfshaft snapring
•
Tri-pot spider
in
the
left
halfshaft
and place
Remove
from the
left front
halfshaft
AWD
assembly
MB990938
tri-pot case.
Remove
4.
—
it
with
the tri-pot spider
the center bearing from the
center bearing bracket
a soft-jawed vise. 3.
assembly
Removing
the beginning of this section.
in
Remove
2.
the tri-pot case by perform-
ing the following procedure:
Do not disassemble the spider
a.
assembly.
Position the inner shaft/tri-pot case
assembly on a hydraulic press supported •
by Tool
Tri-pot boot
MB991248
with the tri-pot case
facing upward. i'
WARNING
b.
Position a bar inside the tri-pot case
on the end If
the boot
is to
be reused, wrap plas-
tape around the shaft splines to
tic
damage.
protect the boot from
of the inner shaft
and press the
case from the inner shaft assembly
Remove and disconnect
5.
•
Bearing
the following
Inner shaft assembly, place
it
in a
Installing the center bearing to the center
soft-jawed vise
To
bearing bracket— left front haltshatt with
install: •
:*
Wrap
WARNING
plastic tape
Center bearing bracket, press
it
from
AWO
the inner shaft with a wheel puller
around the shaft
splines to protect the boot from
MB990938
Inner dust seal
dam-
age. Install a
4.
new small boot clamp onto
the halfshaft followed by the tri-pot boot.
Apply the specified repair
5.
between the spider axle and the Install the tri-pot
6.
kit
grease
roller.
spider assembly
onto the shaft from the spline beveled section direction
Distribute a portion of the specified
7.
repair
kit
grease into the tri-pot case, insert
the spider
Installing the inner dust seal to the center
bearing bracket— left tront haltshatt with
and secure with the snapring.
assembly and add the remaining
Removing shaft
the tri-pot case from the inner
assembly— left
AWD
tront haltshatt with
AWO
grease.
Conventional type
8.
(95
of grease:
3.35 oz
g).
Limited slip type of grease: 3.70 oz.
9.
(105
g).
Install the tri-pot
10.
boot by performing
the following procedure: a.
Position the boots large end on the
tri-pot case. b.
Position the large and small boot
clamps onto the boot. Be sure the boot • •
band
identification
to
check
numbers:
Large band: 20-98 No. BJ 82
Small band: 20-83 No. BJ 82
Removing
the center bearing bracket trom
the inner shaft assembly shaft with
—
Installing the outer dust seal to the center
bearing bracket
left tront hall-
AWD
For Tune-up, Capacities and Firing orders, see Section
AWD
1
of this
manual
—
left front
haltshatt with
CHRYSLER CORP.
7-24
TALON Inner shaft into the center bearing
•
bracket using a hydraulic press and
MB991172
Adapter Tool 7.
Install
the tri-pot case onto the
half-
left
shaft by performing the following procedure:
Lubricate the inner shaft splines
a.
with Multi-Mileage Grease No. 2525035.
Press the inner shaft assembly into
b.
tri-pot case.
Secure the
c.
case with special
tri-pot
MB991248 on
Tool
a hydraulic press
with the case facing upward. Installing the inner shaft into the center d.
new
Position a
9306CG13
seal plate in the
Positioning the Birfield joint boot's small
bearing bracket— left front halfshaft with
center of the tri-pot case.
AWD
diameter Place a 1.18
e.
(30mm)
in.
pipe on
the seal plate and press the seal into the tri-pot case. 8.
MB991561 connect the following:
Install or
assembly
•
Tri-pot joint
•
Left halfshaft
Boot
Birfield Joint
FRONT Before servicing the vehicle, refer to
1.
Installing the inner shaft tri-pot
case
—
left front
assembly
9306CG14
the precautions in the beginning of this secinto the
halfshaft with
AWD
View
of the
band crimper
tool
tion.
Remove
2.
the halfshaft
and place
in
it
a soft jawed vise.
Disassemble or remove the following:
3.
6.
•
Tri-pot joint
•
Dynamic damper,
for Front
Wheel
(FWD)
Drive •
Birfield joint
boot bands
•
Birfield joint
boot
To install:
Assemble
4.
Installing the seal plate into the tri-pot
case— left
front halfshaft with
AWD
5.
or install the following:
•
Birfield joint
boot
•
Birfield joint
boot small band
Place the halfshaft
in
a soft jawed
band vise so that the Birfield joint
is
standing
vertically. •
6.
Center bearing and inner dust seal
from the center bearing bracket
7.
using a hydraulic press, Installer
MB990932 and SnapMB990938
Adapter Tool in
Bar Tool
in.
•
shaft.
that the
jaw opening
is
0.114
Position the small band so there
mating edge. 9. Using a Band Crimper Tool MB991561, crimp the small band until internal measurement of the crimp is
Adapter Tool
MB990932 MB990938
Inner duct seal into the center bear-
0.094-0.110
ing bracket using a hydraulic press, Installer
Adapter Tool
and Snap-in Bar Tool
MB990933 MB990938
Outer duct seal into the center
is
clearance between the boot and the bands
ing bracket using a hydraulic press,
and Snap-in Bar Tool
•
exposed on the
is
Center bearing into the center bear-
Installer
•
groove
(2.9mm). 8.
connect the following:
1
Adjust the Band Crimper Tool
MB991561 so
To install: Install or
Position the boots small diameter so
that only 10.
h
in.
the
(2.4-2.8mm).
Measuring the small band’s crimp
WARNING of
If
the crimp dimension
remove the band
is
install a
not correct,
new
one.
bearing bracket using a hydraulic press, Installer Adapter Tool
MB990931 and Snap-in MB990938
Bar Tool
grease
11.
(0.1-1
Using 3.88
(FWD), 4.59
oz.
3.35 oz. (95 g)
oz.
(130 for
(110 g)
for
g) for turbo
AWD,
in
the repair
kit,
pack the
Birfield
boot.
Position the boot so 0.004-0.061
,55mm)
of clearance exists
in.
between
non-turbo
the boots large diameter end and the Birfield
(FWD)
joint
specified
or
amount
housing shoulder.
12.
Adjust the Band Crimper Tool
CHRYSLER CORP.
7-25
TALON b.
damper so
Position the
the front edge of the
14.60-14 84
in.
damper assembly
(371-377mm)
1
from the drive pinion. •
is
Pinion
seal
oil
To install:
for the
right halfshaft (non-turbo)/left halfshaft
connect the following:
Install or
3.
(turbo) or 7.52-7.76 in. (191-197mm) 16. for the left halfshaft (non-turbo. M/T).
•
New
pinion
oil
drive the
new
Use an
sea
Oil
MB995020
Seal Installer tool
Tighten and secure the damper
c.
companion flange
puller to pull the
the dis-
tance from the front of the Birfield joint to
to
seal into the axle
housing
bands. Install
•
the tri-pot joint.
Grease
oil
and companion
seal lip
flange. Lubricate with Multi9306CG1
REAR
Mileage grease No. 2525035. •
Before servicing the vehicle, refer to the
1
Align the
companion
Positioning the Birfield joint boot's large
precautions
diameter 2.
soft
3.
B.J. boot
band
drive pinion
the beginning of this section.
Remove
jawed
Projection
in
the halfshaft and place
it
in
•
a
Disassemble or remove the following:
flange-to-drive
tool
MB990850
Tri-pot joint
•
Birfield joint
boot bands
•
Birfield joint
boot
lbs.
•
(186
secure the
137
ft.
Nm)
Driveshaft and torque the bolts to
22-25
Assemble
to
flange and torque the nut to
•
To install: 4
New companion
pinion nut. Use an End Yoke Holder
vise.
(large)
D
flange-to-
matchmarks
ft.
lbs.
(29-34 Nm)
or install the following:
•
Birfield joint
boot
•
Birfield joint
boot small band
Differential Carrier
9306CG18
Positioning the Birfield joint boot's large
band
5.
Position the large and small boot
clamps onto the boot. Be sure
to
REMOVAL & INSTALLATION
check the
boot band identification numbers:
MB991561 so
that the
jaw opening
is
0.126
•
(3.2mm).
in.
13.
Install
Before servicing the vehicle, refer to
.
the precautions in the beginning of this sec-
Small band: 20-83 No. BJ 82
tion. 6.
Install the tri-pot joint.
Remove
2.
band so 15. jection
•
and position the large boot
1
Large band: 20-110 No. BJ 87
that
and
a
it
rests against the boot(s) pro-
gap exists between the clamp
Pinion Seal
Halfshafts
•
Driveshaft
and the boot. Using a Band Crimper Tool
14.
MB991 561, crimp
the small
measurement
internal
0.094-0.110
in.
of the
band
•Support
REMOVAL & INSTALLATION until the
crimp
is 1
(2.4-2.8mm).
•
Before servicing the vehicle, refer to in the
2.
•
the crimp dimension is not correct, remove the band install a new one.
If
Remove
or disconnect the follow-ing
•
Driveshaft
•
Companion
flange nut.
Yoke Holder Tool MB990850, install
the
3
Raise the carrier into position. Install or
•
to
a.
with
Slide the damper onto new bands.
the halfshaft
the
companion flange
connect the following:
and torque the
Differential carrier
mount-to-rear crossmember bolt to
secure the companion flange.
~Matchmark
Differential carrier
install:
dynamic damper by performing the following procedure:
bolt
To 4
Use End
mount-to-rear
Differential carrier
crossmember
beginning of this sec-
tion.
equipped with FWD,
the differential carrier with a
jack.
the precautions
If
or disconnect the following
•
72
ft.
lbs (98
Nm)
to •
Driveshaft
•
Halfshafts
the drive pinion. •
Companion
flange
Use a bearing
STEERING AND SUSPENSION Air
** Some
abled before performing service on or
Bag
CAUTION vehicles are equipped with an
bag system, also known as the Supplemental Inflatable Restraint (SIR) or Supplemental Restraint System (SRS). The system must be disair
PRECAUTIONS
around system components, steering column, instrument panel components, wiring and sensors. Failure to follow safety and disabling procedures could result in accidental air bag deployment, possible personal injury and unnecessary system
accidental deployment and possible per-
repairs.
module.
Several precautions must be observed
when handling
the inflator
module
to avoid
sonal injury. •
Never carry the
inflator
module by
the
wires or connector on the underside of the
For complete service labor times, order the Chilton Labor Guide
CHRYSLER CORP.
7-26 When
•
TALON
carrying a live inflator module,
hold securely with both hands, and ensure that the
bag and trim cover are pointed away
Place the inflator module on a bench
or other surface with the
bag and trim cover
With the
module on
inflator
the bench,
that
at least
to retain
one minute before workair
bag system
enough voltage
to
is
deploy
may be thrown
in
the event of
.
in
the
Reconnect the negative battery cable,
turn the ignition switch to the
bag warning
air
ON
position
LOCK
position.
Remove
and insulate the cable end with high-quality non-conductive
proper operation.
aside;
DO NOT
Stabilizer bar
Joint assembly and gear
Power steering pipe connection
•
Tie rod
end from the steering
knuckle
4.
and
•
Left
•
Center
•
Center
right side stays
member assembly member
Power steering gear
1
.
Before servicing the vehicle, refer to the
precautions 2.
in
•
the beginning of this section.
To
Drain the power steering fluid into a
Install or
suitable container.
Remove
Power steering gear assembly
or disconnect the following:
connect the following:
•
Power steering gear assembly
•
Power steering gear
.
5 Cotter pin 6 Tie-rod end and knuckle connection 7 Stay (L.H.) .
.
Stay (R H.)
9 Centermember assembly 10 Clamp 11 Gear box assembly 12 Return tube
28
Nm
21
ft. lbs.
.
.
.
69
Nm
51 ft lbs.
NOTE The fasteners marked
5
* should be temporarily tightened before tightened once the total weight of the engine has been placed on the vehicle body.
are
finally
7922DG14
Exploded view
o.
retaining
install:
.
tfrey
retainers
clamp
1. Brake fluid reservoir assembly 2 A/C compressor 3 Joint assembly and gear box connecting bolt 4. Power steering pipe connection
.
body con-
•
18 Nm 13 (Llbe.
8.
disconnect
•
•
3.
wrapping.
it
•
the
Disconnect the negative battery cable
electrical tape or similar
Air conditioning compressor. Posi-
fluid reservoir
fluid reservoir
necting bolt
REMOVAL & INSTALLATION
key from the ignition lock cylinder. 2.
•
light for
straight-ahead position and place the ignition key in the
Brake
the refrigerant lines
Gear
Position the front wheels
•
tion
Power Rack and Pinion Steering
1
Negative battery cable
Windshield washer
To arm:
an accidental deployment.
DISARMING
• •
the battery has been disconnected.
and check the
never place anything on or close to the
module
designed
4.
facing up. •
Wait
on the vehicle. The
the air bag for a short period of time after
from you. •
3.
ing
power steering gear assembly and related components
retaining
CHRYSLER CORP. TALON clamp and torque the bolts
Nm) member member assembly
ft.
(69
lbs.
•
Center
•
Center
and torque the bolts
•
to 51
7-27
lbs.
(78-88 Nm)
Left
and
to
51-58
lbs.
ft.
ft.
and torque
right side stays
the bolts to
retainers
58-65
(69-78
Nm) •
end
Tie rod
to the steering
and torque’the nut
to
21
knuckle lbs.
ft.
(28
Nm) Power steering pipe connection and
•
torque the nuts to 13
ft.
lbs.
(18
Nm) •
assembly and gear body con-
Joint
necting bolt and torque the bolt to 11
5.
lbs.
ft.
(15
Nm)
•
Stabilizer bar
•
Air conditioning
•
Brake fluid reservoir
•
Windshield washer
•
Negative battery cable
Fill
compressor
the reservoir with
fluid reservoir
power steering 1.
and bleed the system.
fluid
2.
6.
Check
adjust,
if
end alignment and
the front
mounting nut
Stabilizer link
Shock absorber upper mounting
5.
Damper
6.
Shock absorber assembly
lork
nuts 3.
necessary.
Shock absorber lower mounting bolt
4.
Damper
fork
mounting
bolt
Strut Exploded view
of the front strut
mounting
REMOVAL & INSTALLATION •
Upper
strut
.
compartment 1
and torque 1
assembly-to-chassis
nuts, in the engine
Front 4
Before servicing the vehicle, refer to
the precautions in the beginning of this sec-
if
to
32
Check and adjust
lbs.
ft.
(44
Nm)
the front alignment
2
necessary.
tion. 2.
Remove •
or disconnect the following
Upper
strut
Rear
assembly-to-chassis 1
nuts, from the engine •
Front wheel
•
Stabilizer link nut
•
Strut
compartment
Before servicing the vehicle, refer to
the precautions in the beginning of this section. 2.
assembly lower mounting
Remove •
bolts
To 3.
Damper
•
Strut
fork •
Install or
Damper (88
and torque the damper
fork
arm
nut/bolt to
64
ft
Nm)
assembly lower mounting
bolts
and torque the fork bolt to
3.
strut-to-
65-87
ft.
lbs.
ft.
Strut
lbs.
and torque the
(39
Install or
Nm)
Strut
connect the following:
and torque the upper
chassis nuts to 32 4.
Stabilizer link nut
nut to 28
Strut-to-steering knuckle bolt
•
•
(88-118 Nm)
•
•
To install:
Strut
damper •
large nut in the
center of the strut assembly.
fork-to-lower
•
Upper mounting bracket-to-body
• Do not remove the
connect the following:
Strut
lbs.
the luggage compart-
cap and flange nuts
install:
•
lid in
ment
•
•
or disconnect the following
Service
ft.
lbs.
strut-to-
(44
5.
Please
7S22QCi?6
adjustable stand to align the strut lower
mounting holes.
Front wheel
Nm)
Raise the suspension with a jack or
visit
Install or
our web
Exploded view
connect the following:
site at
www.chiltonsonline.com
ot the rear strut
mounting
CHRYSLER CORP.
7-28
TALON Lower
•
strut
mounting
torque to 71
lbs.
ft.
Cap and service
•
bolt
(97
and
Nm)
lid
Coil Spring
REMOVAL & INSTALLATION
Front 1
Before servicing the vehicle, refer to the
.
precautions
Disassembly steps
-
1.
Self-locking nut
7.
2.
Washer
8.
Upper bushing B Cup assembly
3.
Upper bushing A Upper bracket assembly Upper spring pad
9.
Bump
4. 5.
10.
of the front strut
the strut assembly.
CAUTION
Do not use air tools to tighten the compressor tool bolt.
rubber Dust cover
Shock absorber assembly
Compress
3. 7922DG28
Exploded view
the beginning of this section.
11. Coil spring
12.
6. Collar
in
Remove
2.
the coil spring, using
Spring Compressing tools
MB991237 and
MB991239.
assembly
:
WARNING
Be sure
to install the tools
maximum
the
evenly so
length will be attained
within the installation range. 4.
Remove
or disconnect the following:
•
Self-locking nut, by holding the
•
Washer
•
Upper bushing
•
Upper bracket assembly
•
Upper spring pad
•
Collar
•
Upper bushing B
•
Cup assembly Rubber bumper
piston rod
• •
Dust cover
•
Coil spring
A
To assemble: 5.
Use the compressor tools
press the coil spring, then strut.
install
to it
comto the
Align the edge of the coil spring to the
stepped portion of the strut spring seat. 6.
Disassembly steps 1.
Self-locking nut
7.
Collar
2.
Washer
8
Cup assembly
Upper 4. Upper 5. Upper 6 Upper 3.
bushing A bracket assembly spring
pad
bushing B
.
Dust cover 10. Bump rubber 9.
assembly
•
Rubber bumper
•
Cup
•
Upper bushing B
•
Collar
•
Upper spring pad
•
Upper bracket assembly
*»lnstall the
assembly so the position
of the 3 bolts are in the
tion with the
damper
proper orienta-
fork.
•
Upper bushing A
•
Washer and
.
7922DG27
strut
assemble the following:
Dust cover
11. Coil spring
12 Shock absorber
assembly Exploded view of the rear
Install or
•
self-locking nut.
Tem-
porarily, tighten the self-locking nut, then
remove
the spring
com-
CHRYSLER CORP.
7-29
TALON pressor tools and tighten the nut to
14-18
ft.
Lower
torque wrench.
Front wheel(s)
•
Ball Joint
(20-25 Nm) using a
lbs.
Upper
•
REMOVAL & INSTALLATION
Do not use
air tools to tighten the
ball joint is
the lower control
self-locking nut!
Upper
Strut
control
Check and adjust the
7. if
an integral part of
arm assembly, and cannot replacement of the lower
arm assembly. 3.
front alignment,
at the
Upper Control Arm
bolts
Rear .
Upper arm-to-shafts through-bolts
Assemble the upper arm
Before servicing the vehicle, refer to
and nuts
precautions 2.
• •
the beginning of this section.
in
or disassemble the following
Remove
ft.
lbs.
(57 Nm). The
84-86 degrees.
After the
measure dimensions A and B
to
insure correct assembly.
Before servicing the vehicle, refer to the
tion.
Remove
to 41
is
the shafts are connected at the cor-
rect angle, 1
to the shafts
proper angle. Tighten the through-
arm and
the precautions in the beginning of this sec-
2.
Upper arm
•
proper angle
REMOVAL & INSTALLATION 1
•
To install:
«
necessary.
mounting nuts from the
shaft
body
be serviced separately. A worn or damaged ball joint, requires
•
from the steering
MB991113 •
The lower
ball joint
knuckle using special tool
or disconnect the following:
•
A
•
B
— —
11.8 9.2
in.
in.
(299.9mm)
(234.0mm)
Strut
Compress
the spring using a coil
spring compressor •
86
Self-locking nut by holding the pis-
Nm
ton rod •
Upper bracket assembly and spring pad
•
Collar
•
Upper bushing
•
Cup assembly
•
Bump
•
Dust cover
•
Coil spring
rubber
To assemble: 3.
Align the end of the coil spring with
the stepped part of the spring seat the
compressed 4.
coil
spring on the
and
install
strut.
assemble the following:
Install or
•
Dust cover
•
Bump
•
Cup assembly
•
Upper bushing
rubber
Removal steps 1.
Upper arm
Pall joint
and knuckle
Collar
•
Upper spring pad
•
Bracket assembly
•
Upper bushing and washer
•
New
2.
Upper arm
Exploded view
4
of the
upper control arm and related components
self-locking nut on the piston
Carefully,
A B
remove the spring com-
:
299 9 234 0
mm mm
(11 .8 in.)
(9.2 m.)
pressor from the spring. Tighten the selflocking nut to 16 6.
ft.
lbs.
(25 Nm).
Install the strut.
Upper
Ball Joint
REMOVAL & INSTALLATION The upper
Upper arm assembly upper arm shaft assembly
self-locking nut
rod and temporarily tighten the nut 5.
3.
connection
•
ball joint is
the upper control arm.
If
an integral part
of
the upper ball joint
is to
be serviced, the upper control arm
have
to
will
Be sure
to install the shafts
on the control arm
at the correct
be replaced.
Timing belt service
is
covered
in Section
3 of this manual
angle
CHRYSLER CORP.
7-30
TALON
Install or
4.
connect the following:
2.
Control arm assembly and torque
•
the self-locking nuts to
(86
ft.
lbs.
Nm)
Upper
•
62
ball joint-to-steering
ft.
lbs.
(28
adjust,
Compression lower arm
if
•
.
•
2.
install: Install or
•
(81 •
mounting bolts
to
60
ft.
to •
Before servicing the vehicle, refer to the beginning of this sec-
To 3.
knuckle assembly
•
Lateral lower
4.
43-51
ft.
lbs.
arm and
Lateral lower Lateral
arm mounting
install: Install or
connect the following:
Lateral lower
arm and temporarily,
mounting
front
on the
wheel
floor at
height
necessary.
Lateral lower
removal steps
removal steps
Compression lower arm ball joint and knuckle connection Compression lower arm mountinq
arm assembly
4.
Stay
5.
Shock absorber lower mountinq bolt
bolts 3.
arm
6.
Lateral lower
7.
knuckle connection Lateral lower arm mounting Lateral lower arm assembly
Compression lower arm assembly 8.
ball joint
and bfclt
Caution ' :
Indicates parts which should be temporarilly tightened, fully tightened with the vehicle on the ground in the unladen condition.
and then
9300DG03
Exploded view of the lower arms and related components
bolts;
do not
tighten the bolt until the vehicle
Compression lower arm assembly
2.
bolts
arm
Specified grease: MOPAR Multi-mileage Lubricant Part No. 2525035 or equivalent
1
ball joint at
assembly
•
install the
(59-71 Nm)
Check and adjust the if
mounting bolts
•
•
Wheel
alignment,
tion.
j
Strut lower
lbs.
and torque the new self-locking nut
Compression Lower Arm
in
Stay (bracket)
•
the knuckle
Nm)
Ball joint to the
or disconnect the following:
Wheel
•
connect the following:
Compression lower arm and torque the 2
REMOVAL & INSTALLATION
the precautions
Remove •
Compression lower arm
3.
the beginning of this sec-
in
tion.
Both compression lower arm
To
Lower Control Arm
1
Before servicing the vehicle, refer to
bolts
necessary.
Lower Arm
the precautions
MB991113
tool
Nm)
ball joint
knuckle with special
at the steering
to
Perform a front wheel alignment and
5.
Lateral 1
Wheel
•
Front wheel(s)
•
or disconnect the follow-
•
knuckle
and torque the new locking nut
20
Remove
ing:
normal riding
is
CHRYSLER CORP.
7-31
TALON •
knuckle assembly
Ball joint to the
and torque the new self-locking nut to •
43-51
lbs.
ft.
Strut lower
•
lbs.
to
lateral
71-85
lower arm through-
alignment,
(97-118 Nm).
lbs.
ft.
Check and adjust the
5.
51-58
Wheel
and nut
bolt
Nm)
(88
lbs.
(69-78 Nm)
Torque the
4.
ft.
Stay and torque the bolts to ft.
Nm ft.lbs.
mounting bolts and
torque to 64 •
74-88 54-65
(59-71 Nm)
front
wheel
necessary.
if
Nm
49-59 36-43
Wheel Bearings
ftlbs.
ADJUSTMENT
Front
The
front
wheel bearing
is
sealed and not
the wheel bearing
shows signs
adjustable.
If
of play, the
hub assembly must be replaced
Rear The wheel bearing play If
the wheel bearing play
cations, the
is
is
not adjustable.
1.
7. Clip
ABS>
3.
Brake drum Shoe and lever assembly
4.
Caliper assembly
2
hub assembly must be replaced
FRONT WHEEL DRIVE (EWO)
8 Parking brake cable 9 Rear hub assembly 10. Brake pipe connection IV Dus; seal
5 Brake disc 6.
1
Rear wheel speed sensor
4 Caliper assembly 5. Brake disc 1.
6.
Upper arm
ball Joint
is at
the limit value. Specification
(18
kg) or less.
ALL WHEEL DRIVE
and knuckle
(
AWD
conneclion
2.
3.
hub
3.9 lbs
7
Front
hub assemoly
1
Before servicing the vehicle, refer to the
precautions
2
in the
Remove
beginning
the caliper
of this section.
assembly and the
I9H0G2S
brake disc (rotor). Exploded view
ol the front
hub assembly
3.
Place a dial gauge against the hub
surface, then
Heater Core replacement
is
covered
in
Section
2
of this
manual
move
the
hub
in
the axial
7I ~ 0 Q9 £ direction
CHRYSLER CORP. TALON
and check whether or not there
is
ball joints
from the steer-
•
Damper
•
REMOVAL & INSTALLATION
and
fork
lateral
lower con-
tem (ABS)
the steering knuckle
•
4.
install or
'•The front hub assembly is a sealed unit and should not be disassembled. 1
•
the beginning of this sec-
in
"»Do
connect the following:
Remove
2.
or disconnect the following:
•
.
Wheel
•
Halfshaft cotter pin
Lateral
and compression lower
control
arm
•
•
Halfshaft nut by holding the rotor in
•
place with a suitable tool
•
•
Front wheel speed sensor,
17-25
it
•
tem (ABS)
•^o
it
out of the
to ball joint
from
lbs.
(88
Nm)
ft.
(33
lbs.
torque to 43
Front hub assembly
•
Nm)
lbs.
ft.
(59
Nm)
•
order to keep the clearance between
off
ABS
the
145-188
shaft.
If
Install or
lbs.
(196-255 Nm).
'•Tf the cotter pin holes
Be careful not to damage the ball If equipped with ABS, be
joint boot.
careful not to
damage
maximum. the
first
the rotor.
•
Install a
ft.
new
(225
lbs.
(88
Nm)
on
AWD
Parking brake shoe and lining if
equipped with disc
brakes
do not align, lbs.
ft.
assembly,
•
tighten the nut to 188
rotor.
Parking brake cable and retaining clip,
•
ABS
install the
connect the following:
Rear hub and bearing and torque to
65 •
ft.
removed,
4.
•
position while torquing the nut to
press
to
rotor.
5.
Halfshaft nut. Hold the rotor in
the front hub mounting bolts and half-
vehicles equipped with ABS,
To install:
if
equipped
'•Shift the knuckle to the outside in
FWD
use a suitable inner shaft remover
ball joint to the
Front wheel speed sensor,
On
3.
AWD
Rear hub and bearing assembly
•
Brake disc (rotor) and caliper and
•
fhe steering knuckle •
25
equipped with disc
Parking brake cable clip and cable
on
steering knuckle and torque the nut
not disconnect the fluid line.
Upper control arm
ft.
Upper control arm
•
3.
•
•
to
Nm)
lbs. (8.5
65
if
brakes
connect the following:
bolts to
with a piece of wire.
Parking brake shoe and lining
assembly,
Front hub assembly and torque the
•
Caliper and suspend
way
•
Dust shield and torque the bolt
Install or
5.
Brake shoe and lining assembly, on
(24-33 Nm)
lbs.
on Front Wheel
bolt,
(FWD)
AWD
ball joint to the steering
cotter pin
78 inch
if
equipped with Anti-lock Brake Sys-
•
New
ft.
mounting
Clip
Drive
ball joints into the
end
Tie rod
equipped with drum
if
brakes
knuckle and torque the nut to
and discard
Brake drum,
•
steering knuckle
tion.
rear disc
not disconnect the fluid line.
the bolt and nut
Before servicing the vehicle, refer to
.
was removed,
Steering knuckle and hand-tighten
•
equipped with
a suitable piece of wire
the steering knuckle
If
if
brakes and suspend the caliper on
To install: Front
Caliper,
Steering knuckle
•
if
equipped with Anti-lock Brake Sys-
arm from
trol
the precautions
Rear wheel speed sensor,
ing knuckle
(0.05mm).
in.
arm
trol
end-p!ay. End play should not exceed 0.002
Nm)
Shoe and
lining assembly,
on
AWD
cotter pin in
mounting
•
Clip
•
Brake drum,
matching holes. Wheel
if
on
bolt,
FWD
equipped with drum
brakes and torque
to
60
ft.
lbs. (81
Nm) If
necessary
to
remove the steering
Rear
•
knuckle, remove or disconnect the follow1
ing: •
Dust shield
•
Tie rod end from the steering
•
.
Before servicing the vehicle, refer to the
precautions 2.
in
•
or disconnect the following:
•
Wheel
Compression and
•
Halfshaft,
lower con-
(AWD)
on
All
vehicles
if
equipped with
Nm)
Rear wheel speed sensor,
equipped
knuckle and discard the cotter pin lateral
(59
the beginning of this section.
Remove
Rotor and caliper,
disc brakes and torque to 43
on
•
Halfshaft,
•
Front wheel
Wheel Drive
AWD
if
ft.
lbs.
CHRYSLER CORPORATION 1998-02
Dodge/Plymouth-Neon
8-25
DRIVE TRAIN ENGINE REPAIR FUEL SYSTEM
8-2
8-22
PRECAUTIONS STEERING AND SUSPENSION
8-2
Removal &
Fuel Injector
Bag
8-36
Fuel
Disarming
8-36
Precautions
8-36
Alternator Installation
8-2
C Camshaft and
Removal &
Lifters
Installation
Installation
Fuel System Pressure
Removal And
Installation
8-42
8-6
Cylinder Head Installation
Installation
Installation
Removal &
8-2
Exhaust Manifold
8-14
Removal &
8-14
Oil
8-44
Ball Joint
Installation
Oil
Installation
Pump Removal &
Rocker Arms/Shafts
Removal &
Installation
Installation
8-21
8-10 8-10
S 8-18
Motor
Removal &
Installation
8-18 8-40
Removal &
Installation
8-40
T Removal &
8-43 Installation
Transaxle Assembly
Removal
&
Installation
8-43 8-25
8-25
V 8-18 8-18
Adjustment
W Water
8-19
8-36
8-36 8-21
Installation
8-44
8-19
Pan
Removal &
Removal &
Valve Lash
0 8-2
Rear Main Seal
8-11
L
8-6
Engine Assembly
Installation
8-11
i
Removal &
Installation
Tension Strut
8-2
Adjustment Intake Manifold
Lower
Removal &
8-32 8-2
Timing
Removal &
Rack and Pinion Steering Gear
Strut
i
Ignition
8-22
Positioning
Starter
8-32
Halfshafts
E
Installation
8-23
8-22
8-33
Overhaul
8-23
H Removal &
8-22
Piston and Ring
8-23
Relieving
8-33
CV-Joints
8-24
Fuel System Service
8-42
Coil Spring
Removal &
Installation
Precautions
8-31
8-23
8-23
8-31
Adjustment
Removal &
Installation
Pump
8-15 8-15
8-15
8-24
Removal &
8-31
Clutch
Installation
Removal &
8-2
8-15
8-23
Removal &
8-36
Removal &
Installation
Fuel Filter
A Air
P
F Front Crankshaft Seal
Pump
Removal &
8-6 Installation
Wheel Bearings
8-20
Adjustment
8-20
Removal &
8-6
8-45 8-45
Installation
8-45
7/ Q9 direction
CHRYSLER CORP. TALON
and check whether or not there
Damper
•
REMOVAL & INSTALLATION To
install:
4.
If
1
•
Remove
or disconnect the following:
•
•
Wheel
•
Halfshaft cotter pin
•
Halfshaft nut by holding the rotor in
•
place with a suitable tool
•
•
Front wheel speed sensor,
was removed,
'•Do
tem (ABS) •
Caliper and
Lateral
and compression lower
arm
way
New
it
•
from
the steering knuckle
^Shift the knuckle
25
ft.
lbs.
(33
lbs.
torque to 43 •
(88
Nm)
Nm)
lbs.
ft.
(59
•
On
3.
Nm)
off
To
145-188
lbs.
Install or
•
Be careful not to damage the ball If equipped with ABS, be
joint boot.
careful not to
damage
maximum. the
first
the rotor.
•
Install a
new
(225
ft.
lbs.
(88
Nm)
on
AWD
Parking brake shoe and lining
assembly,
if
equipped with disc
brakes
do not align, lbs.
rotor.
Parking brake cable and retaining clip,
•
ABS
install the
connect the following:
Rear hub and bearing and torque to
65
• ft.
removed,
If
5.
(196-255 Nm).
'•If the cotter pin holes
tighten the nut to 188
press
to
install:
•
ft.
vehicles equipped with ABS,
rotor.
4.
Halfshaft nut. Hold the rotor in
shaft.
FWD
ABS
the
if
position while torquing the nut to
the front hub mounting bolts and half-
AWD
use a suitable inner shaft remover
ball joint to the
Front wheel speed sensor,
to the outside in
equipped with disc
Rear hub and bearing assembly
•
equipped
order to keep the clearance between
if
Parking brake cable clip and cable
on
Brake disc (rotor) and caliper and
•
Front hub assembly
•
to
Nm)
steering knuckle and torque the nut
fluid line. ball joint
assembly, brakes
Upper control arm
•
Parking brake shoe and lining
(24-33 Nm)
Front hub assembly and torque the
to
•
AWD
connect the following:
ft.
Wheel
Brake shoe and lining assembly, on
•
lbs. (8.5
65
equipped with drum
(FWD)
Drive
ball joint to the steering
lbs.
if
Clip mounting bolt, on Front
•
cotter pin
bolts to
3.
Upper control arm
ft.
Install or
out of the
with a piece of wire.
'•Do not disconnect the •
end
Brake drum,
•
ball joints into the
Dust shield and torque the bolt
•
suspend
not disconnect the fluid line.
brakes
control
78 inch 5.
rear disc
connect the following:
17-25
if
equipped with
if
a suitable piece of wire
Tie rod
it
equipped with Anti-lock Brake Sys-
Caliper,
brakes and suspend the caliper on
knuckle and torque the nut to
and discard
if
tem (ABS) •
steering knuckle
tion. 2.
Rear wheel speed sensor,
lower con-
the bolt and nut
the beginning of this sec-
in
lateral
the steering knuckle
Steering knuckle and hand-tighten
•
Before servicing the vehicle, refer to
.
and
fork
the steering knuckle
install or
hub assembly is a sealed and should not be disassembled. front
the precautions
•
Steering knuckle
•
Front
unit
from the steer-
equipped with Anti-lock Brake Sys-
arm from
trol
(The
ball joints
ing knuckle
(0.05mm).
in.
arm
trol
is
end-play. End play should not exceed 0.002
Nm)
Shoe and
lining assembly,
on
AWD
cotter pin in
mounting
•
Clip
•
Brake drum,
matching holes. Wheel
if
on
bolt,
FWD
equipped with drum
brakes and torque
to
60
ft.
lbs. (81
Nm) If
necessary
to
remove the steering
Rear
•
knuckle, remove or disconnect the follow1
ing: •
Dust shield
•
Tie rod
•
.
Before servicing the vehicle, refer to the
precautions
end from the steering
2.
in
•
or disconnect the following:
•
Wheel
Compression and
•
Halfshaft,
lower con-
(AWD)
on
All
vehicles
if
equipped with
Nm)
Rear wheel speed sensor,
equipped
knuckle and discard the cotter pin lateral
(59
the beginning of this section.
Remove
Rotor and caliper,
disc brakes and torque to 43
on
•
Halfshaft,
•
Front wheel
Wheel Drive
AWD
if
ft.
lbs.
CHRYSLER CORPORATION 1998-02
Dodge/Plymouth-Neon
DRIVE TRAIN ENGINE REPAIR FUEL SYSTEM
8-25 8-2
8-22
PRECAUTIONS STEERING AND SUSPENSION
8-2
Removal &
8-36
Disarming
8-36
Precautions
8-36
Removal &
Installation
8-2
C Camshaft and
Removal &
Lifters
Installation
Pump
Fuel System Pressure
Installation
8-42
Coil Spring
Removal And
Installation
8-42
Installation
8-6
Cylinder Head Installation
Removal & Lower
Removal &
8-2
Exhaust Manifold
8-14
Removal &
8-14
Oil
Installation
Oil
Installation
Installation
Installation
8-21
8-10
8-10 8-18
&
Installation
8-18
Removal &
Installation
8-40
Removal
8-40
T Removal &
8-43 Installation
Transaxle Assembly
Removal &
Installation
8-43 8-25 8-25
V 8-18
Valve Lash
8-18
Adjustment
W
8-44 Water
8-19
8-36
S Motor
8-11
8-19
Pump Removal &
Installation
Tension Strut
8-44
Pan
Removal &
Installation
8-32
0 8-2
Removal &
8-36 8-21
Strut
8-11
Ball Joint
Removal &
Removal &
Installation
Rocker Arms/Shafts
Starter
L
8-6
Engine Assembly
Installation
8-23
8-2
Intake Manifold
E
Installation
8-23
8-2
Timing
8-33
Overhaul
Rear Main Seal
8-32
Adjustment
8-33
CV-Joints
&
8-24
I
Ignition
Rack and Pinion Steering Gear
Removal
H Halfshafts
Removal &
8-22
Positioning
8-24
8-22
Precautions
8-31
8-23
System Service
8-15 8-15
8-22
Piston and Ring
8-23
Relieving Fuel
8-15
8-23 Installation
8-31
Adjustment
Removal &
Installation
Removal &
8-31
Clutch
Removal &
Fuel
8-2
Alternator
Installation
Fuel Injector
Removal &
Bag
8-15
8-23
Fuel Filter
A Air
Installation
Removal &
8-36
P
F Front Crankshaft Seal
Pump
Removal &
8-6 Installation
Wheel Bearings
8-20
Adjustment
8-20
Removal &
8-6
8-45 8-45
Installation
8-45
^* CHRYSLER CORPORATION
8-2
NEON
PRECAUTIONS
of the following precautions,
all
which deal with personal of
prevention
safety,
IMMEDIATELY seek
brake fluid internally,
Before servicing any vehicle, please be
sure to read
component damage, and important points when servicing a
•
The EPA warns
with used engine
prolonged contact
that
may cause
oil
skin disorders, including cancer!
motor vehicle:
should make every
Never open, service or drain the radia-
system when the engine
tor or cooling hot; serious
burns can occur from the steam
Observe
•
all
applicable safety precaufuel.
Whenever
servicing the fuel system, always work
Do
well-ventilated area.
come
in
not allow
fuel
a
in
spray
contact with a spark,
open flame, or excessive heat
(a hot
effort to
used engine
drop
oil.
oil.
other exposed
Soap and
expo-
water, or
waterless hand cleaner should be used. •
All
new
vehicles are
your vehicle.
If
becomes contaminated, completely
fluid.
Any brake
brake
of
the brake fluid flush the
Never reuse any brake
fluid.
removed from
fluid that is
the system should be discarded. Also,
when changing after
fluid for
system with new
Protective
soon as possible
sure to used engine
of
You
minimize your
oil.
Wash your hands and any skin areas as
when working around
or vapors to
to
gloves should be worn
is
and hot coolant.
tions
exposure
number
a
to take into consideration
•
proper operation of the brake system. You
should always buy the correct type
medical assistance.
now equipped
a painted surface;
it
Never operate the engine without the
•
proper amount and type of engine
so WILL result
Timing
•
belt
doing
oil;
severe engine damage.
in
maintenance
Many models
extremely
is
with an air bag system, often referred to as a
important!
Supplemental Restraint System (SRS) or
ence-type, non-freewheeling engine.
Supplemental
timing belt breaks, the valves
Inflatable Restraint (SIR) sys-
do not
come in contact with will damage the paint.
allow any brake fluid to
an
utilize
interferIf
the
the cylinder
in
tem. The system must be disabled before
head may
extinguisher near the work area. Always
performing service on or around system
tially
keep
components, steering column, instrument
expensive) engine damage. Refer to the
example). Keep a dry chemical
light, for
a container specifically
fuel in
designed
fire
for fuel storage; also,
panel components, wiring and sensors.
always
and disabling proce-
strike the pistons,
causing poten-
serious (also time-consuming and
maintenance
manual
interval charts in the front of
recommended
properly seal fuel containers to avoid the
Failure to follow safety
possibility of fire or explosion. Refer to the
dures could result
additional fuel system precautions later in
deployment, possible personal injury and
timing belt section for belt replacement and
this section.
unnecessary system
inspection.
Fuel injection systems often remain
•
•
accidental air bag
in
repairs.
Always wear safety goggles when
this
ment
•
for the
some
working with, or around, the
turned OFF. The fuel system pressure must
When
be relieved before disconnecting any
sure the bag and trim cover are pointed
tem^) and may
away from your body. When placing a non-
undergo
lines. Failure to
do so may
and/or personal
injury.
fuel
result in fire
wash your hands thoroughly
handling brake
after
brake fluid
in
fluid.
If
irritation persists, or
if
bag on a work surface, always
from the surface. This
motion
you do get
of the
module
will if
it
If
you have taken
•
away
is
accidentally air
bag
later in this section.
Clean, high quality brake fluid from a
sealed container
is
essential to the safe
vehicles
may
interfere with
the functions of the on-board
require the
•
When
is
and
to
process once the neg-
a relearning
ative battery cable
computer sys-
computer
reconnected.
drum
servicing
brakes, only dis-
3. assemble and assemble one side
reduce the
deployed. Refer to the additional
system precautions
your eyes, flush your eyes
with clean, running water for 15 minutes.
eye
air
face the bag and trim cover upward,
ethers and polyglycols. Avoid contact with the eyes and
carrying a non-deployed air bag, be
deployed
Brake fluid often contains polyglycol
•
bag system.
to the
Disconnecting the negative battery
cable on
pressurized, even after the engine has been
air
replace-
and
interval for the timing belt,
at
a time,
leaving the remaining side intact for refer-
ence. •
Only an MVAC-trained, EPA-certified
automotive technician should service the conditioning system or
its
air
components.
ENGINE REPAIR »»The alternator spill shield does not need to be removed.
Alternator
REMOVAL & INSTALLATION
•
1998-99 Models
3 pivot bracket-to-engine bolts
•
Pivot bracket
•
Alternator, by sliding
bolt 1
.
Before servicing the vehicle, refer to
the precautions
in
*lt is not necessary to
the beginning of this sec-
off
it
the “T”
and out through the wheel well
remove the “T”
bolt.
tion. 2.
Remove
To install:
or disconnect the following:
•
Negative battery cable
•
Alternator's
adjustment
Install or
nut,
•
loosen
connect the following:
Alternator, **Be sure to
rocker
arms and spacers
indicated by
when
there
is
locations
in their original
merge
wear on the
roller or
damage
the rocker
rocker
arm
lubrication
shaft oil
if
is
duct.
to the shafts for
damaged
or worn.
hollow and
Check
clogs with a small piece
wear or
is
REMOVAL & INSTALLATION
into
travel is not reduced, replace the
rocker
damage. Replace
arm assembly
to the rocker
damage. Check the location where the
taken up.
SOHC If
are serviced as an
Engine —Except High Output Engines
assem-
The hydraulic lash adjuster and
arm
assem-
1
Before servicing the vehicle, refer to
the precautions in the beginning of this section
bly.
The
used as a
the oil holes for
of wire,
and clean
as required. Lubricate the rocker arms and spacers. Be sure to install
in their original
locations.
To
install:
Set the crankshaft to 3 notches before Top Dead Center (TDC) before installing the rocker arm shafts, otherwise valvetrain damage may occur
when
the mounting bolts are tight-
ened. 4.
Set the crankshaft sprocket to
aligning the
arrow on the off to
5.
TDC
by
mark on the sprocket with the oil
pump
housing, then back
3 notches before TDC. Install the
INTAKE MANIFOLD TO
WATER
INLET
SUPPORT
rocker arm/hydraulic lash
adjuster assembly
making sure
that the
Intake manifold bolt torque
Brake service
is
covered
in
(valve) cover.
Intake Manifold
and pump the plunger
until the lash adjuster travel is
bly.
arms mount
oil
arm
Install the
Connect the negative battery cable.
depressed
is
for scoring,
arm; replace any components showing
rocker
full of oil.
no plunger
the lash adjuster
clean engine
arm
or
excessive plunger travel, sub-
for installation.
Inspect the rocker
little
rocker
7.
8.
sequence— 1998-99
2 OL (VIN C)
Section 4 of this manual
SOHC
engine
8-12
CHRYSLER CORPORATION NEON 2.
Knock Sensor (KS)
•
Properly relieve the fuel system pres-
3.
Remove
• • •
•
Fresh
air inlet
duct from the
air
Clean
4.
Fuel supply line from the fuel tube
To
assembly
5.
SOHC
engine
of
any
install: Install or
connect the following:
•
New
•
Fuel
assembly
•
Intake manifold
•
Brake booster vacuum hose
retainers, in
•
Positive Crankcase Ventilation
lbs. (11
rail
•
(PCV) hose
C)
mating surfaces
all
Fuel injector cover
Fuel
Manifold Absolute Pressure (MAP)
sensor
and discard the
residual gasket material.
•
•
2000-02 2.0L (VIN
Intake manifold
gasket
Negative battery cable
cleaner
sequence—
Starter wiring connectors
•
or disconnect the follow-
ng:
Intake manifold bolt torque
con-
electrical
nector
sure.
electrical
17
connector on 1999
models 6.
ft.
gaskets and seals
and torque the new
sequence,
to
95 inch
Nm)
rail
and torque the screws
lbs.
(23
to
Nm)
•
PCV hose
•
Brake booster hose
Inspect the fuel line quick-connect
tings for
Apply a
fit-
damage and replace necessary. small amount of clean engine oil to if
the fuel inlet tube. •
Fuel supply hose to the fuel
rail
assembly. Ensure the connection
is
fastened securely by pulling on the connector. •
Fuel injector cover
•
MAP
•
KS sensor connector
•
Air inlet duct
•
Negative battery cable
View
of the
sensor wiring
Manifold Absolute Pressure
(MAP) sensor— 2000-02 SOHC engines
- BOLT 2 - BRACKET 3 - BRACKET 1
4 -
1
- KNOCK SENSOR
2 -
BOLT
STARTER MOTOR 9306EG23
9306EG21
View View
of the intake manifold
lower supports
—2000-02 SOHC engines
of the
Knock Sensor (KS)
SOHC engines
— 2000-02
OH OO
CHRYSLER CORPORATION
O
neon 7.
repair
Start the vehicle, if
check
and
for leaks
•
MAP sensor connector MTV actuator connector
•
Oil dipstick
•
Inlet air
•
necessary.
High Output Engine 1
.
Before servicing the vehicle, refer to
Heater hose from the intake manifold
•
Heater tube from the bottom of the
•
Upper
radiator
and coolant recov-
ery hoses
body
•
PCV
•
Fuel injector connectors and har-
the precautions in the beginning of this sec-
•
intake manifold
duct to the manifold and
the throttle
I
•
hose
Fuel
rail
assembly
tion. 2.
ness
to the fuel rail
•
Fuel
rail
•
Fuel supply line
•
Negative battery cable
Properly relieve the fuel system pres-
cover
sure. 3.
Remove
or disconnect the follow-
ing:
t •
6.
check
for leaks
and
Negative battery cable repair
•
Start the vehicle, if
necessary.
DOHC
injectors to rest on
may damage them.
•Cover
the injector openings to pre-
vent debris from entering the ports.
Throttle body-to-intake manifold air
duct
Do not allow the their tips as this
•
Engine
Accelerator,
kickdown and cruise
control cables, 1
Wrap towels around
the precautions
the fitting to
Fuel supply line quick-connect
tube assembly
from the
fuel
•
Fuel
cover from the engine
•
Fuel injector connector and harness
rail
from the injectors and •
•
in
the beginning of this sec-
•
fuel rail
Relieve the fuel system pressure.
3.
Remove
•
or disconnect the following
•
Negative battery cable
•
Air inlet duct fold
connector
Throttle
body vacuum hoses
•
Throttle
body
•
Manifold Absolute Pressure/ldle Air
cal
Wrap towels around
Lower intake manifold support
catch any spilled fuel.
•
the fitting to
Manilold Absolute Pressure (MAP)
models •
Oil dipstick
•
Manifold Absolute Pressure (MAP)
Manifold Tuning Valve (MTV) actu-
•
Fuel supply line quick-connect
from the •
sensor wiring
Knock Sensor (KS) nector.
fuel rail
Intake manifold-to-cylinder
bolts
Engine Coolant Temperature (ECT)
Irom the tab located on the heater tube
for-
ward •
Knock (KS) Sensor wiring
•
Brake boosfer hose
•
Intake manifold
and discard the
gasket
To
install:
4
Clean the mating surfaces of any
residual gasket material. 5.
Install or
•
connect the following:
ifold with a
to the upper mannew gasket and torque
the bolts to
105 inch
Lower manifold
lbs.
(12
Nm). •
Intake manifold
on the cylinder
head with a new gasket •
Engine wiring harness between the middle intake runners
•
KS
•
Brake booster hose and torque the
wiring connector
intake manifold bolts, in sequence, to •
105 inch
lbs.
(12
Nm)
Lower manifold support bracket bolt
and torque the
lbs.
(28
bolt to 21
con-
sensor connector
head
and move the manifold
electrical
Detach the wiring harness
ator wiring •
electri-
connector on 1998 models
sensor electrical connector on 1999
bracket bolt •
•
Throttle Position (TP) sensor elec-
Temperature (TMAP) sensor
(PCV) hose
electri-
•
** CAUTION
Positive Crankcase Ventilation
motor
connector
trical
from the intake mani-
equipped, from
and bracket
Idle Air Control (IAC)
cal
2.
if
the throttle lever
tion.
catch any spilled fuel. •
Before servicing the vehicle, refer to
ft.
Nm) For complete Engine Mechanical specifications, see Section
1
of this
manual
CHRYSLER CORPORATION
8-14
NEON •
MAP
sensor electrical connector on
1999 Models
1999 models •
IAC sensor
connector on
electrical
1999 models
7922EG16
Intake manifold bolt torque sequence
DOHC
2.0L (VINY)
•
KS and
•
Wiring harness to the heater tube tab
•
TP sensor Throttle
•
engine
connectors
starter electrical
•
1
.
electrical
connectors
tion. 2.
Release the
3.
Remove •
body vacuum hoses
Accelerator,
Before servicing the vehicle, refer to
the precautions in the beginning of this sec-
kickdown and speed
control cables,
Fuel supply line from the fuel
•
Air cleaner
•
bracket and throttle lever •
EGR
•
tube and torque to 95 inch
torque to 95 inch •
BOTTOM VIEW
INTAKE MANIFOLD
lbs.
•
Intake manifold side retainers
Air duct to the air
filter
•
DOHC
2.0L (VIN Y)
sequence—
•
•
Right side splash shield
•
Alternator drive belt
•
Alternator spill shield
•
Exhaust pipe from the manifold.
Negative battery cable
engine
Low Emission
Exhaust Manifold Starter electrical connectors
equipped, discard the manifold-to-
•
Exhaust Gas Recirculation (EGR)
flex joint gasket.
•
REMOVAL & INSTALLATION
•
1998 Models
kets 1
^If necessary, separate the upper and lower manifolds.
.
all
of the gasket
mating surfaces.
To install: Install or •
lbs.
ft.
lbs.
•
•
Air cleaner
•
Power steering pump
Fuel
(28
to 21
DO NOT
Upstream Heated Oxygen Sensor
to
ft.
• •
Fuel supply hose to the fuel
outward
if
•
Exhaust manifold and discard the
•
4.
Thoroughly clean the mating surfaces.
Install the
is
fastened
securely by pulling on the connector.
the fasteners to 17
ft.
(23 Nm), starting at the center and
working outward
the fuel inlet tube.
’•Ensure the connection
exhaust manifold with a
new gasket and torque lbs.
oil to
manifold
Upper
radiator
and coolant recov-
in
both directions
’•-Repeat this procedure until
•
ECT sensor
•
Throttle
tener to •
TMAP
electrical
connector
body and torque the 16 ft. lbs. (22 Nm)
sensor
electrical
both directions. Repeat
procedure
until all
Lower heat shield
fasteners
to the
Exhaust pipe
5.
Install or
to the
exhaust
manifold with a
all fas-
21
lbs.
ft.
gasket,
if
fasteners
(28 Nm).
Alternator spill shield
•
Alternator drive belt
•
Right side splash shield
•
HO 2 S
•
Upper heat shield
sensor connector to the
exhaust
manifold
teners are tightened to specifications.
Power steering
reservoir
and
connect the following: bracket
•
Alternator bracket bolt,
•
Exhaust manifold heat shield
•
ery reservoir hoses
and working
•
•
Heater tube and hose to the intake
in
(23 Nm),
lbs.
new manifold-to-flex joint LEV equipped. Torque the
fit-
necessary.
ft.
remove the
to
replace,
17
are tightened to specifications.
To install:
damage and
to
manifold
3.
Apply a small amount of clean engine
•
Exhaust manifold with a new gasket
this
rail
Inspect the fuel line quick-connect
connect the following:
gasket
starting at the center
gasket
assembly
•
New
and torque
lbs.
•
Nm) PCVhose
Install or
•
loosen the
outer exhaust manifold bolt.
17
install:
(HO 2 S) connector
alternator bracket bolt to
to
5.
disconnect
•
•It may be necessary
ft.
Thoroughly clean the mating sur-
•
onto the intake manifold
rail
4.
To
reservoir,
Exhaust manifold heat shield
(23
tings for
aside.
Exhaust manifold and discard the
faces.
assembly and bracket
Nm)
and torque the screws
6.
it
.
•
new gasket
Intake manifold using a
and torque the fasteners
Upper exhaust manifold fasteners
•
the fluid lines.
the bolts to
Lower exhaust manifold fasteners
•
gasket
or disconnect the following:
Negative battery cable
move
Nm)
(28
the exhaust
•
the beginning of this section.
Remove
Upper and lower manifolds with
21
in
•
connect the following:
new gaskets and torque •
Before servicing the vehicle, refer to the
precautions 2.
Thoroughly clean
Lower heat shield from manifold
Upper and lower intake manifold assemblies and discard the gas-
5.
If
Vehicle (LEV)
•
tube
4.
Upstream Heated Oxygen (HO 2 S)
lbs. (3
Nm) Intake manifold bolt torque
Upper heat shield from the exhaust
sensor connector
housing and
torque the clamp to 25 inch 7922EG15
Power steering reservoir bracket
manifold
and
Nm)
lbs. (11
rail
assembly and bracket
and move the reservoir aside
Nm)
(11
Negative battery cable
•
equipped, to their
if
fuel pressure.
or disconnect the following:
HO 2 S
•
Air cleaner bracket
•
Exhaust pipe
(28 •
assembly and bracket
•
Air cleaner
•
Fuel supplyjine to the fuel
•
Negative battery cable
rail
sensor
to the
and assembly
2000-02 Models
manifold and
torque the fasteners to 21
connector
on 1998 models
loosened
Power steering pump reservoir
•
fas-
if
Nm)
Negative battery cable
ft.
lbs.
1.
Before servicing the vehicle, refer to
the precautions tion.
in
the beginning of this sec-
O O
CHRYSLER CORPORATION NEON
-
C U
1I
3.
•
support bracket
bolt,
if
ULEV
equipped. Torque the bolts to 40
Wiring harness heat shield-toif
ULEV equipped
bolt, •
Lower
(15)
Connect negative cable
vehicle.
if
front crankshaft oil seal, using
•
Crankshaft key
•
Crankshaft sprocket using Installer
Wiring harness heat shield-to-
6792
Tool
exhaust manifold support bracket
(14)
New
Crankshaft Installer Tool 6780-1
exhaust manifold, •
or connect the following:
Install •
ft.
(54 Nm).
lbs. •
To install:
Cylinder head-to-exhaust manifold
Make
LEV equipped
sure the word
crankshaft sprocket
Front Crankshaft Seal
Exhaust manifold tightening
•
Timing
•
Crankshaft damper using thrust
belt
bearing washer and bolt from Installer Tool
REMOVAL & INSTALLATION
put Engines
damper or disconnect the following:
•
Negative battery cable
•
Wiring harness heat shield-to-
1
exhaust manifold support bracket if
Low Emission
Vehicle (LEV)
Wiring harness heat shield-toexhaust manifold,
if
Ultra
Low
Emission Vehicle (ULEV) equipped •
Exhaust manifold support bracket
•
if LEV equipped Make up air hose Speed control vacuum
bolt,
•
reservoir,
• • •
clip
in
•
•
Negative battery cable
•
Accessory drive belts
•
Crankshaft damper, using Puller Tool
1026 and
1
Insert Tool
6827-A
•
Timing
•
Crankshaft sprocket using special
•
Tools 6793 and C-4685-C2
•
Timing
Crankshaft sprocket key
•
Crankshaft sprocket with special
Crankshaft
oil seal,
puller Tool
6771
belt
Tools 6793 and insert
using a seal •
Crankshaft
Install or
•
connect the following:
Front crankshaft cial
Exhaust manifold and discard gasket
Tool
6792
Exhaust manifold with a new gasket
Make
and torque the
crankshaft sprocket
16
ft.
lbs.
bolts, in
(23
sequence,
(23
if
ULEV
FRONT
on the
facing outward.
to
16
ft
Removing the
front crankshaft oil seal
•
Timing
Crankshaft damper using thrust
belt
bearing washer and bolt from Installer Tool
damper
lbs. (11
•
if
6792 and torque
bolt to
105
ft
lbs
the
(142
Nm)
Negative battery cable
Camshaft and
Cylinder head cover,
Lifters
ULEV
REMOVAL & INSTALLATION
equipped
Speed control vacuum
reservoir,
if
equipped
SOHC
•
Make up
•
Exhaust manifold support bracket if
is
•
Nm)
Nm) O 2 S sensor connector and harness
M10 M12
sure the word
Nm)
shield,
Upper and lower heat shields and
bolt,
seal with spe-
oil
Tool 6780-1
Crankshaft sprocket with special
•
connect the following:
Upper heat
C-4685-C2
seal with special
oil
install:
3
clip
•
Crankshaft damper with special Tools 1026 and 6287-A
ULEV
if
torque the bolts to 95 inch
•
or disconnect the following:
Negative battery cable
•
belt
the beginning of this section.
in
Remove
2.
Tool 6771
Cylinder head cover,
lbs.
•
Engine
Before servicing the vehicle, refer to the
.
To
equipped and torque bolts
•
Negative battery cable
precautions
Exhaust manifold bolts
to •
•
Upper heat shield
Install or
(142
or disconnect the following:
To install: 3.
lbs.
ft.
Accessory drive belts
the beginning of this sec-
equipped •
105
1
•
DOHC Remove
•
Oxygen (O 2 S) sensor connector
lbs.
tion.
•
and harness
for
Before servicing the vehicle, refer to
if
equipped •
.
Engine
the precautions
2.
equipped •
SOHC
6792. Torque the
bolt to
998—99 models or 100 ft. (136 Nm) for 2000-02 models.
Nm)
bolt,
on the
9306EG25
sequence-2000-02 models and High Out-
Remove
FRONT
facing outward.
Negative battery cable
to battery.
m
2.
is
air
LEV equipped. Torque
1998-1999
the
new
Installing a
bolt to bolt to
40 70
ft.
ft.
lbs.
lbs.
(54 Nm), (95
6780-1: proceed with caution
if
ft.
lbs.
Nm) and
illustrations,
shafts
see Section
in
an aluminum cylinder head. Rocker arm
using sub-
mount
(28 Nm).
For Accessory Drive Bell
MODELS
This engine uses a camshaft running
seal using seal installer
stitute tools
the nut to 21
Engine
hose
1
of this
manual
directly to the cylinder head.
CHRYSLER CORPORATION
8-16
NEON VALVE RETAINING
ROCKER SHAFT RETAINING BOLT
VALVE
RETAINER
SPACER
EXHAUST ROCKER ARM/ HYDRAULIC LASH ADJUSTER ASSEMBLY
4.
INTAKE ROCKER ARM/HYDRAULIC LASH ADJUSTER ASSEMBLY
Exploded view
of the cylinder
Care must be taken to ensure ing
marks align
after cylinder
head and valvetrain assembly
all
valve tim-
head and val-
vetrain service. Please note that the cylinder
head must be removed from the vehicle
to
service the camshaft.
'•After
all
components are
the engine, a
DRB scan
installed on
tool is neces-
To
— SOHC engine camshaft and check the cylinder head
install:
damage. Replace the cylinder head
'•The cylinder head bolts should be checked for stretching before reuse. If the thread area of the bolt is necked down the bolts must be replaced with new. New head bolts are recom-
or
5.
Clean
Before servicing the vehicle, refer to
all
roller for
parts well. Inspect the
feed holes
in
for scoring.
Check
the head for blockage.
of pitting
the
oil
Check
the precautions in the beginning of this sec-
the camshaft bearing journals for scoring.
tion.
light
scratches are present, they
may
2.
Relieve the fuel system pressure.
removed with 400
Remove
deep scratches are present, replace the
•
Negative battery cable
•
Cylinder head cover
show signs
grit
abrasive paper.
If
wear or damage. Replace rocker
If
if
the camshaft lobes
worn
or
show signs
on the nose, flank or base
If
serviced,
the rocker
circle,
arms and
shaft are to be
mark the rocker arms so any
that
are to be returned to service will be installed in their original
arms
off
locations. Slide the rocker
the shaft.
rocker arms
in
the
Keep the spacers and
same
location for
reassembly.
EXHAUST ROCKER ARM ASSEMBLY
7.
'•Mark the rocker arm shaft assemblies to identify them for later installa-
Inspect the rocker
arms
for scoring,
tion. •
Rocker arm shaft bolts
•
Rocker arm assemblies
•
Timing
•
Camshaft sprocket
•
Rear timing belt cover
•
Cylinder head
•
Camshaft Position (CMP) sensor
•
Camshaft from the
belt
der head
of
arm
replace the camshaft. 6.
If
be
3.
or disconnect the following:
the camshaft lobes
damaged. camshaft journals
.
If
arms/hydraulic lash adjuster
sary to perform the camshaft and
1
damaged.
wear, check the corresponding rocker
mended.
crankshaft timing relearn procedure.
for
worn
if
and tensioner
7922EG10
rear of the cylin-
Rocker arm shaft identification— SOHC
Rocker arm shaft notch location— SOHC
engine
engine
O O
CHRYSLER CORPORATION NEON
I
engine
Rocker arm shaft retainers,
•
7I
belt side
up and toward the timing of the
i
original positions
bolts to
17
•
Timing
belt
•
All electrical,
ft.
in their
and torque the
lbs.
(23
Nm)
and tensioner
vacuum and
fluid
connections Negative battery cable.
•
••An
and
oil
filter
change are recom-
mended. Use a DRB scan
16.
tool to perform the
camshaft and crankshaft timing relearn procedure, as follows:
Connect the scan
a.
tool to the
DLC
(located under the instrument panel, near
the steering column). b.
Turn the ignition switch
ON
and
access the "miscellaneous" screen. Select the “re-learn cam/crank"
c.
option, then follow the instructions on
the scan tool screen.
wear on the
damage
roller or
on the end
to the shaft.
screw
Replace parts as necessary.
The rocker arm
8.
used as a lubrication the shaft
oil
duct.
a small wire
all oil
Check
holes on the camshaft.
that
install
fit
It
.
and clean as required.
rearward as
as
To
Move
Read the end-play on the
dial indi-
0 005—0 013 inch
•
oil.
Install the adjuster into the
b.
arm making sure
the adjuster
to
rocker •
least
is at
Submerge
c.
oil
and
the rocker
pump
lash adjuster travel
is
arm
•
clean
in
Install the
Camshaft
lbs. (9.6
taken up.
It
•
travel
rocker
arm on
ft.
lbs.
(115
Throttle cables
•
Throttle Position (TP) sensor
•
Nm)
Cylinder head
the crankshaft sprocket
Tire,
Wheel and
Control (IAC) valve from
Idle Air
Air
body make-up hose from
the air
Air cleaner
•
Timing
•
Camshaft sprocket
•
Cylinder head cover and mark the rocker
belt
arm
shaft assemblies to ease
installation
Rocker arm and shaft assemblies.
•
Rocker arm shaft assembHes
•
Engine Coolant Temperature (ECT)
Position the rocker shafts pointing
Ball Joint specifications, see Section
housing
•
3
Camshaft end-play can be checked,
For
from the intake
cleaner
13.
camshaft target magnet
connector
Air intake duct
•
•
seal flush with the cylin-
notches before Top Dead Center (TDC) on
•
tray
Temperature (IAT) sensor
the throttle
shaft.
Install the
Inlet Air
Nm)
shaft assemblies, set the crankshaft to
using the following procedure:
and
•
Ireely.
Before installing the rocker arm and
15.
the rocker
85
or disconnect the following:
Battery
manifold
arm
a.
Remove •
electrical
Camshaft sprocket and torque the bolt to
the plunger until the
not reduced, replace the adjuster.
d
Drain the cooling system.
der head
partially filled with oil.
engine
3
•
sensor and torque the screws
85 inch
of this section.
Relieve the fuel system pressure.
connect the following
Camshaft, lubricate the bearing
CMP
beginning
in the
2
4
Lubricate the lash adjuster thor-
a.
is
will go.
••Be sure the camshaft turns
oughly with clean engine
Before servicing the vehicle, refer to the
journals thoroughly
fol-
lowing procedure:
.
precautions
the camshaft as far forward
Install or
•
installed on
tool is neces-
crankshaft timing relearn procedure. 1
e.
14.
DRB scan
contact with the
Zero the dial indicator.
it
components are
sary to perform the camshaft and
Be sure the
(0.13-0.33mm).
Replace worn or defective
use the
is in
cator. Specification is
to their origi-
install a lash adjuster,
probe
will go.
d.
f.
all
the engine, a
camshaft
lash adjusters. 12.
touch on
Using a prybar, move the camshaft
dial indicator
rocker arms should be cleaned and checked. Lash adjusters removed from a
nal locations.
the
2000-02 MODELS
dial indicator to
it
the thermostat opens,
drive vehicle to check for proper operation. in
far
the vehicle exhibited a tappet-like
arm should be returned
4 Nm). Be sure
magnet
c.
as
all
warms and
coolant can be added to the radiator. Test
••After
noise, the valve lash adjusters built into the
rocker
the engine
Tighten the
for leaks.
the engine with the radiator cap off so as
of the camshaft.
nose
the
holes for clogging with
original locations. 1 1
Setup a
b.
arm components and spacers, then them on the rocker arm shaft in their
rocker
lbs. (3
to
To assemble, thoroughly lubricate
10.
30 inch
to
the dowels on the
hollow and
clean inside and out.
is
Check
9.
shaft
is
of the camshaft.
engine and check
Start the
17.
Run
sensor electrical connector
1
of this
manual
CHRYSLER CORPORATION
8-18
NEON
•
Heater supply and return tioses
•
•
Heater tube support bracket
•
•
Power Distribution Center (PDC) screws aside
and the
Camshaft Position (CMP) sensor
magnet
and camshaft target
Camshaft from the
•
rear of the cylin-
der head 7922EG19
To install: Lubricate the camshaft journals with
5.
clean engine
oil.
Camshaft and reposition the
•
30 inch
the screw to
CMP
•
Cylinder head cover
•
Negative battery cable
belt
Use a DRB scan
tool to perform the
cedure, as follows:
engine
Connect the scan
tool to the
•
Front camshaft seal,
(located under the instrument panel, near
crankshaft timing relearn procedure.
the steering column). b.
Remove
Turn the ignition switch ON, and
or disconnect the follow-
access the “miscellaneous” screen.
•
Timing
c.
• if
•
Cylinder head cover
•
Timing
•
Both camshaft sprockets
the scan tool screen.
Camshaft sprocket and torque
belt
85
to
7.
Nm)
(115
lbs.
option, then follow the instructions on
cover
belt rear
Timing
•
Rocker arms
belt
to 21
ft.
Cylinder head cover Ignition coil
lbs.
camshaft
Nm)
(28
-The
and spark plug cables
inch lbs. (12
in
sequence, one
the proper order
•
to
bearing caps are identified for
location.
caps
105
Nm)
Valve Lash
at a time.
Remove
If the bearing caps are diffiremove, use a plastic hammer
first.
cult to
Heater tube bracket bolt
to gently tap the rear part of the
Heater tubes
camshaft.
•
ECT sensor
•
Air cleaner
•
Throttle
in
these vehicles do not
Starter Motor
connector
electrical
•
attaching screws
and
The engines
require periodic valve lash adjustment.
•
Battery
ADJUSTMENT
the outside bearing
•
PDC
engine and check for proper
Camshaft bearing caps, loosen the bearing caps
in
•
•
Start the
operation and leaks.
and tensioner
•
•
Select the “re-learn cam/crank”
Negative battery cable
removed
and torque the fasteners
Intake
and exhaust camshafts
To
install:
3.
Before installation, clean the cylinder
REMOVAL & INSTALLATION
tray
housing
head and cover mating surfaces. Make cer-
body connections tain that the rails are
1998-99 Models
flat.
IAT sensor
•
4. Fill
the cooling system to the proper
Lubricate the bearing journals and 1
cam
followers with clean engine
.
2. 5.
Use a DRB scan
tool to
Install or
Remove
oil.
level.
connect the following:
perform the
If
the negative battery cable.
equipped with A/C, perform the
lowing procedure:
camshaft and crankshaft timing relearn procedure, as follows:
Connect the scan
a.
tool to the
DLC
Remove outside bearing caps
first
(located under the instrument panel, near the steering column).
Turn the ignition switch
b.
ON, and
access the “miscellaneous” screen. Select the “re-learn cam/crank"
c.
option, then follow the instructions on
the scan tool screen. 9.
Run
engine and check
Start the
for leaks.
the engine with the radiator cap oft so as
the engine
warms and
the thermostat opens,
coolant can be added to the radiator. Test
check
drive vehicle to
DOHC 1
DLC
sary to perform the camshaft and
sensor
and torque
8.
Timing
DOHC
2.
Nm)
lbs. (3
Camshaft sprockets
•
camshaft and crankshaft timing relearn pro-
•
7.
lbs.
ft.
ing:
•
ft.
fasteners to 18
fas-
Nm)
Identifying the camshaft bearing caps
Camshaft target magnet and torque
•
M8
•
a.
PDC
and heater tubes •
6.
connect the following:
Install or
6.
M6
(24 Nm).
removal •
Bearing caps. Torque the
teners to 105 inch lbs. (12
ease the camshaft
to
Camshafts
for proper operation.
Engine
Be sure
to
observe
all
precautions
in
the beginning of this section.
'After
all
components are
the engine, a
DRB scan
7922EG20
installed on
tool is neces-
Bearing cap removal
sequence— DOHC engine
fol-
CHRYSLER CORPORATION
8-19
NEON Support the engine/transaxle
a.
assembly with a b.
Remove
jack.
mount
the tront engine
Follow the proper tightening
bolt
sequence 9.
from the mount/crossmember bracket.
Lower and
c.
damage
rotate the
engine/transaxle assembly forward to
for the structural collar or
to the collar or oil
pan may
occur.
provide starter clearance. Install the structural collar
»»Do not remove the wiring 3.
Remove
at this time.
or disconnect the following:
•
Both starter-to-transaxle bolts
•
Starter electrical connectors
•
Starter by positioning
and lowering
(54 Nm), Exploded view
of the structural collar
— 1998-99 models
install:
connect the following:
•
Starter
•
Starter electrical connectors
•
Starter-to-transaxle bolts
2.
Drain the engine
3.
Properly support the engine and
Remove
4.
ft.
lbs.
(54
Fill
1 1
Start the
.
.
Front engine
•
Negative battery cable
equipped with A/C, perform the
fol-
mount bracket
•
Powertrain bending strut
•
Oil pan-to-transaxle structural col-
ft.
lbs.
•
(54
bolt
•
Remove
1. •
or disconnect the following
on high output
•
Starter electrical connectors
•
Starter-to-engine bolts
•
Starter
install:
2.
Install or
•
Starter lbs.
Apply silicone sealer
6.
Install or
7.
Remove
and torque bolts
to
40
•
Negative battery cable
•
Oil filter
•
Oil filter adapter
•
Structural collar
bending brace
•
Lateral
•
Transaxle lower dust cover
•
Oil
pan
to the oil
•
New
•
Oil
oil
pan gasket
pan and torque the retainers
Starter electrical connectors
Intake manifold
(12
lbs.
and adapter,
removed
•
Oil filter
Transaxle lower dust cover
•
Power
•
Front engine
train
to
Nm)
•
bending
if
strut
mount and bracket
Torque the front engine mount
8.
Nm)
•
line
ft.
on high output
retainers as follows:
Engine mount bracket bolt
a.
20
1
inch lbs. (3 Nm).
engines
Engine mount bracket bolts
b.
Negative battery cable
and Oil
oil.
or disconnect the following:
connect the following:
105 inch
•
•
the beginning of this section.
Drain the engine
pan
Oil
connect the following:
(54
in
equipped
if
pump-to-engine block parting
engines only
To
for leaks:
and add as nec-
To install:
Negative battery cable Intake manifold
oil.
engine and check
4.
surfaces.
•
lbs.
3.
Thoroughly, clean the gasket mating
5.
2000-02 Models .
ft.
with air conditioning
and
Nm)
and adapter,
Oil filter
engine mount-to
mount/crossmember bracket
40
Raise and safely support the vehicle.
Transaxle lower dust cover
•
engine/transaxle assembly.
1
bolts:
2.
lar
Raise and support the
torque to 40
lbs.
Before servicing the vehicle, refer to the
precautions
Install the front
ft.
2000-02 Models
or disconnect the follow-
ing:
lowing steps:
b.
80
essary.
oil.
transaxle assembly.
and
Nm)
a.
pan
the engine with clean
10.
1
If
lbs.
final torque.
then, recheck the fluid level
Install or
30 inch
lines
mounting
•
Collar-to-oil
c.
torque the bolts to 40
5.
bolts:
Collar-to-transaxle bolts:
b.
aside.
4.
pan
(108 Nm).
it
^lt equipped, move the A/C
To
Collar-to-oil
a.
(3 Nm).
vertically
it
and
torque the retainers as follows:
4:
c.
Pan
1:40 d.
REMOVAL & INSTALLATION
80
ft.
lbs.
2,
(108 Nm).
Engine mount bracket bolts 5 and ft.
lbs.
(54 Nm).
A
Engine mount bracket-to-insulator
assembly through-bolt: 40
ft.
lbs.
(54
e.
f.
the precautions in the beginning of this sec-
LATERAL bend *g brace
2
-
STRUCTURAL COLIAR OUST COVER
Insulator-to-lower radiator cross-
member nuts: 40 Mass damper ft.
Before servicing the vehicle, refer to
-
3 -
Nm).
1998-99 Models
1
lbs.
bolt:
(54 Nm).
40
ft.
lbs.
Exploded view tural collar
(54
models
Nm).
tion.
For Wheel Alignment specifications, see Section
1
of this
manual
of the
bending brace, struc-
and dust cover— 2000-02
CHRYSLER CORPORATION
8-20 5.
NEON
Thoroughly, clean the gasket 'mating
surfaces.
To install: 6.
7.
New
•
Oil
pan gasket
oil
pan and torque the screws
105 inch
lbs.
bending brace
•
Lateral
•
Structural collar
•
Oil filter
•
adapter and torque the
60
bolts to
ft.
the engine with clean
Fill
9.
Start the engine,
Oil
Nm)
(80
lbs.
Oil filter
8.
if
to
Nm)
(12
Transaxle lower dust cover
•
repair
line.
connect the following:
Install or
•
pump-
to the oil
Apply silicone sealer
to-engine block parting
check
oil
for leaks
and
necessary.
Pump
REMOVAL & INSTALLATION PUMP Boor
Oil 1
.
Before servicing the vehicle, refer to
the precautions in the beginning of this section. 2.
Drain the engine
3.
Remove •
oil.
or disconnect the following:
Negative battery cable
•
Crankshaft damper
•
Timing
belt
•
Timing
belt tensioner,
on 2000-02
models • •
Oil
Use calipers
pan
Exploded view
Oil
pickup tube
•
Oil
pump
•
Front crankshaft seal
•
to
measure the outer
rotor
thickness
C-4685-C2
Insert Tool
•
Oil
pump
cover
4.
pump assembly
Crankshaft sprocket, using Tool
6795 and
•
of the oil
Oil
Wash
cover screws and
lift
the
off
pump
rotors
parts in a solvent; then,
all
inspect carefully for
damage
or wear, as fol-
lows: a.
Inspect the mating surface of the
pump should be smooth. Replace pump cover, scratched or grooved.
oil
the
Use a feeler gauge and straightedge
if
b.
pump
check the
cover surface.
If
a 0.003
to
warpage
for
and the inner rotor thickness
in. e.
feeler
Slide the outer rotor into the
gauge can be inserted
between the cover and the straightedge,
Measure the thickness and diame-
the rotor
surement the outer rotor.
If
(79.95mm)
and the housing. is
0.015
in.
If
the
(0.39mm)
in.
(7.64mm)
replace the housing only is
if
fin-
face of the bolt holes.
(0.102mm)
the diameter
is
3.148
if
d.
housing, between the
a feeler
or
gauge
more can be
of
0.004
in.
inserted
between the rotors and the straightedge, replace the
the outer rotor
h.
pump
Inspect the
assembly. oil
pressure
relief
valve
plunger for scoring and free operation
within specification.
in
in. f.
or less, replace the outer
the inner rotor
(7.64mm)
If
or more,
pump
Install the inner rotor into the
housing,
If
its
the clearance between
bore. Small
with
rotor. If
pump
mea-
the outer rotor
thickness measures 0.301 or less, or
pump
housing, press to one side with your
gers and measure the clearance between
the cover should be replaced.
ter of
pump cover
Lay a straightedge across the
(0.076mm)
c.
oil
measures 0.301
the inner and outer rotors
is
0.008
in.
i.
marks may be removed
400 grit wet or dry sandpaper. The relief valve spring has a free
in.
(0.203mm) or less, replace the inner rotor. g.
or more, replace both rotors.
Place a straightedge across the
length of about 2.39
should
test
in.
(60.7mm) and
between 18-19
lbs.
(8.1-8.6
Q Oi o C
CHRYSLER CORPORATION NEON
the metal case of the crankshaft
Crankshaft Sprocket Installer Tool
6792
FEELER
GAUGE
I
seal.
•
Oil
pump
•
Oil
pan
•
Timing
•
pickup tube
Angle the tool through the dust
lip
against the metal case of the seal. belt tensioner,
on 2000-02
Pry out the seal.
models OUTER ROTOR
7922EG30
and
•
Timing
•
Crankshaft damper
DO NOT
•
Accessory drive belts
crankshaft seal surface. Contact of
•
Negative battery cable
belt
front cover
the engine with clean
8.
Fill
9.
Start the
the prytool contact the
the tool blade against the crankshaft oil.
engine and check
then, recheck the fluid level
Measure the outer
let
edge (chamfer)
is
permitted.
for leaks:
and add as nec-
To install:
rotor clearance in the
essary.
housing 3.
Rear Main Seal
the crankshaft edge (chamfer) has any burrs or scratches on the, clean it up with 400 grit sand paper to preIf
REMOVAL & INSTALLATION
damage during new seal.
vent seal 1
.
of the
Before servicing the vehicle, refer to
installation
the precautions in the beginning of this sec-
»No
tion. 2. 7922EG31
Apply a small amount the
of
gasket maker to
pump body cover mounting
surface
Remove
or disconnect the following:
•
Transaxle
•
Flexplate/flywheel
•
Rear main seal. Insert a seal
remover between the dust
when compressed
kg)
to
1
.60
the
pump
is
oil
pressure
for oil
Place Crankcase Seal Pilot Tool
6926-1 on the lip
tool with a
and
4
crankshaft: this
SEAL
pressure loss.
install:
5.
Assemble the pump, using new
parts
as required, as follows: a.
with the
Install the inner rotor
chamfer facing the cast iron
oil
pump
cover. b. oil
Apply Mopar gasket maker
to the
pump. c.
Install the oil ring into the oil
pump
body discharge passage. 6.
by
Prime the
oil
pump
filling the rotor cavity 7.
Install or
•
Oil
The
pump,
align the rotor flats with
may
Torque the
flats.
bolts to 21
ft.
front crankshaft seal
out of the
oil
connect the following:
the crankshaft
pump
before installation
with engine
pump
lbs.
(28 Nm).
MUST
to align or
CRANKSHAFT
be
SEAL DUST
damage
result.
•
New
front crankshaft seal,
Seal Driver Tool •
using
6780
When
prying the seal out. be sure to use the prytool at the proper angle
Crankshaft sprocket, using a
For Maintenance Interval recommendations, see Section
1
a pilot
Position the seal over the Pilot Tool:
for other rea-
To
is
magnetic base.
ENGINE BLOCK
REAR CRANKSHAFT
within specifications, inspect for
worn engine bearings or sons
low and the
is
necessary when
falls
it
if
outside of specifications. If
is
in.
(40.6mm). Replace the spring,
j.
lubrication
installing the seal.
of this
manual
LIP
CHRYSLER CORPORATION
8-22
NEON Gap
of
side
rail
lower^^.
No
1
ring
gap
ft m
F Front of engine
y
No. 2 ring gap and spacer expander gap
Gap rail
2.0L (VIN C and Y) engines Chrysler engine connecting rod and cap
— ensure
Place a proper size pilot tool with a mag-
installation
netic base on the crankshaft
and rod prior
be sure the words THIS SIDE
OUT
to
on the
matchmark
to
of
upper side
— piston
ring
end-gap spacing
the cap
disassembly
Identification
mark
“1
R"
can be read.
seal
^The
pilot tool
should stay on the
crankshaft during installation of the seal. Be sure the seal lip faces the
crankcase during installation. 7922AG56
WARNING
K
2.0L (VIN C)
The arrow If
the seal
flush, this
is
driven
in
or weight
positioning.
marking (L or H) must
the block past
may cause an
face the timing telt side of the engine
leak.
oil
Common
Drive the seal into the block, using
5.
Engine— piston
tion
Chrysler piston ring identifica-
mark locations
Crankshaft Seal Tool 6926-2 and Handle C-
4171,
until the tool
bottoms out against the
block. Install
6.
Lock
&
the flexplate/flywheel. Apply
Seal Adhesive to the bolt treads.
Torgue the bolts
in
70
a star pattern, to
ft.
(95 Nm).
lbs.
Install the transaxle.
7.
Piston and Ring
2.0L (VIN Y) Engine
— piston positioning.
The small arrows on the crown
of the pis-
tons must point toward the front of the
POSITIONING
engine
FUEL SYSTEM Fuel System Service Precautions Safety
is
an important factor
when
ser-
•
Always
relieve the fuel
system pres-
Ensure that
component
tainer.
(injector, fuel rail,
pressure reg-
ulator, etc.), fitting or fuel line
maintenance and repairs
Exercise extreme caution whenever relieving
may
a safe
manner
result in serious personal injury.
tenance and testing
Main-
of the vehicle’s tuel
sys-
tem components can be accomplished safely
and
effectively
by adhering to the
•
To avoid the possibility of
fuel
system pressure,
skin, face
and eyes
to avoid
fol-
trate the skin or
any part
of the
be
may pene-
body
that
it
and per-
•
to
• Do come
not allow fuel spray or fuel vapors into contact with a spark or
Always place a shop towel or cloth
sonal injury, always disconnect the negative
around the
battery cable unless the repair or test proce-
loosening to absorb any excess fuel due to
dure requires that battery voltage be
spillage.
applied.
quickly removed from engine surfaces.
fitting or
Ensure
that
connection prior to
all
fuel spillage is
open
flame. •
Always use a back-up wrench when
loosening and tightening
contacts. fire
extinguisher near the work area.
fire
exposing
to fuel spray. Please
Always keep a dry chemical (Class B)
•
connection.
advised that fuel under pressure
lowing rules and guidelines:
soaked cloths or towels
are deposited into a suitable waste con-
vicing the fuel system. Failure to conduct in
all fuel
sure prior to disconnecting any fuel system
fuel line
tion fittings. This will prevent
and torsion
stress •
pipe
to fuel line piping.
Always replace worn
Do
rings. is
connec-
unnecessary
fuel fitting
0-
not substitute fuel hose where fuel
installed.
Q OQ o L.O
CHRYSLER CORPORATION NEON Fuel System Pressure
Fuel
Fuel Filter A combination
RELIEVING
assembly
tor
is
The
fuel filter/pressure regula-
used, which
is
voir, level
REMOVAL & INSTALLATION
the fuel system. Service vehicles
NEVER smoke while
the precautions in the beginning of this sec-
come
to
a dry chemical fire
an open container due to
in
fire or
1998-99 Models
risk of 1
explosion.
Remove
or disconnect the follow-
Before servicing the vehicle, refer to
1.
•
Negative battery cable
•
Fuel
•
Protective cap from the fuel
filler
cap rail’s
into
an
fuel
pressure
will
bleed
off
Disconnect the quick-connect supply
line
nipple. 5.
Depress the locking spring tab
located on the side of the fuel filter/regulator,
tainer.
sure the upper and lower O-rings are kit
C-4799-B
then rotate 90 degrees and pull out Be
on the
6.
The vehicle
is
now
filter
safe for servic-
ing.
system,
finished working on the fuel
install the fuel filler
clean engine
cap
TEST
in
align the 2
oil.
filter
O-rings with
Insert the filter into the
the fuel
pump module,
•
hold-down tabs with the
tor
filter
clockwise
until the
to
bleed
the container
off
through the hose into
spring tab
pump mod-
Fuel
it
to
electrical lock
unlock
pump module
it
electrical
down on
con-
the
connector retainer and pulling the
in the locating slot
connector
Attach the fuel line to the filter/regula-
5.
Support the
off of the
module
fuel tank with a
transmis-
sion jack
Connect the negative battery cable
•
The Depress the spring pull the fuel filter
pump module
nector by pushing
Relieve the fuel system, allowing the
pressure
Fuel
by sliding
assembly. 9.
Fuel lines from the fuel
nect retainers
then
•
rotate the
or disconnect the following:
Negative battery cable
ule by depressing the quick-con-
While applying downward pressure,
catches 8.
Remove •
flange. 7.
FUEL
4
•
Lightly coat the
opening
When
still
assembly.
To install:
contains hose C-4799-1.
Drain the fuel tank.
The fuel reservoir of the fuel pump module does not empty out when the tank is drained. The fuel in the reservoir will spill out when the module is removed.
from the filter/regulator
through the hose into the gasoline con-
**Fuel pressure gauge
Properly relieve the fuel system pres-
** WARNING
Disconnect the negative battery cable.
4 fuel
other end of the hose to the fuel pressure
The
3.
sure. 3.
approved gasoline container. Connect the
test port.
Properly relieve the fuel system pres-
2.
C-4799-1)
2.
sure.
tion.
Place the open end of a fuel pressure
release hose (tool
5.
Before servicing the vehicle, refer to
tion.
the precautions in the beginning of this sec-
pressure port
4.
.
the precautions in the beginning of this sec-
ing:
3.
pump
REMOVAL & INSTALLATION
contact with a spark or
in
tion. 2.
the fuel
not allow fuel spray or fuel vapors
open flame. Keep
Before servicing the vehicle, refer to
If
pump module.
Do
extinguisher nearby. Never store fuel .
inlet strainer, fuel
requires service, replace the entire fuel
[i]
in
servicing the vehicle!
fuel reser-
sensor, inlet strainer and fuel
only serviceable items.
well ventilated areas and avoid igni-
pump
with the
is integral
pressure regulator and level sensor are the
Relieve the fuel system pressure before servicing any components of
1
pump
pressure regulator. The
CAUTION
tion sources.
fuel
module, which also contains the
located on
pump module.
the top of the fuel
Pump
tab, then rotate
fuel
module assembly contains
pump, pressure
and
assembly out
For Tune-up, Capacities and Firing orders, see Section
Fuel tank strap bolts; then, lower
strainer and level sensor
1
of this
manual
the
regulator, reservoir, inlet
CHRYSLER CORPORATION
8-24
NEON •
Negative battery cable
•
Vapor
line
•
from the Evaporative
EVAP
canister
con-
electrical
nector
Emissions (EVAP) canister tube •
pump module
Fuel
8.
•
Fuel line, to the fuel
•
EVAP
•
pump module
canister
Vapor
line to the
EVAP
canister
tube
7922EG37
To loosen the fuel
pump module
The fuel reservoir of the fuel pump module does not empty out when the tank is drained. The fuel in the reservoir will spill out when the module is removed. •
locknut,
pump mod-
nect retainers with your
repair
•
module
•
Fuel
Fuel
locknut using a
pump module
electrical
pump and
down on
con-
the 2.
Release the
3.
Remove
connector retainer and pulling the
and spanner wrench
connector
discard the O-ring
seal
Fuel
oft of
the
tube and
filler
from the
install:
module filler
fuel tank’s filler
Support the
vent tube
hose
fuel tank with a
transmis-
sion jack. •
Take care
avoid wiping
to
dirt or
debris into the fuel tank opening.
module •
the fuel
pump mounting
Fuel
locknut using a 4.
Fuel
and spanner wrench
pump and
7.
of the tank clean.
connect the following:
New
in
O-ring seal
To
^Be
the tank open-
h
pump
sure the alignment tab on the of the fuel in
wiping
•
Fuel injector(s) and discard the 0-
Fuel
pump module
locknut. Using
torque the locknut to 41
ft.
lbs.
Wipe
7.
•
with the fuel injectors
Install or
connect the following:
new O-rings
Fuel injector(s) using
lbs.
flange
connect the following: in
O-ring seal
Fuel
rail
with the fuel injectors and
torque the bolts to
of the tank clean.
New
Fuel injector retainers
5.
repair
170-230
inch
(20-25 Nm)
•
Fuel injector electrical connectors
•
Fuel line(s) to fuel
•
Negative battery cable
Start the vehicle, if
rail
check
for leaks
and
necessary.
the tank open-
ing •
Fuel tank strap bolts and torque
them
pump mounting
Install or
•
Nm). •
the fuel
and surrounding area
(55
rail
rail
install:
dirt or
the notch on the fuel
the ratchet and spanner wrench,
to
45
ft.
lbs. (61
Nm)
Negative battery cable
2000-02 Models Before servicing the vehicle, refer to
Fuel
pump
'•Be sure the alignment tab on the underside of the fuel pump module flange sits in the notch on the fuel tank. •
the precautions in the beginning of this sec-
Fuel
pump module
the ratchet
tion.
locknut. Using
and spanner wrench,
torque the locknut to 41 Properly relieve the fuel system pres-
ft.
lbs.
(55
Nm). 3 - FUEL INJECTOR
sure.
4.
to avoid
Such contaminants may clog or damage the new fuel pump.
pump module
6.
•
3.
Fuel injector retainers
•
WARNING
Take care
tank.
2.
Fuel
•
debris into the fuel tank opening.
flange sits
.
•
•
Fuel
underside
1
Fuel injector electrical connectors
^Lubricate the O-rings with clean engine oil.
install:
ing •
Fuel line(s) from fuel
•
discard the O-ring
flange
Install or
•
Negative battery cable
•
•
seal
and surrounding area
system pressure.
rings
To
pump module
ratchet •
Wipe
Fuel tank strap bolts; then, lower
fuel
or disconnect the following:
•
the tank slightly for access to the
Such contaminants may clog or damage the new fuel pump. 6.
Before servicing the vehicle, refer to
the precautions in the beginning of this sec-
nector by pushing
•
To
and
for leaks
tion.
pump module
ratchet
check
necessary.
REMOVAL & INSTALLATION 1.
Fuel
if
Fuel Injector
thumb and
forefinger
the tank slightly for access to the
•
Negative battery cable
Start the vehicle,
ule by depressing the quick-con-
5.
use a ratchet and spanner wrench
Fuel line from the fuel
•
Drain the fuel tank.
Remove
or disconnect the following:
•
Fuel tank
•
Fuel
filler
f
tube and
filler
to the fuel tank's filler
9306EG01
vent tube
hose
Exploded view
of the fuel rail
assembly
CHRYSLER CORPORATION NEON
8-25
DRIVE TRAIN 4. •
Transaxle Assembly
REMOVAL & INSTALLATION
Intake manifold support bracket
•
Upper
starter bolt
•
Upper
bell
Install
housing bolt
an engine bridge fixture and
support the engine securely.
Manual Transaxle 1998-99
MODELS
When
installing the halfshafts,
retaining clips
MUST
reuse the old clips.
If
be used.
new NEVER
old clips are
•
Front wheels
used, the inner CV-joints
•
Halfshafts
gage.
may
disen-
Before servicing the vehicle, refer to
1.
the precautions in the beginning of this section. 2.
Drain the transaxle
3.
Remove • •
fluid.
or disconnect the following:
Battery cables
Power Distribution Center (PDC), pull
it
move
up and out it
of
its
bracket and
aside
•
Battery heat shield
•
Battery and tray
equipped
•
Cruise control,
•
Vehicle Speed Sensor (VSS) wire
if
Pull the clutch cable
backward,
to discon-
nect the clutch cable from the bell hous•
Back-up lamp switch wiring from
ing— 1998-99 manual
transaxle
the transaxle
WARNING
Removing bolts
the lower starter mounting
— 1998-99 manual transaxle
Pry with equal amounts of force on both sides of the shifter cable isolator
bushing to avoid damaging the
cable isolator bushing. •
Both gearshift cable ends from the transaxle shift levers, using 2 pry tools
•
Clutch housing vent cap, exposing the clutch cable
end and clutch
release lever •
Clutch cable from the
•
Shift cable (linkage)
•
Accelerator cable shield,
bell
housing
mounting
Remove 1
the clutch cable from the lever
998—99 manual transaxle
bracket
Unfasten the 2 bolts, then remove the bracket (strut) from the engine and
if
equipped
Use 2 prytools
to
transaxle
— 1998-99 manual
transaxle
disconnect the gearshift
cable ends from the shift levers—1998-99
Exploded view
manual transaxle
bracket
of the
linkage mounting
— 1998-99 manual transaxle
Exploded view
of the left
mount through-bolt
For complete service labor times, order the Chilton Labor Guide
manual transaxle
— 1998-99 models
CHRYSLER CORPORATION
8-26 •
NEON
Power hop damper and bracket mounting
•
Lower
•
Transaxle-to-rear lateral bending
starter
bolt
Support the transaxle with a
5.
When
from the engine and transaxle
strut
installing the halfshafts,
MUST
retaining clips
reuse the old clips.
jack.
be used.
If
old clips are
•
Front motor
mount through-bolt
used, the inner cv joints
•
Front motor
mount
gage.
bolts from the
new NEVER
may
disen-
engine and transaxle •
•
Lower dust shield Rotate the crankshaft clockwise
6.
Halfshafts
Front wheels
•
in
12.
order to access the driveplate-to-modular fill
clutch bolts.
Fill
and support. tion
4 driveplate-to-modular
Install the
Upper
bell
•
Upper
starter bolt
•
Intake manifold support bracket
torque the bolts to 70
Push
modular clutch assembly
the
housing
into the transaxle bell
Remove
•
Frame
transaxle
rail-to-left
mount from
Left transaxle
transaxle, then
the
push the mount up
Transaxle
•
Modular clutch assembly from the
•
VSSwire
transaxle input shaft
•
Cruise control,
connect the following:
Install or
•
Modular clutch assembly
to the
transaxle input shaft •
Transaxle and torque the transaxle-
to-engine bolts to 70
Nm) and bolts to 1 1
ft.
lbs.
40
lbs.
ft.
(54
•
mount
Left transaxle
15. jack.
•
lbs.
Frame
(54
rail-to-left transaxle
(108
40
mount
Nm)
in
•
4 driveplate-to-modular clutch bolts
•
Lower dust shield and torque the bolts to
•
to the
108 inch
lbs.
mount
Front engine
(12
lbs.
•
80
lbs.
ft.
Battery
•
Battery heat shield
•
PDC
Nm) and
Battery cables
Be sure the
vehicle’s
back-up
• •
lbs. (61
Adjust the crossover cable
in
order
transaxle
Lower
1
a.
Remove
b.
Loosen the adjusting screw on the
the floor shift console.
Pin the transaxle crossover cable
the
3-4
neutral position using a 14
the
on the top
of the
con-
test the vehicle to
be sure the
operating properly.
Before servicing the vehicle, refer to
.
tion. 2.
Drain the transaxle
3.
Remove
fluid.
or disconnect the follow-
ing: •
Battery
•
Air cleaner/throttle
body assem-
•
Crankcase vent hose
•
Throttle Position Idle Air
Sensor (TPS)
Control (IAC) con-
nectors •
Throttle
bady
air
duct from the
intake manifold
45
ADJUSTMENT
SCREW
t
•
'/i
7922EG47
bolt
crossover cable at the shifter
ft.
Proportional Purge Solenoid
ft.
Power hop damper and bracket and
Nm)
is
and
torque the damper bolts to 40
(54
lip
(PSS)
Loosen the adjustment screw on the
lbs.
all
the precautions in the beginning of this sec-
at the shifter.
c.
Nm) mounting
into
2000-02 MODELS
CROSSOVER
starter
from the
drill bit
fol-
SHIFTER
40
to
the
Reinstall the center shift console.
Road
lights
CABLE
ft.
Remove
Seat the boot
mount through-bolt
and torque the through-bolt
center during screw
bly
Nm)
Front motor
off
sole.
•
to
mechanism
f.
Nm)
mount-to-engine bolt
(54
lbs. (8
Blouse the boot out around the console.
bolts to the
(108
70 inch
gears.
engine mount-to-transaxle
bolt to
front
to
tightening.
engine and transaxle and torque the front
loaded and
check by shifting the transaxle
equipped
Battery tray
crossover cable
ft.
14
nm). Be careful to avoid moving the 16. shift
ensure proper shifter adjustment as
Nm)
drill bit
at least
neutral position. Torque the
in its
lows:
to the
through-bolt and torque to 80 lbs.
to
case
shifter is spring
adjustment screw
and speedometer are functioning properly.
Nm)
transaxle and torque the bolt to ft.
if
•
•
the boss
transaxle case and perform a functional
•
14.
(95
the lateral bending strut
Support the transaxle with a
.
housing
transaxle
To install:
The
e.
•
10.
beil
Back-up lamp switch wiring
•
into the transaxle
d.
transaxle shift levers
to provide clearance
in
(12mm).
mounting
Both gearshift cable ends to the
•
the
in
if
Clutch housing vent cap
•
Align the hole
self-centering. Allow the shifter to rest
Clutch cable to the
•
in. drill bit.
goes
bracket
mount
the 3-4 neutral posi-
crossover lever with the hole
in.
Shift cable (linkage)
or disconnect the following:
in
— 1998-99 manual transaxle
on the transaxle case. Be sure the
equipped
for easier
through-bolt •
Lbs. (95
ft.
Accelerator cable shield,
•
transaxle removal.
•
and
nm)
the clutch.
9.
housing bolt
•
clutch bolts, to separate the driveplate from
8.
the engine bridge fixture
crossover lever
the driveplate and pressure plate before removing any bolts. 7.
Insert a 'A in. diameter drill bit to pin the
Remove
13.
^•For installation purposes, matchmark
the transaxle to the bottom of the
plug hole.
transaxle
— manual
Accelerator cable
equipped
•
Cruise control cable,
•
Battery tray from the bracket
•
Ground cable from the bracket
if
battery tray
CHRYSLER CORPORATION
8-27
NEON Back-up Bell
light
switch connector
•
Driveplate-to-clutch
Clutch cable from the fork and
under the engine’s
transaxle
engine.
Shift cable-to-bracket clips
through-bolt.
Shift selector
and crossover
cables from the levers and
Remove
bolts to
pan and support the
the transaxle’s upper
mount
Left engine-to-transaxle lateral
To
bending brace
housing dust cover
•
If
•
installing a
to
the jack and
Driveplate-to-clutch
and torque
new
or replacement
transaxle, transfer the upper
lateral
Remove
9.
install:
6.
upper mount aligns with the mount
80
ft.
lbs.
mount
bending brace
new
Starter
mount-to-transaxle bolts to 50
Starter lbs.
•
to the
transaxle; then, torque the upper ft.
wooden
block.
Transaxle
•
(95 Nm).
mount bracket through-bolt
transaxle
Structural collar
lbs.
ft.
(108 Nm).
an assistant to support the
Right engine-to-transaxle
until the
Transaxle-to-engine bolts, using
•
Halfshafts
70
Raise the engine/transaxle assembly
8.
bracket hole. Torque the upper mount-to-
to provide clearance.
aside
Bell
oil
Torque the transaxle-to-engine
bolts
wood
Lower the engine/transaxle assembly
5.
move
module
Place a jack and block of
4
housing cap
to
65
ft.
module lbs.
(88
and torque the bolts
(54
bolts
Nm) to
40
Starter electrical connectors
and
torque the positive cable bolt to 89
lbs.
inch lbs. (10
(68
Nm)
Nm). Install or
7.
connect the following
•
Transaxle
•
Transaxle-to-engine bolts, using an assistant to support the transaxle.
1
- AIR
CLEANER ASSY THROTTLE BODY DUCT
2 -
View
of the air
throttle
1
-
SHIFT CABLES
2 -
CUPS
3
BRACKET
-
View
cleaner assembly and
body duct— 2000-02 models
ol
A
the shift
1
-
LATERAL BEKO- *«G BRACE
?
-
STRUCTURAL COLLAR OUST COVER
cables— 2000-02 manual
3 -
transaxle
View
of the left lateral
structural
1
-
2 3 -
CLUTCH CABLE TRANSAXLE BELLHOUSING CAP
1
CONNECTOR 2-SFNSOR 1
3 4
-
-
2 -
O-RlNG
3
SPEEDO PINION
bending brace and
collar— 2000-02 models
TRANSAXLE ENGINE LATERAL BENDING BRACE
S908EQ30
View
of the clutch
View
cable and bell housing
cap— 2000-02 manual
of the
Vehicle Speed Sensor (VSS)
2000—02 manual transaxle
transaxle
Please
visit
our web
site at
ft.
Nm)
View
of the right lateral
2000-02 models
www.chiltonsonlme.com
bending brace
CHRYSLER CORPORATION
8-28
NEON Automatic Transaxle
1998-99
MODELS
Before servicing the vehicle, refer to
1.
the precautions
in
the beginning of this sec-
tion.
The transaxle and torque converter must be removed as an assembly; otherwise the
pump bushing may be damaged. The driveplate
torque converter driveplate, or
oil
will
seal
not support a load; therefore, none of
the weight of the transaxle should be
allowed to rest on the plate during removal. -
1
2 3 -
MOUNT BRACKET
Remove
2.
BOLT 1
MOUNT
-
2 -
or disconnect the following:
MOUNT TRANSAXLE
•
Battery cables
•
Power Distribution Center (PDC),
9306EG33
9306EG35
View
of the
upper mount through-bolt
2000—02 models
•
Left
View
engine-to-transaxle
60
ft.
•
lateral
lbs. (81
Nm)
Install the structural collar
10.
and
torque the bolts as follows:
pan
1
Step
a.
bolts:
b.
—
transaxle bolts:
40
bolts:
1 1
Install or
.
•
80
lbs.
ft.
3— Structural
Step
c.
lbs. (3
2— Structural
pan
ft.
lbs.
to
60
ft.
lbs. (81
VSS
•
Shift selector
electrical
Battery tray
housing cap
Back-up
•
Ground cable
light
•
Vehicle Speed Sensor (VSS) wiring
to the battery tray
•
transaxle
Cruise control cable,
collar-to-oil
•
Air cleaner
Throttle
if
body
air
ft.
WARNING
equipped
assembly and torque the
nuts and bolts to 10
lbs.
(14
Nm)
duct to the intake
manifold
Pry up on both sides of the shift cable isolator bushing, evenly, to
avoid damaging the cable isolator
bushing.
•
TPS and IAC connectors
•
Crankcase vent hose
to the throttle
•
body connector
and crossover cables
Shift cable-to-bracket clips
Neutral safety switch and torque
converter control wiring, from the
•
Nm)
if
bracket
(108 Nm).
•
equipped
Cruise control,
switch connector
Battery tray to the bracket
lateral
and
•
Accelerator cable
to the levers •
•
•
housing dust cover
Bell
•
Battery
transaxle
•
Halfshafts
•
Battery heat shield
•
connect the following:
of its bracket
aside
•
Nm).
Right engine-to-transaxle
up and out it
•
Bell
(54 Nm).
it
Clutch cable to the fork and
collar-to-
bending brace and torque the bolts
•
pull
move
•
Structural collar-to-oil
30 inch
Step
— 2000-02 man-
ual transaxle
bending brace and torque the bolts to
upper mount
of the
•
PSS
•
Battery
to the throttle
body
•
Fill
13.
Road
Gearshift cable bracket bolt from the transaxle
the transaxle to the proper level.
12.
Gearshift cable end from the
transaxle shift lever
test the vehicle
and inspect
•
Throttle pressure control cable from
•
Throttle pressure control cable
•
Transaxle’s dipstick tube
•
Transaxle’s
for
leaks.
the lever
bracket bolts from the transaxle
them •
oil
cooler lines plug
to prevent
contamination
Throttle pressure control cable support bracket bolts
1
~
MODULAR CLUTCH ASSEMBLY
2 - CLIP
3 4 -
TRANSAXLE CLUTCH MODULE BOLT
(4)
9306EG34
Disconnect the gearshift cable end from the transaxle shift lever
Exploded view
of the transaxle
and related components
— 2000-02 manual transaxle
matic transaxle
— 1998-99 auto-
:*
CHRYSLER CORPORATION
3.
housing bolts
•
Upper
bell
•
Upper
starter bolt
an engine bridge
Install
fixture
Front wheels
•
Halfshafts
new DO NOT
must be used.
reuse the old clips. Failure to use new clips could cause the inner CVjoints to
mount
•
VSS
Left
mount-to-transaxle bolts and
•
Cruise control,
•
Battery tray
torque to 40
mount through-bolt was removed
Battery Battery heat shield
from the transaxle, be sure to align the
.
PDC
pump
•
Battery cables
inner gear pilot flats with the torque
Nm) and
The exhaust flex joint must be disconnected from the exhaust manifold anytime the engine is lowered. If the engine is lowered with the flex pipe
ft.
108 inch
strut,
Front engine bracket through-bolt
•
Front engine bracket bolts
Lower
•
Lower dust shield screws
•
Front engine bracket through-bolt
will
•
Transaxle-to-rear lateral bending
the weight of the transaxle should be
^Matchmark
Exhaust pipe
•
Exhaust
new
the converter to the flex-
10.
Remove or disconnect the • Left mount through-bolt
Proportional Purge Solenoid (PSS)
new must be used. DO NOT
installing the halfshatts,
the engine bridge fixture
•
Upper
bell
•
Throttle pressure control cable sup-
•
Transaxle
to
transaxle
work the transaxle and the
C-clamp
housing. This
will
of the crankshaft.
to the
edge
lbs
•
•
cooler lines. Torque
(12
•
Nm) and
cooler line
fitting to
21 •
Transaxle
oil
cooler lines and plug
Shift cable
and bracket from Ihe
Kickdown cable and bracket from the transaxle
Transaxle
bracket bolts to the transaxle
Halfshafts
Throttle pressure control cable to
•
Structural collar
the lever
•
•
transaxle •
Gearshift cable
end
•
oil
pan
Left engine-to-transaxle lateral
bending brace
Gearshift cable bracket bolt to the
to the transaxle
housing duct cover
•
Bell
•
Starter
•
4
Adjust the gearshift and throttle
connect the following:
Neutral safely/back-up light switch
transaxle
(28 Nm).
Torque converter-to-driveplate bolts
Using a jack and a block
of
wood,
support the engine/transaxle assembly
cables.
Rear engine bolt to the transaxle
Torque converter clutch solenoid
the lines to prevent contamination
shift lever
Install or
•
Battery tray from the bracket
•
Support the transaxle with a
9.
•
if
assembly
•
Nm)
transaxle jack.
Air cleaner
Throttle pressure control cable
transaxle and torque the ft.
oil
equipped
Cruise control cable,
•
•
•
Install the
Transaxle kickdown cable
Transaxle's dipstick tube
removal
transaxle-to-cylinder block bolt: 70
lbs.
duct from the
•
•
of the
hold the torque con-
install:
8.
ft.
air
connector
the oil cooler line-to-radiator fitting lbs.
body
connector
Rear engine bolt from the transaxle
108 inch
Throttle
Accelerator cable
port bracket bolts oil
Control (IAC) connectors
•
housing bolts
Transaxle's
Sensor (TPS) and
Idle Air
•
•
•
end
Throttle Position
intake manifold
Front wheels
starter bolt
•
off
Crankcase vent hose
•
cause the inner CV-
Upper
body assembly
•
•
mount
verter in place during transaxle
(95
•
mount-to-transaxle bolts
Attach a small
To
Battery Air cleaner/throttle
•
15.
fluid.
or disconnect the following:
•
Left
the
Remove •
Left
hub from
Drain the transaxle
3.
Halfshafts
•
Carefully
2.
fold bolts
Remove
14
following:
engine block dowels. Disengage the con-
bell
mani-
•
7.
not support a load; therefore, none of
and support.
Support the transaxle with a
torque converter assembly rearward
verter
manifold
flex joint-to-exhaust
clips could
•
transaxle jack. 6.
to the
seal
allowed to rest on the plate during removal.
engine and transaxle
•
oil
joints to disengage.
bolts
plate for alignment during installation. 5.
torque converter driveplate,
starter bolt
reuse the old clips. Failure to use
Rotate the engine clockwise and
4.
remove the converter
pump bushing may be damaged. The driveplate
or
When
starter bolt
The transaxle and torque converter must be removed as an assembly; otherwise the
Front engine bracket bolts
retaining clips
•
Nm)
* WARNING
from the engine and transaxle
•
tion.
Lower
•
Transaxle-to-rear lateral bending
(12
lights
Before servicing the vehicle, refer to
.
•
Exhaust pipe from the manifold
•
1
housing cover bolts
lbs.
back-up
the precautions in the beginning of this sec-
Lower dust shield screws and bell
vehicle’s
•
fold bolts •
Be sure the
2000-2002 MODELS
connect the following:
strut to the
mani-
Fill
17.
to the converter bolts. Install or
the transaxle to the proper level.
16.
and speedometer are working properly.
(68 Nm).
lbs.
will occur.
flex joint-to-exhaust
flex-
(95
lbs.
ft.
Rotate the engine clockwise to get
12.
to
Exhaust
70
the flexplate-to-torque converter
50
bolts:
Torque the
flats.
plate-to-crankshaft bolts to
torque the
•
equipped
•
•
damage
if
•
Left If
13.
attached,
Nm)
wiring
the torque converter
•
access
disengage.
(54
lbs.
ft.
converter impeller hub
installing the halfshafts,
retaining clips
Left
•
11.
WARNING
When
•
and
support the engine. •
8-29
NEON
Neutral safety switch
and torque con-
verter control wiring to the transaxle
Timing belt service
is
covered
in
Section
3
of this
5.
Remove
through-bolt.
manual
the transaxle upper
mount
CHRYSLER CORPORATION
8-30
1
NEON
- SHIFT LEVER
2 - SHIFT
CABLE 9306EG36
View
of the
gear
shift
cable— 2000-02
automatic transaxle
- CLIP BOLT
1
2 -
3
_ TRANSAXLE
4 -
(3)
Exploded view
of the
transaxle and related
CONVERTER BOLT
(4)
components—2000-02 automatic
1 1
Remove
.
12.
and wooden block.
the jack
Install or
transaxle
connect the following:
Torque converter-to-driveplate bolts
•
and torque the bolts (88 •
Starter lbs.
- LEVER
1
2 3 -
BRACKET KICKDOWN CABLE
to
65
and torque the bolts
to
40
ft.
Nm)
(54
Starter electrical connectors
•
lbs.
ft.
Nm)
and
torque the positive cable bolt to 90 9306EG37
Nm)
inch lbs. (10
View
of the
kickdown cable— 2000-02
•
automatic transaxle
•
Bell
housing dust cover
Left
eng ne-to-transaxle bending i
brace and torque the bolts to 60 lbs. (81
13.
ft.
Nm)
the structural collar and
Install
torque the bolts as follows: 9306EG40
View
of the
upper
mount— 2000-02
auto-
matic transaxle
1— Structural
Step
a.
pan
bolts:
b.
30 inch
2— Structural
Step
10.
transaxle bolts: 80 •
-
1
2 4 -
bolts:
14.
Install or
•
Torque converter from the front
•
Halfshafts
pump
•
Speed control
To install:
•
Right engine-to-transaxle
If
installing a
new
new
mount
to
to the
transaxle; then, torque the upper
mount-
Vehicle Speed Sensor (VSS)
2000—02 automatic transaxle
9.
•
upper mount through-bolt may be accessed through the left side wheel house. 6.
for clearance. 7.
Remove
or disconnect the following:
ft.
lbs.
ft.
lbs.
to
•
mount bracket through-bolt
•
(108 Nm).
lbs.
it
equipped lateral
lbs. (81
21
ft.
oil
lbs.
Nm)
cooler lines and
oil
cooler line-to-radia-
108 inch oil
(28
lbs.
(12
cooler line
Nm)
fitting
Nm)
Torque converter clutch solenoid light
switch connectors
upper mount aligns with the mount
ft.
cable,
and neutral safely/back-up
bracket hole. Torque the upper mount-to-
80
ft.
and trans^xle
Raise the engine/transaxle assembly
to
lbs.
tor fitting to
•
(95 Nm).
60
Transaxle
torque the
(68 Nm).
and tighten the
support the transaxle. Torque the transaxle-
to-engine bolts to 70
until the
Lower the engine/transaxle assembly
50
transaxle
transaxle-to-engine bolts, using an assistant to
•The
Install
ft.
connect the following:
bending brace and torque the bolts
or replacement
transaxle, transfer the upper
to-transaxle bolts to of the
(54 Nm).
pan
Transaxle
9306EG38
View
collar-to-oil
assistant to support the transaxle
8.
SENSOR
40
(108 Nm).
lbs.
ft.
3— Structural
Step
Nm). collar-to-
•
CONNECTOR SPEEDO PINION
3 - O-RING
c.
Transaxle-to-engine bolts, using an
collar-to-oil
lbs. (3
Transaxle dipstick tube Gearshift cable bracket bolt to the transaxle
CHRYSLER CORPORATION
8-31
NEON •
plant have modular clutch assemblies.
lever
Battery tray
•
Battery
If
the 11th digit of the VIN code
is
“D”,
cracks, deep grooves or ridges. Replace
the VIN
parts as required.
“T”, the vehicle was produced Toluca assembly plant.
•
Transaxle kickdown cable
•
Cruise control cable,
•
Air cleaner
1998-99 Models
(14
lbs.
ft.
Nm)
TOLUCA BUILT VEHICLES 1
Crankcase vent hose
tion.
to the throttle
body
the transaxle and check for leaks.
15.
Fill
16.
Be sure the vehicle’s back-up
lights
and speedometer are working properly.
Remove
3.
Matchmark
if
0.008
the position of the clutch
hub
mechanism
is
maintains tension on the cable. This tension
and not discolored from exces-
sive heat.
Each
at a time, in a
Wipe the
f.
damage
keeps the clutch release bearing continu-
ment
When and
ing pull it
No manual
if
from the dash panel.
Damage
to
remov-
2.
(11kg) of 1.
mine
If
if
Using a surface All
plate, test the
sections around the
with the surface plate within 0.015
The cover should be a snug
i.
the flywheel dowels.
Inspect for
oil
leakage through the
engine rear main bearing transaxle input shaft seal.
should be fixed
oil seal If
bly
and
there
at this
is
in.
(0.381mm).
If
on
fit
the clutch assem-
does not meet these requirements,
it
should be replaced
leak-
To install:
time
pull the clutch
••The heavy side
draw the
ol the
flywheel
is
indicated by a white paint mark, near the outside diameter.
effort the
2-2.0
in.
the cable
the
h.
cover for flatness.
to
faces.
it
free
the clutch cable housing toward
25
To minimize the effects
lbs.
mechanism
tion procedure:
indi-
a
function
is
Loosely assembly the flywheel
the crankshaft.
does not adjust, deter-
mechanism
of flywheel
unbalance, perform the following installa-
cable housing should
(30-50mm). This
cates proper adjuster 3.
(0.0-0.1mm) below the should also be
attaching bolt holes should be in contact
taut.
Push
It
necessary.
cable
age,
the dash panel. With less than
move
if
••Handle the components carefully
b
release lever end of the cable to
in.
9. outer diameter.
from discoloration, burned areas, cracks,
occur.
With slight pressure,
0 000-0.0039
grooves or ridges
the flywheel,
avoid contaminating the friction sur-
To check the function of the adjuster
cable
assembly
remove
mechanism, use the following procedure: 1.
the clutch pressure plate.
do not
to the
flat-to-
slightly concave, with the inner diameter
Inspect the clutch assembly as fol-
adjust-
installing the clutch cable,
on the clutch cable housing
may
Remove
should be
plate friction area
lows:
servicing this vehicle or
self-adjuster
pressure plate for flatness. The pressure
clutch chatter.
the clutch cover
spirits.
Using a straightedge, check the
dirt
and disc from the flywheel
a.
obtainable.
is
the clutch disc facing
may cause
Remove Remove
8.
ously loaded against the fingers of the clutch cover assembly.
g.
tight.
friction surface of the
pressure plate with mineral
transferred from your hands onto the clutch disc
arched springs
of the
between the facings should be
crisscross
with oily or dirty hands. Oil or
7.
fit
dry. clean
1-2 turns
6.
snug
portions of the disc assembly should be
to prevent the clutch disc
located with the
clutch cable assembly. The preload spring
of the rivet heads.
Loosen the clutch cover attaching
••DO NOT touch
adjuster
(0.20mm)
and damaging the facings
falling
gradually, avoiding cover
This
oil
without signs of excessive wear. Metallic
a clutch alignment tool through
Install
1998-99 Models
for clutch disc wear.
in.
transaxle input shaft should be a
4
pattern. This releases the spring pressure
compensate
or
during installation.
bolts,
tem has a unique self-adjusting mechanism
show grease
The splines on the disc hub and
5.
The manual transaxle clutch release sys-
the facings
soakage, or wear to within less than
the transaxle assembly.
cover and flywheel for proper alignment
from
ADJUSTMENT
The clutch disc should be handled
e.
without touching the facings. Replace the disc
2.
the clutch disc
Clutch
is
warped, replace the flywheel.
Before servicing the vehicle, refer to
.
the precautions in the beginning of this sec-
to the throttle
the surface
If
severely scored, heat checked, cracked or
TPS and IAC connectors body
then wipe the surface
with mineral spirits.
equipped
if
assembly and torque the
nuts and bolts to 10
to
Clean the flywheel face with
d.
medium sandpaper,
Accelerator cable
PSS
friction faces of the flywheel
excessive discoloration, burned areas,
at the if
The
c.
and pressure plate should not have
is
at the
•
•
was produced
Belvidere assembly plant;
code
•
at the
the vehicle
and bracket
•
•
Belvidere assembly
cles
shift lever
Transaxle kickdown cable to the
•
made
Gearshift cable end to the transaxle
If
available, use
new
to
fly-
wheel attaching bolts which have sealant
properly seated
on the threads.
on the bracket.
If
new
able, apply Loctite
REMOVAL & INSTALLATION
bolts are not avail-
sealant to the threads
of the original bolts. This sealant is
required to prevent engine
'Vehicles made at the Toluca, Mexico assembly plant have conventional clutch and flywheel assembles. Vehi-
Exploded view
components
of the
conventional clutch
— 1998-99 vehicles
b.
built in
until the
Toluca
Heater Core replacement
covered
in
Section
2
of this
leakage.
white paint (heavy side)
12 o'clock position.
is
oil
Rotate the flywheel and crankshaft
manual
is at
the
CHRYSLER CORPORATION
8-32 c.
NEON transaxle input shaft seal.
Tighten the flywheel attaching
bolts, in a crisscross pattern, to lbs.
(95 Nm).
10.
Mount
70
ft.
being careful to properly align the
tool,
should be fixed
it
To assembly on the
the clutch
flywheel with the disc centered on the align-
ment
noted,
If
any leakage
lbs.
•
install:
^Always use new
bolts
marked
for
the
new
REMOVAL & INSTALLATION •
Modular clutch assembly onto the Before servicing the vehicle, refer to
input shaft
is installed,
•
align the orange cover balance spot as close
Apply pressure
Center the
tip of
to the
alignment
tool.
the tool into the crankshaft
and the sliding cone
into the clutch fingers.
Tighten the clutch attaching bolts sufficiently
the precautions
Transaxle
Use a crisscross
pattern, until
all
bolts
•
to hold. the disc in position.
ft.
lbs.
•
Transaxle lower support brackets
•
Starter
•
Negative battery cable
until all bolts
Use a crisscross pattern
ft.
lbs.
•The
Remove
13.
Install the transaxle.
2000-02 Models
the clutch alignment tool. 1
precautions
in
• • • •
Modular clutch-to-driveplate
Rear and front transaxle brackets
Modular clutch-driveplate bolts and
•
Modular clutch assembly from the
Install or
•
Transaxle •
come
Modular clutch assembly from the •
•
Front caliper-to-steering knuckle
•
Caliper from the steering knuckle
Support the caliper out
6.
connect the following:
strut.
Modular clutch assembly onto the
it
DO NOT
allow the caliper to hang by
•
Rotor from the hub
•
Outer
tie
rod end-to-steering
knuckle nut by holding the
ft.
end stud with a ”/&
Nm)
New modular
way by
the brake hose.
Transaxle assembly and torque the
(95
of the
with a piece of wire from the
transaxle input shaft
lbs.
•
Front wheel
suspending
transaxle-to-engine bolts to 70
out as an assembly.
or disconnect the following:
•
bolts
install:
3.
Remove
5.
Transaxle assembly
vehicles equipped with
the front wheel speed sensor.
bolts
•
To
On 2000-02
4.
Anti-lock Brake System (ABS), disconnect
transaxle input shaft
'•The transaxle and modular clutch will
•
motor assembly
discard the bolts •
or disconnect the following:
Negative battery cable
nut.
and discard the bolts
or disconnect the following:
Negative battery cable Starter
the beginning of this section.
•
the beginning of this section.
Remove
2.
in
Remove
2.
Before servicing the vehicle, refer to the
.
hub
Before servicing the vehicle, refer to the
.
precautions
BELVIDERE BUILT VEHICLES 1
hub and driveshaft are
front
splined together and retained by the
(28 Nm).
12.
brakes applied, loosen, but do not remove the stub axle-to-hub and bearing retaining nut.
assembly
are seated. Tighten the bolts to a final
torque of 21
locknut and spring
With the vehicle on the ground and
3.
To avoid distorting the clutch cover,
time.
remove the
vehicles,
it),
stub axle.
(75 Nm).
Clutch inspection cover
tighten the bolts gradually, a few turns at a
11.
cotter pin (discard
washer, from the end of the outer CV-joint
are seated. Tighten the bolts to a final
torque of 55
On 1998-99
2.
tighten the bolts gradually a few turns at a time.
the beginning of this sec-
in
tion.
To avoid distorting the driveplate,
5.
as possible to the orange flywheel balance spot.
Negative battery cable
connect the following:
Install or
4.
proper installation.
clutch or flywheel
ft.
Halfshafts
1. If
65
veplate.
before removal. The flywheel side of the is
to
Nm)
(88
when mounting
the modular clutch assembly to the dri-
dowels and the alignment marks made
clutch disc
and torque the bolts
bolts
is
at this time.
clutch-to-driveplate
in.
tie
rod
socket
while loosening the nut
transaxle input shaft.
^Handle
the
components
carefully to
avoid contaminating the friction surface. 3.
Inspect for
oil
leakage through the
engine rear main bearing
ENGINE
UPPER
oil
seal
and
CRANKSHAFT
1
-
2 7922EG51
MODULAR CLUTCH ASSEMBLY CUP
3
- TRANSAXLE
4 -
CLUTCH MODULE BOLT
(4)
The transaxle and modular clutch are
removed as an assembly— 1998-99 vehi-
Exploded view
cles
cles
of the
manual transaxle, clutch module and related components— 2000-02 vehi-
CHRYSLER CORPORATION
8-33
NEON dinner
tripod joint removal
easier
is
which
Remove
the inner tripod joints from
punch
gear.
punch sharply with a hammer
the ball joint stud. 18.
to
dislodge
and washer
—
position the
halfshaft service
left
punch
in
Tie rod
end stud from the steering
hammer
joint
knuckle •
a
Ball joint stud-to-steering
knuckle
7.
to
punch sharply with
from the side
left
Remove
inner tripod
gear.
Be careful when separating the ball joint stud from the steering knuckle,
it
joint
inter-
ing
damaged.
into the steer-
rod end-to-steering tie
rod end.
of the tie rod
end
socket, tighten the
in
Nm).
lbs. (61
ft.
the rotor back onto the
Install
hub
and bearing assembly. 21
Position the caliper on the steering
.
oil seal.
knuckle. Slide the top of the caliper under
the tripod joint, do not
the transaxle-to-tripod joint
lip of
rod end nut to 45
tie
20.
let
the spline or snapring drag across the seal-
so the ball joint seal does not get
'Vx
crow's foot and
and
straight out of the
transaxle side gear and transaxle
When removing
end
tie
knuckle nut onto the stud of the
the inner tripod joint from the
transaxle by pulling
(95 Nm).
lbs.
ft.
While holding the stud
connecting shaft of the driveshaft assembly
nut and bolt
70
stationary, tighten the nut. Then, using a
Hold the inner tripod
1 1
to
Insert the tie rod
ing knuckle. Start the
the groove of the
dislodge the
steering knuckle-to-
stud bolt and nut. Tighten the nut
If
side inner tripod joint,
inner tripod joint. Hit the •
and bolt
NEW
a
Install
ball joint
19.
removing the
of the cotter pin, locknut
Slide the driveshaft back into the
17.
front hub. Install the steering knuckle into
joint. Hit the
the right inner joint from the side gear.
has no
before installing
it
into the steering knuckle.
right side inner tripod joint, position the
punch against the inner tripod
that the outer CV-joint,
into the steering knuckle,
to
removing the
If
fits
debris or moisture on
dislodge the inner tripod joint retaining ring
from the transaxle side
Exploded view
Be sure
16.
hammer.
the transaxle side gears using a
debris and moisture out of
all
the steering knuckle.
punch with a
joint 10. while hitting the
Clean
15.
by applying outward pressure on the
the top abutment on the steering knuckle,
then
bottom
install the
of the caliper against
oil
the bottom abutment of the steering
seal.
knuckle •
from the steering
Ball joint stud
knuckle by prying
down on
** WARNING
1998-00
vehicles, perform the
following steps:
Remove
a.
the
hub and bearing-to-
Install a puller
The driveshaft, when installed, acts as a bolt which secures the front hub and bearing assembly. If the vehicle is to
be supported or
wheels with
stub axle retaining nut b.
on the hub and
moved on
its
install a
and nut to 135 ft. lbs. (183 Nm). This will ensure that the hub bearing cannot loosen.
Install
c.
on the stud.
flat-bladed prytool to keep the turning.
Using the
Install a
hub from
puller, force the outer
To
24
Clean
seal sealing surface
on the tripod
all
lbs. (31
Nm).
vehicles equipped with
front
wheel speed sensor.
foreign matter from the
oil
and tighten the
the threads nut.
With the vehicle's brakes applied to
prevent the axle shaft from turning, tighten
hub nut to 150 ft. lbs (203 Nm) for 1998-99 models or 180 ft. lbs (244 Nm) lor 2000-02 models the
On 1998-99
26.
Thoroughly clean the spline and
ft.
hub nut and washer onto
install:
12.
stub axle from the hub and bearing.
ABS, connect the
25
bolt
a wheel lug nut on wheel stud
caliper-to-knuckle bolts
On 2000-02
23.
Install
through the front hub. Tighten the
to protect the threads
23
of the stub axle
hold
in place.
to
threads of the outer CV-joint stub axle.
removed, proper-sized bolt and nut a driveshaft
bearing assembly, using the lug nuts to it
Install the
and tighten
lower control arm
For
22.
the
vehicles, install the
new
spring washer, locknut and
cotter pin
joint.
into the outer CV-joint stub axle
Lightly lubricate the
Be careful when separating the inner CV-joint during this operation. let
Do
mission
must be sup-
13.
away from
knuckle assembly
the outer CV-joint of the
driveshaft assembly. Support the outer of the driveshaft 9.
pod
Insert a prybar
joint
end
fluid.
100 and interconnecting
between the inner
tri-
and the transaxle case. Pry against
the inner tripod joint until the joint retaining
snapring side gear.
is
disengaged from the transaxle
Install the front
or
ft.
far
Nm) for 1998-99 models Nm) for 2000-02 models.
(128
fluid level,
low-
ering the vehicle as necessary.
as possible by hand.
Carefully align the tripod joint with
CV-Joints
the transaxle side gears. Then, grasp the driveshaft interconnecting shaft
until fully seated.
and push
Be sure the snapring
by hand.
If
the snapring
is fully
OVERHAUL
is
engaged with the side gear by trying remove the tripod joint from the transaxle
fully
to
seated with
Tri-Pot (Inner) Joint 1
the side gear, the tripod joint will not be
is
covered
.
Remove •
or disassemble the following:
Halfshaft
and place
jawed vise
removable by hand.
Brake service
(135
lbs.
tire
nuts and tighten to
Check the transaxle
28.
14.
wheel and
Install the lug
lbs.
ft.
95
shaft,
transaxle side
the tripod joint into the transaxle side gear
assembly.
27
assembly
Holding the driveshaft assembly by
the tripod joint
gear as Pull the steering
out and
seal sealing surface
install the tripod joint into the
ported. 8.
oil
joint with fresh, clean trans-
not
the driveshaft hang by the inner
CV-joint, the driveshaft
on the tripod
in Section
4 of this manual
it
in a soft-
8-34
CHRYSLER CORPORATION NEON
3 4 -
GROOVE INTERCONNECTING SHAFT 9306EG04
Positioning the boot on the
shaft— Tri-pot
and Rzeppa joints 1
- STUB AXLE
4 -
OUTER C/V JOINT OUTER C/V JOINT BOOT TUNED RUBBER DAMPER WEIGHT
5 -
INTERCONNECTING SHAFT
6 -
OUTER
7 -
STUB AXLE
2 3 -
C/V JOINT
8 - OUTER C/V JOINT 9 - RIGHT DRIVESHAFT 10 - INNER TRIPOD JOINT
BOOT
TRIPOD JOINT INNER TRIPOD JOINT 13 - INNER TRIPOD JOINT BOOT 11
- INNER
12 -
BOOT
14 -
INTERCONNECTING SHAFT LEFT DRIVESHAFT 9306EG02
View
of the halfshaft
assemblies—Typical
3 4 -
SEALING BOOT CLAMP INNER TRIPOD JOINT 9306EG05
Adjusting the Tri-pot boot length
—
Hytrel
plastic boot
•
Tri-pot joint boot
boot '
down
clamps and the
the shaft
WARNING
When removing
the spider joint, hold
the rollers in place on the trunions to
keep the rollers and needle bearings in
place. •
Spider/shaft assembly from the
tri-
pot housing •
Snapring from the shaft
•
Spider assembly
**lf necessary, tap the spider
from the shaft with a brass
When removing do not 1
-
HOUSING ASM. RETAINER & SPACER SPIDER. TRIPOTD JOINT
2 - RING. 3 -
11
- CLAMP, SEAL RETAINING
•
'
4 - RING. RETAINING 5 - RETAINER. BALL &
12 - SHAFT.
AXLE (RH SHOWN. LH SIMILAR)
ROLLER
15 - RING.
RACE RETAINING
16 - BALL,
CHROME ALLOY
8 - CLAMP, SEAL RETAINING
18 -
17 - RACE. C/V JOINT INNER
CAGE. C/V JOINT 19 - RACE, C/V JOINT
9 - BUSHING, TRILOBAL TRIPOD 10 - SEAL. DRIVE AXLE INBOARD
If
Boot by sliding
it
oft
the shaft
any parts show excessive wear,
replace the halfshaft assembly; the
OUTER
component 9306EG03
of the halfshaft
the spider assembly,
the outer bearings.
13 - SEAL. DRIVE AXLE OUTBOARD 14 - CLAMP, SEAL RETAINING
6 - BALL. TRIPOD JOINT 7 - ROLLER, NEEDLE
Exploded view
hit
assembly
drift.
assembly
—
Typical
able.
parts are not service-
CHRYSLER CORPORATION
8-35
NEON
h-
©
Position the boot onto the tri-pot
b.
housing retaining groove and retaining
install
the
clamp evenly on the boot.
Using the Crimper Tool C-4975-A,
c.
place the tool over the clamp bridge, tighten the tool nut until the jaws are
completely closed (face-to-face). 8.
installing a
If
low profile latching type
Clamp
boot clamp, position Snap-On - 115 MILLIMETERS
1
2 - SILICONE SEALING
Locking Tool YA3050 prongs
INNER TP POO JOINT HOUSING 2 - TOP BANK OF ClAMP MUST BE RETAJNEE BY TABS AS SHOWN HERE TO CORRECTLY LATCH BOOT ClAMP 3 - SEALING BOOT 1
BOOT
3 - CLAMP 4 - INNER TRIPOD JOINT
-
I
9306EGG6
Secured the low
rubber boot
cone rubber Tri-pot boot
profile boot
clamp band
clamp— Sili-
the lower
is
latched behind the 2 tabs
Rzeppa (Outer) Joint new small boot clamp and
Install a
2.
slide
it
on the
1
shaft.
bead on the inside the boot seal
is in
Remove
.
•
the
4
new
installing a
If
grease
in
boot, distribute
•
Vfe
V2
•
inside
Install or
joint
Rzeppa hitting
the boot.
•
Rzeppa
the boot
the service package inside
the tri-pot housing and the other
1 - SEALING BOOT 2 - SPECIAL TOOL C-4975
and place
Halfshaft
in
it
a soft-
jawed vise
shaft groove.
of the
or disassemble the follow-
ing:
Position the boot so that the raised
3.
joint it
to drive
connect the following
boot clamps and slide
down
the shaft
housing, by sharply
with a soft-faced
hammer
off the shaft
it
Spider assembly, face the cham-
•
Circlip from the shaft
fered side toward the shaft
•
Boot by sliding
it
off
the shaft
CLAMP BRIDGE
** WARNING
93060G13
Tightening the high profile boot Tri-pot joint (Hytrel plastic) boot
Rzeppa
joint
clamp— If
and
necessary, tap the spider assembly
onto the shaft using a brass
boots
be
drift;
careful not to hit the outer bearings. Snapring making sure
•
seated
in the
it
is fully
groove
Spider/shaft assembly into the
•
tri-
pot housing
New
•
inner boot
clamp and posi1
tion
it
evenly on the sealing
-
NTE*CC*#4ECT**J SHAT*
2 -
CROSS
9 -
OJTO OV JO»»T
ASSEUOiY
boot 6.
Using a trim
107mm
length to 1
-
stick, adjust the
(hytrel plastic) or
boot Aligning the cross splines with the shaft
115mm
splines— Rzeppa
CLAMP
2 - SPECIAL 3 - SEALING
joint
(silicone rubber). TOOL YA3050 BOOT
7. 9306EG07
Tightening the low profile boot
clamp—
installing a high profile boot
If
clamp, perform the following procedure:
Silicone rubber Tri-pot boot
Using the Crimper Tool C-4975-
a.
A, place the tool over the
clamp
To assemble:
bridge, tighten the tool nut until the
** WARNING
face).
jaws are completely closed (face-to-
The Tri-pot sealing boots are made
of
** WARNING
2 different types of material; silicon
rubber (high temperature) which
is
and pliable or hytrel plastic (standard temperature) which is stiff and rigid. Be sure to replace the boot
soft
made
on
clamp band.
Install the halfshaft.
9.
5.
3 -
clamp
holes and squeeze the tool until the upper
3306EG06
Adjusting the Tri-pot boot length— Silicone
in the
The seal must not be dimpled, stretched or out of shape.
If
sary, equalize the seal pressure
shape
it
1
-
SOFT FACED HAMMER
2 - STUB AXJJE 9 - OUTER OV JOINT 4 - NUT
neces-
and
by hand. Driving the Rzeppa joint onto the shaft
of the correct material.
For complete Engine Mechanics I specifications, see Section
1
of this
manual
CHRYSLER CORPORATION
8-36
NEON •
Rzeppa
joint, align the shaft
and tap
2.
•
ing
Vfe of
Newsmall boot clamp and
and the other Install the
5.
slide
it
position
onto the shaft
Vfe
the grease
Rzeppa
the ser-
in
hous-
joint
and
by hand.
Position the boot onto the Rzeppa
housing retaining groove and
install the
clamp evenly on the boot.
retaining 8.
inside the boot.
new small boot clamp and
Using the Crimper Tool C-4975-A,
place the tool over the clamp bridge, tighten the tool nut until the jaws are completely
Using the Crimper Tool C-4975-A,
6.
it
locks on the
evenly on the sealing boot
it
sary, equalize the seal pressure
shape 7.
Distribute
4.
assemble the following:
Install or
it
circlip
vice package inside the
To assemble:
splines
onto the shaft with a soft-
hammer so
faced
any parts show excessive wear,
If
replace the halfshaft assembly; the component parts are not serviceable.
it
closed (face-to-face). 9.
•
Boot and slide
•
Circlip,
it
place the tool over the clamp bridge, tighten
onto the shaft
!'
3.
if
removed
Position the boot so that the raised
bead on the inside the boot seal
is in
closed (face-to-face).
The seal must not be dimpled,
the
stretched or out of shape.
shaft groove. •
joint
If
neces-
sary, equalize the seal pressure
Halfshaft
.
WARNING
the tool nut until the jaws are completely
hub nut onto the Rzeppa
threaded shaft so
it
is
flush
shape
The seal must not be dimpled, stretched or out of shape.
If
it
and
by hand.
neces-
with the end
Install the halfshaft.
STEERING AND SUSPENSION Air
connecting and isolating the negative bat-
Bag
**
CAUTION
tery cable.
Allow the
tor at least
2 minutes
removing any
air
air
to
ever the
crossmember
discharge before
vehicle,
it
bag system components.
Rack and Pinion Steering Gear
air
Failure to follow safety and disabling
NET BUILD
front
suspension
alignment settings are determined as the
front
is
designed by the location
suspension components
the body. This
in
it
when handling
the
is
the inflator
module
is
front
to
underbody
method
Several precautions must be observed
still
in
the
of the vehicle
front
suspension toe
be adjusted by the outer
carried out
in
relation to
when
building
of
meter gauge holes located of the vehicle.
With
this
designing and building a vehicle,
no longer possible
1998-99 Models
of the
to adjust a vehicle’s
suspension alignment settings
to the
Before servicing the vehicle, refer to
1.
the precautions
in
the beginning of this sec-
tion.
From
2.
inside the vehicle, disconnect
the steering gear coupler from the steering
column
shaft coupler.
Remove
3.
•
or disconnect the following:
Both front wheels
to avoid STEERING GEAR
•
Never carry the
inflator
module by
the
wires or connector on the underside of the
module. •
When
carrying a live inflator module,
hold securely with both hands, and ensure that the •
bag and trim cover are pointed away.
Place the inflator module on a bench
or other surface with the bag and trim cover facing up. •
With the
inflator
module on the bench,
never place anything on or close to the
module which may be thrown of
in
the event
an accidental deployment.
DISARMING Proper Supplemental Restraint Ssystem (SRS) disarming can be obtained by dis-
tie
REMOVAL & INSTALLATION
accidental deployment and possible per-
sonal injury:
same was
it
alignment settings. This means that the
crossmember
PRECAUTIONS
be replaced
body
when-
removed from a
These vehicles are designed and assembled using
the vehicle, by precisely locating the front
repairs.
settings can
is
rod ends.
vehicle
procedures could result in accidental air bag deployment, possible personal injury and unnecessary system
MUST
location on the
removed from. The
Some
vehicles are equipped with an bag system. The system MUST BE disabled before performing service on or around system components, steering column, instrument panel components, wiring and sensors.
required specifications. As a result,
bag system capaci-
CHRYSLER CORPORATION
8-37
NEON Power steering
• STEERING COLUMN SHAFT COUPLER
FRONT SUSPENSION CROSSMEMBER
fluid
pressure and
hoses from the power steer-
return
ing gear COUPLER PINCH BOLT NUT FRAME RAIL
Before removing the crossmember from the vehicle, the location of the crossmember MUST be scribed or marked on the vehicle. This must be done so the crossmember can be
LOWER STEERING COLUMN COUPLER
/ BOLT
reinstalled in 7922EG57
7922EG54
vehicle— 1998-99 vehicles
ing
exact location.
its
If
done, the proper NET
BUILD alignment specifications
Location of the front crossmember mount-
Disconnect the steering gear coupler from inside the
this is not
not be obtained and
bolts— 1998-99 vehicles
dling and/or tire
may
wear problems.
Matchmark the crossmember
4.
will
lead to han-
to the
chassis.
Place a transmission jack under the
5.
center of the crossmember. The jack will be
used
to lower, support
and raise the cross-
member when removing the steering gear. 6 Remove both front crossmember-toframe DAMPENER
LOWER CONTROL ARM
FRONT SUSPENSION CROSSMEMBER
rails bolts
Then, loosen both rear
crossmember/lower control arm
body
to the
Lower the crossmember while loos-
bolts.
ening the rear bolts.
Some
vehicles are equipped with a bobble
damper
vice
steering
must be removed from the
that
crossmember during steering gear
Lower the crossmember
gear— 1998-99
for
access
Using the transmission
7.
to the
crossmember enough
the
vehicles
removed from the crossmem-
ing gear to be
ser-
— 1998-99 vehicles
STEERING GEAR BOLTS
MOUNTING
ber.
When
not
lei
jack, lower
to allow the steer-
lowering the crossmember, do
the
crossmember hang from
the
lower control arms. The weight should be
supported by the jack
Remove
8
—STEERING GEAR
FRONT SUSdNSION - CROSSMEMBER
or disconnect the following:
•
4 steering gear-to-crossmember bolts
•
Steering gear
"»lf a
new
steering gear
being
is
necessary parts
installed, transfer any
trom the old steering gear
to the
new
steering gear. View
of the steering
gear mounting
To install:
bolts— 1998-99 vehicles Because
of the
the vehicle,
method used
9
Install the steering
crossmember and torque for aligning
rod end stud with an
matchmark the crossmember
"fa
in.
socket
lbs.
while loosening the nut with a wrench.
gear on the
50
the bolts to
It.
(68 Nm).
10.
Using the transmission
jack, raise
installed position prior to steering gear
removal
— 1998-99 vehicles
•
Tie rod
the crossmember/steering gear
ends from the steering
against the chassis frame
knuckles, using a Side Puller Tool •
MB-991
Engine/transaxle bobble damper •
from the front suspension cross-
member,
if
equipped •
^The
bobble strut does not have removed from the transaxle. •
Outer
tie
to
be
is
removed by holding the
Power steering
fluid
the 2
bolts; then,
the 2 front crossmember-to-frame
pressure
rail
volts.
Tighten the 4 bolts until the crossmember
Power steering pressure/return
aligned with the mounting points. Torque
hose routing bracket from the
the bolls to
front
••When
'•The bracket does not have to be removed trom the power steering prestie
crossmember-to-chassis
switch connector
crossmember
rod end-to-steering
knuckle nut
'•The nut
rear
113.
assembly
rails. Start
it
MUST
the
illustrations,
see Section
1
of this
Nm)
crossmember
is
installed,
align with the removal match-
front
tings.
For Accessory Drive Belt
lbs. (2
marks; the purpose
BUILD
sure and return hoses.
20 inch
is
manual
is
maintain NET
suspension alignment set-
CHRYSLER CORPORATION
8-38
NEON
Tap the crossmember into position,
11.
with a rubber mallet, the
until
is
it
aligned with
matchmarks. Once positioned, torque
both rear crossmember/lower control arm
120
bolts to
120
ft.
Power steering
•
(163 Nm).
lbs.
connect the following:
Install or
12.
(163 Nm); then, both
lbs.
ft.
front bolts to
fluid
pressure/return hoses into the steering gear ports and torque the line-to-steering gear tube nuts to
23
ft.
lbs. (31
Nm)
Power steering
•
fluid
pressure/return hose routing bracket and screw on the cross-
member and
torque the bracket-to-
attaching bolt to 17
Nm)
(23
lbs.
ft.
Wiring harness connector onto the
•
power steering
gear’s fluid pressure
switch and securely latch the wiring
FWD
harness connector’s locking tab Tie rod end, into the steering
•
knuckle. While holding the
1
- OUTER TIE
2
- JAM NUT
rod
tie
STEERING GEAR FRONT SUSPENSION CROSSMEMBER
3 4 -
ROD
stud, torque the tie rod end-to-
9306EG42
steering knuckle nut, using a crow’s foot
40
wrench and
ft.
lbs.
W
View
32
in.
power steering gear and crossmember
socket, to
(55 Nm).
Engine/transaxle bobble
•
of the
— 2000-02 vehicle
•Locking the steering wheel keeps the strut,
ing the locking tab
if
equipped, onto the crossmember bracket
clockspring
in
alignment position.
•
Working inside the passenger com-
3.
•
Both front wheels and torque the
•
lug nuts, in a crisscross pattern, to
100
ft.
lbs.
(135
column cou-
ing
column
(28
pling retainer pin, pinch bolt nut/bolt and
shaft coupler,
under the
Remove
4.
•
or disconnect the following:
ft.
•
Outer
'•Remove
•
tie
the proper type of fluid.
NEVER sub-
automatic transmission fluid
the tie rod nut by holding
hose
equipped
tie
•
fluid return
clip
not equipped with a
hose
C-clamps,
if
power steering
fluid cooler
rod ends from the steering •
Power steering
fluid
pressure hose
from the steering gear's routing clips
Tie rod heat shield
Power steering
fluid
pressure
switch wiring connector by releas-
power steering pump
FULL-COLD
proper type and amount of
Outer
Power steering
from the routing
MB991113 •
for the specified fluid.
the
if
rods-to-steering knuckle
knuckle using Remover Tool
and bleeding the power steering system, always use refilling
Refill
fluid cooler
nuts
the stud securely.
reservoir to the
Power steering
with a power steering fluid cooler
Nm)
retaining bolt retention pin
stitute
hose
not
Both front wheels
from the steering gear,
Upper-to-lower steering coupler
When
if
fluid cooler
• •
fluid return
separate the couplings.
dash, and torque the bolt to 21 lbs.
Power steering
from the steering gear,
•
13.
pressure hose
fluid
equipped with a power steering
Nm)
Steering gear coupler to the steer-
•
partment, remove the steering
Power steering
from the steering gear
fluid
level with the
fluid.
Bleed the
system.
2000-02 Models 1.
Before servicing the vehicle, refer to
the precautions in the beginning of this section. 2.
Place the steering wheel
in
the
straight-ahead position. Lock the steering
wheel holder.
in place,
using a steering wheel
View
of the
sure switch
power steering gear
—2000-02 vehicle
fluid pres-
View
of the
power steering gear hoses and
routing clips
— 2000-02 vehicle
CHRYSLER CORPORATION
8-39
NEON
** WARNING Do
not completely
remove the rear
bolts for they are designed to disen-
gage from the body threads and
will
arm rear
stay within the lower control isolator bushing.
••The threaded tapping plates allow the lower control
arm
to stay in
place
on the crossmember. 4 -
POWER STEERING Aliow the tank
to
lower
until the fuel
2.
3.
Remove
the fuel
any gasoline spillage.
to catch
•
Negative battery cable
•
Fuel
Fuel tank straps. Support with a
•
Wrap shop towels around
fuel
Squeeze
fuel filter
Locking tabs on the
•
Strainer and O-ring Inlet filter
fuel
jack prior to loosening the straps.
pump 7.
Carefully lower the tank.
8.
Clean the top
from the assembly
any loose
To
install:
4.
Install or
•
New
•
Locking tabs on the
0-ring and strainer •
fuel
pump
module
supply
(to filter)
the return tube (to fuel
tube and
pump module)
5,.
repair
pump Module
•
Fuel
•
Negative battery cable
Start the vehicle, if
K
check
for leaks
and
necessary.
are permanently attached to the fuel
The ends of the fuel supply and return tubes have different size quickdisconnect fittings. The large quick-dis-
1.
filter.
connect
fitting
Fuel
Pump
REMOVAL & INSTALLATION
attaches to the large
nipple (supply side) on the fuel
pump The in-tank
module. The smaller quick-disconnect fitting
Fuel
pump
wrench
tool.
locknut using Spanner
6856
filter
To install: fuel
pump mod-
ule
lines
^•The
Fuel lines from the fuel
Inlet filter
hose connector
releasing tabs and detach the fuel
Fuel
remove
or disconnect the following:
connect the following: •
•
of the tank to
dirt.
Remove
9.
pump module.
from the
pump module
•
•
Fuel line quick-disconnect fittings
•
filler
or disconnect the following:
hose
CAUTION
•
or disconnect the following:
Fuel tank inlet and from the
•
crossmember.
hoses
Remove
6.
tank neck touches the rear suspension
-
Properly relieve the fuel system pres-
sure.
attaches the small nipple (return
side) on the fuel
the fuel
fuel
pump and
pump module
CAUTION
The fuel reservoir of the fuel pump module does not empty out when the tank is drained. The fuel in the reservoir may spill out when the module is removed.
pump
•
Fuel
•
Fuel tank 0-ring and discard
it
contains
pressure regulator which
adjusts fuel system pressure to approxi-
pump module.
mately 49 psi (337.8 kPa). Voltage to the
pump is supplied through the fuel pump relay. The fuel pump is serviced as part of the fuel pump module. The fuel pump module
fuel
is
installed in the top of the fuel tank
contains the electric fuel pump, fuel reservoir, inlet strainer fuel unit, fuel
supply and return
and the pressure strainer, fuel
regulator.
and
pump
gauge sending line
The
connections inlet
pressure regulator and
level
sensor are the only serviceable items. 7922FG43
Fuel
filter
mounting location
pump requires pump module.
fuel
If
the
service, replace the fuel
Before servicing the vehicle, refer to
Removing
the fuel
pump module
using special tool 6856
lock ring
CHRYSLER CORP CIRRUS
•
SEBRING CONVERTIBLE
To install:
Remove
4.
Thoroughly clean
10.
STRATUS
•
all
Wipe
parts
the
Install or
.
Fuel supply line quick quick-con-
•
nect fitting from the fuel
connect the following:
•
New
O-ring onto the fuel tank
•
Fuel
pump module
in
discard the gasket
the tank
Fuel injector electrical connec-
sure the alignment tab on the
pump module
underside of the
tors
flange •
sits in
rail
Upper intake manifold plenum and
•
•
•Be
or disconnect the follow-
ing:
seal area of the tank clean. 1 1
9-41
BREEZE
•
Fuel
the corresponding notch in the
rail
from the intake mani-
fold fuel tank.
Locking ring and torque
•
ft.
lbs.
to
it
•Cover
40-45
to
(54-61 Nm), using Spanner
keep
Wrench Tool 6856
•
the intake manifold openings dirt
from entering the system.
Fuel injector clip
6.
•
Fuel tank assembly
•
Negative battery cable
12.
Refill
of the fuel
surize the system.
Check
rail
and discard the O-rings
injector— 2. OL. 2.4L and
the fuel tank.
Turn the ignition switch
13.
View
Fuel injector(s) from the fuel
•
9306FG08
To
install:
5.
Install or
engines
ON
to
pres-
the fuel system for
•
Fuel injector electrical connectors
•
connect the following:
Fuel injector to the fuel
new O-rings
leaks.
rail
using
lubricated with engine
Fuel supply line quick quick-con-
•
oil
nect fitting to the fuel
Fuel Injector
rail
Negative battery cable
•
•
Fuel injector clip
•
Fuel
rail
and torque the bolts
Use a Diagnostic Readout Box (ORB)
REMOVAL & INSTALLATION
ft.
scan tool Automatic Shutdown (ASD)
system
Check
2.0L and 2.4L Engines
test to
Before servicing the vehicle, refer to
.
•Be
1
from the
left
.
Fuel injector electrical connec-
ground cable
is
equipped with
•
left
bolts to 13
shock tower.
an insulator grommet which should be placed on the stud to prevent the negative battery
•The
ground cable
grounding. Relieve the fuel system pressure
Fuel supply line quick quick-connect fitting from the fuel
Negative battery cable
Fuel injector electrical connectors
•
Fuel
connectors
Use a Diagnostic Readout Box (DRB)
system 3.
Check
Relieve the fuel system pressure
test to pressurize the fuel
fuel
system
for leaks
using the recommended procedure.
3.0L Engine 1
from the intake manifold
rail
electrical
rail
•
•Cover
Sensor
•
grounding.
recommended procedure. Remove or disconnect the following:
•
•
Nm)
scan tool Automatic Shutdown (ASD)
using the 4.
lbs (18
Throttle cables
equipped with
from accidentally
ft.
•
6 tive battery cable
3.
is
an insulator grommet which should be placed on the stud to prevent the nega-
cable from accidentally
rail
Upper intake manifold plenum using a new gasket and torque the
Disconnect the negative battery cable
from the
Fuel supply line quick quick-connect fitting to the fuel
the precautions in the beginning of this sec-
2.
•The
•
Before servicing the vehicle, refer to
tion.
shock tower.
fuel rail
tors
the precautions in the beginning of this sec-
Disconnect the negative battery cable
8
sure the spacers are located
under the
for leaks.
2.5L and 2.7L Engines
tion, 2.
to
Nm)
fuel
pressurize the fuel system
• 1
(12
lbs.
.
Before servicing the vehicle, refer to
the precautions in the beginning of this section.
the fuel injector holes in the
2.
intake manifold.
Properly relieve the fuel system pres-
sure. • •
Fuelinjectorclip
Fuel injector(s) from the fuel
rail
and
discard the O-rings
Install or
•
connect the following:
Fuel injector to the fuel
new O-rings
rail
using
lubricated with engine 1
- FUEL RAIL BOLTS
oil 930BFGO7
•
Fuelinjectorclip
•
Fuel
and torque the screws
rail
14-19
ft.
Drain the cooling system
4
Remove
or disconnect the follow-
ing:
To install: 5.
3.
lbs.
(19.5-25.5
Nm)
View
of the fuel rail
to
assembly
—
•
Negative battery cable
•
Intake manifold
•
Fuel injector electrical connector
•
Fuel supply and return hoses
•
Vacuum hose
•
Fuel pressure regulator
•
Fuel
•
Insulators
2. 51-
engine
For Wheel Alignment specifications, see Section
1
of this
plenum
manual
rail
with the injectors
CHRYSLER CORP.
9-42 •
CIRRUS
Fuel injectors
•
SEBRING CONVERTIBLE
and discard the
•
Fi-
•
STRATUS
Fuel
•
and torque the bolts
rail
5.
•
To install: Fuel injector with a
lbs. (9
Nm)
new O-ring
lubricated with clean engine •
13
oil
Insulators
•
Fuel pressure regulator and
torque the bolts to 80 inch
connect the following:
Install or
•
to
Nm)
inch lbs. (12
rings
BREEZE
6.
Fuel injector electrical connector
plenum
•
Intake manifold
•
Negative battery cable
Fill
the cooling system to the proper
level.
•
Vacuum hose
•
Fuel return and supply hoses
7.
Start the vehicle,
repair
if
check
for leaks
and
necessary.
DRIVE TRAIN Tra nsaxle
port bracket bolt
Assembly •
REMOVAL & INSTALLATION Manual 2.0L, 2.4L (VIN X)
Upper
bell
housing-to-throttle body
support bracket stud nut
AND 2.5L
body support bracket
•
Throttle
•
Left transaxle
•
Upper
•
Vehicle Speed Sensor (VSS)
•
ENGINES
bell
Back-up
mount upper
bolts
housing bolts
light electrical
connector
from the transaxle Install
3.
an engine support fixture tool
and support the engine. If
the vehicle
its
going to be rolled on
is
wheels while the transaxle
of the vehicle,
is
•
out
•
obtain 2 outer CV-
joints to install in the hubs.
vehicle
is
If
Remove
4.
•
the
•
•
be usable. Before servicing the vehicle, refer to
Remove •
to
side bolts,
from the
left
mount
Engine-to-lower crossbar bolts
mount
Front steel engine
•
3 front aluminum engine mount
•
Starter
•
Rear transaxle mount bracket
•
Transaxle-to-rear lateral bending
bracket
bracket bolts
or disconnect the following:
Negative battery cable from the
left
Lower bracket
•
the beginning of this sec-
tion. 2.
advance
Lower splash shield/battery cover
transaxle
bearings, the bearings will no longer
in
the driveplate clutch bolts
Halfshafts
from the
rolled without the proper
the precautions
Remove
rotate the engine clockwise to
the next bolt
torque applied to the front wheel
1.
or disconnect the following:
Front wheels
left
shock tower.
strut
8.
from engine/transaxle assem-
bly
’•The ground cable
is
equipped with •
an insulator grommet which should be placed on the stud to prevent the nega-
Transaxle bell housing cover
Using a transaxle
5.
jack,
support the
transaxle.
tive battery cable
Rotate the engine clockwise to gain
6.
access
and intake hoses
Air cleaner
•
Clutch housing vent cap
•
Clutch cable from the bell housing
to the driveplate clutch bolts.
•
Driveplate clutch bolts
•
Lower engine-to-transaxle bolts
• 7.
the lower engine-to-transaxle
mounting bolts
from accidentally
grounding. •
Removing
or reinstall the front
Transaxle
To prepare the vehicle for
support the engine with a suitable support
motor mount
to the
engine. Then, reinstall the ball joints to the steering knuckle and install the retaining
rolling,
bolt. Install the
obtained outer CV-joints to
the hubs, install the washers and tighten the
Using equal force, pry up on both sides of the shifter cable isolator
axle nuts to
vehicle
bushings to avoid damaging the
To
Install or
•
•
•
(244 Nm). The
connect the following:
Transaxle and torque the transaxle-
Selector lever and crossover cables
to-engine bolts to 70
Nm)
Shift cable
mounting bracket from
• •
body
(95
Upper
•
body
starter-to-throttle
body sup-
•
appropriate support fixture
(95
to
70
ft.
lbs.
Nm)
Transaxle
bell
housing cover and
torque bolts to 9
Secure the engine assembly with an
lbs.
Lower engine-to-transaxle bolts and torque the bolts
Accelerator cable bracket from the
ft.
Driveplate clutch bolts
Accelerator cables from the throttle
throttle •
lbs.
be safely rolled.
from the transaxle
the transaxle •
ft.
install:
cable isolator bushing. •
180
may now
ft.
lbs.
(12
Nm)
Transaxle-to-rear lateral bending
Q.ylO
CHRYSLER CORP. CIRRUS assem-
strut to the engine/transaxle
bly
and torque the
(54
Nm)
40
bolt to
ft.
•
lbs.
torque the bolts to 40
•
(54
lbs.
ft.
Nm)
lbs. (9
mounting bracket
•
Driveshaft connection
•
Clutch release bearing engagement
housing
•
Clutch housing vent cap
bracket bolts and torque the bolts
•
Air cleaner
•
Negative battery cable
Front steel •engine
•
and torque the
mount bracket
bolt to
45
lbs. (61
ft.
Nm) Engine-to-lower crossbar bolts
•
Lower bracket bolts
to the left
mount and torque 40 ft. lbs. (54 Nm)
transaxle bolts to
to the
left
side
Front wheels fixture tool.
connect the following:
Install or
•
Back-up
•
VSS
•
Upper
Check the transaxle Be sure the reverse
when
in
•
ft.
•
Stabilizer link
and torque the nut
33
Nm)
•
proper oper-
to
40
Transaxle
ON
Upper
3.
Remove
Tranasxle
ENGINES
Rear
•
to
or disconnect the following:
(45
Nm)
•
13
(18
lbs.
ft.
Starter
Nm)
motor and
electrical
connec-
Air cleaner
Front exhaust pipe, 3 0L only
(95
•
Shift
bolts
•
Back-up
switch connection
•
Front exhaust pipe, 3.0L engine
lbs
•
Vehicle Speed Sensor (VSS) con-
•
Air cleaner
nector
•
Battery
assembly
and selection cable connec-
•
VSS
•
Back
•
Shift
ft.
•
Starter
Fill
Clutch release cylinder connector Transaxle assembly upper coupling
Nm)
6
•
Centermember
•
Rear
Accelerator cable bracket to the
•
Transaxle
•
Stabilizer link
•
Wheel Speed Sensor (WSS),
mount bracket and stopper
the vehicle
its
Brake hose clamp
Lower arm
is
going
to
be rolled on
wheels while the transaxle
joints to install to the hubs.
vehicle •
and
for leaks
of the vehicle, obtain 2 outer
end
Tie rod
•
check
necessary.
** WARNING If
•
if
if
equipped •
tray
the transaxle fluid to the proper
Automatic
stopper
roll
assembly
and
Start the vehicle,
repair
port bracket bolt
body
up light switch connector and selection cable connec-
level.
bolts
body sup-
connector
—
tions light
•
throttle
Nm)
(81
•
•
starter-to-throttle
lbs
tors
body
Upper
ft.
stopper and torque the nut lbs.
ft.
Nm)
•
bell housing-to-throttle
(43
33
(57
Clutch release cylinder and torque to
fluid.
support bracket stud nut and torque lbs.
lbs.
ft.
mount stopper and
Centermember
•
5.
roll
to
mount bracket and torque
Battery and tray
body support bracket
ft.
(45
the nut to 42
•
Nm)
Throttle
lbs.
•
lbs.
mount upper
equipped
if
torque the nut to 60
3.0L
to
WSS. ft.
80
Nm)
(28
•
tions
Left transaxle
the nut to 32 •
AND
Drain the transaxle
housing bolts and
and torque the bolts
•
for
lights turn
end and torque the nut
lbs.
ft.
to
•
Before servicing the vehicle, refer to
Nm)
(54
fasteners
•
2.
sensor
torque the bolts to 70
•
all
reverse.
2.4L (VI N G)
connector
light electrical
bell
21
tion.
Remove engine support
10.
to be sure that
3.0L engine
bolt,
Nm)
(108
lbs.
Tie rod
•
and connections made.
ation.
1
ft.
and intake hoses
pan
oil
Lower arm and torque the nut
•
the transaxle.
Refill
13.
bell
the precautions in the beginning of this sec-
Halfshafts
• 9.
the
Lower splash shield/battery cover
•
Check
.
are tightened 12.
•
•
1 1
Nm)
(26
lbs.
Selector lever and crossover cables
3 front aluminum engine mount
Nm)
ft.
to
to the transaxle
•
(54
transaxle bolt to 19
to the
—
the cover
Upper
Clutch cable to the
lbs.
engine bolt to 80 inch
•
•
ft.
to
Nm) and
transaxle
Starter
40
3
BREEZE
•
——
cover
body
•
to
STRATUS
•
Accelerator cables to the throttle
Shift cable
•
Rear transaxle mount bracket and
•
SEBRING CONVERTIBLE
•
Clutch release bearing engagement,
is
If
is
out
CVthe
rolled without the proper
torque applied to the front wheel
3.0L engine
bearings, the bearings will no longer •
Driveshaft connection
•
Upper
oil
pan
be usable. bolt,
3 0L engine
housing cover
•
Bell
•
Transaxle assembly lower coupling
1
bolts •
.
tion
Transaxle assembly
2.
Drain the transaxle.
3.
Disconnect the negative battery cable
To install: 4.
Install or
•
connect the following:
(48 to
connect the ground cable
from the
Nm)
at the
lbs. (71
ft.
•The
lbs.
2.4L engine and to 52
shock tower.
Bell
ground cable
placed on the stud
Nm) 3.0L engine
tive battery cable
housing cover and torque the
grounding.
For Maintenance Interval recommendations, see Section
is
equipped with
an insulator grommet which should be
ft
starter •
left
Transaxle assembly. Torque the
lower coupling bolts to 36
Be sure
Before servicing the vehicle, refer to
the precautions in the beginning of this sec-
1
of this
manual
to
prevent the nega-
from accidentally
MM
CHRYSLER CORP.
9 -*#**
CIRRUS
•
SEBRING CONVERTIBLE
•
STRATUS
Matchmark
BREEZE
•
•
Starter
location. Rotate the crankshaft clockwise to
•
New engine
align the converter bolts.
•
Upper transaxle mount remaining
7.
Install or
8.
the converter-to-flexplate
connect the following:
bolts to the •
•
Crankshaft Position (CKP) sensor, •
Lower splash shields
•
Transaxle electrical connectors
•
Front wheels
Right side steering gear and K-
•
fold
equipped
frame bolts •
Sway
bar
mounts
•
chain, secure the transaxle and support Install or
connect the following:
•
housing-to-engine bolts
•
Bell
•
Transaxle, by
moving
the K-frame
1 1
To prepare the vehicle
.
for rolling,
support the engine with a suitable support or reinstall the front motor
mount
to the
steering knuckle and install the retaining bolt. Install the
obtained outer CV-joints to
the hubs, install the washers and tighten the axle nuts to
vehicle
To
cable and clamp
ft.
Transaxle cooler lines
connect the following:
Air cleaner duct
•
Transmission Control Module
Dipstick tube from the transaxle
Transaxle cooler lines
Air cleaner duct
Negative battery cable
cables. the transaxle.
16.
Refill
1 7.
Check the transaxle
ation.
Be sure the back-up
proper oper-
for
lights
.
Before servicing the vehicle, refer to
the precautions
in
the beginning of this sec-
ft.
2.
(95
lbs.
3.
Drain the transaxle.
Remove
or disconnect the following:
•
Air cleaner
Right side steering gear and K-
•
Transaxle dipstick tube
frame bolts
•
•
Transaxle electrical connectors
CKP
mounts
sensor,
equipped
if
•
Negative battery cable
assembly
Transaxle cooler lines flush with the fittings
•
•
Align the converter-to-flexplate
13.
and
tion.
housing-to-engine bolts and
bar
connector
Adjust the gearshift and throttle
•
•
from the transaxle
•
electrical
•
Solenoid pack electrical connector
•
TCM
Mm) Sway
(TCM) •
•
•
1
moving the K-frame
or disconnect the following:
•
Solenoid pack
SEBRING, STRATUS SEDAN ONLY
Transaxle, by
Bell
Dipstick tube to the transaxle
•
safely rolled.
torque the bolts to 70
Shift lever cable
14
speedometer are working properly.
rearward •
•
(244 Nm). The
lbs.
ft.
may now be Install or
•
•
180
install:
12.
Remove
to
Nm)
•
15.
engine. Then, reinstall the ball joints to the
4.
and torque the nut
(19
bolt
rearward
shift
bolts, to
side
left
lever
Location of the transaxie solenoid assem10.
both sides
Shift lever cable to the transaxle
lbs.
it.
to
Upper transaxle mount top the
Using a transmission jack and a safety
9.
Removing the
exhaust mani-
to the
Converter-to-flexplate bolts
•
8-way connector and retaining
side
left
Exhaust pipe
•
if
bly
oil filter
matchmark. Rotate the crankshaft clockwise
Solenoid/pressure switch assembly
Transmission range sensor connector
lever
Using an engine support
5.
to align the converter bolts.
14.
Install or
support the engine assembly.
Remove
6.
•
•
or disconnect the following:
•
Front wheels
Lower splash shields from both •
Exhaust pipe from the exhaust
Upper transaxle mount remaining bolts from the
•
Engine
108 inch
Both
(61 •
•
left
Shift cable
lateral
lbs.
(12
bending
Nm) 45
ft.
lbs.
from the manual valve
and bracket
•
Crankshaft Position (CKP) sensor
•
Throttle
•
Oxygen Sensor (0 2 S) harness
strut brackets to
body support bracket
retainer •
Nm)
Rear mount bracket
—
to
transaxle case bolts
Radiator’s lower
crossmember and
torque the bolts to 45
side
lever
ft.
and torque the bolts
and torque the bolts
manifold •
55
Nm)
Flexplate cover to
sides •
(74
lbs.
• •
•
nectors
Torque converter and torque the
side
left
Input and output speed sensor con-
connect the following:
converter-to-flexplate bolts to
Upper transaxle mount top bolts from the
•
fixture tool,
ft.
lbs. (61
•
Upper
•
Halfshafts
Rear mount and bracket
starter bolt
Nm)
•
•
Rear mount bracket
•
Front
•
Centermember
•
Starter
•
Torque converter dust shield and
oil filter
Starter
•
Front engine
•
Rear mount bracket through-bolt
•
Centermember
mount bracket
bolts to •
Rear mount bracket
•
Radiator lower
•
Flexplate cover
lateral
lbs. (61
Nm)
bending
mount bracket and mount assembly
Rear mount bracket through-bolt
properly support the
and torque the through-bolt
engine/transaxle assembly
ft.
crossmember •
Both
ft.
and torque the
bolts
•
•
45
bolts
lbs. (61
•
mount bracket and
torque the bolts to 24
Nm)
45
Nm)
Front engine
strut brackets
to
ft.
lbs.
Left
— —
mount bracket
bolts
slightly
(33 •
to
transaxle
and lower the assembly
Transaxle assembly
Q.vIE
CHRYSLER CORP. CIRRUS To install:
70
Nm)
(95
lbs.
ft.
into position
and torque the
through bolt
to
55
(70
lbs.
ft.
assembly sup-
the engine/transaxle
Push the clutch cable housing toward
1. 2—2.0 in.
25
(30-50mm). This
•The
lbs. (11
the cable
move
placed on the stud
indicates tive battery
•
Starter
on the bracket.
•
Rear and front transaxle support
•
Starter
•
Front
REMOVAL & INSTALLATION
•
and lower
if
the
mechanism
is
properly seated
brackets
bolt
Clutch inspection cover
•
mount and bracket Rear mount and bracket
•
Halfshafts
•
Upper
•
0 2 S harness
•
Throttle
•
CKP
•
Gearshift cable to
•
Output and input sensor connectors
leakage through the engine rear crankshaft
•
Transmission range sensor connec-
oil
tor
leakage
Solenoid/pressure switch connec-
this time.
•The
removed
starter bolt
retainer
1
body support bracket
sensor
transaxle assembly must be
manual valve
in
Oil
Modular clutch-to-flywheel bolts
•
Transaxle assembly with the clutch as an assembly
Clutch assembly from the transaxle
•
input shaft
the beginning of this sec-
To install:
tion.
Clean
3.
lever
seal
all
is
noted,
it
shaft seal.
Transaxle dipstick tube
•
Air cleaner
•
Negative battery cable
If
should be corrected
It
is
at
pre-lubricated and
sealed and should not be washed
kit
oil
Examine the throwout or clutch
4.
in solvent.
The bearing should turn smoothly when
A
held in the hand with a light thrust load.
assembly
the transaxle fluid to the proper
light
drag caused by the lubricant
mal.
If
fill
is
nor-
the bearing is noisy, rough or dry,
replace the complete bearing assembly. In Start the vehicle, if
check
for leaks
most cases where a clutch
and
viced, the
necessary.
ENGINE
BOLT
DRIVE PLATE BOLT
TRANSAXLE
The manual transaxle clutch release system has a unique self-adjusting mechanism
compensate
for clutch disc wear.
mechanism
is
clutch cable assembly.
This
located with the
The preload spring
maintains tension on the cable, This tension
keeps the clutch release bearing continuously loaded against the fingers of the clutch cover assembly. is
When and
No manual
adjust-
servicing this vehicle or
if
installing the clutch cable,
on the clutch cable housing
from the dash panel
self-adjuster
may
TRANSAXLE CASE UPPER COVER
necessary.
Damage
to
remov-
DRIVE PLATE
do not
CLUTCH ASSEMBLY
remove
to the cable
occur.
To check the function of the adjuster
being ser-
TO DRIVE PLATE DRIVE PLATE BO LT BACKING TO CLUTCH PLATE
FREE-PLAY
adjuster
is
complete clutch assembly and
CRANKSHAFT
UPPER
COVER
2.0L, 2.4L (VIN X) and 2.5L Engines
it
parts well. Inspect for
and transaxle input
release bearing.
cooler lines using the service
•
Fill
•
assembly.
Before servicing the vehicle, refer to
the precautions
connector
electrical
to service the clutch
ADJUSTMENT
ing
prevent the nega-
mine
Clutch
pull
to
cable from accidentally
grounding.
level.
ment
equipped with
Torque converter dust shield
splice
to
is
does not adjust, deter-
tor
6.
ground cable
an insulator grommet which should be
proper adjuster mechanism function. It
left
shock tower
the dash panel. With less than
3.
or disconnect the following:
Negative battery cable from the
•
port
•
repair
Remove
2.
3 HU
BREEZE
•
•
•
5.
STRATUS
taut.
kg) of effort, the cable housing should
Nm)
Torque converter bolts and remove
•
cable 2.
Upper mount. Raise the assembly
•
pull the clutch
•
release lever end of the cable to draw the
connect the following:
Transaxle and torque the bolts to
•
SEBRING CONVERTIBLE
With slight pressure,
1.
Install or
4.
•
Exploded view
ot the clutch
assembly
mechanism, use the following procedure:
For Tune-up, Capacities and Firing orders, see Section
1
of this
manual
CHRYSLER CORP.
9-46
CIRRUS
•
SEBRING CONVERTIBLE
•
STRATUS
BREEZE
•
release bearing are usually replaced together.
Check the condition
5.
of the stud pivot
spring clips on the back side of the clutch fork.
If
the clips are broken or distorted,
replace the clutch fork. The pivot ball pocket in
the fork
installed
Teflon® coated and should be
is
WITHOUT
grease which
any lubricant such as
break
will
down
the Teflon®
coating. Be sure the ball stud and fork
pocket are clean of contamination and
When assembling
dirt.
the fork to the bearing,
must go over
the small pegs on the bearing the fork arms.
Check
6.
or grooves.
machine
the flywheel for cracks, glazing
any
If
of
these conditions exist,
(reface) or replace the flywheel to
prevent clutch chatter and premature clutch wear.
manual transaxle
i-^The
with a reverse brake.
It
synchronizer, but only
When
not moving.
depressed
if
equipped
is
functions as a the vehicle
the clutch pedal
and held
to the floor
is is 4.
for 3
seconds, and the transaxle shifts to reverse, no gear clash should be present.
If
there
is,
When
be checked.
removed
the input shaft should the transaxle
is
check the
for clutch service,
input clutch shaft, clutch disc splines
and release bearing
for dry rust.
1
- ISOLATORS
2 -
WATTS LINK (LOWER) BELL CRANK
5 -
JOUNCE BUMPER
6 -
3 - SHOCK ABSORBER 4 - WATTS LINK (UPPER)
7 - AXLE 8 - COIL
SPRING 9346JG12
3.
Exploded view
of the clutch
assembly-3. OL engine
If
washer and clutch tube
present, clean rust off and apply a light
•
Insulator,
coat of high temperature bearing
•
Union, union bolt and gasket
and torque the fastener
•
Valve and spring, 3.0L engine
(15
grease on the input shaft splines only
•
Clutch release cylinder
where the clutch disc
•
Clutch cover and disc
the clutch disc slides freely along the
•
Release fork shaft, 3.0L engine
input shaft splines.
•
Left
•
Release fork
•
Clutch release bearing
grease
7.
Install or
•
Apply
to the input shaft splines.
slides. Verify that
connect the following:
Modular clutch assembly onto the
•
transaxle input shaft •
Transaxle assembly
•
New
•
clutch-to-driveplate (flywheel)
bolts. Tighten the bolts, in a criss-
•
ft.
lbs.
(75
at
Fluid line bracket
14
ft.
lbs.
lbs.
and torque the (19
Nm)
Negative battery cable
Check and top
Release fork boot and fulcrum, 2.4L
Release fork boot and maintenance
To
off
the fluid level,
if
Halfshafts
•
Transaxle lower support brackets
•
Starter
•
Negative battery cable
check
2.0L, 2.4L (VIN X) 2.5L and 2.7L
connect the following:
Release fork boot and maintenance cover, 3.0L engine
•
REMOVAL & INSTALLATION
install:
a time
Nm)
test the vehicle to
ft.
cover, 3.0L engine
Clutch inspection cover
Road
to 11
necessary.
•
Engines
"Hf the vehicle
Release fork boot and fulcrum and torque the fulcrum to 26
8.
•
washer and clutch tube
Nm)
bolt to
support spring, 3.0L engine
Install or
55
•
Insulator,
engine
cross pattern, a few turns to
•
ft.
lbs.
(35
Nm) for •
Clutch release bearing
•
Release fork
is going to be rolled while the halfshafts are out of the vehicle, obtain 2 outer CV-joints or proper equivalent tools and install to the hubs.
proper clutch operation.
2.4L (VIN G) and 3.0L Engine
•
Left
support spring and release fork
shaft,
3.0L engine
the vehicle is rolled without the proper torque applied to the front wheel bearings, the bearings will no If
1
.
Before servicing the vehicle, refer to
•
the precautions in the beginning of this section. 2.
Remove
or disconnect the following:
•
Negative battery cable
•
Clutch fluid line bracket
Clutch disc and cover and torque the bolts to 14
ft.
lbs.
(19
Nm)
•
Clutch release cylinder
•
Valve and spring, 3.0L engine
•
longer be usable.
Union, bolt and gasket and torque the bolt to 17
ft.
lbs.
(23
Nm)
1
.
Before servicing the vehicle, refer to the
precautions
in
the beginning of this section.
CHRYSLER CORP. CIRRUS
•
SEBRING CONVERTIBLE
STRATUS
•
•
Q./17 w HI
BREEZE
2.
Remove
2.4L (VIN G) and 3.0L Engine
or disconnect the follow-
ing:
Before servicing the vehicle, refer to
1
• •
Negative battery cable the precautions in the beginning of this sec-
Cotter pin, nut lock and spring
tion.
washer •
Halfshaft nut, loosen
it
Remove
2
while the
is
on the
or disconnect the following:
Negative battery cable
•
vehicle
floor with the •
Front wheel
•
Vehicle Speed Sensor (VSS) cable
brakes applied •
Wheel
•
Brake caliper assembly and support
if
Brake hose clip and cotter pin
•
Driveshaft nut
on a wire
it
•
Brake rotor
and washer
•
Halfshaft nut
•
Tie rod end from the steering
may damage
Inserting the prybar too far
the transaxle seal
•
Lower arm
•
Tie rod end
•
Stabilizer link
•
Driveshaft and circlip
knuckle using joint separation Tool
MB991113 To install: 3.
To
Inspect the halfshaft boot for
Check
or deterioration.
Use
of
improper methods
separation can result
in
of joint
damage
4.
bracket,
•
Sway
•
bar link from the
damper
fork, •
•
Damper
•
Steering knuckle from the lower control
fork
assembly
it
Halfshaft into the
hub by pulling
Washer. Make sure the chamfered
Halfshaft nut
it
from the
•
hub
Control
arm
to the steering knuckle
and torque the nuts
^After pressing the outer shaft, insert a prybar between the transaxle case and the halfshaft and pry the shaft from
lbs. •
Damper
fork
Nm) and
WARNING
•
damages
on the shaft. Doing so
the inboard joint.
43-52
ft
and torque the lower
Do not
•
•
•
ft.
to
17-25
install a
ft.
new
Sway
Brake hose clip
•
VSS
•
Front wheel
•
Negative battery cable
76
lbs
bar link to the
damper
link nut to
ft
if
equipped
Inner Tri-pot Joint
lbs
Nm)
Remove
or disassemble the follow-
•
ft.
Halfshaft
Large and small boot retaining
lbs.
•
Wheel
•
Negative battery cable
down
the shaft
away
housing.
•When
separating the spider joint
from the
tri-pot joint
housing, hold the
vent the rollers and needle bearings
from falling away. 3.
Carefully slide the shaft/spider
assembly from the
the transaxle.
Test drive the vehicle
tri-pot
rollers in place on the trunions to pre-
cotter pin
Refill
Slide the boot
from the
Brake rotor and caliper assembly
New
7.
Negative battery cable
•
clamps
securely tightening the axle
•
6.
•
•
wheel bearings.
to
cable,
fork
29
nut, be sure there is no load on the
NOT
Nm)
OVERHAUL
Lockwasher and axle nut and
• Before
careful
to a
CV-Joints
2.
knuckle— be
it
(226
the driveshaft
•
cot-
(200-260 Nm)
the threads or splines on the joint
lbs.
(88
lbs.
torque the nut to 145-188
remove the outer CV-joint from
ft.
ing:
(39
damage
Driveshaft nut and torque
maximum of 167 New cotter pin to
pin
and torque the
the steering
•
1
ter
Carefully
end
ball joint
Tie rod end, to the steering knuckle
(24-33 Nm) and
insert the prybar too far or the oil
7922FG53
cotter pin to the tie rod
Nm)
and torque the nut pull
to
the upper pinch bolt to
(103
lbs.
ft.
Do not
Lower arm
to
Nm)
(28
New
to
(59-71 Nm)
through-bolt/nut to 65
the transaxle.
end and torque the nut
lbs.
ft.
•
arm
Halfshaft by pressing
Nm)
(44
nut
and tighten temporar-
ily
•
and torque the nut
lbs.
ft.
•
edge faces outward •
Stabilizer link
Tie rod
4
assembly outward
connect the following:
33 21
seated
the knuckle
necessary
if
•
is fully
System (ABS) •
of
Halfshaft into the transaxle until
connection
Driveshaft
connect the following:
Install or
equipped with an Anti-lock Brake
if
Install or
•
Replace the circlips on the ends
ball joint
install:
•
the halfshaft(s). 5.
Speed sensor cable routing
3
and
splines for wear. to
the joint, leading to possible failure. •
damage
the ball joints
equipped
•
Remove and check
tri-pot
housing.
the spider assembly-to-shaft
for
snapring; then, slide the spider assembly
proper operation. the shaft
For complete service labor times, order the Chilton Labor Guide
off
CHRYSLER CORP.
9-48
CIRRUS
•
SEBRING CONVERTIBLE
•
STRATUS
•
- STUB AXLE - OUTER C/V JOINT 3 - OUTER C/V JOINT BOOT
BREEZE
1
8 -
2
9 -
4 -
CA/ JOINT
RIGHT DRIVESHAFT 10 - INNER TRIPOD JOINT BOOT 11 - INNER TRIPOD JOINT 12 - INNER TRIPOD JOINT 13 - INNER TRIPOD JOINT BOOT
TUNED RUBBER DAMPER WEIGHT
- INTERCONNECTING SHAFT 6 - OUTER C/V JOINT BOOT 5
7 -
OUTER
STUB AXLE
14 -
INTERCONNECTING SHAFT LEFT DRIVESHAFT 9306EG02
9.
View
of the halfshaft
assemblies— Typical
of excessive wear.
If
necessary, replace the
necessary, tap the spider assembly
If
off
the shaft using a brass
careful not to hit
be the outer bearings. drift;
^••Component parts are not serviceable and must be replaced as an assembly.
Slide the boot off the shaft.
6.
Throughly inspect
all
&
parts for signs
Slide the inner tri-pot boot clamp
is
visible
shaft just far
shaft.
spider assembly onto the
enough so
that the
WARNING
Tri-pot sealing boots are
made
WARNING
of
2 different types of material; silicon
If
rubber (high temperature) which
onto the shaft using a brass
is
and pliable or Hytrel plastic (standard temperature) which is stiff and rigid. Be sure to replace the boot
made
snapring
can be installed.
soft
1
on the
Install the
I:
The
shaft; then, position the
boot so that only the thinnest (sight) groove
8.
To assemble; 5.
7.
and boot onto the
halfshaft.
necessary, tap the spider assembly drift;
be
careful not to hit the outer bearings. Install the
snapring onto the shaft;
of the correct material.
- SNAP RING
2 - SEALING
BOOT
©
3 -
SPIDER ASSEMBLY 4 - SNAP RING PLIERS 1
5 - INTERCONNECTING SHAFT
2 9306BG1
3
BOOT - RAISED BEAD IN THIS AREA OF SEALING BOOT - GROOVE - SEALING
4 -
View
of the halfshaf? inner tri-pot joint
snapring
1
and
- SEALING
BOOT
2 - SPECIAL TOOL C-4975 3 - CLAMP BRIDGE
INTERCONNECTING SHAFT
9306BG13
9306EG04
View
of the halfshaft
boot and shaft
Securing the halfshaft boot clamp
Q_>IQ
CHRYSLER CORP. CIRRUS
•
SEBRING CONVERTIBLE
housing retaining groove and retaining
14
If
•
STRATUS
•
3
BREEZE
install the
clamp evenly on the boot. using a crimp type boot clamp,
perform the following procedure:
Using the Crimper Tool C-4975-A
a.
place the tool over the clamp bridge, tighten the tool nut until the jaws are
completely closed (face-to-face).
Using the Crimper Tool C-4975-A,
b.
place the tool over the clamp bridge, 1
-
CLAMP
TOOL YA3050 - SEALING BOOT
2 - SPECIAL 3
1
-
2 3 4 -
tighten the tool nut until the jaws are
SOFT FACED HAJ4MER STUB AXLE
OUTER NUT
15.
9306EG07
Tightening the low profile boot
If
9306EG10
using a latching type boot clamp,
Driving the Rzeppa joint onto the shaft
perform the following procedure:
clamp—
Position Snap-On Clamp Locking YA3050 prongs in the clamp holes.
a.
Silicone rubber Tri-pot boot
Tool b.
Squeeze the
clamp band
tool until the
upper
Boot and slide
•
Circlip,
•
4.
Install
•
Rzeppa
in
it
•
Rzeppa hitting
joint
to drive profile boot
clamp— Sili-
cone rubber Tri-pot boot
off
•
Circlip from the shaft
Boot by sliding
it
off
Distribute
5.
hammer
in
that the
snapring
is fully
Install or
6.
New
•
the shaft
WARNING
seated If
of the
If
installing a
grease
in
new
boot, distribute
Vfe
the service package inside
the tri-pot housing
and the other
Vfc
11.
12.
7
any parts show excessive wear,
it
shaft
onto the shaft
hammer so
it
of the grease in the
VS>
inside the boot.
connect the following:
small boot clamp and position
evenly on the sealing boot
Using the Crimper Tool C-4975-A,
the tool nut until the laws are completely
replace the halfshaft assembly; the
component
closed (face-to-face).
parts are not serviceable.
inside
the boot.
** WARNING To assemble:
Carefully, slide the spider
and shaft
flush
place the tool over the clamp bridge, tighten
the groove. 10.
Rzeppa
is
service package inside the Rzeppa joint
it
make sure
it
and align the
housing and the other
the shaft
•
the
locks on the circlip
housing by sharply
with a soft-faced it
joint
with a soft-faced
the shaft
9306EG08
Secured the low
Rzeppa
•
a soft-
boot clamps and slide
down
it
hub nut onto
threaded shaft so
splines and tap
joint
the boot
-
the
with the end
jawed vise
2.
INNER TRIPOD JOINT HOUSING 2 - TOP BANK OF CLAMP MUST BE RETAINED BY TABS AS SHOWN HERE TO CORRECTLY LATCH BOOT CLAMP 3 - SEALING BOOT
joint
and place
is in
or assemble the following:
Halfshaft
or disassemble the following:
Halfshaft
onto the shaft
shaft groove.
Rzeppa (Outer) Joint Remove
it
removed
Position the boot so that the raised
•
1
if
bead on the inside the boot seal
Install the halfshaft into the vehicle.
16.
•
3.
latched behind the 2 tabs
is
on the lower clamp band.
1
GV JONT
completely closed (face-to-face).
assembly
Install or
into the tri-pot housing.
•
Position the inner boot clamp evenly
New
The seal must not be dimpled,
assemble the following
small boot clamp and slide
it
stretched or out of shape.
on 13. the sealing boot.
shape
** WARNING
8.
If
it
neces-
Position the boot onto the Rzeppa
retaining
neces-
9.
and equalize the seal pressure and shape it by hand.
sary, use a trim stick to seat
and
by hand.
housing retaining groove and
The seal must not be dimpled, stretched or out ot shape.
If
sary. equalize the seal pressure
onto the shaft
install the
clamp evenly on the boot.
Using the Crimper Tool C-4975-A,
place the tool over the clamp bridge tighten the tool nut until the jaws are completely
closed (face-to-face). ft>
bead
No.
1
compression stroke
for the
Remove
or disconnect the follow-
•
Water
pump
•
Intake
vacuum
•
ing:
drive pulley
•
(2-3mm) to the
12.
Install the
Accessory drive belts
•
A/C compressor
•
Alternator
•
13
Tighten the camshaft journal cap
For
Tire,
body
and
Wheel and Ball Joint
right intake
manifolds
specifications,
see Section
Step 1:62-106 inch
b.
Step
14.
1
sequence as follows:
a.
Surge tank and supports Lett
in
their original positions.
Exhaust Gas Recirculation (EGR)
Throttle
camshaft journal caps
lines
bolts in •
inch
side cylinder head intake camshaft jour-
tube •
1
and sealant
nal thrust cap. of the
cylinder.
4.
of silicone gasket
head similar left
(TDC)
camshafts with the timing
Apply a 0.08-0. 1
1 1
ixsumi
ter
install the
marks facing up
Balt
left
camshafts Match the
i?N*(6 2
16-21 Nett
Camshaft installation— 3. 4L (VIN N) engine— Right head shown,
lifters in their
camshaft and chain timing marks as shown,
oi
aiapa
RH
Install the
10.
Carnahan journal Thrust Cap (Pan or eo«6) (2 Raj
.
.
hydraulic
Description Carnahan KHiahaeei
6250
7
Waaner (20
Req'd)
6
6
Install the
original positions
Part
of this
Install
2:
a
12-15
ft
lbs.
lbs
new camshaft
manual
(7-12 Nm).
(16-21 Nm). seal with a
-i
9
FORD MOTOR CO
Q O
1 I
I
TAURUS
•
SABLE Remove
3.
the upper intake manifold
and valve covers. Rotate the crankshaft so that the
4.
camshaft lobe
directed
is
away from
the
valve tappet to be measured. Insert a feeler
5.
camshaft lobe
gauge under
the
90 degree angle
at a
to the
camshaft. Clearance for the intake valves
should be 0.006-0.010 inch (0.15-0.25mm). Clearance
exhaust valves should be
for the
0.010-0.014 inch (0.25^).35mm). 6.
pet
If
adjustment
is
required, install Tap-
Compressor T89P-6500-A under
camshaft next
to the lobe
the
and depress the
valve tappet.
Tappet Holder T96P-6500-AH
Install
7.
and remove the compressor
i-* Camshaft journal cap
Cam
bolt tightening
spacer to
Install or
•
and
Left
connect the following: right
(VIN N) engine
Front cover
is
checked with
micrometer. 10.
Install the
Accessory
•
Oil
.
Before servicing the vehicle, refer to
spacer
2.
Disconnect the negative battery cable.
CKP
CMP
installing the tappet
CAM LOBE IN
Repeat the procedure
sensor
for
each valve
requiring adjustment.
POSITION
Install the
13.
sensor
valve covers and the upper
intake manifold.
Crankshaft pulley
•
Power steering pump
•
Left
and
right valve
•
IMRC
Engine control sensor wiring har-
cable and bracket
and
right intake
Surge tank and supports Throttle
To measure the valve clearance, slide the
body
feeler
EGR
Intake
vacuum
•
Water
pump
•
Alternator
•
A/C compressor
•
Accessory drive
•
Engine assembly
the engine
and check
for leaks
Starter Motor
• •
Run
manifolds
•
•
Connect the negative battery cable.
15.
and proper engine operation.
•
Left
14.
covers
ness and brackets
16.
compressor, then
belt idler pulleys
•
•
properly seated.
remove the tappet compressor. 12.
•
is
Release the tappet holder by
tion.
pan
•
replacement adjusting
spacer with the numbers down. Be sure the
the precautions at the beginning of this sec-
pulse ring
•
of the adjusting
spacer or by measuring with a
of the
*The valve clearance the engine COLD.
11.
CKP
the valve adjusting spacer off
spacer by the numbers on the bottom face
3.4L (VIN N) engine
1
•
toward
air
camshaft chain ten-
Timing chain
•
lift
Determine the size
9.
sioners •
tool.
compressed
of the valve tappet.
Seal Replacer T89-6256-A. 15.
jet of
the hole in the face of the valve adjusting
sequence— 3. 4L
T89P-6256-B and Cam
Seal Expander
Direct a
8.
tube
the lines
gauge between the base
cam and
the
REMOVAL & INSTALLATION
circle of
tappet— 3. 4L (VIN N)
1
.
Before servicing the vehicle, refer to
the precautions at the beginning of this sec-
engine
drive pulley
tion. 2.
Remove
or disconnect the follow-
ing:
belts into the vehicle.
Run the engine and check
for leaks
and proper operation.
•
Negative battery cable
•
Splash shield
•
Starter electrical connectors
•
Starter
To install:
Valve Lash
3.
Install or
•
ADJUSTMENT
connect the following:
and tighten the bolts
16-21,ft. lbs. •
to
(21-29 Nm)
Starter electrical connectors
and
tighten the battery cable nut to
3.0L (VIN U and S) Engines The lash adjusters (valve tappets), are hydraulic and are not adjustable.
Starter
80-123
inch lbs. (9-14
Correct positioning of the tappet compres-
•
Splash shield
— 3.4L (VIN N) engine
•
Negative battery cable
sor and holder tools
Nm)
FORD MOTOR CO. TAURUS
SABLE
•
2.
Drain the engine
3.
Remove •
12-19
oil.
or disconnect the following:
Negative battery cable tube
•
Oil dipstick
•
Low
•
Starter
•
Heated Oxygen (HO 2 S) sensor con-
oil level
sensor,
if
equipped
motor and brace
nectors
9346KG24
Remove
Oil
pan— 3.0L
(VIN U) engine
the front splash shield for access 5.
To install: 4
pan with new gaskets.
Install the oil
Step
10
Step
2:
Loosen
all
bolts.
Step
3:
Tighten
all
bolts to
4
Install the oil
to
ft.
to
10
ft.
connect the following:
•
Engine rear plate
• • •
Starter
•
Low
•
Oil dipstick
•
Negative battery cable
5.
:
Step
2:
108 inch Step
Tighten the 4 corner bolts
lbs.
lbs.
3:
(12 Nm).
Tighten the remaining bolts (12 Nm).
Retighten
all
bolts to
Install or
Dual converter Y-pipe
•
Dual converter Y-pipe
HO 2 S
sensor connectors
•
HO 2 S
motor and brace
•
Starter
•
Low
•
Oil dipstick
•
Negative battery cable
oil level
Fill
7.
Start the
sensor,
if
equipped
tube
the crankcase.
engine and check
for leaks.
sensor connectors
motor and brace
oil level
sensor,
if
equipped
tube
the crankcase.
6.
Fill
7.
Start the
engine and check
3.0L (VIN S) Engine .
Before servicing the vehicle, refer to the
the beginning of this section
at
precautions
at
the beginning of this section.
(VIN S) and 3.4L (VIN Oil
N) engines
Pen Removal Sequence
Pan
REMOVAL & INSTALLATION
3.0L (VIN U) Engine Item 1
1998-99 ENGINES
2
Description Upper Cylinder Block
Lower Cylinder Block 0010)
(Pert
of .
Before servicing the vehicle, refer to the
precautions
at the
beginning of this section.
2.
Drain the engine
3.
Remove
oil.
or disconnect the following:
•
Negative battery cable
•
Oil dipstick
•
Low
•
Starter
•
Heated Oxygen (HO 2 S) sensor con-
Pen
3
Otl
4
Stud Bott (5 Req d)
Req
5
Bolt (10
6
Oil
7
Engine Front Cover
d)
Pen Gasket
tube
oil level
sensor,
if
equipped
motor and brace FRONT Of ENGINE
nectors •
Dual converter Y-pipe
•
Engine rear plate
•
Oil
pan
Oil
for leaks.
Before servicing the vehicle, refer to the 1
1
108
connect the following:
Engine rear plate
precautions
Oil
1
•
9346KG26
motor— 3. OL
pan with new gaskets.
inch lbs. (12 Nm).
2000-01 ENGINES
Starter
Step
108 inch
c.
(14 Nm).
6
1
pan
Tighten the bolts as follows:
b.
b.
Install or
Oil
a.
bolts to
c.
lbs.
— 3.0L (VIN U) engine
all
Engine rear plate
•
install:
(14 Nm).
lbs.
Starter motor
Tighten
1:
Dual converter Y-pipe
•
To
Tighten the bolts as follows: a.
•
pan
bolt
removal sequence
—
3 OL (VIN S) engine
For Wheel Alignment specifications, see Section
1
of this
manual
19 on £“£U
ford motor co. TAURUS
I
SABLE
•
6.
connect the following:
Install or
•
Dual converter Y-pipe
•
Negative battery cable the crankcase.
7.
Fill
8.
Start the
engine and check
for leaks
and proper operation.
Oil
Pump
SEALER WSE-M4G323-A1
REMOVAL & INSTALLATION 3.0L (VIN U) Engine NOTE: APPLY 8 (0.31
mm
INCH)
DIAMETER BEAD OF
1
.
Before servicing the vehicle, refer to the
SILICONE GASKET
ANO SEALANT
precautions at the beginning of this section.
F6AZ-19562-AA
GO
OR EQUIVALENT MEETING FORD
2.
Drain the engine
SPECIFICATION
3.
Remove
WSE-M4G323-A6 AT TWO PLACES
AS SHOWN VIEW A SIMILAR
TIGHTEN BOLTS/STUDS
TWO PLACES
I 1
Oil
pan
sequence— 3. OL
bolt tightening
•
Negative battery cable
•
Oil dipstick
•
Low
•
Starter
motor and brace
•
Fleated
Oxygen Sensor (HO 2 S) con-
IN
SEQUENCE SHOWN
(VIN S) engine
oil.
or disconnect the following:
tube sensor,
oil level
if
equipped
nectors 2. 3.
Drain the engine
Remove
oil.
or disconnect the following:
Dual converter Y-pipe
•
Engine rear plate
•
Negative battery cable
•
Oil
pan
•
Dual converter Y-pipe
•
Oil
pump
•
Transaxle support bracket
•
Oil
4.
the
pan by following the bolt
removal sequence shown
To install: 4.
•
•
Oil
15-22
ft.
lbs.
sequence
in
install:
5.
Insert the intermediate shaft into the
pump •
to
71-106
until the
Install or
Oil
inch lbs. (8-12
snapring seats.
connect the following:
pump and
30-40
(20-30 Nm).
Transaxle support bracket. Tighten the nuts to
pump.
oil
To
6.
new gasket and
pan. Use a
tighten the bolts
•
oil
connect the following:
Install or
Separate (he intermediate shaft from
ft.
lbs.
tighten the bolt to
(40-55 Nm)
pan
•
Oil
•
Engine rear plate
•
Dual converter Y-pipe
(20-30 Nm).
•
HO 2 S
•
Dual converter Y-pipe
•
Starter
•
Negative battery cable
•
Low
•
Oil dipstick
•
Negative battery cable
Nm) and
the bolts to
15-22
lbs.
ft.
Oil
the crankcase.
5.
Fill
6.
Start the
pan
bolt tightening
(VIN N) engine
engine and check
for leaks
sequence
—
3.4L
sensor connectors
motor and brace
oil level
and proper operation.
sensor,
if
equipped
tube
APPLY SILICONE
3.4L (VIN N) Engine 1
.
Before servicing the vehicle, refer to the
precautions
at the
beginning of this section.
2.
Drain the engine
3.
Remove •
oil.
or disconnect the following:
Negative battery cable
•
Dual converter Y-pipe
•
Oil
pan
To
install:
4.
Apply a 0.16 inch (4mm) bead
cone sealer on the entire
oil
of sili-
pan sealing
surface. 5.
bolts
Install the oil
and studs
in
pan. Tighten the
sequence
(20-30 Nm). Tighten the case bolts
to
25-34
ft.
to
oil
15-22
pan
ft.
lbs. 7922KG40
oil
lbs.
pan-to-transaxle
(34-46 Nm).
Apply silicone sealant
to the entire sealing surface of the oil
pan— 3.4L
(VIN N) engine
FORD MOTOR CO. TAURUS
Exploded view
of the oil
•
SABLE
lO.OI £ L. I
pump mounting—
3.0L (VIN U) engine
the crankcase.
7.
Fill
8.
Start the
engine and check
for leaks
and proper operation.
3.0L (VIN S) Engine 1
Before servicing the vehicle, refer to the
.
precautions
at the
beginning
of this section
Remove the engine from the vehicle and mount on an engine stand. 3. Remove or disconnect the following: 2.
it
I '
•
Upper intake manifold
•
Valve covers
•
Accessory drive
•
Power steering pump
REMOVE BOLTS IN SEQUENCE SHOWN
OIL
Description
Item
1
Cylinder Block
2
Oil Pan Baffle
3
Nut (5 Req'd)
4
Nut
5
Oil Pump Screen Cover and Tube
6
Oil Pump Inlet Tube Gasket
7
Oil Pump
A
Tighten to 14-25 Nm (11-18 Lb-Ft)
B
Tighten to 8-14 Nm (71-123 Lb-In)
belt
CRANKSHAFT (2
Req'd)
PUMP
BOLT 4 RFQ’O
FRONT OF
CYLINDER BLOCK
ENGINE
9300KG15
Oil
pump
(VIN S) similar
bolt
30CKG16
removal sequence— 3. OL
engine— 3. 4L
(VIN N) engine
is
Exploded view
ot the oil
(VIN S) engine
is
pump
pickup tube and screen
mounting— 3. 4L
similar
For Maintenance Interval recommendations, see Section
1
of this
manual
(VIN N)
engine— 3. OL
I
10 99 L~CC I
FORD MOTOR CO. TAURUS
SABLE
•
3.4L (VIN N) Engine 1
Rear Main Seal
Before servicing the vehicle, refer to
.
the precautions at the beginning of this sec-
REMOVAL & INSTALLATION
tion.
Remove
2.
and mount
the engine from the vehicle
Remove
3.
or disconnect the follow-
1
7922KG43
Oil
pump
bolt tightening
engine—3. 4L
(VIN S)
sequence
—3.0L
(VIN N) engine
•
Accessory drive
•
A/C compressor
•
Alternator
•
Water
pump
•
Intake
vacuum
Exhaust Gas Recirculation (EGR) tube
•
Surge tank and supports
•
Left
A/C compressor and bracket crankshaft accessory drive pul-
ley shaft
has left-hand threads. Rotate
the pulley shaft clockwise to remove.
•
Oil
pump
Front cover
Timing chains
•
Crankshaft timing gears
•
Oil
install:
•
Camshaft Position (CMP) sensor
•
Crankshaft Position (CKP) sensor
•
Oil
pan
•
Oil
pump
•
Accessory
•
Front cover
Front cover Oil
pump
71-106
71-106
Nm), and the nut
•
'The
8.
Check
9.
Start the
•
Oil
to
15-22
ft.
Water
pump
•
Alternator
•
Power steering pump Accessory drive belt
Engine
6.
Start the
fill
as needed. for leaks.
9346KG27
Timing chain
•
CKP
Jet Plug
engine and check
Remover 310-005— 3. OL (VIN U)
engine
pulse ring
•
Front cover
•
Accessory
•
Oil
pump
belt idler pulleys
screen and tube. Tighten
71-123
ft.
lbs.
inch lbs. to
(14-25 Nm).
pan
•
Oil
•
CKP
•
CMP
•
Crankshaft pulley
•
Power steering pump
•
Left
sensor sensor
and
right valve
9346KG28
Rear Seal Replacer 303-323— 3. OL (VIN
covers
•
Surge tank and supports
•
Throttle
•
EGR
•
Intake
vacuum
•
Water
pump
U) engine
body
3.0L (VIN S) and 3.4L (VIN N) Engines
tube lines
drive pulley
•
Alternator
•
A/C compressor
•
Accessory drive belts
•
the vehicle.
and proper operation.
and
inch lbs.
.
Before servicing the vehicle, refer to
the precautions at the beginning of this sec-
2.
Engine
for leaks
6.
Fill
Attach an engine support fixture to
the engine lifting eyes.
into the vehicle 3.
5.
the crankcase.
Fill
fluid levels
engine and check
tion.
intake manifold in
all
tighten the bolts in
80-115
1
•
(73-87 Nm).
lbs.
mounting
A/C compressor and bracket
to
Crankshaft timing sprocket
11-18
•
Upper
lbs.
transaxle and the negative
connect the fotlowing:
pump and
•
inch lbs. (8-12
•
5.
Oil
(8-14 Nm) and the bracket nuts
bracket bolts are torque-to-yield bolts
•
ft.
oil seal.
pump
the tube nuts to
and must be replaced when removed.
Valve covers
main
and tighten the
battery cable.
pulse ring
Install or
Crankshaft pulley
•
54-64
Install the
7.
Crankshaft timing sprocket
inch lbs.
pan
air conditioning
•
bolts to
belt idler pulleys
•
•
(20-30 Nm). Oil
Install the flexplate
6.
CKP
screen and tube. Tighten
the bolts to
•
screen and tube
on Rear Seal
rear of the engine. Tighten the bolts
Timing chain
tighten the bolts in
Timing chains
•
on the
alternately to seat the rear
•
Crankshaft timing gears
•
seal
oil
(9-13 Nm)
(8-12 Nm)
•
Jet
Replacer 303-323. Position the tool and seal
•
connect the following:
to
Use the
Plug Remover to remove the rear main seal.
covers
Position the rear
•
pump and
of Jet Plug
into the seal.
5.
sequence
sequence
•
Remover 310-005
To
4.
pump
Install or
and the cylinder block.
Power steering pump
To install: 4.
lip
Screw the threaded end
To install:
•
Oil
and punch a hole
seal metal surface
Crankshaft pulley
screen and tube
Oil
main
between the seal 4.
right valve
a sharp awl
•
pan
•
the negative battery cable,
•
Crankshaft pulley
•
•
body
and
Use
3.
into the rear
lines
Throttle
pump
Water
•
•
drive pulley
•
is
Remove
2.
transaxle and flexplate.
Alternator
•
'The
tion.
belts
•
similar
•
Before servicing the vehicle, refer to
.
the precautions at the beginning of this sec-
ing:
(71*106 LB-IN)
3.0L (VIN U) Engine
on an engine stand.
it
Remove
or disconnect the following:
the crankcase.
Start the
engine and check
•
Negative battery cable
•
Transaxle
•
Flexplate
for leaks
and proper operation.
19.00
FORD MOTOR CO. TAURUS 4.
Use Seal Remover T95P-6701 -EH
and a slide
hammer
to
remove the
Seal Replacer
•
crankshaft seal.
6.
Install
•
or connect the following:
Rear main seal flush with the cylinder block surface. Use Rear Main
CRANKSHAFT REAR
Timing Chain, Sprockets and Front Cover and Seal
Flexplate and tighten the bolts to
54-64
To install: 5.
T82L-6701-A and
Adapter Bolts T91 P-6701 -A.
rear
SABLE
•
ft.
lbs.
(73-87 Nm)
REMOVAL & INSTALLATION
•
Transaxle
•
Negative battery cable
Run
the engine
and check
for leaks.
3.0L (VIN U) Engine 1
REAR CRANKSHAFT
Before servicing the vehicle, refer to
.
the precautions at the beginning of this section.
Drain the engine
2.
oil
and the cooling
system.
Remove
3. •
or disconnect the following:
Negative battery cable
•
Accessory drive
belt
•
Accessory drive
belt tensioner
and
idler pulley
pump
•
Water
•
Crankshaft pulley
•
Crankshaft Position (CKP) sensor
•
Coolant hoses
pulley
•
Dual converter Y-pipe
•
Oil
•
Front crankshaft seal
•
4
pan
Front cover Rotate the crankshaft until the No.
piston
1
Top Dead Center (TDC) and the
is at
timing sprocket marks are aligned.
Remove
5.
the timing chain
and
sprockets
To /
install:
•The
camshaft
passage
Rear Crankshalt Seal Remover T95P-6701 -EH — 3.0L (VIN S) and 3 4L (VIN N) engines
in
it
has
bolt
for
a drilled oil
timing chain lubrica-
tion. Prior to installation, clean the
passage and be sure
it
Never
clear.
is
replace the camshaft bolt with a stan-
dard bolt. 6
Install the
timing chain and sprock-
ets with the timing
marks aligned Tighten
the camshaft sprocket bolt to
46
ft.
(63
lbs.
Nm).
Use
7.
front cover
a
new gasket and
Apply sealant
3 Tighten bolts 1-10
and
bolts
11-15
Install or
8.
to
19
84 inch
ft
1
,
2 and
lbs (25
lbs
Nm)
(10 Nm).
connect the following
•
Front crankshaft seal
•
Oil
•
Dual converter Y-pipe
pan
•
Coolant hoses
•
CKP
•
Crankshaft pulley and tighten the
sensor
damper
bolt to
107
ft.
lbs.
(145
Nm)
T91 P-6701 -A •
Water
pump
bolts to 16
Rear Seal Replacer T82L-6701-A and Adapters T91P-6701-A— 3.0L (VIN S) and 3.41 (VIN N) •
engines
1
of this
pulley
ft.
manual
and tighten the
lbs. (21
Accessory drive idler pulley
For Tune-up, Capacities and Firing orders, see Section
to
install the
to bolts
Nm)
belt tensioner
and
10
0/1 FORD MOTOR CO. TAURUS
I
•
SABLE
Accessory drive
9. •
•
TIMING MARKS MUST BE IN POSITION SHOWN WITH NO. 1 PISTON AT TDC FIRING
CAMSHAFT SPROCKET
Fill
the cooling system.
10.
Fill
the crankcase.
1 1
Start the
.
Before servicing the vehicle, refer to
the precautions at the beginning of this section. 7922KG47
Remove
2.
and mount Timing chain alignment marks
— 3.0L (VIN U) engine
Application
Slz*
LB-FT
N-m
M8 x
1
25x43
5
F /CTO
BLOCK
20 30
15 22
M8x
1
25x43
5
F/CTO BLOCK
20-30
15 22
W/P A F/C TO BLOCK W/P & F/C TO BLOCK
20-30
15 22
20 30
15 22
M6x
3A 4A
M8x
1
1
25x73
25x 104
3
6A
M8
x
1
25
73
F/CTO BLOCK
20 30
15 22
6A
M8x
1
25x73
20 30
15 22
7A
M8x
1
25
20 30
15-22
20 30
15 22
20 30
15-22
x
16
M6
x
1
x
28 5
12B
M6
x
1
x
28 5
W/P & F/CTO BLOCK W/P A F/C TO BLOCK W/P A F/C TO BLOCK W/P A F/C TO BLOCK F/CTO BLOCK W/P TO F/C W/P TO F/C
t3B
M6 x
1
x
28 5
MB
M6
x
1
x
28 5
15B
M6
x
1
x
28 5
x
73
8A
M8
x
1
25
x
9A
M8x
t
25
x 104 3
10A
M8
x
1
or disconnect the following:
F**t*n*r
No.
2A
the engine from the vehicle
on an engine stand.
Torque Specifications
Fa*t*n*r»
1
it
Remove
3.
Faatanar And Hot*
25
1
104 3
x
52
20-30
15 22
8 12
71 106
(lb-in)
8 12
71-106
(lb in)
W/P TOF/C
8-12
71 106 (lb
W 'PTC F/C W PTOF/C
8 12
7M06 (lb
in)
8 12
71 106 (lb
.n)
-
in)
f
W /P — Water Pump F/C
— Engine Front Cover 7922KG4B
Timing chain
front cover bolt location
and identification
— 3.0L (VIN U) engine
for leaks
3.0L (VIN S) Engine 1.
CHAIN
engine and check
and proper operation.
CRANKSHAFT SPROCKET
TIMING
belt
Negative battery cable
TAURUS pump
Oil
Crankshaft Position (CKP) sensor
camshaft thrust caps must be removed before loosening the remain-
camshaft journal cap bolts
connector
ing
Camshaft Position (CMP) sensor
ensure that the thrust caps are not
connector
damaged.
•
Front cover
•
CKP
sensor pulse
ring.
Note the
Camshaft journal caps. Loosen the
•
keyway alignment
for installation.
bolts in
Access the power steering pump bolts through the holes
in
the
pulley— 3. OL (VIN
is
passes
used on several
keyway
ferent engines. Note the
ment
S) engine
Crankshaft Position Sensor
(CKP) pulse ring
•
in
Valve covers
•
Accessory drive
•
Power steering pump
•
Rotate the crankshaft so that the key-
is at
No.
1
Alternator
Dead Center (TDC)
pump
Water
•
A/C compressor and bracket
Verify that the alignment arrows
crankshaft
1
on
and
has left-hand threads. Rotate
the pulley shaft clockwise to remove. Crankshaft pulley
•
Crankshaft damper
•
Oil
keyway
at the 11
o'clock position. This will position the
left
not, rotate the
If
complete revolution and
cylinder head camshafts to their neutral position.
way
Verify that the alignment arrows
on
Rotate the crankshaft so that the key-
6.
the camshafts are aligned. is at
the 3 o’clock position. This posi-
Remove
tions the right cylinder head camshafts to
Remove
7.
•
the
left
cylinder head timing
chain tensioner retaining bolts and the tim-
the neutral position. •
Rotate the crankshaft 2 revolutions
recheck.
crankshaft accessory drive pul-
ley shaft
Right timing chain and crankshaft
locate the crankshaft
9.
—The
order for installation.
for 8. 10.
the camshafts are aligned.
•
be
sprocket
cylinder.
5.
to
the 11 o’clock position to locate
the crankshaft at Top belt
several
Right timing chain tensioner arm
•
way
in
camshaft
Rocker arms. Keep the rocker arms
•
align-
for installation.
4
Upper intake manifold
sequence and to allow the
raised from the cylinder head evenly.
dif-
•
•
to
Camshaft thrust caps
•
—The
CO. SABLE
—The
screen and tube
•
•
•
•
OE tJ
O 1It
FORD MOTOR
ing chain tensioner. or disconnect the following
Right timing chain tensioner
pan
—The
camshaft thrust caps must be
removed before loosening
the remain-
using a thin prytool. release and hold the liming chain tensioner ratchet/pawl mech-
anism— 3
1
2
3
Exploded view engine
—
left
RH Eahauet Camshaft RH Intake Camshaft RH Timing Chain Crankshaft
6
Timing
Cham
7
Bon
Req
0
Timing
Sprocket
0
Timing Chain Guide
4
RH
6
Boll (2
Timing Chain
Req
10
d)
A
of the right cylinder
side similar
(2
01 (VIN S) engine
Teneaon#/
d)
Cham
Tenetoner Aim
RH Cylinder Heed Tighten to 20 30 N-m Lb-Ft)
(
IS 22
head timing chain and related components— 3. OL (VIN S)
Retain the piston with a paperclip
—
For complete service labor times, order the Chilton Labor Guide
3
1
5mm
OL (VIN S) engine
wire or
n nc
4
FORD MOTOR CO.
I£'"£0
TAURUS
•
SABLE •
THRUST CAPS
•
Right timing chain tensioner arm Right timing chain tensioner and
15-22
tighten the retaining bolts to lbs.
ft.
(20-30 Nm)
'•-The crankshaft
keyway must be
In
the 11 o’clock position to install the
left
cylinder head rocker arms.
••The camshaft journal caps and cylinder heads are numbered to ensure that they are assembled in their original positions. Install the left cylinder
14.
Camshaft journal
bolt
tightening sequence — 3.0L (VIN
arms
S) engine
••Do not
head rocker
positions.
in their original
camshaft journal
install the
thrust caps until the other journal caps
have been installed and tightened. Tighten the
15.
caps
in
passes
to
Install the left
16.
camshaft journal
left
shown and in several 71-106 inch lbs. (8-12 Nm).
the order
camshaft journal thrust
caps and tighten the bolts lbs.
Remove
17. left
to
71-106
inch
(8-12 Nm). the retaining wire from the
timing chain tensioner.
••The crankshaft keyway must be
in
the 3 o’clock position to install the right cylinder
Rotate the crankshaft so that the key-
18.
way
head rocker arms.
is in
the 3 o’clock position.
••The camshaft journal caps and cylinder heads are numbered to ensure that they are assembled in their original
13.
positions. Be sure the timing marks are as shown
after the chain
Install the right
19.
has been installed— 3. OL (VIN S) engine
arms
camshaft journal cap bolts
ing
that the thrust caps are not
Remove
11.
to
ensure
damaged.
ratchet/pawl
mechanism through
access hole
in
or disconnect the follow-
Slowly compress the tensioner.
d.
Lock the piston with a 1.5mm wire
e.
Camshaft journal caps. Loosen the
•
bolts in
passes
sequence and to allow the
in
to
for the right
chain tensioner.
be
still
is
at the 11 o’clock position. Install or
connect the following:
evenly. •
Left
Rocker arms. Keep the rocker arms in
Left
timing chain tensioner arm
•
Left
timing chain and crankshaft
timing chain and crankshaft
camshaft journal
and tighten the bolts
71-106
to
inch lbs. (8-12 Nm). 22.
Remove
the retaining wire from the
sprocket. Align the colored links
••The Crankshaft Position Sensor (CKP) pulse ring is used on several different engines. The keyway position for the 3.0L (VIN S) engine will be marked
•
Left
timing chain tensioner arm
•
Left
timing chain tensioner and
install:
tighten the retaining bolts to
Prepare the timing chain tensioners
ft.
for installation as follows: •
Place the
left
chain tensioner
in
lbs.
15-22
Right timing chain and crankshaft sprocket. Align the colored links
Using a small prytool, release and
hold the timing chain tensioner
30,
30RFF
or wjth an
ORANGE
stripe.
(20-30 Nm)
a
vise. b.
Install the right
with the index marks on the
camshaft and crankshaft sprockets.
a.
shown and in several 71-106 inch lbs. (8-12 Nm).
the order to
order for installation.
•
12.
21.
Tighten the right camshaft journal
right timing chain tensioner.
sprocket
To
in
thrust caps
raised from the cylinder head
•
caps
passes
••Be sure that the crankshaft keyway
several
camshaft
not install the camshaft journal
thrust caps until the other journal caps
20.
Repeat
cylinder head rocker
positions.
have been installed and tightened.
or paperclip.
Camshaft thrust caps
•
•Do
the
the timing chain tensioner.
c.
ing:
in their original
with the index marks on the
camshaft and crankshaft sprockets.
23.
Install the
CKP
sensor pulse
Align the keyway with the proper 24.
Replace the crankshaft seal
front cover with a
engine
oil to
new
the seal
ring.
slot. in
the
one. Apply clean
lip.
FORD MOTOR CO. 1 TAURUS
O 07
\C C!
SABLE
•
25. Apply silicone sealer to the 6 critical
shown
areas
View A,
in
block to prevent
new
Place
26.
to the cylinder
seepage.
oil
front cover gaskets onto the
dowel pins on the cylinder block and heads. 27.
Place the front cover into position.
28.
Install the
6
front cover retaining
and stud bolts where the silicone
bolts
was
sealer
applied.
Tighten the bolts and stud bolts until
29.
the front cover contacts the cylinder block
and heads, then turn the bolts and stud bolts an additional 14 turn.
30.
and stud
Tighten
31.
ing bolts
VIEW A
remaining front cover
Install the
retaining bolts
all
bolts.
of the front cover retain-
and stud bolts
15-22
ft.
•The
air
in
sequence
to
(20-30 Nm).
lbs.
conditioning mounting
bracket bolts are torque-to-yield bolts
and must be replaced. 32.
Install or
CMP
•
connect the following:
sensor connector
CKP sensor connector pump screen and tube
• •
Oil
•
pan
Oil
33.
Install the
crankshaft
damper and
tighten the bolt as follows: To prevent
oil
ft.
FRONT OF ENGINE
• LOCATION
\
fc
w
OF STUDS
FOUR PLACES TIGHTEN BOLTS/STUDS IN SEQUENCE SHOWN FINGER-TIGHT
Step
a.
leakage, apply sealant to the places indicated— 3. OL (VIN S) engine
ft
1
:
Tighten the bolt to
b.
Step
2:
Loosen the
c.
Step
3:
Tighten the bolt to
lbs.
d
78-99
(105-135 Nm)
lbs.
bolt
one
full
turn.
35-39
(47-53 Nm). Step 4 Tighten the bolt
85-95
degrees
34
Install or
•
connect the following
Crankshaft pulley and tighten coun-
70-77
terclockwise to
lbs
ft.
(95-105 Nm) •
pump
Water
•
Alternator
•
35.
A/C compressor and bracket
•
Power steering pump and
tighten
the bolts to 18
Nm)
ft
•
Accessory drive
•
Valve covers
lbs (25 belt
•
Upper intake manifold
•
Engine assembly into the vehicle
Run
the engine
and check
for leaks
and proper operation.
3.4L (VIN N) Engine 1.
Before servicing the vehicle, refer to
the precautions at the beginning of this sec-
* STUD LOCATIONS
tion. 2.
Front cover bolt torque
sequence— 3. OL
3.
Please
visit
Remove
and mount
(VIN S) engine
our web
site at
www.chiltonsonline.com
it
the engine from the vehicle
on an engine stand.
Remove
or disconnect the following:
12-28
FORD MOTOR CO. TAURUS
•
SABLE •
Accessory drive belts
•
A/C compressor
•
Alternator
•
Intake
•
Exhaust Gas Recirculation (EGR)
vacuum
lines
tube
body
•
Throttle
•
Surge tank and supports
•
Left
•
Engine control sensor wiring har-
and
manifolds
right intake
ness and brackets Use the special
tool or a slide
remove the crankshaft
hammer
front oil seal
Left
•
Power steering pump
•
Crankshaft pulley
•
Front crankshaft seal
•
Crankshaft Position (CKP) sensor
to
—3.4L
and
•
Timing chain tensioner— 3. 4L (VIN N)
covers
right valve
engine
(VIN N) engine
Oil
•
Accessory
•
Front cover
CKP
•
(TDC)
No.
1
belt idler pulleys
pulse ring
Set the crankshaft at Top Dead Cen-
4. ter
pan
•
of the
compression stroke
for the
cylinder.
Remove
5.
or disconnect the following:
•
Timing chain tensioner
•
Tensioner arm
•
Timing chain
Do not
more
rotate the crankshaft
than 45 degrees counterclockwise or
more than 90 degrees clockwise from
TDC
the previously set No. 1 cylinder 7922KG53
Timing chain alignment marks
position with the timing chain
removed, or valve
—3.4L (VIN N) engine
to piston contact
could occur.
To 6.
install:
Using a small prybar, release the tim-
ing chain tensioner ratchet/pawl
through the access hole
in
mechanism
the timing chain
tensioner. Insert a small wire into the top of
the piston and unseat the
oil
check
Com-
ball.
press the timing chain tensioner by hand. 7.
With the tensioner compressed,
install a
0.060 inch (1.5mm)
into the small hole
drill bit
above the
engaging the lock groove
in
or wire
ratchet,
the rack of the
timing chain tensioner. 8.
Match the sprocket and chain timing
marks, and
install the
timing chain with the
crankshaft, camshaft and balance shaft
marks aligned. 9.
Install the
arm and
* APPLY 3 mm
(0.118 INCH)
tensioner pivot bolt to
BEAD OF SEALANT MEETING FORD SPECIFICATIONS
ft.
lbs.
(34-53
14-20 ft. lbs. (18-27 Nm). Remove the locking wire from
bolts to 10. 9306KG03
heads—3.4L
25-39
Nm). Tighten the Timing chain tensioner
(WSE-M4G323-A6) PRIOR TO INSTALLATION Apply sealant to the cylinder block and
timing chain tensioner
tensioner. Tighten the timing chain
the
timing chain tensioner. 11.
Apply silicone sealer
(VIN N) engine cal areas of the cylinder
to the
13
criti-
block as shown.
FORD MOTOR CO. -IO TAURUS
•
SABLE
£
OQ
Piston and Ring POSITIONING
TOP COMPRESSION RING
BOTTOM COMPRESSION RING
CONTROL RiNGS AND EXPANDER OIL
CENTER
LINE
OF P STON
PARALLEL TO WRIST PIN BORE
UPPER COMPRESSION RING GAP LOCATION
*922A3 , S
FRONT OF ENGINE Ring end-gap positioning— 3. 4L (VIN N) engine
CONTROL SEGMENT RING GAP OIL
LOCATION
7922KG26
Install the
new
crankshaft front
oil
seal
using a suitable seal driver or the special
tool— 3.4L (VIN N) engine
EXPANDER RING AND LOWER COMPRESSION RING GAP LOCATION
OIL
CONTROL SEGMENT
RING GAP LOCATION
?9Z2«16
Install or
12.
connect the following
•
CKP
•
Front cover and tighten the bolts to
•
Accessory
•
Oil
•
CKP
•
Front crankshaft seal
13.
ft.
lbs.
—
3
0L (VIN S and
U) engines
pulse ring
14-20
Ring end-gap spacing
(18-28 Nm)
belt idler pulleys
PISTON
NOTCH ON PISTON DOME AND BUTTON ON CONNECTING ROO 8200 IDENTIFICATION MARKS MUST BE ON SAME SIDE
pan sensor
Install
the crankshaft pulley and
tighten the bolt as follows:
Step
a. ft.
lbs. b.
1:
Tighten the bolt to
78-99
(105-135 Nm). Step
2:
Loosen the
Step
3:
Tighten the bolt to
bolt
one
full
turn. c. ft.
lbs. d.
35-39
(47-53 Nm). Step
4:
Tighten the bolt
85-95
VIEWED FROM FRONT OF ENGINE
degrees. 14.
Install or
•
connect the following
Power steering pump and
•
Left
•
Engine control sensor wiring har-
right valve
Piston and connecting rod positioning
Piston and connecting rod positioning
3.0L (VIN S and U) engines
3 4 L (VIN N) engine
covers
ness and brackets Left
•
Surge tank and supports
•
Throttle
•
EGR
right intake
manifolds
body
tube
vacuum
•
Intake
•
Alternator
•
A/C compressor
•
Accessory drive belts
•
15.
and
•
lines
Engine assembly
Run
the engine
into the vehicle.
and check
for leaks
Piston ring positioning— 3. 4L (VIN N) engine
and proper operation.
Timing belt service
is
covered
in Section
3
of this
manual
19 QH L“OU
FORD MOTOR CO TAURUS
S
SABLE
•
FUEL SYSTEM Fuel System Service Precautions
Pressure Gauge T80L-9974-A or equivalent, to the valve
Safety
most important
the
is
when
factor
performing not only fuel system maintenance but any type of maintenance. Failure to con-
duct maintenance and repairs
may
ner
death.
a safe
in
man-
result in serious personal injury or
Maintenance and testing
vehicle’s fuel
of the
system components can be effectively
ing to the following rules
and guidelines.
•
To avoid the possibility of
fuel
FUEL LINE DISCONNECT TOOL
through the
T90T-9550-B T90T-9550-C
On
flex-fuel engines,
Pressure Gauge T80L-9974-A or equivalent
and Fuel Pressure Test
Kit
134-R0035
or
equivalent, to the Schrader valve. Drain the
through the drain tube
into a suitable
7.
After the fuel
relieved,
and per-
and
system pressure
remove the
install the
fuel
7922KG55
Push connect
is
cap on the Schrader valve.
8.
Install the fuel
battery cable unless the repair or test proce-
9.
Connect the negative battery cable
dure requires that battery voltage be applied.
install:
sure prior to disconnecting any fuel system
component
Install the fuel filter
tank
fill
cap.
tighten the
system repairs are completed.
after
Fuel Filter
and eyes
advised that
connection.
trate the skin or
any
body
part of the
loosening
that
Connect the negative battery cable.
absorb any excess
it
occur)
is
all
engine and check
fuel
due
1
.
Pump
Before servicing the vehicle, refer to
the precautions at the beginning of this sec-
REMOVAL & INSTALLATION
2.
Disconnect the negative battery cable.
3.
Relieve the fuel system pressure.
4.
Disconnect the
5.
Loosen the
Before servicing the vehicle, refer to
the precautions at the beginning of this sec-
fuel lines.
tion.
to
filter
retaining
clamp and 2.
remove the
fuel spillage
fuel
Relieve the fuel system pressure.
filter.
quickly removed from
engine surfaces. Ensure that
soaked
fuel
all
cloths or towels are deposited into a suit-
able waste container.
Always keep a dry chemical (Class B)
•
extinguisher near the work area.
fire
Do
•
come
not allow fuel spray or fuel vapors to
into contact with a
spark or open flame.
Always use a back-up wrench when
•
loosening and tightening
fuel line
tion fittings. This will prevent
stress
and torsion
connec-
unnecessary
to fuel line piping.
Always
follow the proper torque specifications.
Always replace worn
•
rings with new. or equivalent,
Do
fuel fitting Fi-
not substitute fuel hose
where
fuel
pipe
is
installed.
Fuel System Pressure RELIEVING
1
.
Pump Locking Retainer
1
Fuel Ring
2
Fuel Tank Pressure/ Vacuum Transducer
Before servicing the vehicle, refer to
the precautions at the beginning of this section. 2. 3.
Disconnect the negative battery cable.
Remove
the fuel tank
fill
cap
to relieve
the pressure in the fuel tank. 4.
Remove
the cap from the Schrader
3
Locking Tab
4
Fuel Tank
5
O-Ring Seal
6
Connector
7
Fuel
On
gasoline engines, attach Fuel
f
Pump Module
valve located on the fuel supply manifold. 5.
for fuel
and proper operation.
it
connection prior to
Ensure that
spillage.
(should
to
fit-
heard.
Start the
1.
fitting or
to the filter
tion.
Always place a shop towel or cloth
around the
is
9.
Fuel
Please be
contacts. •
on
REMOVAL & INSTALLATION
exposing
to avoid
to fuel spray.
under pressure may pene-
fuel
retaining clamp. fuel lines
8.
Exercise extreme caution whenever relieving
system pressure,
filter
Push the
pressure reg-
(injector, fuel rail,
ulator, etc.), fitting or fuel line
skin, face
with the flow
tings until an audible click
leaks
fuel
tool
arrow facing the proper direction and
system pres-
relieve the fuel
and removal
6.
7.
Always
fitting
To
pressure gauge
sonal injury, always disconnect the negative
•
OR
connect Fuel
container.
by adher-
fire
6.
fuel
accomplished safely and
and drain the
drain tube into a suitable container.
7922KG58
Exploded view
of the fuel
pump module mounting
19_01 t U
FORD MOTOR CO. TAURUS 3.
Drain the fuel tank.
To
install:
4.
Remove
4.
Install
or disconnect the following:
•
Negative battery cable
•
Fuel lines •
con-
electrical
Fuel tank
•
Fuel
5.
the fuel
Install
ensure the
are not
damaged.
pump module
(Jse a
carefully
float
new O-ring
rod
seal.
pump module and the fuel tank retainer and push the fuel pump module into the fuel tank retainer. When the fuel pump module is properly engaged, a 6.
Align the fuel
definite click will
ing tabs 7.
Fuel supply manifold
of the fuel
—3.0L (VIN U)
engine 5. •
Fuel supply manifold and tighten
89 inch
lbs.
(10
Nm)
vacuum
Fuel pressure regulator
•
Fuel injector electrical connectors
bolts to •
pump.
•
Upper intake manifold
•
Fuel lines
•
Air cleaner outlet tube
•
Negative battery cable
Start the
engine and check
for leaks.
Fuel supply manifold with the injectors attached
be heard engaging 2 lock-
on the outside
Install or
Use new O-ring
line
and hoses and
filter
I
•
pump module
To install:
to
I
or connect the following:
Fuel injectors.
the bolts
nector •
SABLE
seals.
pump module
Fuel
•
•
•
89 inch
and tighten the
lbs.
(10
Fuel pressure regulator
3.4L (VIN N) Engine
Nm) 1
vacuum
.
Before servicing the vehicle, refer to
the precautions in the beginning of this sec-
connect the following:
line
tion.
pump module
•
Fuel
•
Fuel tank
•
Fuel
pump module
locking ring
Fuel injector electrical connectors
•
Upper intake manifold
•
con-
electrical
•
2.
Relieve fuel system pressure.
3.
Remove
or disconnect the follow-
Fuel lines ing:
• • 8.
nector
•
Air cleaner outlet tube
Fuel lines
•
Negative battery cable
Negative battery cable
Add
a
minimum
of
5.
10 gallons
Start the
for leaks.
3.0L (VIN S) Engine
engine and check
Negative battery cable Air cleaner outlet tube
•
Fuel lines
•
Throttle
•
Surge tank
of
clean fuel to the tank. 9.
engine and check
Start the
•
•
for leaks
Fuel injector electrical connectors
tion.
•
Fuel pressure regulator
3.
3.0L (VIN U) Engine
Relieve fuel system pressure.
Remove
or disconnect the following
•
Negative battery cable
•
Air cleaner outlet tube
•
Fuel lines
•
Fuel supply manifold with the
•
Injectors from the supply
Upper intake manitold
To
install:
Fuel injector electrical connectors
4
Install or
tion.
•
Fuel pressure regulator
2. 3.
Relieve fuel system pressure.
Remove
Negative battery cable
•
Air cleaner outlet tube
•
Fuel lines
•
Upper intake manifold
•
Fuel injector electrical connectors
•
Fuel pressure regulator
•
•
•
connect the following:
Fuel injectors Use
new O-ring
seals.
•
Fuel supply manifold
•
Injectors from the lower intake
injectors attached
manifold
bolts to
•
Fuel supply manifold with the
11-16
ft.
and tighten the lbs
•
Fuel pressure regulator
vacuum
•
Fuel injector electrical connectors Left
Fuel supply manifold with the
•
Surge tank
injectors attached
•
Throttle
Injectors from the supply manifold
•
Fuel lines
•
Air cleaner outlet tube
•
Negative battery cable
install: Install or
connect the following:
Fuel injectors. Use
new 0-ring
vacuum
line
•
4
(15-23
Nm)
line
To
•
vacuum
line
or disconnect the following:
•
mani-
fold
•
Before servicing the vehicle, refer to
vacuum
injectors attached
•
.
right intake
line
the precautions in the beginning of this sec-
1
manifolds
Left
•
.
2.
REMOVAL & INSTALLATION
and
•
the precautions in the beginning of this sec-
1
Fuel Injector
Before servicing the vehicle, refer to
body
Retaining bolts (1) and Fuel supply Manifold
(2)—3.0L
5.
(VIN S) engine
Start the
seals.
Heater Core replacement
is
covered
In Section
and
2 of this manual
right intake
manifolds
body
engine and check
for leaks.
0 QO L“OL TAURUS*
FORD MOTOR CO.
•4
SABLE
*
I
DRIVE TRAIN •
Transaxle
Steering rack and pinion gear and
84-113
tighten the nuts to
•
Before servicing the vehicle, refer to
•
ft.
lbs.
(29
Dual converter Y-pipe
•
•
HO 2 S
•
Axle halfshafts and tighten the hub
lifting
Remove
3.
•
and
•
tray
Lower
170-202
assembly
•
Air cleaner
•
Transaxle electrical connectors
•
ft.
35-46
Shift cable
•
Front wheels
•
Transaxle cooler lines
•
Front wheels
•
Shift cable
Stabilizer bar links
•
Transaxle electrical connectors
•
Lower
•
Air cleaner
•
Axle halfshafts
•
Battery and tray
•
Heated Oxygen Sensor (HO 2 S) con-
Starter
•
Steering rack and pinion gear. Support the gear with safety wire.
•
Powertrain support insulators
•
Subframe
•
Torque converter nuts
mission
Start the engine.
Check
For 1999-01
Install the transaxle.
•
Stabilizer bar links
all
(40-60 Nm).
subframe. Use 2 pieces of
ment holes behind the to align the
front
in
the align-
subframe
subframe
to the body.
Tighten the subframe mounting “ bolts to
57-76
ft.
lbs.
•
connect the following:
Tighten the bracket bolts to 65
(88
bolts to
Nm) and 90
ft.
lbs.
away from
Drive the CV-joint
with a brass
in
tie
drift
clamps and
the joint. off
the halfshaft
and a hammer.
the CV-joint with fresh grease and
on
to the halfshaft.
Use new clamps and
install the
CV-
joint boot.
rod ends
if
a vise.
the CV-joint boot
equipped with
air
the subframe
(122 Nm).
•
Wheel speed sensors
•
Steering knuckle from the halfshaft
•
Halfshafts
To install:
3.
Powertrain support insulators.
lbs.
Remove
7.
ball joints
Height sensors,
'•Use new
(77-103 Nm).
Install or
9.
3.
suspension
% inch outside diameter pipe mounts
•
(27-46 Nm).
Install the
the beginning of this section.
Place the halfshaft
Fill
Tighten the torque converter nuts to lbs.
in
2.
slide the joint
30-44
lbs.
Before servicing the vehicle, refer to the
Replace the snapring.
Outer
8.
.
6.
or disconnect the following:
•
ft.
Outer CV-Joint
install:
other engines, tighten the flange bolts to
(33-46 Nm). For
The inner CV-
5.
Lower
lbs.
ft.
(68-92
boot can be serviced by removing the
To
Remove
lbs.
serviced with the
tion.
•
ft.
joint
slide the boot
Before servicing the vehicle, refer to
Front wheels
25-33
is
the precautions at the beginning of this sec-
2.
ft.
outer CV-joint.
•
20-34
and
REMOVAL & INSTALLATION
3.0L (VIN S) engines, tighten the flange
7.
for leaks
4.
To install:
bolts to
The inner CV-joint
'•Whenever the vehicle subframe is removed or lowered, the wheel alignment should be checked.
1.
50-68
axle shaft as an assembly.
Halfshaft
the transaxle flange bolts
(47-63 Nm)
and tighten the
CV-Joint
1
and remove the transaxle.
6.
assembly
jack.
Remove
5.
lbs.
ft.
Front wheels
precautions
Support the transaxle with a trans-
4.
35-46
ball joints
Inner Tripod Joint
proper operation.
•
(77-103 Nm)
rod ends and tighten the
tie
Lower
and tighten the
lbs.
ft.
REMOVAL & REPLACEMENT
•
Dual converter Y-pipe
Outer
57-75
(47-63 Nm)
Transaxle cooler lines
nectors
•
and tighten the
lbs.
ft.
•
•
air
(68-92 Nm)
lbs.
•
ball joints
Stabilizer bar links
fasteners to
lbs.
and tighten the
ft.
Stabilizer bar links
nuts to
10.
51-67
equipped with
if
Nm)
ball joints
nuts to
Height sensors,
nuts to •
(230-275 Nm)
or disconnect the following:
Battery
sensor connectors
retainer nuts to
eyes.
Wheel speed sensors
nuts to
tion.
Attach a powertrain support to the
•
to
Nm)
the precautions at the beginning of this sec-
2.
•
suspension
and tighten the fasteners
Starter
21
engine
•
lbs.
(113-133 Nm)
REMOVAL & INSTALLATION 1.
ft.
ft.
nuts, bolts
Install or
and
circlips.
connect the following:
•
Halfshafts
•
Steering knuckle to the halfshaft
•
Hub retainer nut and tighten to 170-202 ft. lbs. (230-275 Nm)
1
2.
CV-Joint boot
CV-Joint 9306HG07
Removing the outer CV-joint
TAURUS*
19 QQ £ OO
FORD MOTOR CO. SABLE
*
2.
STEERING AND SUSPENSION Check the functioning
RUN air
Some
vehicles are equipped with an
bag system. The system must be disarmed before performing service on, or around, system components, the steering column, instrument panel components, wiring and senair
bag
of the air
system by turning the ignition key
to the
position and visually monitoring the
bag indicator lamp
cluster.
in
the instrument
The indicator lamp should
illumi-
nate for approximately 6 seconds, then turn
OFF
If
lamp does not
the indicator
nate, stays
ON, or flashes
at
has been detected by the
fault
illumi-
any time, a air
bag diag-
nostic monitor.
sors. Failure to follow the safety pre-
cautions and the disarming
procedure could result
in
accidental
bag deployment, possible injury and unnecessary system repairs.
Power Rack and Pinion Steering Gear
air
PRECAUTIONS
REMOVAL & INSTALLATION 1
.
Before servicing the vehicle, refer to
the precautions at the beginning of this sec-
Several precautions
when handling
must be observed
the inflator
accidental deployment
module
to
avoid
and possible per-
tion. 2.
Remove
or disconnect the follow-
ing:
sonal injury.
Support the rear
subframe with 2
of the
jackstands while removing the steer-
tall
ing gear
•
Negative battery cable
•
Intermediate steering shaft
wires or connector on the underside of the
•
Front wheels
•
module.
•
Dual converter V-pipe
•
Left stabilizer link
•
Outer
Never carry the
•
When
inflator
module by
the
Heat shield
tie
rod ends and tighten the
carrying a live inflator module,
•
Outer
hold securely with both hands, and ensure
•
Left stabilizer link
•
Heat shield
•
Dual converter Y-pipe
•
Power steering hose bracket
•
Front wheels
Auxiliary actuator connector,
•
Intermediate steering shaft
•
Negative battery cable
•
that the
bag and trim cover are pointed
away.
Place the inflator module on a bench
•
or other surface with the
•
bag and trim cover •
With the
module on the bench,
inflator
never place anything on or close to the
module which may be thrown 1.
in
•
the event of
•
Rear subframe bolts and lower the
operation
the steering gear to the
Steering gear through the
3.
•
Steering gear. Use fittings.
mounting nuts for the air
bag
before con-
•
tinuing. 6.
connect the following
hydraulic
cable.
to drain
•
ARMING •
After service is
seals on the
Tighten the
85-100
ft.
lbs.
tion. 2.
Remove
completed, connect •
Brake service
or disconnect the follow-
ing:
•
Negative battery cable
Rear subframe bolts and tighten
•
Front wheels
to
57-76
ft.
lbs.
(77-103
•
Nm)
repair.
the battery cables, negative cable last.
to
new
Before servicing the vehicle, refer to
the precautions at the beginning of this sec-
(115-135 Nm). them
Proceed with the
wheel
1
Install or
Disconnect the positive battery
minute
left
To install:
cable.
1
Strut
Front
Disconnect the negative battery
at least
and proper
opening
a straight-ahead position.
Wait
for leaks
REMOVAL & INSTALLATION
•
5.
left
hoses
Position the vehicle with the front
back-up power supply
and bleed the power steering sys-
access the power steering
tion.
4.
Nm)
Steering gear mounting nuts, then
Power steering hoses
3.
(48
necessary
•
in
lbs.
Check the alignment and adjust as
5.
subframe about 4
the precautions in the beginning of this sec-
wheels
Fill
ft.
Check the system
connector
move
Before servicing the vehicle, refer to
4.
tem.
to
2.
if
inches
DISARMING
.
nuts to 35
Power steering pressure switch
rear of the
an accidental deployment.
1
rod ends
equipped
facing up. •
tie
Height sensor and wiring,
equipped with
air
if
suspension
Power steering pressure switch
•
connector
•
Disc brake caliper and rotor
Auxiliaryactuatorconnector.it
•
Wheel speed sensor and wiring
equipped
•
Outer
Power steering hose bracket
•
Stabilizer link
is
covered
in
Section 4 of this manual
Brake hose bracket
tie
rod end
O OA
A
FORD MOTOR CO. TAURUS
SABLE
•
•
Steering knuckle pinch bolt
•
Strut
To
assembly
install: Install or
3.
•
connect the following:
Strut assembly. Tighten the
22-29
nuts to
lbs.
ft.
upper
(30-40
Nm), and the knuckle pinch bolt to
73-97
(98-132
lbs.
ft.
Nm). •
•
Stabilizer link
and tighten the nut
55-75
(75-101 Nm)
Outer
tie
nut to 35 • •
lbs.
ft.
to
rod end and tighten the ft.
lbs.
(48
Nm)
Wheel speed sensor and wiring Disc brake caliper and rotor and tighten the caliper anchor bracket bolts to
65-87
(88-118
lbs.
ft.
Nm) • •
Brake hose bracket Height sensor and wiring,
equipped with
air
•
Front wheels
•
Negative battery cable
Road
4.
if
suspension
test the vehicle
and check
for
proper operation.
Item
Description Front Coil Spring
i
Rear 1
Item
Shock Absorber
2
Front
3
Tie
4
Wheel Hub
Rod End
Description
Wheel Knuckle
5
Front
6
Front Suspension Lower
7
Front Stabilizer Bar
8
StabilLer Bar Link
Arm
Before servicing the vehicle, refer to
.
7922KG61
the precautions at the beginning of this secFront suspension
tion.
Remove
2.
component
identification
or disconnect the follow-
ing: •
Rear package tray trim panel
•
Rear wheels
•
Brake load sensor
•
Brake hose
•
Stabilizer bar bracket
•
Tension strut
•
Spindle pinch bolt
•
Strut
and
link
assembly
To install:
•Use new 3.
mounting nuts and
Install or
•
Strut assembly. bolt
bolts.
connect the following:
and tighten
Use a new pinch to
50-67
lbs.
ft.
(68-92 Nm). Tighten the 3 upper mounting nuts to 19-25 ft. lbs. (25-34 Nm). •
Tension strut and tighten the nut to
35-46 •
ft.
lbs.
(68-92 Nm)
and 60-81 inch
Stabilizer bar link
tighten
the nut to
lbs.
(7-9
Stabilizer bar bracket
the bolts to
25 -33
ft.
and tighten lbs.
(34-46
Nm) • •
1
2
Nm) •
Item
Brake hose Brake load sensor
•
Rear wheels
•
Rear package tray trim panel
Description Rear Stabilizer Bar
Item 10
Rear Spring
3
Shock Absorber
4
Nut
5
Washer
6
Lower Suspension Arm
Description Rear Suspension
Tie
Bushing
(4
Req’d)
(2
Req’d)
Rod
11
Washer
12
Rear Suspension Tension Strut and Bushing (2 Req'd)
13
Rear Suspension Lower Arm (Front) f
(Rear) 7
Rear Wheel Spindle
8
Nut (4 Req'd)
9
Washer
(2 Req'd)
A
Tighten to 68-92 Lb-Ft)
B
Tighten to 46 7-63.3 ap>gMM———b—ega—
FORD MOTOR CO.
—
m—
r
6.
•
Torque converter cover
•
Cruise control cable,
•
Torque converter
•
Accelerator cable
Transaxle fluid cooler lines
•
Air cleaner
Axle halfshafts
•
MAF
•
Intermediate shaft bracket
•
Battery, tray
•
Starter
•
Crankshaft pulley Right engine
•
Transaxle flange bolts. Support the transaxle
To
To install:
sensor connector
Engine front mount
•
Crankshaft Position (CKP) sensor
•
Engine
Fill
9.
Start the
1
engine and check
in
Drain the cooling system.
CKP
4.
Loosen the
•
Engine front mount. Tighten the
bolts to
35
(80
the
35
ft.
and the small bolts
lbs.
(48
16
Remove
5.
Battery, tray
•
Mass
and cables
(120 Nm).
motor
35
lbs.
ft.
(48 Nm).
•
Axle halfshafts
•
Transaxle fluid cooler lines
•
Torque converter. Tighten the nuts to
27
lbs.
ft.
(37 Nm).
•
Torque converter cover
•
Exhaust front pipe
•
Lower
•
A/C compressor,
ball joints.
bolts to
37
ft.
lbs.
•
Power steering pressure pipe
lbs.
(48 Nm).
pipe
assembly and tubes
if
equipped
belt
Power steering pressure switch connector Drive belt cover
•
Transaxle fluid cooler lines
Ignition coil connectors
•
Shift select cable
Heated Oxygen (HO 2 S) sensor con-
•
Coolant expansion tank Radiator hoses
if
equipped
and bracket
nectors
•
Fuel injector harness connectors
•
Coolant bypass hoses
•
Powertrain Control Module
•
Fuel line
(PCM)
vacuum
connectors
•
Intake manifold
•
Radiator cooling fan
•
•
Evaporative Emissions (EVAP) can-
•
EGR vacuum line DPFE system sensor vacuum
line
•
Power brake booster vacuum
line
vacuum
lines
•
Power brake booster vacuum
•
EVAP
•
Delta Pressure Feedback Electronic
•
Radiator cooling fan
(DPFE) system sensor vacuum
(50 Nm).
equipped
ft.
•
ister
Tighten the pinch
if
flex
•
Intermediate shaft bracket. Tighten the bolts to
35
Exhaust
•
•
lbs.
ft.
bolts to •
(PCV) valve and hose
•
88
•
line
canister
vacuum
PCM
•
Fuel injector harness connectors
vacuum
•
HO 2 S
•
Ignition coil connectors
connectors
Drive belt cover Alternator and bracket
•
Intake manifold
•
Power steering high pressure pipe
•
Fuel line
•
Cruise control cable,
•
Power steering pump and reservoir
•
Coolant bypass hoses
•
Accelerator cable
•
Accessory drive
•
Radiator hoses
•
Air cleaner
•
Coolant expansion tank
•
Coolant expansion tank
•
PCV
valve and hose
•
Radiator hoses
•
Shift select cable
•
MAF
sensor connector
•
Coolant bypass hoses
•
Transaxle fluid cooler lines
•
Battery, tray
•
Fuel line
•
Drive belt cover
•
Power steering pressure switch
line
•
Accessory drive
line
•
A/C compressor,
line
vacuum
line
and bracket
1 1
•
Intake manifold
•
•
EGR vacuum line DPFE system sensor vacuum Power brake booster vacuum EVAP canister vacuum lines
•
Power steering pump
•
Radiator cooling fan
•
Power steering pressure pipe
•
PCM
connectors
•
Exhaust
•
HO 2 S
sensor connectors
•
Right engine
•
Fuel injection wiring harness con-
•
Lower
nector
•
Axle halfshafts and intermediate shaft
• •
•
line
connector
flex
belt if
equipped
assembly and tubes
and cables
Tighten the strut center nuts to 35
.
ft.
the cooling system.
12.
Fill
13.
Start the
engine and check
for leaks.
Water Pump
pipe
REMOVAL & INSTALLATION
mount
ball joints
6.
Support the powertrain from below
switch connector
7.
Remove
mounts.
if
equipped
Power steering pump pressure Ignition coil connectors
sensor connectors
(48 Nm).
lbs.
SOHC 1
•
lines
•
line
•
vacuum
line
Exhaust Gas Recirculation (EGR)
•
belt
Nm) lbs.
(50 Nm).
Accessory drive
Cruise control cable,
Starter
ft.
Right engine mount. Tighten the
•
Accelerator cable
to
98
Tighten the pinch
Positive Crankcase Ventilation
•
(48 Nm).
lbs.
lbs.
Power steering pump
•
ft.
ft.
A/C compressor,
Air cleaner
35
37
•
•
Crankshaft pulley. Tighten the bolt
ball joints.
nector
Flow (MAF) sensor con-
Right engine mount. Tighten the bolts to
Lower
•
Air
•
(22 Nm).
•
or disconnect the following:
•
Nm)
ft.
•
front strut center nuts 5
lbs.
to
to
Axle halfshafts and intermediate
bolts to
turns.
(48 Nm).
lbs.
ft.
Nm) and
Transaxle flange bolts. Tighten the large bolts to
•
•
•
•
lbs.
(48
lbs.
ft.
shaft
2.
Relieve the fuel system pressure.
ft.
Rear engine mount. Tighten the
(133 Nm).
the beginning of this sec-
3.
nuts to 59
the
(48 Nm).
lbs.
and the center nut
Engine sensor
ft.
Nm) and
(80
lbs.
ft.
outer nuts to 35
•
•
•
for leaks.
tion.
connect the following:
Install or
35
bolts to
Before servicing the vehicle, refer to
.
Front engine mount. Tighten the nuts to 59
the cooling system.
8.
the precautions
install:
•
•
ft.
connect the following:
Install or
10.
DOHC ENGINE
•
•
Lower the vehicle over the powertrain.
9.
and cables
(48 Nm).
lbs.
mount
Raise the vehicle away from the pow-
8.
ertrain.
Tighten the strut center nuts to 35
7.
•
equipped
housing and tubes
•
•
motor
if
the front
and
rear
engine
.
Engine
Before servicing the vehicle, refer to the
precautions
in
the beginning of this section.
FORD MOTOR CO.
15-5
FOCUS 2.
Drain the cooling system.
3.
Drain the cooling system.
3.
Remove
4.
Relieve the fuel system pressure.
or disconnect the following:
•
Negative battery cable
•
Accessory drive
•
Front cover
•
Timing
belt.
Timing
•
Water
Refer to the Timing
Engine
•
air
cleaner intake tube
Tag and disconnect the vacuum
6.
hoses from the following components:
belt tensioner
pump
Exhaust Gas Recirculation (EGR)
•
?306SG02
valve
connect the following:
Install or
•
—
Positive Crankcase Ventilation
Cylinder head torque sequence
(PCV) valve
SOHC
2.0L
•
Water pump. Tighten the bolts (25 Nm).
•
Throttle
•
Timing
belt tensioner
•
Fuel pressure regulator
•
Upper
•
Timing
belt
•
Intake manifold
•
Heater hose
•
Accessory drive
•
Cylinder head bolts. Loosen the
•
Negative battery cable
18
lbs.
ft.
to
belt
Remove
7. •
the cooling system.
5.
Fill
6.
Start the
engine and check
or disconnect the following:
and
if
Engine
To install:
Speed control cable bracket 2
fuel
hose
Cylinder head and gasket
•
bolt,
if
equipped •
radiator
bolts in sequence.
equipped, the speed
control cable
for leaks.
engine
body
Accelerator cable, throttle control lever
•
DOHC 1
Refer to the Timing
belt.
Belt unit repair section.
To install: 4.
or disconnect the following:
Timing
•
Belt unit repair section. •
Remove
5.
belt
charging wiring electrical
•Use new
cylinder head bolts for
assembly.
Before servicing the vehicle, refer to
.
connections
the precautions in the beginning of this sec•
Install
8.
Crankshaft Position (CKP) sensor
the cylinder head and tighten
the bolts in sequence as follows
tion.
and Heated Oxygen (HO 2 S) sensor
Drain the cooling system.
2.
electrical
Remove
3.
or disconnect the following:
•
Negative battery cable
•
Accessory drive
pump
•
Water
•
Front cover
•
Timing
belt.
connections
Timing
•
Water
Step
1:
37
b
Step
2:
Loosen
c.
Step
3:
37
install:
4.
Install or
13
ft.
d
Step
4:
Plus 90 degrees
Step
6:
Plus 90 degrees
bracket and hose aside Alternator lower bolt, loosen only
•
Alternator upper bolt
Refer to the Timing
Install or
9.
•
•
and pivot the
Engine
oil
connect the following:
Timing
belt tensioner
•
Timing
belt
Front cover
•
Water
pump
•
dipstick tube bracket
Valve cover
•
Exhaust manifold heat shield
•
Air conditioning
•
Catalytic converter
•
Right-hand splash shield
•
Engine
Fill
6.
Start the
Engine
oil
10. •
dipstick tube from the
engine and check
ft.
and lbs.
•
Air conditioning
•
Engine accessory drive bracket
•
Valve cover
compressor
oil
compressor
dipstick tube
Heater and upper radiator hoses
•
Timing
•
Power steering pressure hose
•
CKP
belt
the cooling system.
5.
Right-hand splash shield bolts and
cylinder block
Negative battery cable
15-18
to
•
Accessory drive
lbs
(20-25 Nm)
Exhaust Gas Recirculation (EGR)
pulley
•
ft.
Air conditioning line bracket
lighten the bolt to
the shield
•
30-40
(40-55 Nm)
•
• •
connect the following:
Accessory drive bracket. Tighten
tube
(18 Nm).
•
lbs (50
the fasteners to
alternator forward •
ft
V4 turn
Nm)
e
belt tensioner
lbs.
Nm)
bolts
bracket bolts, then position the pulley
Water pump. Tighten the bolts
(50
Power steering pressure hose
• •
all
•
bolt
To
lbs.
Fuel supply line
belt
pump
ft
•
Belt unit repair section. •
a
belt
and
alternator
sensor and 2 main
fuel
charg-
ing electrical connections •
Engine
•
EGR
for leaks.
Cylinder Head
REMOVAL & INSTALLATION
oil
dipstick tube bolt
valve tube
•
Fuel supply line
•
Catalytic converter
•
Heat shield
•
Speed control cable
bracket,
if
equipped
SOHC
Engine
•
Throttle control lever accelerator
cable and 1.
Before servicing the vehicle, refer to
the precautions in the beginning of this sec-
2.
9J06SG0I
Disconnect the negative battery
following components:
—SOHC
Please
equipped, the speed
Connect the vacuum hoses
tion.
cable.
if
control cable
Cylinder head loosening sequence
•
engine
•
visit
our web
site at
www.chiltonsonline.com
EGR PCV
valve valve
to the
FORD MOTOR CO.
15-6
FOCUS
Exploded view
EGR
valve
EGR
valve gasket
3.
Accelerator cable bracket Throttle
body gasket
16.
Throttle Position (TP) sensor
17.
6.
Idle Air Control (IAC) valve
18.
7.
IAC valve gasket
8.
Throttle
9.
Fuel injection supply manifold
body
19.
20.
21.
10.
Fuel injector
22.
11.
IMRC
23.
12.
Oil filler
actuator
of the cylinder
cap
head, exhaust manifold and intake manifold mounting
body
Throttle
Fuel pressure regulator
•
Intake manifold
•
Air cleaner outlet tube
•
•
12.
Start the
engine and check
•
for leaks.
Engine
the precautions
in
•
Thermostat housing Cylinder head bolts. Mark each bolt
Crankshaft Position (CKP) sensor
with a
and Pleated Oxygen (HO 2 S) sensor
the
connections
Power steering pump and bracket
•
Alternator
punch and loosen them
install:
'The
cylinder head bolts
may be
reused twice. Replace bolts that have
•
Engine
•
Splash shield
•
Air conditioning
•
Spark plug wires
•
Valve cover
•
Upper
•
Heater hose
a.
Step
1:
15
ft.
lbs.
(20
•
Camshafts
b.
Step
2:
30
ft.
lbs.
(40
•
Ignition coil
c.
Step
3:
Plus 90 degrees
the beginning of this sec-
oil
in
sequence shown.
Cylinder head and the gasket
•
To
Fuel line
•
Before servicing the vehicle, refer to
.
•
main engine connector
electrical
the cooling system.
— 2.0L SOHC engine
Fuel charging electrical connectors at the
Negative battery cable Fill
DOHC
14.
15.
4.
•
•
13.
5.
•
11.
1
1.
2.
dipstick tube
compressor
two punch marks. Lubricate the cylinder bolts
8.
engine
when
oil.
tion.
Disconnect the negative battery
2.
cable.
Drain the cooling system.
3. 4.
Relieve the fuel system pressure.
5.
Remove
or disconnect the following:
•
Air cleaner
•
Timing
assembly
belt.
radiator
Install the
9.
hose
the bolts in
cylinder head and tighten
sequence as follows:
Nm) Nm)
outlet tube
Refer to the Timing
Belt unit repair section.
Tag and disconnect the vacuum
6.
hoses from the following components: •
Positive Crankcase Ventilation
•
Throttle
•
Fuel pressure sensor
(PCV) valve
•
Intake manifold
Remove
7 •
body
or disconnect the following:
Speed control and accelerator
Cylinder head bolt loosening sequence
Cylinder head torque
cables from the control lever
DOHC
DOHC
engine
engine
sequence— 2. OL
FORD MOTOR CO.
15-7
FOCUS • 3. •
Rocker arm bolts
To install:
Rocker arms and seats
connect the following:
Seats and rocker arms
•
Rocker arm ft.
S346SG01
Install or
8. •
in their orig-
bolts.
17-22
Tighten to
•
Valve cover
•
Negative battery cable
•
Engine
•
EGR
DOHC
Engine
dipstick tube
oil
manifold tube. Tighten
15-20 •
sequence— DOHC
Valve cover torque
new gasket. 15-22 ft. lbs.
(20-30 Nm).
(23-30 Nm).
lbs.
connect the following:
Intake manifold with a
Tighten the nuts to
positions
inal
the intake manifold
oil
mounting studs.
Install or
•
Clean and
7.
To install:
lbs.
ft.
it
to
(20-28 Nm).
IAC valve and TP sensor
electrical
connections
Engine
The Install or
10.
DOHC
•
engine
is
not equipped with
rocker arms. The camshafts act directly on
connect the following:
Speed control cable bracket
lbs.
•
and the camshafts
•
Ignition coil
•
Heater and upper radiator hoses
•
Valve cover
•
Sparkplugs Spark plug wires Air conditioning
compressor
SOHC
Splash shield
•
Engine
• •
oil
Alternator reservoir
•
Fuel line
•
CKP
dipstick tube
and the power steering
and bracket
sensor,
HCbsensor and 2 main
charging electrical connections
fuel
Accelerator cable and
•
1
if
Connect the vacuum hoses
Connect the vacuum hoses
.
PCV
•
Throttle
•
Fuel pressure sensor
•
Intake manifold
Drain the cooling system Relieve the fuel system pressure
10.
Fill
4.
Remove
1 1
Start the
• •
•
14.
Start the
.
DOHC 1
Exhaust gas Recirculation (EGR)
body
Fuel pressure regulator
•
•
Drain the cooling system
4
or disconnect the following
and
Speed
if
•
Air cleaner outlet tube
•
Throttle Position (TP) sensor con-
nector
by the crankshaft pulley •
Control (IAC) valve and
oil
Main engine control sensor wiring
•
Connectors from the mounting bracket Intake manifold
•
Positive Crankcase Ventilation
dipstick tube bracket
tion.
Remove •
'•Keep
or disconnect the following:
•
Engine
oil
tube located below
dipstick tube from the
•
Drive belt
•
Alternator
•
Fuel line
•
Intake manifold
block
Negative battery cable Valve cover all
EGR manifold the EGR valve
valve train components
•
Intake manifold lower nuts
•
Intake manifold upper nuts
in •
To 5.
install: Install or
•
Intake manifold
order for assembly.
connect the following:
Intake manifold. Tighten the fasteners to 13
Timing belt service
is
covered
lines
(PCV) hose
intake manifold •
vacuum
•
bolt that attaches the tube to the
Before servicing the vehicle, refer to
Heater hoses
•
connections
Engine
Bolt that secures the pipe located
if
Throttle Position (TP) sensor elec-
•
or disconnect the following:
Negative battery cable
•
control cable bracket bolt,
Idle Air
Remove •
equipped, the speed
equipped
trical
Before servicing the vehicle, refer to
Relieve the fuel system pressure.
control cable
•
•
Engine
3.
Accelerator cable, throttle control lever
for leaks.
REMOVAL & INSTALLATION
2.
for
2
Intake manifold
Remove
6.
the precautions in the beginning of this sec-
engine and check
tion.
Positive Crankcase Ventilation
•
Rocker Arms/Shafts
.
the cooling system.
the precautions in the beginning of this sec-
(PCV) valve
•
1
Negative battery cable
coolant leaks.
valve •
SOHC Engine
body
Air cleaner outlet tube
connect the following:
engine and check
to the
hoses from the following components
the cooling system.
Fill
Negative battery cable
Tag and disconnect the vacuum
•
Negative battery cable
13.
•
or disconnect the following
belt
Air cleaner outlet tube
Fuel pressure regulator
3.
Throttle
•
•
2.
•
Timing
Throttle
Intake manifold
body
•
valve
•
Air cleaner outlet tube
valve
Install or
12.
valve
PCV
•
following components: •
EGR
•
•
5.
to the
•
the precautions in the beginning of this sec-
the speed control cable to the con-
1 1
Engine
tion.
equipped,
trol lever
equipped, the speed
following components:
Before servicing the vehicle, refer to
.
if
control cable 9.
•
(8-10 Nm).
Throttle control lever, accelerator
cable and
Intake Manifold
REMOVAL & INSTALLATION
•
if
the valves.
Thermostat housing
•
bolt,
equipped. Tighten to 71-88 inch
in Section
3 of this manual
ft.
lbs.
(18 Nm).
FORD MOTOR CO.
15-8
FOCUS Remove
2.
Fuel line
•
Alternator
•
Negative battery cable
•
Drive belt
•
Fan motor
•
PCV hose
•
Fan shroud
•
Intake manifold
•
Connectors
•
Main engine control sensor wiring
•
Catalytic converter
•
Heater hoses
•
Engine
•
in
vacuum
the
•
lines
trical
Bolt that secures the pipe located by
71-97
bolt to
TP sensor
•
Air cleaner outlet tube
•
Negative battery cable
Fill
7.
Start the
2.
•
(18 Nm).
lbs.
6700-CH,
inch lbs. (8-11 Nm).
seal.
dipstick tube bracket.
oil
Catalytic converter
•
H02sensor
•
Fan shroud and the fan motor
electrical
connection
Rocker arms and valve tappets
•
Camshaft thrust
Cup
Exhaust Gas Recirculation (EGR)
engine and check
Camshaft from the
•
for leaks.
To
Front Crankshaft Seal
1
Power steering pressure hose
cylinder with clean
Before servicing the vehicle, refer to
.
the precautions
bracket
Install or
in
the beginning of this sec-
•
Catalytic converter
•
Exhaust manifold
•
Exhaust manifold. Tighten the nuts to
•
15-18
ft.
lbs.
(20-24 Nm).
Catalytic converter. Tighten the nuts to
26-34
ft.
lbs.
crankthe
seal.
Alternator
•
Power steering pressure hose
To
install:
to
4.
Use
and
Exhaust manifold heat shield. Tighten the nuts to
45-62
HO 2 S
•
Drive belt
sensor
•
Rocker arms
•
Ignition coil bracket
Install the
Apply a
oil to
b.
new
crankshaft sprocket and the
connection
DOHC
engine and check
Camshaft and Valve
Lifters
REMOVAL & INSTALLATION
SOHC
fol-
Use
lip
thin film of
5W-30 motor
of the seal.
seal replacer
T81P-6292-A,
camshaft front
Before servicing the vehicle, refer to
Install the inner
engine front
Install the
timing belt tensioner.
Tighten the tensioner bolt to
(20-30
15-22
ft.
Nth).
tion.
Install the
camshaft sprocket and
the timing belt
Before servicing the vehicle, refer to
the precautions
in
to
seal.
cover.
e.
Engine
Engine
the precautions in the beginning of this section.
coil
for leaks.
1 1
and
camshaft front seal as
inch lbs.
Negative battery cable
Start the
plug and the tappets
cylinder head front face.
belt.
lbs. 4.
bolts.
inch
’•The seal depth should be 0.002-0.04 in. (0.05-1. Omm) below flush with the
d.
•
and the
T81P-6700-A
seal.
c.
electrical
the
install the
Install the
timing
T92C-6700-
(5-7 Nm). •
rear of the
(8-13 Nm).
New cup
7.
front oil seal.
seal replacer tool
install the
5.
•
tool
CH, remove the crankshaft
EGR tube. Tighten the fasteners 45-62 inch lbs. (5-7 Nm).
oil.
lows:
Using seal remover
bracket
the
71-115
•
a.
(34-48 Nm).
•
to damage the when removing
Be careful not shaft surface
3.
•
WARNING
connect the following:
plate
Tighten the bolts to lbs.
install:
in
connect the following:
Camshaft thrust
the timing belt and crank-
shaft sprocket.
:
bore
cylinder head •
Remove
2.
cam
5W-30 motor
Camshaft through the
•
tion.
Alternator
Install or
rear of the cylin-
install:
6.
tube
3.
and the
plug from the rear of the cylin-
’•-Liberally coat the
•
To
plate bolts
plate
der head and discard
REMOVAL & INSTALLATION
Exhaust manifold heat shield
•
and bracket
Ignition coil
•
connection
•
•
or disconnect the follow-
der head
Oxygen (HO 2 S) sensor elec-
Pleated trical
front
•
Drive belt
•
T92C-
remove the camshaft
to
•
Negative battery cable
Start the
4.
seal removal tool
Remove
5.
wiring
or disconnect the following:
the inner engine front
ing:
(8-11 Nm).
•
•
Use
e.
Tighten the retainers to 71-101
Engine
the beginning of this section.
Remove
d.
cover.
Exhaust manifold heat shield.
•
Tighten the bolt to 71-101 inch
Negative battery cable
•
ft.
and remove the tensioner.
bolt
Exhaust manifold. Tighten the fas-
Before servicing the vehicle, refer to the
Remove
T74P-6256-B, and remove the
Unfasten the timing belt tensioner
c.
connect, the following:
teners to 13
lbs.
in
Use cam sprocket holding/remov-
camshaft sprocket.
REMOVAL & INSTALLATION
.
the timing belt.
Exhaust manifold
•
precautions
Align the timing marks and remove
a.
dipstick tube bracket
•
•
Engine
the camshaft front seal as
b.
Install or
for leaks.
Remove
ing tool
Exhaust Manifold
SOHC
4.
Exhaust manifold heat shield
3.
engine and check
the air cleaner and valve
•
the cooling system.
6.
Remove
follows:
To install:
connection
electrical
elec-
connection
oil
3.
cover.
bolt
inch lbs. (8-11 Nm).
•
connection
electrical
Disconnect the negative battery
2.
cable.
Oxygen (HO 2 S) sensor
Pleated
mounting bracket
the crankshaft pulley. Tighten the
1
or disconnect the following:
•
the beginning of this sec-
8.
Install
the valve cover and the air
cleaner assembly. 9.
Connect the negative battery cable.
FORD MOTOR CO.
15-9
FOCUS
uoougi;
Exploded view
of the cylinder
head— SOHC
engine
DOHC
Engine Before servicing the vehicle, refer to
1
the precautions in the beginning of this section.
Remove
2 •
or disconnect the following
Timing
belt
Refer to the Timing
Belt unit repair section.
Remove and Removing
the camshaft front
seal— SOHC
engine
•
Valve cover and camshaft sprockets
•
Oil control
solenoid flange
discard the cup plug located
at the rear ol the cylinder
head
•Mark
— SOHC
a
engine
the camshaft journal caps with
number •
to identity their location.
Camshaft journal caps. Loosen the bolts in
sequence and
in several
passes •
Camshafts
•
Oil control
sensor and bushing
To install: ing
3. Install the oil control solenoid bushand flange on the exhaust camshaft.
4
Coat the surface of the front
camshaft journal cap with gasket maker
E2AZ-19562-B Use seal Replacer T81P-6292-A,
Remove
the camshaft thrust plate retain-
ing bolts (A)
engine
and the plate
(B)
— SOHC
5. to install
the camshaft front seal 0 002—0.04
in.
(0.05-1. Omm) below Hush with the cylinder head front
Heater Core replacement
face— 2.0L SOHC engine
is
covered
in Section
Place the camshafts in position and
lubricate the bearing surfaces with engine
assembly 6.
D9AZ-19579-D new camshaft front oil
lubricant
Install
2 of this manual
seals.
M0T0RC °'
15-10
FOCUS 8.
7.
Apply a thin coat
of silicone gasket
and sealant F6AZ-19562-AA
to the sealing
9.
Install the
caps and tighten the
Inspect the
bolts in several 2-turn passes in the
surface of the of the front camshaft journal
sequence
bearing cap.
(13-17 Nm).
illustrated to
—Camshaft Bearing Cap
10-12
ft.
flange 10. 0-rings for
lbs.
oil
control solenoid
damage
Install the oil
Spark Plug
19
Engine Lifting Eye Bolt
Camshaft Intake
20
Engine Lifting Eye
4
Camshaft Exhaust
21
Camshaft Sprocket
5
Plug
22
Exhaust Camshaft Sprocket
6
Adjusting Shim
Bolt
2
Camshaft Bearing Cap
3
—Valve
—Exhaust
Bolt
Clearance
23
7
Valve Tappets
24
Blanking Plug
8
Valve Spring Retainer Key
25
Bolt
Camshaft Sprocket Intake
Blanking Plug O-Ring
—
Intake
Camshaft
Valve Spring Retainers
26
10
Valve Spring (Color Coding: Exhaust - Blue, Intake - Red)
27
Camshaft Front Seal
28
O-Ring
11
Valve Stem Seal
29
Camshaft Front Seal
12
Camshaft Position Sensor
30
Oil Feed Ring
13
CMP Sensor Bolt
31
Oil Feed Flange Bolts
14
Intake Valves
32
Oil Feed Flange
15
Exhaust Valves
33
Guide Sleeve
16
Cylinder Head
17
Cylinder Head Bolts
9
wear and
control solenoid flange
18
1
or
replace, as necessary.
f
—Front Camshaft
Bearing Cap
34
Fifth
Camshaft Bearing Cap 9300MG06
Exploded view
o!
t!
inder
head and camshaft mounting
— DOHC engine
FORD MOTOR CO. 1
-
FOCUS
9.5-10.5
Nm
(84-92
bolts in this
1 1
i
—DOHC engine
sequence
Nm)
to
84-92
inch lbs.
the sequence.
in
Rotate the camshafts a
.
check
II
control solenoid flange
oil
and tighten the bolts (9.5—10.5
C.1
o
lb 'n)
r
Tighten the
I
full
turn
and
for binding.
12.
Install or
connect the following:
•
Camshaft sprockets and timing
•
Valve cover
belt
Valve Lash
ADJUSTMENT
SOHC
Engine
The lash adjusters are hydraulic and are ^C2IIG66
not adjustable.
Camshaft journal cap loosening sequence— DOHC engine
DOHC 1
.
Engine
Before servicing the vehicle, refer to
the precautions in the beginning of this section.
0—
is
2.
Remove
3
Rotate the crankshaft so that the valve
closed and measure the clearance
between the
rffelWri
the valve cover
base
circle
lifter
shim and the camshaft
Intake valve clearance should be
0 004-0 007 inches Exhaust valve
clear-
ance should be 0.010-0.013 inches 4
Measure each valve and note the
clearance.
5
If
adjustment
the camshafts
is
necessary, remove
and replace the shims To
obtain the correct shim size, measure the
V
vj
ifs r\
13-17
Nm
(10-12
fe
Ib/ft) 33QEHG04
Camshaft journal cap torque sequence— DOHC engine
Brake service
Checking valve clearance— 2. OL engine
is
covered
in Section
4 of this manual
HC
"
S
FORD MOTOR CO.
O L
i 8
FOCUS
current shim, add the
sequence and
measured clearance,
18
tor intake valves
and subtract 0.006 inches
or 0.012 inches for exhaust valves.
connect the following:
Install or
6.
•
Camshafts
•
Valve cover
lbs.
ft.
in
several passes to
(24 Nm).
sensor connector
•
Oil lever
•
Catalytic converter
•
Negative battery cable the crankcase to the correct level.
5.
Fill
6.
Start the
engine and check
for leaks.
Starter Motor 3
)
REMOVAL & INSTALLATION Oil
SOHC 1
.
Before servicing the vehicle, refer to the
7
pan torque sequence— SOHC engine
2.
Drain the engine
3.
Remove
the beginning of this section.
in
Remove
or disconnect the following:
oil.
•
Negative battery cable
•
Catalytic converter
Negative battery cable
•
Intake manifold bracket
•
Intermediate shaft bracket
•
Two
•
Coolant pipe bolt
•
S
•
Oil
top starter motor bolts
terminal wire and the
B terminal
nut and cable from the solenoid
To
install:
Lower
4.
Apply silicone sealant
•
Starter
starter
motor
bolt
and
5.
•
S
mounting
terminal wire,
and
bolt to
nut.
B
18-20
terminal cable
Tighten the nut to
80-120
inch lbs. (9-13.5 Nm). •
Top
•
Air cleaner outlet tube
•
Negative battery cable
starter
bolts to
DOHC
motor
18-20
ft.
ft.
lbs.
pump
Intermediate shaft bracket
•
Intake manifold bracket
•
Catalytic converter
•
Negative battery cable
7.
Start the
Before servicing the vehicle, refer to the in
the beginning of this section.
Remove
or disconnect the following:
Crankshaft Position (CKP) sensor
•
Oil
•
Oil
Lubricate the crankshaft front
Oil
•
Oil
pump. Tighten ft.
pump
for leaks.
•
CKP
•
Oil
•
Timing
Fill
6.
Start the
DOHC
Engine
oil.
or disconnect the following:
1
.
Before servicing the vehicle, refer to
tion.
•
Oil
pan
To install:
'-Apply a bead
•
Starter.
•
Starter electrical connectors
•
Air cleaner
•
Negative battery cable
Tighten the bolts to 26
sealer to the
oil
of silicone
in
the beginning of this sec-
2.
Drain the engine
3.
Remove
gasket
pan flange.
Negative battery cable
•
Timing
belt.
4.
Install or
•
Oil
connect the following:
pan. Tighten the bolts
in
•
Oil
pan
•
Oil
•
Oil
pump pump
pickup tube
To install:
Pan
connect the following:
Install or
•
Oil
pump. Tighten
inch lbs.,(11
REMOVAL & INSTALLATION
•
Oil
pump
SOHC Engine Before servicing the vehicle, refer to the in
the beginning of this section. Oil
pan torque sequence— DOHC engine
the bolts to
97
Nm)
pickup tube. Tighten the
fasteners to
precautions
Refer to the Timing
Belt unit repair section.
4.
1
oil.
or disconnect the following:
•
ft.
(35 Nm).
belt
engine and check for leaks.
Catalytic converter
connect the following:
inch lbs.
the crankcase to the correct level.
5.
•
Install or
71-97
sensor
Air cleaner
connectors
pickup tube. Tighten the
pan
•
Starter electrical
the bolts to
(8-11 Nm).
the precautions
Starter
seal
(13-16 Nm).
lbs.
retaining bolts to
Negative battery cable
•
oil
oil.
connect the following:
Install or
•
•
pickup tube
with clean engine
10-12
Before servicing the vehicle, refer to
Remove
pump pump
Negative battery cable
lbs.
Oil
•
install:
Engine
Drain the engine
belt
pan
•
To install: 3.
3.
Oil
•
tion. 2.
•
3.
and brackets
engine and check
or disconnect the following:
Timing
To
4.
the precautions in the beginning of this sec-
precautions
lip
Remove •
the crankcase to the correct level.
(25-27 Nm).
DOHC
in
(25 Nm).
Coolant pipe bolt
Fill
1.
18
•
6.
Engine
to
•
bolts. Tighten the lbs.
2.
to the oil
Tighten the bolts
sequence
(25-27 Nm)
lbs.
Oil pan.
Before servicing the vehicle, refer to
tion.
connect the following:
Install or
•
motor assembly and tighten
Starter
.
rear seal retainer joints.
connect the following:
Install or
Engine
the precautions in the beginning of this sec-
pan
•
ft.
2.
REMOVAL & INSTALLATION
1
and brackets
Air cleaner outlet tube
the lower
.
Pump
SOHC
•
•
1
Oil
or disconnect the following:
•
To install: 3.
v
Engine
precautions 2.
!
9306SG05
88 inch
lbs.
(10 Nm).
pan
•
Oil
•
Timing
•
Negative battery cable
belt
the crankcase to the correct level.
5.
Fill
6.
Start the
engine and check
for leaks.
FORD MOTOR CO. -IE FOCUS
19 10
TOP COMPRESSION
Rear Main Seal
RING
BOTTOM COMPRESSION
REMOVAL & INSTALLATION
RING 1
CONTROL RINGS AND EXPANDER
OIL
Before servicing the vehicle, refer to
.
the precautions in the beginning of this section.
Remove
2.
or disconnect the following:
•
Negative battery cable
•
Transaxler-
•
Clutch,
•
Flexplate/flywheel
•
Oil seal
if
CENTER
LINE OF PISTON PARALLEL TO WRIST PIN BORE
UPPER COMPRESSION RING GAP LOCATION
equipped
To install: •
)F
connect the following:
Install or
3.
Oil seal. Seat the seal flush with the
CONTROL SEGMENT RING GAP
OIL
rear of the crankshaft oil seal retainer. •
82
lbs.
ft.
(112 Nm).
equipped
•
Clutch,
•
Transaxle
•
Negative battery cable
Start the
4.
LOCATION
Flexplate/flywheel. Tighten the bolts to
if
ENGINE
engine and check
for leaks.
OIL
EXPANDER RING AND LOWER COMPRESSION RING GAP LOCATION
Piston and Ring
CONTROL SEGMENT
RING GAP LOCATION
’322N29
POSITIONING
Ford 2.0L (VIN 3 and P) engines ing.
—
piston ring positioning, end-gap spacing and piston position-
The small directional arrow must lace the
front of the
engine
FUEL SYSTEM Fuel System Service Precautions
trate the skin or
any part of the body
that
it
Fuel System Pressure
contacts.
Safety
the
is
most important
performing not only
nance but any type to
fuel
of
factor
manner may
injury or death.
in
a
result in serious personal of
components can
be accomplished safely and effectively by
adhering
to the following rules
•
(should
fire
Do come •
to
flame.
Always
relieve the fuel
system pres-
component
(injector, fuel rail,
ulator, etc.), fitting or fuel line
pressure reg-
connection
Exercise extreme caution whenever relieving
system pressure,
skin, face
and eyes
advised that
fuel
to
avoid exposing
to fuel spray.
Please be
under pressure may pene-
all fuel
soaked
•
into contact with a spark or
until
fuel line
stress
and torsion
Do
or equivalent,
unnecessary
fuse from the
engine and allow
it
to idle
stalls.
Crank the engine that the fuel
for
5 seconds
to
pressure has been
relieved. 5.
Disconnect the negative battery cable.
6.
When
repairs are completed, connect
the negative battery cable fuel
pump
and replace the
fuse.
fuel fitting
Fuel Filter
0-
not substitute fuel hose
where
fuel
pipe
installed
is
Before servicing the vehicle,
REMOVAL & INSTALLATION
make sure
to refer to the precautions in the of this section
pump
box
to fuel line piping.
Always replace worn
rings with new.
connec-
the fuel
Start the it
ensure
Always use a backup wrench when
tion fittings. This will prevent
•
open
the beginning of this section.
battery junction
4
not allow fuel spray or fuel vapors
in
Remove
2
3.
loosening and tightening
sure prior to disconnecting any fuel system
fuel
quickly removed from
extinguisher near the work area
battery cable unless the repair or test proce-
•
is
Always keep a dry chemical (Class B)
•
sonal injury, always disconnect the negative
applied.
occur)
Before servicing the vehicle, refer to the
.
precautions
able waste container.
and per-
dure requires that battery voltage be
it
1
that all fuel spillage
cloths or towels are deposited into a suit-
fire
To avoid the possibility of
Ensure
engine surfaces. Ensure that
and guide-
lines.
RELIEVING
or connection prior to
fitting
loosening to absorb any excess fuel due to spillage.
Maintenance and testing
the vehicle’s fuel system
Always place a shop towel or cloth
•
around the
maintenance. Failure
conduct maintenance and repairs
safe
when
system mainte-
beginning
as well.
For complete Engine Mechanical specifications, see Section
1
.
Before servicing the vehicle, refer to the
precautions
1
in
the beginning of this section.
of this manual
-|K 1/1 FORD MOTOR CO.
D"1 4
I
FOCUS
2.
Relieve the fuel system pressure.
3.
Remove •
•
Evaporative Emissions (EVAP)
•
Rollover valve line
•
Fuel tank retainer strap. Support
line
Fuel
filter
lines
Fuel
filter
and bracket assembly
•
Fuel
filter
•
•
5.
Fuel
filter
•
Fuel
filter
•
Fuel
EVAP vapor
lines line
engine and check
Start the
pump module
Fuel tank pressure sensor connec-
Fuel tank
•
Fuel
install: Install or
Fuel
Pump
connect the following:
pump module. ft.
Tighten the
lbs.
(80 Nm).
Fuel tank
•
Fuel tank pressure sensor connec-
Fuel
.
Before servicing the vehicle, refer to
the precautions
in
•
pump module
2.
18
harness con-
3.
Remove
or disconnect the following:
•
Exhaust center muffler
•
Heat shield
•
•
Fuel
tiller
Fuel line and retaining clip
•
Pressure regulator vacuum hose
•
Accelerator cable
•
Fuel injector electrical connectors
•
Fuel supply manifold with the
Rollover valve line
•
EVAP vapor
Install or
•
Fuel supply line
•
Fuel
filler
•
injectors attached. Tighten the bolts
5.
and vent hoses
Heat shield
•
Exhaust center muffler
Fuel supply line Start the
new O-ring
Fuel supply manifold with the
to
line
•
and vent hoses
connect the following:
Fuel injectors using
seals
6. 5.
Injectors from the supply manifold
install:
4.
(25 Nm).
lbs.
ft.
•
Relieve the fuel system pressure.
•
Fuel tank retainer strap. Tighten the bolt to
or disconnect the following:
Negative battery cable
•
the beginning of this sec-
tion.
Remove •
•
nector 1
the beginning of this section.
in
Relieve fuel system pressure.
To
tor •
Before servicing the vehicle, refer to the
injectors attached
•
REMOVAL & INSTALLATION
2.
pump module
4.
•
.
3.
•
To
for leaks.
1
precautions
locknut to 59
Fuel
harness con-
tor
and bracket assembly
•
filter
Fuel
nector
connect the following:
•
REMOVAL & INSTALLATION
the fuel tank.
•
•
Install or
Fuel Injector
line
vapor
To install: 4.
Evaporative Emissions (EVAP)
vapor
or disconnect the following:
engine and check
for leaks.
88 inch
(10 Nm).
lbs.
•
Fuel injector electrical connectors
•
Accelerator cable
•
Pressure regulator vacuum hose
•
Fuel line and retaining clip
•
Negative battery cable
•
Air intake pipe
•
Air cleaner
DRIVE TRAIN Transaxle Assembly
REMOVAL & INSTALLATION
•
Rear engine mount and bracket
•
Starter
•
Transaxle flange bolts. Support the
•
MAF
transaxle.
•
Battery and tray
Transaxle
Tighten the strut center nuts to 35
•
Manual
To install:
.
precautions
in
Transaxle. Tighten the flange bolts ft.
lbs.
(48 Nm). 1
Before servicing the vehicle, refer to
the precautions
Loosen the
front strut center nuts 5
the beginning of this sec-
in
Rear engine mount bracket. tion.
Tighten the fastener to 59
ft.
lbs.
turns. 4.
.
motor
Starter
eyes. •
3.
35
Attach a support fixture to the engine •
lifting
Automatic
the beginning of this section. to
2.
ft.
connect the following:
Before servicing the vehicle, refer to the •
assembly
sensor connector
(48 Nm).
lbs.
Install or 1
motor
2.
Attach a support fixture to the engine
(80 Nm).
Remove
or disconnect the following:
lifting
• •
Battery and tray
•
Mass
3.
outer nuts to 35
Flow (MAF) sensor con-
Air
Rear engine mount. Tighten the ft.
(48
lbs.
Nm)
and the center nut
to
98
ft.
lbs. 4.
Air cleaner
•
Air intake pipe
•
Clutch slave cylinder fluid line
•
Shift cables
•
Exhaust
•
Engine front mount
VSS
or disconnect the following:
•
Battery
•
Mass
sensor connector
•
Reverse
•
Drive belt cover
light
and
Air
tray
Flow (MAF) sensor con-
switch connector nector •
• flex
Remove
(133 Nm).
assembly
•
front strut center nuts 5
turns.
nector •
eyes.
Loosen the
Axle halfshafts and intermediate
Positive Crankcase Ventilation
(PCV) hose
pipe shaft •
•
Lower
•
Axle halfshafts and intermediate
Lower
ball joints.
bolts to •
37
ft.
lbs.
Turbine^Shaft Speed (TSS) sensor
(50 Nm).
connector •
Drive belt cover
•
Reverse
•
Vehicle Speed (VSS) sensor con-
light
bolts to
35
Exhaust
flex pipe
ft.
lbs.
Transmission range sensor connec-
(48 Nm). tor
•
switch connector • •
nector
Air intake pipe
•
Right engine mount. Tighten the
shaft •
and resonator
•
Tighten the pinch
ball joints
•
Transaxle harness connector
•
Starter
•
Shift cable
Shift cables
motor
Clutch slave cylinder fluid line
and bracket
NCH wC
FORD MOTOR CO. i FOCUS
•
Front wheels
•
Exhaust front pipe
•
Right engine support
•
Outer
•
Lower
•
Axle halfshafts and intermediate
reservoir until the level reaches the
Clutch
4.
REMOVAL & INSTALLATION
1
Before servicing the vehicle, refer to
.
Transaxl^
•
ml brake
Remove
Torque converter
•
Transaxle
Negative battery cable
•
Transaxle
•
dipstick tube
oil
•
**The transaxle flange bolts vary
in
length. Note their locations for installa-
•
To
install:
5.
Install or
to
35
lbs.
ft.
or connect the following air
Tighten the fastener to 59
ft.
in
V2 turns to
21
ft.
lbs.
1 1
(29
Transaxle
•
Negative battery cable
outer nuts to 35
and
Check the brake
fill
with
DOT
Install or
13. •
lbs.
ft.
to
Nm)
(48
98
ft.
1
(133 Nm).
Torque converter. Tighten the nuts
oil
lbs.
•
Transaxle
•
OSS
Remove
2.
dipstick tube
•
Air cleaner
Air intake pipe
MAF
•
Air cleaner
•
Outer to
•
35
ball joints.
37
•
Mass
Air
-The
is used engine and the MTX75 manual transmission is used with the DOHC engine.
Flow (MAF) sensor con-
•
3.
Air intake pipe
Remove
IB5
with the
fluid
from the brake
fluid
manual transmission
SOHC
ft.
lbs.
Tighten the pinch
(50 Nm).
lbs.
(48 Nm).
Right engine support. Tighten the bolts to
•
35
ft.
lbs.
(48 Nm).
Exhaust front pipe. Tighten the fasteners to
35
ft.
lbs.
(48 Nm).
•
Front wheels
•
Shift cable
•
Starter
•
Transaxle harness connector
•
Transmission range sensor connec-
and bracket
motor
tor •
TSS sensor connector
•
Air intake pipe
•
PCV hose
and resonator
•
MAF
•
Battery and tray
sensor connector
Tighten the strut center nuts to 35
6.
ft.
Left halfshaft lbs.
assembly
Left
rod ends. Tighten the nuts
tie ft.
sensor connector
REMOVAL & INSTALLATION
shaft
bolts to
as necessary.
assembly
nector
cooler lines
oil
or disconnect the following
•
(37 Nm).
sensor connector
Lower
fluid,
connect the following:
•
Axle halfshafts and intermediate
•
fluid reservoir level
4 brake
tion.
Transaxle
•
proper opera-
Before servicing the vehicle, refer to
.
the precautions in the beginning of this sec-
lbs.
•
tt.
for
Halfshaft
and the center nut
27
no more
BLEEDING
lbs.
Rear engine mount. Tighten the
to
Check the clutch
.
12.
•
until
tion.
(80 Nm). •
full
bubbles are seen.
Rear engine mount bracket.
•
the pedal at
Repeat the procedure
10.
Clutch disc and pressure plate
Hydraulic Clutch System
(48 Nm).
the tool.
Close the bleeder before releasing
9.
Transaxle. Tighten the flange bolts
•
system.
travel.
Nm).
connect the following:
pump 80
the clutch pedal.
evenly
Transaxle
Nm) and remove
4-5 times and hold
pedal
steps.
Tighten the pressure plate bolts
Transaxle flange bolts. Support the transaxle.
•
V2 turn
the bleed nipple and
fluid into the clutch control
Have an assistant depress the clutch
8.
Clutch disc
Install
3.
(10
lbs.
To install:
tion. •
in
4 brake fluid.
Tighten the bleed nipple to 88 inch
7.
Pressure plate. Loosen the bolts evenly
Rear engine mount and bracket
•
or disconnect the following:
•
cooler lines
oil
•
Open
6.
tion. 2.
connector
DOT
bleed nipple.
shaft
Output Shaft Speed (OSS) sensor
the reservoir of Special Tool
with
Attach the tool to the slave cylinder
5.
ball joints
the precautions in the beginning of this sec•
Fill
416-D002
rod ends
tie
MIN
mark.
removal— IB5 manual
transaxle
(48 Nm).
For Accessory Drive Belt
illustrations,
see Section
1
of this
manual
HC
-fC FORD MOTOR
lU'IO
CO.
FOCUS To
install:
"•Use a new retaining 6.
Install or
•
clip for
assembly.
connect the following:
Axle halfshaft and intermediate shaft assembly. Tighten the nuts to
18 •
•
ball joint.
bolt to
37
Hub
7.
ft.
Tighten the pinch
(50 Nm).
lbs.
retainer nut. Tighten the nut to
232 •
(25 Nm).
lbs.
ft.
Lower
lbs.
ft.
(316 Nm).
Front wheel
Check the transaxle
fluid
and add, as
necessary. 8.
Tighten the strut center nuts to 35
ft.
(48 Nm).
lbs.
CV-Joints
OVERHAUL ’•The hub nut may be reused 4 times.
Mark the nut
Install or
7.
removal and only use hub nuts with 3 or fewer marks for assembly. i
at
•
•
•
the precautions
in
ball joint.
bolt to
37
Hub 232
Before servicing the vehicle, refer to the beginning of this sec-
connect the following:
Lower
ft.
lbs.
1
(50 Nm).
retainer nut. Tighten the nut to lbs.
ft.
.
2.
3.
Loosen the
Remove • • •
4.
strut center nut
5 turns.
Front wheel fluid
3.
and add, as
or disconnect the following:
retainer nut.
Lower
Mark
the nut.
Separate the inner CV-joint from the
transaxle as follows: •
If
remover
308-256 If
Right
MTX75 manual
transaxle or with an automatic transaxle, use Halfshaft
1
.
6.
Install
the circlip
slide
Remover
2.
Loosen the
3.
Remove
into the
circlip for
to seat.
assembly.
Draw
the stub shaft
wheel hub with Halfshaft
205-379.
Installer
strut center nut
4.
•
Front wheel
•
Hub
•
Lower
•
Intermediate shaft retaining clip
in
a vise.
Tripod joint boot clamps
•
Tripod joint boot
•
Tripod joint housing
•
Snapring
•
Tripod joint
install:
Install or
connect the following:
Tripod joint
•
Snapring
•
Tripod joint housing.
the joint
•
Tripod joint boot
•
Tripod joint boot clamps
Install
the halfshaft.
the nut.
ball joint
Press the stub shaft out of the wheel
Outer CV-Joint The outer CV-joint
is
serviced with the
halfshaft as an assembly.
Remove
Fill
housing with grease.
5.
hub. 5.
it
or disconnect the following:
•
5 turns.
or disconnect the follow-
Mark
Remove
•
the beginning of this sec-
retainer nut.
the axle halfshaft from the
assembly.
ing:
hammer
the halfshaft inner joint so that
is felt
in
the beginning of this section.
"•Use new snaprings and boot clamps for
Before servicing the vehicle, refer to
the precautions
To install:
"•Replace the
To
tion.
equipped with the
205-241 and a
"•The hub nut may be reused 4 times. Mark the nut at removal and only use hub nuts with 3 or fewer marks for assembly.
4.
eguipped with the IB5 manual
transaxle, use Halfshaft
•
ft.
ball joint
Press the stub shaft out of the wheel
hub. 5.
Tighten the strut center nuts to 35
(48 Nm).
lbs.
Front wheel
Hub
necessary. 9.
in
Remove
vehicle and place
tion. 2.
Before servicing the vehicle, refer to the
precautions
(316 Nm).
Check the transaxle
8.
Inner Tripod Joint
Tighten the pinch
the right axle halfshaft and
the intermediate shaft as an assembly.
The outer CV-joint
boot can be serviced by removing the inner tripod joint.
lw 17/
FORD MOTOR CO. -|C FOCUS
I
STEERING AND SUSPENSION bag indicator lamp
The
in
the instrument cluster
lamp should illuminate
indicator
approximately 6 seconds, then turn
•
for
OFF
7.
if
the indicator lamp does not illuminate, stays
These vehicles are equipped with an air bag system. The system must be disarmed before performing service on, or around, system components, the steering column, instrument panel components, wiring and sensors. Failure to follow the safety pre-
• •
on, or flashes at any time, a fault has been
detected by the
tie
35
rod ends. Tighten the nuts
(48
lbs.
ft.
Power Rack & Pinion Steering Gear
Nm)
Front wheels Steering shaft pinch bolt. Tighten the bolt to 21
bag diagnostic monitor.
air
Outer to
ft.
lbs.
(28 Nm).
•
Lower instrument panel cover
•
Negative battery cable
Check the wheel alignment and adjust as necessary.
Strut
REMOVAL & INSTALLATION
cautions and the disarming
procedure could result in accidental bag deployment, possible injury and unnecessary system repairs. air
1
.
1
tion. 2.
PRECAUTIONS
REMOVAL & INSTALLATION
Before servicing the vehicle, refer to
the precautions in the beginning of this sec-
LOCK
ignition to the 3.
Several precautions must be observed
Remove •
.
Before servicing the vehicle, refer to
the precautions in the beginning of this sec-
Center the steering wheel and turn the
tion.
position
2.
or disconnect the following
Remove
or disconnect the following:
Negative battery cable
•
Front wheel
•
Lower instrument panel cover
•
Brake hose bracket
accidental deployment and possible per-
•
Steering shaft pinch bolt
•
Stabilizer bar link
sonal injury.
•
Front wheels
•
Wheel speed sensor,
•
Outer
•
Brake caliper and rotor
wires or connector on the underside of the
•
Stabilizer bar links
•
Outer
module
•
Power steering
•
Lower
•
Steering knuckle pinch bolt. Sepa-
when handling
the inflator
Never carry the
•
When
module
to
avoid
module by
inflator
the
tie
rod ends
fluid cooler
hose
mount
carrying a live inflator module,
•
Right engine
hold securely with both hands, and ensure
•
Steering gear heat shield
•
Power steering hose support clamp
•
that the
bag and trim cover are pointed away
Place the inflator module on a bench
•
or other surface with the
bag and trim cover
•
Power steering hoses
•
6 subframe
facing up inflator
module on
the bench,
never place anything on or close to the
module
may be thrown
that
in
the event of
an accidental deployment Before servicing the vehicle, also be sure to refer to the precautions in the of this section
•
Steering gear pinion extension
•
Steering gear
install:
4
Install or
beginning
•
•
.
the precautions in the beginning of this section. 2.
• 5.
Position the vehicle with the front in
3.
Disconnect the negative battery cable
Nm).
4.
Disconnect the positive battery cable
6.
5.
Wait
at least 1
backup power supply
minute
bag
for the air
to drain before contin-
Proceed with the
7.
Once
repair.
repairs are completed, connect
the battery cables, negative cable
Check
position and visually monitoring the air
For
Tire,
ft
lbs.
upper
(25 Nm).
bolt to
66
Lower
ball joint
Tighten the pinch
37
(50 Nm).
ft
ft
lbs.
lbs.
rod end. Tighten the nut to
Outer
tie
35
lbs (48
ft
(90 Nm).
Nm).
Brake caliper and rotor
(35 Nm).
•
Wheel speed sensor,
Floor seal
•
Stabilizer bar link. Tighten the nut
ft.
lbs.
Subframe Alignment Pins 502-
raise the
subframe
the other bolts to
to
into position.
85
(200
lbs.
ft
ft
37
ft
lbs (50
if
equipped
Nm).
•
Brake hose bracket
•
Front wheel
Check the wheel alignment and adjust
4
(115
lbs
connect the following
•
Power steering hoses
•
Power steering hose support
Shock Absorber REMOVAL & INSTALLATION
•
Steering gear heat shield
•
Right engine bolt to
ignition key to the
18
as necessary
last.
the functioning of the air bag
system by turning the
RUN
•
to
Steering knuckle. Tighten the pinch
bolt to
Nm)
clamp
6.
connect the following
Strut assembly. Tighten the
•
Install or
uing.
8.
(80
Tighten the 4 rear bolts to 147
Nm) and
a straight-ahead position.
•
connect the following
lbs
strut.
mount nuts
assembly
mount nuts
Steering gear pinion extension
Install
002 and
wheels
ft.
knuckle from the
strut
Install or
•
Tighten the pinch bolt to 26
Before servicing the vehicle, refer to
Strut
Steering gear. Tighten the bolts to
59
as well
•
•
Floor seal
DISARMING
1
3.
•
To
Upper
rod end
To install:
frame.
With the
•
•
equipped
ball joint
rate the
Support the sub-
bolts.
tie
if
37
ft.
mount Tighten lbs.
the
3 Door Model
(50 Nm).
•
Power steering
•
Stabilizer bar links. Tighten the
nuts to 37
ft.
fluid cooler
lbs.
hose
1
.
Before servicing the vehicle, refer to the
precautions
in
the beginning of this section.
(50 Nm).
Wheel and Ball Joint specifications, see Section
1
of this manual
“ 1 OO E
i
FORD MOTOR CO. FOCUS
I
1
Remove
2.
or disconnect the following:
Luggage compartment
•
interior trim
panel
Upper shock absorber mounting
•
nut •
Lower shock absorber mounting
•
Shock absorber
bolt
To install:
^Tighten the shock absorber mounting fasteners with the suspension at curb height and the vehicle weight sup-
ported by the wheels. connect the following:
Install or
3.
Shock absorber. Guide the rod
•
into
the locating hole.
Lower shock absorber mounting
•
Tighten the bolt to 85
bolt.
ft.
lbs.
(115 Nm).
Upper shock absorber mounting
•
nut.
Tighten the nut to 13
lbs.
ft.
(18 Nm).
Luggage compartment
•
interior trim
panel
Wagon 1
.
Before servicing the vehicle, refer to
the precautions in the beginning of this secFront strut assembly exploded view
tion.
2.
Remove
the upper and lower
mounting bolts and remove the shock absorber.
To install:
^Tighten the shock absorber mounting fasteners with the suspension at curb height and the vehicle weight sup-
ported by the wheels. 3.
Install the
tighten the
shock absorber and
mounting bolts
to
85
lbs.
ft.
(115 Nm).
Coil spring
REMOVAL & INSTALLATION
Front 1.
Before servicing the vehicle, refer to
the precautions at the beginning of this section. 2.
Remove
3.
Compress the
suitable spring
the strut from the vehicle.
comes away from 4.
Remove
coil
spring using a
compressor
until the
spring
the seat.
the large center nut
and
slowly release the spring compressor.
To
install:
5.
Compress
the strut.
the spring
and
install
it
on Coil spring
compressor and adapters
E 1Q 3
FORD MOTOR CO. H FOCUS Install the
6.
the nut to 7.
35
Install
ft.
upper lbs.
strut
mount. Tighten
(48 Nm).
the strut assembly in the
vehicle.
Front bolt
cannot be adjusted.
Control arm
excessive, check the wheel
To
install:
•Use new washers
Rear
3. 1
.
Before servicing the vehicle, refer to the
precautions
in the
sprincpcompressor 204-167
b.
the coil spring
2:
Step
it.
(120
lbs.
d.
the coil spring and
Step
Front
•The
hub nut may be reused 4 times. nut at removal and only use hub nuts with 3 or fewer marks for assembly.
Mark the
ft.
plus 90 degrees
Check that 125-169 ft.
3
bolt No. lbs.
Ball Joint
the precautions in the beginning of this sec-
REMOVAL & INSTALLATION
•
5.
ball joint is
replaced with the
tion.
Install or •
Before servicing the vehicle, refer to
1.
is
(170-230
Nm) 4.
The lower
ft.
4:
tightened to
Lower
Tighten nut No. 2 to 88
to
1
Tighten bolt No. 3 to 88
3:
remove the
compressor.
ft.
Nm)
To install: Install
connect the following
Lower
ball joint.
bolt to
37
ft.
lbs.
Tighten the pinch
2.
Loosen the
3.
Remove
(50 Nm).
Front wheel
Check
the wheel alignment
and adjust
as necessary.
lower control arm as an assembly.
CONTROL ARM BUSHING REPLACEMENT The lower control arm bushings are
Front wheel
•
Wheel speed sensor,
•
Hub
•
Brake caliper and rotor
•
Outer
•
Lower
4
replaced with the lower control arm as an
strut center nut
5 turns.
or disconnect the following:
•
•
Lower Control Arm REMOVAL & INSTALLATION
is
plus 60 degrees
Nm)
and remove c.
5.
correct,
REMOVAL & REPLACEMENT
74
Tighten nut No.
1:
Nm)
Step
(120
lbs.
Compress
is
required.
assembly.
Step
(100
with Adapters 204-215. 4.
ball bearing
beginning of this section.
Raise and support the vehicle. Install
the torque
If
is
retainer nut
replacement of the wheel bearing
the control arm. Tighten the
Install
lbs. 3.
and
hub
fasteners in sequence as follows: a.
2.
nuts, bolts
for
proper torque.
for
I
wheel bearing play
•
•
If
I
if
equipped
Mark the
retainer nut.
nut.
rod end
tie
ball joint
Steering knuckle pinch bolt
Press the stub shaft out of the wheel
hub.
assembly.
5.
Press the hub out of the wheel bear-
6.
Remove
7.
Press the bearing out of the hub
ing. 1
.
Before servicing the vehicle, refer to
the precautions in the beginning of this sec-
Wheel Bearings
tion. 2.
Remove • • •
or disconnect the following:
To install:
ADJUSTMENT
8
Front wheel
Lower
ball joint
Rear bracket bolts
The bearings on the
the snapring
front
and
Press the bearing into the hub.
9
Install the
snapring.
rear
wheels are a one piece cartridge design and
10
Press the hub into the wheel bearing
1 1
Draw
hub with 12
the stub shaft into the wheel
Install or
•
bolt to
66
Lower
ball joint
bolt to •
•
37
Outer
tie
35
lbs.
ft
ft
ft
lbs (90
Nm).
Tighten the pinch
lbs (50
Nm).
rod end. Tighten the nut to
(48 Nm).
Brake caliper and rotor
Hub
•
232
retainer nut ft.
lbs.
(316
Tighten the nut to
Nm)
•
Wheel speed sensor,
•
Front wheel
if
equipped
Tighten the strut center nuts to 35
lbs (48 14.
connect the following
Steering knuckle Tighten the pinch
•
13.
205-379
Halfshaft installer
ft.
Nm).
Check the wheel alignment and
adjust as necessary.
Rear 1.
Before servicing the vehicle, refer to
the precautions in the beginning of this section.
For Wheel Alignment specifications, see Section
1
of this manual
15-20 2.
Remove
FORD MOTOR CO. FOCUS
or disconnect the following:
•
Rear wheel
•
Dust cap
•
Hub
•
Brake drum
•
Wheel speed sensor tone
•
Snapring
Remove install:
the wheel bearing with a press.
^Use a new wheel speed sensor tone ring for assembly.
nut
equipped
3.
To
•
Snapring
•
Wheel speed sensor tone
• •
ring,
if
4.
brake 5.
Press the wheel bearing into the
drum hub. Install or
connect the following:
ring,
equipped Brake drum
Hub 173
nut. ft.
Tighten the hub nut to
lbs.
•
Dust cap
•
Rear wheel
(235 Nm).
if
FORD MOTOR CO. 2000-01 Lincoln
16-19 16-2
DRIVE TRAIN..' ENGINE REPAIR FUEL SYSTEM
16-18 16-2
PRECAUTIONS
Removal & Fuel
16-20
A 16-20
Disarming
16-20
Precautions
16-20 16-2
Alternator Installation
16-2
Removal
16-2
C Camshaft And Valve
Fuel System Pressure
Lifters
Installation
Installation
16-19
Installation
16-21
Removal &
Installation
Removal &
16-3
Installation
16-8
Exhaust Manifolds Installation
&
Installation
16-7
Intake Manifold
Removal &
Installation
16-18 16-18
16-11
Installation
Rocker Arms/Shafts Installation
16-11
16-7 16-7
S 16-10
Motor
Removal &
Installation
16-10 16-20
Strut
Removal
&
Installation
16-20
T
16-7
Front Cover and Seal
Removal &
Installation
Transmission Assembly
Removal &
Installation
i
Lower
16-21
Ball Joint
Removal &
Installation
Lower Control Arm Control
16-21 16-21
16-21
Replacement Installation
Upper
16-21
&
Installation
Upper Control Arm
Removal & Oil
Pump Removal &
16-10 16-11
16-17 16-17
16-21
16-9 16-9
Adjustment
W Water
Pump
16-5
16-20
Installation
Wheel Bearings
&
16-5 16-21 16-21
Adjustment
Removal
Power Rack and Pinion Steering Gear
16-21
Installation
Valve Lash
Removal &
r
Positioning
16-21 16-21
Replacement
Removal &
16-11 Installation
16-19
V 16-10
Installation
16-19
Arm Bushing
O Pan
16-12
16-21
Ball Joint
Removal Control
Arm Bushing
Removal &
16-12
U
L
Piston and Ring
16-18
Fuel Filter
Fuel Injector
16-3
16-8
F
16-19
16-3
Timing
Adjustment
Oil
16-3
Removal &
16-19
16-5
Engine Assembly
Rear Main Seal
Starter
16-20
16-20
Timing Chain, Sprockets,
16-5
E
Removal &
Installation
Bleeding
16-20
Overhaul Cylinder Head
Removal
Removal &
16-20
CV-Joint
Installation
R
Removal &
16-20
Hydraulic Clutch System
16-21
Coil Spring
Removal &
16-18
Halfshaft
16-19
Removal &
16-18
16-19
Adjustments
16-18
H
16-8 16-8
16-18
Fuel System Service
Ignition
Clutch
Removal &
Installation
Precautions
Bag
16-18 16-18
Relieving
SUSPENSION
Removal &
Installation
Pump
Removal &
STEERING AND
Air
LS
Replacement
16-21
FORO MOTOR CO.
16-2
LINCOLN LS
PRECAUTIONS of the following precautions,
all
which deal with personal of
prevention
safety,
component damage, and important points
when
consideration
to take into
servicing a
motor vehicle:
tor or
cooling system
hot; serious
when
the engine
is
burns can occur from the steam
Observe
tions
all
applicable safety precau-
when working around
fuel.
Whenever
servicing the fuel system, always work well-ventilated area. or vapors to
come
Do
in
a
not allow fuel spray
oil
may cause
a
should always buy the correct type
can-
fluid for
You should make every to
(a hot
mini-
effort to
used engine
oil.
worn when Wash your hands and any
fire
your vehicle.
If
of brake
the brake fluid
becomes contaminated, completely system with new
Any brake
flush the
Never reuse any
fluid.
removed
Protective gloves should be
brake
changing
from the system should be discarded. Also,
oil.
exposure
sible after
Soap and
to
used engine
oil.
hand cleaner
water, or waterless
new
All
now equipped
Supplemental
Inflatable Restraint (SIR) sys-
come in condamage
fluid to
will
it
the paint.
Never operate the engine without the
•
vehicles are
fluid that is
do not allow any brake
should be used. •
fluid.
tact with a painted surface;
proper amount and type of engine
so WILL result
Supplemental Restraint System (SRS) or
drop
example). Keep a dry chemical
Timing
•
belt
maintenance
Many models
important.
doing
oil;
severe engine damage.
in
extremely
is
an
utilize
interfer-
extinguisher near the work area. Always
tem. The system must be disabled before
ence-type, non-freewheeling engine.
keep
performing service on or around system
timing belt breaks, the valves
fuel in a container specifically
and
essential to the safe
proper operation of the brake system. You
of skin disorders, including
mize your exposure
is
prolonged con-
with an air bag system, often referred to as a
contact with a spark,
in
open flame, or excessive heat light, for
used engine
tact with
number
that
other exposed skin areas as soon as pos-
and hot coolant. •
The EPA warns
•
Clean, high quality brake fluid from a
•
sealed container
medical assistance.
cer.
Never open, service or drain the radia-
•
IMMEDIATELY seek
brake fluid internally,
Before servicing any vehicle, please be
sure to read
in
If
the
the cylinder
components, steering column, instrument
head may
panel components, wiring and sensors.
tially
possibility of fire or explosion. Refer to the
Failure to follow safety and disabling proce-
expensive) engine damage. Refer to the
additional fuel system precautions later
dures could result
designed
for fuel storage; also,
always
properly seal fuel containers to avoid the
in
this section.
Fuel injection systems often remain
«
pressurized, even after the engine has been
in
accidental air bag
unnecessary system
ment
Always wear safety goggles when
•
working with, or around, the
be relieved before disconnecting any fuel
tem.
do so may
and/or personal
injury.
•
Brake
fluid often
contains polyglycol
ing a
and wash your hands thoroughly
handling brake
after
brake fluid
fluid.
If
with clean, running water for 15 minutes.
eye
irritation persists, or
if
bag sys-
face,
non-deployed
air
When
plac-
always face the bag and trim cover
reduce the motion of the module
if
it
will
If
you have taken
tional air
bag system precautions
later in
interval charts in the front of
for the
recommended
replace-
and
interval for the timing belt,
to the
inspection.
Disconnecting the negative battery
•
cable on
some
vehicles
may
interfere with
the functions of the on-board
tem^) and may
require the
computer sys-
computer
to
undergo a relearning process once the negative battery cable
When
•
is
accidentally deployed. Refer to the addi-
causing poten-
timing belt section for belt replacement and
air
bag on a work sur-
upward, away from the surface. This
you do get
your eyes, flush your eyes
in
air
carrying a non-deployed
pointed away from your body.
ethers and polyglycols. Avoid contact with the eyes
When
bag, be sure the bag and trim cover are
result in fire
manual
this
turned OFF. The fuel system pressure must
lines. Failure to
maintenance
deployment, possible personal injury and repairs.
strike the pistons,
serious (also time-consuming and
is
servicing
reconnected.
drum
brakes, only dis-
assemble and assemble one side
at a
time,
leaving the remaining side intact for refer-
ence.
this section.
ENGINE REPAIR '•Disconnecting the negative battery cable on
some
vehicles
may
interfere
with the functions of the on board
puter system. The computer
com-
may
•
Lower splash shield
•
Alternator
•
Alternator harness connectors
•
Alternator
INSTALLATION
mounting bolts
3.0L Engine
undergo a relearning process once the negative battery cable
is
reconnected.
Install or
3.9L Engine 1
.
connect the following:
•
Alternator
•
Alternator harness connectors. Tighten
Before servicing the vehicle, refer to
Alternator
the battery cable terminal nut to
70 inch
lbs.
the precautions in the beginning of this sec(8
Nm).
tion.
REMOVAL
• 2.
Remove
Alternator
or disconnect the followbolts to
35
ft.
mounting
lbs.
bolts. Tighten the
(48 Nm).
ing:
3.0L Engine 1
.
•
Before servicing the vehicle, refer to
the precautions
in
the beginning of this sec-
tion. 2.
Remove •
•
or disconnect the following:
Negative battery cable
Accessory drive
belt
•
Lower splash shield
•
Accessory drive
•
Negative battery cable
Negative battery cable
•
Air intake tube
•
Accessory drive
belt
belt
•
Lower splash shield
•
Alternator mounting bolts
•
Alternator harness connectors
•
Alternator
3.9L Engine 1
.
tors,
bolts
Install the alternator
then in
harness connec-
install the alternator.
sequence as follows:
Tighten the
FORD MOTOR CO.
16-3
LINCOLN LS •
Front brake calipers
•
Lower
•
Upper
ball joints
•
Lower
strut
•
Starter
stabilizer bar links
mount
bolts
motor wiring harness con-
nectors •
Power Steering Pressure (PSP) switch connector
•
Steering shaft pinch bolt
•
Torque converter,
front
if
equipped
Support the engine, transmission,
7.
and center crossmembers and the
cooling system with a powertrain
lift
and
transmission support bracket.
Support the rear
8.
of the vehicle with
10. safety stands.
Remove
9.
or disconnect the following:
•
Transmission crossmember bolts
•
Subframe bolts
•
Crossmember
•
Powertrain assembly
2.
bolts
9306TGI
Alternator torque sequence
— 3.9L engine
Attach a hoist to the engine.
Remove
1 1
Step
a.
(48
lbs.
(20
lbs.
(48
lbs.
2:
Nm)
Step
c.
35
ft
Tighten bolt No. 2 to 15
ft
ft
Tighten bolt No.
1
to
Nm)
Step
b.
1:
3:
plus 90 degrees
Tighten bolt No. 3 to 35
Nm)
Install or
connect the following:
•
Air cleaner
• •
housing and outlet tube
Wire harness retainers
Engine appearance cover
•
Starter
Upper
radiator shield
•
Heated Oxygen (HO 2 S) sensor
•
Upper
radiator support brackets
•
A/C pressure switch connector
•
Motor mount nuts
•
Power steering
•
Accessory drive
•
Fuel line
•
Power steering pump
•
Vapor Management Valve (VMV)
•
Hydraulic cooling fan
cover
•
Upper
Lower splash shield
•
Accessory drive
•
Air intake tube
•
VMV
vacuum hose
•
Negative battery cable
•
Cowl
leaf
belt
Timing
ADJUSTMENT
•
screens
•
Chassis vacuum lines
Cross vehicle support bar
•
Fresh
•
Intake manifold rear
intake housing
12 of the
•
torless Ignition
timing the
is
equipped with a Distribu-
System
(DIS).
not adjustable.
is
It
is
Accelerator cable and cruise control
cable
The ignition
To
•
Cable bracket
•
Ground
controlled by
PCM. •
strap
Lift
•
3.0L Engine 1
Before servicing the vehicle, refer to
.
tion.
Drain the cooling system.
2.
Relieve the fuel system pressure.
3.
Main transmission wiring harness
•
Transmission from the engine
install:
14.
Install or
•
the flange bolts to 35
•
charging harness connectors
2
•
A/C
•
Hydraulic cooling fan reservoir
•
Left, right
•
A/C compressor manifold and tube
•
assembly
•
line
mounting bracket
•
Coolant hoses
•
Exhaust front pipe and heat shields
•
Driveshaft
refrigerant.
•
Shift cable
oil.
•
Front wheels
or disconnect the following:
•
lbs.
(48
•
Nm)
lbs (63
Oil cooler
hoses
Transmission
and bracket
Front wheel speed sensor connec-
oil
cooler lines,
if
equipped
Upper radiator hose Hydraulic cooling fan pump. Tighten the bolts to 18
•
ft.
lbs.
(25 Nm).
Power steering pump. Tighten bolts to 18
Drain the engine
Negative battery cable
ft.
Powertrain on the subframe
ft.
•
and center splash shields
Recover the A/C
Remove
connect the following:
Transmission to the engine. Tighten
Tighten the motor mount nuts to 46
5.
•
hoses
Transmission flange bolts
Nm)
4.
6.
or disconnect the following
•
•
the precautions in the beginning of this sec-
if
and transmission out
Oil cooler
Main engine wiring harness con-
fuel
the engine
Remove
connector
REMOVAL & INSTALLATION
cooler lines,
•
nector
Engine Assembly
oil
subframe
13.
main vacuum
hose This vehicle
pump
hose
radiator
Transmission
belt
equipped
•
air
motor
bracket
reservoir
•
Ignition
or disconnect the following:
•
ft
lbs.
•
Accessory drive
•
HO 2 S
belt
sensor bracket. Tighten the
nut to 89 inch lbs. (10 Nm).
tors
For complete service labor times, order the Chilton Labor Guide
the
(25 Nm).
FORD MOTOR CO.
16-4 •
Starter motor. Tighten the bolts to
18 •
•
LINCOLN LS
(25 Nm).
lbs.
ft.
Negative battery cable the crankcase to the correct level.
Powertrain assembly. Tighten the
16.
Fill
the cooling system.
crossmember
17.
Recharge the A/C system.
18.
Start the
76
bolts to
ft.
lbs.
Steering shaft pinch bolt. Tighten
if
switch connector
Alternator harness connectors
Lower transmission flange bolts
•
Torque converter
•
Inner air deflector
•
Engine block heater,
equipped
if
Support the engine, transmission,
Before servicing the vehicle, refer to
.
front
the precautions in the beginning of this sec-
and center crossmembers and the
cooling system with a powertrain
motor wiring harness con-
Starter
motor harness connectors
Starter
•
7. 1
PSP
for leaks.
3.9L Engine
(25 Nm).
lbs.
ft.
•
engine and check
Steering shaft bolt and coupling
and ground cable
equipped.
Torque converter,
•
the bolts to 18
• •
Fill
•
•
Air cleaner
•
15.
Wire harness retainers
(103 Nm).
•
housing and outlet tube
•
and
lift
tion.
nectors •
Lower
mount
strut
129
the bolts to •
Upper to
66
ft.
lbs.
Drain the cooling system. Relieve the fuel system pressure.
(175 Nm).
Recover the A/C
refrigerant.
5.
Drain the engine
oil.
Lower
stabilizer bar links. Tighten
the nuts to 41
ft.
(55 Nm).
lbs.
•
Front brake calipers
•
Front wheel speed sensor connec-
Remove
Front wheels
•
Shift cable
Negative battery cable
•
Air cleaner inlet tube
•
Upper Upper
•
A/C pressure switch connector
•
Driveshaft
•
•
Exhaust front pipe and heat shields
•
Coolant hoses
•
A/C compressor manifold and tube
•
Front
•
Center crossmember bolts
Power steering
Powertrain assembly
•
A/C compressor manifold and tube
•
Power steering pump
•
Hydraulic cooling fan return hose
•
Lower radiator hose
Power steering reservoir Vapor Management Valve (VMV) •
Upper radiator hoses
•
Knock Sensor (KS) connector
lbs. (21
•
Main vacuum supply hose Cowl vent screens
and center splash shields
Left, right
•
Hydraulic cooling fan reservoir
•
A/C
2 fuel charging harness connectors
•
Main transmission wiring harness
Cross vehicle support bar
•
Degas
•
Accelerator cable
bottle
Cruise control cable
Ground Fresh
air filter
and housing
Powertrain harness connectors
Ground
10.
Attach a hoist to the engine.
11.
Remove
the motor
mount nuts and
the powertrain out of the subframe.
Remove
12.
tower
or disconnect the follow-
ing:
•
Fresh
•
Main engine wiring harness con-
(10 Nm).
Hydraulic cooling fan pressure line
at
Main engine wiring harness con89 inch
and
and bracket
lift
•
line
strap
right strut
•
hose
• •
inch lbs. (10 Nm).
Power steering pressure bracket
•
connector. Tighten the bolt to 89
lbs.
Transmission cooler lines and
•
•
nector. Tighten the bolt to
Heater hose
•
bracket
mounting bracket
line
•
•
•
•
canister
•
Nm).
•
vacuum hose and
purge hose
ft.
hose
return
return line clip
cover
assembly. Tighten the bolt to 15
bolts
assembly
•
VMV
crossmember
•
radiator support brackets
•
•
or disconnect the following:
Transmission crossmember bolts
radiator shield
•
and bracket
rear of the vehicle with
•
or disconnect the following:
•
tors •
Remove
9.
(90 Nm). 6.
•
Support the
8.
safety stands.
4.
Tighten the nuts
ball joints.
ft.
2.
3.
bolts. Tighten lbs.
transmission support bracket.
air filter
panel •
strap. Tighten the bolt to
Wiring harness retainers
•
Upper transmission flange bolts
•
Transmission from the engine
nector
89 inch •
lbs.
(10 Nm).
•
Cable bracket. Tighten the bolts
Main transmission wiring harness
To
to
connector
89 inch
lbs.
(10 Nm). •
•
Heater hoses
install:
13. at
Install or
•
valve. Note the locations for
cable Intake manifold rear
main vacuum •
Hydraulic cooling fan reservoir
•
Water control valve harness con-
hose Fresh
•
Cross vehicle support
air intake
to the engine. Tighten
housing
the nuts to
the bolts to 15 •
ft.
lbs.
Tighten
(20 Nm).
• •
Front wheels
•
Inner splash shields
• •
Cowl
leaf
•
VMV VMV
vacuum hose
89 inch
lbs.
•
•
Power steering reservoir
•
•
Brake calipers
•
Lower
A/C pressure switch connector Upper radiator support brackets. Tighten the bolts to 89 inch
• •
Engine appearance cover
30
ft.
lbs.
(40
Hydraulic cooling fan pressure
line
Power steering pressure
line
and
bracket ,
Upper
ball joints
•
Lower
strut
•
Left, right
mount
•
Transmission cooler lines and
•
Heater hose
•
Knock sensor connector
bolts
bracket
and center splash shields
•
A/C suction and discharge
•
Shift cable
lines
lbs.
and bracket
•
Power steering
•
Rack and pinion harness connectors
Upper radiator shield
to
stabilizer bar links
•
(10 Nm).
mount nuts
and bracket •
*
Fuel line
•
•
and harness clips
cover
•
(10 Nm).
Nm).
Wheel speed sensor connectors
screens
lbs.
Powertrain to the subframe. Tighten the
Chassis vacuum lines
ft.
Wiring harness retainers. Tighten
nector bar.
35
(48 Nm). •
•
Transmission
the upper flange bolts to
assembly. •
connect the following:
the water control
Accelerator cable and cruise control
line
frame
rail
•
Upper
radiator
hoses
•
Lower
radiator
hose
•
Hydraulic cooling fan return hose
clip
FORD MOTOR CO.
1I
LINCOLN LS •
Power steering pump
•
Cowl vent screens
•
A/C compressor manifold and tube
•
Main vacuum supply hose
assembly. Tighten the bolt to 15
•
VMV vacuum
lbs. (21
•
return
hose
ft.
Powertrain assembly. Tighten the front to
and center crossmember bolts
76
ft.
Nm) and
(103
lbs.
30 •
(40 Nm).
lbs.
Engine block
heater,
equipped
if
Power steering reservoir
Upper radiator support brackets
•
Upper
•
•
ft.
(38 Nm).
lbs.
Lower transmission flange Tighten the bolts to 35
ft.
bolts.
(47
lbs.
Nm). • •
return line clip
A/C pressure switch connector
•
28
Power steering
•
Inner air deflector
to
cover
•
Torque converter. Tighten the nuts
Drain the cooling system.
3.
Remove
Air cleaner inlet tube
4.
Negative battery cable Fill
the crankcase to the correct level-
15.
Fill
the cooling system.
motor harness connectors
lbs.
ft.
bolt to
Nm) and
(35
22
16.
Recharge the A/C system. engine and check
for leaks.
1
•
Shift cable
•
Left, right
Lower
66
•
bolts. Tighten
129
lbs.
Lower
lbs.
•
Before servicing the vehicle, refer to the
(175
Drain the cooling system
Negative battery cable
•
Air cleaner outlet tube
•
6.
Start the
•
Wheel speed sensor connectors
Upper radiator hose Heater supply hose
Lower radiator hose Water crossover assembly Water
•
Water control valve harness con-
inlet
4
Hydraulic cooling fan reservoir
Accessory drive
water control
belt
and
Relieve the fuel system pressure
Drain the engine
5.
Remove
•
Upper and lower intake manifolds Valve covers
Accessory drive
•
Fresh
air filter
Ground
at
and housing
strap
•
Cruise control cable
•
Accelerator cable
• •
Degas
bottle
hose bar.
ft.
Water
Water crossover assembly
•
Lower radiator hose
lbs.
(20 Nm).
6.
Please
visit
inlet
hose
pump hose
•
Water
•
Heater supply hose
•
Upper
radiator
Motor mount nuts
•
Subframe bolts
•
Oil
•
Front cover
•
Timing chains
•
Camshafts
Engine vent hose
•
Air cleaner outlet tube
our web
engine and check
site at
Exhaust manifolds
•
Ground
•
Positive Crankcase Ventilation
strap
•
Ignition noise suppressor
•
Coolant outlet tube
Engine
oil
Install the
dipstick tube
subframe bolts and
remove the engine support
the cooling system.
Start the
•
• 8.
Negative battery cable
Fill
pan
(PCV) tube
hose
•
or disconnect the follow-
•
idler pul-
•
Tighten 5.
the bolts to 15
(10 Nm).
and
•
•
Cross vehicle support
lbs.
Remove
ing:
•
belt
a support fixture to the engine
eyes.
to
(25 Nm).
89 inch
Accessory drive belts Install
ley
right strut tower •
lbs.
Negative battery cable
•
7
connect the following:
teners to
panel
Powertrain harness connectors
lifting
oil.
or disconnect the following:
•
•
Water pump. Tighten the bolts ft.
Head
4
6
Bracket assembly Tighten the fas-
Main engine wiring harness con-
air filter
for leaks.
Drain the cooling system.
idler pul-
•
Main transmission wiring harness
Fresh
engine and check
Before servicing the vehicle, refer to
•
pump
Water
18
nector •
belt
3.
Bracket assembly
Install or
•
connector •
plus
2.
hose
To install:
valve •
Nm)
3 OL Engine
pump hose
Water
•
•
Front wheels
at the
(10
tion.
•
•
Inner splash shields
Heater hoses
lbs.
REMOVAL & INSTALLATION
1
Engine vent hose
•
•
Brake calipers
nector •
pulley. Tighten the
89 inch
the cooling system.
Fill
ley
•
pump
Accessory drive
5.
and harness clips •
to
plus 90
the precautions in the beginning of this sec-
•
•
(55 Nm).
or disconnect the following
•
•
Nm)
Tighten the nuts
lbs.
the beginning of this section
Remove
stabilizer bar links. Tighten ft.
in
3.
(90 Nm).
the nuts to 41 •
ft.
Water
Cylinder
2.
lines
mount
ball joints. ft.
clip
and center splash shields
strut
Upper to
•
rail
and bracket
the bolts to •
frame
A/C suction and discharge
•
Nm)
45 degrees.
REMOVAL & INSTALLATION
precautions line
Water pump. Tighten the bolts
degrees. •
3.0L Engine
tors
Power steering
connect the following:
Install or •
Water Pump
Rack and pinion harness connec-
•
belt
pulley
the shaft
(30 Nm).
lbs.
ft.
pump Water pump
bolts to
Steering shaft bolt and coupling.
26
•
Water
71 inch lbs. (8
Tighten the coupling pinch bolt to
•
•
To install:
and ground cable •
Accessory drive
Alternator harness connectors Starter
or disconnect the following:
•
•
Start the
the beginning of this sec-
2.
radiator shield
14
17.
in
tion.
VMV
•
Before servicing the vehicle, refer to
.
the precautions
•
•
1
hose and canister
•
•
the
transmission crossmember bolts to ft.
3.9L Engine
purge hose
Nm).
C C U J
for leaks.
www.chiltonsonline.com
9.
Remove
fixture.
the cylinder heads.
Front cover
•
•
Oil
pan
•
Intake manifold
•
Subframe
bolts. Tighten the bolts to
•
Valve covers
76
(103 Nm).
—3.0L
engine
To
in
sequence as follows:
Front cover
Timing chains
belts
• •
Camshafts
•
Valve covers
•
Water outlet pipe
•
Upper and lower intake manifolds
•
•
Negative battery cable
ft.
lbs.
Fill
the crankcase to the correct level.
14.
Fill
the cooling system.
15.
Start the
engine and check
Cylinder head temperature sensor
connector
13.
Step
1:
22
b.
Step
2:
Plus 90 degrees
c.
Step
3:
Loosen
lbs.
ft.
(30
bolts
all
1.
Nm)
a.
for leaks.
5.
•
Exhaust front pipes
•
Exhaust Gas Recirculation (EGR) tube Bolts and stud bolts at the rear of
•
Cylinder heads. Loosen the bolts
•
the precautions in the beginning of this sec-
To install: Install the
Step
4:
22
Step
5:
Plus 90 degrees
f.
Step
6:
Plus 90 degrees
Install the
lbs.
ft.
(30
cylinder heads. Tighten the
tion.
one
full
Nm)
d.
bolts in 2.
Drain the cooling system.
3.
Relieve the fuel system pressure.
sequence as follows:
4.
Remove
or disconnect the following:
b.
•
Step
1:
M10
bolts to
15
ft.
lbs.
(20
Step
2:
M10
bolts to
26
ft.
lbs.
(35
Nm)
Negative battery cable
Nm)
engine support fixture and
remove the subframe
bolts. 1
Install or
12.
in
reverse of the tightening sequence.
Before servicing the vehicle, refer to
a.
e.
.
Accessory drive
(63 Nm).
46
cylinder heads. Tighten
turn
1 1
• •
Accessory drive belts
3.9L Engine
Install the
the bolts
nuts. Tighten the nuts
the cylinder heads
install:
10.
lbs.
•
to
Cylinder head torque sequence
ft.
Motor mount
•
9306TG01
Engine appearance cover
•
10
Nm
(89
lb-in) |
connect the following:
•
Engine
•
Coolant outlet tube
•
Ignition noise
•
PCVtube
•
Ground
•
Exhaust manifolds
oil
dipstick tube
suppressor
strap
•
Camshafts
•
Timing chains
9346TG03
Right cylinder head torque
sequence-
s' engine
Left valve cover torque
sequence
Engine
1
Left valve cover torque
sequence
—3.9L
10
Nm
(89 ItHn)
|
—3.0L
Engine
9346TG02 9346TG04
Right valve cover torque sequence
Engine
— 3.0L
Left cylinder
engine
head torque sequence— 3. 9L
Right valve cover torque sequence
Engine
—3.9L
FORD MOTOR CO.
16-7
LINCOLN LS Step
c.
M10
3:
bolts to
33
ft.
lbs.
(45
Nm) d.
Step
4:
M10
e.
Step
5:
M10
Step
6:
M8
bolts to 15
Step
7:
M8
bolts plus
Positive Crankcase Ventilation
(20
•
Exhaust Gas Recirculation (EGR)
90 degrees
•
vacuum line EGR tube
•
Cowl vent screen
90 degrees
bolts plus
ft.
lbs.
ister
Nm) g.
6.
Install or
•
connect the following:
Cross vehicle support bar
ft.
lbs.
(50 Nm).
•
Exhaust front pipes
•
•
EGR
Fuel pressure sensor shield
•
Upper intake manifold vacuum
Water outlet pipe
Camshafts
•
Timing chains
•
Front cover
•
Accessory drive belts
•
Valve covers
5.
•
Upper
EVR
•
Upper intake manifold vacuum hose
•
Fuel pressure sensor shield
Intake Manifold Tuning Valve
•
EGR
(IMTV) connector
•
Chassis vacuum supply hose
Vacuum
Regulator (EVR)
vacuum
•
pressure transducer
Cross vehicle support bar Tighten the bolts to 15
line
EGR tube EGR vacuum line EVAP canister purge hose
brackets
•
•
Upper intake manifold
•
Fuel line and bracket Fuel pressure sensor
•
PCV hose
•
Negative battery cable
•
Fuel injector harness connectors
•
Throttle
the cooling system.
•
PCV
•
Cable bracket
•
Lower intake manifold assembly
To
Rocker Arms/Shafts
in this
connect the following
Lower intake manifold assembly. Tighten the bolts
in
sequence
to
89
body coolant bypass hose
•
Cruise control cable
•
Accelerator cable
•
IAC valve connector
•
TP sensor connector
•
Air cleaner outlet tube
inch lbs. (10 Nm).
•
Engine appearance cover
•
PCV
•
Negative battery cable
•
Fuel injector harness connectors
section are
equipped with rocker arms/shafts. The
line
tube
Install or
REMOVAL & INSTALLATION The vehicles covered
•
vacuum
install:
•
(20 Nm).
Cowl vent screen
•
for leaks.
lbs.
•
•
engine and check
ft.
Upper intake manifold support
Intake manifold
Start the
89
vacuum
hose
Exhaust
lbs.
IMTV connector
Engine appearance cover
8.
89 inch
valve connector and
•
Fill
to
intake manifold support
•
7.
not
•
pressure transducer
valve connector and •
sequence
line
•
•
•
•
•
Cylinder head temperature sensor
connector
(10 Nm).
inch lbs. (10 Nm).
Chassis vacuum supply hose
37
lbs.
Upper intake manifold. Tighten the
brackets. Tighten the bolts to
•
tube
89 inch
line
(10 Nm). •
•
EGR
•
bolts in
Bolts and stud bolts at the rear of
bolts to
Fuel line and bracket. Tighten the
purge hose
the cylinder heads. Tighten the
•
Fuel pressure sensor
•
bolt to
Evaporative Emissions (EVAP) can-
vacuum
•
(PCV) hose •
degrees
f.
Throttle
•
90
bolts plus
body coolant bypass hose
•
tube
camshaft directly actuates the valves.
6
Fill
7.
Start the
the cooling system.
engine and check
for leaks
3.9L Engine
Intake Manifold 1
Before servicing the vehicle, refer to
the precautions in the beginning of this sec-
REMOVAL & INSTALLATION
tion.
3.0L Engine 1.
the precautions in the beginning of this sec-
Lower intake manifold torque sequence—
tion.
3.0L engine
Drain the cooling system.
3.
Relieve the fuel system pressure.
4.
Remove
or disconnect the following:
•
Negative battery cable
•
Engine appearance cover
•
Air cleaner outlet tube
•
Throttle Position (TP) sensor con-
Idle Air Control (IAC) valve
Accelerator cable
•
Cruise control cable
•
Cable bracket
Remove
or disconnect the following:
•
Negative battery cable
•
Air cleaner outlet tube
•
Cowl vent screen
•
Cross vehicle support bar
•
Accelerator cable
•
Cruise control cable
•
Intake manitold
•
Exhaust Gas Recirculation (EGR)
vacuum hoses
valve
Camshaft Position (CMP) sensor connector
con•
nector •
Relieve the fuel system pressure.
•
nector •
Drain the cooling system
4
Before servicing the vehicle, refer to
2.
2.
3.
Evaporative Emissions (EVAP) canister
Upper intake manifold torque sequence
—
3.0L engine
Timing belt service
is
•
vacuum •
covered
in
Section
3
of this
purge valve
manual
line
Fuel pressure sensor connector and
Fuel line
line
FORD MOTOR CO.
8
1
LINCOLN LS vacuum hoses
•
Knock Sensor (KS) connector
•
Intake manifold
•
Cylinder head temperature sensor
•
Cruise control cable 5.
connector
•
Accelerator cable
•
Sensor connector bracket
•
Cross vehicle support
•
Wiring harness and hose bracket
•
Left
•
Idle Air
•
Throttle Position (TP) sensor
bank
fuel injector
the bolts to 15
connectors
Control (IAC) valve con-
nector
con-
ft.
lbs.
•
Cowl vent screen
•
Air cleaner outlet tube
•
Negative battery cable
bar.
Tighten
(20 Nm).
•
Secondary
•
Exhaust front pipes
air
tubes
•
Lower splash shields
•
Heat shields
•
Negative battery cable
engine and check
Start the
for leaks.
3.9L Engine
the cooling system.
6.
Fill
7.
Start the
1
nector
•
engine and check
.
Before servicing the vehicle, refer to
for leaks.
the precautions
in
the beginning of this sec-
Positive Crankcase Ventilation tion.
(PCV) tube 5.
•
Throttle
Exhaust Manifolds
2.
body coolant hoses
Remove •
•
Right bank fuel injector connectors
•
Delta Pressure Feedback Electronic
REMOVAL & INSTALLATION
•
Power steering pump reservoir
•
Oil dipstick
•
Exhaust front pipes
(DPFE) system sensor •
Intake manifold.
Loosen the
bolts
3.0L Engine
• in
reverse of the tightening 1
sequence.
2.
Install or
connect the following:
Intake manifold. Tighten the bolts in
•
sequence
to
18
ft.
lbs.
(25 Nm).
DPFE system sensor
•
Right bank fuel injector connectors
•
Throttle
•
PCV
body coolant hoses
TP sensor connector
•
IAC valve connector Left
bank
fuel injector
Wiring harness and hose bracket
Sensor connector bracket
Pleat shields
•
Lower splash shields
•
Exhaust front pipes
•
•
Secondary
•
Exhaust front pipes
•
Exhaust Gas Recirculation (EGR)
•
Oil dipstick
tube
•
Power steering pump reservoir
•
Negative battery cable
Install
KS sensor connector Fuel line
Step
1:
b.
Step
2:
•
bolts to 18
tubes
sequence as follows: 15
ft.
lbs.
(20
15
ft.
lbs.
(20
Nm) Nm)
EGR
ft.
lbs.
(25 Nm).
tube
tube
engine and check
Start the
for leaks.
Camshaft and Valve
Lifters
REMOVAL & INSTALLATION
connect the following:
Exhaust Gas Recirculation (EGR) tube
Fuel pressure sensor connector
vacuum
Install or
•
Exhaust manifolds. Tighten the
the exhaust manifolds. Tighten
connector
•
connect the following:
Install or
•
4.
a.
Cylinder head temperature sensor
•
air
3.
Exhaust manifolds
the fasteners in
4.
Exhaust manifolds
install:
Negative battery cable
connectors
•
•
To
•
•
3.
Exhaust Gas Recirculation (EGR)
•
To install:
•
•
or disconnect the following:
tube
tube
the beginning of this section.
in
Remove
tube
•
•
Before servicing the vehicle, refer to the
precautions
To install: •
.
or disconnect the following:
Negative battery cable
3.0L Engine
and 1
line
.
Before servicing the vehicle, refer to
•
EVAP
canister purge valve line
the precautions
•
CMP
sensor connector
3. tion.
•
EGR
2.
valve
Remove
Right exhaust manifold torque sequence
the beginning of this sec-
or disconnect the following:
•
Negative battery cable
•
Valve covers
•
Front cover
•
Timing chains
|:
3.0L engine
in
WARNING
The camshaft journal thrust caps must be removed before loosening the remaining camshaft journal cap bolts to ensure that the camshaft journal thrust caps are not damaged.
^Keep
all
valvetrain
components
in
order for assembly.
9306TG06
Intake manifold torque
engine
sequence
—3.9L
Left
exhaust manifold torque sequence
3.0L engine
To
•
Camshaft journal thrust caps
•
Remaining camshaft journal caps
•
Camshafts
•
Valve tappets and shims
install: Install or
connect the following:
FORD MOTOR CO.
-1C
IU Q 3
LINCOLN LS
6.
3306TC13
6 Camshaft
5.
lift
fools
Remove
—3.0L engine
303-659
the center camshaft bearing
journal caps.
Remove
7
pressed
9306TGH
air
the valve
shims with com-
and replace as required
to
achieve the correct adjustment.
Camshaft journal cap torque sequence—
Camshaft journal bearing cap torque
3.0L engine
sequence
8
—3.9L engine
Valve clearance should be
0.007-0 009
4.
valves or •
Valve tappets and shims
in their
original locations •
Camshafts
•
Camshaft journal caps
journal caps in
sequence
in their orig-
last.
to
Tighten the bolts
89 inch
lbs.
(10
Nm). Timing chains
•
Front cover
•
Valve covers
•
Negative battery cable
Start the
2.
Plus 90 degrees
lbs. (6
•
Timing chains
•
Front cover
1 1
Valve covers
•
Negative battery cable
engine and check
or disconnect the following:
1
the precautions in the beginning of this sec
lbs (10
Nm)
•
Valve covers
•
Ignition coils
•
Engine appearance covers
•
Negative battery cable
Before servicing the vehicle, refer to
the precautions in the beginning of this section.
Remove
2.
or disconnect the following
•
•
Front cover
•
Engine appearance covers
•
Timing chains
•
Ignition coils
Negative battery cable
2.
Remove
or disconnect the following:
•
Negative battery cable
•
Engine appearance covers
•
Ignition coils
Valve covers
•
components
connect the following
Rear bearing journal cap and the
tion.
Valve covers
in 3.
Measure the valve clearance while
order for assembly. the camshaft lobe
is
pointed away from the
Camshaft journal bearing caps
valve shim. Rotate the crankshaft as neces-
•
Camshafts
sary for each valve to be measured.
•
Valve tappets and shims
• Keep
•
the service tools.
Install or
3.9L Engine
•
valvetrain
center bearing journal
bearing journal caps in sequence to
Before servicing the vehicle, refer to
Negative battery cable
all
Remove .
for leaks
for leaks
the beginning of this section
for intake
33—0 38mm)
thrust journal cap Tighten the
engine and check
3.0L Engine
Remove
Install the
•
ADJUSTMENT
1
(0
caps.
10
•
23mm)
in.
exhaust valves. 9.
connect the following:
•
•Keep
for
Valve Lash
Before servicing the vehicle, refer to the in
53 inch
3:
89 inch
3.9L Engine 1.
2:
Step
Start the
•
precautions
Step
Install or
inal positions. Install the thrust
Nm)
b. c.
(0.18-0
in.
0013—0015
To install:
all
valvetrain
components
in
order for assembly. 3.
4.
caps
Install or
connect the following:
•
Valve tappets and shims
•
Camshafts
Install the in their
bolts in a.
4.
camshaft journal bearing
original positions. Tighten the
sequence as follows: Step
1:
Finger tight
Remove
the camshaft thrust cap
and
the rear camshaft bearing journal cap from the camshaft that requires 5.
Install
shim adjustment
Service Tool set 303-659
in
place of the bearing journal caps, with the taller tool in
place of the rear bearing cap
Heater Core replacement
is
covered
in
Section
—3.91
Valve adjustment tool base plate
engine
2 of this manual
FORD MOTOR CO.
16-10
LINCOLN LS 3.
To
install:
connect the following:
Install or
•
Starter motor. Tighten the bolts to
•
Starter
•
Negative battery cable
18
Oil
ft.
lbs.
(25 Nm).
motor wiring connectors
Pan
REMOVAL & INSTALLATION 3.0L Engine Valve adjustment tool attachment
—3.9L engine
1
.
Before servicing the vehicle, refer to
the precautions
in
the beginning of this sec-
tion. 2.
Drain the engine
3.
Install a
lifting
4.
• 3.
the shims with
compressed
air
—3.9L engine
Remove
Negative battery cable
•
Air cleaner outlet tube
•
Accessory drive
•
Alternator
belt
•
Center and right splash shields
•
A/C compressor
•
Electronic Thermactor Air (ETA) if
equipped
•
Rack and pinion steering gear
•
Lower control arm through
Valve covers
is
pointed away from the
valve shim. Rotate the crankshaft as neces-
sary for each valve to be measured. 4.
Valve clearance should be
0.007-0.009
in.
(0.18-0.23mm)
valves or 0.009-0.011 for
in.
for intake
(0.23-0.28mm)
exhaust valves. 5.
If
adjustment
is
necessary, compress
the valves with the special tools and
shim with compressed
the
each valve 6.
to
air.
remove
Repeat
for
be adjusted.
connect the following:
Install or •
Valve covers
•
Ignition coils
•
Engine appearance covers
•
Negative battery cable
Starter Motor
REMOVAL & INSTALLATION 1
.
Before servicing the vehicle, refer to
the precautions
in
the beginning of this sec-
tion. 2.
Remove
or disconnect the following:
•
Negative battery cable
•
Starter
motor wiring connectors
•
Starter
motor
9306TG14
Oil
pan torque sequence— 3. OL engine
engine
or disconnect the following:
•
Measure the valve clearance while the
camshaft lobe
to the
eyes.
bracket,
Remove
oil.
support fixture
bolts
FORD MOTOR CO. 1 LINCOLN LS
•
Transmission cooler
•
Engine mount nuts
•
Left
and
subframe
right
down
the subframe
line bracket
Wiring harness bracket
•
Oil
pan
To
install:
5.
Install or
install:
4
Install the oil
pan. Tighten the bolts in
sequence as follows:
for clearance.
•
•
Pry
bolts.
To
a.
Step
1:
44 inch
b.
Step
2:
108 inch
Nm) (12 Nm)
lbs. (5 lbs.
the crankcase to the correct level.
5.
Fill
6.
Start the
engine and check
for leaks.
connect the following:
Oil pan.
Tighten the pan bolts
sequence
to
18
ft.
(25
lbs.
the transmission bolts to
in
Oil
ft.
lbs.
•
and
REMOVAL & INSTALLATION
subframe
right
(103
lbs.
Nm).
.
Engine mount nuts. Tighten the ft.
lbs.
2.
(63 Nm).
•
Transmission cooler
•
Lower control arm through
line bracket
Tighten the bolts to 129
ft.
bolts. lbs.
(175 Nm).
Rack and pinion steering
gear.
Tighten the nuts to 76
lbs.
ft.
(103
Nm). • •
bracket,
if
equipped
A/C compressor
•
Center and right splash shields
•
Alternator
•
Accessory drive
•
Air cleaner outlet tube
•
6.
ETA
belt
Negative battery cable
Fill
3.
engine and check
.
at
the beginning of this section or disconnect the following:
Upper intake manifold the crankcase.
Before servicing the vehicle, refer to the
•
Crankshaft pulley
•
Front cover
•
Primary timing chains
•
Oil
•
Oil
Accessory drive
•
Power steering pump
•
New
•
Alternator
•
Oil
•
Water
•
A/C compressor and bracket
•
Primary timing chains
•
Crankshaft pulley
•
Front cover
•
Oil
pan
•
Crankshaft pulley
•
Oil
pump
belt
To
install:
3.
Install or
pump
pump. Tighten the
Nm)
bolts to
53
plus 90 degrees
screen and tube
•
Front cover
•
Timing chains
•
Crankshaft timing gears
•
Oil
Rear Main Seal REMOVAL & INSTALLATION
pump
Install or
Oil
3.0L Engine
connect the following:
pump. Tighten the
bolts to
89 1
.
Before servicing the vehicle, refer to the
•
Timing chains Front cover
•
Oil
oil.
pan,
pump
•
•
the beginning of this section.
Oil
Attach an engine support fixture to
the engine lifting eyes
Remove
or disconnect the following:
screen and tube. Tighten
the bolts to •
tion.
at
Crankshaft timing gears
•
the precautions in the beginning of this sec-
oil
connect the following:
gasket
inch lbs. (6
3.
the
bolts
Valve covers
inch lbs. (10 Nm).
Before servicing the vehicle, refer to
Remove
pump mounting pump
•
3.9L Engine
3.
beginning of this section.
or disconnect the following:
•
•
Drain the engine
in the
Remove
precautions
2.
engine and check for leaks.
Upper intake manifold
2.
.
•
belt
•
for
leaks.
1
Valve covers
Start the
2.
Remove
•
Start the
•
To install:
the crankcase to the correct
level. 7.
Power steering pump Accessory drive
5.
Before servicing the vehicle, refer to the
precautions
nuts to 46
•
•
•
Fill
1
3.0L Engine
bolts. ft.
1
•
Alternator
4.
Wiring harness bracket Left
Water
•
precautions
Tighten the bolts to 76
pump
•
3.9L Engine
(47 Nm). •
1I
Pump
Nm) and
35
C U
89 inch
lbs.
(10
Nm)
•
Negative battery cable
•
Transmission
•
Clutch,
•
Flywheel
•
Rear crankshaft seal
pan if
equipped
Crankshaft pulley
A/C compressor and bracket
To install: 4
connect the following:
Install or
•
Rear main seal flush with the cylinder block surface
•
Flywheel. Tighten the bolts to 59 lbs (80
5.
equipped
•
Clutch,
•
Transmission
•
Negative battery cable
Start the
ft.
Nm). if
engine and check
for leaks.
3.9L Engine 1
Oil
pan torque sequence
.
Before servicing the vehicle, refer to
the precautions at the beginning ol this sec-
— 3.9L engine
tion.
Brake service
is
covered
in
Section 4 of this manual
FORD MOTOR CO.
16-12
LINCOLN LS
Attach an engine support fixture to
2.
the engine lifting eyes.
Remove
3.
or disconnect the following:
•
Negative battery cable
•
Transmission
•
Flywheel
•
Rear crankshaft seal
To install: connect the following:
Install or
4.
Rear main seal flush with the cylin-
•
der block surface •
Flywheel
Tighten the flywheel bolts
5.
in
a cross-
ing pattern as follows:
Nm) Nm)
a.
Step
1:
11
ft.
lbs.
(15
b.
Step
2:
81
ft.
lbs.
(110
connect the following:
Install or
6.
•
Transmission
•
Negative battery cable
engine and check
Start the
7.
for leaks. 9.
Timing Chain, Sprockets, Front Cover and Seal
REMOVAL & INSTALLATION
Sprocket
g
4
RH
5
Bolt (2 Req'd)
Timing Chain
10
Timing Chain Guide
rh Cylinder Head
A Tighten
to
20-30 N-m (15-22
Lb-Ft)
3.QL Engine 1
7922KG49
Before servicing the vehicle, refer to
.
the precautions at the beginning of this sec-
Exploded view left
ol the right cylinder
head timing chain and related components— 3. OL engine-
side similar
tion. •
Right timing chain tensioner
intake manifold
•
Right timing chain tensioner arm
•
Right timing chain and crankshaft
•
Upper
•
Valve covers
•
Accessory drive
•
Power steering pump
•
Alternator
•
Water
•
A/C compressor and bracket
•
Crankshaft pulley
•
Oil
pan
•
Oil
pump
•
Crankshaft Position (CKP) sensor
pump
screen and tube
Camshaft Position (CMP) sensor
they are assembled
^The
Front cover
positions.
in their
original
they are assembled
sensor pulse ring
Camshaft thrust caps
Dead Center (TDC)
Camshaft journal caps. Loosen the in
sequence and
in
Verify that the alignment arrows
to allow the
camshaft
to
•
be
or disconnect the following:
Camshaft thrust caps
If
crankshaft
1
complete revolution and
recheck.
Rotate the crankshaft so that the keythe 3 o'clock position. This posi-
tions the right cylinder head camshafts to
the neutral position.
Remove
Camshaft journal caps. Loosen the
evenly.
bolts in
Right bank camshafts
passes
sequence and
in
several
not, rotate the 7.
is at
•
on •
6.
original
cylinder.
the camshafts are aligned.
way
Remove
10.
several
in their
for
raised from the cylinder head
5.
cylin-
positions.
the 11 o’clock position to locate
passes 4.
camshaft journal caps and
der heads are numbered to ensure that
Rotate the crankshaft so that the keybolts
1
ensure that the thrust caps are not
connector
is at
arm
and crankshaft
The camshaft thrust caps must be removed before loosening the remaining camshaft journal cap bolts
damaged.
the crankshaft at Top
No.
Left timing chain
WARNING
to
•
way
Left timing chain tensioner
•
sprocket
damaged.
•
head timing chain ten-
•
"•The camshaft journal caps and cylinder heads are numbered to ensure that
CKP
• 3.
or disconnect the following:
Left cylinder
sioner
WARNING
The camshaft thrust caps must be removed before loosening the remaining camshaft journal cap bolts to ensure that the thrust caps are not
connector
•
•
sprocket
belt
I'
•
Remove
or disconnect the following:
Remove
2.
at the
o’clock position. This will position the
cylinder head camshafts to their neutral
Verify that the alignment arrows
To 1 1
position. 8.
•
1
left
to
be
Left
bank camshafts
install:
Prepare the timing chain tensioners
.
for installation as follows:
on
a.
or disconnect the following:
the camshafts are aligned.
camshaft
raised fifim the cylinder head evenly.
Rotate the crankshaft 2 revolutions
and locate the crankshaft keyway
to allow the
vise.
Place the
left
chain tensioner
in
a
FORD MOTOR CO. i I LINCOLN LS
Using a small prytool, release and
b.
ratchet/pawl
mechanism through
access hole
in
d.
Lock the piston with a
•
Repeat
•Be
for the right
chain tensioner.
sure that the crankshaft keyway
still at
Right timing chain and crankshaft
camshaft and crankshaft sprockets. •
wire
or paperclip. e.
9 O
with the index marks on the
the timing chain tensioner.
Slowly compress the tensioner.
.5mm
I
sprocket. Align the colored links
the
c.
1
H
Camshaft thrust caps
•
•
hold the timing chain tensioner
C O
Right timing chain tensioner arm
Right timing chain tensioner.
Tighten the retaining bolts to
15-22
lbs.
ft.
(20-30 Nm).
is
Remove
16
the 11 o’clock position.
the retaining wire from the
right timing chain tensioner.
12.
Install or
Using a thin prytool, release and hold the
bank camshafts
Camshaft journal caps
front cover with a
•
Camshaft thrust caps
engine
•
Left timing chain
sprocket. Align the colored links
•
Left
timing chain tensioner arm
•
Left
timing chain tensioner. Tighten
the retaining bolts to
15-22
ft.
Remove
1.5mm
wire or
paperclip— 3. OL engine
the retaining wire from the
the 3 o'clock position.
is in
15.
Retain the piston with a
21
lbs.
Rotate the crankshaft so that the key-
14.
Install or
connect the following:
•
Right bank camshafts
•
Camshaft journal caps
Place
in
the
one. Apply clean
lip.
View A.
new
the dowel pins
to the
6
critical
to the cylinder block.
front cover gaskets onto
on the cylinder block and
Place the front cover into position.
.
22. bolts
Install the
23.
6 front cover retaining
and stud bolts where the silicone
sealer
timing chain tensioner.
way
the seal
ring.
in
heads.
(20-30 Nm). 13.
shown
areas 20.
camshaft and crankshaft sprockets.
oil to
new
Apply silicone sealer
19.
with the index marks on the
sensor pulse
Replace the crankshaft seal
•
and crankshaft
CKP
Install
18.
Left
engine
left
the
17.
•
timing chain tensioner ratchet/pawl mech-
anism— 3. OL
connect the following:
was
applied.
Tighten the bolts and stud bolts until
the front cover contacts the cylinder block
and heads an, then turn the bolts and stud bolts an additional V* turn.
24.
Install the
retaining bolts
remaining front cover
and stud
Timing mark alignment— 3. OL engine
For complete Engine Mechanical specifications, see Section
1
of this
manual
bolts.
I
0“ -f I
A FORD MOTOR s
t LINCOLN
CO.
LS Tighten
25.
15-22
ft.
26.
cover retain-
of the front
all
and stud bolts
ing bolts
sequence
in
connect the following:
Install or
•
CMP
•
CKP sensor connector Oil pump screen and tube
• •
Oil
27.
to
(20-30 Nm).
lbs.
sensor connector
pan
Install
damper and
the crankshaft
tighten the bolt as follows:
Step 1:78-99
a.
ft.
(105-135
lbs.
Nm). b.
Step
2:
Loosen one
c.
Step
3:
35-39
d.
Step
4:
Plus an
28.
VIEW A
ft.
full turn.
(47-53 Nm).
lbs.
85-95 degrees.
connect the following:
Install or
•
A/C compressor and bracket
•
Water
•
Alternator
pump
•
Power steering pump
•
Accessory drive
•
Valve covers
•
29.
belt
Upper intake manifold engine and check
Start the
for leaks.
3.9L Engine Before servicing the vehicle, refer to
1.
the precautions in the beginning of this section.
Apply sealant to the places indicated— 3. OL engine 2.
Drain the cooling system.
3.
Remove • •
FRONT OF ENGINE
* LOCATION
\
fc
OF STUDS
or disconnect the following:
Negative battery cable
Engine appearance cover and brackets
FOUR PLACES TIGHTEN BOLTS/STUDS
•
IN w SEQUENCE SHOWN FINGER-TIGHT
Valve covers
•
Engine cooling fan assembly
•
Accessory drive
•
Water
•
Alternator
pump
•
Lower
•
Heater hose
belt
pulley
hose and pipe
radiator
•
Idler pulleys
•
Crankshaft pulley
•
Front crankshaft seal
•
Power steering
•
Power steering pump and bracket
•
Hydraulic cooling fan reservoir
•
Hydraulic cooling fan
reservoir hose
hose and bracket
pump and
bracket •
Front cover wiring harness clips
•
Front cover. Loosen the bolts
in
sequence. • • 4.
*
STUD LOCATIONS
After
Torque converter access panel Cranksfiaft Position
Top Dead Center (ATDC). The crank-
shaft
keyway
tion.
Check
sequence— 3. OL engine
1
full
turn.
be
will
that the
facing upwards. Front cover torque
(CKP) sensor
Rotate the crankshaft to 45 degrees
If
in
the 6 o'clock posi-
camshaft lobes are
not, rotate the crankshaft
—
9306TG19
—3.9L
Timing chain tensioner preparation engine
To install: 1 1
Prepare the primary and secondary
.
timing chain tensioners for installation as follows:
Step
a.
1
:
Use a
thin wire to unseat
the check valve
Step 2: Compress the tensioner
b.
piston fully into the bore by hand
Step
c.
12.
3:
Install or
•
10.
Remove
the wire
connect the following:
Secondary timing chain tensioners. Tighten the bolts to 97 inch lbs. (11 Nm).
•
Intake
and exhaust camshaft
sprockets and secondary timing 330STG16
Front cover loosening 9.
sequence
chain assemblies
— 3.9L engine
•
Left
bank timing chain and crank-
shaft timing sprocket 5.
645
Install
in
Install
6.
530
Crankshaft Holding Tool 303-
place of the
CKP
sensor.
left
bank camshafts and
bank camshafts.
Remove
sprockets forward on the bolts or disconnect the follow-
ing:
tensioner and blanking plate
Tensioner arm
•
Timing chain guide
•
or disconnect the follow-
•
•
Tensioner arm
•
Timing chain guide
Left
Left
13
bank timing chain and crank-
Intake
Intake
tie
97 inch
lbs (11
strap to take
Nm).
up the slack
timing chain.
Secondary timing chain tensioners
9306TG17
Tool—3.9L engine
a
exhaust camshaft
sprockets and secondary timing
Crankshaft Holding
Nm).
and exhaust camshaft
chain assemblies •
lbs. (11
bank primary timing chain tensioner and blanking plate. Tighten
Use Timing Chain Tensioning Tool 303-532 to apply tension to the left bank
and exhaust camshaft
Right bank timing chain and crank-
the locking tool from the
Nm).
14
sprocket bolts •
lbs. (11
Left
Install
in the
shaft timing sprocket •
•
97 inch
Tensioner arm Tighten the bolts to
the bolts to
shaft timing sprocket
Remove
Timing chain guide. Tighten the bolts to
97 inch
Right bank primary timing chain
•
•
bank primary timing chain tensioner and blanking plate
• •
on the
•
camshaft sprocket bolts and slide the
Remove
it
ing:
Loosen the exhaust and intake
8
install
bank camshafts.
Camshaft Locking Tool 303-
to the right 7.
right
Use a Camshaft Locking Tool
—3 9L engine
For Accessory Drive Belt illustrations see Section ,
tie
strap to
remove slack from
primary timing chain— 3. 9L engine
1
of this manual
the
0“ iR O
-ip S
i
FORD MOTOR CO. LINCOLN LS ••Tighten the exhaust camshaft bolt first.
Tighten the
15.
left
bank camshaft
sprocket bolts as follows: a.
Step 1:15
b.
Step
Remove
16.
ft.
lbs.
(20
Nm)
Plus 90 degrees
2:
the locking tool from the
bank camshafts and
install
it
on the
left
right
bank camshafts. 17.
Install or
connect the following:
Right bank timing chain and crank-
•
shaft timing sprocket. Ensure that
the crankshaft sprocket
installed
is
as shown. •
Timing chain guide. Tighten the
•
Tensioner arm. Tighten the bolts to
97 inch
bolts to
lbs. (11
Nm).
9306TG21
Timing Chain Tensioning Tool
97 inch
—3.9L engine
Nm).
lbs. (11
Right bank primary timing chain
•
tensioner and blanking plate.
Tighten the bolts to 97 inch
lbs. (11
Nm). Install a tie strap to
18. in
take up the slack
the timing chain.
Use Timing Chain Tensioning Tool
19.
303-532
to
apply tension to the right bank
exhaust camshaft.
^Tighten the exhaust camshaft
bolt
first.
Tighten the right bank camshaft
20.
sprocket bolts as follows:
Crankshaft sprocket alignment— 3. 9L engine
Nm)
a.
Step
1:
15
b.
Step
2:
Plus 90 degrees
Remove
21.
ft.
lbs.
(20
the camshaft locking
tool.
Apply silicone sealant
22.
to the areas
indicated and install the front cover.
Tighten the front cover bolts
23.
in
sequence as follows: a.
Step
1:
44 inch
lbs. (5
b.
Step
2:
89 inch
lbs.
24.
Nm) Nm)
(10
Remove
the crankshaft locking
Install or
connect the following:
tool.
25. •
CKP
•
Torque converter access panel
•
Front cover wiring harness clips
•
sensor
Hydraulic cooling fan
pump and
bracket. Tighten the bolts to lbs.
•
18
ft.
(25 Nm).
Hydraulic cooling fan reservoir
hose and bracket •
Power steering pump and Tighterrthe bolts to 18
ft.
bracket. lbs.
Nm).
|
3
mm (0.1 2 in) 9306TG23
Apply silicone
sp;»The rear brake calipers must be
Differential front retaining nuts.
Take frequent bearing preload torque
9.
or disconnect the following:
•
•
OFF
tion before raising the vehicle.
connect the following:
Install or
.
rectly. 8.
posi-
1 1
while tightening the flange nut to
luggage com-
partment, must be turned to the
pinion flange nut
Rotate the pinion flange occasion-
7.
the precautions in the beginning of this sec-
2.
or connect the following:
Install
6.
on the left-hand side
Never loosen the pinion nut to reduce bearing preload. II it is necessary to reduce bearing preload, install a new collapsible spacer and pinion nut.
To install:
REMOVAL & INSTALLATION
1.
the pinion flange and
seal.
12.
higher
the differential with gear lubri-
Fill
cant and check for leaks.
than the specification for used bearings,
Turn the
13.
then tighten the pinion flange nut to the
ON
suspension switch
air
to the
position.
original reading as recorded.
preload.
STEERING AND SUSPENSION Air
that the
Bag
bag and trim cover are pointed
flashes or remains
away.
**
•
CAUTION
a fault in the air
vehicles are equipped with an bag system. The system must be disarmed before performing service on, or around, system components, the steering column, instrument panel components, wiring and senair
is
Power Rack and Pinion Steering
and trim cover
Gear
facing up. •
continuously, there
Place the inflator module on a bench
or other surface with the bag
Some
lit
bag system.
With the
inflator
module on
the bench,
never place anything on or close to the
module
that
may be thrown
in the
REMOVAL & INSTALLATION
event of
an accidental deployment 1.
DISARMING
Before servicing the vehicle, refer to
the precautions in the beginning of this sec-
sors. Failure to follow the safety pretion.
cautions and the disarming
procedure could result in accidental air bag deployment, possible injury and unnecessary system repairs.
1.
the precautions
in
the beginning of this sec-
Disconnect both battery cables from
the battery, negative cable
PRECAUTIONS
3.
Wait
1
when handling
the inflator
module
to
avoid
accidental deployment and possible per-
sonal injury. •
Never carry the
module by
the
wires or connector on the underside of the
module. •
When
carrying a live inflator module,
is
the time
required for the back-up power supply
After service
is
in
Remove •
Outer
•
Engine
•
tie
rod ends
oil filter
Power steering
fluid
pressure and
air
OFF
If
•
Steering shaft pinch bolt
•
Steering gear retaining nuts
•
Steering gear
last.
RUN
bag indicator should
To install:
light
4
continuously for approximately 6 seconds, then turn
position
or disconnect the following:
Front wheels
its
completed, reconnect
Turn the ignition switch to the
The
OFF
return lines
the battery cables, negative cable 5.
suspension switch, located on
•
stored energy.
position.
hold securely with both hands, and ensure
3.
first.
the air bag diagnostic monitor to deplete
4.
inflator
air
before raising the vehicle.
minute before proceeding with
the service procedure. This
Several precautions must be observed
The
the left-hand side of the luggage compart-
ment, must be turned to the
tion. 2.
2.
Before servicing the vehicle, refer to
For complete Engine Mechanical specifications, see Section
Install or •
the indicator fails to light,
1
connect the following:
Steering gear. Tighten the retaining
of this
manual
10 10" 14
FORD MOTOR CO. MARK
I
VIII 7.
nuts to
100-143
lbs.
ft.
(135-195
•
Turn the
ON
Nm).
air
suspension switch
to the
30-42
(41-57
lbs.
ft.
Power steering
pressure and
fluid
REMOVAL & INSTALLATION
•
Engine Outer
retaining nuts to
40-53
ft.
power steering
5.
Fill
6.
Check the engine air
posi-
or disconnect the follow-
Rear wheel
•
Air spring solenoid valve harness
Before servicing the vehicle, refer to
Air spring solenoid valve
Depress the 4 plastic locking fingers
5. .
Air spring solenoid valve air line
•
bottom
at the
oil level.
suspension switch
•
•
fluid reservoir. 1
Turn the
OFF
connector
must be supported by the suspension during this procedure.
the precautions 7.
Remove
The weight of the vehicle
lbs.
Front wheels the
Deflate the air springs.
4.
Rear
rod ends. Tighten the
(53-72 Nm). •
3.
oil filter
tie
luggage com-
ing:
return lines
•
of the
tion before raising the vehicle.
Shock Absorber
Nm). •
suspension switch, located
air
partment, must be turned to the
Steering shaft pinch bolt. Tighten the bolt to
The
2.
on the left-hand side
position.
of the air spring piston
and
the beginning of this sec-
in
detach the
to the
spring from the lower control
air
tion.
ON
arm.
position.
The
2. 8.
air
suspension switch, located on
Depress the metal locking tab
6.
Align the vehicle. the left-hand side of the luggage compart-
ment, must be turned
OFF
to the
top of the
air
position
gage the
air
at
the
spring and rotate to disen-
spring cap from the body
before raising the vehicle. bracket.
Remove
3.
or disconnect the follow-ing:
Remove
7.
Rear compartment trim panels
•
To
the air spring.
install:
Upper shock absorber retaining
•
spring solenoid
Install the air
8.
nuts valve. •
Lower shock absorber
•
Shock absorber
bolt Install the air
9.
spring cap to the body
bracket and rotate to lock
in
place.
To install:
Do
not attempt to service the suspen-
sion without
first
Insert the
10.
connect the following:
Install or
4.
deflating the air
•
Shock absorber
•
Upper shock absorber retaining
the lower control arm. 1 1
springs.
nuts. Tighten the nuts to
•-Servicing the air suspension requires
lbs.
a scan tool with bi-directional capabili-
Install or
.
Air spring solenoid valve air line
•
Air spring solenoid valve harness
ft.
connector bolt.
Tighten
the bolt to
83-113
ft.
lbs.
Turn the
12. 1
.
(113-153 Nm).
Before servicing the vehicle, refer to
5.
tion.
The
suspension switch, located on
air
ON
ON
air
suspension switch
to the
position.
Rear compartment trim panels
•
the precautions in the beginning of this sec-
2.
Rear wheel
•
ties to deflate the air springs.
connect the following:
•
(23-31 Nm).
Lower shock absorber
•
17-23
4 plastic locking fingers to
Turn the
air
suspension switch
to the
Upper
position.
Ball Joint
the left-hand side of the luggage compart-
ment, must be turned to the
OFF
position
REMOVAL & INSTALLATION
Air Spring
before raising the vehicle. 3. 4.
5.
REMOVAL & INSTALLATION
Deflate the air springs.
Remove
or disconnect the following:
•
Front wheel
•
Suspension height sensor
•
Air spring solenoid valve
•
Front strut cover cup
•
Upper
•
Lower
Remove
strut
mount nuts
strut
mount
Front
The
Lower front air spring
front strut as
is
.
::
•
Strut
and spring assembly. Tighten
mount nuts to 17-23 (23-32 Nm) and the lower
the upper lbs.
mounting
bolt to
126-169
(170-230 Nm). •
Do
connect the following:
Front strut cover cup
ft.
ft.
lbs.
CAUTION
sion without
first
in
the beginning of this sec-
tion.
not attempt to service the suspendeflating the air
2.
Remove
the vehicle 3.
springs.
arm from
the lower control
and place
it
Press the lower
in
a vise.
ball joint
out of the
control arm. '
—Servicing the air suspension requires a scan tool with bi-directional capabilities to deflate the air springs.
To
install:
4.
Press lower
arm so
that
it
ball joint into the control
is fully
seated to the control
arm.
•
Air spring solenoid valve
•
Suspension height sensor
the precautions
Front wheel
tion.
•
Before servicing the vehicle, refer to
the precautions
To install: Install or
Ball Joint
REMOVAL & INSTALLATION 1
assem-
bly from the vehicle.
6.
serviced with the
ball joint is
serviced with the
an assembly.
Rear
bolt
the strut and spring
The upper
upper control arm as an assembly.
1
Before servicing the vehicle, refer to in
the beginning of this sec-
5.
Install the control
vehicle. 6.
Align the vehicle.
arm
to the
FORD MOTOR CO. H MARK •Servicing the
Upper Control Arm
air
suspension requires
OHIJC
IO
VIII
Lower Control Arm
a scan tool with bi-directional capabilities to deflate the air springs.
REMOVAL & INSTALLATION
1
.
REMOVAL & INSTALLATION
Before servicing the vehicle, refer to
the precautions
in
the beginning of this sec-
Front
Front tion. 2.
The
suspension switch, located on
air
the left-hand side of the luggage compart-
Do not attempt sion without
to service the
first
suspen-
deflating the air
'•Servicing the air suspension requires
Deflate the air springs.
4
Remove
suspension switch, located on
air
springs.
•Servicing the
OFF
•
Upper control arm pivot bolts
ties to deflate the air springs.
•
Upper control arm
the precautions in the beginning of this sec-
suspension
bolts with the
tion.
at curb height.
2.
5.
or connect the following
Install
•
Upper control arm pivot
bolts.
50-68
Front wheel
•
Air
bolt to
suspension height sensor
•
Upper
•
Upper control arm bushing
117-142
ft.
lbs.
3.
Deflate the air springs.
4.
Remove
(158-193
ball joint
Check
the wheel alignment
Front wheel
•
Lower
•
Lower arm
•
Strut
and adjust
bolts
as necessary. •
To
Upper control arm
CONTROL ARM BUSHING REPLACEMENT
'•Use new control arm bushing joint and ball joint pinch bolts for assembly.
To
at curb height.
Upper control arm Upper control arm bushing bolts. Tighten the bolts to
6.
ON
56-88
ft
Tighten the pinch
bolt to
50-68
lbs.
(68-92 Nm)
suspension height sensor
Air
Front wheel
Turn the
air
install:
5.
Remove
the control
3.
•
Remove
the control
arm bushings
suspension switch
to the
•
install:
4.
Press the bushings into the control
arm. Install the control
arm
•
to the
Pivot bolt
Tighten the bolt to
82-114
lbs
Check
the wheel alignment
Strut
and spring assembly lower
118-162
Lower arm
•
Rear •
The control arm bushings are
deflating the air
lbs.
ft.
(160-220
ser-
6.
viced with the control arm as an assem-
ON
bly.
Tighten the nut
lbs.
(120-160
ball joint.
83-113
ft.
Tighten the nut
lbs.
(113-153
Front wheel
Turn the
Check
as necessary.
illustrations,
see Section
1
air
suspension switch
to the
position.
7.
springs.
For Accessory Drive Belt
strut. ft
Nm).
CAUTION
first
89-118
Lower to
sion without
(110-155
Nm).
and adjust
as necessary.
not attempt to service the suspen-
ft
bolt.
to
vehicle. 6.
connect the following:
Lower control arm
Nm).
Rear
Do
bolts with the
curb height.
Nm).
To
5.
position.
**
at
Install or
•
arm from the
with a hydraulic press.
ball joint.
•
Lower control arm
suspension
vehicle.
joint
(75-120 Nm).
•
Before servicing the vehicle, refer to
tion.
Upper
ft.
.
2.
•
lbs.
Pivot bolt
•
the precautions in the beginning of this sec-
connect the following:
•
•
•
•Tighten the bushing 1
Install or
strut
and spring assembly lower
Front
'•Tighten the bushing bolts with the
5.
ball joint
bolt
install:
suspension
or disconnect the follow-
•
Rear wheel
joint 6.
position
ing:
Nm). •
OFF
ft.
(68-92 Nm) and the outer
lbs. •
suspension switch, located on
before raising the vehicle.
Tighten the inner bolt to or disconnect the follow-ing
air
ment, must be turned to the
Upper control arm
Deflate the air springs.
Remove
The
the left-hand side of the luggage compart-
position
before raising the vehicle.
4.
Before servicing the vehicle, refer to
install:
•
3.
suspension requires
a
the left-hand side of the luggage compart-
ment, must be turned to the
air
scan tool with bi-directional capabili-
Rear wheel
1.
To
suspen-
deflating the air
or disconnect the follow-
•Tighten the bushing
tion.
to service the
first
•
Before servicing the vehicle, refer to
the precautions in the beginning of this sec-
The
Do not attempt
ing:
ties to deflate the air springs.
2.
position
sion without
3.
scan tool with bi-directional capabili-
1.
OFF
before raising the vehicle.
springs.
a
ment, must be turned to the
of this manual
the wheel alignment
and adjust
40 0“ iC I
I
FORD MOTOR CO
U
MARK
VII!
Rear
CAUTION Do not attempt sion without
to service the
first
suspen-
deflating the air
Brake caliper and rotor
Tighten the mounting bolts to 87
•
Rear wheel
lbs.
Turn the
6.
ON
•
air
suspension switch
Front wheel
•
to the
ft.
(119 Nm).
position.
Check
7.
the wheel alignment
and adjust
Rear
as necessary.
springs.
CAUTION
L
CONTROL ARM BUSHING REPLACEMENT ^Servicing the
Do not attempt
suspension requires
air
sion without
a scan tool with bi-directional capabili-
Front
ties to deflate the air springs. 1
Before servicing the vehicle, refer to
.
the precautions
in
the beginning of this sec-
.
suspen-
deflating the air
springs. Before servicing the vehicle, refer to
the precautions in the beginning of this sec-
^Servicing the air suspension requires a scan tool with bi-directional capabili-
tion.
tion. 2.
1
to service the
first
The
suspension switch, located on
air
the left-hand side of the luggage compart-
OFF
ment, must be turned to the
position
3.
Deflate the air springs.
4.
Remove
or disconnect the following:
Rear wheel
•
Brake caliper and rotor
•
Rear wheel knuckle and hub
•
Air spring
Parking brake cable
•
Sway
•
Lower shock absorber
•
Control arm inboard pivot bolts
•
Lower control arm
the control
arm bushings
ties to deflate the air springs.
3.
bolt
Before servicing the vehicle, refer to
1.
Remove
the precautions in the beginning of this section.
To
install:
4.
Press the bushings into the control
The
2.
suspension switch, located of the
luggage com-
partment, must be turned to the
arm
5.
Install the control
6.
Check the wheel alignment and adjust
to the vehicle.
3.
Deflate the air springs.
4.
Remove
arm as an assembly.
posi-
Rear wheel
•
Axle hub nut
•
Brake caliper and support
•
Upper control arm pivot
•
Lower control arm pivot bolts
bolt
Rear wheel knuckle and hub
• 5.
Press the hub out of the wheel bearing.
6.
Remove
7.
Press the bearing out of the knuckle.
axle hub nut for assembly.
ADJUSTMENT
or disconnect the following:
•
Wheel Bearings
To
at curb height.
OFF
tion before raising the vehicle.
The control arm bushings are serviced with the control
'•Tighten the bushing bolts with the
air
on the left-hand side
Rear
bar link
To install:
suspension
arm from the
as necessary.
•
new
the control
arm.
•
a
Remove
with a hydraulic press.
before raising the vehicle.
••Use
2.
vehicle.
the wheel bearing snapring.
install:
The wheel bearings are not adjustable. 5.
Install or
connect the following:
They are serviced by replacement
•
Lower control arm
•
Control arm inboard pivot bolts.
lbs.
bolt to
83-113
ft.
bolt.
Tighten
lbs.
new
axle hub nut for assembly.
suspension
.
in
the beginning of this section.
Remove
or disconnect the follow-
to
in
the bore.
the snapring.
Press the hub into the bearing.
10. 1 1
bottoms out Install
9.
Before servicing the vehicle, refer to the
precautions
it
Install or
.
•
ing:
Sway bar link. Tighten the nuts 96-120 inch lbs. (10-14 Nm).
Press the bearing into the knuckle
8.
until
connect the following:
Rear wheel knuckle and hub. Tighten the lower bolts to 94-131
•
Front wheel
•
Disc brake caliper and rotor
ft.
lbs.
(128-178 Nm) and the
117-142
•
Parking brake cable
•
Grease cap
upper bolt
•
Air spring
•
Spindle retainer nut
(158-193 Nm).
Rear wheel knuckle and hub.
•
Hub and
•
Tighten the lower bolts to 94-131
(128-178 Nm) and the upper bolt to 117-142 ft. lbs.
ft.
lbs.
To 3.
Install or
•
188-254
Nm).
ft.
•
connect the following:
•
Hub and
lbs.
(255-345
ft.
lbs.
•
bearing assembly. Tighten
188-254
ON
(255-345).
•
Grease cap
•
Disc brake caliper and
12.
ft.
lbs.
188-254
ft.
lbs.
(255-345 Nm).
Brake caliper and rotor Rear wheel Turn the
air
suspension switch
position.
13. rotor.
to
Axle hub nut. Tighten the hub nut to
the spindle retainer nut to
Axle hub nut. Tighten the hub nut to
bearing assembly
install:
(158-193 Nm). •
bolts with the
at curb height.
Front
2.
(113-153 Nm). •
REMOVAL & INSTALLATION
1
Lower shock absorber the bolt to
a
166-203
(225-275 Nm) and the rear 141-191 ft. lbs. (191-259
Nm). •
••Use
•Tighten the bushing
Tighten the front bolt to ft.
only.
Check th^wheel alignment and
adjust as necessary.
to the
FORD MOTOR
CO.
1998-01
Ford-Crown
Victoria
•
Lincoln-Town Car
19-17 19-2 19-15 19-2
DRIVE TRAIN ENGINE REPAIR FUEL SYSTEM
PRECAUTIONS STEERING AND
•
Mercury-Grand Marquis
19-17
Fuel Injector
Removal & Fuel
Installation
Pump
Removal &
19-19
Installation
19-16 19-15
19-15
Relieving
Air
19-19
Disarming
Removal &
Installation
19-21
19-2
Adjustment
Lower
Removal &
Installation
Lower Control Arm Control
Removal &
Lifters
Installation
&
Installation
Removal &
Installation
19-4
Removal &
19-2
Installation
&
19-2 19-7
Exhaust Manifold Installation
Removal &
Installation
Removal &
19-12
Installation
19-16
Installation
Removal &
19-19 Installation
Positioning
Removal &
19-19 19-15
Power Steering Gear Installation
Front Cover and Seal
Removal & Removal &
Installation
Installation
Upper
Installation
Upper Control Arm Control
Installation
Removal &
19-17
19-22
19-23 19-23
Installation
19-23
V 19-10
Valve Lash
19-10
Adjustment
W Water
Pump
Removal &
19-3 Installation
Wheel Bearings Removal &
19-12
19-17
Arm Bushing
Adjustment
19-12
19-12
19-22
Ball Joint
19-19 19-19
19-12
U
19-15
R Removal &
19-10
T
P Pinion Seal
19-20
19-10
Motor
19-10 19-12
Rear Main Seal
19-16
Starter
Installation
Replacement
Pump
19-7
F Fuel Filter
Oil
Installation
Piston and Ring
E
Engine Assembly
19-23
19-10
19-20 19-4
Cylinder Head
19-23
Pan
Removal &
19-8
Removal &
Removal &
0 Oil
19-8
19-23
Installation
19-18
19-20
Coil Spring
Removal &
19-20
Shock Absorber
19-23
Arm Bushing
Replacement
19-18
C Camshaft and Valve
Installation
19-6
S
Transmission Assembly
19-23
Ball Joint
Removal &
19-2
Removal Axle Shaft, Bearing and Seal
Removal
Installation
19-6
L
19-2
Installation
Removal
Removal &
19-2
Alternator
19-6
Intake Manifold
19-21
Air Spring
19-6 Installation
Timing Chain, Sprockets,
I
19-19
Precautions
&
19-15
Precautions
19-19
Bag
Removal
Removal &
Fuel System Service
A
Rocker Arms
19-16
Fuel System Pressure
SUSPENSION
19-17
19-3
19-23 19-23
Installation
19-24
FORD MOTOR CO.
192
CROWN
•
VICTORIA
TOWN CAR
•
GRAND MARQUIS
PRECAUTIONS of the following precautions,
all
which deal with personal of
component damage, and important points
when
to take into consideration
servicing a
motor vehicle:
tor or
cooling system
hot; serious
when
the engine
is
burns can occur from the steam
Observe
tions
all
applicable safety precau-
when working around
fuel.
Whenever
servicing the fuel system, always work
Do
well-ventilated area. or
vapors
to
light, for
come
in
in a
You should make every
should always buy the correct type
can-
fluid for
oil.
worn when Wash your hands and any
example). Keep a dry chemical
becomes contaminated, completely system with new
flush the
Never reuse any
fluid.
Any brake
removed
brake
from the system should be discarded. Also,
oil.
used engine
sible after
exposure
Soap and
water, or waterless
to
oil.
hand cleaner
new
All
now equipped
Supplemental
Inflatable Restraint (SIR) sys-
fluid to
painted surface;
come in condamage
will
it
the paint.
Never operate the engine without the
•
vehicles are
fluid that is
do not allow any brake tact with a
should be used. •
fluid.
proper amount and type of engine so
WILL
Timing
•
belt
maintenance
Many models
important.
extremely
is
utilize
an
interfer-
tem. The system must be disabled before
ence-type, non-freewheeling engine.
keep
performing service on or around system
timing belt breaks, the valves
designed
container specifically
for fuel storage; also,
always
properly seal fuel containers to avoid the
components, steering column, instrument
head may
panel components, wiring and sensors.
tially
possibility of fire or explosion. Refer to the
Failure to follow safety
additional fuel system precautions later
dures could result
in
this section.
Fuel injection systems often remain
•
in
and disabling proce-
accidental air bag
ment
•
Always wear safety goggles when
turned OFF. The fuel system pressure must
working with, or around, the
be relieved before disconnecting any
tem.
lines. Failure to
do so may
and/or personal
injury.
•
fuel
wash your hands thoroughly
handling brake
brake fluid
in
fluid.
If
eye
if
face,
plac-
work sur-
always face the bag and trim cover
reduce the motion
your eyes, flush your eyes
irritation persists, or
When
upward, away from the surface. This
you do get
with clean, running water for 15 minutes.
bag sys-
ing a non-deployed air bag on a
ethers and polyglycols. Avoid contact with
after
air
carrying a non-deployed air
pointed away from your body.
Brake fluid often contains polyglycol
the eyes and
When
bag, be sure the bag and trim cover are
result in fire
module
of the
if
will
it
is
accidentally deployed. Refer to the addiIf
you have taken
manual
this
tional air
bag system precautions
later in
If
the
the cylinder
causing poten-
serious (also time-consuming and
maintenance
unnecessary system repairs.
pressurized, even after the engine has been
strike the pistons,
in
expensive) engine damage. Refer
deployment, possible personal injury and
doing
oil;
engine damage.
result in severe
extinguisher near the work area. Always fuel in a
brake
of
the brake fluid
If
Protective gloves should be
Supplemental Restraint System (SRS) or
fire
your vehicle.
changing
with an air bag system, often referred to as a
contact with a spark,
and
essential to the safe
is
proper operation of the brake system. You
a
mini-
effort to
mize your exposure to used engine
not allow fuel spray
or excessive heat (a hot drop
open flame,
may cause
oil
of skin disorders, including
other exposed skin areas as soon as pos-
and hot coolant. •
number
prolonged con-
that
used engine
tact with
cer.
Never open, service or drain the radia-
•
The EPA warns
•
Clean, high quality brake fluid from a
•
sealed container
medical assistance.
prevention
safety,
IMMEDIATELY seek
brake fluid internally,
Before servicing any vehicle, please be
sure to read
to the
interval charts in the front of
recommended
for the
interval for the timing belt,
replace-
and
to the
timing belt section for belt replacement and inspection. •
Disconnecting the negative battery
cable on
some
vehicles
may
interfere with
the functions of the on-board
tem^) and may
require the
computer sys-
computer
to
undergo a relearning process once the negative battery cable •
When
is
servicing
reconnected.
drum
brakes, only dis-
assemble and assemble one side
at a time,
leaving the remaining side intact for refer-
ence.
this section.
ENGINE REPAIR Alternator
•
Accessory drive
•
Alternator
ADJUSTMENT
belt
The 4.6L engine
REMOVAL
INSTALLATION tributorless Ignition
is
equipped with a Dis-
System
(DIS).
No
adjustments are necessary. 1
.
Before servicing the vehicle, refer to
the precautions
in
tion. 2.
Install or
the beginning of this sec-
•
to
Remove
or disconnect the following:
15-22 •
connect the following:
Alternator. Tighten the ft.
lbs.
mounting
bolts
Engine Assembly
(20-30 Nm).
Alternator bracket. Tighten the bolts to
REMOVAL & INSTALLATION
•
Negative battery cable
•
Engine cover
•
Accessory drive
•
Pushpins and wiring harness
•
Pushpins and wiring harness
•
Mounting bolts
•
Engine cover
the precautions ir^the beginning of this sec-
•
Alternator bracket
•
Negative battery cable
tion.
71-106
inch lbs. (8-12 Nm). belt
1.
Before servicing the vehicle, refer to
FORD MOTOR CO. CROWN
VICTORIA
•
2.
Drain Ihe engine cooling system.
engine support insulator to the
3.
Recover the refrigerant from the
front
air
conditioning system.
5.
Drain the engine
6.
Remove
10.
Connect engine
Hood
ing brackets
•
Engine cooling
•
Windshield wiper governor and
from the transmission. Do not
support bracket
converter
fan,
shroud and
1 1
to the
the torque
•
Engine/transmission harness con-
engine compartment and position on a
nector from the retaining bracket
workstand.
Accelerator and cruise control
ment.
cables •
•
at
Electrical
the throttle
12.
body
connector and vacuum
Carefully
lift
Remove
To
install:
13.
Engine
the engine out of the
hose from the evaporative emission
engine using a floor crane installed to the lifting
Positive battery cable from the
from the workstand into the
the flywheel
and align the paint marks on
•
Both heater hoses
the flywheel
and torque converter. Be sure
•
Alternator harness from the front
the studs on the torque converter align with
fender apron and the power distri-
the holes in the flywheel. 15.
hoses from the
air
conditioning compressor •
Body ground
•
Fully
16.
strap from the dash •
3 bolts and
transmission knee
•
4 bolts retaining the power steering
pump
to the cylinder block
•
and
•
Engine
Hood
equipment and brack-
•
verter nuts.
Rotate the crankshaft until each of the 4
the crankcase to the correct level.
18
Fill
the cooling system
6 engine-to-transmission retaining
19
Start the
and tighten
to
30-44
ft.
lbs
lbs.
(20-30 Nm)
22-25
ft.
Check
Starter
and proper
fluid lev-
21
Evacuate and recharge the
.
air
condi-
Road
22.
and check the
test the vehicle for
proper opera-
to the
Water Pump cylin-
ft.
lbs.
REMOVAL & INSTALLATION
(20-30
Engine-to-transmission brace and
bolts
Support the transmission with a floor
1
motor
through-bolts
and
and stud
Before servicing the vehicle, refer to
the precautions in the beginning of this section.
1
to
stud. Tighten the
18-31
ft.
2.
Drain the cooling system.
3.
Remove
lbs.
(25-43 Nm).
• •
Bolt retaining the right-hand front
for leaks
tion.
Power steering pump on the
the 3 bolts
wood.
to reach
els.
engine and transmission
lbs.
Transmission housing cover
Engine support insulator (mount)
jack and a block of
it
tioning system.
4 torque converter retaining nuts to
engine and allow
normal operating temperature
Nm). • •
bolts
1
20
Front engine support insulator
Tighten to 15-22
or disconnect the following:
6 transmission-to-engine retaining
Battery
port bracket
der block and the 4 retaining nuts.
accessible and remove the nuts
and shroud
cleaner outlet tube
Fill
cylinder block •
air
7
(20-30 Nm)
Transmission housing cover from the
Remove
engine mount insulator sup-
and tighten
cylinder block to access the torque con-
•
Radiator, cooling fan
ets
ft.
position aside
9.
Fuel supply and return lines
lifting
through-bolts and tighten to 15-22
motor
•
•
support bracket
(40-60 Nm)
stud retaining the
1
power brake booster
Windshield wiper governor and
•
Engine
bolts
to the
Engine/transmission harness con-
•
connect the following
hung from
•
emission
Accelerator and cruise control
the •
front
Starter
•
to the trans-
engine sup-
front
manifolds and support with wire
Retaining nut from the transmission
connector and vacuum
to the evaporative
cables at the throttle body •
•
braces
8.
•
•
crossmember
box and harness
canister purge valve
Bolt retaining the right-hand front
the
Electrical
hose
engine support insulator to the
•
is
power
distribution
Exhaust system from the exhaust
engine
7.
Positive battery cable to the
•
nector to the retaining bracket on
engage the engine
Install or
line bracket •
throttle
Start the converter pilot into
mission and lower onto
•
panel •
Vacuum supply hose to the body adapter vacuum port
port insulators.
Power steering control valve harness connector
•
Both heater hoses
•
engine
compartment.
bution box
bution box
•
Lower the engine
14.
Alternator harness at the front
•
equipment and remove the engine
Vacuum supply hose from the throttle body adapter vacuum port
Air conditioning
•
brackets. Support the
lifting
strap to the dash panel
fender apron and the power distri-
•
•
Air conditioning lines to the air
the engine lifting equip-
canister purge valve
power distribution box and harness
Ground
•
conditioning compressor
Engine
cleaner outlet tube
•
out of the transmission.
fall
•
air
Power steering valve harness connector
carefully separate the engine let
(27-41 Nm). Be sure
crossmember. Adjust as necessary.
lift-
•
and
lbs.
ft.
the exhaust system clears the No. 3
Raise the engine slightly using a
.
floor crane
t
equipment
lifting
Exhaust system to the exhaust
20-30
head and to
Battery
(20-30
manifolds. Tighten the 4 nuts to
the rear of the right-hand cylinder head.
•
lbs.
ft.
Nm).
bracket to the
•
•
nuts
lifting
15-22
Tighten to
•
engine
Install
19-3
GRAND MARQUIS
engine mount insulator sup-
front of the left-hand cylinder
oil.
or disconnect the following:
radiator
•
port bracket
Relieve the fuel system pressure.
4
TOWN CAR
Transmission
line bracket to the
brace stud and
1
or disconnect the following:
Negative battery cable
•
Cooling fan and shroud
•
Accessory drive
retaining nut.
For complete service labor times, order the Chilton Labor Guide
belt
r
FORD MOTOR CO.
4
•10
"*f
I
CROWN
•
VICTORIA a—^Mt w
mmauaa
~i
r«
TOWN CAR
GRAND MARQUIS
«
t
air
suspension switch, located on the
hand side
must be turned
OFF
to the
tor
Drain the engine cooling system.
4.
Properly relieve the fuel system
Be sure
manifold
Exhaust pipes from the exhaust
•
manifolds. Lower the exhaust pipes
or disconnect the following:
and hang with wire from the cross-
•
Negative battery cable
•
Cooling fan and shroud assembly
•
Engine
•
Windshield wiper governor (mod-
harness
ule)
hand cylinder head
pump mount-
water
to tighten the
air
member. •
cleaner outlet tube
Bolts retaining the starter wiring
ing bolts to the specification
4 water pump pulley-to-water pump
•
bolts •
Ignition wires
Ignition wire brackets
Water
pump
4.
Clean the sealing surfaces of the
pressure
block.
•
Accelerator cable bracket from the
•
Vacuum hose from the elbow vacuum port
intake manifold
right-hand
line to the
O-ring, lubricate
it
Wiring to both ignition coils and
with clean
the Camshaft Position
Water pump. Tighten the bolts
15-22 Water
•
ft.
lbs.
pump
to
•
(20-30 Nm).
(CMP) sen-
•
2 bolts retaining the thermostat
bolts to
15-22
ft.
lbs.
(20-30 Nm).
position the upper hose and ther-
front cover nuts. Slide the ignition
mostat housing aside
Fill
7.
Operate the engine to normal operat-
and check
retain the intake manifold.
pulley
bolts
Intake manifold
alternator
•
7 stud bolts and the 4 bolts attaching the engine front cover to the
Alternator
•
Positive battery cable at the
engine
power •
Front cover
Retaining bolt from the positive
•
Both timing chains
battery cable bracket located on the
•
box
Vent hose from the canister purge
•
•
tion.
suspension, the •
LOWER REAR
Positive Crankcase Ventilation
removed due removal
secure the cylinder head bolt
conditioning compressor clutch electri-
connectors
pump
the bolts retaining the
to the cylinder
power
Wire the
Remove
not
pan and
pan gasket
Engine
•
Crankshaft pulley retaining bolt
•
Pulley
head
head gasket
’•The lower rear cylinder head bolt cannot be removed due to interference with the power brake booster. Use a rubber band to hold the bolt away from the cylinder blopk.
Remove
9.
•
oil
or disconnect the following:
Ground
strap,
1
stud and
1
bolt
retaining the heater return line to
the right-hand cylinder head
or disconnect the following:
•
oil
or
block and
come all the power steering pump aside. will
installation of the
damaging the cylinder block
power brake booster
to
the cylinder
head during removal and
7922RG02
cylinder head bolt to ease removal of the
in
cylinder head and to prevent the bolt from
power steering pump
support the rear
the vehicle.
10.
nector from the retaining bracket on
engine front cover. The front lower bolt on the
out.
is
Engine/transmission harness con-
Remove
7.
the
Use a rubber band
(PCV) valve from the cylinder head
in
in
to lack of clearance for
cover
cal
way
The lower
cylinder head until the cylinder head
and canister purge solenoid
6.
the cylinder head.
head bolt must stay
battery cable aside
Crankshaft Position (CKP) sensor,
steering
Remove
8.
rear cylinder
air
So
10 left-hand cylinder head-to-cylinder block bolts
solenoid and position the positive
the •
and gaskets
•
side of the right-hand cylinder head
the precautions in the beginning of this sec-
Use a rubber band
9 intake manifold-to-cylinder heads
junction block, fender apron and
•
Before servicing the vehicle, refer to
air
"•The 2 thermostat housing bolts also
•
Alternator wiring harness from the
distribution
•‘The cylinder head bolts are a torqueto-yield design and cannot be reused. Always use new cylinder head bolts for assembly.
equipped with
pump
Water
•
If
mounting studs
•
REMOVAL & INSTALLATION
2.
the
•
for leaks.
Cylinder Head
1.
off
to the intake
and from the vehicle
the cooling system.
6.
ing temperatures
brackets and ignition wire
assemblies
belt
manifold and
housing
Ignition coil brackets-to-engine
pulley. Tighten the
Accessory drive
body
sor
coil
•
throttle
the heater water hose
antifreeze prior to installation •
and position aside
Heated Oxygen (HO 2 S) sensors and
•
ignition coil bracket
connect the following: •
New
Accelerator and cruise control
cables coil
Bolt retaining the air conditioning
•
pump and •
•
brackets bolts
install:
Install or
der heads
from the
2 ignition wire tray-to-ignition
•
to the rear of the right-
Cylinder head covers to the cylin-
•
belt
from the spark plugs
cylinder head cover studs
4 water pump-to-engine bolts
•
5.
Accessory drive
• •
To water
•
Pulley
•
pressure sensor wiring
tube from the right-hand exhaust
pressure.
Remove
oil
Exhaust Gas Recirculation (EGR)
•
3.
and
connectors and position aside.
position before
raising the vehicle.
5.
Power steering control valve actua-
•
right-
luggage compartment,
of the
•
10 right-hand cylinder head-tocylinder block bolts
Remove
the cylinder head.
The lower
FORD MOTOR CO. CROWN head
rear cylinder
must stay
bolt
removed due removal
to lack of clearance for
secure the cylinder head bolt
head during removal and
to
cylinder
in the
installation of the
plus
3:
loosen
27-32 ft. lbs. (37-43 Nm). plus 85-95 degrees. again, plus 85-95
bolts at least
all
•
Step
4:
e.
Step
5:
f.
Step
6:
damaging the cylinder block
or head gasket.
17.
"••The lower rear cylinder
head
2 retaining bolts.
with the evaporator housing. Use a rub-
away from
tighten the retaining bolt
Exhaust pipes to the exhaust mani-
•
matched
at the center of the
both are
in
camshaft
time. Install
Camshaft Position-
T91P-6256-A, on the
EGR
•
the
flats of
Check
all
gaskets mating surfaces.
the cylinder heads
for flatness.
Check
and cylinder block
the cylinder heads for
combustion chambers
that
degrees
could provide
No.
for the
cylinder.
1
—The
crankshaft must only be rotated
in the
clockwise direction and only as
Rotate the crankshaft counterclock-
20.
should be
•
at the
from the front
9 o'clock position viewed
of the engine. This
tion
Install or
connect the following:
New head New
•
retain with rubber
•
bands as
new
cylinder head bolts,
rear bolts
in
and
install all bolts
Tighten the
16.
new
•
a.
Step 1:28-31
15-22
ft.
New
lbs.
bolts.
(20-30
ft.
lbs.
lbs.
(37-43 Nm).
d.
on the
Be sure the align-
in
•
•
LH CYLINDER
HEAD ASSY 21
7922RG03
Cylinder head torque sequence
SOHC
•
•
—4.6L
•
Please
visit
ft.
lbs
(20-30 Nm). compressor.
CKP
connectors
Engine/transmission harness con-
PCV
valve
in
the right-hand cylin-
der head cover and connect the
ft
(20-30 Nm).
canister purge solenoid vent hose
HO 2 S
•
on
Positive battery cable harness
the right-hand cylinder head •
Accelerator cable bracket on the
•
front
Bolt retaining the cable bracket to
the cylinder head Positive battery cable at the distribution
Accelerator and cruise control
•
Alternator
power
box and battery
and the 2 retaining
Tighten the bolts to 15-22
ft.
bolts. lbs.
(20-30 Nm).
to both places
cover meets the
•
2 bolts retaining the alternator brace to the intake manifold.
Cylinder head covers with
new gas-
on the cylinder heads. Tighten
our web
15-22
Air conditioning
nector on the power brake booster •
Vacuum hose to the throttle body adapter vacuum port
ket
in position
4 retaining bolts Tighten the bolts
electrical
•
cylinder heads.
engine
oil
sensor and canister purge solenoid
(20-30 Nm).
Apply silicone sealer
.
pan and a new gasket
Power steering pump
to
on the cylinder
Heater water hose and both
where the engine
connect the following:
•
cables to the throttle body
CYLINDER HEAD TIGHTENING SEQUENCE
Tighten an additional
Engine
intake manifold
RH CYLINDER HEAD ASSY
turn.
lbs
on the cylinder block
the cylin-
15—22
4:
Install or
sensors •
Step
•
Thermostat, O-ring, thermostat
lbs. •
ft.
85-95 degrees 24.
intake manifold gaskets
Intake manifold
35-39
(47-53 Nm).
Engine front cover and the
the 2 retaining bolts to ft.
(90
lbs.
Loosen one complete
housing and upper hose. Tighten
sequence, as follows:
ft.
Tighten to
15-22
hand-tight
Tighten to 66
3:
Tighten the bolts in sequence, to
cylinder head bolts,
:
2:
heads and the retaining bolts
remove the rubber bands from the lower
1
Step
der heads.
score the surface of the head face. Apply
Step
Step
aligned with the holes
the
a
Nm). b.
cedure
•
crankshaft pulley and
c.
ment tabs on the gaskets are
oil to
Install the
tighten the bolt as follows.
oil
to the
explained during the removal pro-
Position the cylinder heads on the
23.
points where the cover contacts the
cylinder heads.
cylinder block dowels, being careful not to
clean
engine
it
Nm).
bolts in the lower rear bolt
making
junction of the cylinder block and
Tighten to
holes on both cylinder heads and
15.
keyway on the
are aligned.
the cylinder heads.
gaskets on the cylinder
block •
of the
pan and cylinder block and
where the valves do not extend below
•
pressure sensor electri-
Pulley on the crankshaft,
engine front cover seal and
meets the junction
face.
the head face. 14.
New
lower corners of the cover where
Rotate the camshaft to a stable posi-
13.
oil
sure the crankshaft key and keyway
Both timing chains
gasket. Apply silicone sealer to the
ensures
pistons are below the top of the
engine block deck
•
connect the following
Install or
•
all
connectors
crankshaft pulley.
wise 45 degrees. The crankshaft keyway
that
and
cal
as TDC.
Install:
12.
tor
sealer in the rear of the far
To
line nut to
(35-45 Nm).
Apply a small amount of silicone
22.
leak paths.
lbs.
ft.
Power steering control valve actua-
•
Top
to position the crankshaft at
Dead Center (TDC)
scratches near the coolant passages and
26-33
Rotate the crankshaft clockwise 45
19.
tube to the right-hand exhaust
manifold and tighten the
camshafts to keep them from rotating Clean
crossmember. Adjust as nec-
until
essary.
ing Tools
11.
20-30
to
sure the exhaust system clears
the No. 3
the
cylinder block.
4 nuts
(27-41 Nm).
lbs.
ft.
—Be
Rotate the camshafts using the flats
to the
right-hand cylinder head and
folds. Tighten the
bolt 18.
motor wiring harness
Starter
Position the heater return hose and
install the
71-106
inch lbs. (8-12 Nm).
1
turn.
d.
19-5
GRAND MARQUIS
the bolts and stud bolts to
2:
Step
degrees.
cannot be removed due to interference
•
85-95 degrees.
Step
cylinder head and to prevent the bolt from
ber band to hold the bolt
TOWN CAR
b.
full
Use a rubber band
the vehicle.
in
is
•
c.
the
in
cylinder head until the cylinder head
VICTORIA
site at
www.chiltonsonline.com
Tighten to
Nm).
72-96
inch lbs. (8-12
FORD MOTOR CO.
19-6
CROWN
Water
•
pump
bolts to
TOWN CAR
•
GRAND MARQUIS
pulley. Tighten the
15-22
ft.
(20-30 Nm).
lbs.
and
Ignition coil brackets
•
•
VICTORIA
ignition
wire assemblies onto the mounting
and tighten
to
15-22
grommet and
lbs.
ft.
Remove
5.
CMP
and
sensor har-
•
Fuel lines
•
PSP
and tighten the retaining
on
ing unit
brake aside
vacuum booster and
Ignition wires
•
Ignition wire brackets
Engine
air
Ignition wire brackets
Wires
at the
26.
If
equipped with
air
suspension, turn
ON
posi-
Positive battery cable harness on
•
from the
the right cylinder head •
Bolt retaining the cable bracket to
the cylinder head
bottom
•
Positive battery cable at the
of its stroke
and position the camshaft lobe on the base circle.
tion. Refill the
Install
amount 28.
of oil
and replace the
Start the
to
the spring coils to
prevent valve seal damage.
filter.
engine and bring
valve spring spacer tool
T91P-6565-AH between
engine with the correct
normal
When
16.
Install a
8.
valve spring compressor
operating temperature while checking for
under the camshaft and on top
leaks.
spring retainer.
Road
test the vehicle
and check
for
proper engine operation.
Compress
9.
remove the
To
Ignition wire brackets
Wires
•
Windshield wiper module
•
42-pin and transmission harness
the valve spring and
roller follower.
Remove
tip
1 1
1
Before servicing the vehicle, refer to
.
the precautions
in
.
to the
on the studs
spark plugs
connectors Retaining bracket
PSP
•
switch and
pressure send-
oil
the valve ing unit harness. •
Fuel lines
•
Apply engine
oil to
the valve
and
Negative battery cable
stem 17.
and
camshaft
install:
10.
REMOVAL & INSTALLATION
left
•
of the valve
spring compressor and spacer.
Rocker Arms
installing the
•
•
29.
power
box and the battery
cover, install or connect the following:
7.
27.
CKP
sensor
distribution
the air suspension switch to the
on the studs
spark plugs
to the
Canister purge solenoid, air condi-
•
Position the piston of the cylinder
6.
camshaft
camshaft cover grom-
into the
•
Camshaft cover
being serviced
the cooling system.
installing the right
•
position
studs and position the wires aside •
cleaner outlet tube
Negative battery cable Fill
PCV
•
from the spark plugs
•
Fuel supply and return lines
Cooling fan and shroud
and stud bolts and tighten
inch lbs. (8-12 Nm).
When
Windshield wiper module
•
the
covers.
tioning compressor clutch and
shield wiper governor
•
•
and position the harness
from the retaining bracket on the
and the wind-
install the
cover, install or connect the following:
42-pin engine harness connector
•
bolt
head cover studs
•
25.
pressure send-
front
met
and the bracket onto the cylinder
belt
oil
aside
Ignition wires to the spark plugs
Accessory drive
72-106 15.
switch and
where the
new gaskets onto
Position
camshaft covers and
Air inlet tube
the right-hand ignition coil bracket
•
camshaft cover by
to
Air conditioning pressure line
•
left
Install the bolts
•
ness connectors
•
the
of the
cover meets the cylinder head.
removing or disconnecting the following:
Nm) Ignition coil
Clean the sealing surfaces
silicone sealer to the places
remove
compressor
the valve spring
camshaft covers and cylinder heads. Apply
14.
and
inch lbs. (8-12
Remove
the camshaft cover.
2 bolts retaining the ignition wire
71-106
position aside
Bolts and stud bolts and
•
tray to the ignition coil bracket
tighten to
valve from the camshaft cover
of
and spacer. 13.
PCV
bottom
at the
circle.
the wires aside •
must be
piston
stroke and the camshaft at the base
12.
(20-30 Nm)
•
from the spark plugs
Ignition wires
Ignition wire brackets from the
camshaft cover studs and position
brackets to the engine front cover
•
its
•
7 nuts retaining the ignition coil
•
^The
cable aside •
studs •
and position the positive battery
engine and check
Start the
for leaks.
roller follower contact surfaces.
Install
valve spring spacer tool
T91P-6565-AH between the spring coils. Compress the valve spring, and install the
the beginning of this sec-
Intake Manifold
REMOVAL & INSTALLATION
roller follower. tion. 2.
Relieve the fuel system pressure.
3.
Disconnect the negative battery
Before servicing the vehicle, refer to
1.
the precautions
in
the beginning of this sec-
cable. tion.
4 Remove the right camshaft cover by removing or disconnecting the following:
2. air
•
Positive battery cable at the battery
and •
at
the
equipped with
If
hand side
power distribution box
air
suspension, the
suspension switch, located on the of the
must be turned
right-
luggage compartment,
to the
OFF
position before
Retaining bolt from the positive raising the vehicle. battery cable bracket located on the 3.
Disconnect negative battery cable.
4.
Drain the engine cooling system.
5.
Properly relieve the fuel system
side of the right cylinder head •
Crankshaft Position (CKP) sensor, air
•
conditioning compressor clutch
7922RG04
pressure.
and canister purge solenoid con-
After installing the spring spacer,
nectors. Position the harness aside.
press the valve spring and remove the
Vent hose from the purge solenoid
rocker
arm
com-
Remove
6.
•
or disconnect the following:
Fuel supply and return lines
FORD MOTOR CO. CROWN •
VICTORIA
•
TOWN CAR
Windshield wiper governor (mod-
manifold. Tighten the tube nut to
ule)
26-33
•
Engine
air
cleaner outlet tube
•
Accessory drive
Ignition wires from the spark plugs
•
Ignition wire brackets
belt
Position •
•
Oil
from the •
Alternator. Tighten the bolts to
•
2 bolts retaining the alternator
15-22
and the Camshaft
(CMP) sensor
brace to the intake manifold and tighten to
2 bolts retaining the ignition wire
Nm) •
Alternator wiring harness from the
Nm
20-30
(15-22 t>*i
•
7922BGG6
manifold and the
Intake manifold torque sequence alter-
SOHC
nator to the cylinder block
•
Oil
7.
pressure sensor and power
Exhaust Gas Recirculation (EGR)
bracket to the ignition coil brackets.
replacing the intake manifold,
If
the necessary parts.
To install: Clean
9.
Position
all
Ignition wire brackets
gaskets mating surfaces.
new
on the
intake manifold gaskets
•
Wiring connectors to both ignition
•
Accessory drive
fold
the holes in the cylinder heads.
•
Air cleaner outlet tube
•
Windshield wiper governor
•
Fuel supply and return lines
Engine/transmission harness con-
Install the intake
manifold and the 9
from the front of the engine)
before final tightening, then tighten the
compressor (CKP)
sequence,
bolts, in
to
15-22
ft
lbs
(20-30
Nm). 1 1
Inspect and
.
necessary, replace the
if
O-ring seal on the thermostat housing
(PCV) valve from the cylinder head
Position the housing and upper hose and
cover
install the
PCV
15-22 12.
valve
ft.
2 retaining
bolts. Tighten to
connect the following
Fill
14.
If
the engine cooling system.
equipped with
air
suspension, turn
cables from the throttle body
•
HO 2 S
Accelerator cable bracket from the
•
Vacuum hose to the throttle body adapter vacuum port
•
Vacuum hose from
•
Accelerator cable bracket on the
and position aside
adapter port •
ON
posi-
tion.
15
Start the
16
Road
engine and check
test the vehicle
for leaks.
and check
for
Exhaust Manifold
•
Heated Oxygen (HO 2 S) sensor and
Negative battery cable
13.
Heater water hose
Accelerator and cruise control
body
sensor
belt
(20-30 Nm)
lbs.
Install or •
the throttle
CMP
proper operation
•
intake manifold
•
and the
the air suspension switch to the
Positive Crankcase Ventilation
Canister purge vent hose from the
coils
retaining bolts. Hand-tighten the right-rear bolt (viewed
power brake booster
Air conditioning
10
cylin-
der head cover studs
ment tabs on the gaskets are aligned with
noid wiring connectors
sensor
REMOVAL & INSTALLATION 1
Before servicing the vehicle, refer to
.
intake manifold
the precautions in the beginning of this sec-
Accelerator and cruise control
tion.
cables to the throttle body
2.
Drain the engine cooling system.
PCV
3.
Relieve the fuel system pressure.
cover
4.
Discharge the
position the upper hose and ther-
•
Canister purge solenoid vent hose
5.
Remove
mostat housing aside
•
Air conditioning
the heater water
hose
2 bolts retaining the thermostat
housing
to the intake
•
manifold and
valve in the cylinder head
**The 2 thermostat housing bolts are also used to retain the intake manifold.
•
9 bolts retaining the intake manifold to the cylinder
Intake manifold
heads
and gaskets
•
conditioning system
air
or disconnect the following:
compressor
•
Battery cables
sensor and canister
•
Engine
purge solenoid wiring connectors
•
Cooling fan and shroud assembly
Engine/transmission harness con-
•
Fuel supply and return lines
nector the retaining bracket on the
•
Upper
power brake booster
•
Windshield wiper governor and
clutch,
•
Ignition wires to the spark plugs
from the right-hand exhaust mani-
sensor and the canister purge sole-
•
Ignition wires to the ignition coils
• •
8.
inch
•
valve-to-exhaust manifold tube
clutch, Crankshaft position
•
71-106
(8-12 Nm).
on the cylinder heads. Be sure the align-
nector from the retaining bracket on
•
2 bolts retaining the ignition wire
engine
swap over
ness aside
•
•
—4 6L
lbs.
wiring and position the wiring har-
•
assembly on the
Ignition wire
Tighten the bolts to
steering control valve actuator
the
apron
engine
Bolts retaining the alternator brace
Alternator
(8-12
and junction block
and alternator
•
inch lbs.
alternator, right-hand fender
junction block at the fender apron
to the intake
71-106
Alternator wiring harness to the
assembly
•
•
(20-30 Nm).
lbs.
Ignition v^ires from both ignition
Ignition wire
•
ft.
coils
bracket to the ignition coil brackets
•
pressure sensor wiring connec-
tors
•
•
(35-45 Nm).
lbs.
tor •
cylinder head cover studs Ignition coils
ft.
Power steering control valve actua-
•
•
•
19-7
GRAND MARQUIS
•
EGR
CKP
is
covered
in Section
3
radiator
hose
support bracket
valve-to-exhaust manifold •
tube to the right-hand exhaust
Timing belt service
tube
air inlet
of this
manual
Compressor
outlet
hose
at
the
FORD MOTOR CO.
19-0
CROWN
VICTORIA
•
TOWN CAR
GRAND MARQUIS
•
15-22
tighten the bolts to
lbs.
ft.
(20-30 Nm) 1 1
Lower the engine onto the
.
front engine
support insulator and remove the jack. Install or
12.
connect the following:
Left-hand and right-hand engine
•
support insulator through-bolts and tighten to
15-22
lbs.
ft.
(20-30
Nm). Catalytic converter pipes to both
•
exhaust manifolds. Tighten he nuts to
20-30
(27-41 Nm).
lbs.
ft.
'•Be sure the exhaust system clears Left
the No. 3 crossmember. Adjust as nec-
exhaust manifold torque sequence
essary.
compressor and the hose assem-
the cylinder block and the 8 nuts
bly-to-right-hand ignition coil
retaining the exhaust manifold
bracket bolt. Plug both openings. •
the
power brake booster
Heater hose
•
Ground strap-to-right-hand
Install or
7.
Upper stud and lower
•
10. •
Heater blower motor switch resistor
To
Bolt retaining the right-hand front
•
•
to the
8.
Engine support insulator through-
33-48
•
Install or
•
kets.
to •
from
Front engine support insulator from
of the
lbs.
•
26-33
ft.
lbs.
15-22
ft.
and lbs.
Engine/transmission harness con-
•
Retaining bracket on the power
•
Air conditioning
•
in
sequence
compressor
outlet
compressor
Bolt retaining the
hose assembly
•
Upper radiator hose
•
Fuel supply and return lines
•
Windshield wiper governor and
line
to
retaining bracket
(35-45 Nm).
•
Left-hand front engine support insulator to the cylinder block
to the
the right-hand ignition coil bracket
valve and tube assembly to the
nut to
strap onto the stud
Heater hose
hose
(20-30 Nm).
exhaust manifold. Tighten the
with wire.
Left-hand exhaust manifold
EGR
Ground
brake booster
Tighten the bolts ft.
and
(20-30
nector
connect the following:
15-22
bolt
lbs.
ft.
•
Exhaust manifolds, using new gas-
Catalytic converter pipes from both
15-22
•
exhaust manifolds and cylinder heads.
fold.
crossmember
lbs.
Clean the mating surfaces
9.
it
ft.
(45-65 Nm).
lbs.
position
(20-30 Nm)
tube connector and tighten to
ft.
in
Nm)
(37-45 Nm). On
the
the •
27-33
sors
exhaust system and hang
Upper stud and lower
the exhaust manifolds are being
the right-hand exhaust manifold, transfer
exhaust manifolds. Lower the
Heater hose
•
tighten the nut to
Both Heated Oxygen (HO 2 S) sen-
from the right-hand exhaust mani-
•
•
replaced, transfer the heated 02 sensors and
EGR
Heater blower motor switch resistor
tighten to
Manifold and gasket
If
lbs.
using the 2 retaining screws
connect the following:
tighten to
Exhaust Gas Recirculation (EGR)
•
install:
valve-to-exhaust manifold tube nut
•
pan,
sub-frame
bolts •
oil
drain hole. Raise the
and right-hand exhaust manifold
head and position aside
engine support insulator
the engine
ft.
(20-30 Nm)
8 exhaust manifold retaining nuts
•
bolt retaining
the heater hose to the right cylinder
•
oil
to the
sub-frame. Tighten to 15-22
engine approximately 4 inches (100mm).
der head nut •
wood under
rearward of the cylin-
engine support insulator
Position an adjustable jackstand and
6.
a block of
•
Bolt retaining the right-hand front
2 manifold gaskets
nector from the retaining bracket on
sensors
Both
•
Left-hand exhaust manifold and the
•
Engine/transmission harness con-
HO 2 S
•
Engine cooling fan blade and fan
shroud
and
•
Engine
•
Battery cables
air inlet
tube
the cooling system.
13.
Fill
14.
Start the
15.
Properly evacuate and charge the
engine and check
for leaks. air
conditioning system. 16.
Road
test the vehicle
and check
for
proper operation.
Camshaft and Valve
Lifters
REMOVAL & INSTALLATION
1
.
Before servicing the vehicle, refer to
the precautions
Right exhaust manifold torque sequence
tion.
in
the beginning of this sec-
FORD MOTOR CROWN 2. air
equipped with
If
air
suspension, the
suspension switch, must be turned
OFF
tor
and
oil
•
TOWN CAR
control valve actua-
Loosen the camshaft bearing cap
17.
or until the heads of the bolts are free.
adapter
•
Oil filter
•
Cylinder head covers
Tighten
•
Engine front cover
71-106
4.
Drain the engine
5.
Remove
Timing chains
•
oil
or disconnect the following:
•
Negative battery cable
wise no more than 45 degrees from Top
•
Fan blade and fan shroud assembly
Dead Center (TDC)
Fuel supply and return lines from
tons are below the top of the engine block
the fuel injection supply manifold
deck
•
•
Windshield wiper governor (mod-
assembly from the vehicle
ule)
Ignition wires from the spark plugs
6565-AH between
belt
2 bolts retaining the ignition wire
and remove the rocker arm. Repeat the pro-
separator to the ignition coil brack-
cedure
and the
bolt retaining the air
right-hand ignition coil bracket.
their locations, they
Connectors from both ignition coils
same bore
(CMP)
Ignition coils with brackets attached
•
Electrical
connector from the
nator and at the
power
power
1 1
points near the upper bearing halves lift
the camshaft bearing cap
Repeat the removal procedure
.
Remove
12.
upward
Positive Crankcase Ventilation
13.
to
for the
related
damage.
To
Engine/transmission harness con-
14.
for
If
front
steering
will not
come
22.
Install
23.
pan
and crankshaft pulley Engine
install the
Clean and inspect the cylinder head
Apply clean engine
oil to
81-95
Install
Install
install
24
Valve Spring Spacer T91P-
Tighten the in
the rocker
until all rocker
arm Repeat arms
the pro-
45
Top
crankshaft must only be rotated
as TDC.
25.
Install or
connect the following:
Timing chains
individually.
•
Engine front cover
•
bearing cap cluster
tightened individually.
oil filter
covered
on
are installed.
to position the crankshaft at
•
is
is
sequence
inch lbs. (8-12 Nm). Be sure to
-Each camshaft
Be
the valve spring coils.
tighten each camshaft bearing cap cluster
Heater Core replacement
of the valve
the clockwise direction and only as
far
is
and
lbs.
Rotate the crankshaft clockwise
•The
and hand
camshaft cluster retaining bolts
assembly
ft.
base circle Compress the valve spring
its
the
and seat the camshaft bearing
start the retaining bolts
71-106
the flats of
spacers and
a valve spring compressor
Dead Center (TDC).
to
Crankshaft pulley bolt and washer
and
sure that the valve being compressed
out. Oil
T92P-6256-A on
spring retainer.
unusual wear or
install:
Install
adjusters
necessary, install Camshaft Posi-
camshafts on the cylinder heads 16.
the dial indicator.
install the lash
degrees
the
•
Remove
under the camshaft and on top
in
•
5:
6565-AH between
cap cluster assemblies.
all
in
end-play
and replace the cylinder
camshaft journals and lobes. Position the
and
lower bolt on the power
pump
15.
conditioning clutch harness
aside
If
to
cedure
pump
tight,
Install the bolts
sealing surfaces.
power steering
too
washers and tighten
Crankshaft Position (CKP) sensor
to the cylinder block
is
camshaft sprockets
and
Bolts retaining the
end-play
removed,
the camshafts
covers, engine front cover and cylinder head
wire the
•
21.
power brake booster
air
If
(110-130 Nm)
avoid bearing damage.
components
(PCV) valve from the cylinder head
If
tioning Tools
the camshaft straight
Clean and inspect the camshafts and
cover and position aside
pump
4:
binding or foreign material
in their original positions.
opposite cylinder head.
and position
connectors
"The
at
clusters from the cylinder head
nector from the bracket on the
•
for
Step
e.
20
head. Tap upward on the camshaft bearing
bracket located on the right-hand
and
is
excessive, check for worn camshaft
To remove each camshaft, unfasten
10.
and gradually
EVAP
camshaft forward
Specified end-play
head, as required.
Bolt from the positive battery cable
Fuel vapor hose from the
dial
locations tor installation.
caps
box
the positive battery cable aside
•
not mix the camshaft bearing
caps (cluster assemblies) to the cylinder
pulley
canister purge valve
•
check
thrust plate
cylinder head
•
it.
the camshaft thrust bearing.
• Do
distribution
Positive battery cable at the distribution
•
Step
d.
installed in the
they were removed from.
the 14 bolts retaining the camshaft bearing
pump
and zero the
0.0901—0.006 inch (0.025—0 190mm).
alter-
box
Push the camshaft toward
3: Pull the
caps. Note the camshaft bearing cap
•
Water
Step
c.
is
sensor
•
must be
2:
and release
out of their bores in the cylinder head. Note
so the
it
on the camshaft
indicator.
required, pull the lash adjusters
conditioning pressure line to the
and the Crankshaft Position
•
9.
Step
b.
the rear of the engine
the valve spring
rocker arms are removed.
until all If
is
resting
is
sprocket bolt or the front of the camshaft.
on
its
Compress
fol-
a dial indicator on
1: Install
indicator foot
the valve spring coils. Be
sure that the valve being compressed circle.
Step
a.
Valve Spring Spacer T91P-
Ignition wire brackets from the
base
Check camshaft end-play as
the front of the engine. Position
cylinder head cover studs
ets
•
Install
8.
camshafts should turn freely but
lows:
under the camshaft and on top of one of the
•
cleaner outlet tube
sequence, to
with a slight drag.
valve spring retainers.
Accessory drive
•
-The
pis-
valve spring compressor
•
•
all
19.
Install a
Engine
•
ensure that
bolts, again in
inch lbs. (8-12 Nm).
installation for the opposite cylinder head.
face.
7.
•
air
to
all
Repeat the camshaft bearing cap
18.
Rotate the crankshaft counterclock-
6.
Q_Q 3
1
cluster retaining bolts approximately 2 turns
pressure sensor
Properly relieve the fuel system
pressure.
CO.
GRAND MARQUIS
•
position before raising the vehicle.
3.
way
Power steering
•
to the
VICTORIA
in Section
Cylinder head covers. Tighten the cylinder head cover bolts to
71-106
2 of this manual
inch lbs. (8-12 Nm).
4 I
n y"i n U
ford motor co. CROWN
I
TOWN CAR
•
VICTORIA
•
GRAND MARQUIS the air suspension switch to the
ON
posi-
tion.
32.
Start the
33.
Road
engine and check
for leaks.
and check
test the vehicle
for
proper engine operation.
Valve Lash
ADJUSTMENT The valve lash
is
not adjustable.
collapsed lash adjuster clearance
check the camshaft,
rect,
If
the
incor-
is
roller follower
and
valve for wear or damage. 1.
8-12
Nm
(71.4-107.1 Lb-In)
Before servicing the vehicle, refer to the
precautions
in
the beginning of this section.
2.
Disconnect the negative battery cable.
3.
Remove
4.
Rotate the crankshaft until the
camshaft base
the camshaft covers.
circle is contacting the roller
follower. 5.
Use a suitable
lash adjuster. Slowly
tool to bleed
adjuster until the plunger 6.
Use a
feeler
down
compress the
gauge
bottomed.
is
to
check the clear-
ance between the camshaft and the follower.
the
lash
roller
The clearance should be
0.018-0.033 inch (0.45-0.85mm). Tighten the camshatt bearing cap cluster bolts
in
the sequence to avoid
damage
to the
camshaft or bearings
Starter Motor
Power steering control valve actua-
•
•
Positive battery cable harness on
•
connector
Oil
pressure sensor harness con-
•
Bolt retaining the battery cable
shaft
Apply silicone sealer
Evaporative emission hose to the
•
to the crank-
keyway
27.
crankshaft pulley and
•
Positive battery cable at the
tighten the bolt as follows:
Step
1:
distribution
Tighten to 66
ft.
Water
•
(90
lbs.
Nm).
bolts to
Step
b.
Step
c.
2: 3:
Loosen one complete Tighten to
35-39
ft.
•
turn.
Step
4:
Install or
• •
Engine
Tighten an additional
ft.
•
oil
pan
•
•
and
lbs.
to the ignition
sensor
and
2 upper bolts
•
1
Accessory drive
Evaporative emission canister
•
Windshield wiper governor
purge valve harness connector
•
Fuel supply and return lines
Engine/transmission harness con-
•
Fan and shroud assembly
nectors on the power brake booster
•
Negative battery cable
Install or
connect the following:
and lower mounting
•
Starter
•
2 upper mounting bolts. Tighten to
15-20
ft.
lbs.
bolt all
(20-27
Nm). Wires from solenoid and tighten the nut to
40-50
inch lbs.
•
Red solenoid
•
Negative battery cable
safety cap
belt
retaining bracket
29.
Fill
the engine cooling system.
PCV
30.
Fill
the crankcase.
31.
If
equipped with
lower bolt and starter
3 bolts
head cover studs •
safety cap
install:
bolt
sensor
der head cover
•
Ignition wires to the spark plugs
•
CKP
valve to the right-hand cylin-
Wires from solenoid
on
and the brackets onto the cylinder
Air conditioning clutch
Red solenoid
•
•
and the retaining
(20-30
or disconnect the following:
Negative battery cable
•
the right-hand ignition coil bracket
bolts. Tighten ft.
CMP
To 3.
(20-30 Nm).
and the
Remove
ignition
Air conditioning pressure line
Power steering pump on the engine
15-22
lbs.
coils
Nm).
•
(20-30 Nm)
lbs.
ft.
Harness connectors
connect the following:
the bolts to
•
15-22
Tighten the retaining nuts to 15-22
and the 4 retaining
•
pulley and tighten the
wires to the engine front cover.
lbs.
85-95 degrees. 28.
2.
•
Ignition coil brackets
(47-53 Nm). d.
power
box
pump
Before servicing the vehicle, refer to
the precautions in the beginning of this section.
canister purge valve
Install the
a.
1.
bracket to the cylinder head
nector 26.
REMOVAL & INSTALLATION
the right-hand cylinder head
tor
air
Oil
Pan
REMOVAL & INSTALLATION 1.
Before servicing the vehicle, refer to
the precautions in the beginning of this sec-
suspension, turn
tion.
1Q_11 *3
FORD MOTOR CO. CROWN 2.
Drain the engine cooling system
3.
Properly discharge the
air
Remove
7.
condition-
•
Remove
or disconnect the following:
•
Negative battery cable
•
Engine
•
Fuel supply and return lines at the
air
•
the front cover
sub-frame
and inspect the
Bolts retaining the left-hand and
the O-ring. 12.
If
pick-up tube and replace
oil
removed, position the
tube on the
oil
of
and cylinder block. Clean
pick-up
oil
pump and hand
2
start the
retaining bolts. Install the bolt retaining the
Cooling fan and fan shroud
Catalytic converter pipes from both
pick-up tube on the main bearing stud
•
Upper radiator hose
exhaust manifolds. Lower the
spacer,
•
Wiper governor and support
exhaust system and support
bracket
wire from the transmission cross-
bolts to
member.
tighten the pick-up tube-to-main bearing
•
•
A/C compressor
•
Engine/transmission electrical har-
•
•
outlet
hose
Position a jack and a block of
8.
with
hand
tight.
Tighten the pick-up tube-to-oil
13.
72-108
wood
stud spacer bolt to
drain
Nm).
15-22
bracket on the power brake booster
hole. 10. Raise the engine approximately 4
Heater water hose
(100mm) and insert 2 wood blocks approximately 2V2-2 3A inch (60-70mm)
Apply silicone sealer
the right-hand cylinder head
thick under each front engine support insu-
crankshaft rear
Upper stud and loosen the lower
lator.
to
blocks and remove the jack.
hose
right-hand cylinder head and
9.
and
ft.
lbs.
the
oil
oil
the bolt retaining the
pick-up tube to the main bearing stud spacer.
Remove
the pick-up tube.
ft.
new gasket on
Position a
(20-30
lbs.
the
where the
to
pan.
oil
front
cover meets the cylinder block and the seal
oil
and
and
meets
retainer
the cylinder block. Position the
oil
pan
(20 Nm), then rotate the bolts, in
to
install the retaining bolts.
Tighten the bolts in sequence, to 14
pan.
retaining the oil pick-up tube to the
(13-16 Nm)
14.
the engine
necessary, remove the 2 bolts
pump and remove
reinstall the
pan drain plug with a new gasket. Tighten
10-12
Remove If
Heater blower motor switch resistor
the plug to
oil
Lower the engine onto the wood
position aside
oil
pan, rearward of the
inches
Nut retaining the ground strap
Drain the engine
oil
pump
inch lbs. (8-12 Nm), then
under the
to the
•
it
ness connector from the retaining
bolt retaining the heater outlet
oil
support insulator to the lower front
supports
pan and inspect
oil
•
•
6.
Clean the engine
damage. Clean the sealing surfaces
for
mount
I
I
install:
.
Bolt retaining the right-hand engine
insulators to the engine
supply manifold
GRAND MARQUIS
•
To
or disconnect the follow-
right-hand front engine support
cleaner outlet tube
fuel injection
TOWN CAR
1 1
Relieve the fuel system pressure.
5.
•
ing:
ing system. 4.
VICTORIA
ft.
lbs.
pan retaining
oil
sequence an additional 60 degrees
within 4 minutes of applying the silicone sealer.
15
Position the jack and
under the engine drain hole,
and
remove
wood
the
16
blocks. Lower the engine
jack.
Install or
•
oil
engine enough to
raise the
and remove the
wood block
pan, rearward of the
oil
connect the following:
Left-hand and right-hand engine
support insulator through-bolts and
15-22
tighten to
ft.
lbs.
(20-30
Nm) •
Bolt retaining the right-hand engine
support insulator to the lower front sub-frame. Tighten the bolt to
15-22 •
lbs
ft
(20-30 Nm).
Exhaust system to the exhaust
manifolds and tighten the 4 retaining nuts to
Nm) Be
20-30
ft
lbs.
(27-41
sure the exhaust system
clears the
crossmember Adjust as
necessary. •
New engine
•
Heater blower motor switch resistor
oil filter
using the 2 retaining screws • •
Heater water hose
Upper stud and tighten the upper
and lower bolts
to
15-22
ft.
lbs.
(20-30 Nm) •
Ground
strap
tighten to
on the stud and
15-22
ft.
lbs.
(20--30
Nm)
To prevent
oil
leaks, tighten the
oil
pan bolts
in
the
sequence shown
Brake service
is
covered
in Section
4 of this manual
•
Heater water hose
•
Throttle valve cable,
if
equipped
10 19 Sr L 1
FORD MOTOR CO. CROWN
i
VICTORIA
•
TOWN CAR
•
Engine/transmission electrical har-
•
Harness connector on the power
•
Air conditioning
GRAND MARQUIS
•
ness connector
brake booster bracket
hose •
compressor
Bolt retaining the
hand
outlet
compressor
to the
hose
to the right-
ignition coil bracket
hose
•
Upper
•
Fuel supply and return lines
•
Wiper governor and retaining
radiator
7922RG13
bracket
Apply a continuous bead
•
Engine cooling fan and fan shroud
•
Engine
•
Negative battery cable
sealant to the back of the seal retainer
cleaner outlet tube
air
before installing
17.
Fill
the cooling system.
18.
Fill
the engine crankcase with engine
of silicone
8
i
-1
2
it
on the engine
Nm (71 .4 -107.1
Lb -In)
oil.
air
engine and check
for leaks.
19.
Start the
20.
Properly evacuate and recharge the
conditioning system. 21
Road
.
test the vehicle
and check
for
Oil
The
6.
Pump
REMOVAL & INSTALLATION
1
.
Before servicing the vehicle, refer to
the precautions in the beginning of this section. 2.
Remove
or disconnect the following:
•
Negative battery cable
•
Cylinder head covers
•
Engine front cover
•
Engine
•
Timing chains
is
mounted on tne crankshaft
Install or
engine
connect the following:
•
New engine
•
Timing chains
•
Engine
oil
oil filter 7922RG14
pan
To avoid leakage, be sure to tighten the
•
Engine front cover
•
Cylinder head covers
•
Negative battery cable
crankshaft rear
the crankcase.
7.
Fill
8.
Start the
tube to the
oil
attaching the
the retainer and immediately install
and proper engine 9.
Road
oil
engine block. Tighten the bolts
and check
for
to
oil
pick-up tube
to the
REMOVAL & INSTALLATION
oil
pump
to
pump
install:
3.
Rotate the inner rotor of the
to align with the flats
the
install
oil
pump
4.
72-106
Clean the
oil
oil
flush with the cylinder
pick-up tube and
start the
Install the bolt retaining
hand
tight.
pump
bolts
inch lbs. (8-12 Nm). Tighten the
pick-up tube to main bearing stud spacer bolt to
15-22
ft.
lbs.
with the spring side
•
bolts, in a crisscross pattern, to
the beginning of this sec-
•
Transmission
•
Flexplate or flywheel
With a sharp awl, carefully punch a
small hole
in
•
or disconnect the following:
•
connect the following:
Flexplate or flywheel. Tighten the
54-64
Remove
the installation tool.
Install or
ft.
lbs.
(73-87 Nm).
Transmission Negative battery cable
11.
Check the engine
12.
Start the
oil level.
engine and check
for leaks.
the metal portion of the seal.
Remove
the seal using a slide
ham-
mer with
a sheet metal screw attached.
'Hf the
oil
leak
is
Timing Chain, Sprockets, Front Cover and Seal
coming from around
REMOVAL & INSTALLATION
be removed and resealed.
2 retaining bolts.
Tighten the pick-up tube-to-oil
72-106
oil
the pick-up tube to
ihe main bearing stud spacer
to
in
the seal retainer, the retainer must also
Place the pick-up tube on the
pump and hand
3.
4.
and
inch lbs. (8-12 Nm).
replace the O-ring. 5.
the precautions
pump
on the crankshaft and
block. Install the 4 retaining bolts tighten to
Remove
9.
Before servicing the vehicle, refer to
2.
To
oil.
Install the seal
tion.
the cylinder block Oil
sequence
Lubricate the seal and the crankshaft
10. 1.
Pick-up tube
in
inch lbs. (8-12 Nm).
toward the engine.
the bolt
main bearing stud spacer
•
71-107
8.
pick-up
pump and
4 bolts retaining the
of
on the
proper engine operation.
Rear Main Seal
•
back it
pressure.
test the vehicle
7.
•
to the
for leaks
with clean engine
oil
seal retainer bolts in
Apply silicone sealant
6.
engine and check
oil
the correct sequence
pan
oil
2 bolts retaining the
•
pump
oil
at the front of the
proper engine operation.
(20-30 Nm).
To 5.
1
install: If
the seal retainer
was removed,
carefully clean the sealant from the retainer
and engine block using
Remove any
oil
a plastic scraper.
or grease residue from the
Before servfcing the vehicle, refer to
.
the precautions in the beginning of this section. 2.
Drain the engine
3.
Remove
oil.
or disconnect the following:
•
Negative battery cable
•
Cooling fan and shroud
sealing surfaces with a solvent.
CROWN COPPER TIMING
COPPER TIMING LINK
UNK RH CHAIN
LH CHAIN
FORD MOTOR CO. 1
VICTORIA
TOWN CAR
•
GRAND MARQUIS
•
Left-hand camshaft sprocket retain-
•
INSTALLTOOL
9 Q_1IO
CRANKSHAFT
ing bolt, washer, sprocket spacer, 8.
if
and
necessary
necessary, note the position of the
If
crankshaft sprockets and remove the crankshaft sprockets by sliding
them
off
the front
of the crankshaft.
Inspect the plastic running face on
9.
the tensioner
COPPER TIMING LINKS RH AND LH CRANKSHAFT GEARS
worn or damaged, inspect the engine
MARKS
pan
T922RG16
Be sure that the timing marks are aligned
when
the No.
1
piston
arms and chain guides.
TDC on com-
is at
the
for oil
contamination and thoroughly clean pan. Replace the
oil
pick-up tube.
To install: Examine the timing chains, looking
10. installing the timing chains
for the
copper
links.
the copper links are
If
not visible, lay the chain on a •
Accessory drive
pump
Water
4
belt
pulley
the
•
Power steering pump
•
Oil
•
oil
be
Install the crankshaft positioning tool to
sure the crankshaft does not turn while
pression
•
If
:
REMOVAL & INSTALLATION
CAUTION
1998—99 Models
There may still be residual fuel in the system, and a small amount of fuel
may
be released
Pump
gauge
an approved container.
into
for fuel leaks.
bleed hose into an
when
1
.
Before servicing the vehicle, refer to the
precautions
servicing fuel 2.
in
the beginning of this section.
Relieve the fuel system pressure.
lines or connections. In order to
reduce the chance cover the fuel line
of
3.
Drain the fuel tank.
4.
Remove
personal injury,
or disconnect the following:
fittings with a
shop towel before disconnecting to catch any fuel that may leak out.
•
Negative battery cable
•
Fuel tank
•
Evaporative Emissions (EVAP) pipe
•
Fuel Filter
filler
Quick connect
pipe
fuel lines
from the
fuel tank •
REMOVAL & INSTALLATION
•
Rear rubber exhaust hangers Fuel tank strap bolts, support the fuel tank
1.
•
Before servicing the vehicle, refer to
the precautions
in
•
the beginning of this sec-
Lockring and the
fuel
sender
assembly from the tank
tion. 2.
Fuel tank.
Disconnect the negative battery
cable.
>-»Note the direction the strainer
pointing and
3.
Relieve the fuel system pressure.
the
4.
Twist the quick connector 14 turn in
ing.
pump
remove the
by pulling
it
is
strainer from
down and
7922UG34
twistFuel
pump and
level
sender assembly
LE Torque the hose clamp lbs. (2.8
C & H-BODIES-GENERAL MOTORS CORPORATION PARK AVE. • EIGHTY EIGHT • LSS • REGENCY • BONNEVILLE
91 £
.1
C
25 inch
to
filler
pipe to the tank.
Torque the hose clamp lbs. (2.8
•
Nm).
Fuel tank
•
SABRE
25 inch
to
Nm).
Negative battery cable
•
the fuel tank.
8.
Refill
9.
Run the engine and check
for leaks
and proper engine operation.
Park Avenue And 1
2000-01 Models
All
Before servicing the vehicle, refer to
.
the precautions in the beginning of this section. 2.
Relieve the fuel system pressure.
3.
Drain the fuel tank.
4.
Remove
or disconnect the follow-
ing: •
Negative battery cable
•
Spare
•
Trunk lining
and jack
tire
•
Fuel sender access panel
•
Sender and quick connect
fittings
from the sender •
Electrical
connector from the
sender and position harness and
hoses aside
**
CAUTION
The
When removing
pump
service cover
is
located
in
compartment under the spare
the luggage
tire
— Park
the fuel sender from
the tank, the reservoir bucket of fuel.
fuel
Avenue shown others similar
Use caution
in
is full •
Lockring
•
Fuel line quick connectors
•
Sender
•
Fuel sender access cover
•
Trunk
liner
•
Spare
tire
containing the
Fuel Injectors
fuel.
•
Sender retaining ring
•
Sender and take note
•
of its position
Fuel sender O-ring and discard
connector
REMOVAL & INSTALLATION Before servicing the vehicle, refer to the
1
and jack
it
8.
7
—
GENERAL MOTORS CORPORATION N-BODY SKYLARK • ACHIEVA • ALERO • GRAND AM
9.
no
•
Fuel tank
•
Negative battery cable
Pressurize the fuel system and verity
leaks.
Fuel Injector
REMOVAL & INSTALLATION 2.4L Engine 1.
Before servicing the vehicle, refer to
the precautions
in
the beginning of this sec-
tion. 2. 3.
Relieve the fuel system pressure.
Remove • •
1
2
3 4
SNAP RING COVER - TAB
Fuel pressure regulator
vacuum
hose •
MODULAR UNIT WIRE HARNESS - ABOVE COVER
6
FUEL TANK TANK ISOLATION STRIPS
7
RUBBER ISOLATOR
5
or disconnect the following:
Air cleaner outlet resonator
Camshaft Position (CMP) sensor connector
electrical
(3)
•
Fuel injector electrical connectors
•
Fuel inlet pipe at the fuel
•
Fuel return pipe bracket screw and
rail
7922Z325
separate the fuel pipe from the
Exploded view
of the fuel
sender assembly mounting
to the tank
pressure regulator
assembly
•
Fuel
•
Fuel injector retaining clip
•
Fuel injector
rail
To
install:
4.
Lubricate the O-rings with engine
oil
prior to installation. 5.
Install or
connect the following:
Fuel injector with
•
Fuel injector retaining clip
•
Fuel to
rail
19
New
•
ft.
assembly. Torque the bolts
fuel pipe
22
2
CONNECTOR ASSEMBLY - FUEL SENDER WIRING
3
FUEL PIPES (3) COVER ASSEMBLY - FUEL SENOER SEAL - FUEL PUMP OUTLET
4
5 6
O-rings lubricated
oil
Fuel inlet pipe. Torque the
•
HARNESS ASSEM8LY (ABOVE COVER) - FUEL PUMP AND FUEL SENDER WIRING
(26 Nm).
lbs.
with engine
1
new O-rings
•
ft.
lbs.
fitting to
(30 Nm).
SUPPORT ASSEMBLY (THREE HOLLOW SUPPORT OR GUIDE PIPES) - FUEL PUMP RESERVOIR
- FUEL PUMP RESERVOIR CONNECTOR POSITION ASSURANCE (CPA) HARNESS ASSEMBLY (BELOW COVER) - FUEL PUMP 9 10 HARNESS ASSEMBLY (BELOW COVER) - FUEL LEVEL SENDER 7
RETAINER
8
2
11
12
13
14
15 16
17 18
19
14
20
RESERVOIR - FUEL PUMP FUEL SENSOR ASSEMBLY - FUEL LEVEL PUMP ASSEMBLY (JET PUMP ASSEMBLY) FUEL PUMP RESERVOIR STRAINER (EXTERNAL) - FUEL SENDER PAD (BUMPER) - FUEL SENDER
VALVE (SECONDARY UMBRELLA VALVE) FUEL PUMP RESERVOIR INLET CHECK
- FUEL PUMP FUEL BAFFLE (ISOLATOR CUP) - FUEL PUMP PUMP ASSEMBLY (ROLLERVANE) - FUEL OUTLET - FUEL PUMP
STRAINER
9306ZG10 7922Z326
Exploded view Exploded view
of the fuel
pump assembly
engine
of the fuel
injector— 2. 4L
07 OE L\J
N-BODY— GENERAL MOTORS CORPORATION SKYLARK
•
ACHIEVA
•
ALERO
£
GRAND AM
•
»
To install:
** WARNING If
the fuel injector O-rings are color
coded,
black O-ring
install the
in
the
upper position and the brown O-ring in the lower position. 4
Lubricate the O-rings with engine
oil
prior to installation. 5. 9306ZG12
Exploded view 3.4L engine
—
of the fuel rail
assembly—
3.1 L engine is similar
Exploded view engine
—
of the fuel injector
3.1 L engine
is
—3.4L
6
similar
Install
New
•
Fuel injector
•
Fuel injector retaining clip
•
Fuel injector electrical connectors
•
Fuel return pipe to the pressure
•
regulator.
Torque the screw
to
53
inch lbs. (6 Nm).
2.
Relieve the fuel system pressure.
3.
Remove •
CMP
connector
•
Fuel feed pipe
•
Fuel pressure regulator
vacuum
•
Fuel return pipe from the pressure
•
Main
Air cleaner outlet resonator
•
Negative battery cable
•
Main
• fuel injector wiring
connector harness
fuel injector wiring
electrical
connector
New
pipe O-rings lubricated
fuel
oil
•
Fuel feed pipe at the fuel
harness
Torque the pipe nut
connector
electrical
• electrical
assembly
Fuel
Fuel injector electrical connectors
•
Fuel injector-to-fuel
rail
ft.
lbs.
to
13
(17 Nm).
Upper intake manifold
• rail
clip
Before servicing the vehicle, refer to the •
Torque the pipe nut
regulator.
•
lbs.
ft.
Fuel return pipe to the pressure
connector
•
rail.
13
to
(17 Nm).
Engine Coolant Temperature (ECT) sensor
tor leaks.
in
(10 Nm).
electrical
regulator
•
precautions
lbs.
ECT sensor
with engine
3.1L and 3.4L Engines 1
O-rings
assembly. Torque the bolts
rail
89 inch
•
•
Re-pressurize the fuel system and
6.
Upper intake manifold
Fuel injector electrical connectors
hose
check
fuel injector
g:
•
electrical
Fuel to
or disconnect the follow-
•
sensor
or connect the following:
•
Re-pressurize the fuel system and
Fuel injector
the beginning of this section
check
for leaks
DRIVE TRAIN •
Transaxle
Wiring harness from the transaxle
mount bracket
REMOVAL & INSTALLATION
•
Upper transaxle mount
•
Clutch master cylinder from the
1998 1
MODELS Before servicing the vehicle, refer to
.
the precautions in the beginning of this section.
•
Ground wires from
•
Backup
•
Transaxle vent tube
•
light
the transaxle
switch connector
cable. 3.
Drain the transaxle fluid
4
Install
Rear transaxle mount
off
engine mounts.
Remove
5.
• •
or disconnect the following
Left side
sound
•
Left inner fender well
•
Anti-lock Brake System (ABS)
cal
Air cleaner throttle
•
Shift cable
lever
and duct work from the
from the manual
on the transaxle
• •
shift
55
ft.
mount Torque
lbs.
Flywheel housing cover. Torque the
89 inch
lbs (10
suspension support
Left side
Torque the nuts to 22
the transaxle
Nm).
•
•
Lett side
Ball joints
lbs (61
•
Left side stabilizer link
•
Left side
U-bolt from the sway bar
•
Left side
suspension support
•
Halfshafts from the transaxle
lbs
(120
U-bolt to the sway bar.
Flywheel housing cover Vehicle Speed Sensor (VSS) from
from the steering knuck-
ft.
Nm).
connectors
Ball joints
Nm).
Halfshafts to the transaxle
•
•
the
Nm)
(75
Torque the bolts to 89
electri-
les
body
Front transaxle bolts to
ft
Nm).
•
from the clutch pedal •
connect the following:
Transaxle Torque the bolts to 55
bolts to
splash shield
Wheel Speed sensor (WSS)
insulator
Clutch master cylinder pushrod
•
•
Front wheels
the
the transaxle from the
Install or
9.
•
•
an engine support fixture and
use the fixture to take the weight
Remove
lbs (75
the support fixture
Disconnect the negative battery
2.
8
vehicle.
Lower the powertrain assembly with
6.
mount
Front lower transaxle
Support the transaxle with a jack
To install:
slave cylinder
Manual
•
7
•
ft.
(30
Torque the nuts to 45
lbs.
ft
Torque the nuts to
(30 Nm).
•
WSS
•
Left inner fender well
For complete service labor times, order the Chilton Labor Guide
lbs.
Nm).
Stabilizer link
22
ft.
electrical
connectors splash shield
07/ "lO OR t
GENERAL MOTORS CORPORATION— N-BODY skylark
achieva
•
•
•
Front wheels
•
Vehicle Speed Sensor (VSS) to the transaxle. Torque the bolt to
80
alero
grand am
•
6.
Support the suspension crossmem-
7.
Remove
or disconnect the following:
inch lbs. (9 Nm).
•
Suspension crossmember bolts
•
Rear transaxle mount. Torque the
•
Rack and pinion bolts
•
Ground wires
•
Transaxle vent tube
•
Backup
•
Upper transaxle mount. Torque the
44
bolts to
55
(60 Nm).
lbs.
ft.
Raise the vehicle
8.
Remove
9.
(75 Nm).
•
Shift cable to the
manual
on the transaxle. Torque the nut
89 inch •
Shift linkage
Vacuum modulator
Lower the engine and transaxle
•
Front transaxle
•
Rear transaxle mount
sound
the bolt to 81
insulator •
the transaxle.
Refill
MODELS •
Remove
or disconnect the following:
•
Negative battery cable
•
Air cleaner
•
Clutch slave cylinder line and
ft.
assembly
bracket
Cable bracket
•
Vehicle Speed Sensor (VSS) electrical
•
connector
Backup lamp switch
electrical
con-
nector •
Starter
motor
Tie the radiator to the
3.
upper hood
latch panel.
an engine support
4.
Install
5.
Remove
the nuts to
22
Both outer
tie
fixture.
or disconnect the following:
•
Transaxle bolts
•
Lower closeout panel
ft.
180 degree
• •
lbs.
ball joints.
(20
Nm)
plus an
Torque the nuts
Lower
•
Both wheel well splash shields
•
Front wheels
•
Lower closeout panel
to
Remove
Untie the radiator support.
the engine support fixture.
66
and 32
Nm) on 2.4L engines (43 Nm) on 3.4L
•
Lower radiator support
engines.
•
Wheel Speed sensor (WSS)
ft.
(90 lbs.
to
Both outer
•
Both
•
Both stabilizer shaft links
•
Front transaxle
rod ends
ball joints
Backup lamp switch
mount
electrical
con-
•
VSS
•
Shifter cables
•
Clutch slave cylinder bracket and
bolts
Torque converter-to-flywheel bolts
connector
line
a scribe
mark the flywheel-to-
and
Oil level indicator
•
Transaxle cooler lines
fill
tube
•
Vehicle Speed Sensor (VSS)
•
Vacuum
reservoir tank
Position a jack under the transaxle.
Remove
6.
•
electrical
Heater core hose pipe brace-to-
•
5.
nector
•
tie
lbs.
motor
proper reassembly.
connect the following:
Both wheel well splash shields
•
Transaxle converter cover
torque converter relationship to assure
Wheels
electri-
•
•
Torque the bolts
connectors
Starter
transaxle nut and bolt
Starter motor.
cal
Engine-to-transaxle brace
•
•Using
14.
ft.
Both halfshafts
•
•
connectors
13.
frame
suspension support
Left side
•
radiator support
Install or
Left side stabilizer shaft
assembly
turn.
WSS
electrical
from the control
bushing clamp nuts
Nm).
lbs. (61
ball joints
Left side stabilizer shaft link pin
•
•
•
•
Torque
•
15.
84
rod ends. Torque the
nuts to 15
ft.
Both
arms
lbs.
ft.
(30 Nm).
lbs.
ft.
engine splash shields
nectors •
•
links.
additional
45
180
left
bolt
Both stabilizer shaft
Both
Anti-lock Brake System (ABS)
Wheel Speed Sensor (WSS) con-
bolts.
the front bolts to
•
•
Right and
•
(115 Nm).
lbs.
Right front brake hose
from the transaxle
Shifter cables
•
to
•
•
•
Nm) and
•
Torque the
Suspension crossmember
(245
tion.
Both front wheels
•
Torque
(110 Nm).
Torque the rear bolts
the precautions in the beginning of this sec-
engine bolts
(115 Nm).
bolts.
lbs.
ft.
bolts.
lbs.
ft.
Remaining upper transaxle-to-
•
mount
Rack and pinion bolts to 81
Before servicing the vehicle, refer to
84
or disconnect the following: (2) transaxle-to-engine bolts
Rubber hose from the transaxle
Torque
bolt.
(110 Nm).
lbs.
ft.
connector fixture.
vent pipe
mount
Front transaxle the bolts to
•
2000-01
Upper
•
Clutch master cylinder pushrod to
an engine support
Remove
4.
•
the clutch pedal
to the
ft.
(100 Nm).
connector
Shift solenoid electrical Install
3.
Transaxle. Torque the bolts to 74
Rear transaxle mount
Left side
2.
connect the following:
Halfshafts
Negative battery cable
1.
trical
•
•
12.
•
to
body
•
Park/Neutral position switch elec-
•
install:
lbs.
and duct work
•
sion from the vehicle.
(10 Nm).
from the
connector
electrical
Install or
line
Torque Converter Clutch (TCC)
•
Support and remove the transmis-
12.
from the transaxle
modulator
to clear the left side inner
•
Air cleaner throttle
•
lbs.
Air intake duct
•
.
To
shift lever
•
Halfshafts from the vehicle
body panel.
connect the following:
Negative battery cable
•
assembly enough
the engine support fixture.
mount
or disconnect the following:
•
•
cylinder
Install or
Remove
2.
Rear transaxle mount
Wiring harness to the transaxle
Remove
tion.
Front transaxle
•
10.
the front sus-
off of
•
10.
1 1
Before servicing the vehicle, refer to
.
•
Clutch master cylinder to the slave
11.
1
or disconnect the following:
•
mount bracket
MODELS
1998
the precautions in the beginning of this sec-
pension crossmember.
to the transaxle
switch connector
light
bolts to
lbs.
ft.
Automatic
ber.
or disconnect the following:
Transaxle mount-to-body bolts
•
Remaining engine-to-transaxle
•
Transaxle
bolts
'•-Transaxle cooler and lines should be
flushed whenever the transaxle has
•
Side transaxle mount nuts
•
Air cleaner
•
Rear transaxle mount stud
•
Negative battery cable
•
Right brake hose
assembly
been removed ment.
for overhaul or replace-
97.07'
N-BODY— GENERAL MOTORS CORPORATION SKYLARK *ACHIEVA*ALERO* GRAND AM To install:
1 1
11 ** I
N-BODY— GENERAL MOTORS CORPORATION SKYLARK
•
ACHIEVA
ALERO
•
GRAND AM
•
•
Front wheel
•
Halfshaft nut
•
Caliper from the steering knuckle
and support
and washer
it
aside
DO NOT
allow the caliper to hang unsupported from the brake hose. •
Brake rotor
•
3 hub/bearing assembly bolts
•
Halfshaft from the hub/bearing
assembly •
To
Hub/bearing assembly
install:
or connect the following:
Install
3.
•
Hub/bearing assembly onto the halfshaft,
making sure the splines
engage smoothly •
Hub/bearing assembly to the steering knuckle. Torque the bolts to 70
HUB AND BEARING ASSEMBLY STEERING KNUCKLE WASHER DRIVE AXLE NUT - 260 N-m (192 HUB AND BEARING RETAINING BOLT WASHER
1
2
3 4
5 6
ft.
• •
of the front
Caliper onto the steering knuckle.
Torque the bolts to 38
LBS. FT.)
ft.
lbs. (51
Halfshaft nut. Torque the
hub nut
Nm). •
74 N22ZM0
Exploded view
(95 Nm).
lbs.
Brake rotor
lbs (100
ft.
tional
hub/bearing assembly
40 degree
models, or
to
turn for
284
to
plus an addi-
ft.
lbs.
1998 (385 Nm).
1999-01 models.
for
•
Nm)
Front wheel. Torque the nuts to 100
5 ft.
lbs (140
Nm).
Rear
DRUM BRAKE Before servicing the vehicle, reler to
1.
the precautions in the beginning of this section.
2
Remove
or disconnect the follow-
ing •
Wheel
•
Brake drum
•
4 hub/bearing assembly to knuckle nuts
•The
top rear bolt will not clear the
brake shoes and must be removed with the bearing assembly. •
1
2 3 4
5
Anti-lock Brake System (ABS)
speed sensor wire from the
BOLT REAR AXLE ASSEMBLY BACKING PLATE HUB AND BEARING ASSEMBLY LOCKNUT
hub/bearing assembly •
Hub/bearing assembly
To install: 3.
Install or
connect the following:
•
Hub/bearing assembly on the
•
ABS
TO2ZM1
knuckle
Hub and bearing components
For Wheel Alignment specifications, see Section
1
of this
manual
wheel speed sensor
07I L •
flO GENERAL IV10T0RS CORPORATION— N-BODY SKYLARK • ACHIEVA • ALERO • GRAND AM Hub/bearing nuts. Torque the nuts to
44
ft.
lbs.
(60 Nm).
•
Brake drum
•
Wheel. Torque the nuts lbs.
to
100
ft.
(140 Nm).
DISC BRAKE 1
.
Before servicing the vehicle, refer to
the precautions in the beginning of this section. 2.
3.
Remove
or disconnect the following:
•
Wheel
•
Brake rotor
•
Parking brake cable from the lever
•
Wheel Speed Sensor (WSS) cal
•
Rear wheel bearing assembly with disc brakes
— 1999-01 models
electri-
connector
Hub/bearing assembly bolts from
To
install:
lbs.
connect the following:
Install or
ft.
(95
lbs.
the knuckle • •
to the
back-
els.
Torx® bolts from the rear of the ing plate. Tighten the Torx®bolts to
hub/bearing assembly •
Hub/bearing assembly
89 inch
Hub/bearing assembly from the •
lbs.
(10 Nm).
Hub/bearing assembly on the
Nm) on 1999 models or 62 Nm) on 2000-01 mod-
(85
•
WSS
•
Parking brake cable to the lever
electrical
connector
•
Brake rotor
•
Wheel assembly
backing plate knuckle. Torque the bolts to 70
ft.
f
GENERAL MOTORS CORPORATION—V-BODY 1998-01 Cadillac-Catera
DRIVE TRAIN ENGINE REPAIR FUEL SYSTEM
28-13 28-2 28-12 28-2
PRECAUTIONS
Front Crankshaft Seal
Removal &
Air
Removal &
Bag
28-15
Disarming
28-15
Precautions
28-15
Rearming
28-15 28-2
Alternator
28-2
Installation
Axle Shaft, Bearing and Seal
&
Installation
28-14
Pump
Removal &
Installation
Relieving Fuel
Removal &
Installation
Installation
CV-Joints Outer Joint
Ignition
Removal &
Removal &
Installation
Lower
Removal &
Installation
Exhaust Manifold
Removal &
Installation
Rear Main Seal
Removal
28-12
Control
Steering Gear
Removal &
28-6
28-19 28-19
Starter
Removal &
Oil
Installation
Removal &
28-3 Oil
Installation
Pump Removal &
Installation
28-10
28-17
Strut
Removal &
Installation
Transmission Assembly
Removal
&
Installation
28-17
28-13
28-10 28-10
Adjustment
W Water
28-10
28-13
V
28-19 28-10
Pan
28-17
28-10
Motor
Valve Lash
28-20
Installation
28-17
Installation
28-19
Arm Bushing
Removal &
28-15
T
0
28-7
28-15 Installation
Shock Absorber Removal &
28-6
Installation
28-11
Power
S
Assembly
Replacement
28-4
28-7
28-11 Installation
Recirculating Ball
28-12
Installation
Lower Control Arm
28-14
28-3
&
28-12
28-3
Ball Joint
Removal &
E Engine Assembly
28-11
L
28-17
28-14 28-11
Positioning
28-12
28-3
Timing
Adjustment
28-4
Cylinder Head
&
Piston and Ring
28-13
I
28-8
28-14
28-12
28-12
Intake Manifold
28-17
Removal &
Removal
28-14 Installation
System Service
Precautions
28-8
Coil Spring
&
Installation
Fuel System Pressure
28-14
C Camshaft
Inner
Fuel
Pinion Seal
28-8
28-13
28-2
Removal Removal
Installation
Fuel Injector
A
28-8
28-12
Removal &
SUSPENSION
Installation
Fuel Filter
STEERING AND 28-15
P
F
Pump
Removal &
28-4 Installation
Wheel Bearings
28-10
Adjustment
28-10
Removal &
28-4
28-20 28-20
Installation
28-20
GENERAL MOTORS CORPORATION— V-BODY
28-2
CATERA
PRECAUTIONS eye
Before servicing any vehicle, please be
sure to read
of the following precautions,
all
which deal with personal of
prevention
safety,
component damage, and important points when servicing a
irritation persists, or
should always buy the correct type
tance IMMEDIATELY.
fluid for
The EPA warns
•
prolonged contact
that
may cause
to take into consideration
with used engine
motor vehicle:
skin disorders, including cancer!
Never open, service or drain the radia-
• tor or
cooling system
hot, serious
when
the engine
Observe
tions
all
applicable safety precau-
when working around
fuel.
Whenever
servicing the fuel system, always work
Do
well-ventilated area. or vapors to
effort to
used engine
to
come
in
in
a
not allow fuel spray
sure to used engine
You
oil.
water, or
•
new
All
now equipped
vehicles are
becomes contaminated, completely
Any brake
fluid.
flush the
Never reuse any
fluid.
removed
fluid that is
from the system should be discarded. Also,
come in condamage
fluid to
painted surface;
tact with a
will
it
the paint.
Never operate the engine without the
•
proper amount and type of engine
doing so WILL result
waterless hand cleaner should be used.
with an air bag system. The system
contact with a spark,
expo-
of brake
the brake fluid
If
do not allow any brake oil.
other exposed after
your vehicle.
system with new brake
Protective
Soap and
oil.
of
minimize your
soon as possible
skin areas as
number
a
when changing
gloves should be worn
Wash your hands and any
and hot coolant. •
oil
should make every
exposure
is
burns can occur from the steam
proper operation of the brake system. You
you have taken
if
brake fluid internally, seek medical assis-
oil;
severe engine
in
damage.
must be
Timing
•
belt
maintenance
Many models
extremely
is
disabled before performing service on or
important!
around system components, steering col-
ence-type, non-freewheeling engine.
extinguisher near the work area. Always
umn, instrument panel components, wiring
timing belt breaks, the valves
keep
and sensors. Failure
open flame or excessive heat light, for
(a hot
drop
example). Keep a dry chemical
fire
fuel in a container specifically
designed
for fuel storage; also,
to follow safety
disabling procedures could result
always
in
and
head may
acci-
tially
strike the pistons,
dental air bag deployment, possible per-
sonal injury and unnecessary system
maintenance
additional fuel system precautions later in
repairs.
this
Always wear safety goggles when
working with, or around, the
Fuel injection systems often remain
•
pressurized, even after the engine has been
When
turned OFF. The fuel system pressure must
sure the bag and trim cover are pointed
be relieved before disconnecting any fuel
away from your body. When placing
lines. Failure to
do so may
and/or personal
injury.
Brake
•
fluid often
deployed
result in fire
brake fluid
in
bag, be
fluid.
If
of the
module
it
if
system precautions
your eyes, flush your eyes
• If
away
is
is
recommended
interval for the timing belt,
cable on
some
vehicles
may
interfere
some
vehicles
may
the functions of the on-board
tem^) and may
require the
interfere with
computer sys-
computer
and
essential to the safe
When
is
servicing
with the operation of the on board puter system. The computer
com-
drum
brakes, only dis-
is
Alternator electrical connectors
•
Alternator
ence.
INSTALLATION
reconnected. 1.
Install or
•
Alternator
26
1
.
Negative battery cable intake air resonator
•
Drive belt
•
Coolant heater,
2.
erly. if
equipped
(40 Nm).
lbs.
Alternator electrical connectors
Coolant heater,
•
Drive belt
if
equipped
•
Intake air resonator
•
Negative battery cable
Perform a charging system
verify that the
system
to
the upper
•
or disconnect the following:
•
ft.
Nm) and
•
tion.
•
30
Torque the lower nut (35
Cooling duct
Before servicing the vehicle, refer to
Remove
lbs.
•
the precautions in the beginning of this sec-
2.
ft.
nut to
REMOVAL
connect the following:
Alternator.
is
test
and
operating prop-
at a time,
leaving the remaining side intact for refer-
may
undergo a relearning process once the negative battery cable
Alternator cooling duct
•
to
reconnected.
assemble and assemble one side
later in this section.
•
to the
Disconnecting the negative battery
cable on
ENGINE REPAIR ^Disconnecting the negative battery
replace-
and
inspection.
•
bag
Clean, high quality brake fluid from a
sealed container
causing poten-
interval charts in the front of
for the
ative battery cable
accidentally air
the
undergo a relearning process once the neg-
reduce the
deployed. Refer to the additional
you do get
with clean, running water for 15 minutes.
motion
will
If
the cylinder
timing belt section for belt replacement and
•
a non-
bag on a work surface, always
from the surface. This
contains polyglycol
and wash your hands thoroughly
handling brake
after
air
air
face the bag and trim cover upward,
ethers and polyglycols. Avoid contact with the eyes
carrying a non-deployed
manual
ment
bag system.
air
in
interfer-
expensive) engine damage. Refer to the
properly seal fuel containers to avoid the
•
an
serious (also time-consuming and
possibility of fire or explosion. Refer to the
this section.
utilize
Alternator mounting hardware
OQ tO O
ENGINE FRQTT
EMQNC LEFT
ENGINE R1CKT
MARK
A
OIL RING SPACER GAP (tanc in hole or slot
wrm
arc)
CAPS C 2N0 COMPRESSION RING GAP D TOP COMPRESSION RING GAP
B
OIL RINC RAIL
7S224G46
Piston ring end-gap spacing
—3.1L,
3.4L,
3.8L engines
CAM8HAFT TO BALANCE 8HAFT TO CRANKSHAFT CAMSHAFT 7922XG17
Balance shaft-to-camshaft and camshaft-to-crankshaft timing mark alignment— 3. 8L engine
Lower oil Upper oil 3 Top Ring
control
control ring
4
Piston and Ring
5.
POSITIONING
mg
1
2.
Ol
control nng expanoer Second nng
Piston ring end-gap positioning
—
3. 51-
engine
CONNECTING ROD
_
—
o ~\2>/
\C2y-
Piston positioning
— 3.5L engine
ARRO* TOWARDS FRONT Of ENGINE
I922AG5I
Piston positioning
Connecting rod and cap installation. Be
Otten the arrow
is
sure to matchmark the cap and rod prior to
Piston ring positioning— 3. 1 L. 3.4L, 3.5L
replaced by a notch, which also must lace
disassembly, as shown
and 3.8L engines
toward the front
ol the
and 3.8L engines
Heater Core replacement
is
covered
in
Section
2 of this manual
engine
— 3.1L, 3.4L
no no
GENERAL MOTORS CORPORATION— W-BODY
£
CENTURY
•
REGAL
IMPALA
•
LUMINA
•
MONTE CARLO
•
«
INTRIGUE
*
GRAND PRIX
FUEL SYSTEM Fuel System Service Precautions
accidental attempt
is
made
and torque the
to start the
Safety
is
the
most important
factor
when
performing not only fuel system mainte-
nance but any type to
manner may
safe
injury or death.
in
result in serious personal
Maintenance and testing
of
components can be
accomplished safely and
effectively
fitting to
connect
avoid spillage.
and per-
to the to the fuel
5.
bleed hose into an
Install the
approved container and open the valve
battery cable unless the repair or test proce-
bleed fuel system pressure. The fuel con-
dure requires that battery voltage be
nections are 6.
Always
system pres-
relieve the fuel
(injector, fuel rail,
ulator, etc.), fitting or fuel line
now
to
7.
in
the
gauge
Reconnect the negative battery cable
pressure reg-
unless addition service work
connection.
formed.
system pressure, to avoid exposing
skin, face
and eyes
to fuel spray. Please
advised that fuel under pressure trate the skin or
any part
of the
body
• 5.
Always place
around the
shop towel or
a
(should
it
occur)
is
all
10 seconds. Turn the ignition
cloth
fuel
ON
OFF and
for leaks.
Turn the ignition
OFF
and check
for
leaks.
Fuel
Pump
REMOVAL & INSTALLATION
Before servicing the vehicle, refer to
1.
REMOVAL & INSTALLATION
All
in
the beginning of this sec-
tion.
Models
2.
Relieve the fuel system pressure.
3.
Drain the fuel tank with a hand held
siphon Before servicing the vehicle, refer to
until the level is less
Remove
4.
than 14
•
Negative battery cable
tion.
•
Spare
tire
and jack
2.
Relieve fuel system pressure.
•
Floor trunk liner by pulling
3.
Remove
•
Fuel sender access panel
soaked
cloths or towels are deposited into a suit•
or disconnect the following:
Quick-connect
fitting at
the inlet of
•
full.
or disconnect the following:
the precautions in the beginning of this sec-
quickly removed from all
position
for
fuel spillage
engine surfaces. Ensure that
22
it
loosening to absorb any excess fuel due to
Ensure that
ON
two seconds then turn the ignition
6.
to
Nm)
Negative battery cable
the precautions
1.
spillage.
(30
lbs.
for
or connection prior to
fitting
the outlet side of
Turn the ignition to the
contacts. •
fitting to
and using a back up
Except Lumina
Fuel Filter
that
inlet
being per-
is
be
may pene-
on the
safe for servicing.
Drain any fuel remaining
Exercise extreme caution whenever relieving fuel
filter
fitting
filter
an approved container.
into
sure prior to disconnecting any fuel system
component
ft.
check
sonal injury, always disconnect the negative
applied.
(20
lbs.
ft.
wrench, torque the outlet nut
pressure
connection while connecting gauge to
Threaded the
a shop towel around the pressure test
lines.
•
•
charge into an approved gasoline container.
fitting
Quick-connect side of the
connection and another hose to dis-
test
Wrap
by
fire
•
to relieve
This procedure calls for a fuel pres-
4.
adhering to the following rules and guide-
To avoid the possibility of
cap
sure test gauge with a line equipped with a
a
the vehicle’s fuel system
•
fuel filler
tank pressure.
of maintenance. Failure
conduct maintenance and repairs
Loosen the
3.
15
bolt to
Nm)
engine.
it
back
Fuel tank pressure sensor electrical
able waste container. the fuel
Always keep
•
a dry
chemical (Class B) •
Threaded
fitting at
the outlet side of
•
Fuel sender electrical connector
•
Fuel sender assembly quick con-
extinguisher near the work area.
fire
the fuel
Do come •
to
connector
filter
filter.
not allow fuel spray or fuel vapors into contact with a
spark or open
^Have
nect fittings
a container available to •
retrieve any fuel remaining in the
flame.
Retaining snapring from the fuel
filter.
sender
Always use a backup wrench when
•
loosening and tightening
fuel line
tion fittings. This will prevent
connec-
•
unnecessary 4.
stress
and torsion
to fuel line piping.
from the mounting bracket
Filter
To install: Install or
•
Fuel
connect the following:
filter
into the
mounting bracket
Always follow the proper torque specifications.
Always replace worn
•
rings with new. or equivalent,
Do
fuel fitting Fi-
not substitute fuel hose
where
fuel pipe is installed.
Fuel System Pressure RELIEVING
1
.
Before servicing the vehicle, refer to
the precautions in the beginning of this section. 2.
7922Z528
Disconnect the negative battery cable
to prevent possible
discharge of fuel
if
an
Remove
the fuel
pump from
removing the locking
ring
the tank after
W-BODY— GENERAL MOTORS CORPORATION. CENTURY
REGAL
•
IMPALA
•
LUMINA
•
MONTE CARLO
•
torque the nuts to 89 inch
lbs.
•
INTRIGUE
•
GRAND PRIX
OQ OO OU
(10
Nm)
When
the Lockring
is
removed from assembly
10. •
Trunk
liner
•
Spare
tire,
the fuel sender, the sender will
Downward pressure
spring up.
jack and spare
cover
tire
the fuel tank.
Refill
should be kept on the assembly and slowly released to ensure the sender
Lumina
assembly does not get damaged. 1
•
Modular
fuel
sender assembly
Install or
• •
New
connect the following:
O-ring on the fuel tank
2.
Relieve the fuel system pressure.
3.
Drain the fuel tank.
4.
Disconnect the negative battery
Fuel sender cable.
•
Snapring on the
•
Fuel sender electrical connector
•
sender
fuel
Remove
5.
Fuel tank pressure sensor electrical
Clean
6.
Quick connect
the fuel tank from the
vehicle.
connector •
the beginning of this sec-
in
tion.
To install: 5.
Before servicing the vehicle, refer to
.
the precautions
of pipe
all
Also clean
tions.
and hose connec-
areas around the con-
all
fittings at the fuel
nections.
sender
Disconnect the quick-connect
7.
•
Negative battery cable
Add
6.
a small
amount
at
fittings
the fuel sender assembly.
of fuel to the
Remove
8.
the fuel sender
assembly
fuel tank.
Turn the ignition to the
7 for
ON
retaining
ON
ring, the fuel
sender assem-
position
2 seconds then turn the ignition
10 seconds. Turn the ignition
snap
and the O-ring from the
bly
OFF
fuel tank. Dis-
for
and check
Exploded view
card the fuel sender assembly O-ring.
To
of the fuel injector
— 3.1L
and 3.4L engines
install:
for leaks.
Turn the ignition
8.
OFF
Position the
9.
and check
new
fuel
sender assem-
for
on the
bly O-ring
2.
fuel tank.
leaks. 3.
Install or
9. •
connect the following:
Fuel sender access panel and
••Make sure the fuel
pump
strainer
when
restrict fuel flow. Also,
pump
Remove
not to fold over or twist
ensure that the
strainer does not block
Upper intake manifold
•
Fuel inlet and return lines
•
Fuel injector electrical connectors
•
Coolant temperature sensor
arm. sender assembly and
Install the fuel
10.
the 1. fuel sender
assembly retaining snap
1
Connect the quick-connect
.
fittings at
•
Fuel
•
Fuel injector retaining clips
•
Fuel injectors
tank and add fuel
12.
Install the fuel
13.
Pressurize the system as follows to
check
4
5.
for leaks: a.
Turn the ignition switch
ON
for
2
seconds. b.
Turn the ignition switch
OFF
for
10
Coat the new
Install or
c.
Turn the ignition switch to the
d.
Check
Upper O-ring
•
Lower O-ring
•
Fuel injector
•
Fuel injector retaining clips Fuel
•
•
3 4
5
FUEL PIPES (ABOVE COVER) RESERVOIR - FUEL PUMP FUEL SENSOR ASSEMBLY - FUEL LEVEL 7922XG19
Fuel
pump and sending
assembly
unit
•
rail
lbs.
and torque the bolts
(10
Fuel injector electrical connectors Fuel inlet and return lines with
13ft. lbs. (17 •
3.1L and 3.4L Engines
module
the precautions
in
the beginning ot this sec-
6.
repair tion.
Brake service
is
covered
in
Nm)
Section 4 ol this manual
ft
lbs.
(25
Nm)
Negative battery cable
Start the vehicle if
new
fittings to
Upper intake manifold and torque the bolts to 18
•
Before servicing the vehicle, refer to
electri-
connector
O-rings and torque the
REMOVAL & INSTALLATION
to 7
Nm)
Coolant temperature sensor cal
SUPPORT ASSEMBLY - FUEL SENOER COVER ASSEMBLY - FUEL SENDER
connect the following
•
ft.
Fuel Injector
O-rings
Lower backup O-ring
ON
for fuel leaks.
fuel injector
oil.
•
•
seconds.
1
rail
with clean engine
the fuel sender assembly.
2
connector
To install:
ring. 1
electri-
full
cal
travel ot float
or disconnect the following:
•
installing
the fuel sender assembly, as this will
fuel
Relieve the fuel system pressure.
necessary.
and check
for leaks,
OO £
GENERAL MOTORS CORPORATION— W-BODY CENTURY
REGAL
*
•
IMPALA
LUMINA
•
3.5L and 3.8L Engines 1
Before servicing the vehicle, refer to
.
the precautions in the beginning of this section.
MONTE CARLO
•
Relieve the fuel system pressure.
3.
Remove
Fuel injector retaining clips
snap-lock tabs retainers, push
Fuel injectors
down
install:
4.
Coat the new
•
Fuel injector sight shield
•
Fuel feed and return lines
•
Fuel pressure regulator
•
vacuum
connection •
Ignition coil wires from the coil
•
Fuel injector electrical connectors
Fuel
fuel injector
O-rings
•
oil.
connect the following:
Ignition coil wires to the coil
•
Fuel pressure regulator
vacuum
connection
•
Upper O-ring
•
Fuel feed and return lines
•
Lower O-ring
•
Negative battery cable
•
Fuel injector
•
Fuel injector retaining clips
•
Fuel
rail
into
Fuel injector electrical connectors
•
Lower backup O-ring
(10
Nm)
bolt retainers.
it
repair
If
to
7
equipped with
equipped with
and check
Start the vehicle
6.
and torque the bolts
rail
lbs.
ft.
•
snap
until the retainers
place.
Install or
or disconnect the following:
GRAND PRIX
•
To
5.
•
•
with clean engine
2.
INTRIGUE
•
if
for leaks,
necessary.
Install the fuel injector sight shield
7.
and torque the nuts
27 inch
to
lbs. (3
Nm).
DRIVE TRAIN Transaxle Assembly
Torque converter cover
•
Starter
•
Torque converter bolts
•
Oil
•
Drive axles and secure them to the
les
steering knuckles and struts
(85
REMOVAL & INSTALLATION
~These
transaxles were used
in a
variety of General Motor’s vehicles. •
Due
to
model
installed
model and options, the removal and year, vehicle
•
procedures may vary The procedures given here
installation slightly.
should suffice for most using these transaxles.
all
vehicles
1
in
the beginning of this sec-
an engine support
Install
4.
Remove •
fixture.
or disconnect the following:
Negative battery cable
•
Throttle
•
Engine mount struts
•
Wire harness connectors from the
body
air inlet
duct
Front wheels
Vehicle Speed Sensor (VSS) con-
•
Fluid
Remove
•
connect the following:
Install or
•
Transmission
•
Lower transmission bolts and
(25
(75
Nm)
selector cable with the
(20
Range
ft.
Nm)
selector cable to the
PNP
•
New
lbs.
ft.
(75
Nm)
•
frame to body bolts and
125
to
ft.
lbs.
Wire harness connectors
Vacuum hose and
pipe to the
bolts to
Remove
(170
37
ft.
Ibs.
(50
Nm)
•
Throttle
•
Negative battery cable
VSS
35
lbs.
ft.
(47
Nm)
connector
•
WSS
•
Fluid
filler
tube
•
Drive axles to the transmission
•
Upper transmission bolts
•
Oil
•
Wire harness grounds
•
Torque converter bolts and torque
•
Both front wheels
•
Engine splash shields
•
Both
electrical
electrical
air inlet
duct
the transmission with fluid.
10.
Fill
11.
Start the
engine and check the oil level.
Add
oil
if
necessary.
cooler hoses
them
to
46
ft.
lbs.
(63
4T65-E Transmission
Nm) 1
•
body
engine and transaxle
connectors
Nm)
the engine support fixture.
Transmission brace and torque the bolts to
mod-
Engine mount struts and torque the
•
pipe from the
to the
ulator
switch
Starter
Before servicing the vehicle, refer to
.
motor and torque the bolts the precautions in the beginning of this sec-
to
rod ends from the steering
Power steering gear from the frame and secure it to the body of the
32
ft.
lbs.
(43
Nm) tion.
•
knuckles
Torque converter cover and torque
89 inch
the bolts to •
Lower
lbs.
(10
2.
Drain the transmission
3.
Install
4.
Remove
Nm)
ball joints to the steering
fluid.
an engine support
fixture.
or disconnect the following:
knuckle and torque the nuts to 40
vehicle
Power steering cooler
line
ball joints
knuckles
ft.
clamps
Engine mount lower nuts
Lower
Ibs.
ft.
Ibs.
transmission •
PNP
•
Range
•
install:
8.
Park/Neutral Position (PNP) switch
•
•
Ibs.
the transmission from the
•
•
Nm)
switch and torque the bolts to
vehicle.
•
•
and torque
PNP
ft.
switch
Range selector cable from the
tie
bolts
•
55
bracket and torque the nut to 15
7.
Ibs.
to
Frame-to-body bolts
torque them
Vacuum hose and
ft.
tube
filler
Upper transaxle
18
Lower the frame from the
To
knuck-
63
to
them
table to support
6.
torque them to 55
modulator •
Engine splash shields
Lower transmission bolts
ibs.
Nm)
•
Transmission brace
ft.
to the steering
•
9. •
59
and torque the nuts
nectors
• •
ends
Tie rod
Wheel Speed Sensor (WSS) con-
•
transmission •
•
frame.
Drain the transmission fluid.
3.
cooler hoses
frame
to the
bolts to
Nm)
(80
the transmission.
tion. 2.
and torque the
Use a transmission
5.
Before servicing the vehicle, refer to
.
the precautions
•
motor
nectors
4T60-E Transmission
Power steering gear
•
•
lbs.
(55
Nm)
•
Negative battery cable Throttle
•
Engine mount struts
•
Wire harness connectors from the
Engine mount lower nuts and torque them to 32
from the steering
•
•
Power
ft.
lbs.
(43
steering cooler line
Nm)
body
clamps transmission
to the
frame
air inlet
duct
OQ OE OU
W-BODY— GENERAL MOTORS CORPORATION. CENTURY •
REGAL
•
IMPALA
Range selector cable from the Park Neutral Position
•
Range
•
PNP
•
•
•
(PNP) switch
selector cable and bracket
•
Power steering gear
frame
to
•
•
Fluid
filler
tube
•
MONTE CARLO
32
lbs.
ft.
(43
lbs.
Nm)
Brake rotor
Wheel Speed Sensor (WSS)
Lower
ball joints to the steering
•
Engine splash shields
•
Both
it
torque them to 35
body
to the
Power steering cooler
vehicle
•
Engine mount lower nuts
les
•
Lower
(85
•
from the steering
ball joints
clamps
line
59
to
ft.
to the steering
and torque the nuts
63
to
Torque converter cover
•
Front wheels
•
Starter
•
Fluid
•
Torque converter bolts
•
Upper transmission bolts and
•
Oil
•
PNP
•
Wheel Speed Sensor (WSS) cal
•
18
Vehicle Speed Sensor (VSS) elec•
table to support •
Engine mount lower nuts
•
Transmission brace
•
Lower transmission bolts
•
Frame-to-body bolts
•
• •
from the vehicle.
Remove
the transmission.
Install or
•
the •
connect the following:
Transmission
assembly
New
lbs.
ft.
(75
Nm)
to the
pull
on the axle
37
ft.
body
seated
6. ft.
strut
to the
Install or
Do
the snapring
(50
•
Front wheel driveshaft bearing and
•
•
•
Nm) New
lbs.
Adjust the wheel alignment.
13.
Start
engine and check the engine if
neces-
sary.
if
and torque
lbs.
ft.
lbs.
(200
80
Nm) and ft.
lbs.
Front wheel
•
Negative battery cable
7.
Check the transaxle
8
Check the
front
fluid level.
necessary
REMOVAL & INSTALLATION
to
55
ft.
lbs.
(75
Nm) •
Transmission brace and torque the transmission bolts
Nm) and (63
lbs.
to
32
ft.
lbs.
the engine bolts to
46
VSS
•
WSS
•
Drive axles to the transmission
•
Oil
•If equipped with Antilock Brake System (ABS) brakes, use care to avoid
(43
damage age
connector
electrical connectors
cooler hoses
set a 1
ABS toothed ring Dammay cause the selffeature of the ABS system to
to the
to the ring
diagnostic
Nm)
•
electrical
Lumina and 1998-99 Monte Carlo
ft.
system
fault
code.
Before servicing the vehicle, refer to
Use
the precautions in the beginning of this sec-
a puller to press the axle shaft
through the hub/bearing assembly
tion.
For complete Engine Mechanical specifications, see Section
1
of this
manual
148
alignment and adjust
Lower transmission-to-engine bolts and torque them
to
(108 Nm)
•
Nm) •
to
the caliper
Halfshaft (180
it
Nm)
frame-to-body bolts and
torque them to 133
(70
Brake caliper and attaching bracket
bolts to
the transmission with fluid
12.
(215
lbs.
Brake rotor
ft.
Negative battery cable
oil
driveshaft nut ft
ft.
and torque the bracket bolts
duct
Fill
connector
torque the bolts to 52
Nm)
11.
Add
connect the following:
electrical
frame and raise
into position
not is
WSS
PNP
and torque the
air inlet
oil levels.
If
•
159
lbs.
pull outward.
shaft.
properly seated, the axle will remain in
the engine support fixture.
Throttle
is
place.
Nm)
Engine mount
and
of the axle shaft
Nm)
Wire harness connectors to the
and transaxle
install:
9.
Halfshaft into the transaxle
with a prying tool. Grasp the inner housing
Range selector cable
Remove
10.
Lower the transmission and frame
8.
(25
Bearing-to-knuckle bolts, loosely
•
Verify that the snapring
5.
Range selector cable with the
bolts to
engine. 7.
lbs.
•
transmission
Separate the transmission from the
6.
lbs.
switch and torque the bolts to
(20
connect the following:
Halfshaft/bearing assembly
transaxle
switch
the transmission. •
•
tube
filler
ft.
lbs.
connectors
trical
ft.
bracket and torque the nut to 15
Use a transmission
5.
•
electri-
connectors
Install or
properly by tapping on the inner groove
torque them to 55
Drive axles and secure them to the
install:
4.
Nm)
•
steering knuckles
To
knuck-
Engine splash shields
•
assem-
through the knuckle and into the
ends
Tie rod
the halfshaft/bearing
bly through the steering knuckle.
lbs.
•
cooler hoses
Remove
3.
steering gear to the frame
knuckles
motor
Axle shaft using an appropriate
Nm)
(80
Power steering cooler
clamps
Wheel hub/bearing
•
puller
Nm)
(47
frame
Power
•
line
lbs.
ft.
and torque the bolts
of the
•
Engine mount lower nuts and
to the
and secure
Nm)
(55
lbs.
electri-
connector
cal
Both front wheels
•
Brake caliper and bracket assembly
•
•
Power steering gear from the frame
Drive shaft nut
• •
knuckle and torque the nuts to 40
knuckles
•
Torque converter cover and torque
ft.
•
or disconnect the following:
Front wheel
the bolts to 89 inch lbs. (10 Nm).
Upper transmission bolts
rod ends from the steering
£
GRAND PRIX
•
Remove
2.
motor and torque the bolts
ft.
Wire harness grounds
tie
INTRIGUE
•
•
•
•
Nm)
(63
•
•
To
46
to
Starter to
retaining bolts
•
Torque converter bolts and torque
them
switch
LUMINA
•
90 90 L.3“00
GENERAL MOTORS CORPORATION CENTURY
REGAL
*
IMPALA
•
•
LUMINA •
Century, Regal, Impala, Intrigue, Gran Prix and 2000-01 Monte Carlo 1
.
Before servicing the vehicle, refer to
the precautions in the beginning of this sec-
•
*
GRAND PRIX
it
CV-joint boot by sliding
Tri-pot
it
away
tri-pot joint
housing from the
tri-pot
spider
Remove
or disconnect the following:
•
Front wheel
•
Stabilizer shaft link
•
Drive shaft nut
•
Outer
•
•
•
9306XG17
Inboard spacer ring slide
rear-
it
Pliers Tool
measurement— Inner
Boot
(tri-pot) joint
J-8059
•
Outboard retaining ring using
•
Tri-pot joint spider
•
Inboard spacer ring and CV-joint
from the steering knuckle
Ball joint
bushing from the
ward on the shaft using Snapring
rod end from the steering
tie
Trilobal tri-pot
housing
knuckle
3.
INTRIGUE
*
—
Large CV-joint boot clamp, cut and
from the
tion. 2.
MONTE CARLO
•
discard •
—
— W-BODY
Snapring Pliers Tool J-8059
Press the axle shaft through the hub.
assembly
boot
To prevent
damage
CV-
to the inner
do not pull on the axle shaft remove it from the transaxle.
joint,
Throughly clean and inspect
3.
to
To
install:
4. 4.
5.
Install or
connect the following:
Place a drain pan under the transaxle
to catch
when
all
parts.
any transaxle
the axle shaft
Remove
fluid that leaks out
removed.
is
Crimping the large CV-joint boot ring
the axle shaft from the
Inner (tri-pot) joint
transaxle by prying between the transaxle
and the inner CV-joint housing.
To install: 6.
connect the following:
Install or
•
Axle shaft that
the
housing •
Axle shaft through the hub/bearing
Exploded view
of the inner (tri-pot) joint
Ball joint ft.
•
22
lbs.
ft.
tional •
New 118
Nm)
(30
lbs.
(160
if
fol-
ft.
all
it
lbs.
WARNING
8.
Check the
front
Make
sure that there are no pinch
points on the inboard seal.
Positioning the inner CV-joint boot seal
Check the transaxle
the lower half.
Nm)
Front wheel
7.
Position the outboard of the half-
(215
and torque the
(23
the lower half of Tool J-
a vise.
41048 onto
to
except
lbs.
in
Position the upper end of Tool J-
c.
and torque
Impala models
ft.
Mount
shaft in the tool.
plus an addi-
Nm) on
Stabilizer shaft link
nut to 17 •
clamp on the boot.
ring
Secure the swage ring clamp as
6.
b.
to
turn
drive shaft nut
Nm) on
swage
41048
Impala models or 159
•
Position the CV-joint boot seal into
a.
40
Nm)
120 degree
ft.
to
end and torque the nut
Tie rod
clamp
7.
and torque the nut
(55
lbs.
ring
lows:
assembly •
CV-joint boot
the axle shaft's joint seal groove and align
seated by pulling on the
is
it
Swage
5.
the transaxle. Verify
in
•
•
fluid level.
and swage ring— Inner
(tri-pot) joint
alignment and adjust,
d.
hand e.
necessary.
Insert both bolts until
and tighten by
snug.
Tighten each bolt 180 degree
turn) at a time, alternating J
(Vfe
between the
41048
bolts, until
CV-Joint
f.
both sides are bottomed.
Remove Install or
•
OVERHAUL
the tool.
connect the following:
Inboard spacer ring, slide
it
rear-
ward on the shaft using Snapring
J-8059
Pliers Tool
Inner (Tri-Pot) Joint
•
the shaft
Before servicing the vehicle, refer to
1.
the precautions
in
Tri-pot joint spider
•
the beginning of this sec-
assembly onto
r
Outboard retaining ring
into the
axle shaft groove using Snapring
tion.
Remove
2. •
Pliers Tool
or disconnect the following: •
Front wheel
•
Halfshaft
•
Swage
ring using a
View
of the
swage
Inner (tri-pot) joint
hand grinder
ring crimping tool
J-8059
Tri-pot joint spider assembly, slide it
against the outboard retaining
ring
07 OQ Of
W-BODY— GENERAL MOTORS CORPORATION. CENTURY* REGAL Inboard spacer ring, seat
•
it
•
IMPALA
•
LUMINA
•
MONTE CARLO* INTRIGUE* GRAND PRIX
the
in
groove •
V2 kit grease
•
Vz
kit
New
large seal
joint
boot
Lubricate the parts with a light coat
of grease.
Assemble the CV-joint cage and
7. it
inner race, as follows:
over the 9306XG19
assembly
CV-joint boot/clamp, slide
bushing with the seal
lip in
into
the cage centerline.
Disconnecting the outer CV-joint from the axle shaft
lies flat
against
Insert the cage/inner race into the
d.
it
mea-
Assemble the chrome
8.
(125mm).
Using the Crimp Tool J-35910, a
clamp
to
130
ft.
Position a brass
a.
CV-joint cage and tap
lbs.
to
tilt
(176 Nm).
b.
connect the following:
Halfshaft
•
Front wheel
drift it
against the
with a
hammer
the cage. Insert the 1st
chrome
alloy ball into
the cage. Tilt
c.
the cage in the opposite direc-
tion.
Insert the opposite
d.
Outer Joint
chrome
alloy
ball.
Repeat the procedure
e
Before servicing the vehicle, refer to
1.
alloy balls into
the CV-joint cage, as follows:
torque wrench and a breaker bar, crimp the
•
cage
outer race.
Position the CV-joint boot so
Install or
inner
by rotating the inner race downward.
trilobal bushing. the10.
large CV-joint boot
windows with
Insert the inner race into the
c.
’•Make sure the boot
9.
Align the cage
b.
race lands.
the
groove
in.
Rotate the inner race 90 degrees to
a.
it
place, over the trilobal tri-pot
8.
all
install:
6.
clamp onto the CV-
tri-pot joint spider
sures 4.9
from the cage.
Throughly clean and inspect
To
bushing flush with
Tri-pot housing, slide
•
it
the cage from the outer race.
parts.
Trilobal tip-pot
•
Rotate the inner race upward and
5.
the tri-pot housing face •
Remove
d.
remove
into the boot
grease into the tri-pot hous-
ing •
c.
until all
6
balls are inserted.
the precautions in the beginning of this sec-
Install or
9.
connect the following:
tion.
Remove
2.
grease into the CV-joint
•
Vfe kit
•
%
•
Swage
•
CV-joint boot
or disconnect the follow-
boot
ing:
Front wheel
• •
Halfshaft
•
Swage
•
Large boot clamp, cut and discard
ring using a
hand grinder
—Outer CV-
it
10
into the axle shaft's joint seal
CV-joint boot from the axle shaft
a.
Position a brass
CV-joint cage and tap the cage.
b.
Chrome
c.
Tilt
41048 b.
drift it
Position
against the
with a
of seal
hammer
edge
here
c. SVOS22
Positioning the
alloy ball
boot— Outer
the lower half of tool J-
a vise.
Position the outboard of the half-
Position the upper end of tool J-
41048 onto
the lower half.
CV-joint
from the cage.
the cage in the opposite direc-
Disassemble the CV-joint cage and
4.
Make
inner race as follows:
Remove
in
shaft in the tool
tion.
d
Mount
it
Disassemble the chrome alloy balls
tilt
fol-
lows:
from the CV-joint cage as follows:
to
Secure the swage ring clamp as
1 1
Tool J-8059
a.
groove
boot.
ring ears using Snapring Pliers
3.
Position the CV-joint boot seal
and align the swage ring clamp on the
inner race-to-axle shaft retaining
and discard
clamp
groove
away from
CV-joint assembly by spreading the
•
ring
the retaining ring seats into the
the CV-joint •
grease into the CV-joint
CV-joint onto the axle shaft until
•
joint
it
CV-joint boot, slide
•
View the cage and inner race
kit
the opposite
chrome
a.
Pivot the cage
sure that there are no pinch
points on the inboard seal.
alloy
and race 90 degrees
ball.
to the center line of the outer race. e.
Repeat the procedure
until all
d.
6 b.
balls are
Align the cage
windows with
outer
hand
removed.
Insert both bolts until
race lands.
For Accessory Drive Belt
illustrations,
see Section
1
of this
manual
snug.
and tighten by
OO
*3
a
GENERAL MOTORS CORPORATION— W-BODY CENTURY
•
REGAL
Tighten each bolt 18Q degree
e
IMPALA
•
(V2
LUMINA
•
Remove
f.
Install or
12. •
CV-joint boot/clamp, slide
•
seal
large seal
boot
lip in
it
INTRIGUE into
•
GRAND PRIX
torque wrench and a breaker large CV-joint boot
clamp
to
bar,
130
crimp the ft.
lbs.
(176 Nm).
the groove
i->Make sure the boot
connect the following:
New
•
place, over the outer race with the
bottomed.
the tool.
joint
MONTE CARLO
)
turn at a time, alternating between the bolts, until both sides are
•
lies flat
14.
against
Install or
connect the following:
•
Halfshaft
•
Front wheel
the outer race.
clamp onto the C VUsing the Crimp Tool J-35910, a
13.
STEERING AND SUSPENSION Air
ing column.
Bag
The
driver’s side air
bag
is
now
disabled.
**
CAUTION
The vehicles are equipped with the Supplemental Inflatable Restraint (SIR) or air bag system. The SIR system must be disabled before performing service on or around SIR system components, steering column, instrument panel components, wiring and sensors. Failure to follow safety and disabling procedures could result in accidental air bag deployment, possible personal injury and unnecessary SIR system repairs.
6.
Remove
1. 7.
Detach the
connector
at
the right side
CPA and
sound
insulator.
air
bag
is
now
disabled.
Inflatable Restraint (SIR)
CPA
yellow 2-way SIR
the base of the steering wheel.
The passenger's side
Attach the yellow 2-way
2. tal
tor
at the
After
air
bag system as follows:
Be sure the ignition key
is
4.
Attach the yellow 2-way SIR connec-
Several precautions
at the
multi-use bracket
module
is
locked and the
removed.
inflator
7.
Turn the ignition switch to the
the AIR
flashes 7 times, then shuts
off.
the
module. •
When
carrying a live inflator module,
3 4
that the
bag and trim cover are pointed
CONNECTOR POSITION ASSURANCE (CPA) CONNECTOR, STEERING COLUMN WIRING HARNESS
away. •
Place the inflator module on a bench
or other surface with the
SRS 2-way connector
location
—
SRS 2-way connector
location
— passenger’s side
driver’s side
bag and trim cover
facing up. •
With the
inflator
module on
the bench,
never place anything on or close to the
module which may be thrown of
in
the event
an accidental deployment.
DISARMING
1.
Turn the steering wheel so the vehicle
wheels are pointing straight-ahead. 2.
Turn the ignition key to the
position and 3.
remove the
Remove
the AIR
LOCK
key.
BAG
fuse from the
fuse block. 4.
Remove
5.
Detach the Connector Position Assur-
the
left
side sound insulator.
ance (CPA) and yellow 2-way Supplemental Inflatable Restraint (SIR)
connector
at the
multi-use bracket near the base of the steer-
base
insulator.
fuse.
BAG
wires or connector on the underside of the
hold securely with both hands, and ensure
BAG
position and verify the AIR
to avoid
module by
sound
Install
sonal injury.
Never carry the
side
Install the left
6.
accidental deployment and possible per-
•
at the
5.
must be observed
the inflator
insulator.
and Connector Position Assurance
PRECAUTIONS
when handling
sound
side
Install the right
the column.
necessary repairs are made, re-
enable the
of the steering wheel.
3.
(CPA)
ARMING
base
Supplemen-
connector and
light
RUN
of
W-BODY— GENERAL MOTORS CORPORATION. CENTURY
•
REGAL
•
Power Rack and Pinion Steering Gear
IMPALA
•
LUMINA
•
MONTE CARLO
•
INTRIGUE
Negative battery cable
•Set
Front wheels
block tooth on the upper steering shaft
CAUTION
is at the 12 o’clock position. The wheels should be straight ahead. Set
tion. 2.
Remove
or disconnect the following:
stub shaft
may
result in
the steering gear. This
the steering shaft so that the
ignition key lock to the the 3.
Failure to disconnect the intermediBefore servicing the vehicle, refer to
could result
damage to damage may
in
damage
Common
3.4L
Remove
Tire,
Wheel and Ball Joint
to the
SIR
coil
or disconnect the follow-
ing:
ONLY
rack and pinion steering gear mounting
For
posi-
procedures
assembly.
cause a loss of steering control and may cause personal injury.
SHIELD. STEERING GEAR HEAT
LOCK
tion. Failure to follow these
i
16
OQ OQ 3 03
•
ate shaft from the rack and pinion 1.
GRAND PRIX
•
REMOVAL & INSTALLATION
the precautions in the beginning of this sec-
•
specifications, see Section
1
of this
manual
GENERAL MOTORS CORPORATION— W-BODY
29-40
CENTURY
REGAL
•
IMPALA
•
INTRIGUE
•
GRAND PRIX
stub shaft
tion.
REMOVAL & INSTALLATION
•
Both
1
.
Before servicing the vehicle, refer to the
rear.
precautions
>*D0 NOT lower the frame too far. Engine components near the firewall may be damaged.
2.
in
3.
Scribe the strut to the steering
Torx®
or disconnect the following:
Three upper
Lower
bolts from the rear of the
•
Power steering pressure
To
from
line
strut nuts •
Strut
Install or
hose
•
Magnasteer Variable Assist
•
connect the following:
•
Power steering gear through the
5.
to
Power steering gear through
bolts
59
(80
and torque them
24
ft.
lbs.
•
Nm) on Impala models.
Lower
strut bolts
to
Align the strut to the scribe mark on
ft.
lbs.
6.
Install
7.
Road
connector to the power
Power steering
if
lines with
new 0-
rings to the steering gear. Torque the fasteners to
20
(27
lbs.
ft.
•
•
and check the if
necessary.
torque
its
"•The Chevrolet Lumina and 1998-99 Monte Carlo utilize a replaceable cartridge housed within the strut assembly. The cartridge can be replaced without removing the strut assembly from the vehicle.
New
rear to
Tie rod
(30 •
10. •
ends
ft.
lbs.
lbs.
ft.
(110
and
Nm)
the shaft into the car-
ment
(180
rod. Install
9.
service the strut cartridge
to the steering
and torque the nuts
to
spring could result
ft.
mount
insulator as
Step 1:Use a soap solution
is
in
Step
to lubri-
necessary, install an
2:lf
alignment rod tool
on
com-
personal injury.
knuck-
22
the strut
follows:
partially installed
after the
bushing
and position the
as required to assist
is
strut
the bushing
in
installation.
pressed. Otherwise the released coil
Nm)
bumper
Strut
Raise the strut and remove the align-
8.
a.
vehicle keeps the coil spring
frame bolts and torque
133
82
to
cate the bushing for ease of installation.
unless the weight of the vehicle
original
connect the following:
them
it
Compress
•
Front Strut Cartridge
housing
Strut cartridge closure nut
•
the suspension. The weight of the
les
Self-contained replacement car-
b.
Install or
connect the following:
Install or
the front wheel. test the vehicle
end alignment, adjust
DO NOT
position. 8.
the strut housing
install:
•
CAUTION
hose
return
Raise the rear frame to
7.
To
(123 Nm).
Nm).
Power steering
oil in
using a suction pump.
tridge with a strut alignment tool
equipped
•
Strut cartridge
Remove any
Nm)
steering gear assembly,
•
90
front
Mounting
trical
or
wrench
left
Magnasteer Variable Assist elec-
•
closure nut using a Strut Cap Nut
all
tridge into the strut
the
wheel opening
lbs.
and torque
Nm) on
7.
connect the following:
strut into
or disconnect the following:
the steering knuckle. Torque the lower bolts
To install:
ft.
lbs. (41
left
wheel opening
•
strut nuts
ft.
6.
•
•
30
models except Impala (33
Steering gear mounting bolts
Install or
to
if
•
tool in the
Strut closure nut by unscrewing the
•
Three upper
them
equipped
6.
Remove
5
Strut
electri-
connector from the power
steering gear assembly,
Alignment
compress the
install:
•
return
bumper
Strut
Install a Strut
the cartridge. 4.
Power steering
insulator by prying
bladed tool
flat
correct position and
the steering gear •
mount
Strut
strut bolts 4.
50
bit
with a
•
removing the three
Strut shaft nut by using a No.
•
Front wheel
•
•
cal
Strut cover by
or disconnect the follow-
frame. Lower the frame slightly •
•
cover nuts
ing:
Frame
Wheel
the beginning of this section.
Remove
or disconnect the following:
•
knuckle for proper installation.
•
Remove
Remove
3.
center
at the
Scribe the strut cover to body to
2.
Front Strut
Support the frame
the beginning of this sec-
in
assure proper camber adjustment.
rod ends from the steering
tie
knuckles
•
Before servicing the vehicle, refer to
Strut
the precautions
Intermediate steering shaft
5.
•
pinch bolt from the steering gear
•
4.
MONTE CARLO
•
1.
Intermediate steering shaft lower
•
LUMINA
•
Install or
•
connect the following:
Strut shaft nut using the No.
Torx®
bit
tighten
it
to
59
ft.
50
lbs.
(80
Nm)
lbs.
Nm)
Intermediate steering shaft to the steering gear stub shaft and torque the lower pinch bolt to
(48 •
ft.
lbs.
Front wheels
• 9.
35
Nm)
Negative battery cable Fill
and bleed the power steering
system. 10. repair
Start the vehicle if
and check
for leaks, Strut closure nut removal
necessary.
7922Z532
7922Z537
11.
Check the
adjust as needed.
front
end alignment and Strut shaft nut
removal
Strut closure nut
removal
W-BODY— GENERAL MOTORS CORPORATION. OQ_>11 CENTURY
•
REGAL
•
IMPALA
LUMINA
•
MONTE CARLO
•
•
INTRIGUE
•
C-
GRAND PRIX
3
*T
I
To install: connect the following:
Install or
5.
•
Strut
the bolts to •
90
Nm)
and wheel
•
Rear
•
Three strut to body mount nuts and
tire
torque them to 30
ft.
test the vehicle
wheel alignment
rear
(122
lbs.
ft.
Stabilizer shaft link to the strut
Road
6.
and torque
Strut to knuckle bolts
•
if
Nm)
lbs. (41
and adjust the
needed.
LUMINA 1.
Before servicing the vehicle, refer to
the precautions in the beginning of this section. 2.
Remove
Negative battery cable
.
Wheel
•
Brake hose bracket
•
Strut
• (1) Front Stabilizer Shaft Insulator (2) Front Stabilizer Shaft Link Nut
Clamp Bolt/screw
Mount Nut
Front Suspension Strut
(4)
Front Suspension Spring
(12)
(5)
Front Suspension Stmt
(13)
(6)
Strut
(7)
Front Steering Knuckle
(8)
Strut
(11)
To Knuckle Nut
(16)
3.
suspension without replaceable
Install or
Strut
•
37
ft.
lbs.
Nm)
(50
Strut/stabilizer shaft bracket to the
knuckle
strut cartridge
Strut-to-knuckle bolts and nuts
• •
connect the following:
mount-to-body nuts and
tighten to
*
of the front
from
Strut
•
732225
Exploded view
at the strut
body nuts
To install:
Clamp
Front Stabilizer Shaft
to
Strut/stabilizer shaft bracket
•
Lower Control Arm Bolt/screw Front Lower Cotrol Arm Nut Frame
Front
(14) Front Stabilizer Shaft Insulator (15) Front Stabilizer Shaft
To Knuckle Bolt/screw
mount
the knuckle
(9) Front Stabilizer Shaft Link] (10) Front Lower Control Arm
(3)
or disconnect the following:
•
Tighten the nuts to 82
Strut cover while aligning scribe
marks and torque the
bolts to
ft.
lbs.
(112
Nm).
24
ft.
lbs. (33 Nm) A 4-wheel alignment is recommended after any steering/suspension
11
•
Brake hose bracket
•
Wheel
Coil Spring
repairs are performed.
Rear Strut
REMOVAL & INSTALLATION
EXCEPT LUMINA 1
Except Models Equipped With A Front
Before servicing the vehicle, refer to
.
the precautions
in
the beginning of this sec-
Strut Cartridge
tion.
1
Remove
2.
3.
•
Negative battery cable
•
Three
•
Rear
•
Stabilizer shaft link
(2) (3) (4) (5)
From Suspension Slrui Mourn Retainer From Spring Upper Insulator From Spring Front Spnng Seat Front Suspension Strut Bumper
strut to
tire
tion.
2
and wheel
3.
from the
strut
has
if
4 its
to the
the knuckle
strut
that the strut
mounting holes
compressor
drilled for specific
vehicle lines.
the strut to knuckle bolts have been
ball joint or drive axle
Remove the strut from the vehicle. Mount the strut assembly into a strut
compressor. Note
knuckle must be retained after
removed. Damage may occur
Before servicing the vehicle, refer to
the precautions in the beginning of this sec-
body nuts
Scribe the strut to the knuckle.
•The (1)
or disconnect the following:
is
Compress
height after
the strut approximately
initial
contact with the top
cap.
not retained.
WARNING
79222531
4.
Remove
or disconnect the following:
Knuckle and strut assembly with replace-
•
Strut to knuckle bolts
able strut cartridge
•
Strut
For Wheel Alignment specifications, see Section
Never bottom the spring rod!
1
of this
manual
or
damper
V4
OO AO
GENERAL MOTORS CORPORATION— W-BODY CENTURY
*
REGAL
*
IMPALA
LUMINA
•
MONTE CARLO
•
*
INTRIGUE
•
GRAND PRIX
forcing screw while the guiding rod centers 3
When
the assembly.
the threads on the
damper
shaft are visible,
rod and
install
ft.
(85
lbs.
Nm) on
models
or
52
strut or
55
ft.
1 1
the guiding
63
models except Impala
all
lbs.
ft.
(70 Nm), for a front
Nm)
(75
lbs.
Remove
.
remove
the nut. tighten the nut to
(for a rear strut)
the strut from the
compres-
sor. Install the strut to the vehicle.
12.
Models Equipped With A Front
Strut
Cartridge 1
.
Before servicing the vehicle, refer to
the precautions in the beginning of this section. 2.
Remove
the strut assembly from the
vehicle.
2
STRUT ASSEMBLY INSTALL LOCKING PINS THROUGH STRUT ASSEMBLY
3
TIGHTEN NUTS UNTIL FLUSH WITH
4
STRUT COMPRESSOR COMPRESSOR FORCING SCREW
1
h
CAUTION
Do not over compress the Only compress the spring
comes away from
coil spring. until
it
the seat.
7922YG24
3.
View in
a
of a typical strut
Compress
mately Vfunch
assembly mounted
compressor
3
4.
5
7
9 TO
Relieve the spring tension and
remove the spring.
To
install: •
2 3
Exploded view
of the front strut
strut
and make certain
upper and lower seats are
positioned correctly •
assembly
•
and torque
Strut rod nut lbs.
WRENCH SOCKET STRUT ASSEMBLY
Spring to the that the
7922YG27 1
Discard the nut
rotate. 5.
SPRING SPRING LOWER INSULATOR STRUT
8
or disconnect the following:
Strut rod nut with the proper socket
while not allowing the rod to rod to
JOUNCE BUMPER STRUT DUST SHIELD
6
Remove •
SPRING SEAT SPRING UPPER INSULATOR
4
a spring
compressor.
STRUT MOUNT NUT STRUT MOUNT RATE WASHER
1
2
the coil spring approxi-
(13mm) using
(85
to
63
ft.
Nm)
Strut
7922YG25
Use
a socket
damper
and
a
wrench
to
com-
Remove
5.
remove the
shaft nut spring cap while
damper
shaft
the nut from the strut
ing rod on top of the damper shaft. Use the 10. rod to guide the damper shaft straight down
pressing the spring
Lower
Ball Joint
and place an alignment/guid-
REMOVAL & INSTALLATION
through the spring cap while compressing 1
the spring.
To
Remove
.
Before servicing the vehicle, refer to
the components. the precautions
in
the beginning of this sec-
install:
6.
Mount
tion.
the strut assembly
in
the strut 2.
compressor, using the bottom locking pin 3.
Remove Remove
the wheel. the lower control
arm from
only. 7.
Install the
spring over the damper
the vehicle. 4.
and swing the assembly up so the upper
Remove
control
arm by
the ball joint from the lower drilling out the
4
rivets
locking pin can be installed. 8.
Install all shields,
bumpers and
insulators on the spring seat. 1
2
Install the rod to
straight
guide the damper shaft
down through
the spring cap while
compressing the spring
Use an Vs
in. drill bit
through the
STRUT COMPRESSOR STRUT ASSEMBLY
7922YG26
retaining the ball join^to the control arm.
9.
spring. the
Install the
strut
to
make
a pilot hole
Finish drilling the rivets
spring seat on top of the
The spring seat
same
rivets.
using a Vz flat
should be facing 5.
in. drill bit.
Remove
the ball joint.
direction as the centerline of the
assembly spindle.
To install: 6.
Install the
guiding rod and turn the
Install or
connect the following:
^
AO OQ m ‘w
W-BODY— GENERAL MOTORS CORPORATION. CENTURY Ball joint to the control
•
Bolts with the heads facing
50
to
REGAL
•
IMPALA
arm
•
and torque them
•
LUMINA
•
MONTE CARLO
INTRIGUE
•
models tighten the control arm-to-
down
frame nuts to 52 •
(68
lbs.
ft.
•
lbs.
ft.
is
Front wheel
Nm) •
Lower control arm
•
Wheel
to the vehicle
bushing
until the
pressed into the control arm. 11.
Disassemble the
12.
Install or
CONTROL ARM BUSHING REPLACEMENT 1
**A 4-wheel alignment is recommended after any steering/suspension
Tighten the screw
10.
(70 Nm).
GRAND PRIX
•
tools.
connect the following:
•
Lower control arm
•
Front wheel
Before servicing the vehicle, refer to
.
the precautions in the beginning of this sec-
Wheel Bearings
tion.
repairs are performed.
Remove
2.
or disconnect the follow-
ADJUSTMENT
ing:
Lower Control Arm REMOVAL & INSTALLATION
3.
•
Front wheel
•
Lower control arm
The wheel bearings are not adjustable. a wheel bearing
Lubricate the threads of a bushing
must be replaced. Using a
driver with high pressure lubricant. 1
.
9. 4.
Before servicing the vehicle, refer to
the precautions in the beginning of this sec-
Assemble the
check
for looseness.
(0.127mm) on drum bearing wear
5
2.
Remove
or disconnect the following:
•
Front wheel
•
Anti lock Brake
To
speed sensor connector and jumper harness from the retainer
until the
•
Stabilizer shaft link
•
Cotter pin from the ball stud and
7.
Disassemble the
tools.
4.
Remove
Lubricate the
new bushing
outer cas-
install
a
new bushing
into the control
1
arm.
Before servicing the vehicle, refer to the
.
precautions driver/installer
set onto the control arm.
from the steering knuckle.
bolts.
Do
lower control arm and
Front wheel
•
Wheel Speed Sensor (WSS)
not tighten the nuts
at this
time
electri-
connector
•
Brake caliper and bracket
•
Rotor
•
Driveshaft nut
a front hub removal tool to the
Install
3.
beginning of this section.
or disconnect the following:
•
cal
the lower control arm.
Install the
in the
Remove
2.
To install: 5.
excessive and the hub and
REMOVAL & INSTALLATION
the ball stud nut counterclockwise to separate the ball stud
is
bearing should be replaced.
Front 8
removal tool over
in.
or disc brakes the
is
and lower control arm. Rotate
the ball joint
dial indicator,
exceeds 0.005
install:
Assemble a bushing
Install a ball joint
bushing
ing.
loosen the nut 3.
Tighten the tool
pressed from the control arm. 6.
System (ABS) wheel
If it
If
it
tool onto the control
arm bushing.
tion.
out of specification,
is
wheel bearing/hub assembly with three
'•Align the ball stud cotter pin hole
wheel nuts. Use the tool to push the drive-
parallel to the knuckle to ease the cot-
shaft out of the
Remove
4.
ter pin installation.
wheel bearing/hub. the wheel bearing/hub
assembly and discard the bolts 6.
Install or
•
connect the following:
the nut to
Monte
40
Carlo,
To install:
knuckle and torque
Ball stud to the ft.
lbs.
Grand
Nm)
Prix,
15
to
Install or
Nm) on
(55
Century
ft.
lbs.
Removing
the bushing from the lower con-
arm
(20
degrees on Impala models. On
lbs. •
63
cotter pin
Make
wheel speed
wheel speed sensor wire har-
ness
to the retainer clips
•
ABS
wheel speed sensor connector
•
Lower control arm nuts and torque
them
to
83
ft.
lbs.
(113
Nm) on
all
models except Lumina. On Lumina
ft.
and torque
(160 Nm) on ft.
it
to
except
all
lbs.
(215
Impala models
lbs (185
Stabilizer shaft link
ABS
•
lbs
torque the bracket bolts to 137
sensor •
%
Front caliper with the bracket and
•
ends do not make
ABS
to
Brake rotor
•
contact with the
and torque them
Nm)
drive shaft nut ft.
Nm) on
and bend the ends.
certain the
(130
Impala models or 159
ft.
(85 Nm).
New
bolts
lbs.
118
J 21474-19
tighten to
new
New
•
plus an additional 120
Lumina models
connect the following
Wheel bearing/hub assembly using
• trol
and Regal models. On Impala models, tighten
5
Nm) and
mounting bolts
to
•
WSS
connector
•
Front wheel
electrical
ft.
the caliper
63
ft
lbs.
(85
Nm)
Rear Installing the bushing to the lower control
The
arm
into
the
For Maintenance Interval recommendations, see Section
1
rear
one
hub
wheel bearing/hub
unit.
The
or bearing is
of this manual
is
integrated
unit is non-serviceable.
damaged, the com-
If
903 £ plete
ii
A GENERAL• CENTURY
hub and bearing
unit
(V10T0RS CORPORATION— W-BODY REGAL • IMPALA • LUMINA • MONTE CARLO
.
Before servicing the vehicle, refer to
the precautions in the beginning of this sec-
3.
Remove
To
•
Rear wheel
•
Brake drum,
•
Rear caliper and bracket,
if
WSS Brake
•
Rear wheel hub to knuckle bolts
•
•
Parking brake lever bracket and
torque the bracket bolts to 92
parking brake actuator
lbs.
if
•
•
Anfilock Brake System (ABS) Wheel
if
2
KNUCKLE ASSEMBLY, REAR SUSPENSION HUB AND BEARING ASSEMBLY
3
BOLT/SCREW, WHEEL
is
bolted to the knuckle
rotor,
if
connector
equipped
Brake caliper with the bracket and
(125
bolts to
connect the following:
Parking Brake lever bracket and
Hub and
Nm) and
32
ft.
lbs.
•
Brake drum,
•
Rear wheel
if
ft.
the caliper
(44
Nm)
,
if
equipped
A 4 wheel alignment bearing assembly and
torque the bolts to 55
7922Z535
The rear hub/bearing assembly
electrical
equipped
actuator •
equipped
Brake
1
4.
install:
equipped •
rotor,
electrical
Rear wheel hub from the knuckle
Install or
equipped
GRAND PRIX
•
•
or disconnect the following:
*
•
tion. 2.
INTRIGUE
connector
Speed Sensor (WSS)
must be
replaced. 1
«
ft.
lbs.
(75
after
Nm)
is
recommended
any steering/suspension repairs have
been performed.
GENERAL MOTORS CORPORATION — Y-BODY 1998-01 Chevrolet-Corvette
30-18 30-2 30-16 30-2
DRIVE TRAIN.. ENGINE REPAIR FUEL SYSTEM
PRECAUTIONS STEERING AND SUSPENSION
30-28 30-28
Arming
30-28
Disarming
30-28
Precautions
30-28
C Installation
Installation
30-16
Removal &
Installation
Hydraulic Clutch System
30-23
Removal &
Installation
Lower
Removal &
Lower Control Arm Control
30-3
Removal &
30-3
Installation
30-8
Exhaust Manifold Installation
30-8
Fuel Filter Installation
Installation
30-32
Removal &
Installation
Pump Removal &
30-10 30-11
P Piston and Ring
Steering Gear
30-16
Removal &
Removal &
Installation
Transmission Assembly Installation
Removal
&
Installation
30-13 30-18 30-18
Installation
30-30
U 30-31
Ball Joint
Removal &
Installation
Upper Control Arm
30-31
30-32
Arm Bushing 30-32
Replacement
Removal &
Installation
30-32
V 30-10
Valve Lash
30-10
W Water
Pump
30-6
Removal & 30-28
30-13
30-30
Transverse Spring
30-15
30-28
30-10
Timing Chain, Sprockets,
Adjustment
30-15
Positioning
30-16 30-17
30-10 Installation
30-11 Installation
30-29
T
Control
30-10
Pan
Power Rack and Pinion
F
Installation
Motor
Removal &
Upper
30-33
0
Oil
Engine Assembly
30-32
Arm Bushing
Removal & Oil
E
Starter
&
30-32
Replacement
30-2
Distributor
Installation
30-7
30-29
Shock Absorber
Removal & 30-32
Ball Joint
30-6
D
30-7
L
30-6
Cylinder Head
30-7
Installation
30-13 30-7
Installation
Front Cover and Seal
30-24
Overhaul
Removal &
30-23 30-23
Bleeding
30-24
CV-Joints
Installation
Rocker Arms
Removal 30-23
Halfshaft
30-9
30-23
Removal &
S
H
30-22
Adjustment
Removal &
30-16
Intake Manifold
30-22
Clutch
Fuel Injector
30-16
30-13
Rear Main Seal
Fuel System Service
30-9
Camshaft
Removal &
30-16
30-2
Removal
Removal &
Installation
Fuel System Pressure
30-2
Alternator
Removal &
Removal &
R
30-17 30-16
Precautions
Bag
Removal &
Installation
Pump
Relieving
A Air
Removal & Fuel
Installation
30-6
Wheel Bearings 30-33
Adjustment
Removal
&
Installation
30-33
GENERAL MOTORS CORPORATION— Y-BODY
30-2
CORVETTE
PRECAUTIONS eye
Before servicing any vehicle, please be sure to read
following precautions,
of the
all
which deal with personal of
prevention
safety,
component damage, and important points
to take into consideration
when
servicing a
Never open, service or drain the radia-
when
cooling system
tor or
the engine
Observe
all
applicable safety precau-
when working around
tions
fuel.
Whenever
servicing the fuel system, always work
Do
well-ventilated area. or vapors to
fluid for
The EPA warns
•
with used engine
oil
that
prolonged contact
may cause
should make every to
used engine
gloves should be worn
come
in
in
a
not allow fuel spray
sure to used engine
oil.
Soap and
expo-
water, or
waterless hand cleaner should be used. •
new
All
vehicles are
If
now equipped must be
of brake
the brake fluid
becomes contaminated, completely Any brake
fluid.
flush the
Never reuse any
fluid.
removed
fluid that is
from the system should be discarded. Also,
do not allow any brake oil.
other exposed after
your vehicle.
system with new brake
Protective
oil.
with an air bag system. The system
contact with a spark,
of
You
when changing
soon as possible
skin areas as
number
a
minimize your
effort to
Wash your hands and any
and hot coolant. •
should always buy the correct type
tance IMMEDIATELY.
exposure
is
burns can occur from the steam
hot; serious
proper operation of the brake system. You
you have taken
if
skin disorders, including cancer!
motor vehicle: •
irritation persists, or
brake fluid internally, seek medical assis-
fluid to
tact with a painted surface;
come in condamage
will
it
the paint.
Never operate the engine without the
•
proper amount and type
of
doing so WILL result
severe engine
in
engine
oil;
damage. Timing
•
belt
maintenance
Many models
extremely
is
disabled before performing service on or
important!
around system components, steering col-
ence-type, non-freewheeling engine.
extinguisher near the work area. Always
umn, instrument panel components, wiring
timing belt breaks, the valves
keep
and sensors. Failure
or excessive heat (a hot drop
open flame
example). Keep a dry chemical
light, for
fuel in a
designed
fire
container specifically
for fuel storage; also,
to follow safety
disabling procedures could result
always
in
and
head may
acci-
tially
strike the pistons,
sonal injury and unnecessary system
maintenance
additional fuel system precautions later in
repairs.
this
working with, or around, the 3.
Fuel injection systems often remain
•
pressurized, even after the engine has been
OFF. The
turned
fuel
system pressure must
be relieved before disconnecting any lines. Failure to
do so may
and/or personal
injury.
•
brake fluid
in
fluid.
carrying a non-deployed air bag, be
air
from the surface. This
If
of the
module
will if
it
accidentally
system precautions
your eyes, flush your eyes
• If
air
is
causing poten-
interval charts in the front of
for the
recommended
interval for the timing belt,
replace-
and
to the
inspection.
Disconnecting the negative battery
cable on
some
vehicles
may
the functions of the on-board
tem^) and may
interfere with
computer sys-
require the computer to
When
is
servicing
reconnected.
drum
brakes, only dis-
assemble and assemble one side
later in this section.
essential to the safe
ative battery cable •
bag
Clean, high quality brake fluid from a
sealed container
the
undergo a relearning process once the neg-
reduce the is
deployed. Refer to the additional
you do get
with clean, running water for 15 minutes.
motion
away
If
the cylinder
in
timing belt section for belt replacement and
•
bag on a work surface, always
face the bag and trim cover upward,
and wash your hands thoroughly
handling brake
bag system.
sure the bag and trim cover are pointed
deployed
result in fire
Brake fluid often contains polyglycol
after
When
air
manual
ment
away from your body. When placing a non-
fuel
ethers and polyglycols. Avoid contact with the eyes
Always wear safety goggles when
interfer-
expensive) engine damage. Refer to the
dental air bag deployment, possible per-
possibility of fire or explosion. Refer to the
•
an
serious (also time-consuming and
properly seal fuel containers to avoid the
this section.
utilize
and
at a time,
leaving the remaining side intact for refer-
ence.
ENGINE REPAIR To
Distributor All
5.7L (VIN G) engines use a Direct
Ignition
System.
•
install: Install or
•
Alternator
•
Alternator
Alternator rear
(50
mounting bolts and
torque them to 37
ft.
lbs.
(50
Nm)
.
2.
in
• •
Regulator connector and battery to
or disconnect the following:
Negative battery cable Regulator connector and battery to
from the
rear of
the alternator •
Accessory drive
•
Rear mounting bracket
•
Alternator
•
Alternator
belt
9306ZG24
mounting bolts Exploded view
of the
alternator— 5. 7L engine
lbs.
Drive belt
the beginning of this section.
alternator terminal
ft.
•
Before servicing the vehicle, refer to the
Remove
37
•
REMOVAL
1
to
Nm)
Alternator
precautions
mounting bracket
and torque the bolts
connect the following:
Y-BODY— GENERAL MOTORS CORPORATION
30-3
CORVETTE alternator terminals
and torque the
alternator terminal nut to lbs.
•
(13
•
10 inch
Nm)
•
Negative battery cable
Intake Air Temperature (IAT) sensor
connector
Mass
Flow (MAF) sensor elec-
REMOVAL & INSTALLATION
•
and
cleaner
•
Air intake duct
•
Upper
•
Radiator
•
Electronic Brake Control Traction
air
•
radiator support
Electric throttle
motor
Throttle Position
electrical
•
(EBTCM/BPMV) and
Engine Coolant Temperature (ECT) sensor
•
bracket
Sensor (TPS)
connector
electrical
Module/Brake Pressure Modulator Valve
Evaporative Emission (EVAP) sole-
connector
connector
trical
Engine Assembly
Air
•
noid electrical connector
electrical
electrical
A/C compressor
connector electrical
connec-
tor
Before servicing the vehicle, refer to
1.
•
Brake pipes
•
Accessory drive
•
Fuel line from the connector at the
the precautions in the beginning of this sec-
belt
•
Alternator electrical connectors
•
Alternator
•
Brake booster vacuum hose
tion.
The following tools
will
be required
in
front of the
dash
•
Intermediate shaft to steering gear
addition to the basic hand tools: •
Transverse spring compressor and
•Cap
adapters
fuel
and plug
all
openings
bolt
for the •
system
to
prevent contaminants
from entering the system.
•
Ball joint separator
•
Engine support table
• •
Driveshaft support strap
•
Fuel pressure
gauge
2.
Relieve the fuel system pressure.
3.
Drain the cooling system.
4.
Drain the engine
5.
Evacuate the A/C system.
6.
Remove
Fuel
•
Fuel line at the fuel
•
Radiator hoses from the water
•
oil.
•
or disconnect the follow-
ing:
covers
•
•
rail
Intermediate shaft from the steering
gear
Secondary from the
rail
Air Injection (AIR)
left
•
Both front wheels
•
Heated Oxygen (HO2S) sensor con-
pump
nectors from the intermediate
Heater hoses from the water
exhaust pipes
pump
•
Intermediate exhaust pipes
Fuel injector electrical connectors
•
Close-out panel
Ignition coil
main harness connec-
tor
hose
exhaust manifold
•
Starter
motor
•
Starter
motor
•
Oil level
•
Crankshaft Position (CKP) sensor
•
connectors
sensor connector
connector
electrical
•
electrical
A/C compressor hose assembly Engine trical
oil
temperature sensor elec-
connector
Heated Oxygen (HO2S) sensor
•
Left
•
Front stabilizer shaft
•
Connectors from the cooling fans
•
Cooling fan assembly
•
Tie rod
ends from the steering
knuckles •
Antilock Brake System (ABS) electrical
connectors from the cross-
member, •
if
equipped
Electronic Variable Orifice (EVO)
connector clips from the cross-
member, •
if
Real Time tor clips
equipped
Damping (RTD) connec-
from the crossmember,
if
equipped •
Shock absorber lower mounting bolts
•
Front transverse leaf spring
•
Automatic transmission cooler pipes
at
the flywheel housing junc-
tion •
Automatic transmission cooler pipe
clamps from the engine Use a compressor such as engine
J
33432-A
to
compress the
front transverse spring
— 5 7L (VIN G)
•
oil
pan
Automatic transmission cooler pipe
from the radiator
For complete service labor times, order the Chilton Labor Guide
GENERAL MOTORS CORPORATION— Y-BODY
30-4
CORVETTE
CAUTION Failure to use the
minimum
fastener
length specified will prevent the
proper retention
of the propeller shaft
during assembly. For vehicles with an automatic trans-
7.
mission, perform the following steps:
Remove
a.
the two plug bolts
the
in
driveline support assembly. b.
Install
M10
an
55
x
bolt, or longer,
each plug location. Torque the bearing
in
support bolts to 26
On
8.
remove the
sion,
bell
housing inspection
cover, then turn the flywheel
access the bolt and loosen
Remove
9.
(35 Nm).
lbs.
ft.
vehicles with automatic transmis-
hub
collar to
it.
the engine flywheel housing
access plug. Rotate the automatic transmission
10.
collar so that the bolt 1 1
Loosen the
.
is
bolt
facing down.
and unclip the wire
harness from the engine and reposition
it
to
the driveline. 12.
Install a driveline
support tool to the
close out panel flange. 7922Z603
CAUTION On automatic transmission vehicles, remove the plugs from the driveline support assembly and install 2
M10
Never use a driveline support
x 1.5 bolts into the plug holes
tool to
support the weight of the engine
assembly. 13.
It
equipped with a manual transmis-
sion, perform the following steps:
Unclip the clutch actuator hose
a.
from the engine flywheel housing b.
Using a hydraulic clutch
rator tool,
clip.
line
sepa-
depress the white release ring
on the actuator hose and
pull lightly
on
the master cylinder hose. c.
Remove
the flywheel housing bolts
from the driveline support.
Support the engine and crossmem-
14.
ber assembly.
Remove
15. •
Front
or disconnect the following:
crossmember nuts BY
HAND
and lower the engine assembly slightly •
Secondary
Air Injection (AIR) tube
bracket bolt and reposition the bracket to gain access to the
ground strap •
Ground left
•
Engine cal
•
•
bolt
on the flywheel hub collar after turning
for
access
pressure sensor electri-
Camshaft Position (CMP) sensor connector
Manifold Absolute Pressure (MAP)
sensor it
oil
connector
electrical
7922Z604
Loosen the
strap f/om the rear of the
cylinder head
electrical
connector
Y-BODY— GENERAL MOTORS CORPORATION
30-5
CORVETTE •
Front transverse spring and torque
46
the bolts to •
(62
lbs.
ft.
Nm)
Shock absorber lower mounting nuts and torque them to 21
•
lbs.
ft.
Nm)
(28
Front stabilizer shaft and torque the
53
bolts to
ft.
(72
lbs.
Nm)
•
ABS EVO RTD
•
Tie rods to the steering knuckle
•
•
connector
electrical electrical
connector
electrical
connector
torque the nuts to 33
ft.
and
(45
lbs.
Nm). •
•
Radiator
Cooling fan assembly to the radia-
and attach the
tor
electrical
connec-
tors to the fans •
Ground wires
to the
left
side of the
engine •
HO 2 S
•
Engine
sensor connectors temperature sensor con-
oil
nector •
A/C compressor hoses
com-
to the
pressor
Install a Driveline
Support tool
•
•
42203
to the
under cover flange
nector
•
CMP sensor electrical MAP sensor electrical
Front driveline support assembly
•
KS
bolts
•
Install or
Engine from the driveline, by plac-
•
Front driveline support bolts and
Knock Sensor (KS)
•
J
ing a
electrical
con-
•
of the driveline
and the flywheel
•
housing
bolt to
engine away from the pro-
Pull the
16.
•
Raise the vehicle
7.
off of
•
the engine
18. Remove member nuts. 19. Remove
•
the engine mount-to-cross-
•
member.
To
•
Install the
engine on the crossmem-
ber and torque the nuts to
40
ft.
lbs.
Install or
•
•
•
(50
Wire harness
(if
Nm)
Ground
(25
Nm)
strap to the rear of the
•
24
ft.
lbs.
Engine cal
oil
(32
Nm)
pressure sensor electri-
•
connector
visit
the
ft.
lbs (50
ft
lbs (20
Nm) and Nm)
to the rear of the
to
Automatic transmission cooler
•
37
the nuts to 15
•
(if
equipped)
fittings to
26
ft
lbs.
Nm)
(35
MlOx 55mm
•
bolts from
in
AIR hose to the
left
exhaust mani-
after
removing the to
M10 37
x
at the
and torque them
(27
Nm)
to
20
and
site at
bolts to
rear of the oil
•
•
Automatic transmission cooler pipes
pan
www.chiltonsonline.com
Nm)
Alternator bracket
lbs
equipped)
(48
•
cooler
ft.
lbs.
Brake booster vacuum hose
ft
flywheel housing junc-
tion
(if
oil
ft.
•
•
Automatic transmission
Intermediate steering shaft to the steering gear and torque the bolt to
35
the driveline support
Nm)
(50
our web
Nm)
Intermediate exhaust pipe and
and torque the
the driveline support tool.
to the front
Please
and
fold
Two plugs
pipes
left
Nm)
lbs (50
Front wheels
equipped)
lbs.
lbs.
motor and torque the bolts
ft
•
to the clutch
on the engine and torque the bolts ft.
to the
engine
pipes to the radiator
Master cylinder hose
connector
hangers and torque the bolts
Nm)
equipped)
(if
electrical
Driveline close out panel
(12 •
Clutch actuator hose to the flywheel
assembly
connect the following
cylinder head and torque the bolt to
•
lbs.
ft.
37
connector
electrical
sensor
torque the bolts to 106 inch lbs
nuts and torque
55 bolts and torque them
18
•
Nm)
(110
Starter to
Nm)
(50
lbs.
sensor
right side of the
•
Power steering pump and reservoir
to
Wire harness ground wires
the driveline support assembly
Lower the vehicle onto the
engine/crossmember assembly. 22.
37
to
Remove Remove
24.
21.
•
engine 23.
(54
Nm).
ft.
(50
lbs.
ft.
actuator hose
install:
20.
lbs.
ft.
81
housing the engine from the cross-
Oil level
Flywheel housing bolts and torque
them
and crossmember.
CKP
•
and bracket and torque the
37
to
•
connect the following:
New crossmember them
peller shaft. 1
Air tube
A/C compressor line retaining bolt and torque it to 26 ft. lbs. (35 Nm)
connector
connector
electrical
torque them to 37
blade tool between edge
flat
connector
•
•
37
ft.
and torque the (50
lbs.
Nm)
Alternator
and torque the bolts
37
(50
ft.
lbs.
to
Nm)
Alternator connectors
and torque
the nuts to 10
(13
ft.
lbs.
Nm)
Fuel injector electrical connectors Ignition coil
nectors
main
electrical
con-
GENERAL MOTORS CORPORATION— Y-BODY
30-6
CORVETTE
EVAP solenoid
•
connec-
electrical
tors
motor
connector
•
Throttle
• •
ECT sensor electrical connector TPS electrical connector
•
A/C compressor
electrical
connec-
electrical
tor
pump pump
•
Heater hoses to the water
•
Radiator hoses to the water
•
Fuel line to the fuel
•
Fuel
rail
•
Drive belt
•
EBTCM/BPMV 20
the bolts to
bracket and torque
Nm)
(27
lbs.
ft.
EBTCM/BPMV
•
rail
covers
and
to the bracket
torque the nuts to 89 inch
lbs.
(10
Nm) Upper radiator hose
• •
Upper
•
Air cleaner
•
IAT sensor electrical connector
radiator support
and
air intake
•
MAF
•
Negative battery cable
sensor
electrical
duct
connector
new
25.
Fill
the engine with
26.
Fill
the cooling system.
27.
Evacuate and recharge the A/C sys-
oil.
To
install:
4.
Install or
New
•
Water pump. Torque the bolts to 11 ft.
On
vehicles with an automatic trans-
mission, start the engine and allow for
10 minutes. Torque the hub
96
ft.
lbs.
(130
Nm) and
it
to idle
•
collar bolt to
install the
flywheel
Check the vehicle
30.
if
for leaks
and
Water Pump REMOVAL & INSTALLATION
.
to
(if
lbs.
ft.
lbs.
(25 Nm).
pump
pump
Accessory drive
•
Air intake duct
•
MAF
3.
from the rear if
of
removing the
side
Cylinder head
install:
f»New Mil cylinder head bolts must be used when installing the cylinder
•
IAT sensor electrical connector
•
Negative battery cable
5.
connector
Install the
new
6.
the cooling system.
Place the cylinder head on the engine
d.
Mil Mil Mil Mil
e.
M8
a.
and check
cylinder head gasket
onto the locating pins.
and tighten the bolts
b.
for leaks,
necessary.
c.
Cylinder Head
bolts:
in
22
sequence ft.
to:
(30 Nm).
lbs.
90 degrees.
bolts: plus
bolts 1-8: plus
90 degrees.
bolts 9-10: plus bolts (11-15):
50 degrees.
22
(30
lbs.
ft.
Nm).
tion. 2.
To
Before servicing the vehicle, refer to
the precautions in the beginning of this sec-
bolt
if
side
belt
electrical
Start the vehicle
left
side
left
bracket,
head assembly.
•
6.
Ground wire
left
•
(10
Radiator inlet and outlet hoses to
if
•
equipped).
89 inch
•
Fill
repair 1
pulley
5.
removing the
if
the cylinder head,
then to 18
sensor
it,
Power steering pump removing the
ft.
Heater hoses to the water
the water
necessary.
then to 22
•
the engine and
been removed from the vehicle.
repair
Nm) and
pump
Water
Nm) and
A wheel alignment is recommended crossmember have
29.
(15
•
(30 Nm).
Torque the bolts
inspection plug.
when
gasket with the tabs facing up
lbs.
lbs.
Power steering pump and reposition
•
tem. 28.
•
connect the following:
Remove
Negative battery cable Intake Air Temperature (IAT) sensor
1
electrical
connector
Mass
Flow (MAF) sensor elec-
• •
Air intake duct
Accessory drive Inlet
and
water
outlet
belt
hoses from the
Heater hoses from the water
•
Water (if
• •
pump
pulley bolts and pulley
pump Water pump
2.
in
the beginning of this sec-
24 •
to the rear of the
lbs.
ft.
Nm)
3.
Relieve the fuel system pressure.
4.
Remove
•
or disconnect the following:
if
Rocker arm cover
•
Exhaust manifold from the cylinder
•
head
•
Vapor vent pipe
•
removing the
left
side
pulley,
if
(50
ft.
lbs.
(25
Nm)
,
if
t
Power steering pump
pulley,
if
Exhaust manifold and torque the
sequence,
Nm), then
Power steering pump
lbs.
removed •
Intake manifold
ft.
Power steering pump and torque removed
•
removed
removed
the bolts to 18
Negative battery cable
•
if ,
bolts, in
retaining bolts
(32 Nm),
Power steering pump bracket and torque the bolts to 37
Drain the engine coolant.
pump
equipped)
Six water
Before servicing the vehicle, refer to
•
pump
•
.
the precautions tion.
connector
trical
•
connect the following:
Ground wire
cylinder head and torque the bolt to
•
Air
Install or
•
or disconnect the following:
•
•
7.
REMOVAL & INSTALLATION
Drain the cooling system.
•
to
18
ft.
to 11 lbs.
ft.
(25
lbs.
(15
Nm)
Valve rocker arm cover and torque
Y-BODY— GENERAL MOTORS CORPORATION
OU" 7I Ofl
CORVETTE
9.
With the engine
in this position,
tighten the exhaust valve rocker
on cylinders No.
1
,
7 and 8
2.
arm
to
bolts
22
lbs.
ft.
(30 Nm), then, tighten the intake valve
arm
rocker
and 5
bolts on cylinders No. 1. 3, 4
22
to
lbs.
ft.
(30 Nm).
Rotate the crankshaft
10.
1
revolution
(360 degrees). 1 1
With the engine
.
in this position,
tighten the exhaust valve rocker
on cylinders No.
arm
5 and 6 to 22
3. 4.
bolts ft.
lbs.
(30 Nm), then, tighten the intake valve
arm
rocker
and 8
22
to
12.
on cylinders No.
bolts
new gasket and torque lbs.
7
arm cover using
the rocker
Install
2. 6.
(30 Nm).
lbs.
ft.
the bolts to
a
106 inch
(12 Nm).
13.
Negative battery cable.
14.
Start the vehicle
repair
if
and check
for leaks,
necessary.
Intake Manifold
REMOVAL & INSTALLATION Be sure the tab on the edge
ot the
gasket
is
closer to the front ot the engine
when
installed
•The
intake manifold, throttle body,
and rail may be removed from the engine as an assembly. fuel injectors
15
13
^ 3
k 7 xl •
106 inch
Intake manifold
bolts in
Nm)
(12
Nm)
and torque the
sequence
to
to •
lbs.
8
4 ./S\_
(S/
Nm)
the precautions in the beginning of this sec-
Relieve the fuel system pressure
Remove
3.
boll
Nm)
Rocker arm cover
•
Rocker arm
necessary
4.
If
removed,
install the
installed in their original positions.
rocker
piston
Fuel injector electrical connectors
Knock Sensor (KS) connector
KS jumper
arm mounting rocker
PCV
•
Engine cooling
fuel rail
covered
tube Irom the throttle body
in Section
bleed hose from
body heater
Throttle
•
Intake manifold
bolts
air
body
•
and
outlet
hose
fuel stop
bracket
arms but do not
Top Dead Center (TDC).
is
from the
Positive Crankcase Ventilation
To install: 5.
Apply a 0.20
1
in.
(5mm) bead
of
threadlock to the threads of the intake manifold bolts.
Timing belt service
pigtail
•
oil.
Rotate the crankshaft so the No. is at
Sensor (TPS)
connector
the throttle
Lubricate the flange and washer sur-
Install the
Throttle Position
rail
hose
arm covers
arm
tighten the bolts at this time. 8.
Before servicing the vehicle, refer to
•
ventilation
stop bracket
Lubricate the rocker arms and
•Always keep
7.
Vacuum
install:
face of the rocker
6.
•
neces-
if
dud
(PCV) valve pipes from the rocker
pushrods with clean engine
the rocker arms and order so they can be
connector
Air intake
•
REMOVAL & INSTALLATION
in
Flow (MAF) sensor elec-
Air
Fuel line from the fuel
•
pivot support. 5.
pushrods
connector
Mass
•
•
sary
To
Rocker Arms
electrical
electrical
Rocker arm pivot support,
for leaks,
or disconnect the following:
Intake Air Temperature (IAT) sensor
•
•
or disconnect the following
•
Rocker arm, push rods and pedestals
and check
Remove
•
•
Start the vehicle
Relieve the fuel system pressure.
4
rv2B>\!
•
9.
3
•
the cooling system
Fill
Drain the cooling system.
trical
2.
beginning of this section.
in the
2
j>y
Negative battery cable
8.
if
(12
5
tion.
44 inch lbs (5
then to 89 inch lbs. 910
106 inch
precautions
5.7L engine
Vapor vent pipe and torque the
•
repair
lbs.
—
Before servicing the vehicle, refer to the
1
2
1. Cylinder head bolt torque sequence
the bolts to
^
'll
6 _/o\
14
12
11
3 of this manual
1
GENERAL MOTORS CORPORATION— Y-BODY CORVETTE make
sequence
— 5.7L
fc
The
CAUTION
fuel rail stop bracket
must be
installed on the intake manifold in
may
Negative battery cable
•
Left
result in fuel spray
•
Engine coolant
•
Heated Oxygen (HO 2 S) sensor
•
PCVtube
•
Alternator electrical connector
•
PCV
•
•
•
Accessory drive
•
KS sensor jumper pigtail KS electrical connector TPS electrical connector
•
Alternator
•
Fuel injector electrical connectors
•
•
Vacuum
air
(10
outlet
hose
valve pipes
•
IAT sensor electrical connector
•
MAF
•
Negative battery cable
and reposition
Fill
Start the vehicle
connector
and check
Exhaust Manifold
•
Spark plug wires
•
Sparkplugs
•
Exhaust manifold
To
install:
4.
Apply threadlock
Install
5.
new
the exhaust manifold using a
Beginning with the center 2
torque the bolts to 11 Left Side
to the threads of the
gasket.
6.
new gas-
it
bolts.
connect the following:
Intake manifold with a
of
the cylinder head and reposition
for leaks,
necessary.
it
AIR pipe retainer from the rear
•
the cooling system.
7.
hose
Air Injection (AIR)
AIR pipe from the exhaust manifold
•
Fuel line Air intake duct
electrical
belt
from the check valve
•
sensor
connector
electrical
Secondary
vent hose
REMOVAL & INSTALLATION •
Engine Coolant Temperature (EOT) sensor
•
if
nuts from the exhaust manifold studs
bleed hose
causing personal injury. Install or
hand intermediate pipe flange
body heater
lbs.
its
original position. Failure to reinstall this part
•
Throttle
8.
repair
Nm)
•
engine 6.
second pass and tighten the
89 inch
•
Intake manifold torque
a
bolts to
lbs.
ft.
(15
nating from side-to-side until
all
bolts,
Nm)
alter-
the bolts
ket • •
1
Fuel stop bracket Intake manifold bolts
the bolts
Nm)
in
first to
the
and torque
44 inch
.
precautions 2.
lbs. (5
sequence shown, then
Before servicing the vehicle, refer to the
3.
in
the beginning of this section.
Relieve the fuel system pressure.
Remove
or disconnect the following:
same
are tight. Torque the bolts again in the
sequence
18
lbs.
ft.
(25 Nm).
Bend over the exposed portion
7.
gasket 8.
to
at
Install or
•
connect the following:
Spark plugs and torque them ft.
Spark plug wires
•
AIR pipe retainer bolt the cylinder head bolt to
15
to
1
Nm)
(15
lbs.
•
•
of the
the rear of the cylinder head.
lbs.
ft.
to the rear of
and torque the (20
Nm)
AIR pipe with a new gasket and torque the bolts to 15
ft.
lbs.
(20
Nm) •
AIR hose torque
it
to the to
15
check valve and
ft.
lbs.
(20
Nm)
•
Alternator and torque the bolts to
•
Accessory drive
•
Alternator electrical connector
37
ft.
lbs.
(50
•
EOT sensor
•
HO 2 S lbs.
•
•
Nm) belt
electrical
connectors
sensor and torque
(42
it
to
30
ft.
Nm)
Fuel lines
Intermediate pipe flange-to-exhaust
manifold nuts and torque them to
15 • 9.
ft.
lbs.
(20
Nm)
Negative battery cable
Start the vehicle
and check
for leaks,
'
repair
if
necessary.
Right Side 1.
Before servicing the vehicle, refer to
the precautions in the beginning of this sec-
Re sure
to reinstall the fuel stop bracket
when
installing the intake manifold
tion.
Y-BODY— GENERAL MOTORS CORPORATION
Qfl-O OU 3
CORVETTE
AIR pipe using a new gasket and
•
torque the bolts to 15
lbs.
ft.
(20
Nm)
HO 2 S
•
sensor
torque
it
to
in
30
the manifold and
ft.
lbs.
Nm)
(42
Intermediate pipe flange-to-exhaust
•
manifold nuts and torque them to
15
8.
repair
ft.
lbs.
(20
Nm)
Negative battery cable
•
Start the vehicle if
and check
for leaks,
necessary.
Camshaft REMOVAL & INSTALLATION Before servicing the vehicle, refer to
1.
the precautions in the beginning of this section.
2
Drain the cooling system
3.
Relieve the fuel system pressure.
Remove
4.
Exploded view
Remove
2.
of the
exhaust manifold— 5. 7L engine
or disconnect the following:
•
Fuel lines from the fuel
•
Rocker arm covers
•
Rocker arms and pushrods
•
Both cylinder heads
•
Valve
•
Radiator
lifter
guides and the
or disconnect the following:
•
Negative battery cable
•
Right side intermediate exhaust
pipe nuts from the manifold studs •
Heated Oxygen (HO 2 S) sensor
•
Secondary
Air Injection (AIR) pipe
from the exhaust manifold •
Spark plug wires
•
Sparkplugs
•
Oil level indicator
•
Exhaust manifold
To
install:
3.
Apply threadlock
and tube
to the threads of the
bolts. Install the
4.
new
exhaust manifold using a
gasket.
Beginning with the center 2
5.
tighten the bolts to 11
ft.
lbs.
nating from side-to-side until
(15 all
bolts,
Nm)
alter-
the bolts
are tight. Then, tighten the bolts again in the
same sequence to 18 ft. lbs. (25 Nm). 6. Bend over the exposed portion of gasket 7.
at
connect the following:
Oil level indicator
the bolt to 12 •
ft.
tube and torque
lbs.
(16
Nm)
Spark plugs and torque them ft.
•
the
the rear of the cylinder head
Install or
•
lbs.
(15
to
1
Nm)
Spark plug wires
Install three
Heater Core replacement
M8-1.25
is
x
100mm
covered
long bolts into the camshatt to use as a handle
in Section
2 of this manual
rail
lifters
on
U OU“ in
GENERAL MOTORS CORPORATION— Y-BODY CORVETTE
I
•
Engine front cover
•
Oil
pan
•
Oil
pump
•
Camshaft sprocket and timing chain
•
Camshaft Position (CMP) sensor
all
Camshaft
•
•
ADJUSTMENT Oil
The rocker arms on the 5.7L (VIN G)
and sensor
bolt
fold nuts to
Valve Lash
engine are bolted
into position
is
possible.
noisy, suspect low
oil
If
the valves are
Install
M8
3
x
100mm
long bolts
Carefully
6.
remove the camshaft from
the engine, be sure not to
damage
the
To 7.
Negative battery cable
Before servicing the vehicle, refer to
1.
tion.
Starter Motor
REMOVAL & INSTALLATION 1.
Before servicing the vehicle, refer to
the precautions
2.
install:
in
the beginning of this sec-
2.
Drain the engine
3.
Remove
•
or disconnect the following:
Negative battery cable
•
Intermediate exhaust pipe
oil.
•
Starter electrical connectors
Negative battery cable
•
Alternator
•
Washer
•
Engine Coolant Temperature (EOT)
connect the following:
Install or
100mm
long
•
Starter bolts
•
Starter
bolts in the front of the camshaft to
use as a handle
Camshaft
•
Camshaft
•
ket
engine and
Tie rods from the steering linkage
•
Real Time
(25
CMP
Starter to
new gas-
retainer using a
18
to
• •
ft.
Nm)
•
37
connect the following:
•
motor and torque the bolts
ft.
lbs.
(50
Starter electrical
connectors
Intermediate exhaust pipe and
Nm) Timing chain and sprocket and
•
torque the sprocket bolts to 26
Nm) Oil pump and torque the bolts lbs. (25 Nm) Oil pan with a new gasket and lbs.
•
ft.
(35
to
18
ft.
•
torque the bolts pan-to-rear cover
106 inch
bolts to
10.
(25 •
Nm) and
(12
lbs.
the remaining bolts to
18
lbs.
ft.
Nm)
Front cover with a
new gasket and
torque the bolts to 18
ft.
lbs.
(25
Nm) •
Radiator
•
Valve
lifters
and
guides and
lifter
torque the bolts to 106 inch (12
Cylinder heads
•
Pushrods and rocker arms
•
Rocker arm covers with new gaskets
and torque the bolts
inch lbs. (12
9.
Fuel lines to the fuel
•
Negative battery cable Refill
if
to
106
Nm)
•
rail
the cooling system.
Start the
repair
lbs.
Nm)
•
engine and check
Intermediate shaft from the steering
for leaks,
necessary.
Exploded view
of the starter
assembly
Electronic Brake Control
(EBCM/BPMV)
reposition
(25
lbs.
Damping (RTD) sensor
equipped
Stabilizer shaft
Valve
sensor with a new O-ring and ft.
connector
Module/Brake Pressure Modulator
Nm)
torque intermediate pipe-to-mani-
torque the bolt to 18
if
electrical
gear
Install or
•
connector
•
install:
bolts
and torque the bolts
lbs.
•
3.
into the
remove the 3
To
motor
electrical
Headlamp
•
Three M8-1. 25 x
•
reservoir
•
links, 8.
oil.
or disconnect the following:
•
sensor
Remove
Lubricate the camshaft with clean
engine
Nm) and (50 Nm)
Pan
tion.
camshaft bearings.
lbs.
the precautions in the beginning of this sec-
in
the front of the camshaft to use as a handle.
ft.
pressure or worn
All
5.
(20
lbs.
37
REMOVAL & INSTALLATION
valve train components.
camshaft bearings are the same diameter, extreme care must be taken during camshaft removal or installation to avoid damaging them.
ft.
so that no
retainer plate
adjustment
15
other bolts to
—5.7L engine
•
Power steering gear
bracket and
Y-BODY— GENERAL MOTORS CORPORATION 3Q_-|
9346ZGG1
Separate the upper
and lower
(1)
(3) oil
pans 4.
Lower shock absorber mounting
.
bolts
Transverse
.
spring using a suit-
leat
able compressor
Lower control arm bolts trom the suspension crossmember
•
Engine mount lower nuts
•
Wheel Speed Sensor (WSS) wiring harness trom the crossmember
.
Brake
.
Apply sealant
to the
covers attach areas where the tront and rear
engine
from the crossmember
line
Support the suspension crossmember. Crossmember mounting nuts
•
crossmember
•
Front
•
Oil filter
•
Automatic transmission cooler rear retaining
and
front
line
clamp bolts
equipped) Enqine flywheel housing-to-oil pan
(if
.
bolts
Engine flywheel close out bolts • Engine oil level sensor . Engine oil temperature sensor elec-
.
trical
connector
pan assembly
•
Oil
•
Lower
pan bolts and separate
oil
the pans
p*To remove the
necessary it
necessary)
(if
pan gasket
oil
to drill out 3 rivets
it
is
securing
to the pan.
To 5.
lower
install: If
oil
separated, connect the upper and pans with a new gasket and torque
the bolts to 6.
106 inch
Apply a 0.20
sealant directly
lbs. in.
(12 Nm). of
RTV
of the front
and
(5mm) bead
on the tabs
rear cover gaskets that extend
onto the
oil
pan mounting surface following: 7. Install or connect the •
New
gasket on the
necessary to
on the
oil
oil
rivet the
pan.
It
is
not
new gasket
Exploded view
ot
the
oil
pan mounting— 5 7L engine
pan.
Brake service
is
covered
in
Section 4 of this manual
to the
engine block
5 7L
-|
— "3
•
•
I
•
pan-to-engine bolts and torque
Oil
18
to
Nm)
(25
lbs.
ft.
repair
pan-to-rear cover bolts and
Oil
•
Oil
pan
Negative battery cable
•
Oil
•
Oil
pump pump
if
new
oil.
and check
To
tor leaks,
necessary.
5.
Check and adjust
11.
the front
end align-
Nm)
125
Torque the lower control arm bolts lbs.
ft.
to
•
37
to
and
Left
Engine trical
and bolts
Oil
REMOVAL & INSTALLATION
(12
(25
connector
Engine it
8.
•
torque
clamp
2.
Drain the engine
3.
Drain the cooling system.
oil.
(12
lbs.
4.
Nm)
Remove •
Negative battery cable
•
22 inch
to
it
clamp
Engine front cover
to
it
22
Engine front cover
•
Negative battery cable
ft.
lbs.
plug and torque
Oil drain
it
to
18
Fill
the cooling system.
8.
Start the vehicle
necessary.
ft.
Raise the suspension crossmember into position. •
Crossmember mounting torque them to 81
•
(110
Nm)
Engine mount lower nuts and torque them to 48
•
nuts and
lbs.
ft.
WSS
(65
lbs.
ft.
Nm)
wiring harness to the cross-
member •
Brake
•
Transverse
•
at this
(28
DO NOT
and torque them
74
(100
lbs.
ft.
EBCM/BPMV
lbs.
Be sure
to seat the
tube into the
pump
before installing the bolt
Nm)
c£>
bracket and torque
20
(27
lbs.
ft.
Nm)
Intermediate shaft and torque the
Outer to
18
tional •
ft.
Power steering gear and torque the
pinch bolt to 25 •
to 21
Nm)
the bolts to •
to the cross-
torque the bolts
time
bolts to •
spring
Lower shock absorber mounting bolts
•
leaf
Lower control arm
member,
•
crossmember
line to the
ft.
ft.
lbs.
(35
Nm)
rods and torque the nuts
tie
(25
lbs.
Nm)
plus an addi-
180 degree turn
RTD sensor
electrical connector,
it
equipped •
Stabilizer shaft
nuts to 53
clamp
ft.
and torque the
lbs-.
bolts to
43
link
Nm) and the lbs. (58 Nm)
(72 ft.
•
Alternator and torque the bolts to
•
Washer
37
ft.
lbs.
(50
Nm)
reservoir and torque the
nuts to 66 inch lbs. (7.5 •
EOT sensor
electrical
Nm)
connector
Oil
pump assembly mounting— 5. 7L engine
new
the engine with
7.
Nm)
(25
lbs.
ft.
lbs.
lbs.
pan
Fill
it
new 0-ring
106 inch
the nut to 18
Oil
Nm)
(30
Nm) and Nm)
bolt to
•
Nm)
lbs. (3
and torque
Oil filter
screen with a
6.
repair
and
bolt
pump
•
or disconnect the following:
Automatic transmission cooler pipe
torque
•
the beginning of this section.
and
bolt
106 inch
to
it
rear retaining
•
in
Automatic transmission cooler pipe front retaining
•
Before servicing the vehicle, refer to the
precautions
Nm)
(35
lbs.
ft.
.
sensor and torque
oil level
26
to
Oil
and torque the
temperature sensor elec-
oil
drive gear are aligned prop-
Pump •
1
•
pump
106 inch
to
Nm)
(12
lbs.
•
the bolts to 18
erly.
right close outs
and torque the bolts
connect the following:
pump and torque lbs. (25 Nm)
Nm)
(50
lbs.
ft.
Oil
K»Be sure the crankshaft sprocket and
(170 Nm). oil
them
Install or
•
ft.
12.
Flywheel housing bolts and torque
screen
install:
ment.
(12
lbs.
the engine with
Start the vehicle
10.
Nm)
(25
lbs.
ft.
Front headlamp electrical connector
Fill
pan-to-front cover bolts and
Oil
torque them to 106 inch
•
9. •
pan and hand tighten the bolts
Oil
torque them to 18 •
—
I
i
them •
GENERAL MOTORS CORPORATION— Y-BODY CORVETTE i.m^— « a—
o L
1
UUw
oil.
and check
for leaks,
Y-BODY— GENERAL MOTORS CORPORATION Ofl-I CORVETTE
OU
I
Q J
Rear Main Seal REMOVAL & INSTALLATION
•The
rear main seal is a 1-piece unit. can be removed or installed without removing the oil pan or crankshaft. It
1
.
Before servicing the vehicle, refer to the
precautions 2.
in
Remove • •
the beginning of this section.
or disconnect the following:
Transmission Clutch and pressure plate,
if
equipped with a manual transmission
3.
•
Flywheel inspection cover
•
Flywheel
Using a pry
tool, carefully pry the old
seal out.
7.
To install: 4.
Inspect the crankshaft for nicks or
burrs, correct as required. 5.
Clean the area and coat the seal and
crankshaft with engine 6.
Install or
Flywheel torque sequence
oil.
connect the following:
•
Seal, using a seal installer
•
Flywheel and torque the bolts
sequence
to
then to 37 finally to •
ft.
74
15
ft.
(20 Nm) Nm) and (100 Nm)
Flywheel inspection cover and torque the bolts 18
ft.
lbs.
(25
if
Timing Chain, Sprockets, Front Cover and Seal
sion
(50
lbs.
Clutch and pressure plate
equipped with a manual transmis-
lbs.
ft.
lbs.
• in
•
Transmission
Start the vehicle
repair
if
and check
for leaks,
REMOVAL & INSTALLATION
necessary.
Nm)
Before servicing the vehicle, refer to
1
the precautions in the beginning of this section.
Drain the cooling system.
2. 3.
Drain the engine
4
Remove
oil.
or disconnect the follow-
ing: •
Negative battery cable
•
Engine
•
Oil
pan
Oil
pump
•
front
cover
Rotate the crankshaft until the timing
5
marks are aligned. The marks should face each
other.
Remove
the camshaft sprocket
bolts.
•Do
not turn the crankshaft after the
timing chain has been removed.
age
to the pistons or
Remove
6.
valves
may
Damoccur.
or disconnect the following:
Camshaft sprocket and timing
•
chain •
Crankshaft sprocket using a suitable puller
To 7.
install:
Be sure the timing mark on the
crankshaft sprocket
is at
the 12 o'clock
79222634
position.
Use a seal
installer to press the seal
on the crankshaft
For complete Engine Mechanical specifications, see Section
If
not rotate the crankshaft to the
correct position.
1
of this
manual
fl
1
4
GENERAL MOTORS CORPORATION— Y-BODY CORVETTE Install or
8.
•
connect the following:
Crankshaft sprocket with a Crankshaft Balancer
and Sprocket
Installer tool
Timing chain on the camshaft
•
sprocket.
Timing chain and sprocket assem-
•
marks are
bly so the timing
aligned and torque the camshaft (
sprocket bolts to 26
ft.
•
Nm) Oil pump and torque ft. lbs. (25 Nm)
the bolts to 18
•
Oil
•
Front cover with a seal
lbs.
(35
pan with a new gasket
new gasket and
and hand tighten the bolts
at
this time 9.
Install the oil
pan
and hand-tighten them
certain that the front cover
aligned and torque the
cover bolts to 18
ft.
cover bolts
to
at this time.
oil
lbs.
pan-to-front
(25
the remaining bolts to 18
Make
properly
is
ft.
Nm) lbs.
then
(25
Nm). 10.
Connect the negative battery
cable.
A
puller is
needed
to
remove the crankshaft sprocket
11.
Fill
the cooling system.
12.
Fill
the engine with
13.
Start the vehicle
repair
if
new
oil.
and check
for leaks,
necessary.
J 41665-1
7922Z639
Timing chain alignment
—5.7L engine
Be sure
to install the crankshaft
sprocket properly
Y-BODY— GENERAL MOTORS CORPORATION CORVETTE
1
Piston
o
and Ring
POSITIONING
2.
0
ENGINE LEFT
Upper compression
ENGINE FRONT
1I
R J
»
ENGINE RIGHT
piston ring
3 Lower compression piston
ring
4 Oil control piston ring 5 Oil control ring spring w/spacer
C
2rwJ
comoression
ring
gap
D Top compression nng gap 792AG«
7922AG43
Piston ring positioning
OH OU
—5 7L engine
Piston ring end-gap spacing
1
.
— 5.7L engine
Piston
2 Connecting rod LH 3 Connecting rod bearing A Connecting rod 5.
RH
Connecting rod bearing cap
6 Connecting rod bearing cap bolt 7 Crankshaft Piston and connecting rod positioning
— 5.71 engine
For Accessory Drive Belt
illustrations,
see Section
1
of this
manual
GENERAL MOTORS CORPORATION— Y-BODY
Qfl IK IO OU"
CORVETTE
FUEL SYSTEM 4.
Fuel System Service Precautions
5.
Safety
is
most important
the
factor
when
performing not only fuel system mainte-
nance but any type to
of
maintenance. Failure
conduct maintenance and repairs
manner may
safe
a
Maintenance and testing
injury or death.
of
of the fuel
rail
fuel
spray and connect a fuel pressure
and guide-
to the following rules
6.
70
Nm)
(95
lbs.
ft.
6.
Connect the negative battery cable.
7.
Turn the ignition switch
OFF
ignition switch
open the valve
and torque the nuts
Stabilizer shaft to
onds, then
for
back
ON
2 sec-
for
10 seconds. Turn the
ON
and inspect
for
leaks.
to bleed the
system pressure.
Pump
Fuel
Close the valve and disconnect the
gauge. Drain any remaining
fuel
gauge
the
To avoid the possibility of
assembly) to catch any
Place the bleed hose into a suitable
container, then fuel
7.
lines.
•
end
by
effectively
(located on the side or
fitting
gauge.
system components can be
accomplished safely and
•
fuel
pressure valve
result in serious personal
the vehicle's fuel
adhering
in
Remove the left fuel rail cover. Wrap a shop towel around the
from
fuel
REMOVAL & INSTALLATION
into the bleed container.
and per-
fire
These models have 2 sonal injury, always disconnect the negative
Fuel Filter
and
The
left).
battery cable unless the repair or test proce-
sender assembly dure reguires that battery voltage be
REMOVAL & INSTALLATION
fuel
pump
fuel
in
the
is left
tanks (right
part of the fuel fuel tank.
right fuel tank contains a fuel
The
sender
applied.
Always
•
assembly with a siphon
system pres-
relieve the fuel
sure prior to disconnecting any fuel system
component
pressure reg-
(injector, fuel rail,
ulator, etc.), fitting or fuel line
connection.
Exercise extreme caution whenever relieving
system pressure,
fuel
skin, face
and eyes
advised that
exposing Please be
under pressure may pene-
fuel
trate the skin or
to avoid
to fuel spray.
any part
of the
body
that
1
.
Before servicing the vehicle, refer to
around the
a
shop towel or
sender feed pipe. Although there are 2
2.
Relieve the fuel system pressure.
3.
Clean the
(should
Ensure that
quick-connect 4.
it
occur)
is
Remove
•
to
fuel
•
soaked
•
able waste container.
Do come •
to
•
•
spark or open
•
flame.
Always use a back-up wrench when
•
loosening and tightening fuel line connection fittings. This will prevent
stress
and torsion
unnecessary
to fuel line piping.
Always
To
Always replace worn
rings with new. or equivalent,
Do
fuel fitting
0-
5.
3.
Drain the fuel tank(s).
Intermediate pipe-to-muffler bolts
4.
Remove
left
•
muffler
•
Fuel feed and return quick connect
from the
fuel filter
mount
Mark each
6.
nut
Fuel filter/pressure regulator and
them during
fuel
Remove
7.
fuel line to
help identify
installation.
or disconnect the follow-
ing: •
Quick connect
fittings
from the
fuel
sender
Fuel system ground strap Fuel filter/pressure regulator from
•
the bracket
•
Fuel sender electrical connector Fuel tank strap and properly support the fuel tank
•
connect the following:
plastic quick
ers on the inlet •
Fuel tank shield(s)
sender assembly.
Fuel feed pipe from the outlet side
New
or disconnect the following:
Both rear wheels
Clean the area around the
5.
Fuel filter/pressure regulator
Install or
•
connector retain-
and
Fuel sender attaching bolts and
discard them
outlet tubes
Fuel filter/pressure regulator into the bracket
not substitute fuel hose
where
cradle
install:
follow the proper torque specifications. •
Properly relieve the fuel system
2.
pressure.
bracket
not allow fuel spray or fuel vapors into contact with a
for both.
the precautions in the beginning of this sec-
of the fuel filter/pressure regulator
Always keep a dry chemical (Class B)
extinguisher near the work area.
fire
removal and installation
same
tion.
filter.
or disconnect the following:
bracket
cloths or towels are deposited into a suit-
•
the
Before servicing the vehicle, refer to
1.
Rear stabilizer bar from the rear
fittings
quickly removed from all
from the
and lower the
fuel spillage
engine surfaces. Ensure that
fittings
is
it
• all
connections, then
filter
units, the
procedure
depress the locking tabs and detach the
loosening to absorb any excess fuel due to spillage.
pump which
sending
cloth
connection prior
fitting or
jet
tank through the fuel
tion.
contacts.
Always place
left
the precautions in the beginning of this sec-
• •
supplies fuel to the
•
Fuel system ground strap
•
Fuel feed pipe to the outlet side of
fuel pipe is installed.
the fuel filter/pressure regulator
Fuel System Pressure •
Fuel filter/pressure regulator and
bracket to the mounting stud and
RELIEVING
torque the nut to 40 inch
lbs. (4.5
Nm) 1
.
Before servicing the vehicle, refer to
•
the precautions in the beginning of this section.
Fuel return and feed quick connect fittings
•
Muffler and torque the hanger nuts
2.
Disconnect the negative battery cable.
to
3.
Loosen the
mediate pipe bolts
the tank pressure.
fuel filler
cap
to relieve
12
Nm)
ft.
lbs.
(16
Nm) and to
37
the inter-
ft.
lbs.
(50
These models have 2
fuel tanks
by a fuel sender feed pipe
connected
Y-BODY— GENERAL MOTORS CORPORATION CORVETTE •
arm
Float
retaining clip
arm
float
(left
7 If
OU
and the
side sender only)
Fuel sender and gasket
•
To install:
••Always
new
install a
fuel strainer
before installing the fuel sender
assembly. A strainer that has been
exposed to fuel will not unfold comand may interfere with the full
pletely
arm.
travel of the float 9. 8.
a
Install
new gasket on
the fuel
sender.
Do not damage the
float
arm during
installation.
Fold the long strainer over hold the strainer
itself
and
position.
in this
Pinch both strainers upward toward
10.
each other. 1 1
Install
.
the float
arm through
the fuel
tank opening with the folded strainers. ••It
may be necessary
sender
Look
12.
make If
it
is
to rotate the
proper installation.
for
into the fuel tank
opening and
certain that the long strainer
visible.
is
not visible, rotate the fuel sender until
the strainer
is
free
Align the fuel sender gasket tab
13.
with the fuel sender cover
mark and
mark with the
align the cover
fuel tank
mark.
new break away head
Install the
14.
attaching bolts to the fuel sender and
hand
tighten them.
**
CAUTION
The upper hex head portion of the fuel sender attaching bolts is designed to shear off the lower sec-
when
tion of the bolt
torque
is
bolts after the
off of
Fold the strainer on
head
Tighten the
15.
bolts in
the proper
reached. Do not tighten the
sequence
sheared
is
new break away until the
attaching
hex head shears
Install or
•
Fuel sender electrical connector
•
Fuel tank strap and torque the bolts
18
ft.
lbs.
•
ft.
It
will
lit
Into the
opening
Fill
the fuel tank
and
install the fuel
cap.
lbs.
(25
ON for 2 seconds, then ON again and
Turn the ignition
the tuel tank
tor
10 seconds,
Relieve the fuel system pressure
3.
Remove
Fuel Injector 4.
REMOVAL & INSTALLATION
•
Both
•
Fuel feed hose from the fuel
•
Fuel injector electrical connectors
•
Fuel
rail
•
Fuel
rail
1
fuel rail
Spread the
injector
5
Both rear wheels
or disconnect the follow-
ing:
Nm)
from the
precautions
Tire,
in
Wheel and Ball Joint
the beginning of this section.
specifications, see Section
1
covers rail
mounting bolts
injector clip to release the fuel rail.
Fuel injector by spreading the retain-
Before servicing the vehicle, refer to the ing clip.
Negative battery cable
For
in
2.
Nm)
Fuel tank shield and torque the bolts to 18
•
(25
3 times so
inspect the system for leaks
Fuel feed and return pipes
to
7.
OFF
connect the following:
•
•
1
filler
18.
the lower section.
16.
itselt
off.
of this
manual
Oft 1 Q GENERAL MOTORS CORPORATION «jU" BO corvette
**The
Fuel injector into the fuel
•
To install: fuel injector is
stamped with
—Y-BODY •
rail
number identification, manufacturweek code and plant number. Make certain the correct injector is ordered when replacing them.
CAUTION
ing date,
The
•
must be onto the engine. The
fuel rail stop bracket
clean 7.
new
injector seals with
oil.
installed
• •
New New
connect the following:
and personal
fire
on the
the bracket
is
not installed,
fuel could spray possibly
0-ring seals on the injectors retainer clip
If
(10
Nm)
89 inch
fuel
lbs.
connectors to the injec-
•
Fuel feed hose to the fuel
•
Negative battery cable
•
Left
and
right fuel
rail
covers
rail
ON for 2 seconds, then ON again and
Turn the ignition
causing a
OFF
injury.
attaching bolts to
tors
fuel rail in the event of a frontal
crash.
Install or
to the
and torque the
rail
Electrical
8.
bracket serves as protection for the Lubricate the
and ground strap
rail
intake manifold
a
part
6.
Fuel
socket
for
10 seconds,
inspect the system for leaks.
injector
DRIVE TRAIN 5.
Right side muffler and
•
Transmission Assembly
tie
the
Driveline tunnel closeout panel
•
Rear
bell
Automatic
plug
housing access plug and
matchmark the
flexplate to the
torque converter •
Flexplate-to-torque converter bolts
•
2 plug bolts from the front of the
•
Propeller shaft hub clamp bolt
•
Shift cable bracket nuts
•
Shift control cable
driveline support
tion. Install
Disconnect the negative battery
2.
bolts to Shift the transmission into N.
Remove
4.
or disconnect the following:
•
Rear wheels
•
Intermediate exhaust pipe
M10
x 1.5 x
55mm
26
ft.
must remain
remove them
lbs.
the lower control or
Outer
•
Shock absorber lower mounting
tie
bolts
Lower
•
order to maintain the posi-
tion of the input shaft bearing.
arms
rod ends from the knuckle
•
(35 Nm). These bolts
installed until instructed to in
shift
Rear transverse spring and support
•
assembly
longer bolts into the bolt holes. Torque the
cable. 3.
two
from the
lever
Before servicing the vehicle, refer to
1.
the precautions in the beginning of this sec-
or disconnect the following:
Engine flywheel housing access
•
•
REMOVAL & INSTALLATION
Remove
6.
left
side muffler to the underbody
Install
7.
ball joints
from the knuckles
a transmission support fixture
to the transmission.
Wiring harness and brake pipe
•
retainers from the rear
clip
crossmem-
ber •
Lower transmission-to-differential
•
Transaxle mount-to-rear cross-
nut
member
nut
Rear crossmember retaining nuts
•
while supporting the crossmember •
Crossmember
•
Transaxle mount bracket
Separate the axle shafts from the
8.
ferential
and
tie
them
to the
dif-
underbody.
Release the retainer securing the
9.
wiring harness from the “L” shaped brack-
along the driveline support and move
ets
the harness out of the way.
Lower the driveline
10. it
to
slightly
and
tilt
gain access to the electrical connec-
tors. 1 1
Remove
.
•
trical
•
or disconnect the following:
Vehicle Speed Sensor (VSS) elec-
connector
Wire harness retainer from the ferential rear
•
dif-
cover stud
Wire harness retainer
clip
from the
top of the differential •
Transmission harness 20 way connector
•
Park Neutral Position (PNP) switch electrical
Remove
the inspection plug, then
remove the flexplate-to-torque converter
bolts
connectors
OH_1 Q 13 OU
Y-BODY— GENERAL MOTORS CORPORATION CORVETTE •
Bolt securing the wire harness to
the
side of the case
left
Lower the
12.
and angle
driveline
it
while observing the top rear of the differential
and the lowest
ment
compart-
part of the rear
The engine Positive
floor panel.
Crankcase Ventilation (PCV) pipes
not to 13.
will
most
dash panel. Make certain
likely contact the
damage the dash. Remove or disconnect
the following:
•
Wire harness from the retainer
•
Transmission rear
along the top of transmission oil
from the junction
cooler pipes
fittings at the fly-
wheel housing •
5 driveline
to flywheel
housing
bolts after supporting the rear of
the engine
Bend
14.
away from
the wiring harness bracket
the driveline, toward the tunnel
wall to have access to
remove the
driveline.
Separate the driveline from the
15.
engine by prying them apart with a
flat
blade tool
Lower the driveline and
16.
from the engine
tilt it
away
until the input shaft clears
the flywheel housing TO22M3
Remove
the plugs and install two
MIO
x
1.5 x
55mm
Remove
17 •
or longer bolts into the bolt holes to
•
secure the bearing— 5. 7L engine
or disconnect the following:
Driveline
Transmission
from the
oil
cooler rear pipes
fittings
•
Transmission to driveline bolts
•
Separate the transmission from the driveline with a
Using a
18
blade tool
flat
device, place the
lifting
assembly on a bench. •
Rear transmission
oil
cooler fittings
from the transmission •
Transmission-to-driveline assembly
support bolts •
Driveline from the transmission
while supporting the torque converter
To
•
Differential-to-transmission bolts
•
Differential
from the transmission
install:
19
Install or
•
connect the following:
Differential to the
transmission and
torque the bolts to 37
lbs (50
ft
Nm) •
•
Transmission to the driveline support
and torque the bolts
lbs.
(50
Rear transmission
oil
to the transmission fittings to
20.
30
Using a chain
to
gain access to the clamp bolt, then loosen it— 5.7L engine
For Wheel Alignment specifications, see Section
21
1
of this
.
37
ft.
ft
cooler fittings
and torque the
lbs (40
Nm)
hoist, place the
assembly on a transmission Rotate the flywheel
to
Nm)
jack.
Carefully raise the assembly into the
manual
.
GENERAL MOTORS CORPORATION— Y-BODY
30-20
CORVETTE Remove
2.
or disconnect the following:
•
Negative battery cable
•
Both rear wheels
•
Folding top stowage compartment lid
extension panel (on convertible
models)
7922Z645
Transmission-to-differential mounting bolt locations
— 5.7L engine
•
Traction control/ride control switch
•
Console retaining nut covers
•
Console retaining nuts
•
Accessory plug
•
Fuel door release electrical connector
•
Console
•
Shift control
knob button
•
Shift control
knob
•
Shift control
knob
•
and torque the nuts
vehicle while placing the wiring harness
46
the bolts to
Nm)
(62
lbs.
ft.
Wiring harness into the “L" shaped
•
Shift control boot
by grabbing both
sides and pulling
it
assembly
Transmission cable and bracket and
•
connect the following:
Driveline
torque the nuts to 15
the vehicle.
in
toward the
Ashtray
•
Trim plate
•
Retaining screws located behind the
Install or
in
•
brackets
are the same.
•
lbs.
Rear transverse spring and torque
•
driveline will slide into
the rear of the engine as long as the angles
23.
ft.
retainer
lever
22. Align the assembly for installation
The
15
connector
plus an additional 160 degrees
loosely into the harness retaining slots.
into the engine.
to
electrical
ft.
lbs.
•
grill
and behind the ashtray
grill
Instrument panel accessory trim
(20 plate
Nm)
Reposition the wiring harness
•
made during removal and torque the bolts to 47 ft. lbs. (63 Nm)
them
Oil
37
to
ft.
Nm)
•
cooler lines and torque the
tings to
20
ft.
lbs.
Wiring harness to the
left
22 inch
Shift rod
•
Shift control
mounting bolts
•
Shift control
assembly
•
Courtesy lamp
it
side of
•
Remove
25.
the two
M10
x
55mm
Install or
•
•
PNP
switch electrical connector
Left side lower
Transmission harness 20 way con-
port
nector
to
Clutch master cylinder pushrod
connect the following:
Wiring harness
•
clip to the top of
the differential •
VSS
electrical
height. •
Axle shafts
•
Transmission mount
to the cross-
Suspension crossmember and ft.
lbs.
(110
Lower transmission-to-differential it
to
37
ft.
lbs.
(50
Nm)
Lower
clip
crossmember
lbs.
ft.
(50
•
Nm)
Both rear wheels
•
•
Driveline closeout panel
•
Rear transverse spring
•
Outer
•
Lower shock absorber
•
Lower
Negative battery cable Start the vehicle
and allow
it
to reach
engine OFF. Allow the engine to cool
to
ambient temperature, then tighten the
fly-
wheel hub collar bolt 28.
Intermediate exhaust pipe and
secure the mufflers out of the way
Install the bell
to
96
ft.
lbs.
rod ends bolts
ball joints
Support the transmission •
(130 Nm).
housing inspection
tie
Wiring harness and brake lines
from the suspension crossmember •
Lower transmission-to-differential
lbs.
suspension
(70
(220
Outer
Flush the automatic transmission
•
Transmission mount-to-crossmem-
•
Rear suspension crossmember nuts
•
Transmission mount and bracket
oil
cooler.
tie
A front end alignment is recommended when the crossmember is removed. 30.
Nm)
Shock absorber lower mounting bolts and torque them to 162 ft. lbs.
29.
ber nuts ball joints to the
knuckles and torque the nuts to 52
•
Intermediate pipe and torque the
hose
Rear wheels
nut
Wiring harness and brake pipe
ft.
•
•
Right hand muffler assembly
Clutch actuator hose from the master cylinder
plug.
retainers to the •
•
3.
nut and torque
•
and (10
lbs.
normal operating temperature. Turn the
Nm) •
Driveline tunnel closeout panel
37
Clutch actuator cylinder hose from the retainer clip
•
27.
torque the nuts to 81
•
Nm)
•
•
the nuts to 37
ft.
•
(50
torque the bolts to 89 inch
bolts to
member and torque lbs. (50 Nm)
lbs.
Nm)
connector
Raise the transmission to installation
24.
ft.
and the pushrod from the
pedal
assembly and torque the bolts
37
closeout panel while
the hole •
2 plug bolts to the driveline sup-
•
bolt
bolts
from the input shaft front bearing. 26.
clamp
guiding the courtesy lamp through
retainer •
and boot
is
finger tight
Nm)
lbs. (2.5
housing access plug
bell
Propeller shaft hub bolt until
•
fit-
the transmission and torque the bolt to
Rear
Nm)
(27
•
ing nuts
Driveline support-to-flywheel hous-
(50
Shift control closeout boot retain-
torque
converter using the matchmarks
lbs.
•
to the
ate hole in the driveline assembly.
ing bolts and torque
•
Transmission flexplate
•
bracket to align with the appropri-
•
Nm) rod ends to the knuckles
from the
Manual 1
tion.
Axle shafts from the differential and
•
Wiring harness from the driveline
position them out of the
Before servicing the vehicle, refer to
the precautions
in
the beginning of this sec-
differential
•
support assembly
way
00-91 Cl OU
Y-BODY— GENERAL MOTORS CORPORATION CORVETTE
Reverse lockout solenoid
•
electrical
connector
Gear select (skip
•
Transmission
•
sensor
shift)
solenoid
connector
electrical
fluid
electrical
temperature
connector
(if
equipped)
Support the rear of the engine
6. •
Driveline support-to-bell housing bolts
Driveline support
•
assembly out
of
moving the
the bell housing while
assembly rearward Carefully lower the assembly
7.
away
from the vehicle while simultaneously adjusting the angle. Attach a chain hoist to the assembly,
8.
then remove
it
from the jack and place
on
it
a workbench.
Remove
9.
•
or disconnect the following:
Driveline support-to-transmission
mounting
bolts. Carefully pry the
assembly away from the
driveline
transmission while guiding the
shift
rod through the opening in the driveline support
Transmission
• Insert a flat bladed tool
transmission assembly
between the
shifter bracket
and brake
liner retainer before lowering the
shift
rod from the
transmission
—5.7L engine
•
mount-
Transmission-to-differential
ing bolts and separate the differential
from the transmission
To install: 10.
Install or
•
connect the following:
Differential to the
5.
transmission and
torque the bolts to 37
ft.
lbs.
(50
Nm) •
Transmission
•
Driveline support to the transmis-
shift
rod
sion and torque the bolts to 37 lbs (50
To aid
11
m
ft
Nm) later installation
rubber band around the
shift
place a
rod then tape
the shift rod to the driveline support
assem-
bly.
Place the assembly on the transmis-
12.
sion jack with a chain hoist
Begin to raise the assembly into the
13
vehicle while loosely installing the wiring
mounting— 5. 7L engine
Driveline support-to-transmission
harness along the driveline assembly retaining slots.
•
Harness
clip
from the top
Lower the transmission enough
4
of the
remove the wiring harness from the top
differential
Do not lower the top rear portion
of
storage compartment or the will hit the
ing
PCV
damage.
or disconnect the follow-
the
same angle as
to install
ing:
•
Vehicle Speed Sensor (VSS) electrical
pipe
dash panel possibly caus-
Be sure the driveline assembly
15
Remove
•
16.
connect the following:
Input propeller shaft into the clutch
disc
electrical con•
nector
For Maintenance Interval recommendations, see Section
is at
the engine before trying
it.
Install or
•
connector
Backup lamp switch
front of
the driveline support to the bell housing.
of
the assembly.
the differential past the bottom of the
Have an assistant guide the
14
to
1
Wiring harness bracket
of this manual
to align
GENERAL MOTORS CORPORATION— Y-BODY
30-22
CORVETTE
7922Z649
Pull the shift rod up to break the tape
and
hook the rubber band on the rear stud— 5.7L engine
Clutch master cylinder pushrod
•
retainer •
Left
•
Courtesy lamp
17.
Pull
lower closeout panel
up the
rod to break the tape
shift
and hook the rubber band on the on the top •
Shift control
the bolts to
the nuts to
— 5.7L
engine
with the appropriate hole
•
lbs.
(50
and torque them
to
37
tt.
•
fluid
electrical
•
temperature
connector
•
solenoid elec-
connector
trical
•
shift
Reverse lockout solenoid electrical
•
Backup lamp switch
•
Wiring harness to the top of the
electrical
•
•
•
VSS
•
Axle shafts
•
Transmission mount on the
electrical
lbs.
•
in
connector the differential
and torque the bolts
(50
•
differ-
to
37
ft.
Nm)
•
Rear suspension. crossmember and torque the nuts to 81
ft.
lbs.
•
(70
and torque them
Nm)
Outer
tie
to
162
ft.
rod ends and torque the
Nm)
nuts to 15
ft.
additional
160 degrees
lbs.
(20
106 inch
Shift control boot Shift control
knob
•
Shift control
knob
•
Console Fuel door release electrical connector
•
Accessory plug
•
Console retaining nuts and torque to
89 inch
Nm)
•
Traction control/ride control switch
•
Folding top stowage compartment
•
Rear wheels
•
Negative battery cable
18.
lid
Bleed the clutch system.
Clutch
Transverse spring and torque the to
46
ft.
lbs.
(62
ADJUSTMENT
Clutch actuator hose to the master 1
.
Before servicing the vehicle, refer to
Clutch actuator hose to the retain-
the precautions in the beginning of this sec-
ing clip
tion.
Driveline tunnel closeout panel
and
2.
Remove
torque the bolts to 89 inch
(10
3.
FHave an assistant depress the clutch
lbs.
the flywheel inspection cover.
Nm)
pedal until the tension
Muffler assemblies
stepped adjusting
Intermediate exhaust pipe and ft.
lbs.
(50
4.
is
released from the
ring.
Using 2 screwdrivers,
rotate the
stepped adjusting ring counterclockwise until fully
adjusted out.
Continue
Clutch master cylinder pushrod to
tion
the clutch pedal
clutch pedal.
Nm)
(10
connector
Console retaining nut covers
•
(50
lbs.
electrical
•
ber nuts and torque lbs.
and button
•
Rear wheels
ft.
retainer
plus an
Nm) 37
Nm)
•
•
to
Nm)
•
Transmission mount-to-crossmem-
them
(12
lbs.
(30
boot and torque
extension panel
Nm)
(220
torque the bolts to 37
(110
Nm) •
and torque the
lbs.
lbs.
Instrument panel accessory trim plate
them
cylinder hose
dif-
ferential
ential
ball joints ft.
line
Nm)
con-
nector
(50
lbs.
ft.
crossmember
mounting bolts
connector •
37
Shock absorber lower mounting
lbs.
•
Gear select/skip
Lower
bolts
(if
equipped)
to
Wiring harness and brake
nuts to 52
and
attach the connectors
sensor
•
retainers to the
Wiring harness to the retainer on
it
Nm)
Nm)
Transmission
Lower transmission-to-differential nut and torque
the top of the transmission
•
•
Driveline support-to-flywheel housing bolts
•
the dri-
in
assembly
veline
ft.
• 7922Z648
Place a rubber band on the shift rod, then tape the rod to the driveline support assembly
assembly and torque
22
Shift control closeout
•
rear stud
of the driveline tunnel.
5.
to
hold them
in this
posi-
and have the assistant release the
tO OU 9Q
Y-BODY— GENERAL MOTORS CORPORATION Ofl CORVETTE
Hydraulic Clutch System BLEEDING
1
Before servicing the vehicle, refer to
.
the precautions in the beginning of this section. 2.
Fill
the clutch master cylinder with
clean clutch hydraulic fluid.
Raise and safely support the vehicle
3.
with an assistant in
it.
Remove
the intermediate exhaust
5.
Remove
the driveline tunnel cover.
6.
Have the assistant depress and hold
4 pipe.
the clutch pedal down.
Loosen the bleeder screw on the
7.
actuator cylinder to release the
air,
then
tighten the screw
Do not allow the clutch pedal to be until the bleeder screw is closed or air will be drawn into the released
system. Repeat the prior two steps
8.
air
Rotate the stepped adjusting ring counterclockwise
to
the master cylinder fluid level and
compress the springs
until the
has been purged from the system. Check refill
as
needed 6. 7.
Remove Install
the screwdrivers.
•
the inspection cover. Torque
the bolts to 18
ft.
lbs.
(25 Nm).
Install
the driveline tunnel cover.
10
Install
the intermediate exhaust pipe.
11
Lower the
9.
Negative battery cable
•
Exhaust system
•
Driveline support and transmission
vehicle.
as an assembly
REMOVAL & INSTALLATION 1
.
•
Flywheel inspection cover
•
Pressure plate bolts.
Before servicing the vehicle, refer to
access
tion.
•
Remove
or disconnect the follow-
ing:
Halfshaft be nec-
REMOVAL & INSTALLATION
essary to rotate the flywheel to
the precautions in the beginning of this sec-
2.
It
will
To 3.
all
the bolts
Pressure plate and disc
Install or
• i
•
the precautions in the beginning of this sec-
connect the following
tion.
Clutch disc and pressure plate on
2
the flywheel
3.
Apply the parking brake.
Remove
Clutch disc alignment tool through the disc to keep
•
Before servicing the vehicle, refer to
1
install:
in
place
•
Axle nut Rear transverse spring
Turn the flywheel to access
•
Outer
•
Antilock Brake System (ABS)
Torque the bolts
it
all
the
in the
to
52
sequence
ft
lbs.
(70
Inspection cover and torque the
•
ft.
lbs.
(25
~Be
Driveline support and transmission
it
is
Park brake cable Irom the lever and
sure
to
support the halfshaft until
removed. Do not
let
it
hang by the
CV-joint.
•
Exhaust system
•
Negative battery cable
4
Bleed the clutch system.
and
For Tune-up, Capacities and Firing orders, see Section
Wheel
electrical
bracket
Nm)
assembly
5.
rod end from the knuckle
connector •
bolts to 18
tie
Speed Sensor (WSS)
Nm). •
or disconnect the following
•
shown, using 3 steps
Clutch assembly torque sequence
Wheel
Pressure plate bolts finger-tight
bolt holes 4.
•
1
Attach a puller on the wheel studs start to
of this
push the axle
manual
shaft into the
hub
GENERAL MOTORS CORPORATION— Y-BODY
30-24
CORVETTE Rear transverse spring and torque
•
the bolts to •
46
ft.
(62
lbs.
Halfshaft retaining nut
the nut to
118
ft.
lbs.
Nm)
and torque
(160
Nm)
Wheel
.
CV-Joints
OVERHAUL
Inner Joint 1
.
Before servicing the vehicle, refer to
the precautions
in
the beginning of this sec-
tion. 2. 3.
Remove axle Wrap a shop
shaft.
towel around the axle
shaft. 4.
Place the wheel drive shaft horizon-
tally in a 5.
bench
vise.
Remove
the large seal retaining
clamp from the C V joint 6. Use a side cutter tool
seal.
or other suitable
and discard the clamp. 7.
Remove
the small seal retaining
clamp from the 8.
joint seal.
Use a side
cutter or other suitable
7922Z653
tool Insert a large drift through the cooling fins to
ing the retaining
assembly. This ball joint to
keep the hub assembly from turning while remov-
nut— 5.7L engine
and discard the clamp. 9.
Separate the seal from the joint outer
race at the large diameter end.
provide clearance for the
will
be separated from the knuckle
assembly. 5.
Remove
or disconnect the following:
from the knuckle
•
Ball joint
•
Axle shaft from the hub
•
Halfshaft
assembly from the
differ-
by inserting a suitable tool
ential
between the CV-joint and differential
and prying them apart
To install: 6.
Install or •
shaft.
on the
Use
differential
light force to
output
be sure
it
is
ym
seated
fully
•
connect the following:
Halfshaft
Halfshaft through the
hub assembly
V
but do not install completely. This will
provide clearance for installing
53]'Oj w
the ball joint •
•
Ball joint to the
knuckle and torque
the nut to 41
lbs.
ft.
(55
Halfshaft through the
Nm)
ZjjSSS
hub assembly
II
completely •
Park brake cable
to the bracket
\Y/*y \JL-frA
and
!
the lever •
WSS
•
Tie rod
electrical
end
connector
to the
knuckle and
torque the nut to 15
Nm)
ft.
lbs.
(20
plus an additional 160
degrees
7922Z654
Exploded view
of the halfshaft
mounting— 5. 7L engine
Y-BODY
— GENERAL MOTORS CORPORATION OU CORVETTE
LJ
To install:
•Protect the wheel drive shaft boots, seals and clamps from sharp objects
when
servicing on or near the wheel
Damage
drive shaft(s).
to the boot(s),
the seal(s) or the clamp(s)
Remove
to
shaft-inner joint
Position the seal behind the joint
face.
wheel drive
1 1
at the large
joint outer race
diameter end-inner
joint
Position the wheel drive shaft verti-
.
cally in the
bench vise so the inner
Slide the joint outer race
12.
toward the
joint is up.
down
vise.
driver
bladed screw-
between the retaining ring and the
outer race.
away from
may fall race when
balls
and inner removed.
the outer race
Lift
the outer race
Engage the inner race splines onto
is
seal to catch
b
any balls
c
the outer race oft the axle shaft
and inner
balls
from the axle
by the seal
e
vise.
you
the outer race retaining ring
Align the cage lands with the inner
race ball tracks.
21
.
Reposition the cage along the axle
Wipe
23.
Remove
the grease from the inner race.
25.
26.
Remove Remove Remove
Reposition the
Work evenly around
the cage from the axle shaft
using a three jaw puller-inner joint
Clean
al
the wheel drive shaft from
Inspect to be sure that the axle shaft is
exposed
Install
37.
Position the cage so the cage lands
the snap ring to the axle shaft
38
Install the
39
Position the cage
parts thoroughly with clean
Thoroughly
Insert
41
dry
all
windows
race.
to align
approximately 60 percent of kit
into the outer
Position the wheel drive shaft verti-
bench vise so the inner
cally in the
joint
end
up.
42
Apply a small amount
from the service
43 service
air
cage onto the inner
race.
is
solvent.
28.
the inner race
to drive the inner race, until
36
40
the seal from the axle shaft.
•All traces of old grease and any contaminates must be removed. 27.
block along
the inner race seat fully onto the
leel
and inner race the inner race from the axle shaft
wood
the grease from the service
the bench vise.
Remove
to begin to drive the
with the inner race ball tracks
the inner race from the axle
shaft using a three jaw puller
24.
hammer
align with the inner race ball tracks
away from the inner race
22.
a
snap ring groove
shaft.
shaft
block squarely
axle shaft
35
the snap ring from the axle
shaft-inner joint
20.
Use
and continue
shaft.
Remove
wood
axle shaft
balls caught
bench
Remove
first.
Position a
the face of the inner race to avoid the
race.
Position the wheel drive shaft hori-
zontally in the
d
from
17.
19.
to install
inner race onto the axle shaft.
Remove any
the snap ring from the axle
Be sure
the axle shaft splines
16.
18.
onto the axle
over the end of the inner race
Remove any remaining
the cage
the end of the axle
Install the inner race
a.
out of the cage
the outer race from the axle
Use the
b.
9346ZGB6
inner race spline relief must
34.
which are not retained by grease
15.
end faces the vise
shaft as follows:
shaft as follows: a.
cage onto the axle shaft so
away from
axle shaft
shaft-inner joint
shaft.
the inner race spline relief side onto the
Remove
14.
Remove
Install the
•The
934GZGB4
934SZG85
33.
the smaller diameter
Position the retaining ring along
the axle shaft
•The
Install
shaft.
outer race. c.
seal retaining
the seal onto the axle shaft.
32.
face
Pry the retaining ring from the
b.
new small
Install a
clamp onto the wheel drive
Insert a small flat
a.
a bench vise.
31.
ring as follows:
the outer race from the axle
shop towel around the axle
a
Place the wheel drive shaft horizon-
30. tally in
Disengage the outer race retaining
13.
Remove
Wrap
29.
shaft.
shaft.
9346ZG03
Separate the seal from the
and lead
increased noise and possible failure
of the
10.
may cause
lubricant to leak from the joint
the cage from the axle
to the
remaining grease from the
into the seal.
the parts.
For complete service labor times, order the Chilton Labor Guide
of the grease
cage windows
ball tracks.
Insert the kit
kit
GENERAL MOTORS CORPORATION— Y-BODY
30-26
CORVETTE Slide the outer race
c.
down over
the
balls.
Position the wheel drive shaft hori-
49.
zontally
in
bench
the
vise.
Engage the outer
race retaining ring as follows:
Slide the outer race toward the
a.
vise.
Insert the outer race retaining ring
b.
groove along the outer edge of
into the
the outer race.
Position the outer race retaining
c. 9346ZGB8
so the opening
ring
Use a hammer and
a block of
wood
in
the ring aligns
to
with an outer race land (not a ball track). drive the inner race onto the axle
Position the large diameter end of
50. shaft-inner joint
the seal onto the outer race.
clamp onto the neck
of the
omega shape has
a
(2-3mm), with
a difference in the gap
width from side to side no greater than
Measure the distance between the and the edge
of the seal
base
gap width between 0.079-0.118 inch
to the axle shaft.
53.
axle shaft groove closing to
until the
of the seal.
Position the seal and small retaining
52.
clamp edge
Tighten the small seal retaining clamp
Position the small seal retaining
51.
0.016 inch (0.4mm)-inner
joint
of the last
edge and adjust
fit
0.10 inch (2.5mm).
»The
seal retaining clamp must not be
over-tightened or under-tightened.
Crimp
54.
6D percent
Insert approximately
grease from the service
kit into
the small seal retaining
clamp
using tool J 42572. Tighten the small seal
of the
clamp
retaining
the outer
shape has
race-inner joint
inch
a
until the
base
of the
omega
gap width between 0.079-0.118
(2-3mm), with
a difference
in
the gap
width from side to side no greater than
Measure the distance between the end
0.016 inch (0.4mm). The clamping hold time
and adjust the plunging motion
must be no
to
less than 2 seconds.
Measure the distance between the
55.
end
of the seal
and the end
of
the seal and the end of the joint outer race
8.90 inch within 0.16 inch
within
4mm-inner
of the joint
(226mm
joint
of the joint outer
race and adjust the plunging motion of the
8.90 inch within 0.16 inch
joint to
within 56.
Position the large seal retaining
clamp onto the 57.
clamp Measure the distance between the edge the seal and the
edge
of the last axle shaft
groove closing edge and adjust
(2.5mm)-mner
inch
of
fit
to
0.10
joint
Install
the outer race retaining ring
seal.
Position the seal and large retaining to the joint outer race.
Measure the
distance between the edge of the seal and the
edge
of the joint outer race last
closing edge and adjust
fit
to
groove
0.03 inch
seal must not be dimpled,
Measure the distance between the edge
stretched or out of shape in any way.
45.
Position the retaining ring below the
46.
Install
windows
the balls through the cage
to the inner race ball tracks.
Use the
47.
position 48.
if
seal to keep the balls in
necessary.
Install the
outer race onto the axle
shaft as follows: a.
in
Be
careful not to allow the grease
58.
Inspect the seal for proper shape.
the seal
is
NOT shaped
the pressure in the seal
If
If
correctly, equalize
dam-
the seal has been cut or punctured
Align the outer race ball tracks to
the balls.
to
0.03 inch (0.8mm)-inner joint
retaining
clamp
until the
base
of the
0.079-0.118 inch (2-3mm), with
replace the seal.
ence
’•The seal retaining clamp must not be over-tightened or under-tightened.
omega
shape has a gap width between
during assembly, you must discard and
the outer race to leak out. b.
race last groove closing edge and adjust fit
and shape the seal
properly by hand. Inspect the seal for age.
of
the seal and the edge of the joint outer
onto the axle shaft.
cage, toward the vise.
60.
(0.8mm).
•The 44.
(226mm
4mm).
in
the
gap width from side
a differ-
to side
greater than 0.016 inch (0.4mm).
no
The
clamping hold time must be no less than 2 seconds.
59.
Crimp the
large seal retaining
clamp
using tool J 42572. Tighten the small seal
Remove the bench vise.
the wheel drive shaft from
Y-BODY— GENERAL MOTORS CORPORATION CORVETTE Distribute the grease within the inner
61.
CV
Plunge the
62.
joint
Inspect the inner
63.
CV
joint
Hold the wheel drive shaft
a.
cally, b.
follows:
Large ring clamp on the
•
Outer joint onto the axle shaft
in a circular
Compress
Disassemble the chrome alloy balls
boot
the retaining ring using a
from the CV-joint cage as follows:
verti-
Position a brass
a.
to
Install
CV
•
CVboot
Rotate the wheel drive shaft four or
times
retaining ring on the half-
•
CV-joint cage and tap
five
New shaft
Axle shaft retaining ring
with the outer joint at the bottom.
64.
block
•
and wheel
smooth operation as
hammer and wood
using a
10.
back and forth four
or five times.
drive shaft for
•
Outer joint from the axle shaft
• 3.
joint.
00-97 CI OU
the cage.
b.
Remove
motion.
tilt
drift it
against the
with a
chrome
the 1st
hammer alloy ball
from the cage.
the axle shaft.
the cage
Tilt
c.
Outer Joint
the opposite direc-
in
tion. d.
Remove
the opposite
chrome
alloy
Repeat the procedure
until all
6
Before servicing the vehicle, refer to
1.
ball.
the precautions in the beginning of this sece.
tion.
Remove
2.
balls are
or disconnect the follow-
removed.
Disassemble the CV-joint cage and
4
3M6ZGC7
ing: •
Axle shaft from the vehicle
•
Large
•
Small
•
CV
CV CV
inner race as follows: Install the axle shaft retaining a.
boot retaining clamp
Pivot the cage and race 90
ring-outer
joint
degrees to the center
boot retaining clamp
line of the outer
race.
boot from the joint
b.
Align the cage
windows with outer
4
3
race lands.
Remove
c.
the cage from the outer
race. d.
Rotate the inner race upward and
remove
from the cage.
it
To install: Lubricate the parts with a light coat
5.
of grease.
Assemble the CV-joint cage and
6.
2
inner race, as follows:
90 degrees
Rotate the inner race
a.
to
b.
KMWGC5
Separate the outer shaft using a
joint
Align the cage
windows with
inner
Insert the inner race into the
c.
the distance
between the edge
groove closing edge and adjust inch
race lands.
from the axle
Measure
tit
to 0
10
(2.5mm)
cage
by rotating the inner race downward.
hammer and wood
d.
block-outer joint
Insert the cage/inner race into the
outer race.
Assemble
7.
the
chrome
alloy balls into
the CV-joint cage, as follows
Position a brass
a.
CV-joint cage and tap to
tilt
b.
drift it
against the
with a
hammer
the cage. Insert the 1st
chrome
alloy ball into
the cage.
the cage in the opposite direc-
Tilt
c.
tion. d.
Insert the opposite
chrome
alloy
ball. e.
Repeat the procedure
until all
6
balls are inserted. Install
8.
V20
f
the CV-joint.
cage and tap cage-outer
it
drift
with a
against the CV-joint
hammer
to
tilt
joint
Please
visit
•
Small
•
CV
base
ol the
connect the following:
CV
boot retaining ring
site at
a difference in the
gap
width Irom side to side no greater than 0 016 inch
boot on the halfshaft
our web
omega shape has
gap width between 0.07!M).118 inch
(2-3mm), with
Install or
9.
the
Tighten the small seal retaining clamp until the
the grease provided, into
9346ZGC6
Position a brass
of
the seal and the edge ol the last axle shaft
the cage centerline.
www.chiltonsonline.com
(0.4mmH>uter
joint
a
9Q
0U ӣ O
GENERAL MOTORS CORPORATION— Y-BODY CORVETTE 3
Measure the distance between the edge the seal
and the edge
groove closing edge and adjust inch
small
(8mm)— outer flat
of
of the last axle shaft fit
to
0.3
joint
bladed tool while pushing the
outer joint onto the axle shaft. 11.
Seat the outer joint on the shaft
hammer and
using a
Install the
12.
CV
block of wood.
remaining grease into the
boot.
13.
Position the
CV
boot and the small
boot clamp. 9346ZGD2
14. 15.
Crimp the small boot clamp. Position and crimp
in
place the large
of the
between 0.079-0.118 inch (2-3mm), with a difference
boot clamp. 16.
Tighten the small seal retaining clamp until the base
omega shape has
gap width
a
the gap width from side to side no
in
greater than 0.016 inch (0.4mm)-outer joint
Install the Halfshaft in the vehicle.
STEERING AND SUSPENSION Air
3.
Bag
Place the inflator module on a bench
or other surface with the
**
1.
vehicles are equipped with an air
bag system. The system must be disabled before performing service on or around system components, steering column, instrument panel components, wiring and sensors. Failure to follow safety and disabling procedures could result in accidental air bag deployment, possible personal injury and unnecessary system
inflator
module which may be thrown
the
in
the
then
.
Before servicing the vehicle, refer to
the precautions
side lower trim panel,
SIR fuse
to the fuse block.
Turn the ignition switch
to the
RUN
in
the beginning of this sec-
7-9
Verify the SIR indicator light flashes
times, then turns OFF.
system
If
not, inspect
for malfunction.
tion. 2.
3.
Turn the steering wheel to align the in
the straight-ahead position.
Turn the ignition switch
to the
4.
Remove
the AIR
BAG
Power Rack and Pinion Steering Gear
LOCK
position.
PRECAUTIONS
of the steer-
position. 5.
1
Install the left install the
4.
DISARMING
base
at the
column.
ing
3.
event of an accidental deployment.
LOCK
Engage the yellow 2-way connector
and the CPA device
module on the
bench, never place anything on or close to
wheels
repairs.
2.
With the
Turn the ignition switch to the
position.
facing up.
CAUTION
4.
All
bag and trim cover
REMOVAL & INSTALLATION fuse from the
fuse block.
Several precautions must be observed
when handling
the inflator
module
to
5.
avoid
accidental deployment and possible per-
.
the
left
side lower trim panel,
then unplug the Connector Position Assur-
ance (CPA) device and the yellow 2-way
sonal injury. 1
Remove
SIR harness wire connector
Never carry the
inflator
module by
the
at the
base
of
the steering column.
wires or connector on the underside of the
module. 2.
ARMING
When
.
Before servicing the vehicle, refer to
tion. 2.
Drain the powensteering
3.
Remove
bag and trim cover are pointed away.
Negative battery cable
•
Brake Pressure Modulator Valve
(BPMV) After the
necessary repairs have been
made, re-enable the
air
bag system as follows:
fluid.
or disconnect the following:
•
carrying a live inflator module,
hold securely with both hands, and ensure that the
1
the precautions in the beginning of this sec-
bracket,
if
equipped
•
Both front wheels
•
Intermediate shaft shield
90-90 wU
Y-BODY— GENERAL MOTORS CORPORATION CORVETTE
0
Exploded view
of the front
shock absorber
—5.7L engine
mounting
•
Negative battery cable
•
Wheel
• 79227B56
Exploded view
power steering gear mounting
ol the
Real Time
Damper (RTD)
electrical
connector
—5.7L engine
•
Upper mounting nut
retainer
and
insulator •
•
•
Intermediate shaft lower coupling
coupling to the steering gear and
from the power steering gear
torque the bolt to 25
Power steering
•
Magnasteer
Steering cooler pipe from the steer-
•
Wire harness clips to the cross-
•
Power steering cooler
•
Both outer
tie
rod ends from the
Cooler
•
Cooler pipe
to the
•
Stabilizer shaft
ber
torque the
•
Wire harness clips from the cross-
Nm)
electrical
connector
(27
from the crossmem-
•
20
fitting to
a
gear lbs
ft
to the steering fitting to
20
ft
gear and lbs.
(27
c
Remove the tool from the shock. Remove the shock absorber install: Install or
Power steering gear through the
left
4.
Install or
Nm)
•
Both front wheels
•
Negative battery cable
Refill
•
crossmember to
Check and adjust the
front
end align-
•
Shock Absorber
•
6
(110 Nm)
Brake pipe
•
Stabilizer shaft
to the
tie
ing knuckle ft.
tional
lbs.
Front
crossmember
rod ends to the steer-
and torque the nuts
(25
insulator, retainer
and nut
19
to
ft
lbs.
(26
If
RTD
to
21
ft
electrical
lbs.
(28
Nm)
connector
equipped with heavy duty shocks
(FE3) pertorm the following steps
1
Both outer
upper shock
Lower mounting bolts and torque
them
REMOVAL & INSTALLATION
•
Upper
and torque the nut
Torque the crossmember mounting
18
•
lbs.
(100 Nm)
lbs.
to the
Nm)
and torque the nuts
ft.
Shock absorber tower
connect the following:
Steering gear to the
ft.
•
ment.
74
connect the following:
Retainer and insulator to the shock
absorber
and bleed the power steering
system. 7.
compressed
the shock from the
d.
5
6.
is
vehicle
To
Steering gear mounting bolts and
a shock support tool to the it
Remove
(3.5
wheel opening
•
Install
shock while
torque the clamp to 32 inch lbs
install:
•
b
the shock absorber from
upward
ber
To
nuts 81
Compress
the bottom
Brake pipe from the crossmem-
nuts
•
equipped with heavy duty shocks
4
•
loosen the crossmember mounting
•
hose
Inlet
If
Intermediate shaft shield and
member
•
to the steering
Nm)
Magnasteer
tower 3.
crossmember
and torque the
knuckles
Shock absorber from the upper
(FE3) pertorm the following steps:
•
•
•
connector
member
ing gear
5.
•
steering gear
electrical
Shock absorber lower mounting bolts
Nm)
hose from the
inlet
•
(34
lbs.
ft
Nm)
the precautions in the beginning of this sec-
to
plus and addi-
180 degrees
a
Before servicing the vehicle, refer to
tion. 2.
Remove
or disconnect the follow-
a shock support tool to the
b
Install the
shock
to the vehicle.
c.
Install the
upper
insulator,, retainer
and nut and torque the nut
to
19
ft.
lbs
(26 Nm).
ing:
Intermediate shaft lower steering
Timing belt service
Install
shock absorber
d.
is
covered
in
Section
3
of this
manual
Remove
the support tool from the
^
1
Of! GENERAL MOTORS CORPORATION— Y-BODY
OU"Oll shock and
CORVETTE
install a
spring compressor to
bolt
the spring. 7.
Raise the lower control arm and
install the
bolts
and torque them
to 21
ft.
lbs.
Step
Remove
6:
the spring
(28
Before servicing the vehicle, refer to
8.
Install
the precautions
in
•
Negative battery cable
•
Remove
2.
Rear
Negative battery cable Front wheels
Lower
•
.
Cam
Before servicing the vehicle, refer to
the precautions
arm
the beginning of this sec-
in
tion. 2.
Remove
•
Transverse spring bolts and retain-
Transverse spring and the
Negative battery cable
Wheel Rear position sensor electrical connector,
To if
install: Install or
equipped •
•
Lower mounting
•
Upper mounting bolts
bolt •
Shock absorber from
New
the lower to
arm and shock tower
Upper insulator and
retainer
from
the shock absorber
front spring adjuster bolt
Install or
connect the following:
Upper insulator and
gap
height— front
•
assembly
removed
if
Shock absorber
to the
shock tower
and lower control arm •
Upper mounting bolts and torque
them •
to
22
ft.
lbs.
(30
Nm)
Lower shock absorber mounting bolt
(220
and torque
it
to
162
ft.
lbs.
Nm)
•
Rear position sensor electrical con-
•
Wheel
•
Negative battery cable
nector
Exploded view absorber
of the rear
—5.7L engine
shock Exploded view
46
ft.
lbs.
(62
Nm)
Lower control arm
to the cross-
Cam
bolts to the
matchmarks made
during the removal procedure.
retainer to the
shock absorber,
spring retainers and bolts to
crossmember and torque them
member
ease the installation procedure and set-
ting the proper vehicle trim
To install:
•
Measure the to
•
connect the following:
Spring to the crossmember
the
control
com-
pressor tool
•
•
matchmarking them
Lower control arm
6.
3.
bolts from the lower control after
ers
•
•
from the steering
•
•
•
ball joint
or disconnect the follow-
ing: •
from the lower
knuckle •
1
of the lower control
arm
control
•
one
Stabilizer shaft link
or disconnect the following:
•
it.
arms
tion.
Wheel
and compress
or disconnect the following:
bolts from
the beginning of this sec-
or connect the following:
•
spring compressor tool J
to the spring
Lower shock absorber mounting
•
com-
pressor tool.
front spring adjuster
ease the installation procedure
Remove
5.
1.
to
Install a
4.
33432-A Front
a.
gap
and setting the proper vehicle trim height.
REMOVAL & INSTALLATION
shock absorber lower mounting
Nm).
Measure the
3.
Transverse Spring
of the front transverse
spring— 5. 7L engine
Y-BODY— GENERAL MOTORS CORPORATION Ofl
wU U
CORVETTE Hand
cam
tighten the
bolts at this
•
Lower control arm
ball joint
stud to
the steering knuckle
and torque the
nut to 15
Nm)
additional
ft.
lbs.
(20
plus an
210 degrees
•
Shock absorber
•
Shock absorber lower mounting bolts
(28 •
and torque them
ft.
ft.
33432-A
arm and torque (72
degree turn
it.
the spring mounting bolts,
•
Remove
the spring from the vehicle
Front wheels
•
Negative battery cable
Perform a front end alignment.
Torque the control arm cam bolts
WSS
•
Brake rotor
•
Spring to the vehicle
•
Brake caliper and torque the
•
Spring spacers, insulators and
and torque the bolts
to
46
ft.
.
Spring to the lower control arm
•
Lower control arm
to spring bolts
lbs.
ft.
(170
Nm)
tool
125
bolts to
ft.
Wheel front alignment.
Rear
and insulators and release the
compressor
connector
Check and adjust the
5
lbs.
ft.
Nm)
(175
lbs.
lbs.
Nm)
•
to
electrical
mounting bracket
crossmember
1
125
53
to
Nm)
(72 •
to the
(25
Stabilizer shaft link to the control
verse spring
(62
11.
lbs.
turn •
tool.
connect the following:
mounting bolts
Adjust the front trim height.
ft.
plus an additional 180 degree
Spring compressor to the trans-
•
tool
10.
rod to the steering knuckle
tie
arm and torque the nut
Install or
7.
connect the following:
•
Outer
Nm)
and remove the compressor
ft.
210
plus an additional
ber and control arm.
lower control arm supports.
9.
and compress
Nm)
(20
lbs.
and torque the nut to 18
the nut to
compressor
ball joint to the steering
spacers and insulators from the crossmem-
Nm)
the spring
Install or
to the spring
Remove
5.
Lower
knuckle and torque the nut to 15
a spring compressor tool J
Install
from the transverse spring and move the
8.
•
To install:
lbs.
Remove
4.
6.
lbs.
Nm)
control
7.
to 21
Stabilizer shaft link to the lower
53
height to ease the installation procedure and setting the proper vehicle trim height.
time
I
.
Before servicing the vehicle, refer to
the precautions in the beginning of this sec-
•
Rear wheel
•
Negative battery cable
tion. 2.
Rear
8.
Adjust the trim height and place the
retainers 1
.
on the control arm
bolts.
Before servicing the vehicle, refer to 9.
the precautions in the beginning of this sec-
Check and adjust
the alignment,
3.
Wheel Speed Sensor (WSS)
•
or disconnect the following:
•
Negative battery cable
•
Rear wheels
Measure
•
cal
needed.
Remove
electri-
connector
Ball Joint
REMOVAL & INSTALLATION
Damping (RTD)
Real Time sensor,
Upper
the transverse spring stud
or disconnect the following:
Wheel
if
tion. 2.
Remove •
if
•
Brake caliper
•
Brake rotor
•
Shock absorber solenoid connector,
•
Front
Outer
tie
position
equipped
if
electrical
equipped
rod from the suspension
knuckle Before servicing the vehicle, refer to
•
Axle shaft nut
the precautions in the beginning of this sec-
•
Upper control arm from the knuckle
tion.
•
Lower
•
Suspension knuckle from the
1.
2.
Remove
or disconnect the following
•
Wheel
•
Brake caliper
•
Brake rotor
•
3.
from the lower
arm
Wheel Speed Sensor (WSS)
electri-
connector
Outer
tie
knuckle
3.
install:
4
Press the
Upper
•
Steering knuckle from the vehicle
Install or
ball joint
Measure the transverse spring stud height to
ease the installation procedure and set-
ting the proper vehicle trim height
assembly
— rear
install: Install or •
•
•
Lower
•
knuckle
ball joint to the control
to
15
•
lbs.
(55
Nm)
Upper control arm
to the knuckle
and torque the nut
to
15
ft.
lbs.
(20
plus an additional 250 degree
ft.
arm
lbs.
turn
•
(20
covered
in Section
lbs (160
Outer
tie
it
to
1
18
Nm)
rod to the knuckle and
torque the nut to 15
ft
lbs.
(20
Nm)
plus an additional 160 degree turn •
is
Axle shaft nut and torque ft.
plus an additional 250 degree
Heater Core replacement
knuckle and
It.
turn
connect the following
and torque the nut
Nm)
to the vehicle
ball joint to the
torque the nut to 41
from the steering
Ball joint to the steering
Upper
suspen-
connect the following
Knuckle
Nm)
4
Irom the
ball joint into the
•
knuckle.
To
ball joint
sion knuckle
from the control arm
•
Press the
To
5.
rod from the steering
ball joint
Press the upper
knuckle
Stabilizer shaft link
cal •
from the knuckle
vehicle
control •
ball joint
Brake rotor
2 of this manual
nn m nr 0 U OC •
GENERAL IVIOTORS CORPORATION— Y-BODY CORVETTE
Brake caliper and torque the
mounting bracket bolts lbs.
(175
WSS
•
Shock absorber solenoid
electrical
connector,
6.
to
•
RTD
Wheel
ft.
Nm)
•
•
125
if
Negative battery cable
•
Front wheel
•
Real Time link
connector
position sensor,
ing
is
connect the following:
Front
•
Upper control arm
•
Upper control arm shims and bolts
48
to
Before servicing the vehicle, refer to
lbs.
ft.
the precautions in the beginning of this sec-
Nm)
(65
tion.
Ball joint stud into the
•
upper con2.
arm and torque the nut
trol
Before servicing the vehicle, refer to
15
to
Remove •
Nm)
(20
lbs.
the beginning of this sec-
plus an additional
tion.
RTD sensor
•
the lower control
arm from
250 •
Front transverse spring
•
Wheel Speed Sensor (WSS) cal
•
Front wheel
•
Negative battery cable
•
Press the
ball joint
from the control 4.
Real
Time Damping (RTD)
Check and adjust the
front
Support the lower control arm with a
jack stand ball joint into the control
Press the
•
Rear
arm.
Shock absorber from the lower control
the control
arm
in
the vehicle.
1
.
Before servicing the vehicle, refer to
•
the precautions in the beginning of this sec-
2.
Remove
or disconnect the following:
Rear wheel
•
Wheel Speed Sensor (WSS) cal
link,
if
4.
position
equipped
•
Upper control arm bolts
•
Upper control arm
Support the lower control arm with a
bolts to the position
match
dure and hand tighten the bolts •
Lower control arm
ball joint
stud to
the steering knuckle and torque the
Install or
connect the following:
nut to 15
Upper control arm and torque the bolts to 81
ft.
lbs.
(110
Suspension knuckle
additional
ft.
lbs.
(20
Nm)
plus an
210 degrees
Nm)
ball joint
stud
nut into the upper control arm.
may
Cam
marked during the removal proce-
install:
set-lower ball joint
connect the following:
Lower control arm
jack stand •
Ball joint stud
tool
after
Lower control arm from the vehicle
Install or
from the control arm
•
•
from the knuckle
washers and nuts
bolts,
install:
• 5.
Support the lower control arm with a
•
removal and installation
To 4.
Damping (RTD)
jack stand.
To
Cam
•
electri-
connector
Real Time
sensor 3.
Ball joint stud
•
matchmarking them
•
•
from the lower
arm
•
Negative battery cable
•
arm
Stabilizer shaft link
control
tion.
Ball joint
electrical
equipped
wheel 3.
Install
if
alignment.
To install:
5.
electri-
connector
connector,
arm.
4.
Front wheel
link
the vehicle. 3.
or disconnect the following:
ft.
degrees
Remove
is
Lower Control Arm
1
Front and Rear
2.
arm
REMOVAL & INSTALLATION
and torque the bolts
in
control
install: Install or
3.
REMOVAL & INSTALLATION
the precautions
new
arm
Upper control arm
•
To
.
a
shims
wheel
alignment.
1
when
replaced
installed.
Upper control arm bolts and
•
Ball Joint
The manufacturer does not provide a bushing replacement procedure. The bush-
from the upper
ball joint
control
equipped
rear
Damping (RTD) sensor
and support the lower control
Upper
•
if
CONTROL ARM BUSHING REPLACEMENT
arm
electrical
equipped
Check and adjust the
Lower
•
It
be necessary to use an Allen
wrench
to
keep the
ball joint
stud
from spinning while tightening the
Upper Control Arm
ball joint
to
REMOVAL & INSTALLATION
15
ft.
tional •
WSS
•
RTD
Front
stud nut. Torque the nut
lbs.
(20
Nm)
plus an addi-
250 degrees electrical
connector
position sensor link,
if
equipped 1.
Before servicing the vehicle, refer to
the precautions
in
the beginning of this sec-
tion. 2.
5.
Remove
or disconnect the following:
•
Rear wheel
•
Negative battery cable
Check and adjust the
alignment.
rear
7922Z661
wheel
Lower engine
control
arm mounting
bolts
— 5.7L
OH QQ OU OO
Y-BODY— GENERAL MOTORS CORPORATION CORVETTE CONTROL ARM BUSHING REPLACEMENT
Stabilizer shaft link to the lower
•
arm and torque the nut
control
53
lbs.
ft.
Nm)
(72
The manufacturer does not provide a
•
Transverse spring and remove
bushing replacement procedure. The bush-
•
Shock absorber lower mounting
ing
and torque them
bolts
21
to
ft.
lbs.
is
when
replaced
a
new
control
arm
RTD
Brake rotor
•
Stabilizer shaft link
control
is
•
installed.
electrical connector,
if
3.
Wheel Bearings
WSS
Front wheQl
•
Negative battery cable
connector
electrical
ADJUSTMENT
Perform a front wheel alignment.
7.
Tighten the lower control arm nuts to
periodic wheel bearing adjustment
is
To
necessary. The wheel bearings are a sealed unit that
(170 Nm).
•
stud from the
ball joint
Wheel hub mounting
•
Wheel hub/bearing assembly from
must be replaced
if
loose or noisy.
install: Install or
•
connect the following:
Hub/bearing assembly to the steering knuckle.
Front
the precautions in the beginning of this sec1
tion.
Remove
or disconnect the following:
•
Negative battery cable
•
Rear wheel
•
Make
certain that the
•
2.
arm
Shock absorber from Lower
Before servicing the vehicle, refer to
the lower
Remove
•
mounting bolts
to
Lower control arm
to
or disconnect the following: •
•
Negative battery cable
•
Front wheel
•
Wheel Speed Sensor (WSS) cal
ball joint
and torque the
96
ball
55
Outer
ft.
tie
lbs.
(75
•
Cam
and torque the nut •
connector
to
WSS
electrical
after
matchmarking them •
3.
Lower control arm from the vehicle
install:
connect the following:
Install or
•
Lower control arm
•
Cam
bolts to the position
match
marked during the removal procedure and hand tighten the bolts •
Lower
ball joint
stud to the steering
knuckle and torque the nut to 15 lbs.
(20
Nm)
ft.
plus an additional 210
degrees •
Stabilizer shaft link to the lower
control to •
53
lbs.
5.
lbs.
(72
the link nut
Nm)
and torque the bolts
to
162
ft
(220 Nm)
Transverse spring trol
4.
arm and torque
Shock absorber lower mounting bolts
•
ft.
to the
lower con-
arm
•
Rear wheel
•
Negative battery cable
Perform a rear wheel alignment
Torque the lower control arm front
cam
bolt to
rear
cam
107
bolt to
ft.
70
lbs. ft.
(145
lbs.
Nm) and
(95 Nm).
the
Exploded view
Brake service
is
of the front
covered
hub/wheel bearing and knuckle assembly
in Section
4 of this manual
33
ft.
connector
from the lower
washers and nuts
stud to the
Nm)
electri-
arm
bolts,
(130
Nm)
stud nut from the
Stabilizer shaft link
control
lbs.
rod to the steering knuckle
knuckle •
ft.
is
steering knuckle and torque the nut
arm
control •
.
the precautions in the beginning of this sec-
facing rearward
Nm)
tion.
Transverse spring from the lower control
To
bolts
speed sensor cable connection Before servicing the vehicle, refer to
2.
Lower
•
REMOVAL & INSTALLATION
Rear .
rod ball stud
the knuckle
No
6.
1
tie
steering knuckle
•
lbs.
Separate the outer
the lower
from the steering knuckle
•
ft.
from the lower
arm and support arm
control
equipped
125
Brake caliper
•
Nm)
(28 •
•
to
— 5.7L engine
lbs.
(45
Qfl OA tl UU"U •
GENERAL MOTORS CORPORATION— Y-BODY CORVETTE
Stabilizer shaft link to the-lower
speed sensor cable connection
is
arm and torque
facing rearward and torque the
hub
control
55
ft.
(75
lbs.
the nut to
mounting bolts
Nm)
Brake rotor
•
Brake caliper and torque the
•
bracket mounting bolts to 125
(175
lbs.
to
96
Upper control arm
Nm)
(65
lbs.
•
•
Front wheel
•
Negative battery cable
to the steering
Lower control arm
stud to
ball
the suspension knuckle and lbs.
ft.
(75
Nm) •
Axle nut and torque
it
to
1 1
8
ft.
lbs.
Before servicing the vehicle, refer to
the precautions in the beginning of this sec-
Exploded view
tion.
ing
2.
ft.
Nm)
torque the nut to 55
.
(130
knuckle and torque the bolt to 49
ft.
Rear 1
lbs.
ft.
Nm)
•
Remove
of the rear
and knuckle assembly
hub/wheel bear-
— 5.7L engine
•
or disconnect the following:
3.
33
Negative battery cable
•
Axle nut
•
Rear wheel
•
Separate the upper control arm
•
Wheel Speed Sensor (WSS)
• •
•
•
link,
if
•
rod ball stud to the steer-
Brake rotor
Shock absorber solenoid
tie
lbs.
arm
ball joint
stud
and torque the nut
(45
Brake rotor Brake caliper and torque the
mounting bracket bolts (175
to
125
•
if
electrical
equipped
rod end from the suspen-
sion knuckle
To
WSS
•
Shock absorber solenoid
electrical
connector electrical
Hub/bearing bolts Hub/bearing from the knuckle
•
RTD
position sensor link,
install:
equipped Install or
•
connect the following:
Hub/bearing assembly ing knuckle.
Make
•
Rear wheel
•
Negative battery cable
to the steer-
certain that the
ft.
Nm)
•
Suspension knuckle
to
Nm)
connector
•
Outer
tie
Steering knuckle from the lower control
•
Brake caliper
connector,
ft.
lbs.
equipped
•
•
from the suspension knuckle
Time Damping (RTD) position
sensor •
electri-
connector
Real
Outer
ing knuckle
•
cal
Nm)
(160
if
GEO/CHEVROLET 1998-01 Metro
DRIVE TRAIN... ENGINE REPAIR FUEL SYSTEM
PRECAUTIONS STEERING AND SUSPENSION
•
31-19 31-2 31-17 31-2
Exhaust Manifold
31-10
Removal &
31-10
31-27
Fuel Filter
Front Crankshaft Seal
Removal &
31-27
Disarming
31-27 31-27
Precautions
31-3
Installation
Removal & Fuel
Installation
31-11
Fuel System Pressure
31-18 31-17 31-17 31-17
Relieving
31-14 Installation
Removal &
&
Ring
31-16
Positioning
31-16
Piston
Rack and Pinion Steering Gear. ...31-28
Removal &
Installation
Removal &
Installation
Rocker Arms/Shafts
Removal &
Removal &
Installation
Installation
Installation
Installation
Ignition
31-3
Removal &
Installation
31-2
Lower Control Arm
Starter
31-9 31-9
31-14
Motor
Removal &
Installation
31-2
Control
Removal &
Installation
31-4 31-4
31-30
Pan
Front Cover
&
Removal &
Seal Installation
Transaxle Assembly
Removal & 31-33 31-33 31-34
Installation
31-33
Installation
31-14
31-15 31-15 31-19
31-19
V 31-13
Valve Lash
31-13
Adjustment
W Water
Pump
Removal &
31-7 Installation
Wheel Bearings
0 Oil
Timing Chain, Sprockets,
Arm Bushing
Removal &
Removal &
Installation
Replacement
E
Engine Assembly
31-14
31-30
Strut
31-33
Ball Joint
Removal &
Installation
31-9
L
31-7
Removal
31-9
Intake Manifold
Lower
31-2
Installation
31-23
31-3
Timing
Adjustment
D Distributor
31-15
T
31-7
Cylinder Head
31-23 31-23
Bleeding
31-24
Overhaul
Removal &
Hydraulic Clutch System
31-32 31-24
CV-Joints
Installation
31-22 31-32
Coil Spring
Removal &
Removal &
31-22
Adjustment
31-23
Halfshaft
31-12 31-21
Clutch
31-28
31-15
Rear Main Seal
S 31-12
Installation
31-14
P
C Camshaft
31-14
31-17
31-17 Installation
Installation
Pump
31-11
31-18
Pump
Removal &
31-3
Removal
Installation
Fuel Injector
31-3
Alternator
Installation
Removal & Oil
Removal &
31-17
Removal &
Bag
Installation
F
A Air
Prizm
Adjustment
31-7
31-35
31-35
O Qi "4 0
GEO/CHEVROLET METRO
1
PRIZM
•
PRECAUTIONS eye
Before servicing any vehicle, please be
sure to read
of the following precautions,
all
which deal with personal of
prevention
safety,
component damage, and important points consideration when servicing a
irritation persists, or
fluid for
The EPA warns
•
prolonged contact
that
may cause
with used engine
motor vehicle:
skin disorders, including cancer!
Never open, service or drain the radiacooling system
tor or
hot; serious
when
the engine
Observe
applicable safety precau-
all
when working around
tions
fuel.
Whenever
servicing the fuel system, always work
Do
well-ventilated area. or vapors to
to
effort to
used engine
gloves should be worn
come
in
a
in
not allow fuel spray
(a hot
oil.
You
Soap and
expo-
water, or
•
new
All
vehicles are
now equipped must be
disabled before performing service on or
drop
becomes contaminated, completely
Any brake
fluid.
flush the
Never reuse any
fluid.
removed
fluid that is
from the system should be discarded. Also,
come in condamage
fluid to
painted surface;
tact with a
will
it
the paint.
Never operate the engine without the
•
proper amount and type of engine
doing so WILL result
waterless hand cleaner should be used.
of brake
the brake fluid
If
do not allow any brake oil.
other exposed after
your vehicle.
system with new brake
Protective
oil.
with an air bag system. The system
contact with a spark,
open flame or excessive heat
sure to used engine
of
minimize your
soon as possible
skin areas as
number
a
when changing
Wash your hands and any
and hot coolant. •
oil
should make every
exposure
is
burns can occur from the steam
should always buy the correct type
medical assistance.
to take into
•
proper operation of the brake system. You
you have taken
if
IMMEDIATELY seek
brake fluid internally,
oil;
severe engine
in
damage. Timing
•
belt
maintenance
Many models
important!
extremely
is
an interfer-
utilize
around system components, steering col-
ence-type, non-freewheeling engine.
extinguisher near the work area. Always
umn, instrument panel components, wiring
timing belt breaks, the valves
keep
and sensors. Failure
example). Keep a dry chemical
light, for
fuel in a
designed
fire
container specifically
for fuel storage; also,
to follow safety
disabling procedures could result
always
in
and
head may
acci-
tially
strike the pistons,
sonal injury and unnecessary system
maintenance
additional fuel system precautions later
repairs.
this
5. working with, or around, the
Fuel injection systems often remain
•
Always wear safety goggles when
•
air
pressurized, even after the engine has been
When
turned OFF. The fuel system pressure must
sure the bag and trim cover are pointed
be relieved before disconnecting any fuel
away from your body. When placing
lines. Failure to
do so may
and/or personal
injury.
•
Brake
fluid often
handling brake
after
brake fluid
in
fluid.
If
of the
module
system precautions
your eyes, flush your eyes If
vehicles
if
it
is
accidentally air
sealed container
is
require the
ative battery cable •
bag
interfere with
computer
When
is
to
reconnected.
drum
servicing
brakes, only dis-
assemble and assemble one side
later in this section.
essential to the safe
may
on-board computer sys-
undergo a relearning process once the neg-
Clean, high quality brake fluid from a
•
some
tem^) and may
reduce the
deployed. Refer to the additional
you do get
with clean, running water for 15 minutes.
motion
to the
Disconnecting the negative battery
cable on
and trim cover upward, away will
replace-
and
inspection.
the functions of the
from the surface. This
and wash your hands thoroughly
recommended
interval for the timing belt,
timing belt section for belt replacement and
•
a non-
causing poten-
interval charts in the front of
for the
bag on a work surface, always
air
face the bag
contains polyglycol
ethers and polyglycols. Avoid contact with the eyes
carrying a non-deployed air bag, be
deployed
result in fire
manual
ment
bag system.
the
expensive) engine damage. Refer to the
dental air bag deployment, possible per-
possibility of fire or explosion. Refer to the
this section.
If
the cylinder
serious (also time-consuming and
properly seal fuel containers to avoid the
in
in
and
at a time,
leaving the remaining side intact for refer-
ence.
ENGINE REPAIR Remove
Distributor
the distributor from the
Timing Disturbed
engine.
REMOVAL
INSTALLATION
1.
Remove
2.
Place a
hole. 1
.
Before servicing the vehicle, refer to
the precautions
in
tion. 2.
Remove
or disconnect the follow-
Negative battery cable
•
Distributor electrical connector
•
Spark plug wires from the distribu-
mark the position
of the distributor
body and
of the distributor
body
relation to the cylinder head. 4.
2.
Distributor cap
Mark the position
Remove
the distributor
made dur-
and be sure the drive gear engages
properly within the
cap
rotor in relation to the distributor
Align the reference marks
ing removal. Position the distributor care-
•
•
bolts.
ley, until .
fully
tor
3.
Timing Not Disturbed 1
ing:
in
3.
Install or
4.
3.
a
spark plug. the spark plug
rotate the
engine by
wrench on the crankshaft pul-
compression
is felt.
Align the timing mark on the crank-
shaft pulley with the
0 degrees mark on
the timing scale attached to the front of
Dead Center (TDC) on
•
Hold-down
•
Distributor electrical connector
»
Spark plug wires
rotor points to the No.
•
Distributor cap
on the cap.
•
Negative battery cable
bolts but
1
the engine. This places the engine at
slot.
connect the following:
do not tighten
Check and/or adjust the
the
Top
compression
stroke. 4.
5.
ignition tim-
Turn the distributor shaft
Install or
•
y spark
until the
plug tower
connect the following:
Distributor,
by aligning the distrib-
utor housing-to-cylinder head
ing.
hold-down
Have someone
hand using
the beginning of this sec-
the No.
thumb over
Tighten the distributor hold-down
bolts to 11
ft.
lbs.
(15 Nm).
marks made during the removal procedure
01.0 O O
GEO/CHEVROLET METRO
•
PRIZM
I
1
93066Z28
Exploded view 1
Distributor
2
Distributor
of the alternator
— Metro
A
and Prizm models
mounting bolts
Blank (cavity
1)
B Diagnostic request terminal (cavity 2)
7922Z701
C •
Be sure
to tighten the distributor
mounting
belt
— Prizm
•
(cavity 3)
D Ground terminal(cavity 4) E Test switch termmaJ( cavity F Duty check terminai(cavity
Alternator electrical connectors
then torque the alternator bolts to •
Spark plug wires and
•
Distributor cap
•
17
lbs.
ft.
electrical wires
Nm)
(23
assembly
Check and/or adjust
7.
Tighten the distributor hold-down
bolts to 11
ft.
lbs.
ignition timing.
(15 Nm).
2 Jumper
•
Air cleaner
•
Negative battery cable
7922Z7Q2
Jumping terminals
Prizm 1
DLC Install
.
the alternator
Install the alternator belt
2.
and adjust
the tension until a deflection of 0.24-0.31
(6-8mm)
inch
REMOVAL
deflection with
kg) of pressure exerted
used
Metro
belt.
On
a
new
when
22
lbs.
Before servicing the vehicle, refer to
the precautions in the beginning of this sec-
belt the belt deflection
Install or
3.
Remove • •
•
Upper and lower mounting bolts
•
belt
.
7.
Connect a tachometer
timing light to the No. idle
1
spark plug wire.
8
Refer to the vehicle emission control
for ignition timing specifications.
Negative battery cable
belt
9
Remove
the cap from the diagnostic
check connector, located next coil or
Timing
left
to the ignition
side strut tower and insert a
fused jumper wire between appropriate the terminals
On
4 terminal connectors, hold
the connector with the locking tab is
top and
jump
11
1
On 6
•
Accessory drive
tion.
•
Alternator electrical connectors
•
Alternator
the engine until
it
reaches nor-
mal operating temperature. Stop the engine,
tion for approximately
5 seconds.
ON
posi-
Start the
engine again.
Run
3.
connect the following
Alternator
and the
bolts,
allow
do not
tighten the bolts at this time
4.
it
the engine at
2000
RPM
for
to run at idle speed.
Be sure
top
and
all
accessories are turned
left
(D
E).
Loosen the
distributor
bolt
and
rect
timing marks are aligned.
13. bolt to
hold-down
rotate the distributor until the cor-
Tighten the distributor hold-down 1
1-15
ft
lbs.
(15-20 Nm) and
recheck the timing. Be sure the timing
approximately 5 minutes. After 5 minutes, •
at the
inals at the lower
12.
Run
2.
but keep the ignition switch in the
Install or
the
terminal connectors, hold the
Before servicing the vehicle, refer to
.
the precautions in the beginning of this sec-
Metro
at
the lower 2 terminals (C and
D
Metro
Negative battery cable
INSTALLATION
if
Accessory drive
•
belt
Connect a
speed and adjust,
connector with the locking tab or disconnect the following:
nega-
to the
tive terminal of the ignition coil.
Nm)
(23
Before servicing the vehicle, refer to
Remove
in
•
lbs.
tion. 2.
placed
depending on
•
ft
••The ignition timing on the Prizm
the precautions in the beginning of this sec-
shift lever is
PARK
information label (located under the hood)
17
not adjustable. 1
r
transaxle type
10
Prizm
o
Alternator electrical connectors
ADJUSTMENT
Alternator
NEUTRAL
Alternator bolts to
Ignition
Accessory drive
•
Be sure the
needed
connect the following
Alternator electrical connectors
•
Fully
•
or disconnect the following:
assembly
engage the parking brake.
5.
6.
•
Negative battery cable Air cleaner
the 6 terminal
— Metro models
Check the engine
(10 kg) of pressure exerted.
tion. 2.
(10
the
installing a
should be 0.20-0.27 inch (5-7mm) with 22 lbs.
in
and hand-tighten
the bolts.
Alternator
.
6)
DLC
Duty check
1
5)
Negative battery cable
6.
1
Diagnostic output terminal
and adjust as
necessary
bolts to prevent the timing from chang-
ing
Accessory drive
advances according
to
engine speed.
Remove the diagnostic check jumper. Remove the timing light and 14
tachometer.
OFF
For complete service labor times, order the Chilton Labor Guide
GEO/CHEVROLET
31-4
METRO
•
PRIZM
Prizm
•
Engine Assembly
Engine Coolant Temperature (ECT) sensor
‘—If the ignition timing is out ot specifi-
cation, a possible engine electrical
•
REMOVAL & INSTALLATION
electrical
may have occurred. The followprocedure may be used to check
failure
ing
•
Metro
the timing: Before servicing the vehicle, refer to the
.
precautions
in
Warm
2.
the beginning of this section.
the engine to normal operating
temperature. Turn
all
electrical
accessories
OFF.
sure
Connect a tachometer or engine scan and check the engine is
it
speed and be
650-750 rpm.
Connect a timing
4.
idle
light.
Remove
the
cap on the Data Link Connector (DLC).
Using a fused jumper wire, connect terminals El and
TE1.
Before servicing the vehicle, refer to
1.
should be
at
10 degrees Before Top Dead
Center (BTDC).
Remove
6.
DLC and 7.
the
jumper wire from the
Drain the cooling system.
4.
Drain the engine
5.
Drain the transmission fluid,
OFF
•
electrical
Pleated
Oxygen (HO 2 S) sensor
•
connector
Body
Throttle
Injection (TBI) unit
connector
Early Fuel Evaporation (EFE) heater electrical connector,
if
Oil
Alternator connectors
Air cleaner
Coil wire from the distributor
•
•
Radiator and cooling fan assembly
•
•
Evaporative emissions (EVAP)
equipped
pressure switch electrical con-
•
•
elec-
connector
electrical
•
•
sensor
trical
hood
nector
purge solenoid
and disconnect
oil.
or disconnect the following:
ground wires
Manifold Absolute Pressure (MAP)
•
if
connector
•
Flood after scribing the hood hinge to the
Speed Control (ISC) motor
Intake manifold
equipped with an automatic transmisson.
reinstall the cap.
Shut the engine
test
3.
Idle
•
pressure.
Remove
Exhaust Gas Recirculation (EGR)
electrical
Properly relieve the fuel system
•
With the jumper wire connected, the timing
•
tion.
6.
Sensor (TPS)
connector
valve electrical connector
the precautions in the beginning of this sec-
engine and check timing.
Start the
5.
all
ENGINE
2.
3.
tool
1.0L
connector
Throttle Position electrical
• 1
connector
electrical
Coolant Temperature Sending unit
electrical
Starter solenoid electrical
connec-
tor
connector
•
Distributor electrical connector
equipment.
A/C compressor clutch
coil electri-
equipped
cal connector,
if
•
EVAP
vacuum hose
•
MAP
canister
sensor vacuum hose
•
Brake booster hose
•
Accelerator cable from the throttle
body equipped
•
Clutch cable,
•
Gear select cable
if
automatic
for
transmissions •
Speedometer cable
•
Heater
•
Fuel feed and return hoses
inlet
and
outlet
hoses
Support the engine.
7.
•
•
Exhaust pipe from the manifold Gearshift control shaft and exten-
sion rod from the transmission •
Backup lamp switch
electrical
con-
nector •
Crankshaft Position (CKP) sensor electrical
•
Ht
is
connector
Both halfshafts
not necessary to disconnect the
halfshaft from the knuckle. •
A/C compressor without disconnecting the hoses
•
Power steering hoses from the
pump, Attach a
8.
+B El
FP TE1
W MO
SYSTEM VOLTAGE GROUND TERMINAL FUEL PUMP TERMINAL DIAGNOSTIC REQUEST TERMINAL MALFUNCTION INDICATOR LAMP (MIL) TERMINAL DATA LINK CONNECTOR (DLC) (UNDER HOOD) 7922Z703
DLC
pin locations
— Prizm models
if
equipped
lifting
device to the engine.
transmission mount
•
Left side
•
Right side and rear engine
•
Engine/transmission assembly
mount
To install: Install or
9.
• •
connect the following:
Engine/transmission assembly Left
transmission mount and torque
the nut to 41
ft.
lbs.
(55
Nm)
OH C O U
GEO/CHEVROLET METRO •
10.
Right and rear engine
mounts and
torque the bolts to 41
ft.
Nm) Remove
lbs.
device and
lifting
Exhaust pipe
to the
1 1
the bolts to
20
if
electrical
cal •
connector
Direct clutch
and second brake
solenoid electrical connector
equipped. 12.
Fill
the engine with clean
•
Brake booster hose
Nm)
13.
Fill
the cooling system.
•
Accelerator cable
Gearshift control shaft and exten-
14.
Fill
the transmission.
•
Clutch cable,
sion
15.
Fill
the
•
Shift select cable,
•
Backup lamp switch
16.
Start the
•
Speedometer cable
•
Halfshafts
•
Heater
•
Power steering hoses
•
Fuel feed and return hoses
•
A/C compressor and torque the
torque the bolts to 33
•
bolts to
(45
lbs.
ft.
repair
37
ft.
lbs.
(50
•
Speedometer cable
•
Gear select cable, Clutch cable,
•
Accelerator cable
if
power steering
oil.
reservoir.
engine and check
for leaks,
necessary.
pump
ENGINE
1.3L
Nm)
equipped
Install
8.
equipped
if
and
inlet
if
•
Left
tion.
•
Rear engine mount
Properly relieve the fuel system
2.
10.
transmission mount
•
Exhaust pipe from the manifold
•
Gearshift control shaft and exten-
•
Heater inlet/outlet hoses
3.
Dram
•
Engine vacuum lines
4
Evacuate and recover the A/C sys-
•
•
Alternator and torque the bolts to
•
Power steering pump
Drain the engine
•
A/C compressor,
17
(23
lbs.
ft.
Nm)
the cooling system
5.
oil.
•
Fuel return and feed lines
6.
Drain the transmission
•
Distributor electrical connector
7.
Remove
•
Starter solenoid electrical
connec-
tor •
CKP
sensor
•
MAP
sensor electrical connector
•
EVAP purge solenoid
electrical
connector
electrical
Positive
•
Hood
•
Radiator and cooling fan assembly Air cleaner
•
Engine Coolant Temperature (ECT)
•
Coolant temperature sending unit electrical
•
•
•
ISC motor
•
Fuel injector connectors
•
HO 2 S
electrical
valve electrical connector electrical
•
connector
connector
•
sensor connector
ground wires
electrical
•
Alternator electrical connector
•
Fuel injector electrical connectors
•
A/C Compressor clutch
•
Manifold Absolute Pressure (MAP)
cal connector, •
if
coil electri-
equipped
Starter solenoid electrical
connec-
•
MAP
sensor
•
EVAP
canister
electrical
connector
•
vacuum hose Map sensor vacuum hose Brake booster vacuum hose
•
Accelerator cable
•
Clutch cable,
•
Speedometer cable
•
if
•
lbs.
(10
Nm) •
Air cleaner
assembly
visit
lbs (55
Nm)
•
A/C compressor and torque
the bolts to
bolts to 18
25
ft
ft.
lbs
lbs (25
(35
Nm) the
Nm)
•
Both halfshafts
•
Gearshift control shaft and exten-
sion rod
if
Oil
•
A/C compressor clutch
electrical
Exhaust pipe to the manifold and torque the bolts to 37
pressure switch electrical con-
Nm) 15 Remove •
Park/Neutral Position (PNP) switch
•
Heater
•
Accelerator cable
connector
inlet
and
outlet
Ignition coil connectors
•
Clutch cable,
•
Alternator electrical connector
•
Shift select cable,
•
Starter solenoid electrical
•
Speedometer cable
•
Brake booster hose
our web
site at
www.chiltonsonline.com
lbs.
(50
Fuel feed and return hoses
•
connec-
ft
the engine support fixture.
equipped
if
tor
Please
ft
Power steering pump and torque
Power steering pump pressure
electrical
Radiator and cooling fan and
torque the bolts to 89 inch
lbs (55
sensor electrical connector
connector, •
ft.
•
connector
nector •
Nm)
mount and
Rear engine mount and torque the bolts to 41
Heated Oxygen (HO 2 S) sensor elec-
equipped
equipped
•
•
connector
switch electrical connector,
tor •
lbs (55
ft
Right side engine
torque the bolts to 41
Speed Control (ISC) motor
trical
connect the following:
transmission mount and torque
Nm)
Oil
nector
Left
the bolts to 41
connector
•
Idle
electrical
•
Install or
•
Crankshaft Position (CKP) sensor
EFE heater
pressure switch electrical con-
14
•
Intake manifold
•
under the vehicle.
table,
Lower the vehicle onto the
13
connector
•
connector
Place the engine/transmission
12.
connector
•
electrical
the engine support fixture.
engine/transmission assembly.
Camshaft Position (CMP) sensor
electrical
equipped
engine/transmission.
Evaporative emissions (EVAP)
electrical
f
equipped
Raise the vehicle from the
assembly on the
connector
Throttle Position (TPS) sensor
purge solenoid
connector
if
To install:
assembly
electrical
electrical
connector
TPS EGR
•
•
Remove
battery cables
•
equipped
vehicle.
11
sensor
ECT sensor connectors
and negative
if
Both halfshafts
Place an engine table under the
9.
fluid.
or disconnect the following:
•
connector •
sion rod,
tem.
fixture.
mount
the precautions in the beginning of this sec-
pressure.
hoses
and engine support
Right side engine
Before servicing the vehicle, refer to
.
equipped
outlet
•
1
equipped
•
if
if
to the
con-
Vehicle Speed (VSS) sensor electri-
•
gear select cable and accelerator cable play,
manifold and
I
nector
Adjust the clutch pedal free-play,
.
PRIZM
Backup lamp switch
•
ft.
Nm)
(27
Negative battery cable
•
the engine
properly support the engine assembly. •
Hood and torque
•
(55
lbs.
•
if
hoses
equipped if
equipped
Q-1 £ OI"U • • •
GEO/CHEVROLET METRO
PRIZM
•
•
Accelerator cable
connector
•
Intake Air Temperature (IAT) sensor
•
Air cleaner
•
Upper
Drive belt tensioner,
if
32
manual transmission
with
•
•
CMP
•
CKP
•
ISC motor
•
HO 2 S
•
Windshield washer reservoir
•
Fuel injector electrical connectors
•
Oxygen (O 2 S) sensor
•
MAP
•
•
Power steering pump pressure
sensor
sensor
connector
electrical
electrical
sensor
sensor
electrical
connector
electrical
connector connector
electrical
connector
electrical
•
Oil
•
if
pressure switch electrical con-
A/C compressor clutch connector,
electrical
equipped
it
•
PNP
•
Ignition coil connectors
•
Alternator electrical connector
•
Starter solenoid electrical
switch electrical connector
Backup lamp switch
•
VSS
•
Direct clutch
sensor
electrical
electrical
con-
•
Starter
motor
•
Starter
motor
•
Torque converter
equipped
Power steering pump, do not
•
Upper
•
Air cleaner
radiator
Exhaust pipe from the manifold
•
Accelerator cable to the throttle
•
Transmission-to-engine bolts
•
Manifold Absolute Pressure (MAP)
•
Accessory drive
sensor hose
•
A/C compressor and torque
lever
Fill
the engine
Evacuate and recharge the A/C sys-
the transmission fluid.
Fill
20.
Start the
•
for
•
Fuel feed and return hoses Shift select cable
Prizm
9.
Remove
Front and rear transmission
•
Right engine
•
Engine assembly
bolt to
mounts
mount
Fuel return hose
•
Fuel feed pipe to the fuel
ft.
lbs.
(64
Nm)
ft.
lbs.
nuts to 42
Alternator
Crankshaft pulley,
ft.
front
equipped
hoses
to the intake
Radiator and cooling fan and
mount
•
ft.
Nm) and lbs.
(52 ft.
Nm) and lbs.
Remove
11.
•
the 12.
(87
the
(87
the engine hoist and sup-
port the engine. if
outlet
Nm) Hood and torque lbs. (27 Nm)
Nm).
ft.
lbs.
(13
the bolts to
20
ft.
Negative battery cable Adjust the clutch pedal free-play,
gear select cable and accelerator cable play, if
equipped. 13.
Recharge the A/C7system.
14.
Fill
the engine with clean
15.
Fill
the cooling system.
16.
Fill
the transmission.
•
Both halfshafts
17.
Fill
the
•
Front exhaust pipe and torque the
18.
Start the
equipped with
manual transmission
Nm)
and
torque the bolts to 9
rear transmission
lbs.
through-bolt to 64
belt if
(64
lbs.
ft.
Nm). Torque the
Ignition coil electrical connectors
•
47
through-bolt to 64
hood
A/C compressor,
(29
inlet
using
if
Remove or disconnect the following: Hood after scribing the hood hinge
Accessory drive
lbs.
(54
Front and rear transmission
mounts and torque the bolts to
•
ft.
rail,
the bolt to
manifold and fender •
oil.
•
Nm)
Shift cable
22
mount and
Right side engine
(29
•
Engine ground wires
torque them to 47
(69
lbs.
equipped with
(142
•
equipped.
to the
lbs.
Engine-to-transmission bolts and
•
lbs. ft.
•
Nm)
Evacuate the A/C system,
ft.
•
torque the bolts to 40
6.
105
Heater
Drain the cooling system.
Drain the transmission fluid.
if
•
pressure.
equipped
ft.
the nut to 21
Engine assembly
•
the lower
Ignition coil electrical connectors
connect the following:
Install or
Properly relieve the fuel system
Drain the engine
(if
• tion.
5.
lbs.
new gaskets and torque
Before servicing the vehicle, refer to
4.
Nm) and (54 Nm)
(25
•
To install:
the precautions in the beginning of this sec-
the
Nm)
manual transmission, and toque the
or disconnect the follow-
•
10.
ft.
Crankshaft pulley,
•
Attach an engine hoist to the engine.
proper
40
Nm) and Nm)
hoses
ing:
engine and check
lbs.
ft.
torque the bolt to 51 outlet
8.
operation.
18
Drive belt tensioner
and fenders and
(25
lbs.
ft.
with manual transmission) and
the intake mani-
Heater
inlet
18
belt
Alternator and torque the upper bolt
•
•
•
oil.
tem. 19.
bolts to
sensor
Ground wires from fold
18.
Nm)
(10
lbs.
•
nesses
17.
89 inch
IAT sensor electrical connector
•
the cooling system.
hose
•
Nm)
(10
assembly and torque
the bolts to
dis-
bolt to
Fill
•
if
to
16.
•
bolts,
A/C pressure switch wiring har-
Positive and negative battery cables
lbs.
Nm)
connect the hoses
lbs.
Hood
Nm)
torque the bolts to 89 inch
Data Link Connector (DLC) and
assembly
(23
lbs.
ft.
MAP
•
•
Windshield washer reservoir and
•
•
7.
•
•
(10
3.
Engine wiring harness Alternator and torque the bolts to
Radiator and cooling tan assembly
Air cleaner
Nm)
(10
lbs.
hose
•
solenoid electrical connector
89 inch
89 inch
radiator
Brake booster hose
to
Nm)
(30
•
connectors
electrical
lbs.
ft.
Lower
17
Both halfshafts
Nm)
(35
lbs.
ft.
Engine splash shields and torque
•
•
2.
22
26
motor and torque the bolts
the bolts to
hose from the ther-
radiator
Splash shields
connector
and second brake
and torque the bolts
.
to •
•
Lower
to
Starter
Engine wiring harness and place
•
connec-
nector
•
•
with an automatic transmission
tor •
them
hose
radiator
•
•
Torque converter bolts and tighten
•
assembly
mostat housing
nector •
connector
aside
equipped
O 2 S sensor and torque the nuts to ft. lbs. (40 Nm) Power steering pump and torque the bolts to 27 ft. lbs. (37 Nm)
•
•
switch electrical connector,
1
equipped
ECT sensor electrical congector TPS sensor electrical connector EVAP purge solenoid electrical
bolts to
46
ft.
lbs.
(62
Nm)
repair
if
power steering
oil.
reservoir.
engine and check
necessary.
for leaks,
GEO/CHEVROLET METRO Crankshaft pulley and torque the
•
Water Pump
12
bolts to
ft.
lbs.
(16
Nm)
•
Water pump/alternator drive
belt
•
Lower alternator cover
and
REMOVAL & INSTALLATION
plate
torque the bolts to 89 inch
Metro 1
.
Before servicing the vehicle, refer to
tion.
•
Water
or disconnect the following:
Negative battery cable
pump 18
A/C compressor suction pipe
17
bolt to
bracket,
if
•
lbs.
ft.
Water
pump
but do not remove the bolts
pump
Nm)
Right side lower splash shield
•
A/C compressor
drive belt,
if
Lower
•
Water pump/alternator drive
•
Crankshaft pulley
pump
Water
•
Timing
•
Oil level indicator
assembly
Negative battery cable the cooling system.
6.
Refill
7.
Start the if
engine and check
for leaks,
necessary.
belt
1.
pulley
Before servicing the vehicle, refer to
the precautions in the beginning of this sec-
belt
2.
Drain the engine coolant.
Remove
•
pump pump Water pump
3.
water
bolts
and nuts
install:
connect the following
Install or
pump
with a
new gasket and
torque the bolts to 115 inch
•
Nm) New rubber
•
Upper
To
lbs.
4
(13
17
bolt to
ft.
Intake manifold
•
Exhaust manifold
•
Rocker arm cover
•
Timing
•
Camshaft
•
Valve
•
Distributor
•
Cylinder head bolts
•
Cylinder head
lbs.
Negative battery cable
Accessory drive
•
Right side lower splash shield
•
Water
•
Water
pump pump
lifters
To install: 3.
Install
or connect the following:
Cylinder head with a
new gasket in
3 even
bolts
install: Install or
Water
connect the following
pump
with a
new O-ring and
torque the bolts to 8
lbs. (11
ft.
Nm)
(23
Nm)
•
Right side lower splash shield
Oil level indicator
•
Accessory drive
•
Timing
•
Negative battery cable
tube
belt 5.
Fill
belt
Cylinder head torque
the cooling system.
engine
1922170*
To ensure a tight seal, be sure gasket sur-
prepared— Metro
and tensioner
belt
•
faces are properly
belt
or disconnect the following
•
alternator adjusting bracket
and torque the
•
and torque the bolts
•
•
seals
or disconnect the following:
Negative battery cable
•
tion.
tube
Upper alternator bracket from the
Water
Remove •
Prizm
•
Water
2.
alternator cover plate
•
•
tion.
equipped
•
Before servicing the vehicle, refer to
if
•
•
1.
the precautions in the beginning of this sec-
drive belt ten-
Air cleaner
repair
4.
(24
•
equipped
To
lbs.
A/C compressor suction pipe
pulley bolts, loosen
•
Cylinder Head
(23 Nm).
equipped bracket,
•
for leaks,
Metro
pulley and torque the
ft.
Adjust the water
assembly
Air cleaner
•
and check
necessary.
(10
sion and torque the alternator adjustment
•
*
if
Right side lower splash shield
5.
•
belt,
•
Drain the cooling system.
Remove
7
REMOVAL & INSTALLATION
bolts to 3.
Start the vehicle if
O-f
PRIZM
equipped
the precautions in the beginning of this sec-
2.
lbs.
Nm) A/C compressor drive
•
6.
repair
•
—
Cylinder head torque sequence
Timing belt service
is
covered
1
3L engine
in Section
3
of this
manual
sequence— 1. 01
— GEO/CHEVROLET
31-8
METRO
•
PRIZM
A CRANKSHAFT PULLEY SIDE 6053
CYLINDER HEAD GASKET 79222708
Cylinder head gasket positioning
— 1.0L Cylinder head bolt torque
engine
sequence— Prizm
•
Alternator
•
Crankshaft pulley
•
Accelerator cable from the throttle
•
Crankshaft Position (CKP) sensor
body
•
Drive belt tensioner
Intake Air Temperature (IAT) sensor
•
Right side engine
•
Timing chain tensioner
•
Timing chain cover
•
electrical
connector
hose
•
Air cleaner
•
Throttle Position (TPS) sensor
mount bracket
9.
electrical • 1
.
2.
Cylinder
head gasket
Cylinder block
• 7922Z799
Cylinder head gasket positioning
Control (IAC) valve electri-
Idle Air
cal
connector
connector
Manifold Absolute Pressure (MAP)
sensor
electrical
connector
•
Crank sensor reluctor
•
Timing chain slipper
•
Crankshaft sprocket
•
Timing chain
•
Camshaft sprockets
•
Camshaft bearing caps
•
Coolant bypass hoses
•
Camshafts
•
Fuel injector electrical connectors
•
Valve
•
Fuel injector harness from the
•
Intake manifold
1.3L
4.
lifters
engine
54
stages, in sequence, to
(73 lbs.
•
ft.
lbs.
Nm) onl.OL engines or 49 (68 Nm) on 1.3L engines
Valve
ft.
intake manifold
•
Exhaust manifold
•
Intake manifold support bracket
•
Cylinder head
•
Oxygen (O 2 S) sensor
•
•
Camshaft
•
Rocker arm cover and torque the bolts to
• • •
Timing
Install
44 inch belt
Nm)
lbs. (5
17
ft.
and torque the
lbs.
(23
Nm)
Exhaust manifold and torque the
17
ft.
lbs.
(23
Nm)
Negative battery cable
Start the
engine and allow
it
to reach
normal operating temperature. Check
and adjust the
ignition timing,
if
clamp and move
receiver pinch
for leaks
necessary.
in
mount
a.
18
ft.
lbs.
(25 Nm).
b.
36
ft.
lbs.
(49 Nm).
•
Fuel line at the fuel
c.
Plus an additional 90 degrees.
•
Spark plug wires
«
Ignition coils
rail 1 1
Properly relieve the fuel system
Install or
.
•
Fuel
•
Ground wires from
rail
the cylinder head
Drain the engine coolant.
4.
Drain the engine
5.
Remove
oil.'
Negative battery cable
•
Washer tank and pump
•
Accessory drive
belt
ft.
lbs.
(13
Nm)
Camshaft sprockets and torque the
40
Nm)
•
Heater hose from the cylinder head
•
Water bypass pipe
•
Timing chain
•
Camshaft Position (CMP) sensor
•
Timing chain cover and torque the
•
Engine Coolant Temperature (ECT)
•
bolts to
bolts to 14 •
Positive Crankcase Ventilation
1
Dead
Center (TDC) and align the camshaft timing
Remove
8.
•
•
•
105
Power steering
oil
lbs.
ft.
(55
(18
Nm)
ft.
lbs.
(142
Nm)
89 inch
lbs.
(10
Nm)
•
ECT sensor
•
Camshaft sensor and torque the
•
Water bypass
bolt to 11
or disconnect the following:
lbs.
Rocker arm cover and torque the bolts to
piston to Top
ft.
Crankshaft pulley and torque the bolt to
•
Rocker arm cover Set the No.
or disconnect the following:
•
connect the following:
•
sprockets.
3.
the
Camshafts and torque the bearing cap bolts to 10
•
7.
pressure.
in
Ignition coil connectors
(PCV) valve and hoses
the beginning of this sec-
Torque the cylinder head bolts
10.
Right side engine
•
tion.
new
cylinder head with a
following sequence:
sensor
the precautions
Install the
gasket.
•
Before servicing the vehicle, refer to
2.
fixture.
•
Prizm 1.
A/C
an engine support
the receiver aside
and tensioner
Intake manifold
bolts to •
•
Distributor
bolts to •
Exhaust pipe from the manifold
lifters
6.
To install:
pressure switch
bolt to 11
connector
•
Right side lower engine splash
•
ft.
ft.
lbs.
(15
pifre
lbs.
Nm)
and torque the
(15
Nm)
Heater hoses
Ground wires
to the cylinder
shield
and torque the bolts
Power steering pump
(15
Nm)
to 11
ft.
head lbs.
OH O _Q 3
GEO/CHEVROLET METRO •
Fuel ft.
and torque the bolts
rail
lbs.
•
Fuel line to the
•
Ignition coils to
10
rail
Nm)
(14
lbs.
ft.
mount and
torque the bolts to 40
ft.
(54
lbs.
Nm) •
12.
A/C receiver pinch clamp Remove the engine support
•
Rocker arm cover
•
Battery
•
Timing
•
Both battery cables
•
Camshaft sprocket
•
Camshaft Position (CMP) sensor
•
Camshaft
•
•
If
Metro
necessary, remove the rocker
the rocker shafts. Note the order in
ft.
Nm)
lbs. (41
bled
Fuel injector harness brackets
•
Vacuum hoses
•
Intake manifold support bracket ft.
lbs.
and
(50
Nm)
intake and exhaust rocker
shafts are
NOT
the
manifold and torque the bolts
106 inch
lbs.
(12
Upper
Fuel injector connectors
•
Coolant bypass hoses
hose
radiator
MAP
•
IAC valve
•
TPS sensor
•
arm
•
same. Both can be at the ends of
•
arm
3.
shaft with the
disassembled
Lubricate the rocker
lbs.
(10
Nm)
•
Accessory drive
•
Negative battery cable
belt
new
Fill
the engine with
14.
Fill
and bleed the cooling system.
15.
Start the vehicle
and check
Road
necessary.
oil
test
for leaks,
and check
•
97 inch
lbs.
43
ft
lbs.
(60
•
•
Nm)
body
EGR Modulator EGR valve
for
proper operation.
Rocker Arms/Shafts REMOVAL & INSTALLATION The
1
0L and
1
8L engines do not use
rocker arms/shafts, the camshaft directly
actuates the valves.
1.3L Engine 1
Before servicing the vehicle, refer to
the precautions in the beginning of this section.
—
Rocker arm shaft retaining bolts tightening sequence
Heater Core replacement
is
covered
in Section
2
of this
1
equipped
Coolant hoses from the
body
Nm)
if
Fuel feed and return hoses from the throttle
•
Camshaft sprocket and torque the bolt to
connector
Early Fuel Evaporative (EFE) heater electrical connector,
sensor and torque the bolts to lbs. (11
electrical
sensor electrical connector •
bolts, in the
•
CMP
97 inch
13.
oil.
Nm).
Camshaft
body
Manifold Absolute Pressure (MAP)
and torque the
•
the intake mani-
fold
shafts in their original posi-
•
connector
Ground wires from Throttle
correct sequence, to (11
Speed Control (ISC) motor
•
and torque the bolts
the bolt
Idle
•
(23
tions
connector
Exhaust Gas Recirculation (EGR)
Posi-
17
Washer pump and torque
Throttle Position (TPS) sensor
and exhaust rocker
Alternator
arm
•
arms and
Accelerator cable to the throttle body to
connector
unit connector
valve electrical connector •
to the
connect the following
•
Nm)
electrical
ECT sending
electrical
Install or
•
connector
arms on
Engine Coolant Temperature (ECT)
electrical
assemble the
earlier,
tion the intake
89 inch
•
•
shafts with clean engine
lbs.
•
rocker shafts.
4
connector
electrical
If
or disconnect the following:
Air cleaner
sensor
stepped end toward the distributor side.
springs, washers and rocker
sensor electrical connector electrical
the intake rocker
IAT sensor electrical connector
if
Remove
distinguished by looking
•
repair
Drain the cooling system.
4.
To install;
•
•
to
Nm)
•
to
3.
the shafts, which are different. Install
Fuel injector harness to the intake
ft.
Relieve the fuel system pressure.
2.
posi-
tion.
•The
torque the bolts to 37
same order and
in the
Before servicing the vehicle, refer to
.
tion.
removed; they must be re-assem-
30
to
1
ENGINE
the precautions in the beginning of this sec-
which the components are
•
•
1.0L
torque the bolts to 46
(62
REMOVAL & INSTALLATION
and rocker
arms, washers and springs from
lbs.
Nm)
arm
Exhaust pipe with a new gasket and ft.
lbs. (5
Intake Manifold
bolts. Lift out
shafts, with the springs
02sensor and torque the nuts
•
Rocker shaft retaining
the exhaust and intake rocker
(35
lbs.
44 inch
bolts to
arms attached.
ft.
belt
Battery
Exhaust manifold support bracket
26
Rocker arm cover and torque the
•
and torque the
bolt to
Timing
•
•
belt
I
•
Both battery cables
Nm) •
or disconnect the following:
PRIZM
•
fixture
Nm) •
Remove
2.
and torque the bolts
Right side engine
•
10
to
Nm)
(14
•
31 engines
manual
throttle
O
" 1I
1
•
U
METRO
•
PRIZM •
Evaporative Emissions (EVAP) canister
•
GEO/CHEVROLET
fl
vacuum hose
MAP
sensor hose from the intake
Fuel feed and return hoses
•
Intake manifold
(PCV) vacuum hose
•
Canister purge hose
To
Accelerator cable from the throttle
•
Accelerator cable
5.
body
•
Intake manifold bolts
•
Intake manifold
Intake manifold/throttle
body
unit
To connect the following:
Intake manifold with a
and torque the bolts
to
17
PCV hose
•
EVAP
canister
•
MAP
sensor vacuum hose
•
Brake booster
•
Coolant hoses
•
Fuel feed and return hoses
•
ECT sensor
vacuum hose
vacuum hose
electrical
connect the following:
Intake manifold with a
•
new gasket to
•
17
•
Canister purge hose
•
•
Brake booster hose
•
•
Coolant hoses
ft.
Fuel inlet pipe to the fuel fitting to
22
Fuel return hose
Fuel feed and return hoses
•
Wiring harness
ft.
lbs.
Upper
hose and support
radiator
bracket and torque the bolt to 13
Ground wires
to the intake
mani-
lbs.
•
Engine wire harness
to the intake
MAP
lbs.
equipped
•
TPS sensor
ECT switch electrical connector TPS sensor electrical connector EGR solenoid valve electrical con-
•
IAC valve
•
EVAP
nector
•
sensor
Coolant bypass hoses
connector
•
MAP
Accelerator cable
•
IAC valve
•
TPS sensor
•
Air cleaner
Air cleaner
•
Negative battery cable
•
Throttle
•
Wiring harness to the retaining
clamps
injectors
assembly
•
connector
the cooling system.
6.
Fill
7.
Start the vehicle
and check
for leaks,
•
Negative battery cable
1
.
7.
Start the vehicle
connector
•
Throttle valve cable,
if
and torque the bolts
to 11
98 inch
bolts to
(15
Before servicing the vehicle, refer to •
the cooling system.
Fill
electrical
assembly
IAT sensor electrical connector
the precautions in the beginning of this sec6.
connector
Accelerator cable and torque the
assembly
Air cleaner
connector
electrical
electrical
•
Prizm
body and adjust as needed
sensor
•
repair as necessary.
Accelerator cable to the throttle
•
ft.
•
canister purge valve electrical
ISC motor electrical connector
electrical
9
Fuel injector connectors to the fuel
connector
Ground wires body
connector
to
Nm)
(13
•
electrical
electrical
•
manifold
connector
electrical
ft.
Nm)
(18
•
to the intake
(18
Nm) •
to the retaining
fold
if
and
Intake manifold support bracket
manifold and torque the bolt
electrical connector,
(29
lbs.
Fuel injector electrical connectors
EFE heater
and
rail
ft.
•
connector
lbs.
Brake booster vacuum hose
torque the bolts to 13
•
•
13
Nm)
clamps
connector
new gasket
to
Nm)
torque the
Nm)
(23
lbs.
connect the following:
Intake manifold with a
and torque the bolts
•
•
Install or
•
and torque the nuts and bolts
lbs.
Coolant temperature sending unit electrical
•
•
ft.
•
•
ft.
install:
(18
Install or
5.
new gasket
throttle
install:
Nm)
(23
•
Coolant hoses from the
Brake booster hose
Install or
•
•
Upper radiator hose and support bracket
•
Positive Crankcase Ventilation
•
Fuel feed and return hoses
Brake booster vacuum hose
•
•
•
Intake manifold support bracket
•
To install: 5.
•
•
Brake booster vacuum hose
•
•
clamps
body
manifold •
•
Wiring harness from the retaining
lbs. (11
Nm)
equipped ft.
lbs.
Nm)
Negative battery cable the cooling system.
6.
Fill
7.
Start the vehicle
tion.
and check
for leaks, 2.
repair
1.3L
if
Relieve the fuel system pressure.
necessary.
repair
ENGINE
3.
Drain the cooling system.
4.
Remove
.
for leaks,
Exhaust Manifold
Before servicing the vehicle, refer to the
precautions
•
Accelerator cable from the throttle
•
Throttle valve cable from the
the beginning of this section.
in
REMOVAL & INSTALLATION
body 2.
and check
necessary.
or disconnect the follow-
ing: 1
if
Relieve the fuel system pressure.
3.
Drain the cooling system.
4.
Remove
throttle body,
if
equipped
or disconnect the following: •
•
Air cleaner
•
Ground wires from the
electrical
intake
connector
assembly
•
Air cleaner
•
Throttle Position (TPS) sensor
fold
Fuel injector electrical connectors
•
Manifold Absolute Pressure (MAP)
electrical • •
electrical
Throttle Position (TPS) sensor •
Control (IAC) valve electri-
connector
•
tor
electrical
.
Before servicing the vehicle, refer to
2.
Remove
Manifold Absolute Pressure (MAP)
• •
electrical
in
the beginning of this sec-
tion.
or disconnect the follow-
connector
Coolant bypass hoses
Negative battery cable Front pipe from the exhaust manifold
•
Fuel injector electrical connectors
•
•
Wiring harness from the intake
•
Exhaust manifold heat shield
manifold
•
Exhaust manifold
Evaporative Emissions (EVAP) can-
purge valve
1
the precautions
sensor
connector
connector
ister
ENGINE
ing:
Idle Air Control (IAC) valve electri-
cal •
Idle Air
connector
connector cal
electrical »
I.OL
mani-
•
sensor
Metro
Intake Air Temperature (IAT) sensor
connec-
Heated Oxygen (HO 2 S) sensor
01.11 O
GEO/CHEVROLET METRO To install:
•
Install or
3.
•
Exhaust manifold with a new gasket
17
ft.
•
I
I
Heated Oxygen (HO 2 S) sensor and
Front exhaust pipe from the
exhaust manifold
lbs.
Nm)
(23 •
to
PRIZM
sub-oxygen sensor
connect the following:
and torque the bolts
•
•
Exhaust manifold heat shield and
•
Exhaust manifold support bracket
Exhaust manifold upper heat
3.
torque the bolts toll
•
• •
new 33
HO 2 S and (45
lbs.
4.
shield
(15
Front pipe to the exhaust manifold
bolts to
•
lbs.
Nm) with a
•
ft.
seal ft.
and torque the
lbs.
necessary
if
To install: 7922Z713
torque the bolts to 33
connect the following:
Install or
ft.
Nm)
•
Lower heat
shield,
torque the bolts to 11
and check
•
1
ENGINE
(48 •
Before servicing the vehicle, refer to
.
and torque the bolts (15
or disconnect the follow-
•
•
Negative battery cable
•
Front pipe from the exhaust mani-
and torque the bolts (62
•
Oxygen (O 2 S) sensor
electrical
•
Low
side
A/C
line bracket
position aside, •
To 3.
•
if
and
4
equipped
24
ft.
ft.
lbs.
ft.
A/C
line bracket,
lbs.
lbs. (41
ft.
(15
37
and check
(15
to 11
ft.
lbs.
(50
1
.
O2S
Negative battery cable
electrical
in
Remove •
4.
Accessory drive
•
Alternator cover plate and torque
12
ft.
lbs.
Nm)
(16
belt
49 inch
lbs. (5.5
•
Right side splash shield
•
Air cleaner
•
Negative battery cable
assembly
Fill
Start the vehicle if
new
the engine with
7.
oil.
and check
for leaks,
necessary.
Before servicing the vehicle, refer to
.
tion.
Remove
2.
oil.
Negative battery cable
assembly
Air cleaner
•
Right side engine splash shield
•
Lower
Accessory drive
•
Crankshaft pulley
•
Water
•
Timing
pump
seal
belt
Negative battery cable
•
Accessory drive
•
Right side splash shield
•
Crankshaft pulley
•
Crankshaft front seal
4
Rotate the Crankshaft to align the tim-
•
Crankshaft
belt
To
install:
5.
Lubricate the
clean engine
Brake service
Is
oil
seal
lip of
covered
the
new
Install or
In
new
oil
connect the following:
New
•
Crankshaft pulley and torque the
oil seal
105
using a seal driver
ft.
Section 4 of this manual
lbs.
(142
•
Right side splash shield
•
Accessory drive
•
Negative battery cable
Start the vehicle
seal with repair
oil.
the
•
bolt to
tion.
oil to
lubricate the lip of the oil seal with
multi-purpose grease
pulley
ing marks.
Timing
belt
Apply clean engine
and
cover
belt
or disconnect the following:
•
To install: 3.
alternator cover
•
Negative battery cable
Nm)
(24
•
8
or disconnect the following:
the precautions in the beginning of this sec-
or disconnect the follow-
lbs.
Prizm
•
•
Prizm
Remove
ft.
the bolts to
necessary
the beginning of this sec-
Drain the engine
connector
ing:
Nm)
lbs. (11
pulley and torque the
Crankshaft pulley and torque the
for
Before servicing the vehicle, refer to
3.
lbs.
Before servicing the vehicle, refer to
Nm)
the precautions in the beginning of this sec-
2.
Nm)
•
97 inch
pump 18
(27
lbs.
Nm)
Metro
Nm)
•
•
if
ft.
•
Nm)
if
ft
Water
20
cover and torque the
belt
5.
Nm) to
•
lbs.
REMOVAL & INSTALLATION
Front pipe and torque the bolts to
37
2.
ft
Negative battery cable
Start the vehicle
Exhaust manifold stiffener bracket
(50
1.
46
tion.
and torque the bolts
•
30
the precautions
side
Timing
bolts to
1
equipped and torque the bolts
•
to
and torque the ten-
belt
lbs.
lbs.
Exhaust manifold heat shield and
Nm) Low
— Metro
connect the following:
bolts to ft.
Nm)
torque the bolts to 11
•
24
connect the following:
to
•
repair
Exhaust manifold with a new gasket
(32 •
to
Front Crankshaft Seal
and torque the bolts
shown
oil seal
lbs.
Exhaust manifold
Install or
•
ft.
Nm)
exhaust leaks, repair
install:
Timing
H02sensor and torque the fasteners to
Exhaust manifold heat shield
to 11
Nm)
Exhaust manifold stiffener bracket
connector
•
Front pipe to the exhaust manifold
fold
•
New
sioner bolt to
Exhaust manifold support bracket
(32 •
36
•
bolts to
•
•
seal protector as
Install or
6.
lbs.
Nm)
and torque the bolts
ing:
to
ft.
Exhaust manifold upper heat shield
the precautions in the beginning of this sec-
Remove
oil
(15
Nm)
tion. 2.
lbs.
Exhaust manifold with a new gasket
and torque the bolts
1.3L
ft.
Nm)
for
necessary.
if
to the lip of the seal
removed, and
if
use an
Start the vehicle
damage
To prevent
Negative battery cable
exhaust leaks, repair
Lower heat shield from the exhaust manifold,
Nm)
(45
Exhaust manifold
if
necessary.
Nm)
belt
and check
for leaks,
Q1 " 1 C 9 O
GEO/CHEVROLET METRO
I
I
•
PRIZM
O
Camshaft
•
engine
REMOVAL & INSTALLATION
^3 — ENGINE
I.OL 1
A
-
B
-
Before servicing the vehicle, refer to
.
Remove
2.
or disconnect the following:
•
Negative battery cable
•
Rocker arm cover
•
Distributor
•
Timing
•
in
—
and housing
belt sprocket.
rod inserted into the hole
during this procedure. Place a clean
shop cloth between the rod and mating surfaces and use care not to
of the
left
until the is
for the
camshaft journal and
all
oil to
the
the engine
oil
to
pump
or disconnect the following:
Camshaft caps from the cylinder
around the cam,
.
2.
lifter
through the camshaft
holes and check that engine
out from the
oil
holes
in
oil
the valve
Install
Camshaft timing
camshaft journal.
•
Camshaft Position (CMP) sensor
nal positions, 7.
Apply silicone sealant
surface of the No.
which
will
1
to the
mating
and No. 3 bearing cap,
mate with the cylinder head.
Install
'Camshaft bearing cap No. installed
first.
It
Loosen
if
lifters in their
•
Camshaft
To
install:
4.
Apply clean engine
the camshaft
in
the cylinder
oil
ing bolts (11
and torque them
to
freely.
oil to
journals and the
5.
Install or
the
oil
seal.
•
connect the following:
Camshaft Camshaft housings and torque the bolts in
oil
move
1 is
retains the camshaft in
Apply clean engine
valve adjusting screws to
Camshaft housings
camshaft,
the proper position and thrust direc-
11.
belt pulley
•
origi-
being re-used.
all
allow the rocker arms to
There are marks provided on each
for installation. Install the
belt
and housing 3.
tion. the valve
or disconnect the following:
Negative battery cable
•
•
bores.
6.
Remove
surface of each bearing cap against the
bearing cap as indicated by the marks.
install:
Before servicing the vehicle, refer to
Rocker arm cover
and direction
comes
purged and
until the air is
ENGINE
•
the sliding
camshaft bearing cap indicating the position
lifters
oil
to the retain-
97 inch
lbs.
sequence
Nm) New camshaft
to
97 inch
(11 •
oil
seal
Nm).
© ©
©
©
© ©
7922Z714
Position the crankshaft as
shown before
removing the camshaft— Metro with I.OL engines
a
oper-
is
Timing
oil to
Camshaft
oil
may make
the engine
•
Apply clean engine
Valve
journal
when
tion.
is at
•
Pour engine
air is
if
•
8.
10.
head
5.
is started,
the Hydraulic Valve Lash
the precautions in the beginning of this sec-
•
To
engine and check the igni-
Start the
in
1.3L
position the camshaft so the camshaft tim-
9.
•
belt
camshaft bearing
— Metro with I.OL engine
head. After applying engine
crank-
60 degrees
arrow mark on the
Remove
Negative battery cable
trapped
1
case. 4.
»
'When
the lower position.
the
Timing
2000 rpm
ing sprocket pin hole in the camshaft
when loosening.
mark
Distributor
•
the tapping sound ceases.
The mating surface of the cylinder head and cover must not be damaged
shaft sprocket timing
lbs. (5
ated. In such a case, run the engine at
cap bolts
Turn the crankshaft
Nm)
Distributor housing
tapping sound
Torque sequence
3.
(60
lbs.
(HVL) adjuster, the valve in.
the camshaft, before loosening
the rod
ft.
•
13.
the sprocket retaining bolt.
bump
44
tion timing. Adjust the timing as necessary.
Lock the camshaft with a 0.39
(10mm)
Valve cover using a new gasket and
•
Metro with I.OL engine
belt
Camshaft timing
•
Nm)
7922Z715
bearing caps
lip
Camshaft sprocket and torque the
torque the bolts to 44 inch
Indicates direction to timing belt
Directional markings for the camshaft
tion.
seal after applying
the seal
•
Indicates position from timing belt
the precautions in the beginning of this sec-
oil
oil to
bolt to
Metro
connect the following:
Install or
12.
Camshaft
9346XGB1
Camshaft housing torque sequence
lbs.
OH O 19 O
GEO/CHEVROLET METRO •
ft.
bearing cap bolts to 17
(60
lbs.
ft.
Nm) •
•
belt 4.
to adjust
dead b.
ft.
lbs.
(23
number one
Set the
cylinder to top
center.
Ensure the camshaft
is in
phase.
if
and
Adjust valves
d.
Rotate the crankshaft one revolu-
valves. Record the clearance
torque the bolt to 40
for all valves that are not within specifica-
ft.
(55
lbs.
Nm)
tion, in
Timing chain
replacement shims.
•
Negative battery cable
•
Adjust valves
CMP
3, 4, 7,
and
5.
der intake and exhaust valves. Record the
Valve Lash
determine the required replacement shims.
Nm)
lbs. (11
CMP
•
Rocker arm cover and torque the
Nm)
Negative battery cable
camshaft and valve stems, are used to
matically at
b
Insert tool
camshaft and
Prizm and 1.3L Metro
Before servicing the vehicle, refer to
camshaft
J-3987-1 between the
lifter
adjustment shim, to
•
•
Camshaft sprocket
Camshaft bearing cap sequence, by starting
bolts, in at the
ends
and working towards the center
of
the camshaft •
Camshaft from the cylinder head
Install or
•
Camshaft
•
Camshaft bearing caps
to the cylinder
head
in
sequence
to
lifter.
Disconnect the ignition wires.
magnet, remove the adjustment shim
4
Remove
from the top
5
Turn the crankshaft
No.
1
the negative battery cable
the rocker
cylinder
is at
d.
arm cover until the
piston
Top Dead Center
Using a small screwdriver and a
Use
e
of the lifter
the micrometer to
measure the
thickness ol the removed shim Deter-
(TDC) on the compression stroke Align the
mine the thickness
groove
using the formula below For the pur-
in the
crankshaft pulley with the 0
mark on the timing
belt
cover Be sure the
poses
camshaft gears are aligned
The intake valve clearance should be
0 006—0.010
in.
7.
in.
Using a
new shim T =
ol the following formula,
Valve clearance measured;
(0.15-0.25mm) and the
A= N = Thickness
+
gauge, measure the
clearance between the camshaft and valve
For the intake camshaft valves
A—0 008 A
10
in.
(0
N
—0 010
in.
Select a
= T
20mm)
For the exhaust camshaft valves:
11
T +
a jwe’i
new shim
of the required
10.
(0.25-0 35mm).
feeler
of the
Thickness ol the shim removed;
proper location and direction and torque the bolts
on the
of the tool
3.
0.010-0.014
in their
lifter
Remove
exhaust valve clearance should be
connect the following:
to hold the
lifter,
2.
6.
install:
J-39871-2 between the
bottom edge
in
•
Insert tool
camshaft and the
tion.
Negative battery cable
•
Before servicing the vehicle, refer to
away from the camshaft Position the
or disconnect the following:
Timing chain
.
the
down
the precautions in the beginning of this sec-
tion.
Remove
lifter c.
1
the precautions in the beginning of this sec-
3.
of the
directly over the valve (camshaft
lobe pointing away from the valve).
not
is
is
compress the valve spring and push
camshaft.
To
times. Adjustment
required or possible.
the
ft
lbs.
left
fender well
(16
Nm)
Suspension support cage nuts from
Powertrain/frame assembly from
Install or
• •
connect the following:
Powertrain/frame assembly
New frame-to-body
bolts
do not
tighten at this time
Suspension supports with new bolts
and torque the suspension
support and frame bolts to 74
Purge solenoid
•
Rear Heated Oxygen (HO 2 S) sensor
•
Frame-to-body attachment fasten-
Raise the powertrain into the vehicle.
•
•
•
body
install:
and intake duct assem-
Purge hose from the
exhaust manifold and torque
the bolts to 12
the
connector
Air cleaner
electrical
Exhaust from the catalytic converter to the
to the fuse block
•
belt
from the struts
from the steering
Properly support the powertrain and
bly
Heater hoses
Accessory drive
•
Nm)
•
•
electrical
motor and torque the bolts
ball joints
the vehicle
Coolant reservoir hose
lbs.
Suspension support assemblies
•
fluid.
•
ft.
•
or disconnect the following:
To
33
Lower
ers
10.
to
Stabilizer bar links
•
•
Steering gear-to-intermediate shaft
Starter
•
oil.
Both battery cables
them
Tie rods from the steering knuckles
frame assembly.
pressure.
•
•
•
9.
•
(65
A/C compressor without removing
the
Upper and lower radiator hoses
lbs.
•
•
Metal power steering line
ft.
Exhaust system from the catalytic
knuckles
Before servicing the vehicle, refer to
•
torque them to 48
mount
transmission mount
converter to the exhaust manifold
•
•
Left side
MANUAL TRANSMISSION 1.
the
the hoses Start the engine,
2.
Engine mount bracket and torque the bolts to
Right side engine
tion.
hand-tighten them •
•
•
install:
and align
wood blocks between
•
10
mission with a jack
repair
push pin from
pulley and frame.
oil.
•
16.
Install
8.
fluid.
5 seconds and
liner
transmission case and frame and the crank
12.
new
wheel
Left front
the frame
fender well
left
hoses
Secure the radiator to the upper radi-
7.
•
IAT sensor electrical connector
hoses
lower cowl
radiator
•
•
radiator
at the
ator support.
and intake duct assem-
Lower engine-to-transmission bolts lower cowl
shaft lever to the transmission
bly
•
at the
Retaining clips connecting the control
nector
the hoses
To
SW2
connector and hose
•
throttle
lifting
•
Torque the upper
.
connector
electrical
SW1
•
throttle
electrical
body
connector
lbs.
•
electrical
•
ft.
plus 45 degrees
Ball joint to the steering
(100
connec-
Nm)
and torque the nuts
connector
Back-up switch
(100
to
knuckle
74
ft.
lbs.
Nm)
Stabilizer links to the struts
tor
torque the fasteners to 50
Front dash cover
(65
Nm)
ft.
and lbs.
00.7
SATURN LW
•
SCI
•
SC2
•
SL
SL1
•
SL2
•
SW1
•
vC.
SW2
•
I
•
IAT sensor electrical connector
•
Ground wire
•
Main wire feed
•
Battery
•
Steering gear-to-intermediate shaft
to the
fender well
left
to the fuse block
and both cables
and torque the pinch bolt
to
15.
Fill
the engine with coolant.
16
Fill
the engine with
17.
Fill
the power steering fluid.
18.
Prime the
ON
ignition
new
ft.
oil.
system by cycling the
fuel
5 seconds and
for
22
Nm)
(30
lbs.
OFF
10
for
seconds a few times without cranking the engine. Start the engine,
19. repair
if
check
for leaks,
and
necessary
3.0L Engine 1
Before servicing the vehicle, refer to
.
the precautions in the beginning of this section.
Properly relieve the fuel system
2.
pressure.
Powertrain/frame assembly with
table-2. 2L engine
lifting
3.
Drain the engine coolant.
4.
Drain the engine
5
Drain the power steering
6
Remove
Both battery cables
•
Air cleaner
•
Mass
and torque the new nuts lbs.
(65
45
ft.
to the
exhaust
ft.
lbs.
(16
Nm)
A/C compressor and torque the bolts to 18
•
Rear
HO 2 S
tt,
(25
lbs.
sensor
Nm)
electrical
torque the bolts to 41
tt
lbs.
(55
Nm) •
Left
side transmission mount and
torque the bolts to 41
Nm) Remove
12.
Move
lbs.
(55
it
in
connector
(12
Nm)
14
Install
wood
blocks.
place
Black engine harness connector
from under the fuse block panel •
Fuse block
•
Engine harness connector to the
•
Battery tray
•
Evaporative Emissions (EVAP)
of the fuse
•
Fuse block
•
the engine harness to the engine
block
purge connector
Fuel feed and return lines
•
FVAP purge solenoid
•
Upper and lower
•
Heater hoses
•
Brake booster vacuum hose
electrical
connector
boot to the cowl
•
Right front speed sensor connector
•
Front Oxygen (0;S) sensor from the
electrical
•
connector and hose
hoses •
•
•
Purge hose
•
Air cleaner
Timing belt service
is
•
connector
•
Transmission main
electrical
con-
Transmission
shift control electrical
connector
to the throttle
body
•
and intake duct assembly
covered
pipe
nector
Transmission back-up switch electrical
rod as follows:
down
Transmission ground electrical connector
Main harness connector near the master cylinder
rod into the shift
Lower weather pack connector from inside the fuse block and secure
•
•
Install the shift
A/C pressure connector
•
Fuse block
Cowl cover
a.
•
Fuse block and battery trays
•
linkage assembly.
connector by the brake
•
Both front wheels
shift control
inline
•
•
Shift control rod
TCM
Cruise control and throttle cables
•
Adjust the
connector from under
•
Right front splash shield
radiator
lbs
It
or connect the following
Left
push pins
mam
master cylinder
plus 180 degrees
•
liner
•
and use a 3/8 inch punch
PCM PCM
front wheel
Transmission Control Module
the cowl cover
the shift lever to the 5
bottom the
boot
Tighten the pinch bolt to 9
e
assembly
Flow (MAF) sensor elec-
Battery ground cable from the fuse
(TCM)
shift lever
•
•
13.
ft.
d
to hold
mount and
Right side engine
Pull
(reverse gate)
con-
nector •
up the
c.
Air
block •
on the case
lock pin
manifold and torque the bolts to 12
•
clockwise and depress the
trol shaft
spring loaded transmission shift linkage
Exhaust system
•
to
Nm)
•
fluid.
or disconnect the following
•
trical
Rotate the transmission shift con-
b
Tie rods to the steering knuckles
•
oil.
in
Section
3
of this
Rear connector on the Engine Control
manual
Module (ECM)
SATURN
32-8
LW
SCI
•
•
SL1
•
SL2
Brake booster
•
Fuel lines
•
EVAP purge hose and
•
connector
solenoid •
motor
•
Starter
Torque converter bolts
SW2
•
Right front speed sensor electrical
•
•
SW1
Transmission main connector
•
vacuum hose
•
•
SL
•
SC2
•
O 2 S sensor
Front
electrical
connec-
tor
Exhaust system from the catalytic
•
converter to the exhaust manifold
•
Right front speed sensor
EVAP purge solenoid
electrical
connector
•
Transmission nose bracket
•
A/C compressor without removing the hoses
Torque the upper
11. to
48
ft.
lbs.
housing bolts
bell
(65 Nm).
•
Heater hoses at the lower cowl
•
Battery tray
•
Lower engine-to-transmission bolts
•
Fuse block and route the engine
•
Upper and lower radiator hoses
•
coolant reservoir hose
•
•
Metal power steering line
•
Main wire feed
•
Power steering reservoir from the
•
A/C pressure connector
radiator support
•
TCM TCM
Attach an engine
7.
harness
7922Z801
Water pump
Lower weather pack connector
•
device to the
lifting
to the block
to the fuse block
torque the bolts inline
lifting
sequence
main connector under the
cowl cover and secure
eyes.
mount and •
Positive
it
•
13.
Fill
the engine with
14.
Fill
the
15.
Prime the
30
ft.
lbs.
Nm)
(40
30
ft.
lbs.
Nm) and the (55 Nm)
(40 ft.
lbs.
torque the bolts to 30
Nm) Remove
ft.
lbs.
(40
ignition
Metal power steering line
Power steering reservoir
•
Coolant reservoir hose
•
Lower transmission bolts and torque them to 48
ft.
lbs.
(65
(40
ft.
lbs.
(65
Nm)
2.2L Engine
fluid.
1
system by cycling the
5 seconds and
for
if
OFF
for
10
check
for leaks,
and
necessary.
Nm)
.
ft.
(20
(40
to the
Nm) exhaust
•
Fuel feed and return lines
•
Brake booster
Remove
ECM
or disconnect the following:
•
Negative battery cable
•
Air cleaner
•
Exhaust manifold heat shield
assembly
the beginning of this sec-
•
Accessory drive
•
Right front wheel
belt
•
Inner wheel well splash shield
•
Water
pump
the pulley to
pulley bolts and allow
hang
freely
pump hub Water pump flange Water pump
on the
water
vacuum hose
rear connector
or disconnect the following:
Negative battery cable
•
Transmission
in
•
EVAP purge solenoid and hose
•
tion.
Drain the cooling system.
Nm)
•
Before servicing the vehicle, refer to
tion.
Nm)
lbs.
Exhaust system
.
the precautions in the beginning of this sec-
Before servicing the vehicle, refer to
the precautions
manifold and torque the nuts to 15
•
To
install:
4.
Install or
bolts
9346ZG12
shift control electrical
connector • •
fuel
Start the engine,
16.
A/C compressor and torque the 30
for leaks,
oil.
Drain the cooling system.
Heater hoses at the lower cowl
bolts to
and check
necessary.
Remove
3.
lbs.
power steering
if
3.
2. lbs.
Start the vehicle
2.
motor and torque the bolts
ft.
the cooling system.
6.
1.9L Engines
Torque converter and torque them
ft.
Negative battery cable
Fill
engine.
1
•
Right front wheel
•
REMOVAL & INSTALLATION
Upper and lower radiator hoses
•
•
belt
Water Pump
radiator support
•
Right front wheel well splash shield
to the
•
30
Accessory drive
•
seconds a few times without cranking the
repair
•
Starter
ON
new
the engine lifting device.
•
to
(25
connector
electrical
Engine mount bracket and torque
Transmission nose bracket and
•
sensor
the engine with coolant.
lower bolt to 41
•
MAF Fill
48
lbs.
•
5.
repair
12.
to
ft.
fuse
and intake duct assem-
hand-tighten them
bolt to
•
Nm)
hub and
bly •
Engine mount and torque the upper
•
at the
and both cables
Air cleaner
connect the following:
the bolt to •
Battery
•
Upper transmission bolts and
•
10.
•
into the vehicle
on the pins on the transmission.
Install or
9.
main feed cable
(30
pulley to the
housing
Lower the engine
and align
crisscross
lbs.
Nm)
Battery ground cable at the wheel
•
Engine from the vehicle
To install: 8.
pump
ft.
block
Upper transmission bolts
•
22
to the
engine
bracket •
it
Water
to
torque the bolts to 19
Right front engine
•
in a
connector •
engine
sequence-1 .9L
bolt torque
engines
Transmission ground connector
Water
connect the following:
pump
with a
new gasket and
Water pump holding engine
tool
J43651-2.2L
SATURN LW
•
SCI
•
SC2
SL
•
•
SL1
•
2. 3.
SL2
SW1
•
•
32-9
SW2
Drain the cooling system.
Remove
or disconnect the following:
•
Negative battery cable
•
Air cleaner
•
Lett front
•
Wheel
•
Loosen the water pump pulley and
assembly
wheel
well splash shield
power steering pulley
bolts, but
do
not remove them 4.
Install
an engine support
fixture.
mount
•
Right front engine
•
Accessory drive
•
Release the retaining tabs on the
belt
wiring harness channel and remove the front cover
To
-
6
5.
,r
•
Wiring harness from the channel
•
Water
•
Power steering pump pulley
•
Drive belt tensioner Front timing belt cover
•
Water
of the
Install or
•
Thermostat housing
•
Water
•
Water
pump pump
from the Install a
4.
Water
connect the following:
pump
with a
new O-ring and
torque the bolts to 18
ft
lbs.
(25
Nm) Front timing belt cover and torque the bolts to 71 inch lbs (8
water pump-2. 2L engine
•
pump
install:
•
Exploded view
pulley
•
\ritp
) V-
pump
Nm)
feed pipe
sprocket access plate
front
cover
Water
Pump
pump pump
retaining bolts
Holding Tool
J43651. •
Water
•
Water
To
install: Install or
5.
connect the following
•
pump and torque the bolts to lbs. (25 Nm) 18 Water pump sprocket and torque the bolts to 89 inch lbs. (10 Nm) Water pump sprocket access plate
•
Water feed tube
Water
•
ft.
•
after lubricating
the
0-ring
Thermostat housing and torque the
•
bolts to
89 inch
(10
Nm)
Exhaust manifold heat shield
•
Air cleaner
•
Negative battery cable
assembly
the cooling system.
6.
Fill
7.
Start the vehicle
repair
lbs.
•
if
and check
for leaks,
necessary.
3.0L Engine 1
3MUGI)
Before servicing the vehicle, refer to
the precautions in the beginning of this sec-
Timing
belt cover bolt locations— 3
0L engine
tion.
Heater Core replacement
is
covered
in Section
2
of this
manual
1
SATURN
f£
U
I
LW
SCI • SC2
•
•
SL
•
SW1
SW2
«
bolts to
30
ft.
lbs.
(40
pump
Water
bolts to
15
pulley's
ft.
lbs.
removing the
and torque the
(20
Nm) '
Wiring harness into the channel
• •
Wiring harness channel front cover
•
Accessory drive
Remove
Right front wheel
•
Wheel
•
Crankshaft pulley
•
and
torque the bolts to 44 inch
lbs. (5
Front exhaust pipe from the
•
Crankshaft gear retaining and
removal
tool
oil
pan
with the
shown— be
crankshaft tool with the
Front cover
flat
Air cleaner
•
Negative battery cable
side toward the sprocket.
sure to install the
flat
Front tour
oil
side toward oil
•
crankshaft gear retainer tool
Install a
7.
•
Nm) Front wheel
well splash shield
6.
well splash shield
•
lines
•
exhaust manifold
belt
the engine support fixture.
Wheel
•
Power steering pump without
•
Nm)
the bolts to 71 inch lbs. (8 •
front bracket
without removing the hoses
Nm)
Power steering pump and torque
•
A/C compressor and
•
Drive belt tensioner and torque the
•
6.
SL1 • SL2 •
pan bolts and cut the
pan seal away from the front
the gear
cover
and intake duct •
Front cover
Reposition the wire harness out of the cooling system.
7.
Fill
8.
Start the vehicle
^Position the crankshaft 90 degrees off of Top Dead Center (TDC) to make
the way. repair
if
and check
for leaks, •
Spark plug wires
•
Evaporative Emissions (EVAP)
necessary.
purge valve •
certain that the pistons do not touch the
valves during assembly.
vacuum hose
Positive Crankcase Ventilation
(PCV) vacuum hose body connector
•
Throttle
•
Brake booster vacuum hose
•
Upper radiator hose from the cylin-
the engine result
is
cold.
the cylinder head
if
while the engine
is
removed
is hot.
Before servicing the vehicle, refer to
1.
the precautions in the beginning of this section.
Drain the cooling system.
2. 3.
Drain the engine
4.
Properly relieve the fuel system
•
•
Loosen and uniformly remove the
•
Deaeration hose from the intake
in
several
Cylinder head from the dowels on the engine block
To
install:
Heater hose from the intake manifold
•Before
Fuel supply line
should be cleaned and inspected for
Engine torque axis mount
•
Accessory drive
•
Drive belt tensioner
•
Drive belt idler pulley
•
Rocker arm cover
•
Deaeration line from the cylinder
head water
installing the cylinder head,
it
excessive wear or damage.
•
oil.
Camshaft sprocket
•
10 cylinder head bolts
manifold
when Warpage may
Only remove the cylinder head
Timing chain, tensioner and guides
•
passes
der head outlet •
•
belt
8.
Clean the gasket mating surfaces. Be
careful not to
damage
the
aluminum com-
ponents and be sure the block bolt holes are clean of any residual sealer,
oil
or for-
eign matter.
outlet
9.
Using a
dial
gauge, check that the
pressure.
Remove
5.
or disconnect the following:
•
Negative battery cable
•
Air cleaner
•
Rocker cover fresh
•
Accelerator cable from the throttle
body and •
• •
7
10
6
2
4
8
9
5
1
hose
intake manifold bracket electri-
connector
Fuel injector connectors Idle Air cal
•
air
Coolant temperature gauge cal
3
assembly
Control (IAC) valve electri-
connector
Throttle Position (TPS) sensor electrical connector-
•
A/C compressor
electrical
connec-
tor •
Manifold Absolute Pressure (MAP)
sensor •
electrical
connector
Oxygen (O 2 S) sensor
electrical
connector •
Exhaust Gas Recirculation (FGR)
7922Z803
solenoid Gradually remove the cylinder head bolts
in
the sequence
shown
to
prevent warping the head
90-1
SATURN LW
•
SCI
•
SC2
•
SL
•
SL1
•
SL2
•
SW2 vJC
•
I
I
Coat the cylinder head bolts with
13.
clean engine
hand
SW1
and thread the bolts by
oil
until finger-tight.
14.
cylinder head bolts, in
Install the
sequence, as follows: a.
Tighten the bolts to 22
ft.
lbs.
(30
Tighten the bolts to 33
ft.
lbs.
(45
Nm). b.
Nm) for SOHC engines or to 37 (50 Nm) for DOHC engines.
lbs.
ft.
Tighten each bolt an additional 90
c.
degree turn. 15.
Install
the timing chain, sprockets,
guides and tensioners, using the following
procedure Verify that the crankshaft
a.
tioned
is
posi-
90 degrees clockwise past TDC.
The crankshaft key way sprocket timing mark must be aligned with the cylinder block main bearing cap vent piston and valve 10. b.
If
to No.
will
be
at 3 o'clock) to
to
90 degrees past TDC (the crankshaft sprocket timing mark
required, rotate the camshaft
1
TDC
up
position.
90 degrees
Rotate the crankshaft
c.
Rotate the crankshaft clockwise
split line to pre-
damage
counterclockwise to No.
1
TDC
position.
The crankshaft sprocket timing mark
prevent valve damage during assembly
must align with the cylinder block timing cylinder liners are flush or do not deviate
more than 0.0005
in.
(0.013mm).
Be sure the crankshaft degrees past
1 1
TDC and
that the
is still
.
Install the cylinder
carefully guide the
head
head gasket and
into place over the
mark.
16
Install or
•
90
dowels.
camshaft(s)
12.
If
sprocket and under the crankshaft
the head bolts and/or the block
were replaced,
pin(s) at the 12 o'clock position to prevent
in
valve damage.
proper clamp load; then, remove the bolts
sequence
to
install the bolts
48
ft
lbs.
(65
sprocket Slide the camshaft
and tighten
are properly positioned with the dowel
Nm)
connect the following
Timing chain over the camshaft
sprocket onto the camshaft with the
to insure
letters
FRTfacing away from the
cylinder head • •
Camshaft sprocket timing pin Camshaft washer and torque the bolt to 74
bolt
and
lbs.
ft
(100
Nm) •
Fixed chain guide and torque the fastener to 19
ft.
lbs (26
Nm) The
timing chain should be snug against the fixed guide •
Pivoting chain guide making cer-
between the
tain there is clearance
block and head and torque the bolts to •
19
Nm)
(26
168 inch
the bolts to •
lbs
ft
Timing chain tensioner and torque lbs.
(19
Nm)
Crankshaft timing gear retainer tool to align the gerotor oil
pump
to the
front cover •
Front cover and torque the perimeter
bolts to
22
ft.
lbs
(30
the lower center bolt to
(10 •
Oil
Nm) pan and torque the bolts
inch lbs. (9 •
Brake service
is
covered
in
Section 4 of this manual
Nm) and
89 inch lbs
Water
pump
to
80
Nm) pulley and torque the
SATURN
32-12
LW
bolts to 19
lbs.
ft.
•
SC2
(25
Nm)
SCI
•
SL
•
•
SL1
•
SL2
Remove
53 inch
the crankshaft timing gear
retaining tool.
Apply RTV across the cylinder head
18.
and
and
front cover T-joints
install a
new
rocker cover gasket •
Crankshaft pulley and torque the
•
Rocker cover and torque the bolts
159
bolt to
to •
22
•
22
cable
ft.
20
lbs.
ft.
Nm)
(27
Make
not
is
(25 Nm).
lbs.
Fill
the cooling system.
Fill
the engine with
21
Prime the
ON
for
Intake manifold
•
Exhaust manifold flange bolts
new
oil.
•
Fuel lines
•
A/C compressor switch
system by cycling the
5 seconds and
Start the engine, if
check
OFF
for
10
•
for leaks,
and
bolts to
Nm) (if removed) Power steering pump and torque the bolts to 22 ft. lbs. (30 Nm) A/C compressor and torque 18
35
Nm)
(47
Coolant
•
Upper
Accessory drive
•
Upper mount and torque the bracket nuts to
belt
37
bolts to •
Wheel
•
Wheel
37
lbs.
ft.
hose from the
Ignition coil electrical connectors
•
Knock Sensor (KS)
electrical
when Warpage may
Only remove the cylinder head the engine
is
cold.
•
if
the cylinder head
while the engine
is
removed
Before servicing the vehicle, refer to
the precautions
in
connector
hot. •
1.
connector
Front Oxygen (O 2 S) sensor electrical
is
electrical
Fuel injector jumper harness
•
Ignition coil
Power steering pump and secure to the
the beginning of this sec-
lines
2.
Drain the cooling system.
3.
Drain the engine
Properly relieve the fuel system
Remove
•
Camshaft cover ground strap
•
Camshaft cover
•
Upper timing chain guide
oil.
or disconnect the following:
•
Upper timing chain tensioner
•
Camshaft sprocket bolts
cover
well splash shield
•
EVAP
•
Throttle
canister purge
hose
body vacuum harness hose
•
PCVhose
•
Brake booster
•
Upper
•
Heater hose
•
Ground wire
•
O 2 S sensor
•
Fuel injector electrical connectors
•
IAC valve
•
EGR valve electrical connector TPS sensor electrical connector EVAP canister purge valve connec-
vacuum hose
radiator
hose
connectors
electrical
connector
electrical
electrical
connector
tors •
MAP
•
Alternator electrical connectors
sensor connectors
•
Starter
•
A/C compressor
motor
electrical
connectors
electrical
connec-
tors •
Intake manifold support bracket
torque the bolts to 22
ft.
lbs.
and
(30
Nm) •
Deaeration line and torque the cylinder head nut to
80 inch
Nm) and
bracket nut to
97 inch •
the rear
lbs. (11
Fuel feed
and
lift
lbs. (9
9306ZG43
Nm)
return lines with
new
it
engine without removing the
Nm)
(50
con-
Engine Coolant Temperature (ECT) sensor
Nm)
to
cylin-
•
•
5.
(50
lbs.
ft.
bleed hose
nector
pressure.
and then torque the mount
air
radiator
der head
necessary.
2.2L Engine
4.
•
Crankcase vent hose from the
•
tion.
(25
the front bracket bolts to
lbs.
ft.
the
lbs.
ft.
electrical
camshaft cover
•
and torque the
to the
connector
seconds a few times without cranking the
22.
Exhaust manifold down pipe catalytic converter
(32
lbs.
ft.
Nm) and
•
19.
fuel
Negative battery cable
•
•
20.
result
rear bracket bolts to
•
Negative battery cable
hose
air
certain that the
routed properly and
is
Alternator
24
•
•
repair
binding and torque the bolts to 18
•
Fresh
•
Accelerator linkage bracket and the throttle cable.
•
•
Drive belt idler pulley and torque the fastener to
•
Nm)
(30
lbs.
ft.
assembly
Air cleaner
.
to
Nm)
engine.
Drive belt tensioner and torque the fastener to
and torque the fastener lbs. (6
•
ignition
Nm)
(30
lbs.
ft.
Nm)
(215
lbs.
ft.
SW2
•
retainers
(if
removed) 17.
SW1
•
90-10 OL O
SATURN LW •
Camshaft sprockets
•
Plug to gain access to the fixed
•
•
to
may be
It
INTdiamond
com-
A/C suction
line retaining clips
away
install
a crankshaft pulley holder tool.
Crankshaft pulley
•
Front cover bolts except for the one
proceeding
to the next
the timing chain
front
not
is
•
•
•
Front cover
•
Adjustable timing chain guide
Nm)
lbs (85
Fixed timing chain guide lower bolt
(40
To install:
•
to
applying Loctite
12
New
•
•
ft.
•
line
clamps
Camshaft cover and torque the
89 inch
lbs.
it
-
•
to the
to
30
ft
ft
(10 •
Timing chain tensioner and torque ft.
lbs (60
•
Tap the top of the timing chain
•
All
component
89 inch
electrical
Upper
Crankcase ventilation hose
hose
radiator
•
Fuel pressure regulator hose
•
Brake booster vacuum hose
(30
Fuel lines to the bracket and torque the bracket bolt to
89 inch
lbs.
(10
Nm)
Front 4 cylinder head bolts coated
•
with Loctite' and torque them to 18
Exhaust
Nm)
ft.
and
the intake camshaft with the offset slot in
down
pipe to the exhaust
manifold and torque the bolts to 25
Position the exhaust camshaft with
the offset slot in the 2 o’clock position
Nm)
connections
•
plus 155 degrees
(22
(10
lbs.
•
Fuel lines
lbs.
lbs.
Engine wiring harness and torque
•
ft.
89 inch
Wiring harness to the intake mani-
the fasteners to
on the
lbs
new gasket
to
fold bracket
Nm)
cylinder head bolts and torque ft
Nm)
Nm)
New
22
(25
assembly and
Intake manifold with a
EVAP purge hose
to
lbs.
Ignition coil/module
and torque the bolts
lbs
OBENfacing up
sequence
Nm)
Power steering pump and torque
•
in
(10
Camshaft cover ground strap and
torque the bolts to 71 inch lbs (8
Nm)
cylinder head gasket with the
it
Nm)
(100
lbs.
•
Nm)
9.
74
dowels
them •
Crankshaft damper and torque the
the bolts to 18
prevent con-
Cylinder head and align
(55
Nm)
connect the following
side imprinted
lbs.
Right front wheel
plus a
between the pistons and valves. Install or
ft.
•
Nm)
the bolts 44
60 degrees
Top Dead Center (TDC)
lbs (10
threads and torque
Before Top Dead Center (BTDC) or after
Nm)
Engine mount to the bracket and
Right wheel splash shield
connect the following
89 inch
and lbs.
Fixed timing guide bolt access plug after
to
ft.
torque the bolt to 89 inch lbs. (10
Fixed timing guide and torque the bolt to
bolt
Nm)
(90
A/C
•
Install or
1 1
cover bolt which was
'•Set the crankshaft
ft.
lbs.
ft.
torque the fasteners to 41
bolts to
63
66
•
•
30 degree turn
blocked by the mount bracket
pump
to
Nm)
(40
•
Torque the intake and exhaust
Engine mount bracket
Water
marks
links are aligned prop-
camshaft bolts
18
• Accessory drive belt
•
it
lbs.
ft.
rail
bolt to
do not
engine mount
•
•
certain that all timing
If
to
Nm)
** CAUTION
step.
30
Engine mount to the side
10.
Make
it
Engine mount bracket and torque
torque the bolts to 41
age may occur. bolt but
Support the engine and remove the
Upper
new
torque
Drive belt tensioner and torque the
(55 •
aligned properly, severe engine dam-
bracket
•
•
but do not tighten a
Install
(25
lbs.
ft.
pump bolt and (25 Nm)
the bolts to
Nm)
sprocket bolt
erly before
blocked by the engine mount
right side
(10
lbs.
bolts to •
camshaft sprocket with the silver
and colored
•
remove
•
Timing chain around the exhaust
and
Position the crankshaft 60 degrees
Before Top Dead Center (BTDC) and
Water ft.
cylinder head and torque the bolt to
to allow clearance to the
Loosen water pump
•
through the opening on top of the
lbs.
(10
lbs.
Nm)
link aligned with the offset slot.
crankshaft pulley bolt
•
engage
to
new gasket and
torque the bolts to 18
Adjustable timing chain guide
Right front wheel and splash shield
the line
sprocket bolt but do
the timing mark
not be
89 inch
•
Front cover with a
•
with the offset slot
sprocket and align the silver link to
the timing chain can be sup-
Drive belt and tensioner
8.
I
Upper timing chain guide and
•
to
perform the remaining
to
•
tact
SW2
•
between the camshaft sprockets
Timing chain around the crankshaft
•
recommends
•
•
SW1
the tensioner.
not tighten
the crankshaft pulley.
•
•
camshaft sprocket with the copper
New camshaft
ported without slipping or moving on
7.
SL2
•
Timing chain around the intake
it
•
Cylinder head
necessary
•
SL1
Nm)
•
6.
•
Sprocket to the camshaft and align
•
perform the remaining steps
move
SL
torque the bolts to 89 inch
plete this procedure.
•
•
link aligned with the
Cylinder head bolts using the
if
SC2
timing mark