Chilton's Auto Service Manual 2002 Edition [2002 ed.] 0801993466, 9780801993466

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LeRoy Collins

Leon County Public Library 200 W. Park Avenue Tallahassee, FL 32301

EROY COLLINS LEON COUNTY PUBLIC LIBRARY

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The cooling system will bleed itself automatically during warm-up.

f. Turn the engine OFF and recheck the coolant level when the engine is cool 11. Connect the negative battery cable. 12. Enable the SIR system. 13. Reprogram the necessary accessories.

Century, Lumina and Regal REMOVAL & INSTALLATION 1. Disconnect the negative battery cable. 2. lf equipped with a 3.1L engine, remove the air cleaner and duct assembly. 3. If equipped with a 3.8L engine, remove the fuel injector sight shield by performing the following procedures: a. Clean the area around the oil filler cap/tube assembly location. b. Rotate the oil filler cap/tube assembly counterclockwise from the valve cover.

For complete service labor times, order Nichols’ Chilton Labor Guide

Gears 270 c. Place a 2 gallon pan under the radiator to catch the coolant. d. At the bottom of the radiator, open the drain valve and drain the coolant to a level lower than the heater core. e. Remove the radiator cap and open the air bleed screw (2-3 turns) located on top of the thermostat housing. f. After sufficient coolant has been drained from the system, close the drain valve.

O)

+2 CAUTION

~~

a

Engine coolant is a hazardous waste; it should be stored for reuse or submitted for recycling. NEVER dispose of it by dumping it into the environment. 93111601

5. Disconnect and plug the heater

View of the radiator drain valve—Century, Grand Prix, Intrigue, Lumina, Monte Carlo and

hoses at the heater COre.

Regal

6. If equipped, remove the lower center console by removing or disconnecting the

c. Lift the fuel injector sight shield up —ithe systems internal pressure and to

at the front and slide it from the rear

avoid scalding coolant.

engine bracket. d. Reinstall the oil filler cap/tube assembly in the valve cover.

—_—_—_—_—_—_—_—_—_—_—_—_— 4. Drain the cooling system by performing the following procedure: a. Raise and safely support the front

+k CAUTION Before draining the cooling system, allow the engine to cool to relieve

of the vehicle.

following:

.

¢ Cigarette lighter

.

e Automatic transaxle shift handle e Upper console trim plate from the front floor console by unsnapping it e Electrical connectors from the

upper console trim plate and

b. Remove and clean the coolant recovery tank.

93111602 View of the fuel injector sight shield—Century, Grand Prix, Intrigue, Lumina, Monte Carlo and Repl

remove the trim plate CD storage compartment from the front floor console by unsnapping it Raise the front floor console armrest and remove the compartment mat Console-to-chassis bolts and screws Electrical connectors from the console and remove the console from the vehicle 7. Remove the lower instrument panel lower compartment by removing or disconnecting the following: ¢ Lower right instrument panel insuator Compartment-to-panel bolts and screws, from under the instrument panel compartment Instrument panel compartment door screws and the door Instrument panel compartment screws and plastic clips; then slide the compartment from the instrument panel Electrical connector from the compartment Ashtray and bracket, if necessary Lower heater duct Heater core cover and discard the cover seals Heater core mounting clip and

bracket Heater core

HEATER CORES SSS

SSS

9.74

GENERAL MOTORS SSS SS

SSS

1 PANEL, INSTRUMENT PANEL UPPER TRIM 2 DOOR, INFLATABLE RESTRAINT INSTRUMENT PANEL MODULE 3 MODULE, INFLATABSE RESTRAINT INSTRUMENT PANEL 4 FUSE BOX, INSTRUMENT PANEL 5 DOOR, INSTRUMENT PANEL FUSE BOX 6 SWITCH, INSTRUMENT PANEL LOWER COMPARTMENT LIGHT 7 COVER, INSTRUMENT PANEL LOWER COMPARTMENT LIGHT SWITCH 8 OUTLET, HEATER AND AIR CONDITIONING 9 PLATE, INSTRUMENT PANEL TRIM 10 STRIKER, INSTRUMENT PANEL LOWER COMPARTMENT 11 BIN, INSTRUMENT PANEL LOWER COMPARTMENT 12 COMPARTMENT ASSEMBLY, INSTRUMENT PANEL LOWER 13 DOOR, INSTRUMENT PANEL LOWER COMPARTMENT 14 HINGE, INSTRUMENT PANEL LOWER COMPARTMENT 15 INSULATOR, INSTRUMENT PANEL RIGHT SOUND 16 CONTROL, HEATER AND AIR CONDITIONING 17 PLATE, INSTRUMENT PANEL CLUSTER TRIM 18 OUTLET, HEATER AND AIR CONDITIONING 19 PLUG, INSTRUMENT PANEL 20 SWITCH, HEADLAMP 21 COMPARTMENT, FRONT FLOOR CONSOLE FRONT 23 RETAINER, FRONT FLOOR CONSOLE 24 PLATE, FRONT FLOOR CONSOLE TRANSAXLE SHIFT OPENING TRIM 25 HOUSING, FRONT FLOOR CONSOLE LIGHTER ELEMENT i 26 ELEMENT, FRONT FLOOR CONSOLE LIGHTER 27 ASHTRAY, FRONT FLOOR CONSOLE 28 LENS, FRONT FLOOR CONSOLE TRANSAXLE SHIFT OPENING TRIM PLATE 29 TRIM, FRONT FLOOR CONSOLE ARMREST 30 ARMREST, FRONT FLOOR CONSOLE 31 MAT, FRONT FLOOR CONSOLE 32 ASHTRAY, FRONT FLOOR CONSOLE REAR 33 CONSOLE, FRONT FLOOR 34 CUP HOLDER, FRONT FLOOR CONSOLE 35 PLATE, FRONT FLOOR CONSOLE TRIM 36 CLUSTER, INSTRUMENT 37 SWITCH, REAR COMPARTMENT LIO RELEASE 38 ASHTRAY, INSTRUMENT PANEL 39 CUP HOLDER, INSTRUMENT PANEL 40 FILLER, INSTRUMENT PANEL STEERING COLUMN OPENING 41 INSULATOR, INSTRUMENT PANEL LEFT SOUND 42 AUDIO SYSTEM 43 INSTRUMENT PANEL ASSEMBLY 29

93111603

Carlo and Regal Exploded view of the instrument panel—Century, Grand Prix, Intrigue, Lumina, Monte

Please visit our web site at www.chiltonsonline.com

2-12

HEATER CORES GENERAL MOTORS a. Remove the oil filler cap/tube assembly from the valve cover. b. Slide the fuel injector sight shield into the rear engine bracket and lower it into place. c. Reinstall the oil filler cap/tube assembly in the valve cover. Twist it clockwise to lock the detent on the tube into the notch in the valve cover. 13. If equipped with a 3.1L engine, install the air cleaner and duct assembly. 14. Connect the negative battery cable.

Grand Prix, Intrigue and Regal REMOVAL & INSTALLATION

View of the heater core—Century, Grand Prix, Intrigue, Lumina, Monte Carlo and Regal

To install: 8. Install and connect the following: e Heater core in the vehicle e Heater core mounting clip and bracket ¢ New seals on the heater core cover ¢ Heater core cover and torque the bolts to 13 inch Ibs. (1.5 Nm) ¢ Lower heater duct, if removed ¢ Ashtray and bracket, if removed 9. Install the lower instrument panel lower by installing or connecting the following: ¢ Electrical connector to the compartment * Slide the compartment into the instrument panel: then, secure it with screws and plastic clips nstrument panel compartment door and screws Compartment-to-panel bolts and screws, located under the instrument panel compartmen — e Lower right instrument panel insulator 10. If equipped, install the lower center console instal! or connect the following; Console in the vehicle and connect the electrical connectors Console-to-chassis bolts and screws, tighten in sequence beginning at the front right and continue in a clockwise order to 106 inch bs. (12 Nm) e Armrest compartment mat and lower the front floor console armrest

¢ C/D storage compartment into the front floor console e Electrical connectors to the upper console trim plate and snap the trim plate onto the console e Automatic transaxle shift handle and the cigarette lighter e Heater hoses to the heater core and secure with the clamps 11. Refill the cooling system by performing the following procedure: a. Close the radiator drain valve. b. If the air bleed screws (located at the top of the thermostat housing) is closed, open it by turning it 2~3 turns. c. Slowly add coolant until it reaches the radiator neck. d. Wait for 2 minutes and recheck the coolant level: then, add more coolant if

necessary. é. Fill the coolant reservoir to the COLD mark. |. Close the air bleed screw.

Do not over-tighten the air bleed screw for it is made of brass.

g. Install the radiator cap and make sure that the arrows align with the overflow tube. 12. If equipped with a 3.8L engine, install the fuel injector sight shield by performing the following procedures:

1. Disconnect the negative battery cable. 2. Drain the engine coolant into a clean container for reuse. 3. On Grand Prix or Regal equipped with a 3.1L engine, remove the air cleaner and duct assembly. 4. On Grand Prix or Regal equipped with a 3.8L engine, remove the fuel injector sight shield. 5. Remove or disconnect the following: Lower floor console, if equipped Both instrument panel insulators Heater core outlet cover screws and the outlet cover Héater core cover screws and the cover Heater core seals. Discard the seals Heater core outer seal. Discard the Seal Heater core line clamp screw, the retaining clamp and the pipe retainer clamp screw Heater core from the lower case Heater core lower, center, upper and Side seals from the lower heater core case. Discard the seals To install: 6. Install or connect the following: New heater core lower, center, upper and side seals to the lower heater core case Heater core to the lower case Pipe retainer clamp screw, the retaining clamp and the heater core line clamp screw Heater core outer seal Heater core seals Heater core cover and the outlet cover screws, then, tighten the

Screws to 13 inch Ibs. (1.5 Nm) Heater core outlet cover and the outlet cover screws, then, tighten the screws to 13 inch Ibs. (1.5 Nm)

cenenacmorons 2770

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93111G65

View of the heater core outlet cover—Grand Prix, Intrigue and Regal

93111G67

Location of the heater core cover seals—

Grand Prix, Intrigue and Regal

93111668

enna View of the heater core cover—Grand Prix, Intrigue and Regal

View of the heater core outer seal—Grand Prix, Intrigue and Regal

Timing belt service is covered in Section 3 of this manual

2-74 Genera. morons \

e Both instrument panel insulators e Lower floor console, if a,

=

SE

y

=

7. On Grand Prix or Regal equippe io

with a3.8L engine, install the fuel injector sight.shield. 8. On Grand Prix or Regal equipped with a 3.1L engine, install the air cleaner and duct assembly. 9. Refill the engine cooling system. 10. Connect the negative battery cable. 11. Operate the engine to normal operating temperatures; then, check the climate contro! operation and cheek for leaks.

*«¢ CAUTION

93111G69

Some vehicles are equipped an SIR or air bag system. The air bag system must be disabled before performing service on or around the air bag, 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 air bag system repairs. as ee

REMOVAL & INSTALLATION —_—er(rtTte—____

1. If equipped, disable the SIR system by using the following procedure: a. Remove the SIR fuse from the fuse panel. b. Remove the left side sound insulator. c. Disconnect the Connector Positive Assurance (CPA) from the yellow 2-way SIR harness connector at the base of the Steering column and separate the connector. d. Disconnect the negative battery cable. 2. Discharge and recover the air conditioning system refrigerant. 3. Drain the cooling system into a clean container for reuse. 4. Remove the heater/air conditioning housing assembly by removing or disconnecting the following: e Intake manifold * Heater hoses from the heater core ¢ Refrigerant lines from the evaporator core 93111670

View of the heater core lower, center, upper and side seals of the lower heater core case— Grand Prix, Intrigue and Regal

e Drain tube from the heater/air conditioning housing assembly e Upper instrument pad and the ventilation duct assembly

HEATER CORES GENERAL MOTORS

2-19

To install: 5. Install or connect the following: Heater core Heater core pipe screw Heater core-to-heater/air conditioning housing mounting clip screws New outer heater core seal, if

93111GB6

View of the heater/air conditioning housing assembiy—Corvette

Electrical connector from the instrument cluster and remove the instrument cluster Inboard side window glass defroster duct from the windshield defroster duct on both sides DRL electrical connector and the sun load temperature sensor from the windshield defroster duct, if equipped Windshield defroster duct from the heater/air conditioning housing assembly Inside air temperature sensor duct from the heater/air conditioning housing assembly Passenger’s side SIR module electrical connector Passengers side SIR bracket and module assembly Instrument pane! center support bracket. Electrical and vacuum connectors

from the heater/air conditioning control head Knee bolster Driver's floor hush panel Floor air outlet-to-heater/air conditioning housing assembly duct from the left side Passenger’s side floor hush panel Lower air floor air duct from the upper air duct from the right side Upper floor air duct from the

heater/air conditioning housing from the right side Blower motor electrical connector Blower motor from the heater/air conditioning housing Temperature door and the vacuum solenoid electrical connectors, if

equipped with the CJ2 air conditioning system Vacuum source line from the instrument panel harness connection Temperature door control motor electrical connector Rear floor air ducts from the heater/air conditioning housing from both side Heater/air conditioning housing-tobulkhead/heater core module and instrument panel nuts/bolts Heater/air conditioning housing assembly Air inlet, drain and plumbing seals. Discard the seals Heater core cover from the heater/air conditioning housing assembly Heater core cover seals and discard the seals Outer heater core seal and discard the seal Heater core-to-heater/air conditioning housing mounting clip screws Heater core pipe screw

equipped with the CJ2 air conditioning system New heater core cover seals Heater core cover to the heater/air conditioning housing assembly 6. Install the heater/air conditioning housing assembly by installing or connecting thefollowing: New air inlet, drain and plumbing Seals Heater/air conditioning housing assembly Heater/air conditioning housing-tobulkhead/heater core module and instrument panel nuts/bolts Rear floor air ducts to the heater/air conditioning housing on both sides Temperature door control motor electrical connector Vacuum source line to the instrument panel harness connection Temperature door and the vacuum solenoid electrical connectors, if equipped with the CJ2 air conditioning system Blower motor to the heater/air conditioning housing Blower motor electrical connector Upper floor air duct to the heater/air conditioning housing on the right side Lower air floor air duct to the upper air duct on the right side Passenger’s side floor hush panel

Floor air outlet-to-heater/air conditioning housing assembly duct on the left side Driver's floor hush panel Knee bolster Electrical and vacuum connectors to the heater/air conditioning control head Instrument panel center support bracket Passenger’s side SIR bracket and module assembly Inside air temperature sensor duct Windshield defroster duct to the heater/air conditioning housing assembly DRL electrical connector and the sun load temperature sensor, if

e Heater core

Heater Core replacement is covered in Section 2 of this manual

9-76

HEATER CORES

equipped with a windshield defroster duct e Inboard side window glass defroster duct to the windshield defroster duct on both sides e Electrical connectorto the instrument cluster and install the instrument cluster

e Refrigerant lines to the evaporator core e Heater hoses to the heater core e Intake manifold 7. Refill the cooling system. 8. Evacuate, charge and leak test the air conditioning system refrigerant. 9. Connect the negative battery

Assurance (CPA) to the yellow 2-way SIR harness connector at the base of the steering column. . b. Install the left side sound insulator. c. Install the SIR fuse to the fuse panel. ; 11. Operate the engine to normal oper-

e Upper instrument pad and the ven-

cable.

ating temperatures; then, check the cli-

tilation duct assembly e Drain tube to the heater/air conditioning housing assembly

10. If equipped, enable the SIR system by performing the following procedure: a. Connect the Connector Positive

mate contro! operation and check for leaks.

1998-01 GEO

REMOVAL & INSTALLATION 1. 2. into a 3. 4. ing:

Disconnect the negative battery cable. Properly drain the cooling system clean container for reuse. Remove the instrument panel. Remove or disconnect the follow-

Heater hoses from the heater core tubes at the firewall Temperature and mode control cables from the heater housing Air duct from the heater housing to the blower motor assembly (on models not equipped with A/C); otherwise, detach the heater housing from the evaporator assembly 2 bolts and nuts and remove the heater case assembly Heater case halves Heater core from the heater case assembly To install: 9. Install or connect the following: Heater core into the heater case assembly Assemble the heater case assembly Heater assembly and install the 2 bolts and nuts Heater case assembly to the evaporator case assembly, if equipped with A/C ¢ Mode control and the temperature cables to the heater housing Heater hoses to the heater core 6. Install the instrument panel.

7. Refill the cooling system.

8. Connect the negative battery cable.

9. Operate the engine to normal operat-

ing temperatures: then, check for leaks and

the heater operation.

106-A 106-B

HEATER CASE—RIGHT HALF HEATER CASE—LEFT HALF

119

HEATER CORE

120

CONTROL DOOR (DAMPER)

1 oT:

122

CONE

ae ce

CONTROL SHAFT

NR AGE

Exploded view of the heater core, heater case and related components—Metro

93111604

HEATER CORES

SIDE OUTLETS SIDE DEMISTERS CENTER OUTLETS FLOOR OUTLETS DEFROSTER OUTLETS HEATER CASE AIR DUCT BLOWER MOTOR CASE HEATER CONTROL UNIT WHY omanoanr 10 DEFROSTER DUCT 11. SIDE DEMISTER DUCTS 12 CENTER VENT DUCT 13. SIDE VENT DUCTS 14 OUTSIDE AIR 15 RECIRCULATED AIR

9.777

93111GC3

components—Metro Exploded view of the instrument panel, heater housing, ventilation ducts and related

Brake service is covered in Section 4 of this manual

2-78

HEATER CORES

aC OTS . 1. Disconnect the negative battery cable.

2. Drain the cooling system into a clean container for reuse. 3. Discharge and recover the air condi-

4. Remove the heater hoses from the heater core. 5. Remove the instrument panel by removing or disconnecting the following: e Steering wheel-disarm air bag system if equipped

e Right and left front pillar garnish trim Floor console bin

tioning system refrigerant.

e e e e e «

Engine hood release lever Lower finish No. 1 trim panel Steering column cover Center cluster finish panel Cluster finish panel Radio

|

¢ Stereo opening cover or center differential control switch if so equipped

Combination meter assembly Lower finish No. 2 panel with glove compartment door Heater control assembly Lower center finish panel >The defroster nozzle has a boss on the reverse side for clamping onto the clip on the body side. When removing, pull upward at an angle.

No. 1 and No. 2 side defroster nozZles Safety pad assembly from the vehicle Instrument panel reinforcement Blower motor electrical connector and resistor electrical connector Air conditioning compressor control module electrical connector, if equipped

Cruise control servo Refrigerant lines from the evaporator core; then, plug the openings to

93111GC5

Exploded view of the heater core, the evaporator core, the heater/air conditioning housing and related components—Prizm

prevent contamination Ventilation ducts from the heater/air conditioning housing 6 heater/air conditioning housing assembly-to-chassis nuts and the assembly Heater core-to-heater/air conditioning housing clamp screws and the clamps e Heater core To install: 6. Install or connect the following: ¢ Heater core Heater core-to-heater/air conditioning housing clamps and the clamp SCreWS Heater/air conditioning housing assembly and the 6 assembly-tochassis nuts Ventilation ducts to the heater/air conditioning housing Refrigerant lines to the evaporator core Cruise control servo, if equipped Air conditioning compressor control module electrical connector a

ae

enc

Instrument panel reinforcement

HEATER CORES

SATURN

Safety pad assembly in the vehicle No. 1 and No. 2 side defroster nozZles Lower center finish panel Heater control-assembly Lower finish No. 2 panel with glove compartment door Combination meter assembly Stereo opening cover or center dif-

ferential control switch if so equipped Radio Cluster finish panel Center cluster finish panel Steering column covers No. 1 lower finish panel Engine hood release lever Floor console box

1998-01 SATURN REMOVAL & INSTALLATION 1. Disconnect the negative battery cable. 2. Drain the cooling system into a clean container for reuse. 3. Raise and safely support the vehicle. 4. Heater hoses from the heater core ->Carefully, use compressed air to blow the remainder of the coolant from the heater core to prevent spillage of coolant in the interior when removing the heater core.

e Heater core side cover ¢ 4 lower heater core cover-toheater/air conditioning housing assembly screws and the cover ¢ Heater core clamp and the heater core To install: 6. Install or connect the following: e Heater core, the clamp and the heater core-to-heater/air conditioning housing assembly screw e Lower heater core cover and the 4

2 -19

e Right and left front pillar garnish trim ¢ Steering wheel ¢ Heater hoses to the heater core 7. Evacuate, charge and leak test the air conditioning system refrigerant. 8. Refill the cooling system. 9. Connect the negative battery cable.

| cover-to-heater/air conditioning housing assembly screws Heater core side cover and the cover screw, located at the left side of the heater/air conditioning housing assembly Temperature control cable to the heater door hook and secure with the retaining clip

Be careful not to damage the heater duct-to-rear floor heater duct seal

5. Remove or disconnect the following e Lower trim panel extensions (located at both sides of the console-to-center instrument panel), by pulling outward at the dual lock locations; then, rotate the panels outward to disengage the hinges at the console Lower instrument pane! closeout panel (located on the right side of the heater/air conditioning housing), by pulling it out at the top edge and rotating the top downward Lower heater duct-to-heater/air conditioning housing 2 screws and 2 clips (located at the bottom of the heater/air conditioning housing); then, drop the duct down and carefully, slide it out sideways

>< WARNING Be careful not to damage the heater duct-to-rear floor heater duct seal. nn

e Release the retaining clip and disconnect the temperature control

cable from the heater door hook

93111697

View of the lower trim panel extensions—Saturn

For complete Engine Mechanical specifications, see Section 1 of this manual

25

i e Lower heater duct; then, the lower

93111698

Exploded view of the heater core and heater case—Saturn

heater duct-to-heater/air conditioning housing 2 screws and 2 clips, located at the bottom of the heater/air conditioning housing Lower instrument panel closeout panel, located at the right side of the heater/air conditioning housing Console-to-center instrument panel location (on both sides), install the lower trim panel extensions Heater hose-to-heater core clamps 7. Lower the vehicle. 8. Refill the cooling system. 9. Connect the negative battery cable. 10. Operate the engine to normal operating temperatures: then, check the climate contro! operation and check for leaks.

TIMING BELTS GENERAL INFORMATION....... 3-1 TIMING BELT SERVICE.......... 3-2 Interference ENGINES v.ccc.soesdccssnentcess 3-1 MSOeCONiPe Meee 2. Ue 3-2 Removal & Installation... a2

FORD MOTOR COMPANY.......... 3-8 GENERAL MOTORS.............06. 3-14

_ GENERAL INFORMATION Timing belts are typically only used on overhead camshaft engines. Timing belts are used to synchronize the crankshaft with the camshaft, similar to a timing chain on an overhead valve (pushrod) engine. Unlike a timing belt, a timing chain will normally last the life of the engine without needing service or replacement. Timing belts use raised teeth to mesh with sprockets to oper“ate the valvetrain of an overhead camshaft engine. Whenever a vehicle with an unknown service history comes into your repair facility or is recently purchased, here are some points that should be asked to help prevent costly engine damage: e Does the owner know if or when the belt was replaced? e Ifthe vehicle purchased is used or the

|

condition and mileage of the last timing belt replacement are unknown, it is recommended to inspect, replace or at least inform the owner that the vehicle is equipped with a timing belt. ¢ Note the mileage of the vehicle. The average replacement interval for a timing belt is approximately 60,000 miles (96,000 km).

Interference Engines Engines, chain- or belt-driven, can be classified as either free-running or interference, depending on what would happen if the piston-to-valve timing is disrupted. A free-running engine is designed with enough clearance between the pistons and valves to allow the crankshaft to rotate (pistons still moving) while the camshaft stays

in one position (several valves fully open). If this condition occurs normally, no internal engine damage will result. In an interference engine, there is not enough clearance between the pistons and valves to allow the crankshaft to turn without the camshaft being in time. An interference engine can suffer extensive internal damage if a timing belt fails. The piston design does not allow clearance for the valve to be fully open and the piston to be at the top of its stroke. If the belt fails, the piston will collide with the valve and will bend or break the valve, damage the piston, and/or bend a connecting rod. When this type of —failure occurs, the engine will need to be replaced or disassembled for further internal inspection; either choice costing many times that of replacing the timing belt.

3-2

TIMING BELTS TIMING BELT SERVICE.

>For manufacturer’s recommended service interval, refer to the maintenance interval chart located in this manual.

The average replacement interval for a timing belt is approximately 60,000 miles (96,000km). If, however, the timing belt is inspected earlier or more frequently than Suggested, and shows signs of wear or defects, the belt should be replaced at that time.

Never allow antifreeze, oil or solvents to come into with a timing belt. If this occurs immediately wash the solution from the timing belt. Also, never excessive bend or twist the timing belt; this can damage the belt So that its lifetime is severely short-

On interference engines, it is very important to replace the timing belt at the recommended intervals, otherwise expensive engine damage will likely result if the belt fails. Removal & Installation 1001244

Broken tooth may be due to a damaged pulley

S

ened. SS

TS

TS

TS

ES

Inspect both sides of the timing belt. Replace the belt with a new one if any of the following conditions exist: ¢ Hardening of the rubber—back side is glossy without resilience and leaves no indentation when pressed with a fingernail e Cracks on the rubber backing e Cracks or peeling of the canvas backing ¢ Cracks on rib root ¢ Cracks on belt sides ¢ Missing teeth or chunks of teeth e Abnormal wear of belt sides—the sides are normal if they are sharp, as if cut by a knife. If none of these conditions exist, the belt does not need replacement unless it is at the recommended interval. The belt MUST be replaced at the recommended interval.

TCCS1242

Never bend or twist a timing belt excessively, and do not allow solvents, antifreeze, gasoline, acid or oil to come

into contact with the belt

TCCS1245

Back surface worn or cracked from a possible overheated engine or interference with the belt cover

CHRYSLER CORPORATION 2.0L (VIN C) SOHC Engine 1. On Cirrus, Stratus, Breeze, and Sebring Convertible models, disconnect the negative battery cable from the left strut tower. The ground cable is equipped with a insulator grommet which should be placed on the stud to prevent the negative battery cable from accidentally grounding. 2. On Neon models, disconnect the negative battery cable. 3. Remove the drive belts and accessories. 4. Remove the right inner splashshield. 5. Remove the crankshaft damper. 6. Remove the right engine mount. 7. Place a support under the engine. 8. Remove the engine mount bracket. 9. Remove the timing belt cover. 10. Loosen the timing belt tensioner 11. Remove the timing belt and the ten-

CAMSHAFT

TCCS1247

Worn teeth from excessive belt tension, camshaft or distributor not turning properly or fluid leaking on the belt

79225699

TDC alignment for timing belt installation—2.0L (VIN C) SOHC Engine

TIMING BELTS e*When tensioner is removed from the engine it is necessary to compress the plunger into the tensioner body.

12. Place the tensioner in a soft-jawed vise to compress the tensioner. 13. After compressing the tensioner place a pin (a Yea in. Allen wrench will work) into the plunger side hole to retain the plunger until installation. To install: 14. Set the crankshaft sprocket to Top Dead Center (TDC) by aligning the notch on the sprocket with the arrow on the oil pump housing, then back off the sprocket three notches before TDC. 15. Set the camshaft to align the timing marks, 16. Move the crankshaft to Y notch before TDC. 17. Install the timing belt starting at the crankshaft, around the water pump, then around the camshaft last. 18. Move the crankshaft to TDC to take up the belt slack. 19. Reinstall the tensioner to the block but do not tighten it. 20. Using a torque wrench apply 250 inch Ibs. (28 Nm) of torque to the tensioner pulley. 21. With torque being applied to the tensioner pulley, move the tensioner up against the tensioner bracket and tighten the fasteners to 275 inch Ibs. (31 Nm). 22. Remove the tensioner plunger pin, the tension is correct when the plunger pin can be removed and replaced easily. 23. Rotate the crankshaft two revolutions and recheck the timing marks. 24. Reinstall the timing belt cover. 25. Reinstall the engine mount bracket. 26. Reinstall the right engine mount. 27. Remove the engine support. 28. Reinstall the crankshaft damper and tighten to 105 ft. Ibs. (142 Nm). 29. Reinstall the drive belts and accessories. 30. Reinstall the right inner splashshield. 31. Perform the crankshaft and camshaft relearn alignment procedure using the DRB scan tool or equivalent.

2.0L (VIN F) Engine 1. Disconnect the negative battery cable. 2. Remove the engine undercover.

3. Remove the engine mount bracket. 4. Remove the drive belts.

Timing marks

Cylinder had top surface

Counterbalance

~ shaft sprocket / KpasS Belt tension side

GOP nl

Cae

: aN Timing IN marks

Mave

Camshaft sprockets

3-3

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Timing prone

Nie

Crankshaft =< sprocket B

é SS 79225622

2.

Timing marks

Timin

mares

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6 4

Oil pump sprocket

Timing belt “B” timing marks locations— Chrysler 2.0L (VIN F) engines

kk WARNING Do not rotate the camshafts or the

crankshaft while the timing belt is

Crankshaft

removed.

sprocket 79225603

Notice the timing mark on the oil pump

drive sprocket—Chrysler 2.0L (VIN F) engines

5. Remove the belt tensioner pulley. 6. Remove the water pump pulleys. 7. Remove the crankshaft pulley. §. Remove the stud bolt from the engine support bracket and remove the timing belt covers. 9. Rotate the crankshaft clockwise to align the camshaft timing marks. Always turn the crankshaft in the forward direction only. 10. Loosen the tension pulley center bolt. elf the timing belt is to be reused, mark the direction of rotation on the flat side of the belt with an arrow.

11. Move the tension pulley towards the water pump and remove the timing belt. 12. Remove the crankshaft sprocket center bolt using special tool MB99076/ to hold the crankshaft sprocket while removing the center bolt. Then, use MB998778 puller to remove the sprocket. 13. Mark the direction of rotation on the timing belt “B” with a arrow. 14. Loosen the center bolt on the tensioner and remove the belt. 15. To remove the camshaft sprocket, remove the cylinder head cover. Use a wrench to hold the hexagonal part of the camshaft and remove the sprocket mounting bolt.

To install: 16. Use a wrench to hold the camshaft, then install the sprocket and mounting bolt. Tighten the bolt(s) to 65 ft. Ibs. (88 Nm). 17. Install the cylinder head cover. 18. Place the crankshaft sprocket on the crankshaft. Use tool MB990767/ to hold the crankshaft sprocket while tightening the center bolt. Tighten the center bolt to 80-94 ft. lbs. (108-127 Nm). 19. Align the timing marks on the crankshaft sprocket “B” and the balance shaft. 20. Install timing belt “B” on the sprockets. Position the center of the tensioner pulley to the left and above the center of the mounting bolt. 21. Push the pulley clockwise toward the crankshaft to apply tension to the belt and tighten the mounting bolt to 14 ft. Ibs. (19 Nm). Do not let the pulley turn when tightening the bolt because it will cause excessive tension on the belt. The belt should deflect 0.20—-0.28 in. (5—7mm) when finger pressure is applied between the pulleys. 22. Install the crankshaft sensing blade nd the crankshaft sprocket. Apply engine il to the mounting bolt and tighten the bolt 0 80-94 ft. Ibs. (108-127 Nm). om =>->o 23. Use a press or vise to compress the auto tensioner pushrod. Insert a set pin when the holes are aligned.

sto WARNING Do not compress the pushrod too quickly, damage to the pushrod can occur.

For complete service labor times, order Nichols’ Chilton Labor Guide

3-4

TIMING BELTS

24. Install the auto tensioner on the engine. 29. Align the timing marks on the camshaft sprocket, crankshaft sprocket and the oil pump sprocket. 26. After aligning the mark on the oil pump sprocket, remove the cylinder block plug and insert a Phillips screwdriver in the hole to check the position of the counter balance shaft. The screwdriver should go in at least 2.36 in. or more. if not, rotate the oil pump sprocket once and realign the timing mark so the screwdriver goes in. Do not remove the screwdriver until the timing belt is installed. 27. Install the timing belt on the intake camshaft and secure it with a clip. 28. Install the timing belt on the exhaust camshaft. Align the timing marks with the cylinder head top surface using two wrenches. Secure the belt with another clip. 29. Install the belt around the idler pulley, oil pump sprocket, crankshaft sprocket and the tensioner pulley. 30. Turn the tension pulley so the pinholes are at the bottom. Press the pulley lightly against the timing belt. 31. Screw the special tool into the left engine support bracket until it contacts the tensioner arm, then screw the tool ina little more and remove the pushrod pin from the auto tensioner. Remove the special tool and tighten the center bolt to 35 ft. Ibs. (48 Nm). 32. Turn the crankshaft % turn counterClockwise, then clockwise until the timing marks are aligned. 33. Loosen the center bolt. Install speclal tool MD998767 on the tension pulley. Turn the tension pulley counterclockwise with a torque of 2.6 ft. Ibs. (3.5 Nm) and tighten the center bolt to 35 ft. Ibs. (48 Nm). Do not let the tension pulley turn with the bolt. 34. Turn the crankshaft two revolutions to the right and align the timing marks. After 15 minutes, measure the protrusion of the pushrod on the auto tensioner. The standard measurement is 0.150-0.177 in. (3.8-4.5mm). If the protrusion is out of Specification, loosen the tension pulley, apply the proper torque to the belt and retighten the center bolt. 35. Install the crankshaft pulley. Tighten the mounting bolts to 18 ft. Ibs. (25 Nm). 36. Install the water pump. Tighten the mounting bolts to 6.5 ft. Ibs. (8.8 Nm). 37. Install and adjust the drive belts. 38. Install the engine mount bracket. 39. Install the engine undercover. 40. Connect the negative battery cable,

2.0L (VIN Y) Engine Valve timing is critical to engine operation. Use care when servicing the timing belt. There are a number of timing marks that must be properly aligned or engine damage will result. If the timing belt has not broken or jumped teeth, it is recommended that the crankshaft be turned by hand (clockwise) to Top Dead Center (TDC) No.1 cylinder compression stroke (firing position) before beginning work. This should align all the timing marks and serve as a reference for later work. Some technicians will apply a small amount of white paint to all timing marks. This helps make them more visible under the low-light conditions found underhood. 1. Disconnect the negative battery cable. 2. Remove the accessory drive belts. 3. Using C 3281 crankshaft holding tool, remove the crankshaft pulley center retaining bolt. 4. Using puller tools 1026 and 6827, remove the crankshaft pulley. 9. Remove the power steering pump from the bracket and position it aside. Do not disconnect the hoses. 6. Remove the power steering pump bracket from the engine. 7. Use a floor jack with a piece of wood on it and raise the engine to take the weight off of the engine mount. 8. Remove the engine mount and bracket. 9. Remove the front timing belt cover. 10. If not done so previously, align the timing marks. Loosen the timing belt tensioner and remove the belt.

Do not rotate the crankshaft or camshafts after removing the timing belt or valvetrain components may be damaged. Always align the timing marks before removing the timing

Camshaft timing marks together Crankshaft at TDC

79225620

Install the timing belt by starting at the crankshaft sprocket and working around the other pulleys in a counterclockwise direction—Chrysler 2.0L (VIN Y) engine

orientation for when the tensioner is installed on the engine.

c. When the plunger is compressed into the tensioner body, install a pin through the body and plunger to hold the plunger in place until the tensioner is installed. 12. For 1998-01 models: a. Place an 8mm Allen wrench into the belt tensioner, then using the long end of a ¥% in. (3mm) Allen wrench, rotate the tensioner counterclockwise until it slides into the locking hole. 13. Remove the timing belt. To install: 14. Check that all timing marks are still aligned. Bring the crankshaft sprocket to a notch before TDC. 15. Install the timing belt. Starting at the Crankshaft, route the belt around the water pump sprocket, idler pulley, camshaft sprockets, then around the tensioner pulley. 16. Move the crankshaft to TDC to take up the slack in the belt. Install the tensioner Camshaft timing marks

belt.

L,Y

11. For 1997 models:

a. If the timing belt tensioner is to be replaced, remove the retaining bolts and remove the timing belt tensioner. When the timing belt tensioner is removed from the engine, it is necessary to compress the plunger into the tensioner body. b. Place the tensioner in a vise and Slowly compress the plunger. -»Position the tensioner in the vise the

Same way it will be installed on the engine. This is to ensure proper pin

Crankshaft at TDC 79225621

Wrench position for properly locking the tensioner on 1998-01 Chrysler 2.0L (VIN Y) engine

TIMING BELTS SS

to the block but do not tighten the retaining bolts. 17. For 1997 models: a. Using a torque wrench on the tensioner pulley, apply21 ft. Ibs. (28 Nm) of torque to the pulley. b. With the torque being applied to the tensioner pulley, move the tensioner up against the tensioner pulley bracket and tighten the retaining bolts to 23 ft. lbs. (31 Nm). c. Remove the tensioner plunger pin. Pretension is correct when the pin can be removed and installed. 18. For 1998-01 models, remove the wrenches from the tensioner. 19. Rotate the crankshaft two revolutions and check the timing marks. If the timing marks are not properly aligned, remove the belt and reinstall it as described. 20. Install the front timing belt cover. 21. Lower the engine enough to install the engine mount bracket. 22. Install the bracket and remove the floor jack. 23. Install the power steering pump bracket and pump. 24. Install the crankshaft pulley using C4685-C pulley installer. 25. Tighten the mounting bolt to 105 ft. lbs. (142 Nm). 26. Install the accessory drive belts. 27. Connect the negative battery cable. 28. Start the engine. Check for leaks and proper engine operation.

9. Align the timing marks of the timing belt sprockets to the timing marks on the rear timing belt cover and oil pump cover. Loosen the timing belt tensioner bolts. 10. Remove the timing belt and the tensioner. 11. Remove the camshaft timing belt sprockets. 12. Remove the crankshaft timing belt sprocket using special removal tool No. 6793. 13. Place the tensioner into a soft-jawed vise to compress the tensioner. 14. After compressing the tensioner, place a pin (a Yea in. Allen wrench will work) into the plunger side hole to retain the plunger until installation. To install: 15. Using special tool No. 6792, install the crankshaft timing belt sprocket onto the crankshaft. UPPER TIMING BOLT COVER FASTENERS 7 2

\. ENGINE SUPPORT \.

BRACKET

}

4=

BELT COVER FASTENERS 79225627

2.4L (VIN X) Engine

Timing belt cover bolt locations—2.4L

1. Disconnect the negative battery cable from the left strut tower. The ground cable is * equipped with a insulator grommet which should be placed on the stud to prevent the negative battery cable from accidentally grounding. 2. Remove the right inner splashshield. 3. Remove the accessory drive belts. 4 Remove the crankshaft damper. 5. Remove the right engine mount. 6. Place a suitable floor jack under the vehicle to support the engine. 7. Remove the engine mount bracket. 8. Remove the timing belt cover. s>Do not rotate the crankshaft or the camshafts after the timing belt has been removed. Damage to the valve components may occur. Before removing the timing belt, always align the timing marks.

(vin x) Engine

CAMSHAFT TIMING MARKS

DC MARKS

(aS

79225628

Crankshaft and camshaft alignment

marks—2.4L (vin x) Engine

3-0

16. Install the camshaft sprockets onto the camshafts. Install and tighten the AnHie sprocket bolts to 75 ft. Ibs. (101 Nm). 17. Set the crankshaft sprocket to Top Dead Center (TDC) by aligning the notch on the sprocket with the arrow on the oil pump housing. 18. Set the camshafts to align the timing marks on the sprockets. 19. Move the crankshaft to Y notch before TDC. 20. Install the timing belt starting at the crankshaft, then around the water pump sprocket, idler pulley, camshaft sprockets and the tensioner pulley. 21. Move the crankshaft sprocket to TDC to take up the belt slack. 22. Reinstall the tensioner to the block but do not tighten it at this time. 23. Using a torque wrench on the tensioner pulley, apply 250 inch Ibs. (28 Nm) of torque to the tensioner pulley. 24. With torque being applied to the tensioner pulley, move the tensioner up against the tensioner pulley bracket and tighten the fasteners to 275 inch Ibs. (31 Nm). 25. Remove the tensioner plunger pin, the tension is correct when the plunger pin can be removed and replaced easily. 26. Rotate the crankshaft two revolutions and recheck the timing marks. Wait several minutes, then recheck that the plunger pin can easily be removed and installed. 27. Reinstall the front timing belt cover. 28. Reinstall the engine mount bracket. 29. Reinstall the right engine mount. 30. Remove the floor jack from under the vehicle. 31. Install the crankshaft damper and tighten to 105 ft. Ibs. (142 Nm). 32. Install and adjust the accessory drive belts. 33. Install the right inner splash-shield. 34. Reconnect the negative battery cable. 35. Perform-the crankshaft and camshaft relearn alignment procedure using the DRB scan tool or equivalent. 2.4L (VIN B) Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove the A/C refrigerant using approved equipment. 3. Remove or disconnect the following: e Negative battery cable e Right front wheel and inner splash shield

Please visit our web site at www.chiltonsonline.com

3-6

TIMING BELTS

Accessory drive belts Crankshaft damper Lower torque strut Exhaust system from the manifold A/C compressor switch Upper torque strut and bracket Upper radiator support crossmember Power steering pump and bracket without disconnecting the lines Right engine mount through bolt after supporting the engine Engine support bracket 4. Rotate the crankshaft until the Top Dead Center (TDC) mark on the oil pump housing aligns with the TDC mark on the crankshaft sprocket. 5. Install an allen wrench into the tensioner. Rotate the tensioner counterclockwise while pushing on the wrench until it slides into the locking hole. 6. Remove the timing belt. To install: 7. Set the crankshaft sprocket at TDC by aligning the sprocket with the arrow on the oil pump housing. 8. Set the camshafts timing marks so that the exhaust camshaft sprocket is a Yanotch below the intake camshaft sprocket. 9. Install the timing belt by starting at the crankshaft. Go around the water pump sprocket idler pulley, camshaft sprockets and the tensioner. 10. Move the exhaust camshaft sprocket counterclockwise to align the marks and to remove any slack. 11. Remove the wrench from the belt tensioner. 12. Rotate the crankshaft two full revolutions and verify that the TDC marks are properly aligned. 13. Install or connect the following: ¢ Lower timing belt cover and torque the bolts to 40 inch (4.5 Nm) Upper timing belt cover and torque the bolts to 40 inch Ibs. (4.5 Nm) Right engine support bracket and reposition the power steering pump. Torque the bracket bolts to 46 ft. Ibs. (61 Nm). Right engine mount through bolt and torque it to 87 ft. Ibs. (118 Nm) Upper radiator support crossmemer Torque strut bracket Upper torque strut A/C lines and pressure switch Exhaust system to the manifold Crankshaft damper Accessory drive belts Lower torque strut Right splash shie u and wheel

e Negative battery cable 14, Recharge the A/C system. 15. Perform the camshaft/crankshaft synchronization procedure. 2.5L (VIN H) Engine 1. Disconnect the negative battery cable from the left strut tower. The ground cable is equipped with a insulator grommet which should be placed on the stud to prevent the negative battery cable from accidentally grounding. 2. Remove the right inner splashshield. 3. Remove the accessory drive belts. 4. Remove the crankshaft damper. 5. Remove the right engine mount. 6. Place a suitable floor jack under the vehicle to support the engine. 7. Remove the right engine mount bracket. 8. Remove the timing belt upper left Cover, upper right cover and lower cover. 9. Loosen the timing belt tensioner bolts. e>Before removing timing belt, be sure to align the sprocket timing marks to the timing marks on the rear timing belt cover.

10. If the present timing belt is going to be reused, mark the running direction of the timing belt for installation. Remove the timing belt and the tensioner. 11. Remove the camshaft timing belt sprockets from the camshaft, if necessary. 12. Remove the crankshaft timing belt sprocket and key. 13. Place the tensioner into a soft-jawed vise to compress the tensioner, 14. After compressing the tensioner place a pin into the plunger side hole to retain the plunger until installation, CAMSHAFT SPROCKETS ALIGN TO TIMING MARKS

IDLER PULLEY

AUTO TENSIONER CRANKSHAFT SPROCKET ALIGN TO TIMING MARK

79225629

Timing belt engine sprocket timing—2.5L (vin h) Engine

To install: 15. If removed, reinstall the camshaft sprockets onto the camshaft. Install the camshaft sprocket bolt and tighten to 65 ft. lps. (88 Nm). 16. If removed, reinstall the crankshaft timing belt sprocket and key onto the crankshaft. 17. Set the crankshaft sprocket to Top Dead Center (TDC) by aligning the notch on the sprocket with the arrow on the oil pump housing, then back off the sprocket three notches before TDC. 7 18. Set the camshafts to align the timing marks on the sprockets with the marks on the rear timing belt cover. 19. Install the belt on the rear camshaft sprocket first. 20. Install a binder clip on the belt to the sprocket so it won't slip out of position. 21. Keeping the belt taut, install it under the water pump pulley and around the front camshaft sprocket. 22. Install a binder on the front sprocket and belt. 23. Rotate the crankshaft to TDC. 24. Continue routing the belt by the idler pulley and around the crankshaft sprocket to the tensioner pulley. 25. Move the crankshaft sprocket clockwise to TDC to take up the belt slack. Check that all timing marks are in alignment. 26. Reinstall the tensioner to the block but do not tighten it at this time. 27. Using special too! No. MD998767 and a torque wrench on the tensioner pulley, apply 39 inch Ibs. (4.4 Nm) of torque to the tensioner. Tighten the tensioner pulley bolt to 35 ft. Ibs. (48 Nm). 28. With torque being applied to the tenSioner pulley, move the tensioner up against the tensioner bracket and tighten the fasteners to 17 ft. Ibs. (23 Nm). 29, Remove the tensioner plunger pin, the tension is correct when the plunger pin can be removed and replaced easily. 30. Rotate the crankshaft two revolutions clockwise and recheck the timing marks. Check to be sure the tensioner plunger pin can be easily installed and removed. If the pin does not remove and install easily, perform the procedure again. 31. Reinstall the timing belt cover, 32. Reinstall the engine mount bracket. 33. Reinstall the right engine mount, 34, Remove the engine support. 35. Install the crankshaft damper and tighten to 134 ft. Ibs. (182 Nm). 36. Reinstall the accessory drive belts and adjust them. 37. Reinstall the right inner splashshield.

TIMING BELTS 38. Perform the crankshaft and camshaft relearn alignment procedure using the DRB scan tool or equivalent.

2.5L (VIN N) Engine 1. Disconnect the negative battery cable. 2. Remove the accessory drive belts. 3. Using crankshaft holding tools MB990767 and MB998754, remove the crankshaft bolt and remove the pulley. 4. Remove the heated oxygen sensor connection. 5. Remove the power steering pump with the hose attached and position it aside. 6. Remove the power steering pump bracket. 7. Place a floor jack under the engine oil pan, with a block of wood in between, and raise the engine so that the weight of the engine is no longer being applied to the engine support bracket. 8. Remove the upper engine mount. Spraying lubricant, slowly remove the reamer (alignment) bolt and remaining bolts and remove the engine support bracket. >The reamer bolt is sometimes heatseized on the engine support bracket.

9. Remove the front timing belt covers. 10. If the timing belt is to be reused, draw an arrow indicating the direction of rotation on the back of the belt for reinstallation. 11. Align the timing marks by turning the crankshaft with MD998769 crankshaft turning tool. Loosen the center bolt on the timing belt tensioner pulley and remove the belt.

2k WARNING Do not rotate the crankshaft or camshaft after removing the timing belt or valvetrain components may be damaged. Always align the timing marks before removing the timing belt. |

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12. Check the belt tensioner for leaks and check the pushrod for cracks. 13. If the timing belt tensioner is to be replaced, remove the retaining bolts and remove the timing belt tensioner. When the timing belt tensioner is removed from the engine, it is necessary to compress the plunger into the tensioner body. 14. Place the tensioner in a vise and slowly compress the plunger. Take care not to damage the pushrod.

79225602

Camshaft and crankshaft alignment marks—Chrysler 2.5L (VIN N) engines

->Position the tensioner in the vise the same way it will be installed on the engine. This is to ensure proper pin orientation for when the tensioner is installed on the engine.

15. When the plunger is compressed into the tensioner body, install a pin through the body and plunger to hold the plunger in place until the tensioner is installed. To instali: 16. Install the timing belt tensioner and tighten the retaining bolts to 17 ft. Ibs. (24

Nm), but do not remove the pin at this time. 17. Check that all timing marks are still aligned. 18. Use bulldog clips (large paper binder clips) or other suitable tool to secure the timing belt and to prevent it from slacking. Install the timing belt. Starting at the crankshaft, go around the idler pulley, then the front camshaft sprocket, the water pump pulley, the rear camshaft sprocket and the tensioner pulley. 19. Be sure the belt is tight between the crankshaft and front camshaft sprocket, between the camshaft sprockets and the water pump. Gently raise the tensioner pulley, so that the belt does not sag, and temporarily tighten the center bolt. 20. Move the crankshaft % turn counterclockwise, then turn it clockwise to the position where the timing marks are aligned. 21. Loosen the center bolt of the tensioner pulley. Using MD998767 tensioner tool, and a torque wrench apply 3.3 ft. Ibs. (4.4 Nm) tensional torque to the timing belt and tighten the center bolt to 35 ft. Ibs. (48 Nm). When tightening the bolt, be sure that the tensioner pulley shaft does not rotate with the bolt. 22. Remove the tensioner plunger pin. Pretension is correct when the pin can be

3-/

removed and installed easily. If the pin cannot be easily removed and installed it is still satisfactory as long as it is within its standard value. 23. Check that the tensioner pushrod is within the standard value. When the tensioner is engaged the pushrod should measure 0.149-0.177 in. (3.8-4.5mm). 24. Rotate the crankshaft two revolutions and check the timing marks. If the timing marks are not properly aligned remove the belt and repeat Steps 17 through 23. 20. Install the timing belt covers. 26. Install the engine mounting bracket. 27. Lower the engine enough to install the engine mount onto bracket and remove the floor jack. 28. Install the power steering pump bracket and pump. 29. Install the crankshaft pulley and tighten the retaining bolt to 13 ft. Ibs. (18 Nm). 30. Install the accessory drive belts. 31. Properly fill the cooling system. 32. Connect the negative battery cable. 33. Check for leaks and proper engine and cooling system operation. 3.2L (VIN J) and 3.5L (VIN F) Engines Use care when servicing a timing belt. Valve timing is absolutely critical to engine performance. If the valve timing marks on all drive sprockets are not properly aligned, engine damage will result. If only the belt and tensioner are being serviced, do not loosen the camshaft drive sprockets unless they are to be replaced. The sprockets have oversized openings and can be rotated several degrees in each direction on their shafts. This means the sprockets must be retimed, requiring some special too!s.

«kk CAUTION Fuel injection systems remain under pressure, even after the engine has been turned off. The fuel system pressure must be relieved before disconnecting any fuel lines. Failure to do so may result in fire and/or personal injury. 1. Disconnect the negative battery cable. 2. Rotate the engine to Top Dead Center (TDC) on the compression stroke for cylinder No. 1. 3. Release the fuel system pressure using the recommended procedure. 4. Place a pan under the radiator and drain the coolant.

Timing belt service is covered in Section 3 of this manual

3-8 SS

TIMING BELTS Sa

RSS

RES

5. Remove the radiator and cooling fan assemblies. 6. Remove the accessory drive belts. 7. Remove the upper radiator hose. 8. Remove the crankshaft damper with a quality puller tool gripping the inside of the pulley. 9. Remove the stamped steel cover. Do not remove the sealer on the cover; it may be reusable. 10. Remove the left side cast cover. If necessary, remove the lower belt cover,

located behind the crankshaft damper. 11. If the timing belt is to be reused, mark the timing belt with the running direction for installation. 12. Align the camshaft sprockets with the marks on the rear covers. 13. Remove the timing belt and tensioner. 14. If it is necessary to service the camshaft sprockets, use the following procedure: a. Hold the camshaft sprocket with a 36mm box end wrench, loosen and remove the sprocket retaining bolt and washer. >To remove the camshaft sprocket retainer bolt while the engine is in the vehicle, it may be necessary to raise that side of the engine due to the length of the retainer bolt. The right bolt is 8 % in. (213mm) long, while the left bolt is 10 in. (254mm) long. These bolts are not interchangeable and their original location during removal should be noted.

b. Remove the camshaft sprocket from the camshaft. The camshaft sprockets are not interchangeable from side-toside. c. Remove the crankshaft sprocket using Puller L-4407A. To install: 15. If it was necessary to remove the camshaft sprockets, use the following procedure:

A ALIGN CAMSHAR GAA Nifo \\SPROCKET a Gi we ySNMARK BETWEEN® (ro | . Mans ON an yia yj) TIMING BELT COVER wor oh

79225601

Timing belt alignment marks—Chrysler 3.2L and 3.5L engines

NICE

YT

TR

AE

IE

I

>This procedure can only be used when the camshaft sprockets have been loosened or removed from the camshafts. Each sprocket has a D shaped hole that allows it to be rotated several degrees in each direction on its shaft. This design must be timed with the engine to ensure proper performance.

a. Install the crankshaft sprocket, using too! C-4685-C1, thrust bearing, washer and 12mm bolt. b. When the camshaft sprockets are loosened or removed, the camshafts must be timed to the engine. Install the Camshaft Alignment tools 6642-A, to the rear of the cylinder heads. These tools lock the camshafts in the proper position. 16. Preload the belt tensioner as follows: a. Place the tensioner in a vise the same way it is mounted on the engine. b. Slowly compress the plunger into the tensioner body. c. When the plunger is compressed into the tensioner body, install a pin through the body and plunger to retain the plunger in place until the tensioner is installed. 17. Install both camshaft sprockets to the appropriate shafts. The left camshaft sprocket has the Distributorless Ignition System (DIS) pick-up as part of the sprocket. e>The right bolt is 8 % in. (213mm) long, while the left bolt is 10 in. (254mm) long. These bolts are not interchangeable.

18. Apply Loctite®271, to the threads of the camshaft sprocket retainer bolts and install to the appropriate shafts. Do not tighten the bolts at this time. 19. Align the camshaft sprockets between the marks on the rear belt covers. 20. Align the crankshaft sprocket with the TDC mark on the oil pump cover. 21. Install the timing belt, starting at the crankshaft sprocket and going in a counterclockwise direction. After the belt is installed on the right sprocket, keep tension on the belt until it is past the tensioner pulley. 22. Holding the tensioner pulley against the belt, install the timing belt tensioner into the housing and tighten to 21 ft. Ibs. (28 Nm 23, When the tensioner is in place, pull the retainer pin out to allow tensioner to extendto the pulley bracket. e>Be sure that the timing marks on the cam sprockets are still between the marks on the rear cover.

NE

PEN

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24. Remove the spark plug in the No.1 cylinder and install a dial indicator to check for TDC of the piston. Rotate the crankshaft until the piston is exactly at TDC. 25. Hold the camshaft sprocket hex with a 36mm wrench and tighten the right

camshaft sprocket bolt to 75 ft. Ibs. (102 Nm) plus an additional 90 degree turn. Tighten the left camshaft sprocket bolt to 85 ft. Ibs. (115 Nm) plus an additional 90 degree turn. 26. Remove the dial indicator. Install the spark plug and tighten to 20 ft. Ibs. (28 m). 27. Remove the camshaft alignment tools from the back of the cylinder heads and install the cam covers with new Orings. 28. Tighten the fasteners to 20 ft. Ibs.

(27 Nm). Repeat this procedure on the other camshaft. 29. Rotate the crankshaft sprocket two revolutions and check for proper alignment of the timing marks on the camshaft and the crankshaft. If the timing marks do not align, repeat the procedure. 30. Before installing, inspect the sealer on the stamped steel cover. If some sealer is missing, use MOPAR Silicone Rubber Adhesive sealant to replace the missing Sealer. 31. Install the lower belt cover behind the crankshaft damper, if necessary. 32. Install the stamped steel cover and the left side cast cover. Tighten the 6mm bolts to 105 inch Ibs. (12 Nm), the 8mm bolts to 250 inch Ibs. (28 Nm) and the 10mm bolts to 40 ft. Ibs. (64 Nm). 33. Install the crankshaft damper using special tool L-4524, a 5.9 in. long bolt, thrust bearing and washer. Tighten the center bolt to 85 ft. Ibs. (115 Nm). 34. Install the upper radiator hose. 35. Install the accessory drive belts and adjust them to the proper tension. 36. Install the radiator and cooling fan assemblies. 37. Refill and bleed the cooling system. 38. Connect the negative battery cable. 39. With the radiator cap off so coolant can be added, run the engine. Watch for leaks and listen for unusual engine noises.

FORD MOTOR COMPANY 1.3L (VIN H) Engine

1. Disconnect the negative battery cable. 2. Remove the accessory drive belts. 3. Remove the three water pump pulley attaching bolts and remove the water pump pulley.

TIMING BELTS 4. Remove the right front wheel and tire assembly and the right inner fender panel. 5. Remove the four attaching bolts and the screws from the crankshaft pulley. Remove the spacer and outer pulley, if equipped. Remove the inner spacer, inner pulley and the baffle or guide plates, as required. 6. Remove the attaching bolts and the upper and lower covers. 7. Rotate the crankshaft until the sprocket timing marks are aligned. 8. Remove the timing belt tensioner spring, spring cover and timing belt tensioner bolt. Remove the timing belt. e>|f the timing belt is to be reused, mark the direction of rotation on the belt, using a crayon, so the belt can be reinstalled in the same direction.

9. If the camshaft sprocket requires removal, proceed as follows: a. Hold the camshaft stationary with an open end wrench and remove the camshaft sprocket retaining bolt. b. Pull the camshaft sprocket with the dowel pin off of the camshaft. Use care not to drop the dowel pin. 10. If the crankshaft sprocket requires removal, proceed as follows: a. Remove the crankshaft pulley retaining bolt. b. Pull the crankshaft pulley hub, sprocket and key from the crankshaft. Be sure not to drop the crankshaft key. CAMSHAFT TIMING

cranksuartT:

So

W277

TIMING MARKS

79225605

Before removing or installing the timing belt, be sure the crankshaft and both camshaft matchmarks are aligned as

shown—ford 1.3L (VIN H) engine

To install: 11. If removed, install the crankshaft sprocket as follows: a. Install the sprocket with the key onto the crankshaft. b. Install the crankshaft pulley hub. c. Clean the threads of the crankshaft pulley bolt and coat with a non-hardening sealer. d. Install the bolt and tighten to 80-85 ft. Ibs. (108-118 Nm). 12. If removed, install the camshaft sprocket as follows: a. Position the sprocket and dowel pin to the camshaft and install the retain-

ing bolt. b. Hold the camshaft stationary with an open end wrench and tighten the retaining bolt to 36-45 ft. Ibs. (49-61 Nm). 13. Align the camshaft and crankshaft timing marks with the marks located on the cylinder head and oil pump housing. 14. If reusing the original timing belt, install the timing belt with the mark made indicating the direction of rotation. 15. Install the timing belt tensioner spring and cover on the tensioner. Position the tensioner and spring assembly on the engine and install the attaching bolt. Do not tighten the bolt at this time. 16. Rotate the crankshaft two turns in the direction of normal rotation and align the timing marks. Ensure all marks are still correctly aligned. 17. Reconnect the free end of the spring to the spring anchor. Tighten the tensioner bolt to 14-19 ft. Ibs. (19-26 Nm). 18. Install the upper and lower covers. Install the attaching bolts and tighten to 71-97 inch Ibs. (8-11 Nm). 19. Install the crankshaft pulley baffle with the curved lip facing outward or install the large guide plate, then the small guide plate, as required. 90. Install the inner pulley with the deep recess facing outward. Install the spacer, then the outer pulley, spacer and screws. Install the pulley bolts and tighten to 409-152 inch Ibs. (12-17 Nm). 94. Install the inner fender panel. 99. Install the wheel and tire assembly. Tighten the lug bolts to 65-87 ft. IDs. (88-118 Nin). 93. |nstall the water pump pulley and tighten the bolts to 36-45 ft. Ibs. (49-61 m). 94. Install the accessory drive belts. 95. Connect the negative battery cable.

3-9

26. Run the engine and check for proper operation.

1.8L (VIN 8) Engine 1. Disconnect the negative battery cable. 2. Remove the timing belt upper cover and gasket. 3. Remove the accessory drive belts. 4. Remove the water pump pulley bolts and remove the pulley. 5. Remove the right front wheel and tire assembly. 6. Remove the right upper and lower splash-shields. 7. Remove the timing belt middle and lower covers along with the gaskets. 8. Remove the crankshaft pulley hub bolt and hub. 9. Rotate the crankshaft and align the timing marks located on the camshaft sprockets and seal plate. 10. Check that the crankshaft sprocket and the oil pump are aligned. ->lf the timing belt is to be reused, mark an arrow on the belt to indicate it’s rotational direction for installation reference.

11. Loosen the timing belt tensioner bolt. 12. Turn the timing belt tensioner counterclockwise and hand-tighten the tensioner bolt to relieve the tension on the timing bel 13. Remove the timing belt. 14, If the camshaft sprockets are to be removed, continue as follows: a. Disconnect and tag the ignition wires and vacuum lines blocking the removal of the cylinder head cover. b. Remove the cylinder head cover SEAL PLATE ALIGNMENT MARKS

CAMSHAFT PULL TIMING

MARKS 7922561

Camshaft timing alignment marks—Ford 1.8L (VIN 8) engines

of this manual Heater Core replacement is covered in Section 2

3-1 0

TIMING BELTS

TIMING Ss

SPROCKET

Itt

lil 79225614

Crankshaft timing mark position—Ford 1.8L (VIN 8) engines

retaining bolts and remove the cover and gasket. c. While holding the camshaft with a wrench, remove the camshaft sprocket retaining bolt. d. Remove the camshaft sprocket. e. If removing both camshaft sprockets, tag the sprockets for identification at reassembly. 15. If removing the crankshaft sprocket, remove the crankshaft pulley bolt and hub, if not already done. Slide the crankshaft sprocket off the crankshaft. 16. Inspect the timing belt tensioner and spring, replace if necessary. To install: 17. If the crankshaft sprocket was removed, install the crankshaft key with the

tapered end facing the oil pump. Install the crankshaft sprocket onto the crankshaft while making sure to match the alignment grooves. 18. If removed, install the camshaft sprockets as follows a. Turn the camshaft until the dowel pins face straight up. b. Install the camshaft sprocket with the | mark straight up for the intake camshaft or with the E mark straight up for the exhaust camshaft. c. Align the camshaft sprockets with the timing marks on the seal plate. d. While holding each camshaft with a wrench, install the camshaft sprocket retaining bolts. Tighten the bolts to 36-45 ft. Ibs. (49-61 Nm). é. Install a new cylinder head cover gasket onto the cylinder head. f. Place the cylinder head cover into its mounting position and install the retaining bolts. Tighten the cylinder head cover bolts to 43-78 inch Ibs. (4.9-8.8 Nm). g. Install the ignition wires to the spark plugs and connect the vacuum hoses to the cylinder head cover. 19. Temporarily secure the timing belt tensioner in the far left position.

20. Verify that the timing marks on the crankshaft sprocket and the oil pump are aligned. 21. Verify that the timing marks on the camshaft sprockets and the seal plate are aligned. 22. Install the timing belt in a counterclockwise motion. Be sure there is no looseness on the idler side of the timing belt or between the camshaft sprockets.

37. Install the right wheel and tire assembly. Tighten the lug nuts to 65-87 ft. lbs. (88-118 Nm). 38. Install the timing belt upper cover and gasket. Tighten the bolts to 69-95 inch lbs. (7.8-11.0 Nm). 39. Connect the negative battery cable. 40. Run the engine and check for leaks. 41. Road test the vehicle and check for proper engine operation.

e>if using the old timing belt, be sure

1.9L (VIN J) Engine

to install the belt in the same direction of travel as it was removed.

23. Loosen the timing belt tensioner bolt. Allow the tensioner spring to apply tension to the timing belt. 24. Rotate the crankshaft 1 5 turns clockwise and align the timing belt pulley mark with the tension set mark which is located at approximately the 10 o'clock position. 25. Turn the crankshaft two turns clockwise and align the crankshaft sprocket with the tension set mark on the oil pump. 26. Verify that all timing marks are aligned. If not, remove the timing belt and repeat the installation procedures. 27. Apply tension to the timing belt tensioner and tighten the tensioner lockbolt to 2/-38 ft. lbs. (37-52 Nm). 28. Rotate the crankshaft 2 Ye (780 degrees) turns clockwise and verify that the camshaft and crankshaft timing marks are aligned. 29. Measure the timing belt deflection by applying 22 Ibs. (98 N) of pressure on the timing belt between the camshaft sprockets. The timing belt deflection should be 0.35-0.45 in. (9-11.5mm). If necessary to adjust the timing belt deflection, rotate the crankshaft two turns clockwise and ensure that the timing marks are still aligned. If the timing marks are not aligned, repeat the installation procedure. 30. Install the crankshaft pulley hub and tighten the retaining bolt to 80-87 ft. Ibs. (108-118 Nm). 31. Install the crankshaft pulley and washer. Install the retaining bolts and tighten to 109-152 inch Ibs. (12-17 Nm). 32. Install the timing belt middle and lower covers with the gaskets. Tighten the middle and lower timing belt cover retaining bolts to 65-95 inch Ibs. (7.8-11 Nm). 33. Install the power steering drive belt. 34. Install the water pump pulley and retaining bolts. Tighten the bolts to 69-95 inch Ibs. (7.8-11.0 Nm). 39. Install the alternator/water pump drive belt. 36. Install the splash-shields. Tighten the bolts to 69-95 inch Ibs. (7.8-11.0 Nm).

1. Disconnect the negative battery cable. 2. Remove the accessory drive belt automatic tensioner and the accessory drive belt. 3. Remove the timing belt cover. 4. Align the timing mark on the camshaft sprocket with the timing mark on the cylinder head. 5. Confirm that the timing mark on the crankshaft sprocket is aligned with the timing mark on the oil pump housing. 6. Loosen the belt tensioner attaching bolt, pry the tensioner away from the timing belt and retighten the bolt. 7. Remove the spark plugs. Remove the right engine mount. 8. Remove the right side splash-shield. 9. Remove the flywheel inspection shield. 10. Use a-suitable tool to hold the flywheel in place. 11. Remove the crankshaft damper bolt and washer and remove the bolt. 12. Remove the timing belt. e>With the timing belt removed and the No. 1 piston at Top Dead Center (TDC), do not rotate the camshaft. If the camshaft must be rotated, align the crankshaft damper 90 degrees BTDC.

INSTALLED TIMING BELT

79225698

View of timing belt and alignment positions—Ford 1.9L (VIN J) Engine

TIMING BELTS To install: 13. Install the timing belt over the sprockets in a counterclockwise direction Starting at the crankshaft. Keep the belt span ‘from the crankshaft to the camshaft tight while installing over the remaining sprocket. 14. Loosen the belt tensioner attaching bolt, allowing the tensioner to snap against the belt. 15. Rotate the crankshaft clockwise two complete revolutions, stopping at TDC. This will allow the tensioner spring to load the timing belt. ->Do not turn the engine counterclockwise to align the timing marks. Do not rotate the crankshaft with the spark plugs installed.

16. Recheck the camshaft and crankshaft timing marks for alignment, to be sure the timing belt has not skipped a tooth during rotation. Repeat the procedure if the timing marks are not aligned. 17. Tighten the tensioner attaching bolt to 17-22 ft. Ibs. (23-30 Nm). 18. Install the crankshaft dampener and the bolt and washer. Tighten the bolt to 81-96 ft. Ibs. (110-130 Nm). 19. Install the flywheel inspection shield. 20. Install the splash-shield and lower the vehicle. 21. Install the right engine mount. Install the spark plugs. 22. Install the timing belt cover. 23. Install the accessory drive belt automatic tensioner and the accessory drive belt. 24. Connect the negative battery cable.

OIL PAN Be ge

ALIGN CRANKSHAFT TIMING MARKS 79225609

Crankshaft alignment position—Ford 2.0L (VIN 3) engines

EXHAUST CAMSHAFT

INTAKE CAMSHAFT

8. Install the timing belt. 9. Engage the timing belt tensioner tab into the timing cover back plate. 10. Adjust the timing belt tensioner until the index marks are aligned. Tighten the tensioner bolt to 17—20 ft. Ibs. (22-28 Nm). 11. Remove the camshaft alignment tool and the crankshaft TDC peg. 12. Install or connect the following: Timing belt covers Crankshaft pulley. Tighten the bolt

to 81-89 ft. Ibs. (110-120 Nm). Valve cover Water pump pulley Accessory drive belt and idler pulley Right inner splash shield Right front wheel Catalytic converter Spark plugs Negative battery cable 13. Start the engine and check for proper operation.

2.0L (VIN A) Engine CAMSHAFT ALIGNMENT TIMING

TOOL

79225610

Placement of camshaft alignment timing

tool T94P-6256-CH—Ford 2.0L (VIN 3) engines

2.0L (VIN 3) Engine 1. Remove or disconnect the following: e Negative battery cable e Spark plugs e Catalytic converter e Right front wheel e Right inner splash shield e Accessory drive belt and idler pulle 2. Rotate the crankshaft to Top Dead Center (TDC) and install Crankshaft TDC Timing Peg T97P-6000-A. 3. Rotate the crankshaft clockwise against the peg. 4. Remove cr disconnect the following: e Water pump pulley e Valve cover e Crankshaft pulley ¢ Timing belt covers 5. Install Camshaft Alignment Timing Tool T94P-6256-CH into the slots of both

3-11

93464G01

Timing belt tensioner index marks—Ford 2.0L (VIN 3) engines

camshafts at the rear of the cylinder head to lock the camshafts into position. 6. Loosen the timing belt tensioner bolt and relieve the tension on the timing belt by disconnecting the tensioner tab from the timing cover back plate. 7. Remove the timing belt. To install: > Always replace the timing belt after loosening or removing it.

1. Disconnect the negative battery cable” 2. Label and disconnect the spark plug wires and clips from the cylinder head cover. Remove the ignition distributor with wiring and set it aside. 3. Remove the power steering hose brackets from the cylinder head cover. If necessary disconnect the crankshaft position sensor. 4. Disconnect the breather tube and PCV valve from the cylinder head cover. 5. Loosen the cylinder head cover bolts in 2-3 steps. Remove the cylinder head cover. 6. Remove the power steering belt shield. Loosen the power steering adjusting bolt, lockbolt and through-bolt and remove the power steering belt. 7. Loosen the alternator adjusting bolt and upper mounting bolt. Remove the alternator belt. 8. Support the engine with engine support tool 01400750. Raise the engine slightly with a jack and remove the right side engine support insulator (mount). 9. Remove the oil level indicator bolt and four upper timing belt cover bolts and remove the upper timing belt cover. 10. Remove the splash-shields. Using holder tool T92C-6316-AH, hold the crankshaft pulley and remove the pulley bolt. Use a suitable puller to remove the pulley, then remove the guide plate.

Brake service is covered in Section 4 of this manual

3-12

TIMING BELTS

11. Remove the four lower timing belt cover bolts and remove the lower timing belt cover. 12. Temporarily install the crankshaft pulley bolt. 13. Turn the crankshaft until the timing mark on the crankshaft sprocket aligns with the timing mark on the oil pump and the camshaft sprocket timing marks, E and I, align on the camshaft sprockets. 14. Insert camshaft sprocket holding tool T92C-6256-AH, between the camshaft

sprockets. 15. Turn the timing belt tensioner with an Allen wrench and remove the tensioner spring from the tensioner spring pin. 16. If the timing belt is to be reused, mark the direction of rotation on the timing belt. Remove the timing belt. 17. If necessary to remove the sprockets, remove the camshaft sprocket holding tool. Hold the camshaft by placing a suitable wrench on the hexagon which is cast into the camshaft. Place another wrench onto the camshaft sprocket retaining bolt and loosen the bolt. Before removing the camshaft sprocket(s), be sure that the camshafts are still in alignment and tag each sprocket to the camshaft from which it was removed.

18. Remove the camshaft sprocket bolt and the camshaft sprocket from the camshaft. 19. Repeat the camshaft sprocket removal procedure for the opposite camshaft if required. 20. Slide off the crankshaft sprocket and remove the crankshaft key. To install: 21. Install the crankshaft key and slide CAMSHAFT SPROCKETS

TIMING BELT IDLER

CRANKSHAFT SPROCKET

79225606

Be sure that the intake and exhaust camshaft timing marks align so that they face each other—Ford 2.0L (VIN A) engines

the crankshaft sprocket into position. 22. Install the camshaft sprocket onto the proper camshaft, making sure to align the dowel pin. 23. Be sure that the I and E are in alignment.

24. Install the camshaft sprocket bolt. Hold the hexagon on the camshaft with a suitable wrench and tighten the sprocket bolt to 35—-48 ft. Ibs. (47-65 Nm). Be sure the camshaft sprockets are still properly aligned and reinstall the sprocket holding tool. 25. Be sure the timing marks on the camshaft and crankshaft sprockets are still aligned. 26. Install the timing belt. If reusing the original timing belt, be sure it is installed in the same direction of rotation. 27. Turn the tensioner clockwise with an Allen wrench and install the tensioner spring. Remove the holding too! from between the camshaft sprockets. 28. Rotate the crankshaft clockwise two turns and align the timing marks. Be sure all marks are still correctly aligned. e>The timing chain tensioner automatically adjusts the tension on the timing belt.

29. Install the timing belt lower cover and tighten the four bolts to 71-88 inch Ibs.

(8-10 Nm). 30. Install the guide plate, crankshaft pulley and pulley bolt. Secure the pulley with the holder tool and tighten the bolt to 116-123 ft. Ibs. (157-167 Nm). 31. Install the splash-shields and lower the vehicle. 32. Raise the engine slightly with the jack and install the right side engine mount. Tighten the mount through-bolt to 63-86 ft, Ibs. (86-116 Nm) and the mount attaching nuts to 54-76 ft. Ibs. (74-103 Nm) Remove the engine support tool. 33. Install the upper timing belt cover and tighten the bolts to 71-88 inch Ibs. (8-10 Nm). 34. Clean the cylinder head and valve cover mating surfaces thoroughly. 35. Apply silicone sealant to the cylinder head surface in the area adjacent to the front camshaft bearing caps. Apply sealant to a new gasket and install it on the cylinder head cover. 36. Install the cylinder head cover and tighten the bolts. 37. Install the power steering hose brackets and tighten the bolts to 71-88 inch lbs. (8-10 Nm). Connect the spark plug wires and wire clips. Connect the breather tube and PCV valve. If necessary, connect

the crankshaft position sensor. 38. Install the alternator belt and adjust the tension. Tighten the upper mounting bolt to 14-18 ft. Ibs. (19-25 Nm) and the lower through-bolt to 27-38 ft. Ibs. (87-52 Nm). 39. Install the power steering belt and adjust the tension. Tighten the through-bolt to 32-45 ft. Ibs. (43-61 Nm) and the lockbolt to 23-34 ft. Ibs. (31-46 Nm). Install the power steering belt shield and tighten the bolts to 61-86 inch Ibs. (7-9 Nm). 40. Connect the negative battery cable. 41. Run the engine and check for leaks and proper engine operation.

2.0L (VIN P) Engine 1. Remove or disconnect the following: e Negative battery cable ¢ Accessory drive belt and tensioner ¢ Timing belt cover ¢ Right front wheel e Right inner splash shield ¢ Crankshaft pulley 2. Align the timing marks as shown. 3. Refer to the illustration and remove the timing belt as follows: a. Loosen the timing belt tensioner bolt (1). b. Use an 8mm Allen wrench, and turn the tensioner (2) counterclockwise YW turn. c. Insert a % inch drill bit in the hole (3) to lock the belt tensioner in place. d. Remove the timing belt (4). To install: 4. Install the timing belt in a counter-

93005601

Align the timing marks before removing or installing the timing belt—2.0L (VIN P) SOHC engines

TIMING BELTS

Si

EA

93005602

Remove the timing belt by following these 4 numbered steps (refer to the text for an explanation)—2.0L (VIN P) SOHC engine

clockwise direction starting at the crankshaft. 5. Remove the drill bit to unlock the timing belt tensioner. 6.. Rotate the crankshaft two complete turns and check that the timing marks align. 7. Tighten the tensioner bolt to 15-22 ft. lps. (20-30 Nm). 8. Install or connect the following: e Crankshaft pulley. Tighten the bolt to 81-96 ft. Ibs. (110-130 Nm). e Right inner splash shield e Right front wheel e Timing belt cover ¢ Accessory drive belt and tensioner e Negative battery cable 9. Start the engine and check for proper operation.

2.5L (VIN B) Engine 1. Disconnect the negative battery cable. 2. Label and disengage the electrical connectors from the coolant elbow. Label and remove the electrical connectors from the Knock Sensor (KS), if required and the Crankshaft Position (CKP) sensor. 3. Loosen the drive belt tensioner locknuts and adjusting bolts. Remove the accessory drive belts. 4. Remove the lower bolt from the A/C and alternator tensioner bracket. 5. Remove the right wheel and splashshields. 6. Hold the crankshaft pulley (damper) with holder tool T92C-6316-AH, and remove the crankshaft pulley bolt. Remove the crankshaft pulley, using a puller if needed. 7. Remove the 5 front timing belt cover bolts. 8. Hold the water pump pulley with holder tool T92C-6312-AH, remove the four bolts and the water pump pulley.

9. Hold the power steering pump pulley with strap wrench D85L-6000-A and remove the power steering pump pulley nut and pulley. 10. Remove the upper bolt from the belt idler bracket and remove the bracket. 11. Remove the engine oil dipstick tube retaining bolt and the tube. 12. Remove the 8 rear timing belt cover retaining bolts and remove the timing belt covers. 13. Temporarily reinstall the crankshaft pulley bolt. 14. Remove the three nuts and throughbolt from the right-hand engine support insulator and remove the support insulator. Remove the support insulator bracket. 15. Turn the crankshaft to Top Dead Center (TDC) No. 1 cylinder in the direction of normal rotation. Be sure that the timing mark on the crankshaft sprocket aligns with the timing mark on the oil pump. 16. Remove the two bolts from the timing belt tensioner arm, removing the lower bolt first. 17. Remove the timing belt tensioner arm. 18. If the timing belt is to be reused, mark the direction of rotation on the timing belt. 19. Loosen the Allen bolt on the timing belt tensioner. 20. Remove the timing belt. 21. If the timing belt sprockets are to be removed, proceed as follows: a. Remove the intake manifold. b. Label and disconnect the necessary hoses from the cylinder head covers. c. Label and disconnect the spark plug wires from the spark plugs. d. Remove the cylinder head cover retaining bolts and remove the cylinder head covers. e, Hold the camshaft using a suitable wrench on the hexagon cast into the

79225607

Left and right camshaft timing position— Ford 2.5L (VIN B) engines

CRANKSHAFT TIMING

3-13

WATER PUMP

79225608

TDC alignment for the crankshaft—Ford 2.5L (VIN B) engines

camshaft. Remove the camshaft sprocket bolts and the camshaft sprockets. f. Use crankshaft damper puller T74P-6316-A, to remove the crankshaft sprocket. Remove the crankshaft sprocket key. To install: 22. If the timing belt sprockets were removed, proceed as follows: a. Install the crankshaft sprocket key and crankshaft sprocket. b. Install the camshaft sprockets on the camshafts with the retaining bolts. c. Hold the camshaft using a suitable wrench on the hexagon cast into the camshaft. Tighten the camshaft sprocket bolts to 90-108 ft. Ibs. (123-140 Nm). d. Be sure the cylinder head cover and cylinder head contact surfaces are clean and free of dirt, oil and old sealant and gasket material. e. Apply silicone sealant to the cylinder heads in the area adjacent to the front and rear camshaft caps. Install new gaskets on the cylinder heads. f. Install the cylinder head covers and tighten the retaining bolts. g. Connect the spark plug wires to the spark plugs and connect the hoses to the cylinder head covers. h. Install the intake manifold. 23. Position the timing belt tensioner arm ina Suitable press. 24. Compress the tensioner until the hole in the piston is aligned with the 2nd hole in the tensioner case. Insert a 0.060 in. (1.6mm) diameter wire or pin through the nd hole to keep the piston compressed. 25. Align the camshaft sprockets to TDC. 96. Turn the crankshaft counterclockwise until the crankshaft sprocket is offset from TDC by one tooth.

manual For complete Engine Mechanical specifications, see Section 1 of this

3-1 4 SSE

SRE

TIMING BELTS EES D/H WPS

SAT ADEOED SSA

27. Install the timing belt. 28. If the original belt is being reused, be sure it is installed in the same direction of rotation. 29. Turn the crankshaft in the direction of normal engine rotation until the crankshaft sprocket timing mark is at TDC. This should place all of the belt slack in the timing belt tensioner portion of the timing belt. 30. Install the timing belt tensioner arm and two bolts. Tighten the bolts to 14-18 ft. lbs. (19-25 Nm). 31. Remove the wire or pin from the tensioner. e>When properly timed, the crankshaft timing marks will align and the crankShaft sprocket timing mark will no longer be one tooth off.

32. Rotate the crankshaft two complete turns in the direction of normal rotation and align the timing marks. Be sure all marks are still correctly aligned. This will also set the timing belt tension. ->The timing belt tensioner will automatically adjust the timing belt tension.

33. Tighten the timing belt tensioner Allen bolt to 28-32 ft. Ibs. (35-51 Nm). 34. Install the right-hand engine support insulator. Tighten the three nuts to 54-76 ft. Ibs. (74-103 Nm) and the through-bolt to 90-68 ft. Ibs. (67-93 Nm). 35. Remove the crankshaft damper bolt.

36. Install the timing belt covers with the rear8 bolts. Tighten to 71-88 inch Ibs. (8-10 Nm). 37. Install the engine oil dipstick tube and retaining nut. 38. Install the belt idler bracket and the upper retaining bolt. 39. Install the power steering pump pulley and nut. Tighten the nut to 36-43 ft. Ibs. (49-59 Nm) while holding the pulley with a strap wrench. 40. Install the water pump pulley and four bolts. Secure the pulley with the holder tool and tighten the bolts to 71-88 inch Ibs. (8-10 Nm). 41. Install the 5 front timing belt cover bolts and tighten to 71-88 inch Ibs. (8-10 Nm). 42. Install the crankshaft pulley (damper) with the bolt. Hold the crankshaft pulley with the holding tool and tighten to 116-122 ft. Ibs. (157-166 Nm). 43. Install the splash-shields. 44. Install the wheel and tighten the lug nuts to 65-87 ft. Ibs. (88-118 Nm).

45. Install the lower bolt into the A/C and alternator tensioner bracket.

RSVP SSE GS AES IEVTE

ANAS

EI

SONS

PT

IP

PEE

46. Install the accessory drive belts and adjust the tension. 47. Engage the electrical connectors to the sensors at the coolant elbow and the KS and CKP sensors. 48. Connect the negative battery cable. 49. Run the engine and check for leaks and proper engine operation.

1.0L (VIN 6) and 1.3 (VIN 9) Engines

if equipped, the A/C drive belt. e>|t is not necessary to remove the crankshaft timing sprocket bolt (center bolt) to remove the crankshaft pulley.

9. Remove the crankshaft pulley bolts and crankshaft pulley, 6. Remove the water pump pulley. 7. Remove the retaining bolts and nut from the timing belt outside cover.

I

SSP

OT

TIS

8. Remove the timing belt outside cover. 9. Turn the crankshaft to align the timing marks. The mark on the crankshaft sprocket should align with the arrow mark on the oil pump housing. The mark on the camshaft sprocket should align with the V mark on the timing belt inner cover or cylinder head cover. 10. If the timing belt is to be reused, mark the direction of rotation on the belt. 11. Remove the timing belt tensioner, tensioner plate, tensioner spring, spring

GENERAL MOTORS

1. Disconnect the negative battery cable. 2. Remove the clips and right side Splash-shield. 3. Remove the lower alternator cover plate. 4. Remove the alternator drive belt and

TE ET

damper and timing belt. e>Never turn the camshaft or crankshaft independently after the timing belt has been removed. Interference may occur between the pistons and valves, and parts may be damaged.

12. Inspect the timing belt for wear or Cracks, and replace as necessary. Check the tensioner for smooth rotation. 13. If the timing belt sprockets are to be removed, proceed as follows: a. Using a 0.39 in. (10mm) rod inserted into the camshaft, hold the camshaft and remove the retaining bolt and camshaft sprocket.

3

(PSN.—— 4

\Hegsk a,

Z

A | 2 3 4

CAMSHAFT TIMING PULLEY TIMING MARK "V" MARK BELT INSIDE COVER

5 6 7

SLOT NO. 1 SLOT NO. 2 PULLEY PIN

Upper timing pulley position—GM 1.0L (VIN 6) and 1.3L (VIN 9) engines

79225616

TIMING BELTS

plate. Tighten the bolts to 89 inch Ibs. (10 Nm). 2/. Install the right side splash-shield and clips. 28. Connect the negative battery cable. 29. Run the engine. Check for leaks.

A

:

IRE

O

Tint /

b

@

TH

a~

4

~

Se

B

———>

Em

Korn

(© A ARROW MARK ON OIL PUMP CASE B PUNCH MARK ON CRANKSHAFT TIMING GEAR 674 CRANKSHAFT PULLEY TIMING GEAR BOLT 6021 CRANKSHAFT TIMING GEAR 79225617

Crankshaft timing mark—GM 1.0L (VIN 6) and 1.3L (VIN 9) engines

Be careful not to damage the cylinder head or cylinder head cover mating surfaces. Place a clean shop cloth between the rod and cylinder head. Do not bump the rod hard against the cylinder head when loosening the bolt. |e

ES

b. If equipped with a manual transaxle, lock the crankshaft in position by inserting a suitable flat-biaded tool into the hole in the bottom of the bell housing to engage the flywheel teeth. c. If equipped with an automatic transaxle, lock the crankshaft in position by inserting a suitable flat-bladed tool between the flywheel teeth and against the engine block. d. Remove the crankshaft sprocket bolt and crankshaft sprocket. To install: 14. If the timing belt sprockets were removed, proceed as follows: qa. Install the crankshaft sprocket, aligning the keyway. Lock the crankshaft in place and tighten the crankshaft sprocket bolt to 81 ft. Ibs. (110 Nm). b. Install the camshaft sprocket and retaining bolt. Lock the camshaft in place using the rod, and tighten the bolt to 44 ft. Ibs. (60 Nm). Remove the locking rod. 15. Install the tensioner plate to the tenSioner. 16. Insert the lug of the tensioner plate into the hole of the tensioner. 17. Install the tensioner, tensioner plate and spring. Do not fully tighten the tensioner bolt and stud at this time.

3-19

18. Move the tensioner plate in a counterclockwise direction. This should cause the tensioner to move in the same direction. If it does not, remove the tensioner and tensioner plate, and reinsert the tensioner plate lug in the timing plate tensioner nole. 19. Check that the camshaft timing marks are aligned. If not, align the two marks by turning the camshaft. 20. Check that the punch mark on the crankshaft timing belt sprocket is aligned with the arrow mark on the oil pump case. If not, align the two marks by turning the crankshaft. 21. With the timing marks aligned, install the timing belt on the two sprockets. If the old belt is being reused, be sure to install it running in the same direction of original rotation. 22. Install the tensioner spring and spring damper. Turn the timing belt two rotations clockwise after installing the tensioner spring and damper to remove any belt slack. Tighten the tensioner stud to 8 ft. Ibs. (11 Nm), then the tensioner bolt to 20 ft. lps. (27 Nm).

1.6L (VIN 6) and 1.8L (VIN 8) Engines 1. Disconnect the negative battery cable. 2. Remove the windshield washer reservoir from the engine compartment. 3. If equipped with cruise control, proceed as follows: a. Remove the cruise control actuator cover. b. Disconnect the cruise control harnesses. c. Disconnect the control cable. d. Remove the bolts and actuator from the vehicle. 4. Remove the right front wheel. 5. Remove the bolts and plastic clips and the right front wheel housing. 6. Remove the alternator/water pump drive belt. 7. lf equipped with A/C, proceed as follows: a. Remove the A/C compressor drive belt. b. Disconnect the compressor harness. c. Remove the bolts and compressor, without disconnecting the refrigerant lines. Suspend the compressor aside. d. Remove the compressor mounting bracket. 8. Remove the power steering pump drive belt. 9. Disconnect the wiring from the alternator and oil pressure switch. 10. Remove the engine wiring harness cover.

-» Confirm that both sets of timing marks are aligned properly.

23. Using a new seal, install the timing belt cover and tighten the bolts and nut to 97 inch lbs. (11 Nm). 94. |nstall the crankshaft pulley. Fit the keyway on the pulley to the crankshaft timing belt sprocket and tighten the bolts to 8-12 ft. Ibs. (11-16 Nm). 95. Install the alternator drive belt, if equipped, A/C drive belt. 96. Install the lower alternator cover

620

CAMSHAFT TIMING GEAR 79225618

Aligning the camshaft timing marks—GM 1.6L (VIN 6) and 1.8L (VIN 8) engines

For Accessory Drive Belt illustrations, see Section 1 of this manual

3-1 6

TIMING BELTS 24. Remove the timing belt from the sprockets. Inspect the timing belt for cracked or damaged teeth. Replace as necessary.

Do not bend, twist or turn the timing belt.

693

CRANKSHAFT TIMING GEAR 79225619

25. If the camshaft sprocket is to be removed, hold the camshaft stationary using a wrench positioned on the hexagon cast into the camshaft, and remove the sprocket retaining bolt and sprocket.

Crankshaft pulley alignment indicator— GM 1.6L (VIN 6) and 1.8L (VIN 8) engines

11. Remove the wiring harness from the cylinder head cover. 12. Disconnect the ignition wires from the spark plugs, then remove the spark plugs. 13. Remove the PCV hoses from the valve cover. 14. Remove the cap nuts, the seal washers and the cylinder head cover with the gasket. 15. Turn the crankshaft to align the timing mark on the crankshaft pulley at 0, setting the piston in the No. 1 cylinder at Top Dead Center (TDC) on the compression stroke. Check that the valve lash adjusters on the No. 1 cylinder are loose. If not, turn the crankshaft pulley one complete revolution (360 degrees). 16. Remove the engine ground wire from the right fender apron. 17. Install a suitable support under the engine and remove the engine mount. 18. Remove the water pump pulley. 19. Remove the crankshaft pulley using a Suitable puller. 20. Remove the 9 retaining bolts and the timing belt covers. 21. Slide the timing belt guide from the crankshaft. 22. Be sure the timing belt sprockets are properly aligned.

«+ WARNING Do not turn the crankshaft or camshaft independently after removal of the timing belt; binding or damage to engine components could result. If the timing belt is to be reused, mark the belt with an arrow showing the direction of engine revolution. seieseeseassnssscssenatinidsicamsemsnsesbanvasruuneeteeteaensies 23. Remove the timing belt tensioner bolt, tensioner and tension spring.

Be careful not to damage the cylinder head when holding the camshaft in place.

26. If the crankshaft sprocket is to be removed, pry it from the crankshaft using two flat-bladed prybars. To install: 2/7. Align the camshaft key with the groove on the sprocket and slide the sprocket on. Hold the camshaft with the wrench at the hexagonal portion of the camshaft, and tighten the camshaft timing sprocket bolt to 43 ft. Ibs. (69 Nm). 28. Be sure the sprocket is still properly aligned. 29. Install the crankshaft timing sprocket. Align the crankshaft key with the groove on the sprocket and slide it on. 30. Reinstall the timing belt tensioner and the tension spring. Pry the tensioner to the left as far as it will go and temporarily tighten the retaining bolt. 31. Install the timing belt. If installing the old belt, observe the matchmarks made during removal. 32. Loosen the retaining bolt for the timing belt tensioner and allow it to tension the belt. 33. Temporarily install the crankshaft pulley bolt and turn the crankshaft clockwise two full revolutions. Be sure each timing mark realigns exactly. 34, Tighten the timing belt tensioner bolt to 27 ft. Ibs. (37 Nm). 35. Measure the timing belt deflection. Correct deflection should be 0.20—0.24 in. (56mm) at 4 Ibs. (20 Nm) of pressure. If the deflection is not correct, adjust it with the timing belt tensioner. 36. Install the timing belt guide, with the cup side facing outward. 37. Install the timing belt covers, installing the bottom one first. Tighten the 9 cover bolts to 62 inch Ibs. (7 Nm).

38. Install the crankshaft pulley after aligning the pulley key with the slot on the pulley. Hold the pulley with tool J-8614-01, and tighten the pulley bolt to 87 ft. Ibs. (118 Nm). 39. Temporarily install the water pump pulley. 40. Install the engine mount. 41. Install or connect the remaining components.

42. \f equipped with A/C, proceed as follows:

a. Install the compressor mounting bracket and tighten the bolts to 35 ft. Ibs. (47 Nm). b. Install the compressor and tighten the bolts to 18 ft. Ibs. (25 Nm). c. engage the compressor wiring connector. d. Install the compressor drive belt and adjust the tension. 43. If equipped with cruise control, proceed as follows: a. Install the cruise control actuator and tighten the bolts to 89 inch Ibs. (10 Nm). b. Connect the cruise control cable. c. Install the cruise control actuator cover. 44. Connect the negative battery cable. 45. Start the engine and check vehicle operation.

3.0L (VIN R) 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 Intake air resonator Intake plenum Splash shield Secondary air injection (AIR) pipe Accessory drive belt Water pump and power steering pump pulleys Drive belt tensioner Front timing belt cover ¢ Crankshaft balancer 3. Rotate the crankshaft clockwise to 60 degrees before top dead center (BTDC). 4. Loosen the timing belt tensioner and idler pulleys. 9. Remove the timing belt. To install: 6. Start at the crankshaft sprocket and install the timing belt with the double dash (TDC) aligned with the marks on the oil pump and on the belt drive gear. 7. Set the initial timing belt tension as follows:

d

TIMING BELTS

3-1 7

TIMING BELT INSTALLATION AND ADJUSTMENT TABLE [Wale [Yes [No Install the timing belt and align marks on the belt with the marks on the camshaft gears and the crankshaft gear. Check the timing belt deflection between the idler pulley for camshafts 3 & 4 and camshaft number 4.

t cm (0.4 in) maximum

Go to

Is the timing belt installed, the marks aligned and the timing belt deflection adjusted? Set the initial timing belt tension at the timing belt tensioner. Is the initial timing belt tension set?

Rotate the engine two complete revolutions and secure the crankshaft at Top Dead Center (TDC) with the J 42069-10. Has the engine been rotated and the crankshaft secured to TDC?

Starting with camshafts 3 and 4, check the alignment of the marks on the camshaft gears with the marks on the J 42069-20 checking gauge. Do the marks on the camshaft gears align exactly with the marks on J 42069-20? Check the alignment of the marks on camshafts gears 1 and 2 with the marks on the J 42069-20 checking gauge.

Do the marks on the camshaft gears align exactly with the marks on J 42069-20? Do the camshaft gear marks line up to the left (BTDC) of the marks on the J 42069-20 checking gauge?

if

Do the camshaft gear marks line up to the right (ATDC) of the marks on the J 42069-20 checking gauge? Tum the idler pulley eccentric, for camshafts 3 and 4, counterclockwise

Go to Step 8

Go to Step 7

Go to Step 9

Go to

until the marks on the camshaft gear align exactly with the marks on J 42069-20. Rotate the engine two complete revolutions,

lock the crankshaft at TDC with J 42069-10 and recheck the alignment of the camshaft gear marks to the marks on J 42069-20.

Do the marks on the camshaft gears align exactly with the marks on

J 42069-20? Tum the idler pulley eccentric, for camshafts 3 and 4, clockwise until on the marks on the camshaft gear align exactly with the marks ns, revolutio complete two engine the Rotate . J 42069-20

lock the crankshaft at TDC with J 42069-10 and recheck the alignment of the camshaft gear marks to the marks on J 42069-20.

on Do the marks on the camshaft gears align exactly with the marks J 42069-20? 79225635

3.0L (VIN R) engine Timing belt installation and adjustment table—GM

a. Turn the tensioner nut COUNTERCLOCKWISE to full stop, then, turn the nut back until the reference mark is 1 mr (0.003 in) over the flange. b. Tighten the timing belt tensioner locking nut until snug, the locking nut will be tightened to specifications after all final adjustments are made.

8. Rotate the engine in the clockwise direction two revolutions stopping at 60 degrees BIDC. 9. Inspect the alignment of the reference marks on the camshaft gears with the notches on the rear timing belt cover, as well as, the mark on the crankshaft sprocket and oil pump housing.

10. If timing belt adjustment IS NOT required, set the final timing belt tena Sion: a. Loosen the timing belt tensioner locking nut. b. Turn the locking nut counter-_ clockwise to full stop, then back until the reference mark is 2-4 mm (0.078-

on 1 of this manual For Tire, Wheel and Ball Joint specifications, see Secti

3-1 8

TIMING BELTS

[Sep ar Tm TaN iaiAetion/ 7 10 Tig, |e nIvarOS ares A Do the camshaft gear marks line up to the left (BTDC) of the marks on the J 42069-20 checking gauge?

Go to Step 12

Do the camshaft gear marks line up to the right (ATDC) of the marks on the J 42069-20 checking gauge?

“


Wy 79225631 79225630

Crankshaft alignment to 60 degrees BIDC—GM 3.0L (VIN R) engine

0.157 in) ABOVE the reference mark on

the flange. 11. Tighten sean

, the timing belt tensioner a (20 ee ooo

. lighten Ibs. (40 Nm). the idler pulley puney bolts to 30 ft.

13. Install or connect the following:

© Crankshaft bolts to 15 balancer. ft. Ibs. (20Torque Nm). the ¢ Front timing belt cover. Torque Ae to 71 inch lbs. (8

Securing the crankshaft—GM 3.0L (VIN R) engine

Drive belt tensioner. Torque the

bolts topump 30 ft.pulley Ibs. (40 Nm) the * Water Torque bolts to 71 inch Ibs. (8 Nm)

+ Power steering pump pulley.

Torque the bolts to 15 ft. Ibs. (20

TIMING BELTS J 42069 -2

|

J 42069 —1

§93.4Q

79225634

Initial timing belt tension adjustment—GM

3.0L (VIN R) engine

79225632

¢ e e e e

Nm). Accessory drive belt AIR injection pipe Splash shield |ntake plenum |ntake air resonator

3.4L (VIN X) Engine

PP

The 3.4L (VIN X) engine uses a timing chain and camshaft timing belts. 1. Disconnect the negative battery cable. 2. Disconnect and remove the power steering pump from the pump mounting bracket. 3. Remove the left, right and center timing belt covers. 4. Rotate the engine clockwise to align the timing marks, TDC on the No.1 exhaust stroke, on the camshaft sprockets and intermediate shaft. 5. Loosely clamp the two camshaft sprockets on each side of the engine together using clamping pliers or the equivalent. Secure the belt to the right side cam sprocket with a C-clamp and a wide pad on the belt.

ni

79225633

(VIN R) engine Using the tool to pin the timing belt—GM 3.0L

s>\When clamping the sprockets no deflection should be noticed. If any deflection is noticed, loosen the clamping devices. DO NOT mar the camshaft sprockets with the clamping device.

this manual For Wheel Alignment specifications, see Section 1 of

3-20 IRD

VSN

TIMING BELTS YS

A

AT

a

6. Remove the tensioner side plate retaining bolts from the tensioner and remove the side plate from the actuator and base. 7. Rotate the actuator assembly around the arm pivot and out of the base. Removal of the tensioner from the base allows it to extend to its maximum travel. 8. Set the actuator aside on a table ina vertical position to allow the oil to drain into the boot end. The tensioner should be allowed to sit for 5 minutes prior to refilling with oil. 9. Reset the timing belt actuator as follows: a. Straighten out a paper clip or a piece of stiff wire 0.032 in. (0.75mm) diameter to a minimum straight length of 1.85 in. (47mm). Form a double loop in the remaining end. b. Remove the rubber end plug from the rear of the tensioner assembly. This will aid in allowing the oil in the tensioner to escape.

c. Hold the tensioner in your hand with the rubber boot end of the tensioner pointing down. d. DO NOT remove the vent plug. Push the paper clip through the center hole in the vent plug and into the pilot hole. e. Insert a small screwdriver into the screw Slot inside the end of the tensioner. f. Retract the tensioner by rotating the tensioner plunger in a clockwise direction while pushing the rod tip against a table top.

ST

SS

BLE

EE

ET

g. Align the screw slot to align with the vent hole, and push the straight section of the wire into the screw slot to retain the plunger in the retracted position. h. If tensioner oil has been lost, fill the tensioner with SAE 5W30 Mobil 1°. Fill the tensioner to the bottom of the plug. The tensioner MUST be fully retracted before being filled with oil. 10. If the belt is being reused, mark the direction of rotation on the belt. 11. Remove the timing belt tensioner pulley mounting bolt and pulley. 12. Remove the timing belt after first removing the C-clamp retaining the belt to the right side camshaft sprocket. 13. Remove the Torx® head bolts securing the idler pulleys, if the idlers need to be replaced. 14, Remove the intermediate shaft sprocket using the following procedure: a. Use a Suitable tool to hold the engine from turning. b. Remove the intermediate shaft sprocket mounting bolt and washer. c. Using J-38616 sprocket puller, remove the sprocket from the intermediate shaft. 15. If the camshaft sprockets need to be removed, proceed as follows: a. Remove the camshaft carrier cover(s). b. Remove the camshaft sprocket clamping pliers. c. Rotate the camshaft being serviced So the flats on the camshaft are face up.

LOCATION OF TIMING MARKS WITH CAM HOLD DOWN TOOLS J 38613 INSTALLED (#4 TOC COMPRESSION STROKE) B FRONT COVER TIMING MARK C LOCATION OF TIMING MARKS WITH DRIVE BELT INSTALLED D LOCATION WHERE CAM HOLD DOWN TOOLS ARE INSTALLED RH EXHAUST CAMSHAFT SPROCKET RH INTAKE CAMSHAFT SPROCKET LH INTAKE CAMSHAFT SPROCKET LH EXHAUST CAMSHAFT SPROCKET PERMANENT MARKS PAINTED DOTS REMOVE = OrWNH PREVIOUS MARKS IF TIMING IS BEING CHANGED AND MARKS AGAIN IN THESE LOCATIONS 6 CRANKSHAFT BALANCER 7 INTERMEDIATE SHAFT SPROCKET

EE

EE

ES

d. Install a camshaft hold-down tool J-38613, and tighten to 22 ft. Ibs. (30 Nm). e. Remove the camshaft sprocket mounting bolt and washer while holding the camshaft from turning with J-38613 and J-38614. f. Using J-38616 sprocket puller, remove the sprocket from the camshaft. g. Repeat for each camshaft sprocket as necessary. 16. Drain the cooling system. 17. Disconnect the lower radiator hose from water pump inlet pipe. 18. If equipped with a manual transaxle, disconnect the front AIR hose from the AIR pipe. 19. Disconnect the heater hose at the front cover. 20. Remove the heater pipe bracket mounting bolts at the frame. 21. Remove the right front tire and wheel assembly and the right inner fender splashshield. 22. Remove the crankshaft pulley mounting bolts and remove the pulley from the damper. 23. Remove the crankshaft damper as follows: a. While holding the crankshaft from turning using a suitable tool, remove the damper mounting bolt and washer. b. Install tool J-24420-B and remove the damper from the crankshaft. 24. Place an oil catch pan under the oil filter and remove the oil filter.

A

Timing marks with hold-down tool in place—GM 3.4L (VIN X) engines

NOTE; CAMSHAFT BELT REMOVED. CAM FLATS UP. ORIGINAL TIMING MARKS STILL ON. 79225615

TIMING BELTS 20. Remove the A/C compressor mounting bracket bolts. 26. Remove the lower front cover bolts. 27. On automatic transaxle vehicles, remove the halfshaft following the recommended procedure. 28. Remove the rear alternator bracket. 29. Disconnect and remove the starter following the recommended procedure. 30. Remove the intermediate shaft drive belt sprocket retaining bolt and remove the intermediate shaft drive belt sprocket using puller J38616. 31. Remove the upper alternator mounting bolts. 32. Remove the forward light relay center screws and position the relay center aside. 33. Disconnect the oil cooler hose from the front cover. 34. Remove the water pump pulley. 35. Remove the upper front cover bolts and remove the front cover. 36. Mark the intermediate shaft sprocket, chain link, crankshaft sprocket and cylinder block for assembly reference. The marks should be made with paint so they won't be lost when the components are removed. 37. Retract the timing chain tensioner shoe as follows: a. Insert tool J-33875 on both sides of the tensioner. b. Pull on the through-pin in the tensioner arm to retract the spring located in the tensioner arm. c. While compressing the spring, use a suitable tool, a cotter pin or nail, and insert the pin in the hole in the tensioner assembly to hold the tensioner compressed. The tool used must be strong enough to hold the tensioner compressed. >The timing chain, crankshaft sprocket and intermediate shaft sprocket will be removed at the same time. If, when removing the assembly, the intermediate shaft sprocket does not easily come off the intermediate shaft, rotate the crankshaft back and forth to loosen the intermediate shaft sprocket. 38 Install a suitable puller, J-38611 and

J-8433. 39. Tighten the bolt on the puller and slowly pull the crankshaft sprocket off the crankshaft. Be sure the intermediate shaft sprocket is moving along with the crankshaft sprocket.

40. Remove the timing chain and sprockets. 41. Remove the tensioner mounting bolts and remove the tensioner assembly. To install: 42. Install the tensioner assembly and tensioner assembly mounting bolts fingertight first. Tighten the bolt in the slotted hole first to 18 ft. Ibs. (25 Nm), then tighten the remainder of the bolts to 18 ft. Ibs. (25 Nm). 43. Check to ensure that the crankshaft key is fully seated in the crankshaft cutout and the tensioner assembly is fully retracted. 44. Assemble the timing chain, intermediate shaft sprocket and crankshaft sprocket ona work bench. The timing marks made should be in alignment. The large chamfer and counterbore of the crankshaft sprocket are installed facing toward the engine and the intermediate shaft spline sockets are installed facing away from the engine. 45. Install the sprocket and chain assembly onto the engine. As the sprockets are installed, parallel alignment must be maintained. 46. The crankshaft sprocket will have to be pressed on the final 0.31 in. (8mm). This can be done using J-38612 or an equivalent puller. 47. Ensure timing was maintained. 48. Remove the retaining pin from tensioner. Clean all gasket surfaces completely. 49. Apply GM sealer 1052080 to the lower edges of the sealing surface of the front cover. Install a new gasket on the front cover. 50. Install the front cover on the engine. Apply thread sealant to the large bolts and tighten the bolts enough to pull the front cover against the engine block. 51. Install the water pump pulley. 52. Connect the oil cooler hose to the front cover. 53. Position the forward light relay center and install the mounting screws. 54, Install the upper alternator mounting bolt and tighten it to 22 ft. Ibs. (30 Nm). 55. Install the intermediate shaft drive belt sprocket. The sprocket must lock into the intermediate shaft timing chain sprocket. Install the mounting bolt and washer. While holding the engine from turning, tighten the bolt to 95 ft. Ibs. (130 Nm). 56. Connect and install the starter. Tighten the starter mounting bolts to 32 ft. lbs. (43 Nm). 57. Install the halfshaft following the recommended procedure.

3-21

58. Install the rear alternator bracket. Tighten the mounting bolt to 22 ft. Ibs. (30 Nm) and the mounting stud to 41 ft. Ibs. (55 Nm) and the lower bolt to 61 ft. Ibs. (83 Nm). 59. Install the lower front cover bolts and tighten the small bolts to 18 ft. Ibs. (25 Nm). 60. Install the A/C compressor mounting bolts and tighten the mounting bolts to 37 ft. Ibs. (50 Nm). 61. Install a new oil filter. 62. Install the crankshaft damper as follows: a. Coat the seal contact area on the damper with clean engine oil. b. Align the notch inside the damper with the crankshaft key and slide the damper on until the key is started into the notch. c. Using J-29113 puller, press the damper into position on the crankshaft. d. Install the crankshaft pulley and pulley mounting bolts. Tighten the pulley mounting bolts to 37 ft. Ibs. (50 Nm). e. Install the crankshaft damper mounting bolt and washer, and tighten to 78 ft. Ibs. (105 Nm). 63. Install the right side inner fender splash-shield. 64. Install the tire and wheel assembly. 65. Tighten the upper front cover small bolts to 18 ft. Ibs. (25 Nm) and the large bolts to 35 ft. Ibs. (47 Nm). 66. Connect the heater hose to the front cover. 67. Install the heater pipe bracket mounting bolts. 68. If equipped with a manual transaxle, connect the front AIR hose to the AIR pipe. 69. Connect the lower radiator hose to the water pump. 70. Install the right side cooling fan. Install the upper radiator support. 71. Position the torque strut mounting bracket and install the mounting bolts and tighten to 52 ft. Ibs. (70 Nm). 72. Install the front engine lift hook and tighten the mounting bolt to 52 ft. Ibs. (70 Nm). 73. To install the camshaft sprockets, proceed as follows: a. Wipe the camshaft noses with clean engine oil. b. Install the camshaft sprocket onto the nose of the camshaft. c. Install the lockring and shim ring. d. Install, but DO NOT tighten, the carnshaft sprocket mounting bolts at this time.

Section 1 of this manual For Maintenance Interval recommendations, see

3-22

TIMING BELTS

74. Install the intermediate shaft sprocket as follows: a. Lubricate the seal contact area on the intermediate shaft sprocket with clean engine oil. b. Slide the sprocket through the intermediate shaft sprocket seal and engage the locking tangs into the sockets of the chain sprocket. c. Lightly lubricate the shaft seal and place it in position on the end of the intermediate shaft. d. Install the intermediate shaft sprocket mounting bolt and washer. Tighten the bolt to 96 ft. Ibs. (130 Nm) while holding the crankshaft from turning. 79. Install the timing belt idler pulleys and tighten the Torx® bolts to 37 ft. Ibs. (50 Nm). 76. Install the actuator assembly and side plate. Tighten the actuator mounting bracket bolts to 37 ft. Ibs. (50 Nm). 77. \nstall the belt, taking note of direction of rotation if the old belt was used. 78. Install the tensioner pulley to the mounting base. Tighten the bolt to 37 ft. lbs. (50 Nm). 79. Rotate the tensioner pulley counterclockwise into the belt using the cast square

lug on the body and engage the ball end of the actuator into the socket on the pulley arm. 80. Remove the tensioner lockpin allowing the tensioner shaft to extend and the pulley to move into the belt. 81. Rotate the tensioner pulley counterclockwise, applying 14 ft. Ibs. (18 Nm) of torque. 82. Rotate the engine clockwise three times to seat the belt. Align the crankshaft reference marks during the final rotation to TDC. Do not allow the crankshaft to spring back or reverse its direction of rotation. >The timing flats on the camshafts should be 180 degrees apart from the left side to the right side. Both camshafts on the same side should be the same.

83. To perform the camshaft timing procedure, proceed as follows: a. Rotate the camshaft flats up on the right side camshafts and install a camshaft hold-down tool J-38613, and tighten to 22 ft. Ibs. (30 Nm). b. Seat the lockring on the right exhaust and intake camshaft sprockets by threading in the mounting bolt and washer. C. Hold the sprocket from turning using tool J-38614.

Running torque of the bolts before seating should be 55 ft. Ibs. (75 Nm).

d. If less torque is required, replace the shim ring and lockring. e» If more torque is required, replace the shim ring and lockring and inspect the bolts for burrs. f. Seating of the lockring is accomplished when the edge is flush with the sprocket hub. g. With the lockring seated tighten the bolt to final torque of 81 ft. Ibs. (110 Nm). h. Remove J-38613. i. Rotate the engine clockwise one full revolution or any number of odd revolutions. DO NOT rotate the engine backward. j. Be sure the timing mark on the damper aligns with the mark on the front cover. k. Repeat Substeps a through i for the left side. 84. Install the camshaft carrier covers. 85. Install timing the belt left, right and center covers and retaining bolts. 86. Connect the negative battery cable. 87. Start the engine and verify proper Operation and engine performance.

BRAKES CHRYSLER CORP................ 4-1 FORD MOTOR COMPANY .....4-13 GENERAL OS BS 4-32 Brake Caliper (Ford Motor Company)................. 4-13 Removal & Installation.............. 4-13 Brake Caliper (General Motors) .....4-32 Removal & Installation.............. 4-32 Brake Drums (Chrysler Corp.)......... 4-6 Removal & Installation...........0.... 4-6 Brake Drums (General Motors)......4-50 Removal & Installation.............. 4-50

Brake Drums

D

(Ford Motor Company)............ 4-26 Removal & Installation... 4-26 Brake Shoes (Chrysler Corp.).......... 4-8 Removal & Installation... 4-8 Brake Shoes

(Ford Motor Company)............++ 4-28 Removal & Installation.............. 4-28 Brake Shoes (General Motors).......4-53 Removal & Salon Sire, 4-53

Disc Brake Pads (Chrysler Corer aceswee 4-4 Removal & Installation... 4-4 Disc Brake Pads (Ford Motor Company)............. 4-18

Removal & Installation............. 4-18 Disc Brake Pads (General Motors) 0... 4-40 Removal & Installation... 4-40)

Caliper (Chrysler Corp.) ........e 4-1 Removal & Installation... 4-1

1998-02 CHRYSLER CORPORATION

REMOVAL & INSTALLATION el

Chrysler Concorde, New Yorker, LHS Dodge Intrepid Eagle Vision

bag to prevent contamination from entering the hydraulic system. Remove the caliper from the vehicle. To install: 4 Reconnect the brake hose to the GUIDE CALIPER PIN BOLT

SLEEVE

BUSHING

caliper, if removed, using new sealing washers. 5. If new linings are being installed, the caliper pistons must be pushed back into their bore to accommodate the thickness of CALIPER

PISTON SEAL

PISTON

DUST SEAL

FRONT 1. Remove the appropriate wheel and tire assemblies. 9 Remove the 2 caliper guide pin bolts and remove the caliper assembly. If the caliper is not being removed trom the vehicle as during brake pad renewal, simply hang the caliper with a piece of wire to take the weight off the brake hose. If the caliper is being removed for rebuild or replacement, continue to Step 5. 3 Remove the bolt retaining the brake hose to the caliper. Be sure to plug the end of the brake hose or cover it with a plastic

RETRACTOR CLIP WEAR INDICATOR SLEEVE CALIPER GUIDE PIN BOLT

BUSHING

ANTI-RATTLE CLIP

ANTI-RATTLE CLIP

alfa BRAKE SHOE

BRAKE SHOE

RETRACTOR CLIP

93006601

e, New Yorker, LHS, Intrepid, Vision Front brake caliper and related components—Concord

A-2

BRAKES CHRYSLER CORP.

the new lining. Special tools are available for pushing the piston back although a large C-clamp can often be used. It is good practice to remove some (Ys—¥2) brake fluid from the master cylinder reservoir. This prevents overflow caused by brake fluid being forced through the lines as the piston is pushed back. 6. Install the brake pads into the caliper. 7. Install the caliper to the steering knuckle in the correct position. Lightly lubricate the machined areas that support the caliper with high-temperature grease. 8. Install and torque the caliper guide pin bolts. Use care not to cross the threads of the caliper pin bolts. Torque the guide pin bolts to 15 ft. Ibs. (20 Nm). 9. Torque the brake hose fittings to 35 ft. Ibs. (48 Nm). 10. Be sure to bleed the brake system. 11. Install the wheels and lug nuts. Torque the wheel lug nuts in a star pattern sequence to 95-100 ft. Ibs. (129-135 Nm). 12. Before attempting to move the vehicle, pump the brake pedal to seat the pads against the rotors. Make sure the vehicle has a firm brake pedal. Check the level of the brake fluid and add DOT 3 brake fluid, if necessary. 13. Road test the vehicle and make several stops to wear off any foreign material on the brakes and to seat the brake linings, if replaced.

REAR 1. Remove the appropriate wheel and tire assemblies. 2. Remove the 2 caliper guide pin bolts and remove the caliper assembly. If the Caliper is not being removed from the vehicle as during brake pad renewal, simply hang the caliper with a piece of wire to take the weight off the brake hose. If the caliper is being removed for rebuild or replacement, continue to Step 5. 3. Remove the bolt retaining the brake hose to the caliper. Be sure to plug the end of the brake hose or cover it with a plastic bag to prevent contamination from entering the hydraulic system. Remove the caliper from the vehicle. To install: 4. Reconnect the brake hose to the Caliper, if removed, using new sealing washers. 9. If new linings are being installed, the caliper pistons must be pushed back into their bore to accommodate the thickness of the new lining. Special tools are available for this, although a large C-clamp can often

be used. It is good practice to remove some brake fluid from the master cylinder reservoir. This prevents overflow caused by brake fluid being forced through the lines as the piston is pushed back. 6. Install the brake pads into the caliper. 7. Install the brake caliper to the caliper adapter. Lightly lubricate machined areas that support the caliper with high-temperature grease. 8. Install and tighten the caliper guide pin bolts. Use care not to cross the threads of the caliper pin bolts. Torque the guide pin bolts to 17 ft. Ibs. (22 Nm). 9. Torque the brake hose fittings to 35 ft. Ibs. (48 Nm). 10. Be sure to bleed the brake system. 11. Install the wheels and lug nuts. Torque the wheel lug nuts in a star pattern sequence to 95-100 ft. Ibs. (129-135 Nm). 12. Before attempting to move the vehicle, pump the brake pedal to seat the pads against the rotors. Make sure the vehicle has a firm brake pedal. 13. Check the level of the brake fluid and add DOT 3 brake fluid, if necessary. 14. Road test the vehicle and make several stops to wear off any foreign material on the brakes and to seat the brake linings, if replaced.

Chrysler Sebring Dodge Avenger

> CAUTION

FRONT 1. Remove about half of the brake fluid

from the master cylinder.

2. Position a C-clamp, or other suitable tool, over the caliper. Smoothly apply pressure, forcing the caliper piston into the caliper bore until it bottoms. Remove the Cclamp, if used. 3. If the caliper is to be completely removed from the vehicle, remove the brake hose attaching bolt, disconnect the brake hose from the caliper and plug the hose to prevent fluid contamination or loss. 4, Remove the caliper mounting bolts and lift the caliper off of the support bracket. 5. Remove the caliper from the vehicle. If the caliper is only removed for access to other components, support the caliper, with the brake hose attached, so that there is no strain on the brake hose. To install: 6. Position the caliper to the steering knuckle. Lubricate and install the mounting bolts. Torque the bolts to 54 ft. Ibs. (74 Nm). 7. If removed, unplug and install the brake line hose to the caliper and torque the inlet fitting bolt to 22 ft. Ibs. (29 Nm). 8. Fill the master cylinder with fresh brake fluid and, if the brake hose was removed, bleed the brake system. 9. Install the wheel assembly. 10. Depress the brake pedal 3-4 times to seat the brake linings and to restore pressure in the system.

Do not move the vehicle until a firm pedal is obtained.

Pad & wear indicator assembly Pad assembly Clip Outer shim (stainless) Outer shim (coated with rubber) Inner shim (stainless) RL aed Rg i Inner shim (coated with rubber)

93006602

Exploded view of the front brake pads and related compon ents—Sebring, Avenger

BRAKES

CHRYSLER CORP.

REAR

Dodge/Plymouth Neon, PT Cruiser

Unlike many rear disc brake designs, this system does not incorporate the parking brake system, into the rear brake caliper. The rear brake system is serviced the same as the front system. 1. Remove about half of the brake fluid from the master cylinder. 2. Remove the wheel assembly. 3. Position a C-clamp, or other suitable tool, over the caliper. Smoothly apply presSure, forcing the caliper piston into the caliper bore until it bottoms. Remove the Cclamp,ifused. 4. \f the caliper is to be completely removed from the vehicle, remove the brake hose attaching bolt, disconnect the brake hose from the caliper and plug the hose to prevent fluid contamination or loss. 5. Remove the caliper mounting bolts and lift the caliper off of the support bracket. 6. Remove the caliper from the vehicle. If the caliper is only removed for access to other components, support the caliper, with the brake hose attached, so that there is no strain on the brake hose. To install: 7. Position the caliper on the support bracket, lubricate and install the mounting bolts. Torque the bolts to 54 ft. Ibs. (74 Nm). 8. If removed, unplug and install the brake line hose to the caliper and torque the inlet fitting bolt to 22 ft. Ibs. (29 Nm). 9. Fill the master cylinder with fresh brake fluid and, if the brake hose was removed, bleed the brake system. 10. Install the wheel assembly. 11. Depress the brake pedal 3-4 times to seat the brake linings and to restore pressure in the system.

1. On 1998-01 models, isolate the master cylinder as follows: a. Use a brake pedal holding tool and depress the brake pedal past its first one inch of travel and hold it in this position. (This will keep brake fluid from draining from the master cylinder). 2. Remove the front wheels. 3. Remove the 2 caliper guide pin bolts. 4. Disconnect the brake hose from the caliper. 5. Remove the caliper from the steering spindle. To install: 6. Reconnect the brake hose to the caliper and torque to 35 ft. Ibs. (48 Nm). 7. Reinstall the caliper to the steering spindle. 8. Reinstall the caliper guide pin bolts and torque to 16 ft. Ibs. (22 Nm). 9. Properly bleed the brake system. 10. Reinstall the front wheels and lower the vehicle. 11. Pump the brake pedal to seat the front brake pads before moving the vehicle. 12. Road test the vehicle and check for proper operation.

+k CAUTION Do not move the vehicle until a firm

pedal is obtained. Eagle Talon

FRONT 1. Remove the appropriate tire and wheel assembly. ) To disconnect the front brake hose, hold the nut on the brake hose side and loosen the flared brake line nut. Remove the brake hose from the caliper. 3 Remove the caliper guide and lock pins and lift the caliper assembly from the caliper support.

93006G82

Caliper locking pin and guide pin description—Talon

To install: 4 Position caliper onto the caliper support. Install the guide pin and lock pin. Torque guide and locking pins to 54 ft. Ibs. (75 Nm). 5. Reconnect the brake hose. 6. Bleed the brake system. 7. Apply brake pedal and inspect system. Ensure proper operation and no leakage. 8. Reinstall tire and wheel assembly. Torque lug nuts to 87-101 ft. Ibs. (120-140 Nm).

REAR 1. Disconnect the battery negative cable. 2. Remove the appropriate tire and wheel assemblies. Loosen the parking brake cable adjustment from inside the vehicle. 3. Disconnect the parking brake cable end installed to the rear brake caliper assembly. 4. Remove the caliper lock and guide pins. Lift the caliper assembly from the caliper support. 5. Remove the rear brake hose from the caliper. Remove the caliper from the vehicle. To install: 6. Install the rear brake hose onto the caliper with new washers in place. If equipped with brake hose retainer bolt, torque bolt to 25 ft. Ibs. (35 Nm) torque. If no bolt is used, torque the brake hose fitting to 12 ft. Ibs. (17 Nm). 7. Install the caliper over the brake pads. Lubricate and install the lock pin and torque to 23 ft. Ibs. (32 Nm). Reinstall the guide pin and torque to 23 ft. Ibs. (32 Nm). 8. Bleed the brake system. 9. Inspect the brake system for leaks and ensure proper operation. 10. Install tire and wheel assemblies. Torque wheels to 87-101 ft. Ibs. (120-140 N m). 11. Properly adjust parking brake cable.

Chrysler Cirrus, Sebring Dodge Stratus Plymouth Breeze 1. Remove the front wheels. 2. Remove the 2 caliper-to-steering knuckle guide pin bolts. 3. If the caliper is to be removed from completely, for example, for vehicle the overhaul perform the following procedure. a. Disconnect the brake hose from the caliper. b. Cover the opening of the brake hose so the hydraulic system does not become contaminated. 4. Remove the caliper from the steering knuckle. To install: 5. Clean and lubricate both steering knuckle abutments with a coating of multipurpose grease. 6. Position the caliper and brake pad assembly over the brake rotor. Be sure to properly install the caliper assembly into the abutments of the steering knuckle. Be sure the caliper guide pin bolts, rubber bushings and sleeves are clear of the steering knuckle bosses. 7. Reinstall the caliper guide pin bolts

on Labor Guide For complete service labor times, order Nichols’ Chilt

4-4

BRAKES

CHRYSLER CORP.

a

and torque to 16 ft. Ibs. (22 Nm). On Sebring and Avenger models, torque the caliper guide pin bolts to 54 ft. Ibs. (74 Nm). 8. If removed, connect the brake hose to the caliper and torque to 35 ft. Ibs. (48 Nm). 9. Properly bleed the brake system. 10. Reinstall the wheel and tire and torque the lug nuts in a star pattern sequence to half specification. Repeat the tightening procedure to full specified torque of 95-100 ft. Ibs. (129-135 Nm). 11. Pump the brake pedal to seat the front brake pads before moving the vehicle. 12. Road test the vehicle and check for proper operation.

Disc Brake Pads

REMOVAL & INSTALLATION Chrysler Concorde, New Yorker, LHS Dodge Intrepid Eagle Vision

FRONT AND REAR 1. Remove some of the fluid from the master cylinder. 2. Remove the appropriate wheels. 3. Remove the 2 caliper guide pin bolts. Remove the caliper assembly by Swinging the top part of the caliper away from the brake rotor edge, then lift the caliper assembly up. 4. Prevent strain or other damage to the brake hose by supporting the caliper assembly with a strong piece of wire hanging from the strut. 5. Remove the outboard brake pad by prying the brake pad retaining clip over raised area on the caliper. Then slide the pad down and off the caliper. 6. Before removing the inboard brake pad, use a large C-clamp to press the piston back into the caliper. This will prevent possible damage to the caliper piston. It is good practice to remove some (Ys-¥2) of the brake fluid from the reservoir. This is because as the caliper piston is pushed back into the caliper, brake fluid will be pushed back through the lines, back into the master cylinder and fluid reservoir, possibly causing the reservoir to overflow. 7. Remove the inboard brake pad by pulling away from piston until the retainer clip is free from the cavity in the piston. To install: 8. Lubricate both the caliper mating surface and the machined abutment surfaces with multi-purpose lubricant.

9. Before brake pad installation, be sure to lightly coat the outer backing plate surface of the new brake pads with a disc brake pad anti-squeal lubricant, usually a gel-like material that deadens any high-frequency vibration that can be the source of disc brake squeal. 10. Install brake pads into the caliper assembly making sure both pads are seated securely onto the caliper. 11. Install the caliper assembly back into position over the brake rotor and install the caliper guide pin bolts. Torque the front and rear caliper guide pin bolts to 17 ft. Ibs. (23 Nm 12. Install the wheels and lug nuts. Torque the lug nuts, in a star pattern sequence, to 95-100 ft. Ibs. (129-135 Nm). 13. Top off the master cylinder to the appropriate level, using DOT 3 type brake fluid only. 14. Before moving the vehicle, pump the brakes until a firm pedal is obtained. Road test the vehicle to make sure the brake operation is normal.

Chrysler Sebring Dodge Avenger

FRONT 1. Remove some of the brake fluid from the master cylinder reservoir. The reservoir should be no more than ¥% full. When the pistons are depressed into the calipers, excess fluid will flow up into the reservoir. 2. Remove the appropriate tire and wheel assemblies. 3. Remove the caliper guide and lock pins and lift the caliper assembly from the caliper support. Tie the caliper out of the way using wire. Do not allow the caliper to hang by the brake line. >On some models the caliper can be flipped up by leaving the upper pin in place, using it as a pivot point.

4. Remove the brake pads, spring clip and shims. Take note of positioning to aid installation. 5. Install the wheel lug nuts onto the studs and lightly tighten. This is done to hold the disc on the hub. To install: 6. Use a large C-clamp to compress the piston(s) back into the caliper bore. 7. Lubricate the slide points and install the brake pads, shims and spring clip onto the caliper support. Install the caliper over the brake pads. 8. Lubricate and install the caliper guide and lock pins in their original posi-

tions. Torque guide and locking pins to 54 . ft. Ibs. (74 Nm). 9. Install the tire and wheel assemblies.

CAUTION Pump brake pedal several times, until firm, before attempting to move the vehicle. 10. Road test the vehicle and check brakes for proper operation.

REAR Unlike many rear disc brake designs, this system does not incorporate the parking brake system, into the rear brake caliper, therefore, the rear brake system is serviced the same as the front system. 1. Remove some of the brake fluid from the master cylinder reservoir. The reservoir should be no more than ¥% full. When the pistons are depressed into the calipers, excess fluid will flow up into the reservoir. 2. Remove the appropriate tire and wheel assemblies. 3. Remove the caliper guide and lock pins and lift the caliper assembly from the caliper support. Tie the caliper out of the way using wire. Do not allow the caliper to hang by the brake hose. On some models, the caliper can be flipped up by leaving the upper pin in place, using it as a pivot point.

4. Remove the brake pads, spring clip and shims. Take note of positioning to aid installation. 5. Install the wheel lug nuts onto the studs and lightly tighten. This is done to hold the brake disc on the hub. To install: 6. Use a large C-clamp to compress the piston(s) back into the caliper bore. 7. Lubricate the slide points and install the brake pads, shims and spring clip onto the caliper support. Install the caliper over the brake pads. 8. Lubricate and install the caliper guide and lock pins in their original positions. Torque guide and locking pins to 54 ft. Ibs. (74 Nm). 9. Install the tire and wheel assemblies.

i

CAUTION

Pump brake pedal several times, until firm, before attempting to move the vehicle.

10. Road test the vehicle and check brakes for proper operation.

BRAKES

CHRYSLER CORP. Eagle Talon

FRONT 1. Remove some of the brake fluid from the master cylinder reservoir. The reservoir should be no more than half full. When the pistons are pressed into the calipers, excess fluid will flow up into the reservoir. 2. Remove the appropriate tire and wheel assemblies. 3. Remove the caliper guide and lock pins and lift the caliper assembly from the caliper support. Tie the caliper out of the way using wire. Do not allow the caliper to hang by the brake line. =>On some vehicles, the caliper can be flipped up by leaving the upper pin in place and using it as a pivot point.

4. Remove the brake pads, spring clip and shims. Take note of positioning to aid installation. 5. Install the wheel lug nuts onto the studs and lightly tighten. This is done to hold the disc on the hub. To install: 6. Use a large C-clamp to compress piston(s) back into caliper bore. On 2 piston calipers both pistons will have to be retracted together. 7. Lubricate slide points and install the brake pads, shims and spring clip onto the caliper support. Install the caliper over the brake pads. 8. Lubricate and install the caliper guide and lock pins in their original positions. Torque guide and locking pins to 54 ft. Ibs. (75 Nm). 9. Reinstall the tire and wheel assemblies. ->Pump brake pedal several times, until firm, before attempting to move vehicle. 10. Road test the vehicle and check brakes for proper operation.

4 Remove the caliper lock and guide pins and lift the caliper assembly from the caliper support. Tie the caliper out of the way using wire. Do not allow the caliper to hang by the brake line. 5. Remove the outer shim, brake pads and spring clips from the caliper support. Take note of positioning of each to aid in installation. 6. Reinstall the wheel lug nuts onto the Studs and lightly tighten. This is done to hold the disc on the hub. 7. Clean the caliper piston. Using rear disc brake driver tool MB990652, thread the piston into the caliper bore. Be sure, at this point, that the stopper groove of the piston correctly fits into the projection on the replacement brake pads rear surface. To install: 8. Lubricate all sliding and pivot points. Install the brake pads, shims and spring clip to the caliper support. Install the caliper over the brake pads. 9. Lubricate and install the caliper guide and lock pins. Torque the pins to 23 ft. Ibs. (32 Nm). Attach the parking brake cable to the rear brake assembly. 10. Start the engine and forcefully depress the brake pedal 5-6 times. Apply the parking brake and make sure the adjustment is within specifications. Adjust the parking brake cable, as required. 11. Reinstall the tire and wheel assemblies. 12. Test the brakes for proper operation.

4-5

Dodge/Plymouth Neon

1. Remove the front wheels. 2. Remove the 2 caliper to steering knuckle guide pin bolts. 3. Lift the caliper away from the steering knuckle by first rotating the free end of the caliper away from the steering knuckle. Then, slide the opposite end of the caliper out from under the machined end of the steering knuckle. 4. Support the caliper from the upper control arm to prevent the weight of the caliper from being supported by the brake flex hose that will damage the hose. 5. Remove the brake pads from the caliper. Remove the outboard brake pad by prying the pad retaining clip over the raised area on the caliper. Then, slide the pad down and off the caliper. Pull the inboard brake pad away from the piston until the retaining clip is free from the cavity in the piston. 6. If required, the rotor can be removed by pulling it straight off the wheel mounting studs. To install: 7. Clean all parts well. Inspect the caliper for piston seal leaks (brake fluid in and around the boot area and inboard lining) and for any ruptures of the piston dust boot. If the boot is damaged or fluid leak is visible, disassemble the caliper and install a new seal and boot (and piston, if scored). 8. Inspect the caliper pin bushings. Replace if damaged, dry or brittle.

INBOARD

REAR 1. Remove some of the brake fluid from the master cylinder reservoir. The reservoir should be no more than half full. When the pistons are depressed into the calipers, excess fluid will flow up into the reservotr. 9. Remove the appropriate tire and wheel assemblies. Loosen the parking brake cable adjustment from inside the vehicle. 3. Disconnect the parking brake cable end installed to the rear brake caliper assembly.

93006605

Disc brake pad identification—Neon

Please visit our web site at www.chiltonsonline.com

4-6

BRAKES

CHRYSLER CORP.

9. Completely compress the piston into the caliper using a large C-clamp or other suitable tool. 10. Lubricate the area on the steering knuckle where the caliper slides with high temperature grease. 11. Reinstall the rotor if removed. 12. Reinstall the brake pads into the caliper. Note that the inboard and outboard pads are different. Make sure the inboard brake shoe assembly is positioned squarely against the face of the caliper piston.

INBOARD

RIGHT OUTBOARD BRAKE SHOE

LEFT OUTBOARD

->Be sure to remove the noise suppression gasket.paper cover if the pads come so equipped.

13. Carefully position the caliper and brake shoe assemblies over the rotor by hooking the lower end of the caliper over the steering knuckle. Then, rotate the caliper into position at the top of the steering knuckle. Make sure the caliper guide pin bolts, bushings and sleeves are clear of the steering knuckle bosses. 14. Reinstall the caliper guide pin bolts and torque to 16 ft. Ibs. (22 Nm). 15. Reinstall the wheels and torque the mounting bolts to 100 ft. Ibs. (135 Nm). 16. Pump the brake pedal until the brake pads are seated and a firm pedal is achieved before attempting to move the vehicle. 17. Road test the vehicle for proper operation.

Chrysler Cirrus, Sebring Dodge Stratus Plymouth Breeze 1. Remove the front wheels. 2. Remove the 2 caliper-to-steering knuckle guide pin bolts. 3. Lift the caliper away from the steering knuckle by first rotating the free end of the caliper away from the steering knuckle. Then slide the opposite end of the caliper out from under the machined end of the steering knuckle. 4. Support the caliper from the upper control arm to prevent the weight of the caliper from being supported by the brake flex hose which will damage the hose. 5. Remove the brake pads from the caliper. Remove the outboard brake pad by prying the pad retaining clip over the raised area on the caliper. Then slide the pad down and off the caliper. Pull the inboard brake pad away from the piston until the retaining Clip is free from the cavity in the piston. To install: 6. Completely depress the piston into the caliper using a large C-clamp or other Suitable tool.

INDICATOR 93006606

Disc brake pad identification—Cirrus, Sebring, Stratus, Breeze

7. Lubricate the area on the steering knuckle where the caliper slides with high temperature grease. 8. Install the new inboard brake pad into the caliper piston by firmly pressing into the piston bore. Install the brake pads into the caliper. Note that the inboard and outboard pads are different. Make sure the inboard brake pad assembly is positioned squarely against the face of the caliper piston. e>Be sure to remove the noise suppression gasket paper cover if the pads come so equipped.

9. Install the new outboard brake pad onto the caliper assembly. 10. Carefully position the caliper and brake pad assemblies over the rotor by hooking the lower end of the caliper over the steering knuckle. Then rotate the caliper into position at the top of the steering knuckle. Make sure the caliper guide pin bolts, bushings and sleeves are clear of the steering knuckle bosses. 11. Reinstall the caliper guide pin bolts and torque to 16 ft. Ibs. (22 Nm). On Sebring and Avenger models, torque the Caliper guide pin bolts to 54 ft. Ibs. (74 Nm), 12. Reinstall the wheel and tire. Torque the lug nuts in 2 steps, in a star pattern sequence to 95-100 ft. Ibs. (129-135 Nm). 13. Pump the brake pedal until the brake pads are seated and a firm pedal is achieved before attempting to move the vehicle. 14. Road test the vehicle to check for proper operation.

REMOVAL & INSTALLATION Chrysler Concorde, New Yorker, LHS Dodge Intrepid Eagle Vision 1. Remove the rear wheels. 2. Remove the brake drum from the rear hub and bearing assembly. If the drum is difficult to remove, increase the clearance between the brake shoes and the drum as follows: a. Remove the rubber plug from the top of the brake support plate. b. Rotate the automatic shoe adjuster screw with an upward motion using a medium size flat tipped tool. 3. Remove the brake drum from the rear hub and bearing. 4. Inspect the brake shoe linings and drums for wear, contamination and scoring. To install: 5. Install the rear brake drum onto the rear hub and bearing assembly. 6. Adjust the brake shoes as follows: a. Rotate the automatic shoe adjuster in a downward motion using a medium Size flat tip tool. Turn the adjuster until there is a slight drag felt while turning the drum. b. Install the rubber plug back into the top part of the brake support plate. 7. Install the rear wheels and lug nuts. Torque the lug nuts in a star pattern sequence to 95-100 ft. Ibs. (129-135 Nm).

BRAKES

CHRYSLER CORP. Chrysler Sebring Dodge Avenger

variation (oval shape) of the drum braking Surface must not exceed either 0.0025 inch

1. Remove the wheel assembly. 2. Remove the brake drum detent (retaining) screw and remove the drum from the axle. 3. If difficulty is encountered in removing the drum: a. Verify the parking brake is released. b. Loosen the parking brake cable. c. Remove the access hole plug from the backing plate and move the parking brake lever until the lever stop rests on the brake shoe. d. If necessary, turn the adjuster so that it draws in to allow more clearance between the shoe and drum. To install: 4. Inspect all parts. Check the drum for cracks or excessive wear. 5. Turn the adjuster until it is drawn all the way in to the stop. Check that the adjuster turns freely. The nut must NOT lock at the end of the adjuster. Check that the parking brake lever stops are against the edge of the shoe web. 6. Install the brake drum and detent Screw. 7. Install the wheel assembly. 8. Apply the foot brake at least 10 times until clicking of the adjustment actuator can no longer be heard. This procedure will automatically adjust the clearance between the shoe and drum.

Dodge/Plymouth Neon 1. Remove the rear wheels. a. Locate and remove the rubber plug from the top of the brake support plate (backing plate). b. Insert a small prying tool through the adjuster access hole and engage the teeth on the adjuster wheel. c. Rotate the adjuster wheel so it is moved toward the front of the vehicle. This will back off the adjustment of the rear brake shoes. d. Continue moving the adjuster wheel toward the front of the vehicle until it stops moving. 2. Remove the rear brake drum from the hub assembly. To install: 3. Inspect the brake drums for cracks or signs of overheating. Measure the drum runout and diameter. If not to specification, resurface the drum. Runout should not exceed 0.006 inch (0.152mm). The diameter

(0.0635mm) in 30° or 0.0035 inch (0.089mm) in 360°. All brake drums are marked with the maximum allowable brake drum diameter on the face of the drum. 4. Install the rear brake drum onto the hub assembly. 5. Reinstall the wheels and properly adjust the brakes. 6. Road test vehicle to check brake operation.

Chrysler Cirrus, Sebring Dodge Stratus Plymouth Breeze

All vehicles except Sebring Convertible, are equipped with rear wheel, 2-shoe leading/trailing, internal expanding type of drum brakes with automatic self-adjuster mechanisms. The automatic self-adjuster mechanisms used on these vehicles are new designs and function differently than the screw type adjusters used in the past. These new self-adjusters are still actuated each time the vehicle's service brakes are applied. The new adjusters are located directly below the wheel cylinders. The Sebring Convertible’s rear wheel drum brake is a 2-shoe leading/trailing internal expanding type with an automatic self-adjuster mechanism. The automatic self-adjuster mechanism used on this vehicle is the screw type adjuster. The selfadjuster mechanism is actuated each time the vehicle service brakes are applied. Gen-

LUBRICATE THIS SURFACE BETWEEN QUADRANT AND STRUT OF ADJUSTER MECHANISM

4-7

erally, drum brakes with a self-adjusting mechanism do not require manual brake shoe adjustment. Although, in the event that the brake shoes are replaced, it is advisable to make the initial adjustment manually to speed up the initial adjustment time. The initial adjustment procedure must be done prior to driving the vehicle. 1. Remove the rear wheel assembly. 2. For all vehicles, except Sebring Convertible, use the following procedure: a. Locate and remove the rubber plug from the brake support plate (backing plate). b. Insert a brake adjuster tool or similarly shaped prytool through the automatic adjuster access hole and engage the teeth on the adjuster wheel. Rotate the adjuster wheel so it is moved toward the front of the vehicle. Continue moving the adjuster until it stops; this will back off the adjustment of the rear brake shoes. 3. For the Sebring Convertible, use the following procedure for releasing the selfadjusting mechanism: a. Locate and remove the rubber plug from the brake support plate (backing plate). b. Insert a brake adjuster tool or similarly shaped prytool through the automatic adjuster access hole and carefully push the adjuster actuating lever out of engagement with the adjuster starwheel. While holding the lever away from the starwheel, insert a second prytool through the access hole and engage the

KNURLED

AUTOMATIC SELF ADJUSTER MECHANISM

SPRING

QUADRANT Stratus, Breeze Automatic self-adjuster mechanism—Cirrus, Sebring Coupe,

Timing belt service is covered in Section 3 of this manual

93006G07

4-8

BRAKES

CHRYSLER CORP.

OUTBOARD FORWARD SELF ADJUSTER

STAR WHEEL

OUTBOARD REAR

SELF ADJUSTER ACTUATING LEVER 93006608

Rear brake shoe automatic self-adjuster mechanism and actuating lever—Sebring Convertible

teeth on the adjuster wheel. Rotate the adjuster wheel upward away from the ground; this will back off the adjustment of the rear brake shoes. 4 Remove the rear brake drum from the hub assembly. To install: 5. Inspect the brake drums for cracks or Signs of overheating. Measure the drum runout and diameter. If not to specification, resurface the drum. Run-out should not exceed 0.006 in. (0.15mm). The diameter variation (oval shape) of the drum braking surface must not exceed either 0.0025 in. (0.064mm) in 30 degrees rotation, or 0.0035 in. (0.089mm) in 360 degrees rotation. All brake drums are marked with the maximum allowable brake drum diameter on the face of the drum. 6. Install the rear brake drum onto the hub assembly. 7. Reinstall the wheel and tire. Torque

WHEEL CYLINDER
After installing the brake drums, pump the brake pedal several times to partially adjust the brake shoes. To verify proper operation of the self-adjusting parking brake, be sure that both rear brakes are not dragging when the parking brake pedal is released.

24. Road test the vehicle. The automatic adjusters will continue brake adjustment during the road test of the vehicle.

c. Remove the access hole plug from the backing plate and move the parking brake lever until the lever stop rests on the brake shoe. d. If necessary, turn the adjuster so that it draws in to allow more clearance between the shoe and drum.

Chrysler Sebring Dodge Avenger

23. Install the rear wheels and lug nuts. Torque the lug nuts, in a star pattern sequence, to 95 ft. Ibs. (129 Nm).

1. Remove the wheel assembly. 2. Remove the detent screw and brake drum. If difficulty is encountered in removing the drum: a. Verify the parking brake is released. b. Loosen the parking brake cable.

. Brake drum . Shoe-to-lever spring

. Adjuster lever . Auto adjuster assembly . Retainer spring . Shoe hold-down cup . Shoe hold-down spring . Shoe hold-down cup . Shoe-to-shoe spring _ Shoe and lining assembly $$ — OWoOONDNFLWH —_ _ Shoe and lever assembly

4-9

e>Note the location of all springs and clips for proper reassembly.

3. remove 4. 5.

Remove the shoe-to-lever spring and the adjuster lever. Remove the auto adjuster assembly. Remove the retainer spring.

. Retainer . Wave washer

. Parking lever . Shoe and lining assembly . . . .

Shoe hold-down pin Brake pipe connection Wheel cylinder Bleeder screw

. Snap ring . Rear hub assembly . Backing plate

Exploded view of the drum brake assembly—Sebring, Avenger

Heater Core replacement is covered in Section 2 of this manual

93006610

4-10

BRAKES

CHRYSLER CORP. 17. Install the auto adjuster assembly and install the adjuster lever and the shoeto-lever spring. 18. Pre-adjust the shoes so the drum slides on with a light drag and install the brake drum. 19. Adjust the rear brake shoes and install the rear wheels. 20. Adjust the parking brake cable. 21. Check for proper brake operation.

Pin shoe assembly

if

Retainer 93006611

Opening the retainer clip—Sebring, Avenger —

93006612

Adjusting nut and nut holder—Sebring, Avenger

6. Remove the hold-down springs, washers and pins. 7. Remove the shoe-to-shoe spring. 8. Remove the brake shoes from the backing plate. 9. Using a flat-tipped tool, open up the parking brake lever retaining clip. Remove the clip and washer from the pin on the shoe assembly and remove the shoe from the lever assembly. To install: 10. Thoroughly clean and dry the backing plate. Lubricate the backing plate at the brake shoe contact points. 11. Lubricate backing plate bosses, anchor pin, and parking brake actuating mechanism with a lithium-based grease. 12. Install the parking brake lever assembly on the lever pin. Install the wave washer and a new retaining clip. Use pliers or the like to install the retainer on the pin. If removed, connect the parking brake lever to the parking brake cable and verify that the cable is properly routed.

13. Clean and lubricate the adjuster assembly. Make sure the nut-adjuster is drawn all the way to the stop, but the nut must NOT lock firmly at the end of the assembly. 14. Install the brake shoes on the backing plate with the hold-down springs, washers and pins. 15. Install the shoe-to-shoe spring. 16. Install the retainer spring.

Dodge/Plymouth Neon

1. Remove the rear wheels. 2. Remove the drums. 3. Remove the automatic adjuster spring and lever. 4, Remove the hold-down clips and pins. 5. Rotate the automatic adjuster starwheel enough so both shoes move out far enough to be free of the wheel cylinder boots. 6. Disconnect the parking brake cable from the actuating lever. 7. Remove the lower shoe to shoe Spring. 8. With the shoes held together by the upper shoe to shoe spring, remove them from the backing plate. To install: 9. Thoroughly clean and dry the backing plate. To prepare the backing plate, lubricate the bosses, anchor pin and parking brake actuating lever pivot surface lightly with lithium based grease. 10. Remove, clean and dry all brake

components. Lubricate the starwheel shaft threads with anti-seize lubricant and transfer all parts to their proper locations on the new shoes. 11. Reinstall the lower spring. 12. Reconnect the parking brake cable. 13. Reinstall the automatic adjuster lever and spring. 14. Adjust the starwheel. 15. Remove any grease from the linings and install the drum. 16. Reinstall the wheels and properly adjust the brakes. ; 17. Check for proper brake system operation. Chrysler Cirrus, Sebring Coupe Dodge Stratus Plymouth Breeze All vehicles except Sebring Convertible, are equipped with rear wheel, 2 shoe leading/trailing, internal expanding type of drum brakes with automatic self-adjuster mechanisms. The automatic self-adjuster mechanisms used on these vehicles are new designs and function differently than the screw type adjusters used in the past. These new self-adjusters are still actuated each time the vehicles’ service brakes are applied. The new adjusters are located directly below the wheel cylinders. 1. Remove the rear wheel assembly. a. Locate and remove the rubber plug from the top of the brake support plate (backing plate). b. Insert a brake adjuster tool or simi-

AUTOMATIC ADJUSTER SCREW ASSEMBLY_

WHEEL CY MS

La

a RETURN SPRING

od A

HOLD DOWN

oN

CLIP

Sf“

S$

HOLD DOWN CLIP enn os

¥

AUTOMATIC 5, ADJUSTER LEVER\\Y AND SPRING

BRAKESHOE TO ANCHOR SPRING

Sd

AT

UPARK BRAKE yj LEVER PARK BRAKE CABLE

BRAKE ANCHOR PLATE

REAR BRAKE SHOE 93006613

Kelsey Hayes rear brake assembly (left side shown)—Neon

BRAKES CHRYSLER CORP. UPPER RETURN

SPRING LEADING BRAKE SHOE

WHEEL CYLINDER ayToMarICc

ADJUSTER MECHANISM SPRING

“IS 7 On this vehicle, the parking brake actuating lever is permanently attached

to the trailing brake shoe assembly. Do not attempt to remove it from the original brake shoe assembly or reuse the original actuating lever on a replacement brake shoe assembly. All replacement brake shoe assemblies for this vehicle must have the actuating lever as part of the trailing brake shoe assembly.

9. Remove the parking brake cable from the parking brake lever. Do not remove the lever from the brake shoe. 10. Remove the automatic adjuster mechanism from the brake shoe by fully extending the adjuster and rotate the adjuster out to release from the brake shoe. To inspect: 11. Thoroughly clean all parts. The brake lining should show contact across the entire width and from heel to toe; otherwise, replace. Clean and inspect the brake support plate and the automatic adjuster mechanism. Be sure the quadrant (toothed part) of the adjuster is free to rotate throughout its entire tooth contact range and is free to slide the full length of its mounting slot.> Check the Knurled pin. It should be securely attachedto the adjuster mechanism and its teeth should be in good condition. If the adjuster is worn or damaged, replace it. If the adjuster is serviceable, lubricate lightly with high-temperature grease between the strut and the quadrant. Check the brake springs. Overheating indications are paint

4-11

discoloration or distorted end coils. Replace parts as required. 12. Inspect the brake drums for cracks or signs of overheating. Measure the drum run-out and diameter. If not to specification, reface the drum. Run-out should not exceed 0.006 in. (0.15mm). The diameter variation (oval shape) of the drum braking surface must not exceed either 0.0025 in. (0.064mm) in 30 degrees rotation, or 0.0035 in. (0.089mm) in 360 degrees rotation. All brake drums are marked with the maximum allowable brake drum diameter on the face of the drum. To install: 13. Lubricate the 8 brake shoe contact points with high-temperature grease. >The trailing brake shoe assemblies used on the rear brakes of this vehicle are unique to the left and right side of the vehicle. Care must be taken to ensure the brake shoes are properly installed in their correct side of the vehicle. When the trailing shoes are properly installed on their correct side of the vehicle, the park brake actuating lever will be positioned under the brake shoe web. 14. Reinstall the parking brake cable onto the parking brake lever and install the trailing brake shoe and attaching pin. 15. Reinstall the automatic self-adjuster on the leading brake shoe by rotating it inward to attach. Install the leading shoe and adjuster assembly to the brake support plate. 16. Make sure the leading brake shoe is squarely seated on the brake support plate shoe contact areas, and install the brake retainer on the retainer pin. 17. Reinstall the lower return spring. ~The upper brake shoe return spring and adjuster mechanism actuating spring are unique to the side of the vehicle they are used on. The springs are colored for identification. The left side springs are green and the right side springs are blue.

18. Reinstall the upper return spring (blue, right side; green, left side) on the leading brake shoe first, then on the trailing brake shoe. 19. Reinstall the self-adjuster spring on the trailing brake shoe first then attach it to the adjuster. 20. Reinstall the rear brake drums. 21. Reinstall the wheel and tire. Torque the lug nuts in a star pattern sequence to

For complete Engine Mechanical specifications, see Section 1 of this manual

4-12

BRAKES

CHRYSLER CORP.

eS

about 45 ft. Ibs. (61 Nm), then repeat the pattern and final torque to 95-100 ft. Ibs. (129-135 Nm). 22. Adjust the rear brakes by depressing the brake pedal. Brake shoe adjustment will occur the first time the brake pedal is depressed, pushing the rear brake shoes against the braking surface of the rear brake drums. Brake shoes should now be correctly adjusted and will not require any type of manual adjustment. 23. Road test vehicle to check for proper brake operation. Sebring Convertible The Sebring Convertible’s rear wheel drum brake is a 2-shoe leading/trailing internal expanding type with an automatic self-adjuster mechanism. The automatic self-adjuster mechanism used on this vehicle is the screw type adjuster. The selfadjuster mechanism is actuated each time

the vehicle service brakes are applied. Generally, drum brakes with a self-adjusting mechanism do not require manual brake shoe adjustment. Although, in the event that the brake shoes are replaced, it is advisable to make the initial adjustment manually to speed up the initial adjustment time. The initial adjustment procedure must be done prior to driving the vehicle. e>\When removing the rear brake shoes, replace the brake shoes from only one side of the vehicle at a time. This is due to the automatic adjustment feature of the parking brake system. If the brake shoes are removed from both sides of the vehicle at the same time, the automatic adjuster will remove all slack from the parking brake cables, which will make brake shoe installation extremely difficult.

1. Remove the rear wheel assembly. a. Locate and remove the rubber plug from the brake support plate (backing plate). b. Insert a brake adjuster tool or similarly shaped prytool through the automatic adjuster access hole and carefully push the adjuster actuating lever out of engagement with the adjuster starwheel. While holding the lever away from the

starwheel, insert a second prytool through the access hole and engage the teeth on the adjuster wheel. Rotate the adjuster wheel upward away from the ground. This will back off the adjustment of the rear brake shoes. 2. Remove the drum from the hub assembly. 3. Remove the adjusting lever actuating spring from the leading brake shoe. Remove the automatic adjuster actuating lever from the leading brake shoe. 4. Thread the adjuster starwheel all the way into the adjuster, which will remove all tension from the adjuster. 5. Remove the upper and lower return springs from the brake shoes. 6. Remove the brake shoe hold-down Spring and pin attaching the leading brake shoe assembly to the brake support plate. 7. Remove the leading brake shoe from the support plate. 8. Remove the automatic adjuster from the parking brake actuating lever and trailing brake shoe. 9. Remove the retaining clip securing the parking brake actuating lever to the trailing brake shoe. 10. Remove the trailing brake shoe holddown spring and pin attaching the trailing brake shoe assembly to the brake support plate. 11. Remove the trailing brake shoe from the brake support plate and separate the shoe from the parking brake actuating lever. To inspect: 12. Clean all parts well. The brake lining should show contact across the entire width and from heel to toe; otherwise, replace. Clean and inspect the brake support plate and the automatic adjuster mechanism. Be sure the adjuster is free to rotate throughout its entire range. If the adjuster is worn or damaged, replace it. If the adjuster is serviceable, lightly lubricate the threaded portion with high-temperature grease. Check the brake springs. Overheating indications are paint discoloration or distorted end coils. Replace parts as required. 13. Inspect the brake drums for cracks or signs of overheating. Measure the drum run-out and diameter. If not to specification, reface the drum. Run-out should not exceed

0.006 in. (0.15mm). The diameter variation (oval shape) of the drum braking surface must not exceed either 0.0025 in. (0.064mm) in 30° rotation, or 0.0035 in. (0.089mm) in 360° rotation. All brake drums are marked with the maximum allowable brake drum diameter on the face of the drum. To install: 14. Lubricate the 6 brake shoe contact points and the brake shoe anchor points with high-temperature grease. 15. Reinstall the wave washer on the pivot pin of the parking brake actuating lever. 16. Install the trailing brake shoe onto the attaching pin of the parking brake actuating lever. 17. Position the trailing brake shoe onto the brake support plate and be sure the trailing brake shoe is squarely seated on the support plate shoe contact areas and install the brake shoe hold-down spring on the hold-down pin. 18. Reinstall the parking brake actuating lever-to-trailing brake shoe retaining clip. 19. Reinstall the automatic adjuster on the trailing brake shoe and the parking brake actuating lever. 20. Place the leading brake shoe onto the brake support plate in proper position and install the attaching pin and hold-down spring. 21. Reinstall the lower and upper return springs. 22. Reinstall the automatic adjuster actuating lever and spring onto the leading brake shoe. 23. Manually adjust the brake shoes to the furthest adjusted position but not so far

as to interfere with the installation of the brake drum. 24. Reinstall the rear brake drums. Check and adjust the brake shoes as necessary. 29. Reinstall the wheel and tire. Torque the lug nuts in a star pattern sequence to about 45 ft. Ibs. (61 Nm), then repeat the ‘ed and final torque to 100 ft. Ibs. (135 m). 26. Road test vehicle to check for proper brake operation.

BRAKES FORD MOTOR COMPANY

4-13

1998-01 FORD MOTOR COMPANY: Brake Caliper REMOVAL & INSTALLATION Ford Focus

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Front wheel e Brake hose from the support bracket e Outer brake pad retaining clip Brake caliper from the steering knuckle e Brake pads e Brake hose from the caliper To install: 3. Install or connect the following: Brake hose to the caliper. Tighten the fitting to 11 ft. Ibs. (15 Nm). e Brake pads e Brake caliper to the steering knuckle. Tighten the bolts to 21 ft. lbs. (28 Nm). e Quter brake pad retaining clip e Brake hose to the support bracket e Front wheel 4. Bleed the brakes and check for proper operation. Ford Contour, Mercury Mystique

FRONT ;

1. Remove the wheel and tire assembly. 2. Remove the outer disc brake pad spring clip (anti-rattle clip). 3. Remove the 2 locator pin covers and remove the locator pins. 4 Free the hose from its mounting on the strut.

ge 93006618

View of disc brake caliper locating pins—Contour, Mystique

5. Lift the caliper off of the brake rotor. 6. Remove the inboard disc brake pad from the caliper. 7. If the brake caliper is to be removed from the vehicle, place a pan under the caliper to catch the brake fluid for proper disposal. Disconnect the brake hose at the caliper and allow to drain. 8. Remove the brake caliper. 9. If the caliper is not to be serviced, tie off the caliper to prevent strain on the brake hose. To install: 10. If removed, install the brake hose onto the caliper. Torque the fitting to 10 ft. lbs. (14 Nm). 11. Position the inboard disc brake pad into the caliper.

12. Make sure that the outboard disc brake pad is-positioned properly. 13. Reinstall the caliper over the brake rotor and position onto the caliper anchor plate. 14. Reinstall the 2 caliper locator pins and torque to 20 ft. Ibs. (28 Nm). 15. Reinstall the caliper locator pin covers. 16. Reinstall the outer disc brake pad spring clip. 17. Reconnect the brake hose to the front strut. 18. Bleed the brake system of air. Top off the master cylinder when complete. 19. If the brake pedal feels spongy, repeat the brake bleeding procedure. 20. Reinstall the wheel and tire assem-

93006620

93006619

93006617

Position of disc brake pad (brake shoe and lining) spring clip—Contour, Mystique

View of inboard disc brake pad (brake shoe and lining)—Contour, Mystique

Positioning the outboard disc brake pad (brake shoe and lining)—Contour, Mys-

tique

For Accessory Drive Belt illustrations, see Section 1 of this manual

4-14

BRAKES

FORD MOTOR COMPANY

A

bly. Torque the lug nuts to 62 ft. Ibs. (85 Nm 21. Pump the brake pedal several times to position the brake pads before attempting to move the vehicle. 22. Road test the vehicle and check for proper brake system operation.

REAR 1. Remove the wheel and tire assembly. 2. Remove the parking brake rear cable and conduit from the parking brake lever at the disc brake caliper, using a pair of pliers. 3. Remove the cotter pin and guide pin. 4. Remove the caliper locating pin cover and remove the locating pin. 5. Lift the rear disc brake caliper off of the anchor plate. 6. Place a pan under the caliper to catch any lost brake fluid. Dispose of properly. 7. Crack open the rear brake hose fitting and allow the brake fluid to drain. 8. Finish removing the rear brake hose and washers from the caliper. Discard the washers. 9. Remove the disc brake caliper. To install: 10. Retract the piston fully into the caliper using service tool 187P—2588-A. 11. Reconnect the rear brake hose to the caliper using new washers. 12. Fit the rear disc brake caliper over the rotor and position onto the anchor plate.

13. torque 14. cover. 15. pin.

Reinstall the caliper locating pinand to 30 ft. Ibs. (41 Nm). Reinstall the caliper locating pin Reinstall the guide pin and the cotter

16. Reinstall the parking brake rear cable and conduit onto the parking brake lever. 17. Adjust the parking brake by operating the parking brake control several times. 18. Properly bleed the brake system of air. Top off the master cylinder when complete. 19. If the brake pedal feels spongy, repeat the brake bleeding procedure. 20. Reinstall the wheel and tire assembly. Torque the lug nuts to 94 ft. Ibs. (128 Nm 21. Pump the brake pedal several times to position the brake pads before attempting to move the vehicle. 22. Road test the vehicle and check for proper brake system operation. Lincoln LS

FRONT 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Front wheel e Brake fluid hose e Caliper mounting bolts e Brake caliper

PARKING BRAKE REAR CABLE AND CONDUIT

REAR DISC BRAKE CALIPER

—

To install: 3. Install or connect the following: e Brake caliper. Tighten the mounting bolts to 26 ft. Ibs. (35 Nm). e Brake fluid hose. Use new copper washers and tighten the bolt to 35 ft. Ibs. (47 Nm). e Front wheel 4. Bleed the brake system. 5. Before attempting to move the vehicle, pump the brake pedal to seat the pads against the rotors. Make sure the vehicle has a firm brake pedal. Check the level of the brake fluid and add DOT 3 or 4 brake fluid if necessary.

REAR 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Rear wheel e Parking brake cable e Caliper mounting bolts e Brake fluid hose e Brake caliper To install: 3. Install or connect the following: e Brake fluid hose. Use new copper washers and tighten the bolt to 36 ft. Ibs. (48 Nm). e Brake caliper. Tighten the mounting bolts to 25 ft. Ibs. (33 Nm). e Parking brake cable e Rear wheel 4. Bleed the brake system. 5. Before attempting to move the vehicle, pump the brake pedal to seat the pads against the rotors. Make sure the vehicle has a firm brake pedal. Check the level of the brake fluid and add DOT 3 or 4 brake fluid if necessary. Ford Taurus Lincoln Continental

Mercury Sable

*¢ CAUTION On Continentals, the air suspension switch, located in the left side of the luggage compartment, must be turned OFF before raising the vehicle. Failure to do so may result in unexpected inflation or deflation of the air springs that may result in shifting of the vehicle during service.

FRONT 93006621

Method of removing the parking brake cable—Contour, Mystique

t Remove brake fluid from the brake master cylinder reservoir until the reservoir is Va full.

BRAKES

FORD MOTOR COMPANY 2. For Continentals, turn the air suspension switch, located in the left side of _ luggage compartment, to the OFF posiion.

3. Remove the wheel and tire assembly. 4. Mark the disc brake caliper to ensure that it is reinstalled in the correct location. 5. Remove the hollow bolt connecting the brake hose to the disc brake caliper and plug the brake hose. Discard the 2 copper sealing washers. 6. Remove the caliper locating pins and lift the caliper off the rotor using a rotating motion. To install: 7. Retract the disc brake caliper piston fully in the piston bore, using an old brake pad or block of wood and a C-clamp. ->Make sure the clip-on insulators are attached to the brake pads.

8. Install the disc brake pads to the caliper. Make sure the brake pad insulators are correctly attached to the brake pad plate. 9. Position the disc brake caliper and pad assembly above the rotor and install it with a rotating motion. Make sure the inner and outer pads are properly positioned and the outer anti-rattle spring is properly positioned. 10. Lubricate the locating pins and the inside of the insulators with silicone grease. Torque the locating pins to 25 ft. Ibs. (34 Nm). 11. Remove the plug and install the brake hose to the disc brake caliper. Use 2 new copper washers and torque the hollow bolt to 30-40 ft. Ibs. (41-54 Nm). 12. Bleed the brake system, filling the . master cylinder as required. 13. Install the wheel and tire assembly; torque the nuts to 85-104 ft. Ibs. (115-142 Nm). 14, Pump the brake pedal several times to position the brake pads prior to moving the vehicle. 15. For Continentals, turn the air suspension service switch to the ON position. 16. Road test the vehicle and check for proper brake system operation.

REAR 4. Remove brake fluid from the brake master cylinder reservoir until the reservoir is Ye full. 2. For Continentals, turn the air suspension switch, located in the left side of the luggage compartment, to the OFF position.

3. Remove the wheel and tire assembly. 4. Remove the retaining bolt and disconnect the brake hose from the caliper assembly. Discard the copper sealing washers. 5. Remove the retaining clip from the parking brake at the caliper. Disengage the parking brake cable end from the lever arm. 6. Lift the rear disc brake caliper away from the rear disc support bracket. 7. Remove the disc brake caliper locating pins and boots from the rear disc support bracket. To install: 8. Using rear caliper piston adjuster tool T87P-2588-A, rotate the rear disc brake piston and adjuster clockwise until fully seated. ->\Vake sure one of the 2 slots in the rear disc brake piston and adjuster face is positioned so it will engage the nib on the disc brake pad.

9. Apply silicone dielectric compound to the inside of the slider pin boots and the Slider pins. 10. Position the slider pins and boots in the support bracket. Position the caliper assembly on the support bracket. Make sure the brake pads are installed correctly. 11. Remove the residue from the pin retainer threads and apply 1 drop of threadlock and sealer. Install the pin retainers and torque to 23-26 ft. Ibs. (31-35 Nm). 12. Attach the cable end to the parking brake lever. Install the cable retaining clip on the caliper assembly. 13. Using new washers, connect the brake flex hose to the caliper. Torque the retaining bolt to 40 ft. Ibs. (54 Nm). 14. Bleed the brake system, filling the master cylinder as required. 15. Install the wheel and tire assembly; torque the nuts to 85-104 ft. Ibs. (115-142 Nm). 16. Pump the brake pedal several times to position the brake pads prior to moving the vehicle. 17. For Continentals, turn the air suspension service switch to the ON position. 18. Road test the vehicle and check for proper brake system operation.

Ford Escort Mercury Tracer

FRONT 1. Remove the wheel and tire assembly. 2. Remove the disc brake pads.

4-1 0

3. Remove the banjo bolt securing the brake hose to the brake caliper. Discard 2 copper sealing washers. 4. Remove 2 brake caliper retaining bolts and remove the brake caliper. To install: 5. Place the brake caliper in position and install 2 brake caliper retaining bolts. Torque the bolts to 29-36 ft. Ibs. (39-49 Nm). 6. Install the brake hose to the brake caliper and install the banjo bolt with 2 new copper sealing washers. Torque the banjo bolt to 16-22 ft. Ibs. (22-29 Nm). 7. Install the disc brake pads. 8. Bleed the brake system. 9. Install the wheel and tire assembly. Torque the lug nuts to 65-87 ft. Ibs. (88-118 Nm). 10. Pump the brake pedal several times to position the brake pads to the brake rotor. 11. Road test the vehicle and check the brake system for proper operation.

REAR 1. Remove the wheel and tire assembly. 2. Remove the disc brake pads. 3. Remove the parking brake cable bracket bolt and position the bracket aside. 4 Remove the parking brake cable from the operating lever. 5. Remove the banjo bolt securing the brake hose to the brake caliper. Discard 2 copper sealing washers. 6. Remove the upper brake caliper retaining bolt. 7. Slide the brake caliper off the mounting bracket and remove from the vehicle. To install: 8. Place the brake caliper on the mounting bracket and slide into position. 9. Install the upper brake caliper retaining bolt. Torque the bolt to 33-43 ft. Ibs. (45-59 Nm). 10. Install the brake hose to the brake caliper and secure with the banjo bolt using 2 new copper sealing washers. Torque the banjo bolt to 16-22 ft. Ibs. (22-29 Nm). 11. Connect the parking brake cable to the operating lever. Position the bracket and install the bracket bolt. 12. Install the disc brake pads. 13. Bleed the brake system. 14. Install the wheel and tire assembly. Torque the lug nuts to 65-87 ft. Ibs. (88-118 Nm). 15. Pump the brake pedal several times

For Tire, Wheel and Ball Joint specifications, see Section 1 of this manual

4-16

BRAKES

FORD MOTOR COMPANY ting. Install the banjo bolt and torque to 30 ft. Ibs. (40 Nm). 17. Bleed the brake system and check for leaks. Replace the bleeder screw rubber cap. 18. Install the wheel and tire assembly. Torque the lug nuts in a star pattern to 85-105 ft. Ibs. (115-142 Nm). 19. Pump the brake pedal several times to position the brake pads before the vehicle is moved. 20. Road test the vehicle and check for proper brake system operation.

REAR

er

(8)

Spring

| 2 |RearBrakeOperating Lever_| | 4 |BrakeCaliper RearDisc | E05) Wheel Cylinder Bleeder Screw Ls |

Spindle

| 8 |SnapRing 219d DustSealy nits softla 1 PalO'>| Piva 5A 72 de Ral Brake Connecting Link 93006622

Rear disc brake assembly—Escort, Tracer

to position the brake pads to the brake rotor. . 16. Road test the vehicle and check the brake system for proper operation.

Ford Mustang

FRONT 1. Remove the wheel and tire assembly. 2. Mark the disc brake caliper to ensure that it will be installed to the same side if both calipers are being removed. 3, Remove the banjo bolt that connects the brake hose fitting to the disc brake caliper. 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 approximately 90° away from the anchor assembly. 6. Slide the brake caliper away from anchor assembly until the brake caliper disengages from the upper locating pin and remove from the vehicle. 7. On dual piston calipers, remove the clip and washer with the locating pin and remove the disc brake caliper. To install: 8. If required, compress the caliper pis-

ton(s) using a C-clamp and an old disc brake pad or block of wood. 9. On single piston calipers, engage the upper disc brake caliper locating pin into the insulator. 10. Make sure the anti-rattle is properly installed on caliper. 11. Make sure the brake pads are properly installed. 12. Rotate the brake caliper assembly into place on the anchor plate. e>New locating pins are recommended due to the thread locking compound on the threads.

13. Install the lower disc brake caliper locating pin and torque to 23 ft. Ibs. (31 Nm). 14. On dual piston calipers, place the disc brake caliper over the brake rotor with the brake pads installed and lower the caliper onto the brake rotor. 15. Install the disc brake caliper locating pin and clip by pressing the caliper down to compress the bias springs and the locating pin into position and secure with the washer and clip. 16. Unplug and install the brake hose to the disc brake caliper using 2 new copper sealing washers, 1 on each side of the fit-

1. Remove the wheel and tire assembly. 2. Remove the banjo bolt securing the brake hose to the disc brake caliper. Separate the brake hose from the caliper and plug the hose. Discard 2 copper sealing washers. 3. Remove the retaining clip from the parking brake rear cable at the disc brake caliper. Release the tension from the parking brake cable and disengage the cable end from the parking brake lever on the brake caliper. 4. Hold the disc brake caliper locating pin hex-heads with an open-end wrench and remove 2 brake pin retainer bolts. 5. Lift the disc brake caliper assembly away from the disc support bracket and remove the disc brake caliper from the vehicle. 6. Remove the brake caliper locating pins and boots from support bracket. To install: 7. If required, use Caliper Piston Adjuster T87P-2588-A to rotate the caliper piston into the caliper bore. Align the tool tips with the slots in the piston and rotate the too! clockwise until the piston is seated. 8. Apply a suitable silicone dielectric compound to the inside of the locating pin boots and the caliper locating pins. 9. Install the brake caliper locating pins and boots in the disc support bracket. 10. Properly install the disc brake pads and anti-rattle clips. 11. Apply a drop of suitable thread locking compound to the threads of the brake pin retainer bolts and install the brake pin retainers. Torque the brake pin retainer bolts to 23-26 ft. Ibs. (31-35 Nm) while holding the brake caliper locating pins with an open-end wrench. 12. Attach the end of the parking brake Cable to the parking brake lever on the disc brake caliper. 13. Unplug and install the brake hose to the disc brake caliper using 2 new copper sealing washers on the fitting. insert the banjo bolt through both washers and the

BRAKES

FORD MOTOR COMPANY ee line fitting and torque to 30 ft. Ibs. (40 m). 14. Properly bleed the brake system and check for leaks. 15. Install the wheel and tire assembly. Torque the lug nuts in a star pattern to 85-105 ft. Ibs. (115-142 Nm). 16. Pump the brake pedal several times to position the brake pads before moving the vehicle. 17. Road test the vehicle and check the brake system for proper operation.

torque the fitting nut to 10-18 ff. Ibs. (13-24 Nm). 13. Bleed the brake system using clean DOT 3 brake fluid from a closed container. 14. Install the wheel and tire assembly. Torque the lug nuts to 85-105 ft. Ibs. (115-142 Nm). 15. Apply the brake pedal several times before moving the vehicle, to position the brake pads. 16. Road test the vehicle and check for proper brake system operation.

Lincoln Mark VIII

REAR

FRONT

1. Remove the wheel and tire assembly. 2. Disconnect brake pad wear sensor connector (if equipped). 3. Remove the brake fitting retaining bolt from the disc brake caliper and disconnect the flexible brake hose from the caliper. Plug the hose and the caliper fitting. 4. Release the tension from the parking brake cable. Disconnect the cable from the caliper. 5. Remove the disc brake caliper locating pins. Lift the caliper off the brake rotor and anchor plate using a rotating motion. 6. Remove the disc brake pads. To install: 7. Place the Rear Caliper Piston Adjuster T87P-2588-A in the caliper. Be sure the pins on the tool are meshed with the slots on the piston. Rotate the tool clockwise until the piston is seated in the caliper bore. 8. Install the disc pads in the support bracket. Make sure that the pads are on the correct side. 9. Place the disc brake caliper assembly above the brake rotor with the anti-rattle spring located on the lower adapter support arm. Install the caliper over the rotor with a rotating motion. Make sure the inner pad is properly positioned with the nub in the piston slot. 10. Apply a suitable thread-locking compound to the caliper locating pin threads and start them in by hand. Torque the locating pins to 19-26 ft. Ibs. (26-35 Nm). 11. Install the brake hose on the disc brake caliper with a new gasket on each side of the fitting outlet. Insert the retaining bolt and torque to 30-40 ft. Ibs. (40-54 Nm). 12. Connect the parking brake cable to the caliper and adjust the tension. 13. Connect the brake pad wear sensor connector (if equipped). 14, Bleed the brake system using clean DOT 3 brake fluid from a closed container. 15. Install the wheel and tire assembly.

, 1. Remove the wheel and tire assemly. 2. Loosen the brake line fitting that connects the brake hose to the brake line at the frame bracket. Plug the brake line. Remove the retaining clip from the hose and bracket and disengage the hose from the bracket. 3. Remove the hollow bolt attaching the brake hose to the caliper and remove the brake hose. Discard the sealing washers. 4. Disconnect the brake pad wear sensor connector (if equipped). 5. Remove the caliper locating pins and remove the caliper. If removing both calipers, mark the right and left sides so they may be reinstalled correctly. To install: 6. Fully retract piston into caliper bore. 7. Install the caliper over the rotor with the outer brake pad against the rotor’s braking surface. This prevents pinching the piston boot between the inner brake pad and _ the piston. 8. Lubricate the locating pins and the inside of the locating pin insulators with silicone dielectric grease. Install the caliper locating pins and thread them into the spindie/anchor plate assembly by hand. Torque the caliper locating pins to 45-66 ft. Ibs. (61-88 Nm). 9. Connect brake pad wear sensor connector (if equipped). 10. Install new sealing washers on each side of the brake hose fitting outlet and install the hollow bolt through the hose fitting and into the caliper. Torque the bolt to 30 ft. Ips. (41 Nm). 11. Place the brake hose in the bracket and install the retaining clip. Make sure the hose is not twisted. 42. Remove the plug from the brake line, connect the brake line to the brake hose and

4-1 7

Torque the lug nuts to 85-105 ft. Ibs. (115-142 Nm). 16. Apply the brake pedal several times before moving the vehicle, to position the

brake pads. 17. Verify proper parking brake system operation. 18. Road test the vehicle and check for proper brake system operation. Ford Crown Victoria Lincoln Town Car Mercury Grand Marquis

FRONT Before continuing with this procedure, make sure to have available, 2 new disc brake caliper guide pin bolts and 2 banjo bolt sealing washers, per caliper. Once removed, these parts lose their torque holding ability or retention capability and must not be reused.

1. lf equipped with air suspension, the air Suspension switch, located on the righthand side of the luggage compartment, must be turned to the OFF position before raising the vehicle. 2. Remove the front wheel and tire assembly. 3. Loosen and remove the banjo bolt securing the brake hose from the disc brake caliper. Plug the brake hose. Discard the sealing washers. 4. Remove 2 disc brake caliper guide pin bolts and discard. If removing both calipers, mark the right and left sides so they may be reinstalled correctly. 5. Lift the disc brake caliper off of the anchor plate. To install: 6. Retract the disc brake caliper piston fully in the piston bore, using an old brake pad or block of wood and a C-clamp. 7. Install the disc brake pads to the caliper. Make sure that the brake pad insulators are correctly attached to the brake pad plate. 8. Position the disc brake caliper onto the anchor plate. Make sure the inner and outer pads are properly positioned and the anti-rattle spring is properly positioned. The caliper bleed screw should be positioned on top of the caliper when assembled on the vehicle. 9. Install 2 new caliper guide pin bolts. Torque the bolts to 21-26 ft. Ibs. (28-26 Nm). 10. Unplug and install the brake hose to the disc brake caliper using 2 new copper

For Wheel Alignment specifications, see Section 1 of this manual

4-19

BRAKES FORD MOTOR COMPANY

Sealing washers on the banjo bolt. Torque

the bolt to 30-40 ft. Ibs. (41-54 Nm). 11. Bleed the brake system, filling the master cylinder as required. Only use clean DOT 3 brake fluid from a sealed container. 12. Install the wheel and tire assembly. Torque the lug nuts in a star pattern to 85-104 ft. Ibs. (115-142 Nm). 13. If equipped with air suspension, turn the air suspension switch to the ON position. 14. Pump the brake pedal several times to position the brake pads prior to moving the vehicle. 15. Road test the vehicle and check for proper brake system operation.

REAR ->Before continuing with this procedure, make sure to have available, 2 banjo bolt sealing washers, per caliper. Once removed, these parts lose their torque holding ability or retention capability and must not be reused.

1. If equipped with air suspension, the air Suspension switch, located on the righthand side of the luggage compartment, must be turned to the OFF position before raising the vehicle. 2. Remove the rear wheel and tire assembly. 3. Loosen and remove the banjo bolt securing the brake hose to the disc brake caliper. Plug the brake hose and discard both sealing washers. 4. Remove 2 disc brake caliper locating bolts. Lift the disc brake caliper off the rotor and anchor plate using a rotating motion. To install: o. Retract the disc brake caliper piston fully in the piston bore, using an old brake pad or block of wood and a C-clamp. 6. Install the disc brake pads on the caliper. Make sure that the pads are on the correct side. 7. Position the disc brake caliper assembly above the rotor with the anti-rattle spring located on the lower adapter support arm. Install the caliper over the rotor with a rotating motion. 8. Clean the inner surface of the caliper bushings and locating bolts. Lubricate the Caliper locating bolts with a suitable silicone dielectric compound. Install and start the locating bolts by hand only. Torque both bolts to 16-20 ft. Ibs. (22-27 Nm). 9. Unplug and install the brake hose to the disc brake caliper using 2 new copper Sealing washers on the banjo bolt. Torque the bolt to 30-40 ft. Ibs. (41-54 Nm). 10. Bleed the brake system, filling the

master cylinder as required. Only use clean DOT 3 brake fluid from a sealed container. 11. Replace the rubber rear disc brake bleeder screw cap. 12. Install the wheel and tire assembly. Torque the lug nuts in a star pattern to 85-104 ft. Ibs. (115-142 Nm). 13. If equipped with air suspension, turn the air Suspension switch to the ON position. 14. Pump the brake pedal several times to position the brake pads prior to moving the vehicle. 15. Road test the vehicle and check for proper brake system operation. Disc Brake Pads

REMOVAL & INSTALLATION Focus

1. Remove or disconnect the following: e Front wheel e Brake hose from the support bracket ¢ Outer brake pad retaining clip e Brake caliper e Inner and outer brake pads To install: 2. Compress the caliper piston into the caliper bore. 3. Install or connect the following: e Inner and outer brake pads e Brake caliper. Tighten the bolts to 21 ft. Ibs. (28 Nm). e Brake hose to the support bracket ¢ Front wheel

Ford Contour Mercury Mystique Mercury Cougar (1999-01 model)

FRONT 1. Remove ¥% of the brake fluid from the master cylinder reservoir, 2. Remove the wheel and tire assembly. 3. Remove the outer disc brake pad spring clip (anti-rattle clip). 4. Remove the 2 locating pin covers and remove the locating pins. 0. Free the hose from its mounting on the strut. 6. Lift the caliper off of the brake rotor and tie it off to prevent damage to the brake hose, /. Remove the outboard disc brake pad from the anchor plate. 8. Remove the inboard disc brake pad from the brake caliper. To install: 9. If installing new disc brake pads, use

a C-clamp or similar tool to push the caliper piston into the caliper bore. This will allow room for the new pads. 10. Place the inboard disc brake pad into the caliper. 11. Place the outboard disc brake pad into position in the anchor plate. 12. Position the disc brake caliper onto the rotor. 13. Reinstall the 2 locating pins and torque to 20 ft. Ibs. (28 Nm). 14. Reinstall the caliper locating pin covers. ; 15. Secure the brake hose to its support on the strut. 16. Reinstall the disc brake pad spring clip. 17. Reinstall the wheel and tire assembly. Torque the lug nuts to 62 ft. Ibs. (85 Nm). 18. Pump the brake pedal several times to achieve a good pedal before attempting to move the vehicle. 19. Check the brake fluid level in the master cylinder fluid reservoir and add fluid as necessary. 20. Road test the vehicle and check for proper brake system operation.

REAR 1. Remove ¥ of the brake fluid from the master cylinder reservoir. 2. Remove the wheels. 3. Remiove the cotter pin and guide pin. 4. Remove the caliper locating pin cover and remove the locating pin. 5. Swing the rear disc brake caliper away from the brake rotor and anchor plate. There is no need to remove the parking brake cable or brake hose. 6. Remove the inner and outer disc brake pads. To install: /. If installing new disc brake pads, use rear Caliper piston adjuster T87P-2588-A or similar tool, to rotate the rear disc brake piston clockwise, retracting the caliper piston. This will allow room for the new brake pads. 8. Install the inner and outer disc brake pads. 9. Swing the rear disc brake caliper back into position over the disc brake pads. 10. Clean the locating pin threads and apply 1 drop of a thread locking agent or similar sealer. 11. Apply a small amount of disc brake caliper Slide grease to the shaft of the locat-

ing pin. 12. Reinstall the locating pin and torque to 30 ft. Ibs. (41 Nm). 13. Reinstall the guide pin and the cotter pin.

FORD MOTOR FHRERa

4-1 q

14. Adjust the parking brake by operating the parking brake control several times. 15. Reinstall the wheel and tire assemuhTorque the lug nuts to 62 ft. Ibs. (85 m 16. Adjust the parking brake by operating the parking brake control several times. 17. Pump the brake pedal several times to achieve a good pedal before attempting to move the vehicle. 18. Check the brake fluid level in the master cylinder fluid reservoir and add fluid as necessary. 19. Road test the vehicle and check for proper brake system operation. Lincoln LS

FRONT Rear Disc Brake Caliper Anchor Plate

| 4 [AntiRattleClip | eee Parking Brake Lever

93006626

Rear disc brake components—Contour, Mystique

ul

ALIGN NIBS ON TOOL WITH SLOTS IN PISTON

1 | Rear Disc Brake Caliper Rear Caliper Piston Adjuster Nibs (Part of T87P-2588-A) Piston Adjuster Slots (Part of

2B588) Rear Disc Brake Caliper Piston and Adjuster 93006627

Mystique Diagram of rear caliper piston and the adjuster tool—Contour,

1. Remove the master cylinder reservoir cap and check the fluid level in the reservoir. Remove brake fluid until the reservoir is % full. Discard the removed fluid. 2. Remove the wheel and tire assembly. 3. Remove the disc brake caliper locating pins. Lift the caliper assembly from the anchor plate and rotor. 4. Suspend the caliper inside the fender housing with wire. Do not allow the caliper to hang from the brake hose. 5. Remove the inner and outer brake pads. Inspect the rotor braking surfaces for scoring and machine as necessary. To install: 6. Use a C-clamp and an old brake pad or block of wood to seat the caliper piston in its bore. 7. Remove any rust buildup from the inside of the caliper in the brake pad contact area. 8. Install the inner pad in the caliper piston. 9. Install the outer pad onto the anchor plate. Make sure. the clips are properly seated. 10. Install the disc brake caliper onto the anchor plate. 11. Install caliper locating pins and torque to 26 ft. Ibs. (35 Nm). 12. Install wheel and tire assembly and torque lugs nuts to 85-104 ft. Ib. (115-142 Nm). 14. Pump the brake pedal several times prior to moving the vehicle to position the brake pads to the rotor. 15. Refill the master cylinder reservoir as necessary, using only clean DOT 3 or 4 brake fluid from a closed container.

manual For Maintenance Interval recommendations, see Section 1 of this

4-20

BRAKES

FORD MOTOR COMPANY

REAR 1. Remove the master cylinder reservoir cap and check the fluid level in the reservoir. Remove brake fluid until the reservoir is ¥2 full. Discard the removed fluid. 2. Remove the wheel and tire assembly. 3. Remove the disc brake caliper locating pins at the support bracket. 4, Remove the caliper. 5. Remove the disc brake pads. 6. Inspect the rotor braking surfaces for scoring and machine as necessary. To install: 7. Using Rear Caliper Piston Adjuster T87P-2588-A, rotate the piston clockwise until it is fully seated. Make sure one of the slots in the piston face is positioned so it will engage the nib on the brake pad. 8. Install the brake pads in the support bracket. Place the caliper assembly over the rotor into position on the support bracket. Make sure the brake pads are installed correctly. 9. Install and torque the disc brake caliper locating pin to 25 ft. Ibs. (33 Nm). 10. Install the wheel and tire assembly and torque the lug nuts to 85-104 ft. Ibs. (115-142 Nm). 11. Pump the brake pedal several times prior to moving the vehicle, to position the brake pads to the rotor. 12. Refill the master cylinder reservoir if necessary, using only clean DOT 3 or 4 brake fluid from a closed container. 13. Road test the vehicle and check the brake system for proper operation. Ford Taurus Lincoln Continental

Mercury Sable

“« CAUTION For Continentals, the air suspension switch, located in the left side of the luggage compartment, must be turned OFF before raising the vehicle. Failure to do so may result in unexpected inflation or deflation of the air springs that may result in shifting of the vehicle during service. Nis ace A teleSCTESSIS NSRRY a toa SAS EEN)

FRONT 1. Remove the master cylinder reservoir cap and check the fluid level in the reservoir. Remove brake fluid until the reservoir is Ya full. Discard the removed fluid. 2. On Continentals, turn the air suspension switch, located in the left side of the luggage compartment, to the OFF position. 3. Remove the wheel and tire assembly,

93006628

Front disc brake caliper, pads and related components—Taurus, Continental, Sable

4. Remove the disc brake caliper locating pins. Lift the caliper assembly from the anchor plate and rotor using a rotating motion. 5. Suspend the caliper inside the fender housing with wire. Do not allow the caliper to hang from the brake hose. 6. Remove the inner and outer brake pads. Inspect the rotor braking surfaces for scoring and machine as necessary. To install: 7, Use a C-clamp and an old brake pad or block of wood to seat the caliper piston in its bore. 8. Remove any rust buildup from the inside of the caliper in the brake pad contact area. 9. Install the inner pad in the caliper piston. 10. Install the outer pad onto the anchor plate. Make sure the clips are properly seated. e>Mlake sure the insulators are

installed on the brake pads.

11. Install the disc brake caliper onto the anchor plate. 12. Install caliper locating pins and torque to 23-28 ft. Ibs. (31-38 Nm). 13. Install wheel and tire assembly and torque lugs nuts to 85-104 ft. Ib. (115-142 Nm) 14. Pump the brake pedal several times prior to moving the vehicle to position the brake pads to the rotor. 15. Refill the master cylinder reservoir as

necessary, using only clean DOT 3 brake fluid from a closed container. 16. On Continentals, turn the air suspension service switch to the ON position. 17. Road test the vehicle and check the brake system for proper operation.

REAR 1. Remove the master cylinder reservoir cap and check the fluid level in the reservoir. Remove brake fluid until the reservoir is Ya full. Discard the removed fluid. 2. On Continentals, turn the air suspension switch, located in the left side of the luggage compartment, to the OFF position. 3. Remove the wheel and tire assembly. 4. Remove the screw retaining the brake hose bracket to the frame side rail. 9. Remove the retaining clip from the parking brake cable at the disc brake caliper. Remove the cable end from the parking brake lever. 6. Remove the upper disc brake caliper locating pin at the support bracket. Rotate the caliper away from the rotor. 7. Remove the disc brake pads. 8. Inspect the rotor braking surfaces for scoring and machine as necessary. To install: 9. Using Rear Caliper Piston Adjuster T87P-2588-A, rotate the piston clockwise until it is fully seated. Make sure one of the Slots in the piston face is positioned so it will engage the nib on the brake pad. 10. Install the brake pads in the support

BRAKES

FORD MOTOR COMPANY bracket. Rotate the caliper assembly over the rotor into position on the support bracket. Make sure the brake pads are installed correctly. 11. Remove the residue from the rear brake pin retainer bolt threads and apply 1 drop of a suitable threadlock sealer. Install and torque the disc brake caliper locating pin to 23-26 ft. Ibs. (31-35 Nm). 12. Attach the cable end to the parking brake lever. Install the cable retaining clip on the caliper assembly. Position the brake flex hose and bracket assembly to the side rail, and install the retaining screw. Torque to 11 ft. Ibs. (16 Nm). 13. Install the wheel and tire assembly and torque lug nuts to 85-104 ft. Ibs. (115-142 Nm). 14. Pump the brake pedal several times prior to moving the vehicle, to position the brake pads to the rotor. 15. Refill the master cylinder reservoir if necessary, using only clean DOT 3 brake fluid from a closed container. 16. On Continentals, turn the air suspension service switch to the ON position. 17. Road test the vehicle and check the brake system for proper operation. Ford Escort Mercury Tracer

93006629

Front disc brake pads—Escort, Tracer

prior to moving the vehicle to position the brake pads. 13. Check the fluid level in the master cylinder reservoir and fill as needed. 14. Road test the vehicle and check for proper brake system operation.

REAR

FRONT 1. Remove the master cylinder reservoir cap and check the fluid level in the reservoir. Remove brake fluid until the reservoir is ¥% full. Discard the removed fluid. 2. Remove the wheel and tire assembly. 3. Remove the W-spring. 4 Remove 2 disc brake pad locating “pins and remove the M-spring. 5. Remove the brake pads and shims from the brake caliper. 6. Inspect the brake rotor. Resurface or replace if needed. To install: 7. Use a suitable tool to push the piston into the brake caliper bore. 8. Apply a suitable grease between the shims and the disc brake pad guide plates and position the brake pads and shims to the brake caliper. 9. Install the W-spring and 2 brake pad locating pins. 10. Install the M-spring. 11. Install the wheel and tire assembly. Torque the lug nuts to 65-87 ft. Ibs. (88-118 Nm). 12. Pump the brake pedal several times

4-21

1. Remove the master cylinder reservoir cap and check the fluid level in the reservoir. Remove brake fluid until the reservoir is Y full. Discard the removed fluid. 2. Remove the wheel and tire assembly. 3. If necessary, remove the screw plug and turn the adjustment gear counterclockwise with an Allen® wrench to pull the piston fully inward. 4. Remove the lower brake caliper bolt. 5. Using a small prybar, pivot the caliper on its mounting bracket to access the brake pads. If the upper lock bolt requires lubrication or service, remove it and suspend the caliper with mechanics wire. 6. Remove the brake pads, shims, Spring and guides. 7. Inspect the brake rotor. Resurface or replace if needed. To install: 8. Apply an appropriate brake pad grease between the shims and the brake pads. 9. Pivot the caliper on its mounting bracket and position the brake pads, shims, spring and guides to the brake rotor. 10. Lubricate and install the lower

caliper bolt. Tighten the bolt to 33-48 ft. lbs. (45-59 Nm). 11. Turn the adjustment gear clockwise

with an Allen wrench until the brake pads just touch the rotor, then loosen the gear ¥3 of a turn. Install the screw plug and torque to 12 ft. Ibs. (16 Nm). 12. Install the wheel and tire assembly. Torque the lug nuts to 65-87 ft. Ibs. (88-118 Nm). 13. Pump the brake pedal several times prior to moving the vehicle to position the brake pads. 14. Check the brake fluid level in the master cylinder reservoir and fill if needed. 15. Road test the vehicle and check for proper brake system operation. Mustang

FRONT WITH SINGLE PISTON CALIPER 1. Remove and discard ¥ of the brake fluid from the brake master cylinder reservoir. Properly dispose of the used brake fluid. 2. Remove the wheel and tire assembly. 3. Remove 2 anchor plate mounting bolts and lift the disc brake caliper from the anchor plate and rotor using a rotating motion. Hang the disc brake caliper from the body with wire. Do not let the disc brake caliper hang by the brake hose. 4. Remove the outer and inner disc brake pads and the anti-rattle clip from the disc brake caliper. 5. Clean any residue from the caliper

For Tune-up, Capacities and Firing orders, see Section 1 of this manual

4-22

BRAKES

FORD MOTOR COMPANY a

SSS

anchor plate and disc brake pad contact areas. 6. Inspect the disc brake rotor for scoring and wear. Replace or machine, as necessary. 7. Inspect the piston boot and the caliper pin boots for damage. Replace as necessary. To install: 8. Use a large C-clamp and a wood block to push the caliper piston back into its bore. 9. Remove the protective paper from the insulators on the back of the disc brake pads, if equipped. 10. Install the inner and outer disc brake

pads and the anti-rattle clip in the disc brake caliper. 11. Install the disc brake caliper and pads over the rotor and onto the anchor plate using a rotating motion. Hand-start 2 anchor plate mounting bolts. Torque the bolts to 95 ft. Ibs. (130 Nm). 12. Install the wheel and tire assembly and torque the lug nuts in a star pattern to 85-105 ft. Ibs. (115-142 Nm). 13. Repeat the procedure for the opposite disc brake caliper assembly. 14. Pump the brake pedal prior to moving the vehicle to seat the brake pads. 15. Fill the brake master cylinder reser-

NOTE: DO NOT REMOVE FOR CALIPER REPLACEMENT

Caliper Housing (Part of 2B119) Disc Brake Pad Anti-Rattle Clip Caliper Piston if

Piston Seal Dust Boot

Front Disc Brake Caliper Anchor Plate

93006630

Disc brake pads and related components—Mustang with single piston caliper

voir with clean DOT 3 brake fluid from a closed container. 16. Ifthe disc brake calipers were replaced or repaired, be sure to bleed the system. 17. Road test the vehicle and check the brake system for proper operation.

FRONT WITH DUAL PISTON CALIPER 1. Remove and discard 1% of the brake fluid from the brake master cylinder reservoir. Properly dispose of the used brake fluid. 2. Remove the wheel and tire assembly. 3. Remove the clip, washer and disc brake caliper locating pin. 4, Remove the disc brake caliper from the brake rotor and the caliper anchor plate. Hang the disc brake caliper from the body with wire. Do not let the disc brake caliper hang by the brake hose. 5. Remove the outer and inner disc brake pads from the disc brake caliper. 6. Clean any residue from the caliper anchor plate and disc brake pad contact areas. 7. Inspect the disc brake rotor for scoring and wear. Replace or machine, as necessary. 8. Inspect the piston boots and the caliper pin boots for damage. Replace as necessary. To install: 9. Use a large C-clamp and a wood block to push the caliper pistons back into their bores. 10. Remove the protective paper from the insulators on the back of the disc brake pads, if equipped. 11. Install the inner and outer disc brake pads in the disc brake caliper. Make sure the pads are seated properly. 12. Install the disc brake caliper and pads over the rotor and onto the anchor plate using a rotating motion. Make sure that the guiding surfaces of the disc brake pads and the anchor bracket are seating correctly. 13. Press the disc brake caliper down by hand to compress the bias spring and slide the disc brake caliper locating pin into position. 14. Install the washer and clip. 15. Install the wheel and tire assembly. Torque the lug nuts in a star pattern to 85-105 ft. Ibs. (115-142 Nm). 16. Repeat the procedure for the oppoSite disc brake caliper assembly, _ 1/7. Pump the brake pedal prior to moving the vehicle to position the brake pads. 18. Fill the brake master cylinder reservoir with clean DOT 3 brake fluid from a Closed container. 19. If the disc brake calipers were replaced Or repaired, be sure to bleed the system. 20. Road test the vehicle and check the brake system for proper operation.

BRAKES

FORD MOTOR—————————— COMPANY

i

4-23

NN

REAR 1. Remove and discard % of the brake fluid from the brake master cylinder reservoir. Properly dispose of the used brake fluid. 2. Remove the wheel and tire assembly. 3. Remove the screw retaining the brake hose bracket to the shock absorber bracket. 4. Remove the retaining clip from the parking brake cable at the disc brake caliper. 5. Release the tension from the parking brake cable and disengage the parking brake cable end from the parking brake lever on the disc brake caliper. 6. Hold the disc brake caliper locating pin hex-head with an open-end wrench. Remove the upper brake pin retainer. 7. Rotate the disc brake caliper away from the brake rotor. 8. Remove the inner and outer disc brake pads and the anti-rattle clip from the disc support bracket. 9. Inspect the disc brake rotor for scoring and wear. Replace or machine, as necessary. To install: 10. Using Rear Caliper Piston Adjuster T87P-2588-A, rotate the caliper piston clockwise until the piston is fully seated. Ensure that one of the 2 slots in the rear brake piston face is positioned so it will engage the nib on the back of the inner brake pad.

11. Install the disc brake pad anti-ratt e clips and install the inner and outer disc brake pads on the rear disc support bracket. 12. Rotate the disc brake caliper over the brake rotor into position on the disc support bracket. Make sure the disc brake pads and anti-rattle clips are correctly installed. 13. Apply a suitable thread-locking compound to the threads of the upper brake pin retainer. 14. Install the brake pin retainer and tighten to 23-26 ft. Ibs. (31-35 Nm) while holding the disc brake caliper locating pin with an open-end wrench. 15. Install the parking brake cable end to the parking brake lever on the disc brake caliper. Install the retaining clip to the disc brake caliper. 16. Install the wheel and tire assembly. Torque the lug nuts in a star pattern to 85-105 ft. Ibs. (115-142 Nm). 17. Repeat the procedure for the oppoSite disc brake caliper assembly. 18. Pump the brake pedal prior to moving the vehicle to position the brake pads. 19. Fill the brake master cylinder reservoir with clean DOT 3 brake fluid from a closed container. 20. If the disc brake calipers were replaced or repaired, be sure to bleed the

ee

21. Road test the vehicle and check the brake system for proper operation. Mercury Cougar (1998 Model)

FRONT 1. If equipped with air suspension, the air Suspension switch, located on the righthand side of the luggage compartment, must be turned to the OFF position before raising the vehicle. 2. Remove and properly dispose 1% of the brake fluid from the master cylin-der. 3. Remove the front wheel and tire assembly. 4 Remove 2 disc brake caliper locating pins and remove the caliper from the anchor plate and rotor. Suspend the caliper inside the fender housing with a length of wire. Do not let the caliper hang by the brake hose. 5. Remove the disc brake pads from the caliper. 6. Inspect the disc brake rotor for scoring and wear. Replace or machine as necessary. Observe the minimum thickness Specification stamped on the rotor if machining is required.

system.

[7 [Brake Gaipertor| [2 |FrontCaliper eave |

ee Te [calperPston Disc Brake Pad Anti-Rattle Clip

7 [Piston Sea ieges em Th

48) Caliper Housing

Anchor Plate

Brake Shoe and Lining

Ca Piston Seal (2 Req'd) Caliper Piston (2 Req'd)

4 | Dust Boot (2 Req'd) Go

Front Brake Locating Pin

10 | Front Disc Brake Caliper r Anchor Plate 11.

Anti-Rattle Clip and Insulator

} Disc Brake Caliper Locating

Pi n

Wheel Cylinder Bleeder Screw

Tighten to 81 N-m (60 Lb-Ft)

leneS|

93006632

Brake Shoe and Lining 93006631

caliper Disc brake pads and related components—Mustang with dual piston

Front Disc brake pads and related compo-

nents (15 inch wheel)—Cougar

For complete service labor times, order Nichols’ Chilton Labor Guide

4-24

BRAKES

FORD MOTOR COMPANY

To install: 7. Use a C-clamp and an old brake pad, wood block to seat the caliper piston in its bore. Do not allow metal or sharp objects to come into direct contact with the caliper piston surface or damage will result. 8. Install the correct inner disc brake pad to the caliper piston using care not to

bend the anti-rattle clips. 9. Install the correct outer disc brake pad to the caliper making sure to properly install the anti-rattle clip. The outer pads are marked for left-hand or right-hand installation. ; 10. Install the disc brake caliper over the rotor with the outer brake pad against the rotor’s braking surface. This prevents pinching the piston boot between the inner brake pad and the piston. 11. If worn, install 2 new locating pin insulators in the disc brake caliper by fabricating a tool for this purpose. 12. Lubricate the locating pins and the inside of the locating pin insulators with silicone dielectric grease. Install the caliper locating pins and thread them into the spindle/anchor plate assembly by hand. 13. Torque the caliper locating pins to 45-65 ft. Ibs. (61-88 Nm). 14. Install the wheel and tire assembly. Torque the lug nuts in a star pattern to 85-104 ft. Ibs. (115-142 Nm). 15. If equipped with air suspension, turn the air suspension switch to the ON position. 16. Pump the brake pedal prior to moving the vehicle to seat the brake pads. 17. Ifthe disc brake calipers were replaced or repaired be sure to bleed the hydraulic brake system. 18. Fill the master cylinder reservoir with

the disc brake caliper off the rotor and anchor plate using a rotating motion. 6. Remove the inner and outer disc brake pads. 7. Inspect the disc brake rotor for scoring and wear. Replace or machine, as necessary. Observe the minimum thickness specification stamped on the rotor if machining Is required. To install: 8. Use a C-clamp and an old brake pad, 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 result. 9. Position Caliper Piston Tool T87P2088-A on the rear disc brake caliper. Be sure the pins on the tool are meshed with the slots on the piston. Rotate the tool clockwise until the piston is seated in the caliper. 10. Install the inner and outer disc brake pads in the support bracket. Make sure the pads are on the correct sides. 11. Position the disc brake caliper above the rotor with the anti-rattle spring located on the lower adapter support arm. Install the caliper over the rotor with a rotating motion. Make sure the inner pad is properly positioned.

12. Insert 2 disc brake caliper locating pins and thread them in by hand. Torque the pins to 19-26 ft. Ibs. (26-35 Nm). 13. Install the wheel and tire assembly. Torque the lug nuts in a star pattern to 85-104 ft. Ibs. (115-142 Nm). 14. If equipped with air suspension, turn the air suspension switch to the ON position. 15. Pump the brake pedal prior to moving the vehicle to seat the brake pads. 16. If the disc brake caliper was repaired or replaced, make sure to bleed the hydraulic brake system. 17. Fill the master cylinder reservoir with clean DOT 3 brake fluid from a closed container. 18. Road test the vehicle and check for proper brake system operation. Lincoln Mark Vill

FRONT 1. Remove and discard ¥% of the brake fluid from the brake master cylinder. 2. Turn the air suspension service switch to the OFF position. 3. Remove the wheel and tire assembly. 4. Remove the disc brake caliper pin retainers from the locating pins and remove the caliper from the anchor plate and disc

clean DOT 3 brake fluid from a closed container. 19. Road test the vehicle and check for proper brake system operation.

REAR 1. If equipped with air suspension, the air Suspension switch, located on the righthand side of the luggage compartment, must be turned to the OFF position before raising the vehicle. 2. Remove and properly dispose % of the brake fluid from the master cylin-der. 3. Remove the rear wheel and tire assembly. 4. Release the tension from the parking brake cable and disconnect the parking brake cable from the disc brake caliper. 9. Remove 2 caliper locating pins. Lift

bees Disc Brake Caliper Housing

Rear Brake Pin Retainer (2 R C) q'd)

Caliper Piston

ie)isc Brake Caliper Locating Pp in

Brake Piston Seal

Mla 5

| Front Wheel Disc Brake Shoe Insulator (2 Req'd)

Caliper Guide Pin Excluder

12 a 13

Wheel! Cylinder Bleeder S 6 re Ww

| Bleed Screw Cap

Brake Shoe and Lining

7 | Front Disc Brake Caliper Anchor Plate

A | Tighten to 31-38 N.m (23-28 Lb-Ft)

Brake Shoe Hold-Down Spring 93006633

Front disc brake pads and related components—Mark VIII

BRAKES

FORD MOTOR COMPANY brake rotor. Suspend the caliper inside the fender housing with a length of wire. Do not let the caliper hang by the brake hose. 5. Remove the outer, then inner disc brake pads from the caliper.

8. Rotate the caliper away from the disc brake rotor. 9. Remove the inner and outer disc brake pads from the disc brake support bracket.

6. Inspect the disc brake rotor for scoring, runout and wear. Replace or machine as necessary. Do not exceed the minimum allowable thickness stamped on each disc brake rotor. To install: 7. Using a C-clamp and a block of wood press the disc brake caliper piston into the caliper housing to allow for the new disc brake pads to fit the brake rotor. 8. Install the inner, then outer disc brake pads in the caliper. 9. Install the disc brake caliper over the rotor with the outer brake pad against the rotor’s braking surface. This prevents pinching the piston boot between the inner brake pad and the piston. 10. Install the disc brake caliper pin retainers to the locating pins, by hand. Torque the caliper pin retainers to 16-23 ft. lbs. (22-32 Nm). 11. Install the wheel and tire assembly. Torque the lug nuts in a star pattern to 85-105 ft. Ibs. (115-142 Nm). 12. Turn the air suspension service Switch to the ON position. 13. Pump the brake pedal prior to moving the vehicle to seat the disc brake pads. 14. If the disc brake calipers were replaced or repaired, be sure to bleed the brake system. 15. Fill the brake master cylinder as needed with clean DOT 3 brake fluid from a closed container. 16. Road test the vehicle and check for proper brake system operation.

10. Inspect the disc brake rotor for scoring, runout and wear. Replace or machine as necessary. Do not exceed the minimum allowable thickness stamped on each disc brake rotor. To install: 11. Using Caliper Piston Adjuster T87P2088-A, rotate the disc brake caliper piston until it is fully seated in the caliper. Be sure the pins on the tool are meshed with the Slots on the piston. 12. Install the inner and outer disc brake pads in the rear disc support bracket. Check to be sure the pads are on the correct sides, and that the nib on the inner disc brake pad is correctly installed to the slot in the caliper piston. 13. Rotate the disc brake caliper over the rotor into position on the support bracket. Install the caliper pin retainers to the caliper locating pins and thread them in by hand. Torque the pin retainers to 23-26 ft. Ibs. (31-35 Nm). 14. Install the wheel and tire assembly. Torque the lug nuts in a star pattern to 85-105 ft. Ibs. (115-142 Nm). 15. Turn the air suspension service switch to the ON position. 16. Pump the brake pedal prior to moving the vehicle to seat the disc brake pads. 17. If the disc brake calipers were replaced or repaired, be sure to bleed the brake system. 18. Fill the brake master cylinder as needed with clean DOT 3 brake fluid from a closed container. 19. Road test the vehicle and check for proper brake system operation.

REAR 1. Remove and discard 1% of the brake fluid from the brake master cylinder. 2. Verify that the parking brake control is released. 3. Turn the air suspension service switch to the OFF position. 4. Remove the wheel and tire assembly. 5. Remove the retaining clip from the parking brake cable at the disc brake caliper. 6. Release the parking brake cable tension and disengage the cable end from the caliper lever. 7. Remove the disc brake caliper pin retainers securing the caliper to the locating pins.

Ford Crown Victoria Lincoln Town Car

Mercury Grand Marquis ->Before continuing with this procedure, make sure to have available, 2 new disc brake caliper anchor bracket mounting bolts, per caliper. Once removed, these parts lose their torque holding ability or retention capability and must not be reused.

FRONT 1. If equipped with air suspension, the air suspension switch, located on the righthand side of the luggage compartment,

4-2 4)

must be turned to the OFF position before raising the vehicle. 2. Remove ¥ of the brake fluid from the brake master cylinder reservoir. Properly dispose of the used brake fluid. 3. Remove the front wheel and tire assembly. 4. Remove 2 disc brake caliper anchor bracket mounting bolts and discard. Lift the caliper assembly from the disc brake rotor using a rotating motion. Suspend the caliper inside the fender housing with wire. Do not allow the caliper to hang from the brake hose. 5. Remove the inner and outer disc brake pads. Inspect the rotor braking surfaces for scoring and machine as necessary. Refer to the minimum rotor thickness specification when machining. If machining is not necessary, hand-sand the glaze from the braking surfaces with medium grit sandpaper. Make sure to wear an approved respirator.

To install: 6. Use a C-clamp and an old brake pad, 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 result. 7. Remove all rust buildup from the inside of the caliper legs. 8. Make sure the anti-rattle spring is seated in the caliper lining inspection opening and that it is installed from the lining side. 9. Install the inner disc brake pad to the caliper piston. Do not bend the pad clips during installation in the piston or distortion and rattles can occur. Install the outer disc brake pad. Make sure the clips are properly seated. 10. Install the disc brake caliper over the rotor and install 2 new anchor bracket mounting bolts. Torque the bolts to 126-169 ft. Ibs. (170-230 Nm). 11. Install the wheel and tire assembly. Torque the lug nuts in a star pattern to 85-104 ft. Ibs. (115-142 Nm). 12. |f equipped with air suspension, turn the air Suspension switch to the ON position. 13. Pump the brake pedal prior to moving the vehicle to seat the brake pads. 14. Fill the master cylinder reservoir with clean DOT 3 brake fluid from a closed container. 15. If the disc brake calipers were

Please visit our web site at www.chiltonsonline.com

4-26

BRAKES

FORD MOTOR COMPANY necessary, hand-sand the glaze from the braking surfaces with medium grit sandpaper. Make sure to wear an approved respirator. To install: 8. Use a C-clamp and an old brake pad, 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 result. 9. Remove all rust buildup from the inside of the caliper legs. 10. Install the inner disc brake pad to the caliper piston. Do not bend the pad clips during installation in the piston or distortion and rattles can occur. Install the outer disc brake pad. Make sure the clips are properly seated. e>lViake sure the insulators are

installed on the brake pads.

11. Install the disc brake caliper over the disc brake rotor and install 2 caliper retaining bolts. Torque to 16-20 ft. Ibs. (22-27 Nm). 12. Install the wheel and tire assembly. Torque the lug nuts in a star pattern to 85-104 ft. Ibs. (115-142 Nm). 13. If equipped with air suspension, turn the air Suspension switch to the ON position. 14. Pump the brake pedal prior to moving the vehicle to seat the disc brake pads. 15. Fill the master cylinder reservoir with clean DOT 3 brake fluid from a closed container. 16. If the disc brake calipers were replaced or repaired be sure to bleed the system. 17. Road test the vehicle and check for proper brake system operation.

Poe,

[6 [Front DiscBrakeRotor Front Disc Brake Rotor

Shield

| 9 |Front Wheel Spindle Front Disc Brake Caliper Anchor Plate Assembly 93006683

Exploded view of the front disc assembly—Crown Victoria, Town Car, Grand Marquis

replaced or repaired be sure to bleed the system. 16. Road test the vehicle and check for proper brake system operation.

REAR 1. If equipped with air suspension, the alr Suspension switch, located on the righthand side of the luggage compartment, must be turned to the OFF position before raising the vehicle. 2. Remove 2 of the brake fluid from the brake master cylinder reservoir. Properly dispose of the used brake fluid.

3. Remove the rear wheel and tire assembly. 4. Remove 2 disc brake caliper retaining bolts. 5. Lift the disc brake caliper off the disc brake rotor and anchor plate using a rotating motion. 6. Remove the inner and outer disc brake pads. 7. Inspect the disc brake rotor for scoring and wear. Inspect the rotor braking surfaces for scoring and machine as necessary. Refer to the minimum rotor thickness specification when machining. If machining is not

REMOVAL & INSTALLATION Focus

1. Remove or disconnect the following: ¢ Rear wheel ¢ Wheel speed sensor, if equipped e Brake drum, bearing and spindle assembly. To install: 2. Install or connect the following: ¢ Brake drum, bearing and spindle assembly. Tighten the bolts to 49 ft. lbs. (66 Nm). ¢ Wheel speed sensor, if equipped ¢ Rear wheel

BRAKES

FORD MOTOR COMPANY Ford Contour Mercury Mystique

1. Remove the wheel and tire assembly. 2. Remove the brake drum retainers, if installed. 3. Grasp the brake drum and remove. 4. If the drum will not slide off with light force, then the brake shoes will need to be backed off as follows: a. Remove the rubber plug on the backing plate and insert a screwdriver or small brake adjusting tool into the slot to contact the brake strut and quadrant.

b. A forward motion of the tool will separate the quadrant from the knurled wheel and allow the brake shoes to retract. c. Remove the brake drum. To install: 5. Make sure the brake drum and shoes are Clean of any oils or protective coatings. 6. Position the brake drum onto the wheel hub. 7. Install new brake drum retainers if

available. 8. Reinstall the wheel and tire assembly. Torque the lug nuts to 94 ft. Ibs. (128 Nm).

9. Work the parking brake control several times to adjust the rear brake shoes. 10. Pump the brake pedal several times to assure a good pedal before attempting to move the vehicle. 11. Road test the vehicle and check for proper brake system operation. Ford Taurus Mercury Sable

1. Remove IRE the wheel and tire assembly. DaEIRceRave ARSGTITE elf 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 for insertion of a screwdriver and brake tools to disengage brake shoe adjusting lever and back off the brake adjuster screw.

frets Positioning a screwdriver to release the brake shoes—Contour, Mystique

RUBBER PLUG

3. Inspect the drum for scoring and/or other wear. Machine or replace, as necessary. To install: 4 Measure the brake drum inside diameter using D81L-1103-A brake adjustment gauge. 5. Using the brake adjustment gauge, adjust the brake shoes to the same dimensions as the brake drum. 6. Position the brake drum over the brake shoes on the axle hub. 7. Install the wheel and tire assembly. Torque the lug nuts to 85-104 ft. Ibs. (115-141 Nm). 8. Pump the brake pedal several times iti the bra ke shoes and complete to position

the adjustment.

REMOVED

BRAKE SHOE

4-27

|

9. Road test the vehicle and check for

ADJUSTING

proper brake system operation.

LEVER

Ford Escort Mercury Tracer A

a

~

: ; ia.

INSPECTION HOLE

7

ae =p

CCHS ER

Sa 93006639

Retracting the brake shoes to allow drum removal—tTaurus and Sable

1. Remove the wheel and tire assembly. 2. Remove 2 brake drum retaining SCIeWS. 3. Pull the brake drum from the hub. Inspect the drum and refinish or replace, as necessary. If refinishing, check the maximum inside diameter specification. To install: 4. \f needed, adjust the brake shoes to fit the brake drum. 5. Place the brake drum on the hub. 6. Install 2 brake drum retaining screws. Torque to 89-123 inch Ibs. (10-14 Nm). 7. Install the wheel and tire assembly.

Timing belt service is covered in Section 3 of this manual

A-29

BRAKES

FORD MOTOR COMPANY

Torque the lug nuts to 73-100 ft. Ibs. (100-135 Nm). 8. Check the brake system for proper operation.

Ford Mustang

1. Remove the wheel and tire assembly. 2. Remove the drum retaining nuts, if equipped, and remove the brake drum. 3. Inspect the brake drum for scoring and wear. Check the drums for conditioning and wear. Replace or machine as necessary. If machining, observe the maximum diameter specification. To install: 4. If anew brake drum is being installed, remove the protective coating from the drum using brake cleaner. 5. Adjust the brake shoes to the brake drum using Brake Adjusting Gauge D81L1103-A. 6. Install the brake drum. 7. Install the wheel and tire assembly. 8. Complete the brake adjustment by carefully backing the vehicle up several times while applying the brakes with a minimum force of 25 Ibs. (111 N). 9. Road test the vehicle and check the brake system for proper operation.

Brake Shoes

REMOVAL & INSTALLATION Focus

1. Remove or disconnect the following: e Rear wheel Wheel speed sensor, if equipped Brake drum, bearing and spindle assembly Brake shoe hold-down springs and pins Brake shoe assembly from the wheel cylinder and anchor block Parking brake cab fap) Lower return spring Upper return spring Primary shoe from the strut and brake shoe adjuster ¢ Parking brake return spring ¢ Secondary shoe from the strut support To install: 2. Install or connect the following: ¢ Secondary shoe to the strut support ¢ Parking brake return spring ° Primary shoe to the strut and brake shoe adjuster. Rotate the adjuster fully clockwise. e Upper return spring

Cie Orn nar WIG e

Lower return spring Parking brake cable Brake shoe assembly to the wheel cylinder and anchor block Brake shoe hold-down springs and pins Brake drum, bearing and spindle assembly. Tighten the bolts to 49 ft. lbs. (66 Nm). Wheel speed sensor, if equipped Rear wheel 3. Operate the brake pedal to adjust the rear brakes. Ford Contour Mercury Mystique

Rear Brake Strut and Quadrant vag

1. Remove the rear wheel and tire assembly. 2. Remove the brake drum retainers, if equipped. 3. Grasp the brake drum and remove. 4. |f the drum will not slide off with light force, then the brake shoes will need to be backed off: a. Remove the rubber plug on the backing plate and insert a screwdriver or small brake adjusting tool into the slot to contact the brake strut and quadrant. b. A forward motion of the screwdriver will Separate the quadrant from the knurled wheel and allow the brake shoes to retract. c. Remove the brake drum. 5. Remove the brake shoe hold down springs and the brake shoe hold down pins. 6. Remove the brake shoe retracting Springs. 7. Disengage the parking brake cable and conduit from the parking brake lever. 8. Remove the brake shoes. 9. Disengage the rear brake strut and quadrant from the rear brake shoe.

Rear Whee! Cylinder

Rear Brake Shoe and Lining

View

Brake Shoe Retracting Spring

[5_[ Parking BrakeReturnSpring| Brake Shoe Hold Down

Win

Spring

7 | Anchor Block Brake Shoe Hold Down Spring Pin

| 9 | Rear Brake Backing Plate 93006650

Location of brake components— Contour/Mystique

93006652

Lubricating points on backing plate—Contour/Mystique

BRAKE BACKING PLATE

Ca

ml Ps

B

ae

r— 3 sss)

Lyee PARKING BRAKE CABLE ANCHOR PLATE 93006651

Removal of parking brake cable—Contour/Mystique

BRAKES

FORD MOTOR COMPANY

93006653

Measuring the brake drum inner diame-

ter—Contour/Mystique

REAR BRAKE STRUT AND QUADRANT 93006654

Adjusting the brake shoes to fit the drum—Contour/Mystique BRAKE ADJUSTMENT GAUGE

93006655

Measuring the brake shoe adjustment— Contour/Mystique

10. Remove the parking brake rear cable and conduit from the parking brake cable anchor on the trailing brake shoe. To install: 11. Lubricate the rear brake shoe contact points on the backing plate with an appropriate grease. 12. Engage the parking brake rear cable and conduit into the parking brake cable anchor on the trailing brake shoe. 13. Position the trailing brake shoe on the backing plate.

14. Engage the rear brake strut and quadrant. 1D. Reinstall the parking brake rear Spring. 16. Reinstall the brake shoe hold down spring pin and the hold down spring. 17. Insert the leading brake shoe into the slot on the rear brake strut and quadrant. 18. Reinstall the brake shoe hold down pin and hold down spring. 19. Reinstall the brake shoe retracting Springs. 20. Adjust the brake shoes by first measuring the inside drum diameter with an appropriate brake adjustment gauge. 21. Insert a small screwdriver or similar tool into the knurled quadrant of the brake strut and quadrant to adjust the brake shoes to the same measurement of the brake drum by expanding the brake strut and quadrant. 22. Trial fit the brake drum. The shoes should just contact the drum surface when properly adjusted. 23. Make sure that the brake drum and brake shoes are clean of any oils or protective coatings. 24. Reinstall the brake drum. 25. Reinstall new drum retainers, if available. 26. Reconnect the parking brake rear cable and conduit to the parking brake lever. It may be necessary to back off on the parking brake cable adjustment to allow for the new brake shoes. 27. Reinstall the wheel and tire assembly. Torque the lug nuts to 62 ft. Ibs. (85 Nm). 28. Work the parking brake control several times to complete the brake shoe adjustment and to check the parking brake adjustment as well. 29. Pump the brake pedal several times to assure a good pedal. 30. Road test the vehicle and check for proper brake system operation. Ford Taurus Mercury Sable 1. Remove the wheel and tire assembly.

2. Remove the brake drum. 3. Remove the parking brake cable from the parking brake lever. 4. Remove the 2 brake shoe hold-down springs and pins. 5. Lift the brake shoes, springs and

4-29

adjuster assembly off the backing plate and wheel cylinder assembly. When removing the assembly, be careful not to bend the adjusting lever. 6. Remove the retracting springs from the lower brake attachments and upper shoe-to-adjusting lever attachment points. 7. Remove the horseshoe retaining clip and spring washer and slide the lever off the parking brake lever pin on the trailing shoe. Discard the horseshoe clip. To install: 8. Apply a light coating of disc brake caliper slide grease at the points where the brake shoes contact the backing plate. 9. Apply a thin coat of lubricant to the adjuster screw threads and socket end of the adjusting screw. Install the stainless steel washer over the socket end 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 off Y turn. 10. Assemble the parking brake lever to the trailing shoe by installing the spring washer and a new horseshoe retaining clip. Crimp the clip until it retains the lever to the shoe securely. 11. Position the trailing shoe on the backing plate and attach the rear parking brake cable. 12. Position the leading shoe on the backing plate and attach the lower brake shoe adjusting spring to the brake shoes. 13. Install the adjuster assembly in the Slots on the brake shoes. The wide slot on the dual slotted end must fit into the leading shoe. The narrow slot on the dual slotted end fits into the shoe adjusting lever. The single slotted side of the adjuster assembly must fit into the slots on the trailing shoe and the rear parking brake cable bracket. e>The adjuster socket blade is marked R for the right or L for the left brake assemblies. The adjuster blade must be installed with the letter R cr L in the upright position, facing the wheel cylinder. Make sure the adjuster socket fits into the parking brake lever.

14, Complete the installation by reversing the removal procedures. 15. Pump the brake pedal several times to position the brake shoes and finish the brake shoe adjustment.

Heater Core replacement is covered in Section 2 of this manual

4-3 0

BRAKES

FORD MOTOR COMPANY

eat

Rear Wheel Cylinder oa

Parking Brake Lever Pin (inner)

Spring Expander

Piston and Insert Shoe Adjustment Access Hole Wheel Cylinder Retaining

Bolt (2 Req'd)

Brake Adjusting Hole Cover Brake Shoe Hold-Down Spring Pin

Raa

Rear Brake Backing Plate

10 | Trailing Shoe and Lining Brake Shoe Hold-Down Spring Brake Shoe Retracting Spring Parking Brake Lever

Brake Shoe Adjusting Screw Socket a

Brake Shoe Adjusting Lever

Parking Brake Lever Pin Leading Shoe and Lining

Ee Sakeait a0 Giphe nie: pe S Spring

[22 [Brake Adjuster Screw [23 [Washer Cd Parking Brake Lever Pin Retainer Ee

Adjusting Pivot Nut

A | Tighten to 12-18N-m

(107-159 Lb-In) 93006656

Brake shoes and related components—Taurus and Sable

16. Road test the vehicle and check the brake system for proper operation. Ford Escort Mercury Tracer 1. Remove the wheel and tire assem-

bly.

2. Remove 2 brake drum retaining screws and remove the brake drum.

3. Remove 2 brake shoe return springs. 4, Remove the right-hand anti-rattle Spring. 5. Push and turn to release 2 brake shoe hold-down springs and remove the Springs. 6. Remove the leading and trailing shoes from the brake backing plate.

To install: 7. Use a suitable high temperature grease to lightly lubricate the brake shoe contact points on the backing plate. 8. Position the trailing brake shoe on the backing plate and install one of the brake shoe hold-down springs. 9, Position the leading brake shoe on the backing plate and install the other brake shoe hold-down spring. 10. Install the right-hand anti-rattle Spring. 11. Install 2 brake shoe return springs. 12. Using a brake adjusting gauge, meaSure the inside diameter of the brake drum. 13. Compare the brake drum measurement to the brake shoes. 14. Adjust the brake shoes by inserting a

screwdriver into the knurled quadrant of the rear quad operating lever and adjust the shoes to the same measurement as the brake drum. 15, Install the brake drum. 16. Install 2 brake drum retaining SCIeWs. 17. Install the wheel and tire assembly. Torque the lug nuts to 65-87 ft. Ibs.

(88-118 Nm). 18. Complete the brake shoe adjustment by sharply applying the brakes several times while driving the vehicle alternating between forward and reverse gears. 19. Check the brake system operation by making several stops while driving forward.

FORD MOTOR COMbART?

[1 [Parking BrakeLinkSpring__| Pin

BackingPlate _| [3 [RearBrake Spring| RightHand [5 |Anti-Rattle ShoeandLining | [6 |RearBrake 93006657

Brake shoes and related components—Escort/Tracer

Mercury Cougar (1998 Mode!) 1. Remove the wheel and tire assem-

adjuster off of the brake backing plate as an

bly.

brake drum. 2. Remove the the parking brake

3. Disconnect

cable from the parking brake lever.

retainers, brake shoe hold-down springs and hold-down pins. 5. Lift the brake shoes, springs and

rear

4 Remove 2 brake shoe hold-down

assembly using care not to bend the brake shoe adjusting lever.

6. Remove the brake shoe adjusting

screw spring.

93006658

Checking the adjustment of the brake shoes—Escort/Tracer

4-31

7. Separate the brake shoes by removing the brake shoe retracting springs. 8. Remove the parking brake lever pin retainer and spring washer, then remove the brake shoe adjusting lever from the adapter. To install: 9. Apply a light coating of caliper slide grease to the brake backing plate brake shoe contact areas as well as the adjuster screw threads. 10. Assemble the adjuster screw and the brake shoe adjusting screw socket and washer. Turn the brake shoe adjusting screw socket all the way down, then back off ¥ turn. 11. Install the parking brake lever to the trailing shoe with the spring washer and a new parking brake lever pin retainer. Crimp the retainer to securely retain the parking brake lever. 12. Place the trailing shoe on the brake backing plate and attach the parking brake cable. 13. Install the brake shoe hold-down pin, spring and retainers on the trailing brake shoe. 4. Place the leading shoe on the brake backing plate and attach the lower brake shoe retracting spring between both brake shoes. 15. Install the leading brake shoe holddown pin, spring and retainers. 16. install the brake adjuster assembly to the slots between the brake shoes. The brake shoe adjusting screw socket end must fit into the slot in the leading shoe and the adjuster nut end must fit into the slots of the trailing brake shoe and parking brake lever. 17. Install the brake shoe adjusting lever on the pin of the leading shoe and to the slot in the brake shoe adjusting screw socket. 18. Install the upper brake shoe retracting spring in the slot on the trailing shoe and the slot in the brake shoe adjusting 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. Ibs. (115-142 Nm). 22. Apply the brakes several times while backing up the vehicle. After each stop, the vehicle must be moved forward. 23. Road test the vehicle and check for proper brake system operation by making several stops from varying forward speeds.

For complete Engine Mechanical specifications, see Section 1 of this manual

4 3 2?

BRAKES

it

ER CS

GENERAL MOTORS EU

BT

ST

PEE

ITF

ER

EEST ERED

TEESE

TE

ES

OE

EE

1998-01 GENERAL MOTORS 7. Remove the rubber dust boots from

i Brake Callpal

the caliper mounting bolt heads (if equipped).

REMOVAL & INSTALLATION

9. Remove the park brake cable from

the caliper (if working on the rear).

Buick LeSabre, Park Avenue

10. Remove the caliper from the vehicle.

Oldsmobile Eighty Eight Royale, ey SUI pudeney Pontiac Bonneville FRONT & REAR :

eRe TA

UE oa Cie Te tae

cylinder pressure applied by during Jeb

CO

ON LD

ize the system prior to service.

1. Remove brake fluid from the master

cylinder reservoir until the reservoir is

approximately 1 full. 2. Remove the front wheel. Mark the

position of the wheel to the wheel studs,

prior to removal, for installation reference.

3. Install 2 lug nuts to retain the rotor

once the caliper is removed.

ae

C-clamp on the outboard pad and on the round portion of the brake caliper where the

GM E- K- V-BODIES: Cadillac Catera, deVille, Eldorado,

eerille

FRONT 1. Disconnect the negative battery cable. . Zz ie 6 of the brake fluid from the master cylinder.

Nm).

wheel stud for re-installation purposes.

14. Install the ae mounting bolts. Torque the mounting bolts to 38 ft. Ibs. (51 15. Install the park brake cable (if work-

ing on the rear).

16. Install the rubber dust boots over

3. Remove the front wheel. Mark the relationship between the wheel and the

4. Install 2 wheel nuts to keep the rotor

in place.

5. Using a large C-clamp against the

the caliper mounting bolt heads (if

inboard pad, compress the caliper piston

equipped). 17. Check the clearance between the

into the caliper to provide clearance during removal.

brake caliper and caliper bracketstops. If

the clearance is too tight, check the caliper

leading and trailing edges for build up. File

down as necessary.

6. Place a catch pan under the caliper.

7. Disconnect the brake hose from the

caliper. Cap the line to prevent excessive fluid loss or contamination.

18. Connect the brake hose to the

8. Remove the caliper mounting bolts

caliper. Install the brake hose banjo bolt,

and remove the caliper from the vehicle.

using new gaskets, and torque to 33 ft. Ibs. (45 Nm).

9. Inspect the mounting bolts; sleeves and boots for wear and/or damage. Replace

piston is housed.

5. Remove the banjo bolt that fastens

ue

proper braking performance

12. Install the brake pads. Lubricate the Slides where the caliper mounts on the steering knuckle with silicone grease. 13. Install the caliper over the rotor.

4. Using a large C-clamp, bottom the

piston in the caliper bore by positioning the

procedure.

22. Road test the vehicle and check for

8. Remove the caliper mounting bolts.

GM C- & H-BODIES:

the brake system using the recommended

19. Remove the lug nuts used to secure

the rotor.

parts as necessary. To install:

the brake hose to the brake caliper. Discard

20. Install the wheel, aligning the refer-

10. Before installing the caliper, make

6. Cap the brake line to avoid excessive fluid loss or fluid contamination.

torque the lug nuts to 100 ft. Ibs. (140 Nm). 21. Refill the master cylinder and bleed

and the brake pads are properly seated. 11. Lubricate the mounting bolt shafts and inner diameter of the sleeves with silicone grease.

the gaskets.

ence marks made during removal, and

BRACKET

sure the piston is fully seated in the bore

12. Install the caliper in the caliper

CLEARANCE

BETWEEN

mounting bracket and install the mounting bolts. Torque the mounting bolts to 38 ft. Ibs. (61 Nm). 13. Connect the brake hose with the bolt and new gaskets. Torque the brake hose bolt

to 33 ft. Ibs. (45 Nm).

CALIPER AND

BRACKET STOPS SHALL BE 0.13-0.30 MM

(0.005-0.012 NO PLACES IN.)

14. Refill the master cylinder and bleed

the brake system. 15. Remove the 2 wheel nuts securing

the16.rotor,Install

the wheel and tire assembly. 17. Connect the negative battery cable. 18. Road test the vehicle for proper brake system operation.

REAR—DEVILLE, ELDORADO, 93006660 Measuring the caliper clearance—LeSabre, Park Avenue, Eighty Eight Royale, Ninety Eight, Tastee wanmeult

1. Disconnect the negative battery cable. 2. Remove 2% of the brake fluid; from the master cylinder.

BRAKES

GENERAL MOTORS 3. Remove the rear wheel. 4. Install 2 wheel nuts to keep the rotor in place. 5. Place a catch pan under the caliper. 6. Disconnect the brake hose from the caliper. Cap the line to prevent fluid loss or contamination. 7. Loosen the tension on the parking brake at the equalizer. 8. Remove the parking brake cable mounting lever, and remove the cable end by lifting up and disengaging the end. 9. Remove the caliper sleeve bolt. 10. Lift the caliper up and slide the caliper inboard off of the pin sleeve to remove the caliper from the vehicle. 11. Use a suitable tool in the caliper piston slots to turn the piston and thread it into the caliper. After bottoming the piston, lift the iner edge of the boot next to the piston and press out any trapped air the boot must lay flat. To install: 12. Inspect the pin boot, bolt boot and Sleeve boot for cuts, tears or deterioration and replace as necessary. 13. Inspect the bolt sleeve and pin sleeve for corrosion or damage. Pull the boots to gain access to the sleeves for inspection or replacement. Replace corroded or damaged sleeves; do not try to polish away corrosion. 14. If not replaced, remove the pin boot from the caliper and install the small end over the pin sleeve (installed on caliper support) until the boot seats in the pin groove. This prevents cutting the pin boot when sliding the caliper onto the pin sleeve. 15. Hold the caliper in the position as removed and start it over the end of the pin sleeve. As the caliper approaches the pin boot, work the large end of the pin boot in the caliper groove, then push the caliper fully onto the pin. 16. Pivot the caliper down, being careful not to damage the piston boot on the

inboard disc brake pad. Compress the sleeve boot by hand as the caliper moves into position to prevent boot damage. 17. After the caliper is in position, recheck the position of the pad clips. If necessary, use a small prybar to reseat or enter the pad clips on the bracket abutments. 18. Install the sleeve bolt and torque to

20 ft. Ibs. (27 Nm). 19. Install the parking brake cable bracket, with the cable attached, and torque the bolt to 32 ft. Ibs. (43 Nm). 90. Install the parking brake cable onto

the parking brake lever and the retaining clip onto the parking brake cable. 21. Connect the brake hose with the bolt and new gaskets and torque the bolt to 32 ft. Ibs. (43 Nm). 22. Adjust the parking brake cable. 23. Refill the master cylinder and bleed the brake system. 24. Remove the wheel nuts retaining the rotor and install the wheel. 25. Connect the negative battery cable. 26. Road test the vehicle for proper brake system operation.

REAR—CATERA 1. Remove the wheel(s). 2. Attach a hose to the bleeder screw on the caliper. 3. Open the bleeder screw. 4 Compress the pistons into the caliper housing to provide clearance. 5. Use a punch to drive the caliper retaining pins out of the caliper from the outside inward. 6. Remove or disconnect the following: Brake caliper spring retainer Brake pads Brake caliper pipe Caliper mounting bolts e Brake caliper To install: 7. Install or connect the following: e Brake caliper. Torque the bolts to 59 ft. Ibs. (80 Nm). ¢ Brake caliper pipe. Torque the fitting to 12 ft. Ibs. (16 Nm). e Brake pads 8. Install one caliper retaining pin. 9. Install the caliper spring retainer. 10. Install the second retaining pin. 11. Fill and bleed the brake system. 12. Install the wheel(s). GM F-BODY: Chevrolet Camaro Pontiac Firebird

1. Remove % of the brake fluid from the master cylinder. 2. Matchmark the relationship of the wheel and hub, then remove the wheel and tire assembly. 3. If completely removing the caliper from the vehicle for replacement or service, remove the bolt, inlet fitting and 2 gaskets from the caliper housing. Plug the openings in the caliper housing and inlet fitting to prevent system contamination or excessive fluid loss.

|

4-33

4, Remove the circlip and retainer pin. 5. Remove the caliper housing from the rotor and mounting bracket. If the caliper is not being completely removed, it must be suspended from the vehicle using a wire hook in order to prevent damage to the brake lines. To install: 6. Check the inlet fitting bolt for blockage, Clear or replace as necessary. 7. Install the caliper housing over the rotor and onto the mounting bracket. Ensure the guiding surfaces on the inboard and outboard disc brake pads and mounting bracket are seated correctly. 8. Press the caliper housing down to compress the bias springs. Slide a new retainer pin into position and install a new circlip. 9. |f removed, install the inlet fitting, bolt and 2 new gaskets. Torque the bolt to 30 ft. Ibs. (40 Nm). 10. Fill the master cylinder and bleed the brake system. 11. Align the matchmarks made earlier and install the wheel and tire assembly. 12. Lower the vehicle, then with the engine running pump the brake pedal slowly and firmly 3 times to seat then brake pads.

REAR 1. Matchmark the relationship between the wheel and hub, then remove the wheel and tire assembly. Install 2 wheel nuts to retain the rotor. 2. If completely removing the caliper from the vehicle for replacement or service, remove the brake hose bolt inlet fitting and 2 gaskets from the caliper housing. 3. Plug the openings in the caliper housing and inlet fitting to prevent system contamination or excessive fluid loss. 4 Remove the 2 caliper guide pin bolts. 5. Remove the caliper housing from the rotor and mounting bracket. If the caliper is not being completely removed, it must be suspended from the vehicle using a wire hook in order to prevent damage to the brake lines. To install: 6. Inspect the guide pins and boots and replace if corroded, worn or damaged. Check the inlet fitting bolt for blockage, clear or replace as necessary. 7. Install the caliper housing over the rotor and into the mounting bracket. 8. Install 2 caliper guide pin bolts start-

For Accessory Drive Belt illustrations, see Section 1 of this manual

4-34

BRAKES

GENERAL MOTORS

ing with the upper pin and torque the bolts to 27 ft. Ibs. (37 Nm). 9. Attach the brake hose to the caliper using 2 new copper gaskets. Torque the bolt to 22 ft. Ibs. (30 Nm). 10. If the hose fitting was removed, bleed the entire brake system. 11. Lower the vehicle sufficiently and cycle the parking brake. 12. Raise and safely support the vehicle. 13. Inspect the caliper parking brake levers and ensure they are against the stops on the caliper housing. If the levers are not on their stops, check the parking brake adjustment. 14. Remove the 2 nuts securing the rotor, then align the matchmarks made earlier and install the wheel assembly. 15. Lower the vehicle, then with the engine running pump the brake pedal slowly and firmly 3 times to seat then brake pads. 16. Check the hydraulic system for leaks. GM G-BODY: Buick Riviera Oldsmobile Aurora

FRONT 1. Siphon % of the brake fluid out of the master cylinder reservoir. 2. Remove the tire and wheel assembly. 3. Install 2 wheel nuts loosely to secure the rotor when the caliper is removed. 4, Remove the bolts securing the brake hose to the caliper and disconnect the brake hose from the caliper.

(1) Pin Bolts (2) Outboard Pad

(3) Caliper Boot (4) Inboard Pad (5) Piston Seal

93006689

93006688

Caliper mounting bolt and sleeve lubrication points—Riviera, Aurora

Compressing the front caliper piston—Riviera, Aurora

5. Plug the hose to prevent excessive fluid loss and possible fluid contamination. 6. Compress the piston into the caliper bore to provide clearance for removal. 7. Remove the caliper mounting bolts. 8. Remove the caliper from the anchor bracket. 9. If the caliper is being replaced remove the brake pads from the caliper or anchor bracket. To install: 10. Seat the caliper piston fully in its bore. 11. Install the brake pads in the caliper or anchor bracket. 12. Install the caliper on the anchor bracket and install the mounting bolts. 13. Torque the caliper mounting bolts to 38 ft. Ibs. (51 Nm). Torque the mounting bolts to 63 ft. Ibs. (85 Nm). 14. Reconnect the brake hose to the caliper using new washers. Torque the fitting bolt to 33 ft. Ibs. (45 Nm),

(6) Piston (7) Anchor bracket (8) Bleeder Valve

(9) Caliper Housing (10) Caliper Anchor Bracket 93006687

Front caliper and brake pad components—Riviera, Aurora

15. Remove the 2 lug nuts securing the brake rotor. 16. Install the wheel and tire assembly and torque the wheel nuts to 100 ft. Ibs. (140 Nm). 17. Refill the master cylinder with fluid and bleed the brake system. 18. Pump the brake pedal several times to seat the brake pads against the rotor. Verify no hydraulic leaks and a good firm brake pedal.

REAR 1. Siphon % of the brake fluid out of the master cylinder reservoir. 2. Remove the tire and wheel assembly. 3. Install 2 wheel nuts loosely to secure the rotor when the caliper is removed:

4. Remove the bolt securing the brake hose to the caliper and disconnect the brake hose from the caliper. 5. Plug the hose to prevent excessive fluid loss and possible fluid contamination. 6. Remove the park brake cable 7. Remove upper and lower caliper bolts and lift caliper from mounting bracket. To install: 8. Seat the caliper piston fully in its bore. 9. Make sure the notches in the caliper piston are at 6 and 12 o'clock. 10. Mount caliper onto anchor bracket. Install the 2 mounting bolts and torque bolts to 63 ft. Ibs. (85 Nm) 11. Reconnect the brake hose to the caliper using new copper washers. Torque the mounting bolt to 33 ft. Ibs. (45 Nm). 12. Install the park brake cable. 13. Remove the wheel nuts securing the rotor. 14. Reinstall the tire and wheel assembly and torque the wheel nuts to 100 ft. Ibs. (140 Nm). 15. Refill the master cylinder with fluid and bleed the brake system. 16. Pump the brake pedal several times to seat the brake pads against the rotor. Verify no hydraulic leaks and a good firm brake pedal.

cenenarmovons 4730 GM J-BODY: Chevrolet Cavalier Pontiac Sunfire

1

12 13.

PISTON BOOT PISTON ASSEMBLY

3 INBOARD SHOE & LINING

14

PISTON SEAL

4

PAD CLIP

5

WEAR SENSOR

15 16

BLEEDER VALVE CAP BLEEDER VALVE

6 7 8 9 10

PIN BOOT BOLT BOOT SLEEVE BOLT BOLT SLEEVE PIN BOLT

11

PIN SLEEVE

2

SLEEVE BOLT OUTBOARD SHOE & LINING

1. Siphon % of the brake fluid out of the master cylinder. 2. Remove the tire and wheel assembly. 3. Compress the caliper piston back into the caliper bore using a large pair of pliers, C-clamp or special piston retracting tool. 4. |f the caliper is to be completely removed from the vehicle for bench service, disconnect and cap the brake line from the caliper. Discard the old washers. 5. Remove the caliper mounting bolts and sleeves. 6. Remove the caliper from the knuckle. 7. Remove the brake pads from the caliper, if caliper is being replaced. To install: 8. Install the brake pads in the caliper. 9. Install the caliper on the steering knuckle. 10. Install the mounting bolts and sleeves and torque to 40 ft. Ibs. (651 Nm). 11. If the caliper brake line was disconnected, uncap and connect the brake hose to the caliper using new copper washers. Torque the mounting bolt to 35 ft. Ibs. (44 Nm). 12. Refill the master cylinder and bleed the brake system. 13. Install the tire and wheel assembly and tighten to specification. 14. Verify correct brake operation.

17 “LEVER RETURN SPRING 18 BOLT AND WASHER 19 CABLE SUPPORT BRACKET 20 CALIPER BODY ASSEMBLY 21 CALIPER SUPPORT 93006690

Rear caliper and brake pad components—Riviera, Aurora

PISTON SLOTS MUST BE, ALIGNED AS SHOWN BEFORE INSTALLING CALIPER OVER SHOE & LININGS

PISTON BOOT PISTON ASSEMBLY CALIPER BODY — an ASSEMBLY 93006691

Aligning the notches in the piston—Riviera, Aurora

GM L/N and N-BODY: Buick Skylark Chevrolet Malibu Oldsmobile Achieva, Cutlass Pontiac Grand Am 1. Siphon % of the brake fluid out of the master cylinder. 2. Remove the tire and wheel assembly. 3. Compress the caliper piston back into the caliper bore-using a large pair of pliers, C-clamp or special piston retracting tool. 4. Remove the brake hose from the caliper and discard the copper washers. 5. Plug the hose to prevent excessive fluid loss and possible fluid contamination. 6. Remove the caliper mounting bolts and remove the caliper from the knuckle. 7. Remove the brake pads from the caliper, if the caliper is being replaced. To install: 8. Inspect the condition of the caliper support for rust and corrosion that will hinder the travel of the caliper.

For Tire, Wheel and Ball Joint specifications, see Section 1 of this manual

4-36

BRAKES

GENERAL MOTORS

9. Inspect the caliper mounting hardware. New bolts are usually recommended. 10. Lubricate the mounting bushings and sleeves with silicone grease as required. 11. Install the brake pads in the caliper. 12. Install the caliper on the steering knuckle. 13. Install the mounting bolts and torque to 40 ft. Ibs. (51 Nm). 14. Connect the brake hose to the caliper using new copper washers and torque the mounting bolt to 35 ft. Ibs. (44 Nm). 15. Refill the master cylinder and bleed the brake system. 16. Install the tire and wheel assembly. 17. Verify correct brake operation.

GM W-BODY: Buick Century, Regal Chevrolet Lumina, Monte Carlo

Oldsmobile Cutlass Supreme, Intrigue Pontiac Grand Prix

FRONT 1. Remove % of the brake fluid from the master cylinder assembly. 2. Remove the tire and wheel assembly. Mark a relationship between the wheel and the wheel stud for re-installation purposes.

CALIPER SLIDE BOLT OUTBOARD SHOE & LINING INBOARD SHOE & LINING BUSHING ASSEMBLY CALIPER BOOT PISTON o = @mw~vy WN

3. Install 2 wheel nuts to retain the rotor on the vehicle. 4. Install a large C-clamp over top of the caliper housing and against the back of the outboard shoe. Slowly tighten the Cclamp until the piston(s) are pushed into the caliper bore. 5. Disconnect the bolt attaching the brake hose fitting to the brake caliper. 6. Plug the opening in the caliper housing and brake line to prevent brake fluid loss and contamination. 7. Remove the caliper mounting bolts. 8. Remove the brake caliper housing from the rotor and mounting bracket. 9. If the caliper is to be replaced or repaired remove the brake pads from the caliper or mounting bracket. To install: 10. Fully inspect the brake caliper bushing assemblies for cuts, tears or deterioration and replace parts as needed. 11. Inspect the slide bolts for corrosion. If corrosion is found, replace the slide bolts and bushings before installing the brake caliper assembly. 12. Before installing the caliper, make sure the piston(s) are seated in the bore, and that the brake pads are correctly installed. 13. Lubricate the caliper slide bolts with

wo

10 11 12 13° 14

PISTON SEAL CAP BLEEDER CALIPER HOUSING BRACKET WEAR SENSOR

INSIDE OF BUSHING

93006661

Slide bolts lubrication points—Century, Regal, Lumina, Monte Carlo, Cutlass

Supreme, Intrigue, Grand Prix

silicone grease. Do not lubricate the bolt threads. 14. Install brake pads onto caliper or mounting bracket. 15. Install the caliper bolts and torque the bolts to 63 ft. Ibs. (85 Nm). 16. Install the brake hose inlet fitting to the caliper and torque the bolt to 24 ft. Ibs. (32 Nm). 17. Remove wheel nuts securing the brake rotor to the hub. 18. Install the tire and wheel assembly. 19. Fill the master cylinder to the proper level. 20. Bleed the brake system.

21. Verify correct brake operation.

3

93006G62

Caliper attachments—Century, Regal, Lumina, Monte Carlo, Cutlass Supreme, Intrigue, Grand Prix

BRAKES

GENERAL MOTORS REAR 1. Remove 2 of the brake fluid from the master cylinder assembly. 2. Remove the tire and wheel assembly. Mark a relationship between the wheel and the wheel stud for re-installation purposes. 3. Install 2 wheel nuts to retain the rotor. 4. Remove the brake hose from the caliper and discard the copper washers. 5. Plug the openings in the caliper and the brake hose to prevent brake fluid loss and contamination. 6. The following steps are for models with the park brake cable attached to the caliper: a. Disconnect the parking brake cable from the parking brake lever on the caliper. Lift up one end of the cable spring clip free end of the cable from the lever. b. Remove the bolt and washer attaching the cable support bracket to the caliper body assembly. c. Remove the caliper sleeve bolts. 7. For all others, remove the two caliper mounting bolts. 8. Remove the caliper body assembly from the vehicle. Pivot the caliper assembly up to clear the rotor and then slide it inboard off the pin sleeve.

1 2 3 4 5 6

CAP, BLEEDER SCREW SCREW, BLEEDER HOUSING, CALIPER SEAL PISTON, CALIPER

BOOT

7 8 9 10 1 12

To install: 9. Inspect the caliper bolt boots, pins and sleeve bolt for cuts, tears or deterioration. Replace as necessary. 10. Lubricate the mounting surfaces and the mounting sleeves. 11. Hold the caliper body assembly in the position from which it was removed, and start it over the end of the pin sleeve. 12. As the caliper body assembly approaches the pin boot, work the large end of the pin boot in the caliper body groove. Push the caliper body fully onto the pin. 13. Pivot the caliper body assembly down, using care not to damage the piston boot on the inboard shoe. Compress the Sleeve boot by hand as the caliper body moves into position to prevent boot damage. 14. After installing the caliper assembly into position, recheck the installation of the pad clips. If necessary, use a small prying tool to reset or center the pad clips. 15. Install the brake caliper sleeve bolts and torque to 20 ft. Ibs. (27 Nm). 16. On models without caliper mounted park brake cable, torque caliper mounting bolts to 32 ft. Ibs. (43 Nm) 17. To install the park brake cable, the following steps apply (some models).

4-37

a. Install the cable support bracket with the cable attached. Torque bolt to 32 ft. Ibs. (43 Nm). b. Lift up on the end of the cable spring clip and work the end of the parking brake cable into the notch of the parking brake lever. 18. Connect the brake hose to the brake caliper and torque the bolt to 32 ft. Ibs. (44 Nm). 19. Remove the wheel nuts securing the rotor to the hub and bearing assembly. 20. Install the tire and wheel assembly. 21. Fill the master cylinder to the proper level with clean brake fluid. 22. Bleed the brake system using the recommended procedure. 23. Apply approximately 175 Ibs. (79 kg) of force, 3 times, to properly seat the brake shoe and linings against the rotor. 24. Adjust the parking brake cable as necessary (some models). GM Y-BODY: Chevrolet Corvette FRONT

1. Disconnect the negative battery cable and remove % of the brake fluid from the master cylinder reservoir.

PIN, RETAINER PAD, INBOARD BRAKE PAD, OUTBOARD BRAKE BRACKET, CALIPER MOUNTING eeGIRCLIP SPRING, BIAS

Exploded view of the front caliper assembly—Corvette

For Wheel Alignment specifications, see Section 1 of this manual

93006663

4-38

BRAKES

GENERAL MOTORS

2. Mark the relationship between the wheel and axle flange, then remove the tire and wheel assembly. 3. Install 2 wheel nuts to retain the brake rotor. 4. Depress the caliper pistons into the caliper bores in order to provide clearance between the pads and the rotor. 5. Disconnect the brake hose fitting at the caliper by removing the bolt. Discard the 2 copper washers. 6. Plug all openings to prevent fluid contamination or loss. Do not allow the fluid to come into contact with the front transverse spring, as damage to the spring may occur.

7. For Corvette, remove the 2 caliper mounting bolts. 8. Remove the caliper housing from the rotor and the caliper mounting bracket. To install: 9. Install the caliper over the brake rotor and into the caliper mounting bracket. Make sure the shoe lining guiding surfaces are correctly seated in the bracket. 10. Compress the bias springs by applying pressure to the mounting bracket, then install the new retainer pin. 11. Connect the brake hose inlet fitting using 2 new copper washers and the inlet fitting bolt. Torque the bolt to 30 ft. Ibs. (40 Nm). 12. Properly bleed the entire brake system. 13. Remove the wheel nuts retaining the rotor, align the marks made earlier and install the tire and wheel assembly. 14. Check the brake fluid and add as necessary. 15. Connect the negative battery cable, start the engine and pump the brake pedal slowly and firmly 3 times to seat the shoe and lining assemblies.

REAR 1. Mark the relationship between the wheel and axle flange then remove the tire and wheel assembly. 2. Install 2 wheel nuts to retain the brake rotor. 3. Disconnect the brake line fitting at the caliper and discard the 2 copper gaskets. 4. Plug all openings to prevent fluid contamination or loss. 5. Remove the 2 guide pins bolts and discard. 6. Remove the caliper housing from the brake rotor and caliper mounting bracket. To install: 7. Inspect the guide pins for free move-

5

BOLT, UPPER GUIDE PIN BOLT, LOWER GUIDE PIN HOUSING, CALIPER PIN, GUIDE BOOT

6

BRACKET,

7

INSULATOR PAO, OUTBOARD BRAKE SENSOR, WEAR PAD, INBOARD BRAKE

1

2 3 4

8 9 10

MOUNTING

93006664

Exploded view of the rear caliper assembly—Corvette

ment and replace the pins or boots if damaged or corroded. 8. Install the caliper over the brake rotor and into the mounting bracket. 9. Install the caliper mounting bolts and torque to 23 ft. Ibs. (31 Nm). 10. Connect the brake line fitting using 2 new copper washers and the inlet fitting bolt. Torque the bolt to 30 ft. Ibs. (40 Nm). 11. Properly bleed the entire hydraulic brake system. 12. Remove the 2 nuts securing the rotor to the hub. 13. Align the marks made earlier and install the tire and wheel assembly. 14. Check the brake fluid level. 15. Connect the negative battery cable, Start the engine and pump the brake pedal slowly and firmly 3 times to seat the shoe and lining assemblies. GEO Metro

1. Siphon a sufficient quantity of brake fluid from the master cylinder reservoir to prevent the brake fluid from overflowing the master cylinder when removing or installing the calipers. This is necessary, as the piston must be forced into the cylinder bore to provide sufficient clearance to install the caliper.

2. Remove the wheel and tire assembly. 3. Install 2 lug nuts finger tight to hold the disc in place. 4. Disconnect the brake hose fitting at the caliper and discard the 2 copper washers. Use a pan to catch any spilled fluid and immediately plug the disconnected hose. 5. Remove the 2 caliper mounting bolts and then remove the caliper from the mounting bracket. To install: 6. Use a caliper compressor, a C-clamp or large pair of pliers to slowly press the caliper piston back into the caliper. 7. Apply a thin, even coating of antiseize compound to the sliding surfaces. Don't use grease or spray lubricants; they will not hold up under the extreme temperatures generated by the brakes. 8. Install the caliper assembly to the mounting plate. 9. Install caliper mounting bolts and torque to 22 ft. Ibs. (30 Nm ). 10. Install the brake hose to the caliper using 2 new copper washers. Torque the bolt to 17 ft. Ibs. (23 Nm). 11. Bleed the brake system. 12. Remove the 2 lugs holding the disc in place and install the wheel and tire assembly.

SL

SSS

13. Check the level of the brake fluid in the master cylinder reservoir: it should be at least to the middle of the reservoir. GEO Prizm

FRONT 1. Siphon a sufficient quantity of brake fluid from the master cylinder reservoir to prevent the brake fluid from overflowing the master cylinder when removing or installing the calipers. This is necessary, as the piston must be forced into the cylinder bore to provide sufficient clearance to install the caliper. 2. Remove the wheel and tire assembly. 3. Install 2 lug nuts finger tight to hold the brake rotor in place. 4. Disconnect the brake hose at the caliper and discard the 2 copper washers. Use a pan to catch any spilled fluid and immediately plug the disconnected hose. 5. Remove the 2 caliper mounting bolts and then remove the caliper from the mounting bracket.

To install: 6. Use a caliper compressor, a C-clamp Or large pair of pliers to slowly press the caliper piston back into the caliper. 7. Apply a thin, even coating of antiseize compound to the sliding surfaces. Don't use grease or spray lubricants; they will not hold up under the extreme temperatures generated by the brakes. 8. Install the caliper assembly to the mounting plate.

BRAKES GENERAL MOTORS

SS

9. Install the caliper mounting bolts and torque to 25 ft. Ibs. (34 Nm). 10. Install the brake hose to the caliper using 2 new copper washers. Torque the brake hose bolt to 22 ft. Ibs. (30 Nm). 11. Bleed the brake system. 12. Remove the 2 lugs holding the disc in place and install the wheel. 13. Check the level of the brake fluid in the master cylinder reservoir; it should be at least to the middle of the reservoir. Saturn

FRONT 1. Remove the front wheel and tire assembly. 2. Disconnect the brake hose from the caliper and discard the 2 copper washers. 3. Plug the openings to prevent system contamination or excessive fluid loss. 4. Remove the lock pin and guide pin from the caliper. 5. Remove the caliper from the support, being careful not to damage the pin boots. 6. Remove the pin boots from the caliper support and inspect for damage. To install: 7. lf necessary, bottom the caliper piston by hand, or by using a C-clamp. 8. If removed, install the brake pads and clips to the caliper support. 9. Lubricate the pin boots and guide pins with silicone grease. 10. Install the pin boots into the caliper

84229044

Using a large C-clamp to compress the piston back into the caliper bore

4-39

SSC

Support, using the pin to assure that the boot passes all the way through the support. 11. Position the caliper onto the support and over the brake pads. 12. Lubricate the non-threaded portion of the guide and lock pins with silicone

grease. 13. Install the pins through the caliper and torque to 27 ft. Ibs. (36 Nm). e» Make sure the brake line is properly routed with loop to the rear and that the hose is not twisted.

14. Install the brake hose using 2 new copper washers. Torque the fitting bolt to 36 ft. Ips. (49 Nm). 15. Properly bleed the hydraulic brake system. 16. Install the wheel and tire assembly.

REAR 1. Remove the rear wheel and tire assembly. 2. Disconnect the brake hose from the caliper and discard the 2 copper washers. 3. Plug the openings to prevent system contamination or excessive fluid loss. 4. Slip the end of the parking cable off the parking brake lever. 5. Remove the cable outer housing from the cable bracket with SA9151BR cable release tool. 6. Remove the lock pin and guide pin. 7. Remove the caliper from the support, being careful not to damage the pin boots. 8. Remove the pin boots from the caliper support for inspection and lubrication. To install: 9. Make sure the piston is bottomed in the bore. Do not compress the piston using a C-clamp; instead the piston must be rotated into the caliper on its threads using a piston driver tool. 10. If removed, install the brake pads and clips to the caliper support. 11. Lubricate the pin boots and guide pins with silicone grease. 12. Install the pin boots into the caliper support, using the pin to assure that the boot passes all the way through the support. 13. Position the caliper onto the caliper support. 14. Lubricate the non-threaded portion of the guide and lock pins. Install the pins and torque to 27 ft. Ibs. (36 Nm). 15. Install the brake hose using new copper washers and torque the fitting bolt to 36 ft. Ibs. (49 Nm).

For Maintenance Interval recommendations, see Section 1 of this manual

4-40

BRAKES

GENERAL MOTORS

16. Connect the parking brake cable. 17. Properly bleed the hydraulic brake system. 18. Install the wheel and tire assembly.

Disc Brake Pads

REMOVAL & INSTALLATION GM C- and H-BODIES: Buick LeSabre, Park Avenue Oldsmobile Eighty Eight Royale, Ninety Eight, Regency Pontiac Bonneville

1. Remove brake fluid from the master cylinder reservoir until the reservoir is approximately ¥ full. Discard the removed fluid. 2. Remove the front wheel. Mark the position of the wheel to the wheel studs, prior to removal, for installation reference. 3. Install 2 lug nuts to retain the rotor once the caliper is removed. 4 Remove the caliper mounting sleeve bolts. Support the caliper out of the way using wire. DO NOT disconnect the brake hose or allow the caliper to hang from the brake hose. 5. Remove the outboard pad by pushing it in toward the piston until the mounting tabs clear the holes in the caliper body. With the tabs clear of the holes, push the pad out the bottom of the caliper. 6. Remove the inboard pad from the piston by pulling the top of the pad out to disengage the retainer spring. To install: 7. Before installing the pads in the caliper, the piston must be fully seated in the bore. A large C-clamp can be used to compress the piston. 8. Install the inboard pad in the caliper by inserting the top pad ears in first, then Sliding the bottom of the pad into place until the spring clip snaps into place. Make sure the inboard pad seats flush against the caliper piston. 9. Install the outboard pad by lining up the tabs on the rear of the pad with the mounting holes in the caliper body. Press the pad firmly down into the caliper until the tabs snap into the mounting holes. 10. Clean and lubricate the caliper bolt and sleeve assemblies and install them into the caliper. Lubricate the caliper slides and mountings. 11. Install the caliper over the rotor and torque the mounting bolts to 38 ft. Ibs. (51 Nm).

12. Remove the 2 lug nuts used to secure the rotor in place. 13. Install the wheel, aligning the marks - made during removal, and torque the lug nuts to 100 ft. Ibs. (140 Nm). 14. Pump the brake pedal several times to seat the pads against the rotor. 15. Refill the master cylinder using DOT 3 brake fluid only and road test to verify proper brake operation.

GM E-, K- and V-BODIES:

5. Outboard Shoe & Lining 6. Wear Sensor 12. Caliper Housing

Cadillac Catera, deVille, Eldorado, Seville

FRONT 1. Remove % of the brake fluid from the master cylinder reservoir. 2. Remove the front wheel. 3. Remove the caliper mounting bolts. 4. Remove the caliper from the steering knuckle without disconnecting the brake hose. 5. Suspend the caliper from the coil spring with wire. Do not let the caliper hang from the brake hose.

93006667

Supporting the front caliper—Catera, deVille, Eldorado, Seville

93006669

Installing the outboard disc brake pad in the front caliper—Catera, deVille, Eldorado, Seville

6. Remove brake pads from anchor bracket. To install: 7. Fully seat the caliper piston into the bore using a large C-clamp. 8. Lubricate the brake caliper mounting surfaces. 9. Install the brake pads onto the anchor bracket using new shims and clips. 10. Place the caliper onto the anchor bracket and install the mounting bolts. 11. Torque the mounting bolts to 63 ft. lbs. (85 Nm). 12. Install the wheel and tire assembly and torque.to specification. 13. Lower the vehicle. 14. Pump the brake pedal several times to seat the brake pads. 15. Check the fluid level in the master cylinder and fill as necessary. 16. Road test the vehicle for proper brake operation.

REAR—DEVILLE, ELDORADO, SEVILLE 1. Remove % of the brake fluid from the master cylinder reservoir. 2. Remove the rear wheel. 3. Remove the park brake cable from the caliper. e>Some models use a brake pad wear sensor. Disconnect the sensor connector from the vehicle harness.

7. Inboard Shoe & Lining 12. Caliper Housing 17. Shoe Retainer Spring 93006668

Installing the inboard disc brake pad into the front caliper—Catera, deVille, Eldorado, Seville

4. Remove the caliper mounting bolts and position and suspend the caliper from the strut with a wire. Do not let the caliper hang from the brake hose. 5. Remove the inboard and the outboard brake pads from the caliper mounting bracket. To install: 6. Lubricate mounting surfaces and install new brake pad Clips.

BRAKES

GENERAL MOTORS REAR—CATERA

PISTON SLOTS MUST B ALIGNED AS SHOWN “4

1. Remove the wheel(s). 2. Attach a hose to the bleeder screw on the caliper. 3. Open the bleeder screw. 4. Compress the pistons into the caliper housing to provide clearance. 5. Use a punch to drive the caliper retaining pins out of the caliper from the outside inward. _ 6. Remove or disconnect the following: e Brake caliper spring retainer e Brake pads To install: 7. Install the brake pads. 8. Install one caliper retaining pin. 9. Install the caliper spring retainer.

BEFORE INSTALLING

CALIPER OVER & LININGS

1 PISTON BOOT 2 PISTON ASSEMBLY 3 CALIPER BODY ASSEMBLY 93006670

Aligning the slots on the rear caliper—

Caiera, deVille, Eldorado, Seville

7. The caliper piston must be fully seated in the bore. A spanner type tool can be used to bottom the piston into its bore by turning it in. Make sure the slots in the piston are straight across from each other so the notches on the brake pad will seat. 8. Install the inboard pad by inserting the pad into the straight tabs on the retainer, then pressing down and snapping the pad under the S-shaped tabs. The pad should lay flat against the rotor. Make sure the Dshaped notches are in line with the buttons on the back of the pad lining. If they are not in alignment, rotate the piston until the Dshaped notches face the caliper mounting bolt holes. 9. Install the outer pad into the brake pad clips. Make sure the wear indicator is at the leading edge of the pad during forward wheel rotation. 10. Install the caliper on the mounting bracket and install the bolts. Torque the mounting bolts to 63 ft. bs. (85 Nm). 11. Install the parking brake cable onto the caliper. 12. Install the wheel and tire assembly and lu, gue to specification. 13. Fill the master cylinder reservoir to the FULL mark and pump the brake pedal several times to seat the brake pads. 14. Check the fluid level in the master cylinder again and fill as necessary. 15. Road test the vehicie for proper brake operation.

10. Install the second retaining pin. 11. Fill and bleed the brake system. 12. Install the wheel(s).

GM F-BODY: Chevrolet Camaro Pontiac Firebird

FRONT 1. Remove the caliper assembly from the rotor and mounting bracket without disconnecting the brake line, then position aside. Do not allow the caliper to hang by the brake hose, suspend it with a length of wire or a fabricated hook. 2. Remove the outer pad assembly using a small prytool, if necessary, to disengage the show buttons from the caliper assembly. 3. Remove the inner pad. To install: 4. {f not done already, bottom the piston into the caliper using a large C-clamp positioned on the housing and inside the piston well. 5. With the piston bottomed in the caliper bore, lift the inner edge of the boot next to the piston and press out any trapped air. Make sure the boot is flat. 6. Install the inner pad assembly by positioning the retainer spring into the piston. The pad must lay flat against the piston and the boot must not touch the pad. If the boot and pad are in contact, remove the pad and reposition the boot. 7. Install the outer pad assembly, making sure the back of the pad is flat against the caliper. The wear sensor should be at the trailing lower edge of the outer pad during forward wheel rotation or the outer

4-41

pad has been installed on the wrong side. 8. Install the caliper assembly to the rotor and mounting bracket.

REAR 1. Remove % of the brake fluid from the master cylinder reservoir. 2. Matchmark the relationship of the wheel to the axle flange, then remove the wheel and tire assembly. Install 2 wheel nuts to retain the rotor. 3. Position a C-clamp and tighten until the piston bottoms in the base of the caliper housing. Make sure 1 end of the C-clamp rests on the inlet fitting bolt and the other against the outboard disc brake pad. ->It is not necessary to remove the parking brake caliper lever return spring to replace the disc brake pads.

4. Remove the upper caliper guide pin bolt and discard. 5. Rotate the caliper housing on the lower caliper mounting bolt. Be careful not to strain the hose or cable conduit. It may be necessary: to loosen the lower caliper guide pin slightly. 6. Remove the disc brake pads and discard the shim. To install: 7. Clean all residue from the pad guide surfaces on the mounting bracket and caliper housing. Inspect the guide pins for free movement in the mounting bracket. Replace the guide pins or boots, if they are corroded or damaged. 8. Install a new shim, then install the disc brake pads. The outboard pad with insulator is installed toward the caliper housing. The inboard pad with the wear sensor is installed nearest the caliper piston. The wear sensor must be on the leading edge with forward wheel rotation or the pad has been installed on the wrong side. 9. Rotate the caliper housing into its operating position. The springs on the outboard brake pad must not stick through the inspection hole in the caliper housing. If the springs are sticking through the inspection hole in the caliper housing, lift the caliper housing and make the necessary corrections to the outboard brake pad positions. 10. Install a new upper caliper guide pin bolt and torque to 27 ft. Ibs. (37 Nm).

For Tune-up, Capacities and Firing orders, see Section 1 of ti

lanual

4-42

BERR MOTORS GM G-BODY: Buick Riviera Oldsmobile Aurora

FRONT

A 8 9 10

WEAR SENSOR BRACKET, PARKING BRAKE CABLE BOLT/SCREW, LOWER CALIPER GUIDE PIN SHIM BOLT/SCREW, UPPER CALIPER GUIDE PIN HOUSING, REAR BRAKE CALIPER PIN, REAR BRAKE CALIPER GUIDE BOOT, REAR BRAKE CALIPER GUIDE PIN BRACKET, REAR BRAKE CALIPER ANCHOR PAD, REAR DISC BRAKE INNER PAD. REAR DISC BRAKE OUTER DAMPENER, REAR BRAKE VIBRATION NUT, REAR BRAKE VIBRATION DAMPENER 93006692

Exploded view of the rear caliper assembly—Camaro, Firebird

Ensure that the lower caliper guide bolt is torqued to 27 ft. Ibs. (37 Nm). 11. With the engine running, pump the brake pedal slowly and firmly to seat the brake pads. 12. Check the caliper parking brake levers to make sure they are against the Stops on the caliper housing. If the levers are not on their stops, check the parking brake adjustment. 13. Remove the 2 wheel nuts from the rotor, then align the marks and install the

wheel assembly. 14. Check the master cylinder fluid level and road test the vehicle.

10

1. Siphon % of the brake fluid from the master cylinder. 2. Remove the tire and wheel assembly. : 3. Install 2 wheel nuts to secure the rotor on the hub. 4, Remove the caliper mounting bolts and sleeves. ; 5. Remove the caliper from the mounting bracket and support the caliper. DO NOT allow the caliper to hang unsupported from the brake hose. 6. Remove the outboard brake pad from the caliper by pushing the pad inward toward the piston to unseat the buttons on the back of pad from the holes in the caliper. Once the buttons are unseated push the pad out of the caliper. 7. Remove the inboard pad from the caliper by pulling the top of the pad away from the piston and disengaging the spring clip from the caliper. 8. Compress the piston back into the bore using a C-Clamp. To install: 9. Install the inboard pad into the caliper so the spring clip seats in the piston. Make sure lower edge of the spring clip is engaged in the piston and the pad is even against the base of the piston. Push the pad flat against caliper piston. 10. Install the outboard pad into the caliper so the wear indicator is at the trailing edge of the pad during forward wheel rotation. Push the pad the straight down into the caliper so the spring clips rode along the outside of the caliper. The buttons on the pad will snap into the mounting holes when the pad is correctly installed.

CALIPER HOUSING INBOARD SHOE AND LINING OUTBOARD SHOE AND LINING 93006693

Removing the outboard front pad—Riviera, Aurora

BRAKES GENERAL MOTORS

5 9 14°

CALIPER HOUSING INBOARD SHOE AND LINING SHOE RETAINER SPRING 93006694

Installing the inboard front pad—Riviera, Aurora

5 10 11.

‘3 6. Remove the lower caliper mounting olt. 7. Pivot the caliper upward and secure the caliper in a position over the mounting bracket. DO NOT remove the caliper from the upper pivot pin. 8. Remove the inboard and outboard pads from the caliper bracket. 9. Remove the brake pad clips from the mounting bracket. To install: 10. Spin the caliper piston back into the bore. Make sure the piston notches are at 6 and 12 o'clock after the piston is compressed. 11. Install new brake pad clips in the caliper mounting bracket. 12. Install the inboard and outboard pads in the mounting bracket. 13. Pivot the caliper down over the pads. 14. Reinstall the lower mounting bolt and torque to 20 ft. Ibs. (27 Nm). 15. Reinstall the parking brake cable bracket on the caliper and torque the mounting bolt to 32 ft. Ibs. (43 Nm). 16. Pivot the actuator lever and connect the cable end to the actuator. 17. Remove the 2 wheel nuts securing the rotor. 18. Reinstall the tire and wheel assembly and torque the wheel nuts to 100 ft. Ibs. (140 Nm). 19. Refill the master cylinder. Pump the brake pedal several times to seat the pads against the rotor. 20. Check the master cylinder level and add fluid as necessary. GM J-BODY: Chevrolet Cavalier Pontiac Sunfire

CALIPER HOUSING OUTBOARD SHOE AND LINING WEAR SENSOR 93006695

Installing the outboard front pad—Riviera, Aurora

11. Reinstall the caliper onto the steering knuckle and torque the mounting bolts to 38 ft. lbs. (51 Nm). 12. Remove the 2 wheel nuts securing the rotor. 13. Reinstall the tire and wheel assembly and torque the wheel nuts to 100 ft. Ibs. (140 Nm). 14. Refill the master cylinder. Pump the brake pedal several times to seat the pads against the rotor. 15. Check the master cylinder level and add fluid as necessary.

4-43

REAR 1. Siphon 3 of the brake fluid from the master cylinder. 2. Remove the tire and wheel assembly. 3. Install 2 wheel nuts to secure the rotor on the hub. 4. Pivot the parking brake actuator level and disconnect the parking brake cable from the lever. 5. Remove the mounting bolt securing the parking brake cable bracket to the caliper and position the cable and bracket out of the way.

1. Siphon % of the brake fluid out of the master cylinder reservoir. 2. Remove the tire and wheel assembly. 3. Compress the caliper piston back into the caliper bore using a large pair of pliers, C-clamp or special caliper piston retracting tool. 4. Remove the caliper mounting bolts and sleeves. 5. Remove the caliper from the steering knuckle without disconnecting the brake hose. Do not allow the caliper to hang from the brake hose. Support the caliper with a piece of wire. 6. Remove the outboard pad by pushing in on the outside edge of the pad to release the mounting dowel from the hole in

For complete service labor times, order Nichols’ Chilton Labor Guide

4-44

BRAKES

GENERAL MOTORS

a

the caliper. When both dowels are unseated, push the pad out the bottom of the caliper. 7. Remove the inboard pad from the caliper by pulling it out of the caliper. To install: 8. Inspect the caliper for any signs of leakage. If the caliper is leaking, new brake pads will be damaged. Also inspect the condition of the caliper support for rust and corrosion which will hinder the travel on the caliper. 9. Inspect the caliper mounting hardware. New bolts are usually recommended. Clean all parts well. Lubricate the mounting bushings and sleeves with silicone grease as required. 10. Install the inboard pad in the caliper so the spring clip on the pad back engages in the caliper piston. 11. Install the outboard pad over the caliper end until the mounting dowels snap into the mounting holes in the caliper. 12. Install the caliper over the rotor onto the steering knuckle. 13. Install the mounting bolts and Sleeves and torque to 40 ft. Ibs. (51 Nm). 14. Install the tire and wheel assembly. 15. Pump the brake pedal several times to seat the pads against the rotor before attempting to move the vehicle. 16. Check the master cylinder level and add fluid as necessary.

GM L/N and N-BODY: Buick Skylark Chevrolet Malibu Oldsmobile Achieva, Cutlass Pontiac Grand Am 1. Siphon % of the brake fluid out of the master cylinder reservoir. 2. Remove the tire and wheel assembly. 3. Remove the caliper from the steering knuckle without disconnecting the brake hose. DO NOT allow the caliper to hang from the brake hose. Support the caliper with a piece of wire. 4. Remove the outboard pad by pushing in on the outside edge of the pad to release the mounting dowel from the hole in the caliper. When both dowels are unseated push the pad out the bottom of the caliper. 5. Remove the inboard pad from the caliper by pulling it out of the caliper. To install: 6. Install the inboard pad in the caliper so the spring clip on the pad back engages in the caliper piston. 7. Install the outboard pad over the caliper end until the mounting dowels snap into the mounting holes in the caliper.

8. Install the caliper over the rotor onto the steering knuckle. Install the mounting bolts and sleeves and torque to 40 ft. Ibs. (51 Nm). 9. Install the tire and wheel assembly. 10. Pump the brake pedal several times to seat the pads against the rotor before attempting to move the vehicle. 11. Check the master cylinder level and add fluid as necessary. GM W-BODY: Buick Century, Regal Chevrolet Lumina, Monte Carlo Oldsmobile Cutlass Supreme, Intrigue Pontiac Grand Prix

FRONT 1. Siphon % of the brake fluid out of the master cylinder. 2. Mark the relationship of the wheel to the wheel stud for re-installation purposes. Remove the tire and wheel assembly. 3. Install 2 lug nuts to secure the rotor in place when the caliper is removed. 4. Install a large C-clamp over the top of the caliper housing and against the back of the outboard shoe. Slowly tighten the Cclamp until the caliper pistons are pushed into the caliper bore enough to slide the caliper assembly off the rotor. Use care not to tighten the C-clamp too far or the out-

board shoe retaining spring will be deformed and require replacement. 5. Remove the caliper mounting bolts and remove the brake caliper from the mounting bracket. 6. DO NOT disconnect the brake hose from the caliper or allow the brake hose to support the weight of the caliper. Support the caliper on a piece of wire out of the way. 7. Remove the outer brake pad from the caliper using a Suitable prying tool to lift the outboard shoe retaining spring so that it will clear the caliper center lug-and pull the brake pad out of the caliper. 8. Remove the inner brake pad by unsnapping the shoe springs from the piston.

To install: 9. Clean all parts well. If the brake pads were worn so badly that the brake rotor is damaged, it must be replaced. Light scoring of the rotor surfaces not exceeding 0.060 inch (1.5mm) in depth is not harmful to brake operation and may result from normal use. Brake rotors may be refinished. Do not use a rotor that, after refinishing, will not meet the thickness specification cast in the rotor. Always replace with a new rotor. 10. If not done at removal, now use a Cclamp and clamp both pistons at the same time with a metal plate or wooden block across the face of both pistons. Take care not to damage the pistons or caliper boots.

(1) Caliper Housing (2) Inboard Pad (3) Outboard Pad

(4) Wear Sensor 93006671

Front brake pads and caliper—Century, Regal, Lumina, Monte Carlo, Cutlass Supreme, Intrigue, Grand Prix

BRAKES

GENERAL MOTORS e>After bottoming the pistons into the caliper bore, lift the inner edge of each caliper boot next to the piston and press out any trapped air. Make sure each boot convolution is tucked back into place. Boots must lay flat.

11. Inspect the caliper bushings for wear. Replace as necessary. Carefully inspect the Slide bolts for corrosion. If corrosion if found, use new parts including the bushing assemblies when installing the caliper. Do not attempt to polish away corrosion. Lubricate caliper slide bolts with silicone grease. 12. Install the new inner disc brake pad in the caliper by snapping the shoe retainer springs into the piston making sure both sets of locking tabs are seated in the caliper pistons. The pad must seat flat against the pistons. 13. Install the outer pad into the caliper by snapping the outboard shoe retaining Spring over the caliper center lug and into the housing slot. The pad will slide up onto the caliper and the retaining ring will lock into place on the groove in the caliper. 14. The outer pad wear sensor should be at the trailing edge of the shoe during forward wheel rotation. 15. Install the caliper mounting boits and torque to 80 ft. Ibs. (108 Nm). 16. Remove the 2 nuts temporarily securing the rotor. 17. Install the tire and wheel assembly and tighten to specification. 18. Pump the brake pedal several times to seat the pads against the rotor. 19. Check the brake fluid level and top off as necessary. 20. Road test the vehicle to ensure the * proper brake performance.

8. Remove 2 brake lining clips from the Caliper support. To install: >In order for the rear pads to seat in the caliper properly, the cut outs in the caliper piston must be at the 6 and 12 o'clock positions. Failure to align the piston correctly can lead to brake drag, premature brake wear and possible brake failure.

9. Using a suitable type spanner tool turn the piston in to bottom the piston fully into the caliper bore. Once the caliper is fully seated make sure the cutouts in the piston are at the 6 and 12 o'clock positions. 10. After bottoming the piston into the caliper bore, lift the inner edge of boot next to the piston assembly and press out any trapped air. 11. Install 2 pad clips in the caliper support. 12. Lubricate the inner pad where it contacts the piston and mounting surfaces. 13. Install outboard and inboard shoe and linings in caliper support. Position the wear sensors downward at the leading edge of the rotor during forward wheel rotation.

4-45

14. Hold the metal shoe edge against the spring end of clips in the caliper support. Push brake pad in towards the hub, bending spring ends slightly and engage shoe notches with support abutments. 15, Pivot the caliper body assembly down over the brake pad. Compress the sleeve boot by hand as the caliper body moves into position to prevent boot damage. e> After the caliper body assembly is in position, recheck installation of the brake pad clips. If necessary, use a small prying tool to reseat or center the pad clip on the support abutments.

16. Install the sleeve bolts and torque bolt to 20 ft. Ibs. (27 Nm). 17. Install the cable support bracket with the cable attached and bolt washer. Torque bolt to 32 ft. Ibs. (43 Nm). 18. Remove the 2 lug nuts securing the rotor. 19. Install the tire and wheel assembly and tighten to specification. 20. Pump the brake pedal several times to seat the pads against the rotor. 21. Check the brake fluid level and top off as necessary.

PISTON SLOTS MUST BE ALIGNED AS SHOWN BEFORE INSTALLING CALIPER OVER SHOE & LININGS

REAR 1. Siphon % of the brake fluid out of the master cylinder. 2. Remove the tire and wheel assembly. 3. Install 2 lug nuts to secure the rotor in place when the caliper is removed. 4. Remove bolt and washer attaching cable support bracket to caliper body assembly. It is not necessary to disconnect the parking brake lever or disconnect the brake hose. 5. Remove the caliper retaining bolt. 6. Pivot the caliper body assembly up from the rotor and remove from the bracket. Do not completely remove the caliper assembly body. 7. Remove the outboard and inboard shoe and linings from the caliper support assembly.

[13] Piston Boot [14] PISTON ASSEMBLY [21] CALIPER BODY ASSEMBLY 93006672

Supreme, Positioning rear caliper piston slots—Century, Regal, Lumina, Monte Carlo, Cutlass Intrigue, Grand Prix

Please visit our web site at www.chiltonsonline.com

4-46

BRAKES GENERAL MOTORS

a

22. Adjust parking brake as necessary. 23. Road test the vehicle for proper brake performance. GM Y-BODY: Chevrolet Corvette

FRONT 1. Disconnect the negative battery cable. 2. Remove the caliper from the mounting bracket but do not disconnect the brake hose and inlet fitting assembly. 3. Suspend the caliper from the upper control arm with wire to avoid damage to the brake hose. 4. Remove the pad and lining assemblies from the caliper. To install: 5. Clean all residue from the pad and lining assembly guiding surfaces on the caliper housing and the mounting bracket. 6. Install the outboard pad with the insulator to the caliper housing and the inboard pad with the wear sensor into the caliper pistons. Press the pads firmly until they are they are fully seated. 7. Remove the support and install the caliper to the mounting bracket. 8. Connect the negative battery cable.

REAR 1. Disconnect the negative battery cable and remove % of the brake fluid from the master cylinder reservoirs. 2. Mark the relationship between the wheel to the axle flange. 3. Remove the tire and wheel assembly. Install 2 wheel nuts to retain the brake rotor. 4, Use a C-clamp to depress the caliper pistons into the caliper bores to provide clearance between the pads and the rotor. Make sure 1 end of the clamp rests on the inlet fitting bolt while the other end rests on the outboard pad. 5. Remove the caliper upper guide pin bolt and discard, then rotate the caliper on the lower guide pin to access the pad linings. Be careful not to strain the cable conduit or the hoses. 6. Remove the pads from the caliper. To install: 7. Install the outboard pad with the insulator to the caliper housing and the inboard pad with the wear sensor nearest the caliper pistons. The wear sensor must be in the trailing position during forward wheel rotation. Press the pads firmly until they are they are fully seated. 8. Rotate the caliper housing into position, then install a new upper guide pin bolt and torque 26 ft. lbs. (35 Nm).

9. Remove the wheel nuts securing the rotor to the hub and install the tire and wheel assembly. 10. Fill the master cylinder to the proper level with clean brake fluid. 11. Connect the negative battery cable, start the engine and pump the brake pedal slowly and firmly 3 times to seat the shoe and lining assemblies. GEO Metro

1. Set the parking brake and block the rear wheels. 2. Siphon a sufficient quantity of brake fluid from the master cylinder reservoir to prevent the brake fluid from overflowing from the master cylinder when removing or installing the brake pads. This is necessary, as the piston must be forced into the cylinder bore to provide sufficient clearance to install the pads. 3. Remove the wheel, then reinstall 2 lug nuts finger tight to hold the disc in place. 4. Remove the 2 caliper mounting bolts and then remove the caliper from the mounting bracket. Position the caliper out of the way and support it with wire so it doesn’t hang by the brake line. 5. Remove the brake pads, the wear indicators, the anti-squeal shims, the support plates and the anti squeal springs (if so equipped). Disassemble slowly and take note of how the parts fit together. This will save much time during reassembly. 6. Inspect the brake disc for scoring or gouging. Measure the disc for both thickness and run-out. 7. Inspect the pads for remaining thick-

' b ST

84249015

Removing caliper mounting bolts

84249016

Removing the caliper from the rotor

84249017

Removing the outside brake pad

84249014

Front disc brake assembly

84249018

Removing the inside brake pad

BRAKES

GENERAL MOTORS

a

84249019

The inside brake pad is attached to the Caliper piston with a spring clip

84249022

Using a C-clamp to compress the caliper piston

4-47

clamp to slowly press the caliper piston back into the caliper. If the piston is frozen, or if the caliper is leaking hydraulic fluid, the caliper must be overhauled or replaced. 14. Install the caliper assembly to the mounting plate. Before installing the retaining bolts, apply a thin, even coating of antiseize compound to the threads and slide surfaces. Don't use grease or spray lubricants; they will not hold up under the extreme temperatures generated by the brakes. Torque the bolts to specification. 15. Remove the 2 lugs holding the disc in place and install the wheel. 16. Check the level of the brake fluid in the master cylinder reservoir: it should be at least to the middle of the reservoir. 17. Depress the brake pedal several times and make sure that the movement feels normal. The first brake pedal application may result in a very “long” pedal due to the pistons being retracted. Always make several brake applications before starting the vehicle. Bleeding is not usually necessary after pad replacement.

18. Recheck the fluid level and add to the MAX line if necessary.

84249020

Inside pad is at top and outside pad is on bottom. Note wear indicator springs protruding from sides of outside pad

GEO Prizm

FRONT

84249023

Coat the caliper mounting bolts with antiseize during installation

84249021

Removing the anti-squeal springs from the caliper wear indicators

ness and condition. Any sign of uneven wear, cracking, heat checking or spotting is cause for replacement. Compare the wear of the inner pad to the outer pad. While they will not wear at exactly the same rate, the remaining thickness should be about the same on both pads. If one is heavily worn and the other is not, suspect either a binding caliper piston or dirty slides in the caliper mount. 8. Examine the 2 caliper retaining bolts

and the slide bushings in which they run. Everything should be clean and dry. If cleaning is needed, use spray solvents and a clean cloth. Do not wire brush or sand the bolts. This will cause grooves in the metal which will trap more dirt. Check the condition of the rubber dust boots and replace them if damaged. To install: 9. Install the pad support plates onto the mounting bracket. 10. Install new pad wear indicators onto each pad, making sure the arrow on the tab points in the direction of disc rotation. 11. Install new anti-squeal pads to the back of the pads.

12. Install the pads into the mounting bracket and install the anti-squeal springs. 13. Use a caliper compressor, or a C-

1. Siphon a sufficient quantity of brake fluid from the master cylinder reservoir to prevent the brake fluid overflowing from the master cylinder when removing or installing the brake pads. This is necessary, as the piston must be forced into the cylinder bore to provide sufficient clearance to install the pads. 2. Remove the wheel and tire assembly. 3. Install 2 lug nuts finger tight to hold the disc in place. 4. Remove the 2 caliper mounting bolts and then remove the caliper from the mounting bracket. Position the caliper out of the way and support it with wire so it doesn’t hang by the brake line. 5. Remove the 2 brake pads, the 2 wear indicators, the 4 anti-squeal shims, the 4 support plates (anti-rattle springs) and the 2 anti squeal springs, if so equipped. Disassemble slowly and take note of how the parts fit together. This will save much time during reassembly. 6. Inspect the:brake disc for scoring or gouging. Measure the disc for both thickness and run-out. Complete inspection procedures are given later in this section.

Timing belt service is covered in Section 3 of this manual

4-48

BRAKES

GENERAL MOTORS

7. Inspect the pads for remaining thickness and condition. Any sign of uneven wear, cracking, heat checking or spotting is cause for replacement. Compare the wear of the inner pad to the outer pad. While they will not wear at exactly the same rate, the remaining thickness should be about the same on both pads. If one is heavily worn and the other is not, suspect either a binding caliper piston or dirty slides in the caliper mount. 8. Examine the 2 caliper retaining bolts and the slide bushings in which they run. Everything should be clean and dry. If

84229041

Correct placement of the support plates (anti-rattle springs)

84229036

Suspend the caliper assembly out of the way to avoid hanging from the hose

84229042

Make certain the brake wear indicators are correctly installed 84229037

Removing the outer brake pad from the caliper assembly 84229034

You will need a short extension to remove

the front caliper mounting bracket bolts

84229038

Removing the inner brake pad from the caliper assembly

84229035

84229039

Carefully remove the caliper assembly from the rotor

Note the correct position support plates (anti-rattle springs)

Cleaning is needed, use spray solvents and a Clean cloth. Do not wire brush or sand the bolts. This will cause grooves in the metal which will trap more dirt. Check the condition of the rubber dust boots and replace them if damaged. To install: 9. Install the 4 pad support plates (antirattle springs) onto the mounting bracket. 10. Install new pad wear indicators onto each pad, making sure the arrow on the tab points in the direction of disc rotation. 11. Install new anti-squeal pads to the back of the pads. 12. Install the pads into the mounting bracket and install the anti-squeal springs, if So equipped. 13. Use a caliper compressor, a C-clamp Or large pair of pliers to slowly press the Caliper piston back into the caliper. If the piston is frozen, or if the caliper is leaking hydraulic fluid, the caliper must be overhauled or replaced. 14. Install the caliper assembly to the mounting plate. Before installing the retaining bolts, apply a thin, even coating of antiseize compound to the threads and slide Surfaces. Don't use grease or spray lubricants; they will not hold up under the extreme temperatures generated by the

PAE

MOTORS

4-49

brakes. Torque the bolts to 25 ft. Ibs. (34 Nm) 15. Remove the 2 lugs holding the disc in place and install the wheel. 16. Check the level of the brake fluid in the master cylinder reservoir; it should be at least to the middle of the reservoir. 17. Depress the brake pedal several times and make sure that the movement feels normal. The first brake pedal application may result in a very “long” pedal due to the pistons being retracted. Always make several brake applications before starting the vehicle. Bleeding is not usually necessary after pad replacement. 18. Recheck the fluid level and add to the “MAX” line if necessary.

REAR 1. Raise and safely support the rear of the vehicle on jackstands. Block the front wheels. 2. Siphon a sufficient quantity of brake fluid from the master cylinder reservoir to prevent the brake fluid from overflowing the master cylinder when removing or installing the brake pads. This is necessary, as the

84229066

Correct method for raising the rear caliper to gain access to the pads

Union Bolt

Brake Hose poe

4

o—

Bleeder Plug

Main Pin Boot

4

.

|

Gas ket

otor Disc

aa w=

ad

Of Cable Support

Qq

y

|

a.

Br,

GQ 74

:

Brake Cylinder

|

| Sliding Bushing

Couetit

Poe

Bracket

a

\

—-

|

'

Parking Brake Crank ih

i)

Shei pring ge

\

Stopper Pin 4

|

Torque Plate Parking Brake Strut

iS

Sliding Bushing

0 hes

Adjusting Bolt Adjusting Bolt Spring Plate

her

Dust Boot

Spring

O-Ring

Anti-Squeal Shim

4

-

Snap Ring

|Anti-Rattl Spring

Oy. Piston Seal

Adjusting Bolt Stopper :

; Pad Guide Plate

Adjusting Bolt Spring Retainer

if

(Y

Anti-Squeal Shim

Piston

Pad

Cylinder Boot

Set Ring

y)

84229065

Rear disc brake components

Heater Core replacement is covered in Section 2 of this manual

4-50

BRAKES

GENERAL MOTORS

84229067

Installing support plates and anti-rattle shims

9. Install new anti-rattle springs to the upper side of the mounting bracket. To install: 10. Install a new anti-squeal shim to the back of each pad and install the pads onto the mounting bracket. Install the pads so that the wear indicators are on the uppermost side. 11. Use GM tool J-37149, to turn the caliper piston clockwise while pressing it into the caliper bore. Proceed until it locks. 12. Lower the caliper so that the pad protrusion fits into the piston stopper groove. Install the mounting bolts and torque to 14 ft. Ibs. Install the rear wheel. 13. Depress the brake pedal until a firm pedal is obtained. 14. Repeat this procedure on the remaining caliper. 15. Pump the brakes until a firm pedal is felt. Lower the vehicle and fill the master cylinder reservoir to the correct level. Saturn

FRONT 84229068

Using the GM tool to retract the rear Caliper piston

84229069

Align the stopper groove with the pad protrusion

piston must be forced into the cylinder bore to provide sufficient clearance to install the pads. 3. Remove the wheel, then reinstall 2 lug nuts finger tight to hold the disc in place. 4. Remove the lower mounting bolt from the mounting bracket. Do not remove the caliper main (upper) pin. 5. Lift the caliper from the bottom so that it hinges upward on the upper pin. Use a piece of wire to hold the caliper up. Do not allow the brake hose to become twisted or kinked during this operation. 6. Remove the brake pads with their shims, springs and support plates.

7. Check the rotor thickness. 8. Install new pad support plates to the lower sides of the mounting bracket.

1. Remove the front wheels. 2. Remove the caliper lower lock pins. 3. Either pivot the caliper up on the guide pin or remove the upper guide pin and support the caliper from the strut using a coat hanger or length of wire. 4. Remove the 2 brake pads and the pad clips from the caliper support. Discard the old pad clips. 5. Check the caliper pins, pin boots and the piston boot for deterioration or damage. To install: 6. By hand or using a C-clamp, bottom the piston all the way into the caliper bore. 7. Carefully lift the inner edge of the piston boot by hand to release any trapped air. 8. Install new pad clips into the caliper Support. 9. Install the inner and outer brake pads into the support. If installed, remove the temporary support wire from the caliper. 10. Pivot or place the caliper body on the support and upper guide pin into position. Compress the boots by hand as the caliper is positioned onto the support. 11. Lubricate the smooth ends of the removed pin(s) with silicone grease, then install the pin(s) and torque to 27 ft. Ibs. (36 Nm). Do not get grease on the pin threads. 12. Install the wheels. 13. Prior to operating the vehicle, depress the brake pedal a few times until the brake pads are seated against the rotor,

REAR 1. Remove the rear wheels. 2. Remove the caliper lock and guide pins. 3. Remove the caliper from the support, being careful not to damage the pin boots and suspend the caliper fromawire. 4. Remove the brake pads from the support. To install: 5. Using SA91110NE piston driver tool, bottom the piston by rotating it clockwise into the caliper bore; do not use a C-clamp to press the piston into the bore. 6. Align the piston slots so they are perpendicular to the brake pads. 7. Carefully lift the inner edge of the piston boot to release any trapped air. The boot must lie flat below the level of the piston face. 8. Install new pad clips into the caliper support.

9. Install the inner and outer brake pads into the clips on the support. The pad with the wear sensor should be located outboard. The piston indentation slots should be positioned to correctly accept the brake pads. 10. Position the caliper body onto the support. Lubricate the non-threaded portion of the guide and lock pins, then install the pins and torque to 27 ft. Ibs. (36 Nm). 11. Check the position of the pad clips. If necessary, use a small suitable tool to reseat or center the pad clips on the support. Repeat the procedure for the opposite side brake pads. 12. Install the rear wheel assemblies. 13. Prior to operating the vehicle, depress the brake pedal a few times until the brake pads are seated against the rotor.

[Brake Drums REMOVAL & INSTALLATION See A ER YE Ure SR

GM C- and H-BODIES: Buick LeSabre, Park Avenue Oldsmobile Eighty Eight Royale, Ninety Eight, Regency Pontiac Bonneville 1. Remove the rear wheel. Mark the position of the wheel on the wheel studs, prior to removal, for installation reference. 2. Remove the brake drum from the hub. Mark the position of the drum on the wheel studs, prior to removal, for installation reference. 3. If the brake drum is difficult to remove, check the following;

4-51

BRAKES GENERAL MOTORS a. Make sure that the parking brake is released. b. Back off on the parking brake cable adjustment. c. Use a hammer and a small metal punch to bend in the backing plate knockout to provide access to the park brake lever. d. Insert a screwdriver through the hole and press in to push the park brake lever off its stop. This lets the brake shoes retract slightly. e. Apply a small amount of penetrating oil around the drum pilot hole. 4, Remove the brake drum from the vehicle. 5. Inspect the wheel cylinder for leakage and inspect the brake shoes for wear;

replace as necessary. 6. Inspect the brake drum for scoring, cracks or other wear; machine or replace as necessary. If machining, observe the maximum diameter specification. To instali: 7. Measure the inside diameter of the brake drum using clearance gaugeJ 21177A. 8. Turn the starwheel on the adjusting screw assembly until the brake shoe diameter is 0.050 in. (1.27mm) less than the drum inside diameter. 9. Install the brake drum onto the wheel hub, aligning the marks made during removal. 10. Install the wheel, aligning the marks made during removal. Torque the lug nuts to 100 ft. Ibs. (140 Nm). 11. Road test the vehicle and check brake operation. _ GM F-BODY: Chevrolet Camaro Pontiac Firebird 1. Matchmark the relationship of the wheel to the axle flange, then remove the wheel and tire assembly. 2. Matchmark the relationship of the drum to the axle flange and remove the brake drum. If the brake drum is difficult to remove, try the following: a. Ensure the parking brake is released. b. Back off the parking brake cable adjustment. c. Remove the adjusting hole cover or knockout plate from the backing plate. Back off the adjustment screw, using suitable brake adjusting tools. d. Use a rubber mallet to tap gently on the outer rim of the drum and/or

around the inner drum diameter by the spindle. Be careful not to deform the drum by excessive use of force. To install: 3. Adjust the brake shoes. The outside diameter of the shoe and linings should be 0.050 inch (1.27mm) less than the inside diameter of the brake drum on each wheel. 4. Install the drum, aligning the marks on the drum and the axle flange. 5. Install the wheel and tire assembly, aligning the marks on the wheel and axle flange.

GM J-BODY: Chevrolet Cavalier Pontiac Sunfire — 1. Remove the wheel and tire assembly. 2. Pull the brake drum off. It may be necessary to gently tap the rear edge of the drum to start it off the studs. If extreme resistance to removal is encountered, it will be necessary to retract the brake shoe selfadjuster screw, sometimes called the starwheel. Knock out the access hole in the brake drum and turn the adjuster to retract the linings from the drum. Install a replacement hole cover before reinstalling the drum. ->Do not hammer on the brake drum to remove it.

To install: 3. Inspect the inside of the brake drum. If worn, heavily grooved or if the opening is distorted, the drum should be refinished or replaced. If refinishing, observe the maximum drum diameter specification. 4. \nspect the wheel cylinder for signs of brake fluid leakage. Inspect the brake shoe springs and self-adjuster mechanism. The adjuster should usually be disassembled, cleaned and lubricated when the drum is removed for brake service. 5. Install the drum over the brake shoes. 6. Instal! the wheel and tire assembly. 7. Adjust the brakes. 8. Check brake operation. GM L/N and N-BODY: Buick Skylark Chevrolet Malibu Oldsmobile Achieva, Cutlass Pontiac Grand Am 1. Remove the wheel. 9. Pull the brake drum off. It may be necessary to gently tap the rear edge of the

2 } ADJUSTER SOCKET 2 ADJUSTER SCREW 3 PIVOT NUT

|

8 93006673

Brake adjuster—Skylark, Malibu, Achieva, Cutlass, Grand Am

drum to start it off the studs. If extreme resistance to removal is encountered, it will be necessary to retract the brake shoe selfadjuster screw, sometimes called the starwheel. Knock out the access hole in the brake drum and turn the adjuster to retract the linings from the drum. Install a replacement hole cover before reinstalling the drum. «DO NOT hammer on the brake drum to remove it.

To install: 3. Inspect the inside of the brake drum. lf worn, heavily grooved or if the opening Is distorted, the drum should be refinished or replaced. If refinishing, observe the maximum drum diameter specification. 4. Inspect the wheel cylinder for signs of brake fluid leakage. Inspect the brake shoe springs and self-adjuster mechanism. The adjuster should usually be disassembled, cleaned and lubricated when the drum is removed for brake service. 5. Install the drum over the brake shoes. 6. Install the wheel. Adjust the brakes. 7. Check brake operation. GM W-BODY: Buick Century, Regal Chevrolet Lumina, Monte Carlo Oldsmobile Cutlass Supreme, Intrigue Pontiac Grand Prix 1. Mark the relationship of the wheel to the axle flange to help maintain wheel balance after assembly. 2. Remove the tire and wheel assembly. 3. Mark the relationship of the brake drum to the axle flange. 4. |f difficulty is encountered in removing the brake drum, the following steps may be of assistance. qa. Make sure the parking brake is released.

For complete Engine Mechanical specifications, see Section 1 of this manual

4-52

BRAKES GENERAL MOTORS

b. Back off the parking brake cable adjustment. c. Remove the access hole plug from the backing plate. d. Using a screwdriver, back off the adjusting screw. é. Install the access hole plug to prevent dirt or contamination from entering the drum brake assembly. f. Use a small amount of penetrating oil applied around the brake drum pilot hole. g. Carefully remove the brake drum from the vehicle. 5. After removing the brake drum it should be checked for the following: a. Inspecting for cracks and deep grooves. b. Inspect for out of round and taper. c. Inspecting for hot spots (black in color). To install: 6. Install the brake drum onto the vehicle aligning the reference marks on the axle flange. 7. Install the tire and wheel assembly, torquing it to specifications. 8. Road test for proper brake operation. GEO Metro

1. Make sure the parking brake is fully released. 2. Remove the rear wheels. 3. Without ABS, perform the following: a. Remove the dust cap. Using a hammer and punch, unstake the spindle nut. b. Remove the spindle nut and washer. Discard the spindle nut.

4. |f equipped with ABS, perform the following: a. Remove the 2 brake drum retaining SCIeWS. b. Install 2, 8mm screws in the 2 opposite threaded holes on the brake drum. c. Alternately rotate each screw slowly until the 2 screws pull the drum from the hub and wheel studs. 9. Remove the drum from the vehicle. Remove the 2, 8mm screws from the drum. 6. Remove the rear brake drum assembly from the vehicle. /. Remove the brake drum. If the drum is frozen on the hub, tap the drum with a rubber mallet or wooden hammer handle to loosen it. 8. Inspect the brake shoes for wear and/or damage; replace as necessary. Inspect the wheel cylinder for signs of brake fluid leakage; replace as necessary.

9. Inspect the drum for cracks, scoring or other wear; machine or replace as necessary. If machining, observe the maximum drum diameter specification. To install: 10. Install the brake drum assembly onto the spindle. 11. On non-ABS equipped models: a. Install the washer and a new spindle nut. b. Torque the spindle nut to 74 ft. Ibs. (100 Nm). c. Stake the spindle nut. d. Install the dust cap. 12. On ABS equipped models, install the brake drum and tighten the brake drum retaining screws. 13. Install the wheel. 14. To adjust the brakes, depress the brake pedal 3-5 times with approximately 66 Ibs. (30 kg) of pressure. 15. Road test and check brake operation. GEO Prizm

1. Make sure the parking brake is fully released. 2. Remove the rear wheel. 3. Without ABS, perform the following: a. Remove the dust cap. Using a hammer and punch, unstake the spindle nut.

b. Remove the spindle nut and washer. Discard the spindle nut. 4. |f equipped with ABS, perform the following:

a. Remove the 2 brake drum retaining SCrews. b. Install 2, 8mm screws in the 2 opposite threaded holes on the brake drum. c. Alternately rotate each screw slowly

until the 2 screws pull the drum from the hub and wheel studs. 5. Remove the drum from the vehicle. Remove the 2, 8mm screws from the drum. 6. Remove the rear brake drum assembly from the vehicle. 7. Mark the position of 1wheel lug stud in relation to a hole in the drum. This will allow the drum to be reinstalled in the original position. 8. Remove the brake drum. If the drum is frozen on the hub, tap the drum with a rubber mallet or wooden hammer handle to loosen it. 9. Inspect the brake shoes for wear and/or damage and replace as necessary. Inspect the wheel cylinder for signs of brake fluid leakage; replace as necessary. 10. Inspect the drum for cracks, scoring or other wear: machine or replace as necessary. If machining, observe the maximum drum diameter specification. To install: 11. Install the brake drum assembly onto the spindle. 12. On non-ABS equipped models: a. Install the washer and a new spindle nut. b. Torque the spindle nut to 74 ft. Ibs. (100 Nm). C. Stake the spindle nut. d. Install the dust cap. 13. On ABS equipped models, install the brake drum and tighten the brake drum retaining screws. 14. Install the drum, observing the matchmarks made earlier. Keep the drum Straight while installing it, or it could damage the brake shoes. 15. Install the wheel. 16. To adjust the brakes, depress the brake pedal 3-5 times with approximately 66 Ibs. (30 kg) of pressure. 17. Road test and check brake operation. Saturn

93006674

Backing off the rear brake adjuster—Prizm

1. Remove the rear wheel and tire assembly. 2. Remove the brake drum. 3. If necessary, turn the starwheel of the brake adjuster assembly to loosen the brake shoes and allow for drum removal. 4. Remove the drum. To install: 9. Install brake drum over brake shoes and onto hub. 6. Install tire and wheel assembly, Torque to the proper specification. /. Adjust brakes following the proper procedure. 8. Road test for braking operation.

BRAKES

GENERAL MOTORS from the shoe. DO NOT remove the parking brake lever from the cable end unless it is being replaced. 8. Using J 38400, lift the end of the retractor spring from the adjuster shoe assembly. Insert the hook end of the tool between the retractor spring and the shoe. Pry slightly to remove the spring end from the hole in the shoe. Pry the end of the retractor spring toward the axle with the flat end of the tool, until the spring snaps down off the shoe web onto the backing plate. Leave the spring there. Do not remove it. 9. Remove the brake shoe. To install: 10. Check the backing plate attaching bolts to make sure that they are tight. Use fine emery cloth to clean all rust and dirt from the shoe contact surfaces on the plate and lubricate with high temperature grease. Check the wheel cylinder for signs of leakage. 11. Clean all parts completely in brake solvent and air dry. 12. Clean the backing plate shoe contact points. 13. Inspect the inside of the brake drum. lf worn, heavily grooved or if the opening is distorted, the drum should be machined or replaced. If machining, observe the maximum drum diameter specification. 14. Disassemble, clean and lubricate the adjuster screw. 15. Position the brake shoe that connects to the parking brake lever, on the backing

Brake Shoes REMOVAL & INSTALLATION GM C- and H-BODIES: Buick LeSabre, Park Avenue Oldsmobile Eighty Eight Royale, Ninety Eight, Regency Pontiac Bonneville 1. Remove tie rear wheel. Mark the position of the wheel to the wheel studs, prior to removal, for installation reference. 2. Remove the brake drum. Mark the position of the brake drum to the wheel Studs, prior to removal, for installation reference. 3. Using tool J 38400 brake spanner tool and remover, remove the actuator spring from the adjuster lever. Use care not to distort the spring when removing it. 4. Lift the end of the retractor spring from the adjuster shoe assembly. Insert the hook end of the J-38400 between the retractor spring and the shoe. Pry slightly to remove the spring end from the hole in the shoe. 5. Pry the end of the retractor spring toward the axle with the flat end of the tool until the spring snaps down off the shoe web onto the backing plate. 6. Remove the one brake shoe and remove the adjuster assembly. 7. Disconnect the parking brake lever

Bes

1 2 3.

ACCESS

HOLE

ADJUSTER ADJUSTER PIVOT

NUT

PLUG.

SOCKET SCREW

4

RETRACTOR

5

ADJUSTER

6

WHEEL

CYLINDER

7

BLEEDER

8

BOLT

9

SPRING SHOE

VALVE

AND

LINING

10

BACKING

PLATE

PARK

BRAKE

SHOE

BRAKE

LEVER

11

PARK

12

ACTUATOR

SPRING

13.

ADJUSTER

ACTUATOR

AND

LINING

93006677

Avenue, Eighty Eight, Royale, Exploded view of the drum brake components—LeSabre, Park lle Bonnevi , Regency Ninety Eight,

4-53

plate. Using J-38400, pull the end of the retractor spring up to rest on the web of the shoe. Pull the end of the retractor spring up until it snaps into the slot in the brake shoe. 16. Connect the parking brake lever. 17. Install the remaining shoe and the adjuster screw assembly. 18. Position the brake shoe using J38400 and pull the end of the retractor spring up to rest on the web of the shoe. Pull the end of the retractor spring up until it snaps into the slot in the brake shoe. 19. Using J-38400, spread the brake shoes and work the adjuster screw into position. 20. Install the actuator spring with the Ushaped end going through the web. 21. Measure the inside diameter of the brake drum using clearance gaugeJ21177-A. 22. Turn the starwheel on the adjusting screw assembly until the brake shoe diameter is 0.050 in. (1.27mm) less than the drum inside diameter. 23. Install the brake drum onto the wheel hub, aligning the marks made during removal. 24. Install the wheel, aligning the marks made during removal. Torque the lug nuts to 100 ft. Ibs. (140 Nm). 25. Repeat the procedure for the brake shoe assembly on the opposite side of the vehicle. 26. Apply and release the brake pedal 30-35 times with normal pedal force. Pause about 1 second between applications. 27. Road test the vehicle and check brake operation. GM F-BODY: Chevrolet Camaro Pontiac Firebird

1. Matchmark the relationship of the wheel to the axle flange, then remove the wheel and tire assembly. 2. Matchmark the relationship of the drum to the axle flange and remove the brake drum. 3. Remove the return springs using a Suitable tool. 4. Remove the hold-down springs and pins. Remove the actuator pivot. 5. Remove the actuator link while lifting up on the actuator. 6. Remove the actuator lever and lever return spring. 7. Remove the shoe guide, parking brake strut and strut spring. 8. Remove the brake shoes and discon-

For Accessory Drive Belt illustrations, see Section 1 of this manual

4-54 SESSA

a

EAI

BRAKES

GENERAL MOTORS

AS

EE

IO

ETI, EEA SE

nect the parking brake lever from the appropriate shoe. 9. Remove the adjusting screw assembly and spring. To install: 10. Install the parking brake lever on the appropriate shoe by hooking the lever tab into the slot. 11. Install the adjusting screw and spring. Lubricate the adjusting screw with Suitable brake grease.

12. Clean and lubricate the contact points of the backing plate, then install the brake shoe assemblies and the parking brake cable to the backing plate.

1

RETURN SPRING RETURN SPRING HOLD DOWN SPRING 4 BEARING SLEEVE 5S HOLD-DOWN PIN 6 ACTUATOR LINK 7 ACTUATOR LEVER 8 LEVER RETURN SPRING 9 PARKING BRAKE STRUT 10 STRUT SPRING

2 3

ET TEE EOI YEERS

I

SIS

DIES LIE IE IT

LI IT

13. Install the parking brake strut and strut spring by spreading the shoes apart. The strut end with the spring engages the parking brake lever and shoe. The other end engages the opposite shoe. 14. Install the shoe guide, actuator lever and lever return spring. 15. Install the hold-down pins, actuator pivot and springs. 16. Install the actuator link on the anchor pin. Install the actuator link into the actuator lever while holding up on the lever. 17. Install the shoe return springs and adjust the brakes. When properly adjusted,

11. 12 13 14 15 16 17 18 19 20

Exploded view of drum brake components—Cavalier, Sunfire

PRIMARY SHOE AND LINING SECONDARY SHOE AND LINING ADJUSTING SCREW SPRING SOCKET PIVOT NUT ADJUSTING SCREW RETAINING RING PIN PARKING BRAKE LEVER BLEEDER VALVE

EO

DTT EE

OTT IIE

PEL

CET

OT

ET

ETT,

the brake shoe linings will be approximately 0.050 inch (1.27mm) less than the inner diameter of the brake drum. 18. Align and install the brake drum, then the wheel and tire assembly. GM J-BODY: Chevrolet Cavalier Pontiac Sunfire

1. Remove the tire and wheel assembly. 2. Remove the brake drum. It may be necessary to gently tap the rear edge of the drum to start it off the studs. If extreme resistance to removal is encountered, it will

21 22 23 24 25. 26 27 30 32. 33.

BOT BOOT PISTON SEAL SPRING ASSEMBLY WHEEL CYLINDER BACKING PLATE SHOE RETAINER ANCHOR PIN SHOE PADS 93006697

BRAKES

GENERAL MOTORS be necessary to retract the brake shoe selfadjuster screw, sometime called the starwheel. Turn the adjuster to retract the linings from the drum. Do not hammer on the brake drum to remove it.

3. Remove the upper return springs from the shoes using tool J-8057 brake spring tool. 4. Remove the hold-down springs using J-8049 brake spring tool. 5. Remove the shoe hold-down pins from behind the brake backing plate. 6. Lift up the actuator lever for the selfadjusting mechanism and remove the actuating link. Remove the actuator lever, pivot, and the pivot return spring. 7. Spread the shoes apart to clear the wheel cylinder pistons, then remove the parking brake strut and spring. 8. Disconnect the parking brake cable from the lever. Remove the shoes, still connected by their adjusting screw spring. 9. With the shoes removed, note the position of the adjusting spring and remove the spring and adjusting screw. 10. Remove the C-clip from the parking brake lever and remove the lever from the secondary shoe. 11. Use a damp cloth to remove all dirt and dust from the backing plate and brake parts.

To install: 12. Check the backing plate attaching bolts to make sure they are tight. Use fine emery cloth to clean all rust and dirt from the shoe contact surfaces on the plate and lubricate with brake grease. Check the wheel cylinder for signs of leakage. 13. Clean all parts completely in brake solvent and air dry. 14. Clean the backing plate shoe contact points. 15. Inspect the inside of the brake drum. lf worn, heavily grooved or if the opening is distorted, the drum should be refinished or replaced. 16. Inspect the brake shoe springs and self-adjuster mechanism. Disassemble the adjuster mechanism and clean the threads and coat with grease. Make sure the adjuster assembly turns freely before installing in the vehicle. 17. Install the parking brake lever on the secondary shoe and secure with C-clip. 18. Install the adjusting screw and spring on the shoes, connecting them together. The coils of the spring must not be over the star-

wheel on the adjuster. The left and right hand Springs are not interchangeable. 19. Spread the shoe assemblies apart and connect the parking brake cable. Install the shoes on the backing plate, engaging the shoes at the top temporarily with the wheel cylinder pistons. Make sure the starwheel on the adjuster is lined up with the adjusting hole in the backing plate, if equipped. 20. Spread the shoes apart slightly and install the parking brake strut and spring. Make sure the end of the strut without the spring engages the parking brake lever. The end with the spring engages the primary shoe (the one with the shorter lining). 21. Install the actuator pivot, lever and return spring. Install the actuating link in the shoe retainer. Lift up the actuator lever and hook the link into the lever. 22. Install the hold-down pins through the back of the plate using J-805/. Install the lever pivots and hold-down springs. Install the shoe return springs using J8049. Be careful not to stretch or distort the springs. 23. Make sure the linings are in the right place, the self-adjusting mechanism is correctly installed, and the parking brake parts are hooked up. 24. Measure the distance from the edge of the primary lining to the edge secondary lining, then measure the inside width of the drum. Adjust the linings by means of the adjuster so the drum will fit onto the linings. 25. Install the hub and bearing assembly onto the axle if removed. Torque the retaining bolts to 35 ft. Ibs. (55 Nm.). 26. Install the drum. 27. Install the wheel and tire assembly. 28. Adjust the brakes. Install a rubber hole cover in the adjustment knock-out hole after the adjustment is complete. Adjust the parking brake. 29. Road test the vehicle and verify proper brake operation.

GM L/N and N-BODY: Buick Skylark Chevrolet Malibu Oldsmobile Achieva, Cutlass Pontiac Grand Am 1. Remove 2. Remove 3. Remove from the shoes spring tool.

the tire and wheel assembly. the brake drum. the upper return springs using tool J-8057 brake

4-59

4. Remove the hold-down springs using J-8049 brake spring tool. 5. Remove the shoe hold-down pins from behind the brake backing plate. 6. Lift up the actuator lever for the selfadjusting mechanism and remove the actuating link. Remove the actuator lever, pivot, and the pivot return spring. 7. Spread the shoes apart to clear the wheel cylinder pistons and remove the parking brake strut and spring. 8. Disconnect the parking brake cable from the lever. Remove the shoes, still connected by their adjusting screw spring. 9. With the shoes removed, note the position of the adjusting spring and remove the spring and adjusting screw. 10. Remove the C-clip from the parking brake lever and the lever from the secondary shoe. 11. Use a damp cloth to remove all dirt and dust from the backing plate and brake parts. To install: 12. Check the backing plate attaching bolts to make sure they are tight. Use fine emery cloth to clean all rust and dirt from the shoe contact surfaces on the plate and lubricate with brake grease. Check the wheel cylinder for signs of leakage. 13. Clean all parts completely in brake solvent and air dry. Clean the backing plate shoe contact points. 14. Inspect the inside of the brake drum. If worn, heavily grooved or if the opening is distorted, the drum should be refinished or replaced. 15. Inspect the brake shoe springs and self-adjuster mechanism. Disassemble the adjuster mechanism and clean the threads and coat with grease. Make sure the adjuster assembly turns freely before installing in the vehicle. 16. Install the parking brake lever on the secondary shoe and secure with C-clip. 17. Install the adjusting screw and spring on the shoes, connecting them together. The coils of the spring must not be over the starwheel on the adjuster. The left and right hand springs are not interchangeable. 18. Spread the shoe assemblies and connect the parking brake cable. Install the shoes on the backing plate, engaging the shoes at the top temporarily with the wheel cylinder pistons. Make sure the starwheel on the adjuster is lined up with the adjusting hole in the backing plate, if equipped. 19. Spread the shoes slightly and install

For Tire, Wheel and Ball Joint specifications, see Section 1 of this manual

4-56

BRAKES GENERAL MOTORS 27. Road test the vehicle and verify proper brake operation. GM W-BODY: Buick Century, Regal Chevrolet Lumina, Monte Carlo Oldsmobile Cutlass Supreme, Intrigue Pontiac Grand Prix 1. Remove the tire and wheel assembly. 2. Remove the brake drum. 3. Using tool J-38400 brake spanner and remover, remove the actuator spring from the adjuster lever. Use care not to distort the spring when removing it.

>: CAUTION During the following steps when removing the retractor spring from either shoe and lining assembly, do not over stretch the spring. This will reduce its effectiveness. Keep fingers away from retractor spring to prevent fingers from being pinched between the spring and shoe web or spring and the backing plate. 12 (1) Socket, Brake Adjuster (2) Screw, Brake Adjuster (3) Nut, Brake Pivot

(4) Spring, Retractor (5) Brake Shoe and Lining (6) Cylinder, Wheel Brake (7) Valve, Bleeder

(8) Bolts, Wheel Cylinder (9) Plate, Brake Backing (10) Brake Shoe and Lining (11) Lever, Park Brake

(12) Spring Adjuster Actuator 93006678

Drum brake components, exploded view—Skylark, Malibu, Achieva, Cutlass, Grand Am

the parking brake strut and spring. Make sure the end of the strut without the spring engages the parking brake lever. The end with the spring engages the primary shoe (the one with the shorter lining). 20. Install the actuator pivot, lever and return spring. Install the actuating link in the shoe retainer. Lift up the actuator lever and hook the link into the lever. 21. Install the hold-down pins through the back of the plate using J-8057. Install the lever pivots and hold-down springs. Install the shoe return springs using J8049. Be careful not to stretch or distort the Springs. 22. Make sure the linings are in the right

place, the self-adjusting mechanism is correctly installed, and the parking brake parts are hooked up. 23. Measure the distance from the edge of the primary lining to the edge secondary lining, then measure the inside width of the drum. Adjust the linings by means of the adjuster so the drum will fit onto the linings. 24, Install the hub and bearing assembly onto the axle if removed. Torque the retaining bolts to 35 ft. Ibs. (55 Nm). 25. Install the drum and the wheels. 26. Adjust the brakes. Install a rubber hole cover in the adjustment knock-out hole after the adjustment is complete. Adjust the parking brake.

4. Lift the end of the retractor spring from the adjuster shoe assembly. Insert the hook end of the J-38400, between the retractor spring and the shoe. Pry slightly to remove the spring end from the hole in the shoe. 5. Pry the end of the retractor spring toward the axle with the flat end of the tool until the spring snaps down off the shoe web onto the backing plate. 6. Remove the one brake shoe and remove the adjuster assembly. 7. Disconnect the parking brake lever from the shoe. DO NOT remove the parking brake lever from the cable end unless it is being replaced. 8. Using J-38400, lift the end of the retractor spring from the adjuster shoe assembly. Insert the hook end of the J38400, between the retractor spring and the shoe. Pry slightly to remove the spring end from the hole in the shoe. Pry the end of the retractor spring toward the axle with the flat end of the tool until the spring snaps down off the shoe web onto the backing plate. 9. Remove the brake shoe. To install: 10. Clean all the brake spring completely with brake solvent and allow to air dry. 11. Disassemble, clean and lubricate the adjuster screw. Once lubricated, reassemble. 12. Clean the backing plate and after it is

BRAKES

GENERAL MOTORS

4-5/

SPRING, ACTUATOR ACTUATOR, ADJUSTER SHOE AND LINING, ADJUSTER LEVER, PARKING BRAKE SHOE ANDO LINING, PARKING BRAKE SPRING, RETRACTOR woa~wQn— 13 PLATE ASSEMBLY, BACKING 14 PLUG, ACCESS HOLE 1§ BOLT/SCREW ASSEMBLY, ADJUSTING

93006679

Rear brake assembly component alignment—Century, Regal, Lumina, Monte Carlo, Cutlass Supreme, Intrigue, Grand Prix

dry apply a thin coat of brake grease to the brake shoe contact points on the backing plate. 13. Position the brake shoe that connects to the parking brake lever, on the backing plate. Using J-38400, pull the end of the retractor spring up to rest on the web of the shoe. Pull the end of the retractor spring up until it snaps into the slot in the _ brake shoe. 14, Connect the parking brake lever. 15. Install the remaining shoe and the adjuster screw assembly. 16. Position the brake shoe, using J38400, pull the end of the retractor spring up to rest on the web of the shoe. Pull the end of the retractor spring up until it snaps into the slot in the brake shoe. 17. Using J-38400, spread the brake shoes and work the adjuster screw into position. 18. Install the actuator spring with the Ushaped end going through the web. 19. Install the brake drum. 90. Install the tire and wheel assembly. 21. Adjust the brakes. 29. Road test for proper brake operation.

GEO Metro

1. Remove the rear wheels. 2. Remove the brake drum. 3. Remove the upper and lower return springs from the brake shoes. 4. Remove the anti-rattle spring and brake shoe adjustment strut. 5. Remove the primary and secondary brake shoe hold-down springs by pressing in and turning the hold-down pins.

1 2

HOLO-DOWN HOLD-DOWN

SPRINGS PINS 93006G80

Removing the shoe hold-down springs— Metro

6. Remove the parking brake cable. 7. Inspect all parts for wear and/or damage and replace as necessary. 8. Clean the brake backing plate and all parts to be reused with suitable brake parts cleaner and allow it to dry. To install: 9. Lubricate all contact points on the backing plate with grease. 10. Install the hold-down pins on the backing plate. 11. Install the brake cable. 12. Install the primary and secondary brake shoes to the vehicle and secure with the hold-down springs. 13. Install the brake adjustment strut and anti-rattle spring. 14. Install the upper and lower return springs to the primary and secondary brake shoes. 15. Install the brake drum. 16. Install the rear wheels. 17. Press the brake pedal 3-5 times with approximately 66 Ibs. (30 kg) pressure to adjust the brake shoe clearance. 18. Check to ensure the brake drum is free from dragging and proper braking is obtained.

For Wheel Alignment specifications, see Section 1 of this manual

4-5§

q

BRAKES GENERAL MOTORS

GEO Prizm 1. Remove the rear wheels. 2. Remove the brake drum. Inspect the drum for wear and/or damage. Replace or machine the drum as necessary. 3. Remove the upper return spring. 4. Remove the front brake shoe holddown spring, retainers and pin. 5. Remove the anchor spring from the front brake shoe and remove the front brake shoe. 6. Remove the rear brake shoe holddown spring, retainers and pin. 7. Remove the automatic adjusting lever spring and the adjuster. 8. Remove the parking brake cable. 9. Use a suitable tool to spread the Cclips and remove the automatic adjuster lever and parking brake lever from the rear brake shoe. 10. Clean all parts and the brake backing plate with an approved brake parts cleaner. To install: 11. Before reinstallation, apply grease to the contact points on the backing plate and pivot points on the adjuster lever. 12. Install the parking brake and automatic adjuster levers to the rear brake shoe. 13. Install new C-clips and use pliers to install them. Do not bend more than necessary to hold in place. 14. Check the clearance between the parking brake lever and the brake shoe using a feeler gauge. The clearance must be at least 0.0138 in. (0.35mm). If the clearance is not as specified, replace the shim between the lever and shoe. 15. Connect the parking brake cable. 16. Install the adjuster and the lever spring. 17. Install the rear brake shoe on the backing plate with the end of the shoe inserted in the wheel cylinder and the adjuster in place. Install the hold-down spring, retainer and pin. 18. Install the anchor spring between the front and rear shoe. 19. Install the front brake shoe with the end of the shoe inserted in the wheel cylinder and the adjuster in place. 20. Install the hold-down spring, retainers and pin. 21. Connect the return spring. 22. Adjust the brake shoes. When adjusted properly, the outside diameter of the brake shoes will be approximately 0.024 in. (0.6mm) less than the inner diameter of the brake drum. 23. Install the brake drum and the wheel. 24. Road test and check for proper brake operation.

6 backing plate raised shoe contact pads,

Saturn

1. Remove the wheels and brake drums. 2. Remove the lower return and adjuster springs using a universal brake spring remover. Do not over extend the springs or they will damaged and will need to be replaced. 3. Compress the leading brake shoe hold-down cup and spring while removing the pin from the rear of the backing plate. Release spring compression, then remove the hold-down cup and spring. 4. Pull the leading shoe towards the front of the vehicle and remove the adjuster assembly and lever. It may be necessary to turn the adjuster starwheel to shorten the adjuster’s length. 5. Remove the leading shoe by twisting the shoe out of engagement with the upper return spring. 6. Remove the upper return spring from the park brake shoe, then remove the park brake shoe hold-down cup, spring and pin assembly. 7. Push the park brake shoe lever into the cable spring while disengaging the cable from the end lever and remove the parking brake shoe, lever and cable spring from the vehicle. 8. Remove the retainer and wave washer, then remove the park brake lever from the shoe. 9. Disassemble the brake adjuster socket, screw and nut, then clean the components in denatured alcohol. Inspect the assembly, making sure the screw threads smoothly into the adjusting nut over the full threaded length. 10. Inspect the wheel cylinder for signs of leakage and for cut or damaged boots. Do not attempt to repair a damaged cylinder, the assembly must be replaced. To install: 11. Lubricate the adjuster assembly, the

93006681

Rear brake shoe and adjuster installation—Saturn

the brake lever pin and surfaces which contact brake shoe webs with brake lubricant. 12. Install the park brake lever onto the pin on the brake shoe and secure with the wave washer and retainer clip. Crimp the ends of the retainer to secure the brake lever. 13. Install the cable spring into the cage on the park brake lever, then install the cable through the spring and onto the lever. 14. Install the park brake shoe using the hold-down cup assembly; use a universal Spring cup remover/installer tool. Make sure the shoe is correctly engaged into the wheel cylinder (top) and the anchor (bottom). 15. Install the long straight end of the upper return spring into the back hole in the park brake shoe, position the other brake shoe and install the other end of the spring into the back of the leading shoe. 16. Pull the lead shoe toward the front of the vehicle and install the adjuster between the park and leading brake shoes. Verify that the adjuster notches properly engage the brake shoe notches and that the shoe is properly aligned in the wheel cylinder and anchor. 17. Install the adjuster lever and adjuster Spring. Make sure the notch on the lever engages the pin on the park shoe and the notch on the adjusting socket. The lower leg of the lever should engage the teeth of the Starwheel adjuster assembly. 18. Secure the leading brake shoe using the hold-down cup assembly. 19. Install the adjuster spring to the upper side of the brake shoes with the short end to the lead shoe and the long end to the adjuster lever. Then install the lower return spring into the lower holes of the shoes. 20. Verify the correct location of all brake components, if necessary, use the other side brake assembly for comparison. 21. Using a suitable drum clearance gauge, Measure the inner diameter of the brake drum and adjust the outside diameter of the brake shoes to 0.02 inch (0.50mm) less than the inner diameter of the drum. 22. Repeat the procedure for the oppoSite brake shoes and install the brake drums, 23. If the wheel cylinders have been replaced, bleed the hydraulic brake system. 24. Install the rear wheels, _ 25. Apply and release the brake pedal 20 times to allow the adjuster to properly position the brake shoes, 26. Check and adjust the parking brake Cable, as necessary,

CHRYSLER CORPORATION 1998-02 Chrysler-Concorde * LHS * 300M * Dodge-Intrepid * Eagle-Vision 5-22 DRIVES RAINGH coe 5-2 REPAIR.................. ENGINE 5-21 SSR iy. BUELS YSTEMS PRECAUTIONS ................... 5-2 STEERING AND SUSPENSION .................. 5-26

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Ignition Timing

A/C compressor and position it aside without disconnecting the lines \V-band clamps at the exhaust man-

ADJUSTMENT All models utilize a Distributorless Ignition System (DIS). It is a fixed ignition timing system, which means that basic ignition timing cannot be adjusted. All spark advance is permanently set by the Powertrain Control Module (PCM).

ifolds Speed control and throttle cables from the throttle body Heater hoses and the coolant hoses at the recovery tank All vacuum lines, electrical connectors and ground straps from the engine

Engine Assembly

3.5L (VIN F) Engine 1. Install or connect the following: e Alternator B+ wire and terminal nut and torque to 89 inch Ibs. (10 Nm) e Alternator field circuit plug « Alternator e Drive belt e Pivot bolt and lower mounting bolt 2. Using a belt tension gauge, torque the drive belt until the tension gauge reads 120 Ibs. (534 N) for a used belt or 140-160 lbs. (623-711 N) for a new belt. 3. Torque the pivot and lower mounting bolts to 40 ft. Ibs. (54 Nm). 4. Install the bracket and connect the negative battery cable 5. Connect the negative battery cable.

3.2L and 3.5L (VIN G) Engines 1. Install or connect the following: e Alternator B+ wire and terminal nut; then, torque the nut to 89 inch Ibs. (10 Nm) e Alternator field circuit plug e Alternator e Drive belt Pivot bolt and lower mounting bolt 2. Using a belt tension gauge, torque the “V” drive belt until the tension gauge reads 120 Ibs. (534 N) for a used belt or 440-160 Ibs. (623-711 N) for a new belt. 3. Using a belt tension gauge, torque the Poly “V”" belt until the tension gauge reads 120 Ibs. (534 N) for a used belt or 180-200 Ibs. (792-880 N) for a new belt. 4. Install the bracket. 5. Torque the bolts to the following specifications: a. Pivot bolt to 40 ft. Ibs. (54 Nm). b. 8mm mounting bolt to 30 ft. Ibs. (41 Nm). c. 10mm mounting bolt to 40 ft. Ibs. (54 Nm). 6. Connect the negative battery cable.

Catalytic converter down pipes-torear mount fasteners Structural collar mounting bolts and collar

REMOVAL & INSTALLATION 2.7L Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Relieve the fuel system pressure. 3. Drain the cooling system. 4. Drain the engine oil. 5. Remove or disconnect the following: Negative battery cable at the remote terminal near the right strut tower Hood Wiper arms, cowl covers and cowl support Air intake duct and air cleaner assembly Upper radiator crossmember Hood release cable from the latch Cooling fan assembly Upper and lower radiator hoses

6. Matchmark the flexplate-to-torque converter and remove the torque converter bolts. e Both transaxle cooler line-toengine brackets e Starter and Crankshaft Position (CKP) sensor e 2 lower transaxle-to-engine bolts e Exhaust Gas Recirculation (EGR) valve assembly

A/C condenser-to-radiator fasteners Radiator Accessory drive belts Power steering pump and position it aside without disconnecting the lines

STRUCTURAL COLLAR 9300BG02

Removing the structural collar—2.7L engine

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Guide For complete service labor times, order Nichols’ Chilton Labor

5-4

CHRYSLER CORPORATION CONCORDE © LHS © 300M ¢ INTREPID ¢ VISION

¢ Fuel line and engine harness from the throttle body bracket 7. Remove the following brackets from the double-ended transaxle-to-engine bolts: e Wiring harness bracket e Transaxle shift cable bracket e Throttle body support bracket e Upper transaxle-to-engine bolts ¢ Both (right and left) engine mount isolators-to-engine mount bracket fasteners

> WARNING Be careful not to damage the intake manifold or cylinder head covers when lifting the engine. 8. Attach an engine lifting fixture to the engine. 9. Support the transaxle with a jack and remove the engine. To install: 10. Install the engine. 11. Align the engine mounts and install the fasteners, but do not tighten them at this time.

Do not tighten the transaxle-toengine bolts until all of the bolts

have been hand-started and the engine is flush against the transaxle. 12. Install the transaxle-to-engine bolts.

Torque the bolts to 75 ft. Ibs. (102 Nm). 13. Remove the engine support fixture. 14. Torque the engine mount isolator-tobracket fasteners to 45 ft. Ibs. (61 Nm). 15. Align the matchmarks and install the flexplate-to-torque converter bolts. Torque the bolts to 55 ft. Ibs. (75 Nm). 16. Install the starter and the CKP sensor. 17. Install the structural collar using the following sub-steps: a. Torque the vertical collar-to-oil pan bolts to 10 inch Ibs. (1.1 Nm). b. Torque the collar-to-transaxle bolts to 40 ft. Ibs. (65 Nm). c. Torque the center vertical bolt to 40 ft. Ibs. (65 Nm); then, the remaining vertical bolts to the same torque. 18. Complete the installation by reversing the removal procedure. Keep the following in mind: e Use new V-band clamps and torque them to 100 inch Ibs. (11 Nm) ¢ Torque the A/C compressor and power steering pump fasteners to 21 ft. Ibs. (28 Nm) ¢ Negative battery cable

19. level. 20. 21. repair

Fill the cooling system to the proper Fill the engine with clean oil. Start the vehicle, check for leaks and if necessary.

3.2L and 3.5L Engines

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the engine oil. 3. Drain the engine coolant. 4. Properly relieve the fuel system pressure. 5. Remove or disconnect the following: Negative battery cable Hood Wiper arms Cowl covers and supports Air cleaner and air inlet duct Upper radiator support and hood release cable Fan module Accessory drive belts Upper and lower radiator hoses Engine oil and transmission cooler lines at the radiator Alternator, if necessary. A/C compressor mounting bolts and position it aside with the lines connected Power steering pump mounting bolts and position the pump aside \V-band clamp at the right exhaust manifold Right side catalytic converter down pipe bracket fasteners Fuel lines Throttle and cruise control cables All vacuum hoses Ground straps at both cylinder heads

The intake manifold is a composite design and should be removed before lifting the engine or it may be damaged and require replacement.

Engine support fixture attaching points—2.7L engine

9300BG03

¢ Upper intake manifold and cover the openings Heater hoses Throttle body support brackets Upper transaxle-to-engine mounting bolts All electrical and vacuum hose connections Structural collar and matchmark the flexplate-to-torque converter position Flexplate-to-torque converter mounting bolts

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CHRYSLER CORPORATION

CONCORDE ¢ LHS ¢ 300M ¢ INTREPID ¢ VISION

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manifold and torque to 100 inch lbs. (11 Nm) Right-side catalytic converter mounting bracket fasteners A/C compressor and torque the bolts to 21 ft. Ibs. (28 Nm) Alternator and its wiring harness Radiator Power steering pump Engine oil and transaxle cooler lines Radiator hoses and accessory drive belt Hood release cable and upper radi-

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Air cleaner and inlet hose Cowl covers, supports and wiper arms e Hood Negative battery cable 19. Fill the cooling system to the proper level. 20. Fill the engine with clean oil. 21. Start the vehicle, check for leaks and repair if necessary.

Water Pump. 7922BG03

Be careful not to damage the windshield when removing the cowl covers and supports 3.2L and

REMOVAL & INSTALLATION

3.5L models

Left exhaust manifold V-band clamp and left catalytic converter Support brackets Starter Left and right engine mounting bolts Crankshaft Position (CKP) sensor Lower engine-to-transaxle mounting bolts 6. Attach a suitable lifting device to the engine. 7. Support the transaxle using e floor jack with a small block of wood in between. 8. Slowly lift the engine from the vehicle. To install: 9. Install the engine. 10. Align the engine mounts and install the fasteners, but do not tighten them until all of the mounting bolts have been installed. 11. Install the engine-to-transaxle mounting bolts and torque to 76 ft. Ibs. (102 Nm). 12. Remove the engine lifting device. 13. Torque the engine mount nuts/boits 45 ft. Ibs. (61 Nm). 14. Align the flexplate-to-torque converter matchmarks and torque the boltsto 55 ft. Ibs. (75 Nm).

15. Install or connect the following: e CKP sensor and the starter e Left-side exhaust manifold V-band clamp and torque to 100 inch Ibs. (11 Nm) Left-side catalytic converter mounting bracket fasteners 16. Install the structural collar using the following procedure: a. Install the vertical collar-to-oil pan bolts and tighten, temporarily to 10 inch lbs. (1.1 Nm). b. Install the collar-to-transaxle bolts and torque to 40 ft. Ibs. (55 Nm). c. Starting with the center vertical bolt and working outward, torque the bolts to AQ ft. Ibs. (65 Nm). 17. Install or connect the following: e Throttle body support bracket ¢ Heater hoses, all ground straps and vacuum hoses e Upper intake manifold e All engine wiring harnesses 18. Adjust the throttle and cruise control cables e Fuel lines e \-band clamp on the right exhaust

The water pump has a die cast aluminum body and a stamped steel impeller. It bolts directly to the chain case cover using an Oring for sealing. It is driven by the back side of the serpentine belt. It is normal for a small amount of coolant to drip from the weep hole located on the water pump body (small black spot). Ifthis condition exists, DO NOT replace the water pump. Only replace the water pump if a heavy deposit or steady flow of brown/green coolant is visible on the water pump body from the weep hole, which would indicate shaft seal failure. Before replacing the water pump, be sure to perform.a thorough inspection. A defective pump will not be able to circulate heated coolant through the long heater hose. 2.7L Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the cooling system. 3. Remove or disconnect the following: e Negative battery cable ¢ Upper radiator crossmember e Fan module e Accessory drive belts

Please visit our web site at www.chiltonsonline.com

0-6

CHRYSLER CORPORATION

CONCORDE ¢ LHS ¢ 300M ¢ INTREPID ¢ VISION

>The water pump is driven by the primary timing chain.

e Crankshaft damper, timing chain cover, timing chain and all guides e Water pump mounting bolts e Water pump 4. Clean the water pump mounting surfaces. To install: 5. Install or connect the following: ¢ Water pump and gasket and torque the bolts to 105 inch Ibs. (12 Nm) Guides, timing chain and timing chain cover

Crankshaft damper and torque the center bolt to 125 ft. Ibs. (170 Nm) Accessory drive belts Fan module and upper radiator crossmember Negative battery cable 6. Fill the cooling system to the proper level. 7. Start the vehicle, check for leaks and repair if necessary.

3.2L and 3.5L Engines 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the cooling system.

Do not use pliers to open the plastic drain. A

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2. Properly relieve the fuel system

Rotate the pump and check for freedom of movement. e Timing belt. Refer to the appropriate section for the removal and installation procedure. 6. Fill the cooling system by performing the following procedure: a. Close the radiator drain. b. Open the thermostat bleed valve. Install a % in. (6mm) clear hose about 48 in. (1.2m) long to the end of the bleed valve and the other end into a clean container. The intent is to keep coolant off of the drive belt(s). c. Slowly, refill the coolant recovery bottle until a steady stream of coolant flows out of the thermostat bleed valve. Gently squeeze the upper radiator hose until all of the air is removed from the system, d. Close the bleed valve and continue to fill the coolant recovery bottle to the proper level. Install the cap on the bottle and remove the hose from the bleed valve. 7. Reconnect the negative battery cable. Start the engine and allow it to reach normal operating temperatures. 8. Check the cooling system for leaks and correct coolant level. Be sure that the thermostat bleed valve is closed once the cooling system has been bled of any trapped air.

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3. Remove or disconnect the following: e Negative battery cable ¢ Coolant recovery cap and open the thermostat bleed valve ¢ Timing belt. Refer to the appropriate section for the removal and installation procedure. e>|t is good practice to turn the crankshaft until the No. 1 cylinder is at Top Dead Center (TDC) of its compression stroke (firing position).

¢ Water pump mounting bolts and pump. Discard the O-ring seal 4. Clean the gasket sealing surfaces, being careful not to scratch the aluminum Surfaces. To install: 9. Install or connect the following: ¢ New O-ring and wet with clean coolant prior to installation. Be sure to keep the new O-ring free of any oil or grease. Water pump with a new O-ring. Torque the water pump-to-engine bolts to 105 inch Ibs. (12 Nm).

Cylinder Head REMOVAL & INSTALLATION 2.7L Engine

1. Before servicing the vehicle, refer to the precautions in the beginning of this section.

pressure. 3. Drain the cooling system. 4. Remove or disconnect the following: e Negative battery cable e Accessory drive belts e Crankshaft damper e Intake plenum, lower intake manifold and exhaust manifold Place shop rags in the openings to prevent debris from entering the engine.

e Valve and timing chain covers ¢ Coolant connections for the cylinder heads 5. Rotate the crankshaft until the crankshaft timing mark aligns with the timing mark on the oil pump. e Primary timing chain ¢ Camshaft bearing caps, gradually, in the reverse order of the tightening sequence

¢ Camshafts

Be sure the head bolts 9-11 are removed before attempting to remove the cylinder head, the head and/or block may be damaged. ¢ Cylinder head bolts in reverse order of installation starting with bolts 11-9, then 8-1 ¢ Cylinder head(s) To install: 6. Thoroughly clean and dry the mating surfaces of the head and block. Check the cylinder head for cracks, damage or engine coolant leakage. Remove scale, sealing compound and carbon. Clean the oil passages thoroughly. 7. Place a new head gasket on the cylinder block over the locating dowels. 8. Inspect the cylinder head bolts for necking (stretching) by holding a straight-

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Camshaft bolt tightening sequence—2.7L engine

CHRYSLER CORPORATION CONCORDE ¢ LHS ¢ 300M ¢ INTREPID ¢ VISION RIGHT

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CYLINDER

HEAD

5.7

edge against the threads of each bolt. If all of the threads are not contacting the

straightedge, the bolt should be replaced. New head bolts are recommended.

> WARNING Due to the cylinder head bolt torque method used, it is imperative that the bolt threads be inspected for necking (stretching) prior to installation. If the threads are necked down, the bolt should be replaced. Failure to do so may result in parts failure or damage. 9. Lubricate the bolt threads with clean engine oil, then install them. 10. Torque the head bolts in the sequence shown in the illustration, utilizing the following steps and tightening values: a. Step 1: bolts 1through 8: 35 ft. lbs. (48 Nm). b. Step 2: bolts 1 through 8: 59 ft. lbs. (75 Nm). c. Step 3: bolts 1 through 8: 55 ft. lbs. (75 Nm). d. Step 4: bolts 1 through 8: plus 90 degree turn using a torque angle meter. e. Step 5: bolts 9 through 11: 21 ft. 79228604

11. Install or connect the following:

Cylinder head bolt tightening sequence —2.7L engine

REAR COVER ee

Ibs. (28 Nm).

e Camshafts, timing chain and sprockets e Water connections to the cylinder head Valve and timing chain covers Crankshaft damper and torque the center bolt to 125 ft. Ibs. (170 Nm) Lower intake manifold and intake

HEAD

plenum Exhaust manifolds Accessory drive belts Negative battery cable REAR TIMING BELT COVER TO ENGINE BLOCK O-RINGS

REAR COVER TO CYUNDER BLOCK BOLTS iming Ae eat a engines 3.5L

ere PUMP IMPELLER 7922BG09

belt cover-to-cylinder head bolts, noting the bolt locations—3.2L and ;

7922BG10

Right side belt cover, water: pump and 0rings—3.2L and 3.5L engines

Timing belt service is covered in Section 3 of this manual

0-8

CHRYSLER CORPORATION

CONCORDE ¢ LHS ¢ 300M ¢ INTREPID @ VISION

12. Fill the cooling system to the proper level. 13. Start the vehicle, check for leaks and repair if necessary. 3.2L and 3.5L Engines 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. This engine uses aluminum alloy cylinder heads. Use care when working with light alloy components. The heads are common to either cylinder bank, but in practice a

cylinder head should be returned to the side of the engine from which it was removed. Removal of a cylinder head involves removal of the timing belt. Great care is required to install the belt, paying attention to all valve timing marks. Please note that camshaft removal on this engine does require the removal of the cylinder head. 2. Properly relieve the fuel system pressure. 3. Drain the cooling system. 4. Remove or disconnect the following: ¢ Negative battery cable ¢ Radiator and cooling fan assemblies e Air cleaner assembly and intake manifold plenum

a. Place tensioner in a vise the same way it is mounted on the engine. b. Slowly compress the plunger into the tensioner body. c. Once the plunger is compressed, install a pin through the body and plunger to retain it in place until the tensioner is installed. 6. Hold the camshaft sprocket with a 36mm box wrench, loosen and remove the sprocket retaining bolt and washer. e>To remove the camshaft sprocket retainer bolt while the engine is in the vehicle, it may be necessary to raise that side of the engine due to the length of the retainer bolt. The right bolt is 8.370 in. (212.6mm) long, while the left bolt is 10.0 in. (253mm) long. These bolts are not interchangeable and their original location during removal should be noted.

7. Remove or disconnect the following: ¢ Camshaft sprocket from the camshaft e*The camshaft sprockets are not interchangeable.

e Intake manifold assembly using the recommended procedure e Rear timing belt cover-to-cylinder head fasteners

Cover the lower intake manifold during service.

¢ Accessory drive belts ¢ Crankshaft damper using the proper puller e Engine valve covers e Timing belt covers e*Viark the timing belt running direction for installation. Align the camshaft sprockets with the marks on the rear covers.

¢ Timing belt and tensioner 5. Pre-load the timing belt tensioner as follows:

7922BG11

Correct positioning for the head gaskets— 3.2L and 3.5L engines

Cylinder head bolt tightening sequence —3.2L and 3.5L engines

elf the right timing belt cover is to be removed, there are O-rings located behind it for the water pump passages.

e Cylinder head mounting bolts in the reverse order of the tightening Sequence e Cylinder head To install: 8. Thoroughly clean and dry the mating surfaces of the head and block.

When cleaning the cylinder head and block mating surfaces, do not use a metal scraper because the soft aluminum surfaces could be cut or damaged. Instead, use a scraper made of wood or plastic. 9. Check the cylinder head for cracks, damage or engine coolant leakage. Check the head for flatness. End-to-end, the head should be within 0.002 in. (0.051mm) normally with 0.008 in. (0.203mm) the maximum allowed out of true. The resurface limit is 0.008 in. (0.203mm) maximum, the combined total dimension of stock removal from the cylinder head, if any, and block top surface. 10. Place a new head gasket on the cylinder block locating dowels, being sure the gasket is on the correct side. 11. Inspect the cylinder head bolts for necking (stretching) by holding a straightedge against the threads of each bolt. If all of the threads are not contacting the scale, the bolt should be replaced.

Due to the cylinder head bolt torque method used, it is imperative that the threads of the bolts be inspected for necking prior to installation. If the threads are necked down, the bolt should be replaced. Failure to do so may result in parts failure or damage. New bolts are always recommended. a 12. Install the cylinder head into position on the engine block and over the dowels. Install the cylinder head bolts, lubricating the threads with clean engine oil prior to installation. 13. Torque the cylinder head bolts using the proper sequence as follows: a. Step 1: torque in sequence to 45 ft. lbs. (61 Nm). b. Step 2: torque in sequence to 65 ft. Ibs. (88 Nm).

CHRYSLER CORPORATION

LS

C. Step 3: torque in sequence to 65 ft. lbs. (88 Nm). d. Step 4: torque in sequence an additional /% turn by using a torque angle meter. e>Inspect the bolt torque after tightening. The torque should be over 90 ft. Ibs. (122 Nm). If not, replace the cylinder head bolt.

14. Install the rear timing belt cover bolts and torque as follows: a. M6 bolts: 105 inch Ibs. (12 Nm). b. M8 bolts: 21 ft. Ibs. (28 Nm). c. M10 bolts: 40 ft. Ibs. (54 Nm). 15, Install the intake manifold assembly and torque the bolts following the proper sequence to 21 ft. Ibs. (28 Nm). The following procedure can only be used when the camshaft sprockets have been loosened or removed from the shafts. 16. When the camshaft sprockets are loosened or removed, the camshafts must be timed to the engine. Install the Camshaft Alignment tools 6642-A, to the rear of the cylinder heads. 17. Install both camshaft sprockets to the appropriate shafts. The left camshaft sprocket has the Distributorless Ignition System (DIS) pickup as part of the sprocket. 18. Apply thread locking compound to the threads of the camshaft sprocket retainer bolts and install to the appropriate shafts. The right bolt is 8.380 in. (21.3cm) long, while the left bolt is 10.0 in. (25.4cm) long. These bolts are not interchangeable. Do not tighten the bolts at this time. The camshaft marks should be positioned between the marks on the cover. 19. Place the crankshaft sprocket to the Top Dead Center (TDC) mark on the oil pump housing. Install the timing belt starting at the crankshaft sprocket and working in a counterclockwise direction. 20. After the belt is installed around the last sprocket keep tension on the belt until it is past the tensioner pulley. 21. Holding the tensioner pulley against the belt, install the tensioner housing and torque to 21 ft. Ibs. (28 Nm). 22. When the tensioner is in place pull the retainer pin to allow the tensioner to extend to the pulley bracket. 93. Hold the right camshaft sprocket hex with a 36mm box wrench and torque the right camshaft sprocket bolt to 75 ft. Ibs. (102 Nm). Turn the sprocket bolt an additional 90 degrees.

CONCORDE ¢ LHS * 300M ¢ INTREPID SS

24. Hold the left camshaft sprocket hex with a 36mm box wrench and torque the left camshaft sprocket bolt to 85 ft. Ibs. (115 Nm). Turn the sprocket bolt an additional 90 degrees. 29. Install or connect the following: ¢ Camshaft alignment tools from the back of the cylinder heads Cam covers and new O-rings. Torque the fasteners to 20 ft. Ibs. (27 Nm). Repeat this procedure on the other camshaft. Timing belt covers and crankshaft damper and torque the crankshaft damper bolt to 85 ft. Ibs. (115 Nm) Valve covers and torque the bolts to 105 inch Ibs. (12 Nm) Spark plug tube nut and O-ring and torque to 60 inch Ibs. (7 Nm) Spark plug and torque to 20 ft. Ibs. (28 Nm) A/C compressor and torque the mounting bracket bolts to 30 ft. Ibs. (41 Nm) Spark plug wires Accessory drive belts and adjust to the proper tension Intake manifold plenum using the recommended procedure Air cleaner assembly Radiator and cooling fan assemblies Negative battery cable 26. Check to be sure that all hoses, wiring connectors, cables, fluid and vacuum lines are reconnected. 27. Change the engine oil and oil filter. 28. Fill and bleed the cooling system. 29. Run the vehicle with the radiator cap off so coolant can be added as required until the thermostat opens. Watch for leaks and for unusual engine noises. Refill the radiator completely as required. 30. Once the vehicle has cooled, recheck the coolant and oil level.

VISION

0-9

Rocker Arm/Shafts

REMOVAL & INSTALLATION 2.7L Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Disconnect the negative battery cable. 3, Remove the valve covers. 4. Position the camshaft so that the base circle (heel) is facing the rocker arm being serviced.

Depress the valve spring only enough to remove the rocker arm or damage to the spring may result.

5, Using Valve Spring tool 8215 and Adapter 8216, depress the valve spring enough to release the tension on the rocker arm. e»|f the rocker arms are to be reused, identify their positions for reassembly in their original positions.

6. Repeat this procedure for each rocker arm being removed. To install: 7. Lubricate the rocker arms with clean engine oil, prior to installation. 8. Position the camshaft so that the base circle (heel) is facing the rocker arm being installed.

ck WARNING Depress the valve spring only enough to install the rocker arm or damage to the spring may result. 9. Using Valve Spring tool 8215 and SPECIAL TOOL

ADAPTOR 8216 7922BG59

Only depress the valve spring enough to remove the rocker arm—2.7L engine

Heater Core replacement is covered in Section 2 of this manual

0-10

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CONCORDE e LHS ¢ 300M ¢ INTREPID ¢ VISION

Adapter 8216, depress the valve spring enough to install the rocker arm. 10. Install the rocker arm in the original position (if reused) over the valve and lash adjuster. e>Inspect the rocker arm for proper engagement into the lash adjuster and valve tip.

c. Loosen the nut on the screw. This

will pull the dowel pin from the shaft support. d. Remove the rocker arms and pedestals, keeping them in order. e. Check the oil holes for restrictions with a small wire and clean as required. To install: 6. Assemble the rocker shaft as follows:

a. Install the rocker arms and pedestals onto the shaft, keeping them in the original order. b. Press the dowel pins into the pedestals until they bottom out in the pedestals. 7. Position the camshaft so that the timing mark on the right camshaft timing belt sprocket aligns with the timing mark on the

11. Release the tension on the valve

spring and remove the tools. 12. Install the valve covers and connect the negative battery cable.

3.2L and 3.5L Engines 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Relieve the fuel system pressure. 3. Remove or disconnect the following: e Negative battery cable e Air cleaner assembly and the intake manifold plenum e>Cover the lower intake manifold dur-

ing service.

e Cylinder head covers e Rocker arm assembly 4. Inspect the rocker arms for wear or damage. Inspect the roller for scuffing or wear. Replace assembly as necessary.

7922BG13

Left bank rocker arm and shaft identification—3.2L and 3.5L engines

SILVER BOLT MUST BE IN THIS POSITION FOR OIL PASSAGE

Do not remove the lash adjusters from the rocker arm assembly. The rocker arm and the adjuster are serviced as an assembly. 5. Identify the rocker arm assemblies and rocker arms and disassemble the shaft as follows: a. Thread a nut, washer and spacer onto a 4mm screw. b. Insert and tighten the 4mm screw into the dowel pin on the shaft,

ee

~The intake manifold plenum (upper half of the intake manifold assembly) uses 2 different length bolts. Take note of their position and be sure they are installed in the same location during installation.

5. Remove the intake manifold plenum from the intake manifold. Discard the old gasket. Cover the intake manifold openings with tape to keep debris from entering the engine.

6. Remove or disconnect the following: ¢ Upper radiator hose from the thermostat housing e Heater hose from the rear of the intake manifold ¢ Lower intake manifold bolts and manifold e>Clean all gasket mating surfaces and inspect for distortion with a good straightedge.

3.2L and 3.5L Engines 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Properly relieve the fuel system pressure. 3. Drain the cooling system. 4. Remove or disconnect the following: e Negative battery cable e Engine cover from the top of the intake manifold * Accelerator and the speed control cable from the throttle lever

7922BG22

Lower intake manifold loosening and tightening sequence —3.2L and 3.5L

To install:

e»Verify that all intake manifold and cylinder head sealing surfaces are clean.

7. Install or connect the following: e Intake manifold gasket, then the lower manifold. Torque the bolts in the proper sequence to 21 ft. Ibs. (28 Nm). ¢ Upper radiator hose to the thermostat housing Heater hose to the rear of the intake manifold ->Ensure the ignition cables are routed out of the way of the intake plenum.

e Intake manifold plenum with a new gasket in place. Torque the mounting bolts, working from the center outward, to 21 ft. Ibs. (28 Nm) ->Do not overtighten bolts when working with light alloys.

¢ Support bracket bolts ¢ Electrical connectors to the MAP sensor, TP sensor, IAC motor and IAT sensor e Vacuum hose to the manifold tuning valve

¢ EGR tube. Torque the EGR tube-tointake manifold plenum screws to 17 ft. Ibs. (22 Nm).

7922BG21

Upper intake manifold loosening and tightening sequence —3.2L and 3.5L engines

e*Be sure that the insulation on the EGR tube aligns with and contacts the insulation on the vacuum harness at the rear of the engine. Rotate the throttle lever to the wide-open position and reconnect the speed control and throttle cables.

?

¢ PCV valve hose e Air cleaner plenum and plenum hose e Ground wire to the intake manifold plenum Brake booster hose to intake manifold plenum fitting e Throttle body purge tubes e Intake manifold plenum cover Negative battery cable 8. Fill and bleed the cooling system. 9. Change the engine oil and filter. 10. Test run the engine, check for fuel and coolant leaks and verify correct engine operation. Exhaust Manifold

REMOVAL & INSTALLATION 2.7L Engine

RIGHT MANIFOLD 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Negative battery cable Air intake plenum and the air filter housing Battery cable housing tube-totransaxle bolt Ehaust Gas Recirculation (EGR) valve and tube Oxygen (02S) sensor V-band clamp from the manifold ->Do not reuse the V-band clamps.

e Heat shield e Exhaust manifold 3. Remove all traces of the old manifold gasket and clean both gasket mating surfaces. To instal!: 4. Install or connect the following: e Exhaust manifold and new gasket. Torque the bolts to 17 ft. Ibs. (23 Nm) working from the center outward. Heat shields and torque the bolts to

105 inch Ibs. (12 Nm) New V-band clamp and torque to 100 inch Ibs. (11.3 Nm) O2S sensor EGR valve and tube using new gaskets, then torque to 95 inch Ibs. (11 Nm) Battery cable tube-to-transaxle and torque the bolt to 75 ft. Ibs. (101 Nm)

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SS

Ser

° Air inlet plenum and air filter housing e Negative battery cable

LEFT MANIFOLD 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: ¢ Negative battery cable e Exhaust system e \-band clamps and left catalytic converter ->Do not reuse the V-band clamps.

3. Loosen and rotate the transaxle dipstick tube out of the way. 4. Remove or disconnect the following: ¢ Engine wiring harness support bracket from the cylinder head ¢ Oxygen (02S) sensor e Engine oil dipstick tube and manifold heat shield e Exhaust manifold bolts and manifold To install: 5. Remove all traces of the old manifold gasket and clean both gasket mating surfaces. 6. Install or connect the following: Exhaust manifold and new gasket and torque the bolts to 17 ft. Ibs. (23 Nm) working from the center outward Heat shields and torque the bolts to 105 inch Ibs. (12 Nm)

O2S sensor Transaxle dipstick tube O-ring for the engine oil dipstick tube and tube Catalytic converter with a new Vband clamp and torque to 89 inch lbs. (10 Nm) Engine wiring harness support bracket to the cylinder head Exhaust system Negative battery cable

Sl

ils

SS

¢ Exhaust manifold bolts and manifold 3. Inspect the manifold for damage or cracks. Check for distortion against a straight-edge or thickness gauge. Replace manifold if required. 4. Remove all traces of the old manifold gasket and clean both gasket mating surfaces. To install: 5. Install or connect the following: e New manifold gasket and exhaust manifold to the cylinder head and torque to 15 ft. Ibs. (20 Nm) e Exhaust pipe to the exhaust manifold and torque the nuts to 21 ft. Ibs. (28 Nm) e Heat shield and torque the retaining screws to 11 ft. Ibs. (15 Nm) e HOS sensor electrical connector e Negative battery cable 6. Operate the vehicle and inspect for exhaust leaks. Front Crankshaft Seal >The front crankshaft seal procedures are for timing belt equipped engines only. For engines that utilize timing chains, please refer to the applicable procedure later in this section.

REMOVAL & INSTALLATION 3.2L and 3.5L Engines Note that the timing belt must be removed from the vehicle to perform this service. Use care to be sure all valve timing marks are carefully aligned both before removing the belt and after belt installation and all service has been completed. It may be good practice to set the engine to Top Dead Center (TDC) No. 1 cylinder compresPIN PUNCH

3.2L and 3.5L Engines 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Negative battery cable Exhaust pipes from the exhaust manifold Heated Oxygen (HO2S) sensor electrical wiring Heat shield-to-exhaust manifold SCreWS

7922BG23

Removing the timing belt sprocket dowel pin from the crankshaft—3.2L and 3.5L engines

For complete Engine Mechanical specifications, see Section 1 of this manual

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sion stroke (firing position) and aligning all timing marks before removing the timing belt. This serves as a reference for all work that follows. 1. Before servicing the vehicle, refer to the precautions at the beginning of this section. 2. Properly relieve the fuel system pressure. 3. Drain the cooling system. 4. Remove or disconnect the following: e Negative battery cable e Radiator and cooling fan module assembly e Accessory drive belts e Crankshaft damper bolt e Timing belt front cover >The sealer on the timing belt front cover may be reusable and should not be removed. Use silicone rubber adhesive sealant to replace any missing sealer.

e Timing belt and tensioner. Refer to the appropriate section for the removal and installation procedure e Crankshaft timing belt sprocket 5. Locate the small dowel pin in the crankshaft. With a small punch, carefully tap out the dowel from the end of the crankshaft. 6. Remove the crankshaft seal using tool 6341A, taking care not to nick the shaft Seal surface or seal bore during removal.

To install: 7. Inspect the crankshaft seal lip surface for varnish and dirt. Polish the area using 400 grit sandpaper to remove varnish as necessary. 8. Install or connect the following: e Crankshaft seal using seal installer tool 6342 e Rear lower timing belt cover ¢ Dowel into the crankshaft so that it protrudes 0.047 in. (1.2mm) ¢ Timing belt sprocket at the crankshaft using tool C-4685C1, thrust bearing, washer and 12mm bolt or

an equivalent setup to pull the sprocket onto crankshaft. Do not hammer on the sprocket. 9. Verify that all valve timing marks are aligned. ¢ Timing belt and tensioner using the recommended procedure 10. Rotate the crankshaft 2 complete turns and recheck the timing marks on the camshafts and crankshaft. The marks must align with their respective locations. If the marks do not align, repeat the timing belt installation procedure. When correct valve timing has been verified, install the timing belt covers. Crankshaft damper. Hold the crankshaft damper, using tool L-3281, and torque the bolt to 85 ft. Ibs. (115 Nm). Accessory drive belts and adjust to the proper tension Radiator and cooling fan assemblies Negative battery cable 11. Fill and bleed the cooling system. 12. Start the vehicle, check for leaks and repair if necessary.

Camshaft and Valve Lifters

REMOVAL & INSTALLATION 2.7L Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section.

When the timing chain is removed and the cylinder heads are installed,

DO NOT turn the crankshaft or camshaft without first locating the proper crankshaft position. Failure to do so will result in piston-to-valve contact». 2. Remove or disconnect the following: e Primary timing chain ¢ Second chain tensioner mounting bolts 3. Slowly loosen the camshaft bearing cap retaining bolts in the reverse order of the tightening sequence. e Bearing caps e Camshafts, secondary chain and tensioner as an assembly e Tensioner and chain from the crankshaft To install: 4. Assemble the chain on the camshafts. Ensure the plated links are facing toward the front. Align the plated links to the dots on the camshaft sprockets. >There are 2 different styles of camshaft (secondary) chain tensioners . The Early Build tensioners will separate into sub-components, the Later Build tensioners will not. Compress the camshaft (secondary) chain as follows:

5. For early build vehicles: a. Separate the tensioner cylinder from the tensioner housing. b. Carefully drain the oil from the housing using care not to remove the internal tensioner components. c. Assemble the tensioner housing. d. Using hand pressure, compress and lock the tensioner using a fabricated lockpin. 6. For late build vehicles:

i

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SPECIAL TOOL 6342 7922BG24

Installing the crankshaft oil seal—3.2L and 3.5L engines

7922BG60

Camshaft bearing cap tightening sequence—2.7L engine

cd

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CONCORDE ¢ LHS © 300M e INTREPID ¢ VISION

0-19

PLATED CHAIN LINKS TENSIONER BODY

;

CHECK BALL

ASSEMBLY

SPRING

;

THIS SIDE TOWARDS FRONT OF

LOWER CHAIN GUIDE FACE

ENGINE

7922BG61

Exploded view of the camshaft (secondary) chain tensioner, early build—2.7L engine 7922BG63

=~

Proper camshaft (secondary) chain alignment—2.7L engine

LOCK PIN

e Camshaft bearing caps and torque the bolts gradually, in sequence, to 105 inch Ibs. (12 Nm) ¢ Secondary chain tensioner and torque the bolts to 105 inch Ibs. (12 Nm) e Primary timing chain e Negative battery cable 10. Remove the lockpin from the secondary chain tensioner. Fabricate a jockpin, as shown, to keep the tensioner compressed—2.7L engine

a. Place the tensioner in a soft-jawed vise. b. Slowly compress the tensioner until the fabricated lockpin can be installed. c. Remove the compressed and locked tensioner from the vise. 7. Insert the compressed and locked camshaft chain tensioner in between the camshafts and chain. 8. Position the camshafts so that the plated links and dots are facing upward. 9. Install or connect the following: e Camshafts

“stk WARNING

=~

Ensure that the rocker arms are Cor-

rectly seated and in proper positions.

3.2L and 3.5L Engines 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. Camshafts are serviced from the rear of the cylinder head. Although the engine does not need to be removed for camshaft service, the cylinder head must be removed from the vehicle. Note too, that the camshaft sprockets have a D-shaped hole that allows it to rotate several degrees in each direction on its shaft. 2. Properly relieve the fuel system pressure. 3. Drain the cooling system. 4. Remove or disconnect the following: e Negative battery cable e Radiator/cooling fan assemblies and the accessory drive belts e Crankshaft damper and the timing belt covers

Mark the timing belt rotation direction for installation. Align the timing belt sprockets with marks on the rear timing belt covers before removing the timing belt.

e Timing belt tensioner and timing belt. Refer to the appropriate section for the removal and installation procedure ¢ Camshaft timing belt sprockets e Intake manifold assembly using the recommended procedure e Exhaust manifold ->Be sure to clean the gasket mating surfaces between the exhaust manifold and the cylinder head.

5. The rear timing belt cover must be

7922BG27

Rocker arm/shaft tightening sequence—

3.2L and 3.5L engines

a

For Accessory Drive Belt illustrations, see Section 1 of this manual

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removed to remove the cylinder heads. Remove the rear timing belt cover-to-cylinder head bolts. Remove the rear timing belt covers. ->The right-hand side timing belt cover has O-rings located behind it for the water pump passages.

6. Remove the cylinder head bolts and cylinder head. e> Mark the rocker arm assembly to note component locations before disassembly. 7. Remove the rocker arm and shaft assemblies. 8. Remove the rear camshaft cover and

O-ring.

Carefully, remove the camshaft from the rear of the head taking care not to nick or scratch the journals. 9. Inspect camshaft journals for wear or damage. Ifwear is present, inspect the cylinder head for damage. Inspect the head oil holes for clogging. Replace the camshaft as required. 10. Measure the height of the cam using a micrometer. Measure in 2 places: the unworn area and in the wear zone. Subtract the figures to get cam wear. The standard specification is 0.001 in. (0.0254mm) with the wear limit being 0.010 in. (0.254mm). Replace the camshaft if it is worn beyond this specification. To install: 11. Lubricate the camshaft journals and lobes with clean engine oil. 12. Install or connect the following: e Camshaft ¢ Camshaft cover and O-ring and torque the bolts to 21 ft. Ibs. (28 Nm) ¢ Rocker arm assemblies ¢ Cylinder head assembly

New head bolts are recommended.

Exhaust manifold with new gasket e Intake manifold assembly Timing belt covers and crankshaft damper Accessory drive belts and set them to the proper tension Radiator and cooling fan assembly e Negative battery cable 13. Fill and bleed the cooling system. An oil and filter change is recommended. 14. Start the vehicle, check for leaks and repair if necessary.

Valve Lash

ADJUSTMENT These engines use hydraulic roller lifters to take up the free-play in the valve train system, therefore no lash adjustments are necessary.

Starter Motor

REMOVAL & INSTALLATION

Nuts from the catalyst support bracket and mount Starter heat shield 3 starter-to-engine/transaxle bolts . Starter by rotating it toward the engine and sliding it rearward between the catalyst and the engine mount To install: 2. Install or connect the following: Starter by sliding it forward between the catalyst and the engine mount and rotating it away from the engine Starter and torque the 3 starter-toengine/transaxle bolts 40 ft. Ibs. (54 Nm) Starter heat shield Nuts to the catalyst support bracket and mount Positive battery cable and torque the nut to 89 inch Ibs. (10 Nm) Posi-lock connectors Negative battery cable to the remote ground post

3.2L and 3.5L (VIN G) Engines 2.7L Engine 1. Remove or disconnect the following: ¢ Negative battery cable from the remote ground post e Battery feed and posi-lock connectors

1. Remove or disconnect the following: Negative battery cable from the remote ground post Starter-to-engine/transaxle nut and

bolts Positive battery feed wire from the Starter

|

OIL PAN

¢ Rear timing belt covers ¢ Timing belt sprocket, timing belt and timing 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.

7922BG28

Exploded view of the oil pan removal and installation—2.7L and 3.5L (VIN G) engines

CHRYSLER CORPORATION

CONCORDE ¢ LHS ¢ 300M ¢ INTREPID e Starter and position it to gain access to the posi-lock connector 2. Place a support under the engine and Slightly relieve the pressure from the left engine mount. 3. Remove the 3 left engine mount-toengine bolts. 4. Slightly, raise the engine to provide more room. 5. Remove the starter by sliding it rearward between the catalyst and the engine mount. 6. Remove the posi-lock connector. To install: 7. Install or connect the following: e Posi-lock connector e Starter by sliding it forward between the catalyst and the engine mount

~ 8. Slightly, lower the engine. e 3 left engine mount-to-engine bolts e Positive battery feed wire to the starter and torque the nut to 89 inch lbs. (10 Nm) e Starter and torque the starter-toengine/transaxle bolts 40 ft. Ibs. (54 Nm) e Negative battery cable to the remote ground post

REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the engine oil and remove the oil filter. 3. Remove or disconnect the following: ¢ Negative battery cable e Dipstick and housing

¢ Structural collar from the rear of the oil pan and transmission housing ¢ Engine oil cooler lines from the oil pan, if equipped ¢ Transmission oil cooler line clips, if necessary ¢ Oil pan mounting bolts, oil pan and gasket 4. Clean the oil pan and all gasket surfaces. To install: 5. Apply a ¥% in. (3mm) bead of sealer at the parting line of the oil pump body and the rear seal retainer. 6. Install or connect the following: e Oil pan and torque the M8 nuts/bolts to 21 ft. Ibs. (28 Nm) and the M6 nuts/bolts to 105 inch lbs. (12 Nm) 7. Install the structural collar using the following procedure: a. Install the vertical collar to the oil pan mounting bolts and tighten, temporarily to 10 inch Ibs. (1.1 Nm). b. Install the collar-to-transaxle bolts and torque to 40 ft. Ibs. (655 Nm). c. Starting with the center vertical bolt and working outward. Torque the bolts to AO ft. Ibs. (55 Nm). 8. Install the dipstick and housing and connect the negative battery cable. 9. Fill the engine with the proper amount of clean SAE 5W-30 or SAE 10W30 engine oil only. Do not mix the two grades of oil. 10. Start the engine, check for leaks and repair if necessary.

REMOVAL & INSTALLATION 2.7L Engine

APPLY 1/8 INCH WIDE BEAD OF SEALER AT PARTING LINES

7922BG29

To ensure a proper seal, apply sealer as shown—2.7L and 3.5L (VIN F) engines

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the engine oil. 3. Remove or disconnect the following: Crankshaft damper Timing chain cover Timing chain Crankshaft sprocket Oil pan Oil pickup tube and o-ring Oil pump To install: 4. Fill the oil pump rotor cavity with clean engine oil.

VISION

J-1/

7922BG30

Oil pump mounting bolt locations—2.7L engine

5. Carefully, install the oil pump over the crankshaft and into position. 6. Install the oil pump mounting bolts and torque to 21 ft. Ibs. (28 Nm). 7. Lubricate the new pickup tube Oring with clean engine oil and torque the pickup tube mounting bolts to 21 ft. Ibs. (28 Nm). 8. Install or connect the following: e Oil pan e Crankshaft sprocket e Timing chain e Timing chain cover e Crankshaft damper 9. Fill the engine with clean engine oil. 10. Start the vehicle, check for leaks and repair if necessary. 3.2L and 3.5L Engines The timing belt must be removed to access the oil pump located behind the crankshaft drive sprocket. It is good practice to turn the crankshaft to Top Dead Center (TDC) No. 1 cylinder compression stroke (firing position) before starting disassembly. This should align all timing marks and be a

7922BG31

Prime the oil pump before installation, because a dry pump will wear prematurely and cause low oil pressure—3.2L and 3.5L engines

For Tire, Wheel and Ball Joint specifications, see Section 1 of this manual

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good point of reference for all work to follow. 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the engine oil. 3. Drain the cooling system. 4. Remove or disconnect the following: Negative battery cable Accessory drive belts Oil filter Oil pan Oil pump pickup tube Windage tray/oil pan gasket Crankshaft damper using a suitable puller tool Timing belt covers 5. Place matchmarks on the timing belt to aid installation. Align the matchmarks on the camshaft sprockets to marks on the rear timing belt covers before removing the timing. 6. Remove or disconnect the following: e Timing belt. Refer to the appropriate section for the removal and installation procedure. e Crankshaft sprocket using a suitable puller tool e (il pump-to-engine screws and pump e Qil pump cover screws and cover e Qil pump rotors 7. Wash all parts in solvent and inspect carefully for damage or wear. To install: 8. Clean all parts well. There should be no traces of old gasket/sealer on any components. 9. Assemble the oil pump with new parts as required. 10. Install the oil pump cover. Torque the fasteners to 108 inch Ibs. (12 Nm). 11. Prime the oil pump prior to installation by filling the rotor cavity with clean engine oil. 12. Install the oil pump and tighten the oil pump-to-engine screws as follows: a. M8 screws: 21 ft. Ibs. (28 Nm). b. M10 screws: 40 ft. Ibs. (55 Nm). 13. Tighten the oil pan drain plug and install a new oil filter. 14. Install or connect the following: e Oil pump pickup tube ¢ Windage tray/oil pan gasket ¢ Oil pan and torque fasteners to 108 inch Ibs. (12 Nm). Pay attention to sealing the oil pan gasket and its integral windage tray. Crankshaft sprocket using tool C4685C1, thrust bearing, washer and 12mm bolt to draw the sprocket onto the crankshaft

Timing belt. Refer to the appropriate section for the removal and installation procedure. Timing belt covers, thrust bearing, washer plate and vibration dampe using tool L-4524 Accessory drive belts Radiator and radiator hoses e Negative battery cable 15. Fill and bleed the cooling system. 16. Fill the engine with the correct amount of clean SAE 5W-30 or SAE 10W30 engine oil only. Do not mix the two grades of oil. 17. Start the engine, check for leaks and proper oil pressure.

8. Apply a light coating of engine oil to the entire circumference of the oil seal lip. 9. Place the seal over the special tool and tap the seal in place with a plastic mallet. 10. Install the flexplate/flywheel and transaxle. 11. Connect the negative battery cable. 12. Fill the transaxle with the proper fluid. 13. Start the vehicle, check for leaks and repair if necessary.

Timing Chain, Sprockets, Front Cover and Seal

REMOVAL & INSTALLATION 2.7L Engine

Rear Main Seal

REMOVAL & INSTALLATION When aligning the timing marks, 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the transaxle fluid. 3. Remove the negative battery cable. 4, Remove the transaxle, inspection cover and flywheel/flexplate. 5. Using a small prytool, carefully pry out the rear oil seal. Be careful not to nick or damage the crankshaft flange seal surface or the retainer bore. To install: 6. Place the Seal Pilot tool C-4681 on the crankshaft. 7. Lightly coat the oil seal outside diameter with Loctite® Stud N’ Bearing Mount® or the equivalent.

rotate the crankshaft, not the camshafts. DO NOT rotate the

SPECIAL TOOL 8191

7922BG32

Removing the crankshaft center bolt using the Crankshaft Damper Holder tool—2.7L engine

ACCESS PLUG

CAMSHAFT DAMPER

CHAIN GUIDE CAMSHAFT SPROCKETS

or

™ PRIMARY ! TIMIN

%

TENSIONER CHAIN

TENSIONER ARM

:

CH re CRANKSHAFT CHAIN GUIDE

POSITION SENSOR

SPROCKET 7922BG33

Exploded view of the timing chain drive assembly—2.7L engine

:

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CONCORDE @ LHS ¢ 300M CAMSHAFT TIMING MARK

NTACRID VISIOW

0-19

CAMSHAFT TIMING MARK

GUIDES

TIMING CHAIN TENSIONER

WATER

PUMP SPROCKET

SPECIAL TOOL 8186 CHAIN TENSIONER 79228635

CHAIN TENSIONER ARM

Using the Tensioner Resetting Special tool, to purge the oil from the tensioner— 2.7L engine 7 »))

The camshafts will rotate clockwise, when the camshaft sprocket bolts are removed.

RGSS y

na ope SPROCKET

FO,

CRANKSHAFT TIMING MARKS 79228634

After the timing chain is installed, the timing marks should be aligned—2.7L engine

camshafts or crankshaft with the timing chain removed without locating the crankshaft position, piston and/or valve damage may occur. 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: ¢ Upper intake manifold and valve covers ¢ Upper radiator crossmember ¢ Fan module e Accessory drive belts 3. Using Crankshaft Damper Holder tool 8191, hold the crankshaft and remove the center bolt. ¢ Damper using a 3-jaw puller

e Power steering pump and position it aside without disconnecting the hydraulic lines ¢ Accessory drive belt tensioner pulley ¢ Timing chain cover bolts 4. Clean and inspect the sealing surfaces. 5. Align the crankshaft sprocket timing mark with the oil pump housing mark. >The mark on the oil pump housing is 60 degrees at Top Dead Center (TDC).

6. Remove or disconnect the follow-

ing: e Primary timing chain tensioner from the right cylinder head e Camshaft Position (CKP) sensor and timing chain access plug from the left cylinder head

e Right camshaft sprocket mounting bolts, camshaft damper and sprocket ¢ Left camshaft sprocket bolts and sprocket e Lower timing chain guide, tensioner arm and primary timing chain To install: ->Lubricate the timing chain and guides with clean engine oil before installation.

7. Install the timing chain by performing the following procedure: a. Verify that the crankshaft sprocket timing mark is aligned with the mark on the oil pump housing. b. Place the left side primary timing chain sprocket onto the chain, while aligning the timing mark on the sprocket to the 2 plated links on the chain. c. Lower the chain with the left sprocket through the left cylinder head opening.

For Wheel Alignment specifications, see Section 1 of this manual

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d. Loosely position the left camshaft sprocket over the camshaft hub. e. Align the plated link to the crankshaft sprocket timing mark. f. Position the timing chain around the water pump drive sprocket. g. Align the right camshaft sprocket timing mark to the plated link on the timing chain and loosely position the sprocket over the camshaft hub. h. Verify that all the plated links are aligned to their proper timing marks. 8. Install the left lower timing chain guide and tensioner. Torque the bolts to 21 ft. lbs. (28 Nm). Inspect the timing chain guide access plug O-rings before installing. Replace damaged O-rings as necessary.

9. Install the timing chain guide access plug to the left cylinder head and torque to 15 ft. Ibs. (20 Nm). >To reset the timing chain tensioner, oil will first need to be purged from the tensioner.

10. Purge oil from the timing chain tensioner using the following procedure: a. Remove the tensioner from the tensioner housing. b. Place the check ball end of the tensioner into the shallow end of the Tensioner Resetting Special tool 8186. c. Using hand pressure, slowly depress the tensioner until oil is purged from the cylinder. d. Reinstall the tensioner into the tensioner housing. 11. Reset the timing chain tensioner U wning the following procedure: a. Position the cylinder plunger into he deeper side of the Tensioner Resetting special tool 8186. b. Apply a downward force until the ensioner is reset. +

+

Ensure that the tensioner is properly reset. The tensioner body must be bottomed against the top edge of the Tensioner Resetting Special tool 8186. Failure to properly perform the resetting procedure may cause tensioner jamming.

12. Install the chain tensioner into the right cylinder head. 13. At the right cylinder head, insert a ¥% in. 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 damper attaching holes. Install the sprocket attaching bolts and torque to 21 ft. Ibs. (28 Nm). 14. Turn the left camshaft by inserting a ¥% in. 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 damper attaching holes. Install the sprocket attaching bolts and torque to 21 ft. Ibs. (28 Nm). 15. If necessary, rotate the engine Slightly clockwise to remove any slack in the timing chain. 16. To arm the timing chain tensioner: Use a flat-bladed prytool to gently pry the tensioner arm towards the tensioner slightly. Then, release the tensioner arm. Verify the tensioner extends. 17. Inspect and replace the timing chain cover gasket and oil seal. 18. Apply a % in. (3mm) bead of sealer at the parting line of the oil pan and engine block.

Piston and Rings

POSITIONING eT

NO. 1 PISTON RING

lo) »

|

NO. 2 PISTON RING

SIDE RAIL SPACER EXPANDER

OIL RING 9306BG01

Cross-sectional view of the piston rings— 2.7L, 3.2L Engines

NO. 1 PISTON RING

e>When installing the timing cover, guide the seal over the crankshaft to prevent damage to the seal’s lip. . 19. Install or connect the following:

Timing cover and gasket and torque the M10 bolts to 40 ft. Ibs. (64 Nm) and the M6 bolts to 105 inch Ibs. (12 Nm) Crankshaft damper Accessory drive belt tensioner pulley Power steering pump Crankshaft damper Crankshaft center bolt and torque the bolt to 125 ft. Ibs. (170 Nm) using tool 8191 Accessory drive belts Fan module and electrical wiring harness Upper radiator crossmember Negative battery cable

1 -— SIDE RAIL 2 — SPACER EXPANDER

9306BG04

Cross-sectional view of the piston rings— 3.5L Engine

SIDE RAIL UPPER

NO. 1 RING GAP

PISTON PIN

NO. 2 RING GAP AND SPACER EXPANDER GAP

are 9306BG03

Piston ring gap positions—2.7L, 3.2L, 3.5L Engines

v-21

CHRYSLER CORPORATION CONCORDE * LHS «300M « INTREPID VISION FUEL SYSTEM

2 Fuel System Service Precautions Safety is the most important factor when performing not only fuel system maintenance but any type of maintenance. Failure to conduct maintenance and repairs in a safe manner may result in serious personal injury or death. Maintenance and testing of the vehicle's fuel system components can be accomplished safely and effectively by adhering to the following rules and guidelines: e To avoid the possibility of fire and personal injury, always disconnect the negative battery cable unless the repair or test procedure requires that battery voltage be applied. e Always relieve the fuel system pressure prior to disconnecting any fuel system component (injector, fuel rail, pressure regulator, etc.), fitting or fuel line connection. Exercise extreme caution whenever relieving fuel system pressure, to avoid exposing skin, face and eyes to fuel spray. Please be advised that fuel under pressure may penetrate the skin or any part of the body that it contacts. Always place a shop towel or cloth around the fitting or connection prior to loosening to absorb any excess fuel due to spillage. Ensure that all fuel spillage (should it occur) is quickly removed from engine surfaces. Ensure that all fuel soaked cloths or towels are deposited into a suitable waste container. e Always keep a dry chemical (Class B) fire extinguisher near the work area. ¢ Do not allow fuel spray or fuel vapors to come into contact with a spark or open flame. e Always use a back-up wrench when loosening and tightening fuel line connection fittings. This will prevent unnecessary stress and torsion to fuel line ee e Always replace worn fuel fitting Orings with new. Do not substitute fuel hose, where fuel pipe is installed. Before servicing the vehicle, also make sure to refer to the precautions in the beginning of this section as well.

Fuel System Pressure

he

RELIEVING 1. Before servicing the vehicle, refer to the precautions in the beginning of this section.

2. At the Power Distribution Center (PDC), remove the Fuel Pump Relay. 3. Operate the engine until the engine Stalls; then, continue restarting the engine until it will no longer run. 4. Turn the ignition switch OFF.

ee INTERNAL FUEL FILTER

LOCKE

5. Disconnect the electrical connector from any injector. 6. Connect 1 end of a jumper wire (with an alligator clip) to either injector terminal and the other end to the positive side of the battery. 7. Connect 1 end of a second jumper wire to the other injector terminal.

3 WARNING Applying power to an injector for more than a few seconds will damage the injector.

8. Momentarily, touch the other end of the jumper wire to a ground for no more than a few seconds. 9. At the Power Distribution Center (PDC), install the fuel pump relay. =>When the fuel pump relay is 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 to clear the DTC’s.

MZ a) N

>: 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 be forced into a cylinder chamber.

FUEL FLOW TO FUEL INJECTORS

faa

mad

R

RUBBER GROMMET AT PUMP MODULE

FUEL FILTER/FUEL PRESSURE REGULATOR

An

a

4

NAN

AG

CALIBRATED SPRINGS

Ni ollie:

O-RINGS

™* EXCESS FUEL BACK

TO TANK

FUEL INLET 7922BG40

Cut away view of the fuel filter/pressure regulator

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Properly relieve the fuel system pressure. 3. Lower the fuel tank. 4. Remove or disconnect the following: e Negative battery cable e Purge and vent lines e Fuel line from the pressure regulator e Filter/regulator by pushing in the locking tab, turning the regulator to unlock it and pulling the it straight up To install: 5. Push the fuel filter/regulator into the fuel pump module and turn to lock it into position. 6. Connect the fuel lines and install the tank. 7. Start the engine, check for leaks and * repair if necessary.

REMOVAL & INSTALLATION The fuel filter mounts to the frame rail in front of the fuel tank. The inlet and outlet ends of the filter are marked for installation purposes. Install the fuel filter making certain that it is properly orientated.

REMOVAL & INSTALLATION el ee od. ee eS ->The fuel filter is part of the fuel pressure regulator mounted on the fuel pump module.

The in-tank fuel pump module contains the fuel pump and pressure regulator which adjusts fuel system pressure. Fuel pump voltage is supplied through the fuel pump relay. The fuel pump is serviced as part of the fuel pump module. The fuel pump module is installed in the top ofthe fuel tank and contains the electric fuel pump, fuel pump reservoir, inlet strainer fuel gauge sending unit, fuel supply and return line connections

n 1 of this manual For Maintenance Interval recommendations, see Sectio

0-22

CHRYSLER CORPORATION

CONCORDE ¢ LHS ¢ 300M @ INTREPID @ VISION

and the pressure regulator. The inlet strainer, fuel pressure regulator and level sensor are the only serviceable items. If the fuel pump requires service, replace the fuel pump module. 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Properly relieve the fuel system pressure. 3. Remove or disconnect the following: e Negative battery cable e Fuel tank

4. Clean the top of the tank to remove any loose dirt. e Fuel lines from the fuel pump module by squeezing the quick-connect fitting with thumb and forefinger e Fuel pump module electrical connector from the top of the fuel pump module 5. Using special tool 6856, remove the fuel pump locknut by turning it counterclockwise.

> 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.

6. Remove the fuel pump and O-ring from the tank and discard the O-ring. To install: 7. Thoroughly clean all parts. Wipe the seal area of the tank clean. Place a new O-

en Transaxle Assembly REMOVAL & INSTALLATION The 42LE four speed transaxle uses fully-adaptive controls. Adaptive controls are those which perform their functions based on real-time feedback sensor information. The +transaxle is conventional in the use of hydraulically applied clutches to shift a planetary gear train. However, it uses electronics to control virtually all other functions. The following components are serviceable in the vehicle: valve body assembly, solenoid pack, manual valve lever position sensor, input and output speed —_—s chain and sprockets, short sensors, transfer (right side) stub shaft seal and the long (left side) stub shaft == and ball bearing. Note that the factory recommends that before attempt-

Fuel Injector

SPECIAL TOOL #6856

REMOVAL & INSTALLATION

SFUEL PUMP

er

VN

a

KG

‘

LOCKING

RING

ess 7922BG43

Using special tool 6856, remove the fuel pump module locknut

ring on the ledge between the tank threads and the pump module opening. 8. Position the fuel pump module in the tank. Be sure the alignment tab on the underside of the pump module flange sits in the corresponding notch in the fuel tank. 9, While holding the fuel pump module in place install the locking ring and torque to 40 inch Ibs. (5 Nm) using special tool 6856 or a spanner-type tool. 10. Install or connect the following: e Fuel tank e Fuel pump module electrical connector e Negative battery cable 11. Fill the fuel tank with fuel. Install the fuel filler cap. Turn the ignition switch to the ON position to pressurize the system. Check the fuel system for leaks.

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Relieve the fuel system pressure. 3. Remove or disconnect the following: e Negative battery cable e Intake manifold plenum and cover opening with a clean cloth

4, Place a shop rag under the fuel rail’s quick-connect fitting; then, squeeze the quickconnect fitting’s retainer tabs together and pull the fitting assembly off of the fuel tube nipple. e Fuel injector electrical connectors e Fuel rail-to-engine bolts and fuel rail e Fuel injector-to-fuel rail retainer clips e Fuel injectors To install: 5. Lubricate the injector O-rings with clean engine oil. 6. Install or connect the following: e Fuel injector and secure with retaining clips e Fuel rail onto cylinder head and press rail into place. Make sure that the injectors are fully seated. e Fuel rail-to-cylinder head bolts and torque bolts to 100 inch Ibs. (11 Nm) e Intake plenum 7. Lubricate the quick-connect fitting’s O-rings with clean engine oil: then, push the connector together until the retainer seats and a click is heard. 8. Connect the negative battery cable.

DRIVE TRAIN ing any repair on the 42LE four-speed automatic transaxle, always check for proper shift linkage adjustment. Also, check for diagnostic trouble codes with the Chrysler DRB scan tool. Use MOPAR Type 7176 Automatic Transmission Fluid only. Do not substitute transaxle fluid. If the differential sump requires fluid, use 80W-90 petroleum based Hypoid gear lubricant. 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Negative battery cable ¢ Engine air inlet tube e Crankshaft Position (CKP) sensor connector and remove the sensor from the upper right side of the transaxle bell housing

e Transaxle wiring connector block located on the right shock tower. To free the connector from the harness, remove the wire ties. Front wheels Strut-to-steering knuckle bolts on both sides of the vehicle and/or tie rod ends, if required Antilock Brake System (ABS) wheel speed sensor, if equipped Halfshafts e>Remove the halfshafts by inserting a prybar between the halfshaft and the 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 damage the halfshaft seals.

/

CHRYSLER CORPORATION

CONCORDE ¢ LHS

300M ¢ INTREPID e VISION

0-23

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. 3. Remove or disconnect the following: e Engine-to-transaxle brackets e Transaxle bell housing cover 4. Mark the driveplate to the torque converter and remove the torque converter bolts. The driveplate-to-torque converter bolts are not to be reused. e Starter assembly from the bell housing and allow the starter motor to sit between the engine and the frame e Transaxle oil cooler lines and plug the openings e Transaxle dipstick e Transaxle gear selector cable e Exhaust pipe from the exhaust manifold and position out of the way ->|f the clearance will not allow for transaxle removal, remove the exhaust system from the vehicle.

5. Support the transaxle using a transmission jack. Raise the transaxle slightly to relieve the weight off the rear transaxle mount. e Engine-to-transaxle brackets and transaxle mount through-bolt e Rear crossmember ->Pry the transaxle mount rearward to separate the mount from the transaxle.

6. Lower the rear of the transaxle to gain access to the bell housing bolts. Remove the bell housing bolts. 7. Place a drain pan under the dipstick in the transaxle to catch transaxle fluid that will drain out of the case. 8. Remove or disconnect the following: ¢ Transaxle dipstick tube and plug hole e Engine-to-transaxle bolts and transaxle =>The driveplate-to-torque converter bolts and the driveplate-to-crankshaft bolts must not be reused. Install new bolts whenever these boits are removed.

9. Inspect the driveplate for cracks. If cracks are present, replace the driveplate. To install: =>Apply a light coating of grease to the

pilot hole of the crankshaft if the torque converter is being replaced.

When installing the transaxle, be careful that the fuel tubes at the rear of the engine do not contact the following: 10. Install or connect the following: e Transaxle wiring harness Driveplate and torque the fastener to 75 ft. Ibs. (101 Nm) Transaxle and torque the engine-totransaxle case bolts to 75 ft. Ibs. (101 Nm) Rear transaxle case mount and rear crossmember in position and secure all fasteners Transaxle dipstick tube Exhaust pipe—to—engine exhaust manifold Transaxle gear selector cable and oil cooler lines Starter. Torque the bolts to 40 ft. lbs. (54 Nm). Be sure that the starter ground strap is installed correctly. Align torque converter matchmarks and torque new torque converter-todriveplate bolts to 60 ft. Ibs. (81 Nm) Bell housing cover and engine-totransaxle brackets 11. While pulling the top of the steering knuckle outward, install the inner CV-joint, with new retainer clip in place, into the transaxle. e ABS wheel sensor (if removed) and strut-to-steering knuckle bolts Front wheels and torque the lug nuts, in a star pattern to 95-100 ft. lbs. (129-135 Nm) Transaxle dipstick Transaxle wiring harness connector on the right shock tower CKP sensor Air inlet tube and negative battery cable 42. Start the engine and allow it to idle for 2 minutes. Apply the parking brake and move the selector through each gear position, ending in N. Recheck the fluid level and add if necessary. Be sure the vehicle is level when refilling the transaxle. Use Mopar Type 7176 Automatic Transmission Fluid (ATF) only. Do not substitute transaxle fluid. If the differential sump requires fluid, use 80W-90-petroleum based Hypoid gear lubricant. 13. Check the transaxle or proper opéeration. Adjust the shift linkage, if necessary.

REMOVAL & INSTALLATION

Allowing the CV-joint assemblies to dangle unsupported, or pulling or pushing the ends, can damage boots or CV-joints. Always support both ends of the halfshaft to prevent damage or disengagement of the Tri-pot joint. 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 wheels Front caliper assembly from steering knuckle Front brake rotor from the hub Speed sensor cable routing bracket from strut assembly Hub and bearing-to-stub axle retainer nut 3. Install a puller tool onto the hub and bearing assembly and secure it into place using the wheel lug nuts. 4. Protect wheel stud threads by installing a wheel lug nut onto a wheel stud. Use a flat-bladed prying tool to prevent the hub from turning. Using the puller tool, force the halfshaft outer stub axle from the hub and bearing assembly. 5. Dislodge the inner Tri-pot joint from the stub shaft retaining snapring on the transaxle. To do this, insert a prybar

7922BG44

Removing the stub axle from the front

hub/bearing assembly—halfshaft service

1 of this manual For Tune-up, Capacities and Firing orders, see Section

0-24

CHRYSLER CORPORATION

CONCORDE ¢ LHS ¢ 300M ¢ INTREPID @ VISION

STRUT ASSEMBLY

Spit an

bears

STEERING KNUCKLE 7922BG45

Be careful not to damage the threads for the axle nut when removing the outer CVjoint from the steering knuckle—halfshaft service

between the transaxle case and the inner

Tri-pot joint and pry on Tri-pot joint. =>Do not try to remove the inner Tri-pot joint from the transaxle stub shaft at this time. Only disengage the inner Tripot joint from the retainer snapring.

6. Remove the strut assembly-to-steering knuckle attaching bolts from the strut assembly.

The strut assembly-to-steering knuckle bolts are serrated (toothed) where they go through the strut assembly and steering knuckle. When removing the bolts, turn the

nuts off the bolt; do not turn the bolts in the steering knuckle or damage to the steering knuckle will result. 7. Separate the top of the steering knuckle from the lower end of the strut. 8. Hold the outer joint assembly with one hand. Grasp the steering knuckle with the other hand and rotate it out and to the rear of the vehicle, until the outer CV-joint Clears the hub and bearing assembly.

When removing the outer CV-joint from the hub and bearing assembly, do not allow the flange disc on the hub and bearing assembly to become damaged. If this happens, dirt and water can enter the bearing, which will cause premature bearing failure. sieaeessiocintisionitsinannsnessietinsionenissiossssiemsiein 9. Remove the halfshaft inner joint from the transaxle stub shaft by grasping the inner Tri-pot joint and the interconnecting shaft and pulling both pieces at the same

time. Take care not to pull on the interconnecting shaft to remove or separation of the spider assembly will occur. To install: 10. Install the Tri-pot joint side of the halfshaft by performing the following procedure: a. Replace the inner Tri-pot joint retaining circlip and O-ring seal on the transaxle stub shaft. These components are not reusable and must be replaced whenever the halfshaft is removed. b. Apply an even coat of grease on the splines of the inner Tri-pot joint, where the O-ring seats against the Tri-pot joint. c. Install the halfshaft through the hole in the splash shield. Grasp the inner joint in 1 hand and interconnecting shaft in the other. Align the inner Tri-pot joint spline with the stub shaft spline on the transaxle. Use a rocking motion with the inner Tri-pot joint to get it past the circlip on the transaxle stub shaft. d. Continue pushing the Tri-pot joint onto transaxle stub shaft until it stops moving. The O-ring on the stub shaft should not be visible when the inner Tripot joint is fully installed. Check that the inner Tri-pot joint is locked in position by grasping the inner joint and pulling. If locked in position, the joint will not move on the stub shaft. 11. Hold the outer CV-joint assembly with one hand. Grasp the steering knuckle with the other and rotate it out and to the rear of the vehicle. Install the outer CV-joint into the hub and bearing assembly. 12. Install or connect the following: Top of the steering knuckle into the strut assembly. Align the steering knuckle-to-strut assembly mounting holes. Strut assembly-to-steering knuckle attaching bolts. Install the nuts to the attaching bolts and while holding the bolt heads, torque the nuts to 125 ft. lbs. (170 Nm). Turn the nuts on the bolts. DO NOT turn the bolts. New hub and bearing assembly-toStub shaft retainer nut. Tighten but do not torque the nut at this time. Speed sensor cable routing bracket and screw Brake rotor and caliper assembly: then, tighten the caliper guide pin bolts to 30 ft. Ibs. (41 Nm) Front wheels and lug nuts Negative battery cable 13. Pump the brakes until a firm pedal is obtained. 14. Apply the brakes and torque the new

stub shaft-to-hub and bearing assembly retainer nut to 120 ft. Ibs. (163 Nm).

>: WARNING When tightening the stub shaft

retaining nut, be careful not to exceed the maximum torque specification of 120 ft. Ibs. (163 Nm). If this specification is exceeded, failure of the halfshaft could result. 15. Road test the vehicle to check for noise or vibration.

CV-Joints

OVERHAUL Inner (Tri-pot) Joint 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Disconnect the negative battery cable. 3. Remove the halfshaft and retaining clamps. 4. Slide the boot down the shaft away from the tri-pot housing. e>When separating the spider joint from the tri-pot joint housing, hold the rollers in place on the trunions to prevent the rollers and needle bearings

from falling away. 5. Carefully, slide the shaft/spider assembly from the tri-pot housing. 6. Remove the spider assembly-to-shaft Snapring; then, slide the spider assembly off the shaft.

® 1 2 3 4 5

— — — —

SNAP RING SEALING BOOT SPIDER ASSEMBLY SNAP RING PLIERS INTERCONNECTING

SHAFT 9306BG11

View of the halfshaft inner tri-pot joint and snapring

;

CHRYSLER CORPORATION

CONCORDE ¢ LHS ¢ 300M e INTREPID ¢ VISION

1 2 3 4

~ — — ~

SEALING BOOT INTERCONNECTING INTERCONNECTING BOOT CLAMP

SHAFT THINNEST GROOVE SHAFT

9306BG12

View of the halfshaft boot, shaft and boot

clamp

11. Install the snapring onto the shaft; make sure that the snapring is fully seated in the groove. 12. If installing a new boot, distribute 1 of the grease in the service package inside the tri-pot housing and the other 2 inside the boot. 13. Carefully, slide the spider assembly and shaft into the tri-pot housing. 14. Position the inner boot clamp evenly on the sealing boot. 15. Using the Crimper tool C-4975, place the tool over the clamp bridge, tighten the tool nut until the jaws are completely closed (face-to-face).

The seal must not be dimpled, stretched or out of shape. If necessary, equalize the seal pressure and shape it by hand.

1 - SEALING BOOT 2 — SPECIAL TOOL C-4975 3 — CLAMP BRIDGE

9306BG13

Securing the halfshaft boot clamp

If necessary, tap the spider assembly off the shaft using a brass drift; be careful not to hit the outer bearings. Se 7. Slide the boot off the shaft. 8. Throughly, inspect all parts for signs of excessive wear; if necessary, replace the halfshaft.

16. Position the boot onto the tripot housing retaining groove and install the retaining clamp evenly on the boot. 17. Using the Crimper tool C-4975, place the tool over the clamp bridge, tighten the tool nut until the jaws are completely closed (face-to-face). 18. Install the halfshaft into the vehicle.

Outer CV-Joint 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Disconnect the negative battery cable. 3. Remove the halfshaft and the retaining clamps. 4. Slide the boot down the shaft away from the CV-joint housing. 5. Remove the grease to expose the CV-joint-to-shaft retaining ring. 6. Spread the snapring ears apart and slide the CV-joint assembly off of the shaft. 7. Slide the boot off the shaft. 8. Throughly, clean and inspect all parts for signs of excessive wear; if necessary, replace the halfshaft. e>Component parts are not serviceable and must be replaced as an assembly. To install: 9. Slide the outer CV-joint boot clamp and boot onto the shaft; then, position the boot so that only the thinnest (sight) groove is visible on the shaft. 10. Slide the outer CV-joint assembly on the shaft, spread the snapring ears, position the CV-joint and verify that the snapring is fully seated in the shaft groove. 11. If installing a new boot, distribute /2 of the grease in the service package into the

@)

->Component parts are net serviceable and must be replaced as an assembly.

To install: 9. Slide the inner tri-pot boot clamp and boot onto the shaft; then, position the boot so that only the thinnest (sight) groove is visible on the shaft. 10. Install the spider assembly onto the shaft just far enough so that the snapring can be installed.

2k WARNING If necessary, tap the spider assembly onto the shaft using a brass drift; be careful not to hit the outer bearings.

5-20

1 — INTERCONNECTING SHAFT 2 — RETAINING SNAP RING 3 — OUTER C/V JOINT ASSEMBLY View of the halfshaft outer CV-joint and snapring

———

Guide For complete service labor times, order Nichols’ Chilton Labor

9306BG14

0-26

CHRYSLER CORPORATION

CONCORDE ¢ LHS ¢ 300M ¢ INTREPID @ VISION

CV-joint housing and the other ¥ inside the boot. 12. Position the outer boot clamp evenly on the sealing boot. 13. Using the Crimper tool C-4975, place the tool over the clamp bridge, tighten the tool nut until the jaws are completely closed (face-to-face).

The seal must not be dimpled, stretched or out of shape. If necessary, equalize the seal pressure and shape it by hand.

housing retaining groove and install the retaining clamp evenly on the boot. 15. Using the Crimper tool C-4975, place the tool over the clamp bridge, tighten the tool nut until the jaws are completely closed (face-to-face). 16. Install the halfshaft into the vehicle.

14. Position the boot onto the C\V-joint

STEERING AND SUSPENSION in unnecessary system repairs and/or personal injury.

* CAUTION Some 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 repairs.

PRECAUTIONS Several precautions must be observed when handling the inflator module to avoid accidental deployment and possible personal injury. e Never carry the inflator module by the wires or connector on the underside of the module. e When carrying a live inflator module, hold securely with both hands, and ensure that the bag and trim cover are pointed away. e Place the inflator module on a bench or other surface with the bag and trim cover facing up. e With the inflator module on the bench, never place anything on or close to the module which may be thrown in the event of an accidental deployment. Before servicing the vehicle, also make sure to refer to the precautions in the beginning of this section as well.

DISARMING

*«¢ CAUTION The Air Bag system must be disarmed 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 of the air bag, resulting

1. Disconnect the negative battery cable and isolate the cable using an appropriate insulator (wrap with quality electrical tape). 2. Allow the system capacitor to discharge for 2 minutes before starting any repair on any air bag system or related components. This will disable the air bag system.

stk CAUTION Always wear safety goggles when working with or around the air bag system. When carrying a live air bag, 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 accidentally deployed.

Power Rack and Pinion Steering Gear REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Turn the front wheels to the straightahead position. 3. Remove or disconnect the following: Negative battery cable Wiper arms Wiper module cover and cow! cover Reinforcement from the strut towers and wiper module Throttle body's intake air duct and resonator 4. Clamp the steering wheel in the center position with some type of holding device. e Intermediate shaft from the steering column coupler

x e Both tie rods from the steering gear and place them on the transaxle bell housing e Siphon the power steering fluid from the reservoir e Power steering gear fluid lines 5. lf equipped with speed proportional Steering, disconnect the wiring from the solenoid control valve on the end of the steering gear under the master cylinder. e Master cylinder from the booster and position it to the side without disconnecting the fluid lines e Booster vacuum line >It may be helpful to loosen the 2 bolts attaching the right mounting bracket to the steering gear in order the clear the air conditioning lines.

¢ 4 steering gear mounting bolts (2

on each side)

6. Move the steering gear and intermediate shaft into the engine compartment to gain access to the roll pin. e>Special tools are commercially available for removing roll pins. ¢ Roll pin and separate the intermediate shaft from the steering gear e Right front wheel ¢ Tie rod end from the steering arm on the right strut elf equipped with a 2.7L engine, turn the left front tire towards the left as far as possible to provide clearance.

9300BG04

The steering gear is removed or installed through the right side of the vehicle

CHRYSLER CORPORATION

CONCORDE © LHS ¢ 300M ¢ INTREPID ¢ VISION

equipped with Antilock Brake System (ABS) Brake caliper assembly. Support the caliper assembly from the vehicle frame with a strong piece of wire. Do not allow the assembly to hang by the brake hose. Remove the front brake rotor disc

STEERING GEAR BOOT

Be sure the spacer block in the rack is centered before connecting the tie rods to the steering gear.

SPACER BLOCK 9300BG05

Center the spacer block in the steering gear before installing the tie rods

RETAINING TABS

STEERING

GEAR

“

"WASHER

\

9300BG06

Be sure to position the washers between the tie rods and the steering gear as shown

7. Slide the right end of the steering gear out through the tie rod hole while raising the left end of the steering gear upward. To install: 8. Position the tie rod attaching points at the center of the steering gear travel. 9. Install or connect the following: e Steering gear e>lf equipped with a 2.7L engine, turn the left front tire straight-ahead.

e Right tie rod on the steering arm and torque the nut to 27 ft. Ibs. (37 Nm) Right front wheel. Torque the lug nuts in sequence to half of the specified torque, then tighten the nuts in sequence again to 95 ft. Ibs. (129 Nm). Intermediate shaft to the steering gear using the roll pin. Be sure the pin is centered in the joint. 4 steering gear mounting bolts and torque the bolts to 43 ft. Ibs. (58 Nm) Bracket bolts: tighten them (if loosened) to 27 ft. Ibs. (37 Nm) Steering gear fluid lines; torque the nuts to 35 ft. Ibs. (47 Nm) Solenoid valve, if equipped with speed proportional steering

e Tie rods to the steering gear with the washers between the rods and the steering gear. Torque the bolts to 60 ft. Ibs. (82 Nm). e Remaining components in the reverse order of the removal steps e Negative battery cable 10. Add Mopar® power steering fluid to the reservoir and let it settle for at least 2 minutes. Start the engine for a few seconds and turn it OFF. Add fluid as necessary. Repeat this procedure until the fluid level remains constant. 11. Raise the front wheels off the floor and start the engine. Turn the steering from lock-to-lock several times. Do not hold the wheel in the locked position for more than 2 seconds at a time. Refill the reservoir as needed. 12. Lower the vehicle and repeat the procedure. If the fluid is extremely foamy, allow the vehicle to stand with the engine OFF for a few minutes, then repeat the procedure.

REMOVAL & INSTALLATION Front

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. ->Service of the coil spring requires the use of a coil spring compressor tool. It is required that 5 coils be captured within the jaws of the compressor tool. ->Do not support the vehicle by placing supports under the suspension arms. The suspension arms must hang freely.

2. Remove or disconnect the following: ¢ Negative battery cable ¢ Front wheel(s) e Stabilizer bar attaching link at the strut assembly 3. Loosen, but do not remove the outer tie rod end-to-strut assembly steering arm attaching nut. Then, remove the outer tie rod end from the steering arm using puller MB990635. e Speed sensor wiring harness mounting bracket from the strut, if

0-2/

The strut assembly-to-steering knuckle bolts are serrated where they go through the strut and steering knuckle. Do not turn the bolts during removal. If the bolts are turned, damage to the steering knuckle will result. 4. The strut assembly-to-steering knuckle bolts must not be turned during strut removal. Hold the bolt head with a wrench and turn the nuts off the bolts. 5. Remove the 3 strut assembly upper mount-to-shock tower mounting nuts and washers. Remove the strut from the vehicle. 6. Disassemble the strut by performing the following procedure: a. Securely mount the strut assembly into a vise. Using paint, mark the strut unit, lower spring isolator, spring and upper strut mount for indexing of the parts at assembly. b. Position the spring compressor tool onto the strut. Compress the coil spring until all load is off the upper strut mount assembly. c. Install Strut Rod Socket tool L-4558A on the strut shaft nut and a 10mm socket on the end of the strut shaft to prevent it from turning. Remove the strut shaft nut. d. Remove the upper mount assembly, jounce bumper and seat bearing and dust shield as an assembly. e. Remove the coil spring and compressor as an assembly from the strut. Remove the lower spring isolator from the strut assembly lower spring seat. f. Inspect all components for abnormal wear, oil leakage or failure. Replace parts as required. To install: 7. Assemble the strut by performing the following procedure: a. Inspect the strut assembly for signs of leakage. Actual leakage will be a stream of fluid running down the side and dripping off the lower end of the strut. A slight amount of seepage between the strut rod and strut shaft seal

Please visit our web site at www.chiltonsonline.com

0-28

CHRYSLER CORPORATION

CONCORDE ¢ LHS ¢ 300M ¢ INTREPID ¢ VISION

is not unusual and does not affect performance of the strut assembly. b. Install the lower spring isolator on the strut unit. Install the compressed coil spring onto the strut assembly aligning the paint marks made during removal. c. Install the strut bearing into the bearing seat. The bearing must be installed into the seat with the notches on the bearings facing down. d. Lower the seat bearing and dust shield onto the strut and spring assembly. Align the paint marks made during removal. e. Install the jounce bumper and upper mount on the strut shaft, aligning the paint marks. f. Install the strut mount-to-shaft retainer nut. Inspect all alignment marks made during removal and align as required. While holding the strut shaft from turning with a 10mm socket, torque the strut shaft nut to 70 ft. Ibs. (94 Nm). g. Equally loosen the spring compressor tool until all tension is released. Remove the spring compressor tool. 8. Install the front strut into the strut tower. Torque the 3 upper nuts to 25 ft. Ibs. (33 Nm). 9. Position the steering knuckle neck into the strut assembly. Install the strut assembly-to-steering knuckle bolts. Install the nuts onto the attaching bolts and torque to 125 ft. Ibs. (169 Nm). Do not turn the serrated bolt heads during installation. Turn only the nuts.

knuckle will result. SE

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Rear

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. The rear strut assemblies support the weight of the vehicle using coil springs positioned around the struts. The coil Springs are contained between the upper mount of the strut assembly and a lower spring seat on the body of the strut assembly. The strut is attached to the spindle by a split collar on the rear spindle with a pinch bolt to hold the spindle to the strut. 2. Remove or disconnect the following: Rear wheel Caliper assembly and rotor from the hub, if equipped with rear disc brakes Brake flex hose from the support bracket and wheel cylinder, if equipped with rear drum brakes. Plug the brake flex nose to prevent system contamination. Do not allow the rear caliper to hang by the brake hose. Support the caliper off of the frame with a strong piece of wire. Speed sensor cable routing bracket and tube, if equipped with ABS Lateral links to the rear spindle assembly bolts Rear strut assembly-to-stabilizer bar attaching link at the stabilizer bar

e» Service of the coil spring requires the use of a coil spring compressor tool. It is required that 5 coils be captured within the jaws of the compressor tool.

a. Securely mount the strut assembly into a vise. Using paint, mark the strut assembly, lower spring isolator, spring and upper strut mount for indexing of the parts at reassembly. b. Position a spring compressor tool onto the coil spring. Compress the coil spring until all load is off of the upper strut mount assembly.

17 LATERAL LINKS Spon BOLT

At 79228648

Separate the lateral links from the spindle—rear strut service

e>Hold the hex on the attaching link Stud while breaking the nut loose. The attaching link does not have to be removed from the strut.

The strut assembly-to-steering knuckle bolts are serrated (toothed) where they go through the strut and Steering knuckle. Do not turn the bolts during removal. If bolts are turned, damage to the steering ELLE

the lug nuts, in sequence, to 95-100 ft. Ibs. (129-135 Nm). e Negative battery cable

ERO

10. Install or connect the following: Brake rotor and caliper assembly to the adapter and torque the caliper bolts to 14 ft. Ibs. (19 Nm) Front speed sensor cable routing bracket onto the front strut, if equipped Outer tie rod on the steering arm and torque the attaching nut to 27 ft. Ibs. (37 Nm) Stabilizer link assembly onto the strut assembly and torque the attaching nut to 70 ft. Ibs. (95 Nm) Front wheel and lug nuts. Torque

3. Remove the rear spindle-to-strut assembly pinch bolt. Install a center punch in the hole on the spindle and tap the punch into the hole until jammed. This will spread the spindle casting allowing it to be removed from the strut. 4. Using a hammer, tap on the top surface of the spindle, driving the spindle down and off the end of the strut assembly. Let the spindle and assembled components hang from the trailing arm while the strut is being Serviced. 5. From inside the trunk of the vehicle, remove the 3 upper strut mounting bolts and remove the strut from the vehicle. 6. Disassemble the strut by performing the following procedure:

7922BG49

Remove the nut from the stabilizer-to-strut

attaching link stud at the bar—rear strut service

STRUT ASSEMBLY

7922BG50

Loosen, then remove the rear spindle-tostrut pinch bolt—rear strut service

’

CHRYSLER CORPORATION

CONCORDE ¢ LHS ¢ 300M ¢ INTREPID @ VISION

CENTER

7922BG51

Insert a center punch into the hole on the spindle and tap until the casting is spread—rear strut service

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CENTER PUNCH

| 79228652

Tap with a hammer on the surface of the spindle driving it down and off the end of the strut—rear strut service

c. Install the strut rod socket tool L4558 on the strut shaft nut and an 8mm Allen wrench on the end of the strut shaft to prevent it from turning. Remove the strut shaft nut. d. Remove the upper strut mount assembly off of the strut shaft. Remove the coil spring and compressor tool as an assembly from the strut. e. Remove the plate, dust shield and jounce bumper off of the strut unit. f. Inspect all components for abnormal wear, oil leakage or failure. Replace parts as required. To install: 7. Assemble the strut by performing the following procedure: a. Install the lower spring isolator on the strut unit. If it is the original isolator, align the paint marks. b. Install the jounce bumper into the dust shield. Install the plate on top of the dust shield and into the jounce bumper. c. Install the dust shield, jounce — bumper and the top plate onto the strut unit as an assembly. d. Install the coil spring and compressor tool onto the strut unit and align the paint marks on the spring to that of the strut unit.

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_ STRUT ASSEMBLY = Tiga MOUNTING NUTS

VEHICLE

STRUT

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TOWER

7922BG54

Access the 3 upper strut mounting nuts through the trunk—rear strut service

TRAILING ARM

TRUT : ASSEMBLY

z |

LOCATING TAB

BOLT 7922BG55

7922BG53

ear strut service Allow the components to hang from the trailing arm as shown—r

During reassembly, tap the spindle onto the strut until the notch in the spindle is tightly seated against the tab—rear strut

Timing belt service is covered in Section 3 of this manual

0-30

CHRYSLER CORPORATION

CONCORDE ¢ LHS ¢ 300M ¢ INTREPID ¢ VISION

Nm), while holding the stabilizer link stud at the hex with a wrench Rear speed sensor cable routing tube and bracket, if equipped with ABS Rotor and caliper assembly (if equipped with rear disc brakes) and torque the bolts to 16 ft. Ibs. (22 Nm) Rear brake flex hose to the wheel cylinder and support plate, if equipped with rear drum brakes Rear wheel(s) and torque the lug nuts, in sequence, to 95 ft. Ibs. (129 Nm) 11. Bleed the brake system, if equipped with rear drum brakes. 12. Have the rear wheel toe set to specifications.

Coil Springs REMOVAL & INSTALLATION Front

Refer to the front strut removal and installation procedure for coil spring service information. Rear

Refer to the rear strut removal and instal-

lation procedure for coil spring service information.

Lower Ball Joint >The lower ball joints on these vehicles are not serviced separately. The lower ball joints operate with no freeplay. If defective, the entire lower control arm must be replaced.

Lower Control Arm

CRADLE ASSEMBLY

west

Pulling the steering knuckle out from the vehicle after releasing from the ball joint can separate the inner CVjoint. Do not separate the inner CVjoint or it can be damaged.

5. Remove the tension strut-to-cradle attaching nut and washer from the end of the tension strut. When removing the nut, keep the strut from turning by holding the tension strut at the flats using an open end wrench. Discard the tension strut-to-cradle retainer nut. A new nut must be used during installation.

LOWER CONTROL ARM

7922BG57

Loosen the pivot bolt and remove it— lower control arm service

lower control arm from the front cradle assembly. The isolator bushings consist of a metal encased pivot bushing and a solid rubber tension strut bushing. The lower control arm is bolted to the cradle assembly using a pivot bolt through the center of the rubber pivot bushing at the tension strut isolator bushing. The ball joint is built into the lower control arm and is non-serviceable. If the ball joint becomes worn, the entire lower control arm must be replaced. The ball joint seal, however, is replaceable as well as the lower control arm inner bushing. If the lower control arm is damaged, do not attempt to repair or straighten a broken or bent lower control arm. 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove the front wheel(s). 3, Remove the ball joint stud-to-steering knuckle clamp nut and bolt. 4. Carefully insert a prybar between the lower control arm and the steering knuckle and separate ball joint from knuckle. Be sure the ball joint seal does not get damaged during separation.

>A new tension strut-to-cradle attach-

ing nut must be used when installing the tension strut.

6. Loosen and remove the lower control arm pivot bushing-to-cradle assembly pivot bolt. 7. Separate the lower control arm and tension strut from the cradle as an assembly by first removing the pivot bushing from the cradle, then sliding the tension strut out of the isolator bushing. Inspect the control arm and tension strut for distortion, check the rubber bushings for excessive wear or deterioration and replace these components, if necessary. To install:

8. Installorconnect the following: ¢ Tension strut and isolator bushing into the cradle first, then install lower control arm pivot bushing into bracket on the cradle Lower control arm-to-cradle bracket attaching bolt. Do not tighten the bolt at this time. Washer and new nut on the end of the tension strut. Torque the tension strut-to-cradle bracket retainer

REMOVAL & INSTALLATION BALL JOINT SEAL

The front lower control arm is a steel

LOWER CONTROL ARM TENSION STRUT BUSHING

forging with 2 rubber bushings isolating the

NUT

TENSION STRUT

pale

LOWER CONTROL A RM

TENSION STRUT 7922BG56

Remove the tension strut-to-cradle nut and washer—lower control arm service

TENSION STRUT TO CRADLE ISOLATOR BUSHING

LOWER CONTROL ARM PIVOT BUSHING

WORD “FRONT” STAMPED IN CONTROL ARM HERE 7922BG58

Inspect the control arm and tension strut for distortion—lower control arm service

CHRYSLER CORPORATION CONCORDE e LHS ©300M ¢ INTREPID © VISION nut to 110 ft. Ibs. (150 Nm), while holding the tension strut flat with an open end wrench. 9. 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. lbs. (65 Nm). 10. Install the front wheel and lug nuts. Torque the lug nuts, in a star pattern, to 95-100 ft. Ibs. (129-135 Nm). Lower the vehicle so the suspension is supporting the weight of the vehicle 11. Torque the lower control arm pivot bushing-to-cradle bracket attaching bolt to 105 ft. Ibs. (142 Nm).

CONTROL ARM BUSHING REPLACEMENT 1. Remove the lower control arm/tension strut assembly from the vehicle. 2. Remove the nut and separate the tensions strut from the lower control arm. 3. Using an arbor press, position the lower control arm with the large end of the pivot bushing inside the Receiver tool MB990799. 4. Position Remover tool 6644-2 on top of the pivot bushing. 5. Using the arbor press, press the pivot bushing out of the lower control arm. To install: 6. Turn the lower control arm over and reposition it on the Receiver tool MB990799. 7. Using a new pivot bushing, position it in the lower control arm so that it is square with the bushing hole.

41 2 3 4 5

-— — — —

1 2 3 4 5 6

— — — — — —

ARBOR PRESS RAM SPECIAL TOOL 6644-1 SPECIAL TOOL MB990799 PIVOT BUSHING TENSION STRUT BUSHING LOWER CONTROL ARM

1 2 3 4 5

9306BG25

Removing the lower control arm pivot bushing

ARBOR PRESS RAM SPECIAL TOOL 6644-4 SPECIAL TOOL M8990799 TENSION STRUT BUSHING LOWER CONTROL ARM 9306BG23

9306BG22

Installing the lower control arm pivot bushing

8. Position Installer tool 6644-1 on top of the pivot bushing with the pivot bushing Setting in the recessed area of the installer tool. 9. Using the arbor press, press the pivot bushing into the lower control arm until the installer tool squarely bottoms against the surface of the lower control arm. 10. Install the tension strut into the lower control arm’s tension strut bushing with the word FRONT, stamped on the tension strut, facing away from the control arm. 11. Position an open end wrench on the flat of the tension strut to keep it from turning. Torque the tension strut-to-lower control arm nut to 95 ft. Ibs. (130 Nm).

TENSION STRUT BUSHING REPLACEMENT 1. Remove the lower control arm/tension strut assembly from the vehicle. 2. Remove the nut and separate the tensions strut from the lower control arm. 3. Using an arbor press, position the lower control arm with the tension strut bushing inside the Receiver tool MB990799. 4. Position Remover tool 6644-4 on top of the tension strut bushing. 5. Using the arbor press, press the tension strut bushing out of the lower control arm.

ARBOR PRESS RAM SPECIAL TOOL 6644-2 SPECIAL TCOL MB990799 PIVOT BUSHING LOWER CONTROL ARM

— — — — —

=>As the Remover tool is press through the tension strut bushing, it will cut the bushing into 2 pieces.

6. Remove the lower control arm, both bushing pieces and the Remover tool.

J-31

Removing the lower control arm’s tension strut bushing

1 2 3 4 5

— — — — —

ARBOR PRESS SPECIAL TOOL 6644-2 LOWER CONTROL ARM SPECIAL TOOL 6644-3 SPECIAL TOOL MB990799 9306BG24

Installing the lower control arm’s tension strut bushing

To install: 7. Thoroughly, lubricate the new tension strut bushing, the lower control arm and the Installer tool 6644-3 with Rubber Bushing Installation Lube. 8. Press the new tension strut bushing by hand, into the large end of the Installer tool 6644-3 as far as it will go. 9. Position the lower control arm onto on the arbor press so that the tension strut hole is centered on the Receiver tool MB990799. 10. Position Installer tool 6644-3, with the bushing installed, inside the tension strut bushing hole in the lower control arm. 11. Position Installer tool 6644-2 on top of the tension strut bushing. 12. Using the arbor press, press the tension strut bushing into the lower control arm.

Heater Core replacement is covered in Section 2 of this manual

0-32

CHRYSLER CORPORATION

CONCORDE ¢ LHS @ 300M ¢ INTREPID ¢ VISION

e>As the bushing is being installed, a pop will be heard and Installer tool 6644-3 will move slightly up off the control arm.

13. Remove the contro! arm assembly from the arbor press and remove Installer tool 6644-3 from the tension strut bushing; the tension strut bushing is now installed. 14. Install the tension strut into the lower control arm's tension strut bushing with the word FRONT, stamped on the tension strut, facing away from the control arm. 15. Position an open end wrench on the flat of the tension strut to keep it from turning. Torque the tension strut-to-lower control arm nut to 95 ft. Ibs. (130 Nm).

Wheel Bearings

ADJUSTMENT These front wheel drive vehicles are equipped with permanently sealed front and rear wheel bearings. There is no periodic lubrication or maintenance recommended for these units.

REMOVAL & INSTALLATION Front

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove the front wheel. 3. Remove the front caliper assembly from the steering knuckle by removing the 2 guide pin bolts, then rotating the top of the caliper away from the knuckle and lifting the caliper off the machined abutment on the steering knuckle. 4. Suspend the caliper out of the way with a piece of wire.

5. Remove the front brake rotor from the hub by pulling it straight off of the wheel mounting stud. 6. Remove the hub and bearing-to-stub axle retainer nut. >This hub nut is a torque prevailing retaining nut and can not be reused. A NEW retaining nut MUST be used when assembling the hub.

7. Remove the 3 attaching bolts that mount the hub and bearing assembly to the steering knuckle. assembly, elf 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 the flinger disc becomes damaged during the removal procedure, the hub and bearing assembly must be replaced. 8. Remove the hub and bearing assembly from the steering knuckle by sliding it straight out of the knuckle and off the ends of the stub shaft. 9. Gently pry the assembly out with a prybar or tap it out with a soft-faced hammer, if necessary. Be very careful not to damage the hub and bearing assembly. To install: 10. Clean the hub and bearing mounting surfaces of dirt and be sure there are no nicks present. 11. Install or connect the following: e Hub and bearing squarely onto the stub shaft and the steering knuckle ¢ Bearing assembly mounting bolts and tighten equally until the bearing assembly is seated squarely against the front of the steering knuckle. Torque the mounting bolts to 80 ft. Ibs. (110 Nm). PRY BAR

INSERT PRY BAR HERE

KNUCKLE

HUB/BEARING ASSEMBLY 9300BG07

Carefully pry the front bearing/hub assembly away from the steering knuckle

e New hub and bearing assembly-tostub shaft retainer nut. ANEW retaining nut MUST be used when assembling the hub. Tighten but do not torque the nut at this time. Brake rotor and the caliper assembly. Torque the brake caliper guide bolts to 16 ft. Ibs. (22 Nm). Wheel and lug nuts. Torque the lug nuts in a star pattern to 95-100 ft. Ibs. (129-135 Nm). 12. Pump the brakes until a firm pedal is obtained. ] 13. With the weight on the vehicle on its wheels, apply the brakes to keep the vehicle from moving. Torque the hub and bearing assembly-to-stub shaft retaining nut to 120 ft. lbs. (163 Nm).

When tightening the hub and bearing assembly to stub shaft retaining nut, do not exceed the maximum torque of 120 ft. Ibs. (163 Nm). If the maximum torque is exceeded this may result in a failure of the halfshaft. 14. Inspect the toe setting on the vehicle and adjust, if necessary. Rear

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the follow-ing: e Rear wheel Brake caliper and rotor, if equipped with rear disc brakes Brake drum, if equipped with drum brakes Bearing dust cap Cotter pin, nut retainer, nut, washer and bearing/hub assembly from the spindle To install: 3. Install or connect the following: Bearing/hub assembly, the bearing/hub assembly washer and torque the nut to 124 ft. Ibs. (168 Nm) Nut retainer and a new cotter pin e Dust cap Brake drum or rotor and caliper assembly Rear wheel and torque the lug nuts, in a star pattern, to 95-100 ft. Ibs. (129-135 Nm) 4. Road test the vehicle to verify no excessive noise from the rear wheel bearing area.

CHRYSLER CORP. 1998-02 Chrysler-Sebring Coupe * Dodge-Avenger DRIVE TRAING SC ... 6-26 ENGINE REPAIR.............-.0\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 vehicle. Use caution to avoid damaging the boots. To install:

6. Align the rack assembly so the

Splines are inserted into the steering column shaft. 7. Install or connect the following: Steering rack and torque the mounting bolts to 51 ft. Ibs. (69 Nm) Pinch bolt and torque the bolt to 13 ft. Ibs. (18 Nm) Power steering fluid lines; torque the high side fitting to 11 ft. Ibs. (15 Nm) and secure the low side hose with the clamp and raise the engine into position Rear roll stopper through-bolt and torque to 32 ft. Ibs. (43 Nm) Crossmember and torque the front bolts to 58-65ft. Ibs. (78-88 Nm) and the rear bolt to 51-58 ft. Ibs. (69-78 Nm) Front roll stopper bolt and torque the nut to 32 ft. Ibs. (43 Nm) Both triangular braces and torque the bolts to 50-56 ft. Ibs. (69-78 Nm) e Stabilizer bar e Tie rod ends and torque the nuts to 20 ft. Ibs. (27 Nm) Solenoid’s wiring harness connector, if equipped with EPS Front wheels

For Accessory Drive Belt illustrations, see Section 1 of this manual

6-38

CHRYSLER CORP.

SEBRING COUPE ¢ AVENGER

8. Refill the reservoir with power steering fluid and properly bleed the power steering system. 9. Perform a front end alignment. 1

3.0L Engine

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the power steering fluid. 3. Remove or disconnect the following: Negative battery cable from the left shock tower Front exhaust pipe Center member Steering shaft assembly Tie rod end from the steering knuckle Return hose and pressure tube connections Cylinder clamp Steering gear from the vehicle To install: 4. Install or connect the following: Steering gear to the vehicle Cylinder clamp and torque the bolts to 51 ft. Ibs. (69 Nm) Pressure tube and return hoses and torque to 11 ft. Ibs. (15 Nm) Tie rod ends to the steering knuckle and torque the nut to 21 ft. Ibs. (29 Nm) Stay and torque the bolts to 55 ft. lbs. (74 Nm) Steering shaft assembly and torque the bolt to 13 ft. Ibs. (18 Nm) ¢ Center member ¢ Negative battery cable 5. Fill and bleed the power steering system. 6. Start the vehicle, check for leaks and repair if necessary. 7. Perform a front wheel alignment.

$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.

|

103 Nm 75 ft.lbs, ey

Exploded view of the rear shock absorber

Rear

Brass c ie > \eee

79220633

Exploded view of the front shock absorber

we A

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FORK

79220631

Exploded view of the front shock absorber assembly mounting

The rear package shelf front cover(s) must be removed to access the top mounting nuts. Most connections are plastic clips. Use care when removing these components to avoid unnecessary damage. 1. Remove or disconnect the following: e Rear shelf speaker covers ¢ Rear shelf top assembly e Front cover(s) to access the shock absorber top mounting nuts 2. Raise and support lower control arm assembly slightly. e Shock absorber upper mounting nuts e Shock absorber lower mounting bolt e Shock absorber To install: 3. Position the shock absorber assembly so that the lower mounting bolt can be installed and lightly tightened.

22Nm 16 ft.lbs.

1. Self-locking nut 2. Washer 3. Upper bushing A 4. Bracket

7. Collar Cc up 9. Dust cover

7922CG34

Exploded view of the rear shock absorber

For Tire, Wheel and Ball Joint specifications, see Section 1 of this manual

6-40

CHRYSLER CORP.

SEBRING COUPE ¢ AVENGER

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7. 8. 9. 10, 11. 12.

UPPER BUSHING B CUP ASSEMBLY BUMP RUBBER DUST COVER COIL SPRING SHOCK ABSORBER ASSEMBLY 9346FG09

Exploded view of the shock absorber

¢ Top plate nuts and torque the mounting nuts to 32 ft. Ibs. (44 Nm) e Lower mounting bolt and torque the bolt to 71 ft. Ibs. (98 Nm) e Interior trim pieces

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 e Rear shelf trim ¢ Cover from the upper shock tower ¢ Upper mounting nuts ¢ Shock from the rear steering knuckle ¢ Shock assembly To install: 3. Install or connect the following: Shock absorber and torque the shock to steering knuckle bolt to 73 ft. Ibs. (98 Nm) Upper shock nuts and torque to 32 ft. Ibs. (45 Nm) Upper tower cover Rear shelf trim Negative battery cable

REMOVAL & INSTALLATION Front

2.0L AND 2.5L ENGINES 1. Before servicing the vehicle, refer to the precautions in the beginning of this section.

2. Place the shock absorber assembly in Compressor Tools MB991237 and MB991238 spring compressor assembly or equivalent. Tighten the compressor and compress the spring slowly. Make certain the compressor is properly engaged before tightening. 3. After tension has been removed from the shock absorber assembly and shock absorber plate, remove the piston rod nut and washer from the top of the shock absorber assembly. 4. |f the spring is to be replaced, slowly release the tension on the spring compressor. Allow the spring to expand fully. If only the shock absorber is being replaced, the spring may remain in the compressor assembly. 5. By hand, remove the upper shock absorber bearing, washer, mount and shock absorber shield. Remove the upper insulator ring, the spring, the bumper and lower insulator from the spring. Take notice to each components location for proper reassembly. To install: 6. Install the lower insulator, the shock absorber bumper and the uncompressed spring. Install the upper spring insulator, shock absorber shield, mount and washer. /. Install or align the spring compressor. Make certain the spring is correctly positioned relative to the upper and lower insulator rings. Smoothly compress the Spring. 8. Install the washer and piston rod nut. Torque the nut on the front strut to 18 ft, Ibs. (25 Nm) or 16 ft. Ibs. (22 Nm) on the rear strut. Install the dust cap.

9. Carefully release the spring com-_ pressor, watching the spring position as it seats. When the spring is properly seated, release/remove the compressor tools. 10. Reinstall the shock absorber assembly.

3.0L ENGINES 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Disassemble as follows: 3. Remove the strut/shock assembly and place it in a Suitable compressor tool. 4. Install Special Tool MB991176 to secure the strut and remove the dust cover and jam nut. 5. Remove the strut insulator. 6. Remove the upper spring seat and pad. 7. Rempve the bump rubber and dust cover. 8. Remove the coil spring. 9. Remove the lower spring pad. To assemble: 10. Install the lower spring pad and coil spring. 11. Install the dust cover and bump rubber. 12. Install the upper spring pad and seat. 13. Carefully compress the spring and install the insulator and jam nut. 14. When properly aligned, torque the jam nut to 47 ft. Ibs. (64 Nm). 15. Install the dust cover and remove the compressor tools. 16. Install the strut/shock to the vehicle. Rear

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Disassemble as follows: 3. Remove the rear shock from the vehicle. 4. Install the assembly in a spring compressor tool. 5. Remove the jam nut, washer and upper bushing. 6. Remove the upper bracket assembly and spring pad. 7. Remove the collar and bushing. 8. Remove the cup, bump rubber and dust cover. 9. Remove the coil spring To assemble: 10. Install the coil spring to the shock absorber using Compressor Tools MB991237 and MB991239. 11. Install the dust cover and bump rubber. 12. Install the cup and bushing 13. Install the collar, supper spring pad and bracket assembly,

CHRYSLER CORP.

SEBRING COUPE ¢ AVENGER 14. Install the upper bushing and washer. _ 15. When properly aligned, install the jam nut and torque to 17 ft. Ibs. (23 Nm). 16. Remove the compressor tools and install the shock absorber.

86 Nm 62 Bia

ae

2

—

SS ee

—

4

4

Upper Ball Joint

57Nm

Nm 417 fulbs.

41 ft.lbs.

O=P4

REMOVAL & INSTALLATION

Wes

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Saat

The upper ball joint is an integrated part of the upper control arm assembly for the 2.0L and 2.5L engines, and cannot be serviced separately. A worn or damaged ball joint requires replacement of the upper control arm assembly.

Lower Ball Joint

|

|

1. Upper arm ball joint and knuckle connection

2. Self-locking nut for upper arm installation

—

3. Upper arm assembl 4. Upper arm shaft assembly 79220635

REMOVAL & INSTALLATION The front suspension on the 2.0L and 2.5L engines is called a Multi-Link Suspension. There are 2 lower arms used in this front suspension; a curved arm called the Compression Lower Arm and also a straight arm calied the Lateral Lower Arm. Both arms contain lower ball joints since there are 2 sockets in the steering knuckle. Ball joints and lower arms are removed and replaced as an assembly. A front end alignment is required after these procedures.

Upper Control Arm

Exploded view of the upper contro! arm mounting

6-41

trol arm mounting nuts. Remove the nuts and using the joint separation tool, separate the upper arm shafts from the shock absorber tower. 5. Remove or disconnect the following: e Upper control arm assembly e Upper arm shaft assembly-to-upper control arm nuts/bolts and the shaft(s) To install: 6. Install the upper arm shaft assemblies to the upper control arm and torque the nuts and bolts to 41 ft. Ibs. (57 Nm). 7. Align the upper control arm shafts to the shock absorber tower and secure it with the mounting nuts. Torque the mounting nuts to 62 ft. Ibs. (86 Nm). 8. Install or connect the following: e Ball joint to the knuckle and torque the locking nut to 20 ft. Ibs. (28 Nm) e Front wheel 9. Check the wheel alignment and adjust, if necessary. 3.0L Engine

c. If the ball joint stud is out of specification (turns too easily or is too stiff), continue with the ball joint/control arm assembly replacement. >The upper ball joint boot can be removed and the joint greased. A new replacement ball joint boot is recommended.

4. Inside the engine compartment, at the shock absorber tower, locate the upper con-

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Rear wheel e Upper contro! arm from the steering knuckle e Upper control arm assembly Upper control arm bracket e Upper control arm

REMOVAL & INSTALLATION 2.0L and 2.5L Engines 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Front wheel e Ball joint stud from the steering knuckle, using the joint separation Too! MB991113 3. The ball joint can be checked using the following procedure: a. An adapter (MB 990326) is available that fits onto the ball joint stud and adapts to an inch-pound torque wrench. If this tool is not available, a shop-made substitute can be fabricated. b. Turn the bail joint stud with the torque wrench. The factory standard for breakaway torque is 3-13 inch Ibs. (0.34-1.45 Nm).

1. i)

UPPER ARM AND KNUCKLE CONNECTING BOLT UPPER ARM ASSEMBLY MOUNTING BOLTS

3. 4. 5.

Exploded view of the upper control arm assembly

For Wheel Alignment specifications, see Section 1 of this manual

UPPER ARM ASSEMBLY UPPER ARM BRACKET UPPER ARM 9346FG10

6-42

CHRYSLER CORP.

SEBRING COUPE e AVENGER e Ball joint stud from the steering knuckle, using Joint Separator Tool MB991113 ¢ Damper fork-to-lower control arm through-bolt e Lower control arm-to-crossmember bolt e Lower control arm To install: 3. When installing the control arm, temporarily tighten the nuts and/or bolts securing the control arm to the suspension crossmember. Tighten them fully only after the vehicle is sitting on its wheels. 4. Install or connect the following: e Damper fork and torque the fork-tolower control arm through-bolt to 64 ft. Ibs. (88 Nm) e Ball joint stud to the knuckle and torque the nut to 65-80 ft. Ibs. (88-108 Nm). Install a new cotter pin. e Tension rod to the control arm and torque the nuts to 80—94 ft. Ibs. (108-127 Nm)

To install: 3. Install or connect the following: Upper control arm and brackets and torque the bolts to 42 ft. Ibs. (57 Nm) Upper contro! arm assembly and torque the bolts to 29 ft. Ibs. (39 Nm) Upper control arm to the steering knuckle and torque the bolt 73 ft. lbs. (98 Nm) Rear wheel

Lower Control Arm

REMOVAL & INSTALLATION Lateral Lower Arm

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Front wheel e Stay bracket from the crossmember 98-118 Nm 71-85 ft.lbs.

83 Nm

e Stay bracket to the crossmember and torque the mounting bolts to 50-56 ft. Ibs. (69-78 Nm) e Front wheel 5. Once the full weight of the vehicle is on the suspension, torque the inner lower arm mounting bolt nut to 71-86 ft. Ibs. (98-118 Nm). 6. Check the front end alignment and adjust as required. Compression Lower Arm

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Front wheel e Ball joint stud from the steering knuckle, using Joint Separator Tool MB991113 ¢ Lower control arm-to-crossmember bolt To install: 3. Install or connect the following: e Control arm to the crossmember and torque the bolts to 60 ft. Ibs. (83 Nm) e Ball joint stud to the knuckle and torque the nut to 43-51 ft. Ibs. (59-71 Nm) e Front wheel 4. Check the front end alignment and adjust as required.

3.0L ENGINE

59-71.Nm 43 — 51 ft.lbs.

1

Dust cover

69-78 Nm 51 ~ 58 ft.lbs.

Grease: MOPAR Multi-mileage Lubricant Part No. 2525035 or equivalent

=.

Compression lower arm ball joint and knuckle connection . Compression lower arm mounting bolt

nN. QO

Compression

lower arm

Sta Shock absorber lower mounting bolt and nut Lateral lower arm ball joint and knuckle connection Lateral lower arm mounting bolt and nut SN Ss EROS Lateral lower arm assembly

assembly

Caution *: Indicates parts which should be temporarily tightened, and then fully tightened with the vehicte on the groundin the unladen condition. 7922CG36

Exploded view of the lateral lower arm and the compression lower arm mounting

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Front wheel ¢ Lower control arm from the steering knuckle ¢ Lower control arm mounting bolt and clamp ¢ Lower control arm 3. If replacing the bushing, perform the following: a. Apply soapy water between the shaft and old bushing and pry the old bushing out. To install: 4. Apply soapy water to the shaft and new bushing and install the new bushing, if removed. 5. Install or connect the following: ¢ Lower control arm ¢ Lower control arm clamp and torque the bolts to 60 ft. Ibs. (81 Nm) ¢ Lower control arm to the steering knuckle and torque the bolts to 80 ft. Ibs. (108 Nm)

CHRYSLER CORP.

S EBRING COUPE ¢ AVENGER e Front wheel 6. Check and adjust the front toe, if needed.

6-43

88 Nm 65 ft.lbs.

Rear

1. Before servicing the vehicle, refer to Heprecautions in the beginning of this secion. 2. Remove or disconnect the following: e Rear wheel Stabilizer link e Wheel Speed Sensor (WSS), if equipped Lower control arm assembly to steering knuckle Lower control arm To install: 3. Install or connect the following: Lower control arm and torque the bolt to 55 ft. Ibs. (74 Nm) Lower control arm to the steering knuckle and torque the bolt to 80 ft. lbs. (108 Nm) WSS, if equipped Stabilizer link and torque the bolt to 29 ft. Ibs. (39 Nm) Rear wheel

Wheel Bearings

.

ADJUSTMENT Front

To check hub and bearing assembly endplay, remove the caliper and rotor. Position a dial indicator to bear against the hub flange near the center ridge. Wiggle the hub back and forth. If end-play exceeds 0.002 in. (0.05mm), replace the front hub and bearing assembly. Rear

The rear hub and wheel bearing assembly is designed for the life of the vehicle and requires no type of adjustment or periodic rnaintenance. The bearing is a sealed unit with the wheel hub and can only be removed and/or replaced as one unit.

REMOVAL & INSTALLATION Front

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove the cotter pin, halfshaft nut and washer.

196 - 255 Nm 145 — 188 ft.lbs.

5. Brake disc 6. Upper arm connection 7. Front hub assebly

1. Cotter pin 2. Drive shaft nut 3. Front speed sensor

4. Caliper assembly

Caution Do not disassemle the front hub assembly. 7922CG37

Exploded view of the front hub assembly mounting and related components

3. Remove or disconnect the following:

Front wheel Vehicle Speed Sensor (VSS), if equipped Caliper and brake pads: then, support the caliper out of the way using wire Brake rotor from the hub assembly Upper ball joint from the steering knuckle using a press type tool and pull the knuckle outward

i WARNING

_-

Use of improper methods of joint separation can result in damage to joint, leading to possible failure. Never use wedge-type tools or the ball joint can be damaged. e 4 hub-to-steering knuckle bolts ¢ Hub and bearing assembly from the knuckle «>The hub and wheel bearing assembly is not serviceable and should not be disassembled.

To install: 4. Install or connect the following: e Hub-to the steering knuckle and torque the bolts to 65 ft. Ibs. (88 Nm) ¢ Upper ball joint to the steering

knuckle and torque the self-locking nut to 21 ft. Ibs. (28 Nm) 5. Position the rotor on the hub. Install a couple of lug nuts and lightly tighten to hold the rotor on the hub. e Caliper holder and place the brake pads in the holder. Slide the caliper over the brake pads and install the guide pins. Once the caliper is secured, the lug nuts can be removed. e VSS, if equipped e Front wheel e New cotter pin and bend to secure 6. Examine the driveshaft (halfshaft) hub washer. Locate the chamfered side. This side is installed outward, away from the hub. Install the washer and hub nut. Tighten the axle nut with the brakes applied. Torque the nut to 145-188 ft. Ibs. (200-260 Nm).

Pump the brake pedal until hard, before attempting to move the vehicle. Rear

WITH DRUM BRAKES 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following:

For Maintenance Interval recommendations, see Section 1 of this manual

6-44

CHRYSLER CORP.

SEBRING COUPE ¢ AVENGER e VSS, if equipped with ABS

WITH DISC BRAKES 74-88 Nm

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Rear wheel e Vehicle Speed Sensor (VSS), if equipped with Anti-lock Brake System (ABS) e Caliper and brake pads; then, support the caliper out of the way using wire e Brake rotor 3. Remove 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 actuating lever. 4. Remove the 4 hub-to-knuckle bolts. 5. Remove the hub and bearing assembly from the knuckle.

54 -— 65 ft.lbs.

74-88 Nm 54 - 65 ft.lbs.

S

->The hub assembly is not serviceable and should not be disassembled. Rear speed sensor

Caliper assembly . Brake drum Brake disc OpwM a Clip mounting bolt

Caution Do not disassemble the rear hub assembly. 7922CG38

Exploded view of the rear hub assembly mounting

Rear wheel Vehicle Speed Sensor (VSS), if equipped with Anti-lock Brake System (ABS) Brake drum 4 hub to the knuckle bolts Hub and bearing assembly from the knuckle ->The hub assembly is not serviceable and should not be disassembled.

3. If replacing the hub, use special Socket MB991248 and a press, to remove the wheel sensor rotor from the hub. To install: 4. Press the wheel sensor rotor onto the hub. 5. Install or connect the following: e Hub to the knuckle and torque the bolts to 54-65 ft. Ibs. (74-88 Nm) e Brake drum

6. If replacing the hub, use special Socket MB991248 and a press, to remove the wheel sensor rotor from the hub. To install:. 7. Press the wheel sensor rotor onto the hub. 8. Install the hub to the knuckle and torque the bolts to 54-65 ft. Ibs. (74-88 Nm) 9. Install the parking brake shoes. 10. Position the rotor on the hub. Install a couple of lug nuts and lightly tighten to hold rotor on hub. 11. Install the caliper holder and place brake pads in holder. Slide the caliper over brake pads and install guide pins. Once caliper is Secured, lug nuts can be removed. 12. Install the VSS, if equipped 13. Install the rear wheel.

CHRYSLER CORPORATION 1997

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PRECAUTIONS Before servicing any vehicle, please be Sure to read all of the following precautions, which deal with personal safety, prevention of component damage, and important points to take into consideration when servicing a motor vehicle: e Never open, service or drain the radiator or cooling system when the engine is hot; serious burns can occur from the steam and hot coolant. e Observe all applicable safety precautions when working around fuel. Whenever servicing the fuel system, always work ina well-ventilated area. Do not allow fuel spray Or vapors to come in contact with a spark, open flame or excessive heat (a hot drop light, for example). Keep a dry chemical fire extinguisher near the work area. Always keep fuel in a container specifically designed for fuel storage: also, always properly seal fuel containers to avoid the possibility of fire or explosion. Refer to the additional fuel system precautions later in this section. ¢ Fuel injection systems often remain pressurized, even after the engine has been turned OFF. The fuel system pressure must be relieved before disconnecting any fuel lines. Failure to do so may result in fire and/or personal injury. ¢ Brake fluid often contains polyglycol ethers and polyglycols. Avoid contact with the eyes and wash your hands thoroughly after handling brake fluid. If you do get brake fluid in your eyes, flush your eyes with clean, running water for 15 minutes. If eye irritation persists, or if you have taken

brake fluid internally, IMMEDIATELY seek medical assistance. e The EPA warns that prolonged contact with used engine oil may cause a number of skin disorders, including cancer! You should make every effort to minimize your exposure to used engine oil. Protective gloves should be worn when changing oil. Wash your hands and any other exposed skin areas as soon as possible after exposure to used engine oil. Soap and water, or waterless hand cleaner should be used. e All new vehicles are now 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 repairs. e Always wear safety goggles when working with, or around, the air bag system. When carrying a non-deployed air bag, be sure the bag and trim cover are pointed away from your body. When placing a nondeployed air bag on a work surface, always face the bag and trim cover upward, away from the surface. This will reduce the motion of the module if it is accidentally deployed. Refer to the additional air bag system precautions later in this section. ¢ Clean, high quality brake fluid from a sealed container is essential to the safe and proper operation of the brake system. You

ET

LS

7 should always buy the correct type of brake fluid for your vehicle. If the brake fluid becomes contaminated, completely flush the system with new fluid. Never reuse any brake fluid. Any brake fluid that is removed from the system should be discarded. Also, do not allow any brake fluid to come in contact with a painted surface; it will damage the paint. e Never operate the engine without the proper amount and type of engine oil; doing so WILL result in severe engine damage. e Timing belt maintenance is extremely important! Many models utilize an interference-type, non-freewheeling engine. If the timing belt breaks, the valves in the cylinder head may strike the pistons, causing potentially serious (also time-consuming and expensive) engine damage. Refer to the maintenance interval charts in the front of this manual for the recommended replacement interval for the timing belt, 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 computer system(s) and may require the computer to undergo a relearning process once the negative battery cable is reconnected. e When servicing drum brakes, only disassemble and assemble one side at a time, leaving the remaining side intact for reference. ¢ Only an MVAC-trained, EPA-certified automotive technician should service the air conditioning system or its components.

ENGINE REPAIR Alternator

REMOVAL & INSTALLATION Non-Turbo

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Disconnect the negative battery cable. 3. Remove or disconnect the following: ¢ Right wheel ¢ Under cover side panel ¢ Speed control assembly e Alternator drive belt ¢ Alternator electrical connector ¢ Alternator bracket ¢ Alternator

To install:

4. Install or connect the following: e e e e

Alternator Alternator bracket Alternator electrical connector Alternator drive belt

5. Adjust the alternator drive belt deflection and tension to the following specifications: a. Used belt deflection: 0.35-0.47 in. (9.0-12.0mm) b. New belt deflection: 0.30-0.41 in. (7.5-10.5mm) c. Used belt tension: 90-110 Ibs. (400-490 N) d. New belt tension: 110-160 Ibs. (490-712 N) 6. Torque the alternator-to-upper bracket nut to 40 ft. Ibs. (54 Nm) and the

alternator-to-lower bracket nut to 45 ft. Ibs: (61 Nm). 7. Install or connect the following: ¢ Speed control assembly e Under cover side panel e Right wheel ¢ Negative battery cable Turbo

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Disconnect the negative battery cable. 3. Remove or disconnect the following: ¢ Right wheel ¢ Under cover side panel e Alternator drive belt * Power steering pump drive belt ¢ Power steering pump

CHRYSLER CORP. TALON

1-3

Ignition Timing .

ADJUSTMENT Ignition timing is controlled by the Powertrain Control Module (PCM). No adjustment is necessary or possible.

Engine Assembly REMOVAL & INSTALLATION {

. Drive belt (Generator) 2 Generator harness connector 3. Generator bracket 4. Generator 5. Generator brace 9306DG01

Exploded view of the alternator and related components—Non-turbo

2

20-25Nm

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Drive belt (Generator) Generator harness connector Generator Drive belt (power

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Water pump pulley Power steering pulley Generator brace NOoOsONS 9306DG02

Exploded view of the alternator and related components—Turbo

-> Support the power steering pump above the engine without disconnecting the hoses. e Alternator electrical connector e Alternator To install:

4. Install or connect the following: e Alternator e Alternator electrical connector e Alternator drive belt 5. Adjust the alternator drive belt deflection and tension to the following specifications: qa. Used belt deflection: 0.35—-0.45 in. (9-11.5mm). b. New belt deflection: 0.30—0.35 in.

(7-9.0mm). c. Used belt tension: 55.1-110.2 Ibs. (245-490 N). d. New belt tension: 110.2-154.3 Ibs. (490-686 N).

6. Torque the alternator-to-upper bracket bot to 8.7-11 ft. Ibs. (12-15 Nm) and the alternator-to-lower bracket nut/bolt to 14-18 ft. Ibs. (20-25 Nm). 7. Adjust the power steering drive belt deflection and tension to the following Specifications: a. Used belt deflection: 0.22—0.32 in. (5.5-8 mm). b. New belt deflection: 0.18-0.22 in. (4.5-5.5mm). c. Used belt tension: 55.1—-110.2 Ibs. (245-490 N). d. New belt tension: 110.2-154.3 Ibs. (490-686 N). 8. Install or connect the following: e Undercover side panel e Right wheel ¢ Negative battery cable

The following procedure can be used on all vehicles. Slight variations may occur due to extra connections, etc., but the basic procedure should cover all models. 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Relieve the fuel system pressure. 3. Drain the cooling system and the crankcase. 4 Remove or disconnect the following: Negative battery cable Engine undercover, if equipped Hood assembly. Matchmark the _ hood hinges prior to removal to ease alignment during installation. Air cleaner assembly and air intake ducts Radiator, coolant reservoir and intercooler Transaxle and transfer case, if equipped with All Wheel Drive (AWD) Accelerator cable e Heater hoses e Brake vacuum hose e Connection for vacuum hoses e High pressure fuel line e Fuel return line e Oxygen (02S) sensor connection e Coolant temperature gauge connection ¢ Coolant Temperature Sensor (CTS) connector ¢ Connection for thermo switch senSOr Transaxle assembly Idle speed control connection Motor Position (MP) sensor connector Throttle Position (TP) sensor connector Exhaust Gas Recirculation (EGR) temperature sensor connection on California vehicles only Fuel injector connectors

For complete service labor times, order Nichols’ Chilton Labor Guide

7-4

CHRYSLER CORP. TALON

i

Power transistor connector Ignition coil connector Condenser and noise filter connector Crankshaft Position (CKP) sensor Camshaft Position (CMP) sensor connectors Manifold differential pressure sensor connector Distributor and control harness Alternator and oil pressure switch connectors Drive belt and compressor and wire the compressor aside, if equipped. DO NOT discharge the system or disconnect the refrigerant lines Power steering pump and wire aside Exhaust manifold-to-pipe nuts and discard the gasket 5. Attach a hoist to the engine and support the engine weight. e Engine mount bracket e Torque control brackets (roll stoppers)

Accelerator cable Transaxle and torque the upper mounting bolts to 51 ft. Ibs. (69 Nm) and the lower bolts to 32 ft. lbs. (44 Nm) Starter and torque the bolts to 22 ft. lbs. (30 Nm) Radiator and intercooler Air cleaner assembly Control brackets Hood Negative battery cable 8. Fill the engine with clean oil. 9. Fill the cooling system to the proper level. 10. Start the engine, allow it to reach normal operating temperature and check for leaks. 11. Road test the vehicle and check all functions for proper operation.

->Some engine mount pieces have arrows on them for proper assembly. Make certain to note the orientation before removal.

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the cooling system. 3. Remove or disconnect the following: e Timing belt. Refer to the timing belt unit repair section in this manual

e

6. Remove the engine assembly To install: 7. Install or connect the following: e Engine and torque the engine mount bolts to 50 ft. Ibs. (69 Nm)

Water Pump REMOVAL & INSTALLATION

for timing belt removal and installation. e Alternator-to-water pump brace 4. Unfasten the retainers, then remove any brackets for access to the rear cover. ¢ Timing belt rear cover, if necessary e Water pump bolts ¢ Water pump, gasket and O-ring. Discard the gasket and O-ring. To install: 5. Install or connect the following: e New water inlet pipe O-ring => Coat the O-ring with water or coolant.

Do not allow oil or other grease to contact the O-ring. Water pump, using a new gasket. Torque bolts to 10 ft. Ibs. (13 Nm). Alternator-to-water pump brace. Torque the brace pivot bolt to 17 ft. lbs. (24 Nm). Timing belt rear cover, if removed Timing belt Remaining components Negative battery cable 6. Fill the cooling system to the proper level. 7. Start the engine, check for leaks and repair if necessary.

>The front lower mount through-bolt nut should not be tightened until the full weight of the engine is on the mount.

Exhaust pipe and torque the nuts to 36 ft. Ibs. (49 Nm) Vacuum hoses Water hoses Fuel return and high pressure hoses Brake booster vacuum hose Wiring harness connections

12-15 Nm 8.7-11 fi.lbs.

A/C compressor electrical connectors

CKP sensor CMP sensor connector Ignition coils and fuel injector con-

12-15 Nm

87-11 filbs,

17 ftlbs. 12-15 Nm

nectors Manifold differential pressure sensor connector

Capacitor TP sensor connector Ignition power transistor connector ECT sensor Engine coolant temperature gauge connector ¢ Oxygen (02S) sensor connection

12-15 Nm 8.7-11 ftlbs.

24Nm

8.7-11 ft.lbs.

Removal

steps

1. Generator brace 2. Water pump 3. Water pump gasket

4. O-ring

(.31x.87) Bolt diameter x length: mm (in.) 7922DG01

Water pump mounting and bolt locations—2.0L (VIN F) engine

CHRYSLER CORP. TALON Both water pipes and oil feed line can remain attached.

9. Inspect the following items: ¢ Turbine (hot side) and compressor

CHRYSLER CORP. TALON

1-1

Intake Manifold

REMOVAL & INSTALLATION 2.0L (VIN F) Engine

Oil return pipe Gasket Turbocharger

. .

: .

Eye bolt Gasket Water pipe B Eye bolt Gasket Water pipe A Eye bolt a Oil pipe

. Exhaust fitting

yer aa HOONONBRWN ONO —

14. Gasket 7922DG06

Exploded view of the turbocharger assembly—2.OL (VIN F) engine

(cold side) wheels for cracking or other damage Turbine and compressor wheels for ease of movement Oil leakage Wastegate valve operation. If any problem is found, replace the part. e Oil passages for restriction or deposits, clean as required 6. Pressure test the wastegate valve by applying approximately 9 psi (62 kPa) to the actuator to make sure the rod moves.

4 WARNING

|

Do not apply more than 10 psi (71

kPa) for the wastegate diaphragm may be damaged. ->The wastegate actuator should maintain vacuum; if not, replace it.

sk WARNING Do not attempt to adjust the wastegate valve. To install: 7. Prime the oil return line with clean engine oil. Replace all locking nuts. Before

installing the threaded connection for the water inlet pipe, apply light oil to the inner pipe flange surface. 8. Install or connect the following: Turbocharger Exhaust manifold using a new gasket and torque the bolts to 36 ft. lbs. (49 Nm) Water cooling lines and torque to 31 ft. Ibs. (42 Nm) Oil feed line and torque the bolts to 14 ft. Ibs. (19 Nm) Engine hanger and torque the bolts to 10 ft. Ibs. (15 Nm) Power steering pump and bracket, if removed Heat shields Air outlet hose Wastegate hose Air intake bellows Oil dipstick tube and dipstick O2S sensor Radiator assembly Negative battery cable 9. Fill the engine with clean oil. 10. Fill the cooling system to the proper level. 11. Start the vehicle, check for leaks and repair if necessary.

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Relieve the fuel system pressure. 3. Drain the cooling system. 4, Remove or disconnect the following: Negative battery cable Accelerator cable, breather hose and air intake hose Upper radiator hose, heater hose and water bypass hose All necessary vacuum hoses and pipes Brake booster vacuum line High pressure fuel line and fuel return hose 5. Label and disconnect the following the electrical connectors: e Oxygen (02S) sensor e Engine Coolant Temperature (ECT) sensor Thermo switch Idle speed control Exhaust Gas Recirculation (EGR) temperature sensor

Spark plug wires Fuel rail, with injectors and pressure regulator attached Intake manifold bracket Throttle body water hose Water inlet and heater connections Thermostat housing, if necessary Power brake booster and Positive Crankcase ventilation (PCV) valve vacuum lines, if connected Intake manifold To install: 6. Inspect the intake manifold’s mounting surfaces for cleanliness, cracks or other damage and water passages and air passages for clogging. 7. Install or connect the following: e Intake manifold, using a new gasket. Torque the manifold-to-cylinder head bolts in a crisscross pattern, starting from the inside and working outwards, to 11-14 ft. Ibs. (15-19 Nm). Fuel rail, with injectors and pressure regulator, lubricate all seals lightly with oil. Torque the retaining bolts to 84-108 inch Ibs. (10-13

Timing belt service is covered in Section 3 of this manual

Nm).

71-8

CHRYSLER CORP. TALON

a

e e e e

Thermostat housing, if removed \ntake manifold brace bracket Throttle body bracket All hoses, cables and electrical connectors e Negative battery cable 8. Refill the cooling system . 9. Run the engine until the thermostat opens, refill the radiator completely and check for leaks. 10. Adjust the accelerator cable. Check and adjust the ignition timing. Once the vehicle has cooled, recheck the coolant level.

2.0L (VIN Y) Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Properly relieve the fuel system presSure. 3. Drain the cooling system. 4 Remove or disconnect the following: Negative battery cable Vacuum reservoir, if equipped with cruise control Air intake and breather hoses Accelerator cable from the bracket Engine harness retaining clips Manifold Absolute Pressure (MAP) sensor Coolant Temperature (CT) sensor connector Throttle Position (TP) sensor connector Air Injector Service (AIS) motor connector Engine control wiring harness and move it aside Alternator wiring harness Pollution Control Valve (PCV) hose assembly Vacuum hoses Exhaust Gas Recirculation (EGR) pipe Fuel lines from the fuel rail Intake manifold stay and engine hanger Throttle body Intake manifold plenum and gasket Injector connectors Fuel rail with injectors Intake manifold To install: 5. Install or connect the following: e Intake manifold using a new gasket and torque the retainers in a crisscross pattern to 17 ft. Ibs. (23 Nm) ¢ Fuel rail assembly and torque the bolts to 89 inch Ibs. (10 Nm) e Injector connectors

e Intake plenum using a new gasket and torque the bolts to 25 ft. Ibs. (34 Nm) Throttle body using a new gasket e Intake manifold stay and engine hanger and torque the bolts to 17 ft. lbs. (23 Nm) Fuel rail fuel lines using new Orings e EGR pipe e Vacuum hoses and PCV hose assembly e Alternator wiring harness e Engine control wiring harness and reposition and secure with brackets/clips AlS motor and TP sensor Vacuum hose at throttle body MAP and CT sensors Accelerator cable at the bracket and throttle body Breather and air intake hoses Vacuum reservoir, if equipped e Negative battery cable 6. Fill the cooling system to the proper level. 7. Adjust the accelerator cable.

Exhaust Manifold

REMOVAL & INSTALLATION

To install: 5. Clean all gasket material from the mating surfaces and check the manifold for damage. 6. Install or connect the following: e Exhaust manifold and new gasket. Torque the manifold-to-head nuts in acrisscross pattern to 18-22 ft. lbs. (25-30 Nm) and the manifoldto-turbocharger nut/bolts to 40-47 ft. Ibs. (65-65 Nm). Engine hanger, water and oil lines at the turbocharger _ Heat shields and torque the bolts to 89 inch Ibs. (10 Nm) Exhaust pipe using a new gasket and torque the bolts to 33 ft. Ibs. (44 Nm) Condenser cooling fan Power steering pump O2S sensor harness Oil level indicator and tube using a new O-ring e Negative battery cable 7. Fill the engine with clean oil. 8. Fill the cooling system to the proper level. 9. Operate the engine until the thermostat opens.

10. Check for fluid and exhaust leaks. Top off the engine coolant.

2.0L (VIN Y) Engine 2.0L (VIN F) Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the engine oil. 3. Drain the cooling system. 4. Remove or disconnect the following: Negative battery cable Condenser cooling fan, if equipped with A/C Power steering pump and move it aside Oxygen (02S) sensor harness Dipstick tube Exhaust pipe-to-turbocharger nuts, separate the exhaust pipe and discard the gasket Air intake and vacuum hose connections Heat shields at exhaust manifold and turbocharger Exhaust manifold-to-turbocharger bolts and nut Engine hanger, water and oil lines from the turbocharger, if necessary Exhaust manifold and discard gasket

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the cooling system. 3. Remove or disconnect the following: Negative battery cable Air intake hose Upper radiator hose from water outlet Air hose connection Engine control wiring harness from the rear of the engine Water pipe assembly Oil dipstick Upper heat shield Engine hanger Front exhaust pipe from the manifold Lower heat shield Exhaust manifold and discard gasket To install: 4. Install or connect the following: ¢ Exhaust manifold with a new gasket and torque the bolts to 17 ft. Ibs. (23 Nm) ¢ Lower heat shield and torque the bolts to 10 ft. Ibs. (15 Nm) ¢ Front exhaust pipe using a new

1-9

CHRYSLER CORP. TALON gasket and torque the bolts to 33 ft.

lbs. (44 Nm) Engine hanger and torque the bolts to 10 ft. Ibs. (15 Nm)

Upper heat shield and torque the bolts to 10 ft. Ibs. (15 Nm) Oil dipstick and water pipe Engine wiring harness to the rear of the engine Air hose and upper radiator hose Air intake hose e Negative battery cable 5. Fill the cooling system to the proper level. 6. Start the vehicle, check for leaks and repair if necessary.

MB995027

79220G19 7922DG17

To prevent damaging the end of the crankshaft, use the proper sprocket removal tool—2.0L (VIN Y) engine

To avoid damaging the front seal, use the front oil seal installer Tool MB995022— 2.0L (VIN Y) engine

MB995035

Front Crankshaft Seal

and MB995026

|

REMOVAL & INSTALLATION

2.0L (VIN F) Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Negative battery cable e Timing belt. Refer to the timing belt unit repair section in this manual for timing belt removal and installation. ->|f reusing the timing belt, be sure to mark the direction of rotation on the belt. This will ensure the same direction of rotation, thereby extending belt life.

e Crankshaft pulley ¢ Timing belt crankshaft sprocket e»|f the sprocket is difficult to remove, an appropriate puller may be used.

e Crankshaft seal by prying it out using a suitable prytool To install: 3. Install or connect the following: e New crankshaft seal using a driver tool e Crankshaft sprocket e Timing belt. Refer to the timing belt unit repair section in this manual for timing belt removal and installation. e Negative battery cable

2.0L (VIN Y) Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section.

7922DG20

79220618

Using the special tool to remove the front crankshaft seal—2.0L (VIN Y) engine

2. Remove or disconnect the following: Negative battery cable Timing belt. Refer to the timing belt unit repair section in this manual for timing belt removal and installation. Crankshaft sprocket using Crankshaft Sprocket Removal Tool MB995027 Crankshaft oil seal using Crankshaft oil seal Removal Tool MB995020 ->Be careful not the scratch the oil seal bore or the crankshaft sealing surface.

To install: 3. Apply clean engine oil to the oil seal. 4. Install or connect the following: ¢ Oil seal using a seal driver e Crankshaft sprocket using special Tools MB995035 and MB995026 e Timing belt. Refer to the timing belt unit repair section in this manual for tirning belt removal and installation. e Negative battery cable

Installing the front crankshaft sprocket using the Crankshaft Sprocket Installer Tools MB995035 and MB995026—2.0L (VIN Y) engine

Camshaft and Valve Lifters REMOVAL & INSTALLATION 2.0L (VIN F) 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 Accelerator cable from the throttle body

Cable bracket from intake plenum Engine center cover Spark plug cables Breather hose and Pollution Control Valve (PCV) hose, from the rocker cover e Rocker cover 3. Position the No. 1 piston at Top Dead Center (TDC) on the compression stroke. Timing belt. Refer to the timing belt unit repair section in this manual for timing belt removal and installation. ¢ Camshaft sprockets

Heater Core replacement is covered in Section 2 of this manual

T-1 0

Geer CORP. 2. Remove or disconnect the following: Negative battery cable

Dowel pins Plastic hammer

se

Ignition coil pack

3°5'

7922DG09

Exhaust side

Intake side 7922DG08

Tap the camshaft with a plastic hammer to loosen the bearing caps—2.0L (VIN F) engine

Intake side

Exhaust side

|

a 79220616

Identifying the rocker arm shafts—notice the slits in the intake side

e>Use a wrench on the hex shaped part of the camshaft to hold the cam when removing the sprockets.

¢ Bearing caps. Loosen the bearing cap bolts in 2-3 steps. ->|f the bearing caps are hard to remove, tap the rear of the camshaft with a plastic hammer.

For installation, position the camshafts with the dowels facing up, as shown— 2.0L (VIN F) engine

5. Install the bearing caps and torque the bolts evenly, in 2-3 steps to 14 ft. Ibs. (20 Nm). 6. Lubricate the seal lip with engine oil. 7. Install or connect the following: e Front oil seal using Seal Installer MB998713 e Camshaft sprockets e Timing belt. Refer to the timing belt unit repair section in this manual for timing belt removal and installation. e Cylinder head by applying sealant to the semi-circular packing 8. Apply sealant to the lower part of the front and rear bearing caps where they meet the cylinder head. ¢ Rocker cover using a new gasket e PCV hose and breather hose e Spark plug wires e Center cover ¢ Accelerator cable and adjust it ¢ Negative battery cable

2.0L (VIN Y) Engine Bearing caps and rocker arms must be installed in the same location from which they were removed.

1. Before servicing the vehicle, refer to the precautions in the beginning of this section.

,

Pollution Control Valve (PCV) hose and breather hose from cylinder head cover Semi-circular packing from the rear of the head Camshaft Position (CMP) sensor Timing belt. Refer to the timing belt unit repair section in this manual for timing belt removal and installation. e Camshaft sprockets © ->Use tool MB990767 and MB998719, to secure the camshaft sprockets when removing the sprocket mounting bolt.

e Rear timing belt cover and bracket e Qutside camshaft bearing cap e Bearing caps. Gradually, loosen the camshaft bearing caps in the reverse of the tightening sequence,

one camshaft at a time. Keep the bearing caps in order. They must be installed in the location from which they were removed. e Camshafts ~The camshafts are not interchangeable. Mark the camshafts for later identification.

To install: 3. Install or connect the following: Camshafts, lubricate with engine oil Bearing caps and torque the bolts evenly and in sequence to 21 ft. lbs. (28 Nm) Outside camshaft bearing caps, lubricate them with Loctite 518° Camshaft oil seal

¢ Camshaft(s) and seals To install: 4. Install or connect the following: ¢ Camshafts, lubricate with engine oil and position with the dowels facing

WARNING If new camshaft(s) are being installed, remove the rocker arms and install the camshaft(s) and bearing caps. Be sure the camshaft(s) can be turned by hand. After checking, remove the camshafts and install the rocker arms.

7922DG03

Camshaft bearing cap bolt tightening sequence—2.0L (VIN Y) engine

CHRYSLER CORP. 744 Rear timing belt cover and bracket e Camshaft sprockets e Timing belt. Refer to the timing belt unit repair section in this manual for timing belt removal and installation. Semi-circular packing, lubricate with Loctite 5699®, at rear of cylinder head e CMP sensor 4. Install the cylinder head cover. Torque the bolts in the proper sequence, evenly as follows: a. Step 1: 40 inch Ibs. (4.5 Nm). b. Step 2: 80 inch Ibs. (9.0 Nm). C. Step 3: 106 inch Ibs. (12 Nm). 5. Install or connect the following: e Air, breather and PCV hoses e Coil pack e Negative battery cable

sede ADU.

Valve Lash

ADJUSTMENT

ae 54.Nm

Valve clearance is not adjustable. Proper valve clearance is maintained by the hydraulic lash adjusters. Stantel

2

a

e

]

1. Starter terminal 2. Starter

and connector

motor

40 ft.Ibs.

93060603

Exploded view of the starter and related components—Non-turbo

REMOVAL & INSTALLATION

30 Nm

——

22ftlbs.

4

Non-Turbo

1. Before servicing the vehicle, refertothe precautions in the beginning of this section. 2. Remove ordisconnect the following: e Negative battery cable e Starter electrical connectors e Starter bolts and starter To install: 3. Installorconnect the following:

fA\

;

a

e Starter and torque the starter-to-

|

transaxle bolts to 40 ft. Ibs. (54 Nm)

AA

|

-

Se

Ci

Hac

a

Pa

ALN

e Starter electrical connectors e Negative battery cable

30 Nm 22 ft.lbs.

2°

Turbo 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Battery ¢ Air hose “C” e Starter electrical connectors ¢ Starter bolts and starter To install: j 3. Install or connect the following: e Starter and torque the starter-totransaxle bolts to 22 ft. Ibs. (30 Nm)

A09X0122

Removal steps Manns 2. Starter terminal and connector 3. Starter motor

Exploded view of the starter and related components—Turbo

Brake service is covered in Section 4 of this manual

:

46DG01

7-12.

SHRYSLER CORP.

a

e Starter electrical connectors e Air hose “C”

e Battery

REMOVAL & INSTALLATION

2.0L (VIN F) Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the crankcase.

3. Remove or disconnect the following: e Negative battery cable e Exhaust pipe, lower it from the engine manifold e Transfer assembly and right driveshaft, on All Wheel Drive (AWD) models 4, Using the appropriate equipment, support the weight of the engine. e Crossmember e Turbocharger return pipe from the side of the oil pan e (il pan bolts. Tap a thin prytool between the engine block and oil pan to break the seal. 5. Inspect the oil pan for damage and cracks. Replace if faulty. While the pan is removed, inspect the oil screen for clogging, damage and cracks. Replace if faulty. To install: 6. Using a wire brush or other tool, clean all gasket surfaces of the cylinder block and the oil pan so that all loose material is removed. Clean sealing surfaces of all dirt and oil. 7. Apply sealant around the gasket surfaces of the oil pan in such a manner that all bolt holes are circled and there is a continuous bead of sealer around the entire perimeter of the oil pan. >The continuous bead of sealer should be applied in a bead approximately 0.16 in. (4mm) in diameter.

8. Install or connect the following: ¢ Oil pan. Install within 15 minutes after applying sealant. Torque bolts

to 48-72 inch Ibs. (6-8 Nm). Oil return pipe, using a new gasket and torque the retainers to 62-88 inch lbs. (7-10 Nm) Crossmember and torque the bolts

to 72 ft. Ibs. (100 Nm) Left member and torque the forward retainer bolts to 72 ft. Ibs. (100 Nm) and the rearward left member bolts to 58 ft. Ibs. (80 Nm)

e Transfer assembly and right driveshaft e Exhaust pipe using a new gasket. Torque the exhaust pipe-to-manifold flange nuts to 43 ft. Ibs. (60 Nm). e Oil drain plug and torque to 33 ft. Ibs. (42 Nm) e Negative battery cable 9. Fill the engine with clean oil. 10. Start the engine and check for leaks.

2.0L (VIN Y) Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the engine oil. 3. Remove or disconnect the following: e Negative battery cable e Front exhaust pipe e Dipstick and tube assembly e Front plate e Qil pan bolts e Oil pan and discard the gasket To install: 4. Clean all traces of the old gasket or Sealer material from the oil pan and engine block mating surfaces. 5. Apply sealant at the point where the engine block meets the oil pump. 6. Install or connect the following: e (Oil pan using a new gasket and torque the bolts to 107 inch Ibs. (12 Nm) ¢ Front plate and torque the bolts to 80 ft. Ibs. (108 Nm) e Front exhaust pipe ¢ Dipstick and tube assembly e Negative battery cable 7. Fill the engine with clean oil. 8. Start the engine and check for leaks.

REMOVAL & INSTALLATION 2.0L (VIN F) Engine

cylinder is at Top Dead Center (TDC) of its compression stroke. The timing marks should be aligned at this point. 3. Drain the engine oil. 4. Using the proper equipment, support the weight of the engine. 5. Remove or disconnect the following: Front engine mount bracket and accessory drive belts Timing belt upper and lower covers Timing belt and crankshaft sprocket Oil pressure sending unit electrical connector Oil pressure sensorOil filter and bracket Oil pan, oil screen and discard gasket Plug cap in the engine front cover, using special plug removal Too! MD998162 Plug on the side of the engine block. Insert a suitable tool with a shaft diameter of 0.32 in. (8mm) into the plug hole. This will hold the silent shaft in position. Oil pump driven gear-to-silent shaft bolt Front cover mounting bolts ->Note the lengths of the mounting bolts as they are removed for proper installation.

¢ Front case cover and oil pump assembly e>|f necessary, the silent shaft can come out with the cover assembly.

¢ Oil pump cover at the rear of the engine front cover. ¢ Qil pump drive and driven gears 6. After disassembling the oil pump, clean all components and remove all residual gasket material from the mating surfaces. 7. Assemble the oil pump gears into the front case and rotate it to ensure smooth movement and no looseness. Be sure there

> WARNING Whenever the oil pump is disassembled or the cover is removed, the gear cavity must be filled with petroleum jelly. This seals the pump and acts like a primer so the oil pump draws oil as soon as the engine turns. Do not use grease. 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Disconnect the negative battery cable. Rotate the engine so that the No. 1

MDg98783 79220G21

Using the special Tool MD998162 to tighten the plug cap—2.0L (VIN F) engine

CHRYSLER CORP,

cd

SS

SRE

SE

SIS

RIG DST

is No ridge wear on the contact surface between the front case and the gear surface of the oil pump front cover. To install: 8. Install or connect the following: ¢ Qil pump, by aligning the oil pump drive gear with the driven gear timing marks. Lubricate the gears with engine oil. Oil pump cover and torque the bolts to 13 ft. Ibs. (18 Nm) New crankshaft seal using an appropriate driver New front case gasket. Position seal guide Tool MD998285, on the front end of the crankshaft to. protect the seal from damage. Apply a thin coat of oil to the outer circumference of the seal pilot tool. Front case assembly, through a new front case gasket and torque the bolts to 17 ft. Ibs. (24 Nm) Oil filter on the bracket using a new oil filter bracket gasket and torque the bolts to 25 ft. Ibs. (34 Nm) 9. Insert a suitable tool into the hole in the left side of the engine block to lock the silent shaft in place. 10. Secure the oil pump drive gear onto the left silent shaft by installing and tightening the driven gear bolt to 29 ft. Ibs. (40 Nm). 11. Install or connect the following: e Plug cap using a new O-ring in the front case groove. Using the special Tool MD998162, tighten the cap to 20 ft. Ibs. (27 Nm). ¢ Oil screen using a new gasket 12. Clean the oil pan and cylinder block mating surfaces. Apply sealant in the oil pan flange groove, keeping towards the inside of the bolt holes. The width of the sealant bead applied is to be about 0.16 in. (4mm) wide. ->Install the oil pan within 15 minutes of sealant application.

13. Install or connect the following: Oi! pan and torque the bolts to 108 inch Ibs. (12 Nm) Oil pressure gauge unit and oil pressure switch Oil pressure gauge unit and oil pressure switch Electrical harness Oil cooler and torque the bolt to 33 ft. lps. (45 Nm) Oil filter and fill the crankcase Negative battery cable 14, Start the engine. Verify oil pressure and inspect for leaks.

SGN

TY

ZAR

2.0L (VIN Y) Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the engine oil. 3. Remove or disconnect the following: e Negative battery cable ¢ Rear plate e Oil filter and adapter e Qil pan e (il pick-up tube e Timing belt. Refer to the timing belt unit repair section in this manual for timing belt removal and installation. e Crankshaft sprocket using the crankshaft sprocket Removal tool MB995027

> WARNING Do not nick the crankshaft sealing surface or the seal bore. e Crankshaft oil seal using crankshaft oil seal tool MB995020 e Oil pump mounting bolts e Qil pump To install: 4. Apply a bead of sealant to the sealing surface of the oil pump and install a new Oring into the counterbore on the oil pump discharge passage. 5. Install or connect the following: ¢ Oil pump and torque the bolts to 17 ft. Ibs. (23 Nm) ¢ New crankshaft oil seal in the oil pump ¢ Crankshaft sprocket using the proper installation tools e Timing belt. Refer to the timing belt unit repair section in this manual for timing belt removal and installation e Oil pickup tube 6. Apply Loctite® 18718, at the point where the oil pump meets the engine block. e (il pan using a new gasket and torque the bolts to 108 inch Ibs. (12 Nm) Oil filter adapter using a new Oring. Align the roll pin with the hole and torque the assembly to 40 ft. Ibs. (55 Nm). New oil filter Rear plate Negative battery cable 7. Fill the engine with clean oil. 8. Start the engine and check for leaks.

For complete Engine Mechanical specifications, see Section 1 of this manual

TR

AS

743

ET

NO

Rear Main Seal

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 Transaxle Transfer case, if equipped Drive plate, if equipped with an automatic transaxle Bell housing cover and flywheel, if equipped with a manual transaxle Crankshaft rear oil seal case, if leaking; otherwise, the oil seal. Some engines have a separator that should also be removed.

To install: 3. Lubricate the inner diameter of the new seal with clean engine oil. 4. Install or connect the following: e Oil seal in the crankshaft rear oil seal case using Seal Installer Too! MD998376 Press the seal all the way in without tilting it.

5. If removed, drive the oil separator into the oil seal case so the its oil hole is facing downward. 6. Install or connect the following: e Seal case using a new gasket, if removed e Flywheel or drive plate e Transfer case, if equipped e Transaxle e Negative battery cable 7. Refill the crankcase. Start the engine and check for leaks.

Piston and Ring POSITIONING

Cylinder number

Notches 7922AG01

Chrysler engine connecting rod and cap installation—ensure to matchmark the cap and rod prior to disassembly

7-14

CHRYSLER CORP. TALON

{dentification mark “1R”

identification mark “2R”

Gap of lower

en

SIDE RAIL 7922AG02

Chrysler piston ring identification mark locations SIDE RAIL UPPER

No. 1

side oe

Size mark

SPACER EXPANDER

\" gap

Front of engine

No. 2 ring \

and spacer

oS

hea Gap of

expander gap

upper side rail

7922AG05

OIL RING

7922AG03

Piston ring end-gap spacing—2.OL (VIN Y) engine

Piston ring orientation—2.0L Engine

\ ARROW FACES FRONT OF ENGINE

NO. 1 RING GAP

\

{

ref

TERS Timing belt side

i

adSS

NO. 2 RING GAP AND SPACER EXPANDER GAP

\

eee

Viovement of the filter will ease attachment of the fuel lines.

*¢ CAUTION Be sure new O-rings are installed prior to assembly. e Main pipe at the filter. Manually, screw in the main pipe’s flare nut. e Fuel filter nut. Using a back-up wrench, torque the eyebolts to 22 ft. Ibs. (30 Nm) and the flare nut to 25 ft. Ibs. (35 Nm). e Fuel filter mounting bolts and torque to 10 ft. Ibs. (14 Nm) e Negative battery cable 8. Turn the key to the ON position to pressurize the fuel system and check for leaks.

2k CAUTION If repairs of a leak are required, remember to release the fuel pressure before opening the fuel system.

79220622

To service the fuel pump on AWD vehicles, a Fuel Pump Locking Ring Removal tool MB991480 is needed

REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Relieve the fuel system pressure. 3. Remove or disconnect the following: Negative battery cable Rear seat cushion, by pulling the seat stopper near the floor and lifting the cushion up e Harness connector e Fuel lines e Fuel pump assembly from the tank 4. Use Fuel Pump Locking Ring Removal Too! MB991480, to remove the locking ring on the All Wheel Drive (AWD) model. To install: 5. Install or connect the following: e Fuel pump in the tank e Fuel hoses e Harness connector e Rear seat cushion e Negative battery cable

Fuel Injector

REMOVAL & INSTALLATION 29 Nm

2.0L (VIN Y) Engine

22 ft.lbs.—~

29 Nm

22 ft.lbs.

36 Nm

27 ft.lbs.

Exploded view of the fuel filter mounting—2.0L (VIN Y) engine

79220611

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Relieve the fuel system pressure. 3. Remove or disconnect the following: e Battery e Air intake hose ¢ High pressure fuel hose from the fuel rail and discard the O-ring Fuel injector harness connector Fuel rail Fuel injector electrical connectors Fuel injector-to-fuel rail retainer(s) e Fuel injectors and discard the O-rings

For Accessory Drive Belt illustrations, see Section 1 of this manual

7-16

SURYSLER corp.

To install: 4. Installorconnect the following: e New fuel injector O-rings e Fuel injectors

a} q

not allow

engine

8 14 Mb

9 fuel uel h hose connection

1, Highoe ie

MOK WARNING

Do

Cor

3 ypLL,

Lubricate the O-rings with clean engine oil; then, install the injectors into the fuel rail by twisting them (left and right) to make sure that they turn smoothly in the seat.

the fuel rail.

aD

3. Injector harness connector 4. Fuel rail 5. Injector connectors

oil to get into

Ssee 8. O-rings

e Fuel injector-to-fuel rail retainer(s) e Fuel injector electrical connectors e Fuel rail and torque the bolts to 2 ft. Ibs. (3 Nm) e Fuel injector harness connector

9. O-rings

9306CG06

Exploded view of the fuel injector, fuel rail and related components—2.0L (VIN Y) engine

e New high-pressure fuel hose O-ring ->Lubricate the O-ring with clean

engine oil.

nee

> WARNING

gt)

Do not allow engine oil to get into

ie.

Lee

ae ee tee

oe

the fuel rail.

~

e High pressure fuel hose connection

and torque the fuel hose-to-fuel rail

ee

ee

= i:

Wee

es

he %

ne :

kee

bolts to 1.8 ft. Ibs. (2.5 Nm).

hese

e Air intake hose

8.8 Nm

e

6.5 ft.lbs,

Battery

2.0L (VIN F) Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Relieve the fuel system pressure. 3. Remove or disconnect the following: e Negative battery cable °

Spark plug cables

‘a

¢ High pressure fuel line connection .

.

from the fuel rail — * O-ring and discard it

¢ Fuel return line connection + Vacuum hose connection

e Fuel pressure regulator

¢ O-ring and discard it = e Positive Crankcase Ventilation (PCV) hose

a Ml ace

e Fuel rail

pressars fuel hose connection

f

12: Injectors. ia Geeenen

93060605 Exploded view of the fuel injector, fuel rail and related components—2.0L (VIN F) engine

->Lubricate the O-rings with clean engine oil.

WARNING Lc Do not allow the oil to get into the fuel rail. Make sure the fuel injector

¢ O-rings and discard them

turns smoothly.

+ New grommets

S

8. Fuelpressure reguator 7. PCV hose

° Fuel injector(s)

¢ New O-rings

10. Insulators

“rin

¢ Insulators

eeu Sr ie Sae apetT 4. Install or connect the following:

5 Buecet carmeators

3, Fuel return hose connection

.

¢ Fuel injector(s) ° New insulators

¢ Fuel rail and torque the bolts to 2 ft. Ibs. (3 Nm)

¢ Fuel injector connectors * PCV hose

i

e*Lubricate the O-ring with clean

engine oil.

| ck WARNING Do notallow the oil to get into the fuel rail. Make sure the fuel pressure

regulator turns smoothly.

’

CHRYSLER CORP.

TALON

a

e Fuel pressure regulator and torque to 7 ft. Ibs. (9 Nm) e Vacuum hose connection ¢ Fuel return line connection ¢ New O-ring

7-1 T

EE

Lubricate the O-ring with clean engine oil.

¢ High pressure fuel line connection and torque the bolt to 1.8 ft. Ibs. (2.5 Nm) e Spark plug cables e Negative battery cable

> WARNING Do not allow the oil to get into the fuel rail.

DRIVE TRAIN Transaxle Assembly REMOVAL & INSTALLATION Manual

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the transaxle and transfer case fluid, if equipped. 3. Remove or disconnect the following: Battery Air intake hoses Battery tray and support Auto-cruise actuator and bracket, if equipped with cruise control Charcoal canister and bracket Shift and select cables from the transaxle Back-up light switch Vehicle Speed Sensor (VSS) e Starter 4. Attach a support fixture to the engine. e Transaxle mounting bolts e Rear roll stopper bracket mounting bolts e Transaxle mounting bracket nuts e Engine undercover e Transfer case assembly, if equipped with All Wheel Drive (AWD)

sot WARNING. Do not remove or install the axle shaft nut when the vehicle is on the floor or damage to the bearings will occur.

e Halfshafts Slave cylinder from the bell housing. Do not disconnect the fluid line and position it aside. e Bell housing cover Right-hand center member stay (support) e Center member 5. Place a transmission jack under the transaxle and support it. e Transaxle mounting bolt

e Transaxle mount and transaxle To install: 6. Install or connect the following: e Transaxle and mount and torque the through-bolt to 50 ft. Ibs. (69 Nm) and the transaxle assembly bolts to 22-25 ft. Ibs. (30-34 Nm) e Center member assembly and right-hand stay and torque the bolts to 58 ft. Ibs. (78 Nm) e Bell housing cover and slave cylinder and torque the bolts to 9 ft. Ibs. (12 Nm) e Halfshafts e>Be sure to install the washer in the proper direction.

e Engine undercover and lower the vehicle e Transfer case assembly, if removed e Transaxle mounting bracket nuts and torque the bolts to 70 ft. lbs. (95 Nm) e Rear roll stopper bracket mounting bolts and torque to 54 ft. Ibs. (74 Nm) e Transaxle assembly mounting bolts and torque to 35 ft. Ibs. (48 Nm) 7. Remove the engine support fixture. Starter VSS and back-up light connectors Cruise control actuator, if removed Battery tray support and tray Charcoal canister bracket and canister e Air duct and air cleaner assembly 8. Refill the transaxle. On turbocharged models, fill with gear oil of classification GL-4 or higher, SAE 75W-85W or 75W-90. On non-turbocharged models, fill with Mopar MS9417 MTX Fluid P/N 4773167. 9. Refill the transfer case with gear oil of classification GL-4 or higher, SAE 75W85W or 75W-90. Automatic

2. Drain the transaxle fluid. 3. Remove or disconnect the following: e Negative battery cable e Battery and battery tray e Control actuator and bracket, if equipped with auto-cruise e Air cleaner assembly, intercooler and air hose, as required cies. Mark the shift cable’s location. Adjusting nut and shift cable Dipstick and tube assembly Solenoid connector Neutral safety switch (inhibitor Switch) connector Pulse generator kickdown servo Switch connector Oil temperature sensor connector e Speedometer cable and oil cooler lines Starter Upper transaxle-to-engine bolts Transaxle mounting bracket supporting the transaxle Sheet metal undercover Tie rod ends and ball joints from steering knuckle Halfshafts Exhaust pipe and transfer case, on All Wheel Drive (AWD) vehicles Lower bell housing cover Flexplate-to-torque converter special bolts. >To remove the bolts, turn the engine crankshaft with a box wrench and bring the bolts into a position appropriate for removal, one at a time.

>: WARNING After removing the bolts, push the torque converter toward the transaxle so it doesn’t stay on the engine, allowing oil to pour out of the converter hub or cause damage to the converter. REE

1. Before servicing the vehicle, refer to the precautions in the beginning of this section.

OR

SEIT

SALES

TEE LIS

e Lower transaxle-to-engine bolts and transaxle

For Tire, Wheel and Ball Joint specifications, see Section 1 of this manual

7-18

CHRYSLER CORP. TALON

se

To install: 5. Install or connect the following: Transaxle and torque the transaxleto-engine bolts to 35 ft. Ibs. (48 Nm) and the torque converter-todriveplate bolts to 34-38 ft. Ibs. (46-53 Nm) Bell housing cover and torque the bolt to 4 ft. Ibs. (5 Nm) Transfer case and exhaust pipe, using a new gasket, for AWD models and torque the bolts to 51 ft. lbs. (69 Nm) Circlips and halfshafts Tie rods and ball joint and torque the castle nut to 25 ft. Ibs. (84 Nm) Transaxle mounting bracket and torque the bolts to 35 ft. Ibs. (48 Nm) Under-guard e Starter Speedometer cable and oil cooler lines e Solenoid connector Neutral safety switch (inhibitor Switch) connector e Pulse generator kickdown servo switch connector e Oil temperature sensor connector e All remaining components 6. Refill with Dexron®ll, Mopar ATF Plus tr type 7176, Mitsubishi Plus ATF automatic transaxle fluid. If equipped with AWD, check and fill the transfer case. 7. Start the engine and allow it to idle for 2 minutes. Apply the parking brake and move the selector through each gear position, ending in N (neutral). Recheck the fluid level and add, if necessary.

pedal lightly until resistance is met, and measure this distance. The clutch pedal clevis pin play should be within 0.04—0.12 in. (1-3mm). 5. If the clutch pedal height or clevis pin play are not within the standard values, adjust as follows: a. If not equipped with cruise control, turn-and adjust the stop bolt so the pedal height is the standard value, then tighten the locknut. b. If equipped with cruise control, detach the clutch switch connector and turn the switch to obtain the standard clutch pedal height. Then, lock by tightening the locknut. c. Turn the pushrod to adjust the clutch pedal clevis pin play to agree with the standard value and secure the pushrod with the locknut. When adjusting the clutch pedal height or the clutch pedal clevis pin play, be careful not to push the pushrod toward the master cylinder.

d. Check that when the clutch pedal is depressed all the way, the interlock switch changes from ON to OFF.

REMOVAL & INSTALLATION

e Clutch release bearing by unfastening the return clip e Release fork by sliding it away from the fulcrum kk WARNING Be careful not to cause damage to the clip by pushing the fork in any other direction or removing it with force.

¢ Release fork boot and fulcrum To install: 3. Install or connect the following: e Fulcrum and release fork boot e Clutch release fork e Return clip 4. Apply grease to the clutch release fork contact areas. 5. Lubricate the clutch release bearing. 6. Lightly apply multi-purpose grease to the clutch disc splines. 7. Install or connect the following: e Clutch disc using a suitable guide to position the disc on the flywheel e Pressure plate e Clutch release (slave) cylinder and torque the bolts to 13 ft. Ibs. (18 Nm)

2.01 (VIN F) Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Transaxle Clutch oil tubes by unscrewing the fittings

Clutch oil fluid chamber Clutch release (slave) cylinder

e>|f the vehicle has run for less than 15 minutes but more than one minute, the fluid is considered warm and should be above the ADD mark on the dipstick. Do not add fluid unless the level is at or below the ADD mark.

union bolt, gaskets and union Valve plate and valve plate spring Clutch release (slave) cylinder, without disconnecting the fluid line Pressure plate Clutch disc

ADJUSTMENTS Fulcrum

Clutch Pedal Free-Play |. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. 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. (176-182mm). 4. Measure the clutch pedal clevis pin play at the face of the pedal pad. Press the

Clip

4 Release fork

9300DG04

Slide the release fork in the direction of the arrow to disengage it from the pivot

ball

7922DG15

Lubrication points for the clutch release lever and bearing

ra

CHRYSLER CORP. TALON

NN

Hydraulic Clutch System BLEEDING e>Do not allow the reservoir to run out of fluid during bleeding, otherwise the entire procedure must be repeated. Hs

|= _ Clutch cover Ki assembly

7922DG12

Cross-sectional view of proper clutch disc and pressure plate alignment, showing the alignment tool

¢ Valve plate spring and valve plate e Gasket, union, gasket and union bolt, on the release cylinder ¢ Clutch oil fluid chamber. Uncap or unplug the clutch oil tubes, then attach them and tighten the fittings to 11 ft. Ibs. (15 Nm). e Transaxle

2.0L (Vin Y) Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Transaxle e Clutch oil tube by unscrewing the fitting

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Fill the reservoir with clean brake fluid meeting DOT 3 specifications. 3. Attach a hose to the bleeder valve on the slave cylinder with the other end of the hose submerged in a container at least half full of fresh DOT 3 brake fluid from a sealed container. 4. Have an assistant press the clutch pedal to the floor, then loosen the bleed screw on the slave cylinder. 5. Tighten the bleed screw and have your helper release the clutch pedal. 6. Repeat the procedure until the fluid is free of air bubbles.

Transfer Case Assembly REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section.

7-19 eee

2. Drain the transfer oil. 3. Remove or disconnect the following: e Negative battery cable ¢ Front exhaust pipe e Transfer case assembly and torque the bolts to 44 ft. Ibs. (69 Nm) Be careful not to damage the transfer case’s output housing oil seal. Do not let the rear driveshaft hang; suspend it from the body with a piece of wire. Cover the opening in the transaxle and transfer case to keep oil from dripping and to keep dirt out.

To install: 4. Lubricate the driveshaft sleeve yoke and oil seal lip on the transfer extension housing with clean engine oil. 5. Install or connect the following: e Transfer case assembly and torque the transfer case-to-transaxle bolts to 40-43 ft. Ibs. (55-60 Nm) on manual transaxle or 43-58 ft. Ibs. (60-80 Nm) on automatic transaxle. e>Use care when installing the rear driveshaft to the transfer case output shaft.

e Front exhaust pipe using a new gasket and torque the bolts to 33 ft. Ibs. (44 Nm)

->Plug or cap the ends to prevent contamination from entering the line.

e Release (slave) cylinder e Pressure plate and clutch disc e Clutch release bearing e Clutch release lever e Boot To install: 3. Apply a suitable grease to the clutch release lever. 4. Lightly apply multi-purpose grease to the clutch disc splines. 5. Install or connect the following: Boot assembly

54-59 Nm 40-44 ft.lbs. igs

Clutch release lever Clutch release bearing Clutch disc and pressure plate assembly Clutch release (slave) cylinder and torque the bolt to 14 ft. Ibs. (19 Nm) Clutch oil tube and torque to 11 ft. Ibs. (15 Nm) Transaxle

79220613

Exploded view of the transfer case assembly mounting—Vehicles with manual transaxle

For Wheel Alignment specifications, see Section 1 of this manual

7-20

CHRYSLER CORP. TALON

6. Fill the transfer case with gear oil of classification GL-4 or higher, SAE 75W85W or 75W-90. Check the fluid level in the transaxle and add, as required.

Halfshaft

4. Install or connect the following: ¢ Circlips on the halfshaft ends ¢ Halfshaft into the transaxle e>Be sure it is fully seated.

Halfshaft into the hub Center bearing bracket, if equipped and torque the bolts to 33 ft. Ibs. (45 Nm) Washer, face the chamfered edge outward Halfshaft nut, temporarily tighten Tie rod end and ball joint to the Steering knuckle and torque the nut to 21 ft. Ibs. (28 Nm) and the tie rod nut to 17-25 ft. Ibs. (24-33 Nm) Wheel and torque the axle nut to 145-188 ft. Ibs. (200-260 Nm) with the brakes applied New cotter pin

.

REMOVAL & INSTALLATION Front

1. Before servicing the vehicle, refer to the precautions in the beginning of this section.

If the vehicle is going to be rolled with the halfshafts removed, install 2 outer CV-joints tools in the hubs. Also, if proper torque is not applied to the front wheel bearings, the bearings will no longer be usable.

Rear

the prybar too far or the oil seal in the case may be damaged.

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Install or connect the following: Rear wheel(s) Wheel speed sensor, if equipped with Anti-Lock Brake System (ABS) Brake caliper and rotor or brake drum Parking brake shoes (disc brakes) or shoe/lever assembly (drum brakes) Parking brake cable from the backing plate Wheel cylinder brake line, if equipped with drum brakes Shock absorber from the steering knuckle Trailing arm and lower arm from the steering knuckle Toe control arm from the steering knuckle Cotter pin, nut and washer from the halfshatt Differential mount support. Halfshaft by prying it from the differential housing Halfshaft from the hub assembly To install: 3. Install or connect the following: Halfshaft in the hub assembly New circlip on the inner shaft Halfshaft into the differential Differential mount support Washer on the halfshaft in the correct direction Halfshaft nut and torque it to 145-188 ft. Ibs. (196-255 Nm)

To install: 3. Inspect the halfshaft boot for damage or deterioration. Check the ball joints and splines for wear.

elf the cotter pin hole does not align, tighten the nut to 188 ft. Ibs. (255 Nm) and install the cotter pin in the first hole that aligns.

2. Remove or disconnect the following: Negative battery cable. e Cotter pin, halfshaft nut and washer e Speedometer drive from the right extension housing if removing the right halfshaft Tie rod from the steering knuckle e Stabilizer link from the damper fork e Damper fork from the lateral lower arm Lateral lower arm from the steering knuckle

Use of improper methods of joint separation can result in damage to the joint, leading to possible failure.

e Center support bearing bracket bolts, if equipped with an inner shaft on All Wheel Drive (AWD) vehicles e Halfshaft by pressing it from the hub ¢ Halfshaft/inner shaft assembly by tapping it from the transaxle with a plastic hammer on AWD vehicles e Halfshafts by prying it from the transaxle on FWD vehicles

Do not pull on the shaft to dislodge it from the transaxle; doing so damages the inboard joint. Do not insert

Toe control arm, trailing arm and lower arm. Torque the toe control arm nut to 20 ft. Ibs. (28 Nm), trailing arm nut to 85-99 ft. Ibs. (118-137 Nm) and lower arm nut to 71 ft. Ibs. (98 Nm) Lower shock mount to the steering knuckle and torque the bolt to 52 ft. lbs. (71 Nm) Wheel cylinder brake line, if removed Parking brake cable Remaining brake components ABS wheel speed sensor, if removed e Rear wheel e Brake drums, if equipped 4. Bleed the brake system.

| OVERHAUL

The Birfield joint assembly, located on the wheel side of the halfshaft, is not to be disassembled; repair of this joint is only by replacement of the halfshaft. Tri-Pot Joint

FRONT WHEEL DRIVE— (FWD) 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove halfshaft and place it in a soft jawed vise. 3. Disassemble or remove the following: e Tri-pot boot bands e Tri-pot case e>Wipe the grease from the tri-pot case.

e Halfshaft snapring e Tri-pot spider assembly

Do not disassemble the spider assembly. ¢ Tri-pot boot

If the boot is to be reused, wrap plastic tape around the shaft splines to protect the boot from damage. e Dynamic halfshaft, To install: 4. \f removed, by performing the

damper bands from the if necessary install the dynamic damper following procedure:

sia

tri

93060611

Lubricating the tri-pot case assembly installed

9306DG09

Measuring the tri-pot joint boot T.J. repair kit

T.J. boot repair kit 1. T.J. boot band 2. T.J. boot band 3. T.J. case 6. 7. 8. 9.

(large) (smail)

10. B.J. assembly 11. B.J.boot band (small) 12. B.J.boot band (large)

13. B.J. boot

Spider assembly T.J. boot Damper band Dynamic damper

Caution Do not disassemble the B.J. assembly replacement of the B.J. boot.

except

9306DG06

Exploded view of the front halfshaft assemblies—Front wheel drive

WARNING Wrap plastic tape around the shaft splines to protect the boot from damage.

B.J.

Dynamic damper 9306CG09

Positioning the dynamic damper on the front halfshaft assemblies—Front wheel drive

a. Slide the damper onto the halfshaft with new bands. b. Position the damper so the distance from the front of the Birfield joint to the front edge of the damper assembly is 14.60-14.84 in. (371-377mm) for the right halfshaft (non-turbo)/left halfshaft (turbo) or 7.52—7.76 in. (191-197mm) for the left halfshaft (non-turbo, M/T). c. Tighten and secure the damper bands.

5. Install a new small boot clamp onto the halfshaft followed by the tri-pot boot. 6. Apply the specified repair kit grease between the spider axle and the roller. 7. Install the tri-pot spider assembly onto the shaft from the spline beveled section direction and secure with the snapring. 8. Distribute a portion of the 3.7 oz.

ALL WHEEL DRIVE (AWD)— FRONT 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove halfshaft and place it in a Soft jawed vise. 3. Disassemble or remove the following: e Tri-pot boot bands e Tri-pot case (right halfshaft) or tripot case/inner shaft assembly (left halfshaft) e>Wipe the grease from the tri-pot case.

Bevelled section

=)

(105 g) for non-turbo or 4.23 oz. (120 g) for turbo specified repair kit grease into the tripot case, insert the spider assembly and add the remaining grease. 9. Install the tri-pot 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. c. Adjust the boot so that the bands are spaced at 3.03-3.27 in. (77-83mm). d. Tighten the band securely.

e Halfshaft snapring e Tri-pot spider assembly

ae

> WARNING Do not disassemble the spider assembly. 9306CG10

Lubricating the tri-pot spider assembly

e Tri-pot boot

For Maintenance Interval recommendations, see Section 1 of this manual

7 -22

EES EEe CORP. 6. Install a new small boot clamp onto the halfshaft followed by the tri-pot boot. 7. Apply the specified repair kit grease between the spider axle and the roller. 8. Install the tri-pot spider assembly onto the shaft from the spline beveled section direction and secure with the snapring. 9. Distribute a portion of the 3.70 oz. (105 g) specified repair kit grease into the tri-pot case, insert the spider assembly and add the remaining grease. 10. Install the tri-pot 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. c. Adjust the boot so that the bands are spaced at 3.03-3.27 in. (77-83mm). d. Tighten the band securely.

lio

bode"& A B.J. boot repair kit

13

6

15

5 (L.H. only)

ih id

413 bs 14

1. 2. . 4, 5.

T.J. T.J. T.J. T.J. Seal

13, 14. 15. 16. 17. 18, 19,

boot band (iarge) boot band(small) case and inner shaft assembly case plate

10. Center bearing 11. Center bearing bracket 12. Circlip

ALL WHEEL DRIVE (AWD)—REAR

Bracket assembly repair kit

Bearing dust seal

(7a. boot repair kit

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove halfshaft and place it ina Soft jawed vise. 3. Disassemble or remove the following: e Tri-pot boot bands

Snap ring Spider assembly TJ. boot B.J. assembl B.J. boot band (small) B.J. boot band (large) B.J. boot

aution Do not disassemble the B.J. assembly except replacement of the B.J. boot.

9306DG607

Exploded view of the front halfshaft assemblies—AWD

>: WARNING If the boot is to be reused, wrap plastic tape around the shaft splines to protect the boot from damage.

4. |f working with the left halfshaft and it is necessary to replace the tri-pot case, press the case from the inner shaft assembly. To install: 5. If installing a new tri-pot case onto the left halfshaft, perform the following procedure: a. Lubricate the inner shaft splines with Multi-Mileage Grease No. 2525035. b. Press the inner shaft assembly into tri-pot case. c. Secure the tri-pot case with special tool MB991248 on a hydraulic press with the case facing upward. d. Position a new seal plate in the center of the tri-pot case. e. Place a 1.18 in. (30mm) pipe on the seal plate and press the seal into the tri-pot case.

We,

_B.J. boot repair kit i

i!

ay

ba

00+ Tie . B.J. repair kit

2a10

1. TJ. boot band (large) 2. T.J, boot band (smail)

3. 4. 5. 6. 7. 8. 9. 10, 11.

T.J. case Snap ring Spider assembly T.J. boot B.J. boot band (large) B.J. boot band (small) B.J. boot B.J. assembly Circlip

Caution Do not disassemble

Wrap plastic tape around the shaft splines to protect the boot from damage.

the B.J. assembly.

Tw: repair kit 9306DG10

Exploded view of the rear halfshaft assemblies—AWD

CHRYSLER CORP,

793

#

c. Adjust the boot so that the bands are spaced at: ¢ Conventional: 2.99-3.23 in. (76-82mm) e¢ Limited slip: 3.19-3.43 in. (81-87mm) d. Tighten the band securely. 9306DG11

Positioning the tri-pot boot bands—Rear halfshaft assemblies with AWD

e Tri-pot case and clean the case thoroughly e Halfshaft snapring e Tri-pot spider assembly

Do not disassemble the spider assembly. e Tri-pot boot

+k WARNING If the boot is to be reused, wrap plastic tape around the shaft splines to protect the boot from damage. To install:

(95 9).

MB990932

ALL WHEEL DRIVE (AWD)

9306CG21

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove the left halfshaft and place it in a Soft-jawed vise. 3. Remove the tri-pot spider assembly from the tri-pot case. 4. Remove the tri-pot case by performing the following procedure: a. Position the inner shaft/tri-pot case assembly on a hydraulic press supported by Tool MB991248 with the tri-pot case facing upward. b. Position a bar inside the tri-pot case on the end of the inner shaft and press the case from the inner shaft assembly. 5. Remove and disconnect the following: e |nner shaft assembly, place it ina Soft-jawed vise e Center bearing bracket, press it from the inner shaft with a wheel puller

Removing the center bearing from the center bearing bracket—left front halfshaft with AWD

MB990938 MB990932

Bearing 9306CG22

Installing the center bearing to the center bearing bracket—left front halfshaft with

AWD

Inner dust seal

MB990938

MB990933

93060623

9306CG19

Removing the tri-pot case from the inner shaft assembly—left front halfshaft with

Installing the inner dust seal to the center bearing bracket—left front halfshaft with

AWD

AWD Outer dust seal

|

9. Limited slip type of grease: 3.70 02. (105 g). 10. Install the tri-pot 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 to check the boot band identification numbers: Large band: 20-98 No. BJ 82 e Small band: 20-83 No. BJ 82

:

Center Bearing

Wrap plastic tape around the shaft splines to protect the boot from damage. 4. Install a new small boot clamp onto the halfshaft followed by the tri-pot boot. 5. Apply the specified repair kit grease between the spider axle and the roller. 6. Install the tri-pot spider assembly onto the shaft from the spline beveled section direction and secure with the snapring. 7. Distribute a portion of the specified repair kit grease into the tri-pot case, insert the spider assembly and add the remaining grease. 8. Conventional type of grease: 3.35 02.

MB990938

caw

MB990938

MB990931

= 9306CG24 9306CG20

Removing the center bearing bracket from the inner shaft assembly—left front half-

Installing the outer dust seal to the center bearing bracket—left front halfshaft with

shaft with AWD

AWD

For Tune-up, Capacities and Firing orders, see Section 1 of this manual

7-24

CHRYSLER CORP Inner shaft

MB991172 9306CG25

Installing the inner shaft into the center bearing bracket—left front halfshaft with

AWD

iD Inner shaft assembly

e Inner shaft into the center bearing bracket using a hydraulic press and Adapter Too! MB991172 7. Install the tri-pot case onto the left halfshaft by performing the following procedure: a. Lubricate the inner shaft splines with Multi-Mileage Grease No. 2525035. b. Press the inner shaft assembly into tri-pot case. c. Secure the tri-pot case with special Tool MB991248 on a hydraulic press with the case facing upward. d. Position a new seal plate in the center of the tri-pot case. e. Place a 1.18 in. (30mm) pipe on the seal plate and press the seal into the tri-pot case. 8. Install or connect the following: e Tri-pot joint assembly e Left halfshaft

93060613

Positioning the Birfield joint boot’s small diameter -

MB991561

Birfield Joint Boot

FRONT ie

Installing the inner shaft assembly into the tri-pot case—left front halfshaft with AWD

MB991248

9306CG27

Installing the seal plate into the tri-pot case—left front halfshaft with AWD

e Center bearing and inner dust seal from the center bearing bracket using a hydraulic press, Installer Adapter Too! MB990932 and Snapin Bar Tool MB990938 To install: 6. Install or connect the following: e Center bearing into the center bearing bracket using a hydraulic press, Installer Adapter Tool MB990932 and Snap-in Bar Tool MB990938 e |nner duct seal into the center bearing bracket using a hydraulic press, Installer Adapter Tool MB990933 and Snap-in Bar Too! MB990938 Outer duct seal into the center bearing bracket using a hydraulic press, Installer Adapter Tool MB990931 and Snap-in Bar Tool MB990938

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove the halfshaft and place it in a SOft jawed vise. 3. Disassemble or remove the following: e Tri-pot joint e Dynamic damper, for Front Wheel Drive (FWD) e Birfield joint boot bands e Birfield joint boot To install: 4. Assemble or install the following: e Birfield joint boot e Birfield joint boot small band 5. Place the halfshaft in a soft jawed vise so that the Birfield joint is standing vertically. 6. Position the boots small diameter so that only 1 groove is exposed on the shaft. 7. Adjust the Band Crimper Tool MB991561 so that the jaw opening is 0.114 in. (2.9mm). 8. Position the small band so there is clearance between the boot and the bands mating edge. 9, Using a Band Crimper Tool MB991561, crimp the small band until the internal measurement of the crimp is 0.094—0.110 in. (2.4—2.8mm).

If the crimp dimension is not correct, remove the band install a new one.

10. Using 3.88 oz. (110 g) for non-turbo (FWD), 4.59 oz. (130 g) for turbo (FWD) or 3.35 02. (95 g) for AWD, specified amount

Adjusting bolt

93060614

View of the band crimper tool

B.J. boot

—, B.J. boot band (small)

Projection 93060615

}

Positioning the Birfield joint boot’s small band

93060616

Measuring the small band’s crimp

of grease in the repair kit, pack the Birfield boot. 11. Position the boot so 0.004—0.061 in. (0.1-1.55mm) of clearance exists between the boots large diameter end and the Birfield joint housing shoulder. 12. Adjust the Band Crimper Too!

CHRYSLER ane b. Position the damper so the distance from the front of the Birfield joint to the front edge of the damper assembly is 14.60-14.84 in. (371-377mm) for the right halfshaft (non-turbo)/left halfshaft (turbo) or 7.52—7.76 in. (191-197mm) for the left halfshaft (non-turbo, M/T). c. Tighten and secure the damper bands. 16. Install the tri-pot joint. 9306CG17

Positioning the Birfield joint boot’s large diameter

Projection B.J. boot band (large)

D 9306CG18

Positioning the Birfield joint boot’s large band

MB991561 so that the jaw opening is 0.126 in. (3.2mm). 13. Install and position the large boot band so that it rests against the boot(s) projection and a gap exists between the clamp and the boot. 14. Using a Band Crimper Tool MB991561, crimp the small band until the internal measurement of the crimp is 0.094-0.110 in. (2.4-2.8mm).

If the crimp dimension is not correct, remove the band install a new one. |e

RTS

SE

PAPE

STIS

RO

FD

SOE EL

EES

15. \f equipped with FWD, install the dynamic damper by performing the following procedure: a. Slide the damper onto the halfshaft with new bands.

REAR 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove the halfshaft and place it in a soft jawed vise. 3. Disassemble or remove the following: e Tri-pot joint e Birfield joint boot bands e Birfield joint boot To install: 4. Assemble or install the following: e Birfield joint boot e Birfield joint boot small band 5. Position the large and small boot clamps onto the boot. Be sure to check the boot band identification numbers: e Large band: 20-110 No. Bu 87 e Small band: 20-83 No. BU 82 6. Install the tri-pot joint.

REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the follow-ing: e Driveshaft ¢ Companion flange nut. Use End Yoke Holder Too! MB990850, to secure the companion flange. e»Matchmark the companion flange to the drive pinion.

7-25

puller to pull the companion flange from the drive pinion. e Pinion oil seal To install: 3. Install or connect the following: New pinion oil seal. Use an Oil Seal Installer tool MB995020 to drive the new seal into the axle housing Grease oil seal lip and companion flange. Lubricate with MultiMileage grease No. 2525035. Align the companion flange-todrive pinion matchmarks New companion flange-to-drive pinion nut. Use an End Yoke Holder tool MB990850 to secure the flange and torque the nut to 137 ft. lbs. (186 Nm) Driveshaft and torque the bolts to 22-25 ft. Ibs. (29-34 Nm)

Differential Carrier REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Halfshafts e Driveshaft e>Support the differential carrier with a jack. e Differential carrier mount-to-rear crossmember bolt ¢ Differential carrier To install:

3. Raise the carrier into position. 4. Install or connect the following: e Differential carrier and torque the mount-to-rear crossmember bolt to 72 ft. Ibs. (98 Nm) e Driveshaft e Halfshafts

e Companion flange. Use a bearing

STEERING AND SUSPENSION

< CAUTION Some vehicles are equipped with an air bag system, also known as the Supplemental Inflatable Restraint (SIR) or Supplemental Restraint System (SRS). The system must be dis-

abled 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.

PRECAUTIONS Several precautions must be observed when handling the inflator module to avoid accidental deployment and possible personal injury. e Never carry the inflator module by the wires or connector on the underside of the module.

For complete service labor times, order Nichols’ Chilton Labor Guide

ier

CHRYSLER CORP. TALON

a

e When carrying a live inflator module, hold securely with both hands, and ensure that the bag and trim cover are pointed away from you. e Place the inflator module on a bench or other surface with the bag and trim cover facing up. e With the inflator module on the bench, never place anything on or close to the module that may be thrown in the event of an accidental deployment.

DISARMING 1. Position the front wheels in the straight-ahead position and place the ignition key in the LOCK position. Remove the key from the ignition lock cylinder. 2. Disconnect the negative battery cable and insulate the cable end with high-quality electrical tape or similar non-conductive wrapping.

3. Wait at least one minute before working on the vehicle. The air bag system is designed to retain enough voltage to deploy the air bag for a short period of time after the battery has been disconnected. To arm: 4. Reconnect the negative battery cable, turn the ignition switch to the ON position and check the air bag warning light for proper operation.

Power Rack and Pinion Steering Gear REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the power steering fluid into a suitable container. 3. Remove or disconnect the following:

Negative battery cable Windshield washer fluid reservoir Brake fluid reservoir Air conditioning compressor. Position it aside; DO NOT disconnect the refrigerant lines Stabilizer bar Joint assembly and gear body connecting bolt Power steering pipe connection Tie rod end from the steering knuckle Left and right side stays Center member assembly retainers Center member Power steering gear retaining clamp Power steering gear assembly To install: 4. Install or connect the following: Power steering gear assembly Power steering gear retaining

69-78 Nm A13X0236

Brake fluid reservoir assembly A/C compressor Joint assembly and gear box connecting Power steering pipe connection Cotter pin Tie-rod end and knuckle connection Stay (L.H.) Stay (R.H.) CONOAR ON Centermember assembly 10. Clamp 11. Gear box assembly 12. Return tube

NOTE The fasteners marked * should be temporarily tightened before they are finally tightened once the total weight of the engine has been placed on the vehicle body. 79220614

Exploded view of the power steering gear assembly and related components

oli ti era) clamp and torque the bolts to 51 ft. lbs. (69 Nm) Center member Center member assembly retainers and torque the bolts to 58-65 ft. lbs. (78-88 Nm) Left and right side stays and torque the bolts to 51-58 ft. Ibs. (69-78 Nm) Tie rod end to the steering knuckle and torque the nut to 21 ft. Ibs. (28 Nm) Power steering pipe connection and torque the nuts to 13 ft. Ibs. (18 Nm) Joint assembly and gear body connecting bolt and torque the bolt to 11 ft. Ibs. (15 Nm) Stabilizer bar Air conditioning compressor Brake fluid reservoir Windshield washer fluid reservoir Negative battery cable 5. Fill the reservoir with power steering fluid and bleed the system. 6. Check the front end alignment and adjust, if necessary.

72 &

_ 44Nm 32 ft.lbs.

88-118 Nm 65 — 87 ft.lbs.

28 ft.lbs.

pes

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ae

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@-DN 88 Nm

64 ft.lbs.

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1. Stabilizer link mounting nut

5. Damper fork

2. eae absorber upper mounting

6. Shock absorber assembly

nuts 3. ae

absorber lower mounting olt 4. Damper fork mounting bolt 7922DG23

Exploded view of the front strut mounting

REMOVAL & INSTALLATION Front

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: ¢ Upper strut assembly-to-chassis nuts, from the engine compartment e Front wheel

e Stabilizer link nut Strut assembly lower mounting bolts e Damper fork

e Strut To install: 3. Install or connect the following: e Strut

e Upper strut assembly-to-chassis nuts, in the engine compartment and torque to 32 ft. Ibs. (44 Nm) 4 Check and adjust the front alignment, if necessary. Rear

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Service lid in the luggage compartment ¢ Upper mounting bracket-to-body cap and flange nuts

98 Nm

71 ft.lbs. a USD

->Do not remove the large nut in the center of the strut assembly.

e Damper fork and torque the damper fork-to-lower arm nut/bolt to 64 ft. lbs. (88 Nm) e Strut assembly lower mounting bolts and torque the strut-todamper fork bolt to 65-87 ft. Ibs. (88-118 Nm) e Stabilizer link nut and torque the nut to 28 ft. Ibs. (39 Nm) e Front wheel

e Strut-to-steering knuckle bolt

e Strut To install: 3. Install or connect the following: e Strut and torque the upper strut-tochassis.nuts to 32 ft. Ibs. (44 Nm) 4. Raise the suspension with a jack or adjustable stand to align the strut lower mounting holes. 5. Install or connect the following:

Ete 2. Flange nuts 3. Bolt 4. Shock

absorber 7922DG626

Exploded view of the rear strut mounting

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GSES CORP.

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20-25 Nm 14- 18 ft.Ibs.

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REMOVAL & INSTALLATION

5 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove the strut assembly.

8

se

Disassembly steps 1. Self-locking nut 2. Washer 3. Upper bushing A

4. Upper bracket assembly 5. Upper spring pad

6. Collar

¢ Lower strut mounting bolt and torque to 71 ft. Ibs. (97 Nm) e Cap and service lid

>: CAUTION the Upper bushing B

Do not use air tools to tighten the compressor tool bolt.

8. Cup assembly g. Bump rubber 10. Dust cover Tit: Coil spring re Shock absorber assembly 79220628

Exploded view of the front strut assembly

3. Compress the coil spring, using Spring Compressing tools MB991237 and MB991239.

Be sure to install the tools evenly so the maximum length will be attained within the installation range.

Disassembly steps . Self-locking nut Washer Upper bushing A . Upper bracket assembly . Upper spring pad MORON . Upper bushing B

. Collar . Cup assembly ON O . Dust cover 10. Bump rubber 11. Coil spring 12. Shock absorber

assembly

7922DG27

Exploded view of the rear strut assembly

4. Remove or disconnect the following: Self-locking nut, by holding the piston rod Washer Upper bushing A Upper bracket assembly Upper spring pad Collar Upper bushing B Cup assembly Rubber bumper Dust cover Coil spring To assemble: 5. Use the compressor tools to compress the coil spring, then install it to the strut. Align the edge of the coil spring to the Stepped portion of the strut spring seat. 6. Install or assemble the following: e Dust cover Rubber bumper Cup Upper bushing B Collar Upper spring pad Upper bracket assembly eInstall the assembly so the position of the 3 bolts are in the proper orientation with the damper fork.

¢ Upper bushing A ¢ Washer and self-locking nut. Temporarily, tighten the self-locking nut, then remove the spring com-

CHRYSLER CORP.

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SS

A

STS

ST

SN

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pressor tools and tighten the nut to 14-18 ft. Ibs. (20-25 Nm) using a torque wrench.

Do not use air tools to tighten the self-locking nut!

° Strut 7. Check and adjust the front alignment, if necessary.

ISP

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REMOVAL & INSTALLATION The lower ball joint is an integral part of the lower control arm assembly, and cannot be serviced separately. A worn or damaged ball joint, requires replacement of the lower control arm assembly.

Upper Control Arm

e Strut e Compress the spring using a coil

:

REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following:

spring compressor Self-locking nut by holding the piston rod Upper bracket assembly and spring pad

Upper Ball Joint:

OS R

body Upper arm Upper arm-to-shafts through-bolts To install: 3. Assemble the upper arm to the shafts at the proper angle. Tighten the throughbolts and nuts to 41 ft. Ips. (57 Nm). The proper angle is 84-86 degrees. After the arm and the shafts are connected at the correct angle, measure dimensions A and B to insure correct assembly. e¢ A—11.8 in. (299.9mm) e B—9.2 in. (234.0mm)

57Nm 41 ret

eee

3

1 28 Nm ————_—_3—___ 20 ft.lbs.

iN]

steps

3. Upper arm assembly 4. Upper arm shaft assembly

1. Upper arm ball joint and knuckle connection 2. Upper arm self-locking nut

Bracket assembly Upper bushing and washer New self-locking nut on the piston rod and temporarily tighten the nut 5. Carefully, remove the spring compressor from the spring. Tighten the selflocking nut to 16 ft. Ibs. (25 Nm). 6. Install the strut.

71-29 TWEET

57 Nm 41 ft.lbs.

Removal

Collar Upper spring pad

BE

86 Nm

Collar Upper bushing Cup assembly Bump rubber Dust cover Coil spring To assemble: 3. Align the end of the coil spring with the stepped part of the spring seat and install the compressed coil spring on the strut. 4. Install or assemble the following: Dust cover Bump rubber Cup assembly Upper bushing

R

Front wheel(s) Upper ball joint from the steering knuckle using special tool MB991113 Upper shaft mounting nuts from the

Lower Ball Joint

Rear

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disassemble the following:

ADSCW TD

9300DG01

Exploded view of the upper control arm and related components

A: 299.9 mm

(11.8 in.)

B : 234.0 mm (8.2 in.)

V groove

REMOVAL & INSTALLATION The upper ball joint is an integral part of the upper control arm. If the upper ball joint is to be serviced, the upper control arm will have to be replaced.

9300DG02

Be sure to install the shafts on the control arm at the correct angle

Timing belt service is covered in Section 3 of this manual

7-30

CHRYSLER corp.

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ing:

A 1B . Before servicing the vehicle, refer to

a

the precautions in the beginning ofthis sec-

. cree lower arm ball joint

oe

as a

Lateral Lower Arm

2. Remove or disconnect the follow-

4. Install or connect the following: e Control arm assembly and torque

a knuckle e Upper ball joint-to-steering

tion.

at the steering knuckle with special

20 ft. Ibs. (28 Nm) a front wheel alignment and Perform 5. ee)

e Both compression lower arm

= Stay (bracket

oie lower arm ELE e Compression

° Strut aeralower mounting a boltsbairioitak

ale eo arm ‘f all Jo! the knuckle assembly

To install: 3. Install or connect the following:

adjust, if necessary.

e Lateral lower arm mounting bolts e Lateral arm To install: 3. Install or connect the following: e Lateral lower arm and temporarily, install the mounting bolts; do not tighten the bolt until the vehicle is on the floor at normal riding height

e Compression lower arm and torque the 2 mounting bolts to 60 ft. Ibs. (81 Nm) e Ball joint to the knuckle assembly and torque the new self-locking nut to 43-51 ft. Ibs. (69-71 Nm)

Lower Control Arm

REMOVAL & INSTALLATION Compression Lower Arm

1. Before servicing the vehicle, referto

¢ Wheel

4. Check and adjust the front wheel alignment, if necessary.

the precautions in the beginning of this section.

ae

2.P Weaeee disconnect the following:

tool MB991113

and torque the new locking nut to

98-118 Nm* 72-87 ft.lbs.*

81 Nm 60 ft.lbs. 81 Nm

60 ft.lbs.

re 59-71 Nm 43-51 ft.lbs

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69-78 Nm 51-58 ft.lbs.

Lateral lower arm

fee

Specified

grease:

Lubricant

Part No. 2525035

MOPAR

Multi-mileage or equivalent

Compression lower arm assembly removal steps . Compression lower arm ball joint and knuckle connection Zi Compression lower arm mounting bolts 3 3. Compression lower arm assembly =

Lateral lower arm removal steps Stay

assembly

Shock absorber lower mounting bolt Lateral knuckle Lateral tse Soe RL Lateral

lower arm ball joint and connection lower arm mounting bolt lower arm assembly

Caution “: Indicates parts which should be temporarilly tightened,

and then fully tightened with the vehicle on the ground in the unladen condition.

9300DG03

Exploded view of the lower arms and related components

CHRYSLER CORP, e Ball joint to the knuckle assembly and torque the new self-locking nut

794

to 43-51 ft. Ibs. (59-71 Nm)

b465 54-65 ful ft.lbs.

¢ Strut lower mounting bolts and torque to 64 ft. Ibs. (88 Nm) * Stay and torque the bolts to 51-58 ft. lbs. (69-78 Nm)

10 ne Ate =

» Wheel

SS

4. Torque the lateral lower arm throughbolt and nut to 71-85 ft. Ibs. (97-118 Nm).

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5. Check and adjust the front wheel

f

alignment, if necessary.

:

F Wheel Bearings

vk 74-88 Nm 36—43 ftibs.vB fulbs.

ADJUSTMENT Front

The front wheel bearing is sealed and not adjustable. If the wheel bearing shows signs of play, the hub assembly must be replaced. Rear

The wheel bearing play is not adjustable. lf the wheel bearing play is not within specifi:

. Rear wheel speed sensor

ear

5 . see with ABS> Brake drum

cations, the hub assembly must be replaced.

FRONT WHEEL DRIVE (FWD)

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hub

3. Shoe and lever assembly

10. Bike BRetccnneciboa

4. Caliper assembly

11. Dust seal

5, Brake disc

~

6. Shoe and lining assembly

1. Before servicing the vehicle, refer to the precautions in the beginning of this section.

7922DG24

Exploded view of the rear hub assembly

88 Nm

65 ft.lbs.

196-255 Nm

Ud

Sa

di ites

2. Release the parking brake and if equipped, remove the brake drum. 3. If equipped with rear disc brakes, remove the caliper assembly and the brake disc (rotor). 4. Place a dial gauge against the hub surface, then move the hub in the axial direction and check whether or not there is end-play. Specification is 0.002 in (0.05mm),

5. To check for rotary sliding resistance,

turn the hub a few times to seat the bearing. Wind a rope around the hub bolts and turn

the hub by pulling at a 90° angle with a spring scale. Measure to determine whether or not the rotary sliding resistance of the rear hub is at the limit value. Specification is 3.9 Ibs. (1.8 kg) or less. 1. Cotter

2 rv angel speed sensor with ABS> % FVehicles

6. Upper arm bail joint and knuckle

AUT

1. Before servicing the vehicle, refertothe

7, Front hubassembly

precautions in the beginning of this section.

2. Remove the caliper assembly and the

eS ie a alla | ALOISi

ALL WHEEL DRIVE (AWD) é

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ce. peices pin

aaa b assembl

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brake disc (rotor). 3. Place a dial gauge against the hub

surface, then move the hub :in the axial:

Heater Core replacement is covered in Section 2 of this manual

1-32

CHRYSLER CORP. TALON

se

direction and check whether or not there is end-play. End play should not exceed 0.002 in. (0.05mm).

REMOVAL & INSTALLATION Front

->The front hub assembly is a sealed unit and should not be disassembled.

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Wheel Halfshaft cotter pin and discard it Halfshaft nut by holding the rotor in place with a suitable tool Front wheel speed sensor, if equipped with Anti-lock Brake System (ABS) Caliper and suspend it out of the way with a piece of wire. ->Do not disconnect the fluid line.

e Upper control arm ball joint from the steering knuckle e Front hub assembly e> Shift the knuckle to the outside in order to keep the clearance between the front hub mounting bolts and halfshaft.

Be careful not to damage the bail joint boot. If equipped with ABS, be careful not to damage the rotor. 3. If necessary to remove the steering knuckle, remove or disconnect the following:

e Dust shield e Tie rod end from the steering knuckle and discard the cotter pin e Compression and lateral lower con-

trol arm ball joints from the steering knuckle e Damper fork and lateral lower control arm from the steering knuckle e Steering knuckle To install: 4. |f the steering knuckle was removed, install or connect the following: e Steering knuckle and hand-tighten the bolt and nut e Lateral and compression lower control arm ball joints into the steering knuckle Tie rod end ball joint to the steering knuckle and torque the nut to 17-25 ft. Ibs. (24-33 Nm) New cotter pin Dust shield and torque the bolt to 78 inch Ibs. (8.5 Nm) LS). Install or connect the following: Front hub assembly and torque the bolts to 65 ft. Ibs. (88 Nm) Upper control arm ball joint to the steering knuckle and torque the nut to 25 ft. Ibs. (33 Nm) Brake disc (rotor) and caliper and torque to 43 ft. Ibs. (59 Nm) Front wheel speed sensor, if equipped Halfshaft nut. Hold the rotor in position while torquing the nut to 145-188 ft. Ibs. (196-255 Nm). e>|f the cotter pin holes do not align, tighten the nut to 188 ft. Ibs. (225 Nm) maximum. Install a new cotter pin in the first matching holes. e Wheel Rear

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Wheel e Halfshaft, on All Wheel Drive (AWD) vehicles

e Rear wheel speed sensor, if equipped with Anti-lock Brake System (ABS) ¢ Caliper, if equipped with rear disc brakes and suspend the caliper on a Suitable piece of wire e»Do not disconnect the fluid line.

¢ Brake drum, if equipped with drum brakes ¢ Clip mounting bolt, on Front Wheel Drive (FWD) e Brake shoe and lining assembly, on AWD e Parking brake shoe and lining assembly, if equipped with disc brakes e Parking brake cable clip and cable on AWD e Rear hub and bearing assembly 3. On FWD vehicles equipped with ABS, use a Suitable inner shaft remover to press ff the ABS rotor. To install: 4. lf removed, install the ABS rotor. 5. Install or connect the following: e Rear hub and bearing and torque to 65 ft. Ibs. (88 Nm) Parking brake cable and retaining clip, on AWD Parking brake shoe and lining assembly, if equipped with disc brakes Shoe and lining assembly, on AWD Clip mounting bolt, on FWD Brake drum, if equipped with drum brakes and torque to 60 ft. Ibs. (81 Nm) Rotor and caliper, if equipped with disc brakes and torque to 43 ft. Ibs. (59 Nm) Rear wheel speed sensor, if equipped Halfshaft, on AWD Front wheel

CHRYSLER CORPORATION 1998-02

Dodge/Plymouth-Neon DRIVE RAINS i.e scstieek 8-25 ENGINE REPAIR.................. 8-2 FUELS YSIEMA eae 8-22 PRECAUTIONS ................... 8-2

STEERING AND SUSPENSION@ terns SOD ;

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Removal & Installation............. 8-23 Cee cco ee ne 8-24 Removal & Installation.............. 8-24

POG eee eee peer tinteiket 8-36 SAP IMTCT eee

F Front Crankshaft Seal oo... 8-15 Removal & Installation.............. 8-15 UCI RIer aeeatiecc dtscette 2155) 9 8-23

CUCLPUN Dewre tee ate eee 8-23

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Removal & Installation.............. 8-93

PERCAU HON Sam te aesthe aco tisnsdscally 8-36

Fuel System Pressure... 8-93

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& Installation eee

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Camshaft and Lifters... 8-15 Removal & Installation... 8-15 Gs

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P PISTON ANG. RIG. stares antec 8-22 POSHIOMING Gumance tn eee 8-22 R

Rack and Pinion Steering Gear......8-36 Removal & Installation.............. 8-36 hears Mali oealhy,

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8-10

Removal & Installation.............. 8-10

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Removal & Installation... 8-21

S Starter Motor eeu dealin caniedecse Ca armtions 8-18

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Removal & Installation.............. 8-39

Removal & Installation.............. 8-18

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Removal & Installation.............. 8-11

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Removal & Installation... 8-19 SULA pee oe meermneeant 8-20

Removal & Installation............ 8-20

Removal & Installation... 50

Wheel Bearings.....csrsrosesrsrn 8-40 ACJUSIMEN. sesso corse ae

Removal & Installation............. 8-45

8-2

CHRYSLER CORPORATION NEON

a

PRECAUTIONS Before servicing any vehicle, please be Sure to read all of the following precautions, which deal with personal safety, prevention of component damage, and important points to take into consideration when servicing a motor vehicle: e Never open, service or drain the radiator or cooling system when the engine is hot; serious burns can occur from the steam and hot coolant. e Observe all applicable safety precautions when working around fuel. Whenever servicing the fuel system, always work in a well-ventilated area. Do not allow fuel spray Or vapors to come in contact with a spark, open flame, or excessive heat (a hot drop light, for example). Keep a dry chemical fire extinguisher near the work area. Always keep fuel in a container specifically designed for fuel storage; also, always properly seal fuel containers to avoid the possibility of fire or explosion. Refer to the additional fuel system precautions later in this section. ¢ Fuel injection systems often remain pressurized, even after the engine has been turned OFF. The fuel system pressure must be relieved before disconnecting any fuel lines. Failure to do so may result in fire and/or personal injury. e Brake fluid often contains polyglycol ethers and polyglycols. Avoid contact with the eyes and wash your hands thoroughly after handling brake fluid. If you do get brake fluid in your eyes, flush your eyes with clean, running water for 15 minutes. If — eye Irritation persists, or if you have taken

2

brake fluid internally, IMMEDIATELY seek medical assistance. e The EPA warns that prolonged contact with used engine oil may cause a number of skin disorders, including cancer! You should make every effort to minimize your exposure to used engine oil. Protective gloves should be worn when changing oil. Wash your hands and any other exposed skin areas aS Soon as possible after exposure to used engine oil. Soap and water, or waterless hand cleaner should be used. e All new vehicles are now equipped with an air bag system, often referred to as a Supplemental Restraint System (SRS) or Supplemental Inflatable Restraint (SIR) 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 repairs. e Always wear safety goggles when working with, or around, the air bag system. When carrying a non-deployed air bag, be sure the bag and trim cover are pointed away from your body. When placing a nondeployed air bag on a work surface, always face the bag and trim cover upward, away from the surface. This will reduce the motion of the module if it is accidentally deployed. Refer to the additional air bag system precautions later in this section. ¢ Clean, high quality brake fluid from a sealed container is essential to the safe and

ENGINE REPAIR

. eThe alternator spill shield does not need to be removed.

Alternator SPILL SHIELD

REMOVAL & INSTALLATION 1998-99 Models 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Negative battery cable Alternator's adjustment nut, loosen only Plastic lower splash shield Alternator field circuit wiring connector, push theREDlocking tab to release Alternator pivot bolt, loosen only Alternator drive belt

ADJUSTMENT NUT

CQ) Ved

x

7}

| PIVOT BRACKET

MOUNTING BOLTS

PIVOT BRACKET

proper operation of the brake system. You should always buy the correct type of brake fluid for your vehicle. If the brake fluid becomes contaminated, completely flush the system with new fluid. Never reuse any brake fluid. Any brake fluid that is removed from the system should be discarded. Also, do not allow any brake fluid to come in contact with a painted surface; it will damage the paint. e Never operate the engine without the proper amount and type of engine oil; doing so WILL result in severe engine damage. e Timing belt maintenance is extremely important! Many models utilize an interference-type, non-freewheeling engine. If the timing belt breaks, the valves in the cylinder head may strike the pistons, causing potentially serious (also time-consuming and expensive) engine damage. Refer to the maintenance interval charts in the front of this manual for the recommended replacement interval for the timing belt, and to the timing belt section for belt replacement and inspection. e Disconnecting the negative battery cable on some vehicles may interfere with the functions of the on-board computer system(s) and may require the computer to undergo a relearning process once the negative battery cable is reconnected. e When servicing drum brakes, only disassemble and assemble one side at a time, leaving the remaining side intact for reference. ¢ Only an MVAC-trained, EPA-certified automotive technician should service the air conditioning system or its components.

=

9346EG01

Exploded view of the alternator for 1998-99 models

¢ 3 pivot bracket-to-engine bolts e Pivot bracket ¢ Alternator, by sliding it off the “T” bolt and out through the wheel well elt is not necessary to remove the “T” bolt.

To install: 3. Install or connect the following: ¢ Alternator, by moving it through the wheel well and sliding it onto the "T” bolt ¢ Pivot bracket ¢ 3 pivot bracket-to-engine bolts and torque to 40 ft. Ibs. (54 Nm) ¢ Alternator drive belt ¢ Alternator pivot bolt

/

CHRYSLER CORPORATION

NEON

Alternator field circuit wiring connector, push theREDlocking tab in until it snaps in place e Plastic lower splash shield ¢ Tension the drive belt to 100 Ibs. (used) or 135 Ibs. (new) Alternator adjustment nut and torque

all nuts/bolts to 40 ft. Ibs. (54 Nm) Negative battery cable 2000-02 Models

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. a pero ye or disconnect the following: e Negative battery cable Alternator jam nut, loosen only Alternator adjustment nut, loosen only Accessory drive splash shield Alternator lower bolt, loosen only Alternator drive belt Alternator field circuit wiring connector, push theREDlocking tab to release Battery positive terminal Upper and lower bolts, move alternator off pivot bracket Pivot bracket Alternator To install: 3. Install or connect the following: Alternator Pivot bracket and torque the bolts to 40 ft. Ibs. (54 Nm) Alternator, move it onto pivot bracket Alternator field circuit wiring connector, push RED locking tab in until it snaps in place Battery positive terminal Alternator drive belt Tension the drive belt to 100 Ibs. (used) or 135 Ibs. (new) Alternator adjustment bolt Alternator jam nut and torque nut to AO ft. Ibs. (54 Nm)

REMOVAL & INSTALLATION 1998-99 Models

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. e>After all components are installed on the engine a DRB scan tool is necessary to perform the camshaft and crankshaft timing relearn procedure.

with manual transaxle Air cleaner assembly Power steering pump/reservoir assembly and move them aside A/C compressor, if equipped Chassis ground straps 7. Raise the vehicle enough to allow an engine dolly and cradle to be placed under the engine. 8. Loosen the engine support posts in

if may be necessary to move the engine/transaxle assembly with the cradle to clear the body flanges.

4 - OIL PAN 2 — STRUCTURAL COLLAR

9306EG18

Exploded view of the structural collar—

2000-02 models

To install: 18. Install or connect the following: ¢ Engine/transmission assembly to the vehicle and torque the engine mount bolts to 87 ft. Ibs. (118 Nm) ¢ Upper engine torque strut and remove the engine safety straps e Lower bracket and upper mounting bolt Alternator Halfshafts 19. Install the structural collar and torque the bolts, in 3 steps, using the following procedure:

Please visit our web site at www.chiltonsonline.com

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Air cleaner assembly Electrical connectors Throttle cables Air intake duct to the intake manifold e Battery and battery tray 21. Fill the engine with clean oil. 22. Fill the cooling system. 23. After all components are installed, perform the camshaft and crankshaft timing relearn procedure as follows: a. Connect a DRB scan tool to the DLC (located under the instrument panel, near the steering column). b. Turn the ignition switch ON, and access the “miscellaneous” screen. c. Select “re-learn cam/crank” option and follow the directions on the scan tool screen. 24. If equipped with air conditioning, recharge the system. 1 2 3 4 5 6 7

— — -— — — —

Water Pump

SAFETY STRAPS PLACE REAR POSTS INTO LOCATING HOLES SPECIAL TOOL 6848 SPECIAL TOOL 6710 SPECIAL TOOL 6135 SAFETY STRAPS PLACE FRONT POST UNDER BLOCK FLANGE

REMOVAL & INSTALLATION 9306EG20

View of the engine cradle and dolly— 2000-02 models

a. Step 1: Collar-to-oil pan bolts to 30 inch Ibs. (3 Nm). b. Step 2: Collar-to-transaxle bolts to 80 ft. Ibs. (108 Nm). c. Step 3: Collar-to-oil pan bolts to AQ ft. Ibs. (54 Nm). 20. Install or connect the following: Lower engine torque strut and torque the through-bolts to 87 ft. lbs. (118 Nm) Downstream 02S sensor connector Exhaust pipe to the manifold A/C compressor, if equipped Drive belts Right inner splash shield Front wheels Power steering pump and reservoir Clutch cable if equipped with a manual transaxle Shift linkage to the transaxle Automatic transaxle cooler lines, if equipped Fuel lines Heater hoses

Ground wires PCM Engine wire harness Lower radiator hose Fan module assembly Upper radiator hose

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. e» After all components are installed on the engine, a DRB scan tool is necessary to perform the camshaft and crankshaft timing relearn procedure.

2. Drain the cooling system. 3. Remove or disconnect the following: e Negative battery cable e Right inner splash shield e Accessory drive belts ¢ Power steering pump and support the engine from the bottom with a jack Right engine mount Power steering pump bracket bolts, move the pump/bracket assembly aside eit is not necessary to disconnect the power steering lines.

¢ Right engine mount bracket e Timing belt tensioner and timing belt ¢ Camshaft sprocket(s) e Inner timing belt cover ¢ Water pump and discard the O-ring 4. Clean all mating surfaces of any residual gasket material. To install: 5. Install a new O-ring in the water pump groove. e>Hold the O-ring in place with a few small dabs of silicone sealant.

Before proceeding, be sure the Oring gasket is properly seated in the water pump groove before tightening the screws. An improperly installed O-ring could cause a coolant leak. 6. Install or connect the following: e Water pump, torque the bolt to 108 inch lbs. (12 Nm). Use a pressure tester to pressurize the cooling system to 15 psi (103 kPa) and check the water pump shaft seal and Oring for leaks. ->Rotate the pump by hand to check for freedom of movement.

Inner timing belt cover Timing belt and tensioner Right engine mount bracket and engine mount Power steering pump Accessory drive belts Negative battery cable 7. Refill the cooling system. 8. Use a DRB scan tool to perform the camshaft and crankshaft timing relearn procedure, as follows: a. Connect the scan tool to the DLC, located under the instrument panel near the steering column. b. Turn the ignition switch ON, and access the “miscellaneous” screen. c. Select the “re-learn cam/crank” option, then follow the instructions on the scan tool screen.

Cylinder Head IMPELLER

REMOVAL & INSTALLATION O-RING

1998-99 Models 7922EG05

Be sure the O-ring is seated in the groove before installing the new pump

1. Before servicing the vehicle, refer to the precautions in the beginning of this section.

CHRYSLER CORPORATION NEON ROCKER SHAFT RETAINING BOLT

e» After all components are installed on the engine, a DRB scan tool is necessary to perform the camshaft and crankshaft timing relearn procedure.

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2. Properly relieve the fuel system pressure. 3. Drain the cooling system. 4. Remove or disconnect the following: Negative battery cable Air cleaner inlet duct and air cleaner Vacuum lines and electrical wiring Fuel lines from the throttle body

SPRING VALVE SEAL AND VALVE SPRING SEAT ASSEMBLY

ROCKER ARM SHAFT RETAINER SPACER

EXHAUST ROCKER ARM/ HYDRAUUC LASH ADJUSTER ASSEMBLY

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7922EG06

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Exploded view of the cylinder head and valvetrain components—SOHC engine

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Throttle linkage Accessory drive belts Power brake vacuum hose from the intake manifold Exhaust pipe from the manifold Power steering pump, move it aside. DO NOT disconnect the fluid lines. |gnition coil pack wiring connector Ignition coil pack and bracket Camshaft Position (CMP) sensor electrical connector Fuel injector electrical connector Intake manifold Timing belt Timing belt tensioner, for DOHC engine Camshaft sprocket Inner timing belt cover Rocker arm cover Camshaft and cam follower assem-

blies on DOHC engine 5. On SOHC engine, remove or disconnect the following: e Rocker arm shaft assemblies e (il separator, if necessary e Heater hoses e Any remaining hoses or lines 6. Remove or disconnect the following: e Cylinder head bolts, working from the center outward e Cylinder head >The cylinder head bolts must be inspected before they can be reused. If the threads of bolts are stretched, they must be replaced. Check for thread stretching by holding a scale or other straightedge against the threads. If all the threads do not contact the scale, the bolts must be replaced.

VALVE

7922EG07

Exploded view of the cylinder head and valvetrain components—DOHC engine

Use only a plastic scraper to clean the mating surfaces. NEVER use metal, as this may gouge the surfaces and cause leaks!

Timing belt service is covered in Section 3 of this manual

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7. Cover the combustion chambers, then use a plastic scraper to thoroughly and carefully clean the engine block and cylinder head mating surfaces. To install: 8. Install the cylinder head with a new gasket. 9. Lubricate the cylinder head bolt threads. The 4 short bolts (110mm for 1998 or 164mm for 1999) are installed in positions 7, 8, 9 and 10. 10. On SOHC engines, torque the cylinder head bolts, in the sequence, to: a. Step 1: 25 ft. Ibs. (34 Nm). b. Step 2: 50 ft. Ibs. (68 Nm). c. Step 3: 50 ft. Ibs. (68 Nm).

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d. Step 4: An additional % turn using a torque angle wrench. 11. On DOHC engines, torque the cylinder head bolts, in the sequence, in the following order: a. Bolts 1-6: 25 ft. Ibs. (34 Nm) and bolts 7-10: 20 ft. Ibs. (28 Nm). b. Bolts 1-6: 50 ft. Ibs. (68 Nm) and

bolts 7-10: 20 ft. Ibs. (28 Nm). c. Bolts 1-6: 50 ft. Ibs. (68 Nm) and bolts 7-10: 20 ft. Ibs. (28 Nm). d. Tighten all bolts an additional % turn using a torque angle wrench. 12. On SOHC engine, install or connect the following:

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Heater hoses =~ Any removed hoses or lines Oil separator, if necessary Rocker arm shaft assemblies 13. Install or connect the following: Camshaft and cam follower assemblies on DOHC engines Rocker arm (valve) cover e Inner timing belt cover e Camshaft sprocket ¢ Timing belt tensioner, for DOHC engine e Timing belt e Intake manifold e Fuel injector electrical connector e Cam sensor electrical connector e Ignition coil pack and bracket e Ignition coil pack wiring connector e Power steering pump e Exhaust pipe to the manifold e Power brake vacuum hose to the intake manifold Accessory drive belts Throttle linkage Fuel lines to the throttle body Vacuum lines and electrical wiring Air cleaner inlet duct and air cleaner Negative battery cable 14. Refill the cooling system. 15. Use a DRB scan tool to perform the camshaft and crankshaft timing relearn procedure, as follows: a. Connect the scan tool to the DLC, located under the instrument panel near the steering column. b. Turn the ignition switch ON, and access the “miscellaneous” screen. c. Select the “re-learn cam/crank” option, then follow the instructions on the scan tool screen.

2000-02 Models 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. e» After all components are installed on the engine, a DRB scan tool is necessary to perform the camshaft and crankshaft timing relearn procedure.

2. Properly relieve the fuel system pressure. 3. Drain the cooling system. 4. Remove or disconnect the following:

2 LOCATION OF 110 mm (4.330 in.) BOLTS 7922EG09

Cylinder head bolt torque sequence—2.0L (VIN Y) DOHC engine

¢ Negative battery cable ¢ Power steering/air conditioning drive belt ¢ Exhaust pipe from the manifold ¢ Right front wheel e Right side splash shield

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e Fuel line from the fuel rail Coolant recovery container Ground wire and from the cylinder head Upper radiator hose Intake manifold Ignition coil electrical connector Coil pack Spark plug wires Crankcase Closed Ventilation (CCV) hose from the valve cover Cam sensor electrical connector Coolant Temperature (CT) sensor electrical connector Heater tube from the cylinder head Heater hose from the thermostat housing connector Cylinder head cover Cylinder head bolts, working from the center out Cylinder head and discard gasket e>The cylinder head bolts must be inspected before they can be reused. If the threads of bolts are stretched, they must be replaced. Check for thread stretching by holding a scale or other straightedge against the threads. If all the threads do not contact the scale, the bolts must be replaced.

Use only a plastic scraper to clean the mating surfaces. NEVER use metal, as this may gouge the surfaces and cause leaks!

sk LOCATION OF 110 mm (4.330 in.) BOLTS 7922EG09

Cylinder head bolt torque sequence—2.0L (VIN Y) DOHC engine

Alternator drive belt Crankshaft damper Lower torque strut Upper torque strut Ground strap from the engine mount bracket Power steering hose support clip from the engine mount bracket Power steering pump, move it aside 5. Place a jack under the engine and support it. e Right side engine mount-to-bracket through-bolt

e Lower engine mount bracket bolt 6. Slightly raise the engine. ¢ Upper engine mount bracket bolts e Engine mount bracket =>|t may be necessary to raise and lower the engine until the bracket clears the engine components.

e Front timing belt cover . 7. Rotate the crankshaft and align the timing marks. e Timing belt and tensioner e Camshaft nal sprocket e Rear timing belt cover

8. Cover the combustion chambers, then use a plastic scraper to thoroughly and carefully clean the engine block and cylinder head mating surfaces. To install: 9. Install the cylinder head with a new gasket after applying Mopar Gasket Sealant to both sides of the gasket. 10. Lubricate the cylinder head bolt threads. The 4 short bolts (164mm) are installed in positions 7, 8, 9 and 10. 11. Torque the cylinder head bolts, in the sequence, to:

a. b. c. d.

Step Step Step Step

1: 25 ft. Ibs. (34 Nm). 2: 50 ft. Ibs. (68 Nm). 3: 50 ft. Ibs. (68 Nm). 4: An additional % turn using a torque angle wrench. 12. Install or connect the following: e Cylinder head cover e Heater hose to the thermostat housing connector

Heater Core replacement is covered in Section 2 of this manual

8-1 0

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Heater tube to the cylinder head CT sensor electrical connector Cam sensor electrical connector CCV hose to the valve cover Coil pack Spark plug wires Ignition coil electrical connector Intake manifold Upper radiator hose Ground wire to the cylinder head Coolant recovery container Fuel line to the fuel rail Rear timing belt cover Camshaft sprocket Timing belt and tensioner Front timing belt cover Engine mount bracket Upper engine mount bracket bolts Lower engine mount bracket bolt Right side engine mount-tobracket through-bolt and torque it to 87 ft. Ibs. (118 Nm) 13. Remove the jack from under the engine. Power steering pump Power steering hose support clip to the engine mount bracket Ground strap to the engine mount bracket Upper torque strut Lower torque strut Crankshaft damper and torque the bolt to 100 ft. Ibs. (136 Nm) Alternator drive belt Right side splash shield Right front wheel Exhaust pipe to the manifold Power steering/air conditioning drive belt Negative battery cable 14. Refill the cooling system. 15. Use a DRB scan tool to perform the camshaft and crankshaft timing relearn procedure, as follows: a. Connect the scan tool to the DLC, located under the instrument panel near the steering column. b. Turn the ignition switch ON, and access the “miscellaneous” screen. c. Select the “re-learn cam/crank” option, then follow the instructions on the scan tool screen.

EXHAUST ROCKER ARM ASSEMBLY

INTAKE ROCKER ARM ASSEMBLY 7922EG10

Be sure to note the rocker arm shaft component positions before disassembling the rocker arm shafts

the valves are actuated directly by the camshafts and no rocker arms are used.

EXHAUST ROCKER ARM

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Negative battery cable e Cylinder head cover H ADJUSTERS

e*Be sure to note the installed positions of the rocker arm shaft assemblies before removal.

¢ Rocker arm shaft attaching fasteners, loosen them ¢ Rocker arm shaft assembly from the cylinder head

INTAKE ROCKER ARM 7922EG11

Disassembled view of an intake and exhaust rocker arm

Be sure to keep the spacers and rocker arms in their original locations for installation.

3. Inspect the rocker arm for scoring, wear on the roller or damage to the rocker arm: replace any components showing damage. Check the location where the rocker arms mount to the shafts for wear or damage. Replace if damaged or worn. The rocker arm shaft is hollow and is used as a lubrication oil duct. Check the oil holes for clogs with a small piece of wire, and clean as required. Lubricate the rocker arms and spacers. Be sure to install in their original locations. To install:

adjusters are at least partially full of oil. This is indicated by little or no plunger travel when the lash adjuster is depressed. lf there is excessive plunger travel, submerge the rocker arm assembly into clean engine oil and pump the plunger until the lash adjuster travel is taken up. If travel is not reduced, replace the assembly. The hydraulic lash adjuster and rocker arm are Serviced as an assembly.

7. Install the rocker arm (valve) cover. 8. Connect the negative battery cable.

Intake Manifold

REMOVAL & INSTALLATION SOHC Engine —Except High Output Engines 1. Before servicing the vehicle, refer to the precautions in the beginning of this section.

ste WARNING 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 tightened. 4. Set the crankshaft sprocket to TDC by aligning the mark on the sprocket with the arrow on the oil pump housing, then back off to 3 notches before TDC. 5. Install the rocker arm/hydraulic lash adjuster assembly making sure that the

INTAKE MANIFOLD TO WATER INLET SUPPORT Intake manifold bolt torque sequence—1998-99 2.0L (VIN C) SOHC engine

Brake service is covered in Section 4 of this manual

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Fuel supply line from the fuel tube assembly Fuel injector cover Fuel rail assembly Brake booster vacuum hose Out Crankcase Ventilation ose

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Segre Intake manifold bolt torque sequence— 2000-02 2.0L (VIN C) SOHC engine

e Manifold Absolute Pressure (MAP) sensor electrical connector on 1999 models

Knock Sensor (KS) electrical connector Starter wiring connectors Intake manifold and discard the gasket 4. Clean all mating surfaces of any residual gasket material. To install: 5. Install or connect the following: New gaskets and seals Intake manifold and torque the new retainers, in sequence, to 95 inch lbs. (11 Nm) Fuel rail and torque the screws to 17 ft. Ibs. (23 Nm) PCV hose Brake booster hose 6. Inspect the fuel line quick-connect fittings for damage and replace if necessary. Apply a small amount of clean engine oil to 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 sensor wiring KS sensor connector Air inlet duct Negative battery cable

hms 9306EG22

View of the Manifold Absolute Pressure

(MAP) sensor—2000-02 SOHC engines

~ BOLT — BRACKET | BRACKET — fon BOLT

1 — KNOCK SENSOR 2 — STARTER MOTOR

9306EG23

9306EG21

View of the intake manifold lower supports—2000-02 SOHC engines

View of the Knock Sensor (KS)—2000-02 SOHC engines

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7. Start the vehicle, check for leaks and repair if necessary.

High Output Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Properly relieve the fuel system pressure. _ 3. Remove or disconnect the following: e Negative battery cable ¢ Throttle body-to-intake manifold air duct

CAUTION Wrap towels around the fitting to catch any spilled fuel. e Fuel supply line quick-connect from the fuel tube assembly Fuel rail cover from the engine Fuel injector connector and harness from the injectors and fuel rail Positive Crankcase Ventilation (PCV) hose Lower intake manifold support bracket bolt Oil dipstick Manifold Absolute Pressure (IMAP) sensor wiring Manifold Tuning Valve (MTV) actuator wiring Intake manifold-to-cylinder head bolts and move the manifold forward Knock (KS) Sensor wiring Brake booster 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: e Lower manifold to the upper manifold with a new gasket and torque the bolts to 105 inch Ibs. (12 Nm). Intake manifold on the cylinder head with a new gasket Engine wiring harness between the middle intake runners e KS wiring connector Brake booster hose and torque the intake manifold bolts, in sequence, to 105 inch Ibs. (12 Nm) Lower manifold support bracket bolt and torque the bolt to 21 ft. lbs. (28 Nm)

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MAP sensor connector MTV actuator connector Oil dipstick Inlet air duct to the manifold and the throttle body PCV hose Fuel injector connectors and harness to the fuel rail Fuel rail cover Fuel supply line

Negative battery cable 6. Start the vehicle, check for leaks and repair if necessary.

DOHC Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Relieve the fuel system pressure. 3. Remove or disconnect the following: e Negative battery cable e Air inlet duct from the intake manifold

stk CAUTION Wrap towels around the fitting to catch any spilled fuel. e Fuel supply line quick-connect from the fuel rail e Engine Coolant Temperature (ECT) sensor connector

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e Heater hose from the intake manifold e Heater tube from the bottom of the intake manifold e Upper radiator and coolant recovery hoses e Fuel rail assembly

+ WARNING Do not allow the injectors to rest on their tips as this may damage them. ->Cover the injector openings to prevent debris from entering the ports.

Accelerator, kickdown and cruise control cables, if equipped, from the throttle lever and bracket

Idle Air Control (AC) motor electrical connector Throttle Position (TP) sensor electrical connector Throttle body vacuum hoses Throttle body Manifold Absolute Pressure/Idle Air Temperature (TMAP) sensor electrical connector on 1998 models Manifold Absolute Pressure (MAP) sensor electrical connector on 1999 _ models Knock Sensor (KS) electrical connector. Detach the wiring harness from the tab located on the heater tube

9846EG02

engine Intake manifold bolt torque sequence—High Output 2000-02 2.0L (VIN C) SOHC

For complete Engine Mechanical specifications, see Section 1 of this manual

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7922EG16

Intake manifold bolt torque sequence— 2.0L (VIN Y) DOHC engine

INTAKE MANIFOLD BOTTOM VIEW 7922EG15

Intake manifold bolt torque sequence— 2.0L (VIN Y) DOHC engine

e Starter electrical connectors

e Exhaust Gas Recirculation (EGR) tube e Upper and lower intake manifold assemblies and discard the gaskets e>|f necessary, separate the upper and lower manifolds.

MAP sensor electrical connector on 1999 models IAC sensor electrical connector on 1999 models KS and starter electrical connectors Wiring harness to the heater tube tab TP sensor electrical connectors Throttle body vacuum hoses Accelerator, kickdown and speed control cables, if equipped, to their bracket and throttle lever EGR tube and torque to 95 inch Ibs. (11 Nm) Intake manifold side retainers and torque to 95 inch Ibs. (11 Nm) Air duct to the air filter housing and torque the clamp to 25 inch Ibs. (3 Nm) Negative battery cable

Exhaust Manifold

REMOVAL & INSTALLATION 1998 Models 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Negative battery cable Air cleaner assembly and bracket Power steering pump reservoir, move it aside. DO NOT disconnect the fluid lines. Exhaust manifold heat shield Upstream Heated Oxygen Sensor

4. Thoroughly clean all of the gasket mating surfaces. To install: 5. Install or connect the following: e Upper and lower manifolds with new gaskets and torque the bolts to 21 ft. Ibs. (28 Nm) e Intake manifold using a new gasket and torque the fasteners to 21 ft. lbs. (28 Nm) ¢ Fuel rail onto the intake manifold and torque the screws to 17 ft. Ibs. (23 Nm) e PCV hose e Fuel supply hose to the fuel rail assembly 6. Inspect the fuel line quick-connect fittings for damage and replace, if necessary. Apply a small amount of clean engine oil to the fuel inlet tube.

e Exhaust manifold and discard the gasket 3. Thoroughly clean the mating surfaces. To install: 4. Install the exhaust manifold with a new gasket and torque the fasteners to 17 ft. lbs. (23 Nm), starting at the center and working outward in both directions

e»Ensure the connection is fastened securely by pulling on the connector.

e»Repeat this procedure until all fasteners are tightened to specifications.

Heater tube and hose to the intake manifold Upper radiator and coolant recov-

ery reservoir hoses ECT sensor electrical connector

Throttle body and torque the fastener to 16 ft. Ibs. (22 Nm) TMAP sensor electrical connector on 1998 models

(HO2S) connector e>|t may be necessary to loosen the alternator bracket bolt to remove the outer exhaust manifold bolt.

5. Install or connect the following: Alternator bracket bolt, if loosened Exhaust manifold heat shield Power steering pump reservoir HO2S sensor Air cleaner bracket and assembly Exhaust pipe to the manifold and torque the fasteners to 21 ft. Ibs. (28 Nm) Negative battery cable

1999 Models 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Release the fuel pressure. 3. Remove or disconnect the following: Negative battery cable Fuel supply line from the fuel rail Air cleaner assembly and bracket Power steering reservoir bracket and move the reservoir aside Upper heat shield from the exhaust manifold Upstream Heated Oxygen (HO2S) sensor connector Right side splash shield Alternator drive belt Alternator spill shield Exhaust pipe from the manifold. If Low Emission Vehicle (LEV) equipped, discard the manifold-toflex joint gasket. Lower heat shield from the exhaust manifold Lower exhaust manifold fasteners Upper exhaust manifold fasteners Exhaust manifold and discard the gasket 4. Thoroughly clean the mating surfaces.

To install: 5. Install or connect the following: e New gasket Exhaust manifold with a new gasket and torque to 17 ft. Ibs. (23 Nm), starting at the center and working outward in both directions. Repeat this procedure until all fasteners are tightened to specifications. Lower heat shield to the exhaust manifold Exhaust pipe to the manifold with a new manifold-to-flex joint gasket, if LEV equipped. Torque the fasteners to 21 ft. Ibs. (28 Nm). Alternator spill shield Alternator drive belt Right side splash shield HO2S sensor connector Upper heat shield to the exhaust manifold Power steering reservoir and bracket Air cleaner assembly and bracket Fuel supply line to the fuel rail Negative battery cable

2000-02 Models 1. Before servicing the vehicle, refer to the precautions in the beginning of this section.

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e Cylinder head-to-exhaust manifold support bracket bolt, if ULEV equipped. Torque the bolts to 40 ft. Ibs. (54 Nm). Wiring harness heat shield-toexhaust manifold, if ULEV equipped Wiring harness heat shield-toexhaust manifold support bracket bolt, if LEV equipped e Negative battery cable

(14) Lower vehicle. (15) Connect negative cable to battery. 9806EG25

Exhaust manifold tightening sequence—2000-02 models and High Output Engines

2. Remove or disconnect the following: e Negative battery cable e Wiring harness heat shield-toexhaust manifold support bracket bolt, if Low Emission Vehicle (LEV) equipped Wiring harness heat shield-toexhaust manifold, if Ultra Low Emission Vehicle (ULEV) equipped Exhaust manifold support bracket bolt, if LEV equipped Make up air hose Speed contro! vacuum reservoir, if equipped Oxygen (02S) sensor connector and harness clip Upper heat shield Exhaust manifold bolts Cylinder head cover, if ULEV equipped Exhaust manifold and discard gasket To install: 3. Install or connect the following: Exhaust manifold with a new gasket and torque the bolts, in sequence, to 16 ft. Ibs. (23 Nm) Upper heat shield, if ULEV equipped and torque bolts to 16 ft. lbs. (23 Nm) Upper and lower heat shields and torque the bolts to 95 inch Ibs. (11 Nm) 02S sensor connector and harness clip Cylinder head cover, if ULEV equipped Speed control vacuum reservoir, if equipped Make up air hose Exhaust manifold support bracket bolt, if LEV equipped. Torque the M10 bolt to 40 ft. Ibs. (54 Nm), M12 bolt to 70 ft. Ibs. (95 Nm) and the nut to 21 ft. Ibs. (28 Nm).

Front Crankshaft Seal

REMOVAL & INSTALLATION SOHC 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 Accessory drive belts Crankshaft damper, using Puller Tool 1026 and Insert Tool 6827-A Timing belt Crankshaft sprocket using special Tools 6793 and C-4685-C2 Crankshaft sprocket key Crankshaft oil seal, using a seal puller Tool 6771

pecial tool 6771

8-1 5

To install: 3. Install or connect the following: e New front crankshaft oil seal, using Crankshaft Installer Too! 6780-1 e Crankshaft key e Crankshaft sprocket using Installer Too! 6792 e» Make sure the word FRONT on the crankshaft sprocket is facing outward. e Timing belt e Crankshaft damper using thrust bearing washer and bolt from Installer Tool 6792. Torque the damper bolt to 105 ft. Ibs. (142 Nm) for 1998-99 models or 100 ft. lbs. (136 Nm) for 2000-02 models. e Accessory drive belts e Negative battery cable

DOHC Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Negative battery cable e Crankshaft damper with special Tools 1026 and 6287-A e Timing belt ¢ Crankshaft sprocket with special Tools 6793 and insert C-4685-C2 e Crankshaft oil seal with special Tool 6771 To install: 3. Install or connect the following: ¢ Front crankshaft oil seal with special Too! 6780-1 e Crankshaft sprocket with special Tool 6792 e» lake sure the word FRONT on the crankshaft sprocket is facing outward.

7922EG17

Removing the front crankshaft oil seal

Protector

e Timing belt e Crankshaft damper using thrust bearing washer and bolt from Installer Tool 6792 and torque the damper bolt to 105 ft. Ibs. (142 Nm) e Negative battery cable

Camshaft and Lifters REMOVAL & INSTALLATION SOHC Engine 7922EG18

Installing a new seal using seal installer 6780-1; proceed with caution if using substitute tools

1998-1999 MODELS This engine uses a camshaft running in an aluminum cylinder head. Rocker arm shafts mount directly to the cylinder head.

For Accessory Drive Belt illustrations, see Section 1 of this manual

8-16

CHRYSLER CORPORATION NEON

ROCKER SHAFT RETAINING BOLT

VALVE RETAINING LOCKS

RETAINER SPACER ——+-. SPARK PLUG TUBE SEAL

VALVE SPRING

VALVE SPRING RETAINER oar

VALVE SEAL AND VALVE SPRING SEAT ASSEMBLY

ROCKER ARM SHAFT RFTAINER SPACER

CAMSHAFT SEAL

EXHAUST ROCKER ARM/ HYDRAULIC LASH ADJUSTER ASSEMBLY INTAKE ROCKER ARM/HYDRAULIC LASH ADJUSTER ASSEMBLY 7922EG06

Exploded view of the cylinder head and valvetrain assembly—SOHC engine

Care must be taken to ensure all valve timing marks align after cylinder head and valvetrain service. Please note that the cylinder head must be removed from the vehicle to service the camshaft. e> After all components are installed on the engine, a DRB scan tool is necessary to perform the camshaft and crankshaft timing relearn procedure.

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Relieve the fuel system pressure. 3. Remove or disconnect the following: e Negative battery cable e Cylinder head cover

To install:

e>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 recommended.

4. Clean all parts well. Inspect the camshaft journals for scoring. Check the oil feed holes in the head for blockage. Check the camshaft bearing journals for scoring. If light scratches are present, they may be removed with 400 grit abrasive paper. If deep scratches are present, replace the EXHAUST ROCKER ARM ASSEMBLY

e» Mark the rocker arm shaft assemblies to identify them for later installation.

Rocker arm shaft bolts Rocker arm assemblies Timing belt and tensioner Camshaft sprocket Rear timing belt cover Cylinder head Camshaft Position (CMP) sensor Camshaft from the rear of the cylinder head

camshaft and check the cylinder head for damage. Replace the cylinder head if worn or damaged. 5. If the camshaft lobes show signs of wear, check the corresponding rocker arm roller for wear or damage. Replace rocker arms/hydraulic lash adjuster if worn or damaged. If the camshaft lobes show signs of pitting on the nose, flank or base circle, replace the camshaft. 6. If the rocker arms and shaft are to be serviced, mark the rocker arms so any that are to be returned to service will be installed in their original locations. Slide the rocker arms off the shaft. Keep the spacers and rocker arms in the same location for reassembly. 7. Inspect the rocker arms for scoring,

\\\. ROCKER ARM SHAFT RETAINERS

PLASTIC SHAFT SPACERS

iN

JR

eee

NOTCHES FACING UP AND

- TOWARD THE TIMING BELT SIDE

OF THE ENGINE

INTAKE ROCKER ARM ASSEMBLY

7922EG10

Rocker arm shaft identification—SOHC engine

7922EG12

Rocker arm shaft notch location—SOHC engine

CHRYSLER USAT

:

E11 [RRR

EXHAUST ante

SOR

ARM SHAFT

So Sa 7 =

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e

ed

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Ll

up and toward the timing belt side of the engine Rocker arm shaft retainers, in their original positions and torque the bolts to 17 ft. Ibs. (23 Nm) Timing belt and tensioner All electrical, vacuum and fluid connections Negative battery cable.

e>An oil and filter change are recommended.

Rl

_———} ———-—

O\

8-1 Ti

EK

7922EG13

Rocker arm shaft tightening sequence—SOHC engine

wear on the roller or damage to the shaft. Replace parts as necessary. 8. The rocker arm shaft is hollow and used as a lubrication oil duct. Check that the shaft is clean inside and out. 9. Check all oil holes for clogging with a small wire and clean as required. 10. To assemble, thoroughly lubricate all rocker arm components and spacers, then install them on the rocker arm shaft in their original locations. 11. If the vehicle exhibited a tappet-like noise, the valve lash adjusters built into the rocker arms should be cleaned and checked. Lash adjusters removed from a rocker arm should be returned to their original locations. Replace worn or defective lash adjusters. 12. To install a lash adjuster, use the following procedure: qa. Lubricate the lash adjuster thoroughly with clean engine oil. b. Install the adjuster into the rocker arm making sure the adjuster is at least partially filled with oil. c. Submerge the rocker arm in clean engine oi! and pump the plunger until the lash adjuster travel is taken up. If travel is not reduced, replace the adjuster. d. Install the rocker arm on the rocker arm shaft. 13. Camshaft end-play can be checked, using the following procedure: q. Install the camshaft target magnet

on the end of the camshaft. Tighten the screw to 30 inch Ibs. (3.4 Nm). Be sure to fit the dowels on the magnet in the holes on the camshaft. b. Setup a dial indicator to touch on the nose of the camshaft. c. Using a prybar, move the camshaft as far rearward as it will go. Be sure the dial indicator probe is in contact with the camshaft. d. Zero the dial indicator. e. Move the camshaft as far forward as it will go. f. Read the end-play on the dial indicator. Specification is 0.005-0.013 inch (0.13-0.33mm). 14. Install or connect the following: e Camshaft, lubricate the bearing journals thoroughly ->Be sure the camshaft turns freely.

e CMP sensor and torque the screws to 85 inch Ibs. (9.6 Nm) ¢ Camshaft seal flush with the cylinder head ° Camshaft sprocket and torque the bolt to 85 ft. Ibs. (115 Nm) e Cylinder head 15. Before installing the rocker arm and shaft assemblies, set the crankshaft to 3 notches before Top Dead Center (TDC) on the crankshaft sprocket. ¢ Rocker arm and shaft assemblies. Position the rocker shafts pointing

16. Use a DRB scan tool to perform the camshaft and crankshaft timing relearn procedure, as follows: a. Connect the scan tool to the DLC (located under the instrument panel, near the steering column). b. Turn the ignition switch ON, and access the “miscellaneous” screen. c. Select the “re-learn cam/crank” option, then follow the instructions on the scan tool screen. 17. Start the engine and check for leaks. Run the engine with the radiator cap off so as the engine warms and the thermostat opens, coolant can be added to the radiator. Test drive vehicle to check for proper operation.

2000-02 MODELS e» After all components are installed on the engine, a DRB scan tool is necessary to perform the camshaft and crankshaft timing relearn procedure.

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Relieve the fuel system pressure. 3. Drain the cooling system. 4. Remove or disconnect the following: e Battery and tray Inlet Air Temperature (IAT) sensor electrical connector Air intake duct from the intake manifold Throttle cables Throttle Position (TP) sensor Idle Air Control (IAC) valve from the throttle body Air make-up hose from the air cleaner Air cleaner housing Timing belt Camshaft sprocket Cylinder head cover and mark the rocker arm shaft assemblies to ease installation Rocker arm shaft assemblies Engine Coolant Temperature (ECT) sensor electrical connector

For Tire, Wheel and Ball Joint specifications, see Section 1 of this manual

To 5. clean 6.

e Heater supply and return hoses Heater tube support bracket Power Distribution Center (PDC) screws aside to ease the camshaft removal Camshaft Position (CMP) sensor and camshaft target magnet Camshaft from the rear of the cylinder head install: Lubricate the camshaft journals with engine oil. Install or connect the following: Camshaft and reposition the PDC and heater tubes Camshaft target magnet and torque the screw to 30 inch Ibs. (3 Nm) CMP sensor Front camshaft seal, if removed Timing belt rear cover Camshaft sprocket and torque to 85 ft. Ibs. (115 Nm) Timing belt and tensioner Rocker arms in the proper order and torque to 21 ft. Ibs. (28 Nm) Cylinder head cover Ignition coil and spark plug cables and torque the fasteners to 105 inch Ibs. (12 Nm) Heater tube bracket bolt Heater tubes ECT sensor electrical connector PDC attaching screws Battery and tray Air cleaner housing Throttle body connections IAT sensor Fill the cooling system to the proper

7. level. 8. Use a DRB scan tool to perform the camshaft and crankshaft timing relearn procedure, as follows: a. Connect the scan tool to the DLC (located under the instrument panel, near the steering column). b. Turn the ignition switch ON, and access the “miscellaneous” screen. c. Select the “re-learn cam/crank” option, then follow the instructions on the scan tool screen. 9. Start the engine and check for leaks. Run the engine with the radiator cap off so as the engine warms and the thermostat opens, coolant can be added to the radiator. Test drive vehicle to check for proper operation.

gages 7922EG19

Identifying the camshaft bearing caps— DOHC engine

sary to perform the camshaft and crankshaft timing relearn procedure.

2. Remove or disconnect the following: Negative battery cable Cylinder head cover Timing belt Both camshaft sprockets Camshaft bearing caps, loosen the bearing caps in sequence, one camshaft at a time. >The bearing caps are identified for location. Remove the outside bearing caps first. If the bearing caps are difficult to remove, use a plastic hammer to gently tap the rear part of the camshaft.

e Intake and exhaust camshafts To install: 3. Before installation, clean the cylinder head and cover mating surfaces. Make certain that the rails are flat. 4. Lubricate the bearing journals and cam followers with clean engine oil. 9. Install or connect the following:

e Camshafts e Bearing caps. Torque the M6 fasteners to 105 inch Ibs. (12 Nm) and the M8 fasteners to 18 ft. Ibs. (24 Nm). Camshaft sprockets Timing belt Cylinder head cover Negative battery cable 6. Use a DRB scan tool to perform the camshaft and crankshaft timing relearn procedure, as follows: a. Connect the scan tool to the DLC (located under the instrument panel, near the steering column). b. Turn the ignition switch ON, and access the “miscellaneous” screen. c. Select the “re-learn cam/crank” option, then follow the instructions on the scan tool screen. 7. Start the engine and check for proper operation and leaks.

Valve Lash

ADJUSTMENT The engines in these vehicles do not require periodic valve lash adjustment.

Starter Motor

REMOVAL & INSTALLATION 1998-99 Models 1. Remove the negative battery cable. 2. lf equipped with A/C, perform the following procedure:

Remove outside bearing caps first

DOHC Engine 1. Be sure to observe all precautions in the beginning of this section. e>After all components are installed on the engine, a DRB scan tool is neces-

7922EG20

Bearing cap removal sequence—DOHC engine

CHRYSLER Ben a. Support the engine/transaxle assembly with a jack. b. Remove the front engine mount bolt from the mount/crossmember bracket. c. Lower and rotate the engine/transaxle assembly forward to provide starter clearance. Do not remove the wiring at this time.

3. Remove or disconnect the following: e Both starter-to-transaxle bolts e Starter electrical connectors e Starter by positioning it vertically and lowering it

S SS /

i

'

STRUCTURAL COLLAR

Follow the proper tightening sequence for the structural collar or damage to the collar or oil pan may occur.

S

om

4

OIL PAN

8 7922EG24

e>\f equipped, move the A/C lines aside.

To install: 4. Install or connect the following: e Starter e Starter electrical connectors e Starter-to-transaxle bolts and torque the bolts to 40 ft. Ibs. (54 Nm) e Negative battery cable 5. If equipped with A/C, perform the following steps: a. Raise and support the engine/transaxle assembly. b. Install the front engine mount-to mount/crossmember bracket bolt and torque to 40 ft. Ibs. (54 Nm)

2000-02 Modeis 1. Remove or disconnect the following: e Negative battery cable e Intake manifold on high output engines only e Starter electrical connectors e Starter-to-engine bolts e Starter To install: 2. Install or connect the following: e Starter and torque bolts to 40 ft. ibs. (64 Nm) e Starter electrical connectors e Intake manifold on high output engines ¢ Negative battery cable

REMOVAL & INSTALLATION es

1998-99 Models 1. Before servicing the vehicle, refer to the precautions in the beginning of this section.

8-1 9

Exploded view of the structural collar mounting—1998-99 models

2. Drain the engine oil. 3. Properly support the engine and transaxle assembly. 4. Remove or disconnect the following: Front engine mount bracket Powertrain bending strut Oil pan-to-transaxle structural collar Transaxle lower dust cover Oil filter and adapter, if equipped with air conditioning Oil pan 5. Thoroughly, clean the gasket mating Surfaces. To install: 6. Apply silicone sealer to the oil pump-to-engine block parting line. 7. Install or connect the following: e New oil pan gasket ¢ Oil pan and torque the retainers to 105 inch Ibs. (12 Nm) © Oil filter and adapter, if removed e Transaxle lower dust cover Power train bending strut Front engine mount and bracket 8. Torque the front engine mount retainers as follows: a. Engine mount bracket bolt 1: 20 inch lbs. (3 Nm). b. Engine mount bracket bolts 2, 3 and 4: 80 ft. Ips. (108 Nm). c. Engine mount bracket bolts 5 and 1: 40 ft. Ibs. (54 Nm). d. Engine mount bracket-to-insulator assembly through-bolt: 40 ft. Ibs. (54 Nm). e. Insulator-to-lower radiator crossmember nuts: 40 ft. Ibs. (54 Nm). f, Mass damper bolt: 40 ft. Ibs. (54 Nm).

9. Install the structural collar and torque the retainers as follows: a. Collar-to-oil pan bolts: 30 inch Ibs. (3 Nm). b. Collar-to-transaxle bolts: 80 ft. Ibs. (108 Nm). c. Collar-to-oil pan bolts: 40 ft. Ibs. (54 Nm), final torque. 10. Fill the engine with clean oil. 11. Start the engine and check for leaks; then, recheck the fluid level and add as necessary.

2000-02 Models 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Raise and safely support the vehicle. 3. Drain the engine oil. 4. Remove or disconnect the following: e Negative battery cable ¢ Oil filter e Oil filter adapter e Structural collar e Lateral bending brace e Transaxle lower dust cover e Oil pan

1 — LATERAL BENDING BRACE 2 — STRUCTURAL COLLAR 3 - DUST COVER 9306EG26

Exploded view of the bending brace, structural collar and dust cover—2000-02 models

For Wheel Alignment specifications, see Section 1 of this manual

8-20

bOrineen CORPORATION

5. Thoroughly, clean the gasket mating Surfaces. To install: 6. Apply silicone sealer to the oil pumpto-engine block parting line. 7. Install or connect the following: New oil pan gasket Oil pan and torque the screws to 105 inch Ibs. (12 Nm) Transaxle lower dust cover Lateral bending brace Structural collar Oil filter adapter and torque the bolts to 60 ft. Ibs. (80 Nm) Oil filter 8. Fill the engine with clean oil 9. Start the engine, check for leaks and repair if necessary.

O-RING

ay

‘oO

OIL PAN GASKET

OIL FILTER ADAPTER

OIL PAN

NIPPLE

OIL PUMP BODY

OIL PICK-UP TUBE 7922EG25

Exploded view of the oil pump and related component mounting

REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the engine oil. 3. Remove or disconnect the following: Negative battery cable Crankshaft damper Timing belt Timing belt tensioner, on 2000-02 models Oil pan Crankshaft sprocket, using Tool 6795 and Insert Too! C-4685-C2 Oil pickup tube Oil pump Front crankshaft seal Oil pump cover screws and lift the cover off e (il pump rotors 4, Wash all parts in a solvent: then, inspect carefully for damage or wear, as follows: a. Inspect the mating surface of the oil pump should be smooth. Replace the pump cover, if scratched or grooved. b. Lay a straightedge across the pump cover surface. If a 0.003 in. (0.076mm) feeler gauge can be inserted between the cover and the straightedge, the cover should be replaced. Cc. Measure the thickness and diameter of the outer rotor. If the outer rotor thickness measures 0.301 in. (7.64mm) or less, or if the diameter is 3.148 in. (79.95mm) or less, replace the outer rotor. d. If the inner rotor measures 0.301 in. (7.64mm) or less, replace the inner rotor.

OIL PUMP BODY

‘\

(If

yee CGA Ca,

7922EG28 7922EG26

Exploded view of the oil pump assembly

Use calipers to measure the outer rotor thickness ~

7922EG27 7922EG29

Use a feeler gauge and straightedge to check the oil pump cover for warpage

e. Slide the outer rotor into the pump housing, press to one side with your fingers and measure the clearance between the rotor and the housing. If the measurement is 0.015 in. (0.39mm) or more, replace the housing only if the outer rotor is within specification. f. Install the inner rotor into the pump housing, If the clearance between the inner and outer rotors is 0.008 in. (0.203mm) or more, replace both rotors. g. Place a straightedge across the

and the inner rotor thickness

face of the pump housing, between the bolt holes. If a feeler gauge of 0.004 in. (0.102mm) or more can be inserted between the rotors and the straightedge, replace the pump assembly, h. Inspect the oil pressure relief valve plunger for scoring and free operation in its bore. Small marks may be removed with 400 grit wet or dry sandpaper. i. The relief valve spring has a free length of about 2.39 in. (60.7mm) and should test between 18-19 Ibs. (8.1-8.6

CHRYSLER ORAS

8-21

A

Crankshaft Sprocket Installer Too! e Oilpump pickup tube ° Oil pan

the metal case of the crankshaft Seal. e Angle the tool through the dust lip against the metal case of the seal.

e Timing belt tensioner, on 2000-02

models e Timing belt and front cover esingacsen Crankshaftener damper ivabeln

79095620 Measure the outer rotor clearance in the

ig

Negative battery cable 8. Fill the engine with clean oil. 9. Start the engine and check for leaks;

then, recheck the fluid level and add as nec-

Rear Main Seal

MAKER TO ree roey

SANG

REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section.

7922EG31

2. Remove or disconnect the following: * Transaxle

Apply a small amount of gasket maker to

e Flexplate/flywheel

the pump body cover mounting surface

e

kg) when compressed to 1.60 in. (40.6mm). Replace the spring, if it falls

outside of specifications. j. lf the oil pressure is low and the pump is within specifications, inspect for

Rear main seal. Insert a Seal

e Crankshaft sprocket, using a

crankshaft seal surface. Contact of the tool blade against the crankshaft edge (chamfer) is permitted.

To install:

If the crankshaft edge (chamfer) has any burrs or scratches on the, clean : with 400 grit sand paper to preit up vent seal damage during installation of the new seal. >No lubrication is necessary when

installing the seal. 3. Place Crankcase Seal Pilot Tool 6926-1 on the crankshaft; this is a pilot tool with a magnetic base.

REAR

ENGINE

; CRANKSHAFT SEAL

BLOCK REAR

SHAFT CRANK SEAL METAL

PRY TOOL

REAR CRANKSHAFT SEAL DUST LIP

ck WARNING,

Seal Driver Tool 6780

DO NOT let the prytool contact the

4. Position the seal over the Pilot Tool:

To install: 5. Assemble the pump, using new parts as required, as follows: a. Install the inner rotor with the chamfer facing the cast iron oil pump cover. b. Apply Mopar gasket maker to the oil pump. c. Install the oil ring into the oil pump body discharge passage. 6. Prime the oil pump before installation by filling the rotor cavity with engine oil. 7. Install or connect the following: © Oil pump, align the rotor flats with the crankshaft flats. Torque the pump bolts to 21 ft. Ibs. (28 Nm).

+ New front crankshaft seal, using

Pek WARNING

remover between the dust lip and

Deepens | 6

The front crankshaft seal MUST be out of the pump to align or damage may result.

Pry out the seal.

PRY TOOL angle When prying the seal out, be sure to use the prytool at the proper

this manual For Maintenance Interval recommendations, See Section 1 of

sie

8-22

| ee

oapned CORPORATION

——

—~\, SPECIAL S&S) 2) TooL

Gap of lower

No. 1

side “0eae

\" gap

Cylinder number

mn

Front of engine

No. 2 ring \

and spacer TOOL 6926-2 INSTALLER

Place a proper size pilot tool with a magnetic base on the crankshaft

be sure the words THIS SIDE OUT on the Seal can be read.

eee Gap of

upper side

rail

7922AG05 7922AG01

7922EG33

SS

expander gap

Chrysler engine connecting rod and cap installation—ensure to matchmark the cap and rod prior to disassembly

2.0L (VIN C and Y) engines—piston ring end-gap spacing

Identification mark “1R”

Identification mark “2R”

Size mark

The pilot tool should stay on the crankshaft during installation of the seal. Be sure the seal lip faces the crankcase during installation.

WEIGHT DESIGNATION AND DIRECTIONAL ARROW WILL BE IMPRINTED IN THIS AREA 7922AG56

If the seal is driven in the block past flush, this may cause an oil leak. 5. Drive the seal into the block, using Crankshaft Seal Tool 6926-2 and Handle C4171, until the tool bottoms out against the block. 6. Install the flexplate/flywheel. Apply Lock & Seal Adhesive to the bolt treads. Torque the bolts in a star pattern, to 70 ft. lbs. (95 Nm). 7. Install the transaxle.

Piston and Ring POSITIONING

7922AG02

Common Chrysler piston ring identification mark locations

ONT OF ENGINE

WU 7

NO. 1 PISTON RING

ae NO. 2 PISTON RING

SIDE RAIL SPACER EXPANDER

OIL RING

7922AG03

2.0L Engine—piston ring orientation

Fuel System Service Precautions Safety is an important factor when servicing the fuel system. Failure to conduct maintenance and repairs in a safe manner may result in serious personal injury. Maintenance and testing of the vehicle's fuel system components can be accomplished safely and effectively by adhering to the following rules and guidelines: ¢ To avoid the possibility of fire and personal injury, always disconnect the negative battery cable unless the repair or test procedure requires that battery voltage be applied.

2.0L (VIN C) Engine—piston positioning. The arrow or weight marking (L or H) must face the timing belt side of the engine

* Always relieve the fuel system pressure prior to disconnecting any fuel system component (injector, fuel rail, pressure regulator, etc.), fitting or fuel line connection. Exercise extreme caution whenever relieving fuel system pressure, to avoid exposing skin, face and eyes to fuel spray. Please be advised that fuel under pressure may penetrate the skin or any part of the body that it contacts. ¢ Always place a shop towel or cloth around the fitting or connection prior to loosening to absorb any excess fuel due to spillage. Ensure that all fuel spillage is quickly removed from engine surfaces.

720608

2.0L (VIN Y) Engine—piston positioning. The small arrows on the crown of the pistons must point toward the front of the engine

Ensure that all fuel soaked cloths or towels are deposited into a suitable waste container. ¢ Always keep a dry chemical (Class B) fire extinguisher near the work area. * Do not allow fuel spray or fuel vapors to come into contact with a spark or open flame. e Always use a back-up wrench when loosening and tightening fuel line connection fittings. This will prevent unnecessary Stress and torsion to fuel line piping. ° Always replace worn fuel fitting Orings. Do not substitute fuel hose where fuel pipe is installed.

CHRYSLER ANAC

8-23

Fuel System Pressure A combination fuel filter/pressure regulator assembly is used, which is located on the top of the fuel pump module.

RELIEVING

+ CAUTION

REMOVAL & INSTALLATION

Relieve the fuel system pressure before servicing any components of the fuel system. Service vehicles in well ventilated areas and avoid ignition sources. NEVER smoke while servicing the vehicle! 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Negative battery cable e Fuel filler cap e Protective cap from the fuel rail’s pressure port 3. Place the open end of a fuel pressure release hose (tool C-4799-1) into an approved gasoline container. Connect the other end of the hose to the fuel pressure test port. The fuel pressure will bleed off through the hose into the gasoline container. ->Fuel pressure gauge kit C-4799-B contains hose C-4799-1.

4. The vehicle is now safe for servicing. 5. When finished working on the fuel system, install the fuel filler cap.

>: CAUTION Do not allow fuel spray or fuel vapors to come in contact with a spark or open flame. Keep a dry chemical fire extinguisher nearby. Never store fuel in an open container due to risk of fire or explosion. 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Properly relieve the fuel system pressure. 3. Disconnect the negative battery cable. 4. Disconnect the quick-connect fuel supply line from the filter/regulator nipple. 5. Depress the locking spring tab, located on the side of the fuel filter/regulator, then rotate 90 degrees and pull out. Be sure the upper and lower O-rings are still on the filter assembly. To install: 6. Lightly coat the filter O-rings with clean engine oil. Insert the filter into the opening in the fuel pump module, then align the 2 hold-down tabs with the flange. 7. While applying downward pressure, rotate the filter clockwise until the spring tab catches in the locating slot. 8. Attach the fuel line to the filter/regulator assembly. 9. Connect the negative battery cable.

FUEL FILTER/PRESSURE REGULATOR

ATTACHED —~ TO TEST PORT

The fuel pump is integral with the pump module, which also contains the fuel reservoir, level sensor, inlet strainer and fuel pressure regulator. The inlet strainer, fuel pressure regulator and level sensor are the only serviceable items. If the fuel pump requires service, replace the entire fuel pump module.

REMOVAL & INSTALLATION 1998-99 Models 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Properly relieve the fuel system presSure. 3. Drain the fuel tank.

2 WARNING 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. TE

4 Remove or disconnect the following: e Negative battery cable e Fuel lines from the fuel pump module by depressing the quick-connect retainers Fuel pump module electrical lock by sliding it to unlock it Fuel pump module electrical connector by pushing down on the connector retainer and pulling the connector off of the module 5. Support the fuel tank with a transmission jack. e Fuel tank strap bolts; then, lower FUEL PRESSURE REGULATOR

FUEL

7922EG34

LOCATING SLOT

FUEL LEVEL SENSOR

LET STRAINER

RESERVOIR

7922EG36

7922EG39

Relieve the fuel system, allowing the pressure to bleed off through the hose into the container

I

Depress the spring tab, then rotate and pull the fuel filter assembly out

The fuel module assembly contains the pump, pressure regulator, reservoir, inlet strainer and level sensor

For Tune-up, Capacities and Firing orders, see Section 1 of this manual

8-24

Sees CORPORATION e Negative battery cable e Vapor line from the Evaporative Emissions (EVAP) canister tube e EVAP canister

LOCKNUT

7922EG37

To loosen the fuel pump module locknut, use a ratchet and spanner wrench

the tank slightly for access to the module e Fuel pump module locknut using a ratchet and spanner wrench e Fuel pump and discard the O-ring seal To install:

Take care to avoid wiping dirt or debris into the fuel tank opening. Such contaminants may clog or damage the new fuel pump. 6. Wipe the fuel pump mounting flange and surrounding area of the tank clean. 7. Install or connect the following: e New O-ring seal in the tank opening e Fuel pump e>Be sure the alignment tab on the underside of the fuel pump module flange sits in the notch on the fuel tank. e Fuel pump module locknut. Using the ratchet and spanner wrench, torque the locknut to 41 ft. Ibs. (55 Nm). ¢ Fuel tank strap bolts and torque them to 45 ft. Ibs. (61 Nm) ¢ Negative battery cable 2000-02 Models

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Properly relieve the fuel system presSUIe. 3. Drain the fuel tank. 4. Remove or disconnect the following:

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. e Fuel line from the fuel pump module by depressing the quick-connect retainers with your thumb and forefinger Fuel pump module electrical connector by pushing down on the connector retainer and pulling the connector off of the module Fuel filler tube and filler vent tube from the fuel tank's filler hose 5. Support the fuel tank with a transmission jack. ¢ Fuel tank strap bolts; then, lower the tank slightly for access to the module ¢ Fuel pump module locknut using a ratchet and spanner wrench ¢ Fuel pump and discard the O-ring seal To install:

Take care to avoid wiping dirt or debris into the fuel tank opening. Such contaminants may clog or damage the new fuel pump. 6. Wipe the fuel pump mounting flange and surrounding area of the tank clean. 7. Install or connect the following: ¢ New O-ring seal in the tank opening e Fuel pump

¢ Fuel pump module electrical connector ¢ Fuel line, to the fuel pump module e EVAP canister e Vapor line to the EVAP canister tube e Negative battery cable 8. Start the vehicle, check for leaks and repair if necessary.

Fuel Injector REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Release the fuel system pressure. 3. Remove or disconnect the following: Negative battery cable Fuel line(s) from fuel rail Fuel injector electrical connectors Fuel rail with the fuel injectors Fuel injector retainers Fuel injector(s) and discard the Orings To install: 4. Install or connect the following: ¢ Fuel injector(s) using new O-rings ->Lubricate the O-rings with clean engine oil.

Fuel injector retainers Fuel rail with the fuel injectors and torque the bolts to 170-230 inch lbs. (20-25 Nm) ¢ Fuel injector electrical connectors ¢ Fuel line(s) to fuel rail ¢ Negative battery cable 5. Start the vehicle, check for leaks and repair if necessary.

e>Be sure the alignment tab on the underside of the fuel pump module flange sits in the notch on the fuel tank.

¢ Fuel pump module locknut. Using the ratchet and spanner wrench, torque the locknut to 41 ft. Ibs. (55 Nm). ¢ Fuel tank ¢ Fuel filler tube and filler vent tube to the fuel tank's filler hose

1 — RETAINER 2 — FUEL RAIL 3 — FUEL INJECTOR

9306EG01

Exploded view of the fuel rail assembly

CHRYSLER Sua

8-25

sd

DRIVE TRAIN e Intake manifold support bracket e Upper starter bolt e Upper bell housing bolt 4. Install an engine bridge fixture and support the engine securely. e Front wheels e Halfshafts

Transaxle Assembly REMOVAL & INSTALLATION Manual Transaxle

1998-99 MODELS 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the transaxle fluid. 3. Remove or disconnect the following: Battery cables Power Distribution Center (PDC), pull it up and out of its bracket and move it aside Battery heat shield Battery and tray Cruise control, if equipped Vehicle Speed Sensor (VSS) wire Back-up lamp switch wiring from the transaxle

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eat

;

CLUTCH IS aa CABLE TS? Spent

= 7922EG41

Pull the clutch cable backward, to disconnect the clutch cable from the bell housing—1998-99 manual transaxle 7922EG44

tk WARNING 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 bell housing Shift cable (linkage) mounting bracket e Accelerator cable shield, if equipped

i

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SCREWDRIVERS

BEY DA

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When installing the halfshafts, new retaining clips MUST be used. NEVER reuse the old clips. If old clips are used, the inner CV-joints may disengage.

INSPECTIONA WINDOW:

Removing the lower starter mounting bolts—1998-99 manual transaxle

| F=3

\\___- TRANSAXL

7922EG42 SUPPORT BRACKET

Remove the clutch cable from the lever—

7922EG45

1998-99 manual transaxle

LINKAGE BRACKET

Unfasten the 2 bolts, then remove the bracket (strut) from the engine and transaxle—1998-99 manual transaxle

BOLT

7922EG40

Use 2 prytools to disconnect the gearshift cable ends from the shift levers—1998-99 manual transaxle

aa

7922EG46

7922EG43

Exploded view of the linkage mounting bracket—1998-99 manual transaxle

Exploded view of the left manual transaxle mount through-bolt—1998-99 models

Guide For complete service labor times, order Nichols’ Chilton Labor

8-26

Re

CORPORATION

e Power hop damper and bracket e Lower starter mounting bolt e Transaxle-to-rear lateral bending strut from the engine and transaxle 5. Support the transaxle with a jack. e Front motor mount through-bolt e Front motor mount bolts from the engine and transaxle e Lower dust shield 6. Rotate the crankshaft clockwise in order to access the driveplate-to-modular clutch bolts. e>For installation purposes, matchmark the driveplate and pressure plate before removing any bolts.

7. Install the 4 driveplate-to-modular clutch bolts, to separate the driveplate from the clutch. 8. Push the modular clutch assembly into the transaxle bell housing for easier transaxle removal. 9. Remove or disconnect the following: e Frame rail-to-left transaxle mount through-bolt ¢ Left transaxle mount from the transaxle, then push the mount up to provide clearance e Transaxle ¢ Modular clutch assembly from the transaxle input shaft To install: 10. Install or connect the following: ¢ Modular clutch assembly to the transaxle input shaft e Transaxle and torque the transaxleto-engine bolts to 70 ft. Ibs. (95 Nm) and the lateral bending strut bolts to 40 ft. Ibs. (54 Nm) 11. Support the transaxle with a jack. ¢ Left transaxle mount to the transaxle and torque the bolt to 40 ft. Ibs. (64 Nm) Frame rail-to-left transaxle mount through-bolt and torque to 80 ft. lbs. (108 Nm) 4 driveplate-to-modular clutch bolts Lower dust shield and torque the bolts to 108 inch Ibs. (12 Nm) Front engine mount bolts to the engine and transaxle and torque the front engine mount-to-transaxle bolt to 80 ft. Ibs. (108 Nm) and the front mount-to-engine bolt to 40 ft. lbs. (64 Nm) Front motor mount through-bolt and torque the through-bolt to 45 ft. Ibs. (61 Nm) Lower starter mounting bolt Power hop damper and bracket and torque the damper bolts to 40 ft. lbs. (54 Nm)

> WARNING

1/4” DRILL BIT

When installing the halfshafts, new retaining clips MUST be used. NEVER reuse the old clips. If old clips are used, the inner cv joints may disen-

W

ars

SELECTOR CABLE

CROSSOVER CABLE

gage. e Halfshafts e Front wheels 12. Fitl the transaxle to the bottom of the fill plug hole. 13. Remove the engine bridge fixture and support. e Upper bell housing bolt Upper starter bolt Intake manifold support bracket and torque the bolts to 70 ft. Lbs. (95 nm) Accelerator cable shield, if equipped Shift cable (linkage) mounting bracket Clutch cable to the bell housing Clutch housing vent cap Both gearshift cable ends to the transaxle shift levers Back-up lamp switch wiring to the transaxle VSS wire Cruise control, if equipped Battery tray Battery Battery heat shield DC Battery cables 14. Be sure the vehicle's back-up lights and speedometer are functioning properly. 15. Adjust the crossover cable in order to ensure proper shifter adjustment as follows: a. Remove the floor shift console. b. Loosen the adjusting screw on the crossover cable at the shifter. c. Pin the transaxle crossover cable in the 3-4 neutral position using a Y%

oe"

SELECTOR CABLE

:

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7922EG48

Insert a % in. diameter drill bit to pin the crossover lever in the 3-4 neutral position—1998-99 manual transaxle

in. drill bit. Align the hole in the crossover lever with the hole in the boss on the transaxle case. Be sure the drill bit goes into the transaxle case at least % in. (12mm). d. The shifter is spring loaded and self-centering. Allow the shifter to rest in its neutral position. Torque the adjustment screw to 70 inch lbs. (8 nm). Be careful to avoid moving the shift mechanism off center during screw tightening. e. Remove the drill bit from the transaxle case and perform a functional check by shifting the transaxle into all gears. f. Reinstall the center shift console. Blouse the boot out around the console. Seat the boot lip on the top of the console. 16. Road test the vehicle to be sure the transaxle is operating properly.

2000-02 MODELS 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the transaxle fluid. _ 3. Remove or disconnect the following: Battery Air cleaner/throttle body assembly Proportional Purge Solenoid

(PSS) Crankcase vent hose Throttle Position Sensor (TPS) and Idle Air Control (IAC) con-

1k\

Wy >

J ADJUSTMENT

SCREW

‘/ 7922EG47

Loosen the adjustment screw on the crossover cable at the shifter—manual transaxle

nectors Throttle body air duct from the intake manifold Accelerator cable Cruise control cable, if equipped Battery tray from the bracket Ground cable from the battery tray bracket

CHRYSLER mo

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e Back-up light switch connector ¢ Bell housing cap ¢ Clutch cable from the fork and transaxle e Shift cable-to-bracket clips e Shift selector and crossover cables from the levers and move aside e Halfshafts e Structural collar e Left engine-to-transaxle lateral bending brace e Bell housing dust cover e Right engine-to-transaxle lateral bending brace e Starter

e Driveplate-to-clutch module bolts 4. Place a jack and block of wood under the engine's oil pan and support the engine. Remove the transaxle’s upper mount through-bolt. 5. Lower the engine/transaxle assembly to provide clearance. e Transaxle-to-engine bolts, using an assistant to support the transaxle e Transaxle To install: 6. If installing a new or replacement transaxle, transfer the upper mount to the new transaxle; then, torque the upper mount-to-transaxle bolts to 50 ft. Ibs. (68 Nm). 7. Install or connect the following: e Transaxle e Transaxle-to-engine bolts, using an assistant to support the transaxle.

Torque the transaxle-to-engine bolts to 70 ft. Ibs. (95 Nm). 8. Raise the engine/transaxle assembly until the upper mount aligns with the mount bracket hole. Torque the upper mount-tomount bracket through-bolt to 80 ft. Ibs. (108 Nm). 9. Remove the jack and wooden block. e Driveplate-to-clutch module bolts and torque to 65 ft. Ibs. (88 Nm) e Starter and torque the bolts to 40 ft. lbs. (54 Nm) e Starter electrical connectors and torque the positive cable bolt to 89 inch Ibs. (10 Nm)

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1 — AIR CLEANER ASSY. 2 - THROTTLE BODY DUCT

1 —

SHIFT CABLES

2 - CLIPS

9306EG27

3 — BRACKET 9306EG29

View of the shift cables—2000-02 manual

View of the air cleaner assembly and throttle body duct—2000-02 models

1 — LATERAL BENDING BRACE 2 — STRUCTURAL COLLAR 3 -— DUST COVER

9306EG31

transaxle

View of the left lateral bending brace and structural collar—2000-02 models

i| L

The upper mount through-bolt may be accessed through the left side wheel house.

6. Lower the engine/transaxle assembly for clearance. 7. Remove or disconnect the following;

e Transaxle-to-engine bolts, using an assistant to support the transaxle ¢ Transaxle ¢ Torque converter from the front pump To install: 8. If installing a new or replacement transaxle, transfer the upper mount to the new transaxle; then, torque the upper mountto-transaxle bolts to 50 ft. Ibs. (68 Nm). 9. Install transaxle and tighten the transaxle-to-engine bolts, using an assistant to support the transaxle. Torque the transaxleto-engine bolts to 70 ft. Ibs. (95 Nm). 10. Raise the engine/transaxle assembly until the upper mount aligns with the mount bracket hole. Torque the upper mount-tomount bracket through-bolt to 80 ft. Ibs. (108 Nm).

11. Remove the jack and wooden block. 12. Install or connect the following: e Torque converter-to-driveplate bolts and torque the bolts to 66 ft. Ibs. (88 Nm) e Starter and torque the bolts to 40 ft. lbs. (54 Nm) e Starter electrical connectors and torque the positive cable bolt to 90 inch Ibs. (10 Nm) e Bell housing dust cover e Left engine-to-transaxle bending brace and torque the bolts to 60 ft. lbs. (81 Nm) 13. Install the structural collar and torque the bolts as follows: a. Step 1—Structural collar-to-oil pan bolts: 30 inch Ibs. (3 Nm). b. Step 2—Structural collar-totransaxle bolts: 80 ft. Ibs. (108 Nm). c. Step 3—Structural collar-to-oil pan bolts: 40 ft. Ibs. (54 Nm). 14. Install or connect the following: Halfshafts Speed control cable, if equipped Right engine-to-transaxle lateral bending brace and torque the bolts to 60 ft. Ibs. (81 Nm) Transaxle oil cooler lines and torque the oil cooler line-to-radiator fitting to 108 inch Ibs. (12 Nm) and transaxle oil cooler line fitting to 21 ft. Ibs. (28 Nm) Torque converter clutch solenoid and neutral safely/back-up light switch connectors Transaxle dipstick tube Gearshift cable bracket bolt to the transaxle

CHRYSLER COR RCOUON SS

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IPTG

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¢ Gearshift cable end to the transaxle shift lever Transaxle kickdown cable to the lever and bracket Battery tray Battery | Accelerator cable Transaxle kickdown cable Cruise control cable, if equipped Air cleaner assembly and torque the nuts and bolts to 10 ft. Ibs. (14 Nm) TPS and IAC connectors Crankcase vent hose to the throttle body PSS to the throttle body 15. Fill the transaxle and check for leaks. 16. Be sure the vehicle's back-up lights and speedometer are working properly.

ADJUSTMENT 1998-99 Models

The manual transaxle clutch release system has a unique self-adjusting mechanism to compensate for clutch disc wear. This adjuster mechanism is located with the clutch cable assembly. 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. No manual adjustment is obtainable. When servicing this vehicle or if removing and installing the clutch cable, do not pull on the clutch cable housing to remove it from the dash panel. Damage to the cable self-adjuster may occur. To check the function of the adjuster mechanism, use the following procedure: 1. With slight pressure, pull the clutch release lever end of the cable to draw the cable taut. 9. Push the clutch cable housing toward the dash panel. With less than 25 Ibs. (11kg) of effort the cable housing should move 1.2—2.0 in. (30-50mm). This indicates proper adjuster mechanism function. 3. If the cable does not adjust, determine if the mechanism is properly seated on the bracket.

REMOVAL & INSTALLATION eS A enn

SIS UTI

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SOE STE TSWRN

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IT

cles made at the Belvidere assembly plant have modular clutch assemblies. If the 11th digit of the VIN code is “D”, the vehicle was produced at the Belvidere assembly plant; if the VIN code is “T”, the vehicle was produced at the Toluca assembly plant. 1998-99 Models

TOLUCA BUILT VEHICLES 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove the transaxle assembly. 3. Matchmark the position of the clutch cover and flywheel for proper alignment during installation. 4. Install a clutch alignment tool through the clutch disc hub to prevent the clutch disc from falling and damaging the facings. 5. Loosen the clutch cover attaching bolts, 1-2 turns at a time, in a crisscross pattern. This releases the spring pressure gradually, avoiding cover damage. ->D0O NOT touch the clutch disc facing with oily or dirty hands. Oil or dirt transferred from your hands onto the clutch disc may cause clutch chatter.

6. Remove the clutch pressure plate. 7. Remove the clutch cover assembly and disc from the flywheel. 8. Remove the flywheel, if necessary. a. Inspect the clutch assembly as follows: e>Handle the components carefully to avoid contaminating the friction surfaces.

b. Inspect for oil leakage through the engine rear main bearing oil seal and transaxle input shaft seal. If there is leakage, it should be fixed at this time.

SPECIAL TOOL

7922EG50

=>Vehicles made at the Toluca, Mexico assembly plant have conventional — clutch and flywheel assembles. Vehi-

Exploded view of the conventional clutch components—1 998-99 vehicles built in Toluca

ATOR

GS ES GTO

RTI PRTC

SETS

8-31 ES

eee

c. The friction faces of the flywheel and pressure plate should not have excessive discoloration, burned areas, cracks, deep grooves or ridges. Replace parts as required.

d. Clean the flywheel face with medium sandpaper, then wipe the surface with mineral spirits. If the surface is severely scored, heat checked, cracked or warped, replace the flywheel. e. The clutch disc should be handled without touching the facings. Replace the disc if the facings show grease or oil Soakage, or wear to within less than 0.008 in. (0.20mm) of the rivet heads. The splines on the disc hub and transaxle input shaft should be a snug fit without signs of excessive wear. Metallic portions of the disc assembly should be dry, clean and not discolored from excesSive heat. Each of the arched springs between the facings should be tight. f. Wipe the friction surface of the pressure plate with mineral spirits. g. Using a straightedge, check the pressure plate for flatness. The pressure plate friction area should be flat-toSlightly concave, with the inner diameter 0.000-0.0039 in. (0.0-0.1mm) below the outer diameter. It should also be free from discoloration, burned areas, cracks, grooves or ridges. h. Using a surface plate, test the cover for flatness. All sections around the attaching bolt holes should be in contact with the surface plate within 0.015 in. (0.381mm). i. The cover should be a snug fit on the flywheel dowels. If the clutch assembly does not meet these requirements, it should be replaced. To install: >The heavy side of the flywheel is indicated by a white paint mark, near the outside diameter.

9. To minimize the effects of flywheel unbalance, perform the following installation procedure: a. Loosely assembly the flywheel to the crankshaft. If available, use new flywheel attaching bolts which have sealant on the threads. If new bolts are not available, apply Loctite® sealant to the threads of the original bolts. This sealant is required to prevent engine oil leakage. b. Rotate the flywheel and crankshaft until the white paint (heavy side) is at the 12 o'clock position.

Heater Core replacement is covered in Section 2 of this manual

8-32

CHRYSLER CORPORATION NEON

a

c. Tighten the flywheel attaching bolts, in a crisscross pattern, to 70 ft. lbs. (95 Nm). 10. Mount the clutch assembly on the flywheel with the disc centered on the alignment tool, being careful to properly align the dowels and the alignment marks made before removal. The flywheel side of the clutch disc is marked for proper installation. If the new clutch or flywheel is installed, align the orange cover balance spot as close as possible to the orange flywheel balance spot. Apply pressure to the alignment tool. Center the tip of the tool into the crankshaft and the sliding cone into the clutch fingers. Tighten the clutch attaching bolts sufficiently to hold the disc in position. 11. To avoid distorting the clutch cover, tighten the bolts gradually, a few turns at a time. Use a crisscross pattern until all bolts are seated. Tighten the bolts to a final torque of 21 ft. Ibs. (28 Nm). 12. Remove the clutch alignment tool. 13. Install the transaxle.

BELVIDERE BUILT VEHICLES 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: ¢ Negative battery cable e Starter motor assembly e Rear and front transaxle brackets e Modular clutch-driveplate bolts and discard the bolts e Transaxle >The transaxle and modular clutch will come out as an assembly.

¢ Modular clutch assembly from the transaxle input shaft.

transaxle input shaft seal. If any leakage is noted, it should be fixed at this time. To install:

bolts and torque the bolts to 65 ft. lbs. (88 Nm) e Negative battery cable

> Always use new bolts when mounting the modular clutch assembly to the driveplate.

4. Install or connect the following: e Modular clutch assembly onto the input shaft e Transaxle 5. To avoid distorting the driveplate, tighten the bolts gradually a few turns at a time. Use a crisscross pattern, until all bolts are seated. Tighten the bolts to a final torque of 55 ft. Ibs. (75 Nm). e Clutch inspection cover e Transaxle lower support brackets e Starter assembly e Negative battery cable

REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. On 1998-99 vehicles, remove the cotter pin (discard it), locknut and spring washer, from the end of the outer CV-joint stub axle. 3. With the vehicle on the ground and brakes applied, loosen, but do not remove the stub axle-to-hub and bearing retaining nut.

2000-02 Models

>The front hub and driveshaft are splined together and retained by the hub nut.

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Negative battery cable e Modular clutch-to-driveplate bolts and discard the bolts e Transaxle assembly e Modular clutch assembly from the transaxle input shaft To install: 3. Install or connect the following: ¢ Modular clutch assembly onto the transaxle input shaft * Transaxle assembly and torque the transaxle-to-engine bolts to 70 ft. lbs. (95 Nm) ¢ New modular clutch-to-driveplate

4, On 2000-02 vehicles equipped with Anti-lock Brake System (ABS), disconnect the front wheel speed sensor. 5. Remove or disconnect the following: e Front wheel e Front caliper-to-steering knuckle bolts e Caliper from the steering knuckle 6. Support the caliper out of the way by Suspending it with a piece of wire from the strut. DO NOT allow the caliper to hang by the brake hose. e Rotor from the hub e Outer tie rod end-to-steering knuckle nut by holding the tie rod end stud with a 1% in. socket while loosening the nut

e»Handle the components carefully to avoid contaminating the friction surface.

3. Inspect for oil leakage through the engine rear main bearing oil seal and

ENGINE

UPPER

ER

soit

ORIVE PLATE

TO CLUTCH

CRANKSHAFT TO DRIVE PLATE

gout

Bes

TRANSAXLE CASE UPPER COVER DRIVE

PLATE CLUTCH ASSEMBLY

7922EG51

1 — MODULAR CLUTCH ASSEMBLY 2 — CLIP

The transaxle and modular clutch are

removed as an assembly—1998-99 vehicles

3 — TRANSAXLE 4 — CLUTCH MODULE

BOLT (4)

9306EG41

Exploded view of the manual transaxle, clutch module and related components—2000-02 vehi-

cles

’

CHRYSLER EOD ROL SHON

e>Inner tripod joint removal is easier by applying outward pressure on the joint while hitting the punch with a hammer. /

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Exploded view of the cotter pin, locknut and washer—halfshaft service

e Tie rod end stud from the steering knuckle e Ball joint stud-to-steering knuckle nut and bolt

*k:< WARNING

|

Be careful when separating the ball joint stud from the steering knuckle, so the ball joint seal does not get damaged. e Ball joint stud from the steering knuckle by prying down on the lower control arm 7. For 1998-00 vehicles, perform the following steps: a. Remove the hub and bearing-tostub axle retaining nut. b. Install a puller on the hub and bearing assembly, using the lug nuts to hold it in place. c. Install a wheel lug nut on wheel stud to protect the threads on the stud. Install a flat-bladed prytoo! to keep the hub from turning. Using the puller, force the outer stub axle from the hub and bearing.

+k WARNING

Be

Be careful when separating the inner CV-joint during this operation. Do not let the driveshaft hang by the inner CV-joint, the driveshaft must be supported.

8. Pull the steering knuckle assembly out and away from the outer CV-joint of the driveshaft assembly. Support the outer end of the driveshaft assembly. 9. Insert a prybar between the inner tripod joint and the transaxle case. Pry against the inner tripod joint until the joint retaining snapring is disengaged from the transaxle side gear.

10. Remove the inner tripod joints from the transaxle side gears using a punch to dislodge the inner tripod joint retaining ring from the transaxle side gear. If removing the right side inner tripod joint, position the punch against the inner tripod joint. Hit the punch sharply with a hammer to dislodge the right inner joint from the side gear. If removing the left side inner tripod joint, position the punch in the groove of the inner tripod joint. Hit the punch sharply with a hammer to dislodge the left inner tripod joint from the side gear. 11. Hold the inner tripod joint and interconnecting shaft of the driveshaft assembly. Remove the inner tripod joint from the transaxle by pulling it straight out of the transaxle side gear and transaxle oil seal. When removing the tripod joint, do not let the spline or snapring drag across the sealing lip of the transaxle-to-tripod joint oil Seal.

The driveshaft, when installed, acts as a bolt which secures the front hub and bearing assembly. If the vehicle is to be supported or moved on its wheels with a driveshaft removed, install a proper-sized bolt and nut through the front hub. Tighten the bolt and nut to 135 ft. Ibs. (183 Nm). This will ensure that the hub bearing cannot loosen.

To install: 12. Thoroughly clean the spline and oil seal sealing surface on the tripod joint. Lightly lubricate the oil seal sealing surface on the tripod joint with fresh, clean transmission fluid. 13. Holding the driveshaft assembly by the tripod joint and interconnecting shaft, install the tripod joint into the transaxle side gear as far as possible by hand. 14. Carefully align the tripod joint with the transaxle side gears. Then, grasp the driveshaft interconnecting shaft and push the tripod joint into the transaxle side gear until fully seated. Be sure the snapring is fully engaged with the side gear by trying to remove the tripod joint from the transaxle by hand. If the snapring is fully seated with the side gear, the tripod joint will not be removable by hand.

3-33

15. Clean all debris and moisture out of the steering knuckle. 16. Be sure that the outer CV-joint, which fits into the steering knuckle, has no debris or moisture on it before installing into the steering knuckle. 17. Slide the driveshaft back into the front hub. Install the steering knuckle into the ball joint stud. 18. Install a NEW steering knuckle-toball joint stud bolt and nut. Tighten the nut and bolt to 70 ft. Ibs. (95 Nm). 19. Insert the tie rod end into the steering knuckle. Start the tie rod end-to-steering knuckle nut onto the stud of the tie rod end. While holding the stud of the tie rod end stationary, tighten the nut. Then, using a crow’s foot and 12 in socket, tighten the tie rod end nut to 45 ft. Ibs. (61 Nm). 20. Install the rotor back onto the hub and bearing assembly. 21. Position the caliper on the steering knuckle. Slide the top of the caliper under the top abutment on the steering knuckle, then install the bottom of the caliper against the bottom abutment of the steering knuckle. 22. Install the caliper-to-knuckle bolts and tighten to 23 ft. Ibs. (31 Nm). 23. On 2000-02 vehicles equipped with ABS, connect the front wheel speed sensor. 24. Clean ali foreign matter from the threads of the outer CV-joint stub axle. Install hub nut and washer onto the threads of the stub axle and tighten the nut. 25. With the vehicle's brakes applied to prevent the axle shaft from turning, tighten the hub nut to 150 ft. Ibs. (203 Nm) for 1998-99 models or 180 ft. Ibs. (244 Nm) for 2000-02 models. 26. On 1998-99 vehicles, install the spring washer, locknut and new cotter pin into the outer C\V-joint stub axle. 27. Install the front wheel and tire assembly. Install the lug nuts and tighten to 100 ft. Ibs. (135 Nm) for 1998-99 models or 95 ft. Ibs. (128 Nm) for 2000-02 models. 28. Check the transaxle fluid level, lowering the vehicle as necessary.

OVERHAUL Tri-Pot (Inner) Joint

Brake service is covered in Section 4 of this manual

1. Remove or disassemble the following: e Halfshaft and place it in a softjawed vise

8-34

CO eren CORPORATION

1 2 3 4

-— — —

SEALING BOOT RAISED BEAD IN THIS AREA OF SEALING BOOT GROOVE INTERCONNECTING SHAFT

9306EG04

Positioning the boot on the shaft—Tri-pot and Rzeppa joints 1 2 3 4 5 6 7

— — — — — — —

STUB AXLE ~ OUTER C/V JOINT OUTER C/V JOINT BOOT TUNED RUBBER DAMPER WEIGHT INTERCONNECTING SHAFT OUTER C/V JOINT BOOT STUB AXLE

8 — 9 10 11 — 12 13 14 -

OUTER C/V JOINT RIGHT DRIVESHAFT INNER TRIPOD JOINT BOOT INNER TRIPOD JOINT INNER TRIPOD JOINT INNER TRIPOD JOINT BOOT INTERCONNECTING SHAFT LEFT DRIVESHAFT

| | | |

@

9306EG02

View of the halfshaft assemblies—Typical

1 2 3 4

— — —

107 MILLIMETERS HYTREL SEALING BOOT SEALING BOOT CLAMP INNER TRIPOD JOINT

9306EG05

Adjusting the Tri-pot boot length—Hytrel plastic boot

e Tri-pot joint boot clamps and the boot down 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 tripot housing ¢ Snapring from the shaft ¢ Spider assembly elf necessary, tap the spider assembly from the shaft with a brass drift.

When removing the spider assembly, do not hit the outer bearings. LT TT LS A

Fe RINGIERACER

1 —

HOUSING ASM, RETAINER &

je= SHAPE aiSoe PERM

3 4 5 6

SPIDER, TRIPOTD JOINT RING, RETAINING RETAINER, BALL & ROLLER BALL, TRIPOD JOINT

13 14 15 16

— — — -

7 — ROLLER, NEEDLE

8 — CLAMP, SEAL RETAINING

9 — BUSHING, TRILOBAL TRIPOD 10 — SEAL, DRIVE AXLE INBOARD

— — — -

SET

¢ Boot by sliding it off the shaft

SEAL, DRIVE AXLE OUTBOARD CLAMP, SEAL RETAINING RING, RACE RETAINING BALL, CHROME ALLOY

{7 — RACE, C/VJOINT INNER

If any parts show excessive wear,

i SeRAGE avian OUTER

replace the halfshaft assembly; the component parts are not service9306EG03

Exploded view of the halfshaft assembly—Typical

SE

a ble ,

MIT.

eS

:

1 2 3 4

— — —

115 MILLIMETERS SILICONE SEALING BOOT CLAMP INNER TRIPOD JOINT

1 — 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

9306EG06

Adjusting the Tri-pot boot length—Silicone rubber boot

9306EG08

Secured the low profile boot clamp—Silicone rubber Tri-pot boot

2. Install a new small boot clamp and Slide it on the shaft. 3. Position the boot so that the raised bead on the inside the boot seal is in the shaft groove. 4. lf installing a new boot, distribute v2 of the grease in the service package inside the tri-pot housing and the other ¥ inside the boot. 5. Install or connect the following: ° Spider assembly, face the chamfered side toward the shaft

1 -— SEALING BOOT 2 -— SPECIAL TOOL C-4975 3 - CLAMP BRIDGE

93060613

Tightening the high profile boot clamp— Tri-pot joint (Hytrel plastic) boot and Rzeppa joint boots

1 —

CHRYSLER pon ROn SHON

CLAMP

2 — SPECIAL TOOL YA3050 3 -— SEALING BOOT

§306EG07

Tightening the low profile boot clamp— Silicone rubber Tri-pot boot

To assemble:

sick WARNING The Tri-pot sealing boots are made of 2 different types of material; silicon rubber (high temperature) which is soft and pliable or hytrel plastic (standard temperature) which is stiff and rigid. Be sure to replace the boot made of the correct material.

+k

8-35

b. Position the boot onto the tri-pot housing retaining groove and install the retaining clamp evenly on the boot. c. 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). 8. If installing a low profile latching type boot clamp, position Snap-On® Clamp Locking Tool YA3050 prongs in the clamp holes and squeeze the tool until the upper clamp band is latched behind the 2 tabs on the lower clamp band. 9. Install the halfshatt. Rzeppa (Outer) Joint 1. Remove or disassemble the follow-

ing: Halfshaft and place it in a softjawed vise Rzeppa joint boot clamps and slide the boot down the shaft Rzeppa joint housing, by sharply hitting it with a soft-faced hammer to drive it off the shaft e Circlip from the shaft e Boot by sliding it off the shaft

WARNING

If necessary, tap the spider assembly onto the shaft using a brass drift; be careful not to hit the outer bearings.

e Snapring making sure it is fully seated in the groove e Spider/shaft assembly into the tripot housing e New inner boot clamp and position it evenly on the sealing boot 6. Using a trim stick, adjust the boot length to 107mm (hytrel plastic) or 115mm (silicone rubber). 7. If installing a high profile boot clamp, perform the following procedure: a. Using the Crimper Too! C-4975A, place the tool over the clamp bridge, tighten the tool nut until the jaws are completely closed (face-toface).

1 — INTERCONNECTING SHAFT 2 - CROSS 3 — OUTER C/V JOINT ASSEMBLY

9306EG09

Aligning the cross splines with the shaft splines—Rzeppa joint

> WARNING The seal must not be dimpled, stretched or out of shape. If necessary, equalize the seal pressure and shape it by hand.

1 2 3 4

— -

SOFT FACED HAMMER STUB AXLE OUTER C/V JOINT NUT

9306EG10

Driving the Rzeppa joint onto the shaft

For complete Engine Mechanical specifications, see Section 1 of this manual

8-36

icon

CHRYSLER CORPORATION

+k WARNING If any parts show excessive wear, replace the halfshaft assembly; the component parts are not serviceable. To assemble: 2. Install or assemble the following: e New small boot clamp and slide it onto the shaft e Boot and slide it onto the shaft e Circlip, if removed 3. Position the boot so that the raised bead on the inside the boot seal is in the shaft groove. e Halfshaft hub nut onto the Rzeppa joint threaded shaft so it is flush with the end

e Rzeppa joint, align the shaft splines and tap it onto the shaft with a softfaced hammer so it locks on the circlip 4. Distribute Y2 of the grease in the service package inside the Rzeppa joint housing and the other % inside the boot. 5. Install the new small boot clamp and position it evenly on the sealing boot 6. 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).

The seal must not be dimpled, stretched or out of shape. If neces-

sary, equalize the seal pressure and shape it by hand. 7. Position the boot onto the Rzeppa housing retaining groove and install the retaining.clamp evenly on the boot. 8. 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).

The seal must not be dimpled, stretched or out of shape: If necessary, equalize the seal pressure and shape it by hand. 9. Install the halfshaft.

STEERING AND SUSPENSION

+k CAUTION

Some 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 repairs.

PRECAUTIONS Several precautions must be observed when handling the inflator module to avoid accidental deployment and possible personal injury: ¢ 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. e 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 in the event of an accidental deployment.

DISARMING

connecting and isolating the negative battery cable. Allow the air bag system capacitor at least 2 minutes to discharge before removing any air bag system components.

Rack and Pinion Steering Gear These vehicles are designed and assembled using NET BUILD front suspension alignment settings. This means that the alignment settings are determined as the vehicle is designed by the location of the front suspension components in relation to the body. This is carried out when building the vehicle, by precisely locating the front crossmember to meter gauge holes located in the underbody of the vehicle. With this method of designing and building a vehicle, it is no longer possible to adjust a vehicle's front suspension alignment settings to the

required specifications. As a result, whenever the crossmember is removed from a vehicle, it MUST be replaced in the same location on the body of the vehicle it was removed from. The front suspension toe settings can still be adjusted by the outer tie rod ends.

REMOVAL & INSTALLATION 1998-99 Models 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. From inside the vehicle, disconnect the steering gear coupler from the steering column shaft coupler. 3. Remove or disconnect the following: ¢ Both front wheels

STEERING GEAR MOUNTING BRACKET

STEERING GEAR FLUID LINES

INNER TIE D

TIE ROD END

INNER TIE ROD

POWER STEERING FLUID HOSES POWER FLUID

? STEERING

PRESSURE

Jf

TO POWER

STEERING sid

SS

POWER STEERING FLUID RETURN HOSE

:

ay)

(

\\||

FRONT SUSPENSION CROSSMEMBER

4 (Cf

HOSE

TIE ROD END

LOWER

CONTROL ARM

TO FLUID RESERVOIR

oN

Proper Supplemental Restraint Ssystem (SRS) disarming can be obtained by dis-

7922EG53

Identification of the rack and pinion steering gear components—1 998-99 vehicles

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CHRYSLER CORPORATION NEON

S< STEERING COLUMN SHAFT COUPLER

PINCH BOLT NUT

(dj (7

BOLT

(|

»-

J

= ges

LOWER STEERING COLUMN COUPLER

aa

\\\

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RETAINING

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Ni

BRAKE

¢ Power steering fluid pressure and return hoses from the power steering gear

REAR ATTACHING Ty

STEERING COUPLER

&

PINCH

FRONT SUSPENSION CROSSMEMBER

8-3/

PIN

i ae

ATTACHING 7 BOLT

s

sway

LOWER CON}KOL

iBAR

ARM

7922EG54

Disconnect the steering gear coupler from inside the vehicle—1998-S9 vehicles

SS

7922EG57

Location of the front crossmember mounting bolts—1998-99 vehicles

WARNING

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 reinstalled in its exact location. If this is not done, the proper NET BUILD alignment specifications will not be obtained and may lead to han-

dling and/or tire wear problems. \

sTeERING /LLJ II] GEAR COUPLER _~\%

x

ON

CROSSMEMBER

yy

MOUNTING BOLT

ARM

\

TRANSMISSION | 52 JACK

CRORE MBER

7922EG55

Some vehicles are equipped with a bobble damper that must be removed from the

7922EG58

Lower the crossmember for access to the

steering gear—1998-99 vehicles

crossmember during steering gear service—1998-99 vehicies

SCRIBBED UNE FOR LOCATION OF FRONT SUSPENSION 2 CROSSMEMBER

z {

FRONT SUSPENSION

LOWER CONTROL

—

LOWER YH CONTROL ARM

bes fiRNG Se GEAR | ———

DAG

FRONT SUSPENSION —~ CROSSMEMBER

W

STEERING GEAR MOUNTING BOLTS

LAWL

\"]

STEERING | / \ — GEAR \C Sp are

FRONT SUSPENSION — CROSSMEMBER

~+ TRANSMISSION JAK \

a

FRONT SUSPENSION { CROSSMEMBER

=

|

li ii

BAR

7922EG59 as

LOWER CONTROL ARM BUSHING

a

View of the steering gear mounting

MOUNTING BOLT

7922EG56

Because of the method used for aligning the vehicle, matchmark the crossmember installed position prior to steering gear removal—1998-99 vehicles

¢ Engine/transaxle bobble damper from the front suspension crossmember, if equipped =>The bobble strut does not have to be removed from the transaxle.

Outer tie rod end-to-steering knuckle nut ->The nut is removed by holding the tie

bolts—1998-99 vehicles

rod end stud with an 112 in. socket while loosening the nut with a wrench.

¢ Tie rod ends from the steering knuckles, using a Side Puller Tool MB-991113. e Power steering fluid pressure switch connector e Power steering pressure/return hose routing bracket from the front crossmember >The bracket does not have to be

removed from the power steering pressure and return hoses.

4 Matchmark the crossmember to the chassis. 5. Place a transmission jack under the center of the crossmember. The jack will be used to lower, support and raise the crossmember when removing the steering gear. 6. Remove both front crossmember-toframe rails bolts. Then, loosen both rear crossmember/lower control arm to the body bolts. Lower the crossmember while loosening the rear bolts. 7. Using the transmission jack, lower the crossmember enough to allow the steering gear to be removed from the crossmember. When lowering the crossmember, do not let the crossmember hang from the lower control arms. The weight should be Supported by the jack. 8. Remove or disconnect the following: e 4 steering gear-to-crossmember bolts e Steering gear e>|lf a new steering gear is being installed, transfer any necessary parts from the old steering gear to the new steering gear.

To install: 9. Install the steering gear on the crossmember and torque the bolts to 50 ft. lbs, (68 Nm). 10. Using the transmission jack, raise the crossmember/steering gear assembly against the chassis frame rails. Start the 2 rear crossmember-to-chassis bolts; then, the 2 front crossmember-to-frame rail volts. Tighten the 4 bolts until the crossmember is aligned with the mounting points. Torque the bolts to 20 inch Ibs. (2 Nm). e>When the crossmember is installed, it MUST align with the removal matchmarks; the purpose is maintain NET BUILD front suspension alignment settings.

For Accessory Drive Belt illustrations, see Section 1 of this manual

8-38

Reoras CORPORATION

11. Tap the crossmember into position, with a rubber mallet, until it is aligned with the matchmarks. Once positioned, torque both rear crossmember/lower control arm

bolts to 120 ft. Ibs. (163 Nm); then, both front bolts to 120 ft. Ibs. (163 Nm). 12. Install or connect the following: e Power steering fluid pressure/return hoses into the steering gear ports and torque the line-to-steering gear tube nuts to 23 ft. Ibs. (31 Nm) Power steering fluid pressure/return hose routing bracket and screw on the crossmember and torque the bracket-toattaching bolt to 17 ft. Ibs. (23 Nm) Wiring harness connector onto the power steering gear’s fluid pressure Switch and securely latch the wiring harness connector’s locking tab Tie rod end, into the steering knuckle. While holding the tie rod stud, torque the tie rod end-tosteering knuckle nut, using a crows foot wrench and 1% in. socket, to AQ ft. Ibs. (55 Nm). Engine/transaxle bobble strut, if equipped, onto the crossmember bracket Both front wheels and torque the lug nuts, in a crisscross pattern, to 100 ft. Ibs. (135 Nm) Steering gear coupler to the steering column shaft coupler, under the dash, and torque the bolt to 21 ft. lbs. (28 Nm) Upper-to-lower steering coupler retaining bolt retention pin

0)

3 — STEERING GEAR 4 — FRONT SUSPENSION CROSSMEMBER 9306EG42

1 — OUTER TIE ROD 2 — JAM NUT

View of the power steering gear and crossmember—2000-02 vehicle

Locking the steering wheel keeps the clockspring in alignment position.

ing the locking tab Power steering fluid pressure hose from the steering gear Power steering fluid return hose from the steering gear, if not equipped with a power steering fluid cooler Power steering fluid cooler hose from the steering gear, if equipped with a power steering fluid cooler Power steering fluid return hose from the routing clip C-clamps, if not equipped with a power steering fluid cooler Power steering fluid pressure hose from the steering gear’s routing clips

3. Working inside the passenger compartment, remove the steering column coupling retainer pin, pinch bolt nut/bolt and Separate the couplings. 4. Remove or disconnect the following: ¢ Both front wheels ¢ Outer tie rods-to-steering knuckle nuts e>Remove the tie rod nut by holding the stud securely.

¢ Outer tie rod ends from the steering knuckle using Remover Tool MB991113 ¢ Tie rod heat shield ¢ Power steering fluid pressure switch wiring connector by releas-

When refilling and bleeding the power steering system, always use the proper type of fluid. NEVER substitute automatic transmission fluid for the specified fluid.

es eos \)

13. Refill the power steering pump fluid reservoir to the FULL-COLD level with the

Se De

proper type and amount of fluid. Bleed the system.

y

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 in place, using a steering wheel holder.

S 1 2 3 4

~ WIRING HARNESS CONNECTOR — POWER STEERING GEAR - POWER STEERING FLUID PRESSURE SWITCH Bona ~ REAR OF FRONT SUSPENSION CROSSMEMBER

9306EG43

View of the power steering gear fluid pressure switch—2000-02 vehicle

— — — ~—

PRESSURE HOSE TUBE NUT RETURN HOSE POWER STEERING GEAR FRONT SUSPENSION CROSSMEMBER

9306EG44

View of the power steering gear hoses and routing clips—2000-02 vehicle

‘

CHRYSLER CORPORAT ION NEON

8-39

-¢ WARNING Do not completely remove the rear bolts for they are designed to disengage from the body threads and will Stay within the lower control arm rear isolator bushing. e>The threaded tapping plates allow the lower control arm to stay in place on the crossmember.

2 — PINION SHAFT 3 - TAB 4 — POWER STEERING GEAR

9306EG45

View of the pinion shaft dash cover seal—

2000-02 vehicle

9306EG47

Measuring the engine torque bracket— 2000-02 vehicle

~SS SA

“Cz

1 2 3 4

— — —

BOLTS ENGINE MOUNT BRACKET TORQUE STRUT BRACKET UPPER TORQUE STRUT

5 6 7 8

— — —

NS YF\) oe.

CROSSMEMBER LOWER TORQUE STRUT BOLTS RIGHT FENDER 9306EG46

View of the engine torque struts and related components—2000-02 vehicle

e Power steering cooler hose from the steering gear's right routing clip, if equipped e Both power steering cooler screws from the front suspension crossmember, if equipped, and move the cooler aside >The screws are located behind the cooler and can be accessed from above.

e Power steering cooler, if equipped, and move it aside Engine torque strut-to-front suspension crossmember bolt from the right forward corner of the crossmember 5. Matchmark the front suspension crossmember-to-chassis location.

WARNING If the front suspension crossmemberto-chassis location is not matchmarked, the front wheel alignment setting will be lost. 6. Place a transmission jack under the front crossmember and support it. 7. Remove both front suspension crossmember-to-frame rail bolts, one located at each side. 8. Loosen both rear Suspension crossmember-to-frame rail bolts, one located at each side, until they release from the threaded tapping plates in the bolt.

9. Using the transmission jack, lower the front suspension crossmember enough to allow the power steering gear to be removed form the rear of the crossmember. Use the jack to support the crossmember's weight. 10. Remove or disconnect the following: ¢ Lower steering column coupling-topower steering gear pinion shaft's roll pin, using a roll pin punch Lower steering column coupling from the power steering column pinion shaft Pinion shaft dash cover seal from the tabs cast into the power steering gear housing e Power steering gear from the front ‘suspension crossmember To install: 11. Install or connect the following: e Power steering gear onto the front Suspension crossmember and torque the bolts to 45 ft. Ibs. (61 Nm) e Pinion shaft dash cover seal over the shaft and onto the power steering gear housing ->Align the seal holes with the tabs cast into the power steering gear housing.

e Lower steering column coupling by aligning the coupling and steering gear pinion shaft flats e Lower steering column couplingto-pinion shaft's roll pin until it is centered 12. Center the power steering gear rack’s travel. e Front suspension crossmember/power steering gear assembly by raising it with the jack until is aligns with its matchmarks Lower steering column coupling, guide it through the dash panel hole as it is raised Both rear crossmember-to-tapping plate bolts Both front crossmember-to-frame rail bolts and torque them to 20 inch lbs. (2 Nm)

For Tire, Wheel and Ball Joint specifications, see Section 1 of this manual

8-40

ee ON

CORPORATION

LL

Be sure to align the front suspension crossmember-to-chassis matchmarks; otherwise, the front wheel alignment setting will be lost. ¢ Once aligned, torque both rear crossmember-to-rear lower control

arm bolts to 150 ft. Ibs. (203 Nm) and both front crossmember bolts to 105 ft. Ibs. (142 Nm) Engine torque strut to the right forward corner of the front suspension crossmember 13. Adjust the engine torque strut by performing the following procedure: a. Loosen the upper torque strut at the shock tower bracket. b. Position a floor jack on the forward edge of the bell housing to prevent the least amount of upward lifting of the engine. c. Slowly, lift the assembly, allowing the engine to rotate rearward so the distance between center of the engine mount bracket's rearmost attaching stud (point A) and the center of the shock tower bracket’s washer hose clip hole (point B) is 4.70 in. (119mm). d. Torque the upper and lower torque strut bolts to 87 ft. Ibs. (118 Nm). e. Remove the floor jack. 14. Install or connect the following: e Power steering hose-to-power steering gear using a new O-ring ubricated with power steering oil, if not equipped with a power steering cooler Power steering fluid cooler line-topower steering gear, if equipped with a power steering cooler Power steering fluid return hose to the routing clip C-clamps, if not equipped with a power steering fluid cooler Power steering fluid pressure hose to the steering gear's routing clips Power steering cooler hose to the Steering gear’s right routing clip, if equipped Torque the power steering pressure hose-to-power steering gear nut to 25 ft. Ibs. (34 Nm) Both power steering cooler screws to the front suspension crossmember, if equipped Power steering fluid pressure switch wiring connector be sure the locking tab is secure latched Tie rod heat shield, facing outboard Outer tie rod ends to the steering

3. Mark each one right or left, as applicable, if both struts are being removed. 4. Remove the hydraulic brake hose bracket and screw from the strut damper bracket.

knuckle. Torque the nut, using a crowsfoot wrench, to 40 ft. Ibs. (55 Nm), while holding the tie rod stationary Both front wheels and torque the lug nuts, in a crisscross pattern, to 95 ft. Ibs. (128 Nm) Dash-to-lower coupling seal over the lower coupling’s plastic collar

+0 WARNING -

->|f equipped with Anti-lock Brake System (ABS), the hydraulic hose routing bracket is combined with the speed sensor cable routing bracket.

e>Verify that the seal’s lip shows grease at the coupling’s plastic collar contact.

+k WARNING The steering knuckle-to-strut assembly attaching bolts are serrated and must not be turned during removal.

¢ Steering column lower coupling-tosteering column upper coupling pinch bolt and torque the nut to 21 ft. lbs. (28 Nm) e Pinch bolt retainer pin 15. Remove the steering wheel holder. 16. Fill and bleed the power steering system. 17. Check for leaks. 18. Check and/or adjust the front toe setting.

1

EE

TE

SET

5. Remove or disconnect the following: e Steering knuckle nuts while holding the bolts stationary e Steering knuckle nuts by holding the bolts in place e 3 upper strut mount-to-strut tower nuts elf necessary, partially lower the vehicle for access to the upper mounting nuts.

e Strut assembly To install: 6. Install or connect the following: e Strut assembly into the strut tower by aligning the 3 upper strut mount studs with the shock tower holes. Torque the 3 upper strut mount nut/washer assemblies to 23 ft. Ibs. (31 Nm).

REMOVAL & INSTALLATION Front

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove the front wheels.

STEERING GEAR ASSEMBLY MOUNTING BOUT (4)

STRUT SHAFT Nut

STRUT ASSEMBLY MOUNTING NUT

STEERING GEAR MOUNTING BRACKET

STEERING GEAR

|

Se i

GEAI > STEERING GEAR Vee INNER BRACKET ~~ if

GEAR

AN = _ ;

STRUT MOUNT

SPRING

ae) 3 ons

THE ROD END

\ STEERING

ae

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ASSEMBLY

SEAT AND

BEARING ASSEMBLY mE” BUMPER DUST SHIELO

COIL SPRING

ee

[

=

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ay f

pend

a

LOWER CONTROL See

ARM

i

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PIVOT BOLT

L we

STRUT DAMPER

ASSEMBLY

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JOINT

SEAL J NUT &Sy

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BRAKING DISC

SWAY BAR BUSHING SWAY BAR BUSHINGS AND WASHERS (4)

SWAY BAR LINK BOLT

LOWER i CONTROL ARM

CROSSMEMBER ATTACHING BOLT

J SWAY BAR CLAMP BOLT

LOWER CONTROL ARM/CROSSMEMBER ATTACHING BOLT

PINCH BOUL NUT

TIE ROD END ATTACHING NUT

SPACER

7922EG60

Exploded view of the front suspension—1998-99 models

/

CHRYSLER AEE

8-41

hose routing bracket is combined with the speed sensor cable routing bracket.

e Front wheels and torque the lug nuts, in a criss-cross pattern, to 100 ft. Ibs. (135 Nm) for 1998-99 or 95 ft. Ibs. (128 Nm) for 2000-02 Rear

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove the rear wheel. 3. Remove the hydraulic flex hose bracket from the strut bracket. e>|f equipped with Anti-lock Brake System (ABS), the wheel speed sensor cable routing clip is also attached to the strut assembly bracket.

4. Remove the clevis bracket-toknuckle bolts by supporting the rear knuckle, suspension and brake components. ->DO NOT allow the weight of the knuckle and related components to hang without support when the strut is removed.

The knuckle-to-strut attaching bolts are serrated and must not be turned during removal. Remove the nuts while holding the bolts stationary in the knuckle. 11 12 13 14 15 16 17 18 19 20

1 -— VEHICLE STRUT TOWER 2 - OUTER TIE ROD 3 - STEERING GEAR 4 — STRUT ASSEMBLY 5 -— JAM NUT 6 — LOWER CONTROL ARM 7 — CROSSMEMBER 8 — BALL JOINT 9 - STABILIZER BAR 10 — STABILIZER BAR CUSHION AND RETAINER

-— — — — — -— -— — — —

5. Remove both strut-to-knuckle clevis bracket nuts.

STABILIZER BAR LINK HUB KNUCKLE STRUT LOWER SPRING ISOLATOR COIL SPRING JOUNCE BUMPER DUST SHIELD SPRING SEAT AND BEARING UPPER MOUNT

> Access to the rear upper strut mountto-strut tower attaching bolts is through the trunk of the vehicle.

9306EG11

Exploded view of the front suspension—2000-02 models

WARNING The steering knuckle-to-strut assembly attaching bolts are serrated and must not be turned during instailation. ES

e Steering knuckle nuts while holding the bolts stationary Steering knuckle arm and position it into the strut assembly by aligning the strut assembly-to-steering knuckle holes

e Both strut-to-steering knuckle bolts and torque both bolts to 40 ft. Ibs. (53 Nm), plus an additional % turn after the specified torque is met ->The bolts should be installed with the nuts facing the front of the vehicle.

¢ Hydraulic brake hose routing bracket and screw onto the strut damper bracket and torque the bracket bolts to 10 ft. Ibs. (13 Nm) =>If equipped with ABS, the hydraulic

6. Remove the carpet from the top of the strut tower, if necessary. 7. Remove the rubber dust shield from the top of the strut tower. 8. Loosen, but do not remove the 4 upper strut mounting nuts. 9. Remove the 4 strut-to-chassis mount nuts, by supporting it. 10. Remove the strut from the knuckle by sliding the knuckle out of the clevis bracket. To install: 11. Install or connect the following: e Strut and torque the 4 strut mountto-body nuts to 25 ft. Ibs. (34 Nm) e Dust shield onto the top of the strut tower opening ¢ Carpeting on top of the strut tower e Knuckle into the strut assemblies

For Wheel Alignment specifications, see Section 1 of this manual

8-42

CHRYSLER CORPORATION

STRUT TOWER

FRONT

OF CAR

ea STRUT

The mounting bolt with the stud on the head is installed on the inboard side.

e Rear tension strut bayonet bushing making sure that the stepped area faces toward the knuckle

For Maintenance Interval recommendations, see Section 1 of this manual

e Tension strut retainer e Tension strut-to-knuckle nut by holding the strut with a wrench and torque the nut to 70 ft. Ibs. (95 Nm) e Rear wheels and torque the lug

nuts to 100 ft. Ibs. (135 Nm)

3. Check and/or align the rear wheels.

4. Remove or disconnect the following: e Ball joint from the steering knuckle using a prybar | ack WARNING

Be careful when separating the ball

joint stud from the knuckle, so the

see AUN

Lower Ball Joint

MUA ioc

e Front lower control arm bushing-

to-crossmember nut and bolt

REMOVAL & INSTALLATION The front suspension ball joints operate with no free-play. The ball joints are replaceable ONLY as an assembly. Do not attempt any type of repair on the ball joint assembly. The ball joint is a press fit into the lower control arm with the joint stud retained in the steering knuckle by the clamp bolt. To check the ball joint, with the weight of the vehicle resting on the road wheels, grasp the grease fitting and without using any tools, attempt to move the grease fitting. If the ball joint is worn the grease fitting will move easily. If movement is noted, replacement of the ball joint is recommended. 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Wheel e Steering knuckle-to-ball joint stud’s pinch bolt and nut e Stabilizer bar-to-lower control arm links 3. Loosen, but do not remove the bolts holding the stabilizer bar retainers to the crossmember. Then, rotate the stabilizer bar and attaching links away from the lower control arms.

e Rear lower control arm-to-crossmember bolt e Lower control arm

e Ball joint using a prytool 5. Using a hydraulic press, press the ball joint from the lower control arm using tools: e Receiver Tool 6758: 1998-99 vehi-

cles

e ed Too! 6804: 1998-99 vehi-

+ Receiver Too! 6908-2: 2000-02 vehicles

¢ Adapter Tool 6804: 2000-02 vehi; cles To install: 6. Reinstall the ball joint into the lower

SPECIAL TOOL 6804

BALL JOINT SPECIAL TOOL 6758

1 -— PRESS 2 — BALL JOINT

9306EG51

9306EG48

Removing the ball joint from the control arm—1998-99 vehicles

Removing the ball joint from the control arm—2000-02 vehicles

- BALL JOINT STUD - LOWER CONTROL ARM Bona ~— FRONT ISOLATOR BUSHING

Pulling the steering knuckle outward after releasing the ball joint can separate the inner CV-joint. LOWER.

CONTROL ARM(

KJ

|\\Wy

9306EG49

Installing the ball joint to the control arm—1998-99 vehicles

9306EG52

Aligning the ball joint stud notch to the control arm—2000-02 vehicles

STEERING KNUCKLE

LOWER CONTROL ARM FITTING

BALL JOINT SEAL BOOT 1 - PRESS 2 — BALL JOINT

7922EG63

Wiggle the grease fitting with your fingers—if it moves, the ball joint should be replaced

9306EG50

Installing the ball joint boot seal— 1998-99 vehicles

9306EG53

Installing the ball joint to the control arm—2000-02 vehicles

a

CHRYSLER ON

the lower control arms. Install the top stabilizer bar link bushings and nuts. DO NOT tighten the link yet. 13. Install the wheel. 14. Lower the vehicle so the suspension is Supporting the total weight of the vehicle. 15. Torque the stabilizer bar-to-lower control arm links to 21 ft. Ibs. (28 Nm) for

1 — SEAL BOOT UPWARD LIP 2 — BALL JOINT 9306EG54

Installing the ball joint boot seal— 2000-02 vehicles

control arm with the notch in the ball joint stud facing the front lower control arm bushing. 7. Using a hydraulic press, press the ball joint into the lower control arm using tools: a. Receiver Too! 6758 and Adapter Too! 6804. 8. Install or connect the following: e Ball joint boot seal using a driver tool such as a large socket or suitable sized piece of pipe

>, WARNING

1998 models and 17 ft. Ibs. (23 Nm) for 1999-02 models. 16. Torque the stabilizer bar bushing retainer-to-crossmember bolts to 21 ft. Ibs. (28 Nm). 17. Check and/or adjust the toe, as nec-

essary.

8-45

6. Install /% of a Bearing Splitter Tool 1130, between the hub and the bearing retainer plate. The threaded hole in this ¥ is to be aligned with the caliper rail on the steering knuckle. 7. Install the remaining pieces of the bearing splitter on the steering knuckle. Hand-tighten the nuts to hold the splitter in place on the knuckle. 8. When the bearing splitter is installed, be sure the 3 bolts attaching the bearing retainer plate to the knuckle are contacting the bearing splitter. The bearing retainer plate should not support the knuckle or contact the splitter.

Wheel Bearings BEARING RETAINER PLATE

ADJUSTMENT

HUB =

Neons are equipped with sealed hub and bearing assemblies. The hub and bearing assembly is non-serviceable. If the assembly is damaged, the complete unit must be replaced. MOUNTING STUD

REMOVAL & INSTALLATION

STEERING KNUCKLE 7922EG65

Do not use a shop press that was used to install the ball joint, for the press exerts too much force. e Lower control arm into the front crossmember e Rear lower control arm-to-crossmember and frame rail bolt

->DO NOT tighten the rear bolt at this time.

e Front lower control arm-to-crossmember nut and bolt 9. Torque the lower control arm fasteners to: a. Front control arm nut/bolt: 120 ft. lbs. (163 Nm) for 1998-99 models. b. Rear control arm nut/bolt: 120 ft. lbs. (163 Nm) for 1998-99 models. c. Rear pivot bolt: 150 ft. Ibs. (203 Nm) for 2000-02 models. d. Front pivot bolt: 120 ft. Ibs. (163 Nm) for 2000-02 models. 10. Install the ball joint stud into the steering knuckle. Torque the steering knuckle-to-ball joint stud pinch bolt and nut to 70 ft. Ibs. (95 Nm). 11. Assemble the stabilizer bar-to-lower control arm link assemblies and bushings. 12. Rotate the stabilizer bar into position, installing the stabilizer bar links into

Front

Rotate the hub in order to remove the lug

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove the steering knuckle and hub and bearing assembly. 3. Remove a wheel lug stud from the hub flange using a C-clamp and Adapter Tool 4150A. 4 Rotate the hub to align the removed lug stud with the notch in the bearing retainer plate. 5. Rotate the hub so the stud hole is facing away from the brake calipers lower rail on the steering knuckle.

SPECIAL TOOL 4150A

STEERING KNUCKLE

stud

STEERING

PLATE MOUNTING BOLTS 7922EG66

Proper installation of the bearing splitter

STEERING KNUCKLE

WHEEL MOUNTING STUD

WHEEL BEARING

—

Nee

ARBOR PRESS > BLOCKS 7922EG67

7922EG64

Use a proper C-clamp and adapter tool to press out one of the lug studs

Properly support the steering knuckle for

hub and bearing removal

For Tune-up, Capacities and Firing orders, see Section 1 of this manual

8-46

CHRYSLER CORPORATION NEON

a

9. Place the steering knuckle in a hydraulic press, supported by the bearing splitter. 10. Position a driver on the small end of the hub. Using the press, remove the hub from the wheel bearing. The outer bearing race will come out of the wheel bearing when the hub is pressed out of the bearing. 11. Remove the bearing splitter tool from the knuckle. 12. Place the knuckle in a press supported by the press block. The blocks must not obstruct the bore in the steering knuckle so the wheel bearing can be pressed out of the knuckle. Place a driver on the outer race of the wheel bearing, then press the bearing out of the knuckle. 13. Install the bearing splitter on the hub. The splitter is to be installed on the hub so it is between the flange of the hub and the bearing race on the hub. Place the hub, bearing race and splitter in a press. Use a driver to press the hub out of the bearing race. To install: 14. Use clean, dry cloth to wipe and grease or dirt from the bore of the steering knuckle. 15. Clean the rust preventative from the replacement wheel bearing using a clean, dry towel. 16. Place the new wheel bearing into the bore of the steering knuckle. Be sure the bearing is placed squarely into the bore. Place the knuckle in a press with a receiver tool, C-4698—2 supporting the steering knuckle. Place a driver tool on the outer race of the wheel bearing. Press the wheel bearing into the steering knuckle until it is fully bottomed in the bore of the steering knuckle.

e>Only the original or original equipment replacement bolts should be used to mounting the bearing retainer to the knuckle. If a bolt requires replacement when installing the bearing retainer plate, be sure to get the proper type of replacement.

17. Install the bearing retainer plate on the steering knuckle. Install the 3 bearing retainer mounting bolts. Tighten the bolts to 21 ft. Ibs. (28 Nm). 18. Install the removed wheel lug stud into the hub flange. 19. Place the hub with the lug stud installed, in a press supported by Adapter Tool C-4698—1. Press the wheel lug stud into the hub flange until it is fully seated against the back side on the hub flange. 20. Place the steering knuckle with the wheel bearing installed, in a press with special Receiver Tool MB-990799 supporting the inner race of the wheel bearing. Place the hub in the wheel bearing, making sure it is square with the bearing. Press the hub into the wheel bearing until it is fully bottomed in the wheel bearing. 21. Install the steering knuckle and the wheel. 22. Check and/or adjust the front alignment. Rear

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Wheel e Rear brake drum, if equipped ¢ Caliper (suspend on a wire) and the rotor, if equipped with rear disc brakes

ck WARNING DO NOT allow the caliper to hang by the brake hose.

e Dust cap from the rear hub/bearing ¢ Hub/bearing assembly-toknuckle/spindle nut ->Discard the hub nut and replace with a new one during installation.

¢ Hub/bearing from the spindle by pulling it off the end of the spindle by hand To install:

The hub/bearing nut must be tightened to, but NOT over, its specified torque value. The proper specification is crucial to the life of the hub bearing.

3. Position the hub/bearing assembly on the rear spindle/knuckle. Install a NEW hub nut and tighten to 160 ft. Ibs. (217 Nm). 4. Install or connect the following: e Dust cap and seat it using a soft face hammer to carefully tap it into place e Brake drum, if equipped with drum brakes e Rotor, if equipped with disc brakes e Caliper and 2 guide pin bolts, if equipped with disc brakes. Tighten the bolts to 16 ft. Ibs. (22 Nm). 5. Install the wheel and tire assembly. Tighten the lug nuts in a crisscross pattern, to 100 ft. Ibs. (135 Nm) for 1998-99 or 95 ft. Ibs. (128 Nm) for 2000-02.

CHRYSLER CORP. 1998-02 Chrysler-Cirrus * Sebring Convertible * Dodge-Stratus * Plymouth-Breeze ENGINE REPAIR.................. 9-2 DRIVE TRAIN ................... 9-42 FUELSSYSTEM Aah. ceerre 9-39 PRECAUTIONS 42227, aie 9-2 STEERING AND SUSPENSION .................. 9-51 A VIS BSG * oa Sate a os RAR el ten a 9-51 LASTLY sires laaad ia a 9-51 Ee AUWNO Sree gat set nos ecce: 9-51 ETRE eS Oo a ee 9-3 asiaOW Ge Seach etitict ct eae 9-4 FRCUIVOMA ieee erat ed. ina dlgven aancee 9-3

Exhalist anol dssasticattespesscnten 9-25 Removal & Installation.............. 9-25 F Front Crankshaft Seal... 9-26 Removal & Installation.............. 9-26 PUGHEI TS Me reeenten ak scaca tent ar9-39 Removal & Installation.............. 9-39 Fuel lneGtO mien vere arer ent! 9-41 Removal & Installation.............. 9-41 Fuel Picea eccern test eer ai te 9-40 Removal & Installation... 9-40 Fuel. System PreSSure 2 fecus.eccesche 9-39 Relie Wing sts Pat trek eee. Aor. 9-39

Sprockets And Covers... 9-37 Removal & Installation.............. 9-37

HallSMatts eneeth ac etree 9-46

B Balance Shaft Chain,

C

Fuel System Service Precaullonsrecseier eerie! 9-39 Removal & Installation............. 9-46

ESiSlidiimters bate pe Ain eld. 9-28 Removal & Installation.............. 9-28 is(Ups dail ee oe Sa eee 9-45 re tee. eect 9-45 AUUStiMeiioeers Removal & Installation............. 9-45

| [gnition TimitiGt See ee, 9-4 AGHUSHTION ann. aterwencot scot. 9-4 ee teetese 9-20 Nake MiaITTOIC rset Removal & Installation.............. 9-20

Removal & Installation.............. 9-54

Lower Ball Joint.......... gins tate es 9-55

Pots RC rene eee hte, cores > 9-54 Adhne nccssat 9-47

CHGS

Aer ael et ee ae

steal

h

Removal & Installation............... 9-59

9-47

Lower Control AMM .......ceeeeees 9-57

Gylinidet i eathes of os. csoumeenaee 9-11 Removal & Installation............. 9-11

Control Arm Bushing Replacementcccsrcctetsintestsstaus. 9-9/

Removal & Installation.............. 9-57

D

DSC lare mater teteome ocak 9-2 BS tatatiOMAseh ALI Let: g-2 re Mee cas9-2 Barca |iateinrou

EAU ASSEMIDI Ve eat cteee saan 9-4 Removal & Installation.............. 9-4

Oil Ranma

0 Saleen: Sores eta: 9-33

Removal & Installation.............. orooke

OEP

Dee ee eile: 9-35 Removal & Installation.............. 9-35

P

PIStON ANG :HING! wAGhs Bates oeeee POSITIONING nets cement a Power Rack and Pinion SleeringGeal. envi wta cee Removal & EO Wee ae

9-38 9-38

9-51 9-51

RearMainisealy .ancteeaemeee9-37 Removal & Installation... 9-37 ROCKeLANMY/SIait® =. eens te9-18 Removal & atl Ret eee 9-18 SHOCK ADSONDGL Beeatce wee eee, 9-54 Removal & Installation... 9-54 State mA Gt Ot wed ateere cobaltetic9-32 Removal & Installation... 9-32 SITU ss tac Si nnies Seabee fale 9-52 Removal & Installation... 9-52

Transaxle ASSEMDIY .......ceeeeeee 9-42 Removal & Seu Re ee 9-42

Upper Bal Glia

teen

mentee 9-55

Removal & Installation.............. 9-55

Upper GOntrOl AN tre nrc.mee 9-55 Removal & fete a A ete. 9-55 Valve: eaST erent alo 2eee 9-32 ACHUSITICNUE: so pstacet orteeeaeineee 9-32 W Water Pung See ee omens 9-9 Removal & Installation... 9-9 Wheel BearindSf.:cntcmmeene: 9-59

ACIUSUNCNL Ae ot tthe comer eee 9-59 Removal & Installation.............. 9-59

9-2

CHRYSLER CORP.

CIRRUS ¢ SEBRING CONVERTIBLE ¢ STRATUS ¢ BREEZE

Before servicing any vehicle, please be Sure to read all of the following precautions. The following precautions deal with personal safety, preventing of component damage, and important points to take into consideration when servicing a motor vehicle: e Never open, service or drain the radiator or cooling system when the engine Is hot; serious burns can occur from the steam and hot coolant. e Observe all applicable safety precautions when working around fuel. Whenever servicing the fuel system, always work ina well-ventilated area. Do not allow fuel spray or vapors to come in contact with a spark, open flame or excessive heat (a hot drop light, for example). Keep a dry chemical fire extinguisher near the work area. Always keep fuel in a container specifically designed for fuel storage; also, always properly seal fuel containers to avoid the possibility of fire or explosion. Refer to the additional fuel system precautions later in this section. e Fuel injection systems often remain pressurized, even after the engine has been turned OFF. The fuel system pressure must be relieved before disconnecting any fuel lines. Failure to do so may result in fire and/or personal injury. e Brake fluid often contains polyglycol ethers and polyglycols. Avoid contact with the eyes and wash your hands thoroughly after handling brake fluid. If you do get brake fluid in your eyes, flush your eyes with clean, running water for 15 minutes. If eye irritation persists, or if you have taken

PRECAUTIONS

;

brake fluid internally, IMMEDIATELY seek medical assistance. e The EPA warns that prolonged contact with used engine oil may cause a number of skin disorders, including cancer! You should make every effort to minimize your exposure to used engine oil. Protective gloves should be worn when changing the oil. Wash your hands and any other exposed skin areas as soon as possible after exposure to used engine oil. Soap and water, or waterless hand cleaner should be used. e All vehicles are equipped with an air bag system, often referred to as a Supplemental Restraint System (SRS) or as a Supplemental Inflatable Restraint (SIR) 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 unnec-

You should always buy the grade of fluid recommended for your vehicle. If the brake fluid becomes contaminated, drain and flush the system, then refill the master cylinder with new fluid. Never reuse any brake fluid. Any brake fluid that is removed from the system should be discarded. Also, do not allow any brake fluid to come in contact with a painted surface; it will damage the paint. ¢ Never operate the engine without the proper amount and type of engine oil; doing so WILL result in severe engine damage.

essary system repairs. e Always wear Safety goggles when working with, or around, the air bag system. When carrying a non-deployed air bag, be sure the bag and trim cover are pointed away from your body. When placing a nondeployed air bag on a work surface, always face the bag and trim cover upward, away from the surface. This will reduce the motion of the module if it is accidentally deployed. ¢ Clean, high quality brake fluid from a sealed container is essential for the safe and proper operation of the brake system.

e Timing belt maintenance is extremely important! Many models may utilize an interference-type, non-free-wheeling engine. If the timing belt breaks, the valves in the cylinder head may strike the pistons, causing potentially serious (also time-consuming and expensive) engine damage. Refer to the maintenance interval charts in the front of this manual for the recommended replacement interval for the timing belt, and to the timing belt section for belt replacement and inspection. e Disconnecting the negative battery cable on some vehicles may interfere with the functions of the on board computer system(s) and may require the computer to undergo a relearning process once the negative battery cable is reconnected. ¢ When servicing drum brakes, only disassemble and assemble one side at a time, leaving the remaining side intact for reference. ¢ Only an MVAC-trained, EPA-certified, automotive technician should service the air conditioning system or its components.

ENGINE REPAIR Distributor

REMOVAL 2.5L Engine

The 2.5L engine is equipped with a camshaft driven mechanical distributor. This engine uses a fixed ignition timing system. The basic ignition timing is not adjustable. The Powertrain Control Module (PCM) determines spark advance. The Crankshaft Position (CKP) sensor and Camshaft Position (CMP) sensor are Hall Effect devices. The CKP sensor is mounted remotely from the distributor while the CMP sensor is mounted inside the distributor housing. Both sensors generate pulses that are

inputs to the PCM. The PCM determines crankshaft position from these sensors. The PCM calculates injector sequence and ignition timing. There is a resistor built into the distributor cap. An ohmmeter connected between the center button and ignition coil terminal should read 5000 ohms. 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following; ¢ Negative battery cable from the left shock tower e>The ground cable is equipped with an insulator grommet which should be placed on the stud to prevent the negative battery cable from accidentally grounding.

Air inlet resonator-to-intake manifold bolt Air cleaner cover-to-air cleaner housing clamp Positive Crankcase Ventilation

(PCV) air hose from the air inlet tube

Exhaust Gas Recirculation (EGR) tube

Spark plug wires from the distributor cap Distributor cap e>Wlark the rotor position. A scribe mark indicates where to position the rotor when reinstalling the distributor. e Rotor ¢ Both electrical connectors from the distributor

CHRYSLER CORP.

CIRRUS ¢ SEBRING CONVERTIBLE e STRATUS ¢ BREEZE e Distributor hold-down nuts and washers e Spark plug cable mounting bracket e Transaxle dipstick tube e Distributor

e e e e

PCV hose Air cleaner Air inlet resonator Negative battery cable

Alternator

INSTALLATION

REMOVAL

Timing Not Disturbed 1. Inspect the rotor for cracks or a burned electrode. Replace if defective. 2. Install or connect the following: e Rotor onto the distributor e New O-ring on the distributor 3. Carefully, engage the distributor drive with the slotted end of the camshaft. When the distributor is installed properly, the rotor will be aligned with the previously made mark. 4. Verify proper rotor alignment with mark made at disassembly. 5. Install or connect the following: Distributor hold-down nuts and washers. Torque the nuts to 108 inch lbs. (13 Nm). Spark plug cable bracket Both distributor wiring connectors Distributor cap Spark plug cables Transaxle dipstick tube EGR tube. Torque the bolts to 95 inch Ibs. (11 Nm). PCV hose Air cleaner Air inlet resonator Negative battery cable

Timing Disturbed 1. Rotate the crankshaft until No. 1 piston is at Top Dead Center (TDC) of its compression stroke. 2. Rotate the rotor to the No. 1 terminal position on the distributor cap. 3. Lower the distributor into place, engaging the distributor drive with the drive on the camshaft. With the distributor fully seated on the engine, the rotor should be under the No. 1 terminal. 4. Install or connect the following: Distributor hold-down nuts and washers. Torque the nuts to 108 inch Ibs. (13 Nm). Spark plug cable bracket Both distributor wiring connectors Distrioutor cap Spark plug cables Transaxle dipstick tube EGR tube. Torque the bolts to 95 inch Ibs. (141 Nm).

2.0L 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 from the shock tower Belt cover Alternator electrical connectors Alternator adjusting and pivot bolts, loosen them Alternator drive belt Alternator adjusting and pivot bolts, do not drop the pivot bolt's spacer Alternator, by moving it toward the head light bucket area

2.4L Engine (VIN G) 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Negative battery cable from the shock tower Alternator electrical connectors Alternator adjusting and pivot bolts, loosen them Alternator drive belt Alternator adjusting and pivot bolts Anti-lock Brake System (ABS) braking unit, by removing the 2 lower plate mounting bolts Coolant overflow bottle Alternator, by moving it under the refrigerant lines toward the passenger's side

9-3

e Accessory belt e Manifold Absolute Pressure (MAP) sensor from the intake manifold e Alternator

2.9L Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Negative battery cable from the shock tower e Alternator electrical connectors e Upper mounting ear, pivot and idler adjusting bolts, loosen them

9306FG04

Exploded view of the alternator and related components—2.0L engine

9306FG05

Exploded view of the alternator and related components—2.4L engine

2.4L Engine (VIN X) 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Negative battery cable from the shock tower e Accessory belt cover e Alternator electrical connectors ¢ Accessory belt splash shield

9306FG06

Exploded view of the aiternator and related components—2.5L engine

For complete service labor times, order Nichols’ Chilton Labor Guide

Q-4

CHRYSLER CORP

CIRRUS e SEBRING CONVERTIBLE ¢ STRATUS ¢ BREEZE

e Alternator drive belt e Alternator pivot bolt, do not drop the spacer e Upper mounting ear bolt e Upper alternator bracket e Alternator 2.7L 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 from the shock tower Accessory belt splash shield and loosen the belt Alternator electrical connectors A/C pressure switch and clutch electrical connectors Engine oil dipstick Alternator

e Alternator drive belt

2. Using a Belt Tension Gauge, adjust the drive belt tension to 80 Ibs. for a used belt or 150 Ibs. for a new belt. 3. Install or connect the following: e Alternator adjusting and pivot bolts.

Torque the bolts to 40 ft. Ibs. (54 Nm). e Alternator electrical connectors Negative battery cable to the shock tower

2.4L Engine (VIN X) 1. Install or connect the following: e Alternator and torque the bolts to 33 ft. Ibs. (44 Nm) e MAP sensor e Drive belt and splash shield e Alternator electrical connectors e Accessory belt cover e Negative battery cable

3.0L Engine

2.5L Engine

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Negative battery cable e Drive belt e Alternator belt Oil level gauge unit Alternator electrical connectors Alternator brace Alternator

1. Install or connect the following: e Alternator and torque the bolts to 25 ft. Ibs. (33 Nm) e Upper alternator bracket e Upper mounting ear and pivot bolt, do not tighten e Alternator drive belt 2. Using a Belt Tension Gauge, adjust the drive belt tension to 80 Ibs. for a used belt or 150 Ibs. for a new belt. 3. Install or connect the following: e Upper mounting ear and pivot bolts. Torque the bolts to 40 ft. Ibs. (54 Nm). e Alternator electrical connectors ¢ Negative battery cable to the shock tower

INSTALLATION 2.0L Engine 1. Install or connect the following: e Alternator e Alternator drive belt 2. Using a Belt Tension Gauge, adjust the drive belt tension to 80 Ibs. for a used belt or 150 Ibs. for a new belt. 3. Install or connect the following: e Alternator adjusting and pivot bolts. Torque the bolts to 40 ft. Ibs. (54 Nm). e Alternator electrical connectors e Belt cover e Negative battery cable to the shock tower

2.4L Engine (VIN G) 1. Install or connect the following: ¢ Alternator ¢ Coolant overflow bottle e ABS)braking unit. Torque the 2 lower plate mounting bolts to 21 ft. lbs. (28 Nm)

2.7L Engine 1. Install or connect the following: ¢ Alternator and torque the bolts to 40 ft. Ibs. (64 Nm) Engine oil dipstick tube A/C pressure switch and clutch electrical connectors Alternator electrical connectors Drive belt and splash shield Negative battery cable

Alternator belt e Drive belt e Negative battery cable

Ignition Timing ADJUSTMENT These engines use a fixed ignition system. The Powertrain Control Module (PCM) regulates the ignition timing. Basic ignition timing is not adjustable.

Engine Assembly REMOVAL & INSTALLATION 2.0L, 2.4L (VIN G) and 2.5L Engines 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Relieve the fuel system pressure using the recommended procedure. Disconnect the fuel line quick-connect fitting from the fuel rail by squeezing the retainer tabs together and pulling the fuel tube/quickconnect fitting assembly off the fuel tube nipple. 3. Drain the engine oil. 4. Drain the cooling system. 5. Recover the A/C refrigerant. 6. Place.the ignition switch in the OFF unlocked position and turn OFF all accessories. 7. Turn the steering wheel to the extreme left position. 8. Remove or disconnect the battery and battery tray as follows: ¢ Negative battery cable from the left shock tower The ground cable is equipped with an insulator grommet which should be placed on the stud to prevent the nega-

RIGHT ENGINE SUPPORT ASSEMBLY

: :

®

3.0L Engine 1. Install or connect the following: e Alternator and torque the bolts to 33 ft. Ibs. (44 Nm) ¢ Alternator brace and torque the bolts to 36 ft. Ibs. (49 Nm) ¢ Qil level gauge unit and torque the bolt to 10 ft. Ibs. (15 Nm)

& 45 FT. (BS. (61N-M) 7922FG01

Exploded view of the right side engine mount—all engines

CIRRUS © SEBRING CONVERTIBLE

|< | 61 Nem (45 ft. Ibs.) 33 Nem (24 ft. lbs.) TRANSMISSION SUPPORT ASSEMBLY

LEFT FRAME RAIL

cre

_ TRANSMISSION

TRANSMISSION BRACKET

LE

DO NOT reattach the negative battery cable remote connection to the left shock tower at this time.

e e e e

Shield PCM Air cleaner Air inlet duct 15. Recharge the air conditioning system.

16. Check to be sure all ducts, hoses, STRUT P/S BRACKET

ENGINE SUPPORT MOOULE

7922FG04

Exploded view of the rear engine mounting torque bracket—2.0L engine

e e e e

Ground straps Throttle body electrical connectors Throttle body linkage Radiator, cooling fan/shroud assembly and hoses e Transaxle cooler lines to the radiator, if equipped 12. Fill the cooling system. 13. Install a new oil filter and refill the crankcase, if drained. 14. Install or connect the battery tray and the battery as follows: e Battery strap and battery tray Battery blanket heater, if equipped

e Battery ¢ Hold-down bracket and battery strap-to-hold-down bracket bolts. Torque the battery hold-down bracket bolt to 10 ft. Ibs. (14 Nm) e Battery cables. Torque the cables to 13 ft. Ibs. (17 Nm) red

FRONT TORQUE BRACKET

fuel lines and wiring connectors have been properly reattached. 17. Start the engine, check for oil pressure, and run until operating temperature is reached. 18. Check for leaks and proper operation.

2.4L (VIN X) Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Properly relieve the fuel system pressure. 3. Drain the engine oil. 4. Drain the cooling system. 5. Recover the A/C refrigerant. 6. Remove or disconnect the following: Negative battery cable Throttle body air inlet hose Air cleaner assembly Upper radiator crossmember Upper and lower radiator hoses Transmission cooler lines

A/C lines at the condenser Radiator, fan module and A/C condenser Transmission electrical harness A/C COMPRESSOR

STRUT (SOME MODELS) 7922FG05

Exploded view of the rear engine mounting torque bracket—2.4L and 2.5L engines

7922FG06

Exploded view of the front engine mounting torque bracket—2.0L and 2.4L

connectors Transmission shift cable Engine electrical harness from the Powertrain Control Module (PCM) and bulkhead Both front wheels and splash shields

CIRRUS © SEBRING CONVERTIBLE Both halfshafts Drive belts Power steering pump from the bracket and move it aside Heater return hose from the right front frame rail A/C compressor electrical connectors Exhaust pipe from the manifold Through bolts from the front and rear engine mounts Rear mount bracket from the transmission Structural collar and torque reaction bracket Torque converter bolts after matchmarking them Positive battery cable from the battery and the Power Distribution Center (PDC) Ground cable from the left side transmission mount bracket Throttle and speed control cables Coolant overflow hose Heater hose from the thermostat housing Engine ground straps

Brake booster and vacuum purge hoses Fuel lines from the rail Intake manifold Alternator A/C suction line from the compressor and place an engine dolly and cradle in position 7. Loosen the cradle engine mounts and lower the engine/transmission assembly onto the dolly. 8. Remove the vertical engine mount bolts 9. Slowly raise the vehicle and make certain that the cradle is positioned properly. 10. Secure the engine/transmission assembly to the cradle and remove the assembly. To install: 11. Position the engine/transmission assembly under the vehicle and slowly lower the vehicle into position. 12. Continue to the lower the vehicle until the right side engine mount and left side transaxle mount are properly aligned.

ESR TH

EGR ERONRIKE ctmia yee

FS

LS

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|

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FRONT VIEW

93461G01

Place the engine/transmission assembly on the cradle as shown

CHRYSLER CORP.

STRATUS ¢ BREEZE

9-7

13. Install or connect the following: Mounting bolts and torque them to 45 ft. Ibs. (61 Nm). Raise the vehicle and remove the cradle A/C compressor and suction line Alternator Intake manifold and torque the bolts to 105 inch Ibs. (12 Nm) Alternator electrical connectors Fuel line to the rail Brake booster and vacuum purge hoses Engine ground straps Heater hose to the thermostat housing Coolant overflow hose Throttle and speed control cables Ground cable to the left side transmission mount bracket Positive battery cable to the PDC Torque converter bolts Structural collar and the torque reaction bracket Rear mount bracket to the transmission Front and rear engine mount through bolts. Torque the bolts to A5 ft. Ibs. (61 Nm) Exhaust pipe to the manifold and torque the bolts to 21 ft. Ibs. (28 Nm) A/C compressor electrical connectors Heater return hose to the right front frame rail Power steering pump to the bracket Drive belts Both halfshafts Splash shields and front wheels Engine electrical harness to the PCM and the bulkhead connectors Transmission shift cable Transmission electrical connectors Radiator, fan module and A/C condenser A/C lines to the condenser Transmission cooler lines Upper and lower radiator hoses Upper radiator crossmember Air cleaner assembly Throttle body air inlet hose Negative battery cable 14. Fill the engine with clean oil. 15. Fill the cooling system to the proper level. 16. Recharge the A/C system. 17. Start the vehicle, check for leaks and repair if necessary.

Timing belt service is covered in Section 3 of this manual

9-8

CHRYSLER CORP.

CIRRUS ¢ SEBRING CONVERTIBLE ¢ STRATUS e BREEZE

2.7L Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Properly relieve the fuel system pressure. 3. Drain the engine oil. 4. Drain the cooling system. 5. Recover the A/C refrigerant. 6. Remove or disconnect the following: Negative battery cable Throttle body air inlet hose Air cleaner assembly Both front wheels and splash shields Lower front fascia from the crossmember Lower air shield from the crossmember Front fascia Upper radiator crossmember Upper and lower radiator hoses Transmission oil cooler lines A/C lines from the condenser. Radiator, fan and A/C condenser Transmission electrical harness connectors Transmission shift cable

Engine electrical harness from the Powertrain Control Module (PCM) and bulkhead connectors

Antilock Brake System (ABS) brake module from the lower radiator crossmember Brake line from the lower radiator crossmember Both halfshafts Front engine mount through bolt

Front engine mount from the lower radiator crossmember Lower radiator crossmember Drive belts Power steering pump and bracket. Do not disconnect the lines

Heater return hose from the right front frame rail

A/C compressor electrical connectors and reposition the compressor Structural collar Exhaust system cross under pipe Rear engine mount and transaxle bracket Torque converter housing cover and match mark the bolts Positive battery cable from the Power Distribution Center (PDC) Ground cable from the left side transaxle mount bracket Throttle and speed control cables Coolant overflow hose Heater hose

_

e Ground strap from the right shock tower e Fuel lines e Brake booster and vacuum purge hoses e Engine ground straps 7. Loosen the cradle engine mounts and lower the engine/transmission assembly onto the dolly. 8. Remove the vertical engine mount bolts 9. Slowly raise the vehicle and make certain that the cradle is positioned properly. 10. Secure the engine/transmission assembly to the cradle and remove the assembly. To install: 11. Position the engine/transmission assembly under the vehicle and slowly ~ lower the vehicle into position. 12. Continue to the lower the vehicle until the right side engine mount and left side transaxle mount are properly aligned. 13. Install or connect the following: Mounting bolts and torque them to 45 ft. Ibs. (61 Nm). Raise the vehicle and remove the cradle Engine ground straps Brake booster and vacuum purge hoses Fuel lines Ground strap to the right shock tower Heater hose

Coolant overflow hose Throttle and speed control cables

Ground cable to the left transaxle mount bracket Positive battery cable to the PDC Torque converter bolts and cover Rear engine mount and transaxle bracket Exhaust system cross under pipe

Structural collar A/C compressor to the bracket A/C compressor clutch electrical connectors Heater return hose to the right side frame rail

Power steering pump and bracket Drive belts Lower radiator crossmember

Front engine mount to the lower radiator crossmember Both halfshafts Brake line to the lower radiator crossmember ABS module to the lower radiator crossmember Engine electrical harness to the PCM and bulkhead connectors

e Transmission shift cable e Transmission electrical harness connectors

Radiator, fan and A/C condenser A/C lines to the condenser Transmission oil cooler lines Upper and lower radiator hoses Upper radiator crossmember Front bumper fascia and lower air shield e Splash shields and both front wheels Air cleaner assembly and throttle body air inlet hose Negative battery cable 14. Fill the engine with clean oil and replace the filter. 15. Fill the cooling system to the proper level. 16. Recharge the A/C system with the proper refrigerant. 17. Start the vehicle, check for leaks and repair if necessary.

3.0L Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Properly relieve the fuel system pressure. 3. Drain the engine oil. 4. Drain the cooling system.

5. Recover the A/C refrigerant. 6. Remove or disconnect the following: Hood Negative battery cable Strut tower bar Air cleaner Radiator reservoir tank Front exhaust pipe Throttle cable Manifold differential pressure sensor connector Control wiring harness and power steering wiring harness combination connector Exhaust Gas Recirculation (EGR) valve connector Evaporative (EVAP) Emission purge solenoid valve connector Knock Sensor (KS) connector Crankshaft Position (CKP) sensor connector Right bank Heated Oxygen Sensor

(H 0 2S)

Fuel injector connector Distributor connector Control wiring/injector wiring harness combination connector

Throttle Position Sensor (TPS) connector

CHRYSLER CORP.

CIRRUS ¢ SEBRING CONVERTIBLE ¢ STRATUS ¢ BREEZE Idle Air Control (IAC) motor con-

Control wiring harness and power steering harness combination con-

nector

Ground wire Engine Coolant Temperature (ECT) gauge unit ECT sensor connector Left bank Heated Oxygen Sensor (H

0 2S) e ¢ e e e e e e ¢ e

Brake booster vacuum hose Fuel supply and return hoses Heater hoses Starter electrical connectors Oil Pressure switch Alternator wiring Drive belts A/C compressor Power steering pressure switch Power steering oil pump. Do not disconnect the hose e Engine mount stay and install an engine lifter, such as MZ203827 e Engine mount bracket and stopper e Engine assembly To install: 7. Install or connect the following: Engine assembly Engine mount bracket and stopper. Torque the bolts to 60 ft. Ibs. (81 Nm) Engine mount stay and torque the bolts to 26 ft. Ibs. (35 Nm). Remove the engine lifting devise Power steering oil pump and torque the bolts to 31 ft. Ibs. (42 Nm) Power steering pressure switch A/C compressor Drive belts Alternator wiring Oil pressure switch Starter electrical connectors Heater hoses Fuel supply and return lines Brake booster vacuum hose Left bank (H O 2S) ECT sensor connector ECT gauge unit Ground wire IAC motor electrical connector TPS connector Control wiring/injector wiring harness combination corinector Distributor connector Fuel injector connector Right bank (H O 2S) CKP sensor connector KS connector EVAP solenoid valve connector EGR valve connector

e Accessory drive belts and support the engine e Right motor mount ¢ Power steering pump bracket bolts and move the pump/bracket assembly aside

nector

Manifold differential Pressure sensor connector Throttle cable Front exhaust pipe Radiator reservoir tank Air cleaner Strut tower bar Negative battery cable Hood and adjust as needed 8. Fill the engine with clean oil and replace the filter 9. Fill the cooling system to the proper level.

10. proper 11. repair

e>Do not disconnect the power steering fluid lines.

¢ Right engine mount bracket e Timing belt front covers e Timing belt tensioner and timing belt by loosening the tensioner Screws

Recharge the A/C system with the refrigerant. Start the vehicle, check for leaks and if necessary.

Water Pump

9-9

With the timing belt removed, DO NOT rotate the camshaft or crankshaft or damage to the engine could occur.

;

REMOVAL & INSTALLATION 2.0L and 2.4L (VIN X) Engines This engine uses a die-cast aluminum body water pump with a stamped steel impeller. The water pump bolts directly to the block. Cylinder block-to-water pump sealing is provided by a large rubber Oring. The water pump Is driven by the timing belt, that must be removed to service the water pump. 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Disconnect the negative battery cable from the left shock tower.

e Camshaft sprockets ->Do not allow the camshafts to turn when the camshaft sprockets are being removed.

e Rear timing belt cover e Water pump To install: 5. Thoroughly clean all sealing surfaces. Replace the water pump if there are any cracks, signs of coolant leakage from the shaft seal, loose or rough turning bearings, damaged impeller or sprocket or sprocket flange loose or damaged. 6. Install or connect the following: e New rubber O-ring into the water pump

>The ground cable is equipped with an insulator grommet which should be placed on the stud to prevent the negative battery cable from accidentally grounding. >This procedure requires removing the engine timing belt and the autotensioner. The factory specifies that the timing marks should always be aligned before removing the timing belt. Set the engine at Top Dead Center (TDC) on No. 1 compression stroke. This should align all timing marks on the crankshaft sprocket and both camshaft sprockets.

3. Drain the cooling system. 4. Remove or disconnect the following: e Right inner splash shield

7922FG08

When installing the water pump, properly install the O-ring to ensure a tight seal— 2.0L and 2.4L engines

Heater Core replacement is covered in Section 2 of this manual

9-10

CHRYSLER CORP.

CIRRUS ¢ SEBRING CONVERTIBLE ¢ STRATUS ¢ BREEZE

a

Be sure the O-ring is properly seated in the water pump groove before tightening the screws. An improperly located O-ring may cause damage to the O-ring and cause a coolant leak.

e Water pump. Torque the bolts to 105 inch Ibs. (12 Nm) 7. Pressurize the cooling system to 15 psi (103.4 kPa) and check for leaks. If okay, release the pressure and continue the engine assembly process. 8. Install or connect the following: e Rear timing belt cover ¢ Camshaft sprockets. Torque the bolts to 75 ft. Ibs. (101 Nm) ->DO NOT allow the camshafts to turn while the sprockets bolts are being tightened to maintain timing mark alignment.

Do not attempt to compress the tensioner plunger with the tensioner assembly installed in the engine. This will cause damage to the tensioner and other related components. The tensioner MUST be compressed in a vise. e Timing belt tensioner and timing belt. Properly tension the timing belt. Front upper and lower timing belt covers Right engine mount bracket and engine mount Crankshaft damper. Torque the center bolt to 105 ft. Ibs. (142 Nm) Right inner splash shield Power steering pump bracket and power steering pump. Torque the bracket mounting bolts to 40 ft. Ibs. (54 Nm) Accessory drive belts. Properly tension the drive belts 9. Refill and bleed the cooling system. 10. Start the engine and check for proper operation. 11. Check and top off cooling system, if necessary.

¢ Negative battery cable Timing belt tensioner pulley e Alternator brace e Water pump and discard the gasket and O-ring To install: 4. Clean all mating surfaces of any residual gasket material 5. Install or connect the following: e New O-ring gasket ¢ Water pump and torque the bolts to 117 inch Ibs. (14 Nm) e Alternator brace and torque the bolts to 17 ft. lbs. (23 Nm) e Timing belt tensioner pulley e Negative battery cable 6. Fill the cooling system to the proper level. 7. Start the vehicle, check for leaks and repair if necessary. 2.5L Engine The water pump bolts directly to the engine block using a gasket for pump-toblock sealing. The pump is serviced as a unit. The 2.5L engine uses metal piping beyond the lower radiator hose to route coolant to the suction side of the water pump, located in the “V” of the cylinder banks. These pipes also have connections for thermostat bypass and heater return coolant hoses. The pipes use O-rings for sealing. The water pump is driven by the timing belt which must be removed to service the water pump. Timing belt covers must be removed to access the timing belt. 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Disconnect the negative battery cable from the left shock tower. The ground cable is equipped with an insulator grommet which should be placed on the stud to prevent the nega-

3. Drain the cooling system. >This procedure requires removing the engine timing belt and the autotensioner. To help assure proper alignment at assembly, it may be helpful to set the engine at Top Dead Center (TDC) on No. 1 compression stroke. This should align all timing marks on the crankshaft sprocket and both camshaft sprockets.

4. Remove or disconnect the following: e Accessory drive belts e Crankshaft damper e Right engine mount by safely supporting the engine Timing belt covers, in this order: upper left, upper right and lower covers ¢ Timing belt and tensioner Water pump by separating it from the water inlet pipe To install: 5. Thoroughly clean all sealing surfaces. Inspect the pump for damage or cracks, signs of coolant leakage at the vent and excessive looseness or rough turning bearing. Any problems require a new pump. 6. Install or connect the following: e New O-ring on the water inlet pipe by wetting it with water e New-gasket on the water pump e Water pump. Torque the bolts to 20 ft. Ibs. (27 Nm) Timing belt and timing belt tensioner by adjusting tension Timing belt covers Right engine mount Crankshaft damper Accessory drive belts by adjusting tension Negative battery cable 7. Refill and bleed the cooling system. 8. Start the engine and verify proper operation.

2.7L Engine

2.4L Engine (VIN G) 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the cooling system. 3. Remove or disconnect the following:

tive battery cable from accidentally grounding.

GASKET

7922FG09

Exploded view of the water pump mounting—2.5L engine

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the cooling system. 3. Remove or disconnect the following: e Negative battery cable e Timing chain cover e Timing chain and guides ¢ Water pump and discard the gasket To install: 4. Clean all mating surfaces of any residual gasket material.

CHRYSLER CORP.

CIRRUS ¢ SEBRING CONVERTIBLE © STRATUS ¢ BREEZE 9. Install or connect the following: e Water pump with a new gasket and torque the bolts to 105 inch Ibs. (12 Nm) ¢ Timing chain guides and chain e Timing chain cover e Negative battery cable 6. Fill the cooling system to the proper level. 7. Start the vehicle, check for leaks and repair if necessary.

ROCKER SHAFT

RETAINING BOLT >

VALVE RETAINING LOCK OCKS

RETAINER SPACER

6

a )

w SPARK PLUG TUBE SEAL

9-11

TS

i

ie

IG Roe

VALVE SPRING

e i)

J

VALVE SEAL AND VALVE SPRING SEAT ASSEMBLY

3.0L Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the cooling system. 3. Remove or disconnect the following: Negative battery cable Timing belt Thermostat and bracket Water pump and discard the gasket and O-ring To install: 4. Install or connect the following: e Water pump with a new O-ring and gasket. Torque the bolts to 17 ft. Ibs. (23 Nm) Bracket. Torque the bolts to 17 ft. lbs. (23 Nm) Thermostat Timing belt Negative battery cable 5. Fill the cooling system to the proper level. 6. Start the vehicle, check for leaks and repair if necessary.

Cylinder Head

ie

REMOVAL & INSTALLATION 2.0L Engine This engine uses a Single Over Head Camshaft (SOHC) 4-valves per cylinder cross flow aluminum cylinder head. Care must be taken to be sure all valve timing marks align after cylinder head service. 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Relieve the fuel system pressure using the recommended procedure. 3. Disconnect the negative battery cable from the left shock tower. >The ground cable is equipped with an insulator grommet which should be

EXHAUST ROCKER ARM/ HYDRAULIC LASH ADJUSTER ASSEMBLY INTAKE ROCKER ARM/HYDRAULIC LASH ADJUSTER ASSEMBLY 7922FG10

Exploded view of the cylinder head and valvetrain components—2.0L engine

placed on the stud to prevent the negative battery cable from accidentally grounding.

4. Drain the cooling system. 5. Remove or disconnect the following: Air cleaner assembly All vacuum hoses and electrical connectors from the throttle body Fuel line quick-connect fitting from the fuel rail, by squeezing the retainer tabs together and pulling the fuel tube/quick-connect fitting assembly off the fuel tube nipple Throttle linkage Accessory drive belt(s) Power brake booster vacuum hose from the intake manifold Exhaust pipe from the exhaust manifold Power steering pump and move it aside Coil pack wiring connector Spark plug wires from the spark plugs Ignition coil pack Cylinder head cover Cam sensor and fuel injector wiring Intake and exhaust manifolds, if necessary Timing belt cover Timing belt Camshaft sprocket Rear timing belt cover Rocker arm/rocker arm shaft assemblies

e Cylinder head bolts e Cylinder head To install: ~The cylinder head bolts should be checked for stretching before reuse. If the thread area of the bolt is neckeddown the bolts must be replaced with new. New head bolts are recommended.

6. Thoroughly clean all parts. Clean all sealing surfaces. Use care not to scratch the aluminum cylinder head sealing surface.

Check the cylinder head for flatness using a feeler gauge and a straightedge. The cylinder head must be flat within 0.004 in. (0.1mm). 7. Check the cylinder head for cracks or other damage. 8. Install or connect the following: e New cylinder head gasket e Cylinder head 9. Be sure to oil the cylinder head bolt threads with clean engine oil. Install the cylinder head bolts, the 4.330 in. (110mm) short bolts:are to be installed in positions 7, 8, 9 and 10. Tighten the bolts in proper sequence. 10. Torque the cylinder head bolts, in sequence, using the following steps: a. Step 1: 25 ft. Ibs. (34 Nm). b. Step 2: 50 ft. Ibs. (68 Nm). c. Step 3: Again to 50 ft. Ibs. (68 Nim). d. Step 4: an additional % turn. «Do not use a torque wrench for the 4th step.

Brake service is covered in Section 4 of this manual

Q-12

CHRYSLER CORP.

IRRUS ¢ SEBRING CONVERTIBLE ¢ STRATUS ¢ BREEZE fuel lines and wiring connectors have been properly reattached. 15. Start the engine and check for leaks. Run the engine with the radiator cap off so as the engine warms and the thermostat opens, coolant can be added to the radiator. When satisfied that the cooling system is full, shut the engine OFF, install the radiator cap and allow the engine to cool. 16. With the engine cool, check all fluid levels. Add coolant and oil as required. Restart the engine and test drive the vehicle to check for proper operation.

2.4L Engine (VIN X)

7922FG12

Cylinder head bolt torque sequence—2.0L engine

(I

ee

THREADS ARE NOT STRAIGHT ON LINE

STRETCHED BOLT

THREADS ARE STRAIGHT ON LINE jSi AA a

iin UNSTRETCHED

HL _——S

Huu

7922FG11

Before reusing old cylinder head bolts, check them for necking (stretching)—2.0L and 2.4L

->Be sure the cover gasket mating surfaces are clean of any dirt, oil or old gasket material. e e e ¢ e

Timing belt rear cover Camshaft sprocket Timing belt Timing belt cover Intake and exhaust manifolds, if removed

~The ground cable is equipped with an insulator grommet which should be placed on the stud to prevent the negative battery cable from accidentally grounding. 5. Remove or disconnect the follow-

ing:

BOLT

11. Set the crankshaft to 3 notches Before Top Dead Center (BTDC) before installing the rocker arm shafts. 12. Install or connect the following: e Rocker arm/rocker arm shaft assemblies e Cylinder head cover using a new gasket. Torque the bolts to 105 inch Ibs. (12 Nm).

This engine uses a Dual Over Head Camshaft (DOHC) 4-valves per cylinder cross flow aluminum cylinder head. The valves are actuated by roller cam followers which pivot on stationary hydraulic valve adjusters. Care must be taken to be sure all valve timing marks align after cylinder head and valvetrain service. 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Relieve the fuel system pressure. 3. Drain the cooling system. 4. Disconnect the negative battery cable from the left shock tower.

Cam sensor and fuel injector electrical connectors Ignition coil pack Spark plug wires Power steering pump Exhaust pipe to the exhaust manifold Brake booster vacuum line Accessory drive belts and adjust them Throttle linkage All vacuum hoses and electrical connectors to the throttle body Fuel line to the fuel rail Air cleaner assembly e Negative battery cable 13. Refill the cooling system and install a new oil filter. 14. Check to be sure all ducts, hoses,

Air cleaner assembly All vacuum lines, electrical connectors and fuel lines from the throttle body Throttle linkage Accessory drive belts Power brake vacuum hose from the intake manifold Exhaust pipe from the exhaust manifold Power steering pump and move it aside. Do not disconnect the fluid lines Spark plug wires Coil pack electrical connector Coil pack with the spark plug wires Cam sensor and fuel injector electrical connectors Timing belt covers Timing belt Camshaft sprockets Timing belt idler pulley Rear timing belt cover

CHRYSLER CORP.

CIRRUS © SEBRING CONVERTIBLE ¢ STRATUS © BREEZE e Cylinder head cover e Ground strap 6. Identify the camshafts if they are to be reused for later installation. The camshafts are not interchangeable. 7. Remove or disconnect the following: ¢ Camshaft bearing cap bolts in sequence e Camshafts e>Refer to the camshaft removal and installation procedure for correct bolt removal/installation sequence. e Camshaft followers 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 valvetrain components so they may be reinstalled correctly. e |niake and exhaust manifolds e Cylinder head bolts

e Cylinder head ->Be careful not to damage the aluminum gasket surfaces.

8. Remove all gasket material from the cylinder head and engine block. Be careful not to gouge or scratch the sealing surface of the aluminum head. The cylinder head should be checked for flatness using a good straightedge and feeler gauges. The cylinder head must be flat within 0.004 in. (0.1mm). 9. Inspect the camshaft bearing oil feed holes in the cylinder head for clogging. Inspect the camshaft bearing journals for wear or scoring. Check the cam surface for abnormal wear and damage. A visible worn

groove in the roller path or on the cam lobes is cause for replacement. Valve service may be performed at this time. To install: 10. Thoroughly clean all parts. >The cylinder head bolts are stretchtype. New cylinder head bolts are recommended.

11. Thoroughly clean all sealing surfaces. 12. Install or connect the following: e New cylinder head gasket e Cylinder head 13. Before installing the bolts, the threads should be oiled with clean engine oil. 14. Torque the cylinder head bolts in sequence, using the following 4 Steps: a. Tighten all bolts to 25 ft. Ibs. (34 Nm). b. Tighten all bolts to 50 ft. Ibs. (68 N m). c. Tighten all bolts again to 50 ft. Ibs. 8 Nm). d. Tighten all bolts and additional % turn. ->Do not use a torque wrench for the 4th step.

15. Check the camshaft end-play using the recommended procedure, then install the camshaft. 16. Apply Mopar Gasket Maker sealer to the No. 1 and No. 6 bearing caps. Install the bearing caps and tighten the M8 fasteners to 21 ft. Ibs. (28 Nm). The end caps must be installed before the seals may be installed. 17. Apply a light coating of clean engine oil to the lip of the new camshaft seal.

9-13

Install the camshaft seal until it fits flush with the cylinder head. 18. Install or connect the following: e Camshaft sprockets, if removed e Rear timing belt cover e Timing belt and properly align the timing marks e Timing belt cover

Verify that all timing marks are correct. If the timing belt or sprockets are incorrectly installed, engine damage will occur. Take time to be sure all timing marks are correctly aligned. e Intake and exhaust manifolds e New cylinder head cover gasket e Cylinder head cover

DO NOT allow oil or solvents to contact the timing belt as they can deteriorate the rubber and cause tooth skipping. Apply Mopar Silicone Rubber Adhesive Sealant at the camshaft cap corners and at the top edge of the ’2 round seal.

19. Torque the cylinder head cover fasteners, in Sequence, using the following Steps: a. Step 1: 40 inch Ibs. (4.5 Nm). b. Step 2: 80 inch Ibs. (9 Nm). c. Step 3: 105 inch Ibs. (12 Nm). 20. Install or connect the following: Ground strap Coil pack and spark plug wiring Cam sensor and fuel injector wiring Power steering pump assembly Exhaust pipe to the exhaust manifold All vacuum lines and electrical connectors Throttle linkage and fuel lines Accessory drive belts and adjust them Negative battery cable 21. Refill the cooling system. e>An oil and filter change is recommended since coolant can enter the oil system when a head is removed.

7922FG13

Cylinder head boit torque sequence—2.4L (VIN X) engine

22. Connect the remaining air ducting. Test run vehicle. Check for leaks and for proper operation.

For complete Engine Mechanical specifications, see Section 1 of this manual

CHRYSLER CORP. 9-1 4

CIRRUS ¢ SEBRING CONVERTIBLE © STRATUS ¢ BREEZE e Idle Air Control (IAC) motor con-

2.4L Engine (VIN G) 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Relieve the fuel system pressure. 3. Drain the cooling system. 4. Drain the engine oil. 5. Remove or disconnect the following: Negative battery cable Strut tower bar Air cleaner assembly Thermostat case Front exhaust pipe Accelerator cable Purge hose Brake booster vacuum hose Ignition coil Fuel injector electrical connector Ignition failure sensor connector Manifold differential pressure sensor connector Throttle Position Sensor (TPS) connector Heated Oxygen Sensor (H O 2S) connector Capacitor connector

Engine Coolant Temperature (ECT) sensor Camshaft Position (CMP) sensor

nector

Evaporative (EVAP) emission purge solenoid valve Exhaust Gas Recirculation (EGR) valve Fuel supply and return hoses Pressure hose Oil dipstick and guide Ignition coil and spark plug cables Upper radiator hose Positive Crankcase Ventilation (PCV) hose Breather hose e Rocker arm cover e Spark plug guide oil seal e Water hose e Timing belt e Power steering pressure switch ¢ Power steering pump and bracket e Exhaust manifold bracket e Cylinder head and discard the gasket To install: 6. Clean all mating surfaces of any residual gasket material. 7. Lubricate the threads of the cylinder head bolts with clean engine oil. 8. Install or connect the following: e Cylinder head with a new gasket

9. Torque the bolts, at a 90 degree angle with special Tool MB991654, using the following procedure: . Step 1: 58 ft. Ibs. (79 Nm). . Step 2: Fully loosen all the bolts. _ Step 3: 15 ft. Ibs. (20 Nm). . Step 4: An additional 90 degrees. . Step 5: An additional 90 degrees. o eDdDdDoan Exhaust manifold bracket and torque the bolts to 26 ft. Ibs. (35 Nm) Power steering pump and bracket Power steering pressure switch Timing belt Water hose Spark plug guide oil seal Rocker arm cover Breather and PCV hoses Upper radiator hose Ignition coil and spark plug cables Pressure hose Oil dipstick and tube. Torque the bolt to 177 inch Ibs. (14 Nm). Fuel return and supply hoses EGR solenoid valve EVAP purge solenoid valve IAC motor connector CMP sensor ECT sensor Capacitor H 0 2S connector TPS connector Manifold differential pressure sensor connector Ignition failure sensor connector Ignition coil connector Brake booster vacuum hose Purge hose Accelerator and adjust as needed Front exhaust pipe Thermostat case Air cleaner

Strut tower bar Negative battery cable 10. Fill the cooling system to the proper

INTAKE SIDE

—

FRONT OF ENGINE

level, 11. Fill the engine with clean oil. 12. Start the vehicle, check for leaks and repair if necessary.

2.5L Engine

EXHAUST SIDE 93461G02

Cylinder head bolt torque sequence—2.4L (VIN G) engine

This engine uses aluminum alloy cylinder heads with 4-valves per cylinder and pressed-in cast iron valve guides. The cylinders are common to either cylinder bank. Two overhead camshafts are supported by 4 bearing journals which are part of the head with the distributor driven off the right (firewall side) cylinder head. Right and left camshaft drive sprockets are inter-

/

9-15

CHRY

CIRRUS ¢ SEBRING CONVERTIBLE e file? ese BREATHER HOSE

CYLINDER HEAD

PCV VALVE

CYLINDER CAMSHAFT (RIGHT SIDE}

THRUST CASE

INTAKE ROCKER ARM SHAFT

Wi \a O-RING

CAMSHAFT

{LEFT SIDE)

INTAKE EXHAUST ROCKER ARM SHAFT

V4

Xe Sog

SPRING

°°,

S

SEAL

7

~

Valvea

SPRING SEAT Lf VALVE

SEAL

SPRING RETAINER

QBS

EXHAUST ROCKER ARM HYDRAULIC LASH ADJUSTER 7922FG14

Exploded view of the cylinder head, camshafts and rocker assemblies—2.5L engine

changeable. The sprockets and engine water pump are driven by the timing belt. Care must be taken to be sure all valve timing marks align after cylinder head and valvetrain service. ->Please note that for camshaft ser-

vice, the cylinder head must be removed.

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Disconnect the negative battery cable from the left shock tower. ->The ground cable is equipped with an insulator grommet which should be placed on the stud to prevent the negative battery cable from accidentally grounding.

3. Relieve the fuel system pressure using the recommended procedure. 4. Drain the cooling system. 5. Remove or disconnect the following: e Accessory drive belts e Front timing belt covers ¢ Timing belt e Camshaft sprockets

>The intake manifold is a 2-piece unit. The upper part is a large air intake plenum of aluminum alloy. Use care working with light alloy parts.

Air intake plenum Manifold Absolute Pressure (MAP) and Intake Air Temperature (IAT) sensor wiring connectors Air cleaner cover, inlet hoses and air inlet resonator Throttle Position Sensor (TPS) and Idle Air Control (IAC) motor electrical connectors Throttle cable Speed control cable, if equipped Exhaust Gas Recirculation (EGR) tube Lower intake manifold Spark plug wires and move them aside e Cylinder head cover 6. Identify the rocker arm shaft assemblies before removal. 7. Install the Auto Lash Adjuster Retainers MD 998443, to keep the auto lash adjusters from falling out of the rocker arms when the rocker arm assembly is removed. 8. Remove or disconnect the following:

e e e e e

Rocker arm shaft assemblies Distributor assembly Exhaust manifold and crossover Cylinder head bolts Cylinder head 9. If the camshaft(s) are to be serviced, remove the thrust case from the left head assembly and remove the camshaft from the rear of the head. If not already done, remove the distributor from the right cylinder head and remove the camshaft from the rear of the head. 10. Valve service may be performed at this time, if required. To install: 11. Thoroughly clean all parts well. All sealing surfaces on the engine block, cylinder head(s) and both the upper and lower sections of the intake manifold must be clean. Check for cracks, signs of wear in the camshaft bores or other damage. With a straightedge and feeler gauge, check the head for flatness. It should be within 0.0012 in. (0.03mm) along its length. The service limit is 0.008 in. (0.2mm). If the head must be resurfaced, the grinding limit is 0.008 in. (0.2mm). Note that this dimension is a combined total dimension of stock material

For Accessory Drive Belt illustrations, see Section 1 of this manual

9-7

CHRYSLER CORP.

CIRRUS ¢ SEBRING CONVERTIBLE ¢ STRATUS @ BREEZE e Air cleaner cover, inlet hoses and air inlet resonator e MAP and IAT sensor wiring connectors e Accessory drive belts and adjust . them e Negative battery cable 19. Refill the cooling system.

© 4 10 mm

ALLEN

TIMING BELT END

HEX

CYLINDER HEAD BOLT AND WASHER

An oil and filter change is recommended whenever a cylinder head has been removed since coolant can get into the oil system.

20. Check to be sure allducts, hoses, fuel lines and wiring connections have all been properly reattached. 21. Start the engine and check for leaks, abnormal noises and vibrations. Bleed the cooling system. 2.7L Engine

7922FG15

Cylinder head bolt torque sequence—2.5L engine

removal from the cylinder head, if any, and the block top surface is 0.0079 in. (0.2mm). 12. Camshaft end-play can be checked as follows: a. Oil the camshaft journals with clean engine oil and install (if removed) the camshaft without the rocker arm assemblies. b. Move the camshaft as far rearward as it will go. c. Mount a dial indicator to bear on the front of the camshaft. d. Zero the indicator. e. Move the camshaft as far forward as it will go. End-play should be 0.004—0.008 in. (0.1-0.2mm). Maximum allowed end-play is 0.016 in. (0.4mm). 13. If the camshafts were removed, lubricate the camshaft journals and carefully reinstall the camshaft into the cylinder head. Install the thrust case and torque the thrust case mounting bolts to 108 inch Ibs. (13 Nm). 14. Apply a light coating of engine oil to the lip of the camshaft seal(s). Refer to Section 1 of this manual for

the cylinder head torque sequence illustration. The illustration is located

after the Torque Specification Chart.

15. Install or connect the following: e Camshaft seal(s) ¢ Camshaft sprocket(s) and torque the bolts to 65 ft. Ibs. (88 Nm) e New cylinder head gasket

Cylinder head New 10mm Allen hex cylinder head bolts, with washers. Torque the cylinder head bolts, in proper sequence, in 2-3 steps, to 80 ft. lbs. (108 Nm). Lower intake manifold using new gaskets Rocker arm assemblies Exhaust manifold and crossover exhaust pipe Timing belt, properly align the timing marks Timing belt covers 16. Inspect the spark plug tube seals located on the ends of each tube. These seals slide onto each tube to seal the cylinder head cover to the spark plug tube. If these seals show signs of hardness and/or cracks, they should be replaced. 17. Thoroughly clean all sealing surfaces. 18. Remove or disconnect the following: Cover using a new gasket. Torque bolts to 88 inch Ibs. (10 Nm). Distributor assembly Spark plug wires Upper intake manifold (plenum) using a new gasket. Torque the bolts to 13 ft. Ibs. (18 Nm). Plenum support bracket bolts EGR tube Speed control cable, if equipped Throttle cable @ e@ ee e TPS and IAC motor electrical connectors

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Relieve the fuel system pressure. 3. Drain the cooling system. 4. Remove or disconnect the following: Negative battery cable Drive belts Vibration damper Exhaust cross under pipe Catalytic converter Upper and lower intake manifolds Rocker arm covers Water outlet connector and rotate the crankshaft until the sprocket timing mark aligns with the timing mark on the oil pump housing Primary timing chain Camshaft bearing caps gradually Camshafts and valve train components Cylinder head and discard the gasket To install: 9. Clean all mating surfaces of any residual gasket material. 6. Lubricate the threads of the cylinder head bolts with clean engine oil. /. Install or connect the following: * Cylinder head with a new gasket 8. Torque the bolts, in sequence, using the following procedure: a. Step 1: Bolts 1-8: 35 ft. Ibs. (48 Nm). b. Step 2: Bolts 1-8: 55 ft. Ibs. (75 Nm). Cc. Step 3: Bolts 1-8: 55 ft. Ibs. (75 Nm). d. Step 4: Bolts 1-8: An additional 90

p

CH

CIRRUS ¢ SEBRING CONVERTIBLE e Saliee hee

imgat a

CYLINDER HEAD

CYLINDER HEAD |

FRONT 93461603

Cylinder head bolt torque sequence—2.7L engine degrees. Do not use a torque wrench for

Nm).e Valve train components

and the

camshafts Timing chain and sprockets Water outlet connector Rocker arm covers Timing chain cover Crankshaft vibration damper Lower and upper intake manifolds Catalytic converter Exhaust cross under pipe

Drive belts

ternator Intake manifold Exhaust manifold Water inlet pipe Breather and blow by hoses Positive Crankcase Ventilation (PCV) hose Spark plug cables Rocker arm cover Timing belt rear cover Cylinder head and discard the gasket To install: 5. Clean all mating surfaces of any residual gasket material. 6. Lubricate the threads of the cylinder head bolts with clean engine oil. 7. Install or connect the following: e Cylinder head with a new gasket 8. Torque the bolts, in sequence, as follows: a. Step 1: 80 ft. Ibs. (108 Nm). b. Step 2: Loosen all bolts in sequence. c. Step 3: 80 ft. Ibs. (108 Nm). e Rear timing belt cover

* Rocker arm cover

this step.

e. Step 5: Bolts 9-11: 21 ft. Ibs. (28

9-1 7

4. Remove or disconnect the following:

LEFT

RIGHT

:

a

EXHAUST SIDE

INTAKE

FRONT

OF

ENGINE

S

Negative battery cable 9. Fill the cooling system to the proper level. 10. Start the vehicle, check for leaks and repair if necessary.

3.0L Engine 1. Before servicing the vehicle, refer to

eae

in the beginning of this sec-

2. Relieve the fuel system pressure. 3. Drain the cooling system.

EXHAUST

SIDE 93461G04

Cylinder head bolt torque sequence—3.0L engine

For Tire, Wheel and Ball Joint specifications, see Section 1 of this manual

9-18

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Spark plug cables PCV and blow by hoses Breather hose Water inlet pipe Exhaust manifold Intake manifold Alternator Timing belt Negative battery cable 9. Fill the cooling system to the proper level. 10. Start the vehicle, check for leaks and repair if necessary. Rocker Arm/Shaftt

REMOVAL & INSTALLATION The 2.0L and 2.5L engines are equipped with rocker arms/shafts. On the 2.4L (VIN X) engine the camshaft acts directly on the valve, therefore, no rocker arms/shafts are used. 2.0L Engine This engine uses an Single Over Head Camshaft (SOHC) running in an aluminum cylinder head. Rocker arm shafts mount directly to the cylinder head. Care must be taken to be sure all valve timing marks align after cylinder head and valvetrain service. The Hydraulic Lash Adjusters (HLAs) are located in the valve actuating end of the rocker arm and are serviced as an assembly. 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Disconnect the negative battery cable from the left shock tower. >The ground cable is equipped with an insulator grommet which should be placed on the stud to prevent the negative battery cable from accidentally grounding.

3. Relieve the fuel system pressure using the recommended procedure. 4. Remove or disconnect the following: e Spark plug wires e Air inlet duct e Ignition coil pack e Cylinder head cover 5. Thoroughly clean the cylinder head cover and gasket mating surfaces. Be sure the gasket mating surfaces are flat. 6. Mark the rocker arm shaft assemblies to identify them for later installation. 7. Remove or disconnect the following: ¢ Rocker arm shaft bolts e Rocker arm assemblies 8. Mark the rocker arm spacers and

EXHAUST ROCKER ARM ASSEMBLY

KER ARM SHAFT RETAINERS

PLASTIC SHAFT

INTAKE ROCKER ARM ASSEMBLY 7922FG18

Rocker arm shaft identification—2.0L engine

retainers to identify them for correct installation. 9. Disassemble the rocker arm/shaft assemblies as follows: ¢ Bolts from the rocker arm shaft assemblies e Rocker arm/HLA assembly and rocker arm spacers, sliding them off the rocker arm shaft

*k< WARNING Be sure the rocker arms and spacers are reassembled in the same positions they are removed. To install:

e>Inspect the rocker arms and shaft for scoring and/or wear on the rollers or damage to the rocker arm. If scoring, wear or damage is present, replace the rocker arm assemblies. The rocker arm shaft is hollow and, therefore, used as an oil lubrication duct. Inspect the oil holes for clogging, using a small wire and clean, if necessary. Inspect the location where the rocker arms mount to the shaft and replace if damaged or worn.

10. If the camshaft lobes show signs of wear, check the corresponding rocker arm roller for wear or damage. Replace rocker arms/HLAs if worn or damaged. If the camshaft lobes show signs of pitting on the nose, flank or base circle replace the camshaft. 11. Inspect the rocker arms for scoring, wear on the roller or damage to the shaft. Replace parts as necessary. Check that the rocker arm shaft is clean inside and out. Check all oil holes for clogging with a small wire and clean and required. 12. Thoroughly lubricate all rocker arm components and spacers and reinstall on the rocker arm shaft in the original locations. 13. If the vehicle exhibited a tappet-like noise, the valve lash adjusters built into the rocker arms should be cleaned and checked. Lash adjusters removed from a rocker arm should be returned to their original locations. Replacement of worn or defective lash adjusters would require the replacement of the rocker arm/HLAs as an assembly. 14. Install a HLA, by using the following procedure: a. Lubricate the HLA thoroughly with clean engine oil. b. Reinstall the HLA into the rocker arm making sure the HLA is at least partially filled with oil. c. Place the rocker arm in clean engine oil and pump the plunger until the HLA travel is taken up. If travel is not reduced, replace the adjuster with the rocker arm as an assembly. d. Reinstall the rocker arm back on the rocker arm shaft. 15. Before installing the rocker arm and shaft assemblies, set the crankshaft to 3 notches Before Top Dead Center (BTDC) on the crankshaft sprocket.

—.

~~

NOTCHES FACING UP AND TOWARD THE TIMING BELT SIDE OF THE ENGINE

@) 7922FG19

Rocker arm shaft notch locations—2.0L engine

CHRYSLER CORP.

CIRRUS ¢ SEBRING CONVERTIBLE ¢ STRATUS ¢ BREEZE

e>The ground cable is equipped with an insulator grommet which should be placed on the stud to prevent the negative battery cable from accidentally grounding.

EI IRR,

EXHAUST ROCKER ARM SHAFT .

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:

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7922FG20

Rocker arm shaft tightening sequence—2.0L engine

->When installing the intake rocker arm/shaft assembly, be sure the plastic rocker arm spacers do not interfere with the spark plug tubes. If there is interference, rotate the plastic spacers until they are at the proper angle. Do not rotate the spacers by forcing down on the shaft assembly or damage to the spark plug tubes will occur.

16. Reinstall the rocker arm and shaft assemblies with the small notches in the rocker shafts pointing up and toward the timing belt side of the engine. Install the retainers in their original positions on the exhaust and intake shafts. Tighten the bolts in proper sequence to 17 ft. Ibs. (23 Nm). 17. Install or connect the following: Cylinder head cover using a new gasket. Torque the bolts to 105 inch Ibs. (12 Nm) e Ignition coil pack. Torque the fasteners to 17 ft. Ibs. (23 Nm) Spark plug wires Air cleaner inlet duct Negative battery cable 18. Check to be sure all electrical, vacuum and fluid connections are reattached as required. 19. An oil and filter change are recommended. 90, Start the engine and check for leaks. Test drive the vehicle to check for proper operation.

2.4L (VIN G) and 3.0L Engines 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Relieve the fuel system pressure using the recommended procedure. 3. Remove or disconnect the following: Negative battery cable Breather hose Positive Crankcase Ventilation (PCV) hose and valve Rocker arm cover Rocker shaft cap Rocker arms and shafts To install:

4. Install or connect the following: Rocker arms and shafts. When properly aligned, torque the rocker shaft cap to 23 ft. Ibs. (31 Nm) Oil seals Rocker arm cover with a new gasket PCV valve with a new gasket PCV hose Breather hose ® eoeeeeo Negative battery cable

2.5L Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Disconnect the negative battery cable from the left shock tower.

9-19

3. Relieve the fuel system pressure using the recommended procedure. 4. If removing the right (firewall) side rocker arm/shaft assembly, remove the upper intake manifold (air intake plenum), which is a 2-piece unit of aluminum alloy. Use care working with light alloy parts. 5. Remove or disconnect the air intake plenum using the following procedure: Fuel supply tube from the fuel rail. Squeeze the tabs together and pull the fuel tube/quick-connect fitting assembly off the fuel tube nipple Manifold Absolute Pressure (MAP) sensor and Intake Air Temperature (IAT) sensor electrical connections Plenum support bracket bolt located rearward of the MAP sensor Air inlet resonator-to-intake manifold bolt Throttle body air inlet hose clamp Air cleaner housing cover and inlet hoses Throttle Position (TP) sensor electrical connector and Idle Air Control (IAC) motor electrical connections Throttle cable by sliding it out of the bracket Speed control cable by sliding it out of its bracket, if equipped Exhaust Gas Recirculation (EGR) tube from the intake manifold Plenum support bracket bolt from the rear of the EGR tube Upper intake plenum 6. Remove or disconnect the following: e Spark plug wires e Cylinder head cover 7. Identify the rocker arm shaft assemblies before removal. 8. Install the auto lash adjuster retainers Special Tool MD 998443, to keep the auto lash adjusters from falling out of the rocker arms when the rocker arm assembly is removed. 9. Loosen the fasteners and remove the rocker arm shaft assemblies. >The hydraulic automatic lash adjusters are precision units installed in the machined openings in the rocker arm units. Do not disassemble the auto lash adjusters from the rocker arms.

For Wheel Alignment specifications, see Section 7of this manual

9-20

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: ROCKER ARM SHAFT SPRING ORIENTATION |{ | |

= Sy | Ox) Dy DIRECTIONAL FLAT 7922FG16

The flats on the rocker arm shaft aids proper orientation—2.5L engine

INTAKE ROCKER ARM SHAFT TIGHTEN SEQUENCE

13. Clean the cylinder head and cover mating surfaces. 14. Install or connect the following: Cylinder head cover using a new gasket. Torque bolts to 88 inch Ibs. (10 Nm) Spark plug wires Upper intake manifold (plenum) using a new gasket. Tighten the bolts to 13 ft. Ibs. (18 Nm) Plenum support bracket bolts

EGR tube Throttle and speed control cables TP sensor, MAP sensor, IAT sensor and IAC motor electrical connectors Air inlet resonator, air inlet hose and air cleaner housing cover All remaining electrical connectors

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=

Saf

Air tube connections Negative battery cable 15. An oil and filter change is recommended.

ie

2k WARNING

\ : A. H EXHAUST ROCKER ARM SHAFT TIGHTEN SEQUENCE

SS!

7922FG17

Rocker arm shaft tightening sequence— 2.5L engine

To install: 10. The rocker arm shafts are hollow and used as a lubrication oil duct. Be sure all valvetrain parts are clean. Check the rocker arm mounting portion of the shafts for wear or damage. Replace if necessary. Check all oil holes for clogging with a small wire and clean as required. If any rockers were removed, lubricate and install on the shafts in their original positions. 11. For the right cylinder head, install the rocker arm and shaft assemblies with the FLAT in the rocker arm shafts facing the timing belt side of the engine. For the left cylinder head, install the rocker arm and shaft assembly with the FLAT in the rocker arm shaft facing the transaxle side of the engine. Install the retainers and spring clips in their original positions on the exhaust and intake shafts. Tighten the retainer bolts to 23 ft. Ibs. (31 Nm) working from the center, outward. Remove the valve lash retainer tools that should have been installed at disassembly. 12. Inspect the spark plug tube seals ocated on the ends of each tube. These seals slide onto each tube to seal the cylinder head cover to the spark plug tube. If these seals show signs of hardness and/or cracking, they should be replaced.

Operating the engine without the proper amount and type of engine oil will result in severe engine damage. 16. Start the engine and check for leaks, abnormal noises and vibrations. 2.7L Engine

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Relieve the fuel system pressure using the recommended procedure. 3. Remove or disconnect the following: e Negative battery cable e Rocker arm cover and rotate the engine until the cam lobe is on its base circle 4, Using special tools8215—A and 8216—A, depress the valve spring enough to release the tension on the rocker arm. 5. Remove the rocker arm from the cylinder head. To install: 6. Lubricate the rocker arms with clean engine oil. 7. Depress the valve spring far enough to install the rocker arm. 8. Install or connect the following: ¢ Rocker arm into its original position over the valve and lash adjuster. ¢ Rocker arm cover ¢ Negative battery cable

Intake Manifold:

REMOVAL & INSTALLATION 2.0L Engine

The intake manifold is a long branch design made of a molded plastic composition. It is attached to the cylinder head with 10 fasteners. Please note that all seals are to be replaced with new seals and all fasteners are to be replaced with new fasteners. 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Disconnect the negative battery cable from the left shock tower. >The ground cable is equipped with an insulator grommet which should be placed on the stud to prevent the negative battery cable from accidentally grounding.

3. Relieve the fuel system pressure using the recommended procedure. 4. Remove the air inlet resonator as follows: e Air inlet resonator-to-throttle body Screw e Air inlet resonator-to-air inlet tube clamp, loosen it e Resonator 5. Remove or disconnect the following: ¢ Fuel supply line quick-disconnect

fitting from the fuel rail. Squeeze the retainer tabs together and pull the fuel tube fitting from the fuel tube nipple. The retainer will remain on the fuel tube. ->\Vrap shop towels around the fuel line openings to catch any spilling fuel. e Fuel rail

Use care when handling the fuel injectors. Do not set them on their tips. Cover the fuel injector openings after fuel rail removal.

¢ Accelerator, kickdown and speed control cables from the throttle lever and bracket Throttle Position (TP) sensor and Idle Air Control (IAC) motor electrical connections Vacuum hoses from the throttle body Manifold Absolute Pressure (MAP) sensor, Idle Air Control (IAC) motor and Intake Air Temperature (IAT) sensor

CHRYSLER CORP.

CIRRUS ¢ SEBRING CONVERTIBLE © STRATUS © BREEZE

eee

Vapor and brake booster hoses sat sensor electrical con-necor Starter relay electrical connector Wiring harness from the intake manifold tab Transaxle-to-throttle body support bracket fasteners at the throttle body and loosen the fastener at the transaxle end Throttle body assembly Exhaust Gas Recirculation (EGR) tube Intake manifold-to-inlet water tube support fastener Intake manifold fasteners and discard them Intake manifold To install: 6. Clean all sealing surfaces. Check upper and lower manifold gasket surfaces for flatness with a straightedge. Surface must be flat within 0.006 in. (0.15mm) per foot (30cm). ->Replace all seals and fasteners with new ones.

7. Install or connect the following: e Intake manifold with new O-ring seals. Torque the fasteners, in proper sequence, to 105 inch Ibs. (12 Nm) 8. Lubricate the fuel injector O-rings with engine oil. 9. Install or connect the following: e Fuel injector/fuel rail assembly. Torque the fuel rail bolts to 17 ft. lbs. (23 Nm) e Fuel injector electrical connectors 10. Lubricate the quick-connect fittings with engine oil. 11. Install or connect the following: ¢ Fuel supply line to the fuel rail. Pull on the connector to insure it is locked into position. e PCV and brake booster hoses e Throttle body and torque the fasteners to 17 ft. Ibs. (23 Nm) e Transaxle-to-throttle body support bracket. Torque the fasteners to 105 inch Ibs. (12 Nm) =>Tighten the support bracket at the throttle body first; then, at the transaxle. e MAP and IAT sensor electrical connectors

e Knock sensor electrical and starter relay connectors

Wiring harness to the intake manifold tab IAC and TP sensor electrical connectors Throttle body vacuum hoses Accelerator, kickdown and speed control cables, to their bracket(s) and throttle lever EGR tube. Torque the fasteners to 95 inch Ibs. (11 Nm) e>Tighten the EGR tube-to-valve fasteners first; then, at the intake manifold.

Fresh air duct to the air filter housing Air inlet resonator to the throttle body Air inlet tube to the resonator. Torque the clamps to 20-30 inch lbs. (2-3 Nm), ¢ Negative battery cable

2.4L (VIN X) Engine The intake manifold is a long branch design made of cast aluminum. It is attached to the cylinder head with 8 fasteners. 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Disconnect the negative battery cable from the left shock tower. The ground cable is equipped with an insulator grommet which should be placed on the stud to prevent the negative battery cable from accidentally grounding.

3. Relieve the fuel system pressure using the recommended procedure. 4. Remove the air inlet resonator as follows: Both air inlet resonator-to-intake manifold bolts Resonator-to-throttle body screw, loosenit Air inlet resonator-to-air inlet tube clamp, loosen it Resonator 5. Remove or disconnect the following: ¢ Fuel supply line quick-disconnect at the fuel tube assembly e» Squeeze the retainer tabs together and pull the fuel tube/quick-disconnect fitting assembly from the fuel tube nipple. The retainer will remain on the fuel tube. Use shop towels to catch any dripping fuel.

9-21

*k:+ WARNING Use care when handling the fuel injectors. Do not set them on their tips. Cover the fuel injector openings after fuel rail removal. Accelerator, kickdown and speed control cables, from the throttle lever and bracket Idle Air Control (IAC) motor and Throttle Position (TP) sensor electrical connections Throttle body vacuum hoses Manifold Absolute Pressure (MAP) sensor and Intake Air Temperature (IAT) sensor electrical connections Vapor and brake booster hoses Knock sensor electrical connector Wiring harness from the intake manifold tab Transaxle-to-throttle body support bracket fasteners at the throttle body and loosen the fastener at the transaxle end Throttle body Exhaust Gas Recirculation (EGR) tube -Intake manifold support bracket Intake manifold To install: 6. Thoroughly clean all parts. Clean all sealing surfaces 7. Install or connect the following: e New gasket e Intake manifold. Torque the fasteners to 17 ft. Ibs. (23 Nm), in correct sequence, starting at the center and working outward e> Wake sure the fuel injector openings clean.

e Fuel rail assembly to the intake manifold and torque the screws to 17 ft. Ibs. (23 Nm)

‘

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| \

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Nee MAP

SENSO

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SOURCE “7 BRAKE |/— BOOSTER

MAP sensor location—2.4L engine

e Fuel rail

For Maintenance Interval recommendations, see Section 1 of this manual

9-22

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CIRRUS ¢ SEBRING CONVERTIBLE * STRATUS ¢ BREEZE

¢ Positive Crankcase Ventilation (PCV) and brake booster hoses 8. Lubricate the fuel tube with engine oil. 9. Install or connect the following: Fuel supply line to the fuel rail. Pull on the connector to insure it is locked into position Throttle body and torque the fasteners to 17 ft. Ibs. (23 Nm) Transaxle-to-throttle body support bracket. Torque the fasteners to 105 inch Ibs. (12 Nm) at the throttle body first; then, at the transaxle MAP and IAT electrical connectors Knock sensor electrical connector Wiring harness to the intake manifold tab IAC motor and TP sensor electrical connectors Throttle body vacuum hoses Accelerator, kickdown and speed control cables to the throttle lever and bracket EGR tube. Torque the fasteners to 95 inch Ibs. (11 Nm), at the EGR valve first: then, the intake manifold Air inlet resonator to the throttle body Air inlet tube to the resonator and torque the clamps to 20-30 inch lbs. (2.5-3.5 Nm) Both air inlet resonator-to-intake manifold bolts Negative battery cable

2.4L (VIN G) Engine The intake manifold is a long branch design made of cast aluminum. It is attached to the cylinder head with 8 fasteners. 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the cooling system. 3. Properly relieve the fuel system presSure. 4. Remove or disconnect the following: Negative battery cable Throttle body air inlet hose > ir cleaner assembly hrottle and speed control cables xhaust Gas Recirculation (EGR) oomx4 be ngine oil dipstick and tube The ground cable is equipped with an insulator grommet which should be placed on the stud to prevent the negative battery cable from accidentally grounding.

3. Relieve the fuel system pressure using the recommended procedure. 4. Disconnect the fuel supply line quick-disconnect fitting from the fuel rail. Squeeze the fitting retainer tabs together

and separate the connection. > CAUTION Wrap shop towels around the connection to catch any gasoline spillage. e>|t may be helpful to identify and tag each sensor connector as it is being removed. This may save time at assembly.

5. Remove or disconnect the follow-

ing: Manifold Absolute Pressure (MAP) sensor and Intake Air Temperature (IAT) sensor electrical connections Plenum support bracket at the rear of the MAP sensor Air inlet resonator bolt Throttle body air inlet hose clamp, loosenit Air cleaner cover and inlet hoses Throttle Position Sensor (TPS) and Idle Air Control (IAC) motor electrical connections e Throttle cable from the bracket Speed control cable out of the bracket, if equipped

Exhaust Gas Recirculation (EGR) tube from the intake manifold Plenum support bracket at the rear of the EGR tube Upper intake plenum from the intake manifold Fuel injector electrical connectors Fuel rail e>There are spacers under each fuel rail bolt.

¢ Lower intake manifold and discard the gaskets To install: 6. Clean all sealing surfaces. 7. Check upper and lower manifold gasket surfaces for flatness with a straightedge. Surface must be flat within 0.006 in. (0.15mm) per 12 in. (30cm) of manifold length. 8. Install or connect the following: e New gaskets ¢ Lower intake manifold 9. For 1998-99 engines, torque the nuts, in the correct sequence, to 15 ft. Ibs. (21 Nm). 10. For 2000-02 engines, torque each bank nuts in the following order:

CHRYSLE

CIRRUS © SEBRING CONVERTIBLE e Swiee hee

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MANIFOLD

36Nem (26 ft. Ibs.)

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18 Nem (13 ft. ts.) ——~o

9-23

18 Nem (13 ft. Ibs.) E Ae Pata sails

18 Nem (13 ft. Ibs.) UPPER INTAKE

‘

GASKET

RIGHT SIDE

MANIFOLD SUPPORT

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So LOWER INTAKE MANIFOLD

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2\ Nem

(16 F. tbs.) oi DIPSTICK

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SPRIN,G SING 23 Nem

13 Nem

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(10 ft. Ibs.)

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REAR HEAT SHIELD REAR EXHAUST MANIFOLD aN (22 f. Ibs.} EXHAUST

Lge Lae ft. Ibs.) The ground cable is equipped with an insulator grommet which should be placed on the stud to prevent the negative battery cable from accidentally grounding.

3. Remove or disconnect the following: Exhaust pipe from the exhaust manifold Exhaust manifold heat shield Heated Oxygen Sensor (HO2S), if necessary Exhaust manifold and discard the gasket To install: 4. Thoroughly clean all parts. Clean all sealing surfaces of the manifold and cylinder head. Check the manifold gasket surface for flatness with a straightedge and feeler gauge. The surface must be flat within 0.006 in. (0.15mm) per foot (30cm) of manifold length. Inspect the manifold for cracks or distortion. Replace if necessary. 5. Install or connect the following: e New gasket e Exhaust manifold. Torque the bolts, starting at the center and working outward, to 17 ft. Ibs. (23 Nm)

Be sure the gasket mating surfaces are clean and flat before installing the exhaust

manifold—2.0L engine

Be careful not to damage the oxygen sensor when servicing the manifold—2.4L engine

e HQ2S sensor e Heat shield e Exhaust pipe and torque the fasteners to 21 ft. Ibs. (28 Nm) e Negative battery cable 6. Start the engine and allow it to idle while inspecting the manifold for exhaust leaks. 2.5L Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this secTON 2. Disconnect the negative battery cable from the left shock tower. >The ground cable is equipped with an insulator grommet which should be placed on the stud to prevent the negative battery cable from accidentally grounding.

3. Remove or disconnect the following: Exhaust pipe from the rear (cowl side) exhaust manifold, at the flex joint Crossover pipe assembly Heated Oxygen Sensor (HO2S) from the rear manifold Power steering bracket Rear exhaust manifold heat shield Rear exhaust manifold and discard the gasket Front HO2S sensor Front manifold heat shield e Front manifold To install: 4. Thoroughly clean all parts. Inspect the exhaust manifolds for damage or cracks and check for distortion of the cylinder head sealing surface and exhaust crossover sealing surface with a straightedge and thickness gauge. 5. Install or connect the following:

For complete service labor times, order Nichols’ Chilton Labor Guide

9-2

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New front gasket Front manifold and torque the nuts to 22 ft. Ibs. (30 Nm) Front exhaust manifold heat shield and torque the screws to 10 ft. Ibs. (13 Nm) Front HO2S sensor New rear gasket Rear exhaust manifold and torque the nuts to 22 ft. Ibs. (30 Nm) Power steering bracket Crossover pipe and torque the nuts to 22 ft. Ibs. (30 Nm) Rear HO2S sensor Exhaust pipe to the rear manifold

and torque the bolts to 21 ft. Ibs. (28 Nm) Negative battery cable 6. Lower the vehicle. 7. Start the engine and allow the engine to idle while inspecting the vehicle for exhaust leaks at the manifold. 2.7L Engine

FRONT 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Negative battery cable e Cross under pipe e Front catalytic converter e Exhaust manifold and discard the gasket To install: 3. Clean all mating surfaces of any residual gasket material. 4. Install or connect the following: ¢ Exhaust manifold with a new gasket. Torque the bolts, starting in the center and working outward, to 17 ft. Ibs. (23 Nm — ¢ Front catalytic converter and heat shield and torque the bolts to 21 ft. lbs. (28 Nm) ¢ Cross under pipe and torque the bolts to 21 ft. Ibs. (28 Nm) e Negative battery cable 5. Start the vehicle, check for leaks and repair if necessary.

REAR 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: ¢ Negative battery cable ¢ Throttle body air inlet hose e Air cleaner assembly e Exhaust Gas Recirculation (EGR)

tube from the exhaust manifold and EGR valve Exhaust system Cross under pipe Rear catalytic converter Rear Oxygen Sensor (0 2S) Exhaust manifold and discard the gasket To install: 3. Clean all mating surfaces of any residual gasket material. 4. Install or connect the following: Exhaust manifold with a new gasket. Torque the bolts, starting in the center and working outward, to 17 ft. Ibs. (23 Nm) Rear catalytic converter and heat shield and torque the bolts to 21 ft. lbs. (28 Nm) Rear Oxygen Sensor (0 2S) Cross under pipe and torque the bolts to 21 ft. Ibs. (28 Nm) Exhaust system EGR tube with new gaskets Air cleaner assembly and air intake hose Negative battery cable 5. Start the vehicle, check for leaks and repair if necessary. 3.0L Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Battery and tray Front exhaust pipe Air cleaner assembly Oil dipstick guide Strut tower bar Upper and lower heat shields Exhaust Gas Recirculation (EGR) pipe, left side only Exhaust manifold and discard the gasket To install: 3. Clean all mating surfaces of any residual gasket material. 4. Install or connect the following: Exhaust manifold with a new gasket and torque the bolts to 33 ft. Ibs. (44 Nm) EGR pipe, if removed. Torque the bolt to 13 ft. Ibs. (18 Nm) Upper and lower heat shields and torque the bolts to 10 ft. Ibs. (15 Nm) Strut tower bar Oil dipstick guide Air cleaner assembly Front exhaust pipe Battery and tray

5. Start the vehicle, check for leaks and

repair if necessary.

Front Crankshaft Seal

REMOVAL & INSTALLATION 2.0L and 2.4L Engines The timing belt must be removed for this procedure. Use care that all timing marks are aligned after installation or the engine will be damaged. 1. Drain the engine oil. 2. Before servicing the vehicle, refer to the precautions in the beginning of this section. 3. Disconnect the negative battery cable from the left shock tower. >The ground cable is equipped with an insulator grommet which should be placed on the stud to prevent the negative battery cable from accidentally grounding.

4. Remove or disconnect the following: ¢ Accessory drive belts ¢ Crankshaft damper/pulley using a jaw puller tool e Timing belt

¢ Crankshaft timing belt sprocket using a gear/sprocket puller ->Be careful not to nick the seal surface of the crankshaft or the seal bore.

¢ Front crankshaft seal using Seal Removal Tool No. 6771 ->Be careful not to damage the seal contact area of the crankshaft.

To install: 9. Lubricate the new oil seal lip with engine oil. 6. Install or connect the following: ¢ New crankshaft oil seal with the spring facing inward using Oil Seal Installer Tool 6780-1, until it is flush with the front cover ¢ Crankshaft timing belt sprocket using Tool No. 6792 e*Be sure the word “FRONT” on the

timing belt sprocket is facing outward. e¢ Timing belt and timing belt cover ¢ Crankshaft damper/pulley using the thrust bearing/washer and 12M-1.75 x 150mm bolt from special Tool No. 6792. Torque the bolt to 105 ft. Ibs. (142 Nm) ¢ Accessory drive belts and adjust the tension ¢ Negative battery cable

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CIRRUS ¢ SEBRING CONVERTIBLE ¢ STRATUS ¢ BREEZE

Operating the engine without the proper amount and type of engine oil will result in severe engine damage. 7. Fill the engine with clean oil. 8. Start the engine and check for leaks.

2.5L Engine The timing belt must be removed for this procedure. Use care to be sure all timing marks are aligned after this service or the engine will be damaged. 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Disconnect the negative battery cable from the left shock tower. >The ground cable is equipped with an insulator grommet which should be placed on the stud to prevent the negative battery cable from accidentally grounding.

3. 4. Drain 5. ing:

Remove the accessory drive belts. Raise and safely support the vehicle. the engine oil. Remove or disconnect the follow-

Be sure to cover the end of the prytool tip with a shop towel. Be careful not to nick the seal surface of the crankshaft or the seal bore. To install: 6. Lubricate the new oil seal lip with engine oil. 7. Install or connect the following: e New crankshaft oil seal until it is flush with the oil pump cover, using Oil Seal Installer MD998717 ¢ Crankshaft timing belt sprocket and key e Timing belt and timing belt covers

Verify that all timing marks are correctly aligned or the engine will be damaged.

e Crankshaft damper/pulley and torque the bolt to 134 ft. Ibs. (182 Nm) e Right inner splash shield

9-27

e Accessory drive belts and adjust the tension e Negative battery cable

Operating the engine without the proper amount and type of engine oil will result in severe engine damage. 8. Fill the engine with clean oil. 9. Start the engine and check for leaks.

2.7L Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Negative battery cable e Crankshaft damper e Front crankshaft seal with special Tool 6771 To install: 3. Install or connect the following: ¢ New seal with special Tools 6780-2, 8179 and 6780-1 e Crankshaft damper ¢ Negative battery cable

¢ Right inner splash shield e Crankshaft damper/pulley e Timing belt covers and timing belt e Crankshaft timing belt sprocket and key e Crankshaft seal by prying it out with a flat-tipped prytool

7922FG30

To prevent damage to the end of the crankshaft, use Oil Seal Installer MD998717, as shown—2.5L engine

1 - SPECIAL TOOL 6771 Remove the front crankshaft seal with special tool 6771

Please visit our web site at www.chiltonsonline.com

93461G06

9-28

CHRYSLER CORP.

CIRRUS ¢ SEBRING CONVERTIBLE ¢ STRATUS ¢ BREEZE roller for wear or damage. Replace rocker

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Negative battery cable e Timing belt e Crankshaft sprocket ¢ Crankshaft Position (CKP) sensor e Crankshaft sensing blade ¢ Crankshaft spacer and key ¢ Front oil seal To install:

3. Lubricate the oil seal lip with clean engine oil. 4. Install or connect the following: New oil seal with special Tool

MD998717 Crankshaft key and spacer Crankshaft sensing blade CKP sensor Crankshaft sprocket Timing belt Negative battery cable

REMOVAL & INSTALLATION 2.0L Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: * Rocker arm assemblies ¢ Timing belt and camshaft sprocket ¢ Cylinder head ¢ Camshaft Position (CMP) sensor ¢ Camshaft from the rear of the cylinder head To install:

arms/Hydraulic Lash Adjuster (HLAs) if worn or damaged. If the camshaft lobes show signs of pitting on the nose, flank or base circle, replace the camshaft. 5. If the rocker arms and shaft are to be serviced, mark the rocker arms so any that are to be returned to service will be installed in their original locations. 6. Install or connect the following: ¢ Rocker arm on the rocker arm shaft ¢ Camshaft, be sure it turns freely e Cam sensor and torque the screws to 85 inch Ibs. (10 Nm) 7. Camshaft end-play can be checked by using the following procedure: a. Lubricate the camshaft journals and install the camshaft without the rocker arm assemblies. b. Install the cam sensor and torque the screws to 85 inch Ibs. (10 Nm). c. Adjust a dial indicator to touch the camshaft nose. d. Pry the camshaft rearward as far as it will go. Be sure the dial indicator probe is in contact with the camshaft. e. Zero the dial indicator. f. Move the camshaft forward as far as it will go. g. Read the end-play on the dial indicator. Specification is 0.005-0.013 in. (0.13-0.33mm). 8. Install or connect the following: ¢ Camshaft seal until it is flush with the cylinder head ¢ Camshaft sprocket and torque the bolt to 85 ft. Ibs. (115 Nm) ¢ Cylinder head using new bolts 9. Before installing the rocker arm and shaft assemblies, position the crankshaft to 3 notches Before Top Dead Center (BTDC) on the crankshaft sprocket. 10. Install or connect the following: ¢ Rocker arm and shaft assemblies ¢ Camshaft sprocket e Timing belt, by aligning all valve timing marks

e>The cylinder head bolts should be checked for stretching before reuse. If the threaded area of the bolt is neckeddown the bolts must be replaced with new ones. New head bolts are recommended.

2.4L Engine (VIN X)

3. Thoroughly clean all parts. Inspect the camshaft journals for scoring. Check the Oil feed holes in the head for blockage. Check the camshaft bearing journals for scoring. If light scratches are present, they may be removed with 400 grit abrasive paper. If deep scratches are present, replace the camshaft and check the cylinder head for damage. Replace the cylinder head if worn or damaged. 4. If the camshaft lobes show signs of wear, check the corresponding rocker arm

This engine uses a DOHC, 4-valves per cylinder, cross-flow aluminum cylinder head. The valves are actuated by roller cam followers which pivot on stationary hydraulic valve adjusters. Care must be taken to ensure all valve timing marks align after cylinder head and valvetrain service. 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2, Disconnect the negative battery cable from the left shock tower.

9300FG04

Use special tool 6847 to hold the camshaft sprocket while removing or installing the center bolt—2.4L engine

>The ground cable is equipped with an insulator grommet which should be placed on the stud to prevent the negative battery cable from accidentally grounding.

3. Relieve the fuel system pressure using the recommended procedure. 4. Remove or disconnect the following: Spark plugs cables Ignition coil pack with the spark plug cables Cylinder head cover and discard the gasket Ground strap Timing belt covers and timing belt Camshaft sprockets by holding them with Tool 6847, while removing the bolt 9. Take note that the camshaft bearing Caps are numbered for correct location during installation. Remove the outer bearing caps first. 6. Loosen, but do not remove, the camshaft bearing cap retaining fasteners in the correct sequence, inside working outward. Perform this step on one camshaft at a time. 7. Identity the camshafts, if they are to be reused for later installation. The camshafts are not interchangeable.

AZOwN

7922FG31

Camshaft bearing cap identification—2.4L engine

CIRRUS

CHRYSLER CORP.

SEBRING CONVERTIBLE ¢ STRATUS ¢ BREEZE

e Camshaft end seals e Camshaft sprockets, if removed, and torque the bolts to 75 ft. Ibs. (101 Nm) e Timing belt, making sure all timing marks are aligned e Timing belt covers

REMOVE OUTSIDE BEARING CAPS FIRST

°

ae

If the timing belt or sprockets are incorrectly installed, engine damage will occur. Take time to be sure all timing marks are correctly aligned.

een 7922FG32

Camshaft bearing cap bolt removal sequence—2.4L engine

8. Remove or disconnect the following: e Camshaft bearing caps e Camshafts e Camshaft followers 9. 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 valvetrain components so they may be reinstalled correctly. 10. Inspect the camshaft bearing oil feed holes in the cylinder head for clogging. Inspect the camshaft bearing journals for wear or scoring. Check the cam surface for abnormal wear and damage. A visible worn groove in the roller path or on the cam lobes is cause for replacement. To install: 11. Thoroughly clean all camshaft and related parts. 12. Inspect the camshaft end-play using the following procedure: a. Lubricate the camshaft journals and install the camshaft WITHOUT the cam follower assemblies. Install the rear cam caps and tighten to 21 ft. Ibs. (28 Nm). b. Push the camshaft rearward as far as it will go. c. Adjust a dial indicator to rest against the front of the camshaft (the sprocket end). Zero the indicator. d. Move the camshaft forward as far as it will go. Read the dial indicator. Endis 0.002—0.010 in. play ea . (0.05—-0.15mm) aii excessive end-play is present, inspect the cylinder head and camshaft for wear: replace if necessary. 13. If the fit and condition of the camshafts are acceptable, remove the camshafts for installation of the cam followiS. 14. The hydraulic valve lash adjusters

9-29

are inside the roller cam followers. Be sure they are clean, well lubricated with engine oil and properly positioned. Install the cam followers in their original positions on the hydraulic adjuster and valve stem.

Be sure NONE of the pistons are at Top Dead Center (TDC) when installing the camshafts. 15. Lubricate the camshaft bearing journals and cam followers with clean engine oil 16. Install or connect the following: e Camshafts e Right/left-side camshaft bearing caps Nos. 2 through 5 and rightside No. 6. Torque the M6 fasteners to 105 inch Ibs. (12 Nm) in the correct sequence. 17. Apply Mopar® Gasket Maker sealer to the No. 1 and left-side No. 6 bearing caps. 18. Install or connect the following: e Bearing caps and torque the M8 fasteners to 21 ft. Ibs. (28 Nm)

19. Clean all sealing surfaces. Make certain the rails are flat. 20. Install new cylinder head cover gaskets. Apply Mopar® Silicone Rubber Adhesive Sealant, at the camshaft cap corners and at the top edge of the / round seal. e>iInspect the spark plug well seals for cracking and/or swelling and replace if necessary.

21. Install the cylinder head cover and torque the fasteners, in sequence, using the following: a. Step 1: 40 inch Ibs. (4.5 Nm). FRONT CAM CAP

5 mm (.060 in.)

DIAMETER BEAD OF oe GASKET MAKER

LEFT REAR CAM CAP 7922FG34

Apply sealer as shown to prevent oil leakage from the camshaft bearing end caps— 2.4L engine

(fe

r(itmeg Gua S|;

Camshaft bearing cap tightening sequence—2.4L engine

Timing belt service is covered in Section 3 of this manual

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CHRYSLER CORP.

CIRRUS ¢ SEBRING CONVERTIBLE ¢ STRATUS ¢ BREEZE

b. Step 2: 80 inch Ibs. (9 Nm). C. Step 3: 105 inch Ibs. (12 Nm). 22. Install or connect the following: e Ignition coil pack and torque the fasteners to 105 inch Ibs. (12 Nm) e Spark plug cables e Ground strap e All vacuum lines and wiring e Negative battery cable e>An oil and filter change is recommended. 23. Test run vehicle. Check for leaks and for proper operation.

2.4L Engine (VIN G) 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: ¢ Negative battery Air cleaner assembly Timing belt Ignition coils and spark plug cables Positive Crankcase Ventilation (PCV) hose Breather hose Rocker arm cover Camshaft Position (CMP) sensor support ¢ CMP sensing cylinder ¢ Camshaft sprocket ¢ Spark plug guide oil seal ¢ Rocker arm and shaft assembly ¢ Camshaft To install: 3. Install or connect the following:

¢ Camshaft Rocker arm and shaft assemblies in there proper position. Torque the assemblies to 23 ft. Ibs. (31 Nm) Spark plug guide oil seals Camshaft sprocket with special Tools MB990767 and MD998719. Torque the bolt to 65 ft. Ibs. (88 Nm) CMP sensing cylinder and torque the bolt to 16 ft. Ibs. (21 Nm) CMP support and torque the bolt to 10 ft. Ibs. (15 Nm) Rocker arm cover Breather and PCV hoses Ignition coil and spark plug cables Timing belt Air cleaner assembly Negative battery cable

2.5L Engine

This engine uses aluminum alloy cylinder heads with 4-valves per cylinder and pressed-in cast iron valve guides. The cylinders are common to either cylinder

bank. Two overhead camshafts are supported by 4 bearing journals which are part of the head with the distributor driven off the right (firewall side) cylinder head. Right and left camshaft drive sprockets are interchangeable. The sprockets and engine water pump are driven by the timing belt. Care must be taken to be sure all valve timing marks align after cylinder head and valve train service. Please note that for camshaft service, the cylinder head must be removed. 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Disconnect the negative battery cable from the left shock tower. >The ground cable is equipped with an insulator grommet which should be placed on the stud to prevent the negative battery cable from accidentally grounding.

3. Relieve the fuel system pressure using the recommended procedure. 4. Drain the cooling system. 5. Remove or disconnect the following: Timing belt covers and timing belt Camshaft sprockets by holding them with Tool 6847 while removing the bolt Upper intake plenum Manifold Absolute Pressure (MAP) and Intake Air Temperature (IAT) sensor wiring connectors Air cleaner cover, inlet hoses and air inlet resonator Throttle Position Sensor (TPS) and Idle Air Control (IAC) motor electrical connectors Throttle cable Speed control cable, if equipped Exhaust Gas Recirculation (EGR) tube Lower intake manifold and discard the gasket Spark plug cables ¢ Cylinder head cover 6. Identify the rocker arm shaft assemblies. 7. Install the Auto Lash Adjuster Retainers MD 998443 to keep the auto lash adjusters from falling out of the rocker arms when the rocker arm assembly is removed. 8. Remove or disconnect the following: Rocker arm shaft assemblies from the cylinder head Distributor assembly Exhaust manifold and crossover pipe Cylinder head Thrust case from the left cylinder head

e Camshafts from the rear of the cylinder heads e Camshaft oil seals and discard them 9. Inspect the camshafts for scratches or wom. areas. For light scratches, remove them with 400 grit sand paper. For deep scratches, replace the camshaft and check the cylinder head for damage. Check the oil holes to be sure they are open and free of debris. If the camshaft lobes show signs of wear, check the corresponding rocker arm roller for wear or damage. Replace the rocker arm if worn or damaged. If the camshaft shows signs of wear on the lobes, replace it. To install: 10. Check camshaft end-play, as follows: a. Lubricate the camshaft journals with engine oil and install the camshaft WITHOUT the rocker arm assemblies. b. Move the camshaft rearward as far as it will go. c. Mount a dial indicator to rest on the front of the camshaft. d. Zero the indicator. e. Move the camshaft forward as far as it will go. End-play should be 0.004—0.008 in. (0.1-0.2mm). Maximum allowed end-play is 0.016 in. (0.4mm). 11. Lubricate the camshaft journals 12. Install or connect the following: Camshafts Thrust case to the left cylinder head and torque the fasteners to 108 inch Ibs. (13 Nm) New camshaft seal (lubricate the seal lip), until it is flush with the cylinder head surface Camshaft sprocket and torque the bolt to 75 ft. Ibs. (101 Nm) Cylinder head(s) Lower intake manifold using new gaskets 13. The rocker arm shafts are hollow and used as a lubrication oil duct. Be sure all valvetrain parts are clean. Check the rocker arm mounting portion of the shafts for wear or damage, replace if necessary. Check all oil holes for clogging with a small wire and Clean as required. If any rockers were removed, lubricate and install on the shafts in their original positions. 14. Install or connect the following: ¢ Rocker arm/shaft assemblies ¢ Timing belt

Itis very important that all valve timing marks align properly or engine damage will result.

CIRRUS

CHRYSLER CORP.

SEBRING CONVERTIBLE ¢ STRATUS ¢ BREEZE

9-31

15. Inspect the spark plug tube seals located on the ends of each tube. These seals slide onto each tube to seal the cylinder head cover to the spark plug tube. If these seals show signs of hardness and/or cracking, replace them. 16. Clean all sealing surfaces.

17. Install or connect the following: Cylinder head covers using new gaskets and torque the bolts to 88 inch Ibs. (10 Nm) Spark plug cables Upper intake manifold (plenum) using a new gasket and torque the bolts to 13 ft. Ibs. (18 Nm) Plenum support brackets EGR tube Throttle and speed control cables TP sensor and IAC motor electrical connectors MAP and IAT sensor electrical connectors Air inlet resonator, air inlet hose and air cleaner housing cover All remaining electrical connectors Air tube connections and tighten them Negative battery cable 18. Refill the cooling system. An oil and filter change is recommended whenever a cylinder head has been removed since coolant can get into the oil system.

Operating the engine without the proper amount and type of engine oil will result in severe engine damage. ‘2 ate lade SA a ARES a 19. Start the engine and check for leaks, abnormal noises and vibrations. Bleed the cooling system. 2.7L Engine

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Negative battery Timing chain and secondary chain tensioner bolts Camshaft bearing caps Camshafts, secondary chain and tensioner as an assembly Tensioner and chain from the camshafts To install: 3. Install or connect the following:

93461G07

Tighten the camshaft bearing caps in the proper sequence—2.7L Engine

¢ Camshaft chain on the cams and make certain that the plated links are facing forward 4. Compress the chain tensioner as follows: a. Place the tensioner in a soft jaw vise. b. Slowly compress the tensioner until the fabricated lock pin can be installed in the locking holes. Tensioner between the camshafts and chain. Rotate the cams until the plated links and dots are in the 12 o'clock position Cams to the cylinder head Camshaft bearing caps. Slowly, and in sequence, torque the bolts to 105 inch Ibs. (12 Nm) Secondary chain tensioner bolts and torque them to 105 inch Ibs. (12 Nm). Remove the locking pin from the tensioner Primary timing chain Negative battery cable 3.0L Engine

LEFT BANK 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Negative battery ¢ Timing belt ° Thermostat housing ¢ Blow by hose Positive Crankcase Ventilation (PCV) hose e Spark plug cables

e Rocker arm cover e Rocker arm and shaft e Camshaft sprocket e Thrust case e Camshaft To install: 3. Install or connect the following: e. Camshaft e Thrust case and torque the bolt to 109 inch Ibs. (13 Nm) e Camshaft sprocket and torque the bolt to 65 ft. Ibs. (88 Nm) Rocker arm and shaft assembly and torque to 23 ft. Ibs. (31 Nm) e Rocker arm cover and torque the bolts to 35 inch Ibs. (4 Nm) e Spark plug cables e PCV and blow by hoses e Thermostat housing Timing belt Negative battery cable

RIGHT BANK 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Negative battery Timing belt Intake manifold plenum Breather hose connection Blow by hose connection Spark plug cables Rocker cover Rocker arm and shaft assemblies Distributor Camshaft sprocket Camshaft

Heater Core replacement is covered in Section 2 of this manual

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CHRYSLER CORP.

CIRRUS ¢ SEBRING CONVERTIBLE ¢ STRATUS ¢ BREEZE

To install: e Camshaft Camshaft sprocket and using special Tools MB990767 and MD998715 torque the bolt to 65 ft. Ibs. (88 Nm) Distributor by aligning the timing marks on the cylinder head and the camshaft sprocket Rocker arm/shaft assemblies and torque to 23 ft. Ibs. (31 Nm) Rocker cover and torque the bolts to 35 inch Ibs. (4 Nm) e Spark plug cables Breather and blow by hose connections Intake manifold plenum Timing belt Negative battery cable Valve Lash

@

@

1 — GENERATOR OUTPUT WIRE 2 = PUSH ON SOLENOID CONNNECTOR

3 — BATTERY POSITIVE WIRE 9306FG01

Exploded view of the starter and related components—2.0L engine with a manual transaxle

ADJUSTMENT

e Starter and torque the bolts to 40 ft. lbs. (64 Nm)

2.0L and 2.5L Engines

e Electrical connectors to the starter e Air cleaner resonator

The engines are equipped with Hydraulic Lash Adjusters (HLAs) which are precision units installed in machined openings in the valve actuating ends of the rocker arms. Valve clearance adjustments are not performed.

2.4L, 2.7L and 3.0L Engines The valves are actuated by roller cam followers which pivot on stationary Hydraulic Lash Adjusters (HLAs). The HLAs are precision units installed in machined openings of the cam follower. Valve clearance adjustments are not performed.

e Negative battery cable to the shock tower

2.0L and 2.4L (VIN G) Engines

AUTOMATIC TRANSAXLE 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: ¢ Negative battery cable from the shock tower e Air cleaner resonator ¢ Transmission Control Module (TCM) and move it aside

Starter Motor

REMOVAL & INSTALLATION

connector(s). e Upper starter-to-transaxle bolt e Battery cable from the starter ¢ Solenoid connector by unlocking the red tab and compressing it ¢ Lower starter-to-transaxle bolt e Starter To install: 3. Install or connect the following: e Starter Lower starter-to-transaxle bolt and torque the bolt to 40 ft. Ibs. (54 Nm) Electrical connectors to the starter Upper starter-to-transaxle bolt and torque the bolt to 40 ft. Ibs. (54 Nm) TCM Air cleaner resonator Negative battery cable to the shock tower

2.4L (VIN X) Engine

2.0L Engine

MANUAL TRANSAXLE 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Negative battery cable from the shock tower Air cleaner resonator Electrical connectors from the starter Starter-to-transaxle bolts Starter To install: 3. Install or connect the following;

->Do not disconnect the TCM electrical

1 - BATTERY POSITIVE WIRE 2 — PUSH ON SOLENOID CONNECTOR 9306FG02

Exploded view of the starter and related components—2.0L engine with an auto-

matic transaxle and 2.4L 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 e Air cleaner assembly * Starter cover e Starter electrical connectors © Starter To install: 3. Install or connect the following: * Starter and torque the bolt to 23 ft. lbs. (30 Nm) e Electrical connectors to the starter ¢ Starter cover and torque the bolt to 44 inch Ibs. (5 Nm)

CHRYSLER CORP.

CIRRUS ¢ SEBRING CONVERTIBLE ¢ STRATUS ¢ BREEZE e Ait cleaner assembly e Negative battery cable

2.5L Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Negative battery cable from the shock tower Oil filter e Electrical connectors from the starter e Starter-to-transaxle bolts e Starter

41 — PUSH ON SOLENOID CONNECTOR 2 - BATTERY POSITIVE WIRE

9306FG03

Exploded view of the starter and related components—2.5L engine

sa NIPPLE

To install: 3. Install or connect the following: e Starter and torque the bolt to 40 ft. lbs. (64 Nm) e Electrical connectors to the starter ¢ (il filter e Negative battery cable 2.7L Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Negative battery cable e Oxygen Sensor (02S) electrical connector e Front engine mount through bolt e Starter electrical connectors e Starter To install: 3. Install or connect the following: e Starter and hand tighten the lower bolt * Starter electrical connectors and torque the starter bolts to 40 ft. Ibs. (54 Nm) e Engine mount through bolt and torque it to 45 ft. Ibs. (61 Nm)

Gea

e Oossensor and torque it to 20 ft. Ibs. (27 Nm) e Negative battery cable 3.0L Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Negative battery cable e Air cleaner assembly

e Starter electrical connectors e Starter To install: 3. Install or connect the following: e Starter and torque the bolts to 23 ft. Ibs. (30 Nm) e Starter electrical connectors e Air cleaner assembly e Negative battery cable

REMOVAL & INSTALLATION 2.0L Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. OIL PAN GASKET

er

3

OIL PICK-UP TUBE

OIL PUMP BODY

9-33

L engine Exploded view of the oi! pan and pump assembiy—2.0

Brake service is covered in Section 4 of this manual

OIL PAN

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CHRYSLER CORP.

CIRRUS ¢ SEBRING CONVERTIBLE ¢ STRATUS ¢ BREEZE

2. Drain the engine oil. 3. Remove or disconnect the following: Negative battery cable Transaxle bending bracket Front engine mount and bracket Structural collar from the oil pan Transaxle inspection cover Oil filter and oil filter adapter if equipped with A/C Oil pan and discard the gasket 4. Clean the oil pan and gasket sealing surfaces. To install: 5. Using a suitable rubber adhesive gasket sealant, apply a % in. (3mm) bead at the oil pump-to-engine block parting line. 6. Install or connect the following: Oil pan with a new gasket and torque the bolts 105 inch Ibs. (12 Nm) New oil filter and adapter, if removed Transaxle lower dust cover Structural collar to the oil pan Front engine mount and bracket Transaxle bending bracket Oil pan drain plug and gasket and torque the plug to 25 ft. Ibs. (34 Nm). e Negative battery cable 7. Fill the engine with clean oil. 8. Start the vehicle, check for leaks and repair if necessary.

2.4L (VIN G) Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the engine oil. 3. Remove or disconnect the following: e Negative battery cable ¢ Right inner splash shield e Transaxle dust shield ¢ (il pan and discard the gasket 4. Clean all mating surfaces of any residual gasket material. To install: 9. Using a suitable gasket sealant apply a Ya in. (3mm) bead at the oil pump-toengine block parting line. 6. Install or connect the following: ¢ Oil pan with a new gasket and torque the bolts to 105 inch Ibs. (12 Nm) ¢ Transaxle dust shield e Right inner splash shield ° Negative battery cable 7. Fill the engine with clean oil. ¢ Start the vehicle, check for leaks and repair if necessary,

2.4L (VIN X) Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the engine oil. 3. Remove or disconnect the following: ¢ Negative battery cable ¢ Oil dipstick e Front exhaust pipe e Bell housing cover e (Oil pan and discard the gasket 4. Clean all mating surfaces of any residual gasket material. To install: 5. Install or connect the following: e Oil pan with a new gasket and torque the bolts to 62 inch Ibs. (7 Nm) e Bell housing cover and torque the upper bolt to 80 inch Ibs. (9 Nm) and the lower bolt to 19 ft. Ibs. (26 Nm) ¢ Front exhaust pipe e Oil dipstick e Negative battery cable 6. Fill the engine with clean oil. e Start the vehicle, check for leaks and repair if necessary. 2.5L Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the engine oil. 3. Remove the engine support module as follows: Negative battery cable Exhaust cross under pipe Drive belt splash shield Oil dipstick tube Starter Engine to transaxle bending braces Transaxle inspection cover Qil pan and discard the gasket 4. Clean all mating surfaces of any residual gasket material.

7 in {4 mm)

To install: 5. Install or connect the following: Oil pan with a new gasket and torque the bolts to 50 inch Ibs. (6 Nm) Transaxle inspection cover Engine to transaxle bending braces Exhaust cross under pipe Starter Drive belt splash shield Oil dipstick tube Negative battery cable

6. Fill the engine with clean oil. 7. Start the vehicle, check for leaks and repair if necessary. 2.7L Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the engine oil. 3. Remove the engine support module as follows: e Negative battery cable Oil dipstick and tube Structural collar Exhaust cross under pipe Torque converter cover Lower bolt from the A/C compresSor Oil pan and discard the gasket To install: 4. Clean all mating surfaces of any residual gasket material. ¢ Qil pan with a new gasket 5. Torque the oil pan bolts as follows: a. Timing chain cover to oil pan bolts and torque them to 105 inch Ibs. (12 Nm). b. Oil pan bolts to 21 ft. Ibs. (28 Nm). Cc. Oil pan nuts to 105 inch Ibs. (12 Nm). d. A/C compressor bolt to 21 ft. Ibs. (28 Nm). ¢ Torque converter cover e Exhaust cross under pipe ¢ Structural collar ¢ Oil dipstick and tube ¢ Negative battery cable 6. Fill the engine with clean oil. 7. Start the vehicle, check for leaks and repair if necessary,

SEALANT

3.0L Engine

7922FG37

Apply sealer to the oil pan as shown— 2.5L engine

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the engine oil. 3. Remove the engine support module as follows: ¢ Negative battery cable

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CIRRUS ¢ SEBRING CONVERTIBLE * STRATUS ¢ BREEZE

9-39

through the full flow filter to the main oil galley running the length of the cylinder block. The oil pick-up, pump and check valve provide oil flow to the main oil gallery. A vertical hole at the No. 5 bulkhead routes pressurized oil through a restrictor up past a cylinder head bolt to an oil galley running the length of the cylinder head. The camshaft journals are slotted to allow pressurized oil to pass into the bearing cap cavities. Small holes in the bearing caps direct

93461G08

oil to the camshaft lobes. 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the engine oil. 3. Remove the engine support module as follows: Negative battery cable Crankshaft damper Timing belt and tensioner

Camshaft sprocket Rear timing belt cover Oil pan Oil pick up tube Oil pump and discard the gasket 4. Clean all mating surfaces of any residual gasket material. To install: 5. Prime the oil pump before installation.

93461609

Tighten the lower oil pan bolts in sequence

e Front exhaust pipe e Lower oil pan and discard the gasket e Starter electrical connectors

e Starter e Oil dipstick and guide e Cover e Upper oil pan and discard the gasket 4. Clean all mating surfaces of any residual gasket material. To install: 5. Install or connect the following: e Upper oil pan with a new gasket and torque the bolts, in sequence, to 53 inch Ibs. (6 Nm) Cover and torque the bolts to 96 inch Ibs. (11 Nm) e Starter Starter electrical connectors Oil dipstick and guide with a new

O-ring and torque the bolt to 36 ft.

lbs. (48 Nm) e Lower oil pan with a new gasket and torque the bolts to 96 inch Ibs. (11 Nm) ¢ Front exhaust pipe e Negative battery cable 6. Fill the engine with clean oil. e Start the vehicle, check for leaks and repair if necessary.

REMOVAL & INSTALLATION ae ona cial ce i a 2.0L and 2.4L (VIN X) Engines The oil drawn up through the pick-up tube is pressurized by the pump and routed

6. Install or connect the following: Oil pump with the flats aligned with the crankshaft flats and torque the bolts to 21 ft. Ibs. (28 Nm) New front crankshaft seal Crankshaft sprocket Oil pick up tube and oil pan Camshaft sprocket Rear timing belt cover Timing belt and tensioner Front timing belt cover Crankcase damper Negative battery cable 7. Fill the engine with clean oil.

8. Start the vehicle, check for leaks and repair if necessary. 2.4L (VIN G) Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the engine oil. 3. Remove the engine support module as follows: e Negative battery cable e Oil filter e Oil pressure switch e Oil pan and screen

manual For complete Engine Mechanical specifications, see Section 1 of this

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CHRYSLER CORP.

CIRRUS ¢ SEBRING CONVERTIBLE e STRATUS ¢ BREEZE

Flange bolt Relief plug, spring and plunger Oil filter bracket Oil pump case Front case gasket Oil pump cover Oil pump driven gear Oil pump drive gear Oil pump 4. Clean all mating surfaces of any residual gasket material. To install: 5. Prime the oil pump before installation. 6. Install or connect the following: New.oil seal into the front case Oil pump Oil pump drive gear Oil pump driven gear Oil pump cover Front case gasket Oil pump case Oil filter bracket Relief plunger, spring, gasket and

plug

Flange bolt Oil pan and screen Oil pressure switch New oil filter Negative battery cable 7. Fill the engine with clean oil. 8. Start the vehicle, check for leaks and repair if necessary. 2.5L Engine The oil pump assembly is mounted on the timing belt end of the cylinder block with the inner pump rotor indexed and installed on the crankshaft nose. The oil pump case also retains the crankshaft front oil seal and provides oil pan front end closure. Oil pressure can be checked with a mechanical oil pressure gauge installed at the oil switch location. Oil pressure should be 6 psi (41.4 kPa) at idle and 35-75 psi (241.3-517.1 kPa) at 3000 rpm with the engine at operating temperature.

If an oil pressure problem is suspected or if oil pressure is zero at idle, do not run the engine up to 3000 rpm in an attempt to raise oil presSure or the engine will be severely damaged. Se Because the oil pump is driven off the crankshaft, the timing belt must be removed to access the pump. Use care to properly align all valve timing marks.

M8 x 30MM (1 3/16 IN)

M10 x 5OMM () 31/32 IN)

M8 x 60MM

(2 3/8 IN.) 7922FG40

Oil pump mounting bolt locations and dimensions—2.5L engine

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the engine oil. 3. Remove or disconnect the following: e Negative battery cable e Drive belts e Oil pan e Crankshast damper ¢ Timing belt covers e Timing belt ¢ Crankshaft sprocket and key ¢ Oil pick up tube ¢ Oil pump and discard the gasket 4. Clean all mating surfaces of any residual gasket material. To install: 9. Prime the pump before installation by filling the rotor cavity with clean engine oil. 6. Apply Mopar® Gasket Maker sealer to the pump. 7. Install or connect the following: ¢ New O-ring into the pump body counterbore discharge passage Oil pump and torque the M8 bolts to 10 ft. Ibs. (14 Nm) and M10 bolts to 30 ft. Ibs. (41 Nm) Oil pick up tube and torque the bolts to 12 ft. Ibs. (19 Nm) Crankshaft sprocket and key Timing belt and covers Crankshaft damper Oil pan with a new gasket Drive belts Negative battery cable 8. Fill the engine with clean oil. 9. Start the vehicle, check for leaks and repair if necessary. 2.7L Engine

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the engine oil. 3. Remove the engine support module as follows:

e e e e e e

Negative battery cable Crankshaft damper Timing chain cover Timing chain and sprockets Oil pan Oil pick up tube and O-ring and make certain that the crankshaft is at 60 degrees Above Top Dead Center (ATDC) e Oil pump To install: 4. Prime the pump before installation by filling the rotor cavity with clean engine oil. 5. Install or connect the following: e Oil pump over the crankshaft and torque the bolts to 21 ft. Ibs. (28 Nm) Oil pick up tube with a new O-ring and torque the bolt to 21 ft. Ibs. (28 Nm) Oil pan with a new gasket Timing chain and sprockets Timing chain and cover Crankshaft damper Negative battery cable 6. Fill the engine with clean oil. 7. Start the vehicle, check for leaks and repair if necessary. 3.0L Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the engine oil. 3. Remove the engine support module as follows: Negative battery cable Oil filter Oil pressure switch Oil filter bracket Lower and upper oil pan Baffle plate Oil screen and gasket Baffle plate Relief spring and plunger Front crankshaft oil seal Oil pump case Oil pump cover ee 67.0 8: .€\6... "¢ 6,0" 6, 40° 6 Oil pump outer and inner rotors Oil pump case 4. Clean all mating surfaces of any residual gasket material. To install: 9. Prime the oil pump before installation. 6. Install or connect the following: ¢ Oil pump case e Inner and outer rotors ¢ Oil pump cover and torque the bolts to 89 inch Ibs. (10 Nm) ¢ Oil pump case assembly

CHRYSLER CORP.

CIRRUS ¢ SEBRING CONVERTIBLE ¢ STRATUS ¢ BREEZE New front crankshaft oil seal Relief plunger and spring Baffle plate Oil screen with a new gasket Baffle plate Upper oil pan and cover Lower oil pan Oil filter bracket with a new gasket Oil pressure switch New oil filter Negative battery cable 7. Fill the engine with clean oil. 8. Start the vehicle, check for leaks and repair if necessary.

2. Drain the engine oil. 3. Remove or disconnect the following: e (il pan and discard the gasket Chain cover, guide and tensioner Gear cover and balance shaft gears Balance shaft gear and crankshaft chain sprocket Carrier gear cover and balance shafts Balance Shaft Timing and Installation During installation of the balance shafts to crankshaft, the proper timing procedure must be followed to prevent internal engine damage.

1. Install or connect the following: 2. Install the balance shafts and carrier on the crankshaft. Torque the bolts to 40 ft. Ibs. (54 Nm) 3. Turn the balance shafts until both key ways are pointing up. Install the short hub drive gear on the sprocket driven shaft. 4. Make certain that the key ways and the gear timing marks are properly aligned. 5. Install the gear cover and torque the double ended stud and washer to 105 inch lbs. (12 Nm) 6. Align the flat of the balance shaft drive sprocket to the flat on the crankshaft 7. Install the balance shaft drive

Rear Main Seal

REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Negative battery cable from the left shock tower. >The ground cable is equipped with an insulator grommet which should be placed on the stud to prevent the negative battery cable from accidentally grounding.

e Transaxle ¢ Flexplate/flywheel e Rear crankshaft oil seal using a flat-bladed prying tool To install: ->When installing the seal there is no need to lubricate the sealing surface.

3. Install or connect the following: e New seal using a suitable driver or seal installer e Flexplate/flywheel and torque the bolts to 70 ft. Ibs. (95. Nm) e Transaxle e Negative battery cable 4. Start the engine and check for leaks.

Balance Shaft Chain, Sprockets _ And Cover

Bae

-

REMOVAL & INSTALLATION

i

2.4L (VIN X) Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section.

9-3/

MARK ON SPROCKET KEYWAYS UP ALIGN MARKS PLATED LINK - PARTING LINE (BEDPLATE TO BLOCK) - PLATED LINK WN anh Align the key ways and the gear timing marks

For Accessory Drive Belt illustrations, see Section 1 of this manual

93461G10

9-38

CHRYSLER CORP.

CIRRUS ¢ SEBRING CONVERTIBLE ¢ STRATUS ¢ BREEZE

identification mark “1R” identification mark “2R” Size mark

7922AG02

Piston ring identification mark locations

NO. 1 PISTON RING

pil

NO. 2 PISTON RING

SIDE RAIL

1 - 1MM (0.039 IN.) SHIM 2 - TENSIONER (ADJUSTER) BOLT 3 - PIVOT BOLT

SPACER

“oS

OIL RING

9346J1G11

7922AG03

Properly adjust the chain tension

sprocket to the crankshaft with special tool 6052. 8. Turn the crankshaft until the No. 1 cylinder is at Top Dead Center (TDC). 9. Make certain that the timing marks on the chain sprocket are aligned with the parting line on the left side main bearing cap. 10. Install the chain over the crankshaft and be sure the plated link is over the No. 1 cylinder timing mark on the balance shaft crankshaft sprocket. 11. Place the balance shaft sprocket into the timing chain and align the sprocket dot to the lower plate link on the chain, 12. Slide the balance shaft sprocket on the nose of the balance shaft with the key ways pointing at the 12 o'clock position. 13. When properly timed, install the balance shaft bolts and torque to 21 ft. Ibs. (28 Nm) 14. To tighten the chain use the following procedure: a. Loosely install the chain tensioner. b. Position the guide on the double ended stud and make certain that the tab on the guide fits into the slot on the gear cover. C. Install and tighten the nut/washer assembly to 105 inch Ibs. (12 Nm). d. Place a 1mm thick by 70 mm long shim between the tensioner and chain.

Piston ring orientation—2.0L, 2.4L, 2.5L, 2.7L and 3.0L engines

é. With a load applied, torque the top tensioner bolt to 105 inch Ibs. (12 Nm). f. Torque the bottom pivot bolt to 105 inch Ibs. (12 Nm). g. Remove the shim. 15. Install the carrier covers and torque the bolts to 105 inch Ibs. (12 Nm). 16. Install the oil pan. 17. Fill the engine with clean oil. 18. Start the vehicle, check for leaks and repair if necessary,

Gap of lower

side ae

aS

No. 1

a gap

agen Front of engine

No. 2 ring gap and spacer expander gap

Gap of upper side rail

Piston and Ring 7922AG05

Piston ring end-gap spacing—2.0L and 2.4L (VIN X) engines

POSITIONING

SIDE RAIL UPPER

Cylinder number

7922AG01

Engine connecting rod and cap installation—ensure to matchmark the cap and rod prior to disassembly

CA

if

SS

NO. 1 RING GAP

\

‘Vas

PISTON

GAP AND SPACER EXPANDER GAP 7922AG06

Piston ring end-gap Spacing—2.4L (VIN G), 2.5L, 2.7L and 3.0L engine

CHRYSLER CORP.

CIRRUS © SEBRING CONVERTIBLE ¢ STRATUS ¢ BREEZE

Fa

9-39

( =) ere

tt

NYE FORWARD FOR £1 CYLINDERS 2.46 i \ oe

FACE TOWARD = _FRONT OF ENGINE

WEIGHT DESIGNATION AND DIRECTIONAL ARROW WILL BE IMPRINTED IN THIS AREA

= ARROW 7922AG56

Piston positioning. The arrow or weight marking (L or H) must face toward the timing belt side of the engine—2.0L and 2.4L (VIN X) engines

Fuel System Service Precautions Safety is the most important factor when performing not only fuel system maintenance but any type of maintenance. Failure to conduct maintenance and repairs in a safe manner may result in serious personal injury or death. Maintenance and testing of the vehicle’s fuel system components can be accomplished safely and effectively by adhering to the following rules and guidelines. e To avoid the possibility of fire and personal injury, always disconnect the negative battery cable unless the repair or test procedure requires that battery voltage be applied. e Always relieve the fuel system pressure prior to disconnecting any fuel system component (injector, fuel rail, pressure regulator, etc.), fitting or fuel line connection. Exercise extreme caution whenever relieving fuel system pressure to avoid exposing skin, face and eyes to fuel spray. Please be advised that fuel under pressure may penetrate the skin or any part of the body that it contacts. e Always place a shop towel or cloth around the fitting or connection prior to loosening to absorb any excess fuel due to spillage. Ensure that all fuel spillage (should it occur) is quickly removed from engine surfaces. Ensure that all fuel soaked cloths or towels are deposited into a suitable waste container. ¢ Always keep a dry chemical (Class B) fire extinguisher near the work area. ¢ Do not allow fuel spray or fuel vapors

ee)

S

7922AG09

Piston positioning mark locations—2.5L engine

to come into contact with a spark or open flame. e Always use a back-up wrench when ioosening and tightening fuel line connection fittings. This will prevent unnecessary stress and torsion to fuel line piping. e Always replace worn fuel fitting Orings with new. Do not substitute fuel hose where fuel pipe is installed.

Fuel System Pressure

S

RELIEVING EEE EEE

1. Before servicing the vehicle, refer to the fuel system precautions and to the precautions in the beginning of this section. 9. Remove or disconnect the following: 3. Remove the fuel pump relay from the Power Distribution Center (PDC). 4. Start and run the engine until it stalls. 5. Attempt to restart the engine until it no longer runs. 6. Turn the ignition key to the off position.

nently attached to the filter. Please note that the fuel system pressure must be relieved before servicing fuel system components. In addition, quick-disconnect fittings are used on fuel line connections. When the tubes are fully connected, the locking ears and the fuel tube shoulder are visible in the win-

dows of the connector. 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Disconnect the negative battery cable from the left shock tower. ->The ground cable is equipped with an insulator grommet which should be placed on the stud to prevent the negative battery cable from accidentally grounding.

3. Relieve the fuel system pressure using the recommended procedure. 4. From inside the trunk, disconnect the fuel pump module wiring jumper from the main body harness. The 4-pin connector is located under the trunk mat on the left WINDOW

TAS (2)

REMOVAL & INSTALLATION Frame Mounted

The fuel delivery system contains a replaceable inline filter. The fuel filter mounts to the frame above the rear of the fuel tank. The fuel tank assembly must be loosened and lowered slightly to access the filter, The inlet and outlet tubes are perma-

SHOULDER (ON TUBE)

EAR 7922FG42

Be sure the shoulder and locking tabs are visible through the window of the connec-

tor when attached

on 1 of this manual For Tire, Wheel and Ball Joint specifications, see Secti

9-40

CHRYSLER CORP.

CIRRUS ¢ SEBRING CONVERTIBLE ¢ STRATUS ¢ BREEZE

side of the trunk near the base of the shock tower. Locate the body grommet for the jumper near the base of the rear seat. Push the grommet out and feed the jumper completely through the hole in the body. 9. Remove the fuel cap slowly to release tank pressure. 6. Raise and safely support the vehicle. 7. Locate the drain plug on the bottom left of the fuel tank. Place an approved fuel container with a capacity of at least 16 gallons, under the drain plug. Remove the plug and drain the fuel tank. When finished draining, install the plug since there will be 1—2 gallons of fuel remaining. Tighten the drain plug to 32 inch Ibs. (3.6 Nm). 8. Remove or disconnect the following: e Driver's side fuel tank strap e Passenger's side fuel tank strap loosenit -> Allow the tank to lower until the fuel tank neck touches the rear suspension crossmember.

Wrap shop towels around the fuel hoses to catch any gasoline spillage. ESE

¢ Fuel line quick-disconnect fittings from the fuel pump module. Squeeze fuel filter hose connector releasing tabs and detach the fuel lines ¢ Fuel filter To install: ->The fuel supply (to filter) tube and the return tube (to fuel pump module) are permanently attached to the fuel filter. The ends of the fuel supply and return tubes have different size quickdisconnect fittings. The large quick-disconnect fitting attaches to the large nipple (supply side) on the fuel pump module. The smaller quick-disconnect fitting attaches the small nipple (return side) on the fuel pump module.

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FUEL FILTER 7922FG43

Fuel filter mounting location

9. engine 10. ¢ ¢ ¢

Lubricate the fuel filter nipples with oil. Install or connect the following: Fuel tubes Fuel tank raise it into position Fuel tank straps and torque the bolts to 17 ft. Ibs. (23 Nm)

e*Be sure the fuel pump module electrical harness grommet is installed in the body as the tank is raised into position.

¢ Fuel pump module connector ¢ Negative battery cable 11. Refill the fuel tank. Inlet Filter

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Properly relieve the fuel system pressure. 3. Remove or disconnect the following: e Negative battery cable ¢ Fuel pump module e Locking tabs on the fuel pump ° Strainer and O-ring e Inlet filter from the assembly To install: 4. Install or connect the following: e Inlet filter ¢ New O-ring and strainer ¢ Locking tabs on the fuel pump module ¢ Fuel pump Module Negative battery cable 9. Start the vehicle, check for leaks and repair if necessary,

the precautions in the beginning of this section. 2. Disconnect the negative battery cable from the left shock tower. >The ground cable is equipped with an insulator grommet which should be

placed on the stud to prevent the negative battery cable from accidentally grounding.

3. Remove the fuel filler cap and relieve the fuel system pressure using the recommended procedure. 4. Remove or disconnect the following: ¢ Fuel pump harness electrical connector on the left side of the trunk near the base of the shock tower ¢ Fuel pump harness grommet and push the harness through the hole 5. Raise the vehicle and drain the fuel tank. 6. Remove or disconnect the following: e Fuel tank inlet and from the filler hose ¢ Fuel tank straps. Support with a jack prior to loosening the straps. 7. Carefully lower the tank. 8. Clean the top of the tank to remove any loose dirt. 9. Remove or disconnect the following: e Fuel lines from the fuel pump module ¢ Fuel pump locknut using Spanner wrench tool 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 the module is removed.

REMOVAL & INSTALLATION MEP Ra RAT a

TET

to ed

The in-tank fuel pump module contains the fuel pump and pressure regulator which adjusts fuel system pressure to approximately 49 psi (337.8 kPa). Voltage to the fuel pump is supplied through the fuel pump relay. The fuel pump is serviced as part of the fuel pump module. The fuel pump module is installed in the top of the fuel tank and contains the electric fuel pump, fuel pump reservoir, inlet strainer fuel gauge sending unit, fuel supply and return line connections and the pressure regulator. The inlet Strainer, fuel pressure regulator and level sensor are the only serviceable items. If the fuel pump requires service, replace the fuel pump module. 1. Before servicing the vehicle, refer to

¢ Fuel pump ¢ Fuel tank O-ring and discard it

7922FG44

Removing the fuel pump module lock ring using special tool 6856

CHRYSLER CORP.

CIRRUS ¢ SEBRING CONVERTIBLE * STRATUS ¢ BREEZE

4. Remove or disconnect the following: e Fuel supply line quick quick-connect fitting from the fuel rail e Upper intake manifold plenum and discard the gasket ¢ Fuel injector electrical connectors ¢ Fuel rail from the intake manifold

To install: 10. Thoroughly clean all parts. Wipe the seal area of the tank clean. 11. Install or connect the following: e New O-ring onto the fuel tank e Fuel pump module in the tank ->Be sure the alignment tab on the underside of the pump module flange sits in the corresponding notch in the fuel tank.

e Locking ring and torque it to 40-45 ft. Ibs. (64-61 Nm), using Spanner Wrench Tool 6856 e Fuel tank assembly e Negative battery cable 12. Refill the fuel tank. 13. Turn the ignition switch ON to pressurize the system. Check the fuel system for leaks.

Fuel Injector REMOVAL & INSTALLATION 2.0L and 2.4L Engines 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Disconnect the negative battery cable from the left shock tower. ->The ground cable is equipped with an insulator grommet which should be placed on the stud to prevent the negative battery cable from accidentally grounding.

3. Relieve the fuel system pressure using the recommended procedure. 4. Remove or disconnect the following: ¢ Fuel supply line quick quick-connect fitting from the fuel rail e Fuel injector electrical connectors e Fuel rail from the intake manifold

e>Cover the intake manifold openings to keep dirt from entering the system. 1 — FUEL RAIL 2 — FUEL INJECTOR 3 - INJECTOR CLIP

@

9306FG08

View of the fuel injector—2.0L, 2.4L and engines

e Fuel injector electrical connectors ¢ Fuel supply line quick quick-connect fitting to the fuel rail e Negative battery cable 6. Use a Diagnostic Readout Box (DRB) scan tool Automatic Shutdown (ASD) fuel system test to pressurize the fuel system. Check for leaks. 2.5L and 2.7L Engines 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Disconnect the negative battery cable from the left shock tower. ->The ground cable is equipped with an insulator grommet which should be placed on the stud to prevent the negative battery cable from accidentally grounding.

3. Relieve the fuel system pressure using the recommended procedure.

{ - FUEL RAIL BOLTS 9306FG07

View of the fuel rail assembly—2.5L engine

e Fuel injector clip e Fuel injector(s) from the fuel rail and discard the O-rings To install: 5. Install or connect the following: e Fuel injector to the fuel rail using new O-rings lubricated with engine oil ¢ Fuel injector clip e Fuel rail and torque the bolts to 8 ft. lbs. (12 Nm) ->Be sure the spacers are located under the fuel rail

Fuel injector electrical connectors Fuel supply line quick quick-connect fitting to the fuel rail

Upper intake manifold plenum using a new gasket and torque the bolts to 13 ft. Ibs. (18 Nm) Throttle cables Sensor electrical connectors ¢ Negative battery cable 6. Usea Diagnostic Readout Box (DRB) scan tool Automatic Shutdown (ASD) fuel system test to pressurize the fuel system. Check for leaks. 3.0L Engine

->Cover the fuel injector holes in the intake manifold.

e Fuel injector clip ¢ Fuel injector(s) from the fuel rail and discard the O-rings To install: 5. Install or connect the following: ¢ Fuel injector to the fuel rail using new O-rings lubricated with engine oil e Fuel injector clip e Fuel rail and torque the screws to 44-19 ft. Ibs. (19.5-25.5 Nm)

9-41

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Properly relieve the fuel system pressure. 3. Drain the cooling system. 4. Remove or disconnect the following: Negative battery cable Intake manifold plenum Fuel injector electrical connector Fuel supply and return hoses Vacuum hose Fuel pressure regulator Fuel rail with the injectors Insulators

this manual For Wheel Alignment specifications, see Section 1 of

9-42

CHRYSLER CORP.

CIRRUS ¢ SEBRING CONVERTIBLE ¢ STRATUS © BREEZE

e Fuel injectors and discard the Orings To install: 5. Install or connect the following: e Fuel injector with a new O-ring lubricated with clean engine oil e Insulators

e Fuel rail and torque the bolts to 13 inch Ibs. (12 Nm) e Fuel pressure regulator and torque the bolts to 80 inch Ibs. (9 Nm) e Vacuum hose ¢ Fuel return and supply hoses

e Fuel injector electrical connector e Intake manifold plenum e Negative battery cable 6. Fill the cooling system to the proper level. 7. Start the vehicle, check for leaks and repair if necessary.

DRIVE TRAIN Transaxle Assembly

REMOVAL & INSTALLATION Manual

2.0L, 2.4L (VIN X) AND 2.5L ENGINES

If the vehicle is going to be rolled on its wheels while the transaxle is out of the vehicle, obtain 2 outer CVjoints to install in the hubs. If the vehicle is rolled without the proper torque applied to the front wheel bearings, the bearings will no longer be usable. a

ESS

ED

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: ¢ Negative battery cable from the left shock tower. ->The ground cable is equipped with an insulator grommet which should be placed on the stud to prevent the negative battery cable from accidentally grounding.

e Air cleaner and intake hoses ¢ Clutch housing vent cap ¢ Clutch cable from the bell housing

Using equal force, pry up on both sides of the shifter cable isolator bushings to avoid damaging the cable isolator bushing.

port bracket bolt Upper bell housing-to-throttle body support bracket stud nut Throttle body support bracket Left transaxle mount upper bolts Upper bell housing bolts Vehicle Speed Sensor (VSS) Back-up light electrical connector from the transaxle 3. Install an engine support fixture tool and support the engine. 4. Remove or disconnect the following: ¢ Front wheels e Halfshafts e Lower splash shield/battery cover from the left side Lower bracket bolts, from the left transaxle mount Engine-to-lower crossbar bolts Front steel engine mount bracket 3 front aluminum engine mount bracket bolts ° Starter Rear transaxle mount bracket Transaxle-to-rear lateral bending Strut from engine/transaxle assem| Transaxle bell housing cover 9. Using a transaxle jack, support the transaxle. 6. Rotate the engine clockwise to gain access to the driveplate clutch bolts. ¢ Driveplate clutch bolts Lower engine-to-transaxle bolts ¢ Transaxle 7. To prepare the vehicle for rolling,

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ENGINE BRIDGE FIXTURE

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* Selector lever and crossover cables from the transaxle Shift cable mounting bracket from the transaxle Accelerator cables from the throttle body Accelerator cable bracket from the throttle body Upper starter-to-throttle body Sup-

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7922FG45

Secure the engine assembly with an appropriate support fixture

DRIVE PLATE JO CLUTCH BOLTS

is

7922FG46

Remove the driveplate clutch bolts— rotate the engine clockwise to advance to the next bolt

4

LOWER BELL

7922FG47

Removing the lower engine-to-transaxle mounting bolts

Support the engine with a suitable support Or reinstall the front motor mount to the engine. Then, reinstall the ball joints 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 180 ft. Ibs. (244 Nm). The vehicle may now be safely rolled. To install: 8. Install or connect the following: Transaxle and torque the transaxleto-engine bolts to 70 ft. Ibs. (95 Nm) e Driveplate clutch bolts e Lower engine-to-transaxle bolts and torque the bolts to 70 ft. Ibs. (95 Nm) Transaxle bell housing cover and torque bolts to 9 ft. Ibs. (12 Nm) Transaxle-to-rear lateral bending

CHRYSLER CORP.

CIRRUS ¢ SEBRING CONVERTIBLE ¢ STRATUS ¢ BREEZE strut to the engine/transaxle assembly and torque the bolt to 40 ft. Ibs. (54 Nm) Rear transaxle mount bracket and torque the bolts to 40 ft. Ibs. (54 Nm) e Starter 3 front aluminum engine mount bracket bolts and torque the bolts to 40 ft. Ibs. (54 Nm) Front steel engine mount bracket and torque the bolt to 45 ft. Ibs. (61 Nm) Engine-to-lower crossbar bolts Lower bracket bolts to the left transaxle mount and torque the bolts to 40 ft. lbs. (64 Nm) Lower splash shield/battery cover to the left side Halfshafts Front wheels 9. Remove engine support fixture tool. 10. Install or connect the following: Back-up light electrical connector VSS sensor Upper bell housing bolts and torque the bolts to 70 ft. Ibs. (95 Nm) Left transaxle mount upper bolts and torque the bolts to 40 fi. Ibs. (54 Nm) Throttle body support bracket Upper bell housing-to-throttle body support bracket stud nut and torque the nut to 32 ft. Ibs. (43 Nm) Upper starter-to-throttle body support bracket bolt Accelerator cable bracket to the throttle body

7922FG48

Be sure to connect the ground cable at the

starter

e Accelerator cables to the throttle body e Shift cable mounting bracket to the transaxle e Selector lever and crossover cables to the transaxle e Clutch cable to the bell housing e Clutch housing vent cap e Air cleaner and intake hoses e Negative battery cable 11. Check to be sure that all fasteners are tightened and connections made. 12. Refill the transaxle. 13. Check the transaxle for proper operation. Be sure the reverse lights turn ON when in reverse.

2.4L (VIN G) AND 3.0L ENGINES 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the transaxle fluid. 3. Remove or disconnect the following: Battery and tray Air cleaner assembly Front exhaust pipe, 3.0L only Shift and selection cable connections Back—up light switch connection Vehicle Speed Sensor (VSS) connector Starter Clutch release cylinder connector Transaxle assembly upper coupling bolts Centermember Rear roll stopper Transaxle mount bracket and stopper Stabilizer link Wheel Speed Sensor (WSS), if equipped Brake hose clamp Tie rod end Lower arm Clutch release bearing engagement, 3.0L engine Driveshaft connection Upper oil pan bolt, 3.0L engine Bell housing cover Transaxle assembly lower coupling bolts e Transaxle assembly To install: 4. Install or connect the following: e Transaxle assembly. Torque the lower coupling bolts to 36 ft. Ibs. (48 Nm) 2.4L engine and to 52 ft. lbs. (71 Nm) 3.0L engine e Bell housing cover and torque the

9-43

cover—to—engine bolt to 80 inch lbs. (9 Nm) and the cover—to— transaxle bolt to 19 ft. Ibs. (26 Nm) Upper oil pan bolt, 3.0L engine Driveshaft connection Clutch release bearing engagement Lower arm and torque the nut to 80 ft. lbs. (108 Nm) Tie rod end and torque the nut to 21 ft. Ibs. (28 Nm) WSS, if equipped Stabilizer link and torque the nut to 33 ft. Ibs. (45 Nm) Transaxle mount bracket and torque the nut to 42 ft. bs. (67 Nm) Tranasxle mount stopper and torque the nut to 60 ft. Ibs. (81 Nm) Rear roll stopper and torque the nut to 33 ft. Ibs. (45 Nm) Centermember Clutch release cylinder and torque to 13 ft. Ibs. (18 Nm) Starter motor and electrical connectors VSS connector Back—up light switch connector Shift and selection cable connections Front exhaust pipe, 3.0L engine Air cleaner assembly e Battery and tray 5. Fill the transaxle fluid to the proper level. 6. Start the vehicle, check for leaks and repair if necessary. Automatic

Bs WARNING

if the vehicle is going to be rolled on its wheels while the transaxle is out of the vehicle, obtain 2 outer CVjoints to install to the hubs. If the vehicle is rolled without the proper torque applied to the front wheel bearings, the bearings will no longer be usable. 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the transaxle. 3. Disconnect the negative battery cable from the left shock tower. ~The ground cable is equipped with an insulator grommet which should be placed on the stud to prevent the negative battery cable from accidentally grounding.

on 1 of this manual For Maintenance Interval recommendations, see Secti

9-4

CHRYSLER CORP.

CIRRUS ¢ SEBRING CONVERTIBLE ¢ STRATUS ¢ BREEZE

7922FG49

Location of the transaxle solenoid assembly 8-way connector and retaining bolt

7922FG50

Removing the shift cable and clamp

4. Remove or disconnect the following: e Air cleaner duct e Transmission Control Module (TCM) ¢ Solenoid pack electrical connector ¢ Dipstick tube from the transaxle e Transaxle cooler lines e Shift lever cable from the transaxle lever

5. Using an engine support fixture tool, support the engine assembly. 6. Remove or disconnect the following: Upper transaxle mount top bolts from the left side Front wheels Lower splash shields from both

sides Exhaust pipe from the exhaust manifold Upper transaxle mount remaining bolts from the left side Engine oil filter Starter Front engine mount bracket Rear mount bracket through-bolt Centermember bolts Rear mount bracket Radiator lower crossmember Both lateral bending strut brackets Flexplate cover

7. Matchmark the converter-to-flexplate location. Rotate the crankshaft clockwise to align the converter bolts. 8. Install or connect the following: e Converter-to-flexplate bolts e Crankshaft Position (CKP) sensor, if equipped e Transaxle electrical connectors e Right side steering gear and Kframe bolts e Sway bar mounts 9. Using a transmission jack and a safety chain, secure the transaxle and support it. 10. Install or connect the following: ¢ Bell housing-to-engine bolts e Transaxle, by moving the K-frame

rearward 11. To prepare the vehicle for rolling, Support the engine with a suitable support or reinstall the front motor mount to the engine. Then, reinstall the ball joints to the steering knuckle and install the retaining bolt. Install the obtained outer C\V-joints to the hubs, install the washers and tighten the axle nuts to 180 ft. Ibs. (244 Nm). The vehicle may now be safely rolled. To install: 12. Install or connect the following: Transaxle, by moving the K-frame rearward Bell housing-to-engine bolts and torque the bolts to 70 ft. Ibs. (95 Nm) Sway bar mounts Right side steering gear and Kframe bolts Transaxle electrical connectors CKP sensor, if equipped 13. Align the converter-to-flexplate matchmark. Rotate the crankshaft clockwise to align the converter bolts. 14. Install or connect the following: Torque converter and torque the converter-to-flexplate bolts to 55 ft. lbs. (74 Nm) Flexplate cover and torque the bolts to 108 inch Ibs. (12 Nm) Both lateral bending strut brackets and torque the bolts to 45 ft. Ibs. (61 Nm) Radiator's lower crossmember and torque the bolts to 45 ft. Ibs. (61 Nm) Rear mount bracket Centermember bolts and torque the bolts to 45 ft. Ibs. (61 Nm) Rear mount bracket through-bolt and torque the through-bolt to 45 ft. Ibs. (61 Nm) Front engine mount bracket and torque the bolts to 24 ft. Ibs. (33 Nm)

Starter New engine oil filter Upper transaxle mount remaining bolts to the left side Exhaust pipe to the exhaust manifold ‘Lower splash shields to both sides Front wheels Upper transaxle mount top bolts, to the left side Shift lever cable to the transaxle lever and torque the nut to 14 ft. lbs. (19 Nm) Transaxle cooler lines Dipstick tube to the transaxle Solenoid pack electrical connector

TCM Air cleaner duct Negative battery cable 15. Adjust the gearshift and throttle cables. 16. Refill the transaxle. 17. Check the transaxle for proper operation. Be sure the back-up lights and speedometer are working properly.

SEBRING, STRATUS SEDAN ONLY 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the transaxle. 3. Remove or disconnect the following: Negative battery cable

Air cleaner assembly Transaxle dipstick tube Transaxle cooler lines flush with the fittings Solenoid/pressure switch assembly Transmission range sensor connector Input and output speed sensor connectors Shift cable from the manual valve lever and bracket Crankshaft Position (CKP) sensor Throttle body support bracket Oxygen Sensor (0 2S) harness retainer Rear mount bracket—to— transaxle case bolts Upper starter bolt Halfshafts Rear mount and bracket Front mount bracket and mount Starter assembly Torque converter dust shield and properly support the engine/transaxle assembly Left mount bracket —to—transaxle bolts and lower the assembly slightly Transaxle assembly

CHRYSLER CORP.

CIRRUS ¢ SEBRING CONVERTIBLE ¢ STRATUS ¢ BREEZE To install: 4. Install or connect the following: Transaxle and torque the bolts to 70 ft. Ibs. (95 Nm) Upper mount. Raise the assembly into position and torque the through bolt to 55 ft. Ibs. (70 Nm) Torque converter bolts and remove the engine/transaxle assembly support Torque converter dust shield Starter and lower bolt Front mount and bracket Rear mount and bracket Halfshafts Upper starter bolt O 2S harness retainer Throttle body support bracket CKP sensor electrical connector Gearshift cable to manual valve lever Output and input sensor connectors Transmission range sensor connector Solenoid/pressure switch connector Oil cooler lines using the service splice kit Transaxle dipstick tube Air cleaner assembly Negative battery cable 5. Fill the transaxle fluid to the proper level. 6. Start the vehicle, check for leaks and repair if necessary.

1. With slight pressure, pull the clutch release lever end of the cable to draw the cable taut. 2. Push the clutch cable housing toward the dash panel. With less than 25 Ibs. (11 kg) of effort, the cable housing should move 1.2-2.0 in. (30-50mm). This indicates proper adjuster mechanism function. 3. If the cable does not adjust, determine if the mechanism is properly seated on the bracket.

ADJUSTMENT a

>The ground cable is equipped with an insulator grommet which should be placed on the stud to prevent the negative battery cable from accidentally grounding.

e Starter Rear and front transaxle support brackets Clutch inspection cover Modular clutch-to-flywheel bolts Transaxle assembly with the clutch as an assembly Clutch assembly from the transaxle input shaft To install: 3. Clean all parts well. Inspect for oil leakage through the engine rear crankshaft oil seal and transaxle input shaft seal. If leakage is noted, it should be corrected at this time. 4. Examine the throwout or clutch release bearing. It is pre-lubricated and sealed and should not be washed in solvent. The bearing should turn smoothly when held in the hand with a light thrust load. A light drag caused by the lubricant fill is normal. If the bearing is noisy, rough or dry, replace the complete bearing assembly. In most cases where a clutch is being serviced, the complete clutch assembly and

e>The transaxle assembly must be removed to service the clutch assembly.

1. Before servicing the vehicle, refer to the precautions in the beginning of this section.

CLUTCH CABLE AT CLUTCH PEDAL

CLUTCH CABLE AT TRANSAXLE 7922FG51

Clutch cable routing

UPPER COVER 4 BOUT

DRIVE PLATE TO CLUTCH BOLT

2.0L, 2.4L (VIN X) and 2.5L Engines

FREE-PLAY The manual transaxle clutch release system has a unique self-adjustirig mechanism to compensate for clutch disc wear. This adjuster mechanism is located with the clutch cable assembly. 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. No manual adjustment is necessary. When servicing this vehicle or if removing and installing the clutch cable, do not pull on the clutch cable housing to remove it from the dash panel. Damage to the cable self-adjuster may OCCU. To check the function of the adjuster mechanism, use the following procedure:

2. Remove or disconnect the following: e Negative battery cable from the left shock tower

REMOVAL & INSTALLATION

ENGINE

CRANKSHAFT TO DRIVE PLATE

golT BACKING

PLATE DRIVE PLATE BOLT TRANSAXLE

TRANSAXLE CASE UPPER COVER DRIVE PLATE

9-45

CLUTCH ASSEMBLY

Exploded view of the clutch assembly

manual For Tune-up, Capacities and Firing orders, see Section 1 of this

9-46

CHRYSLER CORP.

CIRRUS ¢ SEBRING CONVERTIBLE ¢ STRATUS ¢ BREEZE

release bearing are usually replaced together. 5. Check the condition 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 is Teflon® coated and should be installed WITHOUT any lubricant such as grease which will break down the Teflon® coating. Be sure the ball stud and fork pocket are clean of contamination and dirt. When assembling the fork to the bearing, the small pegs on the bearing must go over the fork arms. 6. Check the flywheel for cracks, glazing or grooves. If.any of these conditions exist, machine (reface) or replace the flywheel to prevent clutch chatter and premature clutch wear. The manual transaxle is equipped with a reverse brake. It functions as a synchronizer, but only if the vehicle is not moving. When the clutch pedal is depressed to the floor and held for 3 seconds, and the transaxle shifts to reverse, no gear clash should be present. If there is, the input shaft should be checked. When the transaxle is removed for clutch service, check the input clutch shaft, clutch disc splines and release bearing for dry rust. If present, clean rust off and apply a light coat of high temperature bearing grease to the input shaft splines. Apply grease on the input shaft splines only where the clutch disc slides. Verify that the clutch disc slides freely along the input shaft splines.

7. Install or connect the following: Modular clutch assembly onto the transaxle input shaft Transaxle assembly New clutch-to-driveplate (flywheel) bolts. Tighten the bolts, in a crisscross pattern, a few turns at a time to 55 ft. Ibs. (75 Nm) Clutch inspection cover Transaxle lower support brackets

Starter Negative battery cable 8. Road test the vehicle to check for proper clutch operation.

2.4L (VIN G) and 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

¢ Clutch fluid line bracket

1 2 3 4

~ — — ~

ISOLATORS JOUNCE BUMPER SHOCK ABSORBER WATTS LINK (UPPER)

5 6 7 8

— — — —

WATTS LINK (LOWER) BELL CRANK AXLE COIL SPRING 9346JG12

Exploded view of the clutch assembly-3.0L engine

Insulator, washer and clutch tube Union, union bolt and gasket Valve and spring, 3.0L engine Clutch release cylinder Clutch cover and disc Release fork shaft, 3.0L engine Left support spring, 3.0L engine Release fork Clutch release bearing Release fork boot and fulcrum, 2.4L engine Release fork boot and maintenance cover, 3.0L engine To install: 3. Install or connect the following; Release fork boot and maintenance cover, 3.0L engine Release fork boot and fulcrum and torque the fulcrum to 26 ft. Ibs. (35 Nm) Clutch release bearing Release fork Left support spring and release fork shaft, 3.0L engine Clutch disc and cover and torque the bolts to 14 ft. Ibs. (19 Nm) Clutch release cylinder Valve and spring, 3.0L engine Union, bolt and gasket and torque the bolt to 17 ft. Ibs. (23 Nm)

e Insulator, washer and clutch tube and torque the fastener to 11 ft. Ibs.

(15 Nm)

¢ Fluid line bracket and torque the bolt to 14 ft. Ibs. (19 Nm) ¢ Negative battery cable 4. Check and top off the fluid level, if necessary.

REMOVAL & INSTALLATION _—

2.0L, 2.4L (VIN X) 2.5L and 2.7L Engines elf the vehicle 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.

If the vehicle is rolled without the proper torque applied to the front wheel bearings, the bearings will no longer be usable.

1. Before servicing the vehicle, refer to the precautions in the beginning of this section.

CHRYSLER CORP.

CIRRUS ¢ SEBRING CONVERTIBLE ¢ STRATUS ¢ BREEZE 2. Remove or disconnect the following: e Negative battery cable Cotter pin, nut lock and spring washer Halfshaft nut, loosen it while the vehicle is on the floor with the brakes applied Wheel e Brake caliper assembly and support it on a wire Brake rotor Halfshaft nut and washer Tie rod end from the steering knuckle using joint separation Tool MB991113

Use of improper methods of joint separation can result in damage to the joint, leading to possible failure. e Speed sensor cable routing bracket, if equipped with an Anti-lock Brake System (ABS) Sway bar link from the damper fork, if necessary Damper fork assembly Steering knuckle from the lower control arm Halfshaft by pressing it from the hub e» After pressing the outer shaft, insert a prybar between the transaxle case and the halfshaft and pry the shaft from the transaxle.

Do not pull on the shaft. Doing so damages the inboard joint. Do not insert the prybar too far or the oil seal in the case may be damaged. HUB/BEARING 7 =

ey} /

@ STEERING KNUCKLE

2.4L (VIN G) and 3.0L Engine INNER TRIPODZ JOINT

'a

PRY BAR

|

\

ee

CASE

he 7922FG54

Inserting the prybar too far may damage the transaxle seal

To install: 3. Inspect the halfshaft boot for damage or deterioration. Check the ball joints and Splines for wear. 4. Replace the circlips on the ends of the halfshaft(s). 5. Install or connect the following: Halfshaft into the transaxle until it is fully seated Halfshaft into the hub by pulling the knuckle assembly outward Washer. Make sure the chamfered edge faces outward Halfshaft nut and tighten temporarily Control arm to the steering knuckle and torque the nuts to 43-82 ft. lbs. (59-71 Nm) Damper fork and torque the lower through-bolt/nut to 65 ft. Ibs. (88 Nm) and the upper pinch bolt to 76 ft. lbs. (103 Nm) Tie rod end, to the steering knuckle and torque the nut to 17-25 ft. Ibs. (24-33 Nm) and install a new cotter pin Sway bar link to the damper fork and torque the link nut to 29 ft. Ibs. (39 Nm) Lockwasher and axle nut and torque the nut to 145-188 ft. Ibs.

(200-260 Nm)

{

a"

->Before securely tightening the axle nut, be sure there is no load on the wheel bearings.

OUTER C/V JOIN

7922FG53

Carefully remove the outer CV-joint from the steering knuckle—be careful NOT to damage the threads or splines on the joint

9-47

e Brake rotor and caliper assembly ¢ New cotter pin e Whee! Negative battery cable 6. Refill the transaxle. 7. Test drive the vehicle and check for proper operation.

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Negative battery cable Front wheel Vehicle Speed Sensor (VSS) cable, if equipped Brake hose clip and cotter pin Driveshaft nut Lower arm ball joint connection Tie rod end Stabilizer link Driveshaft and circlip To install: 3. Install or connect the following: Driveshaft Stabilizer link and torque the nut to

33 ft. Ibs. (44 Nm) Tie rod end and torque the nut to 21 ft. Ibs. (28 Nm) New cotter pin to the tie rod end Lower arm ball joint Driveshaft nut and torque it to a maximum of 167 ft. Ibs. (226 Nm) New cotter pin to the driveshaft nut Brake hose clip VSS cable, if equipped Front wheel Negative battery cable

OVERHAUL ET

Inner Tri-pot Joint

1. Remove or disassemble the follow-

ing: e Negative battery cable e Halfshatt e Large and small boot retaining clamps 2. Slide the boot down the shaft away from the tri-pot housing. ->When separating the spider joint from the tri-pot joint housing, hold the rollers in place on the trunions to prevent the rollers and needle bearings from falling away.

3. Carefully slide the shaft/spider assembly from the tri-pot housing. 4. Remove the spider assembly-to-shatt snapring; then, slide the spider assembly off the shaft.

For complete service labor times, order Nichols’ Chilton Labor Guide

9-48

CHRYSLER CORP.

CIRRUS © SEBRING CONVERTIBLE * STRATUS ¢ BREEZE

®

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®

®

=m

oas(i (ae E) 1 2 3 4 5 6 7

— — — — — — —

©)

©

STUB AXLE OUTER C/V JOINT OUTER C/V JOINT BOOT TUNED RUBBER DAMPER WEIGHT INTERCONNECTING SHAFT OUTER C/V JOINT BOOT STUB AXLE

8 — 9 — 10 — 11 — 12 — 13 14 —

OUTER C/V JOINT RIGHT DRIVESHAFT INNER TRIPOD JOINT BOOT INNER TRIPOD JOINT INNER TRIPOD JOINT INNER TRIPOD JOINT BOOT INTERCONNECTING SHAFT LEFT DRIVESHAFT 9306EG02

View of the halfshaft assemblies—Typical

of excessive wear. If necessary, replace the halfshaft. If necessary, tap the spider assembly off the shaft using a brass drift; be careful not to hit the outer bearings.

e» Component parts are not serviceable and must be replaced as an assembly. To assemble:

5. Slide the boot off the shaft. 6. Throughly inspect all parts for signs The Tri-pot sealing boots are made of 2 different types of material; silicon rubber (high temperature) which is soft and pliable or Hytrel plastic (standard temperature) which is stiff and rigid. Be sure to replace the boot made of the correct material.

1 2 3 4 5

— — — — —

SNAP RING SEALING BOOT SPIDER ASSEMBLY SNAP RING PLIERS INTERCONNECTING

SHAFT 9306BG14

View of the halfshaft inner tri-pot joint and snapring

1 - SEALING BOOT 2 — RAISED BEAD IN THIS AREA OF SEALING BOOT 3 — GROOVE 4 — INTERCONNECTING SHAFT

9306EG04

View of the halfshaft boot and shaft

7. Slide the inner tri-pot boot clamp and boot onto the shaft; then, position the boot so that only the thinnest (sight) groove is visible on the shaft. 8. Install the spider assembly onto the shaft just far enough so that the snapring can be installed.

If necessary, tap the spider assembly onto the shaft using a brass drift; be careful not to hit the outer bearings. SS

SS

9. Install the snapring onto the shaft:

1 — SEALING BOOT 2 — SPECIAL TOOL C-4975 3 — CLAMP BRIDGE

9306BG13

Securing the halfshaft boot clamp

CHRYSLER CORP.

CIRRUS ¢ SEBRING CONVERTIBLE ¢ STRATUS ¢ BREEZE housing retaining groove and install the retaining clamp evenly on the boot. 14. If using a crimp type boot clamp, perform the following procedure: a. 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). b. 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). 15. If using a latching type boot clamp, perform the following procedure: a. Position Snap-On® Clamp Locking Tool YA3050 prongs in the clamp holes. b. Squeeze the tool until the upper clamp band is latched behind the 2 tabs on the lower clamp band. 16. Install the halfshaft into the vehicle.

1 — CLAMP 2 — SPECIAL TOOL YA3050 3 - SEALING BOOT 9306EG07

Tightening the low profile boot clamp— Silicone rubber Tri-pot boot

Rzeppa (Outer) Joint 1. Remove or disassemble the following: Halfshaft and place it in a softjawed vise Rzeppa joint boot clamps and slide the boot down the shaft Rzeppa joint housing by sharply hitting it with a soft-faced hammer to drive it off the shaft Circlip from the shaft Boot by sliding it off the shaft

1 — 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 9306EG08

Secured the low profile boot clamp—Silicone rubber Tri-pot boot

make sure that the snapring is fully seated in the groove. 10. If installing a new boot, distribute Y2 of the grease in the service package inside the tri-pot housing and the other V2 inside the boot. 11. Carefully, slide the spider assembly and shaft into the tri-pot housing. 12. Position the inner boot clamp evenly on the sealing boot.

>

WARNING

If any parts show excessive wear, replace the halfshaft assembly; the component parts are not serviceable. a

RIB

ES

FES

EEE

RE

SES TB

To assemble: 2. Install or assemble the following: e New small boot clamp and slide it onto the shaft

> WARNING

13. Position the boot onto the tri-pot

SOFT FACED HAMMER STUB AXLE OUTER C/V JOINT NUT

9306EG10

Driving the Rzeppa joint onto the shaft

e Boot and slide it onto the shaft e Circlip, if removed 3. Position the boot so that the raised bead on the inside the boot seal is in the shaft groove. 4. Install or assemble the following: e Halfshaft hub nut onto the Rzeppa joint threaded shaft so it is flush with the end e Rzeppa joint and align the shaft Splines and tap it onto the shaft with a soft-faced hammer so it locks on the circlip 5. Distribute 72 of the grease in the service.package inside the Rzeppa joint housing and the other 2 inside the boot. 6. Install or connect the following: e New small boot clamp and position it evenly on the sealing boot 7. 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).

~ tok WARNING The seal must not be dimpled, stretched or out of shape. If necessary, equalize the seal pressure and shape it by hand. 8. Position the boot onto the Rzeppa housing retaining groove and install the retaining clamp evenly on the boot. 9. Using the Crimper Too! C-4975-A, place the tool over the clamp bridge, tighten the tool nut until the jaws are completely closed (face-to-face).

The seal must not be dimpled, stretched or out of shape. If necessary, use a trim stick to seat and equalize the seal pressure and shape it by hand. e>if using a Hytrel (hard plastic) boot, be sure the stick is inserted between the soft rubber insert and the tri-pot housing, not between the hard plastic sealing boot and the soft rubber insert.

if — 2 ~ 3 — Ate

9-49

tok WARNING 1 — INTERCONNECTING SHAFT 2 - CROSS 3 — OUTER C/V JOINT ASSEMBLY

9306EG09

Aligning the cross splines with the shaft splines—Rzeppa joint

The seal must not be dimpled, stretched or out of shape. If necessary, equalize the seal pressure and shape it by hand.

Please visit our web site at www.chiltonsonline.com

10. Install the halfshaft into the vehicle.

9-50

CHRYSLER CORP.

CIRRUS ¢ SEBRING CONVERTIBLE ¢ STRATUS © BREEZE clearance between the boot and the bands

2.4L (VIN G) AND 3.0L ENGINES 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove halfshaft and place it ina Soft jawed vise. 3. Disassemble or remove: e Tri-pot joint e Dynamic damper e Birfield joint boot bands e Birfield joint boot To install: 4, Assemble or install: e Birfield joint boot e Birfield joint boot small band 5. Place the halfshaft in a soft jawed vise so that the birfield joint is standing vertically. 6. Position the boots small diameter so that only 1 groove is exposed on the shaft. 7. Adjust the Band Crimper Too! MB991561 so that the jaw opening is 0.114 in. (2.9mm). 8. Position the small band so there is

mating edge. 9. Using a Band Crimper Tool MB991561, crimp the small band until the internal measurement of the crimp is 0.094-0.110 in. (2.4-2.8mm).

jection and a gap exists between the clamp and the boot. 14. Using a Band Crimper Tool MB991561, crimp the small band until the internal measurement of the crimp is 0.094-0.110 in. (2.4—2.8mm).

> WARNING If the crimp dimension is not correct, remove the band install a new one.

10. Using 5.47 oz. (155g) specified amount of grease in the repair kit, pack the birfield boot. 11. Position the boot so 0.004—0.061 in. (0.1-1.55mm) of clearance exists between the boots large diameter end and the birfield joint housing shoulder. 12. Adjust the Band Crimper Tool MB991561 so that the jaw opening is 0.126 in. (3.2mm). 13. Install and position the large boot band so that it rests against the boot(s) pro-

B.J. boot

—,

If the crimp dimension is not correct, remove the band install a new one.

15. If equipped with a 2.0L (DOHC) engine, install the dynamic damper by performing the following procedure: a. Slide the damper onto the halfshaft with new bands. b. Position the damper so the distance from the front of the birfield joint to the front edge of the damper assembly is 14.60-14.84 in. (371-377mm) for the right halfshaft or 7.52—7.76 in. (191-197mm) for the left halfshaft. c. Tighten and secure the damper bands. 16. Install the tri-pot joint.

B.J. boot band (small)

Projection 9306CG15

93060613

Positioning the birfield joint boot’s small diameter

MB991561

Positioning the birfield joint boot’s small band

}

93060617

Positioning the birfield joint boot’s large diameter

B.J. boot

AY

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Projection B.J. boot band (large)

D Adjusting bolt

9306CG18 9306014

View of the band crimper tool

93060616

Measuring the small band’s crimp

Positioning the birfield joint boot’s large band

9-51

CHRYSLER CORP.

CIRRUS © SEBRING CONVERTIBLE ¢ STRATUS ¢ BREEZE

NN

|

STEERING AND SUSPENSION

2

work, allow the system capacitor 2 minutes to discharge after disconnecting and isolating the negative battery cable.

CAUTION

Some vehicles are equipped with an air bag system, also known as the Supplemental Inflatable Restraint (SIR) 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.

PRECAUTIONS Several precautions must be observed when handling the inflator module to avoid accidental deployment and possible personal injury. ->Before servicing the vehicle, also refer to the precautions in the beginning of this section.

e Never carry the inflator module by the wires or connector on the underside of the module. e When carrying a live inflator module, hold securely with both hands, and ensure that the bag and trim cover are pointed away. e Place the inflator module on a bench or other surface with the bag and trim cover facing up. e With the inflator module on the bench, never place anything on or close to the module which may be thrown in the event of accidental deployment.

DISARMING This air bag system is a sensitive, complex, electromechanical unit. Proper SRS (also called Supplemental Inflatable Restraint, or SIR, or air bag system) disarming can be obtained by disconnecting and isolating the negative battery cable (wrapping the battery cable end with electrical tape is a good method for isolating it). Failure to disconnect the battery could result in accidental air bag deployment and possible personal injury. Before beginning Service

Power Rack and Pinion Steering Gear REMOVAL & INSTALLATION 2.0L, 2.4L (VIN X), 2.5L and 2.7L Engines 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Negative battery cable from the left shock tower

: ¢ 8 crossmember-to-chassis bolts 7. Lower the lifting device enough to gain access to the steering rack. 8. Remove or disconnect the following: Power steering lines and drain the fluid Power steering pressure switch electrical connector Solenoid control module electrical connector, if equipped with speed proportional steering Both steering rack isolator bolts Both steering rack saddle bracket bolts Steering rack

~The ground cable is equipped with an insulator grommet which should be placed on the stud to prevent the negative battery cable from accidentally grounding.

Intermediate shaft coupler pin bolt retaining pin Intermediate shaft coupler pin bolt Front wheels Tie rod ends by holding the tie rod end stud with a 1%2 in. socket and loosen the retaining nut Tie rod end from the steering knuckle

STEERING GEAR

FRONT SUSPENSION CROSSMEMBER

7922FG55

Steering gear rear mounting bolt location

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STEERING GEAR

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->Before removing the front suspension crossmember from the vehicle scribe the front suspension crossmember and the vehicle body. This must be done to retain the proper alignment. The caster and camber are not adjustable.

3. Scribe a line on the body and on the crossmember on all 4 sides. 4. Remove or disconnect the following: e Stabilizer 3 anti-lock brake controller-tocrossmember bolts and secure it to the chassis, if equipped with Antilock Brake System (ABS) Strut clevis from the lower control arm Both engine support bracket-tocrossmember bolts Engine support bracket-to-transaxle mounting bracket bolt 5. Place a lifting device under the front suspension crossmember. 6. Remove or disconnect the following:

7922FG57

Steering gear front mounting bolt location

BOLTS (2} (==

SS STEERING GEAR

ISOLATOR

SAMDIE

, BRACKET

sae: ic

FRONT SUSPENSION CROSSMEMBER

oe 7922FG56

Check the condition of the isolator—if

worn or oil soaked, replace

Timing belt service is covered in Section 3 of this manual

9-52

CHRYSLER CORP.

CIRRUS ¢ SEBRING CONVERTIBLE ¢ STRATUS ¢ BREEZE Pressure tube and return hoses and torque to 11 ft. Ibs. (15 Nm) Tie rod ends to the steering knuckle

e Negative battery cable 12. Refill the power steering system. 13. Start the engine and allow it to run for a few minutes.

To install: 9. Install or connect the following: e Steering rack e lsolator and saddle bracket and torque the bolts to 50 ft. Ibs. (68 Nm) e Power steering pressure and return lines and torque the lines to 23 ft. lbs. (31 Nm) e Crossmember, install the rear bolts first and torque the bolts to 20 inch lbs. (2 Nm) 10. Using a soft faced hammer tap the crossmember into position.

14. power 15. sary. 16.

Raise the front wheels off the ground. 17. Start the engine and turn the wheel from stop-to-stop to bleed any air from the system. 18. Check the fluid level and add, if nec-

essary. 19. Check and adjust the alignment.

->Be sure to align the scribed marks on the crossmember.

11. Install or connect the following: e Crossmember, starting with the rear bolts and torque the bolts to 120 ft. lbs. (163 Nm) Both engine support bracket-tocrossmember bolts Engine support bracket-to-transaxle bracket bolt and torque the 3 bolts to 55 ft. Ibs. (75 Nm) Power steering pressure switch ABS control unit and torque the bolts to 21 ft. Ibs. (28 Nm) Heat shield on the tie rod ends Shock clevis to the lower control arm Tie rod ends and torque the nuts to 45 ft. Ibs. (61 Nm) Both stabilizer clamps Strut clevis bolt and torque the bolt to 68 ft. Ibs. (92 Nm) Wheels and torque the lug nuts to 95 ft. Ibs. (129 Nm) Intermediate shaft pin bolt and retaining pin and torque the pin bolt to 20 ft. Ibs. (27 Nm)

and torque the nut to 21 ft. Ibs. (29 Nm) \ Stay and torque the bolts to 56 ft. lbs. (74 Nm), 2.4L only Steering shaft assembly and torque

Shut OFF the engine and check the steering fluid. Add power steering fluid if neces-

2.4L (VIN G) and 3.0L Engines 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the power steering fluid. 3. Remove or disconnect the following: Negative battery cable from the left shock tower Front exhaust pipe Center member Sway bar, 2.4L only Steering shaft assembly Stay, 2.4L only Tie rod end from the steering knuckle Return hose and pressure tube connections Cylinder clamp Steering gear from the vehicle To install: 4. Install or connect the following: e Steering gear to the vehicle ¢ Cylinder clamp and torque the bolts to 51 ft. Ibs. (69 Nm)

ivi

pie

the bolt to 13 ft. Ibs. (18 Nm) Sway bar, 2.4L Only Center member Front exhaust pipe, 2.4L only Negative battery cable 5. Fill and bleed the power steering system. 6. Start the vehicle, check for leaks and repair if necessary. 7. Perform a front wheel alignment.

REMOVAL & INSTALLATION Front

2.0L, 2.4L (VIN X), 2.5L AND 2.7L ENGINES 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Front wheel Steering knuckle Strut-to-shock clevis pin bolt Clevis-to-lower control arm through-bolt Clevis from the strut by tapping it with a brass drift 4 strut-to-shock tower bolts Strut/upper control arm mounting bracket as an assembly To install: 3. Install or connect the following: ¢ Strut into the shock tower ¢ 4 upper strut mounting bolts and

Saye 13 + 1 ft-tb

15*3N-m

SPECIAL TOOL C3894-A

7424 Nem 55 * 3 ft-lb

69=9Nm

51 +7

ft-lb

7922FG58 93461613

Exploded view of the steering gear assembly—2.4L (VIN G)

Separating the upper ball joint from the steering knuckle

CIRRUS ©SEBRING CONVERTIBLE

CHRYSLER CORP.

STRATUS ¢ BREEZE

9-53

STEERING KNUCKLE

WHEEL SPEED ee CABLE

7922FG59

View of the front strut mount and related

components

SHOCK ABSORBER

CLEVIS MUST BE INSTALLED FLUSH AGAINST LOCATING

LOCATING TAB

SHOCK

\

\

ORIENTATION TAB

CLEVIS SPLIT

7922FG60

Be sure the orientation tab is situated into the clevis split

torque the bolts to 23 ft. Ibs. (31 Nm) Clevis onto the strut, using a brass drift until the clevis is fully seated against the locating tab Clevis pin bolt Clevis onto the lower control arm Clevis througn-bolt Steering knuckle and torque the clevis-to-strut pin bolt to 65 ft. Ibs. (88 Nm) 4. Lower the vehicle to support the lower control arm. 5. Torque the clevis-to-lower control arm mounting bolt 40 ft. Ibs. (54 Nm) 6. Install the front wheel

93461614

Exploded view of the front strut assembly—2.4L (VIN G) and 3.0L

To 3.

2.4L (VIN G) AND 3.0L ENGINES 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 Brake hose clamp Front speed sensor harness clamp, if equipped Sway bar link

4, ment,

e Lower control arm e Strut from the steering knuckle e Upper mounting bolts e Strut assembly install: Install or connect the following: Strut assembly and torque the upper bolts to 33 ft. Ibs. (44 Nm) Strut assembly to the lower control arm and steering knuckle. Torque the bolts to 221 ft. Ibs. (300 Nm) Sway bar link and torque the nut to 33 ft. Ibs. (44 Nm) Front speed sensor harness clamp, if equipped Brake hose clamp Front wheel ¢ Negative battery cable Check and adjustthe front end alignif needed.

2. Remove or disconnect the following: Carpet, pull it back from the rear Strut tower Plastic cover from the top of the strut tower

Both strut assembly-to-chassis nuts Rear wheel Splash shield from the upper strut mount Strut-to-rear knuckle bolt Strut by pushing the rear suspen-

SHOCK ABSORBER—

Rear

2.0L, 2.4L (VIN X), 2.5L AND 2.7L ENGINES 1. Before servicing the vehicle, refer to the precautions in the beginning of this section.

= _SHOCK _—~ TOWER

SHOCK ABSORBER MOUNTING NUTS

7922FG61

Access the rear strut upper mounting from

inside the trunk

Heater Core replacement is covered in Section 2 of this manual

9-54

CHRYSLER CORP.

CIRRUS ¢ SEBRING CONVERTIBLE ¢ STRATUS ¢ BREEZE 2. Remove or disconnect the following: e Negative battery cable e Rear shelf trim ¢ Cover from the upper shock tower e Upper mounting nuts

& SUNS \@

.

SHOCK ABSORBER CLEVIS BRACKET 7922FG62

View of the rear strut lower mounting

sion downward and tilting the top of the strut outward To install: 3. Install or connect the following: Strut by pushing the rear suspension downward and inserting the top of the strut into the vehicle Strut-to-rear knuckle bolt and torque the bolt to 70 ft. Ibs. (95 Nm) Strut upper mounting nuts and torque the nuts to 25 ft. Ibs. (34 Nm) Strut top cover Rear wheel and torque the nuts to

95 ft. Ibs. (125 Nm)

Shock Absorber REMOVAL & INSTALLATION Rear

2.4L (VIN G) AND 3.0L ENGINES 1. Before servicing the vehicle, refer to the precautions in the beginning of this section.

‘a

e Shock from the rear steering knuckle e Shock assembly To install: 3. Install or connect the following: Shock absorber and torque the shock to steering knuckle bolt to 73

ft. Ibs. (98 Nm) Upper shock nuts and torque to 32

ft. Ibs. (45 Nm) e Upper tower cover Rear shelf trim Negative battery cable

REMOVAL & INSTALLATION Front

2.0L, 2.4L (VIN X), 2.5L AND 2.7L ENGINES 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Disassemble as follows: 3. Remove the strut/shock assembly and place it ina suitable compressor tool 4. Set the lower hooks and install the clamp on the lower end of the spring. 5. Rotate the spring so the ball joint sits directly below the front upper hook. e:

23+2N-m

17+ 1 ft-lb

6. Compress the spring until all tension is removed. 7. Remove the retaining nut and washer. 8. Remove the clamp from the bottom of the spring. 9. Remove the strut/shock assembly. 10. Remove the lower spring, jounce bumper and cup. 11. Remove the dust boot and lower bushing washer. 12. Release the tension from the spring. 13. Remove the spring from the compressor tool. To assemble: 14. Install the upper isolator on the mounting bracket. 15. Install the sleeve into the lower isolator bushing. 16. Install the bushing and sleeve into the bottom of the upper mounting bracket. 17. Install the upper isolator bushing into the center of the upper mounting bracket. 18. Install the lower end of the spring in the compressor tool supported by the hooks. 19. Install the upper mounting bracket on top of the coil spring matching the Spring to the isolator on the upper mounting bracket. 20. Install the contro! arm ball joint directly below the front upper hook. 21. Compress the spring. 22. Install the lower spring isolator on the spring seat. 23. Install the jounce bumper with the pointed end downward. 24. Install the collar with the undercut side facing down. 20. Install the dust shield and cup 26. Install the lower bushing retainer washer

27. Install the strut/shock assembly through the coil spring. 28. When properly aligned, install the upper mounting nut and torque the nut to 40 ft. Ibs. (55 Nm). 29. Slowly release the tension from the compressor tool.

30. Install the strut/shock assembly in the vehicle.

2.4L (VIN G) AND 3.0L ENGINES

93461G15

Exploded view of the shock absorber

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Disassemble as follows: 3. Remove the strut/shock assembly and place it in a suitable compressor tool.

CHRYSLER CORP.

CIRRUS ¢ SEBRING CONVERTIBLE e STRATUS © BREEZE

SSS

4. Install special Tool MB991176 to secure the strut and remove the dust cover and jam nut. 5. Remove the strut insulator. Ms Remove the upper spring seat and pad. 7. Rempve the bump rubber and dust cover. 8. Remove the coil spring. 9. Remove the lower spring pad. To assemble: 10. Install the lower spring pad and coil Spring. 11. Install the dust cover and bump rubber. 12. Install the upper spring pad and seat. 13. Carefully compress the spring and install the insulator and jam nut. 14. When properly aligned, torque the jam nut to 47 ft. Ibs. (64 Nm). 15. Install the dust cover and remove the compressor tools. 16. Install the strut/shock to the vehicle. Rear

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Disassemble as follows: 3. Remove the rear shock from the vehicle. 4. Install the assembly in a spring compressor tool. 5. Remove the jam nut, washer and upper bushing. 6. Remove the upper bracket assembly and spring pad. 7. Remove the collar and bushing. 8. Remove the cup, bump rubber and dust cover. 9. Remove the coil spring To assemble: 10. Install the coil spring to the shock

93461616

Compress the coil spring as shown—2.4L (VIN G) and 3.0L

absorber using compressor Tools MB991237 and MB991239. 11. Install the dust cover and bump rubber. 12. Install the cup and bushing 13. Install the collar, supper spring pad and bracket assembly. 14. Install the upper bushing and washer. 15. When properly aligned, install the jam nut and torque to 17 ft. Ibs. (23 Nm). 16. Remove the compressor tools and install the shock absorber.

Upper Control Arm. REMOVAL & INSTALLATION Front

2.0L, 2.4L (VIN X), 2.5L AND 2.7L ENGINES 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Front wheel Ball joint from the steering knuckle using the joint separation Tool MB991113 Strut assembly Upper control arm mounting bracket from the strut assembly Upper control arm shaft-to-bracket nuts Upper contro! arm, from the bracket using the joint separation tool Upper control arm assembly To install: 3. Install or connect the following: e Upper control arm assembly e Upper control arm to the bracket and torque the nuts to 62 ft. Ibs. (86 Nm) e Upper control arm mounting bracket to the strut assembly e Strut assembly

Upper Ball Joint REMOVAL & INSTALLATION The upper ball joint is an integrated part of the upper control arm assembly, and cannot be serviced separately. A worn or damaged ball joint requires replacement of upper control arm assembly.

Lower Ball Joint

;

REMOVAL & INSTALLATION On all vehicles, the ball joint cannot be serviced separately. If the ball joint is defective it will require replacement of the lower control arm.

UPPER CONTROL ARM——___ SHOCK ABSORBER MOUNTING BRACKET

CASTLE NUT

9-59

SS

BALL ~~ JOINT

SHOCK ABSORBER ASSEMBLY

STEERING KNUCKLE PIN 7922FG63

Front upper control arm component identification

Brake service is covered in Section 4 of this manual

9-56

CHRYSLER CORP.

CIRRUS ¢ SEBRING CONVERTIBLE ¢ STRATUS ¢ BREEZE

e Ball joint to the steering knuckle and torque the locking nut to 20 ft. lbs. (28 Nm) e Front wheel 4 Check and/or adjust the wheel alignment, if necessary.

Pe

POSITIONING

HOLE

Rear

2.0L, 2.4L (VIN X), 2.5L AND 2.7L ENGINES 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Both rear wheels Both struts from the knuckles Muffler hanger from the frame rail Rear exhaust pipe hanger from the rear crossmember and allow it to hang Upper control arm ball joint stud from the knuckle 3. Support the center of the rear crossmember with a jack and a block of wood. 4. Remove or disconnect the following: e Speed sensor wiring from the upper control arms, if equipped with an Anti-lock Brake System (ABS) e 4 crossmember-to-frame bolts

REAR SUSPENSION CROSSMEMBER =

Li y Kes

SHOCK y}ABSORBER |

DRIFT 9300FG02

Use a drift to align the rear crossmember to the frame

6. Remove or disconnect the following: e Both upper control arm-to-crossmember bolts e Upper control arm To install: 7. Install or connect the following: e Upper control arm to the crossmember and torque the bolts to 80

Do not damage the rear brake hoses while lowering the crossmember.

ft. Ibs. (108 Nm) ->Be sure to place the flat washers between the crossmember and the pivot bar.

5. Lower the crossmember to access the 2 upper control arm pivot bar mounting bolts.

©

Wa N WOODEN Y,

BLOCK _

e Crossmember using a drift to align the holes and tighten the bolts to 80 ft. Ibs. (108 Nm) 8. Remove the jack 9. Install or connect the following: e Speed sensor wiring to the upper control arms, if equipped with ABS Upper control arm ball joint stud to the. knuckle and torque the ball joint stud nut to 63 ft. Ibs. (85 Nm) Rear exhaust pipe hanger to the rear crossmember Muffler hanger to the frame rail Both struts to the knuckles and torque the lower strut bolt to 70 ft. lbs. (95 Nm) e Both rear wheels

2.4L (VIN G) AND 3.0L ENGINES

4

C\

i

——

TL) \Y

REAR SUSPENSION ES a CROSSMEMBER BY men

D

BE

TRANSMISSION JACK

ESBe sure the Bushing Receiver Tool MB-990799 is square on the lower control arm and Bushing Remover Tool 6602-5 is positioned correctly on the isolator bushing.

5. Tighten Special Tool C-4212-F to press the bushing from the lower control arm. To assemble: 6. Position the Bushing Installer Too!

SHOCK ABSORBER CLEVIS

anes

qu? =)

2.0L, 2.4L (VIN X), 2.5L AND 2.7L ENGINES 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Front wheels Heat shield, if equipped with 15 inch wheels Ball joint clamp nut Sway bar-to-control arm bolts Strut clevis from the lower control arm Sway bar-to-crossmember bolts, loosen them and rotate the sway bar away from the control arm Lower control arm from the steering knuckle using a prybar Both lower control arm bolts Control arm

milDI Ww

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove the lower control arm assembly 3. Install the Bushing Remover Tool 6602-5 and Bushing Receiver Too! MB990799 on Special Tool C-4212-F. 4. Position the lower control arm on the assembled removal tools.

LOWER CONTROL ARM BALL JOINT CAP 7922FG64

Pre-load the suspension before final tightening the control arm to the steering knuckle

For complete Engine Mechanical specifications, see Section 1 of this manual

9-58

CHRYSLER CORP.

CIRRUS ¢ SEBRING CONVERTIBLE * STRATUS ¢ BREEZE

—

LLL 1 2 3 4 5

— -— —

SPECIAL TOOL MB-990789 LOWER CONTROL ARM FRONT ISOLATOR BUSHING SPECIAL TOOL 6602-5 SPECIAL TOOL C-4212-F

9306FG09

Removing the front isolator bushing from the lower control arm

41 2 3 4

— — — —

ay, ®

SPECIAL TOOL C-4366-2 LOWER CONTROL ARM SPECIAL TOOL 6756 SPECIAL TOOL C-4212-F

9306FG11

Removing the rear isolator bushing from the lower control arm

To assemble: 6. Position the Bushing Installer Too! 6760 onto the screw portion of special Tool C-4212-F. 7.. Start the new bushing into the lower control’arm hole’s machined surface side by hand, making sure it is square with its mounting hole with the void in the rubber portion facing away from the ball joint. 8. Assemble special Tools 6760 and 6756; then, position the lower control arm on the assembly, making sure that the tools : are aligned. 9. Tighten special Tool C-4212-F to press the bushing into the lower control arm until it is flush on the machined surface. 10. Install the lower control arm assembly. Clevis Bushing 1. Before servicing the vehicle, refer to the precautions in the beginning of this section.

1 2 3 4 5

— — — -—

SPECIAL TOOL 6876 ISOLATOR BUSHING MACHINED SURFACE SIDE OF LOWER CONTROL ARM SPECIAL TOOL 6758 SPECIAL TOOL C-4212-F

9306FG10

Installing the front isolator bushing to the lower control arm

6876 onto the screw portion of Special Tool C-4212-F. 7. Start the new bushing into the lower control arm hole machined surface side by hand, making sure it is square with its mounting hole. 8. Assemble Special Tools 6758, 6876 and C-4212-F: then, position the lower control arm on the assembly, making sure that the tools are aligned. 9. Tighten Special Too! C-4212-F to press the bushing into the lower control arm until it is flush on the machined surface. 10. Install the lower control arm assembly.

Rear Isolator Bushing 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove the lower control arm assembly 3. Install the Bushing Remover Tool 6756 and Bushing Receiver Tool C-4366-2 on Special Tool C-4212-F. 4 Position the lower control arm on the assembled removal tools.

1 2 3 4 5 6

— — — — —

SPECIAL TOOL C-4212-F REAR BUSHING SPECIAL TOOL 6760 MACHINED SURFACE ON LOWER CONTROL ARM LOWER CONTROL ARM SPECIAL TOOL 6756

9306FG13

Installing the rear isolator bushing to the lower control arm

1 2 3 4

— — — —

SPECIAL TOOL 6877 LOWER CONTROL ARM SPECIAL TOOL 6876 SPECIAL TOOL C-4212-F

9306FG14

Removing the clevis bushing from the lower control arm

1 2 3 4 5

= — — — —

FRONT ISOLATOR BUSHING LOWER CONTROL ARM REAR ISOLATOR BUSHING MACHINED SURFACE VOID IN BUSHING IN THIS DIRECTION

9306FG12

Positioning the rear isolator bushing to the lower control arm

Be sure the Bushing Receiver Tool C4366-2 is square on the lower control arm and Bushing Remover Tool 6756 is positioned correctly on the isolator bushing.

1 2 3 4 § 6

5. Tighten Special Too! C-4212-F to press the bushing from the lower control arm.

Installing the clevis bushing to the lower control arm

— — — — — ~

SPECIAL TOOL 6877 MACHINED SURFACE SIDE OF LOWER CONTROL ARM SPECIAL TOOL 6876 SPECIAL TOOL C-4212-F LOWER CONTROL ARM CLEVIS BUSHING

9306FG15

CHRYSLER CORP.

CIRRUS ¢ SEBRING CONVERTIBLE ¢ STRATUS ¢ BREEZE 2. Remove the lower control arm assembly 3. Install the Bushing Remover Tool 6877 and Bushing Receiver Too! 6876 on special Tool C-4212-F. 4. Position the lower control arm on the assembled removal tools. ->Be sure the Bushing Receiver Tool 6876 is square on the lower control arm and Bushing Remover Tool 6877 is positioned correctly on the clevis bush-

ing. 5. Tighten special Tool C-4212-F to press the bushing from the lower control arm. To assemble: 6. Position the Bushing Installer Tool 6877 onto the screw portion of special Tool C-4212-F. 7. Start the new bushing into the lower control arm hole’s machined surface side by hand, making sure it is square with its mounting hole with the void in the rubber portion facing away from the ball joint. 8. Assemble special Tools 6876 and 6877; then, position the lower control arm on the assembly, making sure that the tools are aligned. 9. Tighten special Too! C-4212-F to press the bushing into the lower control arm until it is flush on the machined surface. 10. Install the lower control arm assembly.

2.4L (VIN G) AND 3.0L ENGINES 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Front wheel e Lower control arm from the steering knuckle e Lower control arm mounting bolt and clamp ¢ Lower control arm 3. If replacing the bushing, perform the following: a. Apply soapy water between the shaft and old bushing and pry the old bushing out. To install: 4. Apply soapy water to the shaft and new bushing and install the new bushing, if removed. 5. Install or connect the following: e Lower control arm e Lower control arm clamp and torque the bolts to 60 ft. Ibs. (81 Nm)

e Lower control arm to the steering knuckle and torque the bolts to 80 ft. lbs. (108 Nm) e Front wheel 6. Check and adjust the front toe, if needed. Rear

2.4L (VIN G) AND 3.0L ENGINES 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Rear wheel Stabilizer link Wheel Speed Sensor (WSS), if equipped Lower control arm assembly to steering knuckle Lower control arm To install: 3. Install or connect the following: Lower control arm and torque the bolt to 55 ft. Ibs. (74 Nm) Lower control arm to the steering knuckle and torque the bolt to 80 ft. lbs. (108 Nm) WSS, if equipped Stabilizer link and torque the bolt to 29 ft. Ibs. (39 Nm) e Rear wheel

Wheel Bearings ADJUSTMENT Front

The front hub wheel bearing is designed for the life of the vehicle and requires no type of adjustment or periodic maintenance. The bearing is a sealed unit with the wheel hub and can only be removed and/or replaced as one unit. Rear

The rear hub and wheel bearing assembly is designed for the life of the vehicle and requires no type of adjustment or periodic maintenance. The bearing is a sealed unit with the wheel hub and can only be removed and/or replaced as one unit. The following procedure may be used for evaluation of bearing condition: 1. Raise and safely support the vehiCle 9. Remove the rear wheels and brake drums.

9-59

3. Turn the hub flange carefully. Excessive roughness, lateral play or resistance to rotation may indicate dirt intrusion or bearing failure. 4. \f the rear wheel bearings exhibit the conditions during inspection, the hub and bearing assembly should be replaced. 5. Damaged bearing seals and resulting excessive grease loss may also require bearing replacement. Moderate grease loss from the bearing is considered normal and should not require replacement of the hub and bearing assembly.

REMOVAL & INSTALLATION Front

The front wheel bearing used on this vehicle is a bolt-in type wheel bearing. The wheel bearing is serviced separately from the front steering knuckle and front hub assembly. Retention of the front wheel bearing into the steering knuckle is by means of 3 bolts installed from the rear of the steering knuckle. The 3 bolts attach the hub/bearing to the front surface of the steering knuckle. Removal and installation of the hub/bearing assembly from the steering knuckle must be done with the steering knuckle removed from the vehicle. The face of the outer CV-joint has a metal bearing shield pressed on it. This design deters direct water splash on the bearing seal while allowing any water that gets in to run out the bottom of the steering knuckle. It is important to thoroughly clean the outer CV-joint and the wheel bearing area in the steering knuckle before it is assembled after servicing the front wheel bearing or driveshaft. At no time when servicing this vehicle, can a sheet metal screw, bolt or other metal fastener be installed in the shock tower to take the place of an original plastic clip. Also, NO holes can be drilled into the front shock tower for the installation of any metal fasteners into the shock tower. Because of the minimum clearance in this area installation of metal fasteners could damage the coil spring's protective coating and lead to corrosion failure of the spring. If a plastic clip is missing, lost or broken during servicing a vehicle, replace only with the equivalent part listed in the Mopar parts catalog. 1. Before servicing the vehicle, refer to the precautions in the beginning of this section.

For Accessory Drive Belt illustrations, see Section 1 of this manual

9-60

CHRYSLER CORP.

CIRRUS ¢ SEBRING CONVERTIBLE ¢ STRATUS ¢ BREEZE

2. Remove or disconnect the following: e Front wheel e Steering knuckle assembly e 3 hub/bearing assembly-to-steering knuckle bolts e Hub/bearing assembly from the steering knuckle. If necessary, tap the bearing out, using a soft-faced hammer >The wheel bearing is transferable to a replacement steering knuckle if the bearing is found in serviceable condition.

To install: 3. Clean all parts well. Thoroughly, clean all the hub/bearing assembly mounting surfaces on the steering knuckle. 4. Install or connect the following: ¢ Hub/bearing assembly and torque the bolts to 80 ft. Ibs. (110 Nm) e Steering knuckle ¢ Front wheel

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Rear wheel Brake drum, if equipped with drum brakes Brake caliper and rotor, if equipped with disc brakes Hub dust cap Hub nut and discard it Hub/bearing assembly by pulling straight off the spindle To install: 3. Install or connect the following: e New bearing on the spindle e Hub using a new nut and torque the nut to 186 ft. Ibs. (250 Nm) e Dust cap e Brake drum or rotor and caliper e Rear wheel and torque the !ug nuts to 95 ft. Ibs. (129 Nm)

Rear

All vehicles are equipped with permanently lubricated and sealed for life rear wheel bearings. There is no periodic lubrication or maintenance recommended for these units. To evaluate the condition of the rear wheel bearings, remove the wheel and brake drum or rotor and rotate the flanged outer ring of the hub. Excessive roughness or resistance to rotation may indicate dirt intrusion or wheel bearing failure. If the rear wheel bearings exhibit these conditions during inspection, the hub and bearing assembly should be replaced. Damaged bearing seals and resulting excessive grease loss may also require bearing replacement. Moderate grease loss from the bearing is considered normal and should not require replacement of the hub and bearing assembly. If service requires removal for inspection or replacement of the rear wheel bearing and hub assembly, use the following procedure.

KNUCKLE

UPPER CONTROL ARM

REAR LATERAL LINK

UPPER CONTROL ARM

FORWARD LATERAL ARM

PIVOT BAR

REAR SUSPENSION CROSSMEMBER

STABILIZER BAR ATTACHING LINK UPPER CONTROL ARM

REAR LATERAL LINK

LZ STABILIZER BAR

x

TRAILING LINK

TRAILING LINK BRACKET

NR”

TRAILING LINK BRACKET

Independent rear suspension component identification

SEs ie

\)) N

REAR KNUCKLE 9300FG03

CHRYSLER CORP. 2001-02 PT Cruiser DRIVE TRAIN.................. 10-14 ENGINE REPAIR ................ 10-2 EUELISYSTEMo4.e. 0 oeeee 10-13 PRECAUTIONS.................. 10-2 STEERING AND SUSPENSION................. 10-18 A “AT AGEUGie de ee, og A a A le 2 10-18 TT SEUEDTTSE ie em ape ae 10-18 PCAONSct.cecshacscekcan stecomen eee10-18 TE) Ee Le 6 ee 10-2 PESTA AUON ated cpnachuectesictokianiees 10-2 GROWeltietcnssiver diel deatleabeaty10-2

Removal & Installation.............. 10-3 Exhaust Maniioldng czte 28. ee:10-7 Removal & Installation.............. 10-7 F Front Crankshaft Seal... 10-8 Removal & Installation........0..... 10-8 LUC=)Main Cc) ye earn Goat! aaa pO Hea 10-13 Pte IWGCIGTRERn etndesekc 10-13 Removal & Installation............ 10-13 PEO l:PUD css, aie camera ckM 10-13 Removal & Installation............ 10-13 Fuel System Pressure... 10-13 RELCVINO ciety tek a isn eR aces 10-13

Removal & Installation... 10-9 ees 2b At ia 10-16 etechisatemniree A AGHISIMIENT eas BS Aas 10-16

Hlalisiiatists Mp Rob pmetee a sare: 10-16 Removal & Installation............ 10-16

oir cpind ee cane

C Camshaft and Lifters... 10-9

Removal & Installation............ 10-16

Fuel System Service Precatitions:< subunits ature10-13

BA

&

|

10-21

IQMitiOn TIMING .......ssssseeeeeeeeeten 10-3

Removal & Installation........... 10-21 He eh eee Ske 10-17 Be las ehes teesaveiceronviene 10-5 SL EAC tecia2pen WVU

POTUSUMIEI Bier crte cue tean 10-3 [neake WiaIMiOl rere ce cceec rors. 10-6 Removal & Wt catenin 10-6

D Distributor............. ba

eon 10-2

Removal & USES Ries ce.8 10-23 ae) 10-10 Ayia heels Melina

ext10-3 REHOME PASSCIIDIY 5 cleeacsssdeeeneres

Removal & Installation............ 10-10

Bee eee after a oe Agee

COWS Pall Joint eete

4 10-23

Gi PUGIO ER ston Heerdaae 10-10 Removal & Installation............ 10-10

PASOMEAMC AIG Biron Cem renter: 10-12 Positioning ....... seige 10-12 Rack and Pinion Steering Gear....10-19 Removal & Installation............ 10-19 RearviditioGalte succes meen 10-11 Removal & Weta Peet od 10-11 SHOCK IADSOL OEleeon ne emetearieceees 10-21 Removal & Installation............ 10-21 Siarterely O10 hamrceseee acento 10-9 Removal & Installation............. 10-9 Streit eaedlaccent as ateti le 10-20 Removal & Installation............ 10-20

Transaxle ASSEMDIY ......ccsceeeeee 10-14 Removal & Sets heels 10-14 Valvedtasti! Rae. Se ta eee 10-9 ACjUSHTIENU Ae. cece: 10-9 W WatercP titi ate stcss iota eee 10-4 Removal & Installation... 10-4 Wheel BearingS..........cccccceeee 10-24 ACIUSETIONL istsencasdemmneene 10-24 Removal & Installation............ 10-24

10-2

CHRYSLER CORP. PT CRUISER

Before servicing any vehicle, please be sure to read all of the following precautions, which deal with personal safety, prevention of component damage, and important points to take into consideration when servicing a motor vehicle: ¢ Never open, service or drain the radiator or cooling system when the engine is hot; serious burns can occur from the steam and hot coolant. ¢ Observe all applicable safety precautions when working around fuel. Whenever servicing the fuel system, always work in a well-ventilated area. Do not allow fuel spray Or vapors to come in contact with a spark, open flame, or excessive heat (a hot drop light, for example). Keep a dry chemical fire extinguisher near the work area. Always keep fuel in a container specifically designed for fuel storage; also, always properly seal fuel containers to avoid the possibility of fire or explosion. Refer to the additional fuel system precautions later in this section. ¢ Fuel injection systems often remain pressurized, even after the engine has been turned OFF. The fuel system pressure must be relieved before disconnecting any fuel lines. Failure to do so may result in fire and/or personal injury. e Brake fluid often contains polyglycol ethers and polyglycols. Avoid contact with the eyes and wash your hands thoroughly after handling brake fluid. If you do get brake fluid in your eyes, flush your eyes with clean, running water for 15 minutes. If eye irritation persists, or if you have taken

PRECAUTIONS

3

brake fluid internally, IMMEDIATELY seek medical assistance. e The EPA warns that prolonged contact with used engine oil may cause a number of skin disorders, including cancer! You should make every effort to minimize your exposure to used engine oil. Protective gloves should be worn when changing oil. Wash your hands and any other exposed Skin areas as soon as possible after exposure to used engine oil. Soap and water, or waterless hand cleaner should be used. e All new vehicles are now equipped with an air bag system, often referred to as a Supplemental Restraint System (SRS) or Supplemental Inflatable Restraint (SIR) 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 repairs. e Always wear safety goggles when working with, or around, the air bag system. When carrying a non-deployed air bag, be sure the bag and trim cover are pointed away from your body. When placing a nondeployed air bag on a work surface, always face the bag and trim cover upward, away from the surface. This will reduce the motion of the module if it is accidentally deployed. Refer to the additional air bag system precautions later in this section. e Clean, high quality brake fluid from a sealed container is essential to the safe and

proper operation of the brake system. You should always buy the correct type of brake fluid for your vehicle. If the brake fluid becomes contaminated, completely flush the system with new fluid. Never reuse any brake fluid. Any brake fluid that is removed from the system should be discarded. Also, do not allow any brake fluid to come in contact with a painted surface; it will damage the paint. e Never operate the engine without the proper amount and type of engine oil; doing so WILL result in severe engine damage. ¢ Timing belt maintenance is extremely important! Many models utilize an interference-type, non-freewheeling engine. If the timing belt breaks, the valves in the cylinder head may strike the pistons, causing potentially serious (also time-consuming and expensive) engine damage. Refer to the maintenance interval charts in the front of this manual for the recommended replacement interval for the timing belt, 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 computer system(s) and may require the computer to undergo a relearning process once the negative battery cable is reconnected. ¢ When servicing drum brakes, only disassemble and assemble one side at a time, leaving the remaining side intact for reference. ¢ Only an MVAC-trained, EPA-certified automotive technician should service the air conditioning system or its components.

_ Distributor The PT Cruiser uses a Direct Ignition System (DIS) and basic ignition timing is not adjustable. Alternator

REMOVAL rr

Remove or disconnect the following: ¢ Negative battery cable e Air cleaner lid e Inlet Air Temperature (IAT) sensor and make-up hose Upper alternator adjustment lock nut, loosen only Right front wheel Splash shield

ENGINE REPAIR Support bracket Lower pivot bolt, loosen only Drive belt T-bolt, loosen only Alternator wiring connectors Alternator belt Axle retaining nut Lower control arm from the steering knuckle Axle shaft Lower mounting bolt from the upper adjustment bracket Alternator

INSTALLATION MNERERIRE Nisei Serer

GT Sache. o

Install or connect the following: e Alternator e Alternator drive belt e Axle shaft

) Lower control arm to the steering knuckle Lower ball joint nut and torque the nut to 70 ft. Ibs. (95 Nm) Axle retaining nut and torque the nut to 120 ft. Ibs. (163 Nm) Support bracket Alternator electrical connectors and torque the B+ terminal nut to 100 inch Ibs. (11 Nm) Splash shield and right front wheel Right front wheel Upper pivot nut and torque to 40 ft. lbs. (54 Nm) ¢ Negative battery cable Air cleaner lid, IAT sensor and make up hose 1. Check the transmission fluid level and top off, if necessary.

CHRYSLER CORP.

PT CRUISER

Battery and battery tray Throttle and cruise control cables Powertrain Control Module (PCM) wiring harness Positive cable from the Power Distribution Center (PDC) and ground wire Ground wire from the body to the engine Brake booster vacuum hose Proportional purge hoses from the intake manifold Coolant recovery hose Heater hoses Upper radiator support crossmember Upper and lower radiator hoses A/C line from the condenser A/C lines from the junction at the

S

upper torque strut Cooler lines, if equipped Fan cooling module assembly Transmission shift linkage and electrical connectors Clutch hydraulic lines, if equipped Both front wheels and the right

“a

1 — LOWER PIVOT BOLT

9346JG01

Remove the lower pivot bolt from the alternator

Ignition Timing

10-3

=~

inner splash shield Halfshafts Accessory drive belts Alternator and support brackets

;

ADJUSTMENT Ignition timing is controlled by the Powertrain Control Module (PCM). No adjustment is necessary or possible.

Engine Assembly REMOVAL & INSTALLATION =>After all components are installed on the engine, a DRB scan tool is necessary to perform the camshaft and crankshaft timing relearn procedure.

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Properly recover the air conditioning system refrigerant. 3. Properly relieve the fuel system pressure. 4. Drain the cooling system. 5. Drain the engine oil. 6. Remove or disconnect the following:

93062683

Front engine mount location and bolt identification

Guide For complete service labor times, order Nichols’ Chilton Labor

10-

CHRYSLER CORP. PT CRUISER

93062684

Exploded view of the left mount through bolt

Downstream Oxygen (02S) Sensor Exhaust system from the manifold Power steering pressure hose Lower engine torque strut Structural collar Torque converter bolts A/C compressor Power steering return line Power steering pump 7. Raise the vehicle enough to allow an engine dolly and cradle to be placed under the engine. 8. Loosen the engine support posts in order to allow movement for positioning onto the engine locating holes and flange on the engine bedplate. Lower the vehicle and position the cradle until the engine is resting on the support posts. Tighten the mounts to the cradle frame. This will keep the support posts from moving when removing or installing the engine and transaxle. 9. Install safety straps around the engine to the cradle; tighten the straps and lock them into position. 10. Raise the vehicle enough to see if the straps are tight enough to hold the cradle assembly to the engine. 11. Lower the vehicle so the weight of the engine and transaxle ONLY is on the cradle. 12. Remove the engine and transaxle mount through-bolts. 13. Raise the vehicle slowly, it might be necessary to move the engine/transaxle assembly with the cradle to allow removal around the body flanges. To install: 14. Install or connect the following: ¢ Engine/transaxle assembly by lowering the vehicle over the assembly e Engine and transaxle mounts and

torque the bolts to 87 ft. Ibs. (118 Nm) Upper torque strut 15. Remove the support fixtures. Alternator and support brackets Halfshafts 16. Install the structural collar and torque the bolts, in 3 steps, using the following procedure: a. Step 1: Collar-to-oil pan bolts to

30 inch Ibs. (3 Nm). b. Step 2: Collar-to-transmission bolts to 80 ft. Ibs. (108 Nm). C. Step 3: Collar-to-oil pan bolts to 40 ft. Ibs. (54 Nm). 17. Install or connect the following: Lower engine torque strut and torque the through bolts to 87 ft. lbs. (118 Nm) Exhaust pipe to the manifold Downstream 02S sensor connec-

tor Power steering pressure hose to the steering gear

A/C compressor Power steering pump Drive belts Right inner splash shield and both front wheels Power steering return hose Clutch hydraulic line, electrical connectors and shift linkage, if equipped Shift linkage and cooler lines, if equipped Fuel lines Heater hoses Engine wiring harness and ground strap Lower and upper radiator hoses Fan module assembly Throttle and speed control cables

¢ PDC, positive battery cable and ground strap e PCM e Battery and battery tray e Battery cables 18. Perform the camshaft and crankshaft synchronization procedure. 19. Fill the engine with clean oil. 20. Fill the cooling system. 21. Recharge the A/C system. 22. After all components are installed, perform the camshaft and crankshaft timing relearn procedure as follows: a. Connect a DRB or equivalent, scan tool to the DLC (located under the instrument panel, near the steering column). b. Turn the ignition switch ON, and access the “miscellaneous” screen. c. Select “re-learn cam/crank” option and follow the directions on the scan tool screen. 23. Start the vehicle and check for leaks, repair if necessary.

Water Pump

REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the cooling system. 3. Remove or disconnect the following: ¢ Negative battery cable e Timing belt e Camshaft sprockets e Rear timing belt cover e Water pump and discard the O-ring To install: 4. Install or connect the following: ¢ New O-ring in the water pump groove

Before proceeding, be sure the Oring gasket is properly seated in the water pump groove before tightening the screws. An improperly installed O-ring could cause a coolant leak. SSD ¢ Water pump and torque the bolts to 105 inch Ibs. (12 Nm) e>Rotate the pump by hand to check for freedom of movement.

Rear timing belt cover Camshaft sprockets Timing belt Negative battery cable 9. Fill the cooling system. 6. Start the vehicle and check for leaks, repair if necessary.

;

Tea (i

1 - PART NUMBER FACES UP 2 — NO. 1 CYLINDER

9346JG04

Install the new gasket with the part number facing upwards

e Power steering pump reservoir and bracket e Cylinder head cover e Camshaft and cam followers e Cylinder head bolts, working from the center outward e Cylinder head

1 — CYLINDER BLOCK 2 —- WATER PUMP

>The cylinder head bolts must be inspected before they can be reused. if the threads of bolts are stretched, they must be replaced. Check for thread stretching by holding a scale or other straightedge against the threads. If all the threads do not contact the scale, the bolts must be replaced.

93062685

Exploded view of the water pump

Power steering pump, move it Ses

Cylinder Head

:

aside. DO NOT disconnect the fluid

y

lines.

REMOVAL & INSTALLATION

Ls

steste

_¢

|

WARNING

Use only a plastic scraper to clean

¢ Ignition coil pack wiring connector

—the mating surfaces. NEVER use

metal, as this may gouge the sur;

f ->After all components are installed on

e Ignition coil pack and bracket : 3

3 Rae eal canner

faces and cause leaks.

er rear are date ; 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Properly relieve the fuel system pressure. 3. Drain the cooling system. 4. Remove or disconnect the following: Negative battery cable Air cleaner inlet duct and air cleaner Inlet Air Temperature (IAT) sensor and make-up air hose Upper intake manifold Fuel supply line from the fuel rail Heater tube support bracket Upper radiator hose Heater supply hoses Accessory drive belt Exhaust pipe from the manifold

e Timing belt idler pulley e Camshaft sprocket

5. Cover the combustion chambers, then use a plastic scraper to thoroughly and

the engine, a DRB scan tool is necesBoe

Cylinder head bolt torque sequence

Please visit our web site at www.chiltonsonline.com

10-6

CHRYSLER CORP. PT CRUISER

carefully clean the engine block and cylinder head mating surfaces. To install: 6. Install the cylinder head with a new gasket. Make certain that the part number on the new gasket is facing up. 7. Lubricate the cylinder head bolt threads with clean engine oil. 8. Torque the cylinder head bolts, in the following sequence: a. Step 1: 25 ft. Ibs. (34 Nm). b. Step 2: 50 ft. Ibs. (68 Nm). c. Step 3: 50 ft. Ibs. (68 Nm). d. Step 4: An additional % turn. 9. Install or connect the following: Camshaft and cam follower assemblies Cylinder head cover Rear timing belt cover and pulley Camshaft sprockets Timing belt Cam sensor wiring connector Ignition coil and spark plug wires Power steering pump reservoir and bracket Exhaust pipe to the manifold Accessory drive belts Lower intake manifold Upper radiator and heater supply hose Heater support bracket Dipstick tube fastener to the intake manifold Power brake vacuum hose to the intake manifold Fuel supply line to the fuel rail Vacuum lines and electrical wiring Upper intake manifold Air cleaner inlet duct and air cleaner IAT sensor and make up hose e Negative battery cable 10. Fill the cooling system. 11. Turn the ignition switch ON, and access the “miscellaneous” screen. 12. Select the “re-learn cam/crank” option, then follow the instructions on the scan tool screen.

~_—INI

oe

SEB

df MPO \

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ak

Vo

1 — INTAKE MANIFOLD 2. EGRWUBE 3 — SEAL 9346JG05

Remove the EGR tube from the upper intake manifold

e Negative battery cable e Inlet Air Temperature (IAT) sensor

e Manifold Absolute Pressure (MAP) sensor ¢ Idle Air Control (IAC) motor electri-

and air hose

¢ Engine cover

cal (connector

¢ Throttle and cruise control cables from the throttle lever bracket

¢ Throttle Position (TPS) sensor wiring connector

—e = : ate

oe, a =i

iz] Wy. f

it (4

Intake Manifold

REMOVAL & INSTALLATION

mans +

Upper

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Properly relieve the fuel system pressure. 3. Remove or disconnect the following:

93062687

Intake manifold bolt torque sequence

CHRYSLER CORP. PT CRUISER e Proportional purge hoses e Brake booster vacuum hose e Positive Crankcase Ventilation (PCV) hose from the intake manifold ¢ Throttle body support bracket bolt e Exhaust Gas Recirculation (EGR) tube from the upper intake manifold ¢ Upper intake manifold 4. Clean the mating surfaces. To install: 5. Install or connect the following: New gaskets and seals Intake manifold on the EGR tube then on the lower intake manifold. Torque the bolts, in sequence, to 105 inch Ibs. (12 Nm). Throttle body support bracket and torque the bolt to 28 ft. Ibs. (20 Nm) EGR retainer plate and torque the smaller bolt to 95 inch Ibs. (11 Nm) and the large bolt to 28 ft. Ibs. (21 Nm) e PCV hose to the intake manifold e MAP sensor electrical connector e Proportional purge hoses e Brake booster hose e IAC motor and TPS connectors e Throttle and speed control cables Air cleaner assembly Engine cover IAT sensor Negative battery cable

jeveveya)

7. 8. 9. repair

Fill the coolant system. Pressurize the fuel system. Start the vehicle and check for leaks, if necessary.

Exhaust Manifold REMOVAL & INSTALLATION

1 - SEALS

9846JG06

Install new seals on the lower intake man-

ifold

To install: 6. Install or connect the following: New gaskets and seals Intake manifold and torque the bolts in sequence to 105 inch Ibs. (12 Nm) Intake manifold-to-lower support bracket bolts and torque to 17 ft. lbs. (23 Nm) Fuel injector wiring harness Fuel supply line quick-connect to the fuel tube assembly Oil dipstick tube to the lower intake manifold Upper radiator hose Air cleaner assembly IAT sensor Negative battery cable

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Negative battery cable Air cleaner assembly and bracket Throttle and speed control cables Manifold Absolute Pressure (MAP) sensor electrical connector Power steering reservoir, move it aside. DO NOT disconnect the fluid lines. Coolant recovery bottle Exhaust manifold upper heat shield Exhaust pipe from the manifold Engine wiring heat shield Manifold support bracket Lower exhaust manifold heat shield Upstream Heated Oxygen (HO2S)

Lower 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Properly relieve the fuel system pressure. 3. Drain the coolant system. 4. Remove or disconnect the following: Negative battery cable Inlet Air Temperature (IAT) sensor and make-up hose Air cleaner Upper intake manifold Upper radiator hose and coolant outlet connector Fuel supply line quick-connect from the fuel rail Fuel injector wiring harness Oil dipstick tube from the lower intake manifold Intake manifold and discard the gaskets and seals 5. Thoroughly clean the gasket mating surfaces.

10-7

Torque the exhaust manifold bolts in sequence

Timing belt service is covered in Section 3 of this manual

sensor connector

Exhaust manifold and discard the gasket

ch fees 3. Thoroughly clean the mating surfaces. To install: 4. Install or connect the following: e New gasket Exhaust manifold and torque the bolts, in sequence, to 17 ft. Ibs. (23 Nm) Alternator bracket bolt, if loosened Exhaust manifold heat shields and torque the bolts to 105 inch Ibs. (12 Nm)

Exhaust manifold support bracket Engine wiring heat shield

Upstream HOzsensor wiring connector

Ay ip

hi &i)ys myst sates

=

Exhaust pipe to the manifold and torque the bolts to 21 ft. Ibs. (28 Nm)

—

Coolant recovery bottle Power steering pump reservoir MAP sensor connector Throttle and speed control cables Air cleaner bracket and assembly Negative battery cable

5. Start the vehicle and check for leaks,

(2)

1 — SPECIAL TOOL 6771

2 — REAR TIMING BELT COVER 9346608

repair if necessary.

Front Crankshaft Seal

Removing the front crankshaft oil seal

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 Crankshaft damper bolt Crankshaft damper, using Puller Too! 1026 and Insert Too! 6827-A Timing belt Crankshaft sprocket, using Tool 6793 and Insert Too! C-4685-C2 Crankshaft oil seal, using a seal puller Tool 6771 e>Be careful not to damage the seal surface of the cover.

To install: 3. Install or connect the following: ¢ New front crankshaft oil seal with the seal spring facing the engine, using Crankshaft Installer Too! 6780 e Crankshaft sprocket with special T 6792

1 — PROTECTOR 2 -— SEAL

e» Make sure the word FRONT on the crankshaft sprocket is facing outward.

3 ~ SPECIAL TOOL 6780 te Installing a new seal using seal installer 6780-1; proceed with caution if using substitute tools

CHRYSLER CORP.

PT CRUISER

e Timing belt ¢ Crankshaft damper using thrust bearing washer and bolt from Installer Tool 6792. Torque the damper bolt to 105 ft. Ibs. (142 Nm) e Negative battery cable 4. Start the vehicle and check for leaks, repair if necessary.

Camshaft Position (CMP) sensor and target magnet Timing belt Camshaft sprocket Rear timing belt cover Loosen the camshaft bearing caps in Sequence from the rear of the cylinder head ¢ Remove the camshafts To install: Make certain that the pistons are NOT at Top Dead Center (TDC) before installing the camshafts. 4. Install the camshafts and cam followers, lubricate the bearing journals thoroughly. 5, Install the left and right camshaft bearing caps, No’s 2-5 and right side No. 6. Torque these fasteners to 105 inch Ibs. (12 Nm). Apply Mopar® gasket maker to No.1 and left side No. 6. Torque these fasteners to 18 ft. Ibs. (24 Nm). 6. Install or connect the following: e Camshaft seals e Rear timing belt cover e Camshaft sprockets and torque the bolt to 85 ft. Ibs. (115 Nm)

Camshaft and Lifters

REMOVAL & INSTALLATION «After all components are installed on the engine, a DRB scan tool is necessary to perform the camshaft and crankshaft timing relearn procedure.

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Relieve the fuel system pressure. 3. Remove or disconnect the following: e Negative battery cable e Cylinder head cover

1 0-9

e Timing belt e Target magnet e CMP sensor and torque the screws to 85 inch Ibs. (9.6 Nm) e Cylinder head cover e Negative battery cable e>An oil and filter change are recommended.

7. Use a DRB scan tool to perform the camshaft and crankshaft timing relearn procedure, as follows: a. Connect the scan tool to the DLC (located under the instrument panel, near the steering column). b. Turn the ignition switch ON and access the “miscellaneous” screen. c. Select the “re-learn cam/crank” option, then follow the instructions on the scan tool screen. 8. Start the engine and check for leaks. Run the engine with the radiator cap off so as the engine warms and the thermostat opens, coolant can be added to the radiator. Test drive vehicle to check for proper operation.

Valve Lash

ADJUSTMENT The engines in these vehicles do not require periodic valve lash adjustment.

D

COs

HG)

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IgG

Starter Motor

o

REMOVAL & INSTALLATION

Oma — ino hh)

1) ©, © nN 93062G90

Camshaft bearing cap tightening sequence

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Negative battery cable e Air cleaner box cover e Engine structural collar e Starter electrical connectors e Starter To install: 3. Install the starter and torque the bolts to 40 ft. Ibs. (54 Nm). Attach the starter electrical connectors. 4. Install the engine structural collar. Torque the bolts in the following sequence: a. Step 1: Collar-to-oil pan bolts to 30 inch Ibs. (3 Nm). b. Step 2: Collar-to-transmission bolts to 80 ft. Ibs. (108 Nm).

Heater Core replacement is covered in Section 2 of this manual

10-1

CHRYSLER CORP. PT CRUISER

7. Install or connect the following: e New gasket on the oil pan ¢ Oil pan and torque the bolts to 105 inch lbs. (12 Nm) ¢ Oil filter and adapter and torque the screws to 105 inch Ibs. (12 Nm)

+ WARNING Follow the proper tightening sequence for the structural collar or damage to the collar or oil pan may occur

93062691

Removal of the starter motor mounting

c. Step 3: Collar-to-oil pan bolts to AQ ft. Ibs. (54 Nm). 5. Install the air cleaner box cover and connect the negative battery cable.

REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the engine oil and remove the oil filter. 3. Support the powertrain assembly. 4. Remove or disconnect the following:

8. Install the structural-collar and torque the bolts as follows: a. Collar-to-oil pan bolts: 30 inch Ibs. (3 Nm). b. Collar-to-transaxle bolts: 80 ft. Ibs. (108 Nm). c. Collar-to-oil pan bolts: 40 ft. Ibs. (54 Nm), final torque. 9. Install or connect the following: e Lower torque strut e Right inner splash shield e Negative battery cable 10. Fill the engine with clean oil and a new filter. 11. Start the vehicle and check for leaks, repair if necessary.

Negative battery cable Right inner splash shield Engine structural collar Lower torque strut Oil filter adapter Oil pan and gasket 5. Thoroughly clean all gasket mating surfaces. To install: 6. Apply silicone sealer to the oil pump-to-engine block parting line.

REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the engine oil. 3. Remove or disconnect the following:

93062692

93062693

Remove the oil filter adapter

Silicone sealer application locations

eee 10 the crankshaft flats and torque the bolts to 21 ft. Ibs. (28 Nm).

The front crankshaft seal MUST be out of the pump to align or damage may result.

Veil

——

c=

=A

e New front crankshaft seal, using Seal Driver Tool 6780 Crankshaft key Crankshaft sprocket, using a Crankshaft Sprocket Installer Tool 6792 Oil pump pickup tube Oil pan Rear timing belt cover Timing belt e Negative battery cable 7. Fill the engine with clean oil. 8. Start the engine and check for leaks; repair if necessary.

(

Te O)AL Se aS CNG 3

On

|

Rear Main Seal

1 - BOLTS

REMOVAL & INSTALLATION

2 - BOLTS 3 — OIL PUMP 93062694

Exploded view of the oil pump mounting bolts

e Negative battery cable e Timing belt and rear cover e Qil pan Crankshaft sprocket, using Too! 6795 and Insert Too! C-4685-C2 e Crankshaft key e Oil pickup tube e Qil pump To install: 4. Wash all parts in a solvent; then, inspect carefully for damage or wear, as follows:

APPLY GASKET MAKER TO OIL PUMP BODY

|

a. Inspect the mating surface of the oil pump should be smooth. Replace the pump cover, if scratched or grooved. b. Apply Mopar® gasket maker to the oil pump. c. Install the O-ring into the oil pump body discharge passage. 5. Prime the oil pump before installation by filling the rotor cavity with engine oil. 6. Install or connect the following: ¢ Oil pump, align the rotor flats with

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Transmission

e Flexplate/flywheel e Rear main seal 3. Insert a seal remover between the dust lip and the metal case of the crankshaft seal. Angle the tool through the dust lip against the metal case of the seal. Pry out the seal.

DO NOT let the prytoo! contact the crankshaft seal surface. Contact of the tool blade against the crankshaft edge (chamfer) is permitted. To install:

O-RING

ok WARNING If the crankshaft edge (chamfer) has any burrs or scratches on the, clean it up with 400 grit sand paper to prevent seal damage during installation of the new seal. e>No lubrication is necessary when installing the seal.

7922EG31

surface Apply a small amount of gasket maker to the pump body cover mounting

4. Place Crankcase Seal Pilot Too! 6926-1 on the crankshaft; this is a pilot tool with a magnetic base

Brake service is covered in Section 4 of this manual

|

eee ENGINE

REAR CRANKSHAFT SEAL ENGINE

5. Position the seal over the pilot Tool;

BLOCK

be sure the words THIS SIDE OUT on the seal can be read.

REAR CRANKSHAFT SEAL METAL CASE

->The pilot tool should stay on the crankshaft during installation of the seal.-Be sure the seal lip faces the crankcase during installation.

kk WARNING

PRY IN THIS _ DIRECTION

If the seal is driven in the block past flush, this may cause an oil leak. |ee aE

a

LEE

ESE

TA

6. Drive the seal into the block, using Crankshaft Seal Tool 6926-2 and handle C4171, until the tool bottoms out against the block.

PRY TOOL

REAR CRANKSHAFT SEAL DUST LIP

PRY TOOL

7. Install or connect the following: e Flexplate/flywheel. Apply Lock &

Seal Adhesive to the bolt treads and torque the bolts in a star pattern, to 70 ft. Ibs. (95 Nm). e Transmission e Negative battery cable 8. Start the vehicle and check for leaks, repair if necessary.

Piston and Ring 7922EG32

POSITIONING

When prying the seal out, be sure to use the prytool at the proper angle

© SPECIAL TOOL 6926-1 PILOT Cree

y

Gap of lower

No. 1

side a

Sd

vi gap

Front of engine

i

No. 2 ring gap ees and spacer expander gap

ais Gap of upper side rail

7922AG05

Piston ring end-gap spacing—2.4L engine

identification mark “1R”

Identification mark “2R”

Size mark

SPECIAL TOOL 6926-2 INSTALLER 7922AG02 7922EG33

Place a proper size pilot tool with a magnetic base on the crankshaft

Common Chrysler piston ring identification mark locations

elicit DEE

y a

Fuel System Service Precautions Safety is an important factor when servicing the fuel system. Failure to conduct maintenance and repairs in a safe manner may result in serious personal injury. Maintenance and testing of the vehicle's fuel system components can be accomplished Safely and effectively by adhering to the following rules and guidelines: ¢ To avoid the possibility of fire and personal injury, always disconnect the negative battery cable unless the repair or test procedure requires that battery voltage be applied. e Always relieve the fuel system pressure prior to disconnecting any fuel system component (injector, fuel rail, pressure regulator, etc.), fitting or fuel line connection. Exercise extreme caution whenever relieving fuel system pressure, to avoid exposing skin, face and eyes to fuel spray. Please be advised that fuel under pressure may penetrate the skin or any part of the body that it contacts. e Always place a shop towel or cloth around the fitting or connection prior to loosening to absorb any excess fuel due to spillage. Ensure that all fuel spillage is quickly removed from engine surfaces. Ensure that all fuel soaked cloths or towels are deposited into a suitable waste container. e Always keep a dry chemical (Class B) fire extinguisher near the work area. e Do not allow fuel spray or fuel vapors to come into contact with a spark or open flame. Always use a back-up wrench when loosening and tightening fuel line connection fittings. This will prevent unnecessary stress and torsion to fuel line piping. e Always replace worn fuel fitting Orings. Do not substitute fuel hose where fuel pipe is installed.

Fuel System Pressure

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove the negative battery cable. 3. Remove the fuel pump relay from the Power Distribution Center (PDC). 4. Start and run the engine until it stalls. 5. Turn the ignition key to the OFF position.

Fuel Filter The fuel filter is part of the fuel pump module located in the fuel tank. Refer to the fuel pump module procedure for the fuel filter.

The fuel pump is integral with the pump module, which also contains the fuel reservoir, level sensor, inlet strainer and fuel pressure regulator. The inlet strainer, fuel pressure regulator and level sensor are the only serviceable items. If the fuel pump requires service, replace the entire fuel pump module.

REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Properly relieve the fuel system presSure. 3. Remove or disconnect the following: Negative battery cable Air cleaner lid Inlet Air Temperature (IAT) sensor and make up air hose Fuel tank Fuel pump module and seal from the tank ¢ Locknut to release the fuel pump

module, using a Ring Spanner Too! No. 6856 ¢ Fuel filter from the fuel pump module e Fuel pump and seal from the fuel tank To install: 4. Install or connect the following: Fuel filter to the fuel pump module Fuel filter lines to the fuel pump module Fuel pump module in the tank Locknut while holding the fuel pump in position. Using Tool 6856, torque the nut to 56 ft. Ibs. (75 Nm) Fuel tank IAT sensor and make-up hose Air cleaner tid Negative battery cable 5. Fill the fuel tank. 6. Start the vehicle and check for leaks, repair if necessary.

Fuel Injector — REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Release the fuel system pressure. 3. Remove or disconnect the following: Negative battery cable Remove the air cleaner lid Inlet Air Temperature (IAT) sensor and the make-up hose Engine cover or throttle control shield, if equipped e Fuel supply tube from fuel rail Intake manifold

a

RELIEVING

3k CAUTION. Relieve the fuel system pressure before servicing any components of the fuel system. Service vehicles in well ventilated areas and avoid ignition sources. NEVER smoke while servicing the vehicle!

Ne/e R

py

DL aSa =

a

cer;

9306ZG96

93062695

Exploded view of the fuel pump module

Remove the fuel rail and injectors as an assembly

For complete Engine Mechanical specifications, see Section 1 of this manual

iia e Fuel injector electrical connectors e Fuel rail with the fuel injectors ¢ Fuel injector(s) and discard the Orings To install: Lubricate the O-rings with clean engine oil.

4. Install or connect the following: Fuel injector(s) to the fuel rail using new O-rings Fuel injector nozzles into the intake manifold and torque the fuel rail bolts to 8 ft. Ibs. (12 Nm) Fuel injector electrical connectors Fuel supply tube to fuel rail

e Intake manifold e Engine cover or throttle control shield, if equipped e IAT sensor and make-up hose e Air cleaner lid ¢ Negative battery cable 5. Start the vehicle and check for leaks, repair if necessary.

DRIVE TRAIN Transaxle Assembly REMOVAL & INSTALLATION Manual

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the transaxle fluid. 3. Remove or disconnect the following: Battery cables Battery and tray Air cleaner Back-up lamp switch wiring from the transaxle Shift selector and crossover cable and move them out of the way

Vehicle Speed Sensor (VSS) wire Clutch master cylinder hydraulic tube from the slave cylinder Both halfshafts Bell housing dust cover Power steering hose from the structural collar Left side engine-to-transaxle lateral bending brace and structural collar Right side engine-to-transaxle lateral bending brace Starter Driveplate-to-clutch module bolts and support the engine at the oil pan Transaxle upper mount bolts and lower the powertrain assembly onto the support Transaxle-to-engine mounting bolts

1 — MODULAR CLUTCH ASSEMBLY 2 — CLIP

Transaxle Clutch module from the input shaft Slave cylinder Upper transaxle mount To install: 4. Install or connect the following: Clutch module to the transaxle input shaft and place the transaxle into position Transaxle-to-engine mounting bolts and torque them to 80 ft. Ibs. (108 Nm) Upper transaxle mount and torque the bolts to 45 ft. Ibs. (62 Nm) Driveplate-to-clutch module bolts and torque to 66 ft. Ibs. (88 Nm) Starter Starter electrical connectors Bell housing dust cover

3 ~ TRANSAXLE

4 - CLUTCH MODULE BOLT (4) 9306ZG0E

Remove the clutch module from the transaxle assembly

| e Left side engine-to-transaxle bending brace and structural brace. Torque the bolts to 60 ft. Ibs. (81 Nm). e Right lateral bending brace and torque the bolts to 60 ft. Ibs. (81 Nm) ¢ Power steering hose to the structural collar e Both halfshafts e Clutch master cylinder tube to the slave cylinder e VSS electrical connector e Shift crossover and selector cables to the shift lever e Cables to the bracket and install a new retainer clip e Back-up lamp switch connector e Battery tray e Battery and cables e Air cleaner assembly 5. Fill the transaxle fluid to the proper level. 6. Be sure the vehicle's back-up lights and speedometer are functioning properly. 7. Start the vehicle and check for leaks, repair if necessary. Automatic

1. Before servicing the vehicle, refer to the precautions in the beginning of this section.

2. Drain the transaxle fluid. 3. Remove or disconnect the following: ¢ Battery cables e Air cleaner assembly e Battery and tray ¢ Upper starter-to-transaxle bell housing bolt e Transaxle dipstick and tube e Gearshift cable end from the transaxle shift lever e Gearshift cable bracket bolt from the transaxle e Transaxle oil cooler lines. Plug the lines to prevent contamination. e Input and output speed sensor electrical connectors e Transaxle range sensor connector e Solenoid/pressure switch assembly connector ¢ Both front wheels e Left front splash shield e Both halfshafts e Power steering hose from the structural collar e Left and right side engine-totransaxle lateral brace and structural collar Starter motor electrical connectors e Starter e Gearshift cable bracket

qnreae dOss + Driveplate-to-torque converter bolts and support the powertrain assembly e Transaxle upper mount to bracket bolts and lower the powertrain assembly e Transaxle To install: 4. Install or connect the following: e Transaxle and torque the bolts to 80 ft. Ibs. (105 Nm) while supporting the transaxle with a jack e Mount-to-transaxle bracket. Torque the bolts to 50 ft. Ibs. (68 Nm) and remove the jack. e Driveplate-to-torque converter bolts and torque the bolts to 65 ft. Ibs. (88 Nm) e Starter and hand tighten the bolts e Dipstick tube and secure the bracket to the transaxle. Torque the upper Starter bolt to 40 ft. Ibs. (54 Nm). e Cable bracket to the bell housing and torque the bolt to 45 ft. Ibs. (61 Nm) e Starter lower bolt and torque the bolt to 40 ft. Ibs. (54 Nm) Starter electrical connections Bell housing dust cover

CSS, Sara

SSyd:fy

93062697

Exploded view of automatic transaxle removal

For Accessory Drive Belt illustrations, see Section 1 of this manual

10-1

CHRYSLER CORP. PT CRUISER

Lower dust shield screws and torque the bell housing cover bolts to 108 inch Ibs. (12 Nm) Right side lateral bending brace and torque the bolts to 60 ft. Ibs. (81 Nm) Both halfshafts Left side splash shield and both wheels Cooler lines to the transaxle and secure with constant tension clamps Solenoid/pressure switch assembly Transmission range sensor connector Input/output sensor connectors Gearshift cable to the bracket and connect it to the manual valve lever Battery tray and battery Air cleaner assembly VSS wiring Battery cables 5. Fill the transaxle fluid to the proper level. 6. Be sure the vehicle's back-up lights and speedometer are working properly.

ADJUSTMENT This vehicle utilizes a modular clutch assembly located between the engine and the transaxle. The modular clutch is serviced as an assembly and is self-adjusting. The self-adjusting feature of the clutch relies on a Sensor ring and adjuster ring.

e Left side lateral bending brace and structural collar Bell housing dust cover Right side lateral bending brace Starter Driveplate-to-clutch module bolts and support the engine at the oil pan Transaxle upper mount bolts and lower the engine/transaxle assembly Modular clutch from the input shaft To install: 3. Install or connect the following: e Clutch module to the input shaft e Transaxle-to-engine mount bolts and torque them to 80 ft. Ibs. (108 Nm) e Upper mount bolts and torque them to 65 ft. Ibs. (88 Nm) e Driveplate-to-clutch module bolts and torque them to 65 ft. Ibs. (88 Nm) e Starter and torque the bolts to 40 ft. lbs. (54 Nm). Make certain that the ground cable is fastened to the upper bolt. e Starter electrical connectors e Bell housing dust cover e Left side lateral bending brace and structural collar e Power steering hose to the structural collar e Right side lateral bending brace and torque the bolts to 60 ft. Ibs. (81 Nm) e Both halfshafts

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 Air cleaner assembly Battery and tray Back-up lamp electrical connector Shift cable-to-bracket clips Shift lever and crossover cable from the levers. Move the cables out of the way. Vehicle Speed Sensor (VSS) electrical connector Clutch master cylinder tube from the slave cylinder using a clutch hydraulic quick connect Tool 6638A Both halfshafts Power steering hose from the structural collar

e Clutch master cylinder tube to the slave cylinder e VSS electrical connector Back-up lamp switch electrical connector e Air cleaner assembly . Battery and tray e Battery cables 4. Fill the transmission to the proper level. 5. Road test the vehicle and check for proper clutch operation. 6. Check the fluid level and adjust if

needed.

;

REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Place the transaxle in the P position, for automatic and neutral for manual. 3. Remove or disconnect the following: Negative battery cable Front wheel Cotter pin, locknut and spring washer from the end of the outer Constant Velocity (CV) joint stub axle Driveshaft to hub and bearing nut Front wheel speed sensor, if equipped Steering knuckle from the ball joint Driveshaft from the steering knuckle and support the outer end of the driveshaft

Be careful when separating the ball joint stud from the steering knuckle, so the ball joint seal does not get damaged. SS

RL WE

ER

SAE

EES

Be careful when separating the inner CV-joint during this operation. Do not let the driveshaft hang by the inner CV-joint, the driveshaft must be supported. Se e>Inner Tri-Pot joint removal is easier by applying outward pressure on the joint while hitting the punch with a hammer. 93062698

Exploded view of the modular clutch

_ A. Inner Tri-Pot joints from the transmission side gears using a punch to dis-

ieee Dg lodge the inner Tri-Pot joint retaining ring from the transmission side gear. If removing the right side inner Tri-Pot joint, position the punch against the inner Tri-Pot joint. Hit the punch sharply with a hammer to dislodge the right inner joint from the side gear. If removing the left side inner Tri-Pot joint, position the punch in the groove of the inner Tri-Pot joint. Hit the punch sharply with a hammer to dislodge the left inner TriPot joint from the side gear. 5. Hold the inner Tri-Pot joint and interconnecting shaft of the driveshaft assembly. Remove the inner Tri-Pot joint from the transaxle by pulling it straight out of the transaxle side gear and transmission oil seal. When removing the Tri-Pot joint, do not let the spline or snapring drag across the sealing lip of the transaxle-toTri-Pot joint oil seal.

The driveshaft, when installed, acts as a bolt which secures the front hub and bearing assembly. If the vehicle is to be supported or moved on its wheels with a driveshaft removed, install a proper-sized bolt and nut through the front hub. Tighten the bolt and nut to 135 ft. lbs. (183 Nm). This will ensure that the hub bearing cannot loosen.

To install: 6. Thoroughly clean the spline and oil seal sealing surface on the Tri-Pot joint. Lightly lubricate the oil seal sealing surface on the Tri-Pot joint with fresh, clean transmission fluid. 7. Holding the driveshaft assembly by the Tri-Pot joint and interconnecting shaft, install the Tri-Pot joint into the transaxle side gear as far as possible by hand

8. Align the Tri-Pot joint with the transmission side gears, grasp the driveshaft interconnecting shaft and push the Tri-Pot joint into the transaxle side gear until fully seated. Be sure the snapring is fully engaged with the side gear by trying to remove the Tri-Pot joint from the transaxle by hand. If the snapring is fully seated with the side gear, the Tri-Pot joint will not be removable by hand. 9. Install or connect the following: Driveshaft back into the front hub Steering knuckle into the ball joint stud New steering knuckle-to-ball joint stud bolt and nut. Torque the nut and bolt to 70 ft. Ibs. (95 Nm). Washer and hub nut to the stub axle and torque the nut to 180 ft. lbs. (244 Nm) Spring washer, locknut and cotter pin e VSS, if equipped e Front wheel e Negative battery cable 10. Check the transaxle fluid and adjust if needed.

OVERHAUL Tri-Pot (Inner) Joint 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove the negative battery cable. 3. Remove the halfshaft. 4 Remove the tri-pot joint boot clamps and slide the boot down the shaft.

When removing the spider joint, hold the rollers in place on the trunions to keep the rollers and needle bearings in place. 5. Spider 6. 7.

Slide the interconnecting shaft and assembly from the tri-pot housing. Remove the snapring from the shaft. Remove the spider assembly.

e>|lf necessary, tap the spider assembly from the shaft with a brass drift.

When removing the spider assembly, do not hit the outer bearings. 8. Remove the boot by sliding it off the shaft.

If any parts show excessive wear, replace the halfshaft assembly; the component parts are not serviceable. To install:

The Tri-pot sealing boots are made of 2 different types of material, silicon rubber (high temperature) which is soft and pliable or hytrel plastic (standard temperature) which is stiff and rigid. Be sure to replace the boot made of the correct material. 9. Install a new small boot clamp and slide it on the shaft. 10. Install the boot and slide it on the Shaft. 11. Position the boot so that the raised

9306ZG0A

93062699

Remove the Tri-Pot joint from the transaxle

install the Tri-Pot housing on to the spider

assembly

For Tire, Wheel and Ball Joint specifications, see Section 1 of this manual

40-19

SHRYSLER corp. PT CRUISER

bead on the inside the boot seal is in the shaft groove. 12. Install the spider assembly, face the chamfered side toward the shaft. 13. Install the snapring making sure it is fully seated in the groove. 14. Install the spider/shaft assembly into the tri-pot housing. 15. Install a new inner boot clamp and position it evenly on the sealing boot. 16. Using a trim stick, adjust the boot length to 115mm (hytrel plastic) or 115mm (silicone rubber). 17. If installing a high profile boot clamp, perform the following procedure: a. Using the Crimper Tool C-4975-A, place the tool over the clamp bridge, tighten the too! nut until the jaws are completely closed (face-to-face).

The seal must not be dimpled, Stretched or out of shape. If necesSary, equalize the seal pressure and shape it by hand. b. Position the boot onto the tri-pot housing retaining groove and install the retaining clamp evenly on the boot. c. Using the Crimper Tool C-4975-A, place the tool over the clamp bridge, tighten the too! nut until the jaws are completely closed (face-to-face). 18. If installing a low profile latching type boot clamp, position Snap-On® Clamp Locking Too! YA3050 prongs in the clamp holes and squeeze the tool until the upper clamp band is latched behind the 2 tabs on the lower clamp band. 19. Install the halfshaft. 20. Connect the negative battery cable.

oe

Outer Joint

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove the halfshaft. 3. Remove the clamps from the CVjoint boot and discard. 4. Remove the boot from the CV-joint housing and slide it down the interconnecting shaft. 5. Remove the outer CV-joint from the interconnecting shaft by sharply hitting it with a soft-faced hammer to drive it off the shaft. 6. Remove the circlip from the shaft. 7. Remove the CV-joint by sliding it off the shaft.

Remove the outer C/V joint from the interconnecting shaft

15. Install a new small boot clamp and position it evenly on the sealing boot.

> CAUTION If any parts show excessive wear, replace the halfshaft assembly; the component parts are not serviceable. To install: 8. Install a new small boot clamp and Slide it onto the shaft. 9. Install the boot and slide it onto the shaft. 10. Install the circlip. 11. Position the boot so that the raised bead on the inside the boot seal is in the shaft groove. 12. Install the halfshaft hub nut onto the joint threaded shaft so it is flush with the end. 13. Align the shaft splines and tap it onto the shaft with a soft-faced hammer so it locks on the circlip. 14. Distribute % of the grease in the service package inside the joint housing and the other % inside the boot.

Clamp the boot to the shaft 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).

The seal must not be dimpled, Stretched or out of shape. If necesSary, equalize the seal pressure and shape it by hand. 16. Position the boot onto the retaining

groove and install the retaining clamp evenly on the boot. 17. Clamp the boot to the outer CV-joint housing using the Crimper Too! C-4975-A, place the tool over the clamp bridge, tighten the tool nut until the jaws are completely closed (face-to-face). 18. Install the halfshaft

STEERING AND SUSPENSION PRECAUTIONS

*«- CAUTION Some 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 repairs. ST

9306ZG0B

RE

EI

ETE IT SE

ES

SERPS

Several precautions must be observed when handling the inflator module to avoid accidental deployment and possible personal injury: 1. Never carry the inflator module by the wires or connector on the underside of the module. 2. When carrying a live inflator module, hold securely with both hands, and ensure that the bag and trim cover are pointed

away. 3. Place the inflator module on a bench or other surface with the bag and trim cover facing up.

. 4. With the inflator module on the bench, never place anything on or close to the module which may be thrown in the event of an accidental deployment.

DISARMING —_ee—_—_————————————

Proper Supplemental Restraint System (SRS) disarming can be obtained by disconnecting and isolating the negative battery cable. Allow the air bag system capacitor at least 2 minutes to discharge before removing any air bag system components.

ae aD Rack and Pinion Steering Gear REMOVAL & INSTALLATION 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 in place, using a steering wheel holder. Locking the steering wheel keeps the Clockspring in alignment position.

3. Remove or disconnect the following: Silencer pad from below the knee blocker panel Knee blocker Steering column coupling retainer pin, pinch bolt nut/bolt and separate the couplings Both front wheels Outer tie rod-to-steering knuckle nuts Outer tie rod ends from the steering knuckle using remover Tool

MB991113 Tie rod heat shield Power steering fluid pressure switch wiring connector by releasing the locking tab

Power Steering fluid pressure hose from the steering gear Power steering fluid return hose from the steering gear, if not equipped with a power steering fluid cooler Power steering fluid cooler hose from the steering gear, if equipped with a power steering fluid cooler Power steering fluid return hose from the routing clip C-clamps, if not equipped with a power steering fluid cooler Power steering fluid pressure hose from the steering gear's routing clips Power steering cooler hose from the steering gear’s right routing Clip, if equipped Both power steering cooler screws from the front suspension crossmember, if equipped, and move the cooler aside Drive belt splash shield Engine torque strut-to-front suspension crossmember bolt from the right forward corner of the crossmember 4. Matchmark the front suspension crossmember-to-chassis location.

3 — STEERING GEAR 4 — FRONT SUSPENSION

1 - OUTER TIE ROD 2 — JAM NUT

CROSSMEMBER 9306EG42

View of the power steering gear and crossmember

If the front suspension crossmemberto-chassis location is not matchmarked, the front wheel alignment setting will be lost. 5. Place a transmission jack under the front crossmember and support it. 6. Remove the front suspension crossmember-to-frame rail bolts, one located at each side. 7. Loosen both rear suspension crossmember-to-frame rail bolts, one located at each side, until they release from the threaded tapping plates in the bolt.

Do not completely remove the rear bolts for they are designed to disengage from the body threads and will stay within the lower control arm rear isolator bushing. >The threaded tapping plates allow the lower control arm to stay in place on the crossmember.

8. Using the transmission jack, lower the front suspension crossmember enough to allow the power steering gear to be removed form the rear of the crossmember. Use the jack to support the crossmember's weight. 9. Remove or disconnect the following: B e Lower steering column couplingto-power steering gear pinion shaft’s roll pin, using a roll pin punch Lower steering column coupling from the power steering column pinion shaft Pinion shaft dash cover seal from the tabs cast into the power steering gear housing Power steering gear from the front Suspension crossmember To install: 10. Install or connect the following: e Power steering gear onto the front suspension crossmember and torque the bolts to 45 ft. Ibs. (61 Nm) Pinion shaft dash cover seal over the shaft and onto the power steering gear housing. Align the seal holes with the tabs cast into the power steering gear housing. e Lower steering column coupling by

For Wheel Alignment specifications, see Section 1 of this manual

10-20

SHRYSLER corP. PT CRUISER

aligning the coupling and steering gear pinion shaft flats Lower steering column couplingto-pinion shaft’s roll pin until it is centered. Center the power steering gear rack’s travel. Front suspension crossmember/power steering gear assembly by raising it with the jack until is aligns with its matchmarks Lower steering column coupling, guide it through the dash panel hole as it is raised Both rear crossmember-to-tapping plate bolts Both front crossmember-to-frame rail bolts and torque the 4 bolts to 20 inch Ibs. (2 Nm)

Torque the nut, using a crowsfoot

wrench, to 40 ft. Ibs. (65 Nm), while holding the tie rod stationary. e Both front wheels e Dash-to-lower coupling seal over the lower coupling's plastic collar e>\Verify that the seal’s lip shows grease at the coupling’s plastic collar contact.

e Steering column lower coupling-tosteering column upper coupling pinch bolt and torque the nut to 21 ft. Ibs. (28 Nm) e Pinch bolt retainer pin e Knee blocker and silencer pad

15. Remove the steering wheel holder. 16. Fill and bleed the power steering system. 17. Start the vehicle and check for leaks, repair if necessary. 18. Check and/or adjust the front toe setting:

REMOVAL & INSTALLATION Front

1. Before servicing the vehicle, refer to the precautions in the beginning of this section.

Be sure to align the front suspension crossmember-to-chassis matchmarks; otherwise, the front wheel alignment setting will be lost. 11. Once aligned, torque both rear crossmember-to-rear lower control arm bolts to 185 ft. Ibs. (250 Nm) and both front crossmember bolts to 113 ft. Ibs. (153 Nm). 12. Install the engine torque strut to the right forward corner of the front suspension crossmember. 13. Adjust the engine torque strut by performing the following procedure: a. Loosen the upper torque strut at the shock tower bracket. b. Position a floor jack on the forward edge of the bell housing to prevent the least amount of upward lifting of the engine. c. Slowly, lift the assembly, allowing the engine to rotate rearward so the distance between center of the engine mount bracket's rearmost attaching the and the center of the shock tower bracket’s washer hose clip hole is 4.70 in. (119mm). d. Torque the upper and lower torque strut bolts to 87 ft. Ibs. (118 Nm). e. Remove the floor jack. 14. Install or connect the following: ¢ Drive belt splash shield ¢ Power steering hose-to-power Steering gear using a new O-ring lubricated with power steering oil, if not equipped with a power steering cooler Power steering fluid cooler line-topower steering gear, if equipped with a power steering cooler Power Steering fluid return hose to the routing clip C-clamps ¢ Tie rod ends to the steering knuckle.

1 — VEHICLE STRUT TOWER 2 - OUTER TIE ROD 3 - STEERING GEAR 4 — STRUT ASSEMBLY 5 — JAM NUT 6 — LOWER CONTROL ARM 7 — CROSSMEMBER 8 — BALL JOINT 9 - STABILIZER BAR 10 — STABILIZER BAR CUSHION AND RETAINER

11 12 13 14 15 16 17 18 19 20

— — — ~ — — — — —

STABILIZER BAR LINK HUB KNUCKLE STRUT LOWER SPRING ISOLATOR COIL SPRING JOUNCE BUMPER DUST SHIELD SPRING SEAT AND BEARING UPPER MOUNT 9306EG11

Exploded view of the front suspension

lace 2. Install or connect the following: e Negative battery cable e Front wheels e Mark each one right or left, as applicable, if both struts are being removed Ground strap from the rear of the strut

Anti-lock Brake System (ABS) wheel speed sensor from the strut, if equipped

>: WARNING The steering knuckle-to-strut assembly attaching bolts are serrated and must not be turned during removal.

e Steering knuckle nuts while holding the bolts stationary e 3 upper strut mount-to-strut tower nuts

e Strut assembly To install: 3. Install or connect the following: e Strut assembly into the strut tower by aligning the 3 upper strut mount studs with the shock tower holes. Torque the 3 upper strut mount nut/washer assemblies to 25 ft. Ibs. (34 Nm)

Shock, Absorber

REMOVAL & INSTALLATION

REMOVAL & INSTALLATION

Rear

Front

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove the rear wheel and position a transmission jack under the center of the axle. Raise the jack enough to support the axle. 3. Remove or disconnect the following: e Shock absorber lower mounting bolt from the axle e Upper mounting bolt e Shock absorber To install: 4. \nstall or connect the following: e Shock absorber eye to the body bracket. Hand tighten the upper mounting bolt. Lower the jack and install the lower mounting bolt through the axle flange and shock absorber. Torque the bolt to 50 ft. Ibs. (68 Nm). Torque the upper mounting bolt to 73 ft. Ibs. (99 Nm). Rear wheel Negative battery cable

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove the wheel. 3. Remove the strut assembly and place it in a Strut Spring Compressor Too! W7200. 4. Set the lower hooks then the upper hooks. Position the clevis bracket straight outward away from the compressor tool 5. Install a clamp on the lower end of the coil spring to secure the strut when the nut is removed.

The steering knuckle-to-strut assembly attaching bolts are serrated and must not be turned during instailation.

->Do not remove the strut shaft nut until the coil spring is compressed. The coil spring is under pressure and must be compressed before the shaft nut is removed.

6. Compress the coil spring until all tension is removed from the upper mount. 7. Install a Strut Nut Socket Tool 6864 once the spring is compressed. 8. Install a socket on the hex end of the strut shaft and remove the nut. 9, Remove or disconnect the following: e Upper mount from the strut shaft

e Steering knuckle nuts while holding the bolts stationary Steering knuckle arm and position it into the strut assembly by aligning the strut assembly-to-steering knuckle holes Both strut-to-steering knuckle bolts. Torque both bolts to 40 ft. lbs. (53 Nm), plus an additional 90 degrees after the specified torque is met. ->The bolts should be installed with the nuts facing the front of the vehicie.

e ABS wheel sensor to the rear of the strut and torque the screw to 120 inch Ibs. (13 Nm) e Ground strap to the rear of the strut and torque the screw to 120 inch lbs. (13 Nm) ¢ Front wheel e Negative battery cable

93062G0C

Shock absorber mounting bolts

For Maintenance Interval recommendations, see Section 1 of this manual

10-2

CHRYSLER CORP. PT CRUISER

Upper spring seat, bearing and upper isolator as an assembly Dust shield and jounce bumper Clamp from the bottom of the coil spring Strut through the bottom of the coil Release the tension from the coil spring by backing off the compressor drive completely Coil spring 10. Inspect the coil spring for any signs of damage To install: 11. Install or connect the following:

e Coil spring in the compressor. Rotate the spring so that the end of the top coil is directly in the front. Slowly compress the coil until enough room is available to install the strut Lower spring isolator on the lower spring seat Strut through the bottom of the of coil spring until the lower spring seat contacts the lower end of the coil spring. Rotate the strut until the clevis bracket is positioned

straight outward away from the compressor. Clamp on the lower end of the coil spring and strut Jounce bumper on the strut shaft with the smaller end pointing ~ downward Dust shield until the bottom of the shield snaps on to the retainer Upper spring isolator Upper spring seat and bearing on top of the coil spring. Position the notch formed into the edge of the upper seat straight out away from the compressor. Strut upper mount over the strut shaft and onto the top of the upper spring seat and bearing. Position the mount so that the third mounting stud is inward toward the compressor. Retaining nut on the strut shaft, loosely 12. Install the strut nut socket on the strut shaft retaining nut. Install a socket on the hex end of the shaft. Secure the strut shaft and torque the nut to 55 ft. Ibs. (75 Nm). 13. Slowly release the tension from the coil spring by backing off the compressor completely. 14. Remove the clamp from the bottom of the coil spring and strut. Push back the spring compressor upper and lower hooks and remove the strut from the compresSOr. 15. Install the strut assembly to the vehicle. Rear

1 2 3

4 5)

—- LOWER CLAMP | STRUT CLEVIS SPRING

HOOKS ASSEMBLY BRACKET COMPRESSOR 9306ZG0D

Coil spring mounted in the coil spring compressor tool

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Both rear wheels Watts link bell crank from the center of the axle Sway bar cushion retainers Sway bar from the rear axle and place a jack under the rear axle Shock absorber and lower the jack Coil springs and rubber isolators To install: 3. Install or connect the following: e Rubber isolator on each end of the coil spring and wrap the finger around the coil ¢ Coil springs on top of the axle spring perches and make certain that the upper coils end near the

apieee102

1 2 3 4

-— — — —

5 6 7 8

ISOLATORS JOUNCE BUMPER SHOCK ABSORBER WATTS LINK (UPPER)

-— — — —

WATTS LINK (LOWER) BELL CRANK AXLE COIL SPRING 9346JG12

Exploded view of the rear suspension

outboard sides of the vehicle and not at 180 degrees of that location Coil springs into the spring mounting brackets Washer and nut on the lower mounting bolts and torque the bolts to 50 ft. Ibs. (68 Nm) Lower end of the sway bar retainers in the slots at the back of the axle Mounting bolt through the cushion retainer and torque to 40 ft. Ibs. (54 Nm)

Watts link bell crank to the center of the axle and torque the bolts to 90 ft. Ibs. (122 Nm) e Rear wheels

Lower Ball Joint

;

REMOVAL & INSTALLATION The front suspension ball joints operate with no free-play. The ball joints are replaceable ONLY as an assembly. Do not attempt

any type of repair on the ball joint assembly. The ball joint is a press fit into the lower control arm with the joint stud retained in the steering knuckle by the clamp bolt. To check the ball joint, with the weight of the vehicle resting on the road wheels, grasp the grease fitting and without using any tools, attempt to move the grease fitting. If the ball joint is worn the grease fitting will move easily. If movement is noted, replacement of the ball joint is recommended. 1. Before servicing the vehicle, refer to

For Tune-up, Capacities and Firing orders, see Section 1 of this manual

1 0-2

CHRYSLER CORP. PT CRUISER

the precautions in the beginning of this section. 2. Remove the wheel. 3. Remove the stabilizer bar-to-lower contro! arm links. 4. Loosen, but do not remove the bolts holding the stabilizer bar retainers to the crossmember. Then, rotate the stabilizer bar

and attaching links away from the lower control arms.

>: WARNING Pulling the steering knuckle outward after releasing the ball joint can separate the inner CV-joint. 5. Remove the steering knuckle-to-ball joint stud’s pinch bolt and nut. 6. Remove the ball joint from the steering knuckle using a prybar.

Be careful when separating the ball joint stud from the knuckle, so the seal does not become damaged.

7. If removing the right lower control arm, perform the following steps: a. Remove the drive belt splash shield. b. Remove the pencil strut from the right front corner of the crossmember c. Remove the engine torque strut. 8. Remove the pivot bolts attaching the lower control arm to the front crossmember. 9. Remove the lower control arm. 10. Remove the ball joint using a pry tool. 11. Using a hydraulic press, press the ball joint from the lower control arm using Receiver tool 6908-2 and Adapter Tool 6804. To install: 12. Reinstall the ball joint into the lower control arm with the notch in the ball joint stud facing the front lower control arm bushing. 13. Using a hydraulic press, press the ball joint into the lower control arm using Receiver Tool 6758 and Adapter tool 6804. 14. Install the ball joint boot seal using a driver tool such as a large socket or suitable sized piece of pipe.

Do not use a shop press that was used to install the ball joint, for the press exerts too much force.

15. Install the lower control arm into the front crossmember. 16. Install the rear lower contro! arm-tocrossmember and frame rail bolt.

->DO NOT tighten the rear bolt at this time.

17. Install the front lower contro! arm-tocrossmember nut and bolt. 18. Torque the lower control arm to rear pivot bolt to 185 ft. Ibs. (250 Nm) and the front pivot bolt 120 ft. Ibs. (163 Nm). 19. Install the ball joint stud into the steering knuckle. Torque the steering knuckle-to-ball joint stud pinch bolt/nut to 70 ft. Ibs. (95 Nm). 20. If the right side lower control arm has been service, install the following: 21. Install the engine torque strut. 22. Install the pencil strut to the right front corner of the crossmember and torque the nuts to 43 ft. Ibs. (58 Nm). 23. Install the drive belt splash shield. 24. Install the front fascia-to-reinforcement Screws.

20. Install the stabilizer bar-to-lower control arm link assemblies and bushings. 26. Rotate the stabilizer bar into position, installing the stabilizer bar links into the lower control arms. 2/. Install the top stabilizer bar link bushings and nuts. DO NOT tighten the link

yet. 28. Install the wheel. 29. Lower the vehicle so the suspension is supporting the total weight of the vehicle. 30. Torque the stabilizer bar-to-lower control arm links to 21 ft. Ibs. (28 Nm). 31. Torque the stabilizer bar bushing retainer-to-crossmember bolts to 21 ft. Ibs.

1 — PRESS 2 — BALL JOINT

(28 Nm). 32. Check and/or adjust the toe, as necessary.

9306EG51

Removing the ball joint from the control

1 —- PRESS 2 — BALL JOINT

9306EG53

Installing the ball joint to the control arm

Wheel Bearings ADJUSTMENT

6758

The PT Cruiser is equipped with a sealed hub and bearing assemblies. The hub and bearing assembly is non-serviceable. If the assembly is damaged, the complete unit must be replaced.

REMOVAL & INSTALLATION onan liane Se eed EEN 1 2 3 4

— — -

BALL JOINT STUD NOTCH LOWER CONTROL ARM FRONT ISOLATOR BUSHING

1 — SEAL BOOT UPWARD 2 — BALL JOINT 9306EG52

Aligning the ball joint stud notch to the control arm

Front

LIP

9306EG54

Installing the ball joint boot seal

1: Before servicing the vehicle, refer to the precautions in the beginning of this section.

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WHEEL MOUNTING STUD

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Use a proper C-clamp and adapter tool to press out one of the lug studs

5. Rotate the hub so the stud hole is facing away from the brake caliper’s lower rail on the steering knuckle. 6. Install 2 of a Bearing Splitter Too! 1130, between the hub and the bearing retainer plate. The threaded hole in this ¥2 is to be aligned with the caliper rail on the steering knuckle.

2. Remove the steering knuckle and hub and bearing assembly. 3. Remove the wheel lug stud from the hub flange, using a C-clamp and Adapter Tool 4150A. 4 Rotate the hub to align the removed lug stud with the notch in the bearing retainer plate.

BEARING RETAINER PLATE

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STEERING KNUCKLE 7922EG65

7. Install the remaining pieces of the bearing splitter on the steering knuckle. Hand-tighten the nuts to hold the splitter in place on the knuckle. 8. When the bearing splitter is installed, be sure the 3 bolts attaching the bearing retainer plate to the knuckle are contacting the bearing splitter. The bearing retainer plate should not support the knuckle or contact the splitter. 9. Place the steering knuckle in a hydraulic press, supported by the bearing splitter. 10. Position a driver on the small end of the hub. Using the press, remove the hub from the wheel bearing. The outer bearing race will come out of the wheel bearing when the hub is pressed out of the bearing. 11. Remove the bearing splitter tool from the knuckle. 12. Remove the 3 bolts mounting the bearing retainer plate to the steering knuckle. 13. Place the knuckle in a press supported by the press block. The blocks must not obstruct the bore in the steering knuckle so the wheel bearing can be pressed out of the knuckle. Place a driver on the outer race of the wheel bearing, then press the bearing out of the knuckle. 14. Install the bearing splitter on the hub. The splitter is to be installed on the hub so it is between the flange of the hub and the bearing race on the hub. Place the hub, bearing race and splitter in a press. Use a driver to press the hub out of the bearing race. To install: 15. Use clean, dry cloth to wipe and grease or dirt from the bore of the steering knuckle. 16. Install a new wheel bearing into the bore of the steering knuckle. Be sure the bearing is placed squarely into the bore. Place the knuckle in a press with a Receiver Tool, C-4698-2 supporting the steering knuckle. Place a driver tool on the outer race of the wheel bearing. Press the wheel bearing into the steering knuckle until it is fully bottomed in the bore of the steering knuckle. e>Only the original or original equipment replacement bolts should be used to mounting the bearing retainer to the knuckle. If a bolt requires replacement when installing the bearing retainer plate, be sure to get the proper type of replacement.

Rotate the hub in order to remove the lug stud

For complete service labor times, order Nichols’ Chilton Labor Guide

0-26 eee e Wheel e Rear brake drum, if equipped e Caliper (suspend on a wire) and the rotor, if equipped with rear disc brakes

> WARNING DO NOT allow the caliper to hang by the brake hose. e Dust cap from the rear hub/bearing e Hub/bearing assembly-toknuckle/spindle nut

->Discard the hub nut and replace with a new one during installation.

e Hub/bearing from the spindle by pulling it off the end of the spindle by hand To install:

«:« WARNING Properly support the steering knuckle for hub and bearing removal

17. Install the bearing retainer plate on the steering knuckle. Install the 3 bearing retainer mounting bolts. Tighten the bolts to 21 ft. Ibs. (28 Nm). 18. Install the wheel lug stud into the hub flange. 19. Place the hub with the lug stud installed, in a press supported by an Adapter Too! C-4698-1 and press the wheel lug stud into the hub flange until it is fully seated against the back side on the hub flange. 20. Place the steering knuckle with the wheel bearing installed, in a press with speCial Receiver Tool MB-990799 supporting

the inner race of the wheel bearing. Place the hub in the wheel bearing, making sure it is Square with the bearing. Press the hub into the wheel bearing until it is fully bottomed in the wheel bearing. 21. Install the steering knuckle and the wheel. 22. Check and/or adjust the front alignment. Rear

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following:

The hub/bearing nut must be tightened to, but NOT over, its specified torque value. The proper specification is crucial to the life of the hub bearing. 3. Position the hub/bearing assembly on the rear spindle/knuckle. Install a NEW hub nut and tighten to 160 ft. Ibs. (217 Nm) 4. Install or connect the following: ¢ Dust cap and seat it using a soft face hammer to carefully tap it into place ¢ Brake drum, if equipped ¢ Rotor, if equipped ¢ Caliper and 2 guide pin bolts, if equipped with disc brakes. Torque the bolts to 16 ft. Ibs. (22 Nm).

FORD MOTOR CO. 1998-01

Ford-Contour * Mercury-Mystique * 1999-01 Cougar DRIVETRAIN 32 cdiais cece secs 11-22 ENGINE REPAIR ................ 11-2 UES VON NUEeee. oe 11-20 PRECAUTIONS.................. 11-2 STEERING AND SUSTHEARIU ee Bete to 11-27

SL [ SE eerie ee GU CNS 2 eee 11-27 / ULLENNCateieead 11-27 PUSATUING) seteerec. canes cstaccesses 11-27 PECANS beet ct, ctcsseledccs11-27 BMT Mal Oheean eee 2c kev c.ceerts 11-2 BIS TA ALIS Lire tte, ceed. | Ne hee a 11-3 Removal............ reseran11-2

FU ENTERs panels ce Rock corer at sper 11-20 Removal & Installation... 11-20

EUCIMMIGCIOR cette dc. cots enast 11-21 Removal & Installation... 11-21

FUCWPUMD We eis teen eeoe.t 11-21 Removal & Installation... 11-21

Fuel System PreSSure ............60 11-20 ROMGVING seaeste tiestsa comes os:11-20 Fuel System Service Precautions........... vse

ci 11-20

HaltSial earn tate atc hes. 11-25 Removal & Installation............ 11-25

Hydraulic Clutch System............. 11-25 Bleeding............. ao

Camshaft and Valve Lifters .......... Removal & Installation............ Afra le eee PROUSETIET Sree oecnntdeveads Removal & Installation............ BE AOIRIS: tee coronas

11-10 11-10 11-24 11-24 11-24 11-26

Removal & Replacement......... 11-26 MCE GAC th reser ea kees neste 11-7 Removal & pen ane

A 11-7

ENGine ASSOMDIY i.,... Disconnecting the negative battery cable on some vehicles may interfere with the operation of the on-board computer system. The computer may undergo a relearning process once the negative battery cable is reconnected.

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:

proper operation of the brake system. You should always buy the correct type of brake fluid for your vehicle. If the brake fluid becomes contaminated, completely flush the system with new fluid. Never reuse any brake fluid. Any brake fluid that is removed from the system should be discarded. Also, do not allow any brake fluid to come in contact with a painted surface; it will damage the paint. e Never operate the engine without the proper amount and type of engine oil; doing so WILL result in severe engine damage. e Timing belt maintenance is extremely important. Many models utilize an interference-type, non-freewheeling engine. If the timing belt breaks, the valves in the cylinder head may strike the pistons, causing potentially Serious (also time-consuming and expensive) engine damage. Refer to the maintenance interval charts in the front of this manual for the recommended replacement interval for the timing belt, 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 computer system(s) and may require the computer to undergo a relearning process once the negative battery cable is reconnected. ¢ When servicing drum brakes, only disassemble and assemble one side at a time, leaving the remaining side intact for reference. ¢ Only an MVAC-trained, EPA-certified automotive technician should service the air conditioning system or its components.

~

Alternator electrical connections Ground cable Right front wheel Right splash shield Radiator splash shield Accessory drive belt Alternator. Remove the upper mounting bolt last. e>There is a limited amount of space in which to remove the alternator. Do not damage any hoses or cables.

2.0L Engine

1998 MODELS 1. Before servicing the vehicle, refer to the precautions in the beginning of this section.

2. Remove or disconnect the following: Negative battery cable Accessory drive belt Right halfshaft Exhaust system Y pipe Right splash shield Alternator wiring connectors Alternator rear support bracket Alternator

1999-01 MODELS 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Negative battery cable e Right front wheel ¢ Right splash shield

FORD MOTOR CO.

CONTOUR ¢ MYSTIQUE ¢ 1999-01 COUGAR

the precautions in the beginning of this section. 2. Drain the engine oil and coolant. 3. Drain the transaxle fluid. 4, Attach an engine support fixture to the engine lifting eyes. 5. Secure the A/C condenser to the radiator support with safety wire. 6. Loosen the suspension strut lock nuts five turns. 7. Remove or disconnect the following: Battery Mass Air Flow (MAF) sensor con-

e Radiator splash shield e Right splash shield e Right front wheel and tighten the lug nuts to 63 ft. Ibs. (86 Nm) e Ground cable e Alternator electrical connections e Air intake resonator e Negative battery cable 9346HG03

2.5L Engine

1998 MODELS Remove the splash shield retainers (1) and the splash shield (2)—2.5L engines

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Install or connect the following: e Alternator and tighten the mounting bolts to 33 ft. Ibs. (45 Nm) e Alternator rear support bracket and tighten the bracket bolts to 18 ft. Ibs. (25 Nm) e Alternator wiring connectors e Right splash shield e Exhaust system Y pipe e Right halfshaft e Accessory drive belt e Negative battery cable

Separate the outer tie rod end from the steering knuckle—2.5L engines

Intake Air Temperature (IAT) sensor connector Air cleaner outlet tube Air cleaner Exhaust Gas Recirculation (EGR) vacuum supply hose, if equipped EGR pressure sensor wiring, if equipped EGR exhaust tube, if equipped Engine wiring harness connector Accelerator cable Upper drive belt cover Front wheels Left, right and center splash shields Accessory drive belt Stabilizer bar links Outer tie rod ends Lower ball joints Lower radiator retainers Both Heated Oxygen (HO2S) sensor connectors

Install or connect the following: e Alternator and tighten the mounting bolts to 33 ft. Ibs. (45 Nm) e Alternator rear support bracket and tighten the bracket bolts to 18 ft. Ibs. (25 Nm) e Alternator wiring connectors ¢ Right outer tie rod end and tighten the nut to 21 ft. Ibs. (28 Nm) ¢ Accessory drive belt e Right splash shield e Right front wheel and tighten the lug nuts to 63 ft. Ibs. (86 Nm) e Negative battery cable

Ignition Timing Alternator rear support bracket— 2.5L engines

e e e e e

nector

1999-01 MODELS 9346HG04

Accessory drive belt Right outer tie rod end Alternator wiring connectors Alternator rear support bracket Alternator

INSTALLATION ee Pieter

Install or connect the following: e Alternator and tighten the mounting bolts to 33 ft. Ibs. (45 Nm) e Accessory drive belt

Power steering hoses Brake booster vacuum line at intake manifold e Steering gear and heat shield e Right support insulator and bracket e Front exhaust pipe Left support insulator

.

ADJUSTMENT The ignition timing is set at 10 degrees Before Top Dead Center (BTDC) and is not adjustable.

Engine Assembly REMOVAL & INSTALLATION ED

2.0L Engine

2.0L Engine

11-3

->The engine and transaxle are removed as an assembly.

1. Before servicing the vehicle, refer to

A/C accumulator attachment bolts 4 subframe bolts and the subframe 8. If equipped with a manual transaxle, place the shift lever in neutral and lock it in place with special tool Gear Lever Aligner T97P-7025-A. e Clutch hydraulic line e Shift cables e Reverse lamp switch connector e Vehicle Speed (VSS) sensor connector 9. If equipped with an automatic transaxle, remove or disconnect the follow-

ing: e Torque converter e Transaxle control wiring connector ¢ Range switch connector

For complete service labor times, order Nichols’ Chilton Labor Guide

11-4

FORD MOTOR CO.

CONTOUR ¢ MYSTIQUE ¢ 1999-01 COUGAR

Ground strap Shift cable VSS and bracket Transaxle cooler lines and fluid tube e Turbine Shaft Speed (TSS) sensor connector 10. For all vehicles, remove or disconnect the following: Axle halfshafts e Upper and lower radiator hoses 2 ground cables from radiator support Coolant hose bracket and power steering hose Coolant hoses at the recovery tank Radiator and cooling fan A/C compressor Power steering pump Heater hoses and bracket Powertrain Control Module (PCM) connector Vacuum hoses at the intake manifold Battery cables at the battery tray e Fuel supply and return lines 11. ee the engine and transaxle assembly from below. 12. Remove or disconnect the following: e Top support fixture

¢ Coolant recovery tank e Front and rear engine mount brackets 13. Raise the vehicle away from the engine and transaxle assembly 14. Support the engine with a shop hoist. 15. Support the transaxle with a transmission jack, 16. Remove or disconnect the following: ¢ Starter

e Ground cable e Transaxle flange bolts e Engine from the transaxle To install: e>Replace all snaprings, split pins and self-locking nuts.

17. Install or connect the following: e Engine to the transaxle and tighten the flange bolts to 35ft. Ibs. (48 Nm) ¢ Ground cable ¢ Starter motor and tighten the bolts to 35 ft. Ibs. (48 Nm) 18. Lower the vehicle onto the engine and transaxle assembly. 19. Install or connect the following: ¢ Front and rear engine mount brackets and tighten the nuts and bolts finger tight ¢ Top support fixture

Fuel supply and return lines Battery cables to the battery tray. Secure with cable ties. Vacuum hoses to the intake manifold PCM connector Heater hoses and bracket Power steering pump and tighten the bolts to 35 ft. Ibs. (47 Nm) A/C compressor and tighten the bolts to 18 ft. Ibs. (25 Nm) Radiator and cooling fan Power steering hose and coolant hose bracket 2 ground cables to the radiator support Upper and lower radiator hoses e Axle halfshafts 20. If equipped with a manual transaxle,

install or connect the following: e Clutch hydraulic line e Shift cables e VSS connector e Reverse lamp switch connector 21. Remove the Gear Lever Aligner. 22. lf equipped with an automatic transaxle, install or connect the following: TSS connector Torque converter and tighten the nuts to 27 ft. Ibs. (86 Nm) Transaxle cooler lines and fluid tube VSS and bracket Shift cable Ground strap Range switch connector Transaxle contro! wiring connector Powertrain Alignment Gauge T94P6000-AH to the subframe Lower radiator retainers to the subframe Subframe and attach the front bolts. Do not tighten the bolts at this time. Steering gear to the subframe and tighten the bolts to 96 ft. Ibs. (130 Nm) Steering gear heat shield Power steering line and coolant line brackets Subframe Alignment Pin Set T94P2100-AH Subframe bolts and tighten the bolts in a diagonal pattern to 96 ft. lbs. (130 Nm) Center bolt to the Powertrain Alignment Tool and tighten it to 22 ft. lbs. (30 Nm) Right engine support insulator 23. Tighten the support insulator center bolt to 88 ft. Ibs. (120 Nm) and the restrictor mounting bolts to 35 ft. Ibs. (48 Nm).

e Rear engine mounting bracket nut and tighten it to 61 ft. bs. (83 Nm)

+ CAUTION Do not twist or strain the front engine mounting bracket.

e Front engine mounting bracket and tighten the fasteners to 61 ft. Ibs. (83 Nm) 24. Remove the Powertrain Alignment Tool. 25. Install the left engine support insulator. Tighten the center bolt to 88 ft. Ibs. (120 Nm) and the restrictor mounting bolts to 35 ft. Ibs. (48 Nm). 26. Install or connect the following: Brake booster vacuum hose A/C accumulator attachment bolts Front exhaust pipe. Use a new gasket and tighten the fasteners to 33 ft. Ibs. (45 Nm) Attach the power steering lines to the subframe HO2S connectors. Secure the wiring harness with cable ties Lower ball joints and tighten the nuts to 61 ft. Ibs. (83 Nm) Outer tie rod ends and tighten the nuts to 19 ft. Ibs. (26 Nm) Stabilizer bar links and tighten the fasteners to 35 ft. Ibs. (47 Nm) Left, right and center splash shields Front wheels and tighten the lug nuts to 63 ft. Ibs. (86 Nm) 27. Remove the top engine support. 28. Install or connect the following: Coolant recovery tank and hoses

Ground cables at the radiator support Accelerator cable Accessory drive belt Upper drive belt cover and tighten the bolts to 18 ft. Ibs. (24 Nm) EGR exhaust tube, if equipped EGR pressure sensor connector, if equipped EGR vacuum supply, if equipped CKP sensor connector ECT sensor connector Main wiring harness connector Air cleaner and air outlet tube IAT sensor connector MAF sensor connector Battery 29. Tighten the suspension strut locknuts to 34 ft. Ibs. (46 Nm), _ 30. Fill the engine crankcase and coolIng system. 31. Fill the transaxle.

32. Start the engine and check for leaks and proper operation.

FORD MOTOR CO.

ro

CONTOUR © MYSTIQUE ¢ 1999-01 COUGAR

(Or 9346HG07 ” 9G46H606

Engine lifting brackets 303-050—2.5L engines

Automatic transaxle drain plug—all mod-

9346HG08 9346HG09

Shift cable bracket (1) and cable (2) removal—2.5L engine

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Throttle cable bracket fasteners—2.5L

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Transmission control

3

Temperature gauge sender unit

4

Transmission range (TR) sensor 9346HG10

Automatic transaxle harness connections—all models

=>Whenever the vehicle subframe is

removed or lowered, the wheel align-

ment should be checked.

2.5L Engine ->The engine and transaxle are removed as an assembly.

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 9. Drain the engine cooling system and engine oil.

3. If equipped, drain the automatic transaxle fluid. 4. Recover the A/C refrigerant. 5. Secure the radiator and fan shroud assembly to the radiator support. §. Remove or disconnect the following: Battery cables Water pump pulley shield Steering shaft joint at the cowl inside the vehicle Air cleaner Catalytic converter Exhaust crossover pipe Front wheels Stabilizer bar links Outer tie rod ends Lower ball joints Axle halfshafts from the hubs A/C accumulator mounting screws Speedometer cable Vehicle Speed (VSS) sensor connector Accelerator cable and bracket Cruise control cable, if equipped Engine control wiring harness connectors Power steering pump reservoir Power steering return hose Power steering pressure hose Powertrain Control Module (PCM) connector and ground strap

11-5

e Coolant recovery tank 7. lf equipped with an automatic transaxle, remove or disconnect the following: e Shift cable and bracket e Transaxle range switch connector e Transaxle oil cooler lines e Torque converter 8. If equipped with a manual transaxle, remove or disconnect the following: e Shift rod and stabilizer bar e Clutch slave cylinder fluid pipe 9. For all models, remove or disconnect the following: Power brake booster vacuum pipe Radiator hoses Heater hoses Block heater wiring, if equipped A/C suction and discharge hoses Lower radiator supports A/C compressor harness connector Bumper cover braces Front engine support insulator and bracket Transaxle support insulator 10. Support the powertrain from below. e Subframe bolts e Powertrain from the vehicle 11. Attach an engine hoist to the engine lifting eyes. 12. Remove the left and right engine support insulators and lift the powertrain away from the subframe. 13. Support the transaxle from below. 14. Remove or disconnect the following: e Axle halfshafts e Starter, wiring harness and ground cable e Engine from the transaxle To install: e>Replace all snaprings, split pins and self-locking nuts.

Please visit our web site at www.chiltonsonline.com

15. Install or connect the following: Engine to the transaxle and tighten the transaxle flange bolts to 25-34 ft. Ibs. (34-46 Nm) Axle halfshafts to the transaxle Starter and wiring harness connectors Ground cable Powertrain Alignment Gauge 194P6000-AH to the subframe and position the powertrain and tighten the center bolt to 20 ft. Ibs. (27 Nm) Right engine support insulator. Leave the bolts finger-tight. Subframe Alignment Pin Set 94P-

11-6

FORD MOTOR CO.

CONTOUR ¢ MYSTIQUE e 1999-01 COUGAR

2100-AH and raise the subframe to the vehicle and tighten the subframe bolts to 92-100 ft. Ibs. (125-135 Nm) 16. Remove the alignment pins. e Front engine support insulator and bracket and tighten the nuts to 84 inch Ibs. (10 Nm) >The left and right support insulators must be aligned in the middle of the support insulator brackets.

e Right engine support insulator-tosubframe bolts to 30-41 ft. Ibs. (41-55 Nm) e Front engine support bracket nuts to 52-70 ft. Ibs. (70-95 Nm) e Engine and transmission support insulator nuts to 30-41 ft. Ibs. (41-55 Nm) for automatic transaxles or 52-70 ft. Ibs. (70-95 Nm) for manual transaxles e Right front engine support insulator through-bolt to 75-102 ft. Ibs. (103-137 Nm) 17. Remove the powertrain alignment gauge. Left front engine support insulator to the subframe. Tighten the retaining bolts to 30-41 ft. Ibs. (41-55 Nm) and the through-bolt to 75-102 ft. Ibs. (103-137 Nm). A/C compressor wiring harness Lower radiator supports and tighten the retaining bolts to 71-97 inch lbs. (8-11 Nm) A/C suction and discharge hoses Block heater wiring, if equipped Radiator hoses Heater hoses Power brake booster vacuum pipe 18. If equipped with an automatic transaxle, install or connect the following: e¢ Transaxle oil cooler lines ¢ Transaxle range switch connector e Shift cable and bracket and tighten the retaining bolts to 15-19 ft. Ibs. (20-25 Nm) ¢ Torque converter and tighten the retaining nuts in an alternating sequence to 54-64 ft. Ibs. (73-87 Nm) 19. If equipped with a manual transaxle, install or connect the following: ¢ Clutch slave cylinder fluid pipe e Shift rod and stabilizer bar. Tighten the shift rod bolt to 17 ft. Ibs. (23 Nm) and the stabilizer nut to 41 ft. lbs. (55 Nm). 20. For all models, install or connect the following: ¢ Coolant recovery tank

PCM connector and ground strap Power steering pressure hose Power steering return hose Power steering pump reservoir Engine control wiring harness connectors Cruise control cable, if equipped Accelerator cable and bracket and tighten the bolts to 71-106 inch lbs, (8-12 Nm)

1. Water pump 2. Water pump housing gaskets 3. Cylinder block

VSS sensor connector Speedometer cable A/C accumulator mounting screws eee ee e Axle halfshafts to the front hubs. Use new nuts and tighten to 246 ft. lbs. (340 Nm). Outer tie rod ends and tighten the nuts to 21 ft. Ibs. (28 Nm) Lower ball joints and tighten the bolts to 37-43 ft. Ibs. (650-58 Nm) Stabilizer bar links and tighten the nuts to 35 ft. Ibs. (48 Nm) Front wheels and tighten the lug nuts to 63 ft. Ibs. (86 Nm) Exhaust crossover pipe Catalytic converter Air cleaner Steering shaft joint and tighten the bolt to 18 ft. Ibs. (24 Nm) Water pump pulley shield Battery cables 21. Fill the crankcase and cooling system. 22. If equipped, fill the automatic transaxle. 23. Check all fluid levels. 24. Evacuate and recharge the air conditioning system. 20. Start the engine and check for leaks and proper operation. e» Whenever the vehicle subframe is removed or lowered, the wheel alignment should be checked.

Water Pump

A. 12-15ft.Ib.(16-20 Nm)

7922JG01

Exploded view of the water pump mounting—2.0L engine

To install: 4. Install or connect the following: e Water pump and tighten the bolts

to 12-15 ft. Ibs. (16-20 Nm) e Timing belt. Refer to the Timing Belt unit repair section. e Accessory drive belt e Lower radiator hose e Negative battery cable 5. Fill the cooling system and inspect for leaks 2.5L Engine e>The 3 water pump bolts are a torqueto-yield design and must be replaced.

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the engine cooling system. 3. Remove or disconnect the following: ¢ Negative battery cable e Water pump pulley shield ¢ Water pump drive belt ¢ Coolant hoses e Water pump and pump housing 4. Separate the water pump from the pump housing.

—

REMOVAL & INSTALLATION 2.0L Engine

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the cooling system. 3. Remove or disconnect the following: ¢ Negative battery cable e Lower radiator hose ° Accessory drive belt ¢ Timing belt. Refer to the Timing Belt unit repair section. ¢ Water pump

1. Bolt 2. Water pump drive belt tensioner 3. Water pump 4. Water pump outlet hose 5. LH cylinder head §. Bolt) A. 71-106 in, Ib.(8-12 Nm) B. 11-18 ft. Ib.(15-18 Nm)

then rotate 85-95° 79225G02

Exploded view of the water pump mounting—2.5L engine

FORD MOTOR CO.

CONTOUR e MYSTIQUE ¢ 1999-01 COUGAR To install: 5. Install or connect the following: Water pump to the pump housing and tighten the fasteners to 16-18 ft. Ibs. (22-25 Nm) Water pump and pump housing to the engine. Use new bolts and tighten them to 11-13 ft. Ibs. (15-18 Nm), plus 85-95 degrees. Coolant hoses Water pump drive belt Water pump pulley shield Negative battery cable 6. Fill the cooling system and check for leaks.

Cylinder Head REMOVAL & INSTALLATION 2.0L Engine >The cylinder head bolts are a torqueto-yield design and must be replaced.

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the cooling system. 3. Remove or disconnect the following: Negative battery cable Accessory drive belt Power steering pump pulley cover Power steering pump Power steering pump support bracket Alternator bracket Valve cover Intake manifold Exhaust manifold Front cover Timing belt. Refer to the Timing Belt unit repair section. Camshafts and valve tappets

2.5L Engine ->The cylinder head bolts are a torqueto-a design and must be replaced.

—+— FRONT OF ENGINE———

TIGHTEN BOLTS IN SEQUENCE SHOWN

7922JG03

Cylinder head torque sequence—2.0L

engine

Right lifting eye Timing belt tensioner pulley Thermostat housing Ignition coil and bracket Spark plugs Cylinder head bolts in the reverse of the installation order e Cylinder head To install: 4 Use a new gasket and install the cylinder head. 5. Use new cylinder head bolts and oil the threads. 6. Tighten the cylinder head bolts in sequence as follows: a. Step 1: 15-22 ft. Ibs. (20-30 Nm) b. Step 2: 30-37 ft. Ibs. (40-50 Nm) c. Step 3: Plus 90-120 degrees 7. Install or connect the following: Ignition coil and bracket Thermostat housing Timing belt tensioner pulley Right lifting eye Camshafts and valve tappets Timing belt. Refer to the Timing Belt unit repair section. Front cover Exhaust manifold Intake manifold Valve cover Alternator bracket Power steering pump support bracket Power steering pump Accessory drive belt Power steering pump pulley cover Spark plugs Negative battery cable 8. Fill the cooling system and check for leaks. 9. Start the engine and check for proper operation.

_ Before servicing the vehicle, referto the Fonte in the beginning of this section. 2. Drain the crankcase and cooling system. 3. Remove or disconnect the following: Negative battery cable Air cleaner housing Accessory drive belts Upper and lower intake manifolds Valve covers Oil pan Alternator and bracket

11-7

LH CYLINDER HEAD 7922JG04

Cylinder head torque sequence—2.5L engine—left side shown

Left and right Heated Oxygen (HO2S) sensors Catalytic converter and exhaust crossover tube Water pump Front cover Timing chains Camshafts and valve tappets Exhaust Gas Recirculation (EGR) pressure Sensor EGR transducer EGR tube Coolant bypass Oil dipstick tube Cylinder head bolts in the reverse of the installation order Cylinder heads To install: 4. Use new gaskets and install the cylinder heads. 5. Use new cylinder head bolts and oil the threads. 6. Tighten the cylinder head bolts in sequence as follows: a. Step 1: 27-32 ft. Ibs. (87-43 Nm) b. Step 2: Plus 85-95 degrees c. Step 3: Loosen the bolts, in sequence, 1 full turn d. Step 4: 27-32 ft. Ibs. (37-43 Nm) e. Step 5: Plus 85-95 degrees f. Step 6: Plus 85-95 degrees 7. Install or connect the following: e Oil dipstick tube Coolant bypass EGR tube EGR transducer EGR pressure sensor Camshafts and valve tappets Timing chains Front cover Water pump eeee#eee#eee @ Catalytic converter and exhaust crossover tube Left and right HO2S sensors

Timing belt service is covered in Section 3 of this manual

11-8

FORD MOTOR CO.

CONTOUR ¢ MYSTIQUE e 1999-01 COUGAR

e Alternator and bracket e Oil pan e Valve covers e Upper and lower intake manifolds e Accessory drive belts e Air cleaner housing e Negative battery cable 8. Fill the cooling system and the engine crankcase. 9. Start the engine and check for leaks and proper operation.

ay SV!

Se

en

SiS

9306HGO2

The 2.0L engineis not equipped with rocker arms, the camshaft directly actuates the valves through a hydraulic lifter.

elf the followers are to be reused, ensure that they are installed in the same position that they were removed from.

9306HG01

Valve cover bolt tightening sequence— 2.5L engine

1

Valve spring compressor—2.5L engine

REMOVAL & INSTALLATION

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Battery Upper manifold Intake Manifold Runner Control (IMRC) actuator Spark plug wires and bracket Coolant reservoir breather hose bracket and wiring Fuel injector wiring harness Ignition coil Wiring harness brackets Valve covers. Remove the bolts in reverse sequence. Spark plugs. 3. Rotate the crankshaft so that the piston on the cylinder to be serviced is at bottom dead center with the valves closed. 4. Install an adapter in the spark plug hole and connect a compressed air supply at 102-144 psi. 5. Install special tool Valve Spring Compressor T94P-6565-BH.

FRONT OF ENGINE

S

6. Compress the valve spring and remove the roller finger follower. Repeat for each follower to be removed.

2.5L Engine

eae

T94P-6565—BH

4

To install: 7. Compress the valve spring and install the roller finger follower. Repeat for each follower to be installed. 8. Install or connect the following: Spark plugs Valve covers and tighten the bolts in sequence to 88 inch Ibs. (10 Nm) Wiring harness brackets Ignition coil Fuel injector wiring harness Coolant reservoir breather hose bracket and wiring Spark plug wires and bracket IMRC actuator Upper manifold Battery 9. Run the engine and check for leaks and proper operation.

Intake Manifold

REMOVAL & INSTALLATION 2.0L 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 Air cleaner outlet pipe Cruise control cable Accelerator cable and bracket Throttle Position (TPS) sensor connector Idle Air Control (IAC) connector Engine Coolant Temperature (ECT) sensor connector Fuel lines

1. Oylinder head 2. Stud (2 req'd) 3. 4. 5. 6. A.

Bolt (8 req'd) Intake manifold gasket Nut (2 req'd) Intake manifold Tighten to 0-10 Nm (0-89 Ib. in.)

B. Tighten to 16-20 Nm (12-15 Ib. ft.) 7922JG06

Exploded view of the intake manifold mounting—2.0L engine

Injector wiring harness Fuel supply manifold with injectors attached Engine wiring harness Vacuum hoses Brake booster vacuum pipe Accessory drive belt Alternator Intake manifold To install: 3. Install or connect the following: Intake manifold with a new gasket and tighten the fasteners to 13 ft. lbs. (18 Nm) Alternator Accessory drive belt Brake booster vacuum pipe Vacuum hoses Engine wiring harness Fuel supply manifold with injectors attached Injector wiring harness Fuel lines Accelerator cable and bracket Cruise control cable ECT sensor connector IAC connector TPS sensor connector Air cleaner outlet pipe e 0 eo, °@ Or. 0) d@ '@. Negative battery cable

2.5L Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section.

11-9

FORD MOTOR CO.

CONTOUR

MYSTIQUE ¢ 1999-01 COUGAR Installation Sequence

Installation Sequence

9346HG13

Coolant line (1), Cover bolts (2) and Water Pump Cover (3)—2.5L engine TIGHTEN BOLTS IN SEQUENCE SHOWN * HOLE LOCATION FOR GASKET LOCATING PINS

FRONT OF ENGINE

FRONT OF ENGINE ., LOCATING PINS (2 EACH PER GASKET)

@ INSTALL BOLTS IN SEQUENCE SHOWN

VIEW A

LOWER INTAKE MANIFOLD 7922JG07 9346HG14

Upper intake manifold loosening

=

.

Lower intake manifold torque sequence— 2.5L engine

sequence—2.5L engine

9346H615

Upper intake manifold. Remove the bolts in the sequence shown. ¢ Fuel injector wiring harness e Fuel lines Lower intake manifold. Remove the bolts in the sequence shown. To install: 3. Install or connect the following: e Lower intake manifold. Use new gaskets and tighten the bolts to 71-106 inch Ibs. (8-12 Nm).

Lower intake manifold loosening

* Fuel lines

sequence—2.5L engine

¢ Fuel injector wiring harness

¢ Upper intake manifold. Use new gaskets and tighten the bolts to 71-106 inch Ibs. (8-12 Nm). IMRC EGR tube PCV valve vacuum hose EGR vacuum regulator connector and vacuum hoses IAC valve connector

2. Remove or disconnect the following: ¢ Negative battery cable Water pump pulley shield Brake booster vacuum pipe Emission vacuum control Cruise control cable Accelerator cable and bracket Throttle Position (TPS) sensor con-

TPS sensor connector

nector

e Idle Air Control (IAC) valve connector

Exhaust Gas Recirculation (EGR)

vacuum regulator connector and vacuum hoses

e PCV valve vacuum hose e EGR tube e |ntake Manifold Runner Control (IMRC)

Accelerator cable and bracket

Cruise control cable Emission vacuum control Brake booster vacuum pipe Water pump pulley shield Negative battery cable 4. Run the engine and check for

leaks

1. Bok (6) 2. Intake manifold, upper 3. Intake maniiold upper gasket 4. Intake manifold, lower 5. lsolator (6) 6, 71-106 in. Ib.(8-12 Nm) 7922JG08

Upper intake manifold torque sequence— 2.5L engine

Exhaust Manifold REMOVAL & INSTALLATION 2.0L 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 Air intake resonators Oil dipstick tube Exhaust manifold heat shield Heated Oxygen (HO2S) sensor Exhaust Gas Recirculation (EGR) tube and bracket, if equipped e Catalytic converter e 9 manifold retaining nuts and the exhaust manifold To install: 3. Install or connect the following: e New gasket e Exhaust manifold and tighten the nuts to 12 ft. Ibs. (16 Nm) e Catalytic converter e EGR tube and bracket, if equipped e HO2S sensor

Heater Core replacement is covered in Section 2 of this manual

11-1

FORD MOTOR CO.

CONTOUR @ MYSTIQUE ¢ 1999-01 COUGAR 4. Run the engine and check for exhaust leaks and proper operation.

— FRONT OF ENGINE —

Front Crankshaft Seal

REMOVAL & INSTALLATION 2.0L Engine

EGR Valve RH Cylinder Head Exhaust Manifold Gasket Stud Bolt (6 Req'd) Nut (6 Req'd)

Cylinder Head Exhaust Manifold Gasket Spacer Exhaust Manifold Nut (9 Req'd)

RH Exhaust Manifold Heated Oxygen Sensor

Stud (9 Req'd) aWNH FAK = Tighten

to 14-17 Nem (13-16

EGR Valve to = WN na @nO

-Ft) 7922JG09

Exhaust manifold and related components—2.0L engine

e Exhaust manifold heat shield e Oil dipstick tube e Air intake resonators ¢ Negative battery cable 4. Run the engine and check for leaks and proper operation 2.5L Engine

RIGHT SIDE 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: ¢ Negative battery cable ¢ Alternator and bracket ¢ Heated Oxygen (HO2S) sensor ¢ Catalytic converter ¢ Halfshaft bearing support bracket ¢ Exhaust Gas Recirculation (EGR) tube e Exhaust manifold To install: 3. Install or connect the following: e New gasket Exhaust manifold and tighten the fasteners to 15 ft. Ibs. (20 Nm) EGR tube Halfshaft bearing support bracket Catalytic converter

HO2S sensor Alternator and bracket Negative battery cable 4. Run the engine and check for exhaust leaks and proper operation.

>

Exhaust Manifold Tube Tighten to 18-22 N-m (13-16

B_

Tighten to 35-45 N-m (26-33

Lb-Ft) Lb-Ft) 7922JG10

Exploded view of the right-side exhaust manifold mounting—2.5L engine

LEFT SIDE 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: ¢ Negative battery cable e Heated Oxygen (HO2S) sensor e Exhaust crossover tube ¢ Radiator hose bracket ¢ 6 manifold retaining nuts and the exhaust manifold To install: 3. Install or connect the following: ¢ New gasket e Exhaust manifold and tighten the nuts to 15 ft. Ibs. (20 Nm) e Radiator hose bracket e Exhaust crossover tube ¢ HOS sensor ¢ Negative battery cable

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Negative battery cable Right splash shield Accessory drive belt Front cover Timing belt. Refer to the Timing Belt unit repair section. Crankshaft sprocket Crankshaft front seal. Use a seal puller to protect the crankshaft surface from damage. To install: 3. Lubricate and install the front crankshaft seal. Use special tool Seal Replacer T81P-6700-A and the crankshaft pulley bolt to press the seal into the oil pump housing. 4. Install or connect the following: e Crankshaft sprocket ¢ Timing belt. Refer to the Timing Belt unit repair section. ¢ Front cover e Accessory drive belt ¢ Right splash shield ¢ Negative battery cable 5. Run the engine and check for leaks and proper operation. ie T92C-6700—CH] ~~

7922JG12

Removing the crankshaft front seal with Ford seal remover T92C-6700-CH—2.0L engine

Camshaft and Valve Lifters

REMOVAL & INSTALLATION BEBE ETASER US die 7922JG11

Exhaust manifold mounting bolt tightening sequence—2.5L engine

KS

2.0L Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section.

FORD MOTOR CO. 44.4

$00

CONTOUR ¢ MYSTIQUE ¢ 1999-01 COUGAR

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———

1. Bolt(20) 2. Camshaft journal

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cap(8)

|

3. Cylinder head 4. Camshaft 5. Camshaft journal thrust cap(2) A. 13-15 ft. Ib.(17-21 Nm)

FRONT OF ENGINE

1. Bolt (10) 2. 3. 4. 5. 6. 7.

Spacer (10) O-ring (10) Oil filler cap Valve cover gasket Cylinder head Valve cover

NOTE: APPLY A3 mm We INCH) BEAD OF SILICONE GASKET AN SEA F1AZ-19562-A OR EQUIVALENT MEETING FORD SPECIFICATION WSE-M4G320-A2 TO SEALING SURFACES OF THE CAMSHAFT JOURNAL THRUST CAPS AS SHOWN.

A. 53-71 in. Ib.(6-8 Nm) 7922JG13

Valve cover and related components—

2.0L engine 7922JG14

During assembly, apply sealant to the camshaft journal thrust cap as shown—2.0L engine

79225G15

Remove the bearing cap bolts in pairs using the sequence shown—2.0L engine

7922JG16

1. Oil passages and match mark 2. Locating tab and bore 9306HGO3

2. Remove or disconnect the following: Negative battery cable Air intake resonators Valve cover Timing cover Timing belt. Refer to the Timing Belt unit repair section. e Intake camshaft sprocket e Exhaust gear oil plug e Exhaust camshaft sprocket and Variable Camshaft Timing (VCT) hydraulic cylinder e Oil feed flange boits =>Mark the camshaft journal caps to the cylinder head for installation in the same position.

Camshaft journal cap retaining bolt tightening sequence—2.0L engine

3. Loosen all of the camshaft journal cap bolts in pairs and in sequence 1 turn at a time.

Alignment of the exhaust camshaft sprocket and the VCT hydraulic cylinder— 2.0L engines

will be installed into their correct positions.

->Remove the camshaft journal thrust caps last.

e Valve lifters from the cylinder head To install:

4. Remove or disconnect the following: e All of the camshaft journal caps » Intake and exhaust camshafts and the camshaft front seals from the cylinder-head

->Before installing the camshafts, the crankshaft must be positioned so that No. 1 cylinder is at TDC on its compression stroke.

->if the valve lifters are to be reused, mark their locations to ensure that they

5. Install or connect the following:

Brake service is covered in Section 4 of this manual

e Valve lifters in their original positions

11-1

FORD MOTOR CO.

CONTOUR ¢ MYSTIQUE ¢ 1999-01 COUGAR

Camshafts and journal caps and tighten the bolts in sequence and in several steps to 10 ft. Ibs. (13 Nm) Oil feed flange bolts. Use a new gasket and tighten the bolts in several Steps to 10 ft. Ibs. (13 Nm). New camshaft seals Intake camshaft sprocket and tighten the bolt to 50 ft. Ibs. (68 Nm) Exhaust camshaft sprocket and VCT hydraulic cylinder. Align the locating tab and bore as shown in the illustration and tighten the bolt to 88 ft. Ibs. (120 Nm). Exhaust gear oil plug and tighten to 27 tt. Ibs. (37:Nm) Timing belt. Refer to the Timing Belt unit repair section. Timing cover Valve cover Air intake resonators Negative battery cable 6. Run the engine and check for leaks and proper operation. 2.5L Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following:

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7922JG18

Right (rear) cylinder head camshaft journal cap retaining bolt loosening sequence—2.5L engine

Left (front) cylinder head camshaft journal Cap retaining bolt loosening sequence— 2.5L engine

e e e « e

Negative battery cable Upper intake manifold Valve covers Accessory drive belts Front cover and timing chains

CAUTION: CAMSHAFTS MUST BE IN TIME WITH RANKSHAFT PRIOR TO INSTALLATION OF ROCKER ARMS

+k WARNING The camshaft thrust caps must be removed before loosening the remaining camshaft journal cap bolts

NOTE: VALVE TAPPET MUST BE PUMPED UP PRIOR TO INSTALLATION

FRONT OF ENGINE

,

CAUTION: REMOVE CYLINDER HEAD JOURNAL THRUST CAPS FIRST. INSTALL CYLINDER HEAD JOURNAL THRUST CAPS LAST.

1. Cylinder head 2. Camshaft journal thrust

cap(2) 3. Camshaft journal cap(7)

CAUTION: ROTATE CRANKSHAFT KEYWAY TO 11 O'CLOCK POSITION PRIOR TO N PRI TO INSTALLATION OF RH CAMSHAFT AND ROCKER ARMS.

5. LH intake camshaft

6. Rocker arm(12) 7. Valve tappet(12) 8.LH

exhaust

camshaft

A. 71-106 in. Ib.(8-12 Nm) 7922JG17

Exploded view of camshaft mounting—2.5L engine

a

—4" of ox@): Or OU)" ‘ll |3) aia ®)

Camshafts Shown Removed From Cylinder Heads For Clarity

4. Bolt(18)

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FORD MOTOR

CO.

CONTOUR ¢ MYSTIQUE ¢ 1999-01 CCGA 1 1 -] 3 _ to ensure that the thrust caps are not damaged. e Camshaft thrust caps e Camshaft journal caps. Loosen the bolts in sequence and in several passes to allow the camshaft to raise off the cylinder head evenly.

The camshaft journal caps and cylinder heads are numbered to ensure that they are assembled in their original positions. Keep the camshaft journal caps from each cylinder head together; do not mix them with caps from another cylinder head. Failure to do so may result in engine damage. e Camshaft journal caps with the retaining bolts installed e Camshafts from the cylinder head. e>|f the rocker arms and hydraulic lifters are to be reused, they must be installed in their original positions. e Rocker arms.

e Hydraulic lifters To install:

The crankshaft keyway must be at the 11 o'clock position before reassembly. Failure to do so may lead to engine damage. 3. Rotate the crankshaft so that the keyway is at the 11 o'clock position for installation of the camshafts. 4. Install or connect the following: e Hydraulic lifters e Rocker arms. ¢ Camshafts. Align the sprocket timing marks. ->Do not install the camshaft journal thrust caps until the rocker arms and timing chains have been installed and the camshaft journal caps are secured into position.

¢ All camshaft journal caps except the thrust caps. e Timing chains. Tighten the camshaft journal cap bolts in reverse of the loosening order and in several steps to 71-106 inch Ibs. (8-12 Nm).

Thrust caps and tighten the bolts to 71-106 inch Ibs. (8-12 Nm) Front cover Accessory drive belts Valve covers Upper intake manifold. Use new gaskets and tighten the bolts to 71-106 inch Ibs. (8-12 Nm). Negative battery cable 5. Run the engine and check for leaks and proper engine operation.

Valve Lash

2.0L Engine

oe 1. Before servicing the vehicle, refer to

the precautions in the beginning of this sec-

tion.

2. Remove the valve cover. 3. Rotate the crankshaft so that the valve is closed and measure the clearance between the lifter shim and the camshaft base circle. Intake valve clearance should be 0.004—0.007 inches. Exhaust valve clearance should be 0.010-0.013 inches. 4. Measure each valve and note the clearance. 5. lf adjustment is necessary, remove the camshafts and replace the shims. To obtain the correct shim size, measure the current shim and add the measured clearance. Subtract 0.006 inches for intake valves, and 0.012 inches for exhaust valves. 6. Install the camshafts and valve cover.

We

REMOVAL & INSTALLATION 2.0L Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Negative battery cable e Air cleaner e Starter electrical connectors e Starter motor 3. Install or connect the following: e Starter motor and tighten the bolts to 18 ft. Ibs. (25 Nm) e Starter electrical connectors

e Air cleaner

¢ Negative battery cable

ae

ewer aCe.”

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Res yt

9346HG19

Starter motor upper bolts—2.0L engine

ma 9346HG20

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Starter Motor

Seraees

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Starter motor lower bolt—2.0L engine

2.5L Engine

CONTOUR AND MYSTIQUE

\ 9306HG04

Checking valve clearance—2.0L engine

2.5L Engine

The lash adjusters are hydraulic and are not adjustable.

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Negative battery cable e Air cleaner ter

support bracket

sans Shift cable bracket, if equipped

this manual For complete Engine Mechanical specifications, see Section 1 of

11-1

FORD MOTOR CO.

CONTOUR ¢ MYSTIQUE e 1999-01 COUGAR

9346HG18

Remove the fuel lines from the support bracket—Contour and Mystique with 2.5L engine

9346HG17

Starter motor support bracket—2.5L engine

SW e Fuel lines e Starter electrical connectors e Starter motor To install: 3. Install or connect the following: Starter motor and tighten the bolts to 18 ft. Ibs. (25 Nm) Starter electrical connectors Fuel lines Shift cable bracket, if equipped Starter support bracket and tighten the bolt to 18 ft. Ibs. (25 Nm), and tighten the nuts to 13 ft. Ibs. (17 Nm) Air cleaner Negative battery cable

COUGAR 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the cooling system. 3. Relieve the fuel system pressure. 4. Remove or disconnect the following: ¢ Negative battery cable e Upper and lower intake manifold ¢ Air cleaner bracket ¢ Starter motor harness connectors e Shift cable and bracket ¢ Starter motor support bracket Fuel lines Cooling system hoses Engine Coolant Temperature (ECT) sensor connector ¢ Positive Crankcase Ventilation (PCV) pipe and hose

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o

, hfs

AR

a's

9346HG16

Air cleaner bracket—2.5L engine

e Water crossover pipe ¢ Starter motor To install: 5. Install or connect the following: Starter motor and tighten the bolts to 18 ft. Ibs. (25 Nm) Water crossover pipe and tighten the bolts to 88 inch Ibs. (10 Nm) PCV pipe and hose ECT sensor connector Cooling system hoses Fuel lines Starter motor support bracket. Tighten the nuts to 13 ft. Ibs. (17 Nm) and the bolt to 18 ft. Ibs. (25 Nm). ¢ Shift cable and bracket ¢ Starter motor harness connectors Air cleaner bracket and tighten the bolts to 18 ft. Ibs. (25 Nm) e Upper and lower intake manifold ¢ Negative battery cable 6. Fill the cooling system. 7. Start the engine and check for leaks.

REMOVAL & INSTALLATION 2.0L Engine

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the engine oil. 3. Attach an engine support fixture to the engine lifting eyes. 4, Remove or disconnect the following: Negative battery cable Catalytic converter Oil lever sensor connector Heater coolant pipe Lower engine rear plate Left and right engine support insulator center bolts Front engine support bracket

LA

Fa VIEW A

LZ NSPa : gé e

\)Y

nore: WHEN OIL PAN IS INSTALLED TO CYLINDER BLOCK SHIMS MAY BE QUIRED TO ALIGN REAR SURFACES OF OIL PAN TO CYLINDER BLOCK

3mm

(0.25 INCH) SEALER

NOTE: APPLY A 3 mm (0.25 INCH) BEAD OF SILICONE GASKET AND SEALANT F1AZ-19562-A OR EQUIVALENT MEETING FORD SPECIFICATION WSE A4G320-A2

View A TYPICAL FOUR PLACES 1 2 3 4 5 6

Oil pan drain plug Bolt (10 req'd) Oll pan Cylinder block Oil pan gasket Oil pan spacer (as req'd)

A Tighten to 21-28 Nm (15-21 Ib-ft)

B Tighten to 20-24 Nm (15-18 Ib-ft) 7922JG20

Exploded view of the oi! pan mounting— 2.0L engine

e>Mark the location of the upper front engine support before removing it from the front engine support bracket.

5. Raise the engine to allow room for removal of the engine oil pan. 6. Remove the oil pan. To install: ->Apply a bead of silicone gasket Sealer to the oil pump parting lines and at the crankshaft rear main seal retainer on the cylinder block.

7. Install or connect the following: ¢ Oil pan. Use a new gasket and tighten the bolts in several passes

to 15-18 ft. Ibs. (20-24 Nm), working from the center of the block towards the ends. Tighten the transaxle case bolts to 25-34 ft. Ibs. (34-46 Nm). ¢ Lower engine rear plate 8. Lower the engine and install or connect: e Front engine support insulator ¢ Left and right engine support insulator center bolts e Heater coolant pipe e Oil lever sensor connector

FORD MOTOR CO. 1 1 -1 5

CONTOUR ¢ MYSTIQUE e Catalytic converter e Negative battery cable 9. Fill the crankcase with the proper amount of engine oil. 10. Run the engine and check for leaks and proper operation.

5. Raise the engine to allow room for removal of the engine oil pan. 6. Remove the oil pan. To install: 7. Apply a bead of silicone sealer to the gasket area where the pan meets the parting lines of the lower cylinder block and the front engine cover. 8. Install or connect the following: e Oil pan. Use a new gasket and tighten the pan bolts in several passes to 15-22 ft. Ibs. (20-30 Nm). Tighten the transaxle case bolts to 25-34 ft. Ibs. (34-46 Nm). e Lower engine rear plate 9. Lower the engine and install or connect: e Front engine support insulator e Left and right engine support insulator center bolts e Exhaust heat shields e Exhaust crossover pipe and bracket e Water pump pulley shield e Negative battery cable 10. Fill the crankcase with the proper amount of engine oil. 11. Run the engine and check for leaks and proper operation.

2.5L Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the engine oil. 3. Attach an engine support fixture to the engine lifting eyes. 4. Remove or disconnect the following: Negative battery cable Water pump pulley shield Exhaust crossover pipe and bracket Exhaust heat shields Lower engine rear plate Left and right engine support insulator center bolts Front engine support bracket e> Mark the location of the upper front engine support before removing it from the front engine support bracket.

1999-01 COUGAR

Oil Pump

:

REMOVAL & INSTALLATION 2.0L Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the engine oil. 3. Remove or disconnect the following: Negative battery cable Accessory drive belt Timing belt cover and timing belt. Refer to the Timing Belt unit repair section. Crankshaft sprocket Catalytic converter Oil pan Oil pump pickup tube Oil filter Oil pump To install: e»Clearance between the cylinder block oil pan sealing surface to the oil pump oil pan sealing surface should not exceed 0.012-0.031 in. (0.3-0.8mm).

4. Install or connect the following: ¢ Oil pump. Use a straight-edge to align the oil pump oil pan sealing surface with the cylinder block oil pan sealing surface and tighten the oil pump retaining bolts to 71-102 inch Ibs. (8-11.5 Nm). Oil filter Oil pump pickup tube. Use a new

OIL PUMP GASKET

SEALER

NOTE:

APPLY 8 inm

G) (0.31 INCH) DIAMETER

3)

BEAD OF BLACK

SILICONE SEALER AT TWO PLACES AS SHOWN

FRONT OF ENGINE

VIEW A TYPICAL 2 PLACES

* LOCATION OF STUDS TIGHTEN BOLTS/STUDS IN SEQUENCE SHOWN

1 Upper cylinder block 2 Lower cylinder block 3 Oil pan

4 Stud boit (5 req'd)

5 6 7 A

W500

Bolt (10 req'd) Oil pan gasket Engine front cover Tighten to 20-30 Nm (15-22 Ib-ft)

TOHTEN TO

(71-102 LB-WN)

(71-102 LB-iN) 7922JG22

7922)G21

mounting bolt and stud tightening Exploded view of the oil pan mounting, showing the sequence—2.5L engine

8-11.5N:

86-11.5N-m

Exploded view of the oil pump mounting— 2.0L engine

For Accessory Drive Belt illustrations, see Section 1 of this manual

11-1

FORD MOTOR CO.

CONTOUR ¢ MYSTIQUE © 1999-01 COUGAR

gasket and tighten the retaining bolts to 71-97 inch Ibs. (8-11 Nm). Use a new self-locking nut and tighten it to 13-15 ft. Ibs. (17-21 Nm). Oil pan Catalytic converter Crankshaft sprocket Timing belt and timing belt cover. Refer to the Timing Belt unit repair section. Accessory drive belt Negative battery cable 5. Fill the crankcase with the proper amount of engine oil. 6. Run the engine and check for leaks and proper operation. 2.5L Engine

To install: 4. Install or connect the following: Oil pump and tighten the bolts to 71-106 inch Ibs. (8-12 Nm) Oil pump pickup tube. Use a new Oring and tighten the retaining bolts to 71-97 inch lbs. (8-11 Nm). Use a new self-locking nut and tighten it to 15-22 ft. Ibs. (20-30 Nm). Crankshaft sprockets Timing cover and timing chains Oil pan Negative battery cable 5. Fill the crankcase with the proper amount of engine oil. 6. Run the engine and check for leaks and proper operation.

Rear Main Seal

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the engine oil. 3. Remove or disconnect the following: ¢ Negative battery cable e Oil pan ¢ Timing cover and timing chains ¢ Crankshaft sprockets ¢ Oil pump pickup tube ¢ Oil pump

REMOVAL & INSTALLATION 2.0L 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 e Transaxle ¢ Clutch, if equipped

TIGHTEN BOLTS IN SEQUENCE SHOWN

e Flywheel e Oil seal To install: 3. Install or connect the following: Oil seal. Seat the seal flush with the rear of the crankshaft oil seal retainer. Flywheel and tighten the bolts to 82 ft. Ibs. (112 Nm) Clutch, if equipped e Transaxle Negative battery cable 4. Start the engine and check for leaks.

2.5L 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 Transaxle Clutch, if equipped Flywheel Oil seal. Use special tool Seal Remover T95P-6701-EH and a slide hammer to remove the seal. To install: 3. Install or connect the following: ¢ Oil seal. Press the seal in evenly until it is flush with the cylinder block. Flywheel and tighten the bolts to 59 ft. Ibs. (80 Nm) Clutch, if equipped Transaxle Negative battery cable 4. Start the engine and check for leaks.

© pm G

OIL PUMP.

| Thread the oil seal remover into the seal, then withdraw the seal using a slide hammer—2.5L engine

BOLT M6 X 1.0 X 33.5 4 REQ'D TIGHTEN TO 8-12 N-m (71-106 LB-IN)

Timing Chain, Sprockets, Front Cover and Seal °

FRONT OF ENGINE

CYLINDER BLOCK

7922JG23

Exploded view of the oil pump mounting, showing the retaining bolt tightening sequence—2.5L

engine

REMOVAL & INSTALLATION et 2.5L Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section.

FORD MOTOR CO. 1 1 -1 7 CONTOUR ¢ MYSTIQUE e 1999-01 COUGAR RH CAMSHAFT TIMIN INDEX MARKS or 0

5. Rotate the crankshaft so that the keyway is at the 11 o'clock position to locate the crankshaft at TDC for No. 1 cylinder. 6. Verify that the alignment arrows on the camshafts are aligned. If not, rotate the crankshaft 1 complete revolution and recheck. 7. Rotate the crankshaft so that the keyway is at the 3 o'clock position. This positions the right cylinder head camshafts to the neutral position. 8. Remove the right cylinder head timing chain tensioner retaining bolts and the timing chain tensioner.

-

S

CBA

©

~4

5)

\

* NOTE: AT TDC NO. 1 FIRING POSITION, ARROWS ON BACK OF CAMSHAFT SPROCKETS POINT DIRECTLY AT EACH OTHER

5 j

Ky y

CRANKSHAFT TIMING INDEX MARK , 7922JG25

View of the timing chains and gears, showing the right timing chain alignment marks properly positioned—2.5L engine

LH CAMSHAFT TIMING INDEX MARKS

11 O'CLOCK POSITION (TDC NO. 1 CYLINDER) i)

CRANKSHAFT TIMING INDEX MARK

#NOTE: AT TOC NO. 1 FIRING POSITION, ARROW HEADS ON BACK OF CAMSHAFT SPROCKETS POINT DIRECTLY AT EACH OTHER

7922JG26

engine Left timing chain alignment mark positioning for servicing the chain—2.5L

2. Attach an engine support fixture to the engine lifting eyes. 3. Drain the engine oil. 4. Remove or disconnect the following: e Negative battery cable e Upper intake manifold e Valve covers Low coolant level sensor connector Coolant recovery reservoir a > iViark the position of the upper front engine support bracket before removing. ¢ Front engine support insulator and bracket

e e i »

Engine wiring harness connectors Accessory drive belt Power steering pump and bracket Right splash shield Alternator Crankshaft pulley Crankshaft Position (CKP) sensor connector Oil pan or Ai Hanae Front cover. Remove the bolts in reverse of the installation sequence. CKP sensor pulse ring

The camshaft thrust caps must be removed before loosening the remaining camshaft journal cap bolts to ensure that the thrust caps are not damaged. ->The camshaft journal caps and cylinder heads are numbered to ensure that they are assembled in their original positions.

9. Remove or disconnect the following: e Camshaft thrust caps e Camshaft journal caps. Loosen the bolts in sequence and in several passes to allow the camshaft to be raised from the cylinder head evenly. Rocker arms. Keep the rocker arms in order for installation. Right timing chain tensioner arm Right timing chain and crankshaft sprocket 10. Rotate the crankshaft 2 revolutions and locate the crankshaft keyway at the 11 o'clock position. This will position the leit cylinder head camshafts to their neutral position. 11. Verify that the alignment arrows on the camshafts are aligned. 12. Remove the left cylinder head timing chain tensioner retaining bolts and the timing chain tensioner. «>The camshaft thrust caps must be removed before loosening the remaining camshaft journal cap bolts to ensure that the thrust caps are not damaged.

«>The camshaft journal caps and cylinder heads are numbered to ensure that they are assembled in their original positions.

1 of this manual For Tire, Wheel and Ball Joint specifications, see Section

41-18

FoR2 motor co. CONTOUR e MYSTIQUE e 1999-01 COUGAR

9306HG05 7922JG27

Using a thin prytool, release and hold the timing chain tensioner ratchet/paw! mechanism—2.5L engine

7922JG30

Camshaft journal! cap tightening sequence—2.5L engine

When installing the CKP sensor pulse ring, be sure to use the correct keyway— 2.5L engine

79225628

Retain the piston with a 1.5mm wire or paperclip—2.5L engine

13. Remove or disconnect the following: ¢ Camshaft thrust caps ¢ Camshaft journal caps. Loosen the bolts in sequence and in several passes to allow the camshaft to be raised from the cylinder head evenly. ¢ Rocker arms. Keep the rocker arms in order for installation. ¢ Left timing chain tensioner arm e Left timing chain and crankshaft sprocket To install: 14. Prepare the timing chain tensioners for installation as follows: a. Place the left chain tensioner ina vise. b. Using a small prytool, release and hold the timing chain tensioner

ratchet/paw! mechanism through the

access hole in the timing chain tensioner. c. Slowly compress the tensioner. d. Lock the piston with a 1.5mm wire Or paperclip. é. Repeat for the right chain tensioner.

APPLY 3 mm (0.118 INCH) BEAD OF SEALANT

VIEW A TYPICAL 6 PLACES

e»Be sure that the crankshaft keyway is

eerie

still at the 11 o’clock position.

15. Install or connect the following: e Left timing chain and crankshaft

To prevent oil leakage, apply sealant to the places indicated—2.5L engine

FORD MOTOR CO.

44.4Q

CONTOUR ¢ MYSTIQUE ¢ 1999-01 COUGAR * LOCATION OF STUDS 8 PLACES TIGHTEN BOLTS/STUDS IN SEQUENCE SHOWN

FRONT OF ENGINE

1. Cylinder head, RH 2. Cylinder block 3. Crankshaft 4. Cylinder block 5. Bolt (8 req'd) 6. Bolt 7. Dust cover 8. Drive belt idler pulley

9, Engine front cover 10. Stud bolt (8 req'd)

11. Crankshaft position sensor pulse ring A. Tighten to 20-30 Nm (15-22 Ib. ft.) 7922)G31

sequence—2.5L engine Exploded view of the front cover mounting, showing the retaining bolt and nut tightening

sprocket. Align the colored links with the index marks on the camshaft and crankshaft sprockets. Left timing chain tensioner arm Left timing chain tensioner and tighten the retaining bolts to 15-22 ft. Ibs. (20-30 Nm) Right timing chain and crankshaft sprocket. Align the colored links with the index marks on the camshaft and crankshaft sprockets. Right timing chain tensioner arm Right timing chain tensioner and tighten the retaining bolts to 15-22 ft. Ips. (20-30 Nm) >The crankshaft keyway must be in the 11 o’clock position to install the left cylinder head rocker arms. ->Do not install the camshaft journal thrust caps until the other journal caps have been installed and tightened. 16. Install the left cylinder head rocker arms in their original positions. 17. Tighten the left camshaft journal caps in the order shown and in several

passes to 88 inch Ibs. (10 Nm).

18. Install the left camshaft journal thrust caps and tighten the bolts to 88 inch Ibs. (10 Nm). 19. Remove the retaining wire from the left timing chain tensioner. e>The crankshaft keyway must be in the 3 o’clock position to install the right cylinder head rocker arms.

90. Rotate the crankshaft so that the keyway is in the 3 o'clock position. 94. Install the right cylinder head rocker arms in their original positions. ->Do not install the camshaft journal thrust caps until the other journal caps have been installed and tightened.

22. Tighten the right camshaft journal caps in the order shown and in several passes to 88 inch Ibs. (10 Nm). 93. Install the right camshaft journal thrust caps and tighten the bolts to 88 inch lbs. (10 Nm). 94. Remove the retaining wire from the right timing chain tensioner. 95. Install the CKP sensor pulse ring. Use the keyway for the 2.5L engine as shown.

26. Replace the crankshaft seal in the front cover with a new one. Apply clean engine oil to the seal lip. 27. Apply silicone sealer to the 6 critical areas shown in View A. 28. Place new front cover gaskets onto the dowel pins on the cylinder block and heads. 99. Place the front cover into position. 30. Install the 6 front cover retaining bolts and stud bolts where the silicone sealer was applied. 31. Tighten the bolts and stud bolts until the front cover contacts the cylinder block and heads, then turn the bolts and stud bolts an additional /% turn. 32. Install the remaining front cover retaining bolts and stud bolts. 33. Tighten all of the front cover retaining bolts and stud bolts in sequence to 15-2? ft. Ibs. (20-30 Nm). 34. Install or connect the following: e A/C hose bracket e A/C compressor e (Qjl pan e CKP sensor connector e Crankshaft pulley e Alternator

this manual For Wheel Alignment specifications, see Section 1 of

11-2

FORD MOTOR CO.

CONTOUR ¢ MYSTIQUE e 1999-01 COUGAR

Right splash shield Power steering pump and bracket Accessory drive belt Engine wiring harness connectors Front engine support insulator and bracket Coolant recovery reservoir Low coolant level sensor connector Valve covers Upper intake manifold. Use new gaskets and tighten the bolts to 71-106 inch Ibs. (8-12 Nm). Negative battery cable 35. Fill the engine with the proper amount and grade of oil. 36. Run the engine and check for leaks and proper operation.

| be

[+

TOP COMPRESSION RING

(z—

BOTTOM COMPRESSION RING OIL CONTROL RINGS AND EXPANDER

CENTER LINE OF PISTON PARALLEL TO WRIST PIN BORE UPPER COMPRESSION RING GAP LOCATION

FRONT OF ENGINE OiL CONTROL SEGMENT RING GAP LOCATION

EXPANDER RING AND LOWER COMPRESSION RING GAP LOCATION

Piston and Ring

OIL CONTROL SEGMENT RING GAP LOCATION

7922AG29

POSITIONING 2.0L and 2.5L engines—piston ring positioning, end-gap spacing and piston positioning. The small directional arrow must face the front of the engine.

Fuel System Service Precautions Safety is the most important factor when performing not only fuel system maintenance but any type of maintenance. Failure to conduct maintenance and repairs in a safe manner may result in serious personal injury or death. Maintenance and testing of the vehicle's fuel system components can be accomplished safely and effectively by adhering to the following rules and guidelines. * To avoid the possibility of fire and personal injury, always disconnect the negative battery cable unless the repair or test procedure requires that battery voltage be applied. ¢ Always relieve the fuel system pressure prior to disconnecting any fuel system component (injector, fuel rail, pressure regulator, etc.), fitting or fuel line connection. Exercise extreme caution whenever relieving fuel system pressure, to avoid exposing skin, face and eyes to fuel spray. Please be advised that fuel under pressure may penetrate the skin or any part of the body that it contacts. ¢ Always place a shop towel or cloth around the fitting or connection prior to loosening to absorb any excess fuel due to spillage. Ensure that all fuel spillage (should it occur) is quickly removed from engine surfaces. Ensure that all fuel soaked

cloths or towels are deposited into a suitable waste container. e Always keep a dry chemical (Class B) fire extinguisher near the work area. ¢ Do not allow fuel spray or fuel vapors to come into contact with a spark or open flame. e Always use a back-up wrench when loosening and tightening fuel line connection fittings. This will prevent unnecessary stress and torsion to fuel line piping. e Always replace worn fuel fitting Orings with new. Do not substitute fuel hose or equivalent, where fuel pipe is installed. Before servicing the vehicle, make sure to refer to the precautions in the beginning of this section as well.

Fuel System Pressure

6. Open the manual valve on the fuel pressure gauge and drain the fuel through the drain tube into a suitable container. 7. Remove the fuel pressure gauge. 8. When service on the vehicle is complete, install the engine air cleaner assembly, tighten the fuel tank filler cap and connect the negative battery cable.

Fuel Filter

REMOVAL & INSTALLATION or

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Relieve the fuel systern pressure. e>The fuel filter is located underneath the vehicle, near the fuel tank.

RELIEVING rr

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Disconnect the negative battery cable. 3. Remove the engine air cleaner assembly. 4. Loosen the fuel tank filler cap to relieve pressure in the fuel tank. S. Connect a fuel pressure gauge to the fuel pressure relief valve located on the fuel rail.

STEEL LINE

SPACERS 7922JG32

Once the retainer clip has been removed from the connector, the fuel line can be removed from the filter

FORD MOTOR CO. 44.94

CONTOUR ¢ MYSTIQUE ¢ 1999-01 COUGAR FUELFILTER

FUEL FILTER BRACKET oO

para

Fi

e Fuel supply manifold with the injectors attached e Injectors from the supply manifold To install: 4. Install or connect the following: Fuel injectors using new O-ring seals Fuel supply manifold with the injectors attached and tighten the bolts to 88 inch Ibs. (10 Nm) Fuel injector electrical connectors Accelerator cable Pressure regulator vacuum hose Fuel lines and retaining clip Negative battery cable

©

fgAaS

WORM GEAR MOUNTING CLAMP (PART OF 9155) 7922JG33

Be sure to install the fuel filter with the arrow pointing in the direction of the fuel flow

3. Remove or disconnect the following: e Retainer clips at both ends of the fuel filter e Fuel lines from the fuel filter e Fuel filter To install: 4. Install or connect the following: e New fuel filter with the arrow pointed in the direction of flow e New retainer clips onto the fuel line fittings before placing the lines onto the fuel filter ends e Fuel lines onto the fuel filter until an audible click is heard. Pull on the fitting to verify a good connection. 5. Start the engine and check for fuel leaks and proper operation.

REMOVAL & INSTALLATION an

EEEEEEEEEEEEEREEEEEEE

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Disconnect the negative battery cable. i FUEL FILTER INLET TUBING,

oe

FUEL AND VAPOR ETURN TUBE

FIN)

h

7922JG35

Remove the locking ring from the fuel pump sender with special tool Fuel Tank Sender Wrench D84P-9275-A

3. Relieve the fuel pressure. 4. Remove or disconnect the following: Rear seat cushion Plastic access panel Fuel pump wiring harness connector Fuel lines Fuel pump module lock ring. Use special tool Fuel Tank Sender Wrench D84P-9275-A. e Fuel pump module To install: 5. Install or connect the following: ¢ Fuel pump module with a new Oring seal Fuel pump module lock ring using special tool Fuel Tank Sender Wrench D84P-9275-A Fuel lines Fuel pump wiring harness connector Plastic access panel Rear seat cushion e Negative battery cable 6. Start the engine and check for leaks and proper operation.

Fuel Injector REMOVAL & INSTALLATION ST

2.0L Engine

PU CONNECT FITTING 79221634

View of fuel pump fittings through the floor pan

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Relieve the fuel system pressure. 3. Remove or disconnect the following: e Negative battery cable e Fuel lines and retaining clip e Pressure regulator vacuum hose ¢ Accelerator cable e Fuel injector electrical connectors

2.5L Engine

EXCEPT RETURNLESS FUEL DELIVERY SYSTEM

|

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Relieve fuel system pressure. 3. Remove or disconnect the following: Negative battery cable Air cleaner outlet tube Fuel lines Upper intake manifold Fuel injector electrical connectors Fuel pressure regulator vacuum line Intake Manifold Runner Control (IMRC) rod ¢ Fuel supply manifold with the injectors attached e Injectors from the supply manifold To install: 4. Install or connect the following: Fuel injectors using new O-ring seals Fuel supply manifold with the injectors attached and tighten the bolts to 88 inch Ibs. (10 Nm) IMRC rod Fuel pressure regulator vacuum line Fuel injector electrical connectors Upper intake manifold. Use new gaskets and tighten the bolts to 71-106 inch Ibs. (8-12 Nm). Fuel lines Air cleaner outlet tube Negative battery cable 5. Start the engine and check for leaks.

RETURNLESS FUEL DELIVERY SYSTEM 1. Before servicing the vehicle, refer to the precautions in the beginning of this section.

manual For Maintenance Interval recommendations, see Section 7 of this

11-2

FORD MOTOR CO.

CONTOUR e MYSTIQUE ¢ 1999-01 COUGAR

2. Relieve fuel system pressure. 3. Remove or disconnect the following: Negative battery cable Air cleaner outlet tube Fuel line Upper intake manifold Fuel injector electrical connectors Fuel pressure sensor electrical connector and vacuum line Intake Manifold Runner Control (IMRC) rod

e Fuel supply manifold with the injectors attached e Injectors from the supply manifold To install: 4. Install or connect the following: e Fuel injectors using new O-ring seals e Fuel supply manifold with the injectors attached and tighten the bolts to 88 inch Ibs. (10 Nm) e IMRC rod

Fuel pressure sensor electrical connector and vacuum line Fuel injector electrical connectors Upper intake manifold. Use new gaskets and tighten the bolts to 71-106 inch Ibs. (8-12 Nm). Fuel line Air cleaner outlet tube e Negative battery cable 5. Start the engine and check for leaks.

DRIVE TRAIN Transaxle Assembly

REMOVAL & INSTALLATION Automatic

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Secure the radiator and fan shroud to the radiator support. 3. Loosen the left and right upper strut mounting nuts 5 turns. 4. Attach an engine support fixture to the engine lifting eyes. 5. Drain the transaxle fluid. 6. Remove or disconnect the following: e Battery e Air cleaner assembly and mounting bracket ¢ Shift cable and bracket e Transaxle control wiring harness connector e Transaxle range sensor e Rear transaxle support insulator ¢ Oil dipstick tube and exhaust manifold heat shield (2.0L engine) Water pump pulley shield (2.5L engine) ¢ Steering column pinch bolt ¢ Front wheels

Left, right and center splash shields Lower ball joints Outer tie rod ends Stabilizer bar links Left and right engine support insulators Power steering oil cooler hoses Bumper cover braces Radiator air deflector Lower radiator supports Exhaust system

A/C accumulator mounting bolts Transaxle cooler lines and bracket Power steering hoses. Lower the subframe for access. Subframe Turbine Speed (TSS) sensor connector Halfshafts and intermediate shaft

Vehicle Speed (VSS) sensor connector Torque converter nuts @ e Starter Front engine support insulator bracket 7. Lower the powertrain until the transaxle is level with the left frame member. 8. Support the transaxle on a transmission jack. 9. Remove or disconnect the following: ¢ Transaxle flange bolts

TURBINE SHAFT SPEED SENSOR (TSS)

TRANSAXLE DRAIN PLUG

ELECTRICAL CONNECTOR

7922JG63

Transaxle drain plug location

TSS sensor location

>Use care when removing the transaxle to prevent the torque converter from falling out. To install: ->Replace all snaprings, split pins and self-locking nuts.

10. Install or connect the following: e Transaxle and tighten the flange bolts to 41-50 ft. Ibs. (655-68 Nm) Torque converter and tighten the nuts to 23-39 ft. Ibs. (31-53 Nm) TSS connector Subframe. Attach the power steering hoses before installing the subframe bolts. Special tool Subframe Alignment Pin Set T95P-2100-AH and the subframe bolts. Tighten the subframe bolts to 81-110 ft. Ibs. (110-150 Nm). Remove the alignment pins. STRAIGHT EDGE

Chen). 10 mm

(7/16

TORQUE CONVERTER

TRANSAXLE PUMP ASSY 7922JG64

e Transaxle from the engine e Transaxle

7922JG36

Be sure that the torque converter is properly seated in the transaxle

FORD MOTOR CO. 44.93

CONTOUR © MYSTIQUE e 1999-01 COUGAR e A/C accumulator bolts e Power steering oil cooler lines

¢ Special tool Powertrain Alignment Gauge T94P-6000-AH in place of the left engine support insulator. Tighten the 2 retaining bolts to 20 ft. Ibs. (27 Nm) and snug the through-bolt. e>The left and right support insulators must be aligned in the middle of the support insulator brackets.

e Right engine support insulator. Tighten the 2 subframe retaining bolts to 30-41 ft. Ibs. (41-55 Nm) and the through-bolt to 75-102 ft.

lbs. (103-137 Nm). e Rear engine support insulator and tighten the nuts to 61 ft. Ibs. (83 Nm) e Front engine support insulator and tighten the nuts to 61 ft. Ibs. (83 Nm) 11. Remove the Powertrain Alignment Tool and install the left engine support insulator. Tighten the center bolt to 88 ft. Ibs. (120 Nm), and the mounting bolts to 35 ft. lbs. (48 Nm). Transaxle oil cooler lines Starter and tighten the bolts to

43-58 ft. Ibs. (69-79 Nm) for the 2.5L engine or 15-20 ft. ibs. (20-27 Nm) for the 2.0L engine VSS sensor connector Halfshafts and intermediate shaft Exhaust system Lower radiator supports Radiator air deflector Bumper cover braces Power steering oil cooler hoses Left and right engine support insulators Stabilizer bar links and tighten the

e Shift cable and bracket e Air cleaner assembly and mounting bracket ¢ Battery 12. Tighten the upper strut mount nuts to 34 ft. Ibs. (46 Nm). 13. Fill the transaxle. 14. Check for leaks and proper operation. e>\Nhenever the vehicle subframe is removed or lowered, the wheel alignment should be checked.

Manual

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Attach an engine support fixture to the engine lifting eyes. 3. Secure the radiator and fan shroud to the radiator support. 4. Loosen the front strut upper mount nuts 5 turns. 5. Remove or disconnect the following: Battery Steering column pinch bolt Air cleaner assembly and bracket Front and rear engine support insulators Reverse lamp switch connector Ground strap Left, right and center splash shields Clutch slave cylinder hydraulic line

Accessory drive belt cover Power steering pulley shield (2.5L engine) Exhaust crossover pipe (2.5L engine) Catalytic converter Front wheels Vehicle Speed Sensor (VSS) Radiator air deflector Shift rod and stabilizer bar A/C accumulator mounting bolts. Halfshafts and intermediate shaft Left and right engine support insulators Lower ball joints Outer tie rod ends Stabilizer bar links Power steering oil cooler lines Lower radiator supports Bumper cover braces Power steering hoses. Lower the Subframe for access. Subframe e Starter 6. Lower the powertrain until the transaxle is level with the left frame member. 7. Support the transaxle on a transmission jack. 8. Remove or disconnect the following: e Transaxle flange bolts e Transaxle from the engine To install: e>Replace all snaprings, split pins and self-locking nuts.

nuts to 35-48 ft. Ibs. (47-65 Nm) Outer tie rod ends and tighten the nuts to 23-35 ft. Ibs. (1-47 Nm) Lower ball joints and tighten the pinch bolt to 61 ft. Ibs. (83 Nm) Left, right and center splash shields Front wheels and tighten the lug nuts to 63 ft. Ibs. (86 Nm) Steering column pinch bolt and tighten the bolt to 15-20 ft. Ibs. (20-27 Nm) Water pump pulley shield (2.5L engine) Oil dipstick tube and exhaust manifold heat shield (2.0L engine) Transaxle range sensor Transaxle control wiring harness connector

eu / Ith Vey ine

A \

ie \

7922JG37

-AH—manual To properly align the subframe, install Subframe Alignment Pin Set T95P-2100 and automatic transaxles

For Tune-up, Capacities and Firing orders, see Section 1 of this manual

41-24 FORD moToR co.

CONTOUR ¢ MYSTIQUE ¢ 1999-01 COUGAR

7922JG38

The Powertrain Alignment Gauge (T94P6000-AH) tool must be installed in the correct position to ensure proper engine/transaxle orientation

9. Install or connect the following: e Transaxle to the engine and tighten the flange bolts to 28-38 ft. Ibs. (38-51 Nm) Starter and tighten the bolts to 35 ft. Ibs. (48 Nm) Subframe. Attach the power steering hoses before installing the subframe bolts. Special tool Subframe Alignment Pin Set T95P-2100-AH and the subframe bolts. Tighten the subframe bolts to 81-110 ft. Ibs. (110-150 Nm). Remove the alignment pins. A/C accumulator bolts Power steering oil cooler lines Special tool Powertrain Alignment Gauge T94P-6000-AH in place of the left engine support insulator. Tighten the 2 retaining bolts to 20 ft. Ibs. (27 Nm) and snug the through-bolt. >The left and right support insulators must be aligned in the middle of the support insulator brackets.

¢ Right engine support insulator. Tighten the 2 subframe retaining bolts to 30-41 ft. Ibs. (41-55 Nm) and the through-bolt to 75-102 ft. lbs. (103-137 Nm). Rear engine support insulator and tighten the nuts to 61 ft. Ibs. (83 Nm) Front engine support insulator and tighten the nuts to 61 ft. Ibs. (83 Nm) 10. Remove the Powertrain Alignment Tool and install the left engine support insulator. Tighten the center bolt to 88 ft. Ibs. (120 Nm), and the mounting bolts to 35 ft. lbs. (48 Nm). ¢ Bumper cover braces e Lower radiator supports and tighten the bolts to 71-97 inch Ibs. (8-11 Nm)

Power steering oil cooler lines Stabilizer bar links and tighten the

13. Road test the vehicle and check for proper operation.

fasteners to 35-48 ft. Ibs. (47-65 Nm)

->Whenever the vehicle subframe is removed or lowered, the wheel align-

ment should be checked:

Outer tie rod ends and tighten the nuts to 23-35 ft. Ibs. (81-47 Nm) Lower ball joints and tighten the pinch bolt to 61 ft. Ibs. (83 Nm) Halfshafts and intermediate shaft A/C accumulator mounting bolts Shift rod and stabilizer bar. Tighten the shift rod bolt to 14-18 ft. Ibs. (19-25 Nm) and the stabilizer bar nut to 28-38 ft. Ibs. (88-51 Nm). Radiator air deflector VSS sensor Front wheels and tighten the lug nuts to 63 ft. Ibs. (86 Nm) Catalytic converter Exhaust crossover pipe (2.5L engine)

ADJUSTMENTS These vehicles are equipped witha hydraulic clutch system. No adjustment is

necessary.

REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Transaxle

° Power steering pulley shield (2.5L

¢ Clutch pressure plate e Clutch disk

engine)

° Flywheel

Accessory drive belt cover Clutch slave cylinder hydraulic line Left, right and center splash shields Ground strap Reverse lamp switch connector Air cleaner assembly and bracket Steering column pinch bolt and tighten the bolt to 15-20 ft. Ibs. (20-27 Nm)

Battery 11. Tighten the strut mounting nuts to 34 ft. Ibs. (46 Nm). 12. Adjust the shift linkage and bleed the hydraulic clutch system as required.

To install: 3. Install or connect the following: e Flywheel and tighten the bolts to 82 ft. Ibs. (112 Nm) for 2.0L engines or to 59 ft. Ibs. (80 Nm) for 2.5L engines e Clutch disk and pressure plate and tighten the pressure plate bolts evenly in several passes to 21 ft. lbs. (29 Nm) e Transaxle 4. Bleed the hydraulic clutch system, if required.

Clutch System

1. Engine rear plate 2. Dow! (flywheel) 3. Bolt(8)

7. Transaxle assy 8. Transaxle mounting bolts 9. Clutch pressure plate

4. Bolt(6) 5. Bolt(3)

10. Clutch disc 11. Flywheel

6. Clutch slave cylinder

12. Dowl bushing (engine plate) 7922JG39

Exploded view of the clutch disc, pressure plate and related component mounting

FORD MOTOR CO. 1 1 -25

CONTOUR ¢ MYSTIQUE e 1999-01 COUGAR air cleaner outlet tube and the Mass Airflow

CLUTCH ALIGNER T74P-7137-K

(MAF) sensor. >The brake master cylinder fluid reservoir is also the reservoir for the hydraulic clutch master cylinder.

CH DISC 7922JG40

Insert an alignment tool through the clutch disc to ensure that it is centered after the pressure plate is installed

3. Remove the rubber inspection cover from the bell housing. 4. Connect a hose to the bleeder valve fitting on the clutch slave cylinder. Submerge the other end of the hose into a container of clean brake fluid. 5. Open the bleeder valve and have an assistant depress the clutch pedal. 6. Close the bleeder before releasing the clutch pedal. 7. Repeat the procedure until no more air bubbles are seen. 8. Install the rubber inspection cover to the bell housing. 9. Top off the brake master cylinder fluid reservoir and install the diaphragm and cap securely. 10. Install the MAF sensor and air cleaner outlet tube. 11. Connect the negative battery cable. 12. Check the clutch for proper operation.

7922JG41

Pressure plate tightening sequence

5. Check the clutch system for proper operation.

REMOVAL & INSTALLATION Left Axle Halfshaft

Hydraulic Clutch System

e>Replace all snaprings, split pins and self-locking nuts.

BLEEDING 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove the negative battery cable,

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Loosen the strut upper mount nut 5 turns. 3. Remove or disconnect the following:

e Wheel e Splash shield ¢ Lower ball joint

DUST COVER

BLEEDER SCREW

7922JG42

Clutch slave cylinder bleeder valve

7922JG43

Front Hub Remover/Replacer 181P-1104-C

Ky ©) leg

Bs

T81P—4026—-A

vi

My

ys

NIE 7922)G45

If the intermediate shaft has been removed, install Differential Rotator T81P4026-A before removing the left halfshaft

M Ar\\\ ea

| aa

»,Le?

ees

U

Lt

_i|

\ Use a slide hammer to pull the inner CVjoint from the transaxle

e Outer tie rod end e Stabilizer bar link 4. Separate the outer C\V-joint and halfshaft from the wheel hub. 5. Install CV-joint puller T86P-3514-A1 between the inner CV-joint and the transaxle case. e>|f the intermediate shaft has already been removed, install Differential Rotator T81P-4026-A into the right side of the differential before removing the left shaft to maintain alignment within the differential.

6. Remove the halfshaft. To install: 7. Install the halfshaft. A non-metallic mallet may be used to aid in seating the inner CV-joint into the differential side gear. Insert the stub shaft into the whee! hub and tighten the hub nut to 246 ft. Ibs. (340 Nm). 8. Install or connect the following: Lower ball joint and tighten the pinch bolt to 61 ft. Ibs. (83 Nm) Outer tie rod end and tighten the nut to 20 ft. Ibs. (28 Nm) Stabilizer bar link and tighten the nut to 14-23 ft. Ibs. (20-32 Nm) Splash shield Wheel and tighten the lug nuts to 63 ft. Ibs. (86 Nm)

For complete service labor times, order Nichols’ Chilton Labor Guide

11-2

FORD MOTOR CO.

CONTOUR ¢ MYSTIQUE ¢ 1999-01 COUGAR

9. Tighten the strut upper mount nut to 34 ft. Ibs. (46 Nm). 10. Road test the vehicle and check for proper operation. Right Axle Halfshaft e>Replace all snaprings, split pins and self-locking nuts.

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Loosen the strut upper mount nut 5 turns. 3. Remove or disconnect the following: e Wheel e Splash shield e Lower ball joint e Outer tie rod end ¢ Stabilizer bar link 4. Separate the outer CV-joint and halfshaft from the wheel hub. 5. Install CV-joint puller T86P-3514-A1 between the inner CV-joint and the intermediate shaft. To install: 6. Install the halfshaft. A non-metallic mallet may be used to aid in seating the inner CV-joint into the differential side gear. Insert the stub shaft into the wheel hub and tighten the hub nut to 246 ft. Ibs. (340 Nm). 7. Install or connect the following: Lower ball joint and tighten the pinch bolt to 61 ft. Ibs. (83 Nm) Outer tie rod end and tighten the nut to 20 ft. Ibs. (28 Nm) Stabilizer bar link and tighten the nut to 14-23 ft. Ibs. (20-32 Nm) Splash shield Wheel and tighten the lug nuts to 63 ft. Ibs. (86 Nm) 8. Tighten the strut upper mount nut to 34 ft. Ibs. (46 Nm). 9. Road test the vehicle and check for proper operation.

2. Remove the right halfshaft. elf the left halfshaft has already been removed, install Differential Rotator T81P-4026-A into the left side of the differential before removing the intermediate shaft to maintain alignment within the differential. 3. Remove the intermediate shaft and support bearing. To install: 4. Install the intermediate shaft and tighten the support bearing nuts to 17—22 ft. lbs. (24-30 Nm). 5. Install the right halfshaft.

9306HG07

Removing the outer CV-joint

To install:

CV-Joints

>Use new snaprings and boot clamps.

REMOVAL & REPLACEMENT Inner Tripod Joint 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Place the halfshaft in a vise. 3. Remove or disconnect the following: ¢ Tripod joint boot e Tripod joint housing e Tripod assembly snapring e Tripod assembly from the halfshaft with Bearing Puller D79L-4621-A

and Remover/Installer T81P-1104-C

a

T81

P-1104—C

{>

(pie

Intermediate Shaft

1. Before servicing the vehicle, refer to the precautions in the beginning of this section.

1. CV-Joint boot 2. CV-Joint

9306HG06

Removing the tripod assembly

4. Install the tripod joint with a new snapring. 5. Fill the tripod joint housing with fresh CV-joint grease. 6. Install the joint housing and fit the boot to the seat groove. 7. \Insert a small prytool under the boot seat to permit air to escape. 8. Slide the tripod joint fully into the joint housing, then pull it back out 3% inches (20mm). 9. Remove the prytool and install the boot clamps. Outer CV-Joint

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Place the halfshaft in a vise. 3. Remove the CV-joint boot clamps and Slide the boot away from the joint. 4. Drive the CV-joint off the halfshaft with a brass drift and a hammer. To install: 5. Replace the snapring. 6. Fill the CV-joint with fresh grease and Slide the joint on to the halfshaft. 7. Fit the CV-joint boot to the seat grooves and install new boot clamps.

FORD MOTOR CO.

44_97

CONTOUR © MYSTIQUE e 1999-01 COUGAR

:

STEERING AND SUSPENSION

ok CAUTION Some 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 precautions and the disarming procedure could result in accidental air bag deployment, possible injury

2. Check the functioning of the air bag system by turning the ignition key to the RUN position and visually monitoring the air bag indicator lamp in the instrument Cluster. The indicator lamp should illuminate for approximately 6 seconds, then turn OFF. If the indicator lamp does not illuminate, stays on, or flashes at any time, a fault has been detected by the air bag diagnostic monitor.

REMOVAL & INSTALLATION

PRECAUTIONS

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Attach an engine support fixture to the engine lifting eyes. 3. Secure the radiator and fan shroud to the radiator support. 4 Remove or disconnect the following: Negative battery cable Steering gear flexible coupling Left, right and center splash shields Catalytic converter Front wheels Lower ball joints Outer tie rod ends Stabilizer bar links Left and right engine support insulators Power steering oil cooler lines A/C accumulator bolts Lower radiator supports Bumper cover braces Power steering hoses. Lower the subframe for access. Subframe with steering gear attached

DISARMING 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Position the vehicle with the front wheels in a straight-ahead position. 3. Disconnect the battery cables, negative cable first. 4. Wait at least 1minute for the air bag back-up power supply to drain before continuing. ; 5. Proceed with the repair.

ARMING

e Steering gear cover plate e Steering gear To install: 5. Install or connect the following: e Steering gear and tighten the bolts to 101 ft. Ibs. (137 Nm) Steering gear cover plate and tighten the bolts to 37 ft. Ibs. (50 Nm) Subframe. Use new seals and attach the power steering hoses

Power Rack and Pinion Steering Gear

and unnecessary system repairs.

Several precautions must be observed when handling the inflator module to avoid accidental deployment and possible personal injury. e Never carry the inflator module by the wires or connector on the underside of the module e When carrying a live inflator module, hold securely with both hands, and ensure that the bag and trim cover are pointed away e 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 in the event of an accidental deployment Before servicing the vehicle, also be sure to refer to the precautions in the beginning of this section as well

|

ee

tel So

x

>The left and right support insulators must be aligned in the middle of the support insulator brackets.

e Right engine support insulator. Tighten the 2 subframe retaining bolts to 30-41 ft. Ibs. (41-55 Nm) and the through-bolt to 75-102 ft. lbs. (103-137 Nm). 6. Remove the Powertrain Alignment Tool and install the left engine support insulator and tighten the center bolt to 88 ft. Ibs.

(120 Nm), and the mounting bolts to 35 ft. lbs. (48 Nm). e Bumper cover braces e Lower radiator supports

FLEXIBLE COUPLING

FLEXIBLE COUPLING STEERING GEAR PINION SHAFT

—L_>-—

Lire

Pin Set T95P-2100-AH and the subframe bolts. Tighten the subframe bolts to 81-110 ft. Ibs. (110-150 Nm). Remove the alignment pins. Special tool Powertrain Alignment Gauge T94P-6000-AH in place of the left engine support insulator. Tighten the 2 retaining bolts to 20 ft. Ibs. (27 Nm) and snug the through-bolt.

Ts

STEERING COLUMN

eel

before bolting the subframe in place. Special tool Subframe Alignment

ff,

1. After repairs are completed, connect the battery cables.

a 7922JG47

7922JG46

Disconnect the steering column shaft from

Disengage the flexible coupling from the

the flexible coupling

steering gear pinion shaft

Please visit our web site at www.chiltonsonline.com

41-28

foro moToR co. CONTOUR ¢ MYSTIQUE ¢ 1999-01 COUGAR

Strut and Spring

REMOVAL & INSTALLATION

Front 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 wheels Upper strut mount nut Stabilizer bar link Brake hose bracket Lower ball joint Wheel speed sensor Brake caliper and caliper support Brake rotor Steering knuckle pinch bolt 3. Work the strut out of the steering knuckle and lower the strut out of the strut

r t) aS (2

a tig

6

——

FRONT OF VEHICLE

FRONT SUB-FRAME SUB-FRAME ALIGNMENT PIN SET T94P-2100-AH

7922JG648

Install Subframe Alignment Pin Set T94P-2100-AH into the subframe to ensure correct positioning

A/C accumulator bolts Power steering oil cooler lines Stabilizer bar links Outer tie rod ends and tighten the nuts to 23-35 ft. Ibs. (31-47 Nm) Lower ball joints and tighten the pinch bolts to 61 ft. Ibs. (83 Nm) Front wheels and tighten the lug nuts to 63 ft. Ibs. (86 Nm) Catalytic converter Left, right and center splash shields

1 2

3

e Steering gear flexible coupling. Tighten the upper bolt to 21 ft. Ibs. (28 Nm), and the lower bolt to 18 ft. Ibs. (24 Nm). e Negative battery cable 7. Fill the power steering system. 8. Run the engine and check for leaks and proper operation. e»\Whenever the vehicle subframe is removed or lowered, the wheel alignment should be checked.

Front Suspension Steering Ball Dust Seal Front Wheel Spindle Connecting End Steering Gear

tower. 4 Compress the spring and remove the upper strut mount. 5. Remove the spring from the strut.

To install: 6. Transfer parts as necessary and install the spring onto the strut. 7. Install or connect the following: e Upper strut mount and tighten the nut to 44 ft. Ibs. (69 Nm) ¢ Strut. Guide the strut into the strut tower and attach the steering knuckle. Tighten the upper mounting nut to 34 ft. Ibs. (46 Nm), and the knuckle pinch bolt to 40 ft. Ibs. (54 Nm). e Brake rotor

Power Steering Gear Rack Balance Tube Power Steering Left Turn Pressure Tube

Power Steering Right Turn Pressure Tube 7922)G49

Power rack and pinion steering gear assembly component identification

CONTOUR © MYSTIO neerleaeears PGuGAE 1 1 -29 e Brake caliper support and tighten the bolts to 88 ft. Ibs. (120 Nm) ¢ Wheel speed sensor e Lower ball joint and tighten the pinch bolt to 61 ft. Ibs. (83 Nm)

¢ Brake hose bracket Stabilizer bar link and tighten the nuts to 35-48 ft. Ibs. (47-65 Nm) e Front wheels and tighten the lug nuts to 63 ft. Ibs. (86 Nm) Negative battery cable Rear

7922JG50

Hold the strut piston with an Allen wrench while removing the retaining nut

)

1]

S ROTUNDA SPRING COMPRESSOR 7922JG51

Compress the coil spring assembly before removing the retaining nut

1 2 3

e Spindle pinch bolt 3. Separate the spindle from the strut by tapping down on the wheel spindle. 4 Compress the coil spring. 5. Remove the 2 top retaining bolts and remove the strut assembly. 6. Compress the coil spring enough to relieve the tension on the spring seat. 7, Remove the top mount nut, rear strut bracket, bushing and spring seat. 8. Remove the coil spring from the strut. To install: 9. Transfer parts as necessary and install the spring to the strut. 10. Install the spring seat, bushing, rear strut bracket and the top mount nut. Tighten the top mount nut to 30-43 ft. Ibs. (41-58 Nm). 11. With the coil spring compressed, install the strut assembly into position. 12. Install or connect the following: e Strut bracket mounting bolts and

REAR SUSPENSION TIE ROD ANO BUSHING

REAR WHEEL SPINDLE 7922JG54

. . and separate the tie rod from the rear wheel spindle

a

ed

: é

SUS) Ep MS } ayy

SPINDLE-TO-SHOCK ~_ ABSORBER PINCH BOLT 7922JG55

Remove the rear strut pinch bolt to release the strut assembly from the spin-

STABILIZER BAR LINK AND BUSHING

Upper Mount

5 6 76 8

Bearing Spring Seat Front Coil Spring Front Shock Absorber Jounce Bumper Dust Shield

=0

>The front and rear control arms must be supported before the removal of the strut attachments.

(23-30 Nm) ¢ Spindle pinch bolt. Tighten the bolt to 52-72 ft. Ibs. (70-98 Nm). Remove the spring compressor. e Tie rod and tighten the bolt to 75-102 ft. Ibs. (102-138 Nm) e Stabilizer bar link e Rear brake hose

Nut Retainer Upper Mount Retainer Nut

4

9

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Negative battery cable e Rear wheels e Wheel speed sensor e Rear brake hose e Stabilizer bar link e Tie rod

tighten the bolts to 17-22 ft. Ibs.

FRONT REAR SUSPENSION ARM AND BUSHING

7922JG56

7922JG53 7922JG52

Exploded view of the strut assembly

Rear Spring Strut Spring Compressor Shock Absorber Mounting Nuts — On

For rear strut removal, disconnect the

sway bar link from the control arm

Compress the coil spring, then unthread the 2 top retaining bolts and remove the strut from the vehicle

Timing belt service is covered in Section 3 of this manual

1 1 -30 FORD MOTOR CO.

CONTOUR ¢ MYSTIQUE

1999-01 COUGAR

9346HG24

Remove the mounting bolts (1) and remove the control arm (2)—right side with vertical bushings shown

~~

Se

ERIN 9346HG25

Control! arm with horizontal bushings

1

2 3

4

Rear Shock Absorber Bracket Shock Absorber Mounting Nut Rear Shock Absorber Dust Boot

Rear Suspension Jounce Bumper Shock Absorber

Rear Spring ON Oa

Spring Seat Shock Absorber Bushing 7922JG57

LEFT SIDE

Exploded view of the rear strut assembly

e Wheel speed sensor ¢ Rear wheels and tighten the lug nuts to 63 ft. Ibs. (86 Nm) ¢ Negative battery cable 13. Bleed the brake system. 14. Check the rear wheel alignment.

Lower Ball Joint. — REMOVAL & INSTALLATION The lower ball joint is serviced with the lower control arm as an assembly.

e Lower ball joint e Lower control arm bushing bolts e Lower control arm To install: 3. Install the lower control arm. If equipped with vertical bushings, tighten the mounting bolts to 85 ft. Ibs. (115 Nm). If equipped with horizontal bushings, tighten the large bolts to 85 ft. Ibs. (115 Nm) and the small bolts to 52 ft. lbs. 970 Nm). 4. Install or connect the following: e Lower ball joint and tighten the pinch bolt to 61 ft. Ibs. (83 Nm) e Splash shield ¢ Wheel and tighten the lug nuts to 63 ft. Ibs. (86 Nm) ¢ Negative battery cable 5. Check the wheel alignment.

Lower Control Arm

REMOVAL & INSTALLATION Front

RIGHT

SIDE

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: ¢ Negative battery cable e Wheel e Splash shield

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Secure the radiator and fan shroud with safety wire to the radiator support. 3. Attach an engine support fixture to the engine lifting eyes. 4. Remove or disconnect the following: ¢ Negative battery cable e Steering column pinch bolt ¢ Left, right and center splash shields e Exhaust crossover pipe (2.5L engine) ¢ Catalytic converter e Front wheel e Vehicle Speed Sensor (VSS)

FORD MOTOR CO. 44.94

CONTOUR ¢ MYSTIQUE ¢ 1999-01 COUGAR >The left and right support insulators must be aligned in the middle of the support insulator brackets.

9346HG26

Remove these bolts to lower the subframe

2

sd cae,

Sol

7502-002 Kt). Rf a)

9346HG27

Subframe alignment guide pin (1), locking pin (2) and guide pin sleeve (3)

Radiator air deflector A/C accumulator mounting bolts Left and right engine support insulators Lower ball joint Power steering oi! cooler lines Lower radiator supports Bumper cover braces 5. Unbolt and lower the subframe to access the left control arm bushing bolts. 6. Remove the control arm. To install: e»Replace all snaprings, split pins and self-locking nuts.

7. Install or connect the following: e Left control arm and tighten the mounting bolts and nuts to 96 ft.

lbs. (130 Nm) Subframe Special tool Subframe Alignment Pin Set T95P-2100-AH and the subframe bolts. Tighten the sub-

frame bolts to 81-110 ft. Ibs. (110-150 Nm). Remove the alignment pins. A/C accumulator bolts Power steering oil cooler lines Special tool Powertrain Alignment Gauge 194P-6000-AH in place of the left engine support insulator. Tighten the 2 retaining bolts to 20 ft. Ibs. (27 Nm) and snug the through-bolt.

¢ Right engine support insulator. Tighten the 2 subframe retaining bolts to 30-41 ft. Ibs. (41-55 Nm) and the through-bolt to 75-102 ft. lbs. (103-137 Nm). 8. Remove the Powertrain Alignment Too! and install the left engine support insulator. Tighten the center bolt to 88 ft. Ibs. (120 Nm), and the mounting bolts to 35 ft. lbs. (48 Nm). Bumper cover braces Lower radiator supports and tighten the bolts to 71-97 inch Ibs. (8-11 Nm) Power steering oil cooler lines Lower ball joint and tighten the pinch bolt to 61 ft. Ibs. (83 Nm) A/C accumulator mounting bolts Radiator air deflector VSS sensor Front wheel and tighten the lug nuts to 63 ft. Ibs. (86 Nm) Catalytic converter Exhaust crossover pipe (2.5L engine) Left, right and center splash shields Steering column pinch bolt and tighten the bolt to 15-20 ft. Ibs. (20-27 Nm) e Battery 9. Road test the vehicle and check for proper operation. e>Whenever the vehicle subframe is removed or lowered, the wheel alignment should be checked.

Rear

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Rear wheels e Rear control arms e Stabilizer bar link e Exhaust system hangers ¢ Wheel spindle tie bar 3. Support the rear crossmember and remove the 4 attaching bolts. 4. Lower the rear crossmember to access the front control arm bolts. 5. Remove the front contro! arm. To install: >The final tightening of the rear suspension components is carried out with the full weight of the vehicle on its wheels.

9346HG28

Tighten the rear crossmember bolts with the alignment pins installed

6. Install or connect the following: e Front control arm and tighten the bolts to 62 ft. lbs. (84 Nm) Rear crossmember. Use special tools Subframe Alignment Pins 194P-2100-AH, and tighten the crossmember bolts to 88 ft. Ibs. (120 Nm). Wheel spindle tie bar and tighten the bolt to 88 ft. Ibs. (120 Nm) Exhaust system hangers Stabilizer bar link and tighten the nuts to 26 ft. Ibs. (35 Nm) Rear control arms and tighten the bolts to 62 ft. Ibs. (84 Nm) Rear wheels and tighten the lug nuts to 63 ft. Ips. (86 Nm) 7. Complete the final tightening of the rear Suspension components with the full weight of the vehicle resting on its wheels.

CONTROL ARM BUSHING REPLACEMENT The control arm bushings are serviced with the control arm as an assembly

Wheel Bearings ADJUSTMENT Front and Rear

The wheel bearings are not adjustable. If the bearings make noise or become loose, they must be replaced.

REMOVAL & INSTALLATION Front

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Negative battery cable e Front wheel

Heater Core replacement is covered in Section 2 of this manual

1 1 -32 FORD MOTOR CO.

CONTOUR ¢ MYSTIQUE e 1999-01 COUGAR FRONT WHEEL

FRONT HUB REMOVER/REPLACER TB1P-1104-C

KNUCKLE

SEES

SPACER

gee

PINION BEARING (PART OF

CUP-REPLACER TB0T-4000-E

175T-1176-A)

4

THREADED ORAWBAR T75T-1176-A

D} (as I URS

~f) T81P-1104-C

SNAP RING

SNAP RING

WHEEL BEARING

FRONT WHEEL KNUCKLE 7922JG59

The wheel bearing is retained in the knuckle by 2 snaprings

PRESS

PINION BEARING CUP REPLACER T80T-4000-E WHEEL BEARING

FRONT WHEEL KNUCKLE

7922JG60

Using a press, install the new wheel bearing in the knuckle

Brake caliper support and rotor Wheel speed sensor Outer tie rod end Wheel hub retaining nut Lower ball joint Steering knuckle pinch bolt Halfshaft from the wheel hub Steering knuckle from the vehicle 3. Install Front Hub Remover/Replacer T81P-1104-C or equivalent with the appropriate adapters and separate the hub from the steering knuckle. e Inner and outer snaprings securing the wheel bearing ¢ Wheel bearing from the steering knuckle. Drive or press the old wheel bearing out as required. To install: e>Replace all snaprings, split pins and self-locking nuts.

03)

7922JG62

EARING PULLING ACHMENT D79L-4621-A 7922J)G58

Use gear or bearing pulling tools to remove the hub from the steering knuckle

3)

7922JG61

Use the special tools shown or a press to install the hub in the knuckle assembly

4. Install the outer snapring into the steering knuckle. 5. Install the wheel bearing using a hydraulic press with Pinion Bearing Cup Replacer T80T-4000-E. 6. Install or connect the following: Inner snapring in the steering knuckle Hub to the steering knuckle using Threaded Drawbar T751-1176-A or equivalent Steering knuckle. Tighten the strut pinch bolt to 40 ft. Ibs. (54 Nm), and the ball joint pinch bolt to 61 ft. Ibs. (83 Nm). Wheel speed sensor Wheel hub retaining nut and tighten the hub nut to 246 ft. Ibs. (40 Nm) Outer tie rod end and tighten the nut to 18-22 ft. Ibs. (24-30 Nm) Wheel speed sensor Brake caliper support and rotor and tighten the bolts to 88 ft. Ibs. (120 Nm) Front wheel and tighten the lug nuts to 63 ft. Ibs. (86 Nm) Negative battery cable 7. Road test the vehicle and check for proper operation. Rear

e>The wheel bearings are contained within the wheel hub and must be replaced as an assembly.

WITH REAR DISC BRAKES 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: ¢ Negative battery cable e Rear wheel e Wheel speed sensor e Brake caliper bracket and rotor e>Do not use an impact gun to remove the hub retainer nut.

After removing the spindle nut, use the special tools or a puller to remove the rear hub/bearing assembly—all models

3. a hub To 4.

© Hub retainer nut Remove the hub from the spindle with puller.

install: \nstall or connect the following: e Hub and bearing assembly and tighten the hub retainer nut to 213 ft. Ibs. (290 Nm) e Brake rotor and caliper bracket and tighten the bracket bolts to 88 ft. lbs. (120 Nm) e Wheel speed sensor e Rear wheel and tighten the lug nuts to 63 ft. Ibs. (86 Nm) e Negative battery cable 5. Road test the vehicle and check for

proper operation.

WITH REAR DRUM BRAKES >The wheel bearings are contained within the wheel hub and must be replaced as an assembly.

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Negative battery cable e Rear wheel e Brake drum e Wheel speed sensor ->Do not use an impact gun to remove the hub retainer nut.

e Wheel hub retainer nut Remove the hub from the spindle with puller. install: Install or connect the following: e Hub and bearing assembly and tighten the hub retainer nut to 213 ft. lbs. (290 Nm) Brake drum Wheel speed sensor Rear wheel and tighten the lug nuts to 63 ft. Ibs. (86 Nm) Negative battery cable 5. Road test the vehicle and check for proper operation.

3. a hub To 4.

FORD MOTOR CO. 1998-01 Ford-Taurus * Mercury-Sable DRIVE TRAIN.................. 12-32 ENGINE REPAIR ................ 12-2 BUELSSY STEM. creisccc. 12-30 PRECAUTIONS.................. 12-2 STEERING AND

SUSPENSION................. 12-33

A 12-33 [AL BILE ha hee Poetee tees oleh fn12-33 ja68401)(aedhedeta

EUG! PR pen ati eee cot ee eth Removal & Installation............ Fuel System Pressure... ROHCVING sae eteee esas ae Fuel System Service

Precantionsmee

12-30 12-30 12-30 12-30

ete: 12-30

R Real Main Sealeca ee oew aun: 12-22 Removal & Installation............ 12-22

Rocker Arms/Shafts ......0.cccceccceen 12-9 Removal & Installation.............. 12-9

5

RPVHISURTELEI Yes ed ban aaa he al 12-32 Removal & Installation............ 12-32

ONOCKADSOICIA at neeeee 12-35 Removal & Installation............ 12-35 Slater MOL ee eens eee ee 12-18

RS: | EREGAULIONS tht, OOM IINING Etta otter IOP src ide Deore ACIUSUMER i sce te tamecas cee 12-3 RESON ede A oe LN ize eos2 -Groe take ManiOl irra aa sawi das 12-10 fyste NallOl ieee ec ceartres.

Removal & Installation............ 12-18 SULTS ban tereee ce eee en aaa 2233 Removal & Installation........... 12-33 u

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Removal & Installation............ 12-10

C Camshaft and Valve Lifters .......... J2-15 Removal & Installation............ 12-15 Bol ODIO teeta cess ate12-35

L © LOWer Ball JOints\Wetenwees ieee 12-35 Removal & Installation............ 12235% Lower Control ALM... esse 12-36

es eeeone PELE OVO Removal & Replacement......... 12-39

REPlaceMents stow reekss.ctoan: 12-36 Removal & Installation............ 12-36

PRET OVET A ete

Removal & Installation............ 12-35

12-6

evimcetiedd. Removal

& Installation.............. 12-6

E Engine ASS@MDIY vs. 12-3 Removal & Installation.............. ee)

a ar ete ire) eiltetens.

F de Sete12-30 ate ateenet

Removal & Installation............ 12-30 Ele fe CONalomicewtnateanrystncrcnng- 12-31 Removal & Installation............ 12-31

Control Arm Bushing

.

0

Timing Chain, Sprockets and

Front Cover and Seal... Removal & Installation........... Transaxle samen paces anne Removal & Installation...........

U

12-23 12-23 12-32 12-32

Upper Control AM ou... 12-35 Control Arm Bushing

Replacement............ Lee 12-36

one eee 12-19 OP aie oer

Removal And Installation........ 12-35

Removal & Installation............ 12-19 Rlbes tbe bats RA aE SRN ole 12-20 Removal & De aR 12-20

V Valve Lash MS Aha ia ath yoke Rete 12-18 Adjustment....... yy ara ae 12-18

omeDistonvand Ring zt. 312-29

Water PUMP sesso ital 12-4

12-29

Removal & Installation.............. 12-4 i GS:eusi kh. ee emearsas12-36 Wheel BOar

ENT

POSIIONIAG Saat eee Power Rack and Pinion

cnrite... 12-33 leering’ Gealteedn 12-33 Installation............ & Removal

Adjustment............ get 12-36 Removal & Installation............ 12-36

12-2

FORD MOTOR CO. TAURUS ¢ SABLE

en

PRECAUTIONS Before servicing any vehicle, please be sure to read all of the following precautions, which deal with personal safety, prevention of component damage, and important points to take into consideration when servicing a motor vehicle: e Never open, service or drain the radiator or cooling system when the engine is hot; serious burns can occur from the steam and hot coolant. e Observe all applicable safety precautions when working around fuel. Whenever Servicing the fuel system, always work in a well-ventilated area. Do not allow fuel spray or vapors to come in contact with a spark, open flame, or excessive heat (a hot drop light, for example). Keep a dry chemical fire extinguisher near the work area. Always keep fuel in a container specifically designed for fuel storage; also, always properly seal fuel containers to avoid the possibility of fire or explosion. Refer to the additional fuel system precautions later in this section. e Fuel injection systems often remain pressurized, even after the engine has been turned OFF. The fuel system pressure must SSe relieved before disconnecting any fuel lines. Failure to do so may result in fire fae)nd/or personal injury. e Brake fluid often contains polyglycol ethers and polyglycols. Avoid contact with the eyes and wash your hands thoroughly after handling brake fluid. If you do get brake fluid in your eyes, flush your eyes with clean, running water for 15 minutes. If

eye irritation persists, or if you have taken brake fluid internally, IMMEDIATELY seek medical assistance. e The EPA warns that prolonged contact with used engine oil may cause a number of skin disorders, including cancer. You should make every effort to minimize your exposure to used engine oil. Protective gloves should be worn when changing oil. Wash your hands and any other exposed skin areas aS soon as possible after exposure to used engine oil. Soap and water, or waterless hand cleaner should be used. All new vehicles are now equipped with an air bag system, often referred to as a Supplemental Restraint System (SRS) or Supplemental Inflatable Restraint (SIR) 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 repairs. e Always wear Safety goggles when working with, or around, the air bag system. When carrying a non-deployed air bag, be sure the bag and trim cover are pointed away from your body. When placing a nondeployed air bag on a work surface, always face the bag and trim cover upward, away from the surface. This will reduce the motion of the module if it is accidentally deployed. Refer to the additional air bag system precautions later in this section.

ENGINE -»Disconnecting the negative battery cable on some vehicles may interfere with the functions of the on board computer system. The computer may undergo a relearning process once the negative battery cable is reconnected.

Alternator

REMOVAL 3.0L (VIN U) Engine 1. Before servicing the vehicle, refer to the precautions at the beginning of this section. 2. Remove or disconnect the following:

:

e e e e e

REPAIR

| 3.0L (VIN S) Engine

Negative battery cable Accessory drive belt Alternator wiring connectors Alternator brace Alternator

Beate [ep aaa

[ US (Hi)

e Clean, high quality brake fluid from a sealed container is essential to the safe and proper operation of the brake system. You should always buy the correct type of brake fluid for your vehicle. If the brake fluid becomes contaminated, completely flush the system with new fluid. Never reuse any brake fluid. Any brake fluid that is removed from the system should be discarded. Also, do not allow any brake fluid to come in contact with a painted surface;-it will damage the paint. ¢ Never operate the engine without the proper amount and type of engine oil; doing so will result in severe engine damage. ¢ Timing belt maintenance is extremely important. Many models utilize an interference-type, non-freewheeling engine. If the timing belt breaks, the valves in the cylinder head may strike the pistons, causing potentially serious (also time-consuming and expensive) engine damage. Refer to the maintenance interval charts in the front of this manual for the recommended replacement interval for the timing belt, and to the timing belt section for belt replacement and inspection. e Disconnecting the negative battery cable on some vehicles may interfere with the functions of the on-board computer system(s) and may require the computer to undergo a relearning process once the negative battery cable is reconnected. e When servicing drum brakes, only disassemble and assemble one side at a time, leaving the remaining side intact for reference.

1998-99 MODELS

Dp cs

~~)

JETS af

=KO NAN hy aC ce

ia Se Nera

9346KG03

Alternator bracket-3.0L (VIN U) engine

1. Before servicing the vehicle, refer to the precautions at the beginning of this section. 2. Remove or disconnect the following: Negative battery cable Accessory drive belt Power steering line and heater hose bracket Upper alternator bolts Right front wheel Right splash shield Alternator splash shield Alternator electrical connectors Lower alternator bolt

FORD MOTOR CO. SS

3. Lower the right side of the subframe for clearance and remove the alternator.

2000-01 MODELS 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: ¢ Negative battery cable e Right front wheel e Right fender splash shield e Accessory drive belt The crankshaft pulley retainer has left-hand threads.

e Crankshaft pulley e Alternator harness connectors e Alternator

100 Nm {74 Ib-ft) 9346KG04

Remove the crankshaft pulley to provide clearance—2000-01 3.0L (VIN S) engine

3.4L (VIN N) Engine 1. Before servicing the vehicle, refer to the precautions at the beginning of this section. 2. Remove or disconnect the following: Negative battery cable Right cow! vent screen Right front wheel Right outer tie rod end Accessory drive belt Alternator electrical connectors Engine contro! sensor wiring Alternator

INSTALLATION

3.0L (VIN U) Engine ->Do not tighten the alternator pivot and bracket bolts until the accessory drive belt is installed.

1. Install or connect the following: e Alternator e Alternator brace. Tighten the bolts to 76-97 inch Ibs. (8-11 Nm), and

SSS

the nut to 15-22 ft. Ibs. (20-30 Nm). ¢ Alternator wiring connectors e Accessory drive belt 2. Tighten the alternator pivot bolt to 30-40 ft. Ibs. (40-55 Nm), and the bracket bolt to 15-22 ft. Ibs. (20-30 Nm). 3. Install the negative battery cable. Start the engine and check for proper operation.

TAURUS ¢ SABLE

12-3

SS

Ignition Timing ADJUSTMENT The base ignition timing is set at 10 degrees Before Top Dead Center (BTDC) and is not adjustable.

Engine Assembly

3.0L (VIN S) Engine

1998-99 MODELS 1. Install or connect the following: Alternator and tighten the bolts to 18 ft. Ibs. (25 Nm) Right subframe bolts and tighten to 66 ft. Ibs. (90 Nm) Alternator electrical connectors Alternator splash shield Right splash shield Right front wheel Power steering line and heater hose bracket Accessory drive belt Negative battery cable 2. Start the engine and check for proper operation.

2000-01 MODELS 1. Install or connect the following: e Alternator and tighten the fasteners to 18 ft. Ibs. (25 Nm) e Alternator harness connectors >The crankshaft pulley retainer has left-hand threads.

e Crankshaft pulley and tighten to 74 ft. Ips. (100 Nm) e Accessory drive belt e Right fender splash shield e Right front wheel e Negative battery cable 2. Start the engine and check for proper operation.

3.4L (VIN N) Engine 1. Install or connect the following: Alternator and tighten the bolts to 15-22 ft. Ibs. (20-30 Nm) Engine control sensor wiring Alternator electrical connectors Accessory drive belt Right outer tie rod end Right front wheel Right cowl vent screen Negative battery cable 2. Start the engine and check for proper operation.

REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions at the beginning of this section. 2. Disconnect the negative battery cable. 3. Drain the engine oil. 4. Drain the cooling system. 5. Recover the A/C refrigerant. 6. On the 3.0L (VIN S) engine, remove or disconnect the following: e Windshield wipers e Cowl extension e Emission vacuum control connector at the right side of the dash panel

7. On the 3.4L (VIN N) engine, remove or disconnect the following: e Battery and tray e Engine appearance cover e Cowl top extension e Windshield wiper module 8. For all vehicles, remove or disconnect the following: e Hood e Steering column pinch bolt e Mass Airflow (MAF) sensor connector e Intake Air Temperature (IAT) sensor e Air cleaner assembly e Idle Air Control (IAC) valve connector e Throttle Position (TP) sensor connector e Fuel lines e |ntake manifold vacuum hoses e Ground straps e Powertrain Control Module (PCM) connector Engine control sensor wiring har-

ness connectors from the bracket located at the top of the transaxle Evaporative emission canister purge valve connector Crankcase vent hose Accelerator cable Cruise control actuator

For complete service labor times, order Nichols’ Chilton Labor Guide

12-4

en

FORD MOTOR CO. TAURUS ¢ SABLE e Heated Oxygen (HO2S) sensors e Dual converter Y-pipe

9346KG06

Throttle and cruise control cables—3.0L

(VIN U) engine shown

9346KG07

Throttle Position (TP) sensor and Intake Air Control (IAC) valve connectors—3.0L (VIN U) engine shown

ROTUNDA POWERTRAIN LIFT 0914-00765

9346KG05

Support the powertrain when removing the subframe bolts

e Shift cable and lever Secondary air injection pump relay connector Main emission vacuum control connector near the fan shroud Radiator hoses Heater hoses Transaxle oil cooler lines Power steering return hose

Alternator wiring harness connectors A/C compressor lines A/C pressure cutoff switch, if equipped Front wheels Stabilizer bar links Lower ball joints Outer tie rod ends Halfshafts Radiator splash shield

e Power steering pressure switch connector ¢ Power steering pressure hose 9. Support the powertrain from below and remove the subframe bolts. 10. Raise the vehicle away from the powertrain. 11, Attach an engine hoist to the powertrain. 12. Remove the left, right, and rear powertrain support insulators and lift the powertrain away from the subframe. 13. Support the transaxle from below. 14. Remove or disconnect the following: e Starter motor e Torque converter e Transaxle flange bolts 15. Separate the engine from the transaxle. To install: 16. Install the engine to the transaxle. For 1999-01 3.0L (VIN S) engines, tighten the flange bolts to 25-33 ft. Ibs. (33-46 Nm). For all other engines, tighten the flange bolts to 30-44 ft. Ibs. (40-60 Nm). Tighten the torque converter nuts to 20-34 ft. lbs. (27-46 Nm). 17. Install or connect the following: ¢ Starter motor and tighten the fasteners to 21 ft. Ibs. (29 Nm) e Powertrain support insulators. Tighten the bracket bolts to 65 ft. lbs. (88 Nm) and the subframe bolts to 90 ft. Ibs. (122 Nm). 18. Lower the vehicle on to the powertrain assembly. Use 2 pieces of % inch outside diameter pipe in the alignment holes behind the front subframe mounts to align the subframe to the body. Tighten the subframe mounting bolts to 57—76 ft. Ibs. (77-103 Nm), 19. Install or connect the following: Power steering pressure hose e Power steering pressure switch connector Dual converter Y-pipe HO2S sensors Radiator splash shield Halfshafts and tighten the hub retainer nuts to 170-202 ft. Ibs. (230-275 Nm) Outer tie rod ends and tighten the nuts to 35—46 ft. Ibs. (47-63 Nm) Lower ball joints and tighten the nuts to 50-68 ft. Ibs. (68-92 Nm) Stabilizer bar links and tighten the

nuts to 30-40 ft. Ibs. (40-55 Nm) Front wheels A/C pressure cutoff switch, if equipped

A/C compressor lines Alternator wiring harness connectors Power steering return hose Transaxle oil cooler lines Heater hoses ‘Radiator hoses Main emission vacuum control connector near the fan shroud Secondary air injection pump relay connector Shift cable and lever Cruise contro! actuator Accelerator cable Crankcase vent hose Evaporative emission canister purge valve connector Engine control sensor wiring harness connectors from the bracket located at the top of the transaxle PCM connector Ground straps Intake manifold vacuum hoses Fuel lines IAC valve connector TP sensor connector Air cleaner assembly IAT sensor MAF sensor connector Steering column pinch bolt Hood 20. On the 3.0L (VIN S) engine, install or connect the following: e Windshield wipers e Cowl extension e Emission vacuum control connector at the right side of the dash panel 21. On the 3.4L (VIN N) engine, install or connect the following: e Battery and tray e Engine appearance cover e Cowl top extension e Windshield wiper module 22. Fill the cooling system, fill the crankcase and recharge the A/C system. 23. Connect the negative battery cable. 24. Start the engine. Check for leaks and proper operation. e>\Nhenever the vehicle’s subframe is

removed or lowered, the wheel alignment should be checked.

Water Pump REMOVAL & INSTALLATION 3.0L (VIN U) Engine 1. Before servicing the vehicle, refer to the precautions at the beginning of this section. 2. Drain the cooling system.

.

FORD MOTOR CO. TAURUS ¢ SABLE 3. Remove or disconnect the following: e Negative battery cable ¢ Accessory drive belt and tensioner ¢ Water pump pulley ¢ Heater hose e Engine control sensor wiring ¢ Water pump To install:

4. Install the water pump. Tighten bolts 1,2, 3, 4,5, 6, 7,8, 9 and 15 to 15-22 ft. lbs. (20-30 Nm). Tighten bolts 10, 11, 12, 13 and 14 to 72-106 inch Ibs. (8-12 Nm). Refer to the accompanying illustration for the bolt locations. 9. Install or connect the following:

e Negative battery cable 6. Fill the cooling system and check for leaks.

3.0L (VIN S) Engine 1. Before servicing the vehicle, refer to the precautions at the beginning of this section. 2. Drain the cooling system. 3. Remove or disconnect the following: e Splash shield ¢ Lower heater hose

e Engine control sensor wiring ¢ Heater hose ¢ Water pump pulley and tighten the bolts to 15-22 ft. Ibs. (20-30 Nm) ¢ Accessory drive belt and tensioner

>The water pump bolts are of different lengths and must be installed in the correct locations.

Torque

Fasteners

Specifications

a Fastener Hole

And

Size

Fastener

No.

Nm

Lb-Ft

Applicatio:

1A

[=x

2A

MS

1.

x

x

1.

43.5

Sse

F/C

W/P

TO

&

BLOCK

F/C

0-30

dip=22

TO

0-30

15-

TO

20-30

5-22

BLOCK

3A

Me

x

1.25

x

W/P

104.3

&

F/C

BLOCK

4A

MB

x

1.25

x

71-3

5A

MS5¢

Be25

sc

74.3

F/C

W/P

TO

0-30

15-22

TO

0-30

15-22

TO

0-30

15>

TO

0-30

15-2

& F/C TO

0-30

1

&

BLOCK

F/C

BLOCK

6A

MG

xc

1-25)

72S

W/P

&

F/C

BLOCK

7A

|

M8

|

= 8A

x

|

1.

x

W/P

104.

| )

x

sae

W/P

104

M8

x

OB

M6

x

1 x

28.5

W/P

11B

13B

1.25

52

F/C

15A

TO

BLOCK

TO

F/C

20-30

15-2

8-12

71-106

(lb-in)

M6

x

1 x

28

W/P

TO

F/C

8-1

71-106

(ib-in)

|

M6

x

1 x

28.5

W/P

TO

F/C

8-1

71-106

(1b-in)

|

M6

xt

28)

W/P

TO

F

8-1

M6

x 1 x 28

W/P

TO

F/C

8-12

T 148

= 15-

BLOCK

9A

12B

F/C

BLOCK

=

M8 x

|

&

M8

x

1.25

x

71.3

N/

E/C

TC

0-30

71-106

| |

71-106

(1b-in)

3

;

(1b-in)

15=22

BLOCK

w/P-Water F/C-Engine

Pump Front

12-5

Cover

9300KG01

engine Exploded view of the water pump and timing front cover bolt locations—3.0L (VIN U)

Please visit our web site at www.chiltonsonline.com

12-6

FORD MOTOR CO. TAURUS @ SABLE

To install: 4. Install or connect the following: e Water pump Connector hose Water pump mounting nuts and tighten them to 15-22 ft. Ibs. (20-30 Nm) A/C compressor brace, if equipped, and tighten the nuts to 15-22 ft. lbs. (20-30 Nm) Thermostat housing Radiator bypass hose assembly Transaxle 10 pin connector Engine vent hose Upper radiator hose Water pump belt Battery and tray Air cleaner assembly Radiator upper front tube bolt Radiator lower tube bolt Lower heater hose Splash shield

NUT TIGHTEN TO 20-30 N-m (15-22 LB-FT) 4REQ'D

9346KG10

Water pump mounting—3.0L (VIN S) engine

Radiator lower tube bolt Radiator upper front tube bolt Air cleaner assembly Battery and tray Water pump belt Upper radiator hose Engine vent hose Transaxle 10 pin connector Radiator bypass hose assembly Thermostat housing A/C compressor brace, if equipped Water pump mounting nuts Connector hose Water pump

5. Fill the cooling system.

6. Start the engine and check for leaks. 3.4L (VIN N) Engine 1. Before servicing the vehicle, refer to the precautions at the beginning of this section. 2. Drain the cooling system.

3. Remove or disconnect the following: Engine appearance cover Battery and tray Water pump drive belt Coolant hoses Thermostat e Water pump | To install: 4. If replacing the water pump, transfer the idler pulley and tighten the bolt to 89-141 inch Ibs. (10-16 Nm). 5. Install or connect the following: e Water pump. Tighten the 2 water inlet bolts to 71-106 inch Ibs. (8-12 Nm) and the 2 remaining bolts to 14-20 ft. Ibs. (18-28 Nm). ¢ Thermostat and tighten the bolts to 71-106 inch Ibs. (8-12 Nm) Coolant hoses Water pump drive belt Battery and tray Engine appearance cover 6. Fill the cooling system and check for leaks.

Cylinder Head REMOVAL & INSTALLATION 3.0L (VIN U) Engine

12

Oil Coolerto Water Return Hose

Return Hose

13

Drive Belt

Water Pump to Throttle Body Supply Hose

14

Bolt

15

Belt Idler Pulley

Bolt (2 Req'd)

16

Water Pump Drive Pulley

Water Pump

17

Collar

Water Thermostat

18

O-Ring

Water Outlet Hose Throttle Body to Water Pump

Oil Cooler Return Tube et Water Hose Connection Bolt (2 Req'd) =ooo WN @ 8 [email protected] Heater Core to Water Pump Return Hose

Stud

19 20

A B

Pump

Water Inlet Hose Bolt

Tighten to 18-28 N-m (14-20 Lb-Ft) Tighten to 10-16 N.m (89-141

Lb-In) C

Tighten to 8-12 N-m (71-106 Lb-In)

7922KG03

Exploded view of the water pump and related components—3.4L (VIN N) engine

1. Before servicing the vehicle, refer to the precautions at the beginning of this section. 2. Drain the cooling system. 3. Set the No. 1 cylinder to Top Dead Center (TDC) of the compression stroke. 4. Remove or disconnect the following: Negative battery cable Air cleaner outlet hose Vacuum hoses from the intake manifold Exhaust Gas Recirculation (EGR) valve EGR transducer EGR vacuum regulator solenoid Intake Air Temperature (IAT) sensor connector Throttle Position (TP) sensor connector Intake Air Control (IAC) valve connector Camshaft Position (CMP) sensor and housing Engine Coolant Temperature (ECT) sensor connector Accelerator cable Cruise control cable Fuel lines Upper intake manifold

rerraURUsesaate 12-7 Fuel injector wiring harness Coolant hoses Ignition coil and bracket Spark plug wires Accessory drive belt and tensioner Alternator Power steering pump Oil dipstick tube Heater supply tube brackets Valve covers Rocker arms and pushrods. Keep the rocker arms and pushrods in order for installation. Lower intake manifold Spark plugs Exhaust manifolds e Cylinder heads To install: >The cylinder head bolts are a torqueto-yield design and cannot be reused.

5. Install the cylinder heads with new gaskets. 6. On 1998 models, tighten the bolts in sequence as follows: a. Step 1: 53-66 ft. Ibs. (70-90 Nm). b. Step 2: Loosen the bolts 1complete turn. c. Step 3: Tighten the bolts to 34—40 ft. Ibs. (45-55 Nm). d. Step 4: Tighten the bolts to 63-73 ft. Ibs. (85-99 Nm).

7. On 1999-01 models, tighten the bolts in sequence as follows: a. Step 1: 36-39 ft. Ibs. (47-53 Nm). b. Step 2: Loosen the bolts 1complete turn. c. Step 3: Tighten the bolts to 20-24 ft. Ibs. (27-33 Nm). d. Step 4: Tighten the bolts 85-95 degrees. e. Step 5: Tighten the bolts 85-95 degrees. 8. Install or connect the following: Exhaust manifolds Spark plugs Lower intake manifold Rocker arms and pushrods in their original locations. Tighten the rocker arm bolts to 24 ft. Ibs. (32 Nm). Tighten each rocker arm bolt with the valve closed and the lifter on the camshaft lobe base circle. Rotate the crankshaft as necessary. Valve covers Heater supply tube brackets Oil dipstick tube and tighten the nut to 13 ft. Ibs. (18 Nm) Power steering pump Alternator Accessory drive belt and tensioner Spark plug wires Ignition coil and bracket. Tighten the fasteners to 30-39 ft. Ibs. (40-55 Nm). e Coolant hoses e Fuel injector wiring harness e Upper intake manifold

Fuel lines Cruise control cable Accelerator cable ECT sensor connector CMP sensor and housing IAC valve connector TP sensor connector IAT sensor connector EGR vacuum regulator solenoid EGR transducer EGR valve Vacuum hoses from the intake manifold Air cleaner outlet hose Negative battery cable 9. Fill the cooling system and check for leaks.

3.0L (VIN S$) Engine 1. Before servicing the vehicle, refer to the precautions at the beginning of this section. 2. Remove the engine from the vehicle and mount it on an engine stand. 3. Remove or disconnect the following: Upper intake manifold Lower intake manifold Exhaust manifolds Valve covers Radiator hose tube and bracket Accessory drive belt Crankcase ventilation tube Heater hose bypass tube Power steering pump

A/C compressor and bracket Water pump The crankshaft accessory drive pulley shaft has left-hand threads. Rotate the pulley shaft clockwise to remove.

e Crankshaft pulley e Oil pan e Front cover 7922KG06

@ REMOVE BOLTS IN SEQUENCE SHOWN

Cylinder head torque sequence—3.0L (VIN

U) engine

OUTBOARD

CYLINDER HEAD TO BLOCK DOWEL MUST SE BOTTOMED OUT

|

FRONT OF ENGINE

INBOARD 7922KG05

Install the cylinder head gasket with the “UP” designation on gasket facing the cylinder head—3.0L (VIN U) engines

TIGHTENING SEQUENCE — VALVE COVER

9300KG04

9300KG08

Valve cover tightening sequence—3.0L

(VIN U) engine

RH SHOWN LH SIMILAR

Cylinder head bolt removal sequence-right side head shown, left side similar—3.0L (VIN S) engine

Timing belt service is covered in Section 3 of this manual

12-8 Thins sabe (ne 2 LOCATION OF STUDS

%* LOCATION OF STUDS @ REMOVE BOLTS/STUDS IN SEQUENCE SHOWN

@ TIGHTEN BOLTS/STUDS IN SEQUENCE SHOWN

e Exhaust manifolds e Lower intake manifold ¢ Upper intake manifold e Engine assembly into the vehicle. 7. Run the engine and check for leaks.

3.4L (VIN N) Engine

LH VALVE COVER

RH VALVE COVER

9300KG05

9300KG03

Left side valve cover bolt tightening sequence—3.0L (VIN S) engine

Right side valve cover bolt removal sequence—3.0L (VIN S) engine

@ REMOVE BOLTS/STUDS IN SEQUENCE SHOWN %* STUD LOCATION

2% LOCATION OF STUDS e TIGHTEN BOLTS/STUDS IN SEQUENCE SHOWN

Ee

9300KG02

9300KG07

Left side valve cover bolt removal

Right side valve cover bolt tightening

sequence—3.0L (VIN S) engine

sequence—3.0L (VIN S) engine

5. Install new gaskets and install the cylinder heads. Use new bolts and tighten as follows: a. Step 1: Tighten the bolts in sequence to 28-31 ft. Ibs. (37-43 Nm).

b. Step 2: Plus 85-95 degrees. c. Step 3: Loosen the bolts in reverse RH SHOWN LH SIMILAR

7 et

ek

: 7922KG07

Cylinder head torque sequence—3.0L (VIN

S) engine

e Timing chains e Camshafts e Valve lash adjusters ->Keep the lash adjusters in order for installation.

4. Remove the cylinder head bolts from the cylinder heads in sequence and remove the cylinder heads. To install: >The cylinder head bolts are a torqueto-yield design and cannot be reused. e>Left and right cylinder head gaskets are not interchangeable.

Sequence 1 full turn. d. Step 4: Tighten the bolts in sequence to 28-31 ft. Ibs. (37-43 Nm). e. Step 5: Tighten the bolts in sequence 85-95 degrees. f. Step 6: Tighten the bolts in sequence 85-95 degrees. 6. Install or connect the following: e Valve lash adjusters in their original locations

Camshafts Timing chains Front cover Oil pan Crankshaft pulley Water pump A/C compressor and bracket Power steering pump Heater hose bypass tube Crankcase ventilation tube Accessory drive belt Radiator hose tube and bracket Valve covers

1. Before servicing the vehicle, refer to the precautions at the beginning of this section. 2. Remove the engine from the vehicle and mount it on an engine stand. 3. Set the crankshaft at Top Dead Center of the compression stroke for the No. 1 cylinder. 4. Remove or disconnect the following: Accessory drive belts A/C compressor Alternator Water pump drive pulley Oil dipstick tube Intake vacuum lines Exhaust Gas Recirculation (EGR) tube Throttle body Surge tank and supports Left and right intake manifolds Engine control sensor wiring harness and brackets Secondary air injection valve, tubes and brackets Exhaust manifolds Intake Manifold Runner Control (IMRC) cable and bracket Lower intake manifold Water crossover pipe

Water pump Left and right valve covers Spark plugs Power steering pump Crankshaft pulley Camshaft Position (CMP) sensor Crankshaft Position (CKP) sensor Oil pan Accessory belt idler pulleys Front cover CKP pulse ring Timing chain Camshafts Cylinder heads To install: e*The cylinder head bolts are a torqueto-yield design and cannot be reused. e>Left and right cylinder head gaskets are not interchangeable.

5. Install new gaskets and install the cylinder heads. Use new bolts and tighten in sequence as follows: a. Step 1: 20-23 ft. Ibs. (27-32 Nm). b. Step 2: Plus 85-95 degrees.

FORD MOTOR CO. TAURUS ¢ SABLE

12-9

Removal Sequence

RH CYLINDER HEAD

FRONT OF ENGINE

ee REMOVE BOLTS IN SEQUENCE SHOWN

|

LH CYLINDER HEAD 9300KG06

Cylinder head bolt removal sequence—3.4L (VIN N) engine

e A/C compressor e Accessory drive belts e Engine assembly into the vehicle. 7. Run the engine and check for leaks.

Rocker Arms/Shafts REMOVAL & INSTALLATION

3.0L (VIN U) Engine

ooo

RH CYLINDER HEAD

FRONT OF ENGINE LH CYLINDER HEAD

Q@rciren BOLTS IN SEQUENCE SHOWN 7922KG08

Cylinder head torque sequence—3.4L (VIN N) engine

6. Install or connect the following: Camshafts Timing chain CKP pulse ring Front cover Accessory belt idler pulleys Oil pan CKP sensor CMP sensor Crankshaft pulley Power steering pump Spark plugs Left and right valve covers Water pump Water crossover pipe

Lower intake manifold IMRC cable and bracket Exhaust manifolds e eee Secondary air injection valve, tubes, and brackets Engine control sensor wiring harness and brackets Left and right intake manifolds Surge tank and supports Throttle body EGR tube Intake vacuum lines Oil dipstick tube Water pump drive pulley @ e@ ee e Alternator

1. Before servicing the vehicle, refer to the precautions at the beginning of this section. 2. Remove or disconnect the following: e Negative battery cable e Upper intake manifold e Valve covers e Rocker arms e>Keep the rocker arms in order for installation. To install:

>The rocker arm bolts are tightened with the valves closed. Rotate the crankshaft as necessary to position the lifter on the base circle of the camshaft lobe before tightening the corresponding rocker arm bolt.

Heater Core replacement is covered in Section 2 of this manual

12-10 Thins’ sabes ¢ Coolant hoses e Upper alternator bracket e Engine control sensor wiring harness and bracket e Upper intake manifold

9346KG01

Valve spring compressor 303-473—3.0L

(VIN S) engine

To install: 6. Compress the valve spring and install the rocker arm. Repeat for each arm to be installed. 7. Install or connect the following: e Valve covers e Upper intake manifold e Negative battery cable 8. Start the engine and check for proper operation.

Bolt (12 Req'd} Rocker Arm Seat (12 Req'd) Rocker Arm (12 Req'd)

Push Rod (12 Req'd)

Cylinder Head (2 Req'd) 2.15-4.69 Oo = nbrwnhrnd

mm (0,085-0. 185

inch) >

Tighten in Two Steps: 7-15 Nem (5-11 Lb-Ft) 26-38 N-m (19-28 Lb-Ft) 7922KG22

Exploded view of the rocker arms and related components—3.0L (VIN U)

3. Install the rocker arms. The rocker arm bolts are tightened in two steps as follows: a. Step 1: 96 inch Ibs. (11 Nm). b. Step 2: 24 ft. Ibs. (82 Nm). 4. Install or connect the following: e Valve covers e Upper intake manifold e Negative battery cable 5. Start the engine and check for proper operation.

3.0L (VIN S) Engine 1. Before servicing the vehicle, refer to the precautions at the beginning of this section. 2. Remove or disconnect the following: e Negative battery cable e Upper intake manifold e Valve covers 3. Rotate the crankshaft so that the camshaft lobe on the valve to be serviced is pointing directly away from the valve. 4. Install special tool Valve Spring Compressor 303-473. 5. Compress the valve spring and remove the rocker arm. Repeat for each arm to be removed. e>if the rocker arms are to be reused, ensure that they are installed in the same position that they were removed from.

3.4L (VIN N) Engine The 3.4L (VIN N) engine does not have rocker arms. The camshaft lobes work directly on the valves. Intake Manifold

REMOVAL & INSTALLATION 3.0L (VIN U) Engine 1. Before servicing the vehicle, refer to the precautions at the beginning of this section. 2. Drain the cooling system. 3. Remove or disconnect the following: Negative battery cable Air cleaner and outlet tube Cruise control cable Accelerator cable and bracket Fuel lines Vacuum lines Exhaust Gas Recirculation (EGR) valve EGR transducer EGR vacuum solenoid Throttle Position (TP) sensor connector Intake Air Control (IAC) valve connector Camshaft Position (CMP) sensor connector ¢ Engine Coolant Temperature (ECT) sensor connector ¢ Coolant temperature indicator sender connector

->Note the position of the CMP sensor electrical connector. Installation requires that the connector be located in the same position. ->Before removing the CMP sensor, position the engine at Top Dead Center (TDC) of the No. 1 cylinder compression stroke.

4. Remove or disconnect the following: CMP sensor and housing Spark plug wires Ignition coil Valve covers @# eeeee No. 3 cylinder intake valve rocker arm and pushrod Lower intake manifold To install: 5. Install the lower intake manifold. Use new gaskets and tighten the bolts in sequence as follows: a. Step 1: 15-22 ft. Ibs. (20-30 Nm). b. Step 2: 19-24 ft. Ibs. (26-32 Nm). e>A special Synchro Positioning tool T95T-12200-A must be used when installing the CMP sensor housing.

6. Attach the Synchro Position tool T95T-12200-A as follows: a. Engage the CMP sensor housing vane into the radial slot of the tool. b. Rotate the tool on the CMP sensor housing until the tool boss engages the notch in the CMP sensor housing. c. Install the CMP sensor housing so the drive gear engagement occurs when the arrow on the locator tool is pointed about 75 degrees counterclockwise from the rear face of the cylinder block. This step will locate the CMP sensor electrical connector in the same position as was noted on removal. d. Install the hold-down clamp and tighten the bolt to 14-22 ft. Ibs. (19-30 Nm). 7. Remove the Synchro Position tool. 8. Install or connect the following: e CMP sensor No. 3 cylinder intake valve rocker arm and pushrod Valve covers Ignition coil and tighten the bolts to

30-40 ft. Ibs. (40-55 Nm) Spark plug wires e Upper intake manifold and tighten the bolts to 15-22 ft. Ibs. (20-30 Nm)

~~

aes aca

Fi

:

cs

SR

: Sf

: " ee %

¢ Engine control sensor wiring harness and bracket e Upper alternator bracket e Coolant hoses ¢ Coolant temperature indicator sender connector ECT sensor connector CMP sensor connector IAC valve connector TP sensor connector EGR vacuum solenoid EGR transducer EGR valve Vacuum lines Fuel lines Accelerator cable and bracket Cruise control cable Air cleaner and outlet tube Negative battery cable 9. Fill the cooling system. 10. Start the engine and check for leaks and proper operation.

q Sh

ih

\RSE

4

3.0L (VIN S) Engine 1. Before servicing the vehicle, refer to the precautions at the beginning of this section. 2. Disconnect or remove: e Negative battery cable e Windshield wipers and cowl top inner panels e Cruise control cable e Accelerator cable and bracket e Vacuum hoses

ENGINE

9300KG09

Exploded view of the upper intake manifold mounting—3.0L (VIN U) engine

AG eas, \] ) ED al mcarela)\m @ ae =me — = =

yee @ REMOVE IN SEQUENCE SHOWN LOWER INTAKE MANIFOLD

ayy ctiemc be

9300KG11

7922KG17

Intake manifold torque sequence—3.0L (VIN U) engine

Lower intake manifold bolt removal

Brake service is covered in Section 4 of this manual

12-1

FORD MOTOR CO. TAURUS ¢ SABLE

e Intake Air Control (IAC) valve supply hose e IAC connector e Throttle Position (TP) sensor connector

7 ‘© -)

(amoe SO) b wr) ct

LOWER INTAKE MANIFOLD 7922KG16

Lower intake manifold torque sequence— 3.0L (VIN S) engine

e Cruise control cable ¢ Windshield wipers and cowl top inner panels ¢ Negative battery cable 7. Run the engine and check for leaks and proper engine operation.

Exhaust Gas Recirculation (EGR) valve Secondary air injection valve bracket Upper intake manifold Fuel lines Fuel injector wiring harness Intake Manifold Runner Control (IMRC) cable Spark plug wires Lower intake manifold To install: 3. Install the lower intake manifold. Use new gaskets and tighten the bolts in sequence to 71-106 inch Ibs. (8-12 Nm). 4. Install or connect the following: e Spark plug wires e IMRC cable e Fuel injector wiring harness e Fuel lines 5. Install the upper intake manifold. Use new gaskets and tighten the bolts in sequence to 71-106 inch Ibs. (8-12 Nm). 6. Install or connect the following: e Secondary air injection valve bracket e EGR valve e TP sensor connector e IAC connector e IAC valve supply hose e Vacuum hoses ¢ Accelerator cable and bracket

x

3.4L (VIN N) Engine 1. Before servicing the vehicle, refer to the precautions at the beginning of this section. 2. Remove or disconnect the following: Negative battery cable Engine appearance cover Right cowl vent screen Throttle body Vacuum lines Exhaust Gas Recirculation (EGR) valve EGR transducer and bracket Surge tank supports Surge tank Left and right intake manifold runners Fuel lines Intake Manifold Runner Control (IMRC) cable e Engine control sensor wiring harness e Lower intake manifold To install: 3. Install or connect the following: ¢ Lower intake manifold. Use new gaskets and tighten the bolts to 14-20 ft. Ibs. (18-28 Nm).

tS

>

Ly =

Lied

i Description

| 1 |Bolt (2 Req'd)

fore

RR

4

Meera

Transducer Mounting Bracket

| 33 | Stud Bolt (2 Req'd)

ren

2)TIGHTEN BOLTS IN SEQUENCE SHOWN

Bolt (2 Req'd)

Intake Manifold Support (2 Req'd) EGR Valve to Exhaust Manifold Tube

LOCATING PIN TWO PLACES PER GASKET

Tighten to 18-28 N-m (14-20 Lb-Ft)

Description

Tighten to 25-35 N-m (19-25 Lb-Ft) 3

isolator (3 Req'd)

4

isolator (3 Req'd)

5

Upper Intake Manifold

6 | Gasket (2 Req'd)

FRONT OF ENGINE

Lower Intake Manifold

Tighten to 8-12 N.m (71-106 Lb-in)

9300KG610

9300KG12

Upper intake manifold torque sequence— 3.0L (VIN S) engine

Exploded view of transducer mounting bracket and intake manifold Support with torque specification—3.4L (VIN N) engine

eNrAURUS saate 12-13 Lower intake manifold

Exhaust Manifold

REMOVAL & INSTALLATION 3.0L (VIN U) Engine

RIGHT SIDE

7922KG19

Exploded view of the lower intake manifold mounting—3.4L (VIN N) engine

Engine control sensor wiring harness IMRC cable Fuel lines Left and right intake manifold runners. Tighten the bolts to 14-20 ft. lbs. (18-28 Nm). Surge tank Surge tank supports and tighten the fasteners to 14-20 ft. Ibs. (18-28 Nm) EGR transducer and bracket EGR valve Vacuum lines Throttle body Right cowl vent screen Engine appearance cover Negative battery cable 4. Run the engine and check for leaks and proper engine operation.

1. Before servicing the vehicle, refer to the precautions at the beginning of this section. _ 2. Remove or disconnect the following: Negative battery cable Cowl vent screen and extension Heated Oxygen (HO2S) sensor connector Exhaust Gas Recirculation (EGR) tube Exhaust manifold heat shield Catalytic converter Exhaust manifold To install: 3. Install the exhaust manifold with a new gasket. Tighten the bolts in sequence as follows: a. Step 1: 89 inch Ibs. (10 Nm) b. Step 2: 16 ft. Ibs. (22 Nm) 4. Install or connect the following: e Catalytic converter and tighten the bolts to 30 ft. Ibs. (40 Nm) e Exhaust manifold heat shield and tighten the bolts to 89 inch Ibs. (10 Nm)

9346KG18

Right side Heated Oxygen (HO2S) sensor connector—3.0L (VIN U) engine

9346KG19

Right exhaust manifold torque sequence—

3.0L (VIN U) engine

e EGR tube e HOS sensor connector e Cowl vent screen and extension e Negative battery cable 5. Start the engine and check for leaks.

LEFT SIDE 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Negative battery cable e Heated Oxygen (HO2S) sensor connector Oil dipstick tube Power steering pressure line Secondary air injection tube, if equipped

Upper intake manifold

9346KG20 7922KG18

Exploded view of the upper intake manifold mounting—3.4L (VIN N) engine

Left side Heated Oxygen (HO2S) sensor connector—3.0L (VIN U) engine

For complete Engine Mechanical specifications, see Section 1 of this manual

i210 see 4. Run the engine and check for exhaust leaks and proper operation.

3.4L (VIN N) Engine 1. Before servicing the vehicle, refer to the precautions at the beginning of this section. 2. Remove or disconnect the following: e Negative battery cable

if the rocker arms, pushrods or lifters are to be reused, they must be installed in the same positions they were removed from.

1. Before servicing the vehicle, refer to the precautions at the beginning of this section. 2. Remove the engine from the vehicle and mount it on an engine stand. 3. Remove or disconnect the following: e Valve covers Rocker arms and pushrods Accessory drive belt and tensioner Alternator and brackets Intake manifold Valve lifter guide plate Valve lifters Crankshaft damper

CYLINDER HEAD 6049

CYLINDER HEAD 6049 BOLT 12 REQ’'D TIGHTEN IN

A: 7-15 Nem (5-11 LB+LB

B: 26-38 N-m (19-28

eg saalARM

CYLINDER HEAD 6049

CYLINDER HEAD 6049 NO. 5 EXH

2€xH NO.

Q'D CAMSHAFT POSITION A RIGHT SIDE

ROCKER SEA MUS:

LEFT SIDE

2.15-4.69mm (0.085-0.185 INCH) WITH VALVE TAPPET FULLY COLLAPSED ON BASE CIRCLE OF CAMSHAFT LOBE AFTER ASSEMBLY

Oil pan Front cover Timing chain and gears Camshaft thrust plate

Camshaft

7922KG630

Tighten the rocker arm nuts according to the position of the camshaft—3.0L (VIN U) engine

For Accessory Drive Belt illustrations, see Section 1 of this manual

12-1

FORD MOTOR CO. TAURUS ¢ SABLE

CAUTION: CAMSHAFTS MUST BE IN TIME WITH

?

CRANKSHAFT PRIOR

Intake

AR

Camshatt

allow the camshaft to raise off the cylinder head evenly. 5. Remove the journal caps and the camshafts.

NOTE: VALVE TAPPET MUST BE PUMPED UP PRIOR TO INSTALLATION

e»>|f the hydraulic lifters are to be reused, they must be kept in order so that they can be installed in their original positions.

Thrust Cap

6. Remove the hydraulic lifters. To install: 7. Rotate the crankshaft so the keyway is at the 11 o'clock position for installation

CAUTION: ROTATE CRANKSHAFT KEYWAY 1 O'CLOCK POSITION PRIOR Os

AM: CAMSHAFT JOURNAL THRUST CAI 7922KG10

of the camshafts.

Exploded view of camshaft mounting—3.0L (VIN S) engine RH CYLINDERae HEAD

LH CYLINDER HEAD 9

THRUST CAPS

THRUST CAPS — ea =

1

10

2

15

7

16

8

13

5

14

6

11 12

3 4 4 ps

>The camshaft journal caps and cylinder heads are numbered to ensure that they are assembled in their original positions. Do not install the camshaft journal thrust caps until the rocker arms and timing chains have been installed and the camshaft journal caps are tightened into position.

ENGINE

MARK HERE

MARK HERE

MARK HERE 7922KG31

7 8

7 8

RH

1

hekoee

1

2

2

3

3

4

4

6

FRONT OF ENGINE

MARK HERE

6

MARK HERE 7922KG32

Camshaft journal bolt tightening sequence—3.0L (VIN S) engine

2. Remove the engine from the vehicle and mount it on an engine stand. 3. Remove or disconnect the following: ¢ Upper intake manifold e Valve covers e*|f the rocker arms are to be reused, they must be kept in order so that they can be installed in their original positions.

¢ ¢ ¢ ¢ e

Rocker arms Accessory drive belt Power steering pump Water pump A/C compressor and bracket

:

8. Install or connect the following: e Hydraulic lifters in their original positions e Camshafts with the timing marks (marked RFF) on the back of the camshaft sprockets aligned

e>The crankshaft accessory drive pulley shaft has left-hand threads. Rotate the pulley shaft clockwise to remove.

¢ Crankshaft pulley e Oil pan ¢ Front cover e Timing chains e*The camshaft journal thrust caps must be removed first, before loosening the remaining camshaft journal cap bolts, to ensure that the camshaft journal thrust caps are not damaged.

4. Loosen the camshaft journal cap bolts in sequence and in several passes to

¢ Camshaft journal caps in their original positions e Timing chains 9. Tighten the camshaft journal cap bolts, in sequence, to 71-106 inch Ibs. (8-12 Nm). 10. Install the thrust caps and tighten the bolts to 71-106 inch Ibs. (8-12 Nm). 11. Install or connect the following: Front cover Oil pan Crankshaft pulley A/C compressor and bracket Water pump Power steering pump Accessory drive belt Rocker arms in their original positions Valve covers Upper intake manifold Engine assembly into the vehicle. 12. 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 section. 2. Remove the engine from the vehicle and mount it on an engine stand. 3. Set the crankshaft at Top Dead Cen-

FORD MOTOR CO. TAURUS ¢ SABLE 1 2-1 T a E. CS prlete= eBesoe 1

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Engine control sensor wiring harness and brackets Intake Manifold Runner Control (IMRC) cable and bracket Left and right valve covers Power steering pump Crankshaft pulley Camshaft Position (CMP) sensor Crankshaft Position (CKP) sensor Oil pan Accessory belt idler pulleys Front cover CKP pulse ring Timing chain Left and right camshaft chain tensioners

4

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LH CYLINDER HEAD

RH CYLINDER HEAD 7922KG33

Camshaft journal cap bolt removal sequence—3.4L (VIN N) engine

~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. 5. Loosen the camshaft journal cap bolts in sequence, in several passes, to allow the camshaft to raise off the cylinder head evenly. 6. Remove the journal caps and the camshafts. >The camshaft journal caps and cylinder heads are numbered to ensure that they are assembled in their original positions.

e>lf the hydraulic lifters are to be reused, they must be kept in order so that they can be installed in their original positions.

» Part Number

Description

Description

Camshaft Journal Cap (Part

Camshaft , RH Exhaust

of 6049)(8 Req'd)

Camshaft Journal Thrust Cap (Part of 6049) (2 Req'd)

Hex Bolt with Washer (20 Req'd) Camshatt , RH Intake Cylinder Block , RH

Tighten in sequence in two

steps 7-12 N-m (62-106 Lb-In) and 16-21N-m (12-15 Lb-F1)

9306KG01

Camshaft installation—3.4L (VIN N) engine—Right head shown, left head similar

ter (TDC) of the compression stroke for the No. 1 cylinder. 4. Remove or disconnect the following: e Accessory drive belts e A/C compressor e Alternator

Water pump drive pulley Intake vacuum lines Exhaust Gas Recirculation (EGR) tube Throttle body Surge tank and supports Left and right intake manifolds

7. Remove the hydraulic lifters. To install: 8. Rotate the crankshaft so the keyway is aligned with the mark on the oil pump at the 11 o'clock position for installation of the camshafts. 9. Install the hydraulic lifters in their Original positions. 10. Install the camshafts. Match the camshaft and chain timing marks as shown, and install the camshafts with the timing marks facing up. 11. Apply a 0.08-0.11 inch (2-3mm) bead of silicone gasket and sealant to the left side cylinder head intake camshaft journal thrust cap. 12. Install the camshaft journal caps in their original positions. 13. Tighten the camshaft journal cap bolts in sequence as follows: a. Step 1: 62-106 inch lbs. (7-12 Nm). b. Step 2: 12-15 ft. Ibs. (16-21 Nm). 14. Install a new camshaft seal with a

For Tire, Wheel and Ball Joint specifications, see Section 1 of this manual

12-1

FORD MOTOR CO. TAURUS ¢ SABLE

=e Te Onais

it 114 ue

aul

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FRONT OF ENGINE

RH CYLINDER HEAD 7922KG34

Camshaft journal cap bolt tightening sequence—3.4L (VIN N) engine

Cam Seal Expander T89P-6256-B and Cam Seal Replacer T89-6256-A. 15. Install or connect the following: Left and right camshaft chain tensioners Timing chain CKP pulse ring Front cover Accessory belt idler pulleys Oil pan CKP sensor CMP sensor Crankshaft pulley Power steering pump Left and right valve covers IMRC cable and bracket Engine control sensor wiring harness and brackets Left and right intake manifolds Surge tank and supports Throttle body EGR tube Intake vacuum lines Water pump drive pulley Alternator A/C compressor Accessory drive belts Engine assembly into the vehicle. 16. Run the engine and check for leaks and proper operation.

Spacer by the numbers on the bottom face

3.4L (VIN N) engine

of the spacer or by measuring with a

«>The valve clearance is checked with

the engine COLD.

1. Before servicing the vehicle, refer to the precautions at the beginning of this section. 2. Disconnect the negative battery cable. CAM LOBE IN POSITION FEELER GAUGE

Starter Motor To measure the valve clearance, slide the feeler gauge between the base circle of

the cam and the tappet—3.4L (VIN N) engine

TAPPET HOLDER T96P-6500-AH Hadas! Meals T89P-6:

ADJUSTMENT

The lash adjusters (valve tappets), are hydraulic and are not adjustable.

micrometer. 10. Install the replacement adjusting spacer with the numbers down. Be sure the Spacer is properly seated. 11. Release the tappet holder by installing the tappet compressor, then remove the tappet compressor. 12. Repeat the procedure for each valve requiring adjustment. 13. Install the valve covers and the upper intake manifold. 14. Connect the negative battery cable. 15. Run the engine and check for leaks and proper engine operation.

7922KG36

Valve Lash

3.0L (VIN U and S) Engines

3. Remove the upper intake manifold and valve covers. 4. Rotate the crankshaft so that the camshaft lobe is directed away from the valve tappet to be measured. 5. Insert a feeler gauge under the camshaft lobe at a 90 degree angle to the camshaft. Clearance for the intake valves should be 0.006—0.010 inch (0.15—-0.25mm). Clearance for the exhaust valves should be 0.010-0.014 inch (0.25-0.35mm). 6. If adjustment is required, install Tappet Compressor T89P-6500-A under the camshaft next to the lobe and depress the valve tappet. 7. Install Tappet Holder T96P-6500-AH and remove the compressor tool. 8. Direct a jet of compressed air toward the hole in the face of the valve adjusting spacer to lift the valve adjusting spacer off of the valve tappet. 9. Determine the size of the adjusting

7922KG35

Correct positioning of the tappet compressor and holder tools—3.4L (VIN N) engine

REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions at the beginning of this section. _ 2. Remove or disconnect the following: e Negative battery cable ¢ Splash shield * Starter electrical connectors e Starter To install: 3. Install or connect the following: ¢ Starter and tighten the bolts to 16-21 ft. Ibs. (21-29 Nm) * Starter electrical connectors and tighten the battery cable nut to 80-123 inch Ibs. (9-14 Nm) e Splash shield e Negative battery cable

revradnussaste_ 12-19 2. Drain the engine oil. 3. Remove or disconnect the following: ¢ Negative battery cable Oil dipstick tube Low oil level sensor, if equipped Starter motor and brace Heated Oxygen (HO2S) sensor conpn gs46KG24

Oil pan—3.0L (VIN U) engine

nectors ¢ Dual converter Y-pipe e Engine rear plate Oil pan

eerie

Remove the front splash shield for access

To install:

To install: 4. Install the oil pan with new gaskets. Tighten the bolts as follows: a. Step 1: Tighten all bolts to 10 ft. lbs. (14 Nm). b. Step 2: Loosen all bolts. c. Step 3: Tighten all bolts to 10 ft. lbs. (14 Nm). oe Starter motor—3.0L (VIN U) engine

4. Install the oil pan with new gaskets. Tighten the bolts as follows: a. Step 1: Tighten the 4 corner bolts to 108 inch Ibs. (12 Nm). b. Step 2: Tighten the remaining bolts to 108 inch Ibs. (12 Nm). ¢. Step 3: Retighten all bolts to 108 inch Ibs. (12 Nm).

5. Install or connect the following:

5. Install or connect the following:

e Engine rear plate e Dual converter Y-pipe e HO2S sensor connectors e Starter motor and brace e Low oil level sensor, if equipped e Oil dipstick tube e Negative battery cable 6. Fill the crankcase. 7. Start the engine and check for leaks.

e Engine rear plate e Dual converter Y-pipe e HO2S sensor connectors e Starter motor and brace ¢ Low oil level sensor, if equipped e Oil dipstick tube e Negative battery cable 6. Fill the crankcase. 7. Start the engine and check for leaks.

2090-01 ENGINES 1. Before servicing the vehicle, refer to the precautions at the beginning of this section.

9346KG26

Starter motor—3.0L (VIN S) and 3.4L (VIN N) engines

3.0L (VIN S) Engine 1. Before servicing the vehicle, refer to the precautions at the beginning of this section. Oil Pan Removal Sequence

REMOVAL & INSTALLATION 3.0L (VIN U) Engine

Description Upper

1998-99

ENGINES

ae

Cylinder Block

Lower sere Block (Part

4

1. Before servicing the vehicle, refer to the

precautions at the beginning of this section. 2. Drain the engine oil. 3. Remove or disconnect the following:

010)

Ure

creaon| [4 [Swas

enone

Negative battery cable

Oil dipstick tube Low oil level sensor, if equipped Starter motor and brace

Heated Oxygen (HO2S) sensor con-

CE

meee

Dual converter Y-pipe Engine rear plate Oil pan

gheecdtor ete

remove gOLrseTU0S Oil pan bolt removal sequence—3.0L (VIN S) engine

For Wheel Alignment specifications, see Section 1 of this manual

FRONT OF ENGINE

fathy

12-20 fans’ saste 6. Install or connect the following: ¢ Dual converter Y-pipe Negative battery cable 7. Fill the crankcase. 8. Start the engine and check for leaks and proper operation.

SEALER WSE-M4G323-A1

REMOVAL & INSTALLATION 3.0L (VIN U) Engine NOTE: APPLY 8 mm (0.31 INCH) DIAMETER BEAD OF SILICONE GASKET AND SEALANT

VIEW A %* VIEW A SIMILAR TWO PLACES

FRONT OF ENGINE

LOCATION OF STUDS TIGHTEN BOLTS/STUDS IN SEQUENCE SHOWN 9306KG02

Oil pan bolt tightening sequence—3.0L (VIN S) engine

2. Drain the engine oil. 3. Remove or disconnect the following: e Negative battery cable e Dual converter Y-pipe e Transaxle support bracket e (il pan by following the bolt removal sequence shown To install: 4. Install or connect the following: e Oil pan. Use a new gasket and tighten the bolts in sequence to 15-22 ft. Ibs. (20-30 Nm). e Transaxle support bracket. Tighten the nuts to 71-106 inch Ibs. (8-12 Nm) and the bolts to 15-22 ft. Ibs. (20-30 Nm). e Dual converter Y-pipe e Negative battery cable 5. Fill the crankcase. 6. Start the engine and check for leaks and proper operation.

16 REQ'D TIGHTEN TO 18-28 N-m (14-20 LB-FT)

7922KG39

Oil pan bolt tightening sequence—3.4L (VIN N) engine

APPLY SILICONE GASKET AND SEALANT F6AZ-19562-AA

3.4L (VIN N) Engine 1. Before servicing the vehicle, refer to the precautions at the beginning of this section.’ 2. Drain the engine oil. 3. Remove or disconnect the following: ¢ Negative battery cable e Dual converter Y-pipe e Oil pan To install: 4. Apply a 0.16 inch (4mm) bead of silicone sealer on the entire oil pan sealing Surface. 5. Install the oi! pan. Tighten the oil pan bolts and studs in sequence to 15-22 ft. Ibs. (20-30 Nm). Tighten the oil pan-to-transaxle case bolts to 25-34 ft. Ibs. (34-46 Nm).

1. Before servicing the vehicle, refer to the precautions at the beginning of this section. 2. Drain the engine oil. 3. Remove or disconnect the following: e Negative battery cable Oil dipstick tube Low oil level sensor, if equipped Starter motor and brace @ eee Heated Oxygen Sensor (HO2S) connectors Dual converter Y-pipe Engine rear plate Oil pan Oil pump 4. Separate the intermediate shaft from the oil pump. To install: 5. Insert the intermediate shaft into the oil pump until the snapring seats. 6. Install or connect the following: e Qi! pump and tighten the bolt to 30-40 ft. Ibs. (40-55 Nm) Oil pan Engine rear plate Dual converter Y-pipe HO2S sensor connectors Starter motor and brace Low oil level sensor, if equipped Oil dipstick tube Negative battery cable

FRONT OF

ENGINE

OIL PAN 7922K640

Apply silicone sealant to the entire sealing surface of the oil pan—3.4L (VIN N) engine

hee De FRONT OF ENGINE

aoe intermediate Shaft

7922KG42

Exploded view of the oil pump mounting—

3.0L (VIN U) engine

7. Fill the crankcase. 8. Start the engine and check for leaks and proper operation.

FRONT OF ENGINE

3.0L (VIN S) Engine 1. Before servicing the vehicle, refer to the precautions at the beginning of this section. 2. Remove the engine from the vehicle and mount it on an engine stand. 3. Remove or disconnect the following: e Upper intake manifold e Valve covers e Accessory drive belt e Power steering pump REMOVE BOLTS IN SEQUENCE SHOWN

1

Cylinder

Block

2

Oil

Pan

3

Nut

(5 Req'd)

4

Nut

(2

5

Oil

Pump

Screen

6

Oil

Pump

Inlet

Oil

Pump

Baffle

CRANKSHAFT

OjL PUMP

BeEa'D

Description

Item

FRONT OF —~ ENGINE

SyuNDER BLOCK

Req'd)

Cover

Tube

Tighten

to

14-25

Tighten

to

8-14

Nm

Nm

and

Tube

Gasket

(11-18

Lb-Ft)

(71-123

Lb-In)

9300KG16

9300KG15

Oil pump bolt removal sequence—3.0L (VIN S) engine—-3.4L (VIN N) engine is similar

L Exploded view of the oil pump pickup tube and screen mounting—3.4L (VIN N) engine—3.0 (VIN S) engine is similar

For Maintenance Interval recommendations, see Section 1 of this manual

12-2

FORD MOTOR CO. TAURUS ¢ SABLE

3.4L (VIN N) Engine

we reel ee FRONT

‘

4

IGHTEN

TO

OF

ENGINE

CYLINDER BLOCK

8-12Nm (71-106 LB-IN)

7922KG43

Oil pump bolt tightening sequence—3.0L (VIN S$) engine—3.4L (VIN N) engine is similar

.

e Alternator ¢ Water pump e A/C compressor and bracket e*The crankshaft accessory drive pulley shaft has left-hand threads. Rotate the pulley shaft clockwise to remove.

e Crankshaft pulley e Oil pan ¢ Oil pump screen and tube e Front cover ¢ Timing chains ¢ Crankshaft timing gears e Qil pump To install: 4. Install or connect the following: Oil pump and tighten the bolts in sequence to 71-106 inch Ibs. (8-12 Nm) Crankshaft timing gears Timing chains ont cover il pump screen and tube. Tighten é bolts to 71-106 inch Ibs. (8-12 m), and the nut to 15-22 ft. Ibs. 20-30 Nm). Soran Wie il pan Ge rankshaft pulley

ee 68e@

e

e*The air conditioning mounting bracket bolts are torque-to-yield bolts and must be replaced when removed.

A/C compressor and bracket Water pump Alternator Power steering pump Accessory drive belt Valve covers Upper intake manifold Engine in the vehicle. 5. Fill the crankcase. 6. Start the engine and check for leaks and proper operation.

1. Before servicing the vehicle, refer to the precautions at the beginning of this section. 2. Remove the engine from the vehicle and mount it onan engine stand. 3. Remove or disconnect the following: Accessory drive belts A/C compressor Alternator Water pump drive pulley Intake vacuum lines Exhaust Gas Recirculation (EGR) tube Throttle body Surge tank and supports Left and right valve covers Power steering pump Crankshaft pulley Camshaft Position (CMP) sensor Crankshaft Position (CKP) sensor Oil pan Oil pump screen and tube Accessory belt idler pulleys Front cover CKP pulse ring Timing chain Crankshaft timing sprocket Oil pump To install: 4. Install or connect the following: Oil pump and tighten the bolts in sequence to 80-115 inch Ibs. (9-13 Nm) Crankshaft timing sprocket Timing chain CKP pulse ring Front cover Accessory belt idler pulleys Qil pump screen and tube. Tighten the tube nuts to 71-123 inch Ibs. (8-14 Nm) and the bracket nuts to 11-18 ft. Ibs. (14-25 Nm). Oil pan CKP sensor CMP sensor Crankshaft pulley Power steering pump Left and right valve covers Surge tank and supports Throttle body EGR tube Intake vacuum lines Water pump drive pulley Alternator A/C compressor Accessory drive belts e Engine into the vehicle 5. Fill the crankcase. 6. Start the engine and check for leaks and proper operation.

Rear Main Seal

REMOVAL & INSTALLATION 3.0L (VIN U) Engine 1. Before servicing the vehicle, refer to the precautions at the beginning of this section. 2. Remove the negative battery cable, transaxle and flexplate. 3. Use a sharp awl and punch a hole into the rear main seal metal surface between the seal lip and the cylinder block. 4. Screw the threaded end of Jet Plug Remover 310-005 into the seal. Use the Jet Plug Remover to remove the rear main seal. To install: 5. Position the rear oil seal on Rear Seal Replacer 303-323. Position the tool and seal on the rear of the engine. Tighten the bolts alternately to seat the rear main oil seal. 6. Install the flexplate and tighten the bolts to 5464 ft: Ibs. (73-87 Nm). 7. Install the transaxle and the negative battery cable. 8. Check.all fluid levels and fill as needed. 9. Start the engine and check for leaks.

9346KG27

Jet Plug Remover 310-005—3.0L (VIN U) engine

9346KG28

Rear Seal Replacer 303-323—3.0L (VIN U) engine

3.0L (VIN S) and 3.4L (VIN N) Engines 1. Before servicing the vehicle, refer to the precautions at the beginning of this section. 2. Attach an engine support fixture to the engine lifting eyes. 3. Remove or disconnect the following: ¢ Negative battery cable ¢ Transaxle ¢ Flexplate

~

erAURUSesaalé 12-23 4. Use Seal Remover T95P-6701-EH and a slide hammer to remove the rear crankshaft seal. To install: 5. Install or connect the following: e Rear main seal flush with the cylinder block surface. Use Rear Main Monae! REAR OIL SEA 6701

Seal Replacer T82L-6701-A and Adapter Bolts 191P-6701-A. e Flexplate and tighten the bolts to 54-64 ft. Ibs. (73-87 Nm) e Transaxle e Negative battery cable 6. Run the engine and check for leaks.

Timing Chain, Sprockets and Front Cover and Seal REMOVAL & INSTALLATION 3.0L (VIN U) Engine 1. Before servicing the vehicle, refer to the precautions at the beginning of this section. 2. Drain the engine oil and the cooling system. 3. Remove or disconnect the following: Negative battery cable Accessory drive belt Accessory drive belt tensioner and idler pulley Water pump pulley Crankshaft pulley Crankshaft Position (CKP) sensor Coolant hoses Dual converter Y-pipe Oil pan Front crankshaft seal Front cover 4. Rotate the crankshaft until the No. 1 piston is at Top Dead Center (TDC) and the timing sprocket marks are aligned. 5. Remove the timing chain and sprockets. To install:

REAR Arpcpebeb car PU SEAL REMOVER T95P-6701-EH

ses

SG SLIDE HAMMER TS0T-100-A

9346KG29

Rear Crankshaft Seal Remover T95P-6701-EH—3.0L (VIN S) and 3.4L (VIN N) engines

CRANKSHAFT 6303

FRONT OF ENGINE CRANKSHAFT REAR OIL SEAL 6701 SEAL REPLACER T82L-6701-A

REAR CRANKSEAL REPLACER ADAPTER T81P-6701-A 9346KG30

(VIN S) and 3.4L (VIN N) Rear Seal Replacer T82L-6701-A and Adapters T91P-6701-A—3.0L engines

>The camshaft bolt has a drilled oil passage in it for timing chain lubrication. Prior to installation, clean the passage and be sure it is clear. Never replace the camshaft bolt with a standard bolt.

6. Install the timing chain and sprockets with the timing marks aligned. Tighten the camshaft sprocket bolt to 46 ft. Ibs. (63 Nm). 7. Use a new gasket and install the front cover. Apply sealant to bolts 1, 2 and 3. Tighten bolts 1-10 to 19 ft. Ibs. (25 Nm) and bolts 11-15 to 84 inch Ibs. (10 Nm). 8. Install or connect the following: Front crankshaft seal Oil pan Dual converter Y-pipe Coolant hoses CKP sensor Crankshaft pulley and tighten the damper bolt to 107 ft. Ibs. (145 Nm) Water pump pulley and tighten the bolts to 16 ft. Ibs. (21 Nm) Accessory drive belt tensioner and idler pulley

For Tune-up, Capacities and Firing orders, see Section 1 of this manual

12-24 frumus nate e Accessory drive belt e Negative battery cable 9. Fill the cooling system. 10. Fill the crankcase. 11. Start the engine and check for leaks and proper operation.

TIMING MARKS MUST BE IN POSITION SHOWN WITH NO. 1 PISTON AT TDC FIRING

CAMSHAFT SPROCKET

3.0L (VIN S) Engine

CRANKSHAFT SPROCKET CHAIN

Boe

7922KG47

1. Before servicing the vehicle, refer to the precautions at the beginning of this section. 2. Remove the engine from the vehicle and mount it on an engine stand. 3. Remove or disconnect the following:

Fastener And Hole

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W/P&F/CTO BLOCK

M8 x 1.25x 1043

W/P&F/CTO BLOCK

20-30

an >

M8 x 1.25x73

F/C TO BLOCK

20-30

@Q >

M8x 1 25x73

W/P&F/CTO BLOCK

20:30

1§-22

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M8x

1.25x73

W/P&F/CTO BLOCK

20-30

16-22

1 25x 104.3

W/P&F/CTO BLOCK

: 20-30

1§-22

o>

M8 x 1.25x 104.3

W/P&F/CTO BLOCK

= OA

MB x 1.25 x 52

M8x

RT GM RTT YM

15-22

TOS

W/P—Water Pump

F /C—Engine Front Cover 7922KG48

Timing chain front cover bolt location and identification—3.0L (VIN U) engine

PeNTAURUS Saale 12-20 ¢ Qil pump screen and tube ¢ Crankshaft Position (CKP) sensor connector ¢ Camshaft Position (CMP) sensor connector e Front cover e CKP sensor pulse ring. Note the keyway alignment for installation. 9346KG31

Access the power steering pump bolts through the holes in the pulley—3.0L (VIN S) engine

e e e e e

Upper intake manifold Valve covers Accessory drive belt Power steering pump Alternator Water pump A/C compressor and bracket

>The crankshaft accessory drive pulley shaft has left-hand threads. Rotate the pulley shaft clockwise to remove.

e Crankshaft pulley e Crankshaft damper e Qil pan

>The Crankshaft Position Sensor (CKP) pulse ring is used on several different engines. Note the keyway alignment for installation.

4. Rotate the crankshaft so that the keyway is at the 11 o'clock position to locate the crankshaft at Top Dead Center (TDC) for No. 1 cylinder. 5. Verify that the alignment arrows on the camshafts are aligned. If not, rotate the crankshaft 1 complete revolution and recheck. 6. Rotate the crankshaft so that the keyway is at the 3 o'clock position. This positions the right cylinder head camshafts to the neutral position. 7. Remove or disconnect the following: e Right timing chain tensioner

e>The camshaft thrust caps must be removed before loosening the remaining camshaft journal cap bolts to ensure that the thrust caps are not damaged.

e Camshaft thrust caps e Camshaft journal caps. Loosen the bolts in sequence and in several passes to allow the camshaft to be raised from the cylinder head evenly. e Rocker arms. Keep the rocker arms in order for installation. e Right timing chain tensioner arm e Right timing chain and crankshaft sprocket 8. Rotate the crankshaft 2 revolutions and locate the crankshaft keyway at the 11 o'clock position. This will position the left cylinder head camshafts to their neutral position. 9. Verify that the alignment arrows on the camshafts are aligned. 10. Remove the left cylinder head timing chain tensioner retaining bolts and the timing chain tensioner. >The camshaft thrust caps must be removed before loosening the remain-

— FRONT OF ENGINE

7922JG27

Using a thin prytool, release and hold the timing chain tensioner ratchet/pawl mechanism—3.OL (VIN S$) engine

RH Exhaust Camshatt

RH Intake Camshaft RH Timing Chain Crankshaft =on Sprocket

RH Timing Chain aa Bolt (2 Req'd)

6

Timing Chain Tensioner

7 Bolt (2 Req'd) 8 9 10

A

Timing Chain Tensioner Arm Timing Chain Guide RH Cylinder Head

Tighten to 20-30 N-m (15-22

Lb-Ft) 7922KG49

ts—3.0L (VIN S) Exploded view of the right cylinder head timing chain and related componen engine—left side similar

7922JG28

Retain the piston with a 1.5mm wire or

paperclip—3.0L (VIN S) engine

For complete service labor times, order Nichols’ Chilton Labor Guide

12-2

FORD MOTOR CO. TAURUS ¢ SABLE

THRUST A

e Right timing chain tensioner arm e Right timing chain tensioner and tighten the retaining bolts to 15-22 ft. Ibs. (20-30 Nm)

CAPS

RH CYLINDER HEAD

>The crankshaft keyway must be in the 11 o’clock position to install the left cylinder head rocker arms.

+ FRONT ENGINE

MARK HERE 7922KG32

>The camshaft journal caps and cylinder heads are numbered to ensure that they are assembled in their original positions.

14. Install the left cylinder head rocker arms in their original positions. Do not install the camshaft journal thrust caps until the other journal caps have been installed and tightened.

15. Tighten the left camshaft journal caps in the order shown and in several passes to 71-106 inch Ibs. (8-12 Nm). 16. Install the left camshaft journal thrust caps and tighten the bolts to 71-106 inch lbs. (8-12 Nm). 17. Remove the retaining wire from the left timing chain tensioner. The crankshaft keyway must be in the 3 o’clock position to install the right cylinder head rocker arms.

11 O'CLOCK POSITION (TOC NO. 1 CYLINDER)

18. Rotate the crankshaft so that the keyway is in the 3 o'clock position.

6

* NOTE: AT TOC NO. 1 FIRING POSITION, ARROWS ON BACK

POINT DIRECTLY AT EACH OTHER 7922KG51

Be sure the timing marks are as shown after the chain has been installed—3.0L (VIN S) engine

ing camshaft journal cap bolts to ensure that the thrust caps are not damaged.

nee Remove or disconnect the follow ‘

Camshaft thrust caps

ratchet/pawl mechanism through the access hole in the timing chain tensioner. c. Slowly the tensioner. d. Lock thecompress piston with a 1.5mm wire

or paperclip.

Camshaft journal caps. Loosen the bolts in sequence and in several passes to allow the camshaft to be raised from the cylinder head evenly. Rocker arms. Keep the rocker arms in order for installation. Left timing chain tensioner arm Left timing chain and crankshatt : sprockel

To install:

12. Prepare the timing chain tensioners for installation as follows:

é. Repeat for the right chain tensioner.

e>Be sure that the crankshaft keyway is still at the 11 o’clock position.

13. Install or connect the following: ¢ Left timing chain and crankshaft sprocket. Align the colored links with the index marks on the camshaft and crankshaft sprockets. ¢ Left timing chain tensioner arm ¢ Left timing chain tensioner and

tighten theEe retaining bolts to 15-22 g eS 6: ft. Ibs. Mae (20-30 Nm)

a. Place the left chain tensioner in a vise

sprocket. Align the colored links

a fete a

with the index marks on the camshaft and crankshaft sprockets.

te

and

Right timing chain and crankshaft

-»>The camshaft journal caps and cylinder heads are numbered to ensure that they are assembled in their original positions.

19. Install the right cylinder head rocker arms in their original positions. ->Do not install the camshaft journal thrust caps until the other journal caps have been installed and tightened.

20. Tighten the right camshaft journal Caps in the order shown and in several passes to 71-106 inch Ibs. (8-12 Nm). 21. Install the right camshaft journal thrust caps and tighten the bolts to 71-106 inch Ibs. (8-12 Nm). 22. Remove the retaining wire from the right timing chain tensioner. e>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 30, 30RFF or with an ORANGE stripe.

23. Install the CKP sensor pulse ring. Align the keyway with the proper slot. 24. Replace the crankshaft seal in the front cover with a new one. Apply clean engine oil to the seal lip.

*,

eNrAURUSsaolé 12-27 29. Apply silicone sealer to the 6 critical areas shown in View A, to the cylinder block to prevent oil seepage. 26. Place new front cover gaskets onto the dowel pins on the cylinder block and heads. 2/7. Place the front cover into position. 28. Install the 6 front cover retaining bolts and stud bolts where the silicone sealer was applied. 29. Tighten the bolts and stud bolts until the front cover contacts the cylinder block and heads, then turn the bolts and stud bolts an additional /% turn. 30. Install the remaining front cover retaining bolts and stud bolts. 31. Tighten all of the front cover retaining bolts and stud bolts in sequence to 15-22 ft. Ibs. (20-30 Nm). ->The air conditioning mounting bracket bolts are torque-to-yield bolts and must be replaced. APPLY 3 mm (0.118 INCH) BEAD OF SEALANT VIEW A TYPICAL 6 PLACES 7922JG29

To prevent oil leakage, apply sealant to the places indicated—3.0L (VIN S) engine

FRONT = ENGINE

# LOCATION OF STUDS FOUR PLACES TIGHTEN BOLTS/STUDS IN SEQUENCE SHOWN FINGER-TIGHT

32. Install or connect the following: e CMP sensor connector e CKP sensor connector e (Oil pump screen and tube e Oil pan 33. Install the crankshaft damper and tighten the bolt as follows: a. Step 1: Tighten the bolt to 78-99 ft. Ibs. (105-135 Nm). b. Step 2: Loosen the bolt one full turn. c. Step 3: Tighten the bolt to 35-39 ft. lbs. (47-53 Nm). d. Step 4: Tighten the bolt 85-95 degrees. 34. Install or connect the following: Crankshaft pulley and tighten counterclockwise to 70-77 ft. Ibs. (95-105 Nm) A/C compressor and bracket Water pump Alternator Power steering pump and tighten the bolts to 18 ft. Ibs. (25 Nm) Accessory drive belt Valve covers Upper intake manifold Engine assembly into the vehicle 35. Run the engine and check for leaks and proper operation. 3.4L (VIN N) Engine

* STUD LOCATIONS

7922KG52

Front cover bolt torque sequence—3.0L (VIN S) engine

1. Before servicing the vehicle, refer to the precautions at the beginning of this section. 2. Remove the engine from the vehicle and mount it on an engine stand. 3. Remove or disconnect the following:

Please visit our web site at www.chiltonsonline.com

12-28 Animus sabe CRANKSHAFT RONT SEAL

PIN REMOVER 7922KG25

Use the special tool or a slide hammer to remove the crankshaft front oil seal—3.4L (VIN N) engine

31.9 DEGREES

Lewache

ay

Timing chain tensioner—3.4L (VIN N) engine

HAIN

INSTALL CHAIN AFTER MATCHING SPROCKET AND CHAIN TIMING MARKS

32.4DEGREES

Of

L198

Ne:

AZ

7.9 DEGREES

gy

(a

30 DEGREES OIL PUMP MARK (RIB ON OIL PUMP)

10 DEGREES 7922KG53

%* APPLY 3 mm (0.118 INCH) BEAD OF SEALANT MEETING FORD SPECIFICATIONS (WSE-M4G323-A6) PRIOR TO INSTALLATION 9306KG03

Apply sealant to the cylinder block and heads—3.4L (VIN N) engine

Accessory drive belts A/C compressor Alternator Intake vacuum lines Exhaust Gas Recirculation (EGR) tube ~ Throttle body Surge tank and supports Left and right intake manifolds eee eo eeee ee Engine control sensor wiring harness and brackets Left and right valve covers Power steering pump Crankshaft pulley _ Front crankshaft seal Crankshaft Position (CKP) sensor Oil pan Accessory belt idler pulleys Front cover CKP pulse ring 4. Set the crankshaft at Top Dead Center (TDC) of the compression stroke for the No. 1 cylinder. 5. Remove or disconnect the following: e Timing chain tensioner e Tensioner arm e Timing chain

Do not rotate the crankshaft more than 45 degrees counterclockwise or more than 90 degrees clockwise from the previously set No. 1 cylinder TDC position with the timing chain removed, or valve to piston contact could occur. To install: 6. Using a small prybar, release the timing chain tensioner ratchet/pawl mechanism through the access hole in the timing chain tensioner. Insert a small wire into the top of the piston and unseat the oil check ball. Compress the timing chain tensioner by hand. 7. With the tensioner compressed, install a 0.060 inch (1.5mm) drill bit or wire into the small hole above the ratchet, engaging the lock groove in 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 timing chain tensioner arm and tensioner. Tighten the timing chain tensioner pivot bolt to 25-39 ft. Ibs. (34-53 Nm). Tighten the timing chain tensioner bolts to 14-20 ft. Ibs. (18-27 Nm). 10. Remove the locking wire from the timing chain tensioner. 11. Apply silicone sealer to the 13 critiCal areas of the cylinder block as shown.

rerrAURUS saate 12-29

s

Piston and Ring CENTERLINE OF PISTON PARALLEL TO WRIST PIN BORE

POSITIONING

45 DEGREES UPPER COMPRESSION RING GAP LOCATION

45 DEGREES

UPPER Ol. CONTROL SEGMI RING GAP LOCATION

— TOP COMPRESSION

>

RING

~N [

FRONT OF ENGINE

\e— BOTTOM COMPRESSION RING OIL CONTROL RING EXPANDER GAP LOCATION

(ke OIL CONTROL RINGS AND EXPANDER CENTER LINE OF PISTON PARALLEL TO WRIST PIN BORE

LOWER OIL CONTROL SEGMENT

LOWER COMPRESSION RING GAP LOCATION

UPPER COMPRESSION RING GAP LOCATION

RING GAP LOCATION

7922AG19

FRONT OF ENGINE

Ring end-gap positioning—3.4L (VIN N) engine CRANKSHAFT SEAL REPLACER/COVER ALIGNER T88T-6701-A

LOCATION

7922KG26

Install the new crankshaft front oil seal using a suitable seal driver or the special

tool—3.4L (VIN N) engine

‘O)

EXPANDER RING ——> AND LOWER COMPRESSION RING GAP LOCATION

Piston

OIL CONTROL SEGMENT RING GAP LOCATION 7922AG16

12. Install or connect the following: e CKP pulse ring e Front cover and tighten the bolts to 14-20 ft. Ibs. (18-28 Nm) Accessory belt idler pulleys Oil pan CKP sensor Front crankshaft seal 13. Install the crankshaft pulley and tighten the bolt as follows: a. Step 1: Tighten the bolt to 78-99 ft. lps. (105-135 Nm). b. Step 2: Loosen the bolt one full turn. c. Step 3: Tighten the bolt to 35-39 ft. Ibs. (47-53 Nm). d. Step 4: Tighten the bolt 85-95 degrees. 14. Install or connect the following: e Power steering pump e Left and right valve covers e Engine control sensor wiring harness and brackets Left and right intake manifolds Surge tank and supports Throttle body EGR tube Intake vacuum lines Alternator A/C. compressor Accessory drive belts Engine assembly into the vehicle. 15. Run the engine and check for leaks and proper operation.

AS o

Ring end-gap spacing—3.0L (VIN S and U) engines

7]

Se Pin

'

Retainer

NI PISTON

NOTCH ON PISTON DOME AND BUTTON ON CONNECTING ROD 6200 IDENTIFICATION MARKS MUST BE ON SAME SIDE

Clip

FRONT OF

ENGINE

Connecting Rod Front Mark

Front

Mark

views 7922AG17

VIEWED FROM FRONT OF ENGINE 7922AG15

Piston and connecting rod positioning— 3.0L (VIN S and U) engines

w

Piston and connecting rod positioning— 3.4L (VIN N) engine

VIEW A

a

TOP COMPRESSION

RING

we VIEW A [+

BOTTOM COMPRESSION RING

OIL CONTROL RINGS AND EXPANDER 7922AG18

Piston ring positioning—3.4L (VIN N) engine

Timing belt service is covered in Section 3 of this manual

12-3 SSE

SB

FORD MOTOR CO. TAURUS ¢ SABLE ES

TS

SER

Fuel System Service Precautions Safety is the most important factor when performing not only fuel system maintenance but any type of maintenance. Failure to conduct maintenance and repairs in a safe manner may result in serious personal injury or death. Maintenance and testing of the vehicle's fuel system components can be accomplished safely and effectively by adhering to the following rules and guidelines. e To avoid the possibility of fire and personal injury, always disconnect the negative battery cable unless the repair or test procedure requires that battery voltage be applied. e Always relieve the fuel system pressure prior to disconnecting any fuel system component (injector, fuel rail, pressure regulator, etc.), fitting or fuel line connection. Exercise extreme caution whenever relieving fuel system pressure, to avoid exposing skin, face and eyes to fuel spray. Please be advised that fuel under pressure may penetrate the skin or any part of the body that it contacts. ¢ Always place a shop towel or cloth around the fitting or connection prior to loosening to absorb any excess fuel due to spillage. Ensure that all fuel spillage (should it occur) is quickly removed from engine surfaces. Ensure that all fuel soaked cloths or towels are deposited into a suitable waste container. e Always keep a dry chemical (Class B) fire extinguisher near the work area. ¢ Do not allow fuel spray or fuel vapors to come into contact with a spark or open flame. ¢ Always use a back-up wrench when loosening and tightening fuel line connection fittings. This will prevent unnecessary stress and torsion to fuel line piping. Always follow the proper torque specifications. e Always replace worn fuel fitting Orings with new. Do not substitute fuel hose or equivalent, where fuel pipe is installed.

Fuel System Pressure

:

TT

SYS

PE SS

TEE

TS

CT

ENS

Pressure Gauge T80L-9974-A or equivalent, to the valve and drain the fuel through the drain tube into a suitable container. 6. On flex-fuel engines, connect Fuel Pressure Gauge T80L-9974-A or equivalent and Fuel Pressure Test Kit 134-R0035 or equivalent, to the Schrader valve. Drain the fuel through the drain tube into a suitable container. 7. After the fuel system pressure Is relieved, remove the fuel pressure gauge and install the cap on the Schrader valve. 8. Install the fuel tank fill cap. 9. Connect the negative battery cable after system repairs are completed.

REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions at the beginning of this section. 2. Disconnect the negative battery cable. 3. Relieve the fuel system pressure. 4. Disconnect the fuel lines. 5. Loosen the filter retaining clamp and remove the fuel filter.

FUEL LINE

7922KG55

Push connect fitting and removal tool

To install: 6. Install the fuel filter with the flow arrow facing the proper direction and tighten the filter retaining clamp. 7. Push the fuel lines on to the filter fittings until an audible click is heard. 8. Connect the negative battery cable. 9. Start the engine and check for fuel leaks and proper operation.

REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions at the beginning of this section. 2. Relieve the fuel system pressure.

FUEL PUMP MUST BE SNAPPED IN RETAINER TWO PLACES

RELIEVING 1. Before servicing the vehicle, refer to the precautions at the beginning of this section. 2. Disconnect the negative battery cable. 3. Remove the fuel tank fill cap to relieve the pressure in the fuel tank. 4, Remove the cap from the Schrader valve located on the fuel supply manifold. 5. On gasoline engines, attach Fuel

1

Fuel Pump Locking Retainer Ring

2

Fuel Tank Pressure/ Vacuum Transducer

Locking Tab Fuel Tank O-Ring Seal Connector NOOO BW Fuel

Pump Module 7922KG58

Exploded view of the fuel pump module mounting

EI

eNTAURUS sable 12-0| 3. Drain the fuel tank. 4. Remove or disconnect the following: e Negative battery cable e Fuel lines ¢ Fuel pump module electrical connector e Fuel tank e Fuel pump module To install: 5. Install the fuel pump module carefully to ensure the filter and hoses and float rod are not damaged. Use a new O-ring seal. 6. Align the fuel 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 definite click will be heard engaging 2 locking tabs on the outside of the fuel pump. 7. Install or connect the following: e Fuel pump module locking ring e Fuel tank e Fuel pump module electrical connector e Fuel lines e Negative battery cable 8. Add a minimum of 10 gallons of clean fuel to the tank. 9. Start the engine and check for leaks.

Fuel Injector REMOVAL & INSTALLATION 3.0L (VIN U) Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Relieve fuel system pressure. 3. Remove or disconnect the following: Negative battery cable Air cleaner outlet tube Fuel lines Upper intake manifold Fuel injector electrical connectors Fuel pressure regulator vacuum line Fuel supply manifold with the injectors attached Injectors from the supply manifold To install: 4. \nstall or connect the following: e Fuel injectors. Use new O-ring seals.

9346KG32

Fuel supply manifold—3.0L (VIN U) engine

Fuel supply manifold with the injectors attached and tighten the bolts to 89 inch Ibs. (10 Nm) Fuel pressure regulator vacuum line Fuel injector electrical connectors Upper intake manifold Fuel lines Air cleaner outlet tube Negative battery cable 5. Start the engine and check for leaks.

3.0L (VIN S) Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Relieve fuel system pressure. 3. Remove or disconnect the following: Negative battery cable Air cleaner outlet tube Fuel lines Upper intake manifold Fuel injector electrical connectors Fuel pressure regulator vacuum line Fuel supply manifold Injectors from the lower intake manifold 10 Nm (89 Ib-in)

9346KG33

Retaining bolts (1) and Fuel supply Manifold (2)—3.0L (VIN S) engine

To install: 4. Install or connect the following: Fuel injectors. Use new O-ring Seals. Fuel supply manifold and tighten the bolts 89 inch Ibs. (10 Nm) Fuel pressure regulator vacuum line Fuel injector electrical connectors Upper intake manifold Fuel lines Air cleaner outlet tube Negative battery cable 5. Start the engine and check for leaks.

3.4L (VIN N) Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Relieve fuel system pressure. 3. Remove or disconnect the following: Negative battery cable Air cleaner outlet tube Fuel lines Throttle body Surge tank Left and right intake manifolds Fuel injector electrical connectors Fuel pressure regulator vacuum line Fuel supply manifold with the injectors attached Injectors from the supply manifold To install: 4. Install or connect the following: Fuel injectors. Use new O-ring Seals. Fuel supply manifold with the injectors attached and tighten the bolts to 11-16 ft. Ibs. (15-23 Nm) Fuel pressure regulator vacuum line Fuel injector electrical connectors Left-and right intake manifolds Surge tank Throttle body Fuel lines Air cleaner outlet tube Negative battery cable a Mm eee e@ ee ® tart the engine and check for leaks.

Heater Core replacement is covered in Section 2 of this manual

2-3 ERS

SU

FORD MOTOR CO. TAURUSRTE¢ SABLE A

VR

ET

2SSG

ST

EO TT DI

IPO

TE

EET

TD EO SLELE LE LET

EL

LE

EE

DRIVE TRAIN Transaxle

.

REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions at the beginning of this section. 2. Attach a powertrain support to the engine lifting eyes. 3. Remove or disconnect the following: Battery and tray Air cleaner assembly Transaxle electrical connectors Shift cable Transaxle cooler lines Front wheels Stabilizer bar links Lower ball joints Axle halfshafts Heated Oxygen Sensor (HO2S) connectors Dual converter Y-pipe Starter Steering rack and pinion gear. Support the gear with safety wire. Powertrain support insulators Subframe Torque converter nuts 4. Support the transaxle with a transmission jack. 5. Remove the transaxle flange bolts and remove the transaxle. To install: 6. Install the transaxle. For 1999-01 3.0L (VIN S) engines, tighten the flange bolts to 25-33 ft. Ibs. (33-46 Nm). For all other engines, tighten the flange bolts to 30-44 ft. Ibs. (40-60 Nm). 7. Tighten the torque converter nuts to 20-34 ft. Ibs. (27-46 Nm). 8. Install the subframe. Use 2 pieces of ¥a inch outside diameter pipe in the alignment holes behind the front subframe mounts to align the subframe to the body. Tighten the subframe mounting bolts to 5/—/6 ft. Ibs. (77-103 Nm). 9. Install or connect the following: ° Powertrain support insulators. Tighten the bracket bolts to 65 ft. lbs. (88 Nm) and the subframe bolts to 90 ft. Ibs. (122 Nm).

Steering rack and pinion gear and tighten the nuts to 84-113 ft. Ibs. (113-133 Nm) Starter and tighten the fasteners to 21 ft. Ibs. (29 Nm) Dual converter Y-pipe

HO2S sensor connectors Axle halfshafts and tighten the hub retainer nuts to 170-202 ft. Ibs. (230-275 Nm) Lower ball joints and tighten the nuts to 51-67 ft. Ibs. (68-92 Nm) Stabilizer bar links and tighten the nuts to 35-46 ft. Ibs. (47-63 Nm) Front wheels Transaxle cooler lines Shift cable Transaxle electrical connectors Air cleaner assembly Battery and tray 10. Start the engine. Check for leaks and proper operation. e>\Whenever the vehicle subframe is removed or lowered, the wheel alignment should be checked.

REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions at the beginning of this section. 2. Remove or disconnect the following: Front wheels Lower ball joints Outer tie rod ends Stabilizer bar links Height sensors, if equipped with air Suspension Wheel speed sensors Steering knuckle from the halfshaft Halfshatts To install:

Wheel speed sensors Height sensors, if equipped with air Suspension Stabilizer bar links and tighten the nuts to 57-75 ft. Ibs. (77-103 Nm) Outer tie rod ends and tighten the nuts to 35-46 ft. Ibs. (47-63 Nm) Lower ball joints and tighten the fasteners to 50-68 ft. Ibs. (68-92 Nm) Front wheels

REMOVAL & REPLACEMENT Inner Tripod Joint The inner C\V-joint is serviced with the axle shaft as an assembly. The inner CVjoint boot can be serviced by removing the outer CV-joint. Outer CV-Joint

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Place the halfshaft in a vise. 3. Remove the CV-joint boot clamps and Slide the boot away from the joint. 4. Drive the CV-joint off the halfshaft

with a brass driftand a hammer. To install: 5. Replace the snapring. 6. Fill the CV-joint with fresh grease and slide the joint on to the halfshaft. 7. Use new clamps and install the CVjoint boot.

e>Use new nuts, bolts and circlips.

3. Install or connect the following: ° Halfshafts ¢ Steering knuckle to the halfshaft e Hub retainer nut and tighten to 170-202 ft. Ibs. (230-275 Nm)

1. CV-Joint boot 2. CV-Joint 9306HG07

Removing the outer CV-joint

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STEERING AND SUSPENSION

+: CAUTION Some 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 precautions and the disarming procedure could result in accidental air bag deployment, possible injury and unnecessary system repairs.

PRECAUTIONS Several precautions must be observed when handling the inflator module to avoid accidental deployment and possible personal injury. e Never carry the inflator module by the wires or connector on the underside of the module. e When carrying a live inflator module, hold securely with both hands, and ensure that the bag and trim cover are pointed away. e Place the inflator module on a bench or other surface with the bag and trim cover facing up. e With the inflator module on the bench, never place anything on or close to the module which may be thrown in the event of an accidental deployment.

DISARMING 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Position the vehicle with the front wheels in a straight-ahead position. 3. Disconnect the negative battery cable. 4 Disconnect the positive battery cable. 5. Wait at least 1minute forthe air bag back-up power supply to drain before continuing. 6. Proceed with the repair.

ARMING sete aoa ties ten

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1. After service is completed, connect the battery cables, negative cable last.

SOR

ES

:

2. Check the functioning of the air bag system by turning the ignition key to the RUN position and visually monitoring the aif bag indicator lamp in the instrument cluster. The indicator lamp should illuminate for approximately 6 seconds, then turn OFF. If the indicator lamp does not illuminate, stays ON, or flashes at any time, a fault has been detected by the air bag diagnostic monitor.

Power Rack and Pinion Steering Gear REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions at the beginning of this section. 2. Remove or disconnect the following: Negative battery cable Intermediate steering shaft Front wheels Dual converter Y-pipe Outer tie rod ends Left stabilizer link Heat shield Power steering hose bracket Auxiliary actuator connector, if equipped Power steering pressure switch connector Rear subframe bolts and lower the rear of the subframe about 4 inches Steering gear mounting nuts, then move the steering gear to the left to access the power steering hoses e Power steering hoses e Steering gear through the left wheel opening To install: 3. Install or connect the following: e Steering gear. Use new seals on the hydraulic fittings. Tighten the mounting nuts to 85-100 ft. Ibs. (115-135 Nm). e Rear subframe bolts and tighten them to 57-6 ft. Ibs. (77-103 Nm) e Power steering pressure switch connector e Auxiliary actuator connector, if equipped e Power steering hose bracket

7922KG60

Support the rear of the subframe with 2 tall jackstands while removing the steering gear

e Heat shield Left stabilizer link e Outer tie rod ends and tighten the nuts to 35 ft. Ips. (48 Nm) e Dual converter Y-pipe e Front wheels e |ntermediate steering shaft e Negative battery cable 4. Fill and bleed the power steering system. Check the system for leaks and proper operation. 5. Check the alignment and adjust as necessary.

REMOVAL & INSTALLATION Front

1. Before servicing the vehicle, refer to the precautions at the beginning of this section. 2. Remove or disconnect the following: ¢ Negative battery cable e Front wheels ¢ Height sensor and wiring, if equipped with air Suspension Brake hose bracket Disc brake caliper and rotor Wheel speed sensor and wiring Outer tie rod end e@6 °@ e@ Stabilizer link

Brake service is covered in Section 4 of this manual

42-34

FORD moTOR Co. TAURUS ¢ SABLE

e Steering knuckle pinch bolt e Strut assembly To install: 3. Install or connect the following: Strut assembly. Tighten the upper nuts to 22-29 ft. Ibs. (30-40 Nm), and the knuckle pinch bolt to 73-97 ft. Ibs. (98-132 Nm). Stabilizer link and tighten the nut to 59-75 ft. Ibs. (75-101 Nm) Outer tie rod end and tighten the nut to 35 ft. Ibs. (48 Nm) Wheel speed sensor and wiring Disc brake caliper and rotor and tighten the caliper anchor bracket bolts to 65-87 ft. Ibs. (88-118 Nm) Brake hose bracket Height sensor and wiring, if equipped with air Suspension Front wheels Negative battery cable 4. Road test the vehicle and check for proper operation. Rear

1. Before servicing the vehicle, refer to the precautions at the beginning of this section. 2. Remove or disconnect the following: Rear package tray trim panel Rear wheels Brake load sensor Brake hose Stabilizer bar bracket and link Tension strut Spindle pinch bolt Strut assembly To install:

Description

ats [promeon seeing |

Front Shock Absorber | 22 |[FrontShock Absorber |

Tie Rod End

eae

Item

Description

i oSal Front Wheel Knuckle Fret Front Suspension Lower Arm 7 | Front Stabilizer Bar

Wheel Hub

Stabilizer Bar Link 7922KG61

Front suspension component identification

e>Use new mounting nuts and bolts.

3. Install or connect the following: Strut assembly, Use a new pinch bolt and tighten to 50-67 ft. Ibs. (68-92 Nm). Tighten the 3 upper mounting nuts to 19-25 ft. Ibs. (25-34 Nm). Tension strut and tighten the nut to 35-46 ft. Ibs. (68-92 Nm) Stabilizer bar link and tighten the nut to 60-81 inch Ibs. (7-9 Nm) Stabilizer bar bracket and tighten the bolts to 25 —33 ft. Ibs. (34-46 Nm) Brake hose Brake load sensor Rear wheels Rear package tray trim panel

Item | Description 1 | Rear Stabilizer Bar 2 | Rear Spring

3

|Shock Absorber

6 | Lower Suspension Arm (Rear) 7 | Rear Wheel Spindle

8 | Nut (4 Req'd) PS Fors Washer (2 Req'd)

7922KG62

Rear suspension component identification—sedan models

FORD MOTOR CO. TAURUS ¢ SABLE

1 2-35

Wagons with rear shock absorbers

Shock Absorber

1. Before servicing the vehicle, refer to the precautions at the beginning of this section. 2. Remove or disconnect the following: e Rear shock absorber e Stabilizer bar link and bracket e Brake hose bracket e Upper ball joint 3. Install spring keepers on the coil springs. 4. Slowly lower the lower control arm until the tension is relaxed on the coil spring. Remove the coil spring and the upper and lower spring insulators. To install:

REMOVAL & INSTALLATION Wagons 1. Before servicing the vehicle, refer to naprecautions at the beginning of this secion. 2. Remove the rear wheels and support the rear control arms on jackstands. 3. Remove or disconnect the following: e Rear compartment access panels e Upper shock mounting nuts and insulators e Lower shock mounting bolts e Shock absorbers To install:

«>Use new mounting nuts and bolts.

5. Install or connect the following: Coil spring with upper and lower Spring insulators Upper ball joint and tighten the nut to 50-68 ft. Ibs. (68-92 Nm) Brake hose bracket Stabilizer bar link and bracket Rear shock absorber

«>Use new mounting fasteners and insulators.

4. Install or connect the following: e Shock absorbers. Tighten the lower bolt to 50-68 ft. Ibs. (68-92 Nm), and the upper nuts to19-25 ft. Ibs. (26-34 Nm). e Rear compartment access panels e Rear wheels

Wey Front Shock Absorber Mounting Bracket

[6 [Washer 7 | Front Suspension Bearing and Seal

Lower Ball Joints

Front Spring Insulator (Part of 18124)

onal Front Coil Spring

Gos

|

REMOVAL & INSTALLATION

Front Shock Absorber Jounce Bumper (Part of 18124)

7922KG63

Exploded view of the front strut and coil

spring assembly

The lower ball joint is an integral part of the steering knuckle. If the lower ball joint is found to be defective, the entire steering knuckle must be replaced.

Upper Control Arm 80 Nm (59 Ib-ft

REMOVAL AND INSTALLATION

9346KG34

Shock absorber lower mounting bolt—

Rear

Wagon

WAGON ONLY

Coil Spring

OXYGEN SENSOR WRENCH

REMOVAL & INSTALLATION pu

7922KG64

Hold the strut rod while loosening or tightening the nut

Struts

1. Before servicing the vehicle, refer to the precautions at the beginning of this section. 9. Remove the strut from the vehicle. 3. Compress the coil spring using a suitable spring compressor until the spring comes away from the seat. 4. Remove the large center nut and slowly release the spring compressor.

To install: 5. Compress the spring and install it on the strut. 6. Install the lower washer and mounting bracket. 7. Install the upper washer and a new nut. Tighten the nut to 39-53 ft. Ibs. (53-72 Nm). 8. Install the strut assembly in the vehicle.

1. Before servicing the vehicle, refer to the precautions at the beginning of this section. 2. Support the lower control arm ona jackstand. 3. Remove or disconnect the following: e Rear wheel e Brake hose bracket e Upper ball joint e Upper control arm To install: >Use new mounting nuts and bolts.

4. Install or connect the following: e Upper control arm. Tighten the ball joint nut to 50-67 ft. Ibs. (68-92 Nm), then tighten the control arm

For complete Engine Mechanical specifications, see Section 1 of this manual

42-36

FORD MoToR co. TAURUS ¢ SABLE

mounting bolts to 73-97 ft. Ibs. (98-132 Nm). e Brake hose bracket e Rear wheel 5. Check the wheel alignment and adjust as necessary.

CONTROL ARM BUSHING REPLACEMENT The control arm bushings are serviced with the control arm as an assembly.

Lower Control Arm

REMOVAL & INSTALLATION Front

1. Before servicing the vehicle, refer to the precautions at the beginning of this section. 2. Remove or disconnect the following: e Front wheel e Wheel speed sensor wiring harness ¢ Lower ball joint ¢ Lower control arm To install: 3. Install or connect the following: ¢ Lower control arm. Tighten the front bolt to 57-75 ft. Ibs. (77-103 Nm), and the rear bolt to 72-97 ft. bs. (98-132 Nm). © Lower ball joint. Use a new nut and tighten to 50-67 ft. Ibs. (68-92 Nm). ¢ Wheel speed sensor wiring harness Front wheel 4. Check the wheel alignment and adjust as necessary.

ment. Each adjustment cam is installed from the front on the rear suspension arm and bushing.

3. Install or connect the following: e Lower control arm and tighten the bolts to 50-67 ft. Ibs. (68-92 Nm) e Proportioning valve e Parking brake cable e Rear wheel 4. Check the wheel alignment and adjust as necessary.

WAGON

1. Before servicing the vehicle, refer to the precautions at the beginning of this section. 2. Remove or disconnect the following: ¢ Rear wheel e Parking brake cable * Proportioning valve ¢ Lower control arm To install: >Use new bolts and nuts.

e>The rear suspension lower control arms are marked BOTTOM on the lower edge. The flange edge of the right side rear suspension arm and bushing stamping must face the front of the vehicle. The other three must face the rear of the vehicle.

e>The rear suspension arms have two adjustment cams that fit inside the bushings at the arm-to-body attach-

>Use new nuts, bolts, and split pins. >The knuckle must be clean enough to allow the wheel hub to be completely seated by hand. Do not press or draw the wheel hub into place.

3. Install or connect the following: e Hub and bearing assembly and tighten the bolts to 61-78 ft. Ibs. (83-107 Nm) Steering knuckle and tighten the pinch bolt to 72-97 ft. Ibs. (98-132 Nm) Lower ball joint and tighten the nut to 50-67 ft. Ibs. (68-92 Nm) Wheel speed sensor Stabilizer bar link and tighten the nut to 57—75 ft. Ibs. (77-103 Nm) Outer tie rod end and tighten the nut to 35—-46 ft. Ibs. (47-63 Nm) Brake caliper and rotor and tighten the caliper anchor bracket bolts to 65-87 ft. Ibs. (88-118 Nm) Hub retainer nut and tighten to 170-202 ft. Ibs. (230-275 Nm) Front wheel

1. Before servicing the vehicle, refer to the precautions at the beginning of this section. 2. Remove or disconnect the following: e Rear wheel

¢ Coil spring e Wheel spindle ¢ Lower control arm To install: ->Use new nuts and bolts.

e>Tighten the control arm fasteners with the vehicle weight resting on the wheels.

3. Install or connect the following: ¢ Lower control arm e Wheel spindle ¢ Coil spring e Rear wheel 4. Tighten the contro! arm-to-body bolt to 40-82 ft. Ibs. (64-71 Nm), and the armto-spindle bolt to 50-67 ft. Ibs. (68-92 Nm). 5. Check the wheel alignment and adjust as necessary.

CONTROL ARM BUSHING REPLACEMENT

Rear

SEDAN

e Stabilizer bar link e Wheel speed sensor e Lower ball joint e Steering knuckle e Hub and bearing assembly To install:

The control arm bushings are serviced with the control arm as an assembly.

Wheel Bearings ADJUSTMENT There is no adjustment for the front or rear wheel bearings due to the nature of their design. These bearings are permanently lubricated and require no periodic maintenance.

REMOVAL & INSTALLATION —_—_———

Front

1. Before servicing the vehicle, refer to the precautions at the beginning of this section. 2. Remove or disconnect the following: ¢ Front wheel e Hub retainer nut ¢ Brake caliper and rotor

¢ Outer tie rod end

Rear

1. Before servicing the vehicle, refer to the precautions at the beginning of this section. 2. Remove or disconnect the following: e Rear wheel Brake hose bracket Brake caliper and rotor, if equipped with rear disc brakes Brake drum, if equipped with rear drum brakes Hub and bearing assembly grease Cap and retaining nut ¢ Hub and bearing assembly To install: e>Use new retaining nuts and grease caps

3. Install or connect the following: ¢ Hub and bearing assembly and tighten the retaining nut to 188-254 ft. Ibs. (255-345 Nm) e Grease cap Brake caliper and rotor, if equipped with rear disc brakes Brake drum, if equipped with rear drum brakes ¢ Brake hose bracket Rear wheel

FORD MOTOR CO. 1998-01 Lincoln-Continental DRIVE TRAIN.................. 13-12 ENGINE REPAIR ................ 13-2

FUCIINGCtOR Ee eeearen 13-11 Removal & Installation............ 13-11

STEERING AND SUSPENSION................. 13-13 A

Fuel System PreSSUre ............s. 13-44 Relleving’ Caereet. 13-11 Fuel System Service

FUEL SYSTEM ................ 132107) BREGAUTIONS-.c0:0.3 20s 13-2

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ReaniViain Seale sethe eases, 13-f Removal & Installation............. 13-7

semen. Giese 13-10

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PratantiOns:

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Removal & Installation............ 43.45

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13-12

Removal & Replacement......... 13-12

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Removal & Installation............ 13-13 R

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Removal & Installation.............. 13-5 L Lower Ball JOINtS .......... cee 13-19 Removal & Installation............ 13-15

Lower Control Arima ued nna). 13-16 Control Arm Bushing

Replacement... 13-16

Removal & Installation........... 13-16

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Timing Chain, Sprockets,

Front Cover And Seal...........-10 13-8 Removal & Installation.............. 13-8 Transaxle ASS@MDIY .......c:scceceeene 13-12 Removal & Installation............ 13-12

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Control Arm Bushing

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Removal & yes cesses 13-19 aerate dete pn pn

13-6

Adjustment....... igOCR

13-6

Valve Lash Ei

Removal & eon Eas ea ie

Removal & Installation.............. 122%

Engine ASSEMDIY .......ccssssecsee 13-2 Removal & Installation.............. 13-2

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Removal & Installation.......... 13-16

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Removal & Installation... (eek)

PION and RING cc 13-10 POSIIOUINU:

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13-2 SESE ELS

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PRECAUTIONS Before servicing any vehicle, please be sure to read all of the following precautions, which deal with personal safety, prevention of component damage, and important points to take into consideration when servicing a motor vehicle: e Never open, service or drain the radiator or cooling system when the engine is hot; serious burns can occur from the steam and hot coolant. ¢ Observe all applicable safety precautions when working around fuel. Whenever servicing the fuel system, always work in a well-ventilated area. Do not allow fuel spray Or vapors to come in contact with a spark, open flame, or excessive heat (a hot drop light, for example). Keep a dry chemical fire extinguisher near the work area. Always keep fuel in a container specifically designed for fuel storage; also, always properly seal fuel containers to avoid the possibility of fire or explosion. Refer to the additional fuel system precautions later in this section. * Fuel injection systems often remain pressurized, even after the engine has been turned OFF. The fuel system pressure must be relieved before disconnecting any fuel lines. Failure to do so may result in fire and/or personal injury. e Brake fluid often contains polyglycol ethers and polyglycols. Avoid contact with the eyes and wash your hands thoroughly after handling brake fluid. If you do get brake fluid in your eyes, flush your eyes with clean, running water for 15 minutes. If eye irritation persists, or if you have taken

; ->Disconnecting the negative battery cable on some vehicles may interfere with the functions of the on board computer system. The computer may undergo a relearning process once the negative battery cable is reconnected.

Alternator

REMOVAL SY

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Negative battery cable ¢ Coolant recovery reservoir ¢ Accessory drive belt e Alternator bracket ¢ Alternator

brake fluid internally, IMMEDIATELY seek medical assistance. e The EPA warns that prolonged contact with used engine oil may cause a number of skin disorders, including cancer. You should make every effort to minimize your exposure to used engine oil. Protective gloves should be worn when changing oil. Wash your hands and any other exposed skin areas aS soon as possible after exposure to used engine oil. Soap and water, or waterless hand cleaner should be used. e All new vehicles are now equipped with an air bag system, often referred to as a Supplemental Restraint System (SRS) or Supplemental Inflatable Restraint (SIR) 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 repairs. ¢ Always wear safety goggles when working with, or around, the air bag system. When carrying a non-deployed air bag, be sure the bag and trim cover are pointed away from your body. When placing a non-deployed air bag on a work surface, always face the bag and trim cover upward, away from the surface. This will reduce the motion of the module if it is accidentally deployed. Refer to the additional air bag system precautions later in this section.

|

e Clean, high quality brake fluid from a sealed container is essential to the safe and proper operation of the brake system. You should always buy the correct type of brake fluid for your vehicle. If the brake fluid becomes contaminated, completely flush the system with new fluid. Never reuse any brake fluid. Any brake fluid that is removed from the system should be discarded. Also, do not allow any brake fluid to come in contact with a painted surface; it will damage the paint. e Never operate the engine without the proper amount and type of engine oil; doing So WILL result in severe engine damage. ¢ Timing belt maintenance is extremely important. Many models utilize an interference-type, non-freewheeling engine. If the timing belt breaks, the valves in the cylinder head may strike the pistons, causing potentially serious (also time-consuming and expensive) engine damage. Refer to the maintenance interval charts in the front of this manual for the recommended replacement interval for the timing belt, and to the timing belt section for belt replacement and inspection. e Disconnecting the negative battery cable on some vehicles may interfere with the functions of the on-board computer system(s) and may require the computer to undergo a relearning process once the negative battery cable is reconnected. ¢ When servicing drum brakes, only disassemble and assemble one side at a time, leaving the remaining side intact for reference.

ENGINE REPAIR

INSTALLATION 1. Install or connect the following: e Alternator. Tighten the bolts to 15-22 ft. Ibs. (20-30 Nm). ¢ Alternator bracket. Tighten the nuts to 71-106 inch Ibs. (8-12 Nm), ¢ Accessory drive belt * Coolant recovery reservoir ¢ Negative battery cable

Ignition Timing ADJUSTMENT RR Re Mian eee STEN The ignition timing is controlled by the Powertrain Control Module (PCM) and is not adjustable.

Engine Assembly

:

REMOVAL & INSTALLATION Le?

-> Disable the air suspension before raising the vehicle. The switch is located on the left side of the luggage compartment.

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Turn the air suspension switch to the OFF position. 3. Recover the A/C refrigerant. 4. Drain the cooling system. 9. Remove or disconnect the following: ¢ Negative battery cable e Hood ¢ Steering column intermediate shaft

FORD MOTOR CO. CONTINENTAL

Engine appearance cover e Intake Air Temperature (IAT) sensor connector Air cleaner outlet tube Upper motor mount Fuel line Dash panel ground straps Powertrain Control Module (PCM) connector Mass Air Flow (MAF) sensor connector Traction control motor connector Throttle Position (TP) sensor connector Cruise control cable Accelerator cable and bracket Shift selector cable Engine control wiring harness (3 connectors) and bracket Intake manifold vacuum lines Transaxle cooler lines Power steering return hose at the fluid reservoir Alternator wiring harness Radiator splash shield Heater hoses Radiator hoses Front wheels Suspension height sensor links Lower ball joints Stabilizer bar links Outer tie rod ends Halfshafts Heated Oxygen (HO2S) sensor connectors Dual converter Y-pipe Block heater connector Power steering cooler lines A/C compressor lines Starter motor Subframe brackets Torque converter shield and torque converter 6. Support the powertrain from below and remove the subframe bolts. 7. Raise the vehicle away from the powertrain. 8. Attach an engine hoist to the powertrain. 9. Remove or disconnect the following: Power steering sensor connector Power steering return line from the steering gear Turbine shaft speed sensor connector Transaxle range sensor connector

Transaxle control harness connector

Radiator splash shield Alternator wiring harness Power steering return hose at the

e Left and right engine support insulators e Right engine support insulator bracket 10. Remove the transaxle flange bolts and separate the engine from the transaxle. To install: e>\When installing suspension components and halfshafts, use new nuts, bolts, circlips and split pins.

11. Install or connect the following: Transaxle. Tighten the flange bolts to 25-34 ft. Ibs. (34-46 Nm). Right engine support insulator bracket. Tighten the bolts to 16-21 ft. lbs. (22-29 Nm). Left and right engine support insulators. Tighten the through-bolts to 64-88 ft. Ibs. (87-119 Nm). Transaxle control harness connector Transaxle range sensor connector Turbine shaft speed sensor connector ¢ Power steering return line from the Steering gear e Power steering sensor connector 12. Lower the vehicle on to the powertrain assembly. Use 2 pieces of % inch outside diameter pipe in the alignment holes behind the front subframe mounts to align the subframe to the body. Tighten the subframe mounting bolts to 57—/6 ft. Ibs. (77-103 Nm). 13. Install or connect the following: Torque converter shield and torque converter. Tighten the torque converter nuts to 20-34 ft. Ibs. (27-46 Nm). Subframe brackets Starter motor A/C compressor lines Power steering cooler lines Block heater connector Dual converter Y-pipe HO2S sensor connectors Halfshafts. Tighten the hub retainer nuts to 170-202 ft. Ibs. (230-275 Nm). Outer tie rod ends. Tighten the nuts to 35-46 ft. Ibs. (47-63 Nm). Stabilizer bar links. Tighten the nuts to 30-40 ft. Ibs. (40-55 Nm). Lower ball joints. Tighten the nuts to 50-68 ft. Ibs. (68-92 Nm). Suspension height sensor links Front wheels Radiator hoses Heater hoses

13-3

fluid reservoir Transaxle cooler lines Intake manifold vacuum lines Engine control wiring harness (3

connectors) and bracket e e e e e e e

Shift selector cable Accelerator cable and bracket Cruise control cable TP sensor connector Traction control motor connector MAF sensor connector PCM connector

e Dash panel ground straps Fuel line Upper motor mount Air cleaner outlet tube IAT sensor connector Engine appearance cover Steering column intermediate shaft Hood Negative battery cable 14. Fill the cooling system. 15. Check and adjust fluid levels as necessary. 16. Recharge the A/C system. 17. Turn the air suspension switch to the ON position. 18. Run the engine and check for leaks. =>\Whenever the subframe is removed

or lowered, the wheel alignment should be checked.

Water Pump © REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the cooling system. 3. Remove or disconnect the following: ¢ Negative battery cable ¢ Coolant reservoir e Accessory drive belt e Alternator ¢ Water pump pulley e Water pump To install: 4. |nstall or connect the following: e Water pump. Use a new O-ring seal and tighten the bolts to 15-22 ft. lbs. (20-30 Nm). e Water pump pulley. Tighten the bolts to 15-22 ft. Ibs. (20-30 Nm). e Alternator

For complete service labor times, order Nichols’ Chilton Labor Guide

13-4

CONTINENTAL bine Exhaust Gas Recirculation (EGR)

CYLINDER BLOCK

vacuum regulator valve

WATER PUMP HOUSING GASKET

EGR tube Injector wiring connectors Intake manifold Left and right exhaust manifolds Front cover Crankshaft Position (CKP) sensor pulse wheel Timing chains Cylinder heads To install:

7922LG01

Exploded view of the water pump mounting

e Accessory drive belt ¢ Coolant reservoir e Negative battery cable 5. Fill the cooling system. 6. Start the engine and check for leaks.

Cylinder Head

:

REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove the engine from the vehicle and mount it on a suitable workstand. 3. Remove or disconnect the following: Accessory drive belt and tensioner Idler pulley Engine Coolant Temperature (ECT) sensor connector Water bypass tube Alternator Water pump Power steering pump Crankshaft pulley Camshaft Position (CMP) sensor Ignition coils Fuel pressure sensor connector and vacuum line e Valve covers e Rocker arms

>The cylinder head bolts are a torqueto-yield design and cannot be reused.

4. Use new gaskets and install the cylinder heads. Tighten the cylinder head bolts in sequence as follows: a. Step 1: 28-31 ft. Ibs. (37-43 Nm). b. Step 2: Tighten the bolts 85-95 degrees. C. Step 3: Loosen all bolts 1 full turn. d. Step 4: Tighten all bolts to 28-31 ft. Ibs. (837-43 Nm). é. Step 5: Tighten the bolts 85-95 degrees. f. Step 6: Tighten the bolts 85-95 degrees. 5. Install or connect the following: Timing chains CKP sensor pulse wheel Front cover Left and right exhaust manifolds Intake manifold Injector wiring connectors EGR tube

e. e e e e e e e e e

EGR vacuum regulator valve Rocker arms Valve covers Fuel pressure sensor connector and vacuum line Ignition coils CMP sensor Crankshaft pulley Water pump Power steering pump Alternator Water bypass tube ECT sensor connector Idler pulley Accessory drive belt and tensioner

REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions at the beginning of this section. 2. Remove or disconnect the following: e Negative battery cable e Ignition coils e Valve covers 3. Rotate the crankshaft so that the piston on the cylinder to be serviced is at bottom dead center with the valves closed. 4. Install special tool Valve Spring Compressor T91P-6565-A for exhaust valves, and Valve Spring Compressor T93P-6565-A for intake valves. 5. Compress the valve spring and remove the rocker arm. Repeat for each arm to be removed. elf the rocker arms are to be reused, ensure that they are installed in the same position that they were removed from.

To install: 6. Compress the valve spring and install the rocker arm. Repeat for each arm to be installed.

8-12 Nm (71-106 lb/in) 9346LG01

RH CYLINDER HEAD

Right valve cover torque sequence

LH CYLINDER HEAD

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FRONT OF ENGINE

7922LG02

Cylinder head torque sequence—4.6L engine

8-12 Nm (71-106 Ib/in)

7922LG604 9346LG02

Left valve cover torque sequence

Rocker arm service tool—exhaust valve tool shown

FORD MOTOR CO. CONTINENTAL

7. Install or connect the following: e Valve covers e Ignition coils e Negative battery cable 8. Start the engine and check for proper operation.

Intake Manifold

REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section.

¢ Intake Manifold Runner Control (IMRC) cables and actuator e Fuel injector connectors e Throttle Position (TP) sensor connector Idle Air Control (IAC) connector

Fuel temperature sensor connector Fuel injection supply manifold Intake manifold. Loosen the bolts in three steps in the sequence shown. e IMRC housings

FRONT OF ENGINE

2. Drain the cooling system. 3. Remove or disconnect the following: Negative battery cable Engine appearance cover Air cleaner outlet tube Fuel lines Fuel pressure sensor vacuum and wiring connectors Upper radiator hose Heater hose Engine Coolant Temperature (ECT) sensor connector Water bypass tube

Cruise control cable Accelerator cable and bracket Crankcase vent hose Chassis vacuum supply line Secondary air injection vacuum lines e Exhaust Gas Recirculation (EGR) vacuum regulator e EGR valve

7922LG07

IMRC torque sequence—4.6L engine

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13-5

4. Install or connect the following: e IMRC housings to the intake manifold e Fuel supply manifold and tighten the bolts to 71-106 inch Ibs. (8-12 Nm) e>Install the long bolts and studs in the outer holes. Install the short bolts and studs in the inner holes.

5. Install the intake manifold assembly. Tighten the bolts in sequence as follows: a. Step 1: Tighten bolts 5, 7, 9, and 11 to 9-11 ft. Ibs. (12-15 Nm). b. Step 2: Tighten all other bolts to 13-16 ft. Ibs. (18-22 Nm). c. Step 3: Tighten all bolts in sequence 85—95 degrees. 6. Tighten the IMRC housing bolts as follows: a. Step 1: 71-89 inch Ibs. (8-10 Nm). b. Step 2: Plus 85-95 degrees. 7. Install or connect the following: Fuel temperature sensor connector IAC connector TP sensor connector Fuel injector connectors IMRC cables and actuator EGR valve EGR vacuum regulator Secondary air injection vacuum lines Chassis vacuum supply line Crankcase vent hose Accelerator cable and bracket Cruise control cable Water bypass tube ECT sensor connector Heater hose Upper radiator hose Fuel pressure sensor vacuum and wiring connectors Fuel lines Air cleaner outlet tube Engine appearance cover Negative battery cable 8. Fill the cooling system. 9. Start the engine and check for leaks.

Exhaust Manifold

=

REMOVAL & INSTALLATION 9306LG02

9306LG01

Intake manifold bolt removal sequence

Intake manifold torque sequence—4.6L

engine

Disable the air suspension before raising the vehicle. The switch is located on the left side of the luggage compartment.

Please visit our web site at www.chiltonsonline.com

13-6

FORD MOTOR CO. CONTINENTAL @

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INTAKE

e CAP ASSY

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7922LG08

Exhaust manifold torque sequence—right side shown, left side similar

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Turn the air suspension switch to the OFF position. 3. Remove or disconnect the following: Negative battery cable Radiator splash shield Heated Oxygen (HO2S) sensor connectors Dual converter Y-pipe Exhaust Gas Recirculation (EGR) tube Secondary air injection tubes Exhaust manifolds To install: 4. Install or connect the following: Exhaust manifolds. Tighten the nuts in sequence to 13-16 ft. Ibs. (18-22 Nm). Secondary air injection tubes. Tighten the nuts to 25-34 ft. Ibs. (34-46 Nm), EGR tube. Tighten the nut to 30-33 ft. Ibs. (40-45 Nm). Dual converter Y-pipe

HO2S sensor connectors Radiator splash shield Negative battery cable 5. Turn the air suspension switch to the ON position. 6. Start the engine and check for leaks.

Camshaft and Valve Lifters

REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove the engine from the vehicle and mount it on a suitable workstand. 3. Remove or disconnect the following: ¢ Accessory drive belt and tensioner e Idler pulley

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3) EXHAUST 4) CAP ASSY

7922LG09

Camshaft cap assembly torque sequence

Alternator Power steering pump Water pump Crankshaft pulley Crankshaft Position (CKP) sensor Camshaft Position (CMP) sensor Ignition coils Valve covers e>|f the rocker arms are to be reused, label them as they are removed so they can be reinstalled in their original locations.

Rocker arms Front cover Crankshaft Position (CKP) sensor pulse wheel Timing chains and sprockets Secondary chains and sprockets Secondary chain tensioners Camshaft cap assemblies Camshafts To install: ->The exhaust camshaft cap assembly outboard bolts are shorter than the other cap assembly bolts.

4. Install the camshafts and camshatt Cap assemblies in their original positions. 9. Tighten the camshaft cap assembly bolts in sequence as follows: a. Step 1: Tighten all bolts to 71-106 inch lbs. (8-12 Nm) b. Step 2: Loosen all bolts 2 turns C. Step 3: Tighten all bolts to 71-106 inch lbs. (8-12 Nm) 6. Install or connect the following: * Secondary chain tensioners ¢ Secondary chains and sprockets e Timing chains and sprockets

CKP sensor pulse wheel Front cover Rocker arms in the original locations Valve covers Ignition coils CMP sensor CKP sensor Crankshaft pulley Water pump Power steering pump Alternator Idler pulley Accessory drive belt and tensioner 7. Remove the engine from the workstand and install in the vehicle. 8. Start the engine and check for leaks.

Valve Lash

ADJUSTMENT The 4.6L DOHC engine uses hydraulic valve lash adjusters that do not require any adjustment.

Starter Motor

i.

REMOVAL & INSTALLATION Ne Sy ie LRP nl 22 +P ->Disable the air suspension before raising the vehicle. The switch is located on the left side of the luggage compartment.

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Turn the air suspension switchto the OFF position.

FORD MOTOR CO.

CONTINENTAL

3. Remove or disconnect the following: ¢ Negative battery cable e Radiator splash shield Starter solenoid connections e Starter To install: 4. Install or connect the following: e Starter. Tighten the bolt and stud to 15-20 ft. Ibs. (20-27 Nm). e Starter solenoid connections e Radiator splash shield e Negative battery cable 5. Turn the air suspension switch to the

6. Install or connect the following: ¢ Power steering pressure hose bracket e Oil level sensor connector « Dual converter Y-pipe e Oil level dipstick e Negative battery cable 7. Fill the crankcase with the correct type and quantity of engine oil. 8. Turn the air suspension switch to the ON position. 9. Start the engine and check for leaks.

ON position. REMOVAL & INSTALLATION

REMOVAL & INSTALLATION e>Disable the air suspension before raising the vehicle. The switch is located on the left side of the luggage compartment.

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Turn the air suspension switch to the OFF position. 3. Remove or disconnect the following: e Negative battery cable e (il level dipstick e Dual converter Y-pipe e (il level sensor connector ¢ Power steering pressure hose bracket e Qil pan To install: 4. Apply a bead of silicone sealer to the oil pan flange. Also apply a bead of sealer to the front cover/cylinder block joint and fill the grooves on both sides of the rear main seal cap. 5. Use a new gasket and install the oil pan. Tighten the bolts in sequence as follows: a. Step 1: 14 ft. Ibs. (20 Nm) b. Step 2: Plus 60 degrees

Oil pan bolt torque sequence

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove the engine from the vehicle and mount it on a suitable workstand. 3. Remove or disconnect the following: Accessory drive belt and tensioner Idler pulley Alternator Power steering pump Water pump Crankshaft pulley Camshaft Position (CMP) sensor Ignition coils Valve covers Rocker arms Front cover Crankshaft Position (CKP) sensor pulse wheel ¢ Timing chains and sprockets e Qil pan ¢ Oil pump pickup screen and tube e Oil pump To install: 4. Install or connect the following: ¢ Oil pump. Tighten the bolts in sequence to 71-106 inch Ibs. (8-12 Nm). e Qil pump pickup screen and tube. Use a new O-ring seal and tighten

Oil pump mounting bolt sequence

1 3-/

the mounting bolts to 71-106 inch lbs. (8-12 Nm). Tighten the bracket bolt to 15-22 ft. Ibs. (20-30 Nm). Oil pan Timing chains and sprockets CKP sensor pulse wheel Front cover Rocker arms Valve covers Ignition coils CMP sensor Crankshaft pulley Water pump Power steering pump Alternator Idler pulley Accessory drive belt and tensioner 5. Remove the engine from the workstand and install in the vehicle. 6. Restore all fluid levels. 7. Run the engine and check for leaks and proper operation.

Rear Main Seal

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REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Transaxle e Flywheel e (il seal retainer e Oil seal To install: 3. Apply a 0.060 inch (1.5mm) continuous bead of silicone gasket sealer to the cylinder block. 4. Install or connect the following: e Oil seal retainer. Tighten the bolts in sequence to 71-106 inch Ibs. (8-12 Nm). ¢ (il seal. Use special tool Seal Installer T82L-6701-A and adapter T91P-6701-A to press the seal into place.

Oil seal retainer torque sequence

Timing belt service is covered in Section 3 of this manual

13-8

FORD MOTOR CO. CONTINENTAL “SECONDARY TIMING CHAIN TENSIONER

7922LG13

Use Seal Installer T82L-6701-A and adapter T91P-6701-A to press the seal into the retainer

e Flywheel. Tighten the bolts to 54-64 ft. Ibs. (73-87 Nm). e Transaxle 5. Check and adjust all fluid levels as necessary. 6. Start the engine and check for leaks.

9306LG03

Secondary timing chain tensioner and locking pin

INTAKE CAMSHAFT

SECONDARY TIMING CHAIN

SECONDARY TIMING CHAIN TENSIONING TOOL 7922LG17

Secondary timing chain tensioning tool

EXHAUST

CAMSHAFT

Timing Chain, Sprockets, Front Cover and Seal REMOVAL & INSTALLATION CAMSHAFT POSITIONING TOOL T93P-6256-A 2 REQ'D

7922LG14

Position the camshafts for timing chain installation

This is an interference engine. When the timing chains are removed and the cylinder heads are installed, the crankshaft and/or camshafts must not be rotated unless as directed in this procedure. Failure to follow these instructions will result in valve and/or piston damage.

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove the engine from the vehicle and mount it on a suitable workstand. 3. Remove or disconnect the following: Accessory drive belt and tensioner Idler pulley Alternator Power steering pump Water pump Crankshaft pulley Front crankshaft seal Crankshaft Position (CKP) sensor Camshaft Position (CMP) sensor Engine control sensor wiring harness Ignition coils Valve covers e*lf the rocker arms are to be reused, label them as they are removed so they can be reinstalled in their original locations.

¢ Rocker arms e Front cover 4. Rotate the crankshaft to place the piston for No. 1 cylinder at Top Dead Center (TDC) on its compression stroke. 9. Remove or disconnect the following: Right primary timing chain tensioner Right primary timing chain tensioner arm and chain guide Right primary timing chain and sprockets Left primary timing chain tensioner Left primary timing chain tensioner arm and chain guide Left primary timing chain and sprockets 6. Compress the secondary chain tensioners and install locking pins. 7. Remove or disconnect the following; ¢ Left and right secondary timing chains and sprockets e Camshaft Holding and Camshaft Positioning tools To install: 8. Position the camshafts as shown for timing chain installation. 9. Install the secondary timing chains and sprockets. Do not tighten the sprocket bolts at this time. 10. Tension the secondary timing chains

9306LG04

Install the Camshaft Positioning tool

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© © CAMSHAFT pees T93P-6256-AH

EXHAUST CAMSHAFT 7922LG15

Install the Camshaft Holding tool to secure the camshafts and prevent damage to the Camshaft Positioning Tool

with the special tool Secondary Timing Chain Tensioning Tool T93P-6256-BH. 11. Install Camshaft Positioning tool T93P-6256-A in the rear D-slots of the camshaft. 12. Install Camshaft Holding tool T93P6256-AH onto the camshafts to keep the camshafts from rotating and to prevent damaging the camshaft positioning tool.

FORD MOTOR CO. CONTINENTAL

, SECONDARY TENSIONER

13-9

90°

90°

SECONDARY TENSIONER

CRANKSHAFT KEYWAY 7922LG03

Turn the crankshaft to the 9 o’clock position for timing chain installation

7922LG19

9306LG05

Crankshaft timing sprocket installation

13. Tighten the secondary timing chain sprocket bolts to 81-95 ft. Ibs. (110-130 Nm). 14, Remove the secondary timing chain tensioner locking pins and remove the tensioner tool. 15. Position the crankshaft so that the keyway is at 9 o'clock as shown. 16. Compress the primary timing chain tensioners and install locking pins. 17. Install the crankshaft timing sprockets arranged as shown. 18. Align the copper colored primary timing chain links with the sprocket timing marks as shown. 19. Install or connect the following: Left primary timing chain and sprockets Left primary timing chain tensioner arm and chain guide Left primary timing chain tensioner Right primary timing chain ana sprockets Right primary timing chain tensioner arm and chain guide Right primary timing chain tensioner

Oe

20-30 Nm

(15-22 Ib/ft 7922LG20

Front cover torque sequence

20. Tighten the camshaft sprocket bolts to 81-95 ft. Ibs. (110-130 Nm). 21. Remove the primary timing chain tensioner locking pins. 92. Remove the Camshaft Holding and Camshaft Positioning tools. 93. Install or connect the following: Front cover. Tighten the bolts in sequence to 15-22 ft. Ibs. (20-30 Nm). © Rocker arms in their original positions e \Valve covers e Ignition coils e CMP sensor

e CKP sensor

e Engine control sensor wiring harness ¢ Front crankshaft seal 24, Install the crankshaft pulley and tighten the bolt as follows: a. Step 1: 89 ft. Ibs. (120 Nm) b. Step 2: Loosen the bolt c. Step 3: 39 ft. Ibs. (63 Nm) d. Step 4: Plus 90 degrees 95. Install or connect the following: e Water pump ¢ Power steering pump e Alternator e Idler pulley and tensioner. Tighten the bolts to 15-22 ft. Ibs. (20-30

Nm).

Heater Core replacement is covered in Section 2 of this manual

13-1

FORD MOTOR CO. CONTINENTAL Sealer Location

2

FRONT OF ENGINE

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VIEW A

VIEW B TYPICAL 2 PLACES

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WSE-M4G320-A2 6710

Description RH Cylinder Head LH Cylinder Head

Ignition Pulse Crankshaft Sensor Ring Cylinder Block Sealer Oil Pan Gasket 9306LG06

Apply sealer to these locations

¢ Accessory drive belt 26. Remove the engine from the workStand and install in the vehicle. 2/. Restore all fluid levels. 28. Run the engine and check for leaks and proper operation.

UPPER SIDE ———$————> RAIL

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TOP7COMPRESSION

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Piston and Ring

COMPRESSION

EXPANDER AND RAILS

POSITIONING

Safety is the most important factor when performing not only fuel system maintenance but any type of maintenance. Failure to conduct maintenance and repairs in a Safe manner may result in serious personal injury or death. Maintenance and testing of the vehicle’s fuel system components can be accomplished safely and effectively by adheringto the following rules and guidelines. * To avoid the possibility of fire and personal injury, always disconnect the negative battery cable unless the repair or test proce-

LOWER SIDE RAIL 7922AG33

Piston ring positioning—4.6L VIN V engine

Fuel System Service Precautions

FRONT DIRECTIONAL NOTCH

Ol

7922AG34

LN

EXPANDER

dure requires that battery voltage be applied, ¢ Always relieve the fuel system presSure prior to disconnecting any fuel system component (injector, fuel rail, pressure regulator, etc.), fitting or fuel line connection. Exercise extreme caution whenever relieving fuel system ene to avoid exposing skin, face and eyesto fuel spray. Please be advised that t fuel under pressure may penetrate the skin or any partofthe body thatit contacts. ° Always nate a shop towel or cloth around the fitting or connection priorto loosening to absorb any excess fuel due to

Piston positioning and ring end-gap spacing—4.6L VIN V engine

Spillage. Ensure that all fuel spillage (should it occur) is quickly removed from engine surfaces. Ensure that all fuel soaked cloths or towels are deposited into a suitable waste container. + Always keep a dry chemical (Class B) fire extinguisher near the work area. * Do not allow fuel spray or fuel vaporsto come into contact with a spark or open flame. ¢ Always use a back-up wrench when loosening and tightening fuel line connectionfittings. This will prevent unnecessary stress and torsion to fuel line piping. Always follow the proper torque specifications.

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#

ne Always replace worn fuel fitting Orings with new. Do not substitute fuel hose or equivalent, 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. Disconnect the negative battery cable. 3. Remove the fuel tank fill cap to relieve the pressure in the fuel tank. 4. Remove the cap from the Schrader valve located on the fuel supply manifold. 5. Attach Fuel Pressure Gauge T80L9974-A to the valve and drain the fuel through the drain tube into a suitable container. 6. After the fuel system pressure is relieved, remove the fuel pressure gauge and install the cap on the Schrader valve. 7. Install the fuel tank fill cap. 8. Connect the negative battery cable only after system repairs are completed.

REMOVAL & INSTALLATION ->Disable the air suspension before raising the vehicle. The switch is located on the left side of the luggage compartment.

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Turn the air suspension service switch OFF. 3. Disconnect the negative battery cable. 4 Relieve the fuel system pressure. 5. Disconnect the fuel lines.

6. Loosen the filter retaining clamp and remove the fuel filter. To install: 7. Install the fuel filter with the flow arrow facing the proper direction and tighten the filter retaining clamp. 8. Push the fuel lines on to the filter fittings until an audible click is heard. 9. Connect the negative battery cable. 10. Start the engine and check for fuel leaks and proper operation. 11. Turn the air suspension switch to the ON position.

tor Fuel supply line

REMOVAL & INSTALLATION ->Disable the air suspension before raising the vehicle. The switch is located on the left side of the luggage compartment.

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Turn the air suspension switch to the OFF position. 3. Relieve the fuel system pressure. 4. Drain the fuel tank. 5. Remove or disconnect the following: ¢ Fuel fill and vent hoses e Fuel supply line ¢ Fuel pump module wiring connece Fuel tank e Fuel pump module locking ring 6. Pull the fuel pump module up and out of the fuel tank until the locking tabs for the fuel pump module are accessible.

1p

—)>fe— 7922LG23 7922LG21

Slide the special tool into the fitting to disengage it

Squeeze both locking tabs together and remove the fuel pump module from the fuel tank. To install: 7. Install or connect the following: Fuel pump module. Use a new Oring seal and push the module into the tank so that the locking tabs engage. Fuel pump module lock ring Fuel tank. Tighten the tank strap bolts to 22-30 ft. Ibs. (30-40 Nm). Fuel pump module wiring connec-

To remove the fuel pump, reach into the tank and press the locking tabs inward

Fuel fill and vent hoses 8. Add 10 gallons of clean fuel to the tank. 9. Turn the air suspension switch to the ON position. 10. Start the engine and check for leaks.

Fuel Injector

|

:

REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Relieve the fuel system pressure. 3. Remove or disconnect the following: e Negative battery cable e Fuel pressure sensor vacuum line and wiring connector e Fuel injector wiring connectors e Fuel supply line e Fuel supply manifold with injectors attached 4. Remove the clips and the injectors from the fuel supply manifold. To install: 5. Install the injectors with new O-ring Seals. 6. Install the fuel supply manifold and tighten the bolts as follows: a. Step 1: 15 ft. Ibs. (20 Nm) b. Step 2: Plus 85-95 degrees 7. Install or connect the following: ¢ Fuel supply line e Fuel injector wiring connectors e Fuel pressure sensor vacuum line and wiring connector e Negative battery cable 8. Start the engine and check for leaks.

Brake service is covered in Section 4 of this manual

13-12 Conrental Transaxle Assembly

REMOVAL & INSTALLATION e>Disable the air suspension before raising the vehicle. The switch is located on the left side of the luggage

compartment. 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Turn the air suspension switch to the

OFF position. 3. Attach a powertrain support fixture to the engine lifting eyes. 4. Drain the transaxle fluid. 5. Remove or disconnect the following: Battery and battery tray Intake Air Temperature (IAT) sensor connector Mass Air Flow (MAF) sensor connector Air cleaner assembly Transaxle control harness connector Transaxle range sensor Turbine shaft speed sensor connector Shift cable Transaxle oil cooler lines Front wheels Suspension height sensors Wheel speed sensors Outer tie rod ends Lower ball joints Stabilizer bar links Halfshafts Heated Oxygen (HO2S) sensor connectors Dual converter Y-pipe Starter Left, right and rear engine support insulators Subframe Transaxle housing cover Torque converter Transaxle flange bolts 6. Separate the transaxle from the engine and lower it from the vehicle. To install: -»When installing suspension components and halfshafts, use new nuts, bolts, circlips and split pins.

7. Install or connect the following: e Transaxle. Tighten the flange bolts to 25-34 ft. Ibs. (34-46 Nm). e Torque converter. Tighten the nuts to 20-34 ft. Ibs. (27-46 Nm). e Transaxle housing cover

DRIVE TRAIN

:

8. Install the subframe. Use 2 pieces of ¥4 inch outside diameter pipe in the alignment holes behind the front subframe mounts to align the subframe to the body. Tighten the subframe mounting bolts to 57-76 ft. Ibs. (77-103 Nm). 9. Install or connect the following: Left, right and rear engine support insulators. Tighten the throughbolts to 64-88 ft. Ibs. (87-119 Nm). Starter. Tighten the bolt and stud to 15-21 ft. Ibs. (21-29 Nm). Dual converter Y-pipe HO2S sensor connectors Halfshafts Stabilizer bar links. Tighten the nuts to 30-40 ft. Ibs. (40-55 Nm). Lower ball joints. Tighten the pinch bolts to 50-68 ft. Ibs. (68-92 Nm). Outer tie rod ends. Tighten the nuts to 35-46 ft. Ibs. (47-63 Nm). Wheel speed sensors Suspension height sensors Front wheels Transaxle oil cooler lines Shift cable Turbine shaft speed sensor connec-

e Suspension height sensors e Wheel speed sensors e Outer tie rod ends e Lower ball joints e. Stabilizer bar links 4. Separate the halfshafts from the wheel hubs and the transaxle and remove the halfshafts. To install:

tor Transaxle range sensor Transaxle control harness connector Air cleaner assembly MAF sensor connector IAT sensor connector Battery and battery tray 10. Fill the transaxle. 11. Check for leaks and proper operation. e» Whenever the subframe is removed or lowered, the wheel alignment should be checked.

e»When installing suspension components and halfshafts, use new nuts, bolts, circlips and split pins.

5. Install or connect the following: Halfshafts. Tighten the hub retainer nuts to 180-200 ft. Ibs. (245-270 Nm). Stabilizer bar links. Tighten the nuts to 30-40 ft. Ibs. (40-55 Nm). Lower ball joints. Tighten the pinch bolts to 50-68 ft. Ibs. (68-92 Nm). Outer tie rod ends. Tighten the nuts to 35-46 ft. Ibs. (47-63 Nm). Wheel speed sensors Suspension height sensors e Front wheels 6. Turn the air suspension switch to the ON position. 7. Road test the vehicle and check for proper operation.

CV-Joint

REMOVAL AND REPLACEMENT Inner Tripod Joint The inner C\V-joint is serviced with the halfshaft as an assembly. The inner CV-joint boot can be serviced by removing the outer CV-joint. Outer CV-Joint

REMOVAL & INSTALLATION Re REE ETI Se ee

1. Before servicing the vehicle, refer to the precautions in the beginning of this section.

e*Disable the air suspension before raising the vehicle. The switch is located on the left side of the luggage compartment.

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Turn the air suspension switch to the OFF position. 3, Remove or disconnect the following: e Negative battery cable ¢ Front wheels

1. CV-Joint boot 2. CV-Joint 9306HGO7

Removing the outer CV-joint

FORD MOTOR CO. rd

2. Place the halfshaft in a vise. 3. Remove the CV-joint boot clamps and slide the boot away from the joint.

4. Drive the CV-joint off the halfshaft with a brass drift and a hammer. To install: 5. Replace the snapring.

}

STEERING AND SUSPENSION

+2 CAUTION

5. Turn the ignition switch to the RUN position. The air bag indicator should light continuously for approximately 6 seconds, then turn OFF. If the indicator fails to light, flashes or remains lit continuously, there is a fault in the air bag system.

Some 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 precautions and the disarming procedure could result in accidental air bag deployment, possible injury

and unnecessary system repairs.

PRECAUTIONS

Power Rack and Pinion Steering

Gear REMOVAL & INSTALLATION

ok CAUTION Do not rotate the steering wheel when the intermediate shaft is dis-

CONTINENTAL 1 3-1 3

6. Fill the C\V-joint with fresh grease and Slide the joint onto the halfshaft. 7. Use new clamps and install the CVjoint boot.

connected. Damage to the air bag sliding contact will result. ->Disable the air suspension before raising the vehicle. The switch is located on the left side of the luggage compartment.

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Turn the air suspension switch to the OFF position. 3. Remove or disconnect the following: e Negative battery cable e Steering column intermediate shaft ¢ Powertrain Control Module (PCM)

Several precautions must be observed

when handling the inflator module to avoid accidental deployment and possible personal injury. e Never carry the inflator module by the wires or connector on the underside of the module. e When carrying a live inflator module, hold securely with both hands, and ensure that the bag and trim cover are pointed away. e Place the inflator module on a bench or other surface with the bag and trim cover facing up. e With the inflator module on the bench, never place anything on or close to the module that may be thrown in the event of an accidental deployment.

DISARMING oY tS A pains 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 9. Disconnect both battery cables from the battery, negative cable first. 3. Wait 1 minute before proceeding with the service procedure. This is the time required for the back-up power Supply in the air bag diagnostic monitor to deplete its Stored energy. 4 After service is completed, reconnect the battery cables, negative cable last.

1 Tie Rod End 2 Nut 3 Front Wheel Spindle Tie Rod (2 Req'd)

9 Screw (2 Req'd) 10 Nut (2 Req'd) 11 Front Wheel Knuckle (LH)

12 Crossmember

4 Front Suspension Steering Ball

13 Nut(2 Req'd)

Stud Dust Seal 5 Power Steering Hose Bracket

14 Steering Shaft U-Joint Shield

6 Bolt (2 Req’d)

16 Power Steering Gear Input Shaft and Control

7 Screw (2 Req’d)

15 Front Wheel Knuckle (RH)

8 Steering Gear

mounting Exploded view of the power rack and pinion steering gear

manual For complete Engine Mechanical specifications, seé Section 1 of this

7922LG26

13-1

FORD MOTOR CO. CONTINENTAL

harness connector and ground straps Upper motor mount Front wheels Outer tie rod ends Suspension height sensor Heated Oxygen (HO2S) sensor connectors Dual converter Y-pipe

Subframe brackets Steering gear attachment nuts Rear subframe bolts. Lower the rear of the subframe about 4 inches for access. Steering gear heat shield and bracket Steering gear harness connectors 4. Rotate the steering gear to clear the mounting bolts from the subframe, and pull the gear to the left to access the fluid lines. ¢ Power steering pressure and return lines ¢ Steering gear through the left fender opening To install: 5. Install or connect the following: Steering gear Power steering pressure and return lines. Use new O-ring seals and tighten the fittings to 25-30 ft. Ibs. (33-41 Nm). teering gear harness connectors Steering gear heat shield and bracket Rear subframe bolts. Tighten the bolts to 57-76 ft. Ibs. (77-103 Nm). Steering gear attachment nuts. Tighten the nuts to 84-112 ft. Ibs. (113-153 Nm). Subframe brackets Dual converter Y-pipe HO2S sensor connectors Suspension height sensor Outer tie rod ends. Use new nuts and tighten to 35-46 ft. Ibs. (47-63 Nm). Front wheels Upper motor mount PCM harness connector and ground straps Steering column intermediate shaft. Tighten the lower bolt to 30-38 ft. lbs. (41-51 Nm), and the upper bolt to 24-30 ft. Ibs. (33-41 Nm). Negative battery cable 6. Fill the power steering system. 7. Turn the air suspension switch to the ON position. 8. Check the system for leaks and proper operation. Adjust the toe setting as necessary.

Shock Absorber

REMOVAL & INSTALLATION

REMOVAL & INSTALLATION

Front

Rear

Disable the air suspension before raising the vehicle. The switch is located on the left side of the luggage compartment.

Disable the air suspension before raising the vehicle. The switch is located on the left side of the luggage compartment.

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Turn the air suspension switch to the OFF position. 3. Remove or disconnect the following: Negative battery cable Front wheels Left and right splash shields Wheel speed sensors Strut actuator connectors, if equipped with semi-active suspension Suspension height sensors Brake line brackets Stabilizer bar links Lower ball joints Steering knuckle pinch bolts 4. Separate the steering knuckles from the struts and remove the struts from the vehicle. To install:

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Turn the air Suspension switch to the OFF position. 3. Remove or disconnect the following: Negative battery cable Luggage compartment side trim panels Rear wheels Shock absorber actuator harness connectors, if equipped with semiactive suspension Shock absorber assemblies To install: 4. If replacing the shock absorbers, transfer the mass dampers and mounting brackets. 5. Turn the shock absorber upside down. Compress and expand the piston several times to remove the air from the working cylinder. 6. Install or connect the following: ¢ Shock absorber assemblies. Tighten the upper bolts to 25-34 ft. lbs. (34-46 Nm), and the lower bolts to 58-68 ft. Ibs. (68-92 Nm). ¢ Shock absorber actuator harness connectors, if equipped with semiactive Suspension ¢ Rear wheels e Luggage compartment side trim panels ¢ Negative battery cable 7. Turn the air suspension system ON.

e>When installing suspension components, use new nuts, bolts, circlips and Split pins.

5. Install or connect the following: Struts. Tighten the shock tower nuts to 23-29 ft. Ibs. (30-40 Nm), and the steering knuckle pinch bolts to 73-97 ft. Ibs. (98-132 Nm). Stabilizer bar links. Tighten the nuts to 30-40 ft. Ibs. (40-55 Nm). Lower ball joints. Tighten the pinch bolts to 50-68 ft. Ibs. (68-92 Nm). Brake line brackets. Tighten the screws to 11 ft. Ibs. (15 Nm). Suspension height sensors Strut actuator connectors, if equipped with semi-active suspension Wheel speed sensors Left and right splash shields Front wheels Negative battery cable 6. Turn the air suspension switch to the ON position. 7. Road test the vehicle and check for proper operation.

< =

=

7922LG28

To bleed the air from the shock, turn it upside down, then compress and expand it several times

ake CONTINENTAL 13-15

REMOVAL & INSTALLATION

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove the strut assembly from the vehicle. 3. Install a spring compressor and retract the spring until the upper mount rotates freely. 4. Remove or disconnect the following: e Flange nut e Strut mounting bracket e Strut bearing plate e Coil spring To install: 5. Install or connect the following: e Coil spring e Strut bearing plate e Strut mounting bracket e Flange nut. Tighten the nut to 63-70 ft. Ibs. (85-95 Nm). 6. Remove the spring compressor and

REMOVAL & INSTALLATION

Lower Ball Joints

Rear

2k CAUTION Do not attempt to service the rear suspension without first deflating the air springs. e>Servicing the air suspension requires a scan tool with bi-directional capabilities to deflate the air springs.

1. Properly deflate the air springs. 2. Turn the air Suspension switch to the OFF position. The switch located on the right kick panel. 3. Remove the rear wheels. 4. Disconnect the air spring solenoid wiring connector and air tine. 5. Depress the locking tabs and remove the air spring from the vehicle. To install: 6. Install or connect the following: Air spring. Press the plastic tab

Air spring solenoid connectors

The lower ball joint is an integral part of the steering knuckle. If the lower ball joint is found to be defective, the entire steering knuckle must be replaced.

Upper Control Arm REMOVAL & INSTALLATION Rear

ck CAUTION Do not attempt to service the rear suspension without first deflating the air springs. eS e>Servicing the air suspension requires a scan too! with bi-directional capabilities to deflate the air springs.

1. Properly deflate the air springs. 2. Turn the air Suspension switch to the OFF position. The switch located on the right kick panel. 3. Support the lower control arm ona jackstand. 4. Remove or disconnect the following: e Rear wheel e Brake hose bracket e Upper ball joint e Upper control arm To install: e>Use new mounting nuts and bolts.

Washer Strut mounting bracket Bearing plate Coil spring Dust boot Jounce bumper Spring insulator

Exploded view of the front strut and coil spring assembly

Las

REMOVAL & INSTALLATION

7922LG29

9306LG07

nectors

e Rear wheels 7. Turn the air suspension switch to the ON position and check for proper operation.

Front

1. 2. 3. 4. 5. 6. 7.

through the suspension until it clicks into place. e Solenoid air line and electrical con-

ensure that the spring seats correctly in the insulators. 7. Install the strut assembly to the vehicle.

7922LG30

Depress the plastic locking tabs to disengage the air spring from the suspension

5. Install the upper control arm. Tighten the ball joint nut to 50-67 ft. Ibs. (68-92 Nm), then tighten the contro! arm mounting bolts to 73-97 ft. Ibs. (98-132 Nm). 6. Install or connect the following: e Brake hose bracket e Rear wheel 7. Turn the air suspension switch to the ON position and check for proper operation. 8. Check the wheel alignment and adjust as necessary.

l For Accessory Drive Belt illustrations, see Section 1 of this manua

13-16

bonne

CONTROL ARM BUSHING REPLACEMENT The control arm bushings are serviced with the control arm as an assembly.

Lower Control Arm

REMOVAL & INSTALLATION Front

Disable the air suspension before raising the vehicle. The switch is located on the left side of the luggage compartment.

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Turn the air suspension switch to the OFF position. 3. Remove or disconnect the following: e Front wheel ¢ Wheel speed sensor wiring harness e Height sensor ¢ Lower ball joint ¢ Lower control arm strut ¢ Lower control arm To install: 4. Install or connect the following: Lower control arm. Tighten the pivot bolt to 73-98 ft. Ibs. (98-132 Nm). Lower control arm strut. Tighten the nut to 73-98 ft. Ibs. (98-132 Nm). Lower ball joint. Use a new nut and tighten to 50-67 ft. Ibs. (68-92 Nm). Wheel speed sensor wiring harness Height sensor Front wheel 5. Turn the air suspension switch to the ON position. 6. Check the wheel alignment and adjust as necessary. Rear

“+ CAUTION Do not attempt to service the rear Suspension without first deflating the air springs. ee ->Disable the air suspension before raising the vehicle. The switch is located on the left side of the luggage compartment.

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Turn the air suspension switch to the OFF position.

3. Remove or disconnect the following: Rear wheel Shock absorber actuator wiring, if equipped with semi-active suspension Air spring Stabilizer bar link Lower control arm To install: 4. Install or connect the following: ¢ Lower control arm. Tighten the bolts to 50-68 ft. Ibs. (68-92 Nm). e Stabilizer bar link. Tighten the nut to 25-34 ft. Ibs. (34-46 Nm). e Air spring ¢ Shock absorber actuator wiring, if equipped with semi-active suspension e Rear wheel 5. Turn the air Suspension switch to the ON position.

CONTROL ARM BUSHING REPLACEMENT The control arm bushings are serviced with the control arm as an assembly.

Wheel Bearings ADJUSTMENT There is no adjustment for the front or rear wheel bearings due to the nature of their design. These bearings are permanently lubricated and require no periodic maintenance.

REMOVAL & INSTALLATION Front

e>Disable the air suspension before raising the vehicle. The switch is located on the left side of the luggage compartment.

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Turn the air suspension switch to the OFF position. 3, Remove or disconnect the following: ¢ Front wheel Hub retainer nut Brake caliper and rotor Outer tie rod end Stabilizer bar link Wheel speed sensor Lower ball joint Steering knuckle 4, Unbolt and remove the hub and bearing assembly.

To install: ->Use new nuts, bolts and split pins. ->The knuckle must be clean enough to allow the wheel hub to be completely seated by hand. Do not press or draw the wheel hub into place.

5. Install or connect the following: Hub and bearing assembly. Tighten the bolts to 61-78 ft. Ibs. (83-107 Nm). Steering knuckle. Tighten the pinch bolt to 72-97 ft. Ibs. (98-132 Nm). Lower ball joint. Tighten the nut to 50-67 ft. Ibs. (68-92 Nm). Wheel speed sensor Stabilizer bar link. Tighten the nut to 57-75 ft. Ibs. (77-103 Nm). Outer tie rod end. Tighten the nut to 35-46 ft. Ibs. (47-63 Nm). Brake caliper and rotor. Tighten the caliper anchor bracket bolts to 65-87 ft. Ibs. (88-118 Nm). Hub retainer nut. Tighten the nut to 170-202 ft. Ibs. (230-275 Nm). Front wheel 6. Turn the air suspension switch to the ON position. Rear

e*Disable the air suspension before raising the vehicle. The switch is located on the left side of the luggage compartment.

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Turn the air suspension switch to the OFF position. 3. Remove or disconnect the following: e Rear wheel e Brake hose bracket ¢ Brake caliper and rotor ¢ Hub and bearing assembly grease cap and retaining nut ¢ Hub and bearing assembly To install: ->Use new retaining nuts and grease caps

4. Install or connect the following: ¢ Hub and bearing assembly. Tighten the retaining nut to 188-254 ft. Ibs. (255-345 Nm). ¢ Grease cap e Brake caliper and rotor e Brake hose bracket ¢ Rear wheel 9. Turn the air suspension switch to the ON position.

FORD MOTOR CO. 1998-01

Ford-Escort * Escort ZX2 * Mercury-Tracer DRIVE TRAIN.................. 14-20 ENGINE REPAIR ................ 14-2 EUELSSYSTEM 42k ke: 14-18 PRECAUTIONS.................. 14-2 STEERING AND SUSPENSION................. 14-27 A [iTS SHEA at ie ei Sie eth a 14-27 PACING) eetce hatacated oxitebianne 14-27 ESISGTIING Meautem nit catasins14-27 PLOCAUONS ees. Arent eikoeeece 14-27 IGE O)fe aotceat, Sen peer 14-2 HS tellalionmaeree 20 recs 14-3 Removal............ rayaenenre 14-2 Camshaft(s) And Valve EATET Se en ee) 14-12 Removal & Installation............ 14-12 GINGA eet ee 14-22

GO GHICH) § ote eae

14-22

Removal & Installation............ 14-23

cal Shae

ee eee ras 14-30

Removal & Installation............ 14-30 (COROT Maite eer chore chs meee ces 14-31

Control Arm and Bushing Replacement .....c.-..ecseseseseee 14-31 Removal & Installation............ 14-31 (CNL NIN ae ee 14-26 OVGrAU ee ee nt uaca ee asad. 14-26

CAG

ek weer ee 14-6 ieee

Removal & Installation........... 14-6

E ENGin@ ASSEMDIY w..swssssscctvecenss 14-3 Removal & Installation... 14-3 ExhaushMMantiond sees: ae 14-10 Removal & Se Hoes: 14-10 Front Crankshaft Seal... Removal & Installation............ aeiciWeacoder iesoc ast bn sear iar Removal & Installation...

14-12 14-12 14-19 14-19

RUCLAOCIO tet eta ceca erntaiute 14-19 Removal & Installation............ 14-19

FUG PUITO! tere cante wtteon are. aenetee14-19 Removal & Installation............ 14-19

Fuel System Pressure.............00. 14-19 Rel eVinGmarer ramen. cee 14-19 Fuel System Service Precautions........... feemcpesd 14-18 Halishaltseecte ter eee 14-25 Removal & Installation........... 14-25

Hydraulic Clutch OV SLOT Geer eccin etc cera Sion 14-23 BIPECIGian Aaa peatane 14-23 LODUUGTTNTRING eter erent, teens 14-3 AGUSUITION getMis an satevteacsthera 14-3 Intake Maniioldvscetl.c. detenaes 14-9 Removal & pstanaton ene 14-9

PME aI CIN cents scacraaers re 14-30 Removal & Installation............ 14-30

OIE Pabiectae Removal OPPURIDE Removal

0 tek ccce ste ecer nen eee & Installation............ aoe aie BUM nees & Installation............

14-16 14-16 14-17 14-17

PIStOM AMG] HIN Cemaemern ciece cae14-18 Positioning ....... Bianaes 14-18 Rack And Pinion Steering (GGal sein cette reer ee eee 14-27 Removal & Installation............ 14-27 Rear Mali oGalaaccsceretcactaeetu14-18 Removal & Installation............ 14-18 RockerArinSa tn caeeeaoeeeee14-9 Removal & poeta Aer SAAR 14-9

Starter: Motor terete ae Benoa ees14-16 Removal & Installation............ 14-16 GHUT os aetecrcooecinacd Eee eee -28 Removal & Installation............ 14-28

Transaxle ASSEMDIY ...... eee: 14-20 Removal & Wee ee

14-20

VANE UASI itrcette otseee 14-15 ACI USTOMeRUaee.c acumen erect: 14-15 W

Water PLIVID a staan

enaeeeas 14-4

Removal & Installation... 14-4 Wheel BearingS........c.ccccceeeee 14-32 Adjustinentixiu..m-netoeness 14-32 Removal & Installation............ 14-32

14-2 SESS SSS SR SECS

FORD MOTOR CO.

ESCORT © ESCORT ZX2 ¢ TRACER

SEA

OIA

DANS YEAS IDET BD EET PIN

LT TIE

EF

TE

A

FE

A

PRECAUTIONS Before servicing any vehicle, please be sure to read all of the following precautions, which deal with personal safety, prevention of component damage, and important points to take into consideration when servicing a motor vehicle: e Never open, service or drain the radiator or cooling system when the engine is hot; serious burns can occur from the steam and hot coolant. e Observe all applicable safety precautions when working around fuel. Whenever servicing the fuel system, always work ina well-ventilated area. Do not allow fuel spray Or vapors to come in contact with a spark, open flame, or excessive heat (a hot drop light, for example). Keep a dry chemical fire extinguisher near the work area. Always keep fuel in a container specifically designed for fuel storage; also, always properly seal fuel containers to avoid the possibility of fire or explosion. Refer to the additional fuel system precautions later in this section. ¢ Fuel injection systems often remain pressurized, even after the engine has been turned OFF. The fuel system pressure must be relieved before disconnecting any fuel lines. Failure to do so may result in fire and/or personal injury. ¢ Brake fluid often contains polyglycol ethers and polyglycols. Avoid contact with the eyes and wash your hands thoroughly alter handling brake fluid. If you do get brake fluid in your eyes, flush your eyes with clean, running water for 15 minutes. If eye irritation persists, or if you have taken brake fluid internally, IMMEDIATELY seek medical assistance.

¢ Drive belt ¢ Power steering hose bracket from the alternator bracket

ISOS EETI

should always buy the correct type of brake fluid for your vehicle. If the brake fluid becomes contaminated, completely flush the system with new fluid. Never reuse any brake fluid. Any brake fluid that is removed from the system should be discarded. Also, do not allow any brake fluid to come in contact with a painted surface; it will damage the paint. ¢ Never operate the engine without the proper amount and type of engine oil: doing so WILL result in severe engine damage. * Timing belt maintenance is extremely important! Many models utilize an interference-type, non-freewheeling engine. If the timing belt breaks, the valves in the cylinder head may strike the pistons, causing potentially serious (also time-consuming and expensive) engine damage. Refer to the maintenance interval charts in the front of this manual for the recommended replacement interval for the timing belt, 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 computer SyStem(s) and may require the computer to undergo a relearning process once the negative battery cable is reconnected. + When servicing drum brakes, only disassemble and assemble one side at a time, leaving the remaining side intact for reference. ¢ Only an MVAC-trained, EPA-certified automotive technician should service the air conditioning system or its components.

¢ Alternator mounting bolts ¢ Alternator electrical connectors

e Battery positive cable

¢ Alternator from the vehicle

Coupe

See

Sedan and Wagon 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: ¢ Negative battery cable

SSE

ENGINE REPAIR

Alternator

REMOVAL a Ar aa eC

ST

:

e The EPA warns that prolonged contact with used engine oil may cause a number of skin disorders, including cancer! You should make every effort to minimize your exposure to used engine oil. Protective gloves should be worn when changing oil. Wash your hands and any other exposed skin areas as soon as possible after exposure to used engine oil. Soap and water, or waterless hand cleaner should be used. e All new vehicles are now equipped with an air bag system, often referred to as a Supplemental Restraint System (SRS) or Supplemental Inflatable Restraint (SIR) 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 repairs. e Always wear safety goggles when working with, or around, the air bag system. When carrying a non-deployed air bag, be sure the bag and trim cover are pointed away from your body. When placing a non-deployed air bag on a work surface, always face the bag and trim cover upward, away from the surface. This will reduce the motion of the module if it is accidentally deployed. Refer to the additional air bag system precautions later in this section. ¢ Clean, high quality brake fluid from a sealed container is essential to the safe and proper operation of the brake system. You

_ ->Disconnecting the negative battery cable on some vehicles may interfere with the operation of the on-board computer system. The computer may undergo a relearning process once the negative battery cable is reconnected.

eI

90982623

Location of the alternator upper and lower mounting bolts—sedan and wagon models

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: ¢ Negative battery cable ¢ Drive belt ¢ Coolant tank reservoir ¢ Alternator electrical connectors ¢ Alternator mounting bolts ¢ Battery positive cable ¢ Alternator from the vehicle

FORD MOTOR CO. ESCORT © ESCORT ZX2 Hf Engine Assembly REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this secia

- ai the cooling system. i Sea tuelae pressure. Gi ante Ae : ei relrigerant, |

2:

90982624

peas

Location of the alternator upper and lower

mounting bolts—coupe model

or disconnect the following:

¢ A/C condenser tube, if equipped ¢ AVC accumulator tube, if equipped e Accessory drive belt and tensioner

e Accessory drive belt idler pulley, if equipped

e Hood

A

e Intake manifold vacuum hoses

e Exhaust Gas Recirculation (EGR) vacuum line

1. Install or connect the following: ¢ Battery positive cable to the alter-

e A/C line bracket, if equipped

: Zale ts hoses

hose

Sedan and Wagon

Power steering hose brackets Fuel line Exhaust manifold heat shield Starter bracket Clutch cylinder fluid line, if equipped e Transaxle cooler lines, if equipped

© Battery and tray

outlet tube +e ArFuelcleaner pressure regulator vacuum

RSE LION

1 4-3

eis

caer

* Catalytic converter

e Axle halfshafts Nees ee : erect: Ree

ea

¢ Positive Crankcase Ventilation

Seadicior

¢ Alternator electrical connections

¢ \acuum tree

oy Alternator harness connectors

* Alternator in position

cable + Throttle Cruise control

nator. Tighten the nut to 7—9 ft. Ibs.

e Alternator mounting bolts. Tighten

cable, if equipped

© Shift cable

the upper mounting bolt to 29-40

ft. bs. (40-55 Nm) and the lower

¢ Constant Control Relay Module

(20-30 Nm).

e EGR backpressure transducer

(CCRM)

mounting bolt to 15-22 ft. Ibs.

e Transaxle range sensor connector,

e Power steering hose bracket to the

if equipped

alternator bracket

* Transaxle solenoid connector, if

» Drive belt

equipped : re ee sensor connector, if

° Negative battery cable colne

e Vehicle Speed (VSS) sensor ¢ Heated Oxygen (HO2S) sensor connectors

1. Install or connect the following: e Battery positive cable to the alternator. Tighten the nut to 5-7 ft. Ibs.

° Ground strap

(7-9 Nm).

¢ Engine cooling fan connector

e Alternator in position

7. Attach a support fixture to the

engine

8. Remove or disconnect the following:

‘SiLeft tront enainé mount mencanle a

e‘ Transaxle tuiitamr ; Hai

© Right engine mount

9, Attach a hoist to the engine and remove the support fixture. 10. Raise the engine and transaxle from the vehicle.

To install: 11. Installation is the reverse of removal, but please note the following important steps.

12. On 2.0L SOHC engines pay special

e Alternator mounting bolts and tighten to 29-40 ft. Ibs. (40-95 Nm) Alternator electrical connections Coolant tank reservoir Drive belt Negative battery cable

Ignition Timing

:

ADJUSTMENT The Powertrain Control Module (PCM) controls ignition timing on these models. No adjustment is necessary Or possible.

engines Properly support the engine as shown—2.0L SOHC

Labor Guide For complete service labor times, order Nichols’ Chilton

44-4

FORD motor co.

|

ESCORT © ESCORT ZX2 © TRACER attention to the following torque specifica.

1. Water pump housing gasket

tions:

2. Water pump 3. Timing belt tensioner

e Right-hand insulator through-bolt: 50-69 ft. Ibs (67-93 Nm)

‘Bs

Wie

4. Front engine support mount-

Soke

14. Crankshaft sprocket

15. Timing belt

Oil pressure sensor Knock sensor Engine block Oil pan

16. 17. 18. 19.

Engine mount bolts: 50-69 ft. Ibs. (67-93 Nm)

:

Het

5. 6. 7. 8.

(38-51 Nm)

10. Crankshaft Position (CKP)

6 ciate

e Transaxle support crossmember outer retainers: 48-65 ft. Ibs.

12. Crankshaft pulley 13. Outer engine front cover

ing bracket

;

ae ete inner retainers: 28-38 ft. Ibs.

11. Camshaft sprocket

Timing belt guide Crankshaft front seal sh Qil pump screen cover and tube Oil pump inlet tube gasket

20. Oil pump

sensor

(64-89 Nm)

Air conditioning compressor mounting bolts: 15-22 ft. Ibs. ) Muffler-to-catalytic converter: 30-40 ft. Ibs. (40-55 Nm) Crossmember bolts: 69-97 ft. Ibs. (94-131 Nm) Power steering pressure hose connection: 15-18 ft. Ibs. (20-25 Nm) Air conditioning line bracket bolt: 15-18 ft. Ibs. (20-25 Nm) Exhaust manifold-to-catalytic converter nuts: 26-34 ft. Ibs. (34-47 Nm) 13. On 2.0L DOHC engines pay special attention to the following torque specifications: ¢ Front isolator nuts and bolts: 50-68 ft. Ibs. (67-93 Nm) ¢ Front engine support isolator through-bolt: 50-68 ft. Ibs. (67-93 Nm) ¢ Front roll restrictor bolts: 48-65 ft. lbs. (64-89 Nm) and the nuts to 50-69 ft. Ibs. (67-93 Nm) ¢ Rear roll restrictor nuts: 28-38 ft. lbs. (38-51 Nm) ¢ Torque converter nuts: 27 ft. Ibs. (37 Nm) 14. Fill the crankcase to the correct level. 15. Fill the cooling system. 16. Recharge the A/C system, if equipped. 17. Start the engine and check for leaks. 9300MG11

Water Pump

REMOVAL & INSTALLATION

: 2.0L SOHC Engine 1. Before servicing the vehicle, refer to

the precautions in the beginning of this section, 2. Drain the cooling system,

3. Remove or disconnect the following: e Negative battery cable e Accessory drive belt

¢ Front cover

¢ Timing belt and tensioner. Refer to the Timing Belt unit repair section.

Exploded view of the water pump, oil pump and timing belt mounting—2.0L SOHC SPI engine

¢ Lower radiator hose from the water pump

* Heater hose ¢ Water pump 2 Hh

ede

+ * INStaY SE CORDES UOEG Water pump with a

new gasket. Tighten the fasteners to 15-22 ft.

Ibs. (20-30 Nm).

Heater hose Lower radiator hose

¢ Timing belt tensioner. Tighten the

boltto15-22 ft. Ibs. (20-30 Nm)

* Timing belt Front cover

nea

7922MG18

.

cation of the water pump (C) mounting

bolts (A) and stud (B)—2.0L SOHC engine

P

e Accessory drive belt e Negative battery cable 5. Fill the cooling system. 6. Start the engine and ch eck for leaks. 2.0L DOHC Engine 1. Before servicing the veh icle, refer to the precautions in the beginning of this section.

Clutch pressure plate Clutch disc Support Flywheel (automatic trans.) Flywheel (manual trans.) PVC valve Oil separator Engine block Knock sensor Oil pressure sensor Oil filter i Re ee RO

FORD MOTOR CO. ESCORT * ESCORT ZX2 * TRACER

To install: 4. Install or connect the following: Water pump. Tighten the bolts to 17 ft. Ibs. (24 Nm). Water pump pulley. Tighten the bolts to 17 ft. Ibs. (24 Nm). Air conditioning compressor Drive belt

2. Drain the cooling system. 3. Remove or disconnect the following: e Negative battery cable e Splash shield Drive belt Air conditioning compressor e Water pump pulley e Water pump

12. Throttle body 13. Fuel injection supply manifold 14, Idle Air Control (IAC) valve

15. Retainer clip 16, 7. 8. 19. 20. 21. 22.

Fuel injector Bracket Water pump housing gasket Water pump Upper timing belt cover Center timing belt cover Water pump pulley

14-5

20) 24, 25. 26. Nf. 28. 29, 30. ell 32. 33,

Crankshaft pulley Crankshaft sprocket Timing belt guide Timing belt ay iming belt idler pulley Oil pump Qil pump housing gasket ntake manifold Oil pump pick-up Crankshatt front seal Lower timing belt cover 9300MG10

—2.0L DOHC Zetec engine g, including water pum p, oil pump and intake manifold Exploded view of peripheral engine component mountin

Please visit our web site at www.chiltonsonline.com

14-6

FORD MOTOR CO.

ESCORT e ESCORT ZX2 ¢ TRACER

7922MG19

Remove the water pump mounting bolts— 2.0L Zetec engine

e Splash shield ¢ Negative battery cable 5. Fill the cooling system. 6. Start the engine and check for leaks.

7922MG26

Cylinder head torque sequence—2.0L SOHC engine

the engine is warm. Always allow the engine to cool entirely before disassembly. 2.0L DOHC Engine

Cylinder Head REMOVAL & INSTALLATION - 2k WARNIN G To reduce the possibility of cylinder head warpage and/or distortion, do not remove the cylinder head while

EGR valve EGR valve gasket Accelerator cable bracket Throttle body gasket Throttle Position (TP) sensor Idle Air Control (IAC) valve IAC valve gasket Throttle body RwONy COONAN Fuel injection supply manifold 10. Fuel injector

11. IMRC actuator 12. Oil filler cap

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Relieve the fuel system pressure. 3. Drain the cooling system. 4. Remove or disconnect the following: ¢ Negative battery cable ¢ Timing belt

Engine air cleaner intake tube Exhaust Gas Recirculation (EGR) valve vacuum hose Positive Crankcase Ventilation (PCV) valve vacuum hose Throttle body vacuum hoses Fuel pressure regulator vacuum hose Intake manifold vacuum hoses Accelerator cable, throttle contro! lever and if equipped, the speed contro! cable Speed contro! cable bracket bolt, if equipped 2 fuel charging wiring electrical connections f Crankshaft Position (CKP) sensor and Heated Oxygen (HO2S) sensor electrical connections Fuel supply line Power steering pressure hose bracket bolts, then position the bracket and hose aside e Alternator

Engine oil dipstick tube bracket bolt that attaches the tube to the intake manifold EGR manifold tube Exhaust manifold heat shield nuts and the heat shield

Catalytic converter-to-exhaust man-

. Valve cover

. 15. 16. 17. 18. 19. 20.

Cylinder head EGR valve-to-exhaust manifold tube Exhaust manifold gasket Exhaust manifold Exhaust manifold shield Intake manifold gasket Intake Manifold Runner Control (IMRC)

21. Intake manifold upper gasket

22. Intake manifold 23, Intake manifold tube

Exploded view of the cylinder head, exhaust manifold and intake manifold mounting—2.0L SOHC SPI engine

9300MG13

P

Eee Water Thermostat Housing Oil Ring Water Temperature Indicator nN Sender Unit Water Thermostat Housing

FORD MOT ESCORT ¢ ESCORT ZX2 a

i 8 20

Bolt (3 Req'd) 5

Engine Coolant Temperature Sensor Water Thermostat

24

Water Thermostat Housing

O-Ring Water Outlet Connection

Bolt (3 Req'd)

Oil Separator Hose

Bolt (3 Req’d)

Bolt (9 Req’d)

Radio Ignition Interference Capacitor 9306MG77

DOHC engine Exploded view of the upper engine components—2.0L

Timing belt service is covered in Section 3 of this manual

:

1 4-7

14-8

FORD MOTOR CO.

ESCORT ¢ ESCORT ZX2 ¢ TRACER

ifold nuts and separate the components Right-hand splash shield bolts and the shield Engine oil dipstick tube from the cylinder block Air conditioning compressor electrical connection Air conditioning compressor retainers and set the compressor aside with the lines still attached Air conditioning line bracket bolt Front engine accessory drive bracket Valve cover Upper radiator hose from the thermostat housing water hose connection Heater hose from the thermostat housing Cylinder head bolts Cylinder head and gasket 5. Discard the old bolts and the gasket. To install: 6. Install a new head gasket on the cylinder block. e»Always use new bolts when installing the cylinder head.

7. Lubricate the new cylinder bolts when engine oil. 8. Install the cylinder head and tighten the bolts in the sequence illustrated in the following order: a. Step 1: 30-44 ft. Ibs. (40-60 Nm) b. Step 2: Back all the bolts off 42 a turn C. Step 3: 30-44 ft. Ibs. (40-60 Nm) d. Step 4: Plus 90 degrees e. Step 5: Plus 90 degrees 9. Install or connect the following: Front engine accessory drive bracket. Tighten the fasteners to 30-40 ft. Ibs. (40-55 Nm). Air conditioning line bracket and tighten the bolt to 15-18 ft. Ibs. (20-25 Nm) Valve cover Air conditioning compressor and tighten the retaining bolts Right-hand splash shield and tighten its retainers Engine oil dipstick tube Heater and upper radiator hoses Timing belt and alternator Power steering pressure hose CKP sensor and 2 main fuel charging electrical connections Engine oil dipstick tube bolt

EGR valve manifold tube connection EGR valve manifold tube to the exhaust manifold

e Fuel supply line to the fuel rail Catalytic converter to the exhaust manifold using a new gasket and tighten the nuts Heat shield and tighten the nuts Speed control cable bracket, if equipped Throttle control lever, accelerator cable and if equipped, the speed control cable 10. Connect the vacuum hoses tagged and removed to the following components: e EGR valve e PCV valve ¢ Throttle body ¢ Fuel pressure regulator e Intake manifold e Air intake tube e Negative battery cable 11. Fill the cooling system. 12. Start the engine and check for leaks. 2.0L DOHC Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the cooling system. 3. Relieve the fuel system pressure. 4. Remove or disconnect the following: ¢ Negative battery cable e Air cleaner assembly outlet tube ¢ Timing belt 5. Tag and disconnect the vacuum hoses from the following components: Positive Crankcase Ventilation Valve (PCV) valve ¢ Throttle body e Fuel pressure sensor e Intake manifold 6. Remove or disconnect the following: Speed control and accelerator cables from the control lever Fuel charging electrical connectors at the main engine connector Crankshaft Position (CKP) sensor and Heated Oxygen (HO2S) sensor electrical connections Fuel line Power steering pump and bracket, then set them aside with the lines still attached Alternator Engine oil dipstick tube Splash shield bolts and the shield Air conditioning compressor electrical connection Air conditioning compressor retainers and set the compressor aside with the lines still attached Spark plug wires and the plugs Valve cover

7922MG27

Cylinder head torque sequence—2.0L DOHC engine 2

Upper radiator hose from the thermostat housing water hose connection Heater hose from the thermostat housing Camshafts Ignition coil Thermostat housing Cylinder head bolts Cylinder head and the gasket To install: 7. Install a new head gasket on the cylinder block. ->Always use new bolts when installing the cylinder head.

8. Lubricate the new cylinder bolts when engine oil. 9. Install the cylinder head and tighten the bolts in the sequence illustrated in the following steps: a. Step 1: 12-18 ft. Ibs. (15-25 Nm) b. Step 2: 26-33 ft. Ibs. (5-45 Nm) C. Step 3: Plus 90 degrees 10. Install or connect the following: Thermostat housing Ignition coil and the camshafts Heater and upper radiator hoses Valve cover Spark plugs Spark plug wires Air conditioning compressor and tighten the retaining bolts Air conditioning compressor electrical connection Splash shield and tighten its retainers Engine oil dipstick tube Alternator and the power steering reservoir and bracket Fuel line CKP sensor, HOzsensor, and 2 main fuel charging electrical connections Accelerator cable and if equipped,

FORD MOTOR CO.

ESCORT ¢ ESCORT ZX2 ¢ TRACER Intake Manifold

REMOVAL & INSTALLATION 2.0L SOHC Engine ay

ge 6-8 Nm (54-70 Ibvin) 9346SG01

Valve cover torque sequence—DOHC Engine

the speed control cable to the control lever 11. Connect the vacuum hoses tagged and removed to the following components: e PCV valve e Throttle body e Fuel pressure sensor e Intake manifold 12. Install or connect the following: e Timing belt e Air cleaner outlet tube e Negative battery cable 13. Fill the cooling system. 14. Start the engine and check for leaks.

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the cooling system. _ 3. Remove or disconnect the following: e Negative battery cable e Air cleaner outlet tube 4. Tag and disconnect the vacuum hoses from the following components: e Exhaust gas Recirculation (EGR) valve Positive Crankcase Ventilation (PCV) valve Throttle body Fuel pressure regulator Intake manifold 5. Remove or disconnect the following: ¢ Accelerator cable, throttle control lever and if equipped, the speed control cable

REMOVAL & INSTALLATION 2.0L SOHC Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Negative battery cable e Valve cover -»Note the location of the valvetrain components for assembly.

¢ Rocker arm bolts e Rocker arms and seats To install: 3. Install or connect the following: e Seats and rocker arms in their original positions ¢ Rocker arm bolts and tighten to 17-22 ft. lbs. (23-30 Nm) e Valve cover « Negative battery cable

7922MG36

Remove the engine oil dipstick tube bracket bolt that attaches the tube to the

intake manifold—2.0L SOHC engine

e Speed control cable bracket bolt, if equipped Idle Air Control (IAC) valve and Throttle Position (TP) sensor electrical connections EGR manifold tube located below the EGR valve e Engine oil dipstick tube e Intake manifold lower nuts e Intake manifold upper nuts e Manifold e Manifold gasket To install: 6. Clean and oil the intake manifold mounting studs. 7. Install or connect the following: Intake manifold and hand-tighten the upper nuts Lower manifold nuts and tighten them to 15-22 ft. Ibs. (20-30 Nm) Engine oil dipstick tube to the block Manifold upper nuts and tighten to 15-22 ft. lbs. (20-30 Nm) EGR manifold tube and tighten it to 15-20 ft. Ibs. (20-28 Nm) Engine oil dipstick tube bolt and tighten to 71-97 inch Ibs. (8-11 Nm) IAC valve and TP sensor electrical connections Speed control cable bracket bolt, if equipped and tighten to 71-88 inch Ibs. (8-10 Nm) Throttle contro! lever, accelerator cable and if equipped, the speed control cable 8. Connect the vacuum hoses tagged and removed to the following components: e EGR valve e PCV valve e Throttle body ¢ Fuel pressure regulator. e Intake manifold 9. Install the air cleaner outlet tube. 10. Fill the cooling system. 11. Connect the negative battery cable. 12. Start the engine and check for coolant leaks. 2.0L DOHC Engine

7922MG37

2.0L DOHC Engine This engine is not equipped with rocker arms. The camshafts act directly on the valves.

14-9

Disconnect the EGR manifold tube located below the EGR valve—2.0L SOHC engine

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the cooling system. 3. Relieve the fuel system pressure. 4. Remove or disconnect the following: e Negative battery cable e Air cleaner outlet tube

Heater Core replacement is covered in Section 2 of this manual

14-1

FORD MOTOR CO.

ESCORT ¢ ESCORT ZX2 ¢ TRACER

Throttle Position (TP) sensor electrical connection Bolt that secures the pipe located by the crankshaft pulley Heater hoses from the core Main engine control sensor wiring Connectors from the mounting bracket Vacuum hoses from the intake manifold by squeezing the tabs, twisting the hoses and pulling them away from the manifold Crankcase ventilation hose from the valve cover Drive belt Alternator mounting bolts and move the alternator aside Fuel lines Intake manifold nuts and bolts in the sequence illustrated Intake manifold and gasket To install: 5. Clean all dirt and gasket residue from the intake manifold mating surfaces. 6. Install or connect the following: ¢ New gasket and place the manifold in position e Manifold bolts and nuts. Tighten in the sequence illustrated to 10-12 ft. Ibs. (14-17 Nm).

ps |

—()

e TP sensor electrical connection e Air cleaner outlet tube 7. Fill the cooling system. 8. Connect the negative battery cable.

SN — (10-12 Ibyft) r

=

Me)

——— Q

Exhaust Manifold

REMOVAL & INSTALLATION 9300MG01

Intake manifold torque sequence—2.0L DOHC engine

Fuel lines Alternator Drive belt Crankcase ventilation hose to the valve cover Vacuum hoses to the manifold making sure the tabs are firmly engaged

Connectors in the mounting bracket Main engine control sensor wiring Heater hoses to the heater core Bolt that secures the pipe located by the crankshaft pulley. Tighten the bolt to 71-97 inch Ibs. (8-11 Nm).

Remove the intake manifold bolts and nuts in this sequence—2.0L Zetec engine

2.0L SOHC Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. j 2. Remove or disconnect the following: Negative battery cable e Drive belt Heated Oxygen (HO2S) sensor electrical connection which is mounted on the cooling fan shroud 5 exhaust manifold heat shield nuts and the shield 2 Exhaust Gas Recirculation (EGR) tube-to-exhaust manifold nuts studs Power steering pressure hose bracket bolts, then position the bracket and hose aside Alternator lower bolt, loosen only Alternator upper bolt and pivot the alternator forward

7922MG39

FORD MOTOR CO.

ESCORT ¢ ESCORT ZX2 ¢ TRACER

ra

14-11

7922MG43

Remove the 2 EGR tube-to-exhaust manifold stud nuts—2.0L SOHC engine

vA

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saiMte yy TIT Te 7TTT

7922MG44

7922MG45

Remove the exhaust manifold nuts and bolts in the sequence illustrated—2.0L Zetec engine Remove the exhaust manifold retaining

nuts—2.0L SOHC engine

e 4 exhaust manifold-to-catalytic converter nuts e 8 exhaust manifold nuts

Manifold and gasket To install: 3. Install or connect the following: New gasket and the exhaust manifold Manifold retaining nuts and tighten to 15-18 ft. Ibs. (20-24 Nm) Exhaust manifold-to-catalytic converter nuts and tighten to 26-34 ft. lbs. (34-47 Nm) Alternator and tighten the upper and lower mounting bolts Power steering pressure hose and bracket, then tighten the retaining bolts 9 EGR tube-to-exhaust manifold nuts studs and tighten to 44.6-62 inch lbs. (6-7 Nm) Exhaust manifold heat shield and tighten the nuts to 45-61 inch Ibs.

(5-7 Nm)

HO2S sensor electrical connection Drive belt Negative battery cable

Og Va

a

A

onl | anne 14-17 Nm (10-12 lb/ft) 7922MG46

to the proper specificaTighten the exhaust manifold nuts and bolts in the sequence illustrated tion—2.0L Zetec engine

Brake service is covered in Section 4 of this manual

14-1

FORD MOTOR CO.

ESCORT ¢ ESCORT ZX2 ¢ TRACER

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Negative battery cable Fan motor electrical connection Fan shroud Heated Oxygen (HO2S) sensor electrical connection e Catalytic converter-to-exhaust manifold bolt and nut, then disconnect the converter from the manifold

Do not break the threadlock seal on the engine oil dipstick tube. If the seal is broken, relock it to prevent any oil leaks from the block. ¢ Engine oil dipstick tube bracket bolt e Exhaust manifold heat shield bolts and nuts, then the shield e 7 exhaust manifold bolts and 2 Studs e Manifold and gasket

ido). 10. 11. 12, 13.

To install: 3. Install or connect the following: e New gasket and the exhaust manifold Manifold retaining bolts and nuts and tighten to 13-16 ft. Ibs. (14-17 Nm) Exhaust manifold heat shield and retainers. Tighten the retainers to 71-101 inch Ibs. (8-11 Nm). Engine oil dipstick tube bracket bolt and tighten to 71-101 inch lbs. (8-11 Nm) Exhaust manifold-to-catalytic converter bolt and nut HOzsensor electrical connection Fan shroud and the fan motor wiring Negative battery cable

Front Crankshaft Seal

REMOVAL & INSTALLATION 2.0L Engines 1. Before servicing the vehicle, refer to the precautions in the beginning of this section.

2. Remove the timing belt and crankshaft sprocket.

Be careful not to damage the crankshaft surface when removing the seal.

3. Using seal remover tool T92C-6700CH, remove the crankshaft front oil seal. To install: 4. Use seal replacer tool T81P-6700-A, install the new seal. 5. Install the crankshaft sprocket and the timing belt.

Camshaft(s) and Valve Lifters REMOVAL & INSTALLATION 2.0L SOHC Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Disconnect the negative battery cable. 3. Remove the air cleaner and valve COVET.

Rocker arm Rocker arm seats Camshaft Position (CMP) sensor Valve tappet Valve tappet guide plate Ignition coil Radio interference capacitor Ignition coil bracket Cup plug Camshaft Water hose connection Thermostat Water hose connection gasket

Exploded view of the cylinder head—2.0L SOHC SPI engine

9300MG12

Pd

FORD MOTOR CO. 44.43

ESCORT ¢ ESCORT ZX2 ¢ TRACER

e Timing belt e Valve cover and camshaft sprockets

ee a

NES

7922MG54

Removing the camshaft front seal—2.0L SOHC engine

e>it may be necessary to rotate the oil control solenoid flange 90 degrees prior to removal.

7922MG56

Remove and discard the cup plug located at the rear of the cylinder head—2.0L engine

7922MG55

Remove the camshaft thrust plate retaining bolts (A) and the plate (B)—2.0L SOHC engine

4 Remove the camshaft front seal as follows: a. Align the timing marks and remove the timing belt. b. Use cam sprocket holding/removing tool T74P-6256-B, and remove the camshaft sprocket. c. Unfasten the timing belt tensioner bolt and remove the tensioner. d. Remove the inner engine front cover. e. Use seal removal tool T92C-6700CH, to remove the camshaft front seal. 5. Remove or disconnect the following: e Ignition coil and bracket Rocker arms and valve tappets Camshaft thrust plate bolts and the plate Cup plug from the rear of the cylinder head and discard Camshaft from the rear of the cylinder head To install: e>Liberally coat the cam bore in the cylinder with clean 5W30 motor oil. 6. Install or connect the following:

¢ Camshaft through the rear of the cylinder head ¢ Camshaft thrust plate and the bolts. Tighten the bolts to 71-115 inch lbs. (8-13 Nm).

7922MG57

Use seal Replacer T81P-6292-At, to install the camshaft front seal 0.002-0.04 in. (0.05-1.0mm) below flush with the cylinder head front face—2.0L SOHC engine

e New cup plug and the tappets e Rocker arms e Ignition coil bracket and coil 7. Install the camshaft front seal as follows: a. Apply a thin film of 5W30 motor oil to the lip of the seal. ->The seal depth should be 0.002-0.04 in. (0.05-1.0mm) below flush with the cylinder head front face.

b. Use seal replacer T81P-6292-A, to install the camshaft front seal. c. Install the inner engine front cover. d. Install the timing belt tensioner. Tighten the tensioner bolt to15—22 ft. lbs. (20-30 Nm). e. Install the camshaft sprocket and the timing belt 8. Install the valve cover and the air cleaner assembly. 9. Connect the negative battery cable.

2.0L DOHC Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 9. Remove or disconnect the following:

e Oil control solenoid flange bolts and the flange e>Mark the camshaft journal caps with a number to identify their location, as they must be replaced in their original position.

e Camshaft journal caps in several passes in the sequence illustrated, then remove the bolts and caps e Camshafts from the cylinder head e Oil control sensor and bushing 3. Inspect the camshafts for damage and wear. To install: 4. Be sure the valve clearance is correct.

5. Install the oil control solenoid bushing and flange on the exhaust camshaft. 6. Coat the surface of the front camshaft journal cap with gasket maker E2AZ-19562-B. 7. Place the camshafts in position and lubricate the bearing surfaces with engine assembly lubricant D9AZ-19579-D. 8. Install new camshaft front oil seals. 9. Apply a thin coat of silicone gasket and sealant F6AZ-19562-AA to the sealing surface of the of the front camshaft journal bearing cap. 10. Install or connect the following: ¢ Caps and tighten the bolts in several 2-turn passes in the sequence illustrated to 10-12 ft. Ibs. (13-17 Nm)

The oil control O-ring seals must not fall out of position in the oil control solenoid flange or poor engine performance may occur. 11. Inspect the oil control solenoid flange O-rings for damage or wear and replace as necessary. ¢ Oil control solenoid flange and tighten the bolts to 84-92 inch Ibs. (9.5-10.5 Nm) in the sequence illustrated 12. Rotate the camshafts a full turn and check for binding.

For complete Engine Mechanical specifications, see Section 1 of this manual

44-14

FORD motor co. ESCORT e ESCORT ZX2 ¢ TRACER

é Spark Plug

Engine Lifting Eye Bolt Engine Lifting Eye Camshaft Sprocket —Exhaust Exhaust Camshaft Sprocket Bolt Clearance

Blanking Plug O-Ring

Blanking Plug Bolt—Intake Camshaft Camshaft Sprocket Intake Valve Spring (Color Coding:

Camshaft Front Seal

Exhaust = Blue, Intake = Red)

O-Ring

—

Camshaft Front Seal to

Oil Feed Ring Oil Feed Flange Bolts Oil Feed Flange

| Re | —Ww |e Nn ph]

(7 [Cylin HeadBol der e

Guide Sleeve—Front Camshaft

Bearing Cap

Fifth Camshaft Bearing Cap 9300MG06

Exploded view of the cylinder head, showing camshaft mounting—2.0L DOHC Zetec engine

ESCORT e iy POM EAGER T 4-1 5 9.5-10.5 Nm (84-92 Ib/in)

iE — OPTRH Cen

IN

7922MG60

i)

(o) 7

m~ }

Tighten the oil control solenoid flange bolts in this sequence—2.0L Zetec engine

e Camshaft sprockets and timing belt e \alve cover

Valve Lash

|

ADJUSTMENT (8)

2.0L DOHC Zetec Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. : 2. Remove the valve cover.

7922MG58

Loosen the camshaft journal caps in several passes in this sequence—2.OL Zetec engine

3. Remove the timing belt.

> Measure each valve’s clearance at the base circle before removing the camshafts. The shims are not serviceable with the camshafts in place. 4. Measure the valve clearances, then remove the camshafts and shims. The correct shims allow the following valve clearances: e Intake valve clearance: 0.0043-0.0071 in. (0.11-0.18mm) e Exhaust valve clearance: 0.0106—-0.0134 in. (0.27-0.34mm) e>A midrange clearance is the most desirable.

5. Select the shims using the following formula: shim thickness = measured clear-

7922MG61

7922MIG59

d to the proper specification—2.0L Tighten the camshaft journal caps in the sequence illustrate Zetec engine

Measure each valve’s clearance at the

base circle before removing the camshafts—2.0L Zetec DOHC engine

For Accessory Drive Belt illustrations, see Section 1 of this manual

14-1

FORD MOTOR CO.

ESCORT ¢ ESCORT ZX2 e TRACER 2.0L DOHC Engine

7922MG62

Example of a valve lifter shim (arrow)— 2.0L Zetec DOHC engine

ance plus the base shim thickness minus the most desirable thickness. 6. Select the correct shims and mark their installation location. 7. Replace the shims and install the camshafts. 8. Check the new valve clearances. 9. Install the timing belt and covers. 10. Install the valve cover. 11. Start the vehicle and check for proper operation.

Starter Motor

REMOVAL & INSTALLATION 2.0L SOHC 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 ¢ Air cleaner outlet tube ¢ Two top starter motor bolts e>A protective cap is covering the B terminal and must be replaced after servicing the starter motor or solenoid.

¢ § terminal wire and the B terminal nut and cable from the solenoid ¢ Lower starter motor bolt ¢ Starter To install: 3. Install or connect the following: Starter motor assembly and tighten the lower mounting bolt to 18-20 ft. Ibs. (25-27 Nm) S terminal wire, B terminal cable and nut. Tighten the nut to 80-120 inch Ibs. (9-13.5 Nm). Top starter motor bolts. Tighten the bolts to 18-20 ft. Ibs. (25-27 Nm). Air cleaner outlet tube Negative battery cable

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Negative battery cable e Air cleaner outlet tube e Lower starter motor bolt e Two starter motor upper bolts 3. Slide the starter motor from its mounting until you can gain access to the wiring. e Integral connector e Starter motor To install: 4. Install or connect the following: e Integral connector and tighten the retaining nuts to 61 inch Ibs. (7 Nm) Starter motor to its mounting Two starter motor upper bolts and tighten to 15-20 ft. Ibs. (20-27 Nm) Lower starter motor bolt and tighten to 15-20 ft. Ibs. (20-27 Nm) Air cleaner outlet tube Negative battery cable

joints and the crankshaft rear oil seal retainer-to-cylinder block joints. ->Be sure the press fit tabs are fully engaged in the oil pan gasket channel when installing the pan and gasket.

5. Install or connect the following: e Gasket 6. When installing the oil pan, be sure the rear of the pan is aligned with the cylinder block by using a straight edge as a guide. e Qil pan bolts and tighten in the sequence illustrated to 15-22 ft. lbs. (20-30 Nm)¢ Oil pan-to-catalytic converter bracket and tighten the bolts to 30-40 ft. Ibs. (40-55 Nm) ¢ Catalytic converter and oil pan drain plug. Tighten the drain plug to 15-22 ft. Ibs. (20-30 Nm). 7. Fill the engine with the proper type and quantity of engine oil. 8. Start the vehicle and check for oil leaks. 2.0L DOHC Engine

REMOVAL & INSTALLATION 2.0L SOHC Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Catalytic converter 3. Drain the engine oil. e Oil pan-to-catalytic converter bracket bolts and the bracket ¢ 10 oil pan bolts evenly ¢ Qil pan and gasket. Discard the old gasket, To install: 4. Apply a 0.125 in. (3.0mm) wide bead of silicone sealant F6AZ-19562-AA or its equivalent at the oil pump-to-cylinder block

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the engine oil. 3. Remove or disconnect the following:

¢ Catalytic converter ¢ 17 oil pan bolts evenly

° Oil pan To install: 4. Apply a 0.1 in. (3.0mm) wide bead of Silicone sealant F6AZ-19562-AA or its equivalent to the oil pan. 9. Install or connect the following: ¢ Oil pan and the bolts. Tighten the oil pan bolts in the sequence illustrated to 15-22 ft. Ibs. (20-30 Nm). ¢ Oil pan drain plug 6. Fill the engine with the proper type and quantity of engine oil. 7. Start the vehicle and check for oil leaks.

7922MG68

Tighten the oil pan bolts in this Sequence to the proper specification—2.0L SOHC engine

FORD MOTOR CO. 44.47

ESCORT ¢ ESCORT ZX2 ¢ TRACER

Tighten the retaining bolts to 71-97 inch Ibs. (8-11 Nm). e CKP sensor electrical connection e Oil pan e Timing belt 5. Fill the engine with the proper type and quantity of engine oil. 6. Start the vehicle and check for oil leaks.

20-30 Nm (15-22 Ib/ft)

2.0L DOHC Engine

7922MG69

Tighten the oil pan bolts in the proper sequence to the correct torque specification—2.0L Zetec

¢ (il pump and gasket. Discard the gasket. To install: 3. Lubricate the crankshaft front oil seal

REMOVAL & INSTALLATION 2.0L SOHC Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Timing belt e Oil pan e Crankshaft Position (CKP) sensor electrical connection * Oil pump screen cover and tube bolts

lip with clean engine oil. 4. Install or connect the following: e Pump gasket and the pump ¢ Oil pump and tighten the bolts to

10-12 ft. Ibs. (13-16 Nm) Oil pump screen cover and tube.

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Timing covers and belt Crankshaft pulley, sprocket and the timing chain guide Oil pan Oil pump cover and screen bolts Cover and screen Lower cylinder block shims, if necessary Lower cylinder block, the gasket and the crankshaft front oil seal, if necessary Oil pump retaining bolts Oil pump and gasket To install: >The clearance between the lower cylinder block sealing surfaces on the oil pump and the cylinder block cannot exceed 0.012-0.031 in. (0.3-0.8mm).

3. Install or connect the following: e New oil pump gasket and the pump ¢ Oil pump bolts and tighten to 88-97 inch Ibs. (10-11 Nm) ¢ Crankshaft front oil seal, if removed e Lower cylinder block and gasket, if removed. Tighten the lower cylinder

e Cover and tube e 6 oil pump retaining bolts (ar Tapa ager

|

koma

20-24Nm

|

| (15-17 lb/ft) |

7922MG73

7922MG72

Remove the oil pump mounting bolts— 2.0L Zetec engine

to the proper torque specificaTighten the lower cylinder block bolts in the sequence illustrated tion—2.0L Zetec engine

manual For Tire, Wheel and Ball Joint specifications, see Section 1 of this

14-1

FORD MOTOR CO.

ESCORT ¢ ESCORT ZX2 ¢ TRACER

block bolts to 15-17 ft. Ibs. (20-24 Nm) in the sequence illustrated. ¢ Oil pump screen cover and tube. Tighten the retaining bolts to 71-97 inch lbs. (8-11 Nm). ¢ Oil pan, timing chain guide, crankshaft sprocket and the pulley e Timing belt and covers 4. Fill the engine with the proper type and quantity of engine oil. 5. Start the vehicle and check for oil leaks.

Gea

Cj

~\[+

2.0L Engine

Ct

OIL CONTROL RINGS AND EXPANDER

CENTER LINE OF PISTON PARALLEL TO WRIST PIN BORE UPPER COMPRESSION RING GAP LOCATION

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove the transaxle and flywheel.

Be careful not to damage the crankshaft surface when removing the seal.

3. Use seal replacer tool T92C-6700Ch, to remove the old seal. To install: 4. Coat the lip of the new seal with clean 5W30 engine oil. 5. Install the new seal using crankshaft rear Seal pilot tool T88P-6701-B2 and Rear seal replacer tool T88P-6701-B1. 6. Install the flywheel and the transaxle.

Piston and Ring POSITIONING —_—_—_—

BOTTOM COMPRESSION RING

Rear Main Seal

REMOVAL & INSTALLATION

TOP COMPRESSION RING

FRONT OF ENGINE OIL CONTROL SEGMENT RING GAP LOCATION

EXPANDER RING AND LOWER COMPRESSION RING GAP LOCATION

OIL CONTROL SEGMENT RING GAP LOCATION

°7922AG29

Ford 2.0L (VIN 3 and P) engines—piston ring positioning, end-gap spacing and piston positioning. The small directional arrow must face the front of the engine.

a Fuel System Service Precautions Safety is the most important factor when performing not only fuel system maintenance but any type of maintenance. Failure to conduct maintenance and repairs in a Safe manner may result in serious personal injury or death. Maintenance and testing of the vehicle's fuel system components can be accomplished safely and effectively by adhering to the following rules and guidelines. ¢ To avoid the possibility of fire and perSonal injury, always disconnect the negative battery cable unless the repair or test proce-

dure requires that battery voltage be applied. ¢ Always relieve the fuel system pressure prior to disconnecting any fuel system component (injector, fuel rail, pressure regulator, etc.), fitting or fuel line connection. Exercise extreme caution whenever relieving fuel system pressure, to avoid exposing skin, face and eyes to fuel spray. Please be advised that fuel under pressure may penetrate the skin or any part of the body that it contacts. ¢ Always place a shop towel or cloth around the fitting or connection prior to loosening to absorb any excess fuel due to

spillage. Ensure that all fuel spillage (should it occur) is quickly removed from engine surfaces. Ensure that all fuel soaked Cloths or towels are deposited into a suitable waste container. * Always keep a dry chemical (Class B) fire extinguisher near the work area. ¢ Do not allow fuel spray or fuel vapors to come into contact with a spark or open flame. e Always use a back-up wrench when loosening and tightening fuel line connection fittings. This will prevent unnecessary stress and torsion to fuel line piping. * Always replace worn fuel fitting O-

FORD MOTOR CO. 44.49

ESCORT ¢ ESCORT ZX2 e TRACER rings with new. Do not substitute fuel hose or equivalent, 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. Remove the Schrader valve cap at the end of the fuel rail and attach a fuel pressure gauge. 3. Open the manual relief valve on the fuel pressure gauge slowly to relive the fuel pressure

¢ Lower hose from the fuel filter and drain any excess fuel into the container. Plug the hose. e Fuel filter To install: 6. Remove the plugs from the lower and upper hoses. 7. Install or connect the following: e Lower hose to the filter e Hose retaining clip e Upper hose to the filter e Hose retaining clip e Fuel filter and tighten the filter mounting clamp e negative battery cable 8. Start the engine and check for leaks.

REMOVAL & INSTALLATION

The fuel pump is located inside the fuel tank.

The inline fuel filter is located in the engine compartment between the fuel tank and the fuel rail. 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Relieve the fuel system pressure. 3. Disconnect the negative battery cable. 4. Position a suitable container below the fuel filter to collect any excess fuel that may leak from the filter and lines. 5. Remove or disconnect the following: ¢ Fuel filter mounting clamp, loosen only Filter from the mounting bracket Retaining clips from the upper fuel filter hose Upper hose from the fuel filter and drain any excess fuel into the container. Plug the hose. Retaining clip from the fuel filter lower hose

REMOVAL & INSTALLATION This procedure will require a new fuel pump gasket for pump installation, so be Sure to have one before starting. 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Relieve the fuel system pressure. 3. Remove or disconnect the following: ¢ Negative battery cable Rear seat cushion Electrical connectors from the fuel pump ¢ 4 pump access cover screws and the cover Pump electrical connector located under the cover, if equipped ¢ Fuel line clip(s) ¢ Fuel line(s) from the pump ¢ Pump locking retaining ring.,

using a fuel pump locking ring removal tool or a brass drift and a hammer e Fuel pump and the gasket from the tank To install: 4. Install or connect the following: New gasket and place the pump into position in the tank Pump locking retaining ring Fuel line(s) to the pump Line retaining clip(s) Fuel pump electrical connection(s), if equipped Access cover and tighten the retainers Pump electrical connector(s) Rear seat cushion Negative battery cable 5. Start the vehicle and check for proper operation.

Fuel Injector — REMOVAL & INSTALLATION

> CAUTION Fuel injection systems remain under pressure, even after the engine has

been turned OFF. The fuel system pressure must be relieved before disconnecting any fuel lines. Failure to do so may result in fire and/or personal injury. 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Relieve the fuel system pressure. 3. Remove or disconnect the following: e Negative battery cable

90985607

Grasp the fuel injector’s body and pull 7922MG79

(1) from the fuel filter Detach the upper and lower hose clips before disconnecting hoses

upward, while gently rocking the fuel injector from side to side

For Wheel Alignment specifications, see Section 1 of this manual

14-2

FORD MOTOR CO.

ESCORT ¢ ESCORT ZX2 ¢ TRACER

e Fuel injection fuel rail e Injector retaining clips, on DOHC engines 4. Grasp the fuel injector body and pull up while gently rocking the fuel injector from side to side. 5. Once removed, inspect the fuel injector cap and body for signs of deterioration. Replace as required.

6. Remove the O-rings and discard. lf an O-ring or end cap is missing, look in the intake manifold for the missing part. To install: 7. Install or connect the following: e New O-rings onto each injector and apply a small amount of clean engine oil to the O-rings

e Injectors using a slight twisting downward motion « Injector retaining clips, on DOHC engines e Fuel injection fuel rail ¢ Negative battery cable 8. Run the engine at idle for 2 minutes, then turn the engine OFF and check for fuel leaks and proper operation.

DRIVE TRAIN Transaxle Assembly REMOVAL & INSTALLATION Manual

1. Before servicing the vehicle, refer to the precautions in the beginning of this section.

2. Remove or disconnect the following: Both battery cables, negative cable first Battery and tray Engine air cleaner outlet tube Constant Control Relay Module (CCRM) module and bracket Slave cylinder line from the slave cylinder hose and plug the hose

Bay

Sis

an ~

‘ Ke

/

7922MG85

Location of the left-hand engine support bracket nuts—2.0L engines

Loosen the transaxle gearshift bolt and remove the gearshift rod and clevis pin from the input shift shaft

Slave cylinder line retaining clip Slave cylinder line from the bracket Heated Oxygen (HO2S) sensor electrical connection Back-up light electrical connection Electrical connector bracket bolt and the bracket Vehicle Speed Sensor (VSS) electrical connection Halfshafts 3. Install Engine Support Bar D88-6000A, and attach it to the engine lifting eyes with suitable chains or cables. e Insulator nuts from the left-hand engine support bracket e Front and rear upper transaxle-toengine bolts 4. Drain the transaxle fluid and install the drain plug. e Air conditioning line from the retainer located on the engine support crossmember e Engine support crossmember bolts and nuts

J Gr I 38. 51 Nm (28-37 Ib/ft)|

cic = Nm (47-65 Ib/ft)|

=a

7922MG86

Install the engine support crossmember and tighten the retainers to specification

FORD MOTOR CO. 44.94

ESCORT ¢ ESCORT ZX2 ¢ TRACER ‘Crossmember Gearshift stabilizer bar-to-transaxle nut

Stabilizer bar and support from the transaxle Transaxle gearshift rod nut Transaxle gearshift bolt Gearshift rod and clevis pin from the input shift shaft Starter motor Lower slave cylinder tube and the Slave cylinder e Lower transaxle-to-engine bolts 5. Position and secure a Suitable transaxle jack under the transaxle. e Catalytic converter e Middle transaxle-to-engine bolts e Transaxle from the vehicle To install: 6. Apply a thin coating of suitable grease to the splines of the input shaft. 7. Place the transaxle onto a suitable transaxle jack. Be sure the transaxle is Secure. 8. Install or connect the following: Transaxle Middle transaxle-to-engine bolts and tighten them to 23-38 ft. Ibs. (38-51 Nm) Lower engine-to-transaxle bolts and tighten them to 23-38 ft. Ibs. (38-51 Nm) clutch slave cylinder and tighten the nuts to 12-17 ft. Ibs. (16-23 Nm) Lower slave cylinder tube and tighten the fitting to 10-16 ft. Ibs. (13-21 Nm) Starter motor Gearshift rod and clevis into position on the input shift shaft Gearshift bolt and gearshift rod nut and tighten to 12-17 ft. Ibs. (16-23 Nm) Gearshift stabilizer bar and tighten the nut to 23-34 ft. Ibs. (31-46 Nm) Halfshafts and the catalytic converter Engine support crossmember.

Tighten the crossmember bolts and nuts to 47-65 ft. Ibs. (64— 89 Nm) and the insulator nuts to 28-37 ft. Ibs. (38-51 Nm). Front and rear upper transaxle-toengine bolt and tighten it to 28-38 | ft. Ibs. (38-51 Nm) Left-hand engine support insulator

nuts and tighten them to 50-68 ft. lbs. (67-93 Nm) 9. Remove the engine support bar. Electrical connector support bracket e All the electrical connectors e Slave cylinder line to the slave cylinder hose and attach the retaining clip. Tighten the fitting to 10-16 ft. Ibs. (13-21 Nm). 10. Bleed the clutch hydraulic system. 11. Add the proper type and amount of fluid to the transaxle. 12. Install or connect the following: e CCRM and bracket assembly, if removed e CCRM retainers and attach the electrical connection e Engine air cleaner tube e Battery tray and the battery e Battery cables, negative cable last 13. Check for fluid leaks and proper clutch operation. 14. Road test the vehicle and check for proper transaxle operation. Automatic

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Battery cables, negative cable first Battery and tray Engine air cleaner assembly Computer Control Relay Module (CCRM) electrical connections, relay retainers, the relay and bracket from the engine Shift control cable and bracket retaining nut from the manual shift lever Shift cabie and bracket clip, then set the bracket and cable assembly aside All electrical connections from the transaxle Starter motor Throttle valve actuating cable bolts and disconnect the cable from the throttle cam, if equipped 3. Install Engine Support D88L-6000A, to the engine. The engine must be properly supported for transaxle removal. 4 Remove or disconnect the following: Transaxle cooler lines at the transaxle Left-hand engine mount Upper transaxle housing bolts Left-hand splash shields, if equipped Transaxle plug and drain the fluid

e Halfshafts. Install 2 transaxle plugs T88C-7025-AH, into the differential side gears

Failure to install the transaxle plugs may cause the differential side gears to become improperly positioned. If the gears become misaligned, the differential will have to be removed from the transaxle to align them. e Engine support crossmember and the catalytic converter Air conditioning line from the retainer located on the engine support crossmember Transaxle support crossmember bolts and nuts, the left-hand engine isolator nuts, then the crossmember Transaxle housing cover bolts and the cover e 4 flywheel-to-torque converter nuts 5. Position a suitable transaxle jack under the transaxle. Secure the transaxle to the jack. e Remaining transaxle-to-engine bolts 6. Slowly lower the transaxle out of the vehicle. 7. Inspect all components including mounts and brackets. To install: ->Prior to installing the transaxle, lubricate the torque converter pilot hub with multi-purpose grease.

8. Align the torque converter studs to the flywheel. 9. Secure the transaxle on the transaxle jack. 10. Install or connect the following: e Transaxle. Tighten the bolts to 40-58 ft. Ibs. (65-80 Nm). Flywheel-to-converter nuts and tighten them to 26-36 ft. Ibs. (35-49 Nm) Transaxle housing cover and tighten the bolts to 40-8 ft. Ibs. (55-80 Nm) Engine support crossmember. Tighten the crossmember bolts and nuts to 47-65 ft. Ibs. (64-89 Nm) and the insulator nuts to 28-37 ft. lbs. (38-51 Nm). Front and rear upper transaxle-toengine bolt and tighten it to 28-38 ft. Ibs. (38-51 Nm)

For Maintenance Interval recommendations, see Section 1 of this manual

14-2

FORD MOTOR CO.

ESCORT ¢ ESCORT ZX2 ¢ TRACER

7922MG88

Connect the throttle valve cable at the throttle cam (B) and tighten the cable retaining bolts (A)

“4 it~ Align the marks on the MLP switch and the manual control lever as shown

11. Install or connect the following: e Halfshafts ¢ Crossmember to the transaxle mounts and the chassis. Tighten the crossmember-to-transaxle mount nuts to 27-38 ft. Ibs. (37-52 Nm). Tighten the crossmember-to-chassis nuts and bolts to 47-66 ft. Ibs. (64-89 Nm). Lower transaxle-to-engine oil pan bolts and tighten to 27-38 ft. Ibs. (37-52 Nm) Engine/transaxle splash shields Starter motor All the electrical connections Upper transaxle-to-engine bolts and tighten to 40-58 ft. Ibs. (55-80 Nm) Left-hand engine mount and tighten the nuts to 50-68 ft. Ibs. (67-93 Nm) Throttle valve cable at the throttle cam, if equipped 12. Remove the engine support. ° Shift cable and bracket to the manual shift lever, the shift cable and bracket clip. Tighten the nut to 12-16 ft. Ibs. (16-22 Nm). ¢ Engine air cleaner assembly ¢ Battery tray and battery ¢ Both battery cables, negative cable last

13. Add the proper type and quantity of transaxle fluid. 14. Check the transaxle for leaks and for

proper operation. 15. Check the MLP switch for proper adjustment, as follows: a. Shift the transaxle into NEUTRAL, then align the marks on the transmission range switch and the manual control lever. b. Install and finger-tighten the switch retaining bolts. c. Attach an ohmmeter between terminals A and B on the switch as shown in the accompanying illustration. d. Adjust the switch by rotating the switch housing on the manual control lever until there is no continuity between the terminals. e. Hold the switch in place, then tighten its retaining bolts to 70-95 inch lbs. (8-11 Nm). f. Remove the ohmmeter and attach the switch electrical connection. g. Place the manual contro! shift outer lever in position and tighten its retaining nut to 33-47 ft. Ibs. (44-64 Nm). 16. Road test the vehicle and check for proper operation.

ADJUSTMENT Pedal Free-Play

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Depress the clutch pedal until resistance can be felt, and measure the distance between the upper clutch height and where the resistance is felt. The free-play should be 0.0—0.40 in. (5.0-13.9mm). 3. If an adjustment is necessary, turn the locknut and equalizer bar-to-clutch release lever rod. 4. After adjustment, measure the disengagement height from the upper surface of the clutch pedal pad to the carpet. The distance should be 2.3 in. (69mm). Pedal Height 1. Measure the distance from the upper surface of the pedal pad to the carpet. The measurement should be 8.35-8.54 in. (212-217mm). 2. If an adjustment is necessary, turn the locknut and the Clutch Pedal Position

9306MG80

Clutch pedal free play measurement

9300MG03

Attach an ohmmeter to terminals A and B on the transmission range switch

9306MG81

Clutch pedal free play adjustment

s

FORD MOTOR CO. 44.99

ESCORT ¢ ESCORT ZX2 ¢ TRACER

4. Remove the transaxle assembly. 5. If the clutch assembly is to be reused, matchmark the pressure plate and the flywheel so they can be assembled in the same position. 6. Install a flywheel holding tool in a transaxle mounting hole on the engine and engage the tooth of the holding tool into the flywheel ring gear. 7. Install a clutch alignment tool. 8. Loosen the pressure plate-to-flywheel retaining bolts 1 turn at a time, in a crisscross pattern, until the spring tension is relieved, to prevent pressure plate damage.

Do not use any cleaners with a petroleum base and do not immerse the clutch pressure plate in solvent.

9306MG79

Cluich pedal height adjustment

(CPP) switch until the pedal height is correct.

REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Disconnect the negative battery cable. 3. Raise and safely support the vehicle.

9. Clean the clutch pressure plate with a Suitable commercial alcohol base solvent. 10. Inspect the pressure plate surface for burns, scores, flatness or ridges. Reface or replace the pressure plate. 11. Inspect the pressure plate diaphragm fingers for wear. Replace the pressure plate if necessary. 12. Using a slide caliper, measure the depth of the rivet heads. If the rivet head is within 0.012 in. (0.3mm) from the clutch Surface, replace the clutch. e>Use emery cloth to remove minor imperfections from the clutch disc lining surface.

16-32 Nm (12-24 lb/ft)

13. Inspect the clutch disc for the following: e Oil or grease saturation e Worn or loose facings ¢ Warpage or loose rivets at the hub ¢ Loose or broken torsion dampening springs e Wear or rust on the splines. 14. If the clutch disc shows any of these conditions, it should be replaced. 15. Use a dial indicator mounted on a metal base to measure the clutch disc runout. If the run-out exceeds 0.0276 in. (0.700mm), replace the disc. 16. Inspect the clutch release for distortion, cracks, excessive release bearing surface wear or damaged tines and replace as

necessary. To install: 17. Clean the pressure plate and flywheel surfaces thoroughly. Position the clutch disc and pressure plate into the installed position and support them with a clutch aligning tool. If the clutch assembly is being reused, align the matchmarks that were made during the removal procedure. 18. Install the pressure plate-to-flywheel retaining bolts. Tighten the bolts in the correct sequence to 12-24 ft. Ibs. (16-32 Nm). Remove the alignment tool. 19. Install the transaxle assembly. 20. Lower the vehicle. 21. Bleed the hydraulic clutch system. 22. Adjust the clutch pedal free-play. 23. Connect the negative battery cable. 24. Road test the vehicle and check the clutch for proper operation.

Hydraulic Clutch System BLEEDING

7922MG95

illustrated to specificaTighten the pressure plate-to-flywheel retaining bolts in the sequence tion

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Check that the brake master cylinder is at least 9% full during the entire bleeding DrOCess. 3. Remove the bleeder screw cap from the clutch slave cylinder and attach a hose to the bleeder screw. Place the other end of the hose into a container to catch the fluid. 4. Have an assistant slowly pump the clutch pedal several times, then hold the clutch pedal down. 5. Loosen the bleeder screw to release the fluid and air. Tighten the bleeder screw. 6. Repeat the bleeding procedure until no more air bubbles are seen in the fluid.

For Tune-up, Capacities and Firing orders, see Section 1 of this manual

1 4-24 eae

a ae e TRACER

al Description

Item

Clutch Slave Cylinder

Clutch Release Fork

2 | Clutch Release Hub and

Bearing

Brake Master Cylinder Reservoir

Clutch Pressure Plate

Clutch Pedal

Clutch Disc 5

Description

Pilot Bearing

A a

Clutch Pedal Position (CPP) Switch

|

Clutch Master Cylinder 9306MG78

Exploded view of the clutch system components

J 7. Tighten the bleeder screw to 52-78 inch lbs. (6-9 Nm). 8. Top off the brake master cylinder to the full line. 9. Check for proper clutch system operation.

FCORT SE SCaHT PRICE

6. Remove the ball joint bolt and nut. Carefully pry down on the lower control arm to separate the ball joint stud from the Steering knuckle. 7. Pull outward on the steering knuckle/brake assembly. Carefully pull the halfshaft from the hub and position it aside. Removal of the left side halfshaft requires removal of the crossmember to allow access with a prybar.

REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Disconnect the negative battery cable. 3. With the vehicle sitting on the ground, carefully raise the staked portion of the halfshaft retaining nut using a suitable small chisel. Loosen the nut. 4. Remove or disconnect the following: e Wheel and tire assembly e Halfshaft retaining nut and discard e Cotter pin and nut from the tie rod end, then separate the tie rod end from the steering knuckle using a Suitable removal tool. Discard the cotter pin. 5. Remove or disconnect the following components to remove the stabilizer bar link: Stabilizer bar end nut (1) and bolt

(2)

Stabilizer bar end retainer (3) End bushing (4) above the stabilizer bar End bushing (5) below the stabilizer bar Stabilizer bar spacer (6) Stabilizer bar end bushings from above (7) and below (8) the subframe Lower stabilizer bar end retainer (9) Stabilizer bar

8. Support the transaxle with a suitable transaxle jack. 9. Unfasten the 4 transaxle crossmember retainers and remove the crossmember. 10. If removing the right side halfshaft, remove the right-hand shield and splash shield. 11. Position a drain pan under the transaxle. 12. Remove the left-hand halfshaft as follows: a. Insert a prybar between the halfshaft and the transaxle case. Gently pry outward to release the halfshaft from the differential side gear. Be careful not to damage the transaxle case, oil seal, C\Vjoint or CV-joint boot. b. Remove the halfshaft. 13. Remove the right-hand halfshaft as follows: a. On models with a manual transaxle, unfasten the center support bearing bolts. b. Lower the halfshaft and remove it from the transaxle. c. Separate the halfshaft from the center support bearing and remove the halfshaft from the vehicle. d. Inspect the center support bearing for damage and replace as necessary. ->Install suitable plugs after removing the halfshafts to prevent the differential

7922MGA1

7922MG97

On models with a manual transaxle, unfasten the center support bearing bolts

During assembly, be sure to install a new circlip on the inner CV-joint spline—2.0L engine

14-25

side gears from moving out of place. Should the gears become misaligned, the differential will have to be removed from the transaxle to align the gears.

To install:

Use new locknuts, split pins and circlips for assembly.

14. Position a new circlip on the inner C\-joint spline so the circlip gap is at the top. Lubricate the splines lightly with a suitable grease. 15. Remove the plugs that were installed in the differential side gears. 16. Position the halfshaft so the CV-joint splines are aligned with the differential side gear splines. Push the halfshaft into the differential. When seated properly, the circlip can be felt snapping into the differential side gear groove.

17. Install the right-hand halfshaft on models with a manual transaxle as follows: a. Position the halfshaft and joint so that the splines line up with the splines in the halfshaft, and push the halfshaft, joint and halfshaft together with the center support bearing. b. Install the halfshaft in the transaxle. 18. Place the center support bearing into position and tighten it retaining bolts to 32-46 ft. Ibs. (46-62 Nm). a. Install the right-hand shield and splash shield. 19. Pull outward on the steering knuckle/brake assembly and insert the halfshaft into the hub. 20. Pry downward on the lower control arm and position the lower ball joint stud in the steering knuckle. 21. Install the crossmember and the crossmember-to-frame bolts. Tighten the bolts to 69-93 ft. Ibs. (94-126 Nm). 22. Remove the transaxle jack. 23. Install or connect the following: Steering knuckle and ball joint nut and bolt. Tighten the nut and bolt to 32-43 ft. Ibs. (43-59 Nm). Stabilizer bar link in reverse order of removal. Tighten the bar end nut until the protruding bar end bolt length is 0.67—75 in. (17-19mm). Tie rod end to the steering knuckle Tie rod end nut and tighten to 32-41 ft. Ibs. (43-56 Nm). Install a new cotter pin. Wheel and tire assembly New halfshaft retaining nut and

For complete service labor times, order Nichols’ Chilton Labor Guide

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FORD MOTOR CO.

ESCORT ¢ ESCORT ZX2 * TRACER

tighten to 174-235 ft. Ibs. (235-319 Nm). Stake the halfshaft retaining nut using a suitable chisel with a rounded cutting edge. 24. Check and refill the transaxle with the proper type and quantity of fluid. 25. Connect the negative battery cable. 26. Road test the vehicle and check for proper operation.

CV-Joints

OVERHAUL Outboard Side 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Halfshaft from the vehicle. Support the assembly in a vise with soft jaws. e Front brake anti-lock sensor indicator off the halfshaft using a punch to drive it off e Two halfshaft boot clamp and discard 3. Slide the boot back out of the way to access the outboard joint. 4. Matchmark the joint-to-halfshaft for reassembly. 5. Use a soft faced mallet to separate the outboard joint by gently tapping it off the halfshaft. 6. Remove or disconnect the following: ¢ Halfshaft bearing retaining circlip and discard * snapring from the outboard side of the halfshaft

ings for damage, grit in the grease, pitting or cracks and replace as necessary. To install: 9. Lubricate the joint bearings with constant velocity grease E43Z-19590-A. 10. Install or connect the following: e Boot and remove the tape e Snapring on the outboard side of the halfshaft e New bearing retaining circlip 11. Use a soft faced mallet to install the outboard joint by gently tapping it onto the halfshaft. 12. Remove any excess grease from the mating surfaces and slide the boot forward onto the joint. 13. Insert a suitable cloth covered tool between the boot and the outer bearing race to allow trapped air to escape from the boot. 14. Use boot clamp pliers to install two new boot clamps. 15. If equipped with anti-lock brakes,

x

use sensing ring replacer tool T94P-20202B, to install the front brake anti-lock sensor indicator onto the halfshaft. 16. Install the halfshaft.

INBOARD SIDE 1.\Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Halfshaft from the vehicle. Support the assembly in a vise with soft jaws. The right-hand side halfshaft on models equipped with a manual transaxle do not have an inboard circlip.

Bearing retaining circlip from the inboard joint housing and discard Joint boot clamps and discard Joint boot from the joint housing Joint housing from the tripod bearing and halfshaft Tripod bearing snapring 3. Matchmark the tripod bearing-tohalfshaft for reassembly. 4, Remove the tripod bearing from the halfshaft. ->Do not remove the tape until after installation of the boot.

5. Wrap the halfshaft splines with tape and then slide the boot from the shaft.

90987615

Clean and inspect the outboard bearings for damage

Do not remove the tape until after installation of the boot.

7. Wrap the outboard halfshaft splines with tape and then slide the boot from the shaft. 8. Clean and inspect the outboard bear-

90987618 90987616

Use boot clamp pliers to install new boot

Remove and discard the bearing retaining circlip from the inboard joint housing

clamps

-BI

-B2

90987614

90987617

If equipped with ABS, use a punch to drive the front brake anti-lock sensor indicator off the halfshaft

Use sensing ring replacer too! T94P20202-B to install the front brake anti-lock sensor indicator onto the halfshaft

90987619

Location of the tripod bearing snapring

PreR Te EeCGke Poerecen 14-27

A/T: 27 mm (1.063 in) M/T: 28 mm (1.102 in) 90987622

90987621 90987G20

Clean and inspect the tripod bearing assembly...

6. Clean and inspect the tripod bearing assembly and outboard joint housing for damage, grit in the grease, pitting or cracks and replace as necessary. To install: 7. Lubricate the tripod bearing and inboard joint housing with constant velocity grease E43Z-19590-A. 8. Install or connect the following: e Boot and remove the tape

. . and outboard joint housing for damage, grit in the grease, pitting or cracks, and replace as necessary

Several precautions must be observed when handling the inflator module to avoid accidental deployment and possible personal injury. e Never carry the inflator module by the wires or connector on the underside of the module. e When carrying a live inflator module, * hold securely with both hands, and ensure that the bag and trim cover are pointed away. e Place the inflator module on a bench or other surface with the bag and trim cover facing up. e With the inflator module on the bench, never place anything on or close to the module that may be thrown in the event of an accidental deployment.

DISARMING 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Disconnect both battery cables, negative cable first. . 3 Wait at least 1minute. This allows

make sure it is within specification

¢ Tripod bearing onto the halfshaft e Tripod bearing snapring e |nboard joint housing onto the tripod bearing e Boot onto the inboard joint housing 9. Insert a suitable cloth covered tool between the boot and the bearing to allow trapped air to escape from the boot. 10. Use boot clamp pliers to install two new boot clamps.

STEERING AND SUSPENSION

PRECAUTIONS

Measure the relaxed state of the halfshaft bearing circlip installed on the shaft, and

time for the back-up power supply to deplete its stored energy. 4 Remove the driver's side air bag module, then the passenger side if required. 5. Use caution when carrying live air bags. Always place the air bag with the cover up. 6. If the battery needs to be reconnected while one or both of the air bags are removed from the system, install Air Bag Simulator 10500010, to the drivers side and/or pasSenger side air bag harness connectors as required. Before removing either air bag simulator, disconnect both battery cables and wait at least 1 minute before continuing.

ARMING 1. Once service is completed and the air bag modules are back in place, connect the negative battery cable and prove out the air bag system by turning the ignition key to the RUN position and visually monitoring the air bag indicator lamp in the instrument cluster. The indicator lamp should illuminate for approximately 6 seconds, then turn OFF. If the indicator lamp does not illuminate, stays ON, or flashes at any time, a fault has been detected by the air bag diagnostic monitor requiring immediate attention.

e» Measure the relaxed state of the halfshaft bearing circlip installed on the shaft. Refer to the accompanying illustration. The wrong size clip will not retain the halfshaft properly. 11. Install a new halfshaft bearing retainer circlip of the correct size onto the outboard halfshaft joint. 12. Install the halfshatt.

— Rack and Pinion Steering Gear REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Turn the key to the ACC position. 3. Remove or disconnect the following: e Steering column tube boot nuts at the base of the column and the tube boots, from inside the passenger compartment e Steering column input shaft cou-

eo

ee

ae

AON 7922MGA4

Unfasten the steering column tube boot nuts at the base of the column and remove the tube boots

Please visit our web site at www.chiltonsonline.com

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FORD MOTOR CO. ESCORT

ESCORT ZX2 ¢ TRACER 7. Check the alignment and adjust as required. 8. Start the engine and check for leaks. 9. Road test the vehicle and check for proper steering system operation.

REMOVAL & INSTALLATION Front

7922MGAS

Unfasten the retaining nuts from the rack and pinion mounting brackets and remove the brackets

pling-to-steering gear input shaft pinch bolt Front wheel and tire assemblies Separate the tie rod ends from the steering knuckles and discard the cotter pins Right-hand lower splash shield Crossmember Pressure and return lines from the rack and pinion assembly and plug the lines Strap holding the hoses to the steering gear and discard Gearshift rod and clevis from the transaxle, if equipped with a manual transaxle Extension bar nut and disconnect the gearshift lever stabilizer bar and support from the transaxle, if equipped with a manual transaxle Retaining nuts from the rack and pinion mounting brackets ¢ Pinion mounting brackets Pushpin and position the righthand boot aside ¢ Rack and pinion assembly from the right-hand side of the vehicle To install: 4. Install or connect the following: ¢ Rack and pinion assembly in its mounting location 5. Align the steering column input shaft coupling and the steering gear input shaft. ¢ Rack and pinion mounting brackets. Tighten the retaining nuts to 28-38 ft. Ibs. (37-57 Nm).

e Gearshift stabilizer bar, support and the gearshift rod and clevis, if equipped with a manual transaxle e>install new Teflon seals on the power Steering pressure hose fitting and be sure the threads are clean before connecting the hose.

Plugs and connect the pressure and return lines to the rack and pinion assembly. Tighten the pressure hose to 21-25 ft. Ibs. (28-33 Nm) and the return line fitting to 20-25 ft. Ibs. (27.3-33.9 Nm). New strap to hold the power steering lines to the rack and pinion housing Crossmember and tighten the bolts to 69-97 ft. Ibs. (94-131 Nm) Right-hand boot shield into position Shield pushpin Right-hand splash shield Tie rod ends to the steering knuckles and the castellated nuts. Tighten to specification. New cotter pins Wheel and tire assemblies Steering column input shaft coupling-to-steering gear input shaft pinch bolt and tighten the bolt to 30-36 ft. Ibs. (40-50 Nm) Steering column tube boots and the 5 retainers. Tighten the retainers to 18-52 inch Ibs. (2-5.9 Nm). Negative battery cable 6. Fill and bleed the power steering system.

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 and tire assembly Clip securing the brake hose to the strut (spring and shock) assembly. Anti-lock brake harness cable and clip, if equipped with anti-lock brakes 2 nuts and 2 bolts securing the strut assembly to the steering knuckle 4 upper strut retaining nuts Strut assembly from the vehicle

> CAUTION Never remove the strut piston rod nut unless the coil spring is compressed. Always wear safety glasses when using a spring compressor. 3. Inspect all components-and replace as needed. To install: 4. Install or connect the following: ¢ Strut assembly into the wheel housing. Be sure the direction indicator on the upper mounting bracket faces inboard. Upper mounting bracket to the strut tower with the retaining nuts. Tighten the nuts to 22-30 ft. Ibs. (29-40 Nm). Strut assembly to the steering knuckle and the retaining bolts and nuts. Tighten to 69-93 ft. Ibs. (93-127 Nm). Brake hose on the strut assembly and secure it with the brake hose clip Anti-lock harness cable and clip, if equipped with anti-lock brakes ¢ Front wheel and tire assembly ¢ Negative battery cable 9. Check the front wheel alignment. 6. Road test the vehicle and check for proper operation.

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CORTE

ate PO CAeR 14-29

Front Shock Absorber Upper Mounting Bracket

Front Suspension Lower Arm Mounting Bolt Bushing (Rear)

Upper Spring Seat (Part of

18198)

Front Wheel Spindle Tie Rod

| 3 |FrontBrakeHose | 4 |DiscBrakeCaliper | ears Coca

11.

| Front Suspension Lower Arm

12

| Front Suspension Lower Arm Mounting Bolt Bushing

(Front) Front Shock Absorber

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Front Coil Spring

9300MG04

Identification of the front suspension components

Rear

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7922MGAG Remove the 2 nuts and 2 bolts securing the strut assembly to the steering knuckle

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Negative battery cable Package tray trim panel, on sedan and coupe models Quarter trim pane, on wagon models 2 upper strut retaining nuts Wheel and tire assembly Clip securing the brake hose to the rear strut assembly ABS sensor bolt, if equipped Nuts and bolts securing the rear strut assembly to the wheel spindle strut assembly from the vehicle To install: 3. Install or connect the following: e Strut assembly into the vehicle wheel housing e Nuts and bolts securing the strut assembly to the rear wheel spindle assembly. Tighten the lower strut bolts and nuts to 76-100 ft. Ibs. (103-136 Nm).

Timing belt service is covered in Section 3 of this manual

14-3

FORD MOTOR CO. ESCORT ¢ ESCORT ZX2 ¢ TRACER

9300MG05

Identification of the rear suspension components

7922MGA8

Location of the 2 rear strut upper retaining nuts (arrows) inside the vehicle

ABS sensor bolt, if equipped Clip securing the flexible brake hose to the rear strut assembly Wheel and tire assembly 2 upper strut retaining nuts and tighten to 34-46 ft. Ibs. (47-62 Nm) Trim panel Negative battery cable

4. Check the rear wheel alignment. 5. Road test the vehicle and check for proper operation.

Coil Spring

2. Remove the strut assembly. 3. Place the strut assembly in a vise. 4. Install a suitable spring compressor tool onto the coil spring and compress the spring. 5. Unfasten the piston rod nut and remove the upper mounting bracket. 6. Remove the bound stopper, dust boot, rubber spring seat, spring, upper spring seat and thrust bearing. To install: 7. Install the thrust bearing, upper spring seat, spring, rubber spring seat, dust boot and the bound stopper. 8. Install the piston rod nut and tighten it to 58-81 ft. Ibs. (79-110 Nm), 9. After the piston rod nut has been tightened to specification, carefully remove the compressor tool from the spring while making sure the spring is properly seated in the upper and lower spring seats. 10. Install the strut assembly in the vehicle. 11. Have the vehicle alignment checked and if necessary, adjusted. Rear

1. Remove the strut assembly. 2. Place the strut assembly in a vise.

REMOVAL & INSTALLATION Front

1. Before servicing the vehicle, refer to the precautions in the beginning of this section.

cover ¢ Piston rod nut and the retainer e Strut insulator ¢ Spring compressor e Rear strut dust boot and stopper seat ¢ Spring and the rear strut insulator To install: 5. Place the strut assembly in a vise. 6. Install or connect the following: ¢ Strut insulator and spring ¢ Stopper seat and dust boot 7. Use the spring compressor tool to compress the strut spring. ¢ Strut insulator and the retainer e Piston rod nut and tighten it to 41—49 ft. Ibs. (65-67 Nm) ¢ Top mounting cover 8. Be sure the spring is properly aligned and carefully release the spring into the seats of the strut. 9. Remove the spring compressor from the coil spring. 10. Install the strut assembly. Lower Ball Joint

kk CAUTION

REMOVAL & INSTALLATION

Always take the necessary precautions when using a spring compres-

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3. Install a suitable spring compressor tool onto the coil spring and compress the spring. 4. Remove or disconnect the following: ¢ Rear strut assembly top mounting

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1. Before servicing the vehicle, refer to the precautions in the beginning of this section.

, 2. Remove or disconnect the following: ¢ Wheel assembly e Nut and bolt attaching the lower ball joint to the steering knuckle e Ball joint from the steering knuckle ¢ Lower control arm ball joint nuts and bolt e Ball joint To install: 3. Install or connect the following: e Ball joint into position on the lower control arm ¢ Ball joint-to-lower control arm retainers. Tighten the nuts and bolt to 69-86 ft. Ibs. (93-117 Nm). 4. Apply Loctite® 290 thread locking compound to the ball joint nut and threads. e Ball joint to the steering knuckle ¢ Ball joint nut and bolt. Tighten the nut and bolt to 32—43 ft. Ibs. (43-59 Nm). e Wheel assembly e Check and adjust the wheel alignment as necessary

FORD MOTOR CO. 4 4_94

ESCORT ¢ ESCORT ZX2 ¢ TRACER

CONTROL ARM BUSHING REPLACEMENT

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90988613 Engage the lower ball joint to the steering knuckle and tighten the pinch bolt and nut to specification

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93-117 Nm (69-86 Ib/ft)

Rear

90988614

Tighten the lower control arm retaining bolts in the sequence shown to the proper specification

REMOVAL & INSTALLATION Front

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Front wheel and tire assembly Stabilizer bar link nuts, retainers, bushings, bolts and sleeves Pinch bolt and nut securing the ball joint to the steering knuckle Lower ball joint from the steering knuckle by prying the lower control arm down with a prybar Front lower control arm pivot bolt Three lower control arm retaining bolts and the lower control arm

90988G12

Unfasten of the lower control arm pivot

bolt (arrow)

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: ¢ Control arm e Nut and control arm mounting bushing (rear) and washer Front bushing from the arm using a Suitable control arm bushing tool, C-frame and clamp assembly Front bushing into the arm using a Suitable control arm bushing tool, C-frame and clamp assembly Washer, control arm mounting bushing (rear) and nut. Tighten the nut to 69 ft. Ibs. (93 Nm). Control arm

3. Inspect the lower control arm, lower control arm bushings and the lower ball joint. The ball joint and bushings can be replaced individually. To install: 4. Install or connect the following: e Lower control arm into position at the bushings e Lower ball joint to the steering knuckle and tighten the pinch bolt and nut to 32-43 ft. Ibs. (48-59 Nm) 5. Use a transmission jack to raise the lower control arm so that it is parallel with the ground. ¢ Control arm retaining bolts and tighten them to 69-86 ft. Ibs. (93-117 Nm) in the order shown in the accompanying illustration e Control arm pivot bolt and tighten to 69-86 ft. Ibs. (93-117 Nm) e Stabilizer bolts, washers, bushings, sleeves and nuts. Tighten the stabilizer nuts so 0.67—-0.75 inches (17-19mm) of thread is exposed at the end of the bolt. e Wheel and tire assembly 6. Check the front wheel alignment. 7. Road test the vehicle and check for proper operation.

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Position a floor jackstand beneath the rear Suspension crossmember. 3. Remove or disconnect the following: e Wheel and tire assembly Stabilizer nuts, washers, bushings, Sleeves and bolts Bolts securing the stabilizer bar brackets and grommets to the rear Suspension crossmember Stabilizer bar Bolts securing the rear Suspension crossmember to the vehicle frame 4. Lower the floor jackstand to allow the rear Suspension crossmember to be lowered from the vehicle frame. e Control arm and bushing nut e Control arm and bushing bolt e Control arm To install: 5. Install or connect the following: e Control arm into position — e Retaining bolt and tighten it to

50-70 ft. Ibs. (68-95 Nm)

90988626

Support the rear suspension crossmember (B) with a floor jackstand (A)

Heater Core replacement is covered in Section 2 of this manual

14-3

FORD MOTOR CO.

ESCORT ¢ ESCORT ZX2 ¢ TRACER

90988627

Unfasten the rear suspension crossmember bolts, then lower the floor jackstand and crossmember

e Control arm and bushing retaining nut, then tighten the nut to 64-86 ft. Ibs. (87-116 Nm) 6. Raise the floor jack and place the crossmember into position. e Crossmember bolts and tighten them to 34-46 ft. Ibs. (47-62 Nm) Grommets onto the stabilizer bar and align the grommets to the positions painted on the bar Stabilizer bar to the rear suspension crossmember and secure it in place with the straps and bolts. Tighten the bolts to 32-43 ft. Ibs. (43-59 Nm). Stabilizer bolts, washers, grommets, sleeves and nuts. Tighten the stabilizer nuts so 0.64—0.71 in. (16.2-18.2mm) of thread is exposed at the end of the bolt. ¢ Wheel and tire assembly 7. Check the wheel alignment.

Wheel Bearings

wire. Do not let the caliper hang on the hose. Brake rotor Halfshaft retaining nut and discard it Cotter pin and castellated nut from the tie rod end and separate the tie rod end from the steering knuckle using a suitable removal tool. Discard the cotter pin. Separate the tie rod end from the wheel knuckle ABS sensor bolt and the sensor, if equipped Strut mounting nuts and the studs which attach the strut assembly to the steering knuckle Strut from the steering knuckle Lower ball joint pinch bolt. Carefully pry down on the lower control arm to separate the ball joint stud from the steering knuckle. Wheel hub, knuckle and bearing assembly from the vehicle To install: 4. Apply Loctite® 290 thread locking compound to the ball joint nut and threads. 5. Install or connect the following: e Wheel hub, knuckle and bearing assembly onto the ball joint and tighten the pinch bolt and nut to 32-43 ft. Ibs. (43-59 Nm) Tie rod end and tighten the nut to 20-33 ft. Ibs. (34-46 Nm). Install a new cotter pin. ABS sensor and tighten the bolt, if equipped

REMOVAL & INSTALLATION

Knuckle to the strut assembly and tighten the strut mounting nuts to 69-93 ft. Ibs. (93-127 Nm) New halfshaft retaining nut and tighten to 174-235 ft. Ibs. (235-319 Nm). Stake the retaining nut using a suitable chisel with the cutting edge rounded off. Brake rotor and caliper ¢ Wheel and tire assembly 6. Check the front wheel alignment. 7. Road test the vehicle and check for proper operation.

Front

Rear

ADJUSTMENT The bearings on the front and rear wheels are a one piece cartridge design and cannot be adjusted. Wheel bearing play can be checked with a dial indicator. If wheel bearing play exceeds 0.002 in. (0.05mm) check the wheel hub retainer nut for proper torque. If the torque is correct, replacement of the wheel bearing is required.

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. With the vehicle sitting on the ground, carefully raise the staked portion of the halfshaft retaining nut using a suitable small chisel. Loosen the nut. 3. Remove or disconnect the following: ¢ Wheel and tire assembly ¢ Brake caliper and secure it out of the way with a piece of mechanic's

e>The wheel bearings are a cartridge design and are not serviceable. If bearing replacement is required, the bearings and hub must be replaced as an assembly.

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: ¢ Wheel and tire assembly e Hub grease cap

Brake drum or disc brake caliper and rotor, as necessary Wheel hub retainer nut securing the hub to the spindle, unstake the nut prior to loosening Hub and bearing assembly. Discard the hub retainer nut. Disc brake shield retaining bolts and the shield, if equipped with disc brakes Backing plate, if equipped with drum brakes Strut-to-spindle retaining bolts and nuts Trailing arm bolt securing the trailing arm to the spindle Stabilizer bar link nuts, retainers, bushings, sleeves and bolts Control arm nut and bolt securing both control arms to the wheel spindle e Spindle from the vehicle 3. Inspect all components. If the wheel spindle is damaged, replace it. Wheel bearings are sealed and must be replaced if damaged with the wheel hub. To install: 4. Install or connect the following: ¢ Wheel spindle in position to the strut ¢ Spindle retaining bolts and nuts. Tighten to 69-93 ft. Ibs. (93-127 Nm). e Trailing arm to the spindle and tighten retaining bolt to 69-93 ft. Ibs. (93-127 Nm) Both control arms in position to the spindle and tighten the retaining bolt and nut to 63-86 ft. Ibs. (85-117 Nm) Stabilizer bar link nuts, retainers, bushings, sleeves and bolts Brake backing plate, if equipped with drum brakes Brake shield and the disc brake shield retaining bolts, if equipped with disc brakes Wheel hub and bearing assembly to the wheel spindle New wheel hub retainer nut and tighten to 130-174 ft. Ibs. (177-235 Nm) 5. Stake the wheel hub retainer nut using a Cape or round end chisel. Do not use a sharp chisel to stake the hub nut. ¢ Brake drum or the disc brake rotor and caliper, as equipped e Hub grease cap ¢ Wheel and tire assembly 6. Pump the brake pedal several times to position the brake lining before attempting to move the vehicle. /. Road test the vehicle and check for proper operation.

FORD MOTOR CO, 2000-01 Ford-Focus DRIVE TRAIN.................. 15-14 ENGINE REPAIR................ 15-2 RUELS SYSTEM}. co.cc scccseuec: 15-13 BREGAULIONS .2).2.Disconnecting the negative battery cable on some vehicles may interfere with the functions of the on board computer system. The computer may undergo a relearning process once the negative battery cable is reconnected.

Alternator

brake fluid internally, IMMEDIATELY seek medical assistance. e The EPA warns that prolonged contact with used engine oil may cause a number of skin disorders, including cancer. You should make every effort to minimize your exposure to used engine oil. Protective gloves should be worn when changing oil. Wash your hands and any other exposed skin areas aS Soon as possible after exposure to used engine oil. Soap and water, or waterless hand cleaner should be used. e All new vehicles are now equipped with an air bag system, often referred to as a Supplemental Restraint System (SRS) or Supplemental Inflatable Restraint (SIR) 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

:

REMOVAL SOHC Engine |. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Negative battery cable ¢ Accessory drive belt

¢ Clean, high quality brake fluid from a sealed container is essential to the safe and proper operation of the brake system. You should always buy the correct type of brake fluid for your vehicle. If the brake fluid becomes contaminated, completely flush the system with new fluid. Never reuse any brake fluid. Any brake fluid that is removed from the system should be discarded. Also, do not allow any brake fluid to come in contact with a painted surface; it will damage the paint. } e Never operate the engine without the proper amount and type of engine oil; doing so WILL result in severe engine damage. e Timing belt maintenance is extremely important. Many models utilize an interference-type, non-freewheeling engine. If the timing belt breaks, the valves in the cylinder head may strike the pistons, causing potentially serious (also time-consuming and expensive) engine damage. Refer to the maintenance interval charts in the front of this manual for the recommended replacement interval for the timing belt, 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 computer system(s) and may require the computer to undergo a relearning process once the negative battery cable is reconnected. e When servicing drum brakes, only disassemble and assemble one side at a time, leaving the remaining side intact for reference.

ENGINE REPAIR ¢ Power steering pipe brackets e Exhaust manifold heat shield e Alternator harness connectors e Alternator

DOHC 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 Accessory drive belt Alternator harness connectors Coolant expansion tank Power steering reservoir Engine wiring harness bracket Ground cable Evaporative Emissions (EVAP) canister purge valve Alternator

INSTALLATION SOHC Engine Install or connect the following: ¢ Alternator. Tighten the bolts to 35 ft. lbs. (45 Nm), e Alternator harness connectors ¢ Exhaust manifold heat shield ¢ Power steering pipe brackets ¢ Accessory drive belt ¢ Negative battery cable

DOHC Engine Install or connect the following: e Alternator. Tighten the bolts to 18 ft. Ibs. (25 Nm). ¢ EVAP canister purge valve

¢ Ground cable

FORD MOTOR CO. FOCUS

a

¢ ¢ ¢ e e ¢

Engine wiring harness bracket Power steering reservoir Coolant expansion tank Alternator harness connectors Accessory drive belt Negative battery cable

Ignition Timing ADJUSTMENT The engines are equipped with a Distributorless Ignition System (DIS). No adjustment is necessary.

Engine Assembly

Coolant expansion tank Accessory drive belt Power steering pump and reservoir Power steering high pressure pipe Radiator cooling fan Catalytic converter Exhaust flex pipe Drive belt cover Shift cable cover Shift cables A/C compressor, if equipped Right engine mount Lower ball joints @eeeeeeeeeee e@ ee Axle halfshafts 6. Support the powertrain from below 7. Remove the front and rear engine mounts.

8. Raise the vehicle away from the pow-

REMOVAL & INSTALLATION

ertrain.

Manual Transaxle

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the cooling system. 3. Relieve the fuel system pressure. 4. Loosen the front strut center nuts 5 turns. 5. Remove or disconnect the following: Battery, tray and cables Mass Air Flow (MAF) sensor connector Air cleaner housing and tubes Accelerator cable Cruise control cable, if equipped Ignition coil connectors Power steering pump pressure switch connector Heated Oxygen (HO2S) sensor connectors Fuel injector harness connectors Powertrain Control Module (PCM) connectors Vehicle Speed (VSS) sensor connector Reverse lamp switch connector Clutch slave cylinder fluid pipe Evaporative Emissions (EVAP) canister vacuum lines Power brake booster vacuum line Delta Pressure Feedback Electronic (DPFE) system sensor vacuum line Exhaust Gas Recirculation (EGR) vacuum line Intake manifold vacuum line Fuel line

Coolant bypass hoses Radiator hoses

19-3

SS

To install: 9. Lower the vehicle over the powertrain. 10. Install or connect the following: Front engine mount. Tighten the nuts to 59 ft. Ibs. (80 Nm) and the bolts to 35 ft. Ibs. (48 Nm). Rear engine mount. Tighten the outer nuts to 35 ft. Ibs. (48 Nm) and the center nut to 98 ft. Ibs. (133 Nm). Axle halfshafts Lower ball joints. Tighten the pinch bolts to 37 ft. Ibs. (50 Nm). Right engine mount. Tighten the bolts to 35 ft. Ibs. (48 Nm). A/C compressor, if equipped Shift cables Shift cable cover Drive belt cover Exhaust flex pipe Catalytic converter Radiator cooling fan Power steering high pressure pipe Power steering pump and reservoir Accessory drive belt Coolant expansion tank Radiator hoses Coolant bypass hoses Fuel line Intake manifold vacuum line EGR vacuum line DPFE system sensor vacuum line Power brake booster vacuum line EVAP canister vacuum lines Clutch slave cylinder fluid pipe Reverse lamp switch connector VSS sensor connector PCM connectors Fuel injector harness connectors HO2S sensor connectors

Power steering pump pressure switch connector Ignition coil connectors Cruise control cable, if equipped Accelerator cable Air cleaner housing and tubes MAF sensor connector Battery, tray and cables 11. Tighten the strut center nuts to 35 ft. lbs. (48 Nm). 12. Fill the cooling system. 13. Start the engine and check for leaks. Automatic Transaxle

SOHC ENGINE 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the cooling system. 3. Relieve the fuel system pressure. 4. Loosen the front strut center nuts 5 turns.

5. Remove or disconnect the following: Battery, tray and cables Mass Air Flow (MAF) sensor connector Air cleaner housing and tubes Accelerator cable Cruise control cable, if equipped Ignition coil connectors Power steering pump pressure Switch connector Heated Oxygen (HO2S) sensor connectors Fuel injection wiring harness connector Powertrain Control Module (PCM) connectors Radiator cooling fan Evaporative Emissions (EVAP) canister vacuum lines Power brake booster vacuum line Delta Pressure Feedback Electronic (DPFE) system sensor vacuum line Exhaust Gas Recirculation (EGR) vacuum line Intake manifold vacuum line Fuel line Coolant bypass hoses Radiator hoses Coolant expansion tank Accessory drive belt Power steering pump and reservoir Power steering high pressure pipe Alternator and bracket Drive belt cover A/C compressor, if equipped Lower ball joints @.° eee eee Exhaust front pipe

For complete service labor times, order Nichols’ Chilton Labor Guide

1 5-4

FORD MOTOR CO. FOCUS

pe

Torque converter cover Torque converter

Transaxle fluid cooler lines Axle halfshafts Intermediate shaft bracket Starter motor Crankshaft pulley Right engine mount Transaxle flange bolts. Support the transaxle Engine front mount Crankshaft Position (CKP) sensor e Engine To install: 6. Install or connect the following: e Engine CKP sensor Engine front mount. Tighten the nuts to 59 ft. Ibs. (80 Nm) and the bolts to 35 ft. Ibs. (48 Nm). Transaxle flange bolts. Tighten the large bolts to 35 ft. Ibs. (48 Nm) and the small bolts to 16 ft. Ibs. (22 Nm). Right engine mount. Tighten the bolts to 35 ft. Ibs. (48 Nm). Crankshaft pulley. Tighten the bolt to 88 ft. Ibs. (120 Nm). Starter motor Intermediate shaft bracket. Tighten the bolts to 35 ft. Ibs. (48 Nm). Axle halfshafts Transaxle fluid cooler lines Torque converter. Tighten the nuts to 27 ft. Ibs. (37 Nm). Torque converter cover Exhaust front pipe Lower ball joints. Tighten the pinch bolts to 37 ft. Ibs. (50 Nm). A/C compressor, if equipped Drive belt cover Alternator and bracket Power steering high pressure pipe Power steering pump and reservoir Accessory drive belt Coolant expansion tank Radiator hoses Coolant bypass hoses Fuel line Intake manifold vacuum line EGR vacuum line DPFE system sensor vacuum line Power brake booster vacuum line EVAP canister vacuum lines Radiator cooling fan PCM connectors HO2S sensor connectors Fuel injection wiring harness connector Power steering pump pressure Switch connector

Ignition coil connectors

e Cruise control cable, if equipped e Accelerator cable e Air cleaner housing and tubes e MAF sensor connector e Battery, tray and cables 7. Tighten the strut center nuts to 35 ft. lbs. (48 Nm). 8. Fill the cooling system. 9. Start the engine and check for leaks.

DOHC ENGINE 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the cooling system. 3. Relieve the fuel system pressure. 4. Loosen the front strut center nuts 5 turns.

5. Remove or disconnect the following: e Battery, tray and cables e Mass Air Flow (MAF) sensor connector e Positive Crankcase Ventilation (PCV) valve and hose e Air cleaner assembly and tubes e Accelerator cable e Cruise control cable, if equipped e Ignition coil connectors e Heated Oxygen (HO2S) sensor connectors e Fuel injector harness connectors e Powertrain Control Module (PCM) connectors e Radiator cooling fan e Evaporative Emissions (EVAP) canister vacuum lines ¢ Power brake booster vacuum line e Delta Pressure Feedback Electronic (DPFE) system sensor vacuum line e Exhaust Gas Recirculation (EGR) vacuum line Intake manifold vacuum line Fuel line Coolant bypass hoses Radiator hoses Coolant expansion tank Shift select cable and bracket Transaxle fluid cooler lines Drive belt cover Power steering pressure switch connector Accessory drive belt

A/C compressor, if equipped Power steering pump Power steering pressure pipe Exhaust flex pipe Right engine mount Lower ball joints Axle halfshafts and intermediate shaft 6. Support the powertrain from below 7. Remove the front and rear engine mounts.

8. Raise the vehicle away from the powertrain.

To install: 9. Lower the vehicle over the powertrain. 10. Install or connect the following: Front engine mount. Tighten the f® nuts to 59 ft. Ibs. (80 Nm) and the bolts to 35 ft. Ibs. (48 Nm). Rear engine mount. Tighten the outer nuts to 35 ft. Ibs. (48 Nm) and the center nut to 98 ft. Ibs. (133 Nm). Axle halfshafts and intermediate shaft Lower ball joints. Tighten the pinch bolts to 37 ft. Ibs. (60 Nm). Right engine mount. Tighten the bolts to 35 ft. Ibs. (48 Nm). Exhaust flex pipe Power steering pressure pipe Power steering pump A/C compressor, if equipped Accessory drive belt Power steering pressure switch connector Drive belt cover Transaxle fluid cooler lines Shift select cable and bracket Coolant expansion tank Radiator hoses Coolant bypass hoses Fuel line Intake manifold vacuum line EGR vacuum line DPFE system sensor vacuum line Power brake booster vacuum line EVAP canister vacuum lines Radiator cooling fan PCM connectors Fuel injector harness connectors HO2S sensor connectors Ignition coil connectors Cruise control cable, if equipped Accelerator cable Air cleaner assembly and tubes PCV valve and hose MAF sensor connector Battery, tray and cables 11. Tighten the strut center nuts to 35 ft. lbs. (48 Nm). 12. Fill the cooling system. 13. Start the engine and check for leaks.

Water Pump REMOVAL & INSTALLATION SOHC Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section.

r

FORD MOTOR CO. FOCUS

2. Drain the cooling system. 3. Remove or disconnect the following: ¢ Negative battery cable ¢ Accessory drive belt ¢ Front cover e Timing belt. Refer to the Timing Belt unit repair section. e Timing belt tensioner ¢ Water pump To install: 4. Install or connect the following: ¢ Water pump. Tighten the bolts to 18 ft. Ibs. (25 Nm). Timing belt tensioner Timing belt Accessory drive belt Negative battery cable 5. Fill the cooling system. 6. Start the engine and check for leaks. DOHC Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the cooling system. 3. Remove or disconnect the following: Negative battery cable Accessory drive belt Water pump pulley Front cover Timing belt. Refer to the Timing Belt unit repair section. Timing belt tensioner Water pump To install: 4. Install or connect the following: e Water pump. Tighten the bolts to 13 ft. Ibs. (18 Nm). e Timing belt tensioner e Timing belt e Front cover Water pump pulley Accessory drive belt Negative battery cable 5. Fill the cooling system. 6. Start the engine and check for leaks.

Cylinder Head

3. Drain the cooling system. 4. Relieve the fuel system pressure. 5. Remove or disconnect the following: ¢ Timing belt. Refer to the Timing Belt unit repair section. ¢ Engine air cleaner intake tube 6. Tag and disconnect the vacuum hoses from the following components: e Exhaust Gas Recirculation (EGR) valve ¢ Positive Crankcase Ventilation (PCV) valve e Throttle body ¢ Fuel pressure regulator e Intake manifold 7. Remove or disconnect the following: Accelerator cable, throttle contro! lever and if equipped, the speed control cable Speed control cable bracket bolt, if equipped 2 fuel charging wiring electrical connections Crankshaft Position (CKP) sensor and Heated Oxygen (HO2S) sensor electrical connections Fuel supply line Power steering pressure hose bracket bolts, then position the bracket and hose aside Alternator lower bolt, loosen only Alternator upper bolt and pivot the alternator forward Engine oil dipstick tube bracket bolt Exhaust Gas Recirculation (EGR) tube Exhaust manifold heat shield Catalytic converter Right-hand splash shield bolts and the shield Engine oil dipstick tube from the cylinder block Air conditioning compressor Engine accessory drive bracket Valve cover

Set

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9306SG02

Cylinder head torque sequence—2.0L SOHC engine

e Upper radiator hose e Heater hose e Cylinder head bolts. Loosen the bolts in sequence. e Cylinder head and gasket To install: >Use new cylinder head bolts for assembly.

8. Install the cylinder head and tighten the bolts in sequence as follows: a. Step 1: 37 ft. Ibs. (50 Nm) b. Step 2: Loosen all bolts ¥% turn

c. Step 3: 37 ft. Ibs. (50 Nm) d. Step 4: Plus 90 degrees e. Step 6: Plus 90 degrees 9. Install or connect the following: Accessory drive bracket. Tighten the fasteners to 30-40 ft. Ibs. (40-55 Nm) Air conditioning line bracket and tighten the bolt to 15-18 ft. Ibs. (20-25 Nm) Valve cover Air conditioning compressor Right-hand splash shield Engine oil dipstick tube Heater and upper radiator hoses Timing belt and alternator Power steering pressure hose CKP sensor and 2 main fuel charging electrical connections Engine oil dipstick tube bolt EGR valve tube Fuel supply line

Catalytic converter Heat shield Speed control cable bracket, if

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SOHC Engine

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1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Disconnect the negative battery cable.

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19-9

equipped Throttle control lever, accelerator cable and if equipped, the speed contro! cable 10. Connect the vacuum hoses to the following components: e EGR valve » PCV valve

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15-6

FORD MOTOR CO. FOCUS

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The DOHC engine is not equipped with rocker arms. The camshafts act directly on the valves.

Intake Manifold

REMOVAL & INSTALLATION SOHC Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the cooling system. 3. Relieve the fuel system pressure. 4 Remove or disconnect the following: e Negative battery cable e Air cleaner outlet tube 5. Tag and disconnect the vacuum hoses from the following components: e Exhaust gas Recirculation (EGR) valve e Positive Crankcase Ventilation (PCV) valve e Throttle body e Fuel pressure regulator e Intake manifold 6. Remove or disconnect the following: Accelerator cable, throttle control lever and if equipped, the speed control cable Speed control cable bracket bolt, if equipped Idle Air Control (IAC) valve and Throttle Position (TP) sensor electrical connections Engine oil dipstick tube bracket bolt that attaches the tube to the intake manifold EGR manifold tube located below

the EGR valve e Engine oil dipstick tube from the block Intake manifold lower nuts

Intake manifold upper nuts Intake manifold

1 5-7

To install: 7. Clean and oil the intake manifold mounting studs. 8. Install or connect the following: Intake manifold with a new gasket. Tighten the nuts to 15-22 ft. Ibs. (20-30 Nm). Engine oil dipstick tube EGR manifold tube. Tighten it to 15-20 ft. Ibs. (20-28 Nm). IAC valve and TP sensor electrical connections Speed control cable bracket bolt, if equipped. Tighten to 71-88 inch lbs. (8-10 Nm). Throttle contro! lever, accelerator cable and if equipped, the speed contro! cable 9. Connect the vacuum hoses to the following components: e EGR valve e PCV valve e Throttle body Fuel pressure regulator Intake manifold Air cleaner outlet tube Negative battery cable 10. Fill the cooling system. 11. Start-the engine and check for coolant leaks. DOHC Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the cooling system. 3. Relieve the fuel system pressure. 4. Remove or disconnect the following: Negative battery cable Air cleaner outlet tube Throttle Position (TP) sensor connector Bolt that secures the pipe located by the crankshaft pulley Heater hoses Main engine control sensor wiring Connectors from the mounting bracket Intake manifold vacuum lines Positive Crankcase Ventilation (PCV) hose Drive belt Alternator Fuel line e Intake manifold To install: 5. Install or connect the following: e Intake manifold. Tighten the fasteners to 13 ft. Ibs. (18 Nm).

Timing belt service is covered in Section 3 of this manual

oe Fuel line Alternator Drive belt PCV hose,

2. Remove or disconnect the following: Negative battery cable Fan motor electrical connection Fan shroud

Intake manifold vacuum lines

Heated Oxygen (HO2S) sensor electrical connection Catalytic converter Engine oil dipstick tube bracket bolt Exhaust manifold heat shield Exhaust manifold To install: 3. Install or connect the following: e Exhaust manifold. Tighten the fasteners to 13 ft. Ibs. (18 Nm). Exhaust manifold heat shield. Tighten the retainers to 71-101 inch lbs. (8-11 Nm). Engine oil dipstick tube bracket. Tighten the bolt to 71-101 inch lbs. (8-11 Nm). Catalytic converter HOzsensor electrical connection Fan shroud and the fan motor wiring . Negative battery cable 4. Start the engine and check for leaks.

Connectors in the mounting bracket Main engine control sensor wiring Heater hoses Bolt that secures the pipe located by the crankshaft pulley. Tighten the bolt to 71-97 inch Ibs. (8-11 Nm). TP sensor electrical connection Air cleaner outlet tube Negative battery cable 6. Fill the cooling system. 7. Start the engine and check for leaks.

Exhaust Manifold

REMOVAL & INSTALLATION SOHC 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 e Drive belt ¢ Heated Oxygen (HO2S) sensor electrical connection Exhaust manifold heat shield ¢ Exhaust Gas Recirculation (EGR) tube Power steering pressure hose bracket Alternator ¢ Catalytic converter e Exhaust manifold To install: 3. Install or connect the following: e Exhaust manifold. Tighten the nuts to 15-18 ft. Ibs. (20-24 Nm). Catalytic converter. Tighten the nuts to 26-34 ft. Ibs. (34-48 Nm). Alternator Power steering pressure hose bracket EGR tube. Tighten the fasteners to 45-62 inch Ibs. (5-7 Nm). Exhaust manifold heat shield. Tighten the nuts to 45-62 inch Ibs. (5-7 Nm). HO2S sensor electrical connection e Drive belt ¢ Negative battery cable 4. Start the engine and check for leaks.

DOHC Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section.

Front Crankshaft Seal

REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove the timing belt and crankshaft sprocket.

Be careful not to damage the crankshaft surface when removing the seal. ssc arenes asesesapesocassseeee een 3. Using seal remover tool T92C-6700CH, remove the crankshaft front oil seal, To install: 4. Use seal replacer tool T81P-6700-A and install the new seal. 9. Install the crankshaft sprocket and the timing belt.

Camshaft and Valve Lifters REMOVAL & INSTALLATION SOHC Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section.

2. Disconnect the negative battery cable. 3. Remove the air cleaner and valve cover. 4. Remove the camshaft front seal as follows: “a. Align the timing marks and remove the timing belt. b. Use cam sprocket holding/removing tool T74P-6256-B, and remove the camshaft sprocket. c. Unfasten the timing belt tensioner bolt and remove the tensioner. d. Remove the inner engine front cover. e. Use seal removal tool T92C6700-CH, to remove the camshaft front Seal. 5. Remove or disconnect the following: e Ignition coil and bracket ¢ Rocker arms and valve tappets e Camshaft thrust plate bolts and the plate Cup plug from the rear of the cylinder head and discard Camshaft from the rear of the cylinder head To install: e>Liberally coat the cam bore in the cylinder with clean 5W-30 motor oil.

6. Install or connect the following: Camshaft through the rear of the cylinder head Camshaft thrust plate and the bolts. Tighten the bolts to 71-115 inch lbs. (8-13 Nm), New cup plug and the tappets ¢ Rocker arms Ignition coil bracket and coil 7. Install the camshaft front seal as follows: a. Apply a thin film of 5W-30 motor oil to the lip of the seal. b. Use seal replacer T81P-6292-A, to install the camshaft front seal. e>The seal depth should be 0.002-0.04 in. (0.05-1.0mm) below flush with the cylinder head front face.

Cc. Install the inner engine front

cover. d. Install the timing belt tensioner. Tighten the tensioner bolt to 15-22 ft, Ibs. (20-30 Nm), é. Install the camshaft sprocket and the timing belt 8. Install the valve cover and the air Cleaner assembly. 9. Connect the negative battery cable.

FORD MOTOR CO. 45.9 . . . . . .

Rocker arm Rocker arm seats Camshaft Position (CMP) sensor Valve tappet Valve tappet guide plate Ignition coil

. Radio interference capacitor . Ignition coil bracket — HM oonronop . Cup plug 10. Camshaft 11. Water hose connection 12. Thermostat 13. Water hose connection gasket

9300MG12

DOHC Engine

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Removing the camshaft front seal—SOHC engine

7922MG55

Remove the camshaft thrust plate retain-

ing bolts (A) and the plate (B)—SOHC engine

Remove and discard the cup plug located at the rear of the cylinder head—SOHC engine

7922MG57

Use seal Replacer T81P-6292-A, to install the camshaft front seal 0.002-0.04 in.

(0.05-1.0mm) below flush with the cylinder head front face—2.0L SOHC engine

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Timing belt. Refer to the Timing Belt unit repair section. e Valve cover and camshaft sprockets e Oil control solenoid flange e» Mark the camshaft journal caps with a number to identify their location.

¢ Camshaft journal caps. Loosen the bolts in sequence and in several passes. e Camshafts e Qil control sensor and bushing To install: 3. Install the oil contro! solenoid bushing and flange on the exhaust camshaft. 4. Coat the surface of the front camshaft journal cap with gasket maker E2AZ-19562-B. 5. Place the camshafts in position and lubricate the bearing surfaces with engine assembly lubricant D9AZ-19579-D. 6. Install new camshaft front oil seals.

Heater Core replacement is covered in Section 2 of this manual

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8. Install the caps and tighten the bolts in several 2-turn passes in the sequence illustrated to 10-12 ft. Ibs. 3-17 Nm).

9. Inspect the olil control solenoid rae O-rings for damage or wear and replace, as necessary. 10. Install the oi! control solenoid flange

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Exploded view of the cylinder head and camshaft mounting—DOHC engine

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FORD MOTOR CO.45.44 9.5-10.5 Nm

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Oil pan torque sequence—DOHC engine

SOHC Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Timing belt e Oil pan e Crankshaft Position (CKP) sensor e Qil pump pickup tube e Oil pump To install: 3. Lubricate the crankshaft front oil seal lip with clean engine oil. 4. Install or connect the following: Oil pump. Tighten the bolts to 10-12 ft. Ibs. (13-16 Nm). Oil pump pickup tube. Tighten the retaining bolts to 71-97 inch Ibs. (8-11 Nm). ¢ CKP sensor e Oil pan e Timing belt 5. Fill the crankcase to the correct level. 6. Start the engine and check for leaks.

DOHC Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the engine oil. 3. Remove or disconnect the following: e Negative battery cable ¢ Timing belt. Refer to the Timing Belt unit repair section. e Qil pan ¢ Qil pump pickup tube

¢ Oil pump To install: 4. Install or connect the following: ¢ Qil pump. Tighten the bolts to 97 inch Ibs. (11 Nm) ¢ Oil pump pickup tube. Tighten the —asteners to 88 inch Ibs. (10 Nm). ¢ Oil pan ¢ Timing belt ¢ Negative battery cable 9. Fill the crankcase to the correct level. 6. Start the engine and check for leaks.

FORD MOTORCO. 45.43 Rear Main Seal

ora pilesCOMPRESSION

REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to precautions in the beginning of this secion. 2. Remove or disconnect the following: e Negative battery cable e Transaxle e Clutch, if equipped ¢ Flexplate/flywheel e Qil seal To install: 3. Install or connect the following: e (il seal. Seat the seal flush with the rear of the crankshaft oil seal retainer. Flexplate/flywheel. Tighten the bolts to 82 ft. Ibs. (112 Nm). Clutch, if equipped Transaxle e Negative battery cable 4. Start the engine and check for leaks.

Piston and Ring

Noe Boney COMPRESSION

—

OIL CONTROL RINGS AND EXPANDER

CENTER LINE OF PISTON PARALLEL TO WRIST PIN BORE UPPER COMPRESSION RING GAP LOCATION

FRONT OF ENGINE OIL CONTROL SEGMENT RING GAP LOCATION

EXPANDER RING AND LOWER COMPRESSION RING GAP LOCATION

OIL CONTROL SEGMENT RING GAP LOCATION

7922AG29

POSITIONING

Ford 2.0L (VIN 3 and P) engines—piston ring positioning, end-gap spacing and piston positioning. The small directional arrow must face the front of the engine.

Fuel System Service Precautions Safety is the most important factor when performing not only fuel system maintenance but any type of maintenance. Failure to conduct maintenance and repairs in a safe manner may result in serious personal injury or death. Maintenance and testing of the vehicle's fuel system components can be accomplished safely and effectively by adhering to the following rules and guidelines. ¢ To avoid the possibility of fire and personal injury, always disconnect the negative battery cable unless the repair or test procedure requires that battery voltage be applied. e Always relieve the fuel system pressure prior to disconnecting any fuel system component (injector, fuel rail, pressure regulator, etc.), fitting or fuel line connection. Exercise extreme caution whenever relieving fuel system pressure, to avoid exposing skin, face and eyes to fuel spray. Please be advised that fue! under pressure may pene-

trate the skin or any part of the body that it contacts. ¢ Always place a shop towel or cloth around the fitting or connection prior to loosening to absorb any excess fuel due to spillage. Ensure that all fuel spillage (should it occur) is quickly removed from engine surfaces. Ensure that all fuel soaked cloths or towels are deposited into a suitable waste container. e Always keep a dry chemical (Class B) fire extinguisher near the work area. e Do not allow fuel spray or fuel vapors to come into contact with a spark or open flame. e Always use a backup wrench when loosening and tightening fuel line connection fittings. This will prevent unnecessary stress and torsion to fuel line piping. e Always replace worn fuel fitting Orings with new. Do not substitute fuel hose or equivalent, where fuel pipe is installed. Before servicing the vehicle, make sure to refer to the precautions in the beginning of this section as well.

Fuel System Pressure

RELIEVING 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove the fuel pump fuse from the battery junction box. 3. Start the engine and allow it to idle until it stalls. 4. Crank the engine for 5 seconds to ensure that the fuel pressure has been relieved. 5. Disconnect the negative battery cable. 6. When repairs are completed, connect the negative battery cable and replace the fuel pump fuse.

REMOVAL & INSTALLATION LT

1. Before servicing the vehicle, refer to the precautions in the beginning of this section.

For complete Engine Mechanical specifications, see Section 1 of this manual

15-14 Fup movan co. 2. Relieve the fuel system pressure. 3. Remove or disconnect the following: e Evaporative Emissions (EVAP) vapor line e Fuel filter lines e Fuel filter and bracket assembly e Fuel filter To install: 4. Install or connect the following: e Fuel filter e Fuel filter and bracket assembly ¢ Fuel filter lines e EVAP vapor line 5. Start the engine and check for leaks.

Fuel Pump REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Relieve the fuel system pressure. 3. Remove or disconnect the following: e Exhaust center muffler e Heat shield e Fuel filler and vent hoses e Fuel supply line

Evaporative Emissions (EVAP) vapor line Rollover valve line Fuel tank retainer strap. Support the fuel tank. Fuel pump module harness connector Fuel tank pressure Sensor connector Fuel tank Fuel pump module To install: 4. Install or connect the following: Fuel pump module. Tighten the locknut to 59 ft. Ibs. (80 Nm). e Fuel tank

Fuel tank pressure sensor connector Fuel pump module harness con-

nector Fuel tank retainer strap. Tighten the bolt to 18 ft. Ibs. (25 Nm). Rollover valve line EVAP vapor line Fuel supply line Fuel filler and vent hoses Heat shield Exhaust center muffler 5. Start the engine and check for leaks.

Fuel Injector — REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Relieve fuel system pressure. 3. Remove or disconnect the following: Negative battery cable Fuel line and retaining clip Pressure regulator vacuum hose Accelerator cable Fuel injector electrical connectors Fuel supply manifold with the injectors attached Injectors from the supply manifold To install: 4. Install or connect the following: Fuel injectors using new O-ring Seals Fuel supply manifold with the injectors attached. Tighten the bolts to 88 inch Ibs. (10 Nm). Fuel injector electrical connectors Accelerator cable Pressure regulator vacuum hose Fuel line and retaining clip Negative battery cable

DRIVE TRAIN Transaxle Assembly REMOVAL & INSTALLATION Manual

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Attach a support fixture to the engine lifting eyes. 3. Loosen the front strut center nuts 5 turns. 4. Remove or disconnect the following: Battery and tray Mass Air Flow (MAF) sensor connector Air cleaner assembly Air intake pipe Clutch slave cylinder fluid line Shift cables Exhaust flex pipe Engine front mount Lower ball joints Axle halfshafts and intermediate shaft e Drive belt cover Reverse light switch connector Vehicle Speed (VSS) sensor connector

Rear engine mount and bracket Starter motor Transaxle flange bolts. Support the transaxle. Transaxle To install: 9. Install or connect the following: Transaxle. Tighten the flange bolts to 35 ft. Ibs. (48 Nm). Starter motor Rear engine mount bracket. Tighten the fastener to 59 ft. Ibs. (80 Nm). Rear engine mount. Tighten the outer nuts to 35 ft. Ibs. (48 Nm) and the center nut to 98 ft. Ibs. (133 Nm). VSS sensor connector Reverse light switch connector Drive belt cover Axle halfshafts and intermediate shaft Lower ball joints. Tighten —he pinch bolts to 37 ft. Ibs. (50 Nm).er Right engine mount. Tighten the bolts to 35 ft. Ibs. (48 Nm).— Exhaust flex pipe Shift cables Clutch slave cylinder f uid line

e Air intake pipe e Air cleaner assembly ¢ MAF sensor connector e Battery and tray 6. Tighten the strut center nuts to 35 ft. lbs. (48 Nm). Automatic

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Attach a support fixture to the engine lifting eyes. 3. Loosen the front strut center nuts 5 turns.

4. Remove or disconnect the following: ¢ Battery and tray e Mass Air Flow (MAF) sensor connector

Positive Crankcase Ventilation (PCV) hose e Air intake pipe and resonator Turbine Shaft Speed (TSS) sensor connector Transmission range sensor connector Transaxle harness connector Starter motor Shift cable and bracket

FORD MOTOR CO.45.45 Front wheels Exhaust front pipe Right engine support Outer tie rod ends Lower ball joints Axle halfshafts and intermediate shaft Output Shaft Speed (OSS) sensor connector Transaxle oil cooler lines Torque converter Transaxle oil dipstick tube Rear engine mount and bracket ~The transaxle flange bolts vary in length. Note their locations for installation.

e Transaxle flange bolts. Support the transaxle. e Transaxle To install: 5. Install or connect the following: Transaxle. Tighten the flange bolts to 35 ft. Ibs. (48 Nm). Rear engine mount bracket. Tighten the fastener to 59 ft. Ibs. (80 Nm). Rear engine mount. Tighten the outer nuts to 35 ft. Ibs. (48 Nm) and the center nut to 98 ft. Ibs. (133 Nm). Transaxle oil dipstick tube Torque converter. Tighten the nuts to 27 ft. Ibs. (37 Nm). Transaxle oil cooler lines OSS sensor connector Axle halfshafts and intermediate shaft Lower ball joints. Tighten the pinch bolts to 37 ft. Ibs. (50 Nm). Outer tie rod ends. Tighten the nuts to 35 ft. Ibs. (48 Nm). Right engine support. Tighten the bolts to 35 ft. Ibs. (48 Nm). Exhaust front pipe. Tighten the fasteners to 35 ft. Ibs. (48 Nm). Front wheels Shift cable and bracket Starter motor Transaxle harness connector Transmission range sensor connector TSS sensor connector Air intake pipe and resonator PCV hose MAF sensor connector Battery and tray 6. Tighten the strut center nuts to 35 ft. lbs. (48 Nm).

REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Negative battery cable e Transaxle e Pressure plate. Loosen the bolts evenly in ¥ turn steps. e Clutch disc To install: 3. Install or connect the following: e Clutch disc and pressure plate. Tighten the pressure plate bolts evenly in ¥ turns to 21 ft. Ibs. (29 Nm). e Transaxle e Negative battery cable

Hydraulic Clutch System

reservoir until the level reaches the MIN mark. 4. Fill the reservoir of Special Too! 416-D002 with DOT 4 brake fluid. 5. Attach the tool to the slave cylinder bleed nipple. 6. Open the bleed nipple and pump 80 ml brake fluid into the clutch control system. 7. Tighten the bleed nipple to 88 inch lbs. (10 Nm) and remove the tool. 8. Have an assistant depress the clutch pedal 4—5 times and hold the pedal at full travel. 9. Close the bleeder before releasing the clutch pedal. 10. Repeat the procedure until no more air bubbles are seen. 11. Check the clutch for proper operation. 12. Check the brake fluid reservoir level and fill with DOT 4 brake fluid, as necessary. 13. Install or connect the following: e Air intake pipe e MAF sensor connector e Air cleaner assembly

BLEEDING 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Air cleaner assembly e Mass Air Flow (MAF) sensor connector e Air intake pipe 3. Remove fluid from the brake fluid

REMOVAL & INSTALLATION Left «>The IB5 manual transmission is used with the SOHC engine and the MTX75 manual transmission is used with the DOHC engine.

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9306SG07

Left halfshaft removal—IB5 manual transaxle

For Accessory Drive Belt illustrations, see Section 1 of this manual

15-1

FORD MOTOR CO. FOCUS

To install: e>Use a new retaining clip for assembly.

6. Install or connect the following: e Axle halfshaft and intermediate shaft assembly. Tighten the nuts to 18 ft. Ibs. (25 Nm). e Lower ball joint. Tighten the pinch bolt to 37 ft. Ibs. (60 Nm). e Hub retainer nut. Tighten the nut to 232 ft. Ibs. (316 Nm). e Front wheel 7. Check the transaxle fluid and add, as necessary. ; 8. Tighten the strut center nuts to 36 ft. lbs. (48 Nm).

CV-Joints 9306SG08

Left halfshaft removal—MTX75 manual transaxle and automatic transaxle

>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.

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Loosen the strut center nut 5 turns. 3. Remove or disconnect the following: e Front wheel e Hub retainer nut. Mark the nut. ¢ Lower ball joint 4. Press the stub shaft out of the wheel hub. 5. Separate the inner C\V-joint from the transaxle as follows: e If equipped with the IB5 manual transaxle, use Halfshaft remover 308-256 e If equipped with the MTX75 manual transaxle or with an automatic transaxle, use Halfshaft Remover 205-241 and a slide hammer To install: e»Replace the circlip for assembly.

6. Install the halfshaft inner joint so that the circlip is felt to seat. Draw the stub shaft into the wheel hub with Halfshaft Installer 205-379.

7. Install or connect the following: ¢ Lower ball joint. Tighten the pinch bolt to 37 ft. Ibs. (50 Nm). ¢ Hub retainer nut. Tighten the nut to 282 ft. Ibs. (316 Nm). e Front wheel 8. Check the transaxle fluid and add, as necessary. 9. Tighten the strut center nuts to 35 ft. lbs. (48 Nm).

Right e>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.

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Loosen the strut center nut 5 turns. _ 3. Remove or disconnect the following: ¢ Front wheel e Hub retainer nut. Mark the nut. © Lower ball joint ¢ Intermediate shaft retaining clip 4. Press the stub shaft out of the wheel hub. 9. Remove the right axle halfshaft and the intermediate shaft as an assembly.

OVERHAUL Inner Tripod Joint

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove the axle halfshaft from the vehicle and place it in a vise. 3. Remove or disconnect the following: * Tripod joint boot clamps ¢ Tripod joint boot ¢ Tripod joint housing e Snapring e Tripod joint To install: e>Use new snaprings and boot clamps for assembly.

4. Install or connect the following: ¢ Tripod joint ¢ Snapring e Tripod joint housing. Fill the joint housing with grease. ¢ Tripod joint boot e Tripod joint boot clamps 5. Install the halfshaft. Outer CV-Joint

The outer CV-joint is serviced with the halfshaft as an assembly. The outer CV-joint boot can be serviced by removing the inner tripod joint.

FORD MOTOR CO.45.47 STEERING AND SUSPENSION

«< CAUTION 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 precautions and the disarming procedure could result in accidental air bag deployment, possible injury and unnecessary system repairs.

PRECAUTIONS Several precautions must be observed when handling the inflator module to avoid accidental deployment and possible personal injury. e Never carry the inflator module by the wires or connector on the underside of the module e When carrying a live inflator module, hold securely with both hands, and ensure that the bag and trim cover are pointed away e Place the inflator module on a bench or other surface with the bag and trim cover facing up e With the inflator module on the bench, never place anything on or close to the module that may be thrown in the event of an accidental deployment Before servicing the vehicle, also be sure to refer to the precautions in the beginning of this section as well

DISARMING 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Position the vehicle with the front wheels in a straight-ahead position. 3. Disconnect the negative battery cable. 4. Disconnect the positive battery cable. 5. Wait at least 1minute for the air bag backup power supply to drain before continuing. 6. Proceed with the repair. 7. Once repairs are completed, connect the battery cables, negative cable last. 8. Check the functioning of the air bag system by turning the ignition key to the RUN position and visually monitoring the air

bag indicator lamp in the instrument cluster. The indicator lamp should illuminate for approximately 6 seconds, then turn OFF. If the indicator lamp does not illuminate, stays on, or flashes at any time, a fault has been detected by the air bag diagnostic monitor.

Power Rack & Pinion Steering Gear

. e Outer tie rod ends. Tighten the nuts to 35 ft. Ibs. (48 Nm). e Front wheels e Steering shaft pinch bolt. Tighten the bolt to 21 ft. Ibs. (28 Nm). e Lower instrument panel cover e Negative battery cable 7. Check the wheel alignment and adjust as necessary.

REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Center the steering wheel and turn the ignition to the LOCK position. 3. Remove or disconnect the following: e Negative battery cable e Lower instrument panel cover Steering shaft pinch bolt Front wheels Outer tie rod ends Stabilizer bar links Power steering fluid cooler hose Right engine mount

Steering gear heat shield Power steering hose support clamp Power steering hoses 6 subframe bolts. Support the subframe. Floor seal Steering gear pinion extension Steering gear To install: 4. Install or connect the following: ¢ Steering gear. Tighten the bolts to 59 ft. Ibs. (80 Nm). ¢ Steering gear pinion extension. Tighten the pinch bolt to 26 ft. Ibs. (35 Nm). e Floor seal 5. Install Subframe Alignment Pins 502002 and raise the subframe into position. Tighten the 4 rear bolts to 147 ft. Ibs. (200 Nm) and the other bolts to 85 ft. Ibs. (115 Nm). 6. Install or connect the following: Power steering hoses Power steering hose support clamp Steering gear heat shield Right engine mount. Tighten the bolt to 37 fl tbs. (50 Nm). Power steering fluid cooler hose Stabilizer bar links. Tighten the nuts to 37 ft. Ibs. (50 Nm).

REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Front wheel Brake hose bracket Stabilizer bar link Wheel speed sensor, if equipped Brake caliper and rotor Outer tie rod end Lower ball joint Steering knuckle pinch bolt. Separate the knuckle from the strut. Upper strut mount nuts Strut assembly To install: 3. Install or connect the following: Strut assembly. Tighten the upper mount nuts to 18 ft. Ibs. (25 Nm). Steering knuckle. Tighten the pinch bolt to 66 ft. Ibs. (90 Nm). Lower ball joint. Tighten the pinch bolt to 37 ft. Ibs. (50 Nm). Outer tie rod end. Tighten the nut to 35 ft. Ibs. (48 Nm). Brake caliper and rotor e@eeWheel speed sensor, if equipped Stabilizer bar link. Tighten the nut to 37 ft. Ibs. (50 Nm). Brake hose bracket e Front wheel 4. Check the wheel alignment and adjust as necessary.

Shock Absorber REMOVAL & INSTALLATION 3 Door Model

1. Before servicing the vehicle, refer to the precautions in the beginning of this section.

For Tire, Wheel and Ball Joint specifications, see Section 1 of this manual

15-18 Foagmovor co 2. Remove or disconnect the following: e Luggage compartment interior trim panel e Upper shock absorber mounting nut e Lower shock absorber mounting bolt e Shock absorber To install:

->Tighten the shock absorber mounting fasteners with the suspension at curb height and the vehicle weight supported by the wheels.

3. Install or connect the following: ¢ Shock absorber. Guide the rod into the locating hole. ¢ Lower shock absorber mounting bolt. Tighten the bolt to 85 ft. Ibs. (115 Nm). e Upper shock absorber mounting nut. Tighten the nut to 13 ft. Ibs. (18 Nm). ¢ Luggage compartment interior trim panel err fate

Wagon 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove the upper and lower mounting bolts and remove the shock absorber. To install:

9306S610

e>Tighten the shock absorber mounting fasteners with the suspension at curb height and the vehicle weight supported by the wheels. 3. Install the shock absorber and

tighten the mounting bolts to 85 ft. Ibs. (115 Nm).

REMOVAL & INSTALLATION Front

1. Before servicing the vehicle, refer to the precautions at the beginning of this section. 2. Remove the strut from the vehicle. 3. Compress the coil spring using a Suitable spring compressor until the spring comes away from the seat. 4. Remove the large center nut and Slowly release the spring compressor. To install: 9. Compress the spring and install it on the strut.

,i

Ys -

it /

9306SG09

Coil spring compressor and adapters

FORD ANGE 6. Install the upper strut mount. Tighten the nut to 35 ft. Ibs. (48 Nm). 7. Install the strut assembly in the vehicle. Rear

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Raise and support the vehicle. 3. Install spring compressor 204-167 with Adapters 204-215. 4. Compress the coil spring and remove it. To install: 5. Install the coil spring and remove the compressor.

Lower Ball Joint

REMOVAL & INSTALLATION The lower ball joint is replaced with the lower control arm as an assembly.

LowerControlArm

~—™

REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Front wheel e Lower ball joint e Rear bracket bolts

e Front bolt e Control arm To install:

e>Use new nuts, bolts and ball bearing washers for assembly.

3. Install the control arm. Tighten the fasteners in sequence as follows: a. Step 1: Tighten nut No. 1 to 74 ft. lbs. (100 Nm) plus 60 degrees b. Step 2: Tighten nut No. 2 to 88 ft. lbs. (120 Nm) c. Step 3: Tighten bolt No. 3 to 88 ft. lbs. (120 Nm) plus 90 degrees d. Step 4: Check that bolt No. 3 is

tightened to 125-169 ft. Ibs. (170-230 Nm) 4. Install or connect the following: e Lower ball joint. Tighten the pinch bolt to 37 ft. lbs. (60 Nm). e Front wheel 5. Check the wheel alignment and adjust

as necessary.

CONTROL ARM BUSHING REPLACEMENT The lower control arm bushings are replaced with the lower control arm as an assembly.

1 5-1 9

cannot be adjusted. If wheel bearing play is excessive, check the wheel hub retainer nut for proper torque. If the torque is correct, replacement of the wheel bearing is required.

REMOVAL & REPLACEMENT Front

e>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.

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Loosen the strut center nut 5 turns. 3. Remove or disconnect the following: Front wheel Wheel speed sensor, if equipped Hub retainer nut. Mark the nut. Brake caliper and rotor Outer tie rod end Lower bail joint Steering knuckle pinch bolt 4. Press the stub shaft out of the wheel hub.

5. Press the hub out of the wheel bearing.

Wheel Bearings ADJUSTMENT The bearings on the front and rear wheels are a one piece cartridge design and

§. Remove the snapring. 7. Press the bearing out of the hub. To install: 8. Press the bearing into the hub. 9. Install the snapring. 10. Press the hub into the wheel bearing. 11. Draw the stub shaft into the wheel hub with Halfshaft installer 205-379. 12. Install or connect the following: Steering knuckle. Tighten the pinch bolt to 66 ft. Ibs. (90 Nm). Lower ball joint. Tighten the pinch bolt to 37 ft. Ibs. (60 Nm). Outer tie rod end. Tighten the nut to 35 ft. Ibs. (48 Nm). e Brake caliper and rotor Hub retainer nut. Tighten the nut to 232 ft. Ibs. (316 Nm). Wheel speed sensor, if equipped e Front wheel 13. Tighten the strut center nuts to 39 ft. lbs. (48 Nm). 14. Check the wheel alignment and adjust as necessary. Rear

9306811

Control arm torque sequence

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 or disconnect the following: Rear wheel Dust cap Hub nut Brake drum ¢ Wheel speed sensor tone ring, if equipped

Snapring

3. Remove the wheel bearing with a press. To install: e>Use a new wheel speed sensor tone ring for assembly.

4. Press the wheel bearing into the brake drum hub. 5. Install or connect the following:

Snapring Wheel speed sensor tone ring, if equipped Brake drum Hub nut. Tighten the hub nut to 173 ft. Ibs. (235 Nm). Dust cap Rear wheel

FORD MOTOR CO. 2000-01 Lincoln LS DRIVE TRAIN.................. 16-19

ENGINE REPAIR ................ 16-2365» FUE SYSTEM 22...0).0000.5 16-18

Removal & Installation............ 16-18

Fue). Pumpeeeneeeretede tear: 16-18

SUSPENSION................. 16-20

A

3

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Removal & Installation............ 16-18

Reat, Maime@alen

RENGVING sccssecssneessnsecsedzonetinense 16218).

Rocker Anms/Shatts tay See teowar-. 1636

PRECAUTIONS.................. 16-2 — Fuel System Pressure... 16-18 STEERING AND

Removal & Installation............ 16-20

— Fuel System Service

Precaliionssmee ee

16-18

sate eae 16-11

Removal & Installation........... 16-11

Removal & Installation............. 16-7

S

aver16-10 starter MOLT saigeenn.tn Removal & Installation........... 16-10 catnet16-20 geeOUUIM yeaa rote meyteeaie Removal & Installation............ 16-20

pieeee 16-20 ASAE BR. anal Nenad STHUATEpe alee aii reea BRE aNONG carats. cies, 16-20 16-2 {ACTH NU a aoc

H tee tete. eee 16-20 GtValichiciieeten Removal & Installation............ 16-20) Hydraulic Clutch System.............. 16-19

REMOVE a eee NON el Yale 16-2 C Camshaft And Valve Lifters............ 16-8 Removal & Installation............. 16-8). ten! Slt) on 16-19 Biri commmreney Si nac16-19 BMS TCM YS cane acccetacs Removal & Installation............ fenoe

Timing Chain, Sprockets, I Front Cover and Seal................. 10gl2 ria totoaNealiner eee ee wre 16-3 Removal & Installation............ 16-12 16-3 Wicre a. uae Adjustmentecsvtwl Assembly............... 16-19 Transmission __ 16-7 tecsone Intake Manifold nets Installation........... 16-19 & Removal 16-7 Removal & Installation.............. U ene Poop Upper Ball JOImt.........eeescsesesssanson 16-21 Lowen Balint, Gaaa.oe: 16-21

[ristallation ..sssseocccsesssesssnsessss 16-2

1 See ee 46-21

Blecdinian

cs its seeestae 16.19,

Removal & Installation............ 16-21

Removal & Installation............ 46-21

Lower Control APM on... 16-21

anaes 16-20

Replacement ac tcsceercsose.e 16-21

BUSI. ie ea ae Arey ie ate

ce 16-20

Control Arm Bushing

ne

nae

Removal & Installation............ 16-21

Upper Control Arm... 16-21

Control Arm Bushing

ReplaceMent.....ssessssssssssssenee 16-21

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ei 16-21

Cylinder Head ......cecsectecceeeeee 16-5

Removal & Installation... 16-21

Removal & pea priya Wess Engine ASSEMbIY ...esccaneeeeee 16-3

(iit Payer mace ea re, meen a 1610 Removal & Installation............ 16-10

ValVe aS is ttnpe cee wtectnscr recs 16-9 Adjustment....... eeyeres 16-9

Removal & Installation............. iG-ce:

si acer ae ial Ui Les que n AraaveteclnetaNationeen

aera Wateh Ri ieesenmans ameataae 16-5

Pistori and Ring asestaes.cssse 16-17

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Mero Biselaion sega 168 Fret Hillelno

conc cgecaat 16-18

Removal & Installation.........16-18

PUTS REELOrt asad dens sdecbessnssdedy 16-18

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Power Rack and Pinion

rae:16-20 SteOriNGGEAl suczocreee

Removal sation... 16

ACJUSEMENL.n..sestseseorc 121

Removal & Replacement......16-21

16-2

FORD MOTOR CO. LINCOLN LS

PRECAUTIONS Before servicing any vehicle, please be sure to read all of the following precautions, which deal with personal safety, prevention of component damage, and important points to take into consideration when servicing a motor vehicle: e Never open, service or drain the radiator or cooling system when the engine is hot; serious burns can occur from the steam and hot coolant. ¢ Observe all applicable safety precautions when working around fuel. Whenever servicing the fuel system, always work ina well-ventilated area. Do not allow fuel spray _ Of vapors to come in contact with a spark, open flame, or excessive heat (a hot drop light, for example). Keep a dry chemical fire extinguisher near the work area. Always keep fuel in a container specifically designed for fuel storage; also, always properly seal fuel containers to avoid the possibility of fire or explosion. Refer to the additional fuel system precautions later in this section. e Fuel injection systems often remain pressurized, even after the engine has been turned OFF. The fuel system pressure must be relieved before disconnecting any fuel lines. Failure to do so may result in fire and/or personal injury. ¢ Brake fluid often contains polyglycol ethers and polyglycols. Avoid contact with the eyes and wash your hands thoroughly after handling brake fluid. If you do get brake fluid in your eyes, flush your eyes with clean, running water for 15 minutes. If eye irritation persists, or if you have taken

brake fluid internally, IMMEDIATELY seek medical assistance. e The EPA warns that prolonged contact with used engine oil may cause a number of skin disorders, including cancer. You should make every effort to minimize your exposure to used engine oil. Protective gloves should be worn when changing oil. Wash your hands and any other exposed skin areas as soon aS possible after exposure to used engine oil. Soap and water, or waterless hand cleaner should be used. e All new vehicles are now equipped with an air bag system, often referred to as a Supplemental Restraint System (SRS) or Supplemental Inflatable Restraint (SIR) 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 repairs. e Always wear safety goggles when working with, or around, the air bag system. When carrying a non-deployed air bag, be sure the bag and trim cover are pointed away from your body. When placing a non-deployed air bag on a work surface, always face the bag and trim cover upward, away from the surface. This will reduce the motion of the module if it is accidentally deployed. Refer to the additional air bag system precautions later in this section.

; -»Disconnecting the negative battery cable on some vehicles may interfere with the functions of the on board computer system. The computer may undergo a relearning process once the negative battery cable is reconnected.

Alternator

REMOVAL 3.0L Engine

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Negative battery cable ¢ Accessory drive belt

ENGINE REPAIR ¢ Lower splash shield e Alternator mounting bolts ¢ Alternator harness connectors e Alternator

3.9L 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 e Air intake tube ¢ Accessory drive belt ¢ Lower splash shield ¢ Alternator mounting bolts e Alternator harness connectors e Alternator

e Clean, high quality brake fluid from a sealed container is essential to the safe and proper operation of the brake system. You should always buy the correct type of brake fluid for your vehicle. If the brake fluid becomes contaminated, completely flush the system with new fluid. Never reuse any brake fluid. Any brake fluid that is removed from the system should be discarded. Also, do not allow any brake fluid to come in contact with a painted surface; it will damage the paint. ; e Never operate the engine without the proper amount and type of engine oil; doing So WILL result in severe engine damage. e Timing belt maintenance is extremely important. Many models utilize an interference-type, non-freewheeling engine. If the timing belt breaks, the valves in the cylinder head may strike the pistons, causing potentially serious (also time-consuming and expensive) engine damage. Refer to the maintenance interval charts in the front of this manual for the recommended replacement interval for the timing belt, and to the timing belt section for belt replacement and inspection. e Disconnecting the negative battery cable on some vehicles may interfere with the functions of the on-board computer system(s) and may require the computer to undergo a relearning process once the negative battery cable is reconnected. e¢ When servicing drum brakes, only disassemble and assemble one side at a time, leaving the remaining side intact for reference.

} INSTALLATION Rae aaaR Ane ea 3.0L Engine Install or connect the following; ¢ Alternator ¢ Alternator harness connectors. Tighten the battery cable terminal nut to 70 inch lbs. (8 Nm). ¢ Alternator mounting bolts. Tighten the bolts to 35 ft. Ibs. (48 Nm). ¢ Lower splash shield ¢ Accessory drive belt e Negative battery cable

3.9L Engine

1. Install the alternator harness connectors, then install the alternator. Tighten the bolts in sequence as follows:

FORD MOTOR CO. LINCOLN LS

16-3

Front brake calipers Lower stabilizer bar links Upper ball joints Lower strut mount bolts Starter motor wiring harness connectors Power Steering Pressure (PSP) switch connector

M4)

c=

aes

SSF ate

9306TG08

Alternator torque sequence—3.9L engine

a. Step 1: Tighten bolt No. 1 to 35 ft. lbs. (48 Nm) b. Step 2: Tighten bolt No. 2 to 15 ft. lbs. (20 Nm) plus 90 degrees c. Step 3: Tighten bolt No. 3 to 35 ft. lbs. (48 Nm) 2. Install or connect the following: e Lower splash shield e Accessory drive belt e Air intake tube e Negative battery cable

Ignition Timing

BBS

ADJUSTMENT This vehicle is equipped with a Distributorless Ignition System (DIS). The ignition timing is not adjustable. It is controlled by the PCM.

Engine Assembly

3

REMOVAL & INSTALLATION EE

3.0L Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the cooling system. 3. Relieve the fue! system pressure.

4 Recover the A/C refrigerant. 5. Drain the engine oil. 6. Remove or disconnect the following: e Negative battery cable

Air cleaner housing and outlet tube Engine appearance cover Upper radiator shield Upper radiator support brackets A/C pressure switch connector Power steering reservoir Fuel line Vapor Management Valve (VMV) cover VMV vacuum hose Cowl leaf screens Chassis vacuum lines Cross vehicle support bar Fresh air intake housing Intake manifold rear main vacuum hose Accelerator cable and cruise control cable Cable bracket Ground strap Main engine wiring harness connector Main transmission wiring harness connector 2 fuel charging harness connectors A/C line mounting bracket Hydraulic cooling fan reservoir Left, right and center splash shields A/C compressor manifold and tube assembly Coolant hoses Exhaust front pipe and heat shields Driveshaft Shift cable and bracket Front wheels Front wheel speed sensor connectors

Steering shaft pinch bolt e Torque converter, if equipped 7. Support the engine, transmission, front and center crossmembers and the cooling system with a powertrain lift and transmission support bracket. 8. Support the rear of the vehicle with Safety stands. 9. Remove or disconnect the following: e Transmission crossmember bolts e Subframe bolts e Crossmember bolts e Powertrain assembly 10. Attach a hoist to the engine. 11. Remove or disconnect the following: Wire harness retainers Starter motor Heated Oxygen (HO2S) sensor bracket Motor mount nuts Accessory drive belt Power steering pump Hydraulic cooling fan pump Upper radiator hose Transmission oil cooler lines, if equipped 12. Lift the engine and transmission out of the subframe. 13. Remove or disconnect the following: e Oil cooler hoses e Transmission flange bolts e Transmission from the engine To install: 14. Install or connect the following: Transmission to the engine. Tighten the flange bolts to 35 ft. Ibs. (48 Nm). Powertrain on the subframe. Tighten the motor mount nuts to 46 ft. Ibs. (63 Nm). @ Oil cooler hoses Transmission oil cooler lines, if equipped Upper radiator hose Hydraulic cooling fan pump. Tighten the bolts to 18 ft. Ibs. (25 Nm). Power steering pump. Tighten the bolts to 18 ff. Ibs. (25 Nm). Accessory drive belt HO2S sensor bracket. Tighten the nut to 89 inch Ibs. (10 Nm).

For complete service labor times, order Nichols’ Chilton Labor Guide

46-4

FORD motor co. LINCOLN LS

Starter motor. Tighten the bolts to 18 ft. Ibs. (25 Nm). Wire harness retainers Powertrain assembly. Tighten the crossmember bolts to 76 ft. Ibs. (103 Nm). Torque converter, if equipped. Steering shaft pinch bolt. Tighten the bolts to 18 ft. Ibs. (25 Nm), PSP switch connector Starter motor wiring harness connectors Lower strut mount bolts. Tighten the bolts to 129 ft. Ibs. (175 Nm). Upper ball joints. Tighten the nuts to 66 ft. Ibs. (90 Nm). Lower stabilizer bar links. Tighten the nuts to 41 ft. Ibs. (55 Nm). Front brake calipers Front wheel speed sensor connectors

Front wheels Shift cable and bracket Driveshaft Exhaust front pipe and heat shields Coolant hoses A/C compressor manifold and tube assembly. Tighten the bolt to 15 ft. Ibs. (21 Nm). Left, right and center splash shields Hydraulic cooling fan reservoir A/C line mounting bracket 2 fuel charging harness connectors Main transmission wiring harness connector. Tighten the bolt to 89 inch Ibs. (10 Nm). Main engine wiring harness connector. Tighten the bolt to 89 inch lbs. (10 Nm). Ground strap. Tighten the bolt to 89 inch lbs. (10 Nm). Cable bracket. Tighten the bolts to 89 inch Ibs. (10 Nm). Accelerator cable and cruise control cable Intake manifold rear main vacuum hose Fresh air intake housing Cross vehicle support bar. Tighten the bolts to 15 ft. Ibs. (20 Nm). Chassis vacuum lines Cowl leaf screens VMV vacuum hose VMV cover Fuel line Power steering reservoir A/C pressure switch connector Upper radiator support brackets. Tighten the bolts to 89 inch Ibs. (10 Nm). Upper radiator shield Engine appearance cover

Air cleaner housing and outlet tube Negative battery cable 15. Fill the crankcase to the correct level. 16. Fill the cooling system.

17. Recharge the A/C system. 18. Start the engine and check for leaks. 3.9L Engine

1. Before servicing the vehicle, refer to the precautions in the beginning of this section.

2. 3. 4. 5. 6.

Drain the cooling system. Relieve the fuel system pressure. Recover the A/C refrigerant. Drain the engine oil. Remove or disconnect the following: Negative battery cable Air cleaner inlet tube Upper radiator shield Upper radiator support brackets

A/C pressure switch connector Power steering return line clip Power steering reservoir Vapor Management Valve (VMV) cover VMV vacuum hose and canister purge hose Main vacuum supply hose Cowl vent screens Cross vehicle support bar Degas bottle hose Accelerator cable Cruise control cable Ground strap Fresh air filter and housing Powertrain harness connectors at right strut tower Fresh air filter panel Main engine wiring harness connector Main transmission wiring harness connector Heater hoses at the water control valve. Note the locations for assembly. Hydraulic cooling fan reservoir Water control valve harness connector Front wheels Inner splash shields Wheel speed sensor connectors and harness clips Brake calipers Lower stabilizer bar links Upper ball joints Lower strut mount bolts Left, right and center splash shields

A/C suction and discharge lines Shift cable and bracket Power steering line frame rail clip Rack and pinion harness connectors

Steering shaft bolt and coupling Starter motor harness connectors and ground cable Alternator harness connectors Lower transmission flange bolts Torque converter Inner air deflector Engine block heater, if equipped 7. Support the engine, transmission, front and center crossmembers and the cooling system with a powertrain lift and transmission support bracket. 8. Support the rear of the vehicle with Safety stands. , 9. Remove or disconnect the following: Transmission crossmember bolts Front crossmember bolts Center crossmember bolts Powertrain assembly

A/C compressor manifold and tube assembly Power steering pump return hose Hydraulic cooling fan return hose Lower radiator hose Upper radiator hoses Knock Sensor (KS) connector Heater hose Transmission cooler lines and bracket Power steering pressure line and bracket Hydraulic cooling fan pressure line and bracket 10. Attach a hoist to the engine. 11. Remove the motor mount nuts and

lift the powertrain out of the subframe. 12. Remove or disconnect the following: ¢ Wiring harness retainers ¢ Upper transmission flange bolts ¢ Transmission from the engine To install: 13. Install or connect the following: Transmission to the engine. Tighten the upper flange bolts to 35 ft. Ibs. (48 Nm). Wiring harness retainers. Tighten the nuts to 89 inch Ibs. (10 Nm). Powertrain to the subframe. Tighten the mount nuts to 30 ft. Ibs. (40 Nm). Hydraulic cooling fan pressure line and bracket Power steering pressure line and bracket Transmission cooler lines and bracket Heater hose Knock sensor connector Upper radiator hoses Lower radiator hose Hydraulic cooling fan return hose

FORD MOTOR CO.

LINCOLN LS

Power steering pump return hose

A/C compressor manifold and tube assembly. Tighten the bolt to 15 ft. lbs. (21 Nm). Powertrain assembly. Tighten the front and center crossmember bolts to 76 ft. Ibs. (103 Nm) and the transmission crossmember bolts to 30 ft. Ibs. (40 Nm). Engine block heater, if equipped Inner air deflector Torque converter. Tighten the nuts to 28 ft. Ibs. (38 Nm). Lower transmission flange bolts. Tighten the bolts to 35 ft. Ibs. (47 Nm). Alternator harness connectors Starter motor harness connectors and ground cable Steering shaft bolt and coupling. Tighten the coupling pinch bolt to 26 ft. Ibs. (35 Nm) and the shaft bolt to 22 ft. lbs. (30 Nm). Rack and pinion harness connectors Power steering line frame rail clip Shift cable and bracket A/C suction and discharge lines Left, right and center splash shields Lower strut mount bolts. Tighten the bolts to 129 ft. Ibs. (175 Nm). Upper ball joints. Tighten the nuts to 66 ft. Ibs. (90 Nm). Lower stabilizer bar links. Tighten the nuts to 41 ft. Ibs. (55 Nm). Brake calipers Wheel speed sensor connectors and harness clips Inner splash shields Front wheels Water control valve harness connector Hydraulic cooling fan reservoir Heater hoses at the water control valve Main transmission wiring harness connector Main engine wiring harness connector Fresh air filter panel Powertrain harness connectors at right strut tower Fresh air filter and housing Ground strap Cruise control cable Accelerator cable Degas bottle hose Cross vehicle support bar. Tighten the bolts to 15 ft. Ibs. (20 Nm).

14. 15. 16. 17.

Cowl vent screens Main vacuum supply hose VMV vacuum hose and canister purge hose VMV cover Power steering reservoir Power steering return line clip A/C pressure switch connector Upper radiator support brackets Upper radiator shield Air cleaner inlet tube Negative battery cable Fill the crankcase to the correct level. Fill the cooling system. Recharge the A/C system. Start the engine and check for leaks.

Water Pump REMOVAL & INSTALLATION 3.0L Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the cooling system. 3. Remove or disconnect the following: Negative battery cable Air cleaner outlet tube Engine vent hose Upper radiator hose Heater supply hose Water pump hose Lower radiator hose Water crossover assembly Water inlet hose Accessory drive belt and idler pulle Bracket assembly e Water pump To install: 4. |nstall or connect the following: Water pump. Tighten the bolts to 18 ft. Ibs. (25 Nm). e Bracket assembly. Tighten the fasteners to 89 inch Ibs. (10 Nm). e Accessory drive belt and idler pulle Water inlet hose Water crossover assembly Lower radiator hose Water pump hose Heater supply hose Upper radiator hose Engine vent hose Air cleaner outlet tube Negative battery cable 5. Fill the cooling system. 6. Start the engine and check for leaks.

1 6-5

3.9L Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the cooling system. 3. Remove or disconnect the following: e Accessory drive belt e Water pump pulley e Water pump To install: 4. Install or connect the following: e Water pump. Tighten the bolts to 71 inch Ibs. (8 Nm) plus 90 degrees. e Water pump pulley. Tighten the bolts to 89 inch Ibs. (10 Nm) plus 45 degrees. e Accessory drive belt 5. Fill the cooling system. 6. Start the engine and check for leaks.

Cylinder Head REMOVAL & INSTALLATION 3.0L Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the cooling system. 3. Relieve the fuel system pressure. 4. Drain the engine oil. 5. Remove or disconnect the following: e Negative battery cable ¢ Upper and lower intake manifolds e Valve covers e Accessory drive belts 6. Install a support fixture to the engine lifting eyes. 7. Remove or disconnect the following: Motor mount nuts Subframe bolts Oil pan Front cover Timing chains Camshafts Exhaust manifolds Ground strap Positive Crankcase Ventilation (PCV) tube e Ignition noise Suppressor ¢ Coolant outlet tube ¢ Engine oil dipstick tube 8. Install the subframe bolts and remove the engine support fixture. 9. Remove the cylinder heads.

Please visit our web site at www.chiltonsonline.com

16-6

FORD MOTOR CO. LINCOLNLS

9306701

Cylinder head torque sequence—3.0L engine

To install: 10. Install the cylinder heads. Tighten the bolts in sequence as follows: a. Step 1: 22 ft. Ibs. (30 Nm) b. Step 2: Plus 90 degrees c. Step 3: Loosen all bolts one full turn d. Step 4: 22 ft. Ibs. (30 Nm) e. Step 5: Plus 90 degrees f. Step 6: Plus 90 degrees 11. Install the engine support fixture and remove the subframe bolts. 12. Install or connect the following: Engine oil dipstick tube Coolant outlet tube Ignition noise suppressor PCV tube Ground strap Exhaust manifolds Camshafts Timing chains

Front cover Oil pan e Subframe bolts. Tighten the bolts to 76 ft. Ibs. (103 Nm). Motor mount nuts. Tighten the nuts to 46 ft. Ibs. (63 Nm), Accessory drive belts Valve covers Upper and lower intake manifolds Negative battery cable 13. Fill the crankcase to the correct level. 14. Fill the cooling system. 15. Start the engine and check for leaks. 3.9L Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the cooling system. 3. Relieve the fuel system pressure. 4. Remove or disconnect the following: e Negative battery cable

Engine appearance cover Intake manifold Valve covers Accessory drive belts Front cover Timing chains Camshafts Water outlet pipe Cylinder head temperature sensor connector Exhaust front pipes Exhaust Gas Recirculation (EGR) tube Bolts and stud bolts at the rear of the cylinder heads Cylinder heads. Loosen the bolts in reverse of the tightening sequence. To install: 5. Install the cylinder heads. Tighten the bolts in sequence as follows: a. Step 1: M10 bolts to 15 ft. Ibs. (20 Nm) b. Step 2: M10 bolts to 26 ft. Ibs. (35 Nm)

9306TG04

Right cylinder head torque sequence— 3.9L engine

Se)

10 Nm (89 b-in)

9346TG03

Left valve cover torque sequence—3.9L Engine

10 Nm (89 Ib-in

9346TG01

Left valve cover torque sequence—3.0L Engine

oY

9346TG02

Right valve cover torque sequence—3.0L Engine

9306TG05

Left cylinder head torque sequence—3.9L engine

9346TG04

Right valve cover torque sequence—3.9L Engine

FORD MOTOR CO.

LINCOLN LS

C. Step 3: M10 bolts to 33 ft. Ibs. (45 Nm) d. Step 4: M10 bolts plus 90 degrees e. Step 5: M10 bolts plus 90 degrees f. Step 6: M8 bolts to 15 ft. Ibs. (20 Nm) g. Step 7: M8 bolts plus 90 degrees 6. Install or connect the following: ¢ Bolts and stud bolts at the rear of the cylinder heads. Tighten the bolts to 37 ft. Ibs. (50 Nm). EGR tube Exhaust front pipes Cylinder head temperature sensor connector Water outlet pipe

Camshafts Timing chains Front cover Accessory drive belts Valve covers Intake manifold Engine appearance cover Negative battery cable 7. Fill the cooling system. 8. Start the engine and check for leaks.

Rocker Arms/Shafts REMOVAL & INSTALLATION The vehicles covered in this section are not equipped with rocker arms/shafts. The camshaft directly actuates the valves.

e Throttle body coolant bypass hose Positive Crankcase Ventilation (PCV) hose Evaporative Emissions (EVAP) canister purge hose Exhaust Gas Recirculation (EGR) vacuum line EGR tube Cowl vent screen Cross vehicle support bar Chassis vacuum supply hose EGR pressure transducer Fuel pressure sensor shield Upper intake manifold vacuum hose e Intake Manifold Tina Valve (IMTV) connector Exhaust Vacuum Regulator (EVR) valve connector and vacuum line Upper intake manifold support brackets Upper intake manifold Fuel line and bracket Fuel pressure sensor vacuum line Fuel injector harness connectors eeeee PCV tube e Lower intake manifold assembly To install: 5. Install or connect the following: e Lower intake manifold assembly. Tighten the bolts in sequence to 89 inch lbs. (10 Nm). e PCV tube e Fuel injector harness connectors

1 6-7

Fuel pressure sensor vacuum line Fuel line and bracket. Tighten the bolt to 89 inch Ibs. (10 Nm). Upper intake manifold. Tighten the bolts in sequence to 89 inch Ibs. (10 Nm). Upper intake manifold support brackets. Tighten the bolts to 89 inch Ibs. (10 Nm). EVR valve connector and vacuum line IMTV connector Upper intake manifold vacuum hose Fuel pressure sensor shield EGR pressure transducer Chassis vacuum supply hose Cross vehicle support bar. Tighten the bolts to 15 ft. Ibs. (20 Nm). Cowl vent screen EGR tube EGR vacuum line EVAP canister purge hose PCV hose Throttle body coolant bypass hose Cable bracket Cruise control cable Accelerator cable IAC valve connector TP. sensor connector Air cleaner outlet tube Engine appearance cover e Negative battery cable 6. Fill the cooling system. 7. Start the engine and check for leaks.

3.9L Engine

Intake Manifold

:

REMOVAL & INSTALLATION 3.0L Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. 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 connector Idle Air Control (IAC) valve connecior Accelerator cable

Cruise control cable Cable bracket

93061G03

Lower intake manifold torque sequence— 3.0L engine

Lea

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< Ca 7 7 ys |10 i a Ib- = 93067G02

Upper intake manifold torque sequence— 3.0L engine

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the cooling system. 3. Relieve the fuel system pressure. 4. 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 manifold vacuum hoses Exhaust Gas Recirculation (EGR) valve Camshaft Position (CMP) sensor connector Evaporative Emissions (EVAP) canister purge valve line Fuel pressure sensor connector and vacuum line e Fuel line

Timing belt service is covered in Section 3 of this manual

16-8 ESAT

FORD MOTOR CO. LINCOLN LS

ULNA

SELLA EON

ERLE RENN SEA PEI ITE NTEAIT

¢ Knock Sensor (KS) connector ¢ Cylinder head temperature sensor connector Sensor connector bracket Wiring harness and hose bracket Left bank fuel injector connectors Idle Air Control (IAC) valve connector

Throttle Position (TP) sensor connector Positive Crankcase Ventilation (PCV) tube Throttle body coolant hoses Right bank fuel injector connectors Delta Pressure Feedback Electronic (DPFE) system sensor Intake manifold. Loosen the bolts in reverse of the tightening sequence. To install: 9. Install or connect the following: e Intake manifold. Tighten the bolts in sequence to 18 ft. Ibs. (25 Nm). DPFE system sensor Right bank fuel injector connectors Throttle body coolant hoses PCV tube TP sensor connector IAC valve connector Left bank fuel injector connectors Wiring harness and hose bracket Sensor connector bracket Cylinder head temperature sensor connector KS sensor connector Fuel line Fuel pressure sensor connector and vacuum line ¢ EVAP canister purge valve line ¢ CMP sensor connector e EGR valve

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Intake manifold vacuum hoses Cruise control cable Accelerator cable Cross vehicle support bar. Tighten the bolts to 15 ft. Ibs. (20 Nm). ¢ Cowl vent screen e Air cleaner outlet tube e Negative battery cable 6. Fill the cooling system. 7. Start the engine and check for leaks.

Exhaust Manifolds

REMOVAL & INSTALLATION 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 ¢ Heat shields ¢ Lower splash shields ¢ Exhaust front pipes ¢ Secondary air tubes e Exhaust Gas Recirculation (EGR) tube ¢ Exhaust manifolds To install: 3. Install the exhaust manifolds. Tighten the fasteners in sequence as follows: a. Step 1: 15 ft. Ibs. (20 Nm) b. Step 2: 15 ft. Ibs. (20 Nm) 4. Install or connect the following: e Exhaust Gas Recirculation (EGR) tube

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e Secondary air tubes e Exhaust front pipes e Lower splash shields e Heat shields e Negative battery cable 5. Start the engine and check for leaks. 3.9L 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 ¢ Power steering pump reservoir ¢ Oil dipstick tube ~ e Exhaust front pipes e Exhaust Gas Recirculation (EGR) tube e Exhaust manifolds To install: 3. Install or connect the following: e Exhaust manifolds. Tighten the bolts to 18 ft. Ibs. (25 Nm). e EGR tube ¢ Exhaust front pipes ¢ Oil dipstick tube ¢ Power steering pump reservoir ¢ Negative battery cable 4. Start the engine and check for leaks.

Camshaft and Valve Lifters

REMOVAL & INSTALLATION 3.0L Engine

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Negative battery cable e Valve covers ¢ Front cover ¢ Timing chains 9306TG09

Right exhaust manifold torque sequence— 3.0L engine

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. nce eee Keep all valvetrain components in order for assembly.

¢ Camshaft journal thrust caps ¢ Remaining camshaft journal caps

¢ Camshafts

9306TG06

Intake manifold torque sequence—3.9L engine

93067610

Left exhaust manifold torque sequence— 3.0L engine

e Valve tappets and shims To install: 3. Install or connect the following:

FORD MOTOR CO.

LINCOLN LS

16-9

The cylinder head bolts are a torqueto-yield design and cannot be reused. Always use new cylinder head bolts for assembly.

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. If equipped with air suspension, the

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LOWER REAR HEAD BOLT

RUBBER (9 “Mini BAND

7922RG02

Use a rubber band to support the rear cylinder head bolt to ease removal of the head

air suspension switch, located on the righthand side of the luggage compartment, must be turned to the OFF position before raising the vehicle. 3. Drain the engine cooling system. 4. Properly relieve the fuel system pressure. 5. Remove or disconnect the following: Negative battery cable Cooling fan and shroud assembly Engine air cleaner outlet tube Windshield wiper governor (module) e Accessory drive belt Ignition wires from the spark plugs e@eee @ Ignition wire brackets from the cylinder head cover studs 2 ignition wire tray-to-ignition coil brackets bolts Bolt retaining the air conditioning pressure line to the right-hand ignition coil bracket Wiring to both ignition coils and the Camshaft Position (CMP) sensor Ignition coil brackets-to-engine front cover nuts. Slide the ignition coil brackets and ignition wire assemblies off the mounting studs and from the vehicle Water pump pulley Alternator wiring harness from the junction block, fender apron and alternator Alternator Positive battery cable at the power distribution box Retaining bolt from the positive battery cable bracket located on the side of the right-hand cylinder head Vent hose from the canister purge solenoid and position the positive battery cable aside Positive Crankcase Ventilation (PCV) valve from the cylinder head cover Engine/transmission harness connector from the retaining bracket on the power brake booster Crankshaft Position (CKP) sensor, air conditioning compressor clutch and canister purge solenoid electrical connectors 6. Remove the bolts retaining the power Steering pump to the cylinder block and engine front cover. The front lower bolt on the power steering pump will not come all the way Out. Wire the power steering pump aside. 7. Remove or disconnect the following: * Engine oil pan and oil pan gasket * Crankshaft pulley retaining bolt ¢ Pulley

Power steering control valve actuator and oil pressure sensor wiring connectors and position aside. Exhaust Gas Recirculation (EGR) tube from the right-hand exhaust manifold Exhaust pipes from the exhaust manifolds. Lower the exhaust pipes and hang with wire from the crossmember. Bolts retaining the starter wiring harness to the rear of the right-

hand cylinder head Cylinder head covers to the cylinder heads Accelerator and cruise contro! cables Accelerator cable bracket from the intake manifold and position aside Vacuum hose from the throttle body elbow vacuum port Heated Oxygen (HO2S) sensors and the heater water hose 2 bolts retaining the thermostat housing to the intake manifold and position the upper hose and thermostat housing aside e>The 2 thermostat housing bolts also retain the intake manifold.

9 intake manifold-to-cylinder heads bolts Intake manifold and gaskets 7 stud bolts and the 4 bolts attaching the engine front cover to the engine Front cover Both timing chains 10 left-hand cylinder head-to-cylinder block bolts 8. Remove the cylinder head. The lower rear cylinder head bolt must stay in the cylinder head until the cylinder head is removed due to lack of clearance for removal in the vehicle. Use a rubber band to secure the cylinder head bolt in the cylinder head during removal and installation of the cylinder head and to prevent the bolt from damaging the cylinder block or 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 block.

9. Remove or disconnect the following: ¢ Ground strap, 1 stud and1 bolt retaining the heater return line to the right-hand cylinder head ¢ 10 right-hand cylinder head-tocylinder block bolts 10. Remove the cylinder head. The lower

7

FORD MOTOR CO.

CROWN VICTORIA ¢ TOWN CAR ¢ GRAND MARQUIS rear cylinder head bolt must stay in the cylinder head until the cylinder head is removed due to lack of clearance for removal in the vehicle. Use a rubber band to secure the cylinder head bolt in the cylinder head during removal and installation of the cylinder head and to prevent the bolt from damaging the cylinder block or head gasket. >The lower rear cylinder head bolt cannot be removed due to interference with the evaporator housing. Use a rubber band to hold the bolt away from the cylinder block.

11. Clean all gaskets mating surfaces. Check the cylinder heads and cylinder block for flatness. Check the cylinder heads for scratches near the coolant passages and combustion chambers that could provide leak paths. To install: 12. Rotate the crankshaft counterclockwise 45 degrees. The crankshaft keyway should be at the 9 o'clock position viewed from the front of the engine. This ensures that all pistons are below the top of the engine block deck face. 13. Rotate the camshaft to a stable position where the valves do not extend below the head face. 14. Install or connect the following: e New head gaskets on the cylinder block e New bolts in the lower rear bolt holes on both cylinder heads and retain with rubber bands as explained during the removal procedure 15. Position the cylinder heads on the cylinder block dowels, being careful not to score the surface of the head face. Apply clean oil to the new cylinder head bolts, remove the rubber bands from the lower rear bolts and install all bolts hand-tight. 16. Tighten the new cylinder head bolts, in sequence, as follows: a. Step 1: 28-31 ft. Ibs. (7-43 Nm).

CYLINDER

LH CYLINDER

HEAD ASSY HEAD ASSY CYLINDER HEAD TIGHTENING SEQUENCE 7922RG03

Cylinder head torque sequence—4.6L SOHC engine

b. Step 2: plus 85-95 degrees. C. Step 3: loosen all bolts at least 1 full turn. d. Step 4: 27-32 ft. lbs. (37-43 Nm). 8. Step 5: plus 85-95 degrees. f. Step 6: again, plus 85-95 degrees. 17. Position the heater return hose and install the 2 retaining bolts. 18. Rotate the camshafts using the flats matched at the center of the camshaft until both are in time. Install Camshaft Positioning Tools 191P-6256-A, on the flats of the camshafts to keep them from rotating. 19. Rotate the crankshaft clockwise 45 degrees to position the crankshaft at Top Dead Center (TDC) for the No. 1 cylinder. The crankshaft must only be rotated in the clockwise direction and only as far as TDC.

20. Install or connect the following: Both timing chains New engine front cover seal and gasket. Apply silicone sealer to the lower corners of the cover where it meets the junction of the engine oil pan and cylinder block and to the points where the cover contacts the junction of the cylinder block and the cylinder heads. Engine front cover and the bolts. Tighten to 15-22 ft. Ibs. (20-30 Nm). New intake manifold gaskets on the cylinder heads. Be sure the alignment tabs on the gaskets are aligned with the holes in the cylinder heads. Intake manifold on the cylinder heads and the retaining bolts. Tighten the bolts in sequence, to 15-22 ft. Ibs. (20-30 Nm). Thermostat, O-ring, thermostat housing and upper hose. Tighten the 2 retaining bolts to 15-22 ft. lbs. (20-30 Nm). @ Heater water hose and both HOzS sensors Vacuum hose to the throttle body adapter vacuum port Accelerator cable bracket on the intake manifold Accelerator and cruise control cables to the throttle body 21. Apply silicone sealer to both places where the engine front cover meets the cylinder heads. e Cylinder head covers with new gasket on the cylinder heads. Tighten

19-5

the bolts and stud bolts to 71-106 inch Ibs. (8-12 Nm). Starter motor wiring harness to the right-hand cylinder head and tighten the retaining bolt Exhaust pipes to the exhaust manifolds. Tighten the 4 nuts to 20-30 ft. Ibs. (27-41 Nm). ->Be sure the exhaust system clears the No. 3 crossmember. Adjust as nec-

essary. EGR tube to the right-hand exhaust manifold and tighten the line nut to 26-33 ft. Ibs. (85-45 Nm). Power steering control valve actuator and oil pressure sensor electrical connectors 22. Apply a small amount of silicone sealer in the rear of the keyway on the crankshaft pulley. Pulley on the crankshaft, making sure the crankshaft key and keyway are aligned. 23. Install the crankshaft pulley and tighten the bolt as follows: a. Step 1: Tighten to 66 ft. Ibs. (90 Nm). b. Step 2: Loosen one complete turn. GC Step 3: Tighten to 35-39 ft. Ibs.

Please visit our web site at www.chiltonsonline.com

(47-53 Nm). d. Step 4: Tighten an additional 85-95 degrees. 24. Install or connect the following: Engine oil pan and a new gasket Power steering pump in position on the cylinder block 4 retaining bolts. Tighten the bolts to 15-22 ft. Ibs. (20-30 Nm). Air conditioning compressor, CKP sensor and canister purge solenoid electrical connectors Engine/transmission harness connector on the power brake booster PCV valve in the right-hand cylinder head cover and connect the canister purge solenoid vent hose Positive battery cable harness on the right-hand cylinder head Bolt retaining the cable bracket to the cylinder head Positive battery cable at the power distribution box and battery Alternator and the 2 retaining bolts. Tighten the bolts to 15-22 ft. Ibs. (20-30 Nm). 2 bolts retaining the alternator brace to the intake manifold. Tighten to 72-96 inch Ibs. (8-12 Nm).

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FORD MOTOR CO.

CROWN VICTORIA e TOWN CAR e GRAND MARQUIS

Water pump pulley. Tighten the bolts to 15-22 ft. Ibs. (20-30 Nm). Ignition coil brackets and ignition wire assemblies onto the mounting studs 7 nuts retaining the ignition coil brackets to the engine front cover and tighten to 15-22 ft. Ibs. (20-30 Nm) 2 bolts retaining the ignition wire tray to the ignition coil bracket and tighten to 71-106 inch Ibs. (8-12 Nm) Ignition coil and CMP sensor harness connectors Air conditioning pressure line on the right-hand ignition coil bracket and tighten the retaining bolt Ignition wires to the spark plugs and the bracket onto the cylinder head cover studs Accessory drive belt and the windshield wiper governor Fuel supply and return lines Cooling fan and shroud Engine air cleaner outlet tube Negative battery cable 29. Fill the cooling system. 26. If equipped with air suspension, turn the air suspension switch to the ON position. 27. Refill the engine with the correct amount of oil and replace the filter. 28. Start the engine and bring to normal operating temperature while checking for leaks. 29. Road test the vehicle and check for proper engine operation.

REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Relieve the fuel system pressure. 3. Disconnect the negative battery cable. 4. Remove the right camshaft cover by removing or disconnecting the following: ¢ Positive battery cable at the battery and at the power distribution box ¢ Retaining bolt from the positive battery cable bracket located on the side of the right cylinder head ¢ Crankshaft Position (CKP) sensor, air conditioning compressor clutch and canister purge solenoid connectors. Position the harness aside. e Vent hose from the purge solenoid

and position the positive battery cable aside e Ignition wires from the spark plugs e Ignition wire brackets from the camshaft cover studs and position the wires aside e PCV valve from the camshaft cover grommet and position aside ¢ Bolts and stud bolts and remove the camshaft cover. 5. Remove the left camshaft cover by removing or disconnecting the following: Air inlet tube ¢ Fuel lines PSP switch and oil pressure sending unit and position the harness aside 42-pin engine harness connector from the retaining bracket on the brake vacuum booster and position aside Windshield wiper module Ignition wires from the spark plugs Ignition wire brackets from the Studs and position the wires aside Camshaft cover 6. Position the piston of the cylinder being serviced at the bottom of its stroke and position the camshaft lobe on the base circle. 7. Install valve spring spacer tool T91P-6565-AH between the spring coils to prevent valve seal damage. 8. Install a valve spring compressor under the camshaft and on top of the valve spring retainer. 9. Compress the valve spring and remove the roller follower. Remove the valve spring compressor and spacer. To install: 10. Apply engine oil to the valve stem and tip and roller follower contact surfaces. 11. Install valve spring spacer tool T91P-6565-AH between the spring coils. Compress the valve spring, and install the roller follower.

VIEWA wine eas SPACER

VALVE SPRING COMPRESSOR VALVE SPRING SPACER

7922RG04 After installing the spring spacer, compress the valve spring and remove the rocker arm

>The piston must be at the bottom of its stroke and the camshaft at the base circle.

12. Remove the valve spring compressor and spacer. 13. Clean the sealing surfaces of the camshaft covers and cylinder heads. Apply silicone sealer to the places where the front cover meets the cylinder head. 14. Position new gaskets onto the camshaft covers and install the covers. Install the bolts and stud bolts and tighten to 72-106 inch Ibs. (8-12 Nm). 15. When installing the right camshaft cover, install or connect the following: PCV into the camshaft cover grommet Ignition wire brackets on the studs Wires to the spark plugs Canister purge solenoid, air conditioning compressor clutch and CKP sensor Positive battery cable harness on the right cylinder head Bolt retaining the cable bracket to the cylinder head Positive battery cable at the power distribution box and the battery 16. When installing the left camshaft cover, install or connect the following: Ignition wire brackets on the studs Wires to the spark plugs Windshield wiper module 42-pin and transmission harness connectors Retaining bracket PSP switch and oil pressure sending unit harness. Fuel lines ¢ Negative battery cable 17. Start the engine and check for leaks.

Intake Manifold

REMOVAL & INSTALLATION re ge ee

eee

1. Before servicing the vehicle, refer to the precautions in the beginning of this section, 2. If equipped with air suspension, the air Suspension switch, located on the righthand side of the luggage compartment, must be turned to the OFF position before raising the vehicle. 3. Disconnect negative battery cable. 4. Drain the engine cooling system. 9. Properly relieve the fuel system

pressure, 6. Remove or disconnect the following: ¢ Fuel supply and return lines

Ud

19-7

FORD MOTOR CO.

CROWN VICTORIA e TOWN CAR e GRAND MARQUIS es wiper governor (module Engine air cleaner outlet tube Accessory drive belt Ignition wires from the spark plugs Ignition wire brackets from the cylinder head cover studs Ignition coils and the Camshaft Position (CMP) sensor Ignition wires from both ignition coils 2 bolts retaining the ignition wire bracket to the ignition coil brackets Ignition wire assembly Alternator wiring harness from the junction block at the fender apron and alternator Bolts retaining the alternator brace to the intake manifold and the alternator to the cylinder block Alternator Oil pressure sensor and power steering control valve actuator wiring and position the wiring harness aside Exhaust Gas Recirculation (EGR) valve-to-exhaust manifold tube from the right-hand exhaust manifold Engine/transmission harness connector from the retaining bracket on the power brake booster Air conditioning compressor clutch, Crankshaft position (CKP) sensor and the canister purge solenoid wiring connectors Positive Crankcase Ventilation (PCV) valve from the cylinder head cover Canister purge vent hose from the PCV valve Accelerator and cruise control cables from the throttle body Accelerator cable bracket from the intake manifold and position aside Vacuum hose from the throttle body adapter port Heated Oxygen (HO2S) sensor and the heater water hose 2 bolts retaining the thermostat housing to the intake manifold and position the upper hose and thermostat housing aside >The 2 thermostat housing bolts are also used to retain the intake manifold.

e bolts retaining the intake manifold to the cylinder heads e Intake manifold and gaskets

|__ 20-30 Nm (15-22 lb/ft)

_| 7922RG06

Intake manifold torque sequence—4.6L SOHC engine

7. \f replacing the intake manifold, Swap over the necessary parts. To install: 8. Clean all gaskets mating surfaces. 9. Position new intake manifold gaskets on the cylinder heads. Be sure the alignment tabs on the gaskets are aligned with the holes in the cylinder heads. 10. Install the intake manifold and the 9 retaining bolts. Hand-tighten the right-rear bolt (viewed from the front of the engine) before final tightening, then tighten the bolts, in sequence, to 15-22 ft. Ibs. (20-30 Nm). 11. Inspect and if necessary, replace the O-ring seal on the thermostat housing. Position the housing and upper hose and install the 2 retaining bolts. Tighten to 15-22 ft. lbs. (20-30 Nm). 12. Install or connect the following: Heater water hose HOS sensor Vacuum hose to the throttle body adapter vacuum port Accelerator cable bracket on the intake manifold Accelerator and cruise control cables to the throttle body PCV valve in the cylinder head cover Canister purge solenoid vent hose Air conditioning compressor clutch, CKP sensor and canister purge solenoid wiring connectors Engine/transmission harness connector the retaining bracket on the power brake booster EGR valve-to-exhaust manifold tube to the right-hand exhaust

manifold. Tighten the tube nut to 26-33 ft. Ibs. (35-45 Nm). Power steering control valve actuator Oil pressure sensor wiring connectors Alternator. Tighten the bolts to 15-22 ft. Ibs. (20-30 Nm). 2 bolts retaining the alternator brace to the intake manifold and tighten to 71-106 inch Ibs. (8-12 Nm) Alternator wiring harness to the alternator, right-hand fender apron and junction block Ignition wire assembly on the engine 2 bolts retaining the ignition wire bracket to the ignition coil brackets. Tighten the bolts to 71-106 inch lbs. (8-12 Nm). Ignition wires to the ignition coils Ignition wires to the spark plugs Ignition wire brackets on the cylinder head cover studs Wiring connectors to both ignition coils and the CMP sensor -Accessory drive belt Air cleaner outlet tube Windshield wiper governor Fuel supply and return lines Negative battery cable 13. Fill the engine cooling system. 14. If equipped with air suspension, turn the air suspension switch to the ON position. 15. Start the engine and check for leaks. 16. Road test the vehicle and check for proper operation.

Exhaust Manifold

!

ia

REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the engine cooling system. 3. Relieve the fuel system pressure. 4. Discharge the air conditioning system 5. Remove or disconnect the following: Battery cables Engine air inlet tube Cooling fan and shroud assembly Fuel supply and return lines Upper radiator hose Windshield wiper governor and support bracket Compressor outlet hose at the

Timing belt service is covered in Section 3 of this manual

19-8

FORD MOTOR CO.

CROWN VICTORIA e TOWN CAR

GRAND MARQUIS tighten the bolts to 15-22 ft. Ibs. (20-30 Nm) 11. Lower the engine onto the front engine support insulator and remove the jack. 12.. Install or connect the following: ¢ Left-hand and right-hand engine support insulator through-bolts and tighten to 15-22 ft. Ibs. (20-30 Nm). ¢ Catalytic converter pipes to both exhaust manifolds. Tighten he nuts to 20-30 ft. Ibs. (27-41 Nm). 7922RG08

Left exhaust manifold torque sequence

compressor and the hose assembly-to-right-hand ignition coil bracket bolt. Plug both openings. Engine/transmission harness connector from the retaining bracket on the power brake booster Heater hose Ground strap-to-right-hand cylinder head nut

Upper stud and lower bolt retaining the heater hose to the right cylinder head and position aside Heater blower motor switch resistor Bolt retaining the right-hand front engine support insulator to the sub-frame Both Heated Oxygen (HO2S) senSOIS

Engine support insulator throughbolts

Exhaust Gas Recirculation (EGR) valve-to-exhaust manifold tube nut from the right-hand exhaust mani-

fold.

Catalytic converter pipes from both exhaust manifolds. Lower the exhaust system and hang it from the crossmember with wire. Left-hand exhaust manifold

Front engine support insulator from

the cylinder block and the 8 nuts retaining the exhaust manifold e Left-hand exhaust manifold and the 2 manifold gaskets 6. Position an adjustable jackstand and a block of wood under the engine oil pan, rearward of the oil drain hole. Raise the engine approximately 4 inches (100mm). 7. Install or connect the following: e 8 exhaust manifold retaining nuts and right-hand exhaust manifold ¢ Manifold and gasket To install: 8. If the exhaust manifolds are being replaced, transfer the heated Oosensors and tighten to 27-33 ft. Ibs. (37-45 Nm). On the right-hand exhaust manifold, transfer the EGR tube connector and tighten to 33-48 ft. Ibs. (45-65 Nm). 9. Clean the mating surfaces of the exhaust manifolds and cylinder heads. 10. Install or connect the following: ¢ Exhaust manifolds, using new gaskets. Tighten the bolts in sequence to 15-22 ft. Ibs. (20-30 Nm). ¢ EGR valve and tube assembly to the exhaust manifold. Tighten the line nut to 26-33 ft. Ibs. (35-45 Nm). ¢ Left-hand front engine support insulator to the cylinder block and

->Be sure the exhaust system clears the No. 3 crossmember. Adjust as necessary.

Both HO2S sensors ¢ Bolt retaining the right-hand front engine support insulator to the sub-frame. Tighten to 15-22 ft. Ibs. (20-30 Nm) Heater blower motor switch resistor using the 2 retaining screws Heater hose in position Upper stud and lower bolt and tighten to 15-22 ft. Ibs. (20-30 Nm) Ground strap onto the stud and tighten the nut to 15-22 ft. Ibs. (20-30 Nm) Heater hose Engine/transmission harness connector Retaining bracket on the power brake booster Air conditioning compressor outlet hose to the compressor Bolt retaining the hose assembly to the right-hand ignition coil bracket Upper radiator hose Fuel supply and return lines Windshield wiper governor and retaining bracket Engine cooling fan blade and fan shroud Engine air inlet tube Battery cables 13. Fill the cooling system. 14. Start the engine and check for leaks. 15. Properly evacuate and charge the air conditioning system. 16. Road test the vehicle and check for

proper operation.

Camshaft and Valve Lifters

REMOVAL & INSTALLATION ee 7922RG09

Right exhaust manifold torque sequence

ee

1. Before servicing the vehicle, refer to the precautions in the beginning of this section.

FORD MOTOR CO.

CROWN VICTORIA e TOWN CAR e GRAND MARQUIS , 2. If equipped with air suspension, the aif Suspension switch, must be turned to the OFF position before raising the vehicle. 3. Properly relieve the fuel system pressure. 4. Drain the engine oil 5. Remove or disconnect the following: Negative battery cable Fan blade and fan shroud assembly Fuel supply and return lines from the fuel injection supply manifold Windshield wiper governor (module) assembly from the vehicle Engine air cleaner outlet tube Accessory drive belt Ignition wires from the spark plugs Ignition wire brackets from the cylinder head cover studs 2 bolts retaining the ignition wire separator to the ignition coil brackets and the bolt retaining the air conditioning pressure line to the right-hand ignition coil bracket. Connectors from both ignition coils and the Crankshaft Position (CMP) sensor Ignition coils with brackets attached Electrical connector from the alternator and at the power distribution box Water pump pulley Positive battery cable at the power distribution box Bolt from the positive battery cable bracket located on the right-hand cylinder head Fuel vapor hose from the EVAP canister purge valve and position the positive battery cable aside Positive Crankcase Ventilation (PCV) valve from the cylinder head cover and position aside Engine/transmission harness connector from the bracket on the power brake booster Crankshaft Position (CKP) sensor and air conditioning clutch harness connectors Bolts retaining the power steering pump to the cylinder block and wire the pump aside >The front lower bolt on the power steering pump will not come all the

way out.

e Qil pan ¢ Crankshaft pulley bolt and washer and crankshaft pulley ¢ Engine oil filter

e Power steering control valve actuator and oil pressure sensor e Oil filter adapter e Cylinder head covers e Engine front cover e Timing chains 6. Rotate the crankshaft counterclockwise no more than 45 degrees from Top Dead Center (TDC) to ensure that all pistons are below the top of the engine block deck face. 7. Install a valve spring compressor under the camshaft and on top of one of the valve spring retainers. 8. Install Valve Spring Spacer T91P6565-AH between the valve spring coils. Be Sure that the valve being compressed is on its base circle. Compress the valve spring and remove the rocker arm. Repeat the procedure until all rocker arms are removed. 9. If required, pull the lash adjusters out of their bores in the cylinder head. Note their locations, they must be installed in the same bore they were removed from. Do not mix the camshaft bearing caps. Note the camshaft bearing cap locations for installation.

10. To remove each camshaft, unfasten the 14 bolts retaining the camshaft bearing caps (cluster assemblies) to the cylinder head. Tap upward on the camshaft bearing caps at points near the upper bearing halves and gradually lift the camshaft bearing cap clusters from the cylinder head. 11. Repeat the removal procedure for the opposite cylinder head. 12. Remove the camshaft straight upward to avoid bearing damage. 13. Clean and inspect the camshafts and related components for unusual wear or damage. To install: 14. Clean and inspect the cylinder head covers, engine front cover and cylinder head sealing surfaces. 15. Apply clean engine oil to the camshaft journals and lobes. Position the camshafts on the cylinder heads. 16. Install and seat the camshaft bearing cap cluster assemblies. Install and hand start the retaining bolts. Tighten the camshaft cluster retaining bolts in sequence to 71-106 inch !bs. (8-12 Nm). Be sure to tighten each camshaft bearing cap cluster individually. =>Each camshaft bearing cap cluster assembly is tightened individually.

19-9

17. Loosen the camshaft bearing cap cluster retaining bolts approximately 2 turns or until the heads of the bolts are free. Tighten all bolts, again in sequence, to

71-106 inch Ibs. (8-12 Nm). 18. Repeat the camshaft bearing cap installation for the opposite cylinder head. >The camshafts should turn freely but with a slight drag.

19. Check camshaft end-play as follows: a. Step 1: Install a dial indicator on the front of the engine. Position it so the indicator foot is resting on the camshaft sprocket bolt or the front of the camshaft. b. Step 2: Push the camshaft toward the rear of the engine and zero the dial

indicator. c. Step 3: Pull the camshaft forward and release it. Specified end-play is 0.0901-0.006 inch (0.025-0.190mm). d. Step 4: If end-play is too tight, check for binding or foreign material in the camshaft thrust bearing. If end-play is excessive, check for worn camshaft thrust plate and replace the cylinder head, as required. e. Step 5: Remove the dial indicator. 20. If removed, install the lash adjusters in their origina! positions. 21. If necessary, install Camshaft Positioning Tools T92P-6256-A on the flats of the camshafts and install the spacers and camshaft sprockets. Install the bolts and washers and tighten to 81-95 ft. Ibs. (110-130 Nm). 22. Install a valve spring compressor under the camshaft and on top of the valve Spring retainer. 23. Install Valve Spring Spacer 191P6565-AH between the valve spring coils. Be sure that the valve being compressed is on its base circle. Compress the valve spring and install the rocker arm. Repeat the procedure until all rocker arms are installed. 24. Rotate the crankshaft clockwise 45 degrees to position the crankshaft at Top Dead Center (TDC). e>The crankshaft must only be rotated in the clockwise direction and only as far as TDC.

25. Install or connect the following: e Timing chains e Engine front cover ¢ Cylinder head covers. Tighten the cylinder head cover bolts to

71-106 inch Ibs. (8-12 Nm).

Heater Core replacement is covered in Section 2 of this manual

19-1

FORD MOTOR CO.

CROWN VICTORIA ¢ TOWN CAR ¢ GRAND MARQUIS

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O

S)

To install: 11. Clean the engine oil pan and inspect for damage. Clean the sealing surfaces of the front cover and cylinder block. Clean and inspect the oil pick-up tube and replace the O-ring. 12. If removed, position the oil pick-up tube on the oil pump and hand start the 2 retaining bolts. Install the bolt retaining the pick-up tube on the main bearing stud spacer, hand tight. 13. Tighten the pick-up tube-to-oil pump bolts to 72-108 inch Ibs. (8-12 Nm), then tighten the pick-up tube-to-main bearing stud spacer bolt to 15-22 ft. Ibs. (20-30 Nm). 14. Position a new gasket on the oil pan. Apply silicone sealer to where the front cover meets the cylinder block and the crankshaft rear oil seal and retainer meets the cylinder block. Position the oil pan to the engine and install the retaining bolts. Tighten the bolts in sequence, to 14 ft. Ibs. (20 Nm), then rotate the oil pan retaining bolts, in sequence an additional 60 degrees within 4 minutes of applying the silicone sealer. 15. Position the jack and wood block under the engine oil pan, rearward of the oil drain hole, and raise the engine enough to remove the wood blocks. Lower the engine and remove the jack. 16. Install or connect the following: Left-hand and right-hand engine support insulator through-bolts and tighten to 15-22 ft. Ibs. (20-30 Nm) Bolt retaining the right-hand engine support insulator to the lower front sub-frame. Tighten the bolt to 15-22 ft. Ibs. (20-30 Nm). Exhaust system to the exhaust manifolds and tighten the 4 retaining nuts to 20-30 ft. Ibs. (27-41 Nm). Be sure the exhaust system clears the crossmember. Adjust as necessary. New engine oil filter Heater blower motor switch resistor using the 2 retaining screws Heater water hose Upper stud and tighten the upper and lower bolts to 15-22 ft. Ibs. (20-30 Nm) Ground strap on the stud and tighten to 15-22 ft. Ibs. (20-30 Nm) Heater water hose Throttle valve cable, if equipped

shown To prevent oil leaks, tighten the oil pan bolts in the sequence

Brake service is covered in Section 4 of this manual

19-1

FORD MOTOR CO.

CROWN VICTORIA © TOWN CAR e GRAND MARQUIS

Engine/transmission electrical harness connector Harness connector on the power

brake booster bracket Air conditioning compressor outlet hose to the compressor Bolt retaining the hose to the righthand ignition coil bracket Upper radiator hose Fuel supply and return lines Wiper governor and retaining bracket Engine cooling fan and fan shroud Engine air cleaner outlet tube Negative battery cable 17. Fill the cooling system. 18. Fill the engine crankcase with engine oil. 19. Start the engine and check for leaks. 20. Properly evacuate and recharge the air conditioning system. 21. Road test the vehicle and check for proper engine operation.

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 oil pan ¢ Timing chains ¢ 2 bolts retaining the oil pick-up tube to the oil pump and the bolt attaching the oil pick-up tube to the main bearing stud spacer Pick-up tube ¢ 4 bolts retaining the oil pump to the cylinder block ¢ Oil pump To install: 3. Rotate the inner rotor of the oil pump to align with the flats on the crankshaft and install the oil pump flush with the cylinder block. Install the 4 retaining bolts and tighten to 72-106 inch Ibs. (8-12 Nm). 4. Clean the oil pick-up tube and replace the O-ring. 5. Place the pick-up tube on the oi pump and hand start the 2 retaining bolts. Install the bolt retaining the pick-up tube to the main bearing stud spacer hand tight. Tighten the pick-up tube-to-oil pump bolts to 72-106 inch Ibs. (8-12 Nm). Tighten the pick-up tube to main bearing stud spacer bolt to 15-22 ft. Ibs. (20-30 Nm).

/ ama 7922RG13

Apply a continuous bead ofsilicone sealant to the back of the seal retainer before installing it on the engine

|

oy

8-12 Nm (71.4 - 107.1 Lb- In) ———/

aes

CYLINDER BLOCK ASSY 7922RG12

The oil pump is mounted on the crankshaft at the front of the engine

6. Install or connect the following: ¢ New engine oil filter ¢ Timing chains e Engine oil pan ¢ Engine front cover ¢ Cylinder head covers e Negative battery cable 7. Fill the crankcase. 8. Start the engine and check for leaks and proper engine oil pressure. 9. Road test the vehicle and check for proper engine operation.

Rear MainSeal

_

REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: ¢ Transmission ¢ Flexplate or flywheel 3. With a sharp awl, carefully punch a small hole in the metal portion of the seal. 4. Remove the seal using a slide hammer with a sheet metal screw attached. e>lf the oil leak is coming from around

7922RG14

To avoid leakage, be sure to tighten the crankshaft rear oil seal retainer bolts in the correct sequence

6. Apply.silicone sealant to the back of the retainer and immediately install it on the engine block. Tighten the bolts in sequence to 71-107 inch Ibs. (8-12 Nm). 7. Lubricate the seal and the crankshaft with clean engine oil. 8. Install the seal with the spring side toward the engine. 9. Remove the installation tool. 10. Install or connect the following: ¢ Flexplate or flywheel. Tighten the bolts, in a crisscross pattern, to 94-64 ft. Ibs. (73-87 Nm). ¢ Transmission e Negative battery cable 11. Check the engine oil level. 12. Start the engine and check for leaks.

Timing Chain, $ prockets, Front Cover and Seal

the seal retainer, the retainer must also be removed and resealed.

REMOVAL & INSTALLATION SE RRA cee se

To install: 9. If the seal retainer was removed, Carefully clean the sealant from the retainer and engine block using a plastic Scraper. Remove any oil or grease residue from the sealing surfaces with a solvent,

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the engine oil. 3. Remove or disconnect the following: ¢ Negative battery cable ¢ Cooling fan and shroud

eee

ra

FORD MOTOR CO. 1 9-1 3

CROWN VICTORIA e TOWN CAR @ GRAND MARQUIS COPPER TIMING

LINK RH CHAIN

COPPER TIMING LINK LH CHAIN TIMING MARK RH CAM GEAR

INSTALL TOOL

CRANKSHAFT POSITIONING

OVER FRONT

COVER ALIGNMENT

DOWEL

TOOL

S

TDC CRANKSHAFT GEAR KEYWAYS

POSITIONED AT 315°

COPPER TIMING LINKS

RH AND LH CRANKSHAFT GEARS

TIMING MARK Patna ae CRANKSHAFT GEAR TIMING

©MARKS

7922RG16

Be sure that the timing marks are aligned when the No. 1 piston is at TDC on compression

Accessory drive belt Water pump pulley Power steering pump Oil pan Crankshaft pulley retaining bolt and washer Crankshaft pulley Bolt retaining the air conditioning pressure line to the right-hand ignition coil bracket Cylinder head covers Wiring at both ignition coils and the Crankshaft Position (CMP) senSor 3 bolts retaining the right-hand ignition coil bracket to the engine front cover. Position the power steering hose aside. 3 nuts retaining the left-hand ignition coil bracket to the engine front cover. Slide both ignition coil brackets and ignition wires off the mounting studs and lay the assembly on top of the engine. Bolts retaining the drive belt idler pulley and the pulley Wiring to the Crankshait Position (CKP) sensor and the sensor CAM POSITIONING TOOL

7922RG17

Use the special tool to maintain camshaft position while installing the timing chains

7922RG18

Install the crankshaft positioning tool to be sure the crankshaft does not turn while installing the timing chains

4. \f equipped, remove the retainers for the oil cooler from the engine front cover retaining stud bolts and position the oil cooler aside. e 9 stud bolts and the 6 standard engine front cover bolts and the cover e Crankshaft oil seal from the cover using a seal driver e CKP sensor pulse wheel 5. Rotate the engine to set the piston for No. 1 to Top Dead Center (TDC) on its compression stroke. 6. Install Camshaft Positioning Adapters T92P-6256-A on the flats of both camshafts. This will prevent accidental rotation of the camshafts. 7. Remove or disconnect the following: e 2 bolts retaining the tensioner to the right-hand cylinder head and the tensioner Right-hand timing chain tensioner arm 2 bolts retaining the right-hand timing chain guide to the cylinder head and remove the timing chain guide. Right-hand timing chain from the camshaft and crankshaft sprockets Right-hand camshaft sprocket retaining bolt, washer, sprocket and spacer, if necessary 2 bolts retaining the timing chain tensioner to the left-hand cylinder head Timing chain tensioner Left-hand timing chain tensioner arm 2 bolts retaining the timing chain guide to the left-hand cylinder head Timing chain guide Left-hand timing chain from the camshaft and crankshaft sprockets

e Left-hand camshaft sprocket retaining bolt, washer, sprocket and spacer, if necessary 8. If necessary, note the position of the crankshaft sprockets and remove the crankshaft sprockets by sliding them off the front of the crankshaft. 9. Inspect the plastic running face on the tensioner arms and chain guides. If worn or damaged, inspect the engine oil pan for contamination and thoroughly clean the oil pan. Replace the oil pick-up tube. To install: 10. Examine the timing chains, looking for the copper links. If the copper links are not visible, lay the chain on a flat surface and pull the chain taught until the opposite sides of the chain contact one another. Mark the links at each end of the chain and use these marks in place of the copper links. 11. Be sure Camshaft Positioning Adapters T92P-6256-A are installed on the flats of the camshafts to prevent them from rotating. 12. Install or connect the following: Left-hand and right-hand timing chain guides and retaining bolts. Tighten the retaining bolts to 71-106 inch Ibs. (8-12 Nm). Left-hand and right-hand camshaft spacers and sprockets, (if removed) on the camshafts, the washers and retaining bolts but do not tighten at this time. Left-hand crankshaft sprocket with the tapered part of the sprocket facing away from the engine block Left-hand timing chain on the camshaft and crankshaft sprockets. Be sure the copper links of the timing chain line up with the timing marks on both sprockets. Right-hand crankshaft sprocket

TIMING MARKS 5 ALIGNED

VIEWA

INCORRECT

CORRECT INSTALLATION 7922RG19

Install the crankshaft sprockets with the tapered sides facing each other

manual For complete Engine Mechanical specifications, see Section 1 of this

49-14 FORD moroR co. CROWN VICTORIA e TOWN CAR ¢ GRAND MARQUIS

TENSIONER PLUNGER

RATCHET STEM

7922RG20

Slowly compress the timing chain tensioner while holding the ratchet lock away

from the stem with a suitable tool

7922RG15

Timing chain front cover bolt tightening sequence

NOTE: Ensure ratchet stem is flush to tensioner body face priorta installing paper clip. 7922RG21

Install a paper clip or wire into the tensioner to hold the plunger in during assembly

with the tapered part of the sprocket facing the left-hand crankshaft sprocket, if removed Right-hand timing chain on the camshaft and crankshaft sprockets. Be sure the copper links of the timing chain line up with the timing marks on both sprockets. 13. It is necessary to bleed the timing chain tensioners before installation. Proceed as follows: a. Step 1: position the timing chain tensioner in a soft-jawed vise. b. Step 2: using a small pick or similar tool, hold the ratchet lock mechanism away from the ratchet stem and slowly compress the tensioner plunger by rotating the vise handle.

The tensioner must be compressed slowly or damage to the internal seals will result. C. Step 3: once the tensioner plunger bottoms in the tensioner bore, continue to hold the ratchet lock mechanism and push down on the ratchet stem until flush with the tensioner face. d. Step 4: while holding the ratchet

Stem flush with the tensioner face, release the ratchet lock mechanism and install a paper clip or similar tool in the tensioner body to lock the tensioner in the collapsed position. e. Step 5: the paper clip must not be removed until the timing chain, tensioner, tensioner arm and timing chain guide are completely installed on the engine. 14. Install the right-hand and left-hand timing chain tensioners and 2 bolts on each. Tighten the bolts to 15-22 ft. Ibs, (20-30 Nm). 15. Crankshaft Positioning Too! T93P6265-A over the crankshaft and the engine front cover alignment dowel to position the crankshaft. 16. Lubricate the timing chain tensioner arm contact surfaces with clean engine oil and install the right-hand and left-hand tensioner arms on their dowel pins. 17. Position a C-clamp around the timing chain tensioner arm and timing chain guide to remove all slack from the timing chain. Use care not to bend the timing chain guide. 18. Remove the locking pins or paper Clips from the timing chain tensioners and be sure that all timing marks are aligned. 19. Using Camshaft Positioning Adapters T92P-6265-A to align and hold the camshafts, tighten the camshaft sprocket retaining bolts to 81—95 ft. Ibs. (110-130 Nm). 20. Position a dial indicator in the No. 1 cylinder spark plug hole to measure intake valve lift. The intake valve should be at maximum lift when the crankshaft is at 114

degrees after TDC. If the intake valve lift is not at maximum lift, loosen the camshaft sprocket bolt and repeat the steps detailing the installation of the timing chain tensioners to the tightening of the camshaft sprockets. 21. Remove the camshaft and crankshaft positioning tools. 22. Install a new crankshaft seal in the front cover. Apply engine oil to the lip of the Seal. 23. Thoroughly clean the sealing surfaces of the front cover, cylinder block and oil pan. Apply silicone sealer to the points where the cylinder head meets the cylinder block. 24. Install or connect the following: Front cover in position using new gaskets Retaining bolts and studs in their proper locations. Tighten in sequence to 15-22 ft. Ibs. (20-30 Nm) within 4 minutes of applying the silicone sealer. Oil cooler to the front cover retaining stud bolts, if equipped CKP sensor and attach the harness connector Drive belt idler pulley Ignition coil brackets and ignition wires as an assembly onto the mounting studs Power steering hose and the nuts retaining the coil brackets to the front cover. Tighten the nuts to 15-22 ft. Ibs. (20-30 Nm). Wiring to both ignition coils and the CMP sensor Cylinder head covers

,

F CROWN VICTORIA e TOWN PAR CRRNEHAAROIS 1 9-1 u e Air conditioning pressure line on the right-hand ignition coil bracket and tighten the retaining bolt 29. Apply a small amount of silicone sealer in the rear of the keyway in the crankshaft pulley. 26. Install or connect the following: Pulley on the crankshaft e Crankshaft pulley bolt and washer and tighten to 114-121 ft. Ibs. (155-165 Nm) Oil pan Power steering pump on the engine. Tighten the bolts to 15-22 ft. Ibs. (20-30 Nm). Water pump pulley. Tighten the bolts to 15-22 ft. Ibs. (20-30 Nm). Accessory drive belt Engine cooling fan and shroud Negative battery cable 27. Fill the engine. 28. Start the engine and check for leaks. 29. Road test the vehicle and check for proper engine operation.

Piston and Ring

< as

[>

yy

TOP COMPRESSION RING BOTTOM COMPRESSION

RING

OIL RING EXPANDER AND RAILS 7922AG32

Ford 4.6L (VIN W and X) engines—piston ring positioning

UPPER SD RAIL

FRONT MARK

EXPANDER

LOWER SIDE RL ee

POSITIONING

7922A622

Ford 4.6L (VIN W and X) engines—piston ring end-gap spacing and piston positioning

Fuel System Service Precautions Safety is the most important factor when performing not only fuel system maintenance but any type of maintenance. Failure to conduct maintenance and repairs in a safe manner may result in serious personal injury or death. Maintenance and testing of the vehicle’s fuel system components can be accomplished safely and effectively by adhering to the following rules and guidelines. To avoid the possibility of fire and personal injury, always disconnect the negative battery cable unless the repair or test procedure requires that battery voltage be applied. e Always relieve the fuel system pressure prior to disconnecting any fuel system component (injector, fuel rail, pressure regulator, etc.), fitting or fuel line connection. Exercise extreme caution whenever relieving fuel system pressure, to avoid exposing

skin, face and eyes to fuel spray. Please be advised that fuel under pressure may penetrate the skin or any part of the body that it contacts. e Always place a shop towel or cloth around the fitting or connection prior to loosening to absorb any excess fuel due to spillage. Ensure that all fuel spillage (should it occur) is quickly removed from engine surfaces. Ensure that all fuel soaked cloths or towels are deposited into a waste container. » Always keep a dry chemical (Class B) fire extinguisher near the work area. ¢ Do not allow fuel spray or fuel vapors to come into contact with a spark or open flame. e Always use a back-up wrench when loosening and tightening fuel line connection fittings. This will prevent unnecessary stress and torsion to fuel line piping. Always follow the proper torque specifications.

e Always replace worn fuel fitting Orings with new. Do not substitute fuel hose or equivalent, where fuel pipe is installed.

Fuel System Pressure RELIEVING Fuel supply lines on all fuel injected engines will remain pressurized for some period of time after the engine is shut OFF. This pressure must be relieved before servicing the fuel system. Pressure is relieved through the fuel pressure relief valve, located on the fuel rail. To relieve the fuel system pressure, first remove the fuel tank cap to relieve pressure in the tank, then remove the cap on the fuel pressure relief valve. Attach a fuel pressure gauge and drain the system through the drain tube into a container. Remove the fuel pressure gauge and replace the cap on the relief valve.

For Accessory Drive Belt illustrations, see Section 1 of this manual

19-1

FORD MOTOR CO.

CROWN VICTORIA ¢ TOWN CAR e GRAND MARQUIS

ebuel Filler REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Disconnect the negative battery cable. 3. Relieve the fuel system pressure. 4. lf equipped with air suspension, turn the air Suspension switch to the OFF position. 5. Remove the hairpin clip push connect fittings from both ends of the fuel filter as follows: a. Step 1: Inspect the visible internal portion of the fitting for dirt accumulation. If more than a light coating of dust is present, clean the fitting before disassembly. b. Step 2: Some adhesion between the seals in the fitting and the filter will occur with time. To separate, twist the fitting on the filter, then push and pull the fitting until it moves freely on the filter. c. Step 3: Remove the hairpin clip from the fitting by first bending and breaking the shipping tab. Next, spread the 2 clip legs by hand about ¥% inch each, to disengage the body and push the legs into the fitting. Lightly pull the triangular end of the clip and work it Clear of the filter and fitting. d. Step 4: Grasp the fitting and pull in an axial direction to remove the fitting from the filter. Be careful on 90 degree elbow connectors, as excessive side loading could break the connector body. e. Step 5: After disassembly, inspect the inside of the fitting for any internal parts such as O-rings and spacers that may have been dislodged from the fitting. Replace any damaged connector. 6. Remove the filter retaining clamp and remove the fuel filter. Note the direction of the flow arrow on the filter, so the replacement filter can be reinstalled in the same position.

7922RG22

The fuel filter is located near the center of the vehicle on the frame rail

To install: 7. Install or connect the following: e¢ Fuel filter with the flow arrow facing the proper direction and tighten the filter retaining clamp Rubber insulator rings on the new filter. Replace the insulator rings if the filter moves freely after the retainer is installed. Filter into the retainer with the flow arrow pointing out the open end of the retainer Retainer on the bracket and tighten the mounting bolts to 27—44 inch lbs. (3-5 Nm) 8. Install the hairpin clip push connect fittings at both ends of the fuel filter as follows: a. Step 1: Install a new connector if damage was found. Insert a new clip into any 2 adjacent openings with the triangular portion pointing away from the fitting opening. Install the clip until the legs of the clip are locked on the outside of the body. Piloting with an index finger is

necessary. b. Step 2: Before installing the fitting on the filter, wipe the filter end with a clean cloth. Inspect the inside of the fitting to be sure it is free of dirt and/or obstructions. c. Step 3: Apply a light coating of engine oil to the filter end. Align the fitting and filter axially and push the fitting onto the filter end. When the fitting is engaged, a definite click will be heard. Pull on the fitting to be sure it is fully engaged. 9. If equipped with air suspension, turn the air Suspension switch to the ON position. 10. Reconnect the negative battery cable. 11. Start the engine and check for fuel leaks and proper operation.

tank during fuel pump removal and installation. 6. Remove or disconnect the following: ¢ Fuel supply and return line fittings at the fuel pump using fuel line disconnect tools e Fuel pump module electrical connector e 6 retaining bolts around the perimeter of the fuel pump module : e Fuel pump module and seal from the fuel tank To install: 7. Clean the fuel pump module mounting flange and fuel tank mounting surface. 8. Install or connect the following: e New seal and the fuel pump module using care not to damage the inlet filter and fuel sending unit float arm 6 retaining bolts and tighten to 80-107 inch Ibs. (9-12 Nm) Fuel pump module electrical connector Fuel supply and return lines to the fuel pump module. Pull on the fuel line fittings to verify engagement. 9. Minimum of 10 gallons (38L) of clean fuel to the fuel tank and check leaks. 10. Install a Fuel pressure gauge Schrader valve on the fuel injection manifold. 11. Connect the negative battery

for

to the supply

cable. 12. Cycle the ignition switch from the OFF to ON position 5-10 times for 3 second intervals or until the fuel pressure gauge shows at least 35 psi (241 kPa). 13. Check for fuel leaks. 14. Remove the fuel pressure gauge. 15. Start the engine and recheck for fuel leaks. 16. Road test the vehicle and check for proper operation.

REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Disconnect the negative battery cable. 3. Relieve the fuel system pressure. 4. Install a hose into the fuel filler pipe and drain or siphon the fuel into a storage tank designed for fuel storage. 5. Remove any dirt that has accumulated around the fuel pump and fuel lines to prevent the entry of contaminants into the

7922RG23

Tighten the fuel pump mounting bolts to

80-107 inch Ibs. (9-12 Nm)

FORD MOTOR CO. 1 9-1 7

CROWN VICTORIA ¢ TOWN CAR e GRAND MARQUIS

Fuel Injector REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Relieve the fuel system pressure.

nes

3. Remove or disconnect the following: e Injector supply manifold ¢ Wiring e Injector by pulling it up and gently rocking it side to side e O-rings and discard To install: 4. Lubricate new O-rings with clean engine oil.

5. Install or connect the following: e O-rings e Fuel injector using a light, twisting and pushing motion e Injector supply manifold e Wiring

DRIVE TRAIN

Transmission Assembly REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the. precautions in the beginning of this section. 2. Drain the transmission. 3. If equipped with air suspension, the air suspension switch, located on the righthand side of the luggage compartment, must be turned to the OFF position before raising the vehicle. 4. Remove or disconnect the following: Negative battery cable Exhaust system as necessary for transmission removal Converter bottom access cover and

adapter plate bolts Torque converter drain plug, to allow the converter to drain into a container, if equipped. After the converter has drained, reinstall the drain plug and tighten. 4 torque converter-to-flywheel retaining nuts Driveshaft (mark for installation), plug the transmission extension housing to prevent fluid leakage Vehicle Speed Sensor (VSS) or if equipped, the speedometer cable from the transmission extension housing Shift cable from the transmission manual control lever the throttle valve cable from the transmission throttle valve lever, if equipped Transmission wiring harness connectors. Starter motor retaining bolts and place the starter motor aside 5. Position a transmission jack under the transmission and raise it enough to allow crossmember removal. 6. Remove or disconnect the following:

e Engine rear support-to-crossmember bolts and the crossmember-toframe side support retaining bolts e Crossmember and transmission support insulator 7. Lower the transmission jack and allow the transmission to hang. 8. Place a jack to the front of the engine and raise the engine enough to gain access to the 2 upper transmission-tocylinder block retaining bolts. Do not remove the bolts at this time. 9. Remove or disconnect the following: e Transmission cooler lines at the transmission. Plug all openings to keep dirt out. e Lower transmission-to-cylinder block retaining bolts ¢ Transmission fluid fill tube and plug the opening in the transmission 10. Secure the transmission to the transmission jack with a safety strap or chain. 11. Remove the 2 upper transmissionto-cylinder block bolts. 12. Carefully move the transmission rearward to disengage the bell housing from the dowel pins and the torque converter studs from the flywheel. 13. Remove or disconnect the following: e Transmission ¢ Torque converter to prevent the converter from dropping out of the transmission causing possible damage or personal injury To install: 14, Remove the safety stand and block of wood supporting the rear of the engine, if installed. 15. Install or connect the following: e Torque converter drain plug to 21-23 ft. Ibs. (28-30 Nm), if equipped ¢ Torque converter on the transmission and rotate into position to be sure the drive flats are fully engaged in the pump gear. When fully seated, the center of the torque con-

verter should be about “Ae—%e Inch (10.2-14.4mm) below the transmission mounting surface 16. Mount the transmission on a transmission jack and secure with a safely strap or chain. Raise the transmission and align with the cylinder block dowel pins. 17. Rotate the converter until the studs and drain plug are in alignment with the holes in the flywheel. Align the orange balancing marks on the converter stud and flywheel bolt hole, if balancing marks are present. 18. Slide the transmission assembly forward into position, being careful not to damage the flywheel and converter pilot. 19. Install or connect the following: e 2 transmission housing-to-cylinder block bolts at the engine dowel pin locations. Tighten the bolts to 41-50 ft. Ibs. (65-68 Nm). e Transmission housing-to-cylinder block bolts. Tighten the bolts to 41-50 ft. Ibs. (65-68 Nm). 20. Remove the safety strap or chain from around the transmission. 21. Install or connect the following: e Transmission fluid fill tube. Tighten the bolt to 28-38 ft. Ibs. (38-51 Nm). ¢ Oil cooler lines to the transmission case. Tighten the cooler line fittings to 15-19 ft. Ibs. (20-26 Nm). DIMENSION A TO BE 10.23-14.43 mm (7/16-9/16 INCH) APPROXIMATELY

7922RG24

To prevent transmission damage, be sure that the torque converter is fuliy seated in

the front pump of the transmission

For Tire, Wheel and Ball Joint specifications, see Section 1 of this manual

19-1

FORD MOTOR CO.

CROWN VICTORIA ¢ TOWN CAR e GRAND MARQUIS

22. Remove the jack supporting the front of the engine. 23. Install or connect the following: e Crossmember using the proper jack e Crossmember and transmission Support insulators in position e Engine rear support-to-crossmember retaining bolts and the crossmember-to-frame side support retaining bolts 24. Remove the transmission jack. 25. Install or connect the following: Transmission wiring harness connectors Starter motor and wiring 4 torque converter-to-flywheel retaining nuts. Tighten to 20-33 ft. Ibs. (27-46 Nm). Torque converter access cover and cover plate bolts. Tighten the bolts to 12-16 ft. Ibs. (16-22 Nm). Exhaust system VSS and the wiring, or if equipped, the speedometer cable to the transmission extension housing Driveshaft, aligning the marks that were made during removal Shift cable to the transmission manual control lever Throttle valve cable to the transmission throttle valve lever, if equipped 26. If equipped with air suspension, turn the air Suspension switch to the ON position. 2/7. Fill the transmission. 28. Start the engine and check the transmission for leakage. 29. Road test the vehicle and check for proper transmission operation.

Axle Shaft, Bearing and Seal REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. If equipped, turn the air suspension service switch to the OFF position before raising the vehicle. 3. Remove or disconnect the following ¢ Wheel ¢ Brake caliper and rotor e Anti-lock brake speed sensor, if equipped 4. Clean all dirt from the area of the axle housing cover. 5. Place a drain pan under the axle housing.

SPEED SENSOR

rae

SPEED SENSOR RING

DISC BRAKE ROTOR

ASSY

7922RG34

Exploded view of the rear axle shaft assembly

» SE \°

AXLE SHAFTS

N

DIFFERENTIAL PINION SHAFT

7922RG36 7922RG35

Removal of differential pinion shaft

6. Remove or disconnect the following: e Axle housing cover retaining bolts and the cover, draining the axle lubricant from the housing ¢ Differential pinion shaft lockbolt and the differential pinion shaft 7. Push the flanged end of the axle shaft being removed toward the center of the vehicle 8. Remove or disconnect the following: ¢ C-lock from the button end of the axle shaft ¢ Axle shaft from the housing, being careful not to damage the oil seal and anti-lock brake sensor ring, if equipped. 9. Insert an axle bearing remover in the axle housing bore and position it behind the wheel bearing so the tangs on the tool engage the bearing outer race. 10. Remove the wheel bearing and seal as an assembly using an impact slide hammer attached to the bearing remover tool To install: 11. Lubricate the new wheel bearing with ear axle lubricant. 12. Install the wheel bearing into the axle housing bore using a bearing replacer.

Removing. axle shaft C-lock clips

13. Lubricate the lips of a new wheel bearing oil seal with wheel bearing grease. 14. Install or connect the following: ¢ New wheel bearing seal using a seal replacer Axle shaft into the axle housing without damaging the bearing/seal assembly or anti-lock brake sensor ring, if equipped. Start the splines into the side gear and push firmly until the button end of the axle shaft can be seen in the differential case. C-lock on the button end of the axle shaft splines, then push the shaft outboard until the shaft splines engage and the C-lock seats in the counterbore of the differential side gear. Differential pinion shaft through the Case and pinion gears, aligning the hole in the shaft with the lockbolt hole Apply a thread locking compound to the lockbolt threads and place in the case and pinion shaft. Tighten

to 15-30 ft. Ibs. (20-41 Nm).

FORD MOTOR CO. 49.49

CROWN VICTORIA e TOWN CAR e GRAND MARQUIS 15. Cover the inside of the differential case with a shop rag and clean the sealing surface of the axle housing and the axle housing cover. Remove the shop rag. 16. Apply a Y—%e inch (3.18-4.76mm) wide bead of silicone sealer to the cover. 17. Install the axle housing and bolts and tighten in a crisscross pattern. Final torque the cover retaining bolts to 28-38 ft. lbs. (88-52 Nm). 18. Add the appropriate rear axle lubricant to the axle housing to a level %a—“e inch (6—14mm) below the bottom of the fill hole. If equipped with a limited slip differential, add 4 oz. (118.3 ml) of the appropriate friction modifier. 19. Install or connect the following: e Axle housing fill plug and tighten to 15-30 ft. Ibs. (20-41 Nm) e Anti-lock brake speed sensor, if equipped. Tighten the retaining bolt to 40-60 inch Ibs. (4.5-6.8 Nm). e Brake calipers and rotors e Wheel 20. If equipped with air suspension, turn the air suspension switch to the ON position. 21. Road test the vehicle and check for proper operation.

Saat

ek CAUTION Some 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 precautions and the disarming procedure could result in accidental air bag deployment, possible injury and unnecessary system repairs.

PRECAUTIONS ae rome

ee

Several precautions must be observed when handling the inflator module to avoid accidental deployment and possible personal injury. ° Never carry the inflator module by the wires or connector on the underside of the module. ¢ When carrying a live inflator module,

REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Driveshaft e Rear wheels e Rear brake calipers >The rear brake calipers must be removed so that there is no additional drag when measuring pinion bearing preload.

3. Use an inch Ib. torque wrench and measure the amount of torque required to maintain pinion rotation through several revolutions. 4 Remove the pinion flange and remove the seal. To install: 5. Install or connect the following: e Pinion seal and flange e New pinion flange nut 6. Rotate the pinion flange occasionally while tightening the flange nut to make sure the pinion bearings seat correctly.

7. Take frequent bearing preload torque readings. 8. If the preload recorded prior to disassembly is lower than the specification for used bearings, then tighten the pinion flange nut to specification. If the preload recorder prior to disassembly is higher than the specification for used bearings, then tighten the pinion flange nut to the original reading as recorded. 9. The pinion bearing preload specifications are as follows: a. Used bearings: 8-14 inch Ibs. (0.9-1.6 Nm). b. New bearings: 16-29 inch Ibs. (1.8-3.2 Nm).

> CAUTION Never loosen the pinion nut to reduce bearing preload. If it is necessary to reduce bearing preload, install a new collapsible spacer and pinion nut. 10. Install or connect the following: e Driveshaft e Brake calipers e Rear wheels 11. Fill the differential with gear lubricant and check for leaks.

3

STEERING AND SUSPENSION hold securely with both hands, and ensure that the bag and trim cover are pointed away. e Place the inflator module on a bench or other surface with the bag and trim cover facing up. e With the inflator module on the bench, never place anything on or close to the module which may be thrown in the event of an accidental deployment.

DISARMING 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Position the vehicle with the front wheels in a straight-ahead position. 3. Disconnect both battery cables. 4. Wait at least 1minute for the air bag back-up power supply to deplete its stored energy before continuing. 5. Proceed with the repair. 6. Once the repair is complete. 7. Reconnect both battery cables. 8. Prove out the air bag system by turning the ignition key to the RUN position and

|

visually monitoring the air bag indicator lamp in the instrument cluster. The indicator lamp should illuminate for approximately 6 seconds, then turn OFF. If the indicator lamp does not illuminate, stays on, or flashes at any time, a fault has been detected by the air bag diagnostic monitor.

Power Steering Gear REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. If equipped with air suspension, the air suspension switch must be turned to the OFF position before raising the vehicle. 3. Center the steering wheel and turn the key to the locked position. 4. Remove or disconnect the following: ¢ Negative battery cable e Bolt and the intermediate shaft from the steering gear 5. On the Town Car, separate the 2 halves and remove the steering gear cover.

For Wheel Alignment specifications, see Section 1 of this manual

19-2

FORD MOTOR CO.

CROWN VICTORIA ¢ TOWN CAR e GRAND MARQUIS

7922RG25

Remove the bolt and separate the intermediate shaft from the steering gear input shaft

gear. Tighten the bolt to 31-41 ft. lbs. (41-55 Nm). e Negative battery cable 12. If equipped with air suspension, turn the air suspension switch to the ON position. 13. Fill the reservoir with the correct power steering fluid and turn the steering wheel from stop-to-stop to distribute the fluid. Check the fluid level and add fluid, if necessary. 14. Start the engine and turn the steering wheel from left to right. Check for leaks. 15. On the Town Car, install the steering gear cover.

Shock Absorber

REMOVAL & INSTALLATION Front

7922RG26

Remove the locknut and separate the Pitman arm from the center link using the appropriate puller

6. Tag the power steering pressure and return lines so they may be reassembled in their original positions. 7. Place a drain pan under the steering gear 8. Remove or disconnect the following: e Pressure and return lines. Plug the lines and ports in the gear to prevent the entry of dirt. e Pitman arm from the center link using a puller. It is not necessary to remove the Pitman arm from the steering gear. 9. Support the steering gear 10. Remove or disconnect the following: e Steering gear-to-frame rail retaining bolts e Steering gear To install: 11. Install or connect the following: ¢ Steering gear on the frame rail. Tighten the steering gear-to-frame retaining bolts to 50-67 ft. Ibs. (66-90 Nm). ¢ Pitman arm to the center link. Tighten the retaining nut to 52-60 ft. Ibs. (70-81 Nm). ¢ Power steering pressure and return lines to the steering gear and tighten the lines to 12-18 ft. Ibs. (16-24 Nm) e Intermediate shaft to the steering

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. If equipped with air suspension, the air Suspension switch, located on the righthand side of the luggage compartment, must be turned to the OFF position before raising the vehicle. 3. Remove or disconnect the following: e Nut, washer and bushing from the upper end of the shock absorber ¢ 2 bolts retaining the shock absorber to the lower control arm ¢ Shock absorber To install: 4. Prior to installation, prime the new shock absorber. Fully extend the shock absorber while in the right side up (installed) position. Turn the shock absorber upside down and fully compress it. Repeat the procedure at least 3 times to purge any air trapped in the shock absorber. 5. Install or connect the following: ¢ New bushing and washer on the stud on the top of the new shock absorber and position the unit inside the front coil spring 2 lower retaining bolts and tighten them to 10-12 ft Ibs. (18-17 Nm), New bushing and washer on the shock absorber top stud New retaining nut. Tighten the retaining nut to 25-34 ft. Ibs. (34-46 Nm). 6. If equipped with air suspension, turn the air suspension switch to the ON position. Rear

2. If equipped with air suspension, turn the air suspension service switch OFF. 3. Be sure the ignition switch is in the OFF position. 4. Support the rear axle assembly with a jack. 5. Remove or disconnect the following: ¢ Top retaining nut, washer and bushing ¢ Bottom retaining nut and washer e Shock absorber To install: 6. Install or connect the following: e Shock absorber so the upper stud enters the hole in the frame e Top bushing, washer and retaining nut. Tighten to 26-34 ft. Ibs. (34-46 Nm). 7. Extend the shock absorber and place the lower stud through the hole in the bracket 8. Bottom retaining washer and nut. Tighten to 57-75 ft. Ibs. (76-103 Nm). 9. Remove the jack from the axle assembly. 10. Turn the air suspension service Switch to the ON position.

REMOVAL & INSTALLATION Front

1. Before servicing the vehicle, refer to the precautions in the beginning of this section.

1

Upper Ball

5

Lower Ball Nut

2 3 4

Compression Rod Forcing Nut Thrust Washer

6 7

Plate Pin 7922RG27

1. Before servicing the vehicle, refer to the precautions in the beginning of this section.

Exploded view of Spring Compressor

D78P-5310-A

FORD MOTOR CO.

CROWN VICTORIA e TOWN CAR * GRAND MARQUIS

7922RG28

Compress the coil spring until it moves away from its seat

2. lf equipped with air Suspension, turn the air Suspension service switch to the OFF position before raising the vehicle. 3. Remove or disconnect the following: e Wheel e Shock absorber e Center link from the Pitman arm 4. Using a spring compressor perform the following steps: a. Step 1: install 1 plate with the pivot ball seat facing downward into the coils of the spring. Rotate the plate so it is flush with the upper surface of the lower arm. b. Step 2: Install the other plate with the pivot ball seat facing upward into the coils of the spring. Insert the upper ball nut through the coils of the spring, so the nut rests in the upper plate. c. Step 3: Insert the compression rod into the opening in the lower arm, through the upper and lower plate and upper ball nut. Insert the securing pin through the upper ball nut and compression rod. d. Step 4: With the upper ball nut secured, turn the upper plate so it walks up the coil until it contacts the upper spring seat. Then, back off ¥2 turn. e. Step 5: Install the lower ball nut

SO

Fasteners

;

and thrust washer on the compression rod and screw on the forcing nut. Tighten the forcing nut until the spring is compressed enough so it is free in its seat. 5. Remove or disconnect the following: ¢ 2 lower control arm pivot bolts ¢ Lower arm from the frame crossmember e Coil spring 6. If a new coil spring is to be installed, mark the position of the upper and lower plates on the spring with chalk. With an assistant, compress a new spring for installation and measure the compressed length and the amount of curvature of the old spring. 7. Loosen the forcing nut to relieve the spring tension and remove the tools from the spring. To install: 8. Assemble the spring compressor and locate in the same position as marked during disassembly. 9. Before compressing the coil spring, be sure the upper ball nut securing the pin is inserted properly. 10. Compress the coil spring until the spring height reaches the dimension measured during disassembly. 11. Position the coil spring assembly into the lower arm and position the lower arm into the frame crossmember. 12. Install both the front and rear lower control arm pivot bolts through the frame and lower arm bushings. Tighten the bolts and nuts to 109-148 ft. Ibs. (148-201 Nm). 13. Remove the spring compressor from the coil spring. 14. Install or connect the following: e Drag link to the Pitman arm. Tighten the retaining nut to 60 ft. lbs. (80 Nm). e Shock absorber inside the coil spring e Retaining bolts e Wheel. Tighten the lug nuts to 85-105 ft. Ibs. (115-142 Nm). 15. Place a washer and retaining nut on the shock absorber top stud. Tighten the nut to 25-34 ft. Ibs. (34-46 Nm). 16. \f equipped with air suspension, turn the air suspension switch to the ON position. 17. Check the front end alignment.

ee

Lower Arm7922RG29

Remove the fasteners attaching the lower arm to the frame, then lower the arm and

remove the spring with the compressor

Rear

1. Before servicing the vehicle, refer to the precautions in the beginning of this section.

49.9

2. Place a hoist under the rear axle housing and raise and safely support the vehicle. 3. Support the frame side rails with 2 jackstands. 4. Remove or disconnect the following: e Rear sway bar e Lower studs of both rear shock absorbers from the mounting brackets on the axle tube e Parking brake cable from the upper arm retainer before lowering the axle housing 5. Lower the axle housing until the coil springs are released. If the axle housing is supported by the hoist, lower the hoist allowing the rear of the vehicle to rest on the jackstands. If the vehicle’s axle housing is supported by the jackstands, leave the hoist stationary and lower the jackstands or raise the hoist to release the tension on the coil springs. 6. Remove the coil springs and insulators. To install: 7. Install or connect the following: e Coil spring in the upper and lower seats with an insulator between the upper end of the spring and frame seat Axle housing and connect the lower Studs of the shock absorbers to the mounting brackets Parking cable into the upper arm retainer e Sway bar 8. Road test the vehicle and check for proper operation.

REMOVAL & INSTALLATION

+2 CAUTION Before servicing any air suspension component, disconnect power to the system by turning the air suspension service switch OFF or by disconnecting the negative battery cable. Do not remove an air spring under any Circumstances when there is pressure in the air spring. Do not remove any components supporting an air spring without either exhausting the air or providing support for the air spring. 1. Before servicing the vehicle, refer to the precautions in the beginning of this section.

For Maintenance Interval recommendations, see Section 1 of this manual

1 9-2

FORD MOTOR CO.

CROWN VICTORIA ¢ TOWN CAR ¢ GRAND MARQUIS

2. Turn the air Suspension switch to the OFF position. 3. Raise and safely support the vehicle so the suspension is fully down with no load. 4 Remove or disconnect the following: e Heat shield, as required e Spring retainer clip e Air spring solenoid valve electrical connector e Air line e Air spring solenoid retainer 5. Rotate the solenoid valve counter-

clockwise to the first stop. 6. Pull the solenoid valve straight out slowly to the second stop to bleed air from the system.

> CAUTION Do not fully release the solenoid until the air is completely bled from the air spring or personal injury may result. 7. After the air is fully bled from the system, rotate the solenoid valve counterclockwise to the third stop and remove the solenoid valve from the solenoid housing. Remove the large O-ring from the solenoid housing. 8. Remove the air spring. To install: 9. Check the solenoid valve O-rings for cuts or abrasions. Replace the O-rings as required. Lightly grease the O-ring area of the solenoid valve and the larger solenoid housing O-ring with silicone dielectric compound. 10. Insert the solenoid into the air spring end cap and rotate clockwise to the third stop, push in to the second stop, then rotate clockwise to the first stop.

HEAT SHIELD

ae eo

SPRING RETAINER |

AIR SPRING WITH INTEGRAL SOLENOID

7922RG30

Exploded view of the air spring mounting

11. Install or connect the following: Air spring solenoid retainer. Inspect the wiring harness connector and ensure the rubber gasket is in place ~ at the bottom of the connector cavity Air spring into the frame (upper) spring seat, taking care to keep the solenoid air and electrical connections clean and free of damage Push-on ring spring retainer clip to the knob of the spring cap from the top side of the frame spring seat Air line and electrical connector to the solenoid Heat shield to the frame spring seat, if removed Align the air spring piston-to-axle (lower) seat. Squeeze to increase pressure and push downward on the piston, snapping the piston to the axle seat at rebound and supported by the shock absorber. Negative battery cable.

The air springs may be damaged if the suspension is allowed to compress before the spring is inflated. 12. Refill the air spring as follows: a. Step 1: Turn the air suspension switch to the ON position. The ignition switch must be ON and the engine running or a battery charger must be connected to the battery to reduce battery drain. b. Step 2: Fold back or remove the right-hand luggage compartment trim panel and connect Super Star II Tester 007-0041-A to the air suspension DLC, which is located near the air suspension switch. C. Step 3: Set the tester to EEC-

IV/MCU mode. Also set the tester to FAST mode. Release the tester button to the HOLD (up) position and turn the tester ON. d. Step 4: Depress the tester button to TEST (down) position. A Code 10 will be displayed. Within 2 minutes a Code 13 will be displayed. After Code 13 is displayed, release the tester button to the HOLD (up) position, wait 5 seconds and depress the tester button to TEST (down) position. Ignore any codes displayed. €. Step 5: Release the tester button to the HOLD (up) position. Wait at least 20 seconds, then depress the tester button to TEST (down) position. Within 10 seconds, the codes will be displayed in the order shown.

f. Step 6: Within 4 seconds after Code 26 is dispiayed, release the tester button to the HOLD (up) position. Waiting longer than 4 seconds may result in Functional Test 31 being entered. The compressor will fill the air springs with air as long as the tester button is in the HOLD (up) position. To stop filling the air springs, depress the tester button to the TEST (down) position. g. Step 7: To exit Functional Test 26, disconnect the tester and turn the ignition switch to the OFF position. 13. Install the luggage trim panel, if removed.

Upper Ball Joint REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. lf equipped with air suspension, the aif Suspension switch to the OFF position before raising the vehicle. 3. Place supports under both sides of the frame just behind the lower control arms. 4. Remove the wheel. 5. Place a floor jack under the lower control arm at the lower ball joint area. The floor jack will support the spring load on the lower control arm. 6. Remove the retaining nut and pinch bolt from the upper ball joint stud. 7. Mark the position of the alignment cams. When replacing the upper ball joint this will approximate the current alignment. 8. Remove or disconnect the following: ¢ 2 nuts retaining the upper ball joint to the upper control arm ¢ Upper ball joint from the upper control arm and spread the slot in the wheel spindle with a prybar to remove the ball joint stud from the wheel spindle. To install: 9. Install or connect the following: Upper ball joint to the upper control arm Ball stud into the wheel spindle Upper ball joint pinch bolt and retaining nut. Tighten to 56-77 ft. lbs. (76-104 Nm). Alignment cams to the approximate position at removal. If not marked, install in the neutral positions. 2 nuts retaining the upper ball joint to the upper control arm. Hold the cams and tighten the nuts to 107-129 ft. Ibs. (145-175 Nm).

FORD MOTOR CO.

CROWN VICTORIA ¢ TOWN CAR ¢ GRAND MARQUIS e Wheel and tire assembly. Tighten the lug nuts in a star pattern to 85-105 ft. Ibs. (115-142 Nm). 10. Remove the floor jack from under the lower control arm. 11. If equipped with air suspension, turn the air suspension switch to the ON position. 12. Check and adjust the front wheel alignment.

Lower Ball Joint

:

REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. If equipped with air suspension, the air Suspension service switch to the OFF position before raising the vehicle. 3. Place supports under both sides of the frame behind the lower control arms. 4. Remove or disconnect the following: e Wheel e Wheel spindle e Ball joint boot seal and discard e Ball joint

BALL JOINT REMOVER

FRONT SUSPENSION LOWER ARM

RECEIVING CUP 7922RG31

Use a ball joint press to remove the ball joint from the lower control arm

RECEIVING CUP

U-JOINT TOOL

FRONT SUSPENSION LOWER ARM BALL JOINT REPLACER

To install:

e*When installing a new ball joint, the protective cover should be left on to protect the ball joint seal during installation. It may be necessary to trim the cover so it can pass through the installation tool.

5. Install the ball joint. 6. Discard the protective cover and be sure the new ball joint is fully seated in the lower control arm. Ensure that the ball joint seal is not damaged. 7. Install or connect the following: e Wheel spindle e Wheel. Tighten the lug nuts to 85-105 ft. Ibs. (115-142 Nm). 8. lf equipped with air suspension, turn the air suspension service switch to the ON position. 9. Check the front end alignment.

Upper Control Arm REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. If equipped with air suspension, the air suspension switch, located on the righthand side of the luggage compartment, must be turned to the OFF position before raising the vehicle. 3. Remove or disconnect the following: e Front whee e Upper ball joint. Support the lower control arm. e Upper control arm pivot bolts e Upper control arm To install: 4. Install or connect the following: e Upper control arm. Tighten the pivot bolts to 110-148 ft. Ibs. (148-201 Nm). ¢ Upper ball joint. Tighten the pinch bolt to 56-76 ft. Ibs. (76-104 Nm). e Front wheel 5. \f equipped with air suspension, turn the air suspension service switch to the ON position. 6. Align the vehicle.

CONTROL ARM BUSHING REPLACEMENT

BALL JOINT REPLACER 7922RG32

Use a ball joint press to install the new ball joint into the lower contro! arm

19-23

ee

The control arm bushings are serviced with the control arm as an assembly.

REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. lf equipped with air suspension, the aif Suspension switch, located on the righthand side of the luggage compartment, must be turned to the OFF position before raising the vehicle. 3. Remove or disconnect the following: Front wheel Wheel speed sensor Brake caliper and rotor Sway bar link

Shock absorber Drag link Lower ball joint Coil spring Lower control arm pivot bolts Lower control arm To install: 4. Install or connect the following: Lower control arm. Tighten the pivot bolts to 110-148 ft. Ibs. (148-201 Nm). Coil spring Lower ball joint. Tighten the nut to 110-148 ft. Ibs. (148-201 Nm). Drag link. Tighten the nut to 35-46 ft. — Ibs. (47-63 Nm). e Shock absorber e Sway bar link e Brake caliper and rotor e Wheel speed sensor e Front wheel 5. If equipped with air suspension, turn the air suspension service switch to the ON position. 6. Align the vehicle.

CONTROL ARM BUSHING REPLACEMENT The control arm bushings are serviced with the control arm as an assembly.

Wheel Bearings — ADJUSTMENT

The front wheel bearings are of a hub unit design and are pre-greased, sealed and require no maintenance. The bearings are preset and cannot be adjusted.

For Tune-up, Capacities and Firing orders, see Section 1 of this manual

49-24 FORD moror co. CROWN VICTORIA ¢ TOWN CAR ¢ GRAND MARQUIS

REMOVAL & INSTALLATION

FRONT WHEEL SPINDLE

Front

WHEEL HUB FRONT DISC BRAKE ROTOR

1. Before servicing the vehicle, refer to the precautions in the beginning of this section.

2. lf equipped, turn the air suspension service switch to the OFF position before raising the vehicle. 3. Remove or disconnect the following Front wheel Grease cap from the hub Disc brake caliper. Suspend the caliper with a length of wire. Do not let it hang from the brake hose: Discard the disc brake caliper mounting bolts. Disc brake rotor. If the factory installed push on nuts are installed, remove them first. Wheel hub retainer nut and discard Hub and bearing assembly To install: 4. Install or connect the following: Hub and bearing assembly New wheel hub retainer nut and tighten to 189-254 ft. Ibs. (255-345 Nm) Disc brake rotor and push on nuts, if equipped

7922RG33

Front hub and bearing assembly

e New grease cap seal e Disc brake caliper using the 2 new disc brake caliper mounting bolts. Tighten the bolts to 125-170 ft. lbs. (170-230 Nm). e Wheel. Tighten the lug nuts to 85-104 ft. Ibs. (115-142 Nm).

5. If equipped with air suspension, turn the air Suspension switch to the ON position. 6. Pump the brake pedal several times to position the brake pads prior to moving the vehicle. 7. Check the front end alignment.

FORD MOTOR CO. DRIVE TRAIN.................. 20-14 ENGINE REPAIR ................ 20-2 FUEL SYSTEM ...............- 20-13 PRECAUTIONS =:csic.csee eens 20-2 STEERING AND SUSPENSION ba SCR 20-15

Removal & Installation

Fuel System Pressure

Fuel System Service

/NT 43010 ko aha ey eee ee oe aOnR 20-15

SEIN ATINO ee

20-15

PIDCAUNONS preaessaoe hae 20-15 PLCRU ALO brome: ures cay ett atuateo sees 20-2 Haskell ate hse memes coke bateocwas 20-3 Removal ..........-. eee 20-2 Camshaft and Valve Lifters ............ 20-7 Removal & Installation............ 20-7

sessed ehtate20-15 WORDING eet

Removal & Installation............ 20-15 cra cs fa eee 20-14 Crone 20-14 OETA Eee

GVTINC STCA ck tee eysesewe csoruns-e=napes 20-4 Removal & ne

Removal & poe!

Removal & en

Removal & Installation Lower Control Arm

Control Arm Bushing Removal & Meee

hay Ar 20-4

Engine ASSEMDIY wu::...s.-ee-escsereseee 20-3

Removal & Installation............. 20-3 Exhatist: ManiiOnds:Disconnecting the negative battery cable on some vehicles may interfere with the functions of the on board computer system. The computer may undergo a relearning process once the negative battery cable is reconnected.

Alternator REMOVAL SASS ce SS

. RE Sl Sl

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Negative battery cable e Air intake tube ¢ Accessory drive belt e Lower splash shield e Alternator mounting bolts

48 Nm (35 Ib-ft) |= !

Alternator torque sequence—3.9L engine

9306TG08

FORD MOTOR CO. THUNDERBIRD

eT

a

ASE

A

Alternator harness connectors Alternator

INSTALLATION 1. Install the alternator harness connectors, then install the alternator. Tighten the bolts in sequence as follows: a. Step 1: Tighten bolt No. 1 to 35 ft.

Ibs. (48 Nm)

b. Step 2: Tighten bolt No. 2 to 15 ft. lbs. (20 Nm) plus 90 degrees C. Step 3: Tighten bolt No. 3 to 35 ft. lbs. (48 Nm) 2. Install or connect the following: Lower splash shield Accessory drive belt Air intake tube Negative battery cable Ignition Timing ADJUSTMENT This vehicle is equipped with a Distributorless Ignition System (DIS). The ignition timing is not adjustable. It is controlled by the PCM.

Engine Assembly. REMOVAL & INSTALLATION i

1. Before servicing the vehicle, refer to ons in the beginning of this secprecauti the tion.

2. 3. 4. 5. 6.

Drain the cooling system. Relieve the fuel system pressure. Recover the A/C refrigerant. Drain the engine oil. Remove or disconnect the following: Negative battery cable Air cleaner inlet tube Upper radiator shield Upper radiator support brackets A/C pressure switch connector Power steering return line clip Power steering reservoir Vapor Management Valve (VMV) cover VMV vacuum hose and canister purge hose Main vacuum supply hose Cowl vent screens Cross vehicle support bar Degas bottle hose Accelerator cable Cruise control cable

TST

TD

SR

ES RE

SET

Ground strap Fresh air filter and housing Powertrain harness connectors at right strut tower Fresh air filter panel Main engine wiring harness connector Main transmission wiring harness connector Heater hoses at the water control valve. Note the locations for assembly. Hydraulic cooling fan reservoir Water control valve harness connector Front wheels

Inner splash shields Wheel speed sensor connectors and harness clips Brake calipers Lower stabilizer bar links Upper ball joints Lower strut mount bolts Left, right and center splash shields A/C suction and discharge lines Shift cable and bracket Power steering line frame rail clip Rack and pinion harness connectors Steering shaft bolt and coupling Starter motor harness connectors and ground cable Alternator harness connectors Lower transmission flange bolts Torque converter Inner air deflector Engine block heater, if equipped 7. Support the engine, transmission, front and center crossmembers and the cooling system with a powertrain lift and transmission support bracket. 8. Support the rear of the vehicle with safety stands. 9. Remove or disconnect the following: Transmission crossmember bolts Front crossmember bolts Center crossmember bolts Powertrain assembly A/C compressor manifold and tube assembly Power steering pump return hose Hydraulic cooling fan return hose Lower radiator hose Upper radiator hoses Knock Sensor (KS) connector Heater hose Transmission cooler lines and bracket Power steering pressure line and bracket

EET

SAESIE GEO PN LIE PGR

20-3

ETS SOOT SE S RTD

Hydraulic cooling fan pressure line and bracket 10. Attach a hoist to the engine. 11. Remove the motor mount nuts and lift the powertrain out of the subframe. 12. Remove or disconnect the following: Wiring harness retainers Upper transmission flange bolts Transmission from the engine To install: 13. Install or connect the following: Transmission to the engine. Tighten the upper flange bolts to 35 ft. Ibs. (48 Nm). Wiring harness retainers. Tighten the nuts to 89 inch Ibs. (10 Nm). Powertrain to the subframe. Tighten the mount nuts to 30 ft. Ibs. (40 Nim). Hydraulic cooling fan pressure line and bracket Power steering pressure line and bracket Transmission cooler lines and bracket Heater hose Knock sensor connector Upper radiator hoses Lower radiator hose Hydraulic cooling fan return hose Power steering pump return hose A/C compressor manifold and tube assembly. Tighten the bolt to 15 ft. lbs. (21 Nm). Powertrain assembly. Tighten the front and center crossmember bolts to 76 ft. Ibs. (103 Nm) and the transmission crossmember bolts to 30 ft. Ibs. (40 Nm). Engine block heater, if equipped Inner air deflector Torque converter. Tighten the nuts to 28 ft. bs. (38 Nm). Lower transmission flange bolts. Tighten the bolts to 35 ft. Ibs. (47 Nm). Alternator harness connectors Starter motor harness connectors and ground cable

Steering shaft bolt and coupling. Tighten the coupling pinch bolt to 96 ft. Ibs. (35 Nm) and the shaft bolt to 22 ft. Ibs. (30 Nm). Rack and pinion harness connectors Power steering line frame rail clip Shift cable and bracket

e@e

A/C suction and discharge lines Left, right and center splash shields

Chilton Labor Guide For complete service labor times, order Nichols’

20-4 Thunpensin Lower strut mount bolts. Tighten the bolts to 129 ft. Ibs. (175 Nm). Upper ball joints. Tighten the nuts to 66 ft. Ibs. (90 Nm). Lower stabilizer bar links. Tighten the nuts to 41 ft. Ibs. (65 Nm). Brake calipers Wheel speed sensor connectors and harness clips Inner splash shields Front wheels Water control valve harness connector Hydraulic cooling fan reservoir Heater hoses at the water control

e Water pump. Tighten the bolts to 71 inch Ibs. (8 Nm) plus 90 degrees. e Water pump pulley. Tighten the bolts to 89 inch Ibs. (10 Nm) plus 45 degrees. e Accessory drive belt 5. Fill the cooling system. 6. Start the engine and check for leaks.

Cylinder Head

REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the cooling system.

valve Main transmission wiring harness

connector Main engine wiring harness con-

14. 15. 16. 17.

nector Fresh air filter panel Powertrain harness connectors at right strut tower Fresh air filter and housing Ground strap Cruise control cable Accelerator cable Degas bottle hose Cross vehicle support bar. Tighten the bolts to 15 ft. Ibs. (20 Nm). Cowl vent screens Main vacuum supply hose VMV vacuum hose and canister purge hose VMV cover Power steering reservoir Power steering return line clip A/C pressure switch connector Upper radiator support brackets Upper radiator shield Air cleaner inlet tube Negative battery cable Fill the crankcase to the correct level. Fill the cooling system. Recharge the A/C system. Start the engine and check for leaks.

9306TG04

Right cylinder head torque sequence—3.9L engine

Water Pump REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the cooling system. 3. Remove or disconnect the following: e Accessory drive belt ¢ Water pump pulley e Water pump To install: 4. Install or connect the following:

Left cylinder head torque sequence—3.9L engine

RAT GHOFEBIRD é

Mias)y | (

os

20-5

3. Relieve the fuel system pressure. 4 Remove or disconnect the following: Negative battery cable Engine appearance cover Intake manifold Valve covers Accessory drive belts Front cover Timing chains Camshafts Water outlet pipe Cylinder head temperature sensor connector Exhaust front pipes Exhaust Gas Recirculation (EGR) tube Bolts and stud bolts at the rear of the cylinder heads Cylinder heads. Loosen the bolts in reverse of the tightening

Sequence. To install: 5. Install the cylinder heads. Tighten the

Gace

bolts in sequence as follows: a. Step 1: M10 bolts to 15 ft. Ibs. (20

10 Nm (89 Ib-in)

' c. Step 3: M10 bolts to 33 ft. Ibs. (45

Left valve cover torque sequence—3.9L Engine

N m) b. Step 2: M10 bolts to 26 ft. Ibs. (35 Nm

m)

d. Step 4: M10 bolts plus 90 degrees e. Step 5: M10 bolts plus 90 degrees

f. Step 6: M8 bolts to 15 ft. Ibs. (20 Nm) g. Step 7: M8 bolts plus 90 degrees 6. Install or connect the following: e Bolts and stud bolts at the rear of the cylinder heads. Tighten the bolts to 37 ft. Ibs. (50 Nm). EGR tube Exhaust front pipes Cylinder head temperature sensor connector Water outlet pipe

Camshafts Timing chains Front cover Accessory drive belts Valve covers Intake manifold Engine appearance cover Negative battery cable 7. Fill the cooling system. 8. Start the engine and check for

| Right valve cover torque sequence—3.9L Engine

leaks.

Please visit our web site at www.chiltonsonline.com

20-6 fhinoensino Rocker Arms/Shafts

REMOVAL & INSTALLATION The vehicles covered in this section are not equipped with rocker arms/shafts. The camshaft directly actuates the valves.

Intake Manifold

3. Relieve the fuel system pressure. 4. 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 manifold vacuum hoses Exhaust Gas Recirculation (EGR) valve

REMOVAL & INSTALLATION

Camshaft Position (CMP) sensor connector

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the cooling system.

Evaporative Emissions (EVAP) canister purge valve line Fuel pressure sensor connector and vacuum line

Fuel line Knock Sensor (KS) connector Cylinder head temperature sensor connector Sensor connector bracket Wiring harness and hose bracket Left bank fuel injector connectors Idle Air Control (IAC) valve connector

Throttle Position (TP) sensor connector Positive Crankcase Ventilation (PCV) tube Throttle body coolant hoses Right bank fuel injector connectors Delta Pressure Feedback Electronic (DPFE) system sensor Intake manifold. Loosen the bolts in reverse of the tightening sequence. To install: 5. Install or connect the following: Intake manifold. Tighten the bolts in sequence to 18 ft. Ibs. (25 Nm). DPFE system sensor Right bank fuel injector connectors Throttle body coolant hoses PCV tube TP sensor connector IAC valve connector Left bank fuel injector connectors Wiring harness and hose bracket Sensor connector bracket Cylinder head temperature sensor connector KS sensor connector Fuel line Fuel pressure sensor connector and vacuum line EVAP canister purge valve line

=e©

CMP sensor connector EGR valve Intake manifold vacuum hoses Cruise control cable Accelerator cable Cross vehicle support bar. Tighten the bolts to 15 ft. Ibs. (20 Nm). Cowl vent screen Air cleaner outlet tube ¢ Negative battery cable 6. Fill the cooling system. 7. Start the engine and check for leaks.

Exhaust Manifolds

25 Nm (18 Ib-fi)

REMOVAL & INSTALLATION eee

9306TG06

Intake manifold torque sequence—3.9L engine

—

1. Before servicing the vehicle, refer to the precautions inthe beginning of this section.

eae UBDEREIAG 2. Remove or disconnect the following: e Negative battery cable e Power steering pump reservoir e (il dipstick tube e Exhaust front pipes e Exhaust Gas Recirculation (EGR) tube e Exhaust manifolds To install: 3. Install or connect the following: e Exhaust manifolds. Tighten the bolts to 18 ft. Ibs. (25 Nm). e EGR tube e Exhaust front pipes

e Oil dipstick tube e Power steering pump reservoir e Negative battery cable 4. Start the engine and check for leaks.

Negative battery cable Valve covers Front cover Timing chains

«>Keep all valve train components in order for assembly.

Camshaft and Valve Lifters REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this sec.

e e e e

20-7

2. Remove or disconnect the follow-

e Camshaft journal bearing caps e Camshafts e Valve tappets and shims To install: 3. Install or connect the following: e Valve tappets and shims

e Camshafts 4. |nstall the camshaft journal bearing caps in their original positions. Tighten the bolts in sequence as follows: a. Step 1: Finger tight b. Step 2: 53 inch Ibs. (6 Nm) c. Step 3: Plus 90 degrees 5. Install or connect the following: e Timing chains e Front cover e Valve covers e Negative battery cable 6. Start the engine and check for leaks. Valve Lash

ADJUSTMENT EEE EEEEEEE EEIESEEEEEEEEE

93067612

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: ¢ Negative battery cable e Engine appearance Covers e |gnition coils e Valve covers 3. Measure the valve clearance while the camshaft lobe is pointed away from the valve shim. Rotate the crankshaft as necessary for each valve to be measured. 4. Valve clearance should be 0.007—0.009 in. (0.18-0.23mm) for intake valves or 0.009-0.011 in. (0.23-0.28mm) for exhaust valves. 5. lf adjustment is necessary, compress the valves with the special tools and remove the shim with compressed air. Repeat for each valve to be adjusted. 6. Install or connect the following: e Valve covers e Ignition coils

nce—3.9L engine Camshaft journal bearing cap torque seque

Timing belt service is covered in Section 3 of this manual

20-8 Tiunoensino e Engine appearance covers e Negative battery cable Starter Motor

REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Negative battery cable ¢ Starter motor wiring connectors ¢ Starter motor To install: 3. Install or connect the following:

9301JG15

9301JG16

Remove the shims with compressed air—3.9L engine

9301JG17

FORD MOTOR CO. THUNDERBIRD

e Starter motor. Tighten the bolts to 18 ft. Ibs. (25 Nm). e Starter motor wiring connectors e Negative battery cable

REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the engine oil. 3. Remove the oil pan. To install: 4. Install the oil pan. Tighten the bolts in sequence as follows: a. Step 1: 44 inch Ibs. (5 Nm) b. Step 2: 108 inch Ibs. (12 Nm) 5. Fill the crankcase to the correct level. 6. Start the engine and check for leaks.

REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Crankshaft pulley Front cover Primary timing chains Oil pump mounting bolts Oil pump

To install: 3. Install or connect the following: e New gasket e Qil pump. Tighten the bolts to 53 inch lbs. (6 Nm) plus 90 degrees. e Primary timing chains e Front cover e Crankshaft pulley

Rear Main Seal

REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions at the beginning of this section. 2. Attach an engine support fixture to the engine lifting eyes. 3. Remove or disconnect the following: e Negative battery cable e Transmission e Flywheel e Rear crankshaft seal To install: 4. Install or connect the following: e Rear main seal flush with the cylinder block surface e Flywheel 5. Tighten the flywheel bolts in a crossing pattern as follows: a. Step 1: 11 ft. Ibs. (15 Nm) b. Step 2: 81 ft. Ibs. (110 Nm) 6. Install or connect the following: e Transmission ¢ Negative battery cable 7. Start the engine and check for leaks.

93067615

Oil pan torque sequence—3.9L engine

20-9

Timing Chain, Sprockets, Front Cover and Seal REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the cooling system. 3. Remove or disconnect the following: Negative battery cable Engine appearance cover and brackets Valve covers Engine cooling fan assembly Accessory drive belt Water pump pulley Alternator Lower radiator hose and pipe Heater hose Idler pulleys Crankshaft pulley Front crankshaft seal Power steering reservoir hose Power steering pump and bracket Hydraulic cooling fan reservoir hose and bracket Hydraulic cooling fan pump and bracket Front cover wiring harness clips Front cover. Loosen the bolts in sequence. Torque converter access panel Crankshaft Position (CKP) sensor 4. Rotate the crankshaft to 45 degrees After Top Dead Center (ATDC). The crankshaft keyway will be in the 6 o'clock position. Check that the camshaft lobes are facing upwards. If not, rotate the crankshaft 1 full turn. 5. Install Crankshaft Holding Tool 303645 in place of the CKP sensor. 6. Install Camshaft Locking Tool 303530 to the right bank camshafts. 7. Loosen the exhaust and intake camshaft sprocket bolts and slide the sprockets forward on the bolts. 8. Remove or disconnect the following: e Right bank primary timing chain tensioner and blanking plate e Tensioner arm e Timing chain guide e Right bank timing chain and crankshaft timing sprocket 9. Remove the locking tool from the right bank camshafts and install it on the left bank camshafts. 40. Remove or disconnect the following:

l Heater Core replacement is covered in Section 2 of this manua

20-10 fiiNoensino N\

[308-645

9306TG17

Crankshaft Holding Tool—3.9L engine

(@

a 9306TG19

Timing chain tensioner preparation—3.9L engine

¢ Left bank primary timing chain tensioner and blanking plate e Tensioner arm Timing chain guide Left bank timing chain and crankshaft timing sprocket e¢ Intake and exhaust camshaft sprocket bolts e Intake and exhaust camshaft sprockets and secondary timing chain assemblies Secondary timing chain tensioners 9306TG16

To

install:

11. Prepare the primary and secondary timing chain tensioners for installation as follows: a. Step 1: Use a thin wire to unseat the check valve b. Step 2: Compress the tensioner piston fully into the bore by hand C. Step 3: Remove the wire 12. Install or connect the following: ¢ Secondary timing chain tensioners, Tighten the bolts to 97 inch Ibs.

(11 Nm). Intake and exhaust camshaft

sprockets and secondary timing chain assemblies Left bank timing chain and crankshaft timing sprocket Timing chain guide. Tighten the

93067618 Camshaft Locking Tool—3.9L engine

bolts to 97 inch Ibs. (11 Nm). Tensioner arm. Tighten the bolts to 97 inch Ibs. (11 Nm). Left bank primary timing chain tensioner and blanking plate. Tighten the bolts to 97 inch Ibs. (11 Nm)

SULA HISHOEGBIAD 20-1 1 13. Install a tie strap to take up the slack in the timing chain. 14. Use Timing Chain Tensioning Tool 303-532 to apply tension to the left bank exhaust camshaft. e>Tighten the exhaust camshaft bolt first.

Use a tie strap to remove slack from the primary timing chain—3.9L engine

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Crankshaft sprocket alignment—3.9L engine

15. Tighten the left bank camshaft sprocket bolts as follows: a. Step 1: 15 ft. Ibs. (20 Nm) b. Step 2: Plus 90 degrees 16. Remove the locking tool from the left bank camshafts and install it on the right bank camshafts. 17. Install or connect the following: e Right bank timing chain and crankshaft timing sprocket. Ensure that the crankshaft sprocket is installed as shown. Timing chain guide. Tighten the bolts to 97 inch Ibs. (11 Nm). Tensioner arm. Tighten the bolts to 97 inch Ibs. (11 Nm). Right bank primary timing chain tensioner and blanking plate. Tighten the bolts to 97 inch Ibs. (11 Nm). 18. Install a tie strap to take up the slack in the timing chain. 19. Use Timing Chain Tensioning Tool 303-532 to apply tension to the right bank exhaust camshaft. e>Tighten the exhaust camshaft bolt first.

20. Tighten the right bank camshaft sprocket bolts as follows: a. Step 1: 15 ft. Ibs. (20 Nm) b. Step 2: Plus 90 degrees 21. Remove the camshaft locking tool. 22. Apply silicone sealant to the areas indicated and install the front cover. 23. Tighten the front cover bolts in sequence as follows: a. Step 1: 44 inch Ibs. (5 Nm) b. Step 2: 89 inch Ibs. (10 Nm) 24. Remove the crankshaft locking tool. 25. Install or connect the following: CKP sensor Torque converter access panel Front cover wiring harness clips @e« ee Hydraulic cooling fan pump and bracket. Tighten the bolts to 18 ft. lbs. (25 Nm). Hydraulic cooling fan reservoir hose and bracket ¢ Power steering pump and bracket.

Brake service is covered in Section 4 of this manual

20-1

PUUNREORIEDS Be Tighten the bolts to 18 ft. Ibs. (25 Nm). e Power steering reservoir hose e Front crankshaft seal 26. Install the crankshaft pulley and tighten the bolt as follows: a. Step 1: 59 ft. Ibs. (80 Nm) b. Step 2: Loosen the bolt 2 complete

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Heater hose Lower radiator hose and pipe Alternator Water pump pulley. Tighten the bolts to 89 inch Ibs. (10 Nm) plus 45 degrees. Accessory drive belt Engine cooling fan assembly Valve covers Engine appearance cover and

Noval

e Negative battery cable 28. Fi i SEAE

93061G24

Front cover torque sequence—3.9L engine

StepEp 3:o. 37 ft.: Ibs. (50 Nm)

d. Step 4: Plus 90 degrees 27. Installorconnect the following: e Idler pulleys. Tighten the bolts to 18 ft. Ibs. (25 Nm).

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FUEL SYSTEM

| Fuel System Service Precautions Safety is the most important factor when performing not only fuel system maintenance but also any type of maintenance. Failure to conduct maintenance and repairs in a Safe manner may result in serious personal injury or death. Maintenance and testing of the vehicle's fuel system components can be accomplished safely and effectively by adhering to the following rules and guidelines. e To avoid the possibility of fire and personal injury, always disconnect the negative battery cable unless the repair or test procedure requires that battery voltage be applied. e Always relieve the fuel system pressure prior to disconnecting any fuel system component (injector, fuel rail, pressure regulator, etc.), fitting or fuel line connection. Exercise extreme caution whenever relieving fuel system pressure, to avoid exposing skin, face and eyes to fuel spray. Please be advised that fuel under pressure may penetrate the skin or any part of the body that it contacts. e Always place a shop towel or cloth around the fitting or connection prior to loosening to absorb any excess fuel due to spillage. Ensure that all fuel spillage (should it occur) is quickly removed from engine surfaces. Ensure that all fuel soaked cloths or towels are deposited into a suitable waste container. e Always keep a dry chemical (Class B) fire extinguisher near the work area. e Do not allow fuel spray or fuel vapors to come into contact with a spark or open flame. e Always use a back-up wrench when loosening and tightening fuel line connection fittings. This will prevent unnecessary stress and torsion to fuel line piping. e Always replace worn fuel fitting Orings with new. Do not substitute fuel hose or equivalent 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. Disconnect the negative battery | 3. Connect the fuel injection pressure test equipment JD 209 to the valve on the fuel supply manifold. 4. Insert the drain/bleed tube into the fuel container. 5. Follow the manufacturer's instructions and depressurize the fuel system.

Fuel Filter

REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Relieve the fuel system pressure. 3. Remove or disconnect the following: e Negative battery cable e Fuel filter bracket cover e Fuel lines e Fuel filter To install: 4. Install or connect the following: ¢ Fuel filter into the bracket making sure the flow direction is correct. Tighten the clamp to 15-25 inch Ibs. (2-3 Nm). ¢ Fuel lines. Tighten the fittings to 22 ft. Ibs. (30 Nm). 5. Start the engine and check for leaks.

Fuel Pump

es

REMOVAL & INSTALLATION 1. 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 following: Negative battery cable Trunk liner Trunk seal retainer Rear lamp assembly interior trim finisher Left and right side liners Fuel feed and return lines Fuel filler and vent hoses Fuel tank wiring connectors

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AENGENBIAD 20-1 3 SPORT Tp IRC

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:

e Fuel filler cap e Fuel tank retaining straps e Fuel tank e Fuel pump module To install: 5. Install or connect the following: Fuel pump module Fuel tank Fuel tank retaining straps Fuel filler cap Fuel tank wiring connectors Fuel filler and vent hoses Fuel feed and return lines Left and right side liners Rear lamp assembly interior trim finisher Trunk seal retainer Trunk liner e Negative battery cable 6. Fill the fuel tank with at least 10 gallons (38L) offuel. 7. Start the engine and check for leaks.

Fuel Injector

REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Relieve fuel system pressure. 3. Remove or disconnect the following: Negative battery cable ngine appearance covers uel lines uel pressure regulator uel cross over elbow uel injector connectors uel injector clamping plates uel injectors Acad ala mech) aes lil oe sald Sse To install: 4. |nstall or connect the following: e Fuel injectors. Use new O-ring Seals. Fuel injector clamping plates Fuel injector connectors Fuel cross over elbow Fuel pressure regulator Fuel lines Engine appearance covers Te @.-6Negative battery cable e 5. Start the engine and check for leaks.

manual For complete Engine Mechanical specifications, see Section 1 of this

20-1

FORD MOTOR CO. THUNDERBIRD

DRIVE TRAIN Transmission Assembly REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Install a support fixture to the engine lifting eyes. 3. Drain the transmission fluid. 4. Remove or disconnect the following:

Negative battery cable Engine appearance covers Mass Air Flow (MAF) meter Air intake assembly Coolant recovery tank Exhaust front pipes Driveshaft Shift selector cable Transmission electrical connectors Transmission oil cooler lines Torque converter Transmission mount and bracket Transmission flange bolts Transmission To install: 9. Install or connect the following: Transmission to the engine. Tighten the flange bolts to 32-42 ft. Ibs. (43-57 Nm). Transmission mount and bracket. Tighten the mount bolts to 22-30 ft. Ibs. (30-40 Nm) and the bracket bolts to 16-21 ft. Ibs. (22-28 Nm). Torque converter. Tighten the bolts to 32-42 ft. Ibs. (43-57 Nm). Transmission oil cooler lines Transmission electrical connectors Shift selector cable Driveshaft. Tighten the bolts to 99-65 ft. Ibs. (75-88 Nm). Exhaust front pipes Coolant recovery tank Air intake assembly MAF meter Engine appearance covers Negative battery cable

9301JG25

Driveshaft flange bolts

6. Fill the transmission to the correct level with the proper fluid. Do not over-fill. 7. Start the engine and check for leaks.

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 e Rear wheel ¢ Brake caliper e Wheel speed sensor ¢ Hub carrier pivot bolt ¢ Hub retaining nut 3. Press the stub shaft out of the hub and pry the inner joint out of the differential, To install: 4. Install or connect the following: ¢ Halfshaft inner joint to the differential e Halfshaft in the wheel hub by

applying Loctite® 270 thread locking compound to the splines Hub carrier pivot bolt by aligning the bolt head matchmarks. Tighten it to 66-81 ft. Ibs. (90-110 Nm). Hub retaining nut. Tighten the new nut to 221 ft. Ibs. (300 Nm). Wheel speed sensor Brake caliper Rear wheel Negative battery cable 5. Check the wheel alignment and adjust as necessary, e*lf the hub is removed for any reason, a new bearing assembly must be installed. Never attempt to re-use a bearing.

OVERHAUL The CV-joints are serviced with the axle halfshaft as an assembly,

GENERAL MOTORS CORPORATION—C & H-BODIES 1998-01 Buick-Le Sabre * Park Ave. * Oldsmobile-Eighty Eight LSS * Regency * Pontiac-Bonneville DRIVETRAIN

orn

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FUCHIN GClOKSe

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ENGINE REPAIR ................ 21-2 FUELSSYSTEM ....0...22.02. 21-13

Removal & Installation............ 21-15 UC HPUIT ee eerern acelin 21-14

STEERING AND

Fuel System PreSSUre .........sssese 24214

PRECAUTIONS 40st

ees 21-2

..202: seven 21-20 SUSPENSION’ Note the direction the strainer is pointing and remove the strainer from the pump by pulling it down and twisting.

7922UG34

Fuel pump and level sender assembly

C & H-BODIES-GENER

LE SABRE ¢ PARK AVE. ¢ EIGHTY BTS

ONE EMEHEDOMABHII

21 “1 4

Torque the hose clamp to 25 inch lbs. (2.8 Nm). e Fuel tank filler pipe to the tank. Torque the hose clamp to 25 inch lbs. (2.8 Nm). e Negative battery cable 8. Refill the fuel tank. 9. Run the engine and check for leaks and proper engine operation. Park Avenue And All 2000-01 Models

1. Before servicing the vehicle, refer to precautions in the beginning of this secion. 2. Relieve the fuel system pressure. 3. Drain the fuel tank. 4, Remove or disconnect the following: Negative battery cable Spare tire and jack Trunk lining Fuel sender access panel Sender and quick connect fittings from the sender e Electrical connector from the sender and position harness and hoses aside

One transaxle bolt is located between the transaxle case and the engine block and is installed in the Opposite direction.

To install: 12. Install or connect the following: e Transaxle, support it with a jack ¢ Lower transaxle-to-engine bolts. Torque the bolts to 55 ft. Ibs. (76 Nm).

Oil cooler lines at the transaxle Frame assembly. Torque the frameto-body bolts to 83 ft. Ibs. (112 Nm). Front frame mount-to-right frame member and the left frame-to-body bolts. Torque the bolts to 83 ft. Ibs. (112 Nm). Torque converter bolts, by aligning the matchmarks. Torque the bolts to 46 ft. Ibs. (62 Nm). Oil cooler lines to the transaxle Torque converter cover

Stabilizer shaft link-to-control arm bolt. Torque the bolt to 13 ft. Ibs. (17 Nm). Transaxle brace to the engine bracket. Torque the bolts to 70 ft. lbs. (95 Nm). Left rear transaxle mount-totransaxle bolts Torque strut bracket to the transaxle Left front transaxle mount Halfshafts Lower ball joints Front wheels 13. Turn the steering wheel to the straight-ahead position. 14. Remove the support fixture from the engine. 15. Install or connect the following: ¢ 3 top transaxle-to-engine bolts. Torque the bolts to 55 ft. Ibs. (76 Nm). Vacuum modulator hose to the modulator Fuel pipe retainers Transaxle park/neutral position Switch Back-up light switch

C & H-BODIES-GENERAL MO LE SABRE e PARK AVE. ¢ EIGHTY EIGHT e LSS ES

Transaxle electrical connector Vehicle Speed Sensor (VSS) Shift control linkage and mounting bracket at the transaxle Cruise control cable at throttle body Air intake duct Inboard strut nuts Crossbrace assembly, with through-bolts and the inboard strut nuts. Torque the fasteners to 18 ft. Ibs. (24 Nm). e Negative battery cable 16. Check the transaxle fluid level. 17. Start the engine and check for leaks. 18. Road test the vehicle. Park Avenue And All 2000-01 Models

1., Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Negative battery cable Air cleaner cover Transaxle electrical connector Shift control cable bracket with cable attached Top transaxle case bolts Top bolt from rear transaxle mount Left side steering rack mount bolts Oxygen (02S) sensor connector Install an engine support fixture. (Se)_ Both front tires Both splash shields Power steering line bracket Both transaxle mounts Right steering rack mount bolts Transaxle cooler lines Sway bar mounts Lower ball joints Front subframe bolts and lower subframe Both drive axles Torque converter cover Flexplate bolts Input Speed (ISS) sensor connector Engine to transaxle bracket Transaxle fluid filler tube Rear engine mount @ eeeee#eeee—e¢ @© eo @©eeeeee#ee @® Remaining transaxle to engine bolts Transaxle from vehicle To install 4. Install or connect the following: e Transaxle to vehicle e Transaxle to engine bolts. Torque the bolts to 55 ft. Ibs. (75 Nm). e Rear engine mount e Transaxle fluid filler tube. Torque

e ¢ e

e

the filler tube bolt to 15 ft. Ibs. (20 Nm). Engine to transaxle bracket. Torque the bolts to 44 ft. Ibs. (60 Nm). ISS electrical connectors Flexplate bolts. Torque the bolts to A6 ft. Ibs. (62 Nm). Torque converter cover

e>Use care when installing the right side drive axle into the transaxle case. The splined shaft of the axle can easily damage the seal.

Left and right drive axles to transaxle Engine frame bolts. Torque the bolts to 83 ft. Ibs. (112 Nm), Lower ball joints to steering knuckles. Torque the nuts to 88 in. Ibs. (10 Nm). Sway bar mounts to the lower control arms Transaxle cooler lines to the frame Right steering rack mount bolts to engine frame. Torque the bolts to 45 ft. Ibs. (65 Nm). Right and left transaxle mount to frame Power steering line bracket to frame Right and left splash shields Both front tires. Torque the wheel nuts to 100 ft. Ibs. (140 Nm). O2S sensor electrical connector Left side steering rack mount bolts. Torque the bolts to 48 ft. Ibs. (65 Nim). Top bolt of the rear transaxle mount. Torque the bolt to 42 ft. Ibs. (58 Nm). Shift contro! cable and bracket Transaxle electrical connector on C @)° e Air cleaner cover Negative battery cable 5. Check and adjust transaxle fluid level. 6. Road test vehicle and check for transaxle leaks.

pO

21 -1 T

extension of the joint could result in separation of internal components and possible joint failure. 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Install a boot protector on the outer C\V-joint boot. 3. Remove or disconnect the following: e Front wheel 4. Loosen the stabilizer shaft link assembly bolt (to accommodate ball joint separation). 5. Remove the ball joint cotter pin and nut. Loosen the joint. >The grease fitting may have to be removed from the ball joint for tool access.

6. Separate the lower control arm from the joint. 7. Remove or disconnect the following: e Hub nut e Halfshaft from the hub 8. Move the strut and knuckle rearward. 9 Remove the halfshaft from the transaxle. -

Slide ‘Hammer 7922UG15

Use a slide hammer with the special adapter J-3308, to remove the halfshaft from the transaxle—1998-99 models

Transaxle

REMOVAL & INSTALLATION 1998-99 Models

ok WARNING Use care when removing the halfshaft to prevent the inner CV-joint from becoming over-extended. Over-

Protector 7922UG14

Insert the seal protector in the transaxle to prevent seal damage while the halfshaft is being installed—1998-99 models

manual For Tire, Wheel and Ball Joint specifications, see Section 1 of this

21 -1 § Hetil uae

RPORATION-C & H-BODIES

ORLY EIGHT ¢ LSS ¢ REGENCY ¢ BONNEVILLE ->Tighten the nut up to one more flat in order to align the slot with the hole in the stud.

+k WARNING If equipped with anti-lock brakes, care must be used to prevent damage to the toothed sensor ring on the halfshaft and the wheel speed sensor on the steering knuckle. To install:

elf installing the right halfshaft, install a seal protector, so that it can be pulled out after the halfshaft is

installed. 10. Install the halfshaft into the transaxle by placing a drift pin or punch into the groove on the joint housing and tapping lightly until seated. Verify that the halfshaft is seated by grasping the inner joint housing and pulling. DO NOT pull on the halfshaft. 11. Install or connect the following: e Halfshaft into the hub/bearing assembly with new hub nut and tighten to 107 ft. Ibs. (145 Nm) e Ball joint into the steering knuckle. Torque the nut to 88 inch Ibs. (10 Nm), plus an additional 120 degree turn during which a torque of 41 ft. lbs. (65 Nm) must be obtained. Tighten the nut up to one more flat in order to align the slot with the hole in the stud.

12. Install or connect the following: ¢ Stabilizer shaft link assembly. Torque the nut to 14 ft. Ibs. (17 Nm). ¢ Front wheel 13. Ifa seal protector was installed, remove it by pulling in line with the handle. 14. Road test for proper operation.

2000-01 Models

Use care when removing the halfshaft to prevent the inner CV-joint from becoming over-extended. Overextension of the joint could result in separation of internal components

and possible joint failure. 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Install a boot protector on the outer CV-joint boot. 3, Remove or disconnect the following: ¢ Front wheel 4. Loosen the stabilizer shaft link assembly bolt (fo accommodate ball joint separation).

9346UG07

12. Install or connect the following: e Stabilizer shaft link assembly. Torque the nut to 14 ft. Ibs. (17 Nm). e Front wheel 13. Ifa seal protector was installed, remove it by pulling in line with the handle. 14. Road test for proper operation.

Remove the halfshaft from the transaxle using tool J 42128 Axle Shaft Remover and tool J 2619-01 Slide Hammer

OVERHAUL 5. Remove the ball joint cotter pin and nut. Loosen the joint. >The grease fitting may have to be removed from the ball joint for tool

access.

6. Separate the lower control arm from the joint. 7. Remove or disconnect the following: e Hub nut e Halfshaft from the hub using tool J 28733 8. Move the strut and knuckle rearward. 9. Remove the halfshaft from the transaxle using tool J 42128 Axle Shaft Remover and tool J 2619-01 Slide Hammer.

>: WARNING If equipped with anti-lock brakes, care must be used to prevent damage to the toothed sensor ring on the halfshaft and the wheel speed sensor on the steering knuckle. To install:

elif installing the right halfshaft, install a seal protector, so that it can be pulled out after the halfshaft is installed.

10. Install the halfshaft into the transaxle by placing a drift pin or punch into the groove on the joint housing and tapping lightly until seated. Verify that the halfshaft is seated by grasping the inner joint housing and pulling. DO NOT pull on the halfshaft. 11. Install or connect the following:

e Halfshaft into the hub/bearing assembly with new hub nut and tighten to 118 ft. Ibs. (160 Nm) e Ball joint into the steering knuckle. Torque the nut to 88 inch Ibs. (10 Nm), plus an additional 120 degree turn during which a torque of 41 ft. lbs. (65 Nm) must be obtained.

Inner (Tripod) Joint 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Raise and safely support the vehicle. 3. Remove or disconnect the following: Front wheel Halfshaft and place it in a vise Small CV-joint boot clamp, cut and discard it Large CV-joint boot clamp, cut and discard it CV-joint boot by sliding it away from the tripod joint Tripod housing from the tripod spider Inboard spacer ring and slide it rearward on the shaft Outboard retaining ring Tripod joint spider assembly Inboard spacer ring and discard it Tripod joint spider assembly by tapping it from the halfshaft with a brass drift Tripod spider retaining ring and discard it Trilobal tripod bushing from the housing e CV-joint boot 4. Thoroughly clean and inspect all parts. To install: 9. Install or connect the following: ¢ Small boot clamp ¢ C\-joint boot ¢ New inboard spacer ring. Slide it rearward on the shaft past the 2nd groove e Tripod joint spider assembly onto the shaft until it passes the 2nd groove 6. Assemble the tripod spider assembly onto the halfshaft as follows: a. Position the tripod spider assembly onto the shop press plate.

C & H-BODIES-GENERAL MOTORS CORPORATION

LE SABRE ¢ PARK AVE. ¢ EIGHTY EIGHT © LSS ¢ REGENCY ¢ BONNEVILLE

21 -1 g

9306XG19

Disconnecting the outer CV-joint from the axle shaft

9306XG20 1- RING, RETAINING

13 - SHAFT. AXLE (RH SHOWN, LH SIMILAR)

2- HOUSING ASM, RETAINER & 3- RING. SHAFT RETAINING

14- SEAL DRIVE AXLE OUTBOARD

Tilting the cage—Outer CV-joint

4- SPIDER, TRIPOT JOINT

CLAMP. SEAL RETAINING 7 - BUSHING. TRILOBAL TRIPOT 11- SEAL, ORIVE AXLE INBOARD

20 - RACE, CV JOINT OUTER

12- RING. SWAGE

9306UG06

Exploded view of the halfshaft assembly

b. Position the halfshaft onto the tripod spider assembly, in the shop press. c. Press the halfshaft into the tripod spider assembly until the spider assembly passes the 2nd groove.

sek WARNING

e Tripod housing, slide it over the tripod joint spider assembly e CV-joint boot/clamp, slide it into place, over the trilobal tripod bushing with the seal lip in the groove Make sure the boot lies flat against the trilobal bushing.

-

When assembling the tripod assembly onto the halfshaft, do not exceed 4,000 Ibs. pressure. 7. Remove the halfshaft from the shop press and place it in vise. 8. Install or connect the following: ¢ New outboard retaining ring into the axle shaft groove ¢ Tripod joint spider assembly, slide it against the outboard retaining ring using a brass drift ¢ |nboard spacer ring, seat it in the

groove

9. Use 1% of the grease supplied in the kit into the boot and the other Yzinto the tripod housing.

¢ Trilobal tripoa bushing flush with the tripod housing face + New large seal clamp onto the CVjoint boot

10. Using the crimp tool, a torque wrench and a breaker bar, crimp the small CV-joint boot clamp to 100 ft. Ibs. (136 Nm). 11. Using the crimp tool, latch the large CV-joint boot clamp. 12. Install the halfshaft and the front wheel. Outer CV-Joint

1. Before servicing the vehicle, refer to s in the beginning of this secprecaution the tion. 2 Remove or disconnect the following: Front wheel Halfshaft

Swage ring using a hand grinder Large boot clamp C\-joint boot, slide it away trom

the C\V-joint

9306XG21

View the cage and inner race—Outer CV-

joint

inner race-to-axle shaft retaining ring ears using Snapring Pliers e CV-joint boot from the axle shaft 3. Disassemble the chrome alloy balls from the CV-joint cage as follows: a. Position a brass drift against the CV-joint cage and tap it with a hammer to tilt the cage. b. Chrome alloy ball from the cage. c. Tilt the cage in the opposite direction. d. Remove the opposite chrome alloy ball.

e. Repeat the procedure until all 6 balls are removed. 4. Disassemble the CV-joint cage and

inner race as follows:

CV-joint assembly by spreading the

l For Wheel Alignment specifications, see Section 1 of this manua

21-2

RS CORPORATION-C & H-BODIES trSABRE»PARK AVE «EIGHTY EIGHT * LSS ¢ REGENCY ¢ BONNEVILLE 7. Assemble the CV-joint cage and inner race, as follows: a. Rotate the inner race 90 degrees to

Position edge of seal here 9306x622

Positioning the boot—Outer CV-joint

a. Pivot the cage and race 90 degrees to the center line of the outer race. b. Align the cage windows with outer race lands. c. Remove the cage from the outer race. d. Rotate the inner race upward and remove it from the cage. 5. Thoroughly clean and inspect all parts.

To install: 6. Lubricate the parts with a light coat of grease.

the cage centerline. b. Align the cage windows with inner race lands. c. Insert the inner race into the cage by rotating the inner race downward. d. Insert the cage/inner race into the outer race. 8. Assemble the chrome alloy balls into the C\V-joint cage, as follows: a. Position a brass drift against the CV-joint cage and tap it with a hammer to tilt the cage. b. Insert the 1st chrome alloy ball into the cage. c. Tilt the cage in the opposite direction. d. Insert the opposite chrome alloy

ball. e. Repeat the procedure until all 6 balls are inserted. 9. Install or connect the following: ¢ Swage ring clamp e CV-joint boot e CV\-joint onto the axle shaft until

the retaining ring seats into the groove 10. Position the C\-joint boot seal into the axle shaft’s joint seal groove and align the swage ring clamp on the boot. 11. Secure the swage ring clamp using appropriate crimping tool.

Make sure that there are no pinch points on the inboard seal. 12. Install or connect the following: e Yakit grease into the CV-joint boot e Ykit grease into the CV-joint e New large seal clamp onto the C\Vjoint boot e CV-joint boot/clamp, slide it into place, over the outer race with the seal lip in the groove e»Make sure the boot lies flat against the outer race.

13. Using a Crimp tool, a torque wrench and a breaker bar, crimp the large CV-joint boot clamp to 130 ft. Ibs. (176 Nm). 14. Install the halfshaft and the front wheel.

STEERING AND SUSPENSION

ek CAUTION Some vehicles are equipped with an air bag system. The system must be disabled before performing service on or around system components, the steering column, instrument panel components, wiring and sensors. Failure to follow safety precautions and the disarming procedures could result in accidental air bag deployment, possible personal injury and unnecessary system repairs. SSS

PRECAUTIONS a

Several precautions must be observed when handling the inflator module to avoid accidental deployment and possible personal injury. ¢ Never carry the inflator module by the wires or connector on the underside of the module. e When carrying a live inflator module, hold it securely with both hands, and ensure that the bag and trim cover are pointed away. e Place the inflator module on a bench

or other surface with the bag and trim cover facing up. e With the inflator module on the bench, never place anything on or close to the module which may be thrown in the event of an accidental deployment.

DISARMING

-k-¢ CAUTION The Supplemental Inflatable Restraint system (SIR) must be disarmed before performing service around the air bag or SIR wiring. Failure to do so may cause accidental deployment of the air bag, resulting in unnecessary SIR repairs and/or personal injury.

1. Turn the steering wheel so the front wheels are in the straight-ahead position. 2. Turn the ignition switch to the LOCK position. 3. Remove or disconnect the following: e Negative battery cable ¢ Air bag fuse from the fuse panel e»The position of the fuse on the panel varies according to model and year. Consult the vehicle owner’s manual for fuse location.

e Left-hand sound insulator trim panel under the instrument panel ¢ Connector retainer clip and the yellow 2-way connector at the base of the steering column ¢ Connector retainer and detach the passenger side yellow 2-way connector. Located behind the right side sound insulator.

ARMING rr

After the necessary repairs have been made, re-enable the air bag system as follows: 1. Turn the steering wheel so the front wheels are in the straight-ahead position. 2. Turn the ignition switch to the LOCK position. 3. Disconnect the negative battery cable. 4. Install or connect the following:

Yellow 2-way connector at the base ~

of the steering column and the connector retainer Left-hand sound insulator Yellow 2-way connector on the right side and the connector retainer Sound insulator and/or glove box Air bag fuse Negative battery cable

C & H-BODIES-GENERAL MOT

LE SABRE ¢ PARK AVE. e EIGHTY EIGHT

es OETA

COHNEHILEE 21 -21

5. Turn the ignition switch to the RUN position. Verify that the INFLATABLE RESTRAINT indicator lamp flashes 7-9 times, then remains OFF. If the lamp does not function as specified, there is a malfunction in the air bag system.

Power Rack and Pinion Steering Gear REMOVAL & INSTALLATION 1998-99 Park Avenue

ck WARNING

1 2 3 4

CONNECTOR, SIR BRACKET, MULTIUSE MODULE CONNECTOR POSITION ASSURANCE CONNECTOR, STEERING COLUMN WIRING HARNESS

The wheels of the vehicle must be straight-ahead and the steering column in the LOCK position before disconnecting the steering column or intermediate shaft from the steering gear. Failure to do so will cause the Supplemental Inflatable Restraint (SIR) coil assembly in the steering column to become off-center, which will cause damage to the coil assembly.

(CPA)

7922UG35

1. Before servicing the vehicle, refer to the precautions at the beginning of this section. 9. Disconnect negative battery cable. 3. Remove or disconnect the following: Both front tires Exhaust system Wheel house splash shield Intermediate shaft lower connection Tie rod ends from steering knuckles Power steering heat shield Electrical connector .° ee @FLe 60> 08, @' Power steering gear outlet and inlet hoses from steering gear Steering gear mounting bolts 4. Support the rear the of frame. 5. Remove the rear frame bolts, and lower the rear the of frame to allow steering gear removal. 6. Remove the steering gear through the right wheel opening. To install 7. Install or connect the following: + Steering gear through right wheel opening 8. Raise the rear the of frame and torque the frame bolts to 142 ft. Ibs. (192

Drivers side air bag connector

1 MODULE, INFLATOR 2

BRACKET,

MULTIUSE

3 CONNECTOR, SIR Passenger’s side air bag connector

—

7922UG36

Nm). 9. Install three steering gear mounting bolts. Tighten bolts in the sequence shown to 48 ft. Ibs. (65 Nm).

see Section 1 of this manual For Maintenance Interval recommendations,

21 -22 GENERAL MOTORS CORPORATION-C & H-BODIES

LE SABRE ¢ PARK AVE. ¢ EIGHTY EIGHT ¢ LSS ¢ REGENCY © BONNEVILLE e Intermediate shaft-to-rack/pinion assembly pinch bolt e Outer tie rods

> CAUTION

9346UG01

Torque sequence for steering gear mounting bolts—Park Avenue models

10. Install or connect the following: Power steering gear outlet and inlet hoses. Torque the hose connections to 20 ft. Ibs. (27 Nm). Electrical connector Steering gear heat shield Tie rod ends to steering knuckles. Torque the tie rod end nuts to 35 ft. lbs. (47 Nm). Cotter pin. Tighten the nut up to 52 ft. Ibs. (70 Nm) max to align cotter pin slot. Intermediate shaft lower connection. Torque the bolt to 35 ft. Ibs. (47 Nm). Exhaust system. Torque the bolts to 18 ft. Ibs. (25 Nm). Wheelhouse splash shield Tires. Torque the lug nuts to 100 ft. lbs. (140 Nm). 11. Fill and bleed power steering system. 12. Inspect the system for leaks.

Failure to disconnect the intermediate shaft from the rack and pinion stub shaft can result in damage to the steering gear and/or intermediate shaft. This damage can cause loss of Steering control which could result in personal injury. e Power steering line retainers and retaining clips ¢ Power steering lines from the rack and pinion assembly 3. Support the rear of the subframe with a jack. Loosen the front frame bolts and remove the rear bolts, then lower the frame about 3 in. (76mm) for clearance purposes.

Do not lower rear of frame too far, as damage to the engine components nearest to the cowl may result. 4. Remove or disconnect the following: e Rack and pinion mounting bolts

e Rack and pinion through the left wheel opening To install: 5, Install the rack and pinion through the left wheel opening. 6. Raise the rear of the frame. 7. Apply Loctite® or equivalent, to the threads of the rack and pinion mounting bolts. 8. Torque the rack and pinion mounting bolts, in sequence, to 50 ft. Ibs. (68 Nm). 9. Raise the subframe into position. Torque the bolts to 76 ft. Ibs. (103 Nm). 10. Remove the jack. 11. Install or connect the following: ¢ Power steering hoses. Torque the fittings to 22 ft. Ibs. (30 Nm). ¢ Power steering lines to the retainers e Tie rod ends to the steering knuckles. Torque the nuts to 35 ft. Ibs. (47 Nm). elf necessary tighten the nuts up to 60 degrees to align the holes for the new cotter pin.

e Intermediate shaft. Torque the pinch bolt to 33 ft. Ibs. (45 Nm). e Front wheels. Torque the lug nuts to 100 ft. Ibs. (140 Nm). e Negative battery cable

1998-99 Models—Except Park Avenue

The wheels of the vehicle must be Straight-ahead and the steering column in the LOCK position before disconnecting the steering column or intermediate shaft from the steering gear. Failure to do so will cause the Supplemental Inflatable Restraint (SIR) coil assembly in the steering column to become off-center, which will cause damage to the coil assembly. ee ae 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Negative battery cable ¢ Both front wheels

1 BOLT; 68 Nm (50 L B. TIGHTEN 2 3 4 S

FI) IN SEQUENCE A ihiRU Ey STEERING GEAR NUT; 47 Nem (35 LB. FT. MAXIMU MUM PERMISSIBLE TORQUE TO’ALIGN COTTER PIN SLORIS2 76 Nem (52 LB. PTS: : WASHER STEERING KNUCKLE

Torque the steering gear mounting bolts in the sequence shown

7922UG16

C & H-BODIES-GENERAL MOTORS CORPORATION

LE SABRE ¢ PARK AVE. ¢ EIGHTY EIGHT e LSS ¢ REGENCY ¢ BONNEVILLE

21

Z

23

gear and tighten the pinch bolt to 33 ft. Ibs. (45 Nm) 8. Remove the steering column anti rotation pin from the steering column. 9. Fill and bleed the power steering system.

12. Refill the reservoir with fluid and bleed the air from the system. 13. Start the engine, check for leaks and proper steering operation. 14. Check the wheel alignment.

2000-01 Models 1. Before servicing the vehicle, refer to the precautions at the beginning of this section.

REMOVAL & INSTALLATION

> CAUTION Make sure the wheels of the vehicle are straight ahead and the steering column in the LOCK position before disconnecting the steering column or intermediate shaft from the steering gear. Failure to do so will cause the coi! assembly in the steering column to become uncentered which will cause damage to the coil assembly. 2. Lock the steering column by

installing the Steering Column Anti Rotation Pin tool J 42640 into the underside of the steering column. 3. Disconnect negative battery cable. 4. Remove or disconnect the following: e Intermediate shaft lower coupling e Pressure and return pipes from the rack and pinion gear e Electrical connector, if equipped e Stabilizer shaft links at lower control arms 5. Rotate the stabilizer shaft to access steering gear bolts. e Rack and pinion attaching bolts e Rack and pinion assembly To install: 6. Install or connect the following: e Rack and pinion assembly and tighten the bolts to 70 ft. Ibs. (95 Nm) e Flectrical connector, if equipped

9346UG09

Front

Steering gear mounting bolts—2000-01 models

e Pressure and return lines to the steering gear and tighten the fittings to 22 ft. Ibs. (30 Nm) e Heat shield and bolts. Tighten the bolts to 7 ft6. Lbs. (10 Nm) 7. Align stabilizer shaft. e Links to lower control arms e Intermediate shaft to the steering

The steering knuckle must be retained after the strut-to-steering knuckle bolts have been removed. Failure to observe this may cause ball joint and/or halfshaft damage. 1. Before servicing the vehicle, refer to the precautions in the beginning of this section.

; sy)

ee,

9346UG08 the Lock the steering column by installing J Steering Column Anti Rotation Pin tool ng 42640 into the underside of the steeri column

NUTS, 47 Nem (35 LB. FT.) WASHER NUTS, 185 Nem (136 LB. FT.) KNUCKLE BOLT STRUT and aAnr =

7922UG17

g knuckle and the body—tront strut shown The strut assembly is mounted between the steerin

on 1 of this manual For Tune-up, Capacities and Firing orders, see Secti

21 -24 GENERAL MOTORS CORPORATION-C & H-BODIES

LE SABRE ¢ PARK AVE. ¢ EIGHTY EIGHT ¢ LSS ¢ REGENCY ¢ BONNEVILLE

2. Matchmark the strut-to-steering knuckle location. 3. If equipped with electronic ride control, detach the electrical connection. 4. Remove or disconnect the following: ¢ 3 upper strut mount nuts and allow the control arms to hang free Anti-lock Brakes System (ABS) front wheel speed sensor Wheel speed sensor bracket from the strut Brake line bracket from the strut Strut-to-steering knuckle bolts and the strut To install: 5. Install or connect the following: Strut. Torque the 3 nuts to 18 ft. Ibs. (24 Nm) on all models except 1998-99 models and all Park Avenue models or 30-35 ft. Ibs. (40-47 Nm) on 2000-01 models and all Park Avenue models. Electronic ride control electrical connector, if removed Strut-to-knuckle bolts. Torque the bolts to 140 ft. Ibs. (190 Nm) on all models except 1998-99 models and all Park Avenue models or 135 ft. Ibs. (185 Nm) on 2000-01 models and all Park Avenue models. Brake line bracket to the strut Wheel speed sensor bracket to the

seatback to gain access to the upper shock mounting nuts,. 3. Using a floor jack and a block of wood, support the lower control arm. 4. Remove or disconnect the following:

- Shock Absorber

REMOVAL & INSTALLATION Rear

EXCEPT PARK AVENUE AND 2000-01 MODELS 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove the rear seat cushion and

e Rear wheel e

ntin eee shock absorber mounting

¢ Electronic Leveling Control (ELC), if equipped e Lower shock absorber bracket-toknuckle bolts e Shock absorber To install: 5. Install or connect the following: ¢ Shock absorber and loosely thread the upper and lower shock absorber mounting nuts e Upper shock absorber mounting

7922UG21

Remove the cover to gain access to the

upper shock absorber mounting components—rear suspension

nuts and torque to 35 ft. Ibs. (47 Nm). ¢ Strut bracket-to-knuckle bolts and torque to 140 ft. Ibs. (190 Nm). ¢ ELC, if equipped 6. For ELC equipped vehicles, lightly pressurize the ELC system by momentarily grounding terminal “B” at the height sensor connector before lowering the vehicle. e Rear wheel. Torque the lug nuts to 100 ft. Ibs. (140 Nm).

strut

ABS front wheel speed sensor connector Front wheel. Torque the lug nuts to 100 ft. Ibs. (140 Nm). 6. Check and adjust the wheel alignment. Rear

EXCEPT PARK AVENUE AND ALL 2000-01 MODELS 1. Remove rear seat cushion and seatback to gain access to the strut tower mounting nuts. 2. Remove tire. 3. Support the control arm. 4. Remove or disconnect the following: * Strut to knuckle bolts ¢ Upper strut nuts

¢ Strut from vehicle To install: 9. Install or connect the following: e Strut ¢ Upper strut nuts. Torque the nuts to

35 ft. Ibs. (47 Nm). ¢ Strut to knuckle bolts. Torque the bolts to 140 ft. Ibs. (190 Nm). e Rear seatback and cushion e Tire. Torque the lug nuts to 100 ft. Ibs. (140 Nm).

7922UG22

Exploded view of the lower shock absorber mounting to the knuckle assembly—rear suspension

C& H-BODIES-GENERAL MOTOR LE SABRE ¢ PARK AVE. * EIGHTY EIGHT ¢ LSS ¢ REGENCY4BONNEVILLE 21 -20 d. Step 4: Install Rod tool J 34013-38 to help guide the strut shaft from the

7. Check the wheel alignment and adjust if necessary.

2000-01 MODELS AND ALL PARK AVENUE MODELS 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove the tire and wheel assembly. 3. Support the contro! arm with a jack stand. 4. Remove or disconnect the following: ¢ Electronic Ride Control (ELC) air tube from the shock Two bolts securing the shock to the control arm Trunk trim to gain access to the shock upper mounting nuts. Cover, the two nuts, and the reinforcement from the top of the shock Shock from the vehicle To install: 5. Install or connect the following: Shock, reinforcement, and the two nuts. Tighten the mounting nuts to 15 ft. Ibs. (20 Nm). Shock cover Trunk trim Shock-to-contro! arm bolts and tighten the bolts to 18ft. Ibs. (24 Nm) ELC air tube to the shock. Tire and wheel assembly

7922UG19

Use a Torx® socket to keep the piston rod from turning while removing the upper nut—front strut shown

upper mount assembly. e. Step 5: Loosen the spring compressor tool until the coil spring and mount can be removed as an assembly. Remove the lower spring insulator, if equipped. To install: 3. Assemble the strut as follows: a. Step 1: Place the strut in compressor tool. b. Step 2: Install the coil spring over the strut. c. Step 3: Compress the coil spring while guiding strut shaft through the top of the strut assembly. d. Step 4: Install the top strut nut. Torque the nut to 55 ft. Ibs. (75 Nm). e. Step 5: Remove the strut from the

compressor. Rear

EXCEPT 2000-01 MODELS AND ALL PARK AVENUE MODELS 7922UG18

Install Rod J 34013-38 to help guide the strut shaft from the upper mount assembly—front strut shown

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following:

Coil Spring REMOVAL & INSTALLATION

The coil springs are under a considerable amount of tension. Be very careful when removing or installing them; they can exert enough force to cause very serious injury. Front

1. Remove the strut from the vehicle. 9. Disassemble the strut as follows: a. Step 1: Place the strut assembly into compressor tool, to compress the coil spring. b. Step 2: Compress the spring slightly. c. Step 3: Hold the strut shaft from turning using a No. 50 Torx® socket and rernove the 24mm nut on the top end of the strut.

ing—H body Exploded view of the rear coil spring mount

Chilton Labor Guide For complete service labor times, order Nichols’

RATION-C & H-BODIES

21 -26 isonet PARATE Sent EIGHT ¢ LSS ¢ REGENCY ¢ BONNEVILLE 16. With the vehicle resting on its wheels, torque the contro! arm through-bolt nuts to 85 ft. Ibs. (115 Nm). 17. Torque the sway bar link bolt to 13 ft. Ibs. (17 Nm). 18. Check wheel alignment and adjust if necessary. 19. Road test the vehicle for proper operation.

2000-01 MODELS AND ALL PARK AVENUE MODELS

J 23028 — 01 7922UG24

Use support bracket tool J-23028-01 mounted on a jack to support the rear lower control arm— H body

e Rear wheel e Height sensor link from the right control arm, if equipped with Electronic Leveling Control (ELC) e Parking brake cable retaining clip from the left control arm, if removing the left side coil spring e Rear stabilizer shaft from the bracket on the knuckle, if equipped 3. Use support bracket tool J23028-01, mounted on a jack, to support lower control arm bushings. 4. Place a chain around the spring and through the control arm as a safety meaSure. 5. Raise the jack to remove tension from the control arm pivot bolts. 6. Remove the rear nut and throughbolt from the control arm. 7. Slowly maneuver the jack to relieve tension from the front control arm bolt, 8. Remove the front nut and throughbolt from the control arm. e>Do not apply force to the control arm and/or ball joint to remove the spring. Proper maneuvering of the Spring will allow for easy removal.

9. Lower the jack to pivot the control arm downward. When all compression is

removed from the spring, remove the safety chain, spring and insulators. 10. Inspect the spring insulators and replace them if they are cut or torn. If the vehicle has been driven more than 50,000 miles (80,500 km), replace them regardless of condition. To install: 11. Snap the upper insulator onto the Spring. 12. Position the lower insulator and Spring in the vehicle. 13. Using the jack and tool J-23028-01, raise the control arm into place. 14. Maneuver the jack to permit installation of the control arm bolts and nuts. e>Do not torque the nuts until the weight of the vehicle is on the suspension. 15. Install or connect the following: ¢ Rear sway bar to the knuckle bracket with the link assembly if equipped, do not torque the link bolt Height sensor link to the right control arm or connect the parking brake cable retaining clip to the left control arm, as required Rear wheel. Torque the lug nuts to 100 ft. Ibs. (140 Nm).

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Tire e Electronic Leveling Control (ELC) air tube 3. Support the control arm. ¢ Two lower shock bolts e Trunk trim * Cover, 2 nuts and the reinforcement from the top of the shock ¢ Cotter pin and hex nut on contro! arm 4. Separate the adjustment link from the knuckle. 5. Slowly lower the control arm. 6. Remove the spring with the lower insulator. To install 7. Install or connect the following: ¢ Coil spring with insulator ¢ Lower shock bolts. Torque the bolts to 18 ft. Ibs. (24 Nm). Adjustment link. Torque the nut to 88 inch Ibs. (10 Nm) on 1998-99 Park Avenue models or 36 ft. Ibs. (50 Nm) On all 2000-01 models including Park Avenue. Tighten an additional turn to align the cotter pin. ELC air tube Tire. Torque the lug nuts to 100 ft, Ibs. (140 Nm).

Lower Ball Joint

REMOVAL & INSTALLATION tess SS

Shed

Front

EXCEPT ALL 2000-01 AND PARK AVENUE MODELS 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: ¢ Front wheel ¢ Cotter pin from the lower ball joint and loosen the nut

C & H-BODIES-GENERAL M

LE SABRE © PARK AVE. © EIGHTY EIGHT ¢ 38

REGENCY iBONNEVILLE 21-2/

6. Check and adjust the wheel alignment.

2000-01 AND ALL PARK AVENUE MODELS The ball joint is an integral part of the lower control-arm and if found to be defective the control arm should be replaced. Rear

1)

FIN

2 NUT, BALL JOINT TO KNUCKLE, TIGHTEN TO 10 Nem (88 LB. IN.) THEN TIGHTEN

2 FLATS TO

55 Nem (41 LB. FT.), MIN.

KNUCKLE & =

BALL JOINT MOUNTING BOLTS MUST

nn

CONTROL ARM

6

BALL JOINT MOUNTING NUTS 68 Nem (50 LB. FT.)

FACE DOWN

7 SERVICE BALL JOINT 7922UG25

The replacement ball joint should be attached to the control arm using 3 bolts

and nuts—except Park Avenue

¢ Ball joint from the steering knuckle Stabilizer shaft link assembly 3. Drill out the 3 rivets retaining the ball joint. 4, Remove the ball joint. To install: 5. Install or connect the following: e Lower ball joint to the steering knuckle Ball joint to the lower control arm, making sure the bolts face downward. Torque the nuts to 50 ft. Ibs.

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: ¢ Rear wheel ¢ Height sensor link from the right control arm ¢ Parking brake cable retaining clip from the left control arm ¢ Adjustment link from the knuckle 3. Support the control arm with a jack. 4. Remove the ball joint stud cotter pin and nut. 5. Reinstall the nut on the stud with the flat side of the nut facing up; do not torque the nut. 6. Remove or disconnect the following: e Stud from the knuckle Slotted hex nut from the ball joint stud 7. Press the ball joint out of the control arm To install: 8. Install or connect the following: ¢ New ball joint, press it into the control arm ¢ Ball joint stud into the knuckle. Torque the nut to 88 inch Ibs. (10 Nm), plus an additional 4 flats. The minimum torque on the nut should be 40 ft. Ibs. (55 Nm). e New cotter pin

(68 Nm). Stabilizer shaft link assembly. Torque the nut to 13 ft. Ibs. (7 Nm). Lower ball joint nut. Torque the nut to 88 inch Ibs. (10 Nm) plus an additional 120 degree turn, during

which a torque of 41 ft. Ibs. (55 Nrn) must be obtained. ¢ New cotter pin to the lower ball joint Tighten the nut up to one more flat in in order to align the slot with the hole the stud. to ~ Front wheel. Torque the lug nuts

100 ft. ps. (140 Nm).

J 9519-18 7922UG27

Installing the ball joint into the lower control arm—except Park Avenue

-Tighten the nut up to one more flat in order to align the slot with the hole in the stud.

e Adjustment link to the knuckle. Torque the slotted nut to 33 ft. Ibs. (45 Nm). ¢ New cotter pin ->Tighten the nut up to one more flat in order to align the slot with the hole in the stud..

e Height sensor link to the right control arm e Parking brake cable retainer to the left control arm ¢ Rear wheel

Lower Control Arm REMOVAL & INSTALLATION Front

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 9. Allow the control arms to hang free. 3. Remove or disconnect the following:

J 9519-17 9306UG09 7922UG26

Removing the ball joint from the lower control arm—except Park Avenue

Lower control arm assembly—except Park Avenue

ne.com Please visit our web site at www.chiltonsonli

21 -28

RPORATION-C & H-BODIES

heey Peale Sees EIGHT ¢ LSS ¢ REGENCY ¢ BONNEVILLE

7922UG37

Lower control arm mounting—Park Avenue

e Front wheel

¢ Stabilizer shaft link assembly from the control arm

¢ Cotter pin from the lower ball joint and remove the nut

e Ball joint from the steering knuckle ¢ Lower control arm from the frame To install: 4. Install or connect the following: ¢ Lower control arm to the frame

->Do not tighten the lower control arm nuts at this time. The weight of the vehicle must be supported by the control arms, since the vehicle design trim heights are obtained before tightening the lower control arm mounting nuts.

¢ Ball joint stud to the steering knuckle. Torque the lower ball joint nut to 88 inch Ibs. (10 Nm), then an additional 120 degree turn, during which a torque of 41 ft. Ibs. (55 Nm) must be obtained. ¢ New cotter pin e>Align the slot in the nut with the hole in the lower ball joint stud. Torque the ball joint nut up to one more flat. Never loosen the nut to align the slot.

¢ Control arm rear mounting bolts to 117 ft. Ibs. (158 Nm), then the front mounting nut to 117 ft. Ibs. (158 Nm) * Stabilizer shaft link assembly, Torque the nuts to 13 ft. Ibs. (17 Nm). ¢ Front wheel. Torque the lug nuts to 100 ft. Ibs. (140 Nm). 9. Torque the front lower control arm mounting nut to 140 ft. Ibs. (190 Nm) and the rear lower control arm nut to 91 ft, Ibs. (123 Nm). 6. Check and adjust the wheel alignment, Rear

EXCEPT 2000-01 AND ALL PARK AVENUE MODELS 1. Before servicing the vehicle, refer to the precautions in the beginning of this section.

2. Remove or disconnect the following: Adjustment link retaining nut Adjustment link from the control arm Spring Cotter pin and hex nut from the ball joint. Turn the nut over and install the nut with the flat portion facing upward. Do not tighten the nut. Separate the knuckle from the ball joint stud and remove the nut Control arm To install: 3. Install or connect the following: ¢ Lower control arm ball joint stud in the knuckle boss New hex nut and tighten to 88 inch lbs. (10 Nm). Tighten the nut an additional four flats; torque should be 40 ft. Ibs. (55 Nm) minimum. It may be necessary to partially load the joint to keep the ball stud from rotating while the nut is being tightened. Tighten the nut up to one more flat to align the slot with the cotter pin hole. Cotter pin Spring Adjustment link to the control arm and tighten the link retaining nut to 63 ft. Lbs. (85 Nm) e>Tighten the control arm nuts with the vehicle on its wheels at its normal ride height. Failure to follow this procedure may adversely affect the ride and handling of the vehicle.

4. Tighten the control arm nuts to 85 ft. Ibs. (115 Nm). Optional torque: Tighten the control arm bolts to 143 ft. Ibs. (182 Nm) 9. Tighten the stabilizer shaft link bolt to 13 ft. Ibs. (17 Nm).

e>Tighten the control arm nuts with the vehicle unsupported and resting on the wheels at the normal trim height.

e e ¢ e ¢

Bolts and the nuts Hub and bearing ABS electrical connector Tie rod Stabilizer link assembly to the control arm e Height sensor e Rear wheel 4. Lower the vehicle and tighten the control arm nuts to 78 ft. Ibs. (106 Nm).

CONTROL ARM BUSHING REPLACEMENT Except Park Avenue

FRONT 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: ¢ Front wheel ¢ Lower control arm 3. Press the control arm bushing out of the control arm. To install: 4. Insert the new bushing into control arm. 5. Press the new bushing into the control arm. 6. Install the lower control arm. 7. Install the front wheel. Torque the lug nuts to 100 ft. Ibs. (140 Nm).

REAR—1998-99 MODELS 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. e>There are two different sized bushings used in the control arm. These

2000-01 AND ALL PARK AVENUE MODELS 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Rear suspension support assembly Electronic Ride Control height sensor Tie rod Stabilizer link assembly from the control arm Antilock Brake System (ABS) electrical connector Hub and bearing Lower control arm bolts and the control arm To install: 3. Install or connect the following: ¢ Lower control arm to the frame.

J 21474—-13 9306UG07

Removing the bushing from the control

arm

J 21474-13 9806UG08

Installing the bushing into the contro l arm

C & H-BODIES-GENERAL M LE SABRE e PARK AVE. ¢ EIGHTY EIGHT e eee

bushings are not interchangeable, and require different combinations of special tools for removal and installation.

2. Remove the control arm. 3. Place the control arm upside-down on the bench and install the tools shown in the accompanying illustration. 4. Installl spacer J22222-5 on bushing 1 or on bushing 2 use J 21474-12 (refer to the accompanying illustration). 5. Position the receiver tube and the J 29376-7 on the outer side of the control arm. Be sure the receiver tube does not contact the bushing flange. 6. Coat the threaded area of the long bolt with the high pressure lubricant J 23444-A and install the bolt through the receiver, the cap, and the bushing. 7. Install the remover on the bolt at the inner side of the control arm. Position the remover so the small diameter end contacts the bushing. On bushing 1 use J 22222-2 or bushing 2 use J 28685. 8. Place the bearing on the bolt and install the J 21474-18 long nut. The bearing must be installed between the nut and the remover.

J 28685 —2

=.

J 29376 -7

J 28685 —2

Soe 9346UG02

Removing the bushing from the rear control arm—19S$8-99 models

4

2

J 25317 —2

J 21474-19

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-1 J 29376—7 eae

— 9346UG03

Installing the bushing into the rear contro! arm—1998-99 models

Draw the bushing out of the control arm by tightening the nut. To install: 9. With the control arm upside-down on the bench, position the new bushing in the control arm. e>When installing new bushings, the flange end of the bushing must face outward when installed in the control arm.

10. Install the appropriate tools: as follows: a. Install the spacer. On bushing 1 use tool J 22222-5, or on bushing 2 use tool J 21474-12. 11. Position the receiver tube and the J 29376-7 cap on the inner side of the control arm. Center the receiver tube over the hole. 12. Coat the threaded area of the long bolt with the high pressure lubricant and install the bolt through the receiver, the cap, and the bushing. 13. Position installer J28685 on the bolt at the outer side of the control arm. Position the installer with the large diameter contacting the bushing flange. 14. Place the bearing on the bolt and install J 21474-18 long nut. The bearing must be positioned between the nut and the installer. 15. Draw the bushing into the control arm by tightening the nut. Tighten the nut until the bushing flange seats firmly against the control arm. 16. Reinstall the control arm in the vehicle and inspect the rear wheel alignment.

REAR—2000-01 MODELS 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove the control arm. 3. Place tool J 21474-27 with the washer through tool J 41014-2 over the bushing against the control arm. 4. Lubricate the bolt threads with high pressure lubricant. 5. Install tool J 41014-1 (with small end facing the bushing), the thrust bearing and tool J 21474-4 onto tool J 21474Zia 6. Tighten the nut until the bushing Is driven out of the control arm. 7. Remove the bushing tools. To install: 8. Start the bushing into the control arm.

POR BORAGON

J 41014—2

J 21474 -27

21 -29

J 21474—4

J 41014-1 9346UG04

Removing the bushing from the rear control arm—2000-01 models

J 21474 —-13

j21474—4

J 41014-2

J 21474 —27 9346UG05

Installing the bushing into the rear control

arm—2000-01 models

9. Make sure that the flat on the bushing is vertical and facing rearward. Place tool J 21474-27 with the washer through tool J41014-1 over the bushing against the control arm. 10. Lubricate the bolt threads with high pressure lubricant. 11. Install tool J 21474-13 (making sure the large end is facing the bushing), the thrust bearing and tool J 21474-4 onto tool J 21474-27. 2. Tighten the bolt until the bushing is fully seated into the control arm. 13. Remove the bushing tools. 14. Install the control arm. Park Avenue

The lower control arm is replaced as a unit. The bushing can not be removed.

Wheel Bearings ADJUSTMENT The wheel bearings are not adjustable. If a wheel bearing is out of specifications, It must be replaced. Using a dial indicator, check for looseness. If play exceeds 0.005 inch (0.127mm), the bearing wear is excessive and the hub/bearing should be replaced.

Timing belt service is covered in Section 3 of this manual

21 -30 GENERAL MOTORS CORPORATION-C & H-BODIES LE SABRE * PARK AVE. e EIGHTY EIGHT © LSS * REGENCY @ BONNEVILLE REMOVAL & INSTALLATION Front

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: ¢ Front wheel eInsert a drift punch through the caliper and into the rotor cooling fins to prevent the rotor from turning.

Halfshaft nut and washer Brake caliper Brake rotor Anti-Lock Brake System (ABS) speed sensor 3 hub/bearing assembly bolts Dust shield Hub/bearing assembly from the halfshaft, using a puller Hub/bearing assembly from the steering knuckle To install: 3. Install the hub/bearing assembly over the halfshaft splines. Be sure the splines engage smoothly.

4. Apply a light coating of grease to the steering knuckle bore. 5. Slide the hub assembly onto the halfshaft as far as possible. If the hub will not bottom out on the halfshaft, install the hub mounting bolts and use the halfshaft nut to draw the hub onto the halfshaft.

6. Once the hub is flush with the steer-

ing knuckle, remove the mounting bolts and install the dust shield. 7. Install or connect the following: 8. Install the mounting bolts. Torque the bolts to 70 ft. Ibs. (95 Nm). 9. Place the transaxle in N. 10. Install or connect the following: ¢ ABS front wheel speed sensor connector, and clip to the dust shield e Brake rotor ¢ Caliper. Torque the bolts to 38 ft. lbs. (51 Nm). 11. Torque the halfshaft nut to 107 ft. Ibs. (145 Nm) on 1998-99 models or 118 ft. Ibs. (160 Nm) on 2000-01 models. 12. Install the front wheels. Torque the lug nuts to 100 ft. Ibs. (140 Nm). 13. Road test the vehicle. Rear

1998-99 MODELS 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: ¢ Rear wheel ¢ Brake drum ¢ Anti-Lock Brake Systems (ABS) sensor wire, if equipped

7922UG29

Use a puller such as J 28733-B to press the halfshaft from the hub assembly

7922UG28

Exploded view of the front hub and wheel

bearing assembly

The hub assembly mounting bolts also secure the backing plate assembly. Once the bolts are removed, the

backing plate must be supported with wire or other means. Do not allow the brake line or ABS electrical wire to support the brake assembly.

¢ 4 hub/bearing assembly bolts and the hub assembly To install: 3. Install or connect the following: ¢ Hub/bearing assembly onto the rear knuckle. Torque the bolts to 52 ft. lbs. (70 Nm). e ABS sensor connector, if equipped ¢ Brake drum e Rear wheel. Torque the nuts to 100 ft. Ibs. (140 Nm). 4. Road test for proper operation.

2000-01 MODELS 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Wheel and the tire Brake caliper Brake rotor ABS sensor wire connector. Four bolts from the control arm Hub and bearing from the contro! arm Brake shield from the control arm

To install:

3. Clean the control arm face and the bore before installing the hub and the bearing. 4. Install or connect the following: e Brake shield and the hub and the bearing to the control arm with the four bolts. Reconnect the ABS senSor. Tighten the hub and bearing bolts to 52 ft. Ibs. (70 Nm). e Brake rotor ¢ Brake caliper ¢ Wheel and the tire

7922UG30

Exploded view of the rear hub/wheel bearing assembly—1998-99 models

9346UG06

Exploded view of the rear hub/wheel bearing assembly—2000-01 models

GENERAL MOTORS CORPORATION-E & K- BODIES 1998-01 Cadillac-Deville * Eldorado # Seville DRIVE TRAIN Gir. cc. occ 22-23 ENGINE REPAIR................ 22-2 BUELSSYSTEM xe shee ne 22-19 PRECAUTIONS.................. 22-2 STEERING AND SUSPENSION................. 22-29

F PU irilhe tia setae OP. lias wane de 22-20 Removal & Installation............ 22-20 Fuel injectorsi exten iss, 22-22 Removal & Installation............ 22-22 UCP UND mecrmern ie teak 22-2 |

P PIStOnialnd, RING in. aeeeeueae 22-18 POSITIONING Giese ee one, 22-18 Power Rack and Pinion SIGeRING, Gear nc See eeaeen ae 22-30 Removal & Installation............ 22-30

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seerase, 22-9 Intake Manitoldgotera Removal & Installation.............. 22-9

Timing Chain, Sprockets, Front Cover and Seal............. 22-15

Removal & Installation............22-33 OU Nomisst ee ee Pee

Soy eet. st:22-34 Lower Ballons Removal & Installation............ 22-34

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PRECAUTIONS Before servicing any vehicle, please be sure to read all of the following precautions, which deal with personal safety, prevention of component damage, and important points to take into consideration when servicing a motor vehicle: e Never open, service or drain the radiator or cooling system when the engine is hot; serious burns can occur from the steam and hot coolant. e Observe all applicable safety precautions when working around fuel. Whenever servicing the fuel system, always work in a well-ventilated area. Do not allow fuel spray Or vapors to come in contact with a spark, open flame or excessive heat (a hot drop light, for example). Keep a dry chemical fire extinguisher near the work area. Always keep fuel in a container specifically designed for fuel storage; also, always properly seal fuel containers to avoid the possibility of fire or explosion. Refer to the additional fuel system precautions later in this section. e Fuel injection systems often remain pressurized, even after the engine has been turned OFF. The fuel system pressure must be relieved before disconnecting any fuel lines. Failure to do so may result in fire and/or personal injury. e Brake fluid often contains polyglycol ethers and polyglycols. Avoid contact with the eyes and wash your hands thoroughly after handling brake fluid. If you do get brake fluid in your eyes, flush your eyes with clean, running water for 15 minutes. If eye irritation persists, or if you have taken

brake fluid internally, IMMEDIATELY seek medical assistance. e The EPA warns that prolonged contact with used engine oil may cause a number of skin disorders, including cancer! You should make every effort to minimize your exposure to used engine oil. Protective gloves should be worn when changing oil. Wash your hands and any other exposed Skin areas as soon as possible after exposure to used engine oil. Soap and water, or waterless hand cleaner should be used. ¢ All new vehicles are now equipped with an air bag system, often referred to as a Supplemental Restraint System (SRS) or Supplemental Inflatable Restraint (SIR) 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 repairs. e Always wear safety goggles when working with, or around, the air bag system. When carrying a non-deployed air bag, be sure the bag and trim cover are pointed away from your body. When placing a nondeployed air bag on a work surface, always face the bag and trim cover upward, away from the surface. This will reduce the motion of the module if it is accidentally deployed. Refer to the additional air bag system precautions later in this section. ¢ Clean, high quality brake fluid from a sealed container is essential to the safe and

SEBRIE!

EERE LEDSU

ET LER SYSETI

! proper operation of the brake system. You should always buy the correct type of brake fluid for your vehicle. If the brake fluid becomes contaminated, completely flush the system with new fluid. Never reuse any brake fluid. Any brake fluid that is removed from the system should be discarded. Also, do not allow any brake fluid to come in contact with a painted surface; it will damage the paint. e Never operate the engine without the proper amount and type of engine oil: doing so WILL result in severe engine damage. e Timing belt maintenance is extremely important! Many models utilize an interference-type, non-freewheeling engine. If the timing belt breaks, the valves in the cylinder head may strike the pistons, causing potentially serious (also time-consuming and expensive) engine damage. Refer to the maintenance interval charts in the front of this manual for the recommended replacement interval for the timing belt, 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 computer system(s) and may require the computer to undergo a relearning process once the neg-

ative battery cable is reconnected.

¢ When servicing drum brakes, only disassemble and assemble one side at a time, leaving the remaining side intact for reference. ¢ Only an MVAC-trained, EPA-certified automotive technician should service the air conditioning system or its components.

ENGINE REPAIR Alternator

REMOVAL Eldorado and 1998-99 Deville

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the cooling system. 3. Remove or disconnect the following: Negative battery cable Accessory drive belt Alternator upper mounting bolt Engine splash shield Radiator support access panel Rear alternator bracket from the engine

¢ ¢ ¢ ¢ e

Alternator mounting bolts Duct on the back of the alternator Electrical connectors Front alternator-to-A/C bracket Alternator

1998 Seville and 2000-01 Deville

4. Before servicing the vehicle, refer to the precautions in the beginning of this section. 9. Drain the cooling system. 6. Remove or disconnect the following: e Negative battery cable ¢ Accessory drive belt e Radiator ¢ Air conditioning condenser ¢ Alternator cooler outlet hose ¢ Alternator cooler inlet hose

CLEEETIED ELS GEIS EES LEE

| ¢ Electrical connectors

e Alternator mounting bolts e Alternator

1999-01 Seville 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the cooling system. 3. Remove or disconnect the following: Negative battery cable Accessory drive belt Cooling fans Alternator cooler outlet hose Alternator cooler inlet hose Electrical connectors Alternator mounting bolts Alternator

E & K-BODIES-GENERAL MOTORS CORPORATION DEVILLE ¢ ELDORADO SEVILLE 1999-01 Seville

9306AG01

Alternator mounting and wires

Throttle and cruise control cables from the throttle body Shift cable from the manual shift lever and the bracket Vacuum hose from the brake booster Fuel lines Coolant reservoir Coolant hoses from the pipes at the front of the engine Negative battery cable from the left cylinder head Positive battery cable from the battery and body retainer Powertrain Control Module (PCM) case and the PCM Right sound insulator Engine wire harness electrical connector and the vacuum line under the instrument panel Wire harness from the pass through at the cowl and pull the harness through the cowl 3 electrical connectors from the A/C line near the engine cowl Vacuum hose from the T” fitting near the engine harness pass through Right and left front wheel speed sensor electrical connectors Manifold Absolute Pressure (MAP) sensor and the control motor near the master cylinder Engine harness retainer from the brake booster 2 hoses from the power steering cooler Engine harness from the hood fuse panel 3 relays from the lower radiator and the electrical connector from the Antilock Brake System (ABS) modulator Tires and wheels Drive axles from the steering knuckle Post Oxygen (02S) sensor heat shield and wire harness connector from the body Intermediate pipe hangers from the intermediate pipe Catalytic converter from the pipe

1. Install or connect the following: Alternator. Torque the bolt to 37 ft. lbs. (50 Nm). Electrical connectors. Torque the battery connection nut to 115 inch lbs. (13 Nm). Alternator cooler inlet hose Alternator cooler outlet hose. Torque the bolt to 80 inch Ibs. (9 Nm). Cooling fans Accessory drive belt Negative battery cable 2. Refill the cooling system.

Ignition Timing

INSTALLATION Eldorado and 1998-99 Deville 1. Install or connect the following: ¢ Alternator

e Front alternator-to-A/C bracket. Torque the bolt to 35 ft. Ibs. (47 Nm). Electrical connectors. Torque the battery connection nut to 115 inch lbs. (13 Nm). Duct on the back of the alternator Alternator mounting bolts. Torque the bolts to 35 ft. Ibs. (47 Nm). Upper front bolt. Torque the bolt to 35 ft. Ibs. (47 Nm). Rear bracket to the engine. Torque the bolt to 35 ft. Ibs. (47 Nm). Radiator support access panel Engine splash shield Accessory drive belt Negative battery cable 2. Refill the cooling system. 1998 Seville and 2000-01 Deville

1. Install or connect the following: Alternator Alternator mounting bolts. Torque the bolts to 37 ft. Ibs. (50 Nm). Electrical connectors. Torque the battery connection nut to 115 inch lbs. (13 Nm). Alternator cooler inlet hose Alternator cooler outlet hose. Torque the bolt to 80 inch Ibs. (9 Nm). Radiator Air conditioning condenser Accessory drive belt Negative battery cable efill the cooling system. 2. Say e V

ADJUSTMENT The 4.6L Northstar engine is equipped with a Distributorless Ignition System (DIS). The ignition timing is controlled by the Powertrain Control Module (PCM). Therefore no adjustments are necessary.

Engine Assembly

cee

REMOVAL & INSTALLATION 1998-99 Models 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Disable the Air bag system. 3. Recover the air-conditioning system. 4 Drain the cooling system. 5. Recover the refrigerant from the air conditioning system. 6. Relieve the fuel pressure. 7. Drain the crankcase. 8. Remove or disconnect the following: Tower-to-tower brace Air intake duct Air cleaner assembly Radiator hose at the crossover Engine cover Radiator upper cover eo e @ e@ Upper radiator hoses from the engine Forward discriminating sensor from the radiator support and set it aside Cooling fans Transmission cooler lines from the radiator e Cruise control servo connections

22-3

Steering coupling from the steering e

gear Fuel line bundle from the transmission Battery wire from the generator A/C manifold from the A/C compressor

For complete service labor times, order Nichols’ Chilton Labor Guide

22- 4

GENERAL MOTORS CORPORATION-E & K-BODIES DEVILLE e ELDORADO ¢ SEVILLE

ABS modulator from the frame and support 9. Position the powertrain support table

J39580 under the frame and lower the vehicle onto the table. 10. Remove the 6 frame-to-body bolts. 11. Raise the body off the powertrain. 12. Remove or disconnect the following: Coolant crossover pipe from the engine

Park/Neutral switch from the transmission Engine wire harness Exhaust Y¥ pipe Accessory drive belt Power steering pump and hoses Alternator and the bracket A/C compressor and bracket Idler pulley Right engine-to-transmission brace Lower engine-to-the transmission brace Left engine-to-transmission brace 13. Attach the engine lift to the engine. Left engine mount and bracket Left exhaust manifold Flywheel inspection cover Torque converter from the flywheel Right engine mount bracket from the engine Transmission-to-engine bolts. Engine from the transmission and frame Exhaust Gas Recirculation (EGR) cross under pipe Right exhaust manifold Engine To install: 14. Install or connect the following: Engine-to-transmission and frame assembly 4 transmission-to-engine bolts and tighten to 55 ft. Ibs. (75 Nm) Right engine mount bracket to the engine Torque converter to the flywheel and tighten the bolts to 35 ft. Ibs. (47 Nm) Flywheel inspection cover Left exhaust manifold e Left engine mount and bracket 15. Remove the engine lift from the

engine. Left engine-to-transmission brace Lower engine-to-transmission brace Right side engine-to -transmission brace Right side coolant pipes to the engine Power steering lines to the pump and the pump to the engine

Coolant reservoir, hoses and electrical connector Fuel lines Vacuum hose to the brake booster _ Shift cable to the manual shift lever

Idler pulley and tighten the bolts to 37 ft. Ibs. (50 Nm) A/C compressor and the brackets Alternator and bracket Power steering pump pulley Accessory drive belt Exhaust manifold rear pipe Engine wire harness Park/Neutral switch and bracket Coolant crossover pipe 16. Position the powertrain assembly under the body and lower the body onto the powertrain assembly. Frame-to-body bolts and tighten to 74 ft. Ibs. (100 Nm) ABS modulator A/C manifold to the A/C compressor Battery wire to the alternator Fuel line bundleto the transmission Steering couplingto the steering

19.

gear Catalytic converter

20. 21.

Intermediate pipe hangers Post converter Ozsensor electrical connection and heat shield Drive axle to the hubs Tie rods Height sensor links Stabilizer shaft links Tire and the wheels 17. Lower the vehicle. 3 relays to the radiator support 2 hoses to the power steering cooler Engine harness to under the hood fuse panel Engine harness retainer to the brake booster Engine harness left front wheel speed sensor, cruise contro! motor and MAP sensor electrical connections Right front wheel speed sensor connection Vacuum hose to the T fitting

3 electrical connections to the A/C line near the cowl 18. Push the engine wire harness through the cowl and attach pass through to the cowl. 2 engine wire harness electrical connections and the vacuum line Right sound insulator PCM case, the PCM and the electrical connection Positive battery cable to the battery and body retainer Negative battery cable to the left cylinder head Coolant hoses to the pipes at the front of the engine

22. 23. 24.

and bracket Throttle and cruise cables to the throttle body Cooling fans Transmission cooler lines to the radiator Forward discriminating sensor to the radiator support Upper and lower radiator hoses Engine mount struts and adjust to zero preload Radiator upper cover Engine cover Air cleaner assembly Aiir intake duct Fill cooling system. Recharge the A/C system. Enable the air bag system Fill the cooling system. Fill the crankcase. Bleed the power steering system

2000-01 Models

1. Before servicing the vehicle, refer to the precautions in the beginning of this section.

2. Disable the air bag system. 3. Recover the air-conditioning system. 4. Drain the cooling system. 5. Recover the refrigerant from the air conditioning system. 6. Relieve the fuel pressure. 7. Drain the crankcase. 8. Remove or disconnect the following: Upper filler panel Connectors from the Powertrain Control Module (PCM) Air cleaner assembly 2 nuts from the intake manifold sight shield Sight shield from the engine Inlet radiator hose from the engine and the outlet radiator hose from the thermostat housing Upper transaxle oil cooler line retaining bolt from the fan shroud Plastic cap off the upper transaxle oil cooler line fitting Internal spring clip from the transaxle oil cooler fitting Upper transaxle oil cooler line from the radiator Lower transaxle oil cooler line from the radiator Surge tank inlet pipe from the engine

E & K-BODIES-GENERAL MOTORS CORPORATION DEVILLE * ELDORADO ¢ SEVILLE

ck CAUTION In order to avoid possible injury or vehicle damage, always replace the accelerator cable with a NEW cable whenever you remove the engine from the vehicle. Also to avoid cruise control cable damage, position the cable out of the way when removing or installing the engine. Never pry or lean against the cruise control cable or kink the cable. If the cable is damaged it must be replaced. Accelerator cable from the throttle

body Cruise contro! cable from the throttle body

Heater hoses from the engine 2 brake pipes from the master cylinder and plug the lines to prevent system contamination Bracket and shift cable from the manual shift lever and set’ aside Vacuum hose from the brake

booster e Evaporative Emission (EVAP) hose from the EVAP purge valve e Fuel inlet and return fittings from the fuel rail e Engine ground cable from the body frame rail Main engine harness Electrical harness from the underhood fuse block Right and left strut tower bolts Wheels Real time dampening sensor links from the lower control arms Both wheel speed sensor connectors Both road sensing suspension electrical connectors 2 brake pipes from both front frame brackets 2 rear brake pipes at the rear of the engine frame Air deflector >The engine oil cooler quick connect fittings must be replaced whenever they are removed from the engine oil filter adapter.

e Engine oil cooler fittings from the engine oil filter adapter, with the oil lines still attached, and position aside ¢ Dust cover from the quick connect joint

e Internal spring clip from the engine oil cooler fittings e Engine oil cooler lines from the cooler fittings e A/C discharge and suction hoses from the compressor e>|ake sure the wheels of the vehicle are in the straight ahead position and the steering column in the Lock position before disconnecting the steering column or intermediate shaft from the steering gear. Failure to do so will cause the coil assembly in the steering column to become uncentered which will cause damage to the coil assembly.

9. Lock the steering column by removing the ignition key from the lock cylinder. 10. Remove or disconnect the following: Intermediate shaft pinch bolt Intermediate shaft from the steering gear Wheel speed and brake wear sensors at the right and left strut towers Post Heated Oxygen (HO2S) sensor at the sensor pigtail Exhaust front pipe Brace between the engine oil pan and the transaxle case Torque converter cover Torque converter-to-flywheel bolts 11. Position a powertrain support dolly under the engine assembly. If a powertrain support dolly is unavailable, support the powertrain with four suitable jackstands. ° Nut attaching the right engine mount to the engine mount bracket e Nut attaching the left transaxle mount to the transaxle mount bracket

ek CAUTION To avoid any vehicle damage, serious personal injury or death when major components are removed from the

vehicle and the vehicle is supported by a hoist, support the vehicle with jack stands at the opposite end from which the components are being removed. 12. Secure the front hoist pads to the vehicle. 13. Remove the 6 frame mount bolts (3), raise the vehicle slowly and attach an engine lift to the engine.

22-5

Heater pipes Nut attaching the coil cassette ground wire to the cylinder head Engine wiring harness from the engine Bolt attaching the crossover pipe to the cylinder head Power steering pump Bolt attaching the rear transaxle brace to the transaxle Nuts attaching the rear transaxle brace to the cylinder head Rear transaxle brace Bolt attaching the front transaxle brace to the cylinder head Bolts attaching the transaxle brace to the transaxle Bolts securing the transaxle brace to the engine Nut attaching the front engine mount to the engine frame Bolts attaching the engine to the transaxle Engine from the frame and transaxle assembly To install: 14. Attach the engine to the frame and transaxle assembly.. 15. Install or connect the following: Bolts attaching the engine to the transaxle and tighten to 55 ft. Ibs. (75 Nm) Nut attaching the front engine mount to the engine frame and tighten to 52 ft. Lbs. (70 Nm) 4 bolts attaching the transaxle brace to the engine and tighten to 37 ft. Ibs. (50 Nm) Bolt attaching the front transaxle brace to the cylinder head and tighten the bolts to 37 ft. Ibs. (50 Nm) Rear transaxle brace and tighten the bolt to 37 ft. Ibs. (60 Nm) and the nuts to 37 ft. lbs. (50 Nm) Bolt attaching the crossover pipe to the cylinder head and tighten the bolt to 18 ft. Ibs. (25 Nm) Engine wiring harness to the engine Nut attaching the coil cassette ground wire to the cylinder head and tighten to 13 ft. Ibs. (17 Nm) Heater pipes ¢ Power steering pump 16. Remove the engine lift from the engine. Position the engine/transaxle assembly under the vehicle. Carefully lower the vehicle over the engine/transaxle

Please visit our web site at www.chiltonsonline.com

22-6

GENERAL MOTORS CORPORATION-E & K-BODIES DEVILLE e ELDORADO ¢ SEVILLE

assembly. Place dowel pins in the alignment holes, align the engine frame with the vehicle. e 6 frame mounting bolts and tighten to 141 ft. Ibs. (191 Nm) e Nut attaching the left transaxle mount to the transaxle mount bracket and tighten to 59 ft. Ibs. (80 Nm) e Nut securing the right engine mount to the engine mount bracket and tighten to 59 ft. Ibs. (80 Nm) 17. Remove the powertrain support dolly from under the engine assembly. Torque converter to flywheel bolts and tighten to 44 ft. Ibs. (60 Nm) Torque converter cover Oil pan to transaxle brace bolts and tighten and tighten to 37 ft. Ibs. (50 Nm) Exhaust front pipe Post HO2S sensor pigtail Wheel speed and brake wear sensors at the strut towers Intermediate shaft to the steering gear Pinch bolt and tighten to and tighten to 33 ft. Ibs. (45 Nm) A/C suction and discharge hoses to the compressor and tighten the nuts to 15 ft. Ibs. (20 Nm)

Shift cable to the manual shift lever and bracket Vacuum hose to the brake booster EVAP hose to the EVAP purge valve Fuel lines Heater hoses Brake pipes to the master cylinder and tighten the brake pipes to 11 ft. lbs. (15 Nm) Surge tank inlet pipe NEW accelerator control cable Cruise control cable to the throttle body Lower transaxle oil cooler line to the radiator and tighten to 26 ft. lbs. (35 Nm) Spring clip to the fitting. Push the upper transaxle oil cooler line into the radiator quick connect fitting, until a “click” is heard. Tug gently on the cooler line to ensure proper retention. Slide the plastic cap (1) over the quick connect joint. Upper transaxle oil cooler line retaining bolt to the fan shroud and tighten to 53 inch Ibs. (6 Nm) Inlet and outlet radiator hoses Intake manifold sight shield and tighten the nuts to 27 inch Ibs. (3 Nm) Air cleaner assembly

e PCM connections e Upper filler panel 19. Fill the cooling system 20. Recharge the A/C Refrigerant System 21. Connect the negative battery cable. 22. Fill the crankcase. 23. Perform the Crankcase Position (CKP) system variation learn procedure. 24. Bleed the brake system 25. Align the vehicle.

Water Pump REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the coolant. 3. Remove or disconnect the following: Negative battery cable Upper fill panel, if equipped AIR injection control valve, if equipped Air cleaner Oil level indicator tube nut, if necessary e Water pump belt cover Water pump drive belt Lower radiator hose

>The engine oil cooler quick connect fittings must be replaced whenever they are removed from the engine oil filter adapter.

e Engine oil cooler quick connect fittings to the engine oil filter adapter and tighten to 13 ft. Ibs. (18 Nm) 18. Push the engine oil cooler lines fully into the oil cooler quick connect fittings, until a click is heard. Slide the dust cover over the quick connect joint. Air deflector Dampening sensor links Road sensing suspension connectors Wheel speed sensor connectors Brake pipes to both front frame brackets and tighten to 11 ft. Ibs. (15 Nm) Rear brake pipes at the rear of the engine frame and tighten to 11 ft. lbs. (15 Nm) Struts to the strut towers Wheels Strut tower bolts and washers and tighten to 30 ft. Ibs. (40 Nm) Engine ground cable Main engine harness Electrical harness to the underhood fuse block

| WATER PUMP ASSEMBLY 2 O-RING SEAL 3

WATER PUMP

HOUSING ASSEMBLY 7922VG01

To ensure proper operation, be sure to install a new O-ring

E & K-BODIES-GENERAL MOTORS CORPORATION DEVILLE ¢ ELDORADO SEVILLE ¢ Thermostat bypass hose from the coolant inlet housing e Water pump cover 4. Remove the water pump by rotating it clockwise using special Tool J 38816-1A (water pump remover/installer). To install: 5. Install the Water pump with a new Oring, by turning it counterclockwise using the J 38816-1A, until it stops. Torque the water pump to 73 ft. Ibs. (100 Nm). 6. Install or connect the following: e Water pump cover. Torque the bolts to 89 inch Ibs. (10 Nm). Lower radiator hose Thermostat bypass hose to the coolant inlet housing Water pump drive belt Water pump belt cover Oil level indicator tube nut, if necessary Air cleaner AIR injection control valve, if equipped Upper fill panel, if equipped e Negative battery cable 7. Refill and bleed the cooling system. 8. Run the engine and check for leaks.

Cylinder Head REMOVAL & INSTALLATION 1998-99 Models «>The manufacturer recommends that the entire powertrain be removed from the vehicle before removing the cylinder heads.

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the cooling system. 3. Properly relieve the fuel system pressure. 4. Remove or disconnect the following: Negative battery cable Powertrain assembly from the vehicle Intake manifold

22-1

e Timing chain tensioner ¢ Camshaft sprockets ~The timing chain remains in the chain case.

Timing chain guides. Access for the retaining screw is through the plugs at the front of the cylinder head. Water crossover Exhaust manifolds Cylinder head bolts by reversing the torque sequence Cylinder head

7922VG02

Left cylinder head bolt torque sequence— 1998-99 4.6L engine

With the camshafts remaining in the cylinder head some valves will be open at all times. Do not rest the cylinder head on a flat surface with the cylinder face down, or valve damage will resuit.

Be careful when cleaning aluminum gasket surfaces to prevent damage to the sealing surfaces. 5. Check the cylinder head for warpage; it must be less than 0.002 inches (0.05mm). lf the cylinder head was resurfaced, the dimension between the combustion chamber gauge pad and the deck surface must be at least 10.5mm. To install: 6. Install the cylinder head with a new gasket. Lubricate the bolts with engine oil prior to installation. 7. Torque the M11 bolts in sequence as follows: a. Step 1: 22 ft. Ibs. (30 Nm), plus an additional 60 degrees. b. Step 2: Turn an additional 60 degrees. c. Step 3: Turn an additional 60 degrees (total 180 degrees).

7922VG03

Right cylinder head bolt torque sequence—1998-99 4.6L engine

8. Torque the M6 bolts to 106 inch Ibs. (12 Nm). 9. Install or connect the following: Camshaft covers. Torque the screws to 89 inch Ibs. (10 Nm). Oil pump. Torque the bolts to 20 ft. lbs. (27 Nm). Crankshaft balancer. Torque the bolt to 37 ft. Ibs. (60 Nm) plus an additional 120 degrees. Camshaft sprockets. Torque the bolts to 90 ft. Ibs. (120 Nm). Timing chain tensioner. Torque the bolts to 20 ft. Ibs. (27 Nm).

id

Camshaft covers Crankshaft balancer

10.5mm

Timing chain front cover Oil pump

ck WARNING—

GAUGE PAD

Align all timing marks before performing the next step.

7922VG04

Minimum head resurface dimension

Timing belt service is covered in Section 3 of this manual

22- 8

GENERAL MOTORS CORPORATION-E & K-BODIES DEVILLE e ELDORADO « SEVILLE

Timing chain guides. Torque the bolts to 20 ft. Ibs. (27 Nm). Timing chain front cover. Torque the bolts to 89 inch Ibs. (10 Nm). Camshaft covers. Torque the screws to 89 inch Ibs. (10 Nm). Intake manifold. Torque the bolts to 89 inch Ibs. (10 Nm). Water crossover. Torque the bolts to 18 ft. Ibs. (25 Nm). Exhaust manifolds. Torque the nuts to 22 ft. Ibs. (30 Nm) and the bolts

to 18 ft. Ibs. (25 Nm). Powertrain assembly to the vehicle Negative battery cable 10. Fill the cooling system. 11. Run the engine and check for leaks.

2000-01 Models LEFT SIDE 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the cooling system. 3. Properly relieve the fuel system pressure. 4 Remove or disconnect the following: Negative battery cable Exhaust manifold Alternator Water crossover Intake manifold Valve cover Timing cover Secondary camshaft drive chain Power steering return hose retaining bolt from the cylinder head 3 M6 external drive bolts from the front portion of the cylinder head 10 M11 internal drive cylinder head bolts Cylinder head and gasket. 5. Clean the head mating surfaces.

9346AG27

Left cylinder head bolt torque sequence— 2000-01 4.6L engine

To install:

6. Install the cylinder head with a new gasket. Lubricate the bolts with engine oil prior to installation. 7. Torque the M11 bolts in sequence as follows:

a. Step 1: 30 ft. Ibs. (40 Nm), plus an additional 70 degrees b. Step 2: Turn an additional 60 degrees c. Step 3: Turn an additional 60 degrees (total 190 degrees) 8. Torque the M6 bolts to 106 inch Ibs. (12 Nm) 9. Install or connect the following: Power steering return hose retaining bolt to the cylinder head and tighten to 37 ft. Ibs. (50 Nm) Secondary camshaft drive chain Timing cover Valve cover Intake manifold Water crossover Exhaust manifold Negative battery cable 10. Change the oil and filter. 11. Fill the cooling system.

RIGHT SIDE 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the cooling system. 3. Properly relieve the fuel system

pressure. 4, Remove or disconnect the follow-

ing:

Negative battery cable Exhaust manifold Water crossover Intake manifold Valve cover Timing cover Secondary camshaft drive chain Electrical connector from the Engine Coolant Temperature (ECT) sensor Nut attaching the coil cassette ground wire to the cylinder head Boltattaching the exhaust crossover pipeto the cylinder head Boltattaching the right transaxle mount bracketto the cylinder head Boltattaching the rear transaxle brace to the transaxle Nuts attaching the rear transaxle brace to the cylinder head Rear transaxle brace 3 M6 external drive bolts from the front portion of the cylinder head

e 10 M11 internal drive cylinder head bolts ¢ Cylinder head and gasket 5. Clean the head mating surfaces. To install: 6. Install the cylinder head with a new gasket. Lubricate the bolts with engine oil prior to installation. 7. Torque the M11 bolts in sequence as follows: a. Step 1: 30 ft. Ibs. (40 Nm), plus an additional 70 degrees. b. Step 2: Turn an additional 60 degrees. c. Step 3: Turn an additional 60 degrees (total 190 degrees). 8. Torque the M6 bolts to 106 inch Ibs.

(12 Nm). 9. Install or connect the following: Rear transaxle brace over the studs located at the rear of the right cylinder head Nuts attaching the rear transaxle brace to the cylinder head, loosely Bolts attaching the rear transaxle braces to the transaxle and tighten to 37 ft. Ibs. (50 Nm) Nuts attaching the rear transaxle brace to the cylinder head and tighten 37 ft. Ibs. (60 Nm) Electrical connector to the ECT sensor Bolt attaching the exhaust crossover pipe to the cylinder head and tighten to 18 ft. Ibs. (25 Nm) Nut attaching the coil cassette ground wire to the cylinder head and tighten to 13 ft. Ibs. (17 Nm) Secondary camshaft drive chain Timing cover Valve cover Intake manifold Water crossover Exhaust manifold Negative battery cable

wey CKShe NG

po acial The intake manifold carrier gaskets are attached to the intake manifold through a snap-lock feature. When removing the intake manifold, the carrier gaskets will remain attached to the intake manifold. DO NOT replace the intake manifold gaskets after intake manifold removal. The gaskets are reusable. The gaskets should be

7922VG05

Exploded view of the intake manifold mounting—4.6L engine

replaced if the plastic housing or the rubber seals are damaged.

To install: 5. Intake manifold. Torque the bolts and studs to 89 inch Ibs. (10 Nm). Start at the center of the manifold and work outward in a circular pattern. DO NOT torque the intake manifold bolts when the engine is HOT or at operating temperature. 6. Install or connect the following: Fuel injector harness connector PCV hose

Fuel bracket at the EGR valve Fuel lines to the fuel rail Fuel rail ground wire. Torque the bolt to 97 inch Ibs. (11 Nm). Brake booster vacuum hose EGR pipe. Torque the bolt to 21 ft. lbs. (28 Nm). PCV pipe at the throttle body spacer Throttle body coolant hoses Surge tank pipe Alternator coolant hoses Purge solenoid harness. Torque the retaining bolt to 106 inch Ibs. (12 Nm). Spark plug wires Throttle cable Cruise contro! cable TPS sensor electrical connector IAC valve electrical connector Transaxle vent hose Transaxle shift cable at the bracket Air inlet duct Negative battery cable 7. Turn the ignition switch to RUN to pressurize the fuel system and inspect for leaks. 8. Install the engine cover. Torque the cover nuts to 89 inch Ibs. (10 Nm). 9, Fill and bleed the cooling system 10. Road test the vehicle.

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Relieve the fuel system pressure. 3. Drain the cooling system. 4 Remove or disconnect the following: Negative battery cable Intake manifold heat shield Sight shield Coil module connectors from the coil modules located on the valve covers Positive Crankcase Ventilation (PCV) hose and valve from the valve cover Fuel regulator vacuum tube Vacuum tubes from the AIR solenoid Fuel inlet and return lines Fuel rail bracket retaining nut at the rear lift bracket 2 pushnuts attaching the engine coolant heater wire and set it aside, if equipped Alternator coolant pipe/surge tank pipe and position aside from the fuel rail studs Fuel injector electrical connections Fuel rail and injectors Plenum duct clamp at the rear of the intake manifold, loosen Intake manifold bolts and the manifold 5. Clean the manifold mating surfaces. To install: 6. Grease the inside edge of the rubber plenum duct, 7. Position the intake manifold by performing the following sub-steps: a. Place the rear of the intake manifold into the plenum duct. b. Place the front of the intake manifold downward on to the cylinder heads. 8. Install the intake manifold bolts and torque to 89 inch Ibs. (10 Nm). Start at the center of the manifold and work outward in a circular pattern. DO NOT torque the intake manifold bolts when the engine is HOT or at operating temperature. 9, Make sure the plenum duct is fully attached to the rear of the intake manifold and tighten the plenum duct clamp to 20 inch Ibs. (2.25 Nm). 10. Install or connect the following: e Fuel rail and injectors and tighten the rail retainers to 35 inch Ibs. (4 Nm) e Fuel injector electrical connections

Heater Core replacement is covered in Section 2 of this manual

22-1 0 GENERAL MOTORS CORPORATION-E & K-BODIES DEVILLE * ELDORADO « SEVILLE Alternator coolant pipe/surge tank pipe and position onto the fuel rail studs Engine coolant heater wire onto the Studs and install the pushnuts, if equipped Fuel rail bracket retaining nut at the rear lift bracket and tighten to 35 inch Ibs. (4 Nm) Fuel inlet and return lines Vacuum tubes to the AIR solenoid Fuel regulator vacuum tube Positive Crankcase Ventilation (PCV) valve and hose to the valve cover Coil module connectors to the coil modules located on the valve covers Sight shield Intake manifold heat shield Negative battery cable 11. Fill and bleed the cooling system.

e Engine mount-to-mount bracket nuts * Y-pipe from the front of the catalytic converter 4. Raise the engine. e Engine mount and bracket e Rear alternator bracket ¢ Manifold outlet flange bolts ¢ Oxygen (02S) sensor connector e Exhaust manifold To install: 5. Install or connect the following: e Exhaust manifold with a new gasket by inserting the outlet pipe partially into the exhaust crossover pipe. Torque all the bolts to 18 ft. Ibs. (25 Nm). OS sensor connector Rear alternator bracket. Torque the crankcase bolts to 44 ft. Ibs. (60 Nm), and the alternator bolts to 22

ft. Ibs. (30 Nm). Exhaust Manifold

REMOVAL & INSTALLATION Left Side

1998-99 MODELS 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: ¢ Negative battery cable e Radiator cover panel ¢ Air cleaner assembly ¢ Left and right engine torque struts e Engine cooling fans 3. Support the engine. e Engine mount-to-engine cradle nuts ¢ Engine mount bracket-to-crankcase bolts e Engine mount bracket-to-cylinder head bolts

Manifold outlet flange bolts. Torque the bolts to 25 ft. Ibs. (30 Nm). 6. Lower the engine into position. Guide the engine mount studs into the cradle holes and loosely install the fasteners. 7. Install or connect the following: e Engine mount-to-engine cradle nuts. Torque the nuts to 22 ft. Ibs.

(30 Nm). Engine mount bracket-to-crankcase bolts. Torque the bolts to 22 ft. Ibs.

(30 Nm). Engine mount bracket-to-cylinder head bolts. Torque the bolts to 22 ft. Ibs. (30 Nm). Engine mount-to-mount bracket nuts. Torque the nuts to 22 ft. Ibs.

(30 Nm). Converter-to-exhaust Y-pipe. Torque the bolts to 20 ft. Ibs. (27 Nm) 8. Remove the engine support fixture. Engine cooling fans Air cleaner assembly Left and right engine torque struts. Torque the bolts to 44 ft. Ibs. (60 Nm). Radiator cover panel Negative battery cable 9. Run the engine and check for exhaust leaks.

e e e e e.

Engine mount and bracket 2 bolts at the manifold outlet flange Oxygen (02S) sensor, if necessary Exhaust manifold bolts Manifold and the gasket. Discard the gasket. To install: 3. Install or connect the following: ¢ Exhaust manifold by inserting the outlet pipe partially into the exhaust crossover pipe ¢ Exhaust manifold with a new gasket. Torque the nuts to 25 ft. Ibs. (30 Nm). ¢ 02S sensor. Torque the sensor to 30 ft. Ibs. (40 Nm). ¢ Engine mount and bracket ¢ 2 nuts attaching the AIR tube to the exhaust manifold and tighten to 106 inch Ibs. (12 Nm) ¢ Negative battery cable

Right Side

1998-99 MODELS 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Negative battery cable ¢ Oxygen (02S) sensor and the harness clip e Y-pipe from the front of the catalytic converter ¢ Suspension position sensor from the lower control arm on both sides ¢ Intermediate shaft from the steering gear 3. Place a support below the rear crossmember of the engine cradle and remove the 4 cradle to body bolts. 4. Lower the rear of the engine cradle. e Y-pipe from the exhaust crossover and manifold e Exhaust manifold

2000-01 MODELS

9300VG03

Exploded view of the left exhaust manifold

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Negative battery cable ¢ 2 nuts attaching the AIR tube to the exhaust manifold

9300VG04

Exploded view of the right exhaust manifold

E & K-BODIES-GENERAL MOTORS CORPORATION ELDORADO ¢ SEVILLE

DEVILLE To install: 5. Install or connect the following: * QoS sensor. Torque the sensor to 30 ft. Ibs. (40 Nm). Exhaust manifold with a new gasket. Torque the nuts to 25 ft. Ibs. (30 Nm). Y-pipe using 4 new bolts. Torque the M10 bolts to 35 ft. Ibs. (50 Nm) and the M8 bolts to 25 ft. Ibs. (30 Nm). Engine cradle. Torque the bolts to 79 ft. Ibs. (100 Nm). Intermediate shaft to the steering gear. Torque the bolts to 35 ft. Ibs. (50 Nm). Y-pipe to the catalytic converter. Torque the bolts to 35 ft. Ibs. (50 Nm). Suspension position sensors to the lower control arms

¢ (2S sensor harness clip e Negative battery cable 6. Run the engine and check for exhaust

leaks.

1998-99 MODELS 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Negative battery cable Oxygen (02S) sensor 2 nuts attaching the AIR tube to the exhaust manifold Exhaust front pipe Real time dampening sensor links from the lower control arms Intermediate shaft from the steering gear 3. Support the rear cross member of the engine cradle with a tall screw jack. e 4 rearward cradle-to-body bolts, then lower the rear of the engine cradle Right side cylinder head to the transaxle brace e Exhaust manifold nuts e Manifold and the gasket To install: 4. \nstall or connect the following: e Exhaust manifold with a new gasket. Torque the nuts to 25 ft. Ibs. (30 Nm). e Right side cylinder head to the transaxle brace and tighten the bolt and nut to 35 ft. Ibs. (47 Nm) 5. Raise the engine cradle into position. ¢ 4 rearward cradle-to-body bolts

and tighten to 141 ft. Ibs. (191 Nm)

6. Remove the screw jack. ltermediate shaft to the steering gear and tighten the pinch bolt to

35 ft. Ibs. (47 Nm) ¢ Real time dampening sensor links to the lower control arms e Exhaust front pipe ¢ New gasket to the AIR tube e 2 nuts attaching the AIR tube to the exhaust manifold and tighten to 106 inch Ibs. (12 Nm) ¢ 02S) sensor Negative battery cable

Camshaft and Valve Lifters REMOVAL & INSTALLATION 1998-99 Models

LEFT SIDE 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the coolant. 3. Disconnect the negative battery cable.

a omer ee y

sy

22-1 1

4, Remove the camshaft cover. 5. Secure the camshaft sprocket to the timing chain by installing tie-wraps through the camshaft sprocket holes. Use 4 tiewraps per sprocket. e>The sprocket/chain relationship must be maintained throughout this procedure or camshaft timing will be lost and require further engine disassembly to retime.

6. Working from behind the sprockets, install Camshaft Chain Holder J-38222 so that it is positioned between the chain tensioner and chain guide. Apply tension to the tool by tightening the tension adjusting Screw. 7. Remove or disconnect the following: e Camshaft sprocket bolts e Sprockets off the camshafts e» Alternately loosen the camshaft bearing cap screws a few turns at a time until all valve spring pressure has been released.

e Camshaft bolts and caps e Camshaft e Valve lifters

8

ave

9300VG01

Use the Camshaft Chain Holder tool J-38822 to keep the chain in position while removing the camshafts

Brake service is covered in Section 4 of this manual

22-1

GENERAL MOTORS CORPORATION-E & K-BODIES DEVILLE e ELDORADO e SEVILLE

8. Inspect the lifters for wear and/or damage; replace as necessary. 9. Inspect the camshaft for excessive lobe wear. Check the bearing journals, making sure they are not scored or burned. Replace the camshaft as necessary. To install: 10. Install the valve lifters in the same bore from which they were removed. 11. Lubricate the camshaft lobes and the camshaft journals with clean engine oil. 12. Install or connect the following: e Camshaft e Camshaft bearing caps e»Each cap is identified for position and direction. The arrow points towards the front of the engine. AnE indicates a cap for the exhaust camshaft. Anl indicates a cap for the intake camshaft. Position No. 1 is towards the front of the engine.

13. Install the camshaft bearing cap bolts loosely. 14. Alternately, tighten the camshaft bearing cap bolts a few turns at a time against valve spring pressure until all the bolts are snug. Torque the bolts to 106 inch lbs. (12 Nm). 15. Using the hex cast into the camshaft, rotate the camshafts until the drive pins are in position to engage the camshaft sprockets over the camshafts, and install the retaining bolts. Torque the bolts to 90 ft. lbs. (120 Nm). 16. Remove the Chain Holder Tool J38222. 17. Remove the tie-wraps from the camshaft sprockets. 18. Install or connect the following: ¢ Camshaft cover. Torque the screws to 89 inch Ibs. (10 Nm), ¢ Negative battery cable 19. Refill the cooling system. 20. Run the engine and check for leaks.

RIGHT SIDE 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Negative battery cable e Exhaust manifold rear pipe at the converter Ignition Control Module (ICM) wiring harnesses ICM Spark plug wires on the right bank Positive Crankcase Ventilation (PCV) valve Purge canister solenoid from the rear of the camshaft cover

e Wiring harness from the camshaft cover e Camshaft cover screws 3. Support the front of the engine cradle. e Mounting screws at the front of the cradle e Right and left torque struts 4. Lower the engine cradle or raise the vehicle to provide clearance at the rear of the engine compartment. 5. Remove the camshaft cover. e»>The spark plug seals may be reused if undamaged.

6. Secure the camshaft sprocket to the timing chain by installing tie-wraps through the camshaft sprocket holes. Use 4 tiewraps per sprocket. e>The sprocket/chain relationship must be maintained throughout this procedure or camshaft timing will be lost and require further engine disassembly to retime.

7. Working from behind the sprockets, install Camshaft Chain Holder J-38222 so that it is positioned between the chain tensioner and chain guide. Apply tension to the tool by tightening the tension adjusting Screw. ¢ Both camshaft sprocket bolts ¢ Sprockets off the camshafts 8. Alternately loosen the camshaft bearing cap screws a few turns at a time until all valve spring pressure has been released. ¢ Camshaft bolts and caps ¢ Camshaft 9. Inspect the camshaft for excessive lobe wear. Check the bearing journals, making sure they are not scored or burned. Replace the camshaft, as necessary. To install: 10. Lubricate the camshaft lobes and camshaft journals with clean engine oil. 11. Install or connect the following: ¢ Camshaft ¢ Camshaft bearing caps e>Each cap is identified for position and direction. The arrow points towards the front of the engine. An E indicates a cap for the exhaust camshaft. An | indicates a cap for the intake camshaft. Position No. 1 is towards the front of the engine.

12. Install the camshaft bearing cap bolts loosely. 13. Alternately, tighten the camshaft bearing cap bolts a few turns at a time against valve spring pressure until all the bolts are snug. Torque the bolts to 106 inch

Ibs. (12 Nm).

14. Using the hex cast into the camshaft, rotate the camshafts until the drive pins are in position to engage the camshaft sprockets over the camshafts and install the retaining bolts. Torque the bolts to 90 ft. Ibs. (120 Nm).

15. Remove the Chain Holder Tool J38222. 16. Remove the tie-wraps from the camshaft sprockets. 17. Install or connect the following: e Spark plug and camshaft cover seals : e Camshaft cover. Torque the screws to 84 inch Ibs. (10 Nm). ¢ Engine cradle. Torque the bolts to

75 ft. Ibs. (100 Nm). 18. Install the right and left torque struts and torque the bolts to 45 ft. Ibs. (60 Nm). e>|t is important during installation that the engine torque struts are not preloaded in their installed position. Adjustment is provided at the point the Strut fastens to the core support bracket. Be sure this bolt is loose during assembly.

¢ Wiring harness to the camshaft cover ¢ Purge canister solenoid e PCV valve ¢ ICM ¢ Spark plug wires on the right bank ¢ ICM wiring harnesses ¢ Negative battery cable e Exhaust manifold rear pipe to the converter. Torque the bolts to 20 ft. Ibs. (27 Nm). 19. Run the engine and check for leaks. 2000-01 Models

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove both camshaft covers. 3. Secure the camshaft sprockets to the timing chain by installing tie wraps through the camshaft sprocket holes, 4. Working behind the sprockets, install camshaft Chain Holder J38822 so that it is positioned between the chain tensioner and guide. Apply tension to the tool by tightening the tension adjusting screw. 9. Remove or disconnect the following: ¢ Both camshaft sprocket bolts ¢ Both camshaft sprockets _ 6. Alternately loosen the camshaft bearINg Cap Screws a few turns at a time until all valve spring pressure has been released. 7. Remove the bolts and bearing caps. 8. Remove the camshaft.

E & K-BODIES-GENERAL MOTORS CORPORATION 22-1 3 DEVILLE ¢ ELDORADO SEVILLE To install: 9. Lubricate the camshaft lobes and camshaft journals with clean engine oil. 10. Position the camshaft bearing caps in the cylinder head and loosely install the bolts. 11. Tighten the camshaft bearing cap bolts in the sequence shown, to 44 inch Ibs. (5 Nm), plus 30 degrees. 12. Using the hex cast into the camshaft, position the camshafts to accept the camshaft sprockets.

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13. Install the camshaft sprockets onto the camshafts. Torque the bolts to 89 ft. Ibs. (120 Nm). 14, Remove the Chain Holder J38822 and the tie wraps. 15. Install the left and right camshaft Covers.

Valve Lash

ADJUSTMENT The valve clearance cannot be adjusted. The engines in this section are equipped with hydraulic lifters and no adjustment is possible.

Starter Motor

2

REMOVAL & INSTALLATION

9346AG01

Torque sequence for the camshaft bearing cap bolts.

7922VG06

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Negative battery cable e Intake manifold e Starter electrical connectors

e Starter motor To install: 3. Install or connect the following: e “S” terminal wire. Torque the nut to 26 inch Ibs. (3 Nm). Starter electrical connectors. Torque the nut to 70 inch Ibs. (8 Nm). Starter motor Mounting bolts. Torque the bolts to 22 ft. Ibs. (30 Nm). Intake manifold Negative battery cable

Left cylinder head camshaft bearing cap torque sequence—4.6L engine

9306AG02

View of starter motor removal and wires

REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the crankcase. 3. Remove or disconnect the following: e Negative battery cable e (il level indicator harness connector, if equipped e Exhaust crossover pipe e Transaxle assembly from the vehicle e Oil pan bolts and the oil pan To install: >The oil pan gasket is reusable unless it is damaged. Do not remove the gasket from the oil pan groove unless gasket replacement is required.

4 Thoroughly clean the inside of the oil pan and the cylinder block contact surface. lf the oil pan gasket is being reused, be careful not to damage it. Do not expose the gasket to cleaning solvents.

7922VG07 7922VG08

Right cylinder head camshaft bearing cap torque sequence—4.6L engine

Oil pan bolt torque sequence

For complete Engine Mechanical specifications, see Section 1 of this manual

22-1 4 GENERAL MOTORS CORPORATION-E & K-BODIES DEVILLE e ELDORADO « SEVILLE 5. Ifa new gasket is being installed, start the gasket into the oil pan groove and work the gasket into the groove in both directions. Once the gasket is exposed to oil, it will expand and no longer stay in the groove without wrinkles. If this condition exists, replace the gasket. 6. Install or connect the following: Oil pan. Torque the bolts in sequence to 89 inch Ibs. (10 Nm). Oil level indicator connector, if equipped Exhaust crossover pipe Transaxle assembly Oil pan drain plug. Torque it to 15 ft. Ibs. (20 Nm). Negative battery cable 7. Refill the crankcase. 8. Run the engine and check for leaks.

Accessory drive belt Power steering hose retainer Right front wheel Wheel well splash shields Oil pan-to-transaxle brace Crankshaft balancer Drive belt tensioner Drive belt idler pulley Front cover and gasket >The front cover gasket is reusable as long as it is not damaged.

¢ Oil pump mounting bolts e Oil pump e Drive spacer from the pump housing ¢ Screws holding the pump housing halves together e Inner (drive) and outer (driven) rotors from the housing e Pressure relief valve

REMOVAL & INSTALLATION

e>|f any components show signs of excessive wear or damage, replace the pump assembly.

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: ¢ Negative battery cable

To install: 3. Install the inner and outer rotors to the pump cover in the same orientation as removed. 4. Install the pressure relief valve seat, spring and pilot in the pump housing.

1. 2. 3. 4.

Gerotor assembly Outer gear Inner gear Housing

5. Pack the pump housing halves with Amojell® or white petroleum grease to ensure pump priming. 6. Assemble the housing and cover over the locating dowel. 7. Insert a 9mm drill in the pump mounting hole on the opposite side to aid alignment of the housing and cover. Install the 2 screws and torque to 108 inch Ibs. (12 Nm). 8. Install or connect the following: e Qil pump drive spacer into the oil pump from the rear so the drive flat engages the pump rotor e Qil pump over the crankshaft e Qil pump bolts, finger tight 9. Hold the pump in its furthest up position. Torque the mounting bolts (1, 2 and 3), in sequence, to 89 inch Ibs. (10 Nm); then an additional 35 degrees. 10. Place a small amount of RTV sealant at the split line of the upper and lower crankcases. 11. Install or connect the following: Front cover gasket on the dowel pins on the block Front cover. Torque the bolts to 89 inch Ibs. (10 Nm). Drive belt idler pulley. Torque the bolt to 37 ft. Ibs. (50 Nm). Drive belt tensioner. Torque the bolt to 37 ft. Ibs. (50 Nm). Crankshaft balancer. Torque the bolt to 37 ft. Ibs. (50 Nm) plus an additional 120 degree turn. Qil pan-to-transaxle brace. Torque the bolts to 37 ft. Ibs. (50 Nm). Wheel well splash shield Wheel Power steering hose retainer Accessory drive belt Negative battery cable 12, Run the engine and check for proper engine oil pressure, and for possible leaks.

5. Drive spacer 6. Relief valve 7. Cover 7922VG09

Exploded view of the oil pump

9346AG02

Oil pump torque sequence

E & K-BODIES-GENERAL MOTORS CORPORATION 22-1 5 DEVILLE ¢ ELDORADO « SEVILLE Rear Main Seal

REMOVAL & INSTALLATION 1998-99 Models 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Transaxle e Flexplate e Rear main seal using a suitable prytool

Use care not to damage the crankshaft seal surface with a pry tool. To install: 3. Before installing, lubricate the seal bore and seal surface with clean engine oil. 4. Install the new seal using seal installer J38817. = Check to see that the seal is squarely seated in the bore.

5. Install or connect the following: e Flexplate. Torque the bolts to 11 ft. lbs. (15 Nm) plus an additional 50 degree turn. e Transaxle 6. Start the engine and check for leaks.

2000-01 Models 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Transaxle e Flexplate 3. Place oil seal removal Too! J 42841 on to the crankshaft.

4. Install the tool retaining bolts. 5. Using a drill with a socket adapter, install eight one-inch self-drilling crews into the seal using the guide holes in the removal tool. When drilling, make sure you reduce the drill speed when the screw begins threading into the seal. 6. With all eight removal screws installed, remove the removal tool retaining bolts. 7. Install the removal tool center screw. 8. Tighten the screw until the seal is removed. To install: 9. Clean any debris from the crankshaft rear oil seal drain using wire or an unbound plastic tie-wrap. 10. Coat the outer diameter of the cylinder block crankshaft rear oil seal area with clean engine oil ->DO NOT allow any engine oil on the area where the crankshaft rear oil seal is to be pressed onto the crankshaft. The green coating pre-applied to the inner diameter of the crankshaft rear oil seal must not be contaminated.

11. Wipe the outer diameter of the flywheel flange clean with a lint-free cloth. 12. Lubricate the outer rubber surface of the crankshaft rear oil seal with clean engine oil. 13. Loosen the center bolt of the removal tool until the center hub protrudes approximately one-half inch beyond the outer plate. It is not necessary to completely unthread the center bolt and separate the two pieces of the installation Tool J 42842. Place the installation tool on to the crankshaft. 14. Thread the three mounting bolts into the crankshaft flange. 15. Tighten the bolts until the installation tool is firmly mounted on the crankshaft.

J ee 9346AG20 9300VG05

Exploded view of the rear main oil seal

Removing the rear main seal—2000-01

models

9346AG21

Clean any debris from the crankshaft rear oil seal drain using wire or an unbound plastic tie-wrap—2000-01 models

16. Install the crankshaft rear oil seal by tightening the center bolt until the installation tool bottoms against the crankcase. 17. Loosen the center bolt to release pressure on the crankcase. 18. Loosen the three mounting bolts. 19. Remove the installation tool from the crankshaft flange. 20. Inspect to ensure the installation depth is equal around the crankshaft rear oil seal’s circumference. If the depth is not equal reinstall the tool and repeat the installation procedures. 21. Install the flexplate. Torque the bolts to 11 ft. Ibs. (15 Nm) plus an additional 50 degree turn. 22. Install the transaxle. 23. Start the engine and check for leaks.

Timing Chain, Sprockets, Front Cover and Seal REMOVAL & INSTALLATION The left and right-side secondary timing chains can be removed with the engine in the vehicle. If the primary timing chain or intermediate shaft sprocket need to be replaced, the engine must be removed from the vehicle and supported on an engine stand. e»Setiing the camshaft timing is necessary whenever the camshaft drive system has been disturbed, meaning the relationship between any chain and sprocket has been lost. Correct timing exists when the crankshaft and intermediate shaft sprocket timing marks are in alignment and all 4 camshaft drive pins are perpendicular (90 degrees) to the cylinder head surface.

For Accessory Drive Belt illustrations, see Section 1 of this manual

22-1

GENERAL MOTORS CORPORATION-E & K-BODIES DEVILLE * ELDORADO ¢ SEVILLE

SECOND PUSH DOWN

FIRST PRESS IN

7922VG11

Rotating tensioner release lever

9300VG02

and the camshaft drive pin remains perpendicular to the cylinder head face. A hex is cast into the camshafts behind the lobes for cylinder No. 1, So an open end wrench may be used to provide minor repositioning of the camshafts. 7. Install or connect the following: e Both camshaft sprocket bolts loosely ¢ Chain tensioner. Torque the mounting bolts to 20 ft. Ibs. (27 Nm). 8. Torque the camshaft sprocket bolts

to 90 ft. Ibs. (120 Nm). e Spark plug and camshaft cover Seals

Correct timing chain alignment

Right Side Secondary Chain 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Negative battery cable Exhaust Y-pipe at the converter Tower-to-tower brace Ignition Control Module (ICM) wiring connectors and mounting bolts ICM Spark plug wires on the right bank Positive Crankcase Ventilation (PCV) valve Canister purge solenoid from the rear of the cover Front cover Camshaft cover screws Right and left torque struts 3. Safely support the front of the engine cradle and remove the 2 mounting bolts at the front of the cradle. 4. Lower the engine cradle or raise the vehicle to provide clearance at the rear of the engine compartment. ¢ Camshaft cover

¢ Camshaft cover. Torque the screws e»The camshaft cover gasket is reusable as long as it is not damaged.

e Right side secondary chain tensioner ¢ Right side chain guide. Access the upper chain guide mounting bolt through the hole in the cylinder head capped with the plastic plug. ¢ Right side camshaft sprocket bolts and camshaft sprockets ¢ Secondary drive chain To install: 5. Install the secondary timing chain over the outer row of teeth on the intermediate shaft sprocket. Route the chain over the chain guide and install the exhaust camshaft sprocket so the RE (Right Head Exhaust) pin engages the sprocket notch. There should be no slack in the lower section of the timing

chain and the camshaft drive pin must be perpendicular to the cylinder head face.

~The right exhaust (RE) camshaft sprocket must contain the Camshaft Position (CMP) sensor pick-up.

6. Install the intake camshaft sprocket into the chain so the sprocket notch RI (Right Head Intake) engages the camshaft

to 84 inch Ibs. (10 Nm). e Engine cradle. Torque both bolts to 75 ft. Ibs. (100 Nm). 9. Install the right and left torque struts. Torque the retaining bolts to 45 ft. Ibs. (60 Nm).

e>|t is important during installation that the engine torque struts are not preloaded in their installed position. Adjustment is provided at the point the Strut fastens to the core support bracket. Be sure this bolt is loose during assembly.

Front cover. Torque the bolts to 89 inch lbs. (10 Nm). Strut-to-core support bracket bolt. Torque it to 45 ft. Ibs. (60 Nm). Canister purge solenoid to the rear of the cover PCV valve ICM and the wiring connectors Spark plug wires on the right-bank Tower-to-tower brace Exhaust Y-pipe to the converter. Torque the bolts to 20 ft. Ibs. (27 Nm). Negative battery cable 10. Start the engine and check for leaks.

E & K-BODIES-GENERAL MOTORS CORPORATION

DEVILLE e ELDORADO « SEVILLE

Left Side Secondary Chain 1. Before servicing the vehicle, refer to ieprecautions in the beginning of this secion. 2. Drain the cooling system. 3. Remove or disconnect the following: Negative battery cable Accessory drive belt Front cover bolts Front cover and gasket Power steering hose Right front wheel Splash shields from the wheel well Flexplate cover Crankshaft balancer bolt 4. Support the engine cradle. ¢ 3 right-side engine cradle bolts ¢ Road Sensing Suspension (RSS) sensor from the right control arm 5. Lower the cradle to gain access for the crankshaft balancer puller. e Crankshaft balancer Drive belt tensioner Drive belt idler pulley Upper radiator hose at the water CrOSSOver Spark plug wires Right side cooling fan Battery cable at the alternator Battery cable harness at the camshaft cover Positive Crankcase Ventilation (PCV) fresh air tube from the camshaft cover Water pump pulley Camshaft seal retainer screws and the seal Battery cable retainer at the front of the camshaft cover Camshaft cover by pivoting the entire cover around the water pump driveshaft. Continue moving the cover upward and pivoting so that the edge of the cover closely follows the left edge of the intake manifold cover. >The camshaft cover gasket is reusable as long as it is not damaged.

Right side secondary chain Left side secondary chain tensioner Left side chain guide. Access the upper chain guide mounting bolt through the hole in the cylinder head capped with the plastic plug. Left side camshaft sprocket bolts and sprockets Secondary drive chain

i vy

(a)

Uf a) 1 RELEASE TO FIRST CLICK 2 INSTALL LOCK PIN 7922VG12

22-1 T

Crankshaft balancer. Torque the bolt to 44 ft. Ibs. (60 Nm) plus an additional 120 degree turn. Engine cradle. Torque the bolts to 75 ft. Ibs. (102 Nm). RSS sensor Wheel well splash shields Flexplate cover Spark plug and camshaft cover Seals Intake camshaft through the hole in the camshaft cover

Locking the tensioner in the collapsed position

To install: 6. Route the secondary timing chain for the left side over the inner row of intermediate sprocket teeth. 7. Install or connect the following: e Secondary timing chain over the inner row of teeth on the intermediate shaft sprocket. Route the chain over the chain guide and install the exhaust camshaft sprocket so the LE (Left Head Exhaust) pin engages the sprocket notch. There should be no slack in the lower section of the timing chain and the camshaft drive pin must be perpendicular to the cylinder head face. Intake camshaft sprocket into the chain so the sprocket notch LI (Left Head Intake) engages the camshaft and the camshaft drive pin remains perpendicular to the cylinder head face. A hex is cast into the camshafts behind the lobes for cylinder No. 2, so an open-end wrench may be used to provide minor repositioning of the camshafts. ° Both camshaft sprocket bolts loosely Chain tensioner. Torque the mounting bolts to 20 ft. Ibs. (27 Nm). 8. Torque the camshaft sprocket bolts to 90 ft. Ibs. (120 Nm). ¢ Front cover gasket on the dowel pins on the block Front cover. Torque the bolts to 89 inch Ibs. (10 Nm). Apply a dab of RTV to the split line between the upper and !ower crankcase assemblies. Drive belt idler pulley. Torque the bolt to 35 ft. Ibs. (47 Nm). Drive belt tensioner. Torque the nut to 35 ft. Ibs. (47 Nm).

Use care to prevent the exposed section of the camshaft cover seal from being damaged by the edge of the cylinder head casting. Camshaft cover Camshaft cover screws. Torque the screws to 84 inch Ibs. (10 Nm). Battery cable retainer to the front of the camshaft cover Battery cable at the alternator Camshaft seal to the end of the intake camshaft. Seal the screw threads with sealer. Water pump pulley PCV fresh air tube to the camshaft cover Right side fan Spark plug wires Upper radiator hose to the water crossover 9. Refill the cooling system.

Primary Chain/Intermediate Sprocket 1. Before servicing vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Engine e Accessory drive belt e Drive belt pulley e Dive belt tensioner e Front cover e Right and left camshaft covers Align all timing marks prior to removal of the timing chains.

Timing chain tensioners Camshaft sprocket bolts Camshaft sprockets (4) Right and left secondary chains Intermediate shaft sprocket bolt and the sprocket Primary timing sprockets and primary chain off the engine

For Tire, Wheel and Ball Joint specifications, see Section 1 of this manual

22-1 8 GENERAL MOTORS CORPORATION-E & K-BODIES DEVILLE e ELDORADO @ SEVILLE

To install:

>The following procedure must be followed to set the camshaft timing on the vehicle.

3. chain 4. drive 5.

Install the primary and secondary guides. Rotate the crankshaft until the sprocket key is at the 1 o'clock position. Install or connect the following: e Crankshaft sprocket and intermediate shaft sprocket in the primary timing chain so the timing marks are aligned e Primary timing chain assembly

>The crankshaft sprocket keyway will have to slide over the key on the crankshaft. If it is necessary to turn the crankshaft sprocket, the intermediate shaft sprocket will also have to be turned so the timing mark remains aligned with the crankshaft sprocket.

1 INTERMEDIATE SHAFT 2 PRIMARY CHAIN

3 INTERMEDIATE SHAFT SPROCKET 4 CRANKSHAFT SPROCKET KEY 5 SPROCKET

¢ Intermediate shaft sprocket bolt. Torque the bolt to 45 ft. Ibs. (61 Nm).

Primary timing chain tensioner. Torque the tensioner mounting bolts to 20 ft. Ibs. (27 Nm). Right and left secondary chains with the timing marks aligned Camshaft sprockets (4). Torque the bolts to 90 ft. Ibs. (120 Nm). Right and left camshaft covers. Torque the bolts to 89 inch Ibs. (10 Nm). Front engine cover. Torque the bolts to 89 inch Ibs. (10 Nm). Accessory drive belt Drive belt pulley Drive belt tensioner Engine 6. Refill the cooling system. 7. Start the engine and check for leaks.

Piston and Ring POSITIONING

Primary drive chain components

1. 2. 3. 4.

Oil ring segment gap Upper compression ring gap Oil ring segment gap Expander & lower compression ring gaps

Piston ring and ring end-gap positioning—4.6L engine

5. Expander ring 6. Oil segment rings 7. Lower compression ring 8. Upper compression ring 7922AG52

E & K-BODIES-GENERAL MOTORS CORPORATION

DEVILLE ¢ ELDORADO ¢ SEVILLE

%

1 8)

PISTON ARROW TOWARD CHAINCASE ON BOTH SIDES

RIGHT BANK

as

a

a

RIGHT BANK

BOTTOM

22

(ae

VIEW

LEFT BANK

8

(PAN - SIDE UP) TOP VIEW

(PAN - SIDE DOWN) ROD CAPS

BEARING CAP NOTCHES POINT TOWARD EACH OTHER ON PAIRED RODS

@FRT LOCATOR LUGS INDICATE PISTON FRONT TOWARDS ENGINE FRONT

ROD CAP

@FRT

BEARING CAP NOTCHES POINT TOWARD EACH OTHER ON PAIRED RODS

ROD CAP VIEW 7922AG53

Piston and connecting rod assembly positioning—4.6L engine

FUEL SYSTEM

Fuel System Service Precautions Safety is the most important factor when performing not only fuel system maintenance but also any type of maintenance. Failure to conduct maintenance and repairs in a safe manner may result in serious personal injury or death. Maintenance and testing of the vehicle's fuel system components can be accomplished safely and effectively by adhering to the following rules and guidelines. e To avoid the possibility of fire and personal injury, always disconnect the negative battery cable unless the repair or test procedure requires that battery voltage be applied. e Always relieve the fuel system pressure prior to disconnecting any fuel system component (injector, fuel rail, pressure regulator, etc.), fitting or fuel line connection. Exercise extreme caution whenever relieving fuel system pressure, to avoid exposing skin, face and eyes to fuel spray. Please be

advised that fuel under pressure may penetrate the skin or any part of the body that it contacts. e Always place a shop towel or cloth around the fitting or connection prior to loosening to absorb any excess fuel due to spillage. Ensure that all fuel spillage (should it occur) is quickly removed from engine surfaces. Ensure that all fuel soaked cloths or towels are deposited into a suitable waste container. Always keep a dry chemical (Class B) fire extinguisher near the work area. e Do not allow fuel spray or fuel vapors to come into contact with a spark or open flame. e Always use a back-up wrench when loosening. Torque the fuel line connection fittings. This will prevent unnecessary stress and torsion to fuel line piping. e Always replace worn fuel fitting Orings with new. Do not substitute fuel hose or equivalent, where fuel pipe is installed.

Fuel System Pressure RELIEVING

ste CAUTION The fuel injection system remains under pressure, even when the engine has been turned OFF. The fuel system pressure must be relieved before disconnecting any fuel lines. Failure to do so may result in fire and/or personal injury. 1. Before servicing vehicle, refer to the precautions at the beginning of this section. 2. Loosen the fuel filler cap to relieve tank vapor pressure.

tek CAUTION: Observe all applicable safety precautions when working around fuel. Whenever servicing the fuel system,

For Wheel Alignment specifications, see Section 1 of this manual!

22-2

GENERAL MOTORS CORPORATION-E & K-BODIES DEVILLE e ELDORADO e SEVILLE

always work in a well-ventilated area. Do not allow fuel spray or vapors to come in contact with a spark or open flame. Keep a dry chemical fire extinguisher near the work area. Always keep fuel in a container specifically designed for fuel Storage; also, always properly seal fuel containers to avoid the possibility of fire or explosion. 3. Be sure the ignition switch is in the OFF position. 4. Disconnect the negative battery cable. 5. Remove the engine cover.

+k CAUTION

:

There may still be residual fuel in the system, and a small amount of fuel may be released when servicing fuel lines or connections. In order to reduce the chance of personal injury, cover the fuel line fittings with a shop towel before disconnecting to catch any fuel that may leak out. 6. Install a fuel pressure gauge with a

drain hose attached, J-34730-1, or equivalent. Wrap a shop towel around the fitting while connecting the gauge to avoid spillage.

7. Install the drain hose into an approved container and open the valve to drain the system pressure. Fuel connections are now Safe for servicing. 8. Drain any remaining fuel from inside the gauge into the approved container.

REMOVAL & INSTALLATION 1.FUEL

FILTER

2.QUICK

1998-99 Models

CONNECTOR

3.BOLT/SCREW

4.FUEL

FILTER

BRACKET 7922VG14

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Properly relieve the fuel system presSure. 3. Remove or disconnect the following: e Negative battery cable ¢ Fuel filter retainer locking tabs ¢ Quick connect fuel lines from the fuel filter by releasing the locking tabs on the quick disconnect fittings e Fuel filter To install: 4. Apply a few drops of engine oil to the tips of the fuel filter. 9. Install or connect the following:

Exploded view of the fuel filter mounting

e Fuel filter in the bracket e Fuel lines to the fuel filter and snap the quick-connect into place. Be Sure the tabs on the quick-connects lock into place. ¢ Negative battery cable 6. Turn the ignition key ON for 2 seconds, then OFF for 5 seconds. Again turn the ignition key ON and check for fuel leaks. 2000-01 Models

1. Before servicing the vehicle, refer to the precautions in the beginning of this section.

q

1 . Cartridge regulator ASM - fuel pressure 2. 3. 4. 5. 6. 7. 8. View of the fuel rail assembly, showing the fuel system service port location

Rail ASM - fuel Cap - fuel pressure connector Core ASM - fuel pressure port Clip - MFI fuel injector retainer O-ring - MFI fuel injector upper Injector ASM - MFI fuel O-ring - MFI fuel injector lower 7922VG13

E & K-BODIES-GENERAL MOTORS CORPORATION

DEVILLE e ELDORADO e SEVILLE

2. Properly relieve the fuel system pressure. 3. Remove or disconnect the following: e Negative battery cable ¢ Quick connect fuel line from the fuel filter inlet e Threaded fitting at the outlet e Fuel filter To install: 4. Apply a few drops of engine oil to the tips of the fuel filter. 5. Instal! or connect the following: e Fuel filter in the bracket e Inlet line to the fuel filter and snap the quick-connect into place. Be sure the tabs on the quick-connects lock into place. e Threaded fitting at the outlet e Negative battery cable 6. Turn the ignition key ON for 2 seconds, then OFF for 5 seconds. Again turn the ignition key ON and check for fuel leaks.

REMOVAL & INSTALLATION The modular fuel sender assembly must be disassembled in the exact order described.

1. 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. Clean the fuel tank in the area of the modular fuel sender assembly. 5. Remove or disconnect the following: e Fuel tank from the vehicle e Locking nut e Modular fuel sender assembly from the fuel tank

>: CAUTION The modular fuel sender assembly may spring up from its position. When removing the assembly, be aware that the reservoir bucket is full of fuel. Tip the assembly slightly during removal to avoid damaging the float. Have a shop towel ready to absorb any leakage.

6. Slide the fuel sender seal downward, past the reservoir and carefully over the float arm assembly. 7. Disconnect the connector retainer clip from the wiring harness under the modular fuel sender assembly cover. 8. Locate the curved side of the modular unit's reservoir. Beginning at locking tab

22-21

1, squeeze the reservoir to release the first locking tab. 9. Moving clockwise to locking tab 2, apply gentle pressure to the guide rod to release the second locking tab. 10. At locking tab 3, gently twist and squeeze to release the reservoir from the retainer. 11. Remove or disconnect the follow-

ing: e Cover and the retainer from the reservoir. Be careful not to damage the crossover tube. The unit will still be attached by the fuel pipe and the crossover tube. e External strainer by prying the strainer ferrule off the reservoir.

kk CAUTION Excessive force may dislodge the jet pump. e Rubber bumper pad. The fuel pump and the sleeve assembly are attached to the retainer when pulled from the reservoir. Depress the flex member on the pump sleeve and rotate the sleeve counterclockwise to remove the fuel pump from the retainer. Note the orientation of the pump to the retainer.

At Lierny

1. Locking tab 1

2. Locking tab 2

3. Locking tab 3

Modular fuel sender disassembly

this manual For Maintenance Interval recommendations, see Section 1 of

22-22 GENERAL MOTORS CORPORATION-E & K-BODIES DEVILLE * ELDORADO « SEVILLE 12. Slide the lower connector assembly out of the retainer to remove the fuel pulse damper from the lower connector. Note the orientation of the seal (the modular unit is now held together by the crossover tube only). Discard the fuel pulse damper. To install: 13. Install the fuel pulse damper. e» Always use a new damper when installing a new fuel pump.

14. Slide the lower connector into the retainer. 15. Push the pump outlet tube into the fuel pulse damper and rotate the flex member back to its original position. Align the pump outlet tube into the retainer opening. All 3 sleeve tabs should protrude through the retainer before rotating. Rotate the pump clockwise until a click is heard. Be Sure fit is snug before rotating. Place the fuel pump back into its reservoir. The crossover tube must be placed in its proper slot. 16. Install or connect the following: New rubber bumper pad. Insert the drain tube into the proper retainer and bumper pad slots. New strainer, being careful not to dislodge the jet pump Fuel pump wire connector Wiring harness connector Connector retainer clip New lip seal on the modular fuel sender assembly

Fuel Injectors

7

REMOVAL & INSTALLATION 1998-99 Models 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Relieve the fuel system pressure. 3. Remove or disconnect the following: e Intake manifold cover e Fuel injector electrical connectors e Fuel rail from intake manifold ¢ Fuel injectors ¢ Upper and lower O-rings To install: 4. Install or connect the following: New O-rings lubricated with clean engine oil Fuel injector into the fuel rail Fuel rail into the intake manifold. Be sure all locking tabs engage fully. Fuel injector electrical connectors Negative battery cable 5. Inspect for fuel leaks as follows: a. Step 1: Turn ignition switch to the ON position for 2 seconds.

2000-01 Models

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Relieve the fuel system pressure. 3. Remove or disconnect the following: Intake manifold cover Intake Air Temperature (IAT) sensor electrical connector Mass Airflow (MAF) sensor electrical connector Air cleaner intake duct Quick-connect fittings from the fuel rail ¢ Fuel pressure regulator vacuum hose ¢ Positive Crankcase Ventilation (PCV) air tube ¢ Fuel rail end-point bracket retainer nut e Fuel injector electrical connectors Fuel rail attaching bolts Fuel injectors from the intake mani-

fold with injector removal tool J 43013 Fuel rail Injector from the rail and discard the O-rings To install:

-» Always use a new seal when servicing the modular fuel sender assembly. Lightly lubricate the inside diameter of the lip seal with clean engine oil. The lip seal should be positioned over the float arm assembly, moved up over the reservoir and half-way up the guide posts.

¢ Modular fuel assembly into the tank. Seat the lip seal into the tank opening by aligning the arrows on top of the fuel tank to the arrow on the modular assembly. 17. Slowly apply pressure to the top of the spring-loaded sender until the lip seal is flush between the fuel tank and the modular cover. 18. Install or connect the following: ¢ Locking nut. Torque to 37 ft. Ibs. (50 Nm). ¢ Fuel tank e Negative battery cable 19. Refill the fuel tank. 20. Pressurize the fuel system and verify there are no fuel leaks.

b. Step 2: Turn ignition switch OFF for 10 seconds. c. Step 3: Turn ignition switch ON. d. Step 4: Check for leaks. 6. Install the intake manifold cover. Torque the nuts to 27 inch Ibs..(3 Nm).

e>Each fuel injector is calibrated for a specific flow rate. Be sure to use the correct part number when ordering replacement fuel injectors. 9306AG03

Exploded view of the fuel rail

'

iy 9306AG04

Exploded view of the fuel injector

4. Install or connect the following: New O-rings lubricated with clean engine oil Fuel injector into the fuel rail Fuel rail into the intake manifold and tighten the attaching bolts to 89 inch Ibs. (10 Nm) Fuel injector electrical connectors Fuel rail end-point bracket retainer

nut and tighten to 89 inch Ibs. (10 Nm) PCV air tube Fuel pressure regulator vacuum hose se ae ee fittings from the fuel rai Air cleaner intake duct

E & K-BODIES-GENERAL MOTORS CORPORATION

DEVILLE ¢ ELDORADO e SEVILLE

e MAF sensor electrical connector e IAT sensor electrical connector e Negative battery cable 5. Inspect for fuel leaks as follows:

a. Step 1: Turn ignition switch to the ON position for 2 seconds. b. Step 2: Turn ignition switch OFF for 10 seconds.

~ Transaxle Assembly REMOVAL & INSTALLATION

1998-99 Models 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Negative battery cable Headlight housing upper filler panel and diagonal brace Air cleaner assembly Shift contro! cable and bracket at the transaxle Torque struts Oil cooler lines at the cooler Oil sending line at the transaxle 2 upper transaxle-to-engine bolts Power steering return hose at the auxiliary cooler 3. Support the engine to take the weight of the powertrain off the mounts and frame. e Front wheels Splash shields from both front wheel wells Both front suspension position sensors from the lower control arms Both stabilizer links from the struts Tie rod ends from the steering knuckles Lower ball joints from the steering knuckles Halfshafts

DRIVETRAIN

c. Step 3: Turn ignition switch ON. d. Step 4: Check for leaks. 6. Install the intake manifold cover. Torque the nuts to 27 inch Ibs. (3 Nm).

~

Fuel filter bracket A/C splash shield Power steering filter at the cradle Air conditioning splash shield Anti-lock Brake System (ABS) modulator from the bracket Engine oil pan-to-transaxle bracket Torque converter cover Torque converter bolts Powertrain mount nuts from the frame 4. Rotate the intermediate steering shaft until the steering gear stub shaft clamp bolt is accessible at the left wheel well. Remove the clamp bolt and disconnect the intermediate steering shaft from the steering gear.

ck CAUTION If the intermediate steering shaft is not disconnected from the steering gear stub shaft, damage to the steering gear and/or intermediate shaft may result. This damage can cause loss of steering control, which could result in personal injury.

st WARNING Do not turn the steering wheel or move the position of the steering

: gear once the intermediate steering shaft is disconnected as this will offcenter the air bag coil in the steering column. If the air bag coil becomes off-centered, it may be damaged during vehicle operation.

5. Disconnect the electrical harness and connector from the engine cradle. 6. Support the rear of the cradle with a jack, then remove the 4 rear cradle bolts. 7. Lower the jack a few inches to gain access to the power steering gear heat Shield and return line fitting. 8. Remove or disconnect the following: e Heat shield e Power steering return line ¢ Power steering electrical connector 9. Raise the jack and reinstall 1 rear cradle bolt on each side finger-tight to support the cradle. Remove the jack. 10. Support the frame with a jack and remove the 6 frame mount bolts. Lower the frame and/or raise the vehicle with the steering gear attached. Electrical connectors to the transaxle e Vehicle Speed Sensor (VSS) electrical connector e Transaxle harness from the transaxle clip

1 75 Nm (55 LB. FT.) 2 LOCATING PIN (NO BOLT AT THIS POSITION) 3 TIGHTEN BOLTS TWICE IN SEQUENCE TO 62 Nm (46 LB. FT.)

LOCATING PIN

7922VG16

Exploded view of the crossbrace-to-strut

towers mounting

22-20

Exploded view of the engine-to-transaxle attachments

manual For Tune-up, Capacities and Firing orders, See Section 1 of this

22-24

GENERAL MOTORS CORPORATION-E & K-BODIES DEVILLE e ELDORADO ¢ SEVILLE

¢ Fuel line bundle from the transaxle e Left and right transaxle mounts and brackets 11. Support the transaxle with a jack. e Engine-to-transaxle heat shield and bracket e Remaining transaxle-to-engine bolts e Manual shaft linkage e Neutral safety switch e VSS and oil return line e Transaxle To install: 12. Install or connect the following: Transaxle. Torque the transaxle to engine bolts to 55 ft. Ibs. (75 Nm).

Oil return line and the VSS Neutral safety switch. Torque the bolts to 106 inch Ibs. (12 Nm). Manual shaft linkage. Torque the manual shaft nut to 15 ft. Ibs. (20 Nm). Engine-to-transaxle bracket and heat shield. Torque the bolts to 35 ft. Ibs. (47 Nm). 13. Remove the transaxle jack. e¢ Right and left transaxle bracket and mount to the transaxle. Torque the nuts/bolts to 35 ft. Ibs. (47 Nm). ¢ Fuel line bundle to the transaxle e Electrical connectors to the transaxle and VSS e Transaxle harness to the transaxle Clip 14. Raise the frame and/or lower the vehicle while locating the engine and transaxle mount studs into the frame. 15. Install the 2 front and 2 rear cradle bolts finger-tight to support the cradle, then remove the cradle support. 16. Support the rear of the cradle with a jack and remove the 2 rear cradle bolts. 17. Lower the jack a few inches to gain access to the power steering gear. 18. Install or connect the following; Hose at the steering gear. Torque the fitting to 20 ft. Ibs. (27 Nm), Power steering gear electrical connector Steering gear heat shield Engine cradle. Torque the bolts to 120 ft. Ibs. (163 Nm). Electrical harness to the front of the cradle Intermediate steering shaft to the Steering gear and the clamp bolt. Torque the bolt to 35 ft. Ibs. (47 Nm). Left and right transaxle mount nuts and right engine mount nuts at the frame. Torque the nuts to 35 ft. Ibs, (47 Nm).

Flexplate. Torque the bolts to 36 ft. lbs. (47 Nm). e Torque converter cover. Torque the bolts to 106 inch Ibs. (12 Nm). e Engine oil pan-to-transaxle bracket. Torque the bolts to 35 ft. Ibs. (47 Nm). ABS modulator to the bracket and the air conditioning splash shield at the frame Halfshafts. Torque the halfshaft nuts to 110 ft. Ibs. (145 Nm). Lower ball joints into the steering knuckles, use new cotter pins Tie rod ends into the steering knuckles, use new cotter pins Stabilizer links to the struts. Torque the nuts to 49 ft. Ibs. (65 Nm). Front suspension position sensors to the lower control arms Power Steering filter to the cradle Splash shields in the wheel wells Wheels. Torque the lug nuts to 100 ft. Ibs. (140Nm). Power steering hose at the auxiliary cooler Remaining transaxle-to-engine bolts. Torque the bolts to 35 ft. Ibs. (47 Nm). 19. Flush the transaxle oil cooler. The transaxle oil cooler and lines should be flushed before the oil cooler lines are connected to the transaxle. Oil cooler lines to the transaxle. Torque the fittings to 16 ft. Ibs. (22 Nm) Torque struts Neutral safety switch Shift control cable and bracket to the transaxle. Torque the bracket bolts to 106 inch Ibs. (12 Nm), Air cleaner assembly Headlight housing upper filler panel and diagonal brace Negative battery cable 20. Fill the transaxle. Bleed the power Steering system. 21. Check and adjust the front alignment. ->The PCM maintains 3 types of transaxle adapt parameters which are used to modify transaxle line pressure. The line pressure is modified to maintain shift quality regardless of wear or tolerance variations within the transaxle. Whenever the transaxle is replaced, the transaxle adapts must be reset as follows:

a. Enter b. (TPS

Step 1: Turn the ignition key ON. the self-diagnostic system. Step 2: Select PCM override PS13 SENSOR LEARN).

c. Step 3: Press the WARMER button. The Driver Information Center (DIC) should display 09, indicating that the Garage Shift Adapt value has been reset. d. Step 4: Select PCM override PS14 (TRAN ADAPT). e. Step 5: Press the COOLER button. The DIC should display 90, indicating the Upshift Adapt (UA) value has been reset. f. Step 6: Press the WARMER button. The DIC should display 09, indicating the Steady State Adapt (SSA) value has been reset. «>The PCM maintains a value for transaxle oil life. This value indicates the percentage of oil life remaining and is calculated based on transaxle temperature and speed. When the vehicle is new, the transaxle oil life value is 100. As the vehicle operates, the percentage will decrease. Whenever the transaxle is replaced, the transaxle oil life indicator should be reset to 100 as follows:

g. Step 1: Turn the ignition key ON, but leave the engine OFF. h. Step 2: Press and hold the OFF and REAR DEFOG buttons on the DIC until the message TRANSAXLE OIL LIFE RESET is displayed on the DIC.

2000-01 Models 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the cooling system. 3. Remove or disconnect the following: Negative battery cable Upper filler panel Air cleaner upper plenum and intake tube Surge tank outlet pipe Oil cooler lines at the cooler and Oil sending line at the transmission and plug the lines to system contamination Shift cable from the shift linkage Shift linkage assembly from the transmission Upper transmission to engine bolts e»Load the support fixture by tightening the wing nuts several turns in order to take the weight of the powertrain off of the mounts and the frame. 4, Install an engine support fixture. Raise the left side of the assembly 1 inch (25.4mm) above the resting position with the adjusting screws.

E & K-BODIES-GENERAL MOTORS CORPORATION 22-25 DEVILLE ¢ ELDORADO SEVILLE Tires and wheels Lower slash shield Front suspension position sensors links from the lower control arms and position aside Stabilizer links from the lower control arms and let the stabilizer shaft sit loosely on the engine frame Stabilizer shaft insulator brackets from the engine frame Drive axle nuts Drive axles from the hubs Tie rod cotter pins and nuts Tie rods from the steering knuckles Lower ball joint cotter pins and nuts Ball joints from the steering knuckles Drive axles from the transmission Brake Pressure Modulator Valve

(BPMV) and bracket from the engine frame and support the valve with a bungee cord Rear transmission mount bracket nut and bolts Rear transmission mount bolt and nuts from the left frame rail Left engine mount nut from the engine frame Right engine mount nuts from the engine frame Steering rack bolts from the engine frame Brake line and power steering line fasteners from the engine frame Post Oxygen (02S) sensor heat shield and sensor connector One center exhaust hanger to allow easy movement of the exhaust in the rearward direction 5. Support the engine frame. ¢ 6 engine frame mount bolts and separate the tie rod ends and lower ball joints from the steering knuckles 6. Raise the vehicle slowly away from the eyo frame. e Engine frame and support table from under the vehicle Steering rack heat shield from the rack Power steering lines from the steering rack Right rear engine to transmission bracket upper bolt, nuts, and bracket Right transmission mount bracket lower bolts and bracket from the transmission

7. lt is necessary to support the steering rack in a position that allows access to the bracket bolts. Steering rack from the vehicle Right front re -to-transmission brace bolt, nut, brace and heat shield e Right front engine-to-transmission bracket e Engine oil pan-to-transmission bracket e Torque converter cover brace and the cover Flywheel-to-converter bolts Transmission electrical connectors Engine-to-transmission heat shield and bracket 8. Support the transmission with a transmission jack. e Engine-to-transmission bolts e Transmission To install: 9. Install or connect the following: e Rear transmission mount bracket onto the stud before the transmission is all the way up into the vehicle e Rear transmission mount (loosely) to the left frame rail with the nuts and bolt 10. Raise the transmission into position. Guide the rear mount bracket and the rear mount together as the transmission is raised into the vehicle. 11. Align the transmission and position the transmission onto the dowels on the engine. e Engine-to-transmission bolts and tighten to 55 ft. Ibs. (75 Nm), then remove the transmission jack Right front engine-to-transmission heat shield and brace, then tighten the bolts to 55 ft. Ibs. (75 Nm) Right front engine-to-transmission bracket and tighten the bolts to 37

ft. Ibs. (60 Nm) Right transmission mount bracket and the lower bolts. Tighten the bolts to 81 inch Ibs. (110 Nm) Steering rack into position (loosely) onto the vehicle and insert the tie rod ends into the steering knuckles Right rear engine-to-transmission bracket and tighten the bolt 81 inch Ibs. (110 Nm) and the nuts to 37 ft. Ibs. (50-Nm) Power steering lines to the power steering rack and tighten to 20 ft. Ibs. (27 Nm)

Power steering rack heat shield Flywheel to converter bolts and tighten to 44 ft. lbs. (60 Nm) Torque converter cover All electrical connectors Drive axles into the hubs and both drive axle nuts and tighten to 110 ft. Ibs. (145 Nm) Engine frame on to the engine support table Stabilizer bar onto the engine frame in its approximate position 12. Lower the vehicle onto the engine frame while locating all the mounting points. e Engine frame mounting bolts, finger tight 13. Raise the vehicle away from the engine support table and tighten the engine frame bolts to 142 ft. lbs. (192 Nm). e Steering intermediate shaft to the steering gear and install the clamp bolt. Tighten the bolt to 37 ft. Ibs. (50 Nm) e Steering gear bolts and tighten to 77 ft. Ibs. (105 Nm) e Transmission mount nuts and the right engine mount nuts to the frame and tighten to 37 ft. Ibs. (50 Nm) e>When tightening the ball joint nut, a minimum torque of 37 ft. Ibs. (50 Nm) must be reached. If the proper torque is not obtained, inspect for stripped threads. If threads are satisfactory, replace the ball joint and knuckle. If required, turn the nut up to an additional 60 degrees to allow for installation of the cotter pin.

¢ Lower ball joints into the steering knuckles e Ball joint nuts and cotter pins. Tighten the ball joint nut to 84 inch lbs. (10 Nm), then tighten the nut an additional 120 degrees. e>When tightening the tie rod end nut, a minimum torque of 33 ft. Ibs. (45 Nm) must be reached. If the proper torque is not obtained, inspect for stripped threads. If the threads are satisfactory, replace the tie rod end and knuckle.

e Tie rod end nut to 74 ft. Ibs. (100 Nm), then an additional 1/3 turn (or 2 flats) e Brake and power steering line retainers to the engine frame

For complete service labor times, order Nichols’ Chilton Labor Guide

22-2

14.

15. 16. 17.

GENERAL MOTORS CORPORATION-E & K-BODIES DEVILLE ¢ ELDORADO SEVILLE

Brake pressure modulator valve and bracket to the engine frame Sway bar insulators onto the sway bar Stabilizer links to the control arms and tighten the nuts to 49 inch Ibs. (65 Nm) Front Suspension position sensors to the lower control arms Lower close out panel Center exhaust hanger Post 02S sensor and heat shield Front tire and wheel assemblies Remove the Engine Support Fixture. Upper bell housing bolts Transmission cooler pipe fittings at the transmission and tighten to 16 ft. Ibs. (22 Nm) Transmission oil sending pipe to the transmission Shift linkage assembly to the transmission Shift cable to the shift linkage Surge tank outlet hose Surge tank inlet hose Air cleaner assembly Negative battery cable Bleed the power steering system. Fill the transmission with fluid. Fill the cooling system.

18. Check the front suspension alignment and as necessary. >The PCM maintains 3 types of transaxle adapt parameters which are used to modify transaxle line pressure. The line pressure is modified to maintain shift quality regardless of wear or tolerance variations within the transaxle. Whenever the transaxle is replaced, the transaxle adapts must be reset as follows:

a. Step 1: Turn the ignition key ON. Enter the self-diagnostic system. b. Step 2: Select PCM override PS13 (TPS SENSOR LEARN). c. Step 3: Press the WARMER button. The Driver Information Center (DIC) should display 09, indicating that the Garage Shift Adapt value has been reset. d. Step 4: Select PCM override PS14 (TRAN ADAPT). e. Step 5: Press the COOLER button. The DIC should display 90, indicating the Upshift Adapt (UA) value has been reset. f. Step 6: Press the WARMER button.

The DIC should display 09, indicating the Steady State Adapt (SSA) value has been reset.

>The PCM maintains a value for transaxle oil life. This value indicates the percentage of oil life remaining and is calculated based on transaxle temperature and speed. When the vehicle is new, the transaxle oil life value is 100. As the vehicle operates, the percentage will decrease. Whenever the transaxle is replaced, the transaxle oil life indicator should be reset to 100 as follows:

g. Step 1: Turn the ignition key ON, but leave the engine OFF. h. Step 2: Press and hold the OFF and REAR DEFOG buttons on the DIC until the message TRANSAXLE OIL LIFE RESET is displayed on the DIC.

REMOVAL & INSTALLATION

Use care when removing the halfshaft to prevent the inner CV-joint from becoming over-extended. Overextension of the joint could result in separation of internal components and possible joint failure.

KNUCKLE & HUB ASSEMBLY DRIVE AXLE INNER JOINT DRIVE AXLE OUTER JOINT

HUB NUT

WASHER

os FRONT

FRONT

Removing the halfshaft from the transaxle

DRIVE AXLE — INNER JOINT INNER JOINT

7922VG18

E & K-BODIES-GENERAL MOTORS CORPORATION 22-21 DEVILLE * ELDORADO SEVILLE 7. Torque the hub nut to 107 ft. Ibs. (145 Nm) on 1998-99 models or 118 ft. Ibs. (160 Nm) on 2000-01 models. 8. Install the stabilizer link. Torque the nut to 13 ft. Ibs. (17 Nm). 9. If a halishaft protector was used, remove it now. 10. Install the wheel. Torque the lug nuts to 100 ft. Ibs. (140 Nm). 11. Road test and check vehicle operation.

7922VG19

Removing the halfshaft from the hub

OVERHAUL Inner (Tripod) Joint

1998-99 MODLES 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following:

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove the front wheel. 3. Install a boot protector on the outer CV-joint boot to protect it from damage. 4. Remove or disconnect the following: e Hub nut e Stabilizer link e Ball joint cotter pin and nut e Ball joint from the steering knuckle Partially install the hub nut to protect the threads when removing the halfshaft from the hub. 5. Remove the halfshaft from the transaxle. ->|f equipped with anti-lock brakes, care must be used to prevent damage to the toothed sensor ring on the halfshaft and the wheel speed sensor on the steering knuckle.

To install: 6. Install or connect the following: e Halfshaft into the transaxle ->To verify the halfshaft is properly seated, grasp the inner CV-joint housing and pull it outward. DO NOT puil on the halfshaft. If the CV-joint is properly seated, the halfshaft will not pull back out.

e Halfshaft into the hub/bearing assembly e New hub nut loosely e Ball joint into the steering knuckle e Ball joint castle nut. Torque the nut to 88 inch Ibs. plus an additional 150 degrees. A minimum of 41 ft. lbs. (51 Nm) of torque must be attained. »>|f necessary, the nut can be tightened up to 20 degrees additional. NEVER loosen the castle nut to install the cotter pin.

Assembly, Tripot Housing Ring, Soacer

Soider Assembly, Tripot Jcint Ring, Spacer Sushing, Tripot Clamp. Seal Retaining Seal. Tripot Joint Ciamo, Smail Seai Retaining Snar. Axie GN & Ot 0) >) Gi (O

10. 11. 12.

Clamp. Small Seal Retaining Seal, CV Joint Fing, Swage

Ring, Race Retaining 14. 1§.

Bail Race. CV Joint Inner

16.

Caae. CV Joint

17. 8.

Face. CV Joint Cuter ing, Deflector 9306AG08

Exploded view of CV-joints

Please visit our web site at www.chiltonsonline.com

22-2

GENERAL MOTORS CORPORATION-E & K-BODIES DEVILLE ¢ ELDORADO SEVILLE

Front wheel Halfshaft and place it in a vise Small CV-joint boot clamp Large CV-joint boot clamp CV-joint boot by sliding it away from the tripod joint Tripod housing from the tripod spider Inboard spacer ring, slide it rearward on the shaft ¢ Qutboard retaining ring ¢ Tripod joint spider assembly e Inboard spacer ring e CV-joint boot ¢ Trilobal tripod bushing from the housing To install: 3. Install or connect the following: e New snapring onto the stub shaft ¢ Small boot clamp e CV-joint boot 4. Using a crimp tool, a torque wrench and a breaker bar, crimp the small CV-joint boot clamp to 130 ft. Ibs. (176 Nm). e Inboard spacer ring, slide it rearward on the shaft past the 2nd groove Tripod joint spider assembly onto the shaft until it passes the 2nd groove Outboard retaining ring into the axle shaft groove Tripod joint spider assembly, slide it against the outboard retaining ring Inboard spacer ring, seat it in the groove 5. Place ¥% of the grease provided in the service kit into the boot and the other 1% of the grease into the tripod housing. ¢ Trilobal tripod bushing flush with the tripod housing face e New large seal clamp onto the CVjoint boot ¢ Tripod housing, slide it over the tripod joint spider assembly ¢ CV-joint-boot clamp, slide it into place, over the trilobal tripod bushing with the seal lip in the groove ->lake sure the boot lies flat against the trilobal bushing.

6. Using a crimp tool, latch the large CV-joint boot clamp. 7. Install the halfshaft and the front wheel. Torque the lug nuts to 100 ft. Ibs. (140 Nm).

2000-01 MODELS 1. Before servicing the vehicle, refer to the precautions in the beginning of this section.

125 mm (4.9")

9346AG26 9346AG25

Crimp the small CV-boot clamp as shown

2. Remove or disconnect the following: Front wheel Halfshaft and place it in a vise Small CV-joint boot clamp Large CV-joint boot clamp CV-joint boot by sliding it away from the tripod joint Tripod housing from the tripod spider Inboard spacer ring, slide it rearward on the shaft ¢ Qutboard retaining ring ¢ Tripod joint spider assembly ¢ Inboard spacer ring e CV-joint boot ¢ Trilobal tripod bushing from the housing To install: 3. Install or connect the following: ¢ New snapring onto the stub shaft ¢ Small boot clamp ¢ CV-joint boot 4. Using a crimp tool, a torque wrench and a breaker bar, crimp the small CV-joint boot clamp to 100 ft. Ibs. (136 Nm) until the crimped gap measures .085 inch (2.15mm). ¢ Inboard spacer ring, slide it rearward on the shaft past the 2nd groove Tripod joint spider assembly onto the shaft until it passes the 2nd groove Outboard retaining ring into the axle shaft groove Tripod joint spider assembly, slide it against the outboard retaining ring Inboard spacer ring, seat it in the groove 9. Place V2 of the grease provided in the service kit into the boot and the other % of the grease into the tripod housing. ¢ Trilobal tripod bushing flush with the tripod housing face ¢ New large seal clamp onto the C\joint boot

Position the boot as illustrated before clamping the large clamp

¢ Tripod housing, slide it over the tripod joint spider assembly e C\V-joint-boot clamp, slide it into place, over the trilobal tripod bushing with the seal lip in the groove e» Make sure the boot lies flat against the trilobal bushing.

6. Make sure the boot is positioned as illustrated, then using a crimp tool, latch the large CV-joint boot clamp. 7. Install the halfshaft and the front wheel. Torque the lug nuts to 100 ft. Ibs. (140 Nm). Outer CV-Joint

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Front wheel Halfshaft Swage ring using a hand grinder Large boot clamp CV-joint boot, slide it away from the CV-joint CV-joint assembly by spreading the inner race-to-axle shaft retaining ring ears using Snapring Pliers C\V-joint boot from the axle shaft 3. Disassemble the chrome alloy balls from the C\V-joint cage as follows: a. Position a brass drift against the CV-joint cage and tap it with a hammer to tilt the cage. b. Chrome alloy ball from the cage. c. Tilt the cage in the opposite direction. : i Remove the opposite chrome alloy

all. é. Repeat the procedure until all 6 balls are removed,

4. Disassemble the CV-joint cage and inner race as follows: a. Pivot the cage and race 90 degrees to the center line of the outer race.

E & K-BODIES-GENERAL MOTORS CORPORATION

22-29

DEVILLE « ELDORADO e SEVILLE

Position edge of seal here

9306XG19

Disconnecting the outer CV-joint from the axle shaft

9306XG22

Positioning the boot—Outer CV-joint

b. Align the cage windows with outer race lands. c. Remove the cage from the outer race. d. Rotate the inner race upward and remove it from the cage. 5. Thoroughly clean and inspect all parts. 9306XG20

Tilting the cage—Outer CV-joini

To install: 6. Lubricate the parts with a light coat of grease. 7. Assemble the CV-joint cage and inner race, as follows: a. Rotate the inner race 90 degrees to the cage centerline. b. Align the cage windows with inner race lands. c. Insert the inner race into the cage by rotating the inner race downward. d. Insert the cage/inner race into the outer race. 8. Assemble the chrome alloy balls into

9306XG21

View the cage and inner race—Outer CV-

the CV-joint cage, as follows: a. Position a brass drift against the CV-joint cage and tap it with a hammer

b. Insert the 1st chrome alloy ball into the cage. c. Tilt the cage in the opposite direction. : t Insert the opposite chrome alloy all. e. Repeat the procedure until all 6 balls are inserted. 9. Install or connect the following: e Swage ring clamp e CV-joint boot e CV-joint onto the axle shaft until the retaining ring seats into the groove 10. Position the CV-joint boot seal into the axle shaft’s joint seal groove and align the swage ring clamp on the boot. 11. Secure the swage ring clamp using appropriate crimping tool.

kk WARNING Make sure that there are no pinch points on the inboard seal. 12. Install or connect the following: e 1% kit grease into the C\V-joint boot ¢ 1% kit grease into the CV-joint ¢ New large seal clamp onto the CVjoint boot e C\-joint boot/clamp, slide it into place, over the outer race with the Seal lip in the groove => Make sure the boot lies flat against the outer race.

13. Using a Crimp tool, a torque wrench and a breaker bar, crimp the large CV-joint boot clamp to 130 ft. Ibs. (176 Nm). 14. Install the halfshaft and the front wheel.

to tilt the cage.

joint

_ STEERING AND SUSPENSION PRECAUTIONS

sot CAUTION

,

Some vehicles are equipped with an air bag system. The system must be disabled before performing service on

or around system components, steer-

ing 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.

Several precautions must be observed when handling the inflator module to avoid accidental deployment and possible personal injury. Never carry the inflator module by the wires or connector on the underside of the module. e 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. e With the inflator module on the bench, never place anything on or close to the module, which may be thrown in the event of an accidental deployment.

DISARMING EEE

toa! sbeclp

ofeete

EEE

CAUTION

The air bag system must be disarmed before performing service procedures around the air bag or wiring. Failure

Timing belt service is covered in Section 3 of this manual

22-30 GENERAL MOTORS CORPORATION-E & K-BODIES DEVILLE ¢ ELDORADO « SEVILLE Power Rack and Pinion Steering. Gear REMOVAL & INSTALLATION

>< CAUTION

1. Steering column

2. Connector, SRS (yellow) 7922VG20

Detach the SRS yellow 2-way connector

to do so may cause accidental deployment, resulting in unnecessary repairs and/or personal injury. 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Turn the steering wheel so that the vehicle's wheels are pointing straightahead. 3. Turn the ignition switch to the LOCK position and remove the key. 4. Remove or disconnect the following: ¢ Negative battery cable ¢ AIR BAG fuse from the fuse block ¢ Left sound insulator 5. Disconnect the connector retainer clip from the yellow 2-way connector at the base of the steering column, and detach the harness. 6. Remove the connector retainer clip and detach the yellow 2-way connector from the passenger air bag lead located behind the instrument panel.

ARMING After the applicable service is concluded, enable the air bag system as follows: 1. Turn the ignition switch to the LOCK position and remove the key. 2. Install or connect the following: ¢ Yellow 2-way connector at the base of steering column and secure it with the connector retainer clip. Attach the yellow 2-way connector at the passenger air bag lead and secure it with the connector retainer Clip. ¢ Left sound insulator ae e AIR BAG fuse in the fuse block 3. Connect the negative battery cable. 4, Turn the ignition switch to the RUN position and verify that the AIR BAG warning lamp flashes 7 times, then turns

Failure to disconnect the intermediate shaft from the rack and pinion stub shaft can result in damage to the steering gear and/or intermediate shaft. This damage can cause loss of Steering control, which could result in personal injury.

The wheels of the vehicle must be straight-ahead and the steering column in the LOCK position before disconnecting the steering column or intermediate shaft from the steering gear. Failure to do so will cause the coil assembly in the steering column to become off-centered, which will

e Outer tie rod ends from the steering knuckles e Y-pipe from the catalytic converter 3. Support the rear of the subframe with a jack. 4. Remove the rear subframe bolts. 5. Slowly lower the subframe to gain access. 6. Remove or disconnect the following: Heat shield Power steering line retainer Power steering pressure and return lines Speed Sensitive Steering (SSS) solenoid valve connector 5 power steering rack-to-subframe bolts Rack and pinion unit out the left wheel well To install: 7. Install or connect the following: Rack and pinion through the left wheel well. Torque the bolts to 50 ft. Ibs. (68 Nm). SSS solenoid valve connector

cause damage to the coil assembly.

Power steering pressure and return lines. Torque the fittings to 20 ft.

lbs. (27 Nm). 1998-01 Eldorado and 1998-99 Deville

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 wheels ¢ Bolt holding the intermediate shaft to the steering shaft e Road Sensing Suspension (RSS) sensor from the lower control arm

STEERING @ KNUCKLE Se

RACK AND PINION STEERING GEAR

Power steering line retainer Heat shield Subframe. Torque the bolts to 76 ft.

lbs. (103 Nm). Y-pipe to the catalytic converter. Torque the bolts to 20 ft. Ibs. (27 Nm).

Outer tie rod ends to the steering knuckle using new cotter pins. Torque the nuts to 7.5 ft. Ibs. (10 Nm). RSS sensor to the lower control arm

BOLT

WASHER

PIN

TIE ROD END NUT

7922VG21

Exploded view of the power steering rack components

E & K-BODIES—GENERAL MOTORS CORPORATION DEVILLE e ELDORADO e SEVILLE e Intermediate shaft to the steering shaft. Torque the bolt to 35 ft. Ibs. (47 Nm). e Front wheels. Torque the lug nuts to 100 ft. Ibs. (140 Nm). e Negative battery cable 8. Refill and bleed the power steering system. 9. Check the wheel alignment. 10. Road test the vehicle.

e Intermediate shaft to steering gear. Torque the pinch bolt to 33 ft. Ibs. (45 Nm). 5. Remove the steering column anti rotation pin from the steering column. 6. Fill and bleed the power steering system.

9346UG08

2000-01 Deville

Lock th e steering column by installing the Steerin g Column Anti Rotation Pin tool J

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Lock the steering column by placing the wheels in the straight ahead position and remove the keys. 3. Remove or disconnect the following: Intermediate shaft pinch bolt and Intermediate shaft lower coupling Heat shield Rear transaxle mount Pressure and return lines from steering gear e Electrical connector e Steering gear attaching bolts e Steering gear assembly To install 4. Install or connect the following: e Steering gear into vehicle. Torque the bolts to 89 ft. Ibs. (120 Nm). Electrical connector Pressure and return lines. Torque the lines to 22 ft. Ibs. (30 Nm). Heat shield Rear transaxle mount Intermediate shaft to steering gear. Torque the pinch bolt to 33 ft. Ibs. (45 Nm). 5. Fill and bleed the power steering system.

42640 into the underside of the steering

REMOVAL & INSTALLATION Front

column

Steering gear attaching bolts Steering gear assembly To in stall 4. Install or connect the following: Steering gear into vehicle. Torque the bolts to 89 ft. Ibs. (120 Nm). Electrical connector Pressure and return lines. Torque the lines to 22 ft. Ibs. (30 Nm). Heat shield Right transaxle mount. Torque the nuts to 37 ft. Ibs. (50 Nm).

1998-99 MODELS AND 1998-01 ELDORADO

When working near the halfshafts, use care to prevent the inner Tripod CV-joint from being overextended. If the joint is overextended, the internal joint components could separate, resulting in CV-joint failure. 1. Before servicing the vehicle, refer to the precautions in the beginning of this section.

Seville 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Lock the steering column by installing the Steering Column Anti Rotation Pin tool J 42640 into the underside of the steering column. 3. Remove or disconnect the following: e Intermediate shaft lower coupling e Heat shield e Right transaxle mount e Pressure and reiurn lines from steering gear e Electrical connector

22-31

Exploded view of the strut mounting

Heater Core replacement is covered in Section 2 of this manual

22-32 GENERAL MOTORS CORPORATION-E & K-BODIES DEVILLE ¢ ELDORADO « SEVILLE 2. Remove or disconnect the following: Negative battery cable e Front wheel Electrical connector from the top of the strut, if equipped Upper strut mounting nuts Road Sensing Suspension (RSS) position sensor from the lower control arm, if equipped Anti-lock Brake System (ABS) wheel speed sensor, if equipped Wheel speed sensor from the strut bracket, if equipped Brake line bracket from the strut Stabilizer link from the strut 3. Scribe a mark on the strut referencing the lower strut bracket to the steering knuckle. 4. Remove the strut. To install: 5. Install or connect the following: e Strut assembly into the vehicle e Strut-to-knuckle bolts and nuts, but do not torque yet Stabilizer link to the strut assembly, but do not torque the nuts yet Brake line bracket to the strut Speed sensor bracket on the strut, if equipped ABS sensor, if equipped

by the frame allowing the control arms to hang free. e Front wheel e Wheel speed sensor connector e Wheel speed sensor bracket from the strut e Brake line bracket from the strut 4. Scribe a mark on the strut referencing the lower strut bracket to the steering knuckle. e Strut-to-knuckle bolts e Strut from the vehicle To install: e Strut e 3 upper strut mount bolts and washers. Tighten the bolts to 35 ft. lbs. (48 Nm) on 1998-99 Seville models or 49 ft. Ibs. (66 Nm) on all meadels. 5. Align the scribe marks made on the steering knuckle with the strut. e Strut-toknuckle bolts and nuts and hand tighten e Brake line bracket to strut e Wheel speed sensor bracket to strut e Wheel speed sensor connector 6. Tighten the strut-to-knuckle bolts to 125 ft. Ibs. (170 Nm) on 1998-99 Seville models or 131 ft. Ibs. (177 Nm) on all other models.

7. Tighten the brake line and wheel speed sensor bracket to 13 ft. Ibs. (17 Nm) on 1998-99 Seville models or 17 ft. Ibs. (23 Nm) on all other models. 8. Install the front wheel. Shock Absorber

REMOVAL & INSTALLATION Rear

1998-99 DEVILLE AND 1998-01 ELDORADO 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Rear wheel e Negative battery cable e Shock absorber electrical connector from the rear suspension support 3. Support the lower control arm with a jack to relieve the tension on the shock absorber. e Lower shock absorber mounting bolt and nut e Upper mounting nut, retainer and insulator

RSS sensor to the lower control arm, if equipped Electrical connector to the top of the strut, if equipped Upper strut mounting nuts. Torque the nuts to 15 ft. Ibs. (21 Nm). 6. Torque the stabilizer link nuts to 41 ft. lbs. (65 Nm). 7. Torque the strut-to-knuckle bolt to 140 ft. Ibs. (190 Nm). 8. Install the front wheel. Torque the lug nuts to 100 ft. Ibs. (140 Nm),

2000-01 MODELS—EXCEPT ELDORADO MODELS

When working near the halfshafts, use Care to prevent the inner Tripod CV-joint from being overextended. If

Q

the joint is overextended, the internal joint components could separate, resulting in CV-joint failure.

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Negative battery cable e 3 strut mount bolts 3. Raise the vehicle and suitably support

9300VG06

Exploded view of the rear shock absorber mounting

E & K-BODIES—-GENERAL MOTORS CORPORATION

DEVILLE e ELDORADO @ SEVILLE

e Shock absorber, compress by hand and remove through the upper control arm To install: 4. Position the top of the shock absorber with the insulator attached into the Suspension support. 5. Install or connect the following: ¢ Upper shock insulator, retainer and nut. Torque the nut to 55 ft. Ibs. (74 Nm). ¢ Shock absorber lower mounting nut and bolt. Torque the nut to 75 ft. lbs. (102 Nm). e Shock absorber electrical connector to the rear Suspension support e Rear wheel. Torque the lug nuts to 100 ft. Ibs. (140 Nm). e Negative battery cable

2. Remove the strut from the vehicle. 3. Disassemble the strut as follows: a. Step 1: Place the strut assembly into compressor tool, to compress the coil spring. b. Step 2: Compress the spring Slightly. ¢. Step 3: Hold the strut shaft from turning using a No. 50 Torx® socket and remove the 24mm nut on the top end of the strut. S1>Step 4: Install Rod Tool J 34013-

38 to help guide the strut shaft from the upper mount assembly. d. Step 5: Loosen the spring compressor tool until the coil spring and mount can be removed as an assembly. Remove the lower spring insulator, if equipped. To install: 4. Assemble the strut as follows: a. Step 1: Place the strut in compresSor tool. b. Step 2: Install the coil spring over the strut.

SEVILL AND 2000-01 DEVILLE 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove the tire and wheel assembly. 3. Support the control arm with a jack stand. 4 Remove or disconnect the following: Electronic Level Control (ELC) air tube from the shock Two bolts securing the shock to the control arm Trunk trim to gain access to the shock upper mounting nuts. Cover, the two nuts, and the reinforcement from the top of the shock e Shock from the vehicle To install: 5. Install or connect the following: Shock, reinforcement, and the two nuts. Tighten the mounting nuts to 15 ft. Ibs. (20 Nm). Shock cover Trunk trim Shock-to-contro! arm bolts and tighten the bolts to 18ft. Ibs. (24 Nm) ELC air tube to the shock. Tire and wheel assembly

Coil Spring

NUT, STRUT TO MOUNT

[2] STRUT [3] FRONT

MOUNT

SPRING SEAT

[4] FRONT SPRING UPPER INSULATOR [5] JOUNCE BUMPER

6| DUST SHIELD [6] SPRING

REMOVAL & INSTALLATION ET

Front

1. Before servicing the vehicle, refer to the precautions in the beginning of this section.

22-303

FRONT SPRING LOWER INSULATOR [2] FRONT STRUT 7922VG23

Disassembled view of strut

Brake service is covered in Section 4 of this manual

22-34

GENERAL MOTORS CORPORATION-E & K-BODIES DEVILLE e ELDORADO e SEVILLE

7922UG19

Use a Torx® socket to keep the piston rod from turning while removing the upper nut—front strut shown

5. Slowly lower the control arm until Spring pressure is released. 6. Remove the spring. To install: 7. Place spring into lower control arm. 8. Raise the lower control arm until the spring is properly seated. Install the bolts finger tight, do not torque the bolts until proper trim height is obtained. 9, Insert the ball joint into the knuckle. Torque the nut to 129 ft. Ibs. (175 Nm). 10. Install the shock absorber lower mounting bolt. Torque the bolt to 80 ft. Ibs. (108 Nm). 11. Connect the stabilizer link lower mounting bolt. Do not torque the bolt at this time. 12. Install the wheel. Torque the lug nuts to 100 ft. Ibs. (140 Nm). 13. Lower the vehicle to allow the suspension to obtain proper trim height. 14. Torque the lower control arm nuts to 80 ft. Ibs. (108 Nm). 15. Torque the stabilizer link bolt to 38 ft. Ibs. (52 Nm).

2000-01 DEVILLE AND SEVILLE

7922UG18

Install Rod J 34013-38 to help guide the Strut shaft from the upper mount assembly—front strut shown

C. Step 3: Compress the coil spring while guiding strut shaft through the top of the strut assembly. d. Step 4: Install the top strut nut. Torque the nut to 55 ft. Ibs. (75 Nm). e. Step 5: Remove the strut from the compressor. Rear

1998-99 DEVILLE, SEVILLE AND 1998-01 ELDORADO 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Support the outboard end of the lower control arm, 3. Remove or disconnect the following: e Wheel e Stabilizer link lower mounting bolt ¢ Shock absorber lower mounting bolt ¢ Height sensor link attachment from the lower control arm 4. Separate the ball joint from the control arm.

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Support the outboard end of the lower control arm. 3. Remove or disconnect the following: e Wheel ¢ Electronic level control tube from the shock, if equipped ¢ Adjustment link bolt and separate it from the knuckle ¢ Shock absorber lower mounting bolt 4. Separate the ball joint from the control arm. 5. Slowly lower the control arm until spring pressure is released. 6. Remove the spring. To install: 7. Place spring into lower control arm making sure the insulator is properly seated. 8. Raise the lower control arm until the spring is properly seated. 9. Tighten the shock lower bolts to 18 ft. Ibs. (25 Nm). 10. Connect the adjustment link bolt and tighten to 22 ft. Ibs. (30 Nm) 11. Connect the electronic level contro! tube to the shock, if equipped. 12. Install the wheel. 13. Check the alignment.

Lower Ball Joint

REMOVAL & INSTALLATION 1998-99 Models

EXCEPT COMMERCIAL CHASSIS 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Allow the front suspension to hang free. 3. Remove or disconnect the following: e Front wheel ‘

> CAUTION Be careful when working in the area of the CV-boot. Damage to the boot could result in eventual joint failure.

e Road Sensing Suspension (RSS) position sensor from the lower control arm, if equipped e Ball joint from the steering knuckle e Ball joint by drilling out the 3 ball joint-to-lower control arm rivets To install: 4. Install the new ball joint to the lower control arm with 3 new bolts and nuts. The bolts must be installed from the bottom of the control arm. Torque the nuts to 50 ft. lbs. (68 Nm). 5. Install or connect the following: ¢ Ball joint to the steering knuckle. Torque the nut to 84 inch Ibs. (10 Nm) plus an additional 120 degree turn during which a minimum torque of 37 ft. Ibs. (60 Nm) must be obtained. elf the minimum torque is not obtained, check for stripped threads. If the threads are okay, replace the ball joint and knuckle.

¢ New cotter pin ¢ RSS position sensor to the lower control arm if equipped 6. If used, remove the CV-Joint boot protector tool. 7. Install the front wheel. Torque the lug nuts to 100 ft. Ibs. (140 Nm).

COMMERCIAL CHASSIS—FRONT 1. Before servicing the vehicle, refer to the precautions in the beginning of this section,

Be careful when working in the area of the CV-boot. Damage to the boot could result in eventual joint failure. LT

SS

E & K-BODIES—GENERAL MOTORS CORPORATION

DEVILLE e ELDORADO ¢ SEVILLE

|

~ COTTER

a-— ©

A

Lower Control Arm

PIN BALL JOINT MOUNTING NUTS 68 N-m

NUT

22 35

REMOVAL & INSTALLATION Front

1998-99 SEVILLE

CONTROL

ap) | ~ STEERING

|

KNUCKLE

SERVICE BALL JOINT BALL JOINT MOUNTING BOLTS MUST FACE UP 7922VG25

Exploded view of the lower ball joint mounting

2. Remove or disconnect the following: e Wheel e Ball joint cotter pin and nut e Ball joint from steering knuckle 3. Press the ball joint from the lower control arm. To install: 4. Press the ball joint into the control arm. 5. Install or connect the following: e Hex nut. Torque the nut to 129 ft. lbs. (175 Nm). e New cotter pin

3. Support the lower control arm. The tension of the coil spring must be supported with a suitable jack stand.

4 Remove the cotter pin and ball stud nut.

6. Install the wheel and torque the lug nuts to 100 ft. Ibs. (140 Nm).

5. Separate the ball joint from the knuckle. 6. Press the ball joint out of the control arm. To install: 7. Press the ball joint into the control arm. 8. Install the ball joint into the knuckle. 9. Install the ball stud nut. Torque the nut to 129 ft. Ibs. (175 Nm) and install a new cotter pin. 10. Remove the support from the lower control arm. 11. Install the wheel. Torque the lug nuts to 100 ft. Ibs. (140 Nm).

COMMERCIAL CHASSIS—REAR

2000-01 Models

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove the wheel.

The ball joint is an integral part of the lower control arm and if found to be defective the control arm should be replaced.

->If the cotter pin cannot be installed because the hole in the stud does not align with a nut slot, torque the nut an additional 60 degrees to allow for installation. NEVER loosen the nut to provide for cotter pin installation.

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Wheel Road Sensing Suspension (RSS) sensor, if equipped Stabilizer link bolt from the control arm Ball joint from the steering knuckle Mounting bolts Lower control arm To install: 3. Install or connect the following: e Lower control arm and handtighten the bolts e Stabilizer link bolt to the control arm and hand-tighten e Ball joint to lower control arm. 4. Torque the stabilizer link bolt to 13 ft. Ibs. (17 Nm). 5. Torque the nut to 88 inch Ibs. (10 Nm) plus an additional 120 degree turn till the torque is a minimum 41 ft. Ibs. (55Nm). e New cotter pin e Wheel. Torque the lug nuts to 100 ft. Ibs. (140 Nm). 6. Lower the vehicle and torque the control arm front nut to 116 ft. Ibs. (157 Nm)) and the rear nut to 117 ft. Ibs. (158 Nm).

1998-99 DEVILLE AND ELDORADO 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Wheel ¢ Road Sensing Suspension (RSS) SENSOT

Exploded view of the lower control arm

For complete Engine Mechanical specitications, see Section 1 of this manual

22-36 GENERAL MOTORS CORPORATION-E & K-BODIES DEVILLE ¢ ELDORADO SEVILLE e Lower ball joint from the steering knuckle

3. On the left control arm, support the transaxle and remove two transaxle mount nuts. Then raise the transaxle to access the control arm bolt. 4 Remove or disconnect the following: e Control arm nuts and bolts e Control arm To install: 5. Install or connect the following: Control arm Front and rear bolts, do not tighten yet Transaxle mount and lower the transaxle Lower ball joint. Torque nut to 84 inch lbs. (10 Nm) then an additional 120 degrees, reaching a minimum of 37ft. Ibs. (60 Nm). RSS position sensor Wheel. Torque the lug nuts to 100 ft. Ibs. (140 Nm). 6. Lower vehicle and allow the vehicle to assume proper trim heights. 7. Torque the contro! arm front bolt to 93 ft. Ibs. (126 Nm). 8. Torque the control arm rear bolt to 116 ft. Ibs. (157 Nm).

2000-01 DEVILLE AND SEVILLE 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Wheel ¢ Stabilizer link bolt from the control arm ¢ Ball joint from the lower control arm ¢ Control arm mounting nuts and bolts ¢ Control arm To install: 3. Install or connect the following: ¢ Control arm e¢ Front and rear bolts, do not tighten yet ¢ Stabilizer link to control arm ¢ Ball joint stud in the lower control arm 4. Tighten the stabilizer shaft link assembly nut to 17 ft. Ibs. (23 Nm). 5. Tighten the ball joint stud nut to 22 ft. lbs. (30 Nm), then tighten the nut an additional 190 degrees. ¢ Cotter pin e Wheel 6. Lower the vehicle. 7. Bounce the vehicle and tighten the front lower control arm nut to 120 ft. Ibs. (162 Nm) and the rear nut to 108 ft. Ibs. (146 Nm).

2000-01 ELDORADO 1. On the left control arm, support the transaxle and remove two transaxle mount nuts. Then raise the transaxle to access the control arm bolt. 2. Remove or disconnect the following: e Control arm nuts and bolts e Control arm To install: 3. Install or connect the following: Control arm Front and rear bolts, do not tighten yet Transaxle mount and lower the transaxle Lower ball joint. Torque nut to 84 inch Ibs. (10 Nm) then an additional 120 degrees, reaching a min-

imum of 37 ft. Ibs. (50 Nm). RSS position sensor Wheel. Torque the lug nuts to 100 ft. Ibs. (140 Nm). 4. Lower vehicle and allow the vehicle to assume proper trim heights. 5. Torque the control arm front bolt to

93 ft. Ibs. (126 Nm). §. Torque the control arm rear bolt to 116 ft. Ibs. (157 Nm). Rear

1998-99 DEVILLE AND SEVILLE 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Wheels Exhaust system Coil springs Brake calipers Wheel speed sensor electrical connectors Antilock Brake System (ABS) electrical connectors Electronic level control electrical connectors 3. Support the rear suspension support assembly. 4. Remove the bolts and lower the support assembly from the vehicle. ¢ Stabilizer link bolt e Hub and bearing ¢ Lower control arm To install 9. Install or connect the following: ¢ Lower control arm. Do not torque the bolts at this time. ¢ Hub and bearing. Torque the bolts to 52 ft. Ibs. (70 Nm). ° Sttabilizer link. Torque the bolt to 11 ft. Ibs. (15 Nm),

6. Raise the rear Suspension support assembly into place. Torque the bolts to 141 ft. Ibs. (191 Nm). Electronic level control electrical connectors ABS electrical connectors Wheel speed sensor electrical connectors Brake calipers. Torque the bolts to 63 ft. Ibs. (85 Nm). Coil springs Exhaust system e Wheels 7. To obtain proper trim height, raise the control arm until the spindle face is parallel to the ground and torque the nuts to 78 ft. lbs. (106 Nm).

1998-99 DEVILLE, SEVILLE AND 2000-01 ELDORADO 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Support the outboard end of the lower control arm. 3. Remove or disconnect the following: e Wheel ¢ Electronic level control tube from the shock, if equipped e Adjustment link bolt and separate it from the knuckle ¢ Shock absorber lower mounting bolt 4. Separate the ball joint from the control arm. 5. Slowly lower the control arm until spring pressure is released. 6. Remove the spring. 7. Remove the control arm bolt and the arm To install: 8. Lower control arm and inboard control arm bolt and nut and tighten to 75 ft. Ibs. (102 Nm). 9. Install the spring and insulators. 10. Raise the lower control arm until the spring is properly seated. 11. Install the stabilizer link lower attachment. 12. Remove the transmission jack. Place the jack under the outboard end ofthe lower control arm in order to bring the suspension _ to the Suspension's design position. 13. The inner control arm nuts must be tightened in the design position in order to reduce wind up in the bushings as follows: a. Stabilizer link lower nut to 44 ft, lbs. (60 Nm). b. Tighten the shock absorber lower nut to 75 ft. Ibs. (102 Nm).

E & K-BODIES-GENERAL MOTORS CORPORATION 22-31 DEVILLE ¢ ELDORADO « SEVILLE —

C. Tighten the lower control arm inner nuts to 75 ft. Ibs. (102 Nm). 14. Install the wheel.

2000-01 DEVILLE AND SEVILLE 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Wheels e Exhaust system

e Coil springs e Brake calipers e Wheel speed sensor electrical connectors Antilock Brake System (ABS) electrical connectors Electronic level control electrical connectors 3. Support the rear Suspension support assembly. 4. Remove the bolts and lower the support assembly from the vehicle. e Stabilizer link bolt e Hub and bearing e Lower control arm To install 5. Install or connect the following: e Lower control arm. Do not torque the bolts at this time. ¢ Hub and bearing. Torque the bolts to 52 ft. Ibs. (70 Nm). e Stabilizer link. Torque the bolt to 11 ft. Ibs. (15 Nm). §. Raise the rear suspension support assembly into place. Torque the bolts to 141 ft. Ibs. (191 Nm). Electronic level control electrical connectors ABS electrical connectors Wheel speed sensor electrical connectors Brake calipers. Torque the bolts to 63 ft. Ibs. (85 Nm). Coil springs Exhaust system e Wheels 7. To obtain proper trim height, raise the control arm until the spindle face is parallel to the ground and torque the nuts to 78 ft. lbs. (106 Nm).

3. Press the bushing out of the lower control arm. To install 4. Lubricate the outer case of the new bushing. 5. Press the new bushing into the control arm. 6. Install or connect the following: e Lower control arm e Wheel. Torque the lug nuts to 100 ft. Ibs. (140 Nm).

Wheel Bearings ADJUSTMENT The wheel bearings are not adjustable. If a wheel bearing is out of specifications, it must be replaced. Using a dial indicator, check for looseness. If play exceeds 0.005 inches (0.127mm), the bearing wear is excessive and the hub and bearing should be replaced.

REMOVAL & INSTALLATION Front

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. WHEEL DRUM

2. Remove or disconnect the following: Front wheel Halfshaft nut and washer Caliper from the steering knuckle and support it on a wire Brake rotor Anti-lock Brake System (ABS) Speed sensor electrical connector

3 hub/bearing assembly to steering knuckle bolts Dust shield Hub and bearing assembly from the halfshaft Hub and bearing assembly from the steering knuckle To install: 3. Install the hub and bearing assembly over the halfshaft splines. ->Be sure the splines engage smoothly.

4. Apply a light coating of grease to the steering knuckle bore. 5. Install the hub/bearing assembly onto the halfshaft as far as possible. If the hub will not bottom out on the halfshaft, install the hub bolts and use the hub nut to draw the hub onto the halfshaft. 6. Once the hub is flush with the steering knuckle, remove the mounting bolts and

BEARING LOOSENESS

DIAGNOSIS DISC BRAKE

BRAKE

Mount dial indicator. Grasp bearing flange; using a push-pull movement, note indicator readings.

Free shoes from the disc, or remove calipers. Reinstall two wheel! nuts to secure disc. Mount dial indicator. Grasp disc; using a push-pull movement, note indicator readings.

If looseness exceeds 0.1270 mm (0.005 inch), replace hub and

If looseness exceeds 0.1270 mm (0.005 inch), replace hub and

bearing assembly.

bearing assembly.

CONTROL ARM BUSHING REPLACEMENT

ee

Front

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 9. Remove or disconnect the following: e Wheel e Lower control arm

MOUNTING DIAL INDICATOR WITH DRUM BRAKES

MOUNTING DIAL INDICATOR WITH DISK BRAKES 7922VG33

Inspect the wheel bearings for play with a dial indicator

For Accessory Drive Belt illustrations, see Section 1 of this manual

22-3 8 GENERAL MOTORS CORPORATION-E & K-BODIES DEVILLE e ELDORADO SEVILLE e Halfshaft nut. Torque it to 107 ft. Ibs. (145 Nm). ¢ Wheel. Torque the lug nuts to 100 ft. Ibs. (140 Nm). 8. Road test the vehicle for proper operation.

COMMERCIAL CHASSIS

Rear

EXCEPT COMMERCIAL CHASSIS 7922VG26

Exploded view of the front wheel bearing

mounting

install the dust shield. Reinstall the mounting bolts and torque to 70 ft. Ibs. (95 Nm)

on 1998-99 models (except Seville) or 95

e>The wheel bearing and hub are serviced as an assembly. The individual components are not serviceable separately. ig

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following:

* Rear wheel

ft. Ibs. (130 Nm) on all Seville and all

¢ Caliper bracket from the knuckle

2000-01 models .

e Brake rotor

7. Install or connect the following: e ABS speed sensor electrical connector ¢ Brake rotor ¢ Caliper. Torque the bolts to 38 ft, Ibs. (51 Nm).

Exploded view of the rear wheel bearing hub mounting

e Brake rotor e Caliper. Torque the new bolts to 83 ft. lbs. (113 Nm). e Wheel. Torque the lug nuts to 100 ft. Ibs. (140 Nm). 4. Road test the vehicle.

:

* Hub and bearing assembly bolts ¢ Hub and bearing assembly To install: 3. Install or connect the following: e Hub and bearing assembly. Torque the bolts to 52 ft. Ibs. (70 Nm).

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: ¢ Wheel e Brake drum ¢ Brake shoes and cable e Brake line e Wheel speed sensor 3. Support the lower control arm. 4. Separate the ball joint from the knuckle. ¢ Upper knuckle bolt ¢ Bearing retainer ¢ Nut from backside of knuckle 5. Press the hub from the knuckle. 6. Remove the brake backing plate from the knuckle. 7. Press the bearing from the knuckle. To install 8. Press the bearing into the knuckle. 9. Install the backing plate and bolts. Torque the bolts to 37 ft. Ibs. (560 Nm). 10. Press the hub into the bearing. 11. Install the speed sensor ring and nut. Torque the nut to 145 ft. Ibs. (200 Nm). 12. Install or connect the following: Upper knuckle bolt and nut. Torque the nut to 80 ft. Ibs. (108 Nm), Ball joint to knuckle Brake line Wheel speed sensor Brake shoes and cable Brake drum 13. Bleed the brake system. 14. Install the wheel. Torque the lug nuts to 100 ft. Ibs. (140 Nm). 15. Check the brake system for leaks,

GENERAL MOTORS CORPORATION—F-BODY 1998-01 Chevrolet-Camaro * Z28 * Pontiac-Firebird * Trans Am DRIVESTRAIN Gets cee 23-24 ENGINE REPAIR ................ 23-2 BUELSSYSTEME er es oo 23-21 PRECAUTIONS..............0.5 23-2 STEERING AND SUSPENSION sugar ria 23-26

FUGIP UCD steers Specter ceeetes sekathe Removal & Installation............ Fuel System PreSSUre.........s.se0 Relieving ar secece re err. Meare Fuel System Service Precautions........... abe ais

iS\iEASEVa URCe eee lee:Mae (11 TA eed hse e Oe

Hydraulic Clutch System............. 23-20 BICC cenematt. cetera. 23-25

23-26 23-26

PI SaniTi Opens tonto oar ea23-26

PIeCAUONS ease, c-feuinsde. 23-26 NICHES a ee eee 23-2

23-22 23-22 23-2 | 23-21 23-21

|

IQMIfION TIMING ........ssssssssssssssssssees 23-3 OUST See ee eer esetee 23-3

R Rear Mali S@allaeeen... iam 23-17 Removal & Installation............ 23-17 Rocker Aringa:. eee cee an eee 23-8 Removal & ye et ion Yat 23-8 Shock ADSOrDer Bans tenet Removal & Installation............ Starter Wot... getee eae eee Removal & geen irs ty

Timing Chain, Sprockets,

tac 23-25

Lower Ball Joint aancech aes renereaeseanennes 23-30

Front Cover and Seal..........c.065 Removal & Installation............ TRANSMISSION aeees ere erate Removal & pect ens

C Lifters .......... 93-14 Valve and Camshaft

Removal & Installation............ 23-30 Lower Control Arm eet 23-31

UppemBallJoiniiees

oe ice 0329 Installation seeteee

200. Veorares 23-2 Removal@atiet

Axle Shaft, Bearing and Seal........23-25 Removal

& Installation Bett

die deco haere23-8 IitakenWViaiitOlGnsten.

Removal & Installation............... 23-8 ,

Control Arm Bushing REPIACEMICNL AS... chenne

Removal & Installation........... 23-14 ens home 23-24 Ghicieeee

Removal & Installation........... 93-24 Balt Syl eeeeemd enema 23-29

Removal & Installation............ 93-99

Cylinder Head ...ccsescsssseceeseense 23-6J ae pees siareleh Se 23-3 cesnseetinnt EUR SSEMDIV es:i, czy se

L

Upper Control Arm... eee 23-31 Control Arm Bushing Replacement..........-cssceesee 23-31

tenis 23-16

Removal & Meer oe. Bate tt 23-31

OP an ee

..... ate AeLITO neates& Installation..... neha Mersey.caren -

Removal & Installation............ Perllp

ae

Removal & Installation............. 23-10

23-20 Piston ANG RING ......ssesseesssreroe eo...23-20

23-21 ld Its] eas go eS eee 23-21 .......... Installation.. & Removal

Power Rack and Pinion Steering Gear............. sretssseerse 23-27

FilelM THECION eee cre ee ceaceneeee 23-23

Removal & Installation............ 23-23

aa aera 23-29

Removal & Installation............ 23-29

23-32

PiplOMoBallm. cern Sybil ee 23-26

F

23-18 23-18 23-24 23-24

Removal & Hsu eae 23-31

Removal & Installation... Dene)

Exhaust Manifold... see 23-10

23-2/ 23-2/ 23-15 23-15

_ Removal & Installation.........23-26 POSIONinGaest

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Removal & Installation........... 23-27

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AGI aStinert Acer eee: 23-33 Removal & Installation............ 23-33

23-2

GENERAL MOTORS CORPORATION-F-BODY CAMARO ¢ 228 ¢ FIREBIRD * TRANS AM

PRECAUTIONS Before servicing any vehicle, please be sure to read all of the following precautions, which deal with personal safety, prevention of component damage, and important points to take into consideration when servicing a motor vehicle: e Never open, service or drain the radiator or cooling system when the engine is hot; serious burns can occur from the steam and hot coolant. ¢ Observe all applicable safety precautions when working around fuel. Whenever servicing the fuel system, always work in a well-ventilated area. Do not allow fuel spray Or vapors to come in contact with a spark, open flame or excessive heat (a hot drop light, for example). Keep a dry chemical fire extinguisher near the work area. Always keep fuel in a container specifically designed for fuel storage; also, always properly seal fuel containers to avoid the possibility of fire or explosion. Refer to the additional fuel system precautions later in this section. ¢ Fuel injection systems often remain pressurized, even after the engine has been turned OFF. The fuel system pressure must be relieved before disconnecting any fuel lines. Failure to do so may result in fire and/or personal injury. e Brake fluid often contains polyglycol ethers and polyglycols. Avoid contact with the eyes and wash your hands thoroughly after handling brake fluid. If you do get brake fluid in your eyes, flush your eyes with clean, running water for 15 minutes. If eye irritation persists, or if you have taken

brake fluid internally, IMMEDIATELY seek medical assistance. e The EPA warns that prolonged contact with used engine oil may cause a number of skin disorders, including cancer! You should make every effort to minimize your exposure to used engine oil. Protective gloves should be worn when changing oil. Wash your hands and any other exposed skin areas aS Soon as possible after exposure to used engine oil. Soap and water, or waterless hand cleaner should be used. ¢ All new vehicles are now 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 repairs. e Always wear safety goggles when working with, or around, the air bag system. When carrying a non-deployed air bag, be sure the bag and trim cover are pointed away from your body. When placing a nondeployed air bag on a work surface, always face the bag and trim cover upward, away from the surface. This will reduce the motion of the module if it is accidentally deployed. Refer to the additional air bag system precautions later in this section. ¢ Clean, high quality brake fluid froma sealed container is essential to the safe and proper operation of the brake system. You

should always buy the correct type of brake fluid for your vehicle. If the brake fluid becomes contaminated, completely flush the system with new fluid. Never reuse any brake fluid. Any brake fluid that is removed from the system should be discarded. Also, do not allow any brake fluid to come in contact with a painted surface; it will damage the paint. e Never operate the engine without the proper amount and type of engine oil; doing so WILL result in severe engine damage. e¢ Timing belt maintenance is extremely important! Many models utilize an interference-type, non-freewheeling engine. If the timing belt breaks, the valves in the cylinder head may strike the pistons, causing potentially serious (also time-consuming and expensive) engine damage. Refer to the maintenance interval charts in the front of this manual for the recommended replacement interval for the timing belt, and to the timing belt section for belt replacement and inspection. e¢ Disconnecting the negative battery cable on some vehicles may interfere with the functions of the on-board computer system(s) and may require the computer to undergo a relearning process once the negative battery cable is reconnected. ¢ When servicing drum brakes, only disassemble and assemble one side at a time, leaving the remaining side intact for reference. ¢ Only an MVAC-trained, EPA-certified automotive technician should service the air conditioning system or its components.

ENGINE REPAIR Alternator

;

REMOVAL 3.8L Engine

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Negative battery cable e Accessory drive belt e Alternator electrical connectors

e Evaporative Emissions (EVAP) canister purge solenoid ¢ Rear alternator brace-to-alternator bolt ¢ Both front alternator bolts e Alternator

5.7L Engine

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Negative battery cable ¢ Accessory drive belt

e ¢ e ¢ e

Alternator rear inner brace Transmission oil cooler line clips Alternator bolts Alternator electrical connectors Alternator

INSTALLATION hee 3.8L Engine Install or connect the following: ° Alternator. Torque the upper (drive belt tensioner) bolt to 22 ft. Ibs. (30 Nm) and the lower bolt to 37 ft. Ibs. (560 Nm)

F-BODY-GENERAL MOTORS CORPORATION CAMARO ¢ 228 FIREBIRD ¢ TRANS AM

BOLT/SCREW, GENERATOR BRACE TO BRACKET BOLT/SCREW, GENERATOR BRACE GENERATOR BOLT/SCREW, GENERATOR BOLT/SCREW, GENERATOR BRACE, GENERATOR REAR ~~ =w wa-onr 9306WG01

Exploded view of the alternator and related components—3.8L engine

e Rear alternator brace-to-alternator bolt.

Torque the bolt to 22 ft. Ibs. (30 Nm). e EVAP canister purge solenoid e Alternator electrical connectors. Torque the battery cable nut to 16 ft. Ibs. (22 Nm). e Accessory drive belt e Negative battery cable

5.7L Engine Install or connect the following: e Alternator e Alternator bolts. Torque the bolts to 37 ft. lbs. (50 Nm). e Transmission oil cooler line clips e Alternator rear inner brace. Torque the nut to 18 ft. Ibs. (25 Nm). e Alternator electrical connectors. Torque the battery cable nut to 16 ft. Ibs. (22 Nm). e Accessory drive belt ¢ Negative battery cable

9346WG02

Exploded view of the alternator and related components—5.7L engine

Ignition Timing ADJUSTMENT On these vehicles, base timing is preset when the engine is manufactured. All timing changes are, then controlled directly by the Powertrain Control Module (PCM) based on information from the ignition and knock sensor systems. No adjustments are necessary or possible.

Engine Assembly REMOVAL & INSTALLATION ->The engine, transmission and suspension assembly is removed from the bottom of the vehicle. After the assembly is removed, separate the engine from the transmission and frame.

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove both battery cables. 3. Relieve the fuel system pressure. 4. Recover the refrigerant from the AC system using approved equipment. 5. Drain the cooling system, crankcase and transmission fluid. 6. Remove or disconnect the following: e Intake air temperature (IAT) sensor electrical connector Air intake duct Front wheels 3-way catalytic converter Propeller shaft

23-3

Torque arm Starter motor Transmission range selector lever cable from the range selector lever at the transmission by unsnapping it, on models equipped with a automatic transmission Retainer from the range selector lever cable Range selector lever cable from the cable bracket Clutch actuator cylinder line from the actuator cylinder using Tool J36221, on models equipped with a manual transmission Left side front air deflector Stabilizer bar bracket bolts and brackets Steering gear coupling shield Intermediate steering shaft bolt and shaft from the rack Wiring harness ground bolt and radio frequency ground strap and cruise contro! ground lead from the front rail Knock sensors electrical connectors Wheel speed sensors electrical connectors

A/C compressor and condenser hose bolt. Discard the O-ring.

A/C compressor and condenser hose nut at the condenser. Discard the O-ring. Front fuel pipe heat shield nuts Front fuel pipe heat shield Brake lines from the brake pipe clip Engine wiring harness ground bolt Engine ground A/C compressor and condenser hose bolt at the accumulator. Discard the O-ring. Heater hoses from the drive belt tensioner Fuel feed pipe from the fuel rail Fuel return pipe from the fuel rail Evaporative Emissions (EVAP) pipe at the engine Cruise control and accelerator control cables from the throttle body and bracket Accelerator control cable bracket bolts and bracket Inlet hose from the water outlet Outlet hose from the water pump Brake booster vacuum hose from the intake manifold fitting Front two brake pipes from the brake modulator

For complete service labor times, order Nichols’ Chilton Labor Guide

23-4

GENERAL MOTORS CORPORATION-F-BODY CAMARO ¢ 228 ¢ FIREBIRD ¢ TRANS AM

Secondary captured locks Forward lamp harness from the engine harness Engine harness vacuum tube from the bottom of the vacuum check valve Powertrain Control Module (PCM) connectors PCM Right side insulator panel Hinge pillar trim panel Engine wiring harness from the instrument panel wiring harness e Engine wire harness through the front of the dash 7. Place the harness on top of the engine. ¢ Floor shift control, if equipped e Transmission control, if equipped Right and left lower shock bolts from the lower control arms Cotter pins and nuts from the left and right upper ball joints ¢ Separate the upper control arms from the steering knuckles and support both steering knuckles 8. Position Engine Support TableJ 39580 below the vehicle. Lower the vehicle and lay the engine wire harness on top of the engine. ¢ Transmission support bolts e Engine and transmission from the vehicle 9. Secure the crossmember to the engine support table. 10. Position a hex-head socket on the belt tensioner pulley bolt. 11. Rotate the drive belt tensioner clockwise to relieve belt tension. 12. Remove or disconnect the following: Drive belt A/C compressor rear bolts A/C compressor rear bracket stud A/C compressor rear bracket A/C compressor bolts A/C compressor Drive belt tensioner bolts and the tensioner Power steering pump nuts and reposition the power steering pump to the crossmember Alternator electrical connector Positive cable nut from the alternator Alternator 13. Install a suitable lifting devise to the engine. ¢ Right engine mount bracket bolts and bracket e Left engine mount bracket bolts, Stud and the bracket

14. Raise the engine and transmission | from the crossmember. 15. If equipped with the automatic transmission remove or disconnect the follow-

ing: e Right side transmission support brace bolts, nut and the brace e Left side transmission support brace bolts, nut and the brace e Torque converter cover e Flywheel-to-torque converter bolts 16. If equipped with the manual transmission remove or disconnect the following: Right side transmission support bolts and the support Left side transmission support bolts and the support Electrical connectors from the transmission Transmission-to-engine bolts and nut, then separate the transmission from the engine, if equipped with an automatic transmission Flywheel housing to engine bolts and nuts, then separate the flywheel housing from the engine, if equipped with a manual transmission Pressure plate and clutch, if equipped with a manual transmission Flywheel bolts and flywheel, if equipped with a manual transmission To install: 17. Install or connect the following: ¢ Flywheel bolts and flywheel, if equipped with a manual transmission. Tighten the flywheel bolts to 11ft. Ibs. (15 Nm), then tighten an additional 50 degrees. Clutch and pressure plate, if equipped with a manual transmission. Tighten the pressure plate bolts to 15 ft. Ibs. (20 Nm) and tighten an additional 45 degrees. 18. Align the flywheel housing to the engine. * Flywheel housing-to-engine bolts and nuts, if equipped with a manual transmission and tighten to 70 ft.

lbs. (95 Nm). ¢ Transmission-to-engine bolts and

ut and tighten to 70 ft. Ibs. (95 m), if equipped with an automatic = ansmission

ectrical connectors to the transission 19. po Ifee equipped with the manual transmission install or connect the following; ¢ Left side transmission support

e Left side transmission support brace bolts and tighten to 37 ft. Ibs. (50 Nm) e Left side transmission support brace bolts and tighten to 21 ft. Ibs. * (28 Nm) e Right side transmission support bolts and tighten to 37 ft. Ibs. (50 Nm) 20. If equipped with the automatic transmission install or connect the following: e Torque converter-to-flywheel bolts and tighten to 47 ft. Ibs. (63 Nm) e Torque converter cover e Left side transmission support, bolts and nut e Right side transmission support 21. Lower the engine and transmission to the crossmember. e Left engine mount bracket, stud and bolts. Tighten the bolts to 74 ft. lbs. (100 Nm) and the stud 64 ft. Ibs. (87 Nm). ¢ Right engine mount bracket and the bolts 22. Remove the engine lifting device. ¢ Alternator and wiring ¢ Power steering pump and tighten the nuts to 22 ft. Ibs. (30 Nm) ¢ Drive belt tensioner and bolts, and tighten to 37 ft. Ibs. (60 Nm) ¢ A/C compressor and tighten to 37 ft. lbs. (60 Nm) ¢ A/C compressor rear bracket. and tighten the stud to 37 ft. Ibs. (50 Nm) and the bolts to 22 ft. Ibs. (30 Nm) e Drive belt 23. Remove the crossmember from the table security straps. 24. Lower the vehicle and install the engine and transmission to the vehicle. 25. Align the crossmember to the vehicle body. 26. Install or connect the following: Front crossmember bolts. Tighten the lower 2 to 107 ft. Ibs. (145 Nm) and the upper 4 cradle bolts to 92 ft. Ibs. (125 Nm). Transmission support bolts and tighten to 42 ft. Ibs. (65 Nm) Ball stud to the steering knuckle Nuts and cotter pins to the left and right upper ball joints. Tighten to 39 ft. Ibs. (63 Nm). Right and left lower shock bolts to the lower control arms Transmission control, if equipped Floor shift control, if equipped Engine wire harness through the front of dash

F-BODY-GENERAL MOTORS CORPORATION CAMARO ¢ 228 ¢ FIREBIRD ¢ TRANS AM Engine wiring harness to the instrument panel wiring harness Hinge pillar trim panel Right side insulator panel

e Air intake duct e IAT sensor electrical connector

PCM and electrical connectors Engine harness vacuum tube Forward lamp harness Engine harness Secondary captured locks Front two brake pipes Brake booster vacuum hose Outlet hose to the water pump Inlet hose to the water outlet Accelerator control cable bracket and bolts. Tighten to 12 ft. Ibs. (16 Nm). Accelerator control and cruise control cables to the throttle body and bracket EVAP pipe Fuel return pipe Fuel feed pipe Heater hoses New O-ring A/C compressor and condenser hose bolt at the accumulator and tighten to 36 ft. Ibs. (48 Nm) Engine ground and bolt and tighten to 18 ft. Ibs. (25 Nm) Brake lines Front fuel pipe heat shield and bolts A/C compressor and condenser hose nut at the condenser. Tighten to 12 ft. Ibs. (16 Nm). Wheel speed sensors electrical connectors Knock sensors electrical connectors Radio frequency ground strap, cruise control ground lead and wiring harness ground bolt to the front rail Intermediate steering shaft and bolt to the rack. Tighten to 35 ft. Ibs.

(47 Nm). Steering gear coupling shield Stabilizer bar brackets and bolts Tighten to 41 ft. Ibs. (55 Nm). Left side front air deflector Clutch actuator cylinder line to the actuator cylinder, if equipped Range selector lever cable, if equipped Starter motor Torque arm Propeller shaft 3-way catalytic converter Front wheels

e Battery cables 2/. Refill the engine oil, transmission fluid and coolant 28. Recharge the A/C system. 29. Bleed the brakes. 30. Bleed the clutch hydraulic system. 31. Connect the negative battery cable.

23-9

5.7L Engines 1. Before servicing the vehicle, refer to the precautions in the beginning of this section.

2. Drain the cooling system by removing the block coolant drain plug and the knock SENSOr.

Water Pump REMOVAL & INSTALLATION 3.8L Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the cooling system. 3. Remove or disconnect the following: e Negative battery cable e Accessory drive belt e Radiator inlet hose from the water DUMP e Water pump pulley e Water pump To install:

4. Install or connect the following: e Water pump using a new gasket. Torque the water pump bolts to 11 ft. Ibs. (15 Nm), plus an additional 80 degree rotation. e Water pump pulley. Torque the bolts to 115 inch Ibs. (13 Nm). e Accessory drive belt e Radiator inlet hose to the water

pump e Negative battery cable a Refill the cooling system. 6. Start the engine and check for leaks.

3. Remove or disconnect the following: Negative battery cable Electrical connector from the cooling fan Intake Air Temperature (IAT) sensor electrical connector Mass Airflow (MAF) sensor electrical connector Air intake duct Outlet hose from the water outlet Inlet hose from the water pump Air cleaner assembly Inlet hose from the radiator Both cooling fan assemblies Drive belt Drive belt tensioner pulley Vent hose from the radiator Water pump pulley Water pump To install: 4. Install or connect the following: Drain plug Water pump using a new gasket. Torque the bolts to 18 ft. Ibs. (25 Nm) on 1998-99 models and 22 ft. lbs. (30 Nm)on 2000-01 models. Water pump pulley. Torque the bolts to 18 ft. Ibs. (25 Nm). Vent hose to the radiator Drive belt tensioner pulley. Torque the bolt to 37 ft. Ibs. (50 Nm), Drive belts Cooling fans Inlet hose to the radiator Air cleaner assembly. Torque the

7922WG03

Exploded view of the water pump mounting—3.8L engine

Please visit our web site at www.chiltonsonline.com

23

i

GENERAL MOTORS CORPORATION-F-BODY CAMARO ¢ 228 ¢ FIREBIRD e TRANS AM

SHAFT, WATER PUMP TAB ON GASKET PUMP ASSEMBLY, WATER GASKET, WATER PUMP COUPLING, WATER PUMP DRIVESHAFT BOLT/SCREW, WATER PUMP BOLT/SCREW, WATER PUMP ORIVESHAFT ASSEMBLY, WATER PUMP B2zZsB8Sar 156 SEAL, WATER PUMP DRIVESHAFT 7922WG04

Exploded view of the water pump mounting and related components—5.7L engines

bolts to 106 inch Ibs. (12 Nm). e Inlet hose to the water pump

¢ Qutlet hose to the water outlet e Air intake duct e IAT and MAF sensor electrical connectors ¢ Coolant fan electrical connectors ¢ Negative battery cable 5. Refill the cooling system. 6. Start the engine and check for leaks.

¢ Rocker arm cover, rocker arms and push rods ¢ Cylinder head To install: 5. Install the cylinder head with a new gasket and secure with NEW head bolts. 6. Torque the head bolts in sequence as follows:

a. Step 1: 37 ft. Ibs. (50 Nm). b. Step 2: Plus 120 degree turn. 7. Install or connect the following: e Rocker arms and push rods e Rocker arm cover. Torque the bolts to 89 inch Ibs. (10 Nm). e Left exhaust manifold

Cylinder Head REMOVAL & INSTALLATION 3.8L Engine

LEFT SIDE 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Relieve the fuel system pressure. 3. Drain the cooling system. 4. Remove or disconnect the following: ¢ Negative battery cable ¢ Fuel lines from the fuel rail ¢ Upper and lower intake manifolds

TIGHTENING SEQUENCE BOLT/SCREW, CYLINDER HEAD, CYLINDER

GASKET, CYLINDER HEAD

LOCATOR PINS

° Spark plugs

e Left exhaust manifold

HEAD

7922WG06

Cylinder head bolt torque sequence—3.8L (VIN K) engine

F-BODY-GENERAL MOTORS CORPORATION

CAMARO ¢ 228 ¢ FIREBIRD ¢ TRANS AM

e Spark plugs and torque them to 20 ft. lbs. (27 Nm). e Lower and upper intake manifolds e Negative battery cable 8. Refill the cooling system. 9. Start the engine and check for leaks.

15 13 °o 40 3 iz isoe 6 °

°

1 1 2

°o

2 «#14 ° or) aithe8 G

°

23-/

e Coolant air bleed pipe e Intake manifold e Negative battery cable 9. Refill the cooling system. 10. Change the oil and filter. 11. Start the engine and check for leaks.

79222612

RIGHT SIDE

RIGHT SIDE

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Relieve the fuel system pressure. 3. Drain the cooling system. 4. Remove or disconnect the following: e Negative battery cable e Fuel lines from the fuel rail e Upper and lower intake manifolds e Spark plugs e Right exhaust manifold e Rocker arm cover, rocker arms and

push rods e Cylinder head To install: 5. Install the cylinder head with a new gasket and secure with NEW head bolts. Torque the bolts in sequence as foliows: a. Step 1: 37 ft. Ibs. (60 Nm). b. Step 2: Plus a 120 degree turn 6. Install or connect the following: Rear alternator brace. Torque the bolts to 18 ft. Ibs. (25 Nm). Drive belt tensioner. Torque the bolts to 37 ft. Ibs. (60 Nm). Rocker arms and push rods Rocker arm cover. Torque the bolts to 89 inch Ibs. (10 Nm). Right exhaust manifold. Torque the bolts to 106 inch Ibs. (12 Nm). Spark plugs. Torque the plugs to 20 ft. Ibs. (27 Nm). e Lower and upper intake manifolds e Negative battery cable 7. Refill the cooling system. 8. Start the engine and check for leaks. 5.7L Engines

LEFT SIDE 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the cooling system. 3. Remove or disconnect the following: e Negative battery cable e Coolant air bleed pipe +» Power steering pump pulley and hoses ¢ Power steering pump and bracket e Exhaust manifold

Cylinder head bolt tightening sequence— 5.7L (VIN G) engine

e Intake manifold e Rocker arm cover

e Rocker arms, pedestals and push rods e Ground wires from the back of the head

e Cylinder head To install:

4. Install the cylinder head with a new gasket. -> Before installing the head bolts, be sure to mark the short bolts so the correct tightening specifications are used.

5, Lubricate the M11 bolts with clean engine oil, then install them. 6. Apply a 0.2 inch (5mm) bead of threadlock GM P/N 12345382 to the threads of the M8 cylinder head bolts. 7. Torque the cylinder head bolts in sequence as follows: a. M11 bolts 1-10: 22 ft. Ibs. (30 Nm). b. M11 bolts 1-10: an additional 90 degrees. c. M11 bolts 1-8: an additional 90 degrees. d. M11 bolts 9-10: an additional 50 degrees. e. M8 bolts 11-15: 22 ft. Ibs. (30 Nm). Begin at the center and alternate side-to-side working outward. 8. Install or connect the following: Ground wires to the back of the head. Torque the bolt to 37 ft. Ibs. (50 Nm). Rocker arms, pedestals and push rods Exhaust manifold Rocker arm cover. Torque the bolts to 106 inch Ibs. (12 Nm). Power steering pump bracket. Torque the bolts to 37 ft. Ibs. (50 Nm). Power steering pump. Torque the

bolts to 18 ft. Ibs. (25 Nm). Power steering pump hoses and pulley

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the cooling system. 3. Remove or disconnect the following: Negative battery cable Coolant air bleed pipe Intake manifold Exhaust manifold Rocker arm cover Rocker arms, pedestals and push rods Wiring clip bolt from the cylinder head Tranmission dipstick tube bolt from the cylinder head Cylinder head To install: 4. Install the cylinder head with a new gasket. Before installing the head bolts, be sure to mark the short bolts so the correct tightening specifications are used.

5. Lubricate the M11 bolts with clean engine oil, then install them. 6. Apply a 0.2 inch (5mm) bead of threadlock GM P/N 12345382 to the threads of the M8 cylinder head bolts. 7. Torque the cylinder head bolts in sequence as follows: a. M11 bolts 1-10: 22 ft. Ibs. (30 Nm). b. M11 bolts 1-10: an additional 90 degrees. c. M11 bolts 1-8: an additional 90 degrees. d. M11 bolts 9-10: an additional 50 degrees. e. M8 bolts 11-15: 22 ft. Ibs. (30 Nm). Begin at the center and alternate side-to-side working outward. Wiring clip bolt to the cylinder head Tranmission dipstick tube bolt to the cylinder head Rocker arms, pedestals and push rods Exhaust manifold Rocker arm cover. Torque the bolts to 106 inch Ibs. (12 Nm).

Timing belt service is covered in Section 3 of this manual

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GENERAL MOTORS CORPORATION-F-BODY CAMARO ¢ 228 ¢ FIREBIRD e TRANS AM

¢ Coolant air bleed pipe e Intake manifold e Negative battery cable 8. Refill the cooling system. 9. Change the oil and filter. 10. Start the engine and check for leaks.

REMOVAL & INSTALLATION Be sure to keep all the components in the exact order of removal so they may be installed in their original locations. Coat the replacement rocker arm and ball with engine oil before 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 e Rocker arm cover ¢ Rocker arm bolts and rocker arms e Retainer e Push rods To install: 3. Lubricate the bearing surfaces with a thin coating of Molykote® or equivalent. 4. Install or connect the following: 5. The push rods, retainer, rocker arms and bolts. 6. On 3.8L engines, tighten the bolts to 11 ft. Ibs. (15 Nm) plus an additional 90 degrees. 7. Adjust the rocker arm bolts for the 5.7L engine as follows: a. Step 1:Rotate the crankshaft until number 1 piston is at Top Dead Center (TDC), b. Step 2:Tighten exhaust rocker arms 1,2,7 and 8 to 22 ft. Ibs. (30 Nm). A

LOCKS CAP

SEAL SHIELD

7922WG08

Exploded view of common rocker arm components and valve spring retainer

c. Step 3:Tighten intake rocker arms 1,3,4 and 5 to 22 ft. Ibs. (30 Nm). d. Step 4:Rotate the crankshaft 360 degrees. e. Step 5:Tighten exhaust rocker arms

3,4,5 and 6 to 22 ft. Ibs. (30 Nm). f. Step 6:Tighten intake rocker arms 2,6,7 and 8 to 22 ft. Ibs. (30 Nm). 8. Install the rocker arm cover and torque the bolts to 106 inch Ibs. (12 Nm). 9. Install the negative battery cable. 9346WG08

Intake Manifold

REMOVAL & INSTALLATION

Upper intake manifold torque sequence—

1998-99 3.8L engine

3.8L Engine

UPPER MANIFOLD 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Relieve the fuel system pressure. 3. Drain the cooling system.

4. Remove or disconnect the following: Negative battery cable Intake Air Temperature (IAT) sensor electrical connector Drive belt tensioner Fuel pressure regulator vacuum and Evaporative Emission (EVAP) emission canister purge harness from the manifold vacuum source, purge solenoid valve and the fuel pressure regulator valve Manifold vacuum source electrical connector Manifold vacuum source screws Manifold vacuum source from the upper intake manifold Canister purge solenoid valve electrical connector and hose Evaporative emissions canister purge solenoid valve Idle Air Control (IAC) valve Fuel lines from the fuel rail EVAP pipe at the engine Accelerator control cable bracket and control cables from the throttle body Ignition control module and coil pack assembly Brake booster hose from the upper manifold Alternator brace Throttle Position (TPS) sensor electrical connector Mass Air Flow (MAF) sensor electrical connector Wiring harness from the fuel rail clips

9346WG10

Upper intake manifold torque sequence— 2000-01 3.8L engine

¢ Throttle body

¢ Electrical connectors from the fuel injectors e Fuel rail ¢ Upper intake manifold To install: 9. Install the 1998-99 models upper intake manifold using a new gasket. Torque the bolts as follows: a. Bolts 1-10, in sequence: 11 ft. Ibs. (15 Nm). b. Coolant outlet bolts: 20 ft. Ibs. (27 Nm). C. Side bolts: 22 ft. Ibs. (30 Nm). 6. Install the 2000-01 models upper intake manifold using a new gasket. Torque the bolts as follows: a. Tighten the upper intake manifold bolts (1, 3 & 4): in sequence: 11 ft. Ibs. (15 Nm). b. Tighten the nine upper intake manifold bolts (4): to 89 inch Ibs. (10 Nm). C. Tighten the two upper intake manifold bolts (1) to 22 ft. Ibs. (30 N). 7. Install the fuel rail as follows: a. Install new fuel injector O-rings lubricated with engine oil. b. Install the fuel injectors into the manifold bores.

F-BODY-GENERAL MOTORS CORPORATION CAMARO e 228 ¢ FIREBIRD » TRANS AM c. Insert the fuel rail until the injectors are properly seated. d. Torque the nuts to 75 inch Ibs. (8.5 Nm). 8. Install or connect the following: Fuel injector electrical connectors Thermostat and thermostat housing. Torque the housing bolts to 20 ft. Ibs. (27 Nm). Throttle body and tighten the retainers to 89 inch lbs. (10 Nm) Wiring harness to the fuel rail clips Electrical connectors to the IAC, TPS, MAF and IAT sensors Alternator brace Brake booster hose Ignition contro! module and coil pack assembly Accelerator cable bracket and cruise control cables to the throttle body. Torque the bracket bolts to 12 ft. Ibs. (16 Nm). Accelerator and cruise control cables Fuel lines to the fuel rail IAC valve Fuel pressure regulator Canister purge harness Evaporative emissions canister purge solenoid valve MAP sensor and vacuum source Drive belt tensioner. Torque the bolts to 37 ft. Ibs. (60 Nm). Air intake duct IAT sensor connector Drive belt Negative battery cable 9. Refill the coolant system. 10. Start the engine and check for leaks.

9346WGO09

Lower intake manifold torque sequence— 3.8L engine

New gaskets and seals Lower manifold. Torque the manifold bolts in sequence to 11 ft. Ibs. (15 Nm). ECT sensor Upper intake manifold Negative battery cable 5.7L Engines

1998-98 MODELS 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Relieve the fuel system pressure. 3. Drain the coolant system. 4. Remove or disconnect the following: Negative battery cable Transmission fluid level indicator tube bolt Fuel lines from the fuel rail Vapor line from the fuel vapor purge valve Intake Air Temperature (IAT) sensor electrical connector

Mass Airflow (MAF) sensor electri-

LOWER MANIFOLD 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. >There are 2 bolts that are hidden under the upper manifold. They are located in the front and left rear corners of the lower manifold. It is necessary to remove the upper manifold to service the lower manifold.

2. Remove or disconnect the following: ¢ Negative battery cable e Upper intake manifold e Engine Coolant Temperature (ECT) sensor e Lower intake manifold To install: 3. Install or connect the following:

cal connection Air inlet duct Idle Air Control (IAC) valve and Throttle Position (TPS) sensor electrical connections from the throttle body Drive belt Exhaust Gas Recirculation (EGR) solenoid electrical connector EGR valve pipe Cruise control and throttle cables from the throttle body Cruise control servo bracket Fuel injector electrical connectors Fuel rail Manifold Absolute Pressure (MAP) sensor electrical connector Vacuum hose from the vacuum port on the MAP sensor housing

23-9

Knock sensor harness electrical connector Remaining electrical connections from the intake manifold Fresh air tube from the throttle body and rocker cover Vapor vent tube from the throttle body Throttle body heater outlet hose from the throttle body Evaporative emission (EVAP) canister purge tube Canister purge valve and bracket from the intake manifold Intake manifold bolts and the mani-

fold To install: 5. Install the intake manifold with new gaskets. 6. Torque the bolts in sequence as follOWS: a. First pass in Sequence: 44 inch

Ibs. (5 Nm)

b. Final pass in sequence to 89 inch lbs. (10 Nm). 7. Install or connect the following: Canister purge valve and bracket to the intake manifold EVAP canister purge tube Throttle body heater outlet hose to the throttle body Vapor vent tube to the throttle body Fresh air tube to the throttle body and rocker cover PCV valve pipe from the rocker

cover PCV pipe strap nut Knock sensor harness electrical connector MAP sensor electrical connector Vacuum hose to the vacuum port on the MAP sensor housing Fuel rail Fuel injector electrical connectors All remaining electrical connections Cruise control servo bracket Cruise control and throttle cables to the throttle body 8. Apply a light coating of clean engine oil to a NEW O-ring seal and install the seal onto the EGR valve pipe. EGR valve pipe into the intake manifold. Finger start the EGR valve pipe to the intake manifold bolt and the EGR valve pipe to the cylinder head bolts. 9. Finger start a NEW EGR valve pipe exhaust manifold gasket and bolts and tighten as follows:

Heater Core replacement is covered in Section 2 of this manual

23-1

GENERAL MOTORS CORPORATION-F-BODY CAMARO ¢ 228 e FIREBIRD e TRANS AM

79222614

Intake manifold torque sequence—5.7L

(VIN G) engine

a. Tighten the EGR valve pipe to the exhaust manifold bolts to 22 ft. Ibs. (30 Nm). b. Tighten the EGR valve pipe-tocylinder head bolts to 37 ft. Ibs. (60 Nm). c. Tighten the EGR valve pipe-to-intake manifold bolt to 89 inch Ibs. (10 Nm). EGR solenoid electrical connector e Drive belt IAC valve and TPS sensor electrical connections to the throttle body Air inlet duct IAT and MAF sensor electrical connector Fuel lines to the fuel rail Vapor line to the fuel vapor purge valve Transmission fluid level indicator tube bolt Negative battery cable

2000-01 MODELS 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Relieve the fuel system pressure. 3. Drain the coolant system. 4. Remove or disconnect the following: ¢ Negative battery cable e Transmission fluid level indicator tube bolt Fuel lines from the fuel rail Vapor line from the fuel vapor purge valve e Intake Air Temperature (IAT) sensor electrical connector ¢ Air inlet duct e Idle Air Control (IAC) valve and Throttle Position (TPS) sensor electrical connections from the throttle body ¢ Drive belt Exhaust Gas Recirculation (EGR) solenoid electrical connector EGR valve pipe O-ring seal from the EGR valve

pipe. Discard the exhaust manifold gasket and O-ring seal. Cruise control and throttle cables from the throttle body Cruise control servo bracket Fuel injector electrical connectors Secondary Air Injection (AIR) solenoid electrical connector Fuel rail Fresh air tube from the throttle body and rocker cover Vapor vent tube from the throttle body Throttle body heater outlet hose from the throttle body Evaporative emission (EVAP) canister purge tube Canister purge valve and bracket from the intake manifold Knock sensor harness electrical connector

Manifold Absolute Pressure (MAP) sensor electrical connector Vacuum hose from the vacuum port on the MAP sensor housing Remaining electrical connections from the intake manifold Intake manifold bolts and the manifold To install: 5. Install the intake manifold with new gaskets. 6. Torque the bolts in sequence as follows: a. First pass in sequence: 44 inch lbs. (5 Nm) b. Final pass in sequence to 89 inch lbs. (10 Nm). 7. Install or connect the following: MAP sensor electrical connector Vacuum hose from the vacuum port on the MAP sensor housing Knock sensor harness electrical connector Canister purge valve and bracket to the intake manifold EVAP canister purge tube Throttle body heater outlet hose to the throttle body Vapor vent tube to the throttle body Fresh air tube to the throttle body and rocker cover Fuel rail AIR solenoid electrical connector Fuel injector electrical connectors All remaining electrical connections Cruise control servo bracket e@ e Cruise control and throttle cables to the throttle body 8. Apply a light coating of clean engine oil to a NEW O-ring seal and install the seal onto the EGR valve pipe. EGR valve pipe into the intake man-

ifold. Finger start the EGR valve pipe to the intake manifold bolt and the EGR valve pipe to the cylinder head bolts. 9. Finger start a NEW EGR valve pipe exhaust manifold gasket and bolts and tighten as follows: a. Tighten the EGR valve pipe-to-intake manifold bolt to 89 inch Ibs. (10 Nm). b. Tighten the EGR valve pipe-tocylinder head bolts to 37 ft. Ibs. (60 Nm). C. Tighten the EGR valve pipe to the exhaust manifold boltsto22 ft. Ibs. (30 Nm). EGR solenoid electrical connector Drive belt IAC valve and TPS sensor electrical connections to the throttle body Air inlet duct IAT and MAF sensor electrical connector Fuel lines to the fuel rail Vapor line to the fuel vapor purge valve Transmission fluid level indicator tube bolt 10. Refill the cooling system. Negative battery cable

Exhaust Manifold

REMOVAL & INSTALLATION 3.8L Engine

LEFT SIDE 1. Before servicing the vehicle, refer to the precautions in the beginning of this section.

2. Remove or disconnect the following: Negative battery cable Catalytic converter pipe Connector position assurance (CPA) retainer, if equipped

Oxygen Sensor (02S) electrical connector

02S sensor Spark plug Exhaust Gas Recirculation (EGR) valve adapter from the exhaust manifold, if equipped 2 rear exhaust manifold studs and nut from the exhaust manifold Exhaust manifold heat shields Exhaust manifold and gasket To install: 3. Install or connect the following: Exhaust manifold with a new gasket. Tighten the 2 front exhaust manifold studs and nuts to the exhaust manifold to 11 ft Ibs. (15

F-BODY—GENERAL MOTOR

CAMARO ¢ 228 « AEA EPa

25 46 116 117 118 119 120 121 122 123

23-1 1

MANIFOLD, UPPER INTAKE MANIFOLD, LEFT EXHAUST BOLT/SCREW, EGR VALVE OUTLET PIPE PIPE, EGR VALVE OUTLET NUT, EGR VALVE OUTLET PIPE ADAPTER, EGR VALVE NUT, EGR VALVE ADAPTER STUD, EGR VALVE ADAPTER BOLT/SCREW, EGR VALVE ADAPTER BRACKET, ENGINE LIFT

9300WG01

Exploded view of the EGR valve adapter and outlet pipe—3.8L engine

Nm) and the nuts to 13 ft. Ibs. (18

Nm). e Exhaust manifold heat shield and nuts. Tighten the to 89 inch Ibs.

(10 Nm). ¢ Spark plugs and wires

¢ 2 rear exhaust manifold studs and nut to the exhaust manifold. Tighten the 2 rear exhaust manifold studs to 11 ft Ibs. (15 Nm) and the nuts to 13 ft. Ibs. (18 Nm). e (QoS sensor

¢ Catalytic converter pipe

2. Remove or disconnect the following:

¢ Connector position assurance

e Negative battery cable

(CPA) retainer, if equipped e FGR valve adapter, if equipped and

¢ Connector position assurance (CPA) retainer, if equipped

e Negative battery cable

connector e Spark plugs and wires e 2 rear exhaust manifold studs and nut from the exhaust manifold e Exhaust manifold heat shields e Exhaust manifold and gasket

torque the bolt to 18 ft. Ibs. (25 Nm)

RIGHT SIDE 1. Before servicing the vehicle, refer to the precautions in the beginning of this section.

Brake service is covered in Section 4 of this manual

¢ Exhaust catalytic converter pipe ¢ Oxygen Sensor (028) electrical

23-1

GENERAL MOTORS CORPORATION-F-BODY CAMARO ¢ 228 ¢ FIREBIRD ¢ TRANS AM To install: 3. Install or connect the following: e Exhaust manifold with a new gasket. Tighten the 2 front exhaust manifold studs and nuts to the exhaust manifold to 11 ft Ibs. (15 Nm) and the nuts to 13 ft. Ibs. (18 Nm). Exhaust manifold heat shield and nuts. Tighten the to 89 inch Ibs. (10 Nm). Spark plugs and wires 2 rear exhaust manifold studs and nut to the exhaust manifold. Tighten the 2 rear exhaust manifold studs to 11 ft Ibs. (15 Nm) and the nuts to 13 ft. Ibs. (18 Nm). ¢ (02S sensor ¢ Catalytic converter pipe e Connector position assurance (CPA) retainer, if equipped e Negative battery cable 4

A CYLINDER HEAD !

50. MANFOUD, RIGHTEXHAIST 51

‘

Cae

"LN

as

GASKET, EXHAUST MANIFOLD

ee

5.7L Engines

2

= \

N

LEFT SIDE—1998-99 MODELS

.

= i

1. Before servicing the vehicle, refer to the precautions in the beginning of this sec9300WG02

tl0 n.

2. Relieve the fuel system pressure.

16 17 18 19 20 21 26

MANIFOLD, EXHAUST GASKET, EXHAUST MANIFOLD GASKET, EXHAUST MANIFOLD MANIFOLD, EXHAUST STUD, EXHAUST MANIFOLD BOLT/SCREW, EXHAUST MANIFOLD SPACER, EXHAUST MANIFOLD BOLT

21 7922WG36

Exploded view of right and left exhaust manifold mounting—5.7L engines

F-BODY-GENERAL MOTORS CORPORATION

CAMARO ¢ 228 ¢ FIREBIRD e TRANS AM

3. Remove or disconnect the following: ¢ Negative battery cable Rocker arm cover Fuel lines Positive Crankcase Ventilation (PCV) hose Spark plug wires Spark plugs Secondary Air Injection (AIR) hose AIR pipe with check valve Coolant sensor Exhaust manifold bolts Oxygen (02S) sensor Exhaust manifold pipe nuts Catalytic converter nuts Exhaust manifold To install: Install or connect the following: e Exhaust manifold with a new gas-

ket. Torque the catalytic converter nuts to 18 ft. Ibs. (25 Nm). Exhaust manifold pipe nuts. Torque the nuts to 26 ft. Ibs. (35 Nm). 02S. Torque the sensor to 31 ft. lbs. (42 Nm). Exhaust manifold bolts. Torque the bolts to 18 ft. Ibs. (25 Nm). Coolant sensor AIR pipe. Torque the bolts to 15 ft. lbs. (20 Nm). AIR hose Spark plugs. Torque the spark plugs to 11 ft. Ibs. (15 Nm). Spark plug wires PCV hose Fuel lines Negative battery cable

LEFT SIDE—2000-01 MODELS 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: * Negative battery cable e Rocker arm cover ¢ Spark plug wires

e Spark plugs Left side catalytic converter Exhaust manifold bolts e Exhaust manifold and gasket To install: 3. Apply a 0.2 inch (5mm)) wide band of threadlock GM P/N 12345493 to the threads of the exhaust manitold bolts.

4 Install a NEW exhaust manifold gasket and the exhaust manifold. 5. Install the exhaust manifold bolts and tighten as follows:

a. Tighten the exhaust manifold bolts

on first pass to 11 ft. Ibs. (15 Nm). Tighten the manifold bolts beginning with the center 2 bolts. Alternate from side-to-side, and work toward the outside bolts. b. Tighten the exhaust manifold bolts on final pass to 18 ft. Ibs. (25 Nm). Tighten the exhaust manifold bolts beginning with the center 2 bolts. Alternate from side-to-side, and work toward the outside bolts. 6. Using a flat punch, bend over the exposed edge of the exhaust manifold gasket at the rear of the cylinder head. Install or connect the following: e Left side catalytic converter e Rocker arm cover e Spark plug wires e Spark plugs e Negative battery cable

RIGHT SIDE—1998-99 MODELS 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Negative battery cable Oil level indicator and tube Exhaust manifold pipe nuts Secondary Air Injection (AIR) hose AIR pipe with check valve Ignition coil main electrical connector Spark plug wires Spark plugs Rocker arm cover Exhaust Gas Recirculation (EGR) valve electrical connector EGR valve pipe e Exhaust manifold To install: 3. Install the exhaust manifold with a new gasket. Torque the bolts to 18 ft. Ibs. (25 Nm). 4. Install the EGR valve pipe. Torque the bolts as follows: a. EGR valve pipe-to-exhaust manifold bolts to 18 ft. Ibs. (25 Nm). b. EGR valve pipe-to-cylinder head bolt to 37 ft. Ibs. (50 Nm). c. EGR valve pipe-to-throttle body bolt to 106 inch Ibs. (12 Nm). 5. Install or connect the following: e EGR valve electrical connector e Rocker arm cover. Torque the bolts

to 106 inch Ibs. (12 Nm). e Spark plugs. Torque the spark plugs to 12 ft. Ibs. (15 Nm). e Spark plug wires

23-1 3

e Ignition coil main electrical connector AIR pipe. Torque the bolts to 18 ft. lbs. (25 Nm). AIR hose Exhaust manifold pipe nuts. Torque the nuts to 26 ft. Ibs. (35 Nm). Oil level indicator and tube Negative battery cable

RIGHT SIDE—2000-01 MODELS 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Negative battery cable Rocker arm cover Spark plug wires Spark plugs Right side catalytic converter Exhaust Gas Recirculation (EGR) valve electrical connector EGR valve pipe bolts EGR valve pipe up out of the intake manifold, using mild force O-ring seal from the EGR valve pipe. Discard the exhaust manifold gasket and O-ring seal. Exhaust manifold bolts Exhaust manifold and gasket To install: 3. Apply a 0.2 inch (5mm)) wide band of threadlock GM P/N 12345493 to the threads of the exhaust manifold bolts. 4. Install a NEW exhaust manifold gasket and the exhaust manifold. 5. Install the exhaust manifold bolts and tighten as follows: a. Tighten the exhaust manifold bolts on first pass to 11 ft. Ibs. (15 Nm). Tighten the manifold bolts beginning with the center 2 bolts. Alternate from side-to-side, and work toward the outside bolts. b. Tighten the exhaust manifold bolts on final pass to 18 ft. Ibs. (25 Nm). Tighten the exhaust manifold bolts beginning with the center 2 bolts. Alternate from side-to-side, and work toward the outside bolts. 6. Using a flat punch, bend over the exposed edge of the exhaust manifold gasket at the rear of the cylinder head. 7. Apply a light coating of clean engine oil to a NEW O-ring seal and install the seal onto the EGR valve pipe. 8. Install the EGR valve pipe into the intake manifold. Finger start the EGR valve pipe to the intake manifold bolt and the EGR valve pipe to the cylinder head bolts.

For complete Engine Mechanical specifications, see Section 1 of this manual

23-1

GENERAL MOTORS CORPORATION-F-BODY CAMARO ¢ 228 ¢ FIREBIRD ¢ TRANS AM

9. Finger start a NEW EGR valve pipe exhaust manifold gasket and bolts and tighten as follows: a. Tighten the EGR valve pipe-tointake manifold bolt to 89 inch Ibs. (10 Nm). b. Tighten the EGR valve pipe-tocylinder head bolts to 37 ft. Ibs. (50 Nm). c. Tighten the EGR valve pipe to the exhaust manifold bolts to 22 ft. Ibs. (30 Nm). Install or connect the following: e EGR solenoid electrical connector

e ¢ e e e

Right side catalytic converter Rocker arm cover Spark plug wires Spark plugs Negative battery cable

Camshaft and Valve Lifters REMOVAL & INSTALLATION 3.8L Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Recover the refrigerant in the air conditioning system. 3. Drain the engine cooling system. 4. Remove or disconnect the following: Negative battery cable Radiator with the air conditioning condenser assembly Upper intake manifold Rocker arm covers Rocker arms and the push rods Lower intake manifold Valve lifter guides Valve lifters Front cover Camshaft sprocket and timing chain Balance shaft gear Camshaft thrust plate Camshaft key 5. Install 3 6-18 x 4-inch bolts in the camshaft bolt holes. 6. Carefully rotate and pull the camshaft assembly out of the bearings. To install: 7. Install or connect the following: ¢ Camshaft lubricated with assembly lubricant

¢ Camshaft key e Thrust plate. Torque the bolts to 11 ft. Ibs. (15 Nm). e Balance shaft gear

e e e e e e e

Camshaft sprocket Timing chain Front cover Valve lifters Valve lifter guides Lower intake manifold Rocker arms and push rods

e»\Vlake sure the push rods are seated in the lifter seat.

8. The engine must be on the No. 1 firing position before proceeding. 9. Tighten exhaust valves No. 1, 2 and 3; then intake valves No. 1, 5 and 6. 10. Loosen the adjusting nut until lash is felt at the push rod. 11. Tighten the adjusting nut until all lash is removed, then tighten the nut an additional 1 % turns to center the lifter plunger. 12. Rotate the crankshaft 1 revolution until the “O” timing mark is once again aligned. 13. Adjust exhaust valves No. 4, 5 and 6 and intake valves No. 2, 3 and 4. 14. Install or connect the following: e Rocker arm cover ¢ Upper intake manifold e Radiator with the air conditioning condenser assembly ¢ Negative battery cable 15. Evacuate and recharge the air conditioning system. 16. Refill the cooling system. 17. Start the engine and check for leaks. 5.7L Engines

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Recover the refrigerant from the air conditioning system. 3. Drain the engine cooling system. 4, Remove or disconnect the following: Negative battery cable Intake manifold Exhaust manifold Rocker arm covers Rocker arms and push rod assemblies Cylinder head Valve lifters Radiator with the condenser Front cover Oil pan Oil pump drive assembly Timing chain and sprocket

Camshaft retainer

> WARNING All camshaft journals are the same diameter so care must be used when removing the camshaft to avoid damaging the bearings. 5. Install 3 46-18 x 4-inch bolts in the camshaft bolt holes. 6. Carefully rotate and pull the camshaft assembly out of the bearings. To install: ->When installing a new camshaft assembly, coat the camshaft lobes with “Molykote”® or equivalent. When installing a new camshaft, replace all valve lifters to ensure durability of the camshaft lobes and lifters.

7. Install or connect the following: Camshaft Camshaft retainer. Torque the bolts to 18 ft. Ibs. (25 Nm). Timing chain and camshaft sprocket Oil pump drive assembly. Torque the bolt to 25 ft. Ibs. (34 Nm). Oil pan Front cover Radiator with the air conditioning condenser Air conditioning receiver and dehydrator hose to the condenser Air conditioning compressor and condenser hose to the condenser Valve lifters Cylinder head with a new gasket Push rods and rocker arms e»\Viake sure the push rods are seated in the lifter seat.

8. Place the engine on Top Dead Center (TDC)of the No. 1 firing position. 9. Tighten the exhaust valves No. 1, 2, 7 and 8;then intake valves No. 1, 3, 4.and5 to 22 ft. Ibs. (30 Nm). 10. Rotate the crankshaft1 revolution until the “O” timing mark is once again aligned. 11. Adjust exhaust valves No. 3, 4,5 and 6; then intake valves 2, 6, 7 and Btto 22 ft. Ibs. (30 Nm). 12. Install or connect the following: e Exhaust manifold ¢ Rocker arm covers ¢ Intake manifold with a new gasket ¢ Negative batttery cable 13. Recharge the air conditioning system. 14. Fill the engine cooling system.

F-BODY-GENERAL MOTORS CORPORATION

23-1 5

CAMARO « 228 e FIREBIRD e TRANS AM Valve Lash

ADJUSTMENT e>The engines in this section utilize hydraulic valve lifters no adjustment is necessary.

Starter Motor

REMOVAL & INSTALLATION 3.8L Engine

90 DRIVE ASSEMBLY, OIL PUMP 91 BOLT/SCREW, OIL PUMP DRIVE CLAMP 92 CLAMP, OIL PUMP DRIVE

7922WG12

Unfasten the retaining bolt and clamp, then remove the oil pump drive—5.7L Engines

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Negative battery cable e Starter shield e Starter bolt and nut e Starter electrical connectors e Starter motor To install: Install or connect the following: e Starter motor, do not install the bolts at this time e Starter electrical connectors. Torque the lead nut to 17 inch Ibs. (2 Nm) and the positive battery nut to 89 inch Ibs. (10 Nm). e Starter bolt and nut. Torque the starter motor bolt to 35 ft. Ibs. (47 Nm) and the nut to 33 ft. Ibs. (45 Nm). e Starter shield ¢ Negative battery cable

9306WG04

View of the starter—3.8L engine

5.7L Engine

A BOLTS 100 CAMSHAFT ASSEMBLY

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 9. Remove or disconnect the following: e Negative battery cable e Left side catalytic converter 7922WG11

removal and installation—5.7L Engines Thread 3 bolts into the camshaft to facilitate

Starter bolts e Starter electrical connectors e Starter motor

this manual For Accessory Drive Belt illustrations, see Section 1 of

23-1 6 GENERAL MOTORS CORPORATION-F-BODY CAMARO ¢ 228 ¢ FIREBIRD ¢ TRANS AM

13 14 15 16 21

2. Drain the engine oil. 3. Support the engine with suitable support fixture. 4. Remove or disconnect the following: e Negative battery cable e Right and left engine mount-to-cradle bolts e Right and left lower shock bolts e Intermediate steering shaft bolt 5. Support the engine cradle with appropriate equipment.

SHIM, STARTER MOTOR SINGLE SHIM, STARTER MOTOR DOUBLE MOTOR, STARTER BOLT/SCREW, STARTER MOTOR STUD, STARTER MOTOR

*k:¢ WARNING 9306WG06

View of the starter—5.7L engine

To install: Install or connect the following: ¢ Starter motor, do not install the bolts at this time e Starter electrical connectors. Torque the lead nut to 18 inch Ibs. (2 Nm) and the positive battery nut to 89 inch Ibs. (10 Nm). e Starter bolts. Torque the bolts to 37 ft. Ibs. (50 Nm). ¢ Left side catalytic converter. Torque the bolts to 26 ft. Ibs. (35 Nm). e Negative battery cable

REMOVAL & INSTALLATION 3.8L Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section.

59 93 94 95

COVER, FRONT PAN, OIL BOLT/SCREW, OIL PAN GASKET, OIL PAN

The oil level switch, located in the oil pan, must be removed before removing the pan. If the pan is removed first, the switch may be damaged.

* Oil level sensor from the oil pan ¢ Starter motor ¢ Front crossmember bolts ° Oil pan To install: 6. Install or connect the following: ¢ Oil pan with a new gasket. Torque the bolts to 10 ft. Ibs. (14 Nm). Front crossmember bolts. Torque the upper 4 bolts to 92 ft. Ibs. (125 Nm) and the lower 2 bolts to 107 ft. Ibs. (145 Nm). Starter motor. Torque the bolts to 37 ft. Ibs. (50 Nm). Qil level sensor. Torque the sensor to 15 ft. Ibs. (20 Nm). Intermediate shaft. Torque the bolt to 35 ft. Ibs. (47 Nm). Right and left lower shock bolts. Torque the bolts to 48 ft. Ibs. (65 Nm). Right and left engine mount to cradle bolts. Torque the bolts to 43 ft. lbs. (58 Nm). e Negative battery cable 7. Refill the crankcase. 8. Start the engine and check for leaks.

A SEALER 7922WG14

Exploded view of the oil pan and gasket— 3.8L engine

53 54 SS

5.7L Engines

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. . 2. Drain the crankcase. 3. Support the engine with suitable support fixture. 4. Remove or disconnect the following: ¢ Negative battery cable e Oil filter ¢ Left and right engine mount-to-cradle bolts ¢ Left and right lower shock bolts e Intermediate steering shaft bolt 5. Support the engine cradle. ¢ Oil level sensor ¢ Starter motor ¢ Left and right closeouts 6. Loosen the six cradle bolts. 7. Lower the cradle and remove the oil pan. 8. Drill out the oil pan gasket rivets and remove the gasket from the oil pan. 9. Discard the old gasket and rivets. To install: 10. Apply a 0.2 inch (5mm) bead of sealant RTV sealer 0.8 inch (20mm) long to the engine block. Apply the sealant directly onto the tabs of the front cover gasket that protrudes into the oil pan surface 11. Pre-assemble the oil pan gasket to the pan. 12. Install or connect the following: ¢ Gasket onto the pan ¢ Oil pan bolts to the pan through the gasket ¢ Oil pan, gasket and bolts to the engine block. Snug the oil pan bolts finger tight. Do not overtighten. * 2 lower bellhousing bolts to position the oil pan correctly, Snug the lower bellhousing bolt finger tight. Do not overtighten. 13. Tighten the bolts as follows:

F, . Wi:

REINFORCEMENT, OIL PAN PAN, OIL GASKET, OIL PAN

Oil pan sealer and gasket location—5.7L engine s

7922WG13

F-BODY-GENERAL MOTORS CORPORATION 23-1 7 CAMARO ¢ 228 FIREBIRD ¢ TRANS AM a. Tighten the oil pan-to-block and oil pan-to-oil pan front cover bolts to 18 ft. Ibs. (25 Nm). b. Tighten the oil pan-to-rear cover bolts to 106 inch Ibs. (12 Nm). c. Tighten the bellhousing bolts to 37 ft. Ibs. (50 Nm). 14. Install or connect the following: Engine cradle. Torque the upper four bolts to 92 ft. Ibs. (125 Nm) and the lower two bolts to 107 ft. lbs. (145 Nm). Side closeouts and bolts. Tighten the bolts to 106 inch Ibs. (12 Nm). Starter motor. Torque the bolts to 37 ft. Ibs. (60 Nm). Oil level sensor. Torque it to 26 ft. lbs. (35 Nm). Intermediate steering shaft bolt. Torque the bolt to 35 ft. Ibs. (47 Nm). Left and right lower shock bolts. Torque the bolts to 48 ft. Ibs. (65 Nm). Left and right engine mount-to-cradle bolts. Torque the bolts to 43 ft. lbs. (68 Nm). e Oil filter Negative battery cable 15.. Refill the crankcase. 16. Start the engine and check for leaks.

2. Remove or disconnect the following: e Negative battery cable e Front cover e Oil filter adapter, pressure valve and spring e Oil pump cover e Oil pump gear set To install: 3. Lubricate the gear set with petroleum jelly. 4. Install the oil pump gear set into the front cover. 5. Pack the gear cavity with petroleum jelly for proper priming. 6. Install or connect the following: ¢ Oil pump cover. Torque the screws to 98 inch Ibs. (11 Nm). e (il filter adapter with a new gasket, pressure valve and spring. Torque the bolts to 11 ft. Ibs. (15 Nm). e Front cover. Torque the bolts to 11 ft. Ibs. (15 Nm). e Negative battery cable 5.7L Engines 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the crankcase. 3. Remove or disconnect the following: e Front cover e Qil pan e Oil pump screen ¢ Oil pan deflector e Oil pump and propeller shaft

REMOVAL & INSTALLATION eS

3.8L Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section.

To install: 4. Install or connect the following: Oil pump and propeller shaft. Torque the bolts to 18 ft. Ibs. (25 Nm). Oil pan deflector. Torque the nuts to 18 ft. Ibs. (25 Nm). Oil pump screen. Torque the bolt to 106 inch Ibs. (12 Nm). Oil pan Front cover. Torque the bolts to 18 ft. lbs. (25 Nm). 5. Refill the crankcase. Rear Main Seal

REMOVAL & INSTALLATION ->The rear main seal is a 1-piece unit. It can be removed or installed without removing the oil pan or crankshaft.

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Transmission e Clutch and pressure plate, if equipped e Flywheel e Rear main seal 3. Inspect the crankshaft for nicks or burrs and correct as required. To install: 4. Install a new rear seal lubricated with engine oil. 5. Install or connect the following: e Flywheel. Torque the bolts to 74 ft. lbs. (100 Nm) if equipped with a manual transmission, or to 44 ft. lbs. (60 Nm) if equipped with an automatic. ¢ Clutch and pressure plate, if equipped e Transmission DUST LIP VA

89 95 118 119 120

96

59 COVER, FRONT 96 BOLT/SCREW, Ol PUMP COVER 97 COVER, OIL PUMP 98 GEAR SET, OIL PUMP 7922WG16

Exploded view of the oil pump gear set— 3.8L engine

DRIVESHAFT, OIL PUMP RETAINER, OIL PUMP DRIVESHAFT PUMP, OIL DEFLECTOR, CRANKSHAFT OIL BOLT/SCREW, OIL PUMP

7922WG18

7922WG17

Exploded view of the oil pump and propeller shaft mounting—5.7L engine

When prying the rear main seal out, be careful not to damage the crankshaft sealing surface or the seal bore

Section 1 of this manual For Tire, Wheel and Ball Joint specifications, see

23-1 8 GENERAL MOTORS CORPORATION-F-BODY CAMARO ¢ 228 e FIREBIRD ¢ TRANS AM

6. Check the fluid levels. 7. Start the engine and check for leaks.

Timing Chain, Sprockets, Front Cover and Seal REMOVAL & INSTALLATION 3.8L Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section ;

5

5

2. Drain the crankcase and cooling system.

3. Remove or disconnect the following: e Negative battery cable

CHAIN, TIMING BOLT/SCREW, CAMSHAFT

SPROCKET

Oo RLnee ae

68 GOLT/SCREW, BALANCE SHAFT GEAR

¢ Air cleaner and intake air duct

¢ Coolant pump pulley bolts, loosen

e Drive belt tensioner

A B C 40 54 58

62 63

64 ee ee CAMSHAFT 65 GEAR, BALANCE SHAFT DRIVEN

i

ASSEMBLED VIE - GEARS W

a Picpem ay

7922620

Exploded view of the timing chain and sprockets and timing mark alignment—3.8L engine

LOCATOR PINS STUDS BOLTS/SCREWS SEAL, CRANKSHAFT FRONT OIL BOLT/SCREW, CRANKSHAFT BALANCER GASKET, FRONT COVER

BO

’

59 COVER, FRONT 60

STUD, FRONT COVER

61

BOLT/SCREW,

FRONT COVER

Exploded view of the front cover mounting and bolt locations—3.8L engine

ypeasy4 54 7922WG37

F-BODY-GENERAL MOTORS CORPORATION 23-1 8] CAMARO ¢ 228 FIREBIRD ° TRANS AM 5.7L Engines

69

72

68 69 70 71 72 73

BOLT/SCREW, BALANCE SHAFT GEAR GEAR, BALANCE SHAFT BOLT/SCREW, BALANCE SHAFT RETAINER RETAINER, BALANCE SHAFT BUSHING, BALANCE SHAFT REAR SHAFT, BALANCE 9300WGO03

Exploded view of the balance shaft assembly—3.8L engine

e Power steering pump pulley, if necessary e Inlet hose from the power steering pump, if necessary 4. Reposition the hose clamp on the return line, if necessary. e Reservoir hose return line from the power steering pump, if necessary Power steering pump, if necessary Crankshaft balancer e Crankshaft Position (CKP) sensor shield and the sensor Oil pan-to-front cover bolts Oil pan bolts, loosen and lower the pan slightly Water pump Radiator outlet hose from the front cover Front cover bolts and studs Cover and gasket Crankshaft seal from the cover 5. Align the timing marks on the sprockets so they are as close together as possible. e Timing chain damper ¢ Camshaft sprocket and timing chain © Crankshaft sprocket To install: 6. If the crankshaft has been turned in the engine, perform the following: a. Turn the crankshaft so the No. 1 piston is at top Dead Center (TDC) of its compression stroke. b. Turn the camshaft so that, with the

sprocket temporarily installed, the timing mark is straight down. 7. Install or connect the following: e Timing chain on the sprockets with the timing marks aligned ¢ Timing chain and sprockets. Torque the bolt to 74 ft. Ibs. (100 Nm) plus an additional 90 degrees. e Timing chain damper. Torque the bolt to 16 ft. Ibs. (22 Nm). 8. Rotate the engine 2 revolutions, then check to be sure the timing marks are aligned. Front cover with a new crankshaft oil seal. Torque the fasteners to 15 ft. lios. (20 Nm) plus 40 degrees. Radiator outlet hose to the front cover Water pump Oil pan-to-front cover bolts. Torque the bolts to 125 inch Ibs. (14 Nm). Oil pan bolts CKP sensor and torque the fasteners to 15 ft. Ibs. (20 Nm) plus 40 degrees CKP sensor shield Crankshaft balancer Power steering pump, hoses and pulley, if necessary Drive belt tensioner Air cleaner assembly Negative battery cable 9. Refill the crankcase and cooling system.

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the crankcase and cooling system. 3. Remove or disconnect the following: e Negative battery cable Mass Air flow (MAF) sensor electrical connector Intake Air Temperature (IAT) sensor electrical connector Air intake duct Drive belt Radiator hoses from the water pump and water outlet Upper radiator support Fan shroud Drive belt tensioner Overflow hose from the radiator Throttle body heater hose from the radiator Drive belt idler pulley Water pump Starter motor Crankshaft balancer Oil pan Front cover Oil pump 4. Rotate the crankshaft until the timing marks on the crankshaft and camshaft sprockets are aligned. 5. Remove or disconnect the following: e Camshaft sprocket and timing chain e Crankshaft sprocket

Do not turn the crankshaft after the timing chain has been removed to prepistons or valves. vent damage to the ERE a ea kaha hc

To install: 6. Install or connect the following:

7922WG21

When assembled, be sure the marks on the gears are facing each other—5.7L

engine

10. Start the engine and check for leaks.

1 of this manual For Wheel Alignment specifications, see Section

23-20

GENERAL MOTORS CORPORATION-F-BODY CAMARO ° 228

FIREBIRD ¢ TRANS AM

¢ Overflow hose to the radiator Drive belt tensioner. Torque the bolts to 37 ft. Ibs. (50 Nm). Fan shroud Upper radiator support Radiator hoses to the water pump and water outlet Drive belt Air intake duct MAF sensor electrical connector IAT sensor electrical connector Negative battery cable 8. Refill the engine crankcase. 9. Refill the cooling system. 10. Operate the engine and check for leaks.

Piston and Ring POSITIONING 7922WG22

CONNECTING ROD

Use a gear puller to remove, and a large socket to install, the crankshaft sprocket— 5.7L engine shown

Crankshaft sprocket Camshaft sprocket and timing chain assembly. Torque the bolts to 26 ft. Ibs. (35 Nm). ¢ Oil pump NEW crankshaft oil seal to the front cover /. Apply a 0.20 inch (5mm bead of RTV Sealant to the corner where the oil pan meets the engine block. Front cover. Torque the bolts to 18 ft. Ibs. (25 Nm). Oil pan. Torque the oil pan-to-block and oil pan-to-front cover bolts to 18 ft. Ibs. (25 Nm) and the oil panto-rear cover bolts to 106 inch Ibs. (12 Nm). Crankshaft balancer. Torque the bolt to 37 ft. Ibs. (50 Nm), then an additional 120 degrees. Starter motor. Torque the bolts to 35 ft. Ibs. (47 Nm). ¢ Water pump. Torque the bolts to 105 inch Ibs. (12 Nm).

WARNING

|

The camshaft sprocket and water pump propeller shaft gears must mesh or damage to the camshaft retainer may occur.

¢ Drive belt idler pulley. Torque the bolt to 37 ft. Ibs. (50 Nm). e Throttle body heater hose to the radiator

MATCHING NUMBERS 7922AG48

Piston ring positioning—3.8L engine

G

ARROW TOWARDS FRONT OF ENGINE

CAP—+

)

7922AG51

Piston positioning. Often the arrow is replaced by a notch, which also must face the front of the engine—3.8L engine

O

ENGINE FRONT

ENGINE RIGHT

B. Cc ,

A.D.

B A. QOll RING SPACER GAP (TANG IN HOLE OR SLOT Wht ARC) B. OIL RING RAIL GAPS C. 2ND COMPRESSION RING GAP D. TOP COMPRESSION RING GAP 7922AG46

Piston ring end-gap spacing—3.8L engine

F-BODY-GENERAL MOTORS C

CAMARO e 228 « ee

ali

iSaat

23-21

= ETE A 2

1. Piston

2. 3. 4. 5.

Upper compression piston ring Lower compression piston ring Oil contro! piston ring Oil control ring spring w/spacer 7922AG43

Piston ring positioning—5.7L engine

NOTE: LARGE HAMFERS OW CONNECTING RODS MUST FACE CRANKSHAFT COUNTERWEIGHTS.

ees

ENGINE RIGHT

ENGINE FRONT

ENGINE LEFT all

1, Piston 2. Connecting rod LH @—=

—

3. Connecting

AD

4. 5. 6. 7.

———

rod bearing

Connecting rod RH Connecting rod bearing cap Connecting rod bearing cap bolt Crankshaft

A. Oil ring spacer gap B. Oil ring rail gaps C. 2nd compression ring gap

7922AG44

D. Top compression ring gap

Piston and connecting rod assembly positioning—5.7L engine

7922AG42

Piston ring end-gap spacing—5.7L engine

Fuel System Service Precautions Safety is the most important factor when performing not only fuel system maintenance but any type of maintenance. Failure to conduct maintenance and repairs in a safe man-

ner may result in serious personal injury or death. Maintenance and testing of the vehicle’s fuel system components can be accomplished safely and effectively by adhering to the following rules and guidelines. © To avoid the possibility of fire and personal injury, always disconnect the negative battery cable unless the repair or test procedure requires that battery voltage be applied. e Always relieve the fuel system pressure prior to disconnecting any fuel system component (injector, fuel rail, pressure regulator,

etc.), fitting or fuel line connection. Exercise extreme caution whenever relieving fuel system pressure, to avoid exposing skin, face and eyes to fuel spray. Please be advised that fuel under pressure may penetrate the skin or any part of the body that it contacts. e Always place a shop towel or cloth around the fitting or connection prior to

loosening to absorb any excess fuel due to spillage. Ensure that all fuel spillage (should it occur) is quickly removed from engine surfaces. Ensure that all fuel soaked cloths or towels are deposited into a suitable waste container. ¢ Always keep a dry chemical (Class B) fire extinguisher near the work area. ¢ Do not allow fuel spray or fuel vapors to come into contact with a spark or open flame. e Always use a back-up wrench when loosening and tightening fuel line connection fittings. This will prevent unnecessary stress and torsion to fuel line piping. ¢ Always replace worn fuel fitting Orings with new. Do not substitute fuel hose or equivalent, where fuel pipe is installed.

Fuel System Pressure

:

RELIEVING 1. Before servicing the vehicle, refer to the precautions in the beginning of this section.

9. Disconnect the negative battery cable to prevent fuel discharge if the key is accidentally turned to the RUN position. 3. Loosen the fuel filler cap to relieve the tank pressure and do not tighten until service has been completed. 4. Connect a fuel pressure gauge to the fuel pressure valve. Wrap a shop cloth around the fitting while connecting the gauge to avoid spillage. 5. Place the end of the bleed hose into a suitable container and open the valve to relieve the fuel system pressure.

REMOVAL & INSTALLATION Ciiciea Selokate ee Nile

ec i

=

The inline fuel filter is located on the fuel feed pipe before the fuel injection system and mounted directly in front of the rear axle. The filter housing is constructed of steel with quick-connect inlet and threaded outlet fittings. The threaded fitting Is sealed with an O-ring. In order to disengage quick-

Section 1 of this manual For Maintenance Interval recommendations, see

23-2

1

GENERAL MOTORS CORPORATION-F-BODY CAMARO ¢ 228 ¢ FIREBIRD * TRANS AM

THREADED FITTING

2

«IN-LINE FUEL FILTER

3

QUICK-CONNECT FITTING

4

IN-LINE FUEL FILTER BRACKET 7922WG23

The inline fuel filter is mounted in a bracket located under the vehicle, directly in front of the rear axle

connect fittings, a fuel line quick-connect separator tool set, such as J-37088-A or equivalent, is required. There is no service interval for fuel filter replacement. We suggest replacing the filter every 30-40 thousand miles. 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Relieve the fuel system pressure. 3. Clean both the inlet and the outlet fittings on the fuel filter. 4. Disengage the quick-connect fittings at the fuel filter inlet as follows:

a. Slide the dust covers from the quick-connect fittings. b. Grasp both sides of the fitting. Twist the female connector % turn in each direction to loosen any dirt within the fitting. Using compressed air and Safety glasses, blow any accumulated dirt out of the fitting. c. If equipped with the plastic hand releasable fitting, squeeze the plastic retainer release tabs and pull the connection apart. d. If equipped with metal fittings, choose the correct size quick release tool and insert the tool into the female connector, then push inward to release the locking tabs. Pull the connector apart. e. Use a clean lint free rag to clean male pipe ends. Inspect both ends of the fitting for dirt and burrs. Clean or replace components as required. If it is necesSary to remove rust or burrs from the fuel

pipe, use emery cloth in a radial motion with the pipe end to prevent damage to the O-ring sealing surface. 5. Remove the threaded outlet fitting from the chassis fuel pipe. Slide the fuel filter from the bracket. 6. Inspect the fuel pipe O-ring for cuts, nicks, swelling or distortion. Replace if necessary. To install: 7. Slide the fuel filter into the bracket. 8. Tighten the outlet fitting to the chasSis fuel pipe. Torque the fitting to 22 ft. Ibs. (30 Nm). 9, Engage the quick-connect inlet fitting as follows: a. Apply a few drops of clean engine oil to the male pipe end. This will ensure proper reconnection and prevent a possible fuel leak. b. Push both sides of the fitting together to cause the retainer tabs to snap in place. Once installed, pull on both sides of the fitting to ensure connection is secure. c. Reposition dust cover over the quick-connect fitting. 10. Tighten the fuel filler cap. 11. Confirm that the ignition is in the OFF position. Connect the negative battery cable. 12. Pressurize the fuel system by cycling the ignition without attempting to start the

engine. Turn the ignition switch to the ON

position for 2 seconds, then turn to the OFF position for 10 seconds. Again, turn to the ON position and check for fuel leaks.

Fuel Pump

REMOVAL & INSTALLATION 1. 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, Clean the area surrounding the sender assembly to prevent contamination of the fuel system. 5. Remove or disconnect the following: e Fuel tank ¢ Fuel sender-to-fuel tank retaining ring ¢ Fuel sender from the fuel tank e Fuel pump from the sending unit To install: 6. Install or connect the following: e Fuel pump with new strainer onto the sending unit ¢ New O-ring in the tank opening

groove ¢ New O-ring on the fuel sender feed tube ->The fuel pump strainer must be ina horizontal position and must not block the float arm travel.

1

2

3

SENDER -FUEL

FUEL PUMP AND RESERVOIR ASSEMBLY

A

VAPOR VENT HOSE

B

FUEL PUMP FLEX PIPE AND QUICK - CONNECT FITTING

C

FUEL RETURN HOSE

STRAINER - FUEL PUMP

7922WG24

Fuel sender/pump assembly component identification

F-BODY-GENERAL MOTORS CORPORATION 20-20 CAMARO ° 228 FIREBIRD * TRANS AM 7. Fold the strainer over itself and Slowly position the sending assembly in the tank so the strainer is not damaged or trapped by the sump walls. e Retaining ring. Torque the nuts to 63 inch Ibs. (7 Nm). e Fuel tank. Torque the bolts to 24 ft.

lbs. (33 Nm). e Fuel filler cap e Negative battery cable 8. Turn the ignition switch to the ON position for 2 seconds, OFF for 10 seconds, then back to the ON position. Check for fuel leaks.

Fuel Injector REMOVAL & INSTALLATION 3.8L Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Relieve the fuel system pressure. 3. Remove or disconnect the following: e Fuel feed and return lines from the fuel rail Fuel injector electrical connectors Vacuum line from the fuel pressure regulator Manifold Absolute Pressure (MAP) sensor electrical connector Vacuum line from the vacuum switch at the fuel pipe bundle e Fuel injector harness fasteners Fuel rail hold-down bolts

e Fuel rail with fuel injectors e Fuel injectors by removing the retainer clips To install:

if the new O-rings are different colors (black and brown), install the black one in the upper portion and the brown one in the lower portion of the fuel injector. 4. Coat the injector O-rings with clean engine oil prior to installation. 5. Install or connect the following: Fuel injectors with new O-rings to the fuel rail by installing the retainer clips Fuel rail with fuel injectors. Torque the bolts to 89 inch Ibs. (10 Nm). Fuel injector harness fasteners Vacuum line to the vacuum switch at the fuel pipe bundle MAP sensor electrical connector Vacuum line to the fuel pressure regulator Fuel injector electrical connectors Fuel feed and return lines to the fuel rail e Negative battery cable 6. Perform the following procedure in order to check for leaks: a. Turn the ignition switch ON for2 seconds. b. Turn the ignition switch OFF for 10 seconds. c. Turn the ignition switch ON and check for fuel leaks.

5.7L Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Relieve the fuel system pressure. 3. Remove or disconnect the following: Fuel feed hose from the fuel rail Accelerator cable and cable bracket Fuel injector electrical connectors Electrical harness from the fuel rail Fuel rail assembly Fuel injectors from the fuel rail by spreading the injector retainer clips To install: 4 Lubricate the new injector O-ring seals with clean engine oil prior to installation. 5. Install or connect the following: e New O-rings on the fuel injectors e Fuel injectors to the fuel rail using new retaining clips ->Position the fuel injector electrical connector facing outward.

e Fuel rail assembly. Torque the bolts to 89 inch Ibs. (10 Nm). e Flectrical harness to the fuel rail e Fuel injector electrical connectors e Accelerator cable and cable bracket e Fuel feed hose to the fuel rail ¢ Negative battery cable 6. Perform the following procedure: a. Turn the ignition switch ON for 2 seconds. b. Turn the ignition switch OFF for 10 seconds. c. Turn the ignition switch ON and check for fuel leaks.

9306WG09 9306WG08

View of the fuel rail assembly—3.8L

engine

Exploded view of the fuel injector—3.8L engine

Exploded view of the fuel injector and fuel rail assembly—5.7L engine

on 1 of this manual For Tune-up, Capacities and Firing orders, see Secti

20-24

GENERAL MOTORS CORPORATION-F-BODY CAMARO ¢ 228 @ FIREBIRD ¢ TRANS AM

. DRIVE TRAIN Transmission

—

REMOVAL & INSTALLATION Manual

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the oil from the transmission. 3. Remove or disconnect the following: Negative battery cable Shift control lever boot assembly Shift contro! lever Propeller shaft Rear axle torque arm Right side catalytic converter Electrical connectors from the transmission Starter motor Wiring harness and bracket from the transmission Transmission brace bolts and the braces, on M49 transmissions Flywheel housing cover 4. Depress the white circular release ring on the actuator hose and simultaneously pull on the master cylinder hose to disconnect. 5. Support the transmission. 6. Remove or disconnect the following: e Transmission support e Transmission mounting bolts e Transmission from the vehicle To install: 7. Install or connect the following: Transmission to the vehicle. Torque the bolts to 75 ft. Ibs. (90 Nm) on M49 transmissions and 37 ft. Ibs. (50 Nm) on MM6 transmissions. Transmission support. Torque the bolts to 43 ft. Ibs. (57 Nm). Clutch actuator hose to the clutch master cylinder hose. Flywheel housing cover and tighten the bolts to 80 inch Ibs. (9 Nm) On M49 transmissions Transmission brace bolts and the braces. Tighten the right transmission brace bolts to 37 ft. Ibs. (60 Nm). Tighten the left transmission brace bolts (to transmission) to 37 ft. Ibs. (50 Nm) and the bolts to the engine to 21 ft. Ibs. (28 Nm). Wiring harness and bracket Electrical connectors Starter motor Right side catalytic converter. Torque the bolts to 18 ft. Ibs. (25 Nm). Rear axle torque arm. Torque the

bolts to 37 ft. Ibs. (50 Nm) and the nuts to 30 ft. Ibs. (41 Nm). e Propeller shaft. Torque the bolts to 16 ft. Ibs. (22 Nm). e Transmission oil drain plug. Torque the plug to 20 ft. Ibs. (27 Nm). 8. Refill the transmission with oil. 9. Bleed the clutch hydraulic system. 10. Install or connect the following: ¢ Shift control lever. Torque the bolts to 13 ft. Ibs. (18 Nm). e Shift control lever boot assembly ¢ Negative battery cable Automatic

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Negative battery cable Intake Air Temperature (IAT) sensor electrical connector Air intake duct Catalytic converter Range selector cable from the transmission Propeller shaft Rear axle torque arm Torque converter cover Torque converter bolts Transmission oil cooler lines Wiring harness from the transmission Transmission 20-way connector Vehicle Speed sensor (VSS) electrical connector Transmission support Transmission fill tube wa

RUS

e Transmission nuts and bolts e Transmission from the vehicle To install: 3. Install or connect the following: Transmission to the vehicle. Torque the bolts and nuts to 70 ft. Ibs. (95 Nm) on 3.8L engines and 37 ft. Ibs. (50 Nm) on 5.7L engines e Transmission fill tube Transmission support. Torque the bolts to 66 ft. Ibs. (90 Nm). e VSS electrical connector 20-way connector Wiring harness clamp to the transmission. Torque the bolt to 22 inch lbs. (2.5 Nm). e Transmission oil cooler lines ¢ Torque converter bolts. Torque the bolts to 47 ft. Ibs. (63 Nm). Torque converter cover e Rear axle torque arm. Torque the bolts to 37 ft. Ibs. (60 Nm) and the nuts to 30 ft. Ibs. (41 Nm). Propeller shaft. Torque the bolts to 16 ft. Ibs. (22 Nm). e Range selector cable Catalytic converter. Torque the bolts to 18 ft. Ibs. (25 Nm). e Air intake duct e IAT sensor electrical connector

Negative battery cable

REMOVAL & INSTALLATION V—_—e—eeeeeeee——————

1. Before servicing the vehicle, refer to the precautions in the beginning of this section.

PilotA

“a, Bearing

7922WG25

Exploded view of the clutch disc, pressure plate and related components—5-speed transmission

F-BODY-GENERAL MOTORS CORPORATION

23-25

CAMARO e Z28 ¢ FIREBIRD ¢ TRANS AM 2. Remove or disconnect the following: e Negative battery cable e Transmission assembly e Flywheel housing cover e Flywheel housing 3. Install a clutch disc alignment tool through the center of the disc and into the pilot bearing to prevent the disc from falling when the pressure plate is removed. 4. Remove or disconnect the following: e Pressure plate retaining bolts ¢ Pressure plate with clutch disc To instail: 5. Install or connect the following: ¢ Clutch plate to the flywheel e Pressure plate and cover. Do not torque the bolts at this time. 6. Align the clutch plate with the pilot bearing and clutch pressure plate. 7. On 3.8L models, torque the clutch pressure plate and cover bolts in a star pattern to 15 ft. Ibs. (20 Nm), plus an additional 45 degree turn. 8. On 5.7L models, torque the bolts using a star pattern torque sequence to 52 ft. lps. (70 Nm). 9. Install or connect the following: e Flywheel housing ¢ Flywheel housing cover e Transmission e Negative battery cable

Hydraulic Clutch System BLEEDING oe

_

4. Have an assistant slowly depress and hold the clutch pedal. 5. Loosen the bleeder to purge air. 6. Tighten the bleeder. 7. Repeat the above 3 steps until all air is completely purged from the system. 8. Refill the clutch master cylinder reservoir, |

> WARNING Do not damage the rear wheel speed sensor reluctor wheel (3) during axle shaft removal.

Axle Shaft, Bearing and Seal REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Wheel e Brake rotor e Rear axle housing cover

» Pinion gear shaft lock bolt (2)

e Pinion gear shaft 3. Push the axle shaft into the housing in order to gain access to the rear axle shaft C-clip (1). 4. Remove the C-clip and remove the axle from the housing.

5. Remove or disconnect the following: e Brake backing plate ¢ Brake caliper mounting bracket ¢ Oil seal, by prying it out e Rear wheel bearing with suitable puller To install: 6. Lubricate the new wheel bearing with ear Oil. 7. Install or connect the following: e Wheel bearing, using suitable installation tool e (il seal, using suitable installation tool ti

a

Se ete ae

e Brake backing plate e Axle shaft and C-clip ->Be sure the splines on the end of the axle engage with the splines of the differential side gear.

b

a

Use a container to catch the oil that may flow from the axle housing once the yoke is removed.

9306WG12

View of the drive pinion gear yoke nut removal tools

1

J 8614-2

J 8614-01 93061613 View of the drive pinion gear yoke removal tools

¢ Pinion seal

STEERING AND SUSPENSION

-«-¢ CAUTION The vehicles covered in this section 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 repairs.

wires or connector on the underside of the module. e 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. e With the inflator module on the bench, never place anything on or close to the module, which may be thrown in the event of an accidental deployment.

DISARMING aeRO as es

es

eT

PRECAUTIONS EIA SY Sta 2 ADE)

1. Align the steering wheel so the vehicle wheels are pointing in the straightahead position.

Several precautions must be observed when handling the inflator module to avoid accidental deployment and possible personal injury. ° Never carry the inflator module by the

position and remove the key. 3, Remove the SIR or AIR BAG fuse from the fuse block. 4. Remove the left instrument panel insulator.

2. Turn the ignition switch to the LOCK

e>|t may be necessary to use a blunt chisel to drive the seal from the housing.

To install: 4. Install or connect the following: e New pinion seal, lubricated with chassis grease using pinion oil seal installer Tool J 8614-01 until it is flush with the housing Drive pinion gear yoke using Tool J 8614-01 and a socket wrench Drive pinion gear nut, tighten to Ye in. (1.59mm) beyond the alignment mark made earlier Propeller shaft. Torque the propeller shaft-to-pinion yoke bolts to 16 ft. Ibs. (22 Nm) and the propeller shaft-to-center support to 37 ft. Ibs. (50 Nm) for 2-piece shaft. 9. Refill the axle housing.

: 5. Remove the connector retainer, then disengage the yellow 2-way SIR wiring harness connector at the base of the steering column. 6. Remove the right instrument panel insulator. 7. Remove the connector retainer, then disengage the yellow 2-way SIR wiring harness connector located behind the IP compartment door.

ARMING ea SES

ee

1. Engage the yellow 2-way connector at the base of the steering column and behind the IP compartment door, then install the connector retainer. 2. Install the instrument panel insulators. 3. Reinstall the SIR or AIR BAG fuse. 4. Turn the ignition switch to the RUN position. 0. Verify the SIR indicator light flashes /-9 times, if not, inspect system for malfunction.

FO

aie

MOTORS CORPORATION

Qa-21

AMARO ¢ Z28 ¢ FIREBIRD ¢ TRANS AM

Power Rack and Pinion Steering Gear

REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Serpentine belt Air intake resonator Front wheels ae tie rod ends from the knuckes Alternator Left side engine mount through bolt Inlet and outlet hoses from the steering gear Steering gear coupling shaft from the steering gear 3. Steering gear retainers e Steering gear from the vehicle To install: 4. \nstall or connect the following: Steering gear and its retainers Steering gear to the crossmember. Torque the bolts to 63 ft. Ibs. (85 Nm). Steering gear to the coupling shaft. Torque the bolt to 35 ft. Ibs. (47 Nm). Inlet and outlet hoses to the steering gear. Torque the hoses to 21 ft. lbs. (28 Nm). Left side engine mount through bolt e Alternator Outer tie rod ends to the steering knuckle. Torque the nuts to 35 ft. lbs. (47 Nm). e Front wheels e Serpentine belt » Air intake resonator 5. Refill and bleed the power steering system.

Shock Absorber

=|

3

REMOVAL & INSTALLATION Front 4. Before servicing the vehicle, refer to secthe precautions in the beginning of this tion. 9) if removing the driver's side spring and shock assembly, unbolt the brake mas-

Steering Wheel

7922WG26

OL ARM ASSEMBLY, FRONT UPPER CONTR OL ARM BALL STUD ASSEMBLY, FRONT UPPER CONTR COTTER ARM OL CONTR UPPER FRONT PIN, 53 Nem (39 LB. FT.) NUT, FRONT UPPER CONTROL ARM, KNUCKLE ASSEMBLY, STEERING NUT, FRONT LOWER CONTROL ARM, 110 Nem (81 LB. FT.) COTTER PIN, FRONT LOWER CONTROL ARM CONTROL ARM BALL STUD ASSEMBLY, FRONT LOWER BER, ABSOR SHOCK FRONT BOLT/SCREW, Onur wn oon 65 Nem (48 LB. FT.) CONTROL ARM ASSEMBLY, FRONT LOWER ABSORBER LOWER BRACKET, eaeNUT, FRONT SHOCK a 65 Nem (48 LB. FT. SPRING ASSEMBLY, FRONT SHOCK ABSORBER ASSEMBLY, FRONT MOUNT, NUT, FRONT SHOCK ABSORBER UPPER a) BON 43 Nem (32 LB. FT.) UPPER BER ABSOR SHOCK FRONT BOLT/SCREW, MOUNT, 50 Nem (37 LB. FT.) WHEEL FRONT 16 HUB ASSEMBLY, SHOCK ABSORBER 17 MOUNT ASSEMBLY, FRONT UPPER ARM ROL 18 SUPPORT, FRONT UPPER CONT

7922WG27

suspension components ed view of the shock absorber unit and related

online.com Please visit our web site at www.chiltons

23-2

GENERAL MOTORS CORPORATION-F-BODY CAMARO 228 ¢ FIREBIRD * TRANS AM driver's side shock and to mounting

holes A-X-P (upper left) and C-H (lower right) for the passenger's side shock. c. Install J-34013-114 and J 3401388. e» Make certain that J-34013-114 and J34013-88 are aligned so that they can open and close together. If not properly aligned, they will not function.

FRONT SPRING ASSEMBLY J 34013-114

J 34013-88

FRONT SHOCK ABSORBER ASSEMBLY

d. Attach the shock unit to the tools. 7922WG28

Shock absorber compressor mounting hole locations

J34013-114

e» Make certain that the top of the shock is flat against J-34013-114. e. Close the tools and install the locking pin. e> Wake certain that the mounting ears of the shock are facing downward toward the rear of J-34013-B, otherwise the shock will not align properly.

\

\

f. Turn the screw of J-34013-B counterclockwise to raise the shock up to J34013-114. Be sure that the studs go through the guide holes in J-34013-114 and the top of the shock is flat against the tool.

J 34013-88

7922WG29

> CAUTION

Install the strut compressor adapter on the Spring compressor

ter cylinder from the booster and position it aside, but do not disconnect the brake lines. 3. Remove or disconnect the following: ¢ Upper spring/shock mounting bolts and nuts e Front wheels ¢ Stabilizer bar (shaft link) from the contro! arm 4. Matchmark the lower coil spring mount location to the upper coil spring mount location before removing the shock absorber. 9. Remove or disconnect the following: ¢ Lower shock absorber nuts and bolts ¢ Lower ball joint stud from the steering knuckle ¢ Spring/shock absorber unit from the vehicle 6. Remove the spring from the shock absorber assembly by performing the following steps: elf using other than a GM spring compressor, follow the manufacturers instructions regarding the use of the specific tool you are using.

a. Assemble J-34013-B and J34013-114 on the spring unit. b. Use the wing nuts to secure the tool to mounting holes C-H (lower left corner) and P (upper right corner) for the

Do not over-compress the spring! Over-compression can cause tool failure, resulting in severe bodily injury!

g. Compress the spring approximately 2 in. (13mm) or 3-4 complete turns of the screw on J-34013-114. h. Insert J-39642-1 on the shock nut, then insert J-39642-2 through J-39642-1 to hold the shock absorber rod in place. i. Remove the shock absorber nut with J-39642-1, while holding the shock rod from rotating with J-39642-2. j. Discard the shock absorber nut. k. Turn J-34013-B clockwise to fully relieve spring pressure and remove the spring from the shock. To install: 7. Assemble the shock absorber/spring assembly by performing the following procedure: a. Assemble J-34013-B spring compressor and J-34013-114 adapter on the spring unit. Use wing nuts to secure the tool to mounting holes C-H (lower left corner and P (upper right corner) for the driver's side shock and to mounting holes A-X-P (upper left) and C-H (lower right) for the passenger's side shock. b. Install Tools J-34013-114 and J34013-88. c. Attach the shock unit to the tools.

7922WG30

Installing the shock absorber on the com-

pressor J 34013-115

J 34013-8

J 34013-114

FRONT SHOCK ABSORBER ROD FRONT SHOCK ABSORBER ASSEMBLY FRONT SPRING ASSEMBLY

7922WG31

Inserting the shock assembly alignment rod

e» Make certain that the mounting ears of the shock are facing downward towards the rear of J 34013-B!

d. Close the tools and install the locking pin. e. Be sure that the spring seats are positioned properly. e> Make certain that the top of the shock is flat against J-34013-114.

f. Turn the screws of J-34013-B counterclockwise to raise the shock up to J-34013-114. Be sure that the studs go through the guide holes in J-34013-114 and the top of the shock is flat against the tool. e>Turn the screw only enough to secure the shock. DO NOT compress the spring.

g. Place J-34013-115 down through the top of J-34013-B, through the top of the shock absorber and onto the rod. e» Make certain that J-34013-115 is

Straight with the shock.

ck CAUTION Do not over-compress the Spring! Over-compression can cause tool failure, resulting in severe bodily injury! SG

F-BODY-GENERAL MOTORS CORPORATION 23-29 CAMARO ¢ 228 ¢ FIREBIRD ¢ TRANS AM h. Turn the operating screw clockwise to compress the spring until the threaded portion of the rod is through the top of the shock. Remove J-34013-115. i. Install a new shock absorber nut. j. Install J-39642-1 on the nut, insert J-39642-2 through J-39642-1 and tighten the nut while holding J-39642-2. 8. Remove the shock/spring assembly from the tool. 9. Install or connect the following: Shock/spring assembly on the lower control arm. Torque the lower nuts to 48 ft. Ibs. (65 Nm). Lower ball joint to the steering knuckle Stabilizer shaft link Front wheel Upper shock/spring assembly. Torque the bolts to 37 ft. Ibs. (60 Nm) and the nuts to 32 ft. Ibs. (43 Nm). Master cylinder

3. Remove or disconnect the following: e Rear seat back by folding it down e Quarter panel trim assembly e Carpet by folding it back >The rear axle must be supported before removing the upper mounting nut to avoid any possible damage to the brake hose lines, tie rods and propeller shaft.

e Upper shock nut, retainer and upper insulator e Lower insulator and retainer e Lower shock-to-rear axle nut e Shock absorber from the vehicle To install: 4. Install or connect the following: e Rear shock absorber. Torque the lower shock-to-axle nut to 66 ft. lbs. (90 Nm). ¢ Lower insulator and retainer ¢ Upper insulator and retainer e Upper shock mounting nut. Torque the nut to 13 ft. Ibs. (17 Nm).

Rear

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Place a support under the rear axle.

kt WARNING Turning the shock absorber while tightening the nut could damage the

shock. To prevent damage, keep the shock absorber stationary when tightening the nut.

e Carpet ¢ Quarter panel trim assembly

REMOVAL & INSTALLATION TEE EEESSESUEEnSESEESEEESE eee

RE

Front

Refer to the from shock absorber removal and installation procedure in this manual for coils spring removal & installation. Rear

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 9. Raise and safely support the vehicle by the frame so that the rear axle can be independently raised and lowered. 3. Support the rear axle with an adjustable support. 4. Remove or disconnect the following: ¢ Brake hose brackets, if equipped, allowing the hoses to hang free ->Perform the previous step only if the hoses would be stretched and damaged when the axle is lowered.

e Lower shock absorber bolts 5. Lower the rear axle. 6. Remove or disconnect the following: e Upper insulator e Spring ->The springs are painted with a protective coating. Take care to avoid damaging this coating. If the coating is chipped or damaged, paint the exposed spring to prevent rust.

ly installation A Typical rear shock absorber assemb (right-hand shown) B Underbody pan assembly 1 Rear axle assembly Ib. ft.) 2 Rear shock absorber nut 17 Nm (13

or retainer 3 Rear shock absorber upper insulat or 4 Rear shock absorber upper insulat or 5 Rear shock absorber lower insulat

6 Rear shock absorber assembly (66 Ib. ft.) 7 Rear shock absorber nut 90 Nm

ber mounting Exploded view of the rear shock absor

To install: 7. Install or connect the following: ¢ Spring on the axle with the open lower end facing forward ¢ Upper insulator 8. Raise and safely support the rear axle. e Lower shock absorber nuts e Brake hose brackets, if removed

‘Upper Ball Joint REMOVAL & INSTALLATION

7922WG32

1. Before servicing the vehicle, refer to the precautions in the beginning of this section.

manual Timing belt service is covered In Section 3 of this

23-30 GENERAL MOTORS CORPORATION-F-BODY CAMARO © 228 ¢ FIREBIRD * TRANS AM Lower Ball Joint

|

REMOVAL & INSTALLATION >To prevent component damage, an on-car ball joint press should be used.

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove the front wheel. 3. Position a support under the shock mount for support.

«: WARNING The support must remain in place for the entire duration of the procedure to hold the spring and lower control arm in proper position.

1 2 3 4

Front Front Front Front

upper upper upper upper

control control control control

arm assembly ball stud assembly arm cotter pin arm nut 53 Nm (39 Ib. ft.)

5 Steering knuckle assembly 6 Service kit bolt/screw 7 Service kit nut 7922WG33

Position the new upper ball joint stud in the control arm and secure with the replacement nuts

and bolts

2. Remove the front wheel. 3. Position a floor jack under the shock mount for support.

The jack must remain in place for the entire duration of the procedure to hold the spring and lower control arm in proper position. 4. Remove or disconnect the following: ¢ Cotter pin Ball stud nut 4 ball joint rivets by drilling them 0.25 in. (6mm) deep using a % in. (3.175mm) bit Rivet heads by drilling them off using a ¥ in. (12.7mm) bit Rivets by using a small drift to punch them out Upper ball joint from the control arm To install: 9. Install or connect the following: ¢ New upper ball joint to the control arm. Torque the nuts and bolts according to the specifications given in the replacement kit. e Ball joint to the steering knuckle.

Torque the nut to 39 ft. Ibs. (53 Nm). e>Advance the nut to align the nearest cotter pin hole; NEVER back off the nut to align a hole!

¢ New cotter pin ¢ Front wheel

Ball Joint Removal J 9519-18

4. Remove or disconnect the following: ¢ Lower ball joint cotter pin ¢ Lower ball joint stud nut ¢ Lower ball joint from the steering knuckle 5. Press the lower ball joint from the lower control arm using Tools J-9519-7, J9519-18 and J-9519-23 as illustrated. To install: 6. Press the new lower ball joint into the lower control arm using Tools J 9519-9, J 9519-18 and J 9519-23 as illustrated. 7. Install or connect the following: ¢ Ball joint to the steering knuckle. Torque the nut to 81 ft. Ibs. (110 Nm). ->Continue to tighten the nut just until the cotter pin holes align; NEVER back off the nut to align the holes!

Ball Joint Installation FRONT LOWER CONTROL ARM ASSEMBLY

J 9519-23

FRONT LOWER CONTROL ARM ASSEMBLY

‘oe

Lower ball joint replacement requires the use of special tools, such as the ones shown

7922WG34

F-BODY-GENERAL MOTORS CORPORATION 20-01 CAMARO ¢ 228 FIREBIRD ¢ TRANS AM e New cotter pin e Front wheel 8. Check and/or adjust the alignment.

Upper Control Arm

REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Brake master cylinder, if removing the drivers side control arm e Upper shock absorber mount bolts e Front wheel e Stabilizer shaft link e Lower shock absorber bolts e Upper ball joint nut 3. Support the steering knuckle. e Upper ball joint from the steering knuckle e Upper control arm with the shock absorber ¢ Upper control arm from the shock absorber To install: 4. Install or connect the following: e Upper control arm to the shock absorber with the bolts finger tight e Upper control arm and shock absorber to the vehicle. Torque the upper control arm-to-chassis bolts to 72 ft. Ibs. (98 Nm). e Upper ball joint to the steering knuckle. Torque the upper ball joint nut to 39 ft. Ibs. (53 Nm). e>Never loosen the ball joint nut to align the cotter pin; the nut can be over torqued ¥% of a turn maximum.

¢ New cotter pin 5. Remove the steering knuckle support. Lower shock absorber to the steering knuckle. Torque the bolts to 48 ft. lps. (65 Nm). Stabilizer shaft link. Torque the nuts to 17 ft. Ibs. (23 Nm). Front wheel Upper shock absorber. Torque the nuts to 30 ft. Ibs. (41 Nm) and the bolts to 37 ft. Ibs. (60 Nm). Brake master cylinder. Torque the nuts to 21 ft. Ibs. (29 Nm).

CONTROL ARM BUSHING REPLACEMENT aerate 1. Before servicing the vehicle, refer tothe precautions in the beginning of this section.

2. Remove or disconnect the following: e Upper control arm e Upper control arm from the upper control arm support 3. Remove the bushing from the upper control arm by performing the following procedure: a. Thread the Upper Control Arm Screw Tool J-21474-19 through the Upper Control Arm Bushing Receiver/Installer Tool J-39930; the 3 tangs must-be against the screw head. b. Thread the Upper Control Arm Screw Tool J-21474-19 through the upper control arm bushing. c. Run the smaller end of the Control Arm Bushing Receiver Tool J-21474-5 onto the Upper Control Arm Screw Tool J-21474-19; then, place the thrust washer onto Tool J-21474-19 with the seams facing Tool J-21474-5. d. Position the Half Moon Spacer Too! J-39872 around the outside of the bushing to prevent metal distortion during removal. e. Ensure that the tools are aligned; then, install the Upper Control Arm Nut Tool J-21474-18 on the Upper Control Arm Screw Tool J-21474-19.

J 21474-19

9306WG18

Removing the upper control arm bushing

f. Tighen the Upper Control Arm Nut Tool J-21474-18 and Upper Control Arm Screw Tool J-21474-19 until the busing is pressed from the upper control arm. To install: 4. Install the bushing to the upper control arm by performing the following procedure: a. Thread the Upper Control Arm Screw Tool J-21474-19 through the Upper Control Arm Bushing Receiver/Installer Too! J-39930; the 3 tangs must NOT be against the screw head. b. Install a new bushing onto the Upper Control Arm Screw Tool J-2147419 with the 3 indentations facing the 3 tangs on the Upper Control Arm Bushing Receiver/Installer Tool J-39930. c. Install the threaded end of the Upper Control Arm Screw Tool J-2147419 to the upper control arm from the outside. d. Install the Control Arm Bushing Receiver Tool J-21474-5 onto the Upper Control Arm Screw Tool J-21474-19 from the inside. e. Place the thrust washer onto Tool J-21474-19 with the seam facing the bushing. f. Position the Half Moon Spacer Too! J-39872 around the outside of the bushing to prevent metal distortion during installation. g. Install the Upper Control Arm Nut Tool J-21474-18 on the Upper Control Arm Screw Tool J-21474-19; ensure that the 3 tangs on the Upper Control Arm Bushing Receiver/Installer Tool J-39930 fit into the bushing indentations. h. Tighen the assembly until the busing is pressed into the upper control arm. 5. Install or connect the following: e Upper control arm to the upper control arm support. Torque the nuts/bolts to 72 ft. Ibs. (98 Nm). e Upper control arm

Lower Control Arm REMOVAL & INSTALLATION En

9306WG17

Installing the upper control arm bushing

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 9. Remove or disconnect the following: ¢ Front wheel e Stabilizer shaft link e Outer tie rod end from the steering knuckle

this manual Heater Core replacement is covered in Section 2 of

23-3

GENERAL MOTORS CORPORATION-F-BODY CAMARO ¢ 228 ¢ FIREBIRD * TRANS AM

e Lower shock absorber bolts e Lower ball joint from the steering knuckle e Lower control arm nuts e Lower control arm To install: 3. Install or connect the following: e Lower control arm.

e On 1998-99 models, torque the lower control arm-to-crossmember horizontal nut to 74 ft. Ibs. (100 Nm) and the vertical nut to 86 ft. lbs. (115 Nm) e On 2000-01 models, torque the lower control arm-to-crossmember horizontal nut 39 ft. Ibs. (63 Nm). ¢ Lower ball joint to the steering knuckle. Torque the ball joint nut to 81 ft. Ibs. (110 Nm).

9306WG19

Removing the lower control arm front bushing

Rear Bushing

=> Never loosen the ball joint nut to align the cotter pin; the nut can be over torqued % of a turn maximum in order to align the slots for the cotter pin.

¢ New lower ball joint cotter pin e Lower shock absorber. Torque the bolts to 48 ft. Ibs. (65 Nm). ¢ Outer tie rod end to the steering knuckle. Torque the nut to 35 ft. lbs. (47 Nm). ¢ New outer tie rod end cotter pin * Stabilizer shaft link. Torque the nut to 17 ft. Ibs. (23 Nm). e Front wheel

CONTROL ARM BUSHING REPLACEMENT Front Bushing 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove the lower control arm. 3. Remove the front bushing from the upper control arm by performing the following procedure: a. Install the Lower Control Arm Bushing Screw Tool J-21474-3 through the large end of the Control Arm Bushing Receiver Tool J-21474-6. b. Install the Lower Control Arm Bushing Screw Tool J-21474-3 through the front bushing and the open end of the Lower Control Arm Bushing Receiver Tool J-39876. c. Place the thrust washer onto the Lower Control Arm Bushing Screw Tool J-21474-3 so the seam faces the front bushing. d. Install the Half Moon Spacer Too! J-39875 around the outside of the bushing to avoid metal distortion during removal.

f. Place the thrust washer onto the Lower Control Arm Bushing Screw Tool J-21474-3 threaded end with the seam facing the control arm. g. Ensure that the tools align; then, install the Lower Control Arm Bushing Nut and the Lower Control Arm Bushing Screw Tool J-21474-3. h. Tighten the assembly until the front bushing is flush with the lower control arm. 5. Install the lower control arm.

9306WG20

Installing the lower control arm front bushing

e. Ensure that the tools align; then, install the Lower Control Arm Bushing Nut Tool J-21474-4 and tighten the assembly until the bushing is pressed from the control arm. To install: 4. Install the front bushing to the lower control arm by performing the following procedure: a. Thread the Lower Control Arm Bushing Screw Tool J-21474-3 through the Control Arm Bushing Receiver Too! J-21474-5. b. Install the Lower Control Arm Bushing Screw Tool J-21474-3 through the new front bushing and the lower control arm. c. Thread the Lower Control Arm Bushing Screw Tool J-21474-3 and accessories into the front lower control arm. d. Install the Lower Control Arm Bushing Receiver Too! J-39876 onto the Lower Control Arm Bushing screw Too! J-21474-3 with the open end facing the control arm. €. Install the Half Moon Spacer Too! J-39875 around the outside of the bushing to avoid metal distortion during installation.

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove the lower control arm. 3. Remove the rear bushing from the upper control arm by performing the following procedure: a. Install the Lower Control Arm Bushing Receiver Too! J-39874 onto the Lower Control Arm Bushing Screw Tool J-21474-3. b. Install the Lower Control Arm Bushing Screw Tool J-21474-3 through the rear bushing, the contro! arm and into the small end of the Lower Control Arm Bushing Receiver Tool J-39931.

J39e31

J 39874

9306WG21

Removing the lower control arm rear

bushing

9306WG22

Installing the lower control arm rear bushing

F-BODY-GENERAL MOTORS CORPORATION

CAMARO « Z28 ¢ FIREBIRD ¢ TRANS AM

c. Place the thrust washer onto the Lower Control Arm Bushing Screw Tool J-21474-3 so the seam faces the control arm. d. Install the Lower Control Arm Bushing Nut Tool J-21474-4 onto the Lower Control Arm Bushing Screw Tool J-21474-3: then, ensure that the assembly aligns with the bushing. e. Tighten the assembly until the bushing is pressed from the control arm. To install: 4. Install the rear bushing to the lower control arm by performing the following procedure: a. Thread the Lower Control Arm Bushing Screw Tool J-21474-3 through the small end of the Lower Control Arm Bushing Receiver Tool J-39931. b. Install the Lower Control Arm Bushing Screw Tool J-21474-3 through the new rear bushing and the closed end of the lower control arm. c. Place the small end of the Control Arm Bushing Receiver Tool J-21474-5 onto the Lower Control Arm Bushing Screw Tool J-21474-3. d. Place the thrust washer onto the Lower Control Arm Bushing Screw Tool J-21474-3 with the seam facing the control arm. e. Ensure that the tools align and the window on the Lower Control Arm Bushing Receiver Tool J-39931 faces straight up and is visible. f. Install the Lower Control Arm Bushing Nut Tool J-21474-4 onto the Lower Control Arm Bushing Screw Tool J1474-3; then, tighten the assembly until the rubber protrusion on the Lower Control Arm Bushing Receiver Tool J-39931 side bottoms against Too! J-39931. 5. Install the lower control arm.

Wheel Bearings

g

2. Remove or disconnect the following: e Front wheel Brake caliper Brake rotor Wheel speed sensor electrical connector

e Hub bolts e Hub/bearing assembly by pulling it from the spindle To install: 3. Install or connect the following: e Hub/bearing assembly on the spindle. Torque the bolts to 63 ft. Ibs. (86 Nm). e Wheel speed sensor electrical connector

Be sure the wheel speed sensor electrical connector is reattached to the sensor wire bracket and sensor or the

wires could be damaged. e Brake rotor

e Brake caliper e Front wheel

23-30

Rear

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Rear wheel e Brake rotor or brake drum and components, as equipped 3. Clean the axle housing cover and surrounding area to prevent dirt or contamination from entering the housing. 4. Remove the axle housing cover. 5. Install an Anti-lock Brake System (ABS) tone ring protector kit. 6. Remove or disconnect the following: e Rear axle pinion shaft lock screw e Pinion gear shaft 7. Push the flanged end of the axle shaft into the axle housing in order to access the rear axle shaft lock. 8. Remove or disconnect the following: e Shaft lock C-clip from the axle shaft e Axle shaft from the axle housing 9. Use a small suitable pry tool to

e

ADJUSTMENT

The front wheel bearing assembly used on these vehicles is a sealed, non-serviceable unit. No wheel bearing adjustments (front or rear) are necessary OF possible.

REMOVAL & INSTALLATION Front

1. Before servicing the vehicle, refer to the precautions in the beginning of this section.

1 2 3 4 5 6 7

Steering knuckle assembly Front brake rotor assembly Front brake caliper assembly Front brake caliper bolt/screw Front wheel bolt/screw 86 Nm (63 Ib. ft.) Wheel speed sensor wire bracket Front wheel hub assembly

g Exploded view of the wheel hub/bearing unit mountin

l Brake service is covered in Section 4 of this manua

7922WG35

23-34

GENERAL MOTORS CORPORATION-F-BODY CAMARO 228 ¢ FIREBIRD ° TRANS AM remove the oil seal from the axle housing. Be careful not to score or damage the housing. 10. Install an axle bearing remover into the bore of the axle housing and position it behind the bearing, ensure the tangs of the tool engage the outer race. Remove the bearing using a slide hammer. To install: 11. Install a new bearing lubricated with gear oil with a suitable driver so the tool bottoms against the shoulder in the axle housing. ; 12. Position a new seal lubricated with gear oil on a suitable seal installer, then insert the seal into the housing bore. 13. Install or connect the following: e Axle shaft ¢ C-clip so it seats in the axle side gear counterbore

e Pinion gear shaft through the differential case, thrust washer and 16 22 26 29 39 54

HOUSING, REAR AXLE CAP, DIFFERENTIAL CARRIER BOLT/SCREW, DIFFERENTIAL BOLT/SCREW, DIFFERENTIAL LOCK WHEEL, REAR WHEEL SPEED LOCK, REAR AXLE SHAFT

BEARING BEARING CAP PINION GEAR SHAFT SENSOR RELUCTOR 7922WG38

Differential component identification

pinion gears ¢ Shaft lock screw. Torque it to 27 ft. lbs. (36 Nm). e New axle housing cover with gasket. Torque the bolts in a crosswise pattern to 22 ft. Ibs. (30 Nm). ->When refilling a limited slip differential rear axle with gear oil, 4 oz. (118ml) of limited slip additive should be added.

14. Refill the rear axle with SAE 80-90W GL-5 gear lubricant, then install the plug. e Rear brake assemblies e Rear wheels

16 44 49 63 70

HOUSING, REAR AXLE BEARING, REAR AXLE SHAFT SEAL, REAR AXLE SHAFT BEARING SHAFT, REAR AXLE (DRUM BRAKE ASSEMBLY) SHAFT, REAR AXLE (DISC BRAKE ASSEMBLY) 7922WG39

Cut-away view of the rear axle bearing and seal

GENERAL MOTORS CORPORATION—G-BODY 1998-01 Buick-Riviera * Oldsmobile-Aurora 24-39 A ENGINE REPAIR ................ 24-2 3-222: 25i.00 24-36 FUEL SYSTEM/.. PRECAUTIONS.................. 24-2

STEERING AND SUSPENSION................. 24-43 RE SORe

Cee

A tet cae 24-43

Fuelsiiieclotetiare: shearawdaies 24-37 Removal & Installation............ 24-37 cee centr cremate 24-37 PUCIREITID Etec Removal & Installation............ 24-37

Fuel System PreSSUre ..........ssee 24-36 cecance. 24-36 Relieving Weve

Rea Main Seal .........seseseesseeseeeeen 24-27 Removal & Installation........... 24-27

acca. 24-36

Removal & Installation............ 24-12 S

Fuel System Service

PReraUlONs me tei H

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Removal & Installation............ 94-17

Lower Ball Joints iinceccry ames 24-46

PIeCaUlOnS semanas aAbscst 24-43

Camshaft and Valve Lifters .......... 24-17

on Male 94-45 CONSHING eae Removal & Installation............ 94-45 at ne 94-44 Go lniniet ie teen Removal & Installation............ 94-41 OUINCaECIA eatsao ater24-8

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Removal & Installation............ Lower Control Arn? 22.2 rece Control! Arm Bushing ReplaCeMent,...-.sssesssersesoneee Removal & Dea iets are

24-46 24-46 24-47 24-46

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Engine ASSEMDLY ....cccsseesessssseee 24-3

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Removal & Installation...........-- Bese

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Removal & Installation.......... 94-15 F

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Removal & Installation............ 24-36

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Removal & Installation............ 94-25

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24-22 24-44 24-44 24-13

Removal & Installation............ 24-13

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Timing Chain, Sprockets, Front Cover and Seal............008 24-27 Removal & Installation............ 24-27 Transmission ASSeMbly............ 24-39 Removal & ee Longest 24-39

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24-22

ACIUSIMGQ eect heqaptesueder24-22

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Water PUMD..........06 Aoi

24-7

Removal & Installation.is.cxeees 24-7 Wheel Bearings......c.ccccccsecerecees 24-49

Adjustnentaameneeyit may be necessary to use a gear installer to fully seat the gear. Be sure the timing mark on the crankshaft gear is pointing straight up.

e Camshaft sprocket with the chain. Torque the bolt to 74 ft. Ibs. (100 Nm) plus and additional 90 degree turn.

The camshaft and crankshaft timing marks should be aligned.

¢ Timing chain damper. Torque the mounting bolts to 16 ft. Ibs. (22 Nm).

(1) Flywheel Bolt

2) Flywheel 3) Crankshaft Rear Oil Seal 4) Oil Pan Gasket (Includes Baffle) 5 ) Engine Oil Pan 6) Oil Level Sensor

7)

Oil Pan Bolt

8) Oil Pan Drain Plug 9) Oil Pan Drain Gasket ) Crankshaft Position Sensor Shield ) Crankshaft Balancer

2) Crankshaft Balancer Washer 3) Crankshaft Balancer Bolt 4) Water Pump Pulley Bolt 5) Water Pump Pulley

6) Water Pump

7)

Water Pump Gasket

Exploded view of lower engine components—3.8L (VIN 1) engines

Front cover with a new gasket and seal. Torque the bolts to 11 ft. Ibs. (15 Nm) plus an additional 40 degrees. Oil pan-to-front cover bolts to 10 ft. Ips. (14 Nm) CKP sensor electrical connector and shield Crankshaft balancer. Torque the bolt to 111 ft. Ibs. (150 Nm); then an additional 75 degree turn. Belt tensioner. Torque the bolts to 37 ft. Ibs. (60 Nm). Alternator

(18) Engine Front Cover

(19) (20) (2 1 ) (22) (23 )

Engine Front Cover Gasket Oil Pump Cover Bolt Engine Crankshaft Crankshaft Balancer Key Crankshaft Upper Bearing

(24 ) Side

Main Bolt

(25) Crankshaft Main Bearing Cap Bolt (26) Crankshaft Lower Bearing (27) Crankshaft Main Bearing Cap (28) Oil Pump Cover (29) Oil Pump Gear Set

) 31) Crankshaft Front Oil Seal 32) Camshaft Position Sensor 33) Camshaft Position Sensor Bolt 34) Water Pump Bolt 9300XG04

G-BODY—GENERAL MOTORS CORPORATION

RIVIERA e AURORA

24-31

e Vacuum reservoir

CAMSHAFT GEAR A. CAMSHAFT SPROCKET B

e Negative battery cable 13. 14. 15. proper

TIMING CHAIN

Refill the cooling system. Start the vehicle and check for leaks. Road test the venicle and ensure operation.

4.0L Engine

LEFT SIDE SECONDARY CHAIN >The secondary timing chains can be removed without removing the engine from the vehicle.

DAMPER ASSEMBLY CRANKSHAFT SPROCKET 7922XG16

Exploded view of the timing chain and sprockets—3.8L (VIN 1) engines

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Negative battery cable e Drive belt e Tower to tower brace e Exhaust Y-pipe at the converter e Front wheels e Wheel well splash shields e Crankshaft balancer bolt 3. Support the engine cradle. e 3 right-side engine cradle bolts e Vehicle Speed Sensor (VSS) from the right control arm 4. Lower the cradle to gain access for the crankshaft damper puller. 5. Remove or disconnect the following: e Crankshaft balancer e Drive belt tensioner and idler pulley e Front cover and gasket >The front cover gasket is reusable as long as it is not damaged.

ee aa

BALANCE SHAFT TO

CAMSHAFT

CAMSHAFT TO CRANKSHAFT

a

—3.8L (VIN 1) Balance shaft-to-camshaft and camshaft-to-crankshaft timing mark alignment engines

e Engine mount bracket. Torque the bolts to 65 ft. Ibs. (87 Nm). e Drive belt Torque axis mount. Torque the torque axis mount-to-frame bolts to

5? ft. lbs. (70 Nm) and the through-bolts to 65 ft. Ibs. (87 Nm). 11, Remove the engine support fixture 12. Install or connect the following:

6. Partially drain the cooling system. e Upper radiator hose at the water crossover Spark plug wires Right side fan Battery cable at the alternator Spark plug wires Wiring harness at the rocker arm cover Positive Crankcase Ventilation (PCV) tube from the rocker arm cover Right and left torque struts Battery cable retainer at the front of — the rocker arm cover Ignition Control Module (ICM) Rocker arm cover by pivoting it around the water pump drive shaft ->Continue moving the cover upward and pivoting so that the edge of the cover closely follows the left edge of the intake manifold cover. The gasket

Heater Core replacement is covered in Section 2 of this manual

24-3

GENERAL MOTORS CORPORATION—G-BODY RIVIERA e AURORA

is reusable as long as it is not damaged.

¢ Left side secondary chain tensioner e Left side chain guide e>Access the upper chain guide mounting bolt through the hole in the cylinder head capped with the plastic plug.

e Secondary drive chain and sprockets To install: Correct timing exists when the crankshaft and intermediate shaft sprocket timing marks are in alignment and all 4 camshaft drive pins are perpendicular (90 degrees) to the cylinder head sur-

face.

1.

INTAKE POSITION

2 3

EXHAUST POSITION TIMING MARKS

©

7. Assemble the left side secondary timing chain as follows: a. Route the timing chain over the intermediate sprocket teeth outer row. b. Route the timing chain over the chain guide and install the exhaust camshaft sprocket so the LE (Left Head Exhaust) pin engages the sprocket notch. There should be no slack in the lower section of the timing chain and the camshaft drive pin must be perpendicular to the cylinder head face.

c. Install the intake camshaft sprocket into the chain so the sprocket notch LI (Left Head Intake) engages the camshaft

Primary and secondary timing mark alignment—4.0L (VIN C) engine

and the camshaft drive pin remains perpendicular to the cylinder head face. e» A hex is cast into the camshafts behind the lobes for cylinder No. 2, so an open end wrench may be used to provide minor repositioning of the cams.

8. Install or connect the following: e Exhaust and intake camshaft sprockets, do not tighten the bolts Chain guide Camshaft sprocket bolts. Torque the bolts to 90 ft. Ibs. (120 Nm). Chain tensioner. Torque the bolts to 20 ft. Ibs. (27 Nm). e Rocker arm cover. Torque the screws to 89 inch Ibs. (10 Nm).

7922XG18

G-BODY—GENERAL MOTORS CORPORATION RIVIERA « AURORA 24-33 SECOND PUSH DOWN

e Left side secondary timing chain e Right side secondary chain ten-

FIRST PRESS IN

sioner e Right side chain guide e>Access the upper chain guide mounting bolt through the hole in the cylinder head capped with the plastic plug.

1 RELEASE TO FIAST CLICK 2 INSTALL LOCK PIN 7922XG26

Rotating tensioner release lever—4.0L (VIN C) engine

7922XG27

Locking the tensioner into position—4.0L (VIN C) engine

e ICM e Battery cable retainer to the front of the rocker arm cover 9. Install the right and left torque struts and torque the bolts as follows: e>|t is important during installation that the engine torque struts are not preloaded in their installed position. Adjustment is provided at the point the strut fastens to the core support bracket. Be sure this bolt is loose during assembly.

a. Step 1: Strut bracket-to-cylinder head (M10) bolt: 35 ft. Ibs. (50 Nm). b. Step 2: Strut bracket-to-water manifold (M8) bolts: 20 ft. Ibs. (25 Nm). c. Step 3: Strut-to-core support bracket bolt: 45 ft. Ibs. (60 Nm). 10. Install or connect the following: e PCV fresh air tube to the rocker

arm cover Wiring harness to the cover Spark plug wires Battery cable at the alternator Right side fan Upper radiator hose to the water

crossover e Front cover with a new gasket. Torque the bolts to 89 inch Ibs. (10 Nm). 11. Apply a dab of RTV to the split line between the upper and lower crankcase assemblies. 12. Install or connect the following: e Drive belt idler pulley. Torque the

bolt to 35 ft. Ibs. (47 Nm). Drive belt tensioner. Torque the nut to 35 ft. Ibs. (47 Nm).

¢ Crankshaft balancer. Lubricate the bolt threads with engine oil and torque the bolt to 44 ft. Ibs. (60 Nm) then an additional 120 degree turn.

VSS sensor Engine cradle. Torque the bolts to 75 ft. Ibs. (102 Nm). Wheel well splash shields Wheels Exhaust Y-pipe to the converter. Torque the bolts to 20 ft. Ibs. (25 Nm). Tower-to-tower brace Drive belt Negative battery cable 13. Refill the cooling system. 14. Start the engine and check for leaks.

RIGHT SIDE SECONDARY CHAIN «The secondary timing chains can be removed without removing the engine from the vehicle.

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Exhaust Y-pipe from the converter Tower-to-tower brace Ignition Control Module (ICM) Spark plug wires from the right bank Positive Crankcase Ventilation (PCV) valve Purge canister solenoid from the rear of the cover Rocker arm cover 3. Safely support the front of the engine cradle. 4. Remove or disconnect the following: e 2 mounting bolts at the front of the cradle e Right and lett torque struts 5. Lower the engine cradle (or raise the vehicle) to provide clearance at the rear of the engine compartment. 6. Remove or disconnect the following:

e Right side camshaft sprocket bolts and camshaft sprockets e Secondary drive chain To install: e>Correct timing exists when the crankshaft and intermediate shaft sprocket timing marks are in alignment and all 4 camshaft drive pins are perpendicular (90 degrees) to the cylinder head surface.

7. Install the secondary timing chain guide. 8. Assemble the right side secondary timing chain as follows:

a. Over the intermediate shaft sprocket inner row of teeth. b. Over the chain guide. c. Exhaust camshaft sprocket so the RE (Right Head Exhaust) pin engages the sprocket notch. e»There should be no slack in the lower section of the timing chain and the camshaft drive pin must be perpendicular to the cylinder head face.

d. Intake camshaft sprocket into the chain so the sprocket notch RI (Right Head Intake) engages the camshaft and the camshaft drive pin remains perpendicular to the cylinder head face. e>A hex is cast into the camshafts behind the lobes for cylinder No. 1, so an open end wrench may be used to provide minor repositioning of the cams.

9. Install or connect the following: e Exhaust and intake camshaft sprockets, do not tighten ¢ Timing chain tensioner. Torque the bolts to 20 ft. Ibs. (27 Nm). e Camshaft sprocket bolts. Torque the bolts to 90 ft. Ibs. (120 Nm). e Left side secondary timing chain

Brake service is covered in Section 4 of this manual

e Torque struts Engine cradle. Torque the bolts to

75 ft. Ibs. (102 Nm). Rocker arm cover. Torque the screws to 84 inch Ibs. (10 Nm). Purge canister solenoid PCV valve

24-34 e e ¢ ¢

GENERAL MOTORS CORPORATION—G-BODY RIVIERA e AURORA

Spark plug wires ICM Tower to tower brace Exhaust Y-pipe to the converter. Torque the bolts to 20 ft. Ibs. (25 Nm).

PRIMARY CHAIN The engine must be removed from the vehicle and supported on an engine stand. 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Engine ¢ Both secondary timing chains ¢ Primary timing chain tensioner e Intermediate shaft sprocket e Primary chain and sprocket assembly by sliding it off the shafts To install: 3. Install or connect the following: ¢ Crankshaft sprocket, intermediate shaft sprocket and primary timing chain assembly

e Intermediate shaft sprocket bolt. Torque the bolt to 45 ft. Ibs. (61 Nm). e Primary timing chain tensioner bolts. Torque them to 20 ft. Ibs. (27 Nm). ¢ Both secondary timing chains e Engine

Piston and Ring POSITIONING

e>\f it is necessary to turn the crankshaft sprocket, the intermediate shaft sprocket will also have to be turned so the timing mark aligns with the crankshaft sprocket.

1. Lower oil control ring

2. 3. 4. 5.

CONNECTING ROD MATCHING NUMBERS

Upper oil control ring Top Ring Oil control ring expander Second ring 9306XG05

Piston ring end-gap positioning—3.5L

engine

7922AG51

Connecting rod and cap installation. Be sure to matchmark the cap and rod prior to disassembly, as shown

ZINE 9306XG06

Piston positioning—3.5L engine

1 2 3 4 5

INTERMEDIATE SHAFT PRIMARY CHAIN INTERMEDIATE SHAFT SPROCKET CRANKSHAFT SPROCKET KEY SPROCKET 7922XG25

Primary drive chain components—4.0L (VIN C) engine

7922AG48

Piston ring positioning—3.5L and 3.8L engines

G-BODY—GENERAL MOTORS CORPORAT

AIVIEAA @RUCOKR 24-35

oo

NGINE LEFT B.

c

eS

ENGINE FRONT

NGIN

PISTON ARROW TOWARD CHAINCASE ON BOTH SIDES

RIGHT BANK

C.

A.D.

B. RIGHT BANK

A. OIL RING SPACER GAP

(TANG IN HOLE OR SLOT WITH ARC)

B. OIL RING RAIL GAPS

BOTTOM VIEW (PAN - SIDE UP)

C. 2ND COMPRESSION RING GAP D. TOP COMPRESSION RING GAP 7922AG46

TOP VIEW (PAN - SIDE DOWN)

Piston ring end-gap spacing—3.8L engine

ROD CAPS

G

ARROW TOWARDS FRONT OF ENGINE

BEARING CAP NOTCHES POINT TOWARD EACH OTHER ON PAIRED RODS

@FRT LOCATOR LUGS INDICATE PISTON FRONT TOWARDS ENGINE FRONT

Ep %

ROD CAP

@FAT

BEARING CAP NOTCHES POINT TOWARD EACH OTHER ON PAIRED RODS

PISTON

7922AG47

VIEW B

Piston positioning. Often the arrow is replaced by a notch, which also must face toward the front of the engine—3.8L engine

1. 2. 3. 4.

7922AG53

Piston and connecting rod assembly positioning—4.0L engine

Oil ring segment gap Upper compression ring gap Oil ring segment gap Expander & lower compression ring gaps

5. 6. 7. 8.

Expander ring Oil segment rings Lower compression ring Upper compression ring

Piston ring and end-gap positioning—4.0L engine

For complete Engine Mechanical specifications, see Section 1 of this manual

7922AG52

24-36

GENERAL MOTORS CORPORATION—G-BODY RIVIERA ¢ AURORA

_ FUEL SYSTEM Fuel System Service Precautions Safety is the most important factor when performing not only fuel system maintenance but any type of maintenance. Failure to conduct maintenance and repairs in a safe manner may result in serious personal injury or death. Maintenance and testing of the vehicle's fuel system components can be accomplished safely and effectively by adhering to the following rules and guidelines. e To avoid the possibility of fire and personal injury, always disconnect the negative battery cable unless the repair or test procedure requires that battery voltage be applied. e Always relieve the fuel system pressure prior to disconnecting any fuel system component (injector, fuel rail, pressure regulator, etc.), fitting or fuel line connection. Exercise extreme caution whenever relieving fuel system pressure, to avoid exposing skin, face and eyes to fuel spray. Please be advised that fuel under pressure may penetrate the skin or any part of the body that it contacts. e Always place a shop towel or cloth

1. 2. 3. 4. 5. 6.

around the fitting or connection prior to loosening to absorb any excess fuel due to spillage. Ensure that all fuel spillage (should it occur) is quickly removed from engine surfaces. Ensure that all fuel soaked cloths or towels are deposited into a suitable waste container. e Always keep a dry chemical (Class B) fire extinguisher near the work area. * Do not allow fuel spray or fuel vapors to come into contact with a spark or open flame. e Always use a back-up wrench when loosening and tightening fuel line connection fittings. This will prevent unnecessary stress and torsion to fuel line piping. ¢ Always replace worn fuel fitting Orings with new. Do 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. Disconnect the negative battery cable. 3. Remove the fuel filler cap from the filler neck. 4 Connect J-34730-1 fuel pressure gauge to the fuel pressure test port. Wrap a shop towel around the fitting while connecting the gauge to prevent fuel spillage. 5. Install the gauge bleed hose into a Suitable container and open the valve to bleed the system. 6. Drain any remaining fuel from the gauge into the container and remove the gauge from the test port.

REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Relieve the fuel system pressure. 3. Remove or disconnect the following: * Quick connect fitting at the fuel filter inlet ¢ Fuel filter outlet fitting from the fuel filter while holding the filter fitting with a back-up wrench

Fuel Feed Pipe In-Line Fuel Filter Fuel Return Pipe Fuel Pump Flex Pipe Integral Reservoir Fuel Pipe Shut-off Adapters

7. Fuel Pressure Gauge 8. Fuel Pressure Connection S) . Fuel Rail 1 0. Fuel Pressure Regulator Fuel system circuit showing the pressure test port on the supply rail—4.0L engine

9300XG07

G-BODY—GENERAL MOTORS CORPORATION

RIVIERA e AURORA

e Fuel filter from the vehicle To install: 4. Position the new fuel filter in the bracket. 5. Install a new plastic retainer on the fuel inlet line. 6. Apply a drop of oil on the fuel filter inlet fitting and snap the fitting onto the fuel filter. 7. Reconnect the fuel outlet line to the filter by holding the filter with a back-up wrench and tightening the line fitting to 22 ft. Ibs. (30 Nm). 8. Pressurize the fuel system and verify no leaks.

e Fuel sender access panel e Fuel sender assembly quick connect fittings e Fuel sender assembly electrical connector

When the lock-ring is removed from the fuel sender, the sender assembly will spring up. Downward pressure should be kept on the assembly and slowly released to ensure the sender assembly does not get damaged. e Lock-ring from the fuel sender

9306XG07

Exploded view of the fuel rail assembly-3.5L engine

>: CAUTION

Fuel Pump REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this sec-

tion. 2. Relieve the fuel system pressure. 3. Drain the fuel tank. 4. Remove or disconnect the following: e Spare tire and jack e Floor trunk liner by pulling it back

.

N

=Cs VOLE

ku

\

FMW — SS) =:

e Sender assembly from the tank To install: 5. Install or connect the following: New O-ring on top of the tank Sender assembly into the tank Retainer on top of the fuel tank, compress the sender until the retainer can be engaged; then lock it in place Quick connect fittings to the fuel sender assembly Sender assembly electrical connector e Negative battery cable 6. Pressurize the fuel system and verify no leaks. 7. Install or connect the following:

e Spare tire and jack

Fuel Injector

|

REMOVAL & INSTALLATION ES

3.5L Engine

SUPPORT ASSEMBLY COVER ASSEMBLY ~ FUEL PIPES (ABOVE RESERVOIR - FUEL Newn SENSOR ASSEMBLY

- FUEL SENDER FUEL SENDER COVER) PUMP FUEL — FUEL LEVEL 7922XG19

Fuel pump and sending unit module assembly

i

The reservoir bucket on the fuel sender assembly will be full of fuel when it is removed from the tank. Be sure to have a catch pan nearby to drain the sender into.

e Fuel sender access panel e Trunk liner

EEOC TOTO CURE

24-37

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Relieve the fuel system pressure. 3. Remove or disconnect the following: e Fuel injector sight shield e Fuel injector electrical connectors e Vacuum hose from the fuel pressure regulator e Positive Crankcase Ventilation (PCV) hose from the throttle body

a5 9306XG08

Exploded view of the fuel injector—3.5L engine

¢ Throttle body vacuum port hose e Wiring harness from the fuel rail ¢ Fuel rail from the intake manifold by pushing the locking tab away from the center of the intake manifold e Fuel injector from the fuel rail and by spreading the retainer clip to release it

To install: ck WARNING If the O-rings are different colors, install the black O-ring in the upper position and the brown O-ring in the lower position. 4. Install or connect the following: e New O-rings on the fuel injectors e Fuel injector on the fuel rail by pushing the retainer far enough to engage the clip -»Position the fuel rail so the electrical connectors may be installed easily

e Fuel rail onto the intake manifold by pushing the locking tab until it locks in place

For Accessory Drive Belt illustrations, see Section 1 of this manual

24-38

GENERAL MOTORS CORPORATION—G-BODY RIVIERA e AURORA

e Wiring harness to the fuel rail ¢ Throttle body vacuum port hose ¢ Positive Crankcase Ventilation (PCV) hose to the throttle body e Vacuum hose onto the fuel pressure regulator ¢ Fuel injector electrical connectors e Negative battery cable 5. Pressurize the fuel system and check for leaks. 6. Install the fuel injector sight shield. Torque the bolts to 27 inch Ibs. (3 Nm).

9306XG10

Exploded view of the fuel rail assembly— 3.8L (VIN 1) engine

3.8L Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Relieve the fuel system pressure. 3. Remove or disconnect the following: Fuel injector sight shield Fuel feed and return lines from the fuel rail Vacuum line from the fuel pressure regulator Vacuum line from the throttle body Ignition coil wires Retainer clips from the top of the supercharger Alternator and rear mount bracket Fuel injector electrical connectors Fuel rail hold-down bolts Fuel Rail by applying equal force on both sides Fuel injector-to-fuel rail retainer clips Fuel injectors To install:

+ WARNING If the O-rings are different colors, install the black O-ring in the upper position and the brown O-ring in the lower position. 4. Install or connect the following: ¢ New O-rings on the fuel injectors

9306XG11

Exploded view of the fuel rail assembly— 3.8L (VIN K) engine

¢ Fuel injectors onto the fuel rail and secure with the retainers Fuel rail. Torque the bolts to 7 ft. lbs. (10 Nm) and the stud to 18 ft. Ibs. (25 Nm). Alternator and rear mount bracket. Torque the bolts to 37 ft. Ibs. (50 Nm). Fuel injector electrical connectors Ignition coil wires Retainer clips to the top of the supercharger Vacuum line to the fuel pressure regulator Vacuum line to the throttle body Fuel feed and return lines to the fuel rail by squeezing the tabs and pulling the lines apart ¢ Negative battery cable * Rear seat cushion 9. Pressurize the fuel system and check for leaks. 6. Install the fuel injector sight shield. Torque the bolts to 18 inch Ibs. (2 Nm).

2. Relieve the fuel system pressure. 3. Remove or disconnect the following: Air intake duct Exhaust Gas Recirculation (EGR) pipe at throttle body spacer Brake booster vacuum hose at intake manifold vacuum fitting Front bank spark plug wires Manifold Absolute Pressure (MAP) sensor electrical connector from the Mass Air Flow (MAF) sensor Fuel injector electrical connectors e6° ee Fuel rail ground wire bolt at the rear cylinder head Fuel pressure regulator from the fuel rail Crankcase ventilation vacuum lines Quick-connect fittings at the fuel rail Fuel rail end-point bracket retainer bolt Throttle body mount bolts Throttle body Throttle body spacer Intake manifold to throttle body spacer O-ring seal Fuel rail-to-intake manifold locking tab, release it by pushing it toward the center of the intake manifold Fuel injector from the fuel rail by using removal tool J 41081 Fuel injector

Exploded view of the fuel rail and fuel injector—4.0L engine

4.0L Engine 9306XG09

Exploded view of the fuel injector—3.8L engine

1998-99 MODELS 1. Before servicing the vehicle, refer to the precautions in the beginning of this section.

9306XG13

Exploded view of the fuel rail and intake manifold—4.0L engine

G-BODY—GENERAL MOTORS CORPORATION RIVIERA e AURORA To install: 4. Lubricate the new O-rings with engine oll. 5. Install or connect the following: Fuel injector using a new retainer clip and new O-rings

Fuel rail onto the intake manifold until the retainers latch Fuel injector electrical connectors Intake manifold to throttle body spacer O-ring seal Throttle body spacer and tighten to 106 inch Ibs. (12 Nm) Throttle body Throttle body mount bolts and tighten to 106 inch Ibs. (12 Nm) Fuel pressure regulator to the fuel rail Quick-connect fittings at the fuel rail Crankcase ventilation vacuum lines Fuel rail ground wire bolt at the rear cylinder head Fuel injector electrical connectors MAP sensor electrical connector to the MAF sensor Front bank spark plug wires

Brake booster vacuum hose at intake manifold vacuum fitting EGR pipe at throttle body spacer Fuel rail end-point bracket retainer bolt and tighten to 97 inch Ibs. (11 Nm) Air intake duct Negative battery cable : 6. Pressurize the system and check for eaks.

2001 MODELS 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Relieve the fuel system pressure. 3. Remove or disconnect the following: Air intake duct Quick-connect fittings at the fuel rail Fuel pressure regulator and Positive Crankcase ventilation Valve (PCV) vacuum hoses Fuel rail end-point bracket retainer bolt Fuel injector electrical connectors Fuel rail bolts

Rail and injectors as an assembly from the manifold Fuel injector from the fuel rail by Spreading the retainer Fuel injector To install: 4. Lubricate the new O-rings with engine oll.

5. Install or connect the following: Fuel injector using a new retainer clip and new O-rings Rail and injectors as an assembly into the manifold until fully seated Fuel rail bolts and tighten to 88 inch Ibs. (10 Nm) Fuel injector electrical connectors Fuel rail end-point bracket retainer bolt and tighten to 88 inch Ibs. (10 Nm) Fuel pressure regulator and PCV vacuum hoses Quick-connect fittings at the fuel rail Air intake duct e Negative battery cable 6. Pressurize the system and check for leaks.

e

"DRIVETRAIN Transmission Assembly REMOVAL & INSTALLATION Riviera

1. Before servicing the vehicle, refer to the precautions in the beginning of this section.

2. Remove or disconnect the following: Negative battery cable Air intake duct Transmission electrical connector Range selector cable and bracket Top transmission bolts @ eeoeee#e Oxygen (02S) sensor electrical connector Wheels Front air deflector Stabilizer links Splash shield at the front crossmember Wiring harness from the front crossmember Intermediate shaft Heat shield Rack and pinion cooler pipe Rack and pinion

e Front and rear transmission mounts e Torque strut 3. Support the frame. 4. Remove the bolts and lower the frame. 5. Remove or disconnect the following: Flexplate cover Torque converter bolts Input Speed Sensor (ISS) electrical connectors Engine-to-transmission bracket Transmission filler tube Rear engine mount Remaining (lower) transmission bolts ¢ Transmission To install: 6. Install or connect the following: Transmission. Torque the bolts to 55 ft. Ibs. (75 Nm). Rear engine mount. Torque the bolts to 52 ft. Ibs. (70 Nm). Transmission filler tube. Torque the bolt to 15 ft. Ibs. (20 Nm). Transmission brace. Torque the bolts to 44 ft. Ibs. (60 Nm). ISS electrical connectors Torque converter. Torque the bolts to 46 ft. Ibs. (62 Nm).

24-39

:

Flexplate cover. Torque the bolts to 115 inch Ibs. (13 Nm). Engine frame. Torque the bolts to 66 ft. Ibs. (90 Nm). 7. Remove the frame support fixture. 8. Install or connect the following: Torque strut. Torque the bolt to 30 ft. Ibs. (40 Nm). Front and rear transmission mounts. Torque the bolts to 30 ft. lbs. (40 Nm). Rack and pinion. Torque the bolts to 48 ft. Ibs. (65 Nm). Intermediate shaft. Torque the inch bolt to 35 ft. Ibs. (47 Nm). ack and pinion cooler pipe eat shield. Torque the bolts to 89 SSS Se inch Ibs. (10 Nm). Wiring harness to the front crossmember Splash shield to the front crossmember Stabilizer links. Torque the nuts to 13 ft. Ibs. (17 Nm). Front air deflector Wheels (02S) electrical connector Range selector cable and bracket Transmission electrical connector

manual For Tire, Wheel and Ball Joint specifications, see Section 1 of this

24-4

GENERAL MOTORS CORPORATION—G-BODY RIVIERA e AURORA

e Air intake duct ¢ Negative battery cable 9. Check and adjust the transmission fluid level. 10. Road test the vehicle and check for leaks.

e Transmission main wiring harness e Engine to transmission bracket Flexplate cover Torque converter bolts Right transmission bracket 8. Support the transmission. 9. Remove the lower transmission bolts

Aurora

and lower the transmission towards the left so it can clear the starter motor.

ofl ASS

lON

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: ¢ Negative battery cable Air intake duct Range selector cable from the transmission Upper transmission oil cooler line from the radiator Lower transmission oil cooler line from the transmission Both heater tube retainers from the upper Case side cover Coolant temperature sensor electrical connector Ground wire at the rear of the transmission Left front Wheel Speed Sensor (WSS) electrical connector Vehicle Speed Sensor (VSS) from the transmission Rack and pinion electrical connector Transmission Ver vent hose Upper transmission bolts 3. Install an engine support fixture. 4. Remove or disconnect the following: Vacuum reservoir Ball joints from the steering knuck-

les

¢ Antilock Brake System (ABS) module bate hp * Secondary Air Injection (AIR) PUMPS Left and right splash shields e Air deflector

» Power steering line brackets at the

frame ie * Front and rear transmission mount nuts

Rack and pinion from the frame 5. Support the engine frame. 6. Remove the 6 frame bolts and lower the frame from the body, 7. Remove ordisconnect the following; ¢ Left and right halfshafts e Exhaust heat shield e Transmission-to-engine brace e Front engine-to-transmission pencil brace e Three ground connections at the front of the transmission

To install:

10. Install or connect the following: Transmission. Torque the transmission-to-engine bolts to 55 ft. Ibs. (75 Nm). Right transmission bracket. Torque the bolt to 55 ft. Ibs. (75 Nm). Torque converter bolts. Torque the bolts to 47 ft. Ibs. (63 Nm). Flexplate cover. Torque the bolts to 20 ft. Ibs. (27 Nm). Transmission brace to the engine. Torque the bolts to 44 ft. Ibs. (60 Nm). Transmission main wiring harness Three ground connections to the transmission Front engine-to-transmission pencil brace Engine-to-transmission bracket Exhaust heat shield Left and right halfshafts Engine frame. Torque the bolts to 142 ft. Ibs. (192 Nm). 11. Remove the frame support fixture. 12. Install or connect the following: e Rack and pinion. Torque the bolts to 48 ft. Ibs. (65 Nm). Front and rear transmission mounts. Torque the nuts to 48 ft.

e Both heater tube retainers from the upper case side cover

e e ¢ > e

Lower transmission oil cooler line Upper transmission oil cooler line Range selector cable and bracket Air intake duct Negative battery cable 15. Check and adjust the transmission fluid level.

16. Check the front end alignment.

4765-E TRANSMISSION

iF Before servicing the vehicle, refer to the precautions in the beginning of this section.

2. Install a suitable engine support fixture

3. Remove or disconnect the following: Negative battery cable Air cleaner assembly Transaxle electrical connector Shift contro! cable bracket with cable attached Upper transaxle case-to-engine bolts Upper bolt from the rear transaxle mount

Oxygen (02S) sensor connector Engine frame Left and right drive axles from the transaxle Torque converter cover Flywheel-to-torque converter bolts Input Speed Sensor (ISS) electrical

connectors Engine-to-transaxle brace Transaxle fluid filler tube Right transaxle mount Remaining transaxle-to-engine

Ibs. (65 Nm).

¢ Power steering line brackets. Torque the bolts to 53 inch Ibs. (6 Nm). Air deflector Left and right splash shields ¢ AIR pumps

¢ ABS module

¢ Lower ball joints 13. Remove the engine support fixture. 14. Installorconnect the following: Vacuum reservoir Upper transmission bolts. Torque

bolts

¢ Transaxle from vehicle To install: 4. Install or connect the following: ¢ Transmission. Torque the transmission-to-engine bolts to 55ft. Ibs. (75 Nm).

¢ Right transmission bracket. Torque

the bolt to 55 ft. Ibs. (75 Nm). e Transaxle fluid filler tube ° Engine-to-transaxle brace and

the bolts to 55 ft. Ibs. (75 Nm).

Transmission vent hose Rack and pinion electrical connector VSSto the transmission WSS electrical connector Ground wire at the rear of the transmission Coolant temperature sensor electrical connector

e

tighten to 44 ft. Ibs. (60 Nm) ISS electrical connectors Flywheel-to-torque converter bolts and tighten to 47 ft. Ibs. (63 Nm) Torque converter cover Left and right drive axles from the transaxle Engine frame and tighten the 6 frame insulator bolts to 142 inch Ibs. (192 Nm) 02S sensor connector Upper transaxle case-to-engine

G-BODY—GENERAL MOTORS CORPORATION

RIVIERA ¢ AURORA 24-41

bolts and tighten to 55 ft. Ibs. (75 Nm) Upper bolt from the rear transaxle mount and tighten to 42 ft. Ibs. (58 Nm) Shift control cable bracket with cable attached Transaxle electrical connector Air cleaner assembly ¢ Negative battery cable 5. Check and adjust the transmission fluid level. 6. Check the front end alignment.

REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Front wheel e Sway bar link kit e Lower ball joint e Halfshaft hub nut e Halfshaft from the hub e>Once the halfshaft is clear of the knuckle, swing the strut assembly rearward.

e Halfshaft from the transmission using a slide hammer and adapter To install: 3. If installing the right side halfshaft, install a tear away axle seal protector over the seal. 4. Install or connect the following: e Halfshaft into the transmission ->Be sure the joint is properly seated by grasping the inboard joint and making sure it won't pull out of the trans-

yeecas 1 TRANSAXLE 2

B

mission. DO NOT pull on the shaft itself or the inboard joint can become damaged.

e Halfshaft through the hub. Torque the nut to 107 ft. Ibs. (145 Nm). e Ball joint to the steering knuckle. Torque the castle nut to 41 ft. Ibs. (55 Nm). e>|f necessary to align the cotter pin holes, rotate the nut up to an additional 60 degree turn. NEVER loosen the nut to align the holes.

e Sway bar link kit. Torque the bolt to 13 ft. Ibs. (17 Nm). 5. Remove the tear away seal protector. Be sure no pieces of the protector remain in the transmission. 6. Install the front wheel and torque the nuts to 100 ft. Ibs. (140 Nm).

9306XG15

Positioning the inner CV-joint boot seal and swage ring—Inner (tri-pod) joint J 41048

REMOVAL & INSTALLATION Inner (Tri-Pod) Joint 9306XG16

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Front wheel Halfshatt Swage ring Large CV-joint boot clamp CV-joint boot by sliding it away from the tri-pod joint Tri-pod housing from the tri-pod spider Trilobal tri-pod bushing from the housing Inboard spacer ring slide, it rearward on the shaft Outboard retaining ring Tri-pod joint spider assembly

View of the swage ring crimping tool— Inner (tri-pod) joint

9306XG17

Boot measurement—Inner (tri-pod) joint

5 TO 7 O'CLOCK HANDLE POSITION

RH ORIVE AXLE 7922XG20

Installing the right side axle with the tear away seal protector

9306XG18

9306XG14

Crimping the large CV-joint boot ring—

Exploded view of the inner (tri-pod) joint

Inner (tri-pod) joint

For Wheel Alignment specifications, see Section 1 of this manual

24-42

GENERAL MOTORS CORPORATION—G-BODY RIVIERA ¢ AURORA

e Inboard spacer ring and CV-joint boot To install: 3. Install or connect the following: ¢ Swage ring clamp e CV-joint boot 4. Position the CV-joint boot seal into the axle shaft’s joint seal groove and align the swage ring clamp on the boot. 5. Secure the swage ring clamp as follows: a. Mount the lower half of tool J41048 in a vise. b. Position the outboard of the halfShaft in the tool. c. Position the upper end of tool J41048 onto the lower halt.

2k WARNING Make sure that there are no pinch points on the inboard seal. d. Insert both bolts and tighten by hand until snug. é. Tighten each bolt 180 degree (7) turn at a time, alternating between the bolts, until both sides are bottomed. f. Remove the tool. 6. Install or connect the following: e Inboard spacer ring slide it rearward on the shaft Tri-pod joint spider assembly onto the shaft Outboard retaining ring into the axle shaft groove Tri-pod joint spider assembly, slide it against the outboard retaining ring Inboard spacer ring Ya kit grease into the boot Ya kit grease into the tri-pod housing Trilobal tri-pod bushing flush with the tri-pod housing face New large seal clamp onto the CVjoint boot Tri-pod housing, slide it over the tri-pod joint spider assembly CV-joint boot/clamp, slide it into place over the trilobal tri-pod bushing with the seal lip in the groove e»Make sure the boot lies flat against the trilobal bushing.

Outer Joint

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Front wheel Halfshaft Swage ring Large boot clamp C\V-joint boot, slide it away from the CV-joint CV-joint assembly by spreading the inner race-to-axle shaft retaining ring ears CV-joint boot from the axle shaft 3. Disassemble the chrome alloy balls from the CV-joint cage as follows: a. Position a brass drift against the CV-joint cage and tap it with a hammer to tilt the cage. b. Remove the 1st chrome alloy ball from the cage. c. Tilt the cage in the opposite direction. d. Remove the opposite chrome alloy ball. e. Repeat the procedure until all 6 balls are removed. 4. Disassemble the CV-joint cage and inner race as follows: a. Pivot the cage and race 90 degrees to the center line of the outer race. b. Align the cage windows with outer race lands, C. Remove the cage from the outer race.

d. Rotate the inner race upward and remove it from the cage. To install: 5. Lubricate the parts with a light coat of grease. 6. Assemble the CV-joint cage and inner race, as follows: a. Rotate the inner race 90 degrees to the cage centerline. b. Align the cage windows with inner race lands. c. Insert the inner race into the cage by rotating the inner race downward. d. Insert the cage/inner race into the outer race. 7. Assemble the chrome alloy balls into the CV-joint cage, as follows: a. Position a brass drift against the CV-joint cage and tap it with a hammer to tilt the cage. b. Insert the 1st chrome alloy ball into the cage. c. Tilt the cage in the opposite direction. d. Insert the opposite chrome alloy ball. e. Repeat the procedure until all 6 balls are inserted. 8. Install or connect the following: ¢ Y2kit grease into the CV-joint boot ¢ Yekit grease into the CV-joint

9306XG21

View the cage and inner race—Outer CVjoint 9306XG19

Disconnecting the outer CV-joint from the axle shaft

/. Position the CV-joint boot so it measures 4.9 in. (125mm). 8. Using a crimp tool, a torque wrench and a breaker bar, crimp the large CV-joint boot clamp to 130 ft. Ibs. (176 Nm). 9. Install or connect the following: ¢ Halfshaft ¢ Front wheel

9306XG20

Tilting the cage—Outer CV-joint

Position edge of seal here 9306XG22

Positioning the boot—Outer CV-joint

G-BODY—GENERAL MOTORS CORPORAT RIVIERA e oa ¢ Swage ring clamp e CV-joint boot e CV\-joint onto the axle shaft until the retaining ring seats into the groove 9. Position the C\-joint boot seal into the axle shaft’s joint seal groove and align the swage ring clamp on the boot. 10. Secure the swage ring clamp as follows: a. Mount the lower half of tool J41048 in a vise. b. Position the outboard of the halfshaft in the tool.

c. Position the upper end of tool J41048 onto the lower half.

Make sure that there are no pinch points on the inboard seal.

d. Insert both bolts and tighten by hand until snug. e. Tighten each bolt 180 degree (¥2) turn at a time, alternating between the bolts, until both sides are bottomed. f. Remove the tool. 11. Install or connect the following:

STEERING AND SUSPENSION DISARMING

«:k 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,

1. Turn the steering wheel so the vehicle wheels are pointing straight-ahead. 2. Turn the ignition key to the LOCK position and remove the key. 3. Remove the AIR BAG fuse from the fuse block. 4. Remove the left side sound insulator. 5. Detach the Connector Position Assurance (CPA) and yellow 2-way Supplemental

steering column, instrument pane! 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. PRECAUTIONS Several precautions must be observed when handling the inflator module to avoid accidental deployment and possible personal injury. e 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 way. : Place the inflator module on a bench or other surface with the bag and trim cover facing up. e With the inflator module on the bench, never place anything on or close to the module, which may be thrown in the event of an accidental deployment.

CONNECTOR, SIR BRACKET, MULTIUSE MODULE CONNECTOR POSITION ASSURANCE CONNECTOR, STEERING COLUMN Fun WIRING HARNESS

(CPA)

7922XG21

SRS 2-way connector location—driver’s side

24-43

e New large seal clamp onto the CVjoint boot e C\V-joint boot/clamp, slide it into place over the outer race with the Seal lip in the groove e> Make sure the boot lies flat against the outer race.

12. Using a crimp tool, a torque wrench and a breaker bar, crimp the large CV-joint boot clamp to 130 ft. Ibs. (176 Nm). 13. Install or connect the following: e Halfshatt e Front wheel

: Inflatable Restraint (SIR) connector at the multi-use bracket near the base of the steering column. The driver's side air bag is now disabled. 6. Remove the right side sound insulator. 7. Detach the Connector Position Assurance (CPA) and yellow 2-way SIR connector at the base of the steering wheel. The passenger’s side air bag is now disabled.

ARMING — After necessary repairs are made, reenable the air bag system as follows: 1. Be sure the ignition is locked and the key is removed. 2. Attach the yellow 2-way Supplemental Inflatable Restraint (SIR) connector and Connector Position Assurance (CPA) at the base of the steering wheel. 3. Install the right side sound insulator. 4. Attach the yellow 2-way SIR connector and Connector Position Assurance (CPA) at the multi-use bracket at the base of the column. 5. Install the left side sound insulator. 6. Install the AIR BAG fuse. 7. Turn the ignition switch to the RUN position and verify the AIR BAG light flashes 7 times, then shuts off.

Power Rack-and Pinion Steering Gear REMOVAL & INSTALLATION OO

1 MODULE, INFLATOR 2 BRACKET, MULTIUSE 3 CONNECTOR, SIR

SRS 2-way connector location—passenger’s side

Except Aurora

1. Before servicing the vehicle, refer to the precautions in the beginning of this section.

1 of this manual For Maintenance Interval recommendations, see Section

24-44

GENERAL MOTORS CORPORATION—G-BODY RIVIERA e AURORA

2. Lock the steering wheel in the straight-ahead position. 3. Remove or disconnect the following: e Front wheel ¢ Outer tie rod end from the steering knuckle Exhaust pipe from the rear manifold Intermediate exhaust pipe hangers Intermediate shaft from the rack and pinion stub shaft Rack and pinion heat shield Magnasteer®electrical connector Power steering lines from the rack and pinion and cap them Rack and pinion-to-chassis bolts 4. Support the rear of the subframe. 5. Remove both rear subframe-to-chassis bolts. 6. Lower the frame enough to remove the rack and pinion assembly. 7. Remove the rack and pinion assembly through the right side wheel well. To install: 8. Install or connect the following: e Rack and pinion through the right side wheel well ¢ 3 rack and pinion-to-chassis bolts, do not tighten ¢ Subframe. Torque the bolts to 142 ft. Ibs. (192 Nm). 9. Remove the subframe support. 10. Install or connect the following: e Rack and pinion bolts. Torque the bolts in sequence to 48 ft. Ibs. (65 Nm). e»Start with the vertically installed bolt closest to the pinion housing and work toward the passenger side of the vehicle.

* Power steering lines to the rack and pinion. Torque the fittings to 20 ft. lbs. (27 Nm). Magnasteer®electrical connector Rack and pinion heat shield Intermediate shaft to the rack and Pinion stub shaft. Torque the pinch bolt to 35 ft. Ibs. (47 Nm). Exhaust pipe to the exhaust manifold Intermediate exhaust pipe hangers Tie rod ends to the steering knuckles. Torque the castle nuts to 35 ft, lbs. (47 Nm). e*lif necessary to align the cotter pin holes, tighten the nut up to an additional 60 degree turn. NEVER loosen the castle nut to align the cotter pin holes.

e Front wheel. Torque the nuts to 100 ft. Ibs. (140 Nm).

o> Whenever the vehicle sub-frame is removed or lowered, the front wheel alignment should be checked.

11. Refill and bleed the power steering system. Check for leaks. 12. Check the front end alignment and adjust as necessary. Aurora

1. Before servicing the vehicle, refer to the precautions at the beginning of this section.

*-k CAUTION

9346UG09

Steering gear mounting bolts—Aurora

Make sure the wheels of the vehicle are straight ahead and the steering column in the LOCK position before disconnecting the steering column or intermediate shaft from the steering gear. Failure to do so will cause the coil assembly in the steering column to become uncentered which will cause damage to the coil assembly. pais Sale ae DL le ci Iapes Sl a 2. Lock the steering column by installing the Steering Column Anti Rotation Pin tool J 42640 into the underside of the steering column. 3. Disconnect negative battery cable. 4. Remove or disconnect the following; ¢ Intermediate shaft lower coupling e Pressure and return pipes from the rack and pinion gear e Electrical connector, if equipped ¢ Stabilizer shaft links at lower control arms 9. Rotate the stabilizer shaft to access Steering gear bolts. ¢ Rack and pinion attaching bolts e Rack and pinion assembly To install: 6. Install or connect the following:

e Rack and pinion assembly and tighten the bolts to 70 ft. Ibs. (95 Nm) e Electrical connector, if equipped ¢ Pressure and return lines to the steering gear and tighten the fittings to 22 ft. Ibs. (30 Nm) e Heat shield and bolts. Tighten the bolts to 7 ft. Lbs. (10 N) 7. Align stabilizer shaft. e Links to lower control arms ¢ Intermediate shaft to the steering gear and tighten the pinch bolt to 33 ft. Ibs. (45 Nm) 8. Remove the steering column anti rotation pin from the steering column. 9. Fill and bleed the power steering system.

REMOVAL & INSTALLATION i Front

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 Anti-lock Brake System (ABS) wheel speed sensor electrical connector

9346UG08

Lock the steering column by installing the Steering Column Anti Rotation Pin tool J 42640 into the underside of the Steering

column—Aurora

ABS speed sensor bracket from the Strut Brake line bracket, if removing the left strut 3. Matchmark the lower strut bracket to the steering knuckle. 4. Support the steering knuckle, 9. Remove or disconnect the following: ° Lower strut bracket nut and through-bolts ¢ 3 upper strut plate mounting nuts and washers ¢ Strut from the vehicle

G-BODY—GENERAL MOTORS CORPORATION RIVIERA e AURORA 24-45 2. Support the lower control arm at such a height that the upper shock bolts will still be accessible. 3. Remove or disconnect the follow-

ing:

1 2

NUTS, 47 Nm (35 LB. FT.) WASHER

3. NUTS, 185 Nm (136 LB. FT.) 4 5

KNUCKLE BOLT

Rear wheel Electronic Level Control (ELC) air tube from the shock Both lower shock mount bolts Trunk trim panel to access the upper shock mount bolts Upper shock cap Both upper shock mount nuts and reinforcement e Shock To install: 4. Install or connect the following: e Shock Reinforcement and upper shock mounting nuts. Torque the nuts to 15 ft. Ibs. (20 Nm). Upper shock cap and inner trunk trim Lower shock bolts. Torque the bolts to 18 ft. Ibs. (24 Nm). ELC air tube to the shock Rear wheel. Torque the nuts to 100 ft. Ibs. (140 Nm).

6 STRUT

Coil Spring

7922XG23

Exploded view of the upper and lower strut mounting components

REMOVAL & INSTALLATION

To install: 6. Install or connect the following: e Strut, do not tighten the upper strut plate-to-body nuts e Lower strut through-bolts by aligning the matchmarks. Torque the nuts to 136 ft. Ibs. (185 Nm). 7. Remove the steering knuckle support. 8. Install or connect the following: Brake line bracket to the strut, if removed ABS wheel speed sensor bracket on the strut ABS sensor electrical connector Front wheel. Torque the nuts to 100 ft. Ibs. (140 Nm). Upper strut plate nuts. Torque the nuts to 35 ft. Ibs. (47 Nm). Negative battery cable 9. Check the front end alignment and adjust as necessary.

Shock Absorber

i (sti

REMOVAL & INSTALLATION Rear

1. Before servicing the vehicle, refer to the precautions in the beginning of this section.

Front

1. Remove the strut from the vehicle. 2. Disassemble the strut as follows: a. Step 1: Place the strut assembly into compressor tool, to compress the coil spring. b. Step 2: Compress the spring Slightly. c. Step 3: Hold the strut shaft from turning using a No. 50 Torx® socket and remove the 24mm nut on the top end of the strut.

SHOCK U-NUTS

CONTROL ARM BOLTS 24 Nem (18 LB. FT.) COVER NUTS 20 Nem (15 LB. FT.) REINFORCEMENT MOUNT, UPPER ~~ OMOnNnnFranrds 7922XG34

Exploded view of the rear shock mounting

7922UG19

Use a Torx® socket to keep the piston rod from turning while removing the upper nut—tront strut shown

manual For Tune-up, Capacities and Firing orders, see Section 1 of this

24-46

GENERAL MOTORS CORPORATION—G-BODY RIVIERA e AURORA

d. Step 4: Install the top strut nut. Torque the nut to 55 ft. Ibs. (75 Nm). e. Step 5: Remove the strut from the compressor. Rear

7922UG18

Install Rod J 34013-38 to help guide the Strut shaft from the upper mount assembly—front strut shown

d. Step 4: Install Rod tool J 34013-38 to help guide the strut shaft from the upper mount assembly. d. Step 5: Loosen the spring compresSor tool until the coil spring and mount can be removed as an assembly. Remove the lower spring insulator, if equipped. To install: 3. Assemble the strut as follows: a. Step 1: Place the strut in compresSor tool. b. Step 2: Install the coil spring over the strut. C. Step 3: Compress the coil spring while guiding strut shaft through the top of the strut assembly.

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Support the lower control arm. 3. Remove or disconnect the following: e Rear wheel e Electronic Level Control (ELC) air tube from the shock absorber ¢ Both lower shock absorber-to-control arm bolts e Adjustment link outer bal! stud nut e Ball stud from the knuckle 4. Lower the control arm until the arm bottoms out on the rear suspension support. 9. Using a suitable prying tool, pry under the lower spring insulator to unseat it from the control arm. 6. Remove or disconnect the following: e Insulator and coil spring ¢ Upper spring insulator, if necessary To install: 7. Install or connect the following: e Upper spring insulator, if removed e> Engage the retainer on the back of the insulator in the upper mount hole. ->Be sure to seat the lower insulator in the control arm hole.

e>lf necessary to align the cotter pin holes, tighten the nut up to an additional 60 degree (1) turn. NEVER loosen the castle nut to align the cotter pin holes. ¢ ELC air tube to the shock absorber

¢ Rear wheel. Torque the nuts to 100 ft. Ibs. (140 Nm).

Lower Ball Joint REMOVAL & INSTALLATION Sen TERS PERE Is 7922XG35

Exploded view of the rear coil Spring and related components

Exploded view of the lower control arm— Front suspension

Lower Control Arm

REMOVAL & INSTALLATION Front

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: ¢ Front wheel © Sway bar link kit ->Take note of the positions of the washers and insulators for installation purposes.

¢ Lower ball joint from the steering knuckle

¢ Coil spring and lower insulator

8. Raise the control arm into position. 9. Install a or connect the following: e Lower shock absorber-to-control arm bolts. Torque both bolts to 18 ft. Ibs. (24 Nm). e Adjustment link ball stud to the knuckle. Torque the castle nut to 36 — Ibs. (50 Nm), ft.

JOUNCE BUMPER SPRING LOWER SPRING INSULATOR CONTROL ARM unr Wp — RETAINER

9306XG23

e

The ball joint is an integral part of the

control arm. If defective the control arm must be replaced.

Be careful not to overextend the half-

Shaft tri-pod joint.

¢ Lower control arm-to-engine frame nuts and bolts ¢ Lower control arm To install: 3. Install or connect the following: ¢ Lower control arm, do not tighten the nuts and bolts ¢ Lower ball joint to the steering knuckle. Torque the castle nut to 41

ft. Ibs. (55 Nm),

elf necessary, tighten the castle nut up to an additional 60 degree (1% turn to align the cotter pin holes. NEVER loosen the nut to make the alignment.

° Sway bar link kit. Torque the nut to 13 ft. Ibs. (17 Nm). ¢ Front wheel. Torque the nuts to 100 ft. Ibs. (140 Nm). 4. Lower the vehicle in order to achieve proper trim height, 9. On all except Aurora, torque the lower control arm-to-frame rear bolt to 117 ft. Ibs. (158 Nm) and the lower control arm-toframe front nut to 93 ft. Ibs. (126 Nm)

G-BODY—GENERAL MOTORS CORPORATI TER EEO

9306XG24

Exploded view of the support assembly— Rear suspension

6. On Aurora, torque the lower control arm-to-frame rear bolt to 117 ft. Ibs. (158 Nm) and the lower control arm-to-frame front nut to 117 ft. Ibs. (158 Nm). Rear

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Rear wheels e Exhaust system e Coil springs e Parking brake cable from the brake calipers Brake calipers from the control arms Parking brake cable from the rear suspension support assembly Support assembly electrical connectors Electronic Level Control (ELC) electrical connector and vent hose ELC air tube from the air compresSor 3. Support the rear suspension support assembly. 4. Remove or disconnect the following: ¢ 3 support bracket-to-chassis bolts at each side Both front and both rear support assembly bolts

Support assembly ELC height sensor link from the left control arm Stabilizer link bolt and nut Anti-lock Brake System (ABS) electrical connector Wheel/hub assembly

e Lower control arm-to-rear suspension support assembly nuts and bolts e Lower control arm To install: 5. Install or connect the following: Lower control arm Lower control arm-to-rear suspension support assembly nuts and bolts, do not tighten Wheel/hub assembly ABS electrical connector Stabilizer link nut and bolt. Torque the nut to 11 ft. Ibs. (15 Nm). ELC height sensor link to the left control arm Support assembly Both front and both rear support assembly bolts. Torque the front support assembly bolts to 141 ft. lbs. (191 Nm) and the rear support assembly bolts to 122 ft. Ibs. (165 Nm). 3 support bracket-to-chassis bolts at each side. Torque the bolts to 63 ft. bs. (86 Nm). ELC air tube from the air compresSor ELC electrical connector and vent hose Support assembly electrical connectors Parking brake cable to the rear suspension support assembly Brake calipers to the control arms

Parking brake cable to the brake calipers

Coil springs Exhaust system Rear wheels. Torque the nuts to 100 ft. Ibs. (140 Nm). 6. Lower the vehicle in order to achieve proper trim height.

24-47

J 21474 -—27

9306XG26

Installing the bushing to the lower controi arm—Front suspension

7. Torque the lower control arm nuts to 78 ft. Ibs. (106 Nm).

CONTROL ARM BUSHING REPLACEMENT Front

EXCEPT AURORA—FRONT The rear (horizontal) control bushing is replaced with the control arm and cannot be replace separately. 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Front wheel ¢ Lower control arm 3. Assemble the bushing tools as follows: a. Position the Bolt Assembly tool J21474-27 with a washer, through the Bushing Receiver tool J-21474-5 with the larger diameter end over the bushing against the control arm. b. Lubricate the bolt threads with high pressure lubricant. c. Install the Bushing Remover tool J-

J 41014-1

J 21474-27

9306XG25

nt suspension Removing the bushing from the !ower control arm—Fro

Labor Guide For complete service labor times, order Nichols’ Chilton

24-48

GENERAL MOTORS CORPORATION—G-BODY RIVIERA e AURORA

NNN

41014-1 (large end facing the bushing), the thrust bearing and Nut J-21474-4 onto the Bolt Assembly J-21474-27. 4. Tighten the nut until the bushing is driven from the control arm. 5. Remove the tools. To install: 6. Start the new busing into the control arm. 7. Assemble the bushing tools as follows: a. Position the Bolt Assembly tool J21474-27 with a washer, through the Bushing Receiver tool J-21474-5 with the larger diameter end over the bushing against the control arm. b. Lubricate the bolt threads with high pressure lubricant. c. Install the Bushing Installer tool J21474-13 (large end facing the bushing), the thrust bearing and Nut J-21474-4 onto the Bolt Assembly J-21474-27, 8. Tighten the nut until the bushing is fully seated in the control arm. 9. Remove the tools. 10. Install or connect the following: ¢ Lower control arm ¢ Front wheel

Ee

J 21474 -13

ee

J 2147427 9306XG28

Installing the bushing to the lower control arm—Rear suspension

tee

ie

J 21474—4

J 21474 —27

Taga

AURORA—REAR The control arm bushings are not a serviceable component and if found to be defective the control arm assembly must be replaced. 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Rear wheel ¢ Lower control arm 3. Assemble the bushing tools as follows:

a. Assemble the Puller Bolt/Thrust Bearing tool J-21474-19 through the Bushing Receiver tool J-14014-2 over the bushing against the control arm. b. Lubricate the bolt threads with high pressure lubricant. C. Install the Bushing tool J-22222-2 (with the small end facing the bushing) and the Long Nut J-21474-18 onto the Puller Bolt/Thrust Bearing tool J-2147419. 4. Tighten the Long Nut J-21474-18 until the bushing is pressed from the control arm. 9. Remove the bushing tools. To install: 6. Start the bushing onto the control arm. -»Position the bushing flat vertical and rearward.

9306XG27

Removing the bushing from the lower control arm—Rear suspensi on

On 1” 2

3

DUST SHIELD WHEEL SPEED SENSOR CONNECTOR STEERING KNUCKLE

4

HUB AND

BEARING

NUT, DRIVE AXLE. 145 Nem (107 LB. FT.)

oO

RETAINING BOLT, 95 Nm (75 LB. FT.)

Exploded view of the front hub mounting and related components

G-BODY—GENERAL MOTORS 7. Assemble the bushing tools as follows: a. Position the Puller Bolt/Thrust Bearing tool J-21474-19 through the Bushing Receiver tool J-14014-2 over the bushing against the control arm. b. Lubricate the bolt threads with high pressure lubricant. c. Install the Bushing Installer too! J-28685 (large end facing the bushing) and Long Nut J-21474-18 onto the Puller Bolt/Thrust Bearing tool J21474-19. 8. Tighten the Puller Bolt/Thrust Bearing tool J-21474-19 until the bushing is fully seated in the control arm. 9. Remove the tools. 10. Install the lower control arm. 11. Install the front wheel.

CORPORATI Ant

24-49

. 2. Remove or disconnect the following:

Wheel Bearings

e Negative battery cable

ADJUSTMENT The wheel bearings are not adjustable. If the wheel bearings are defective, the hub and bearing assembly must be replaced.

REMOVAL & INSTALLATION

e Front wheel 3. Lubricate the threads on the halfshaft with clean engine oil. 4. Remove or disconnect the following: e Halfshaft hub nut

¢ Caliper from the steering knuckle

Front

The front wheel bearings are not serviced separately. If the front wheel bearings are defective, the hub and bearing assembly must be replaced. 1. Before servicing the vehicle, refer to the precautions in the beginning of this section.

DO NOT allow the brake hose to support the weight of the caliper. Brake rotor Anti-lock Brake System (ABS) sensor from the backing plate Hub and bearing assembly from the backing plate Hub and bearing assembly from the halfshatt Hub and bearing assembly To install: 5. Install or connect the following: Hub and bearing assembly onto the halfshaft Hub and bearing assembly to the backing plate. Torque the 3 bolts alternately and evenly to 70 ft. Ibs. (95 Nm). ABS sensor Brake rotor Caliper on the steering knuckle. Torque the bolts to 38 ft. Ibs. (51 Nm). Halfshaft nut. Torque it to 107 ft. lbs. (145 Nm) on all Riviera and 1998-99 Aurora models or 118 ft. los. (160 Nm) on 2001 Aurora models. e Front wheel. Torque the nuts to 100 ft. Ibs. (140 Nm). e Negative battery cable Rear

BOLT HUB & BEARING BRAKE SHIELD REAR SUSPENSION > PWN ASSEMBLY CONTROL ARM On

SUPPORT

7922XG37

The rear wheel bearings are not serviced separately. If the rear wheel bearings are defective, the hub and bearing assembly must be replaced. 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 9. Remove or disconnect the following: ¢ Negative battery cable e Rear wheel e Caliper and bracket assembly from the brake rotor

related components Exploded view of the rear hub mounting and

Please visit our web site at www.chiltonsonline.com

24-50

GENERAL MOTORS CORPORATION—G-BODY RIVIERA e AURORA

DO NOT allow the brake hose to support the weight of the caliper and bracket. SL ee Dh ia e Brake rotor

e Anti-lock Brake System (ABS) sensor electrical connector

e Hub and bearing assembly from the rear control arm To install: 3. Install or connect the following: ¢ Hub and bearing assembly onto the control arm, loosely install the bolts ¢ ABS sensor electrical connector ¢ Hub and bearing bolts. Torque the

bolts alternately and evenly to 52 ft. lbs. (70 Nm). Brake rotor Caliper and bracket assembly. Torque the bolts to 35 ft. Ibs. (48 Nm). Rear wheel. Torque the nuts to 100 ft. Ibs. (140 Nm). Negative battery cable

GENERAL MOTORS CORPORATION—J-BODY 1998-01 Chevrolet-Cavalier « Pontiac-Sunfire DRIVE TRAIN.................. 25-21 ENGINE-REPAIR 20.3 22 25-2 FUELSSYOREN crete ose. 25-18 PRECAUTIONS...::............. 25-2

STEERING AND

Removal & Installation............ 25-19 nck cree nie 20-20 Fuel tiiGCtoremense Removal & Installation............ 25-20 FUCL PUM ee tng ne eee 25-19

Removal & Installation............ 25-19

P PISTON anc RING erate tne 25-17 meee ee 25-17 POSITIONING recess R

Rack and Pinion Steering Gear....25-2/

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Removal & Installation............ 25-15 ROCKERAIINS vx: tenets eset 25-10 Removal & Installation............ 20-10

C Camshaft and Valve Lifters .......... 25-12 Removal & Installation............ 25-12

| rithm RIG) ek os, ee cere: 25-2 oe. 25-2 PC IUSUMEN eee own carte

Removal & Installation............ 25-13 eae 25-28 STUTET, Es ee Removal & Installation............ 20-28

Removal & Installation............ 25-22

Removal & Installation............ 25-10

Timing Chain, Sprockets,

L DOWer Balin ore mice: 25-30 Removal & Installation............ 25-30 Lower Control ArM ou... 25-31

Front Cover and Seal................-. 20-16 Removal & Installation............ 25-16 Transmission Assembly ..............- 25-21 Removal & Installation............ 29-21

Arm Bushing Control Replacement:.:civt samuel:

25-31

Valve Lash gut canadien tiem fer ghtanen beac: 20213

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Removal & Installation............ 25-32

29-2

GENERAL MOTORS CORPORATION CAVALIER ¢ SUNFIRE

NN

_ PRECAUTIONS Before servicing any vehicle, please be sure to read all of the following precautions, which deal with personal safety, prevention of component damage, and important points to take into consideration when servicing a motor vehicle: e Never open, service or drain the radiator or cooling system when the engine is hot; serious burns can occur from the steam and hot coolant. ¢ Observe all applicable safety precautions when working around fuel. Whenever servicing the fuel system, always work ina well-ventilated area. Do not allow fuel spray OF vapors to come in contact with a spark, open flame, or excessive heat (a hot drop light, for example). Keep a dry chemical fire extinguisher near the work area. Always keep fuel in a container specifically designed for fuel storage; also, always properly seal fuel containers to avoid the possibility of fire or explosion. Refer to the additional fuel system precautions later in this section. ¢ Fuel injection systems often remain pressurized, even after the engine has been turned OFF. The fuel system pressure must be relieved before disconnecting any fuel lines. Failure to do so may result in fire and/or personal injury. ¢ Brake fluid often contains polyglycol ethers and polyglycols. Avoid contact with the eyes and wash your hands thoroughly after handling brake fluid. If you do get brake fluid in your eyes, flush your eyes with clean, running water for 15 minutes. If eye Irritation persists, or if you have taken

brake fluid internally, IMMEDIATELY seek medical assistance. ¢ The EPA warns that prolonged contact with used engine oil may cause a number of skin disorders, including cancer! You should make every effort to minimize your exposure to used engine oil. Protective gloves should be worn when changing oil. Wash your hands and any other exposed Skin areas as soon as possible after expoSure to used engine oil. Soap and water, or waterless hand cleaner should be used. ¢ All new vehicles are now equipped with an air bag system, often referred to as a Supplemental Restraint System (SRS) or Supplemental Inflatable Restraint (SIR) 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 repairs. e Always wear safety goggles when working with, or around, the air bag system. When carrying a non-deployed air bag, be Sure the bag and trim cover are pointed away from your body. When placing a nondeployed air bag on a work surface, always face the bag and trim cover upward, away from the surface. This will reduce the motion of the module if it is accidentally deployed. Refer to the additional air bag system precautions later in this section. ¢ Clean, high quality brake fluid from a sealed container is essential to the safe and

| Alternator

REMOVAL ee Lee SS enon 2.2L Engines

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Negative battery cable ¢ Accessory drive belt ¢ Alternator mounting bolts ¢ Alternator electrical connectors ¢ Alternator

2.4L Engines

1. Before servicing the vehicle, refer to the precautions in the beginning of this section.

proper operation of the brake system. You should always buy the correct type of brake fluid for your vehicle. If the brake fluid becomes contaminated, completely flush the system with new fluid. Never reuse any brake fluid. Any brake fluid that is removed from the system should be discarded. Also, do not allow any brake fluid to come in contact with a painted surface; it will damage the paint. e Never operate the engine without the proper amount and type of engine oil: doing So WILL result in severe engine damage. ¢ Timing belt maintenance is extremely important! Many models utilize an interference-lype, non-freewheeling engine. If the timing belt breaks, the valves in the cylinder head may strike the pistons, causing potentially serious (also time-consuming and expensive) engine damage. Refer to the maintenance interval charts in the front of this manual for the recommended repiacement interval for the timing belt, and to the timing belt section for belt replacement and inspection. e Disconnecting the negative battery cable on some vehicles may interfere with the functions of the on-board computer system(s) and may require the computer to undergo a relearning process once the neg-

ative battery cable is reconnected. ¢ When servicing drum brakes, only disassemble and assemble one side at a time, leaving the remaining side intact for reference. ¢ Only an MVAC-trained, EPA-certified automotive technician should service the air conditioning system or its components.

ENGINE REPAIR

2. Remove or disconnect the following: e Negative battery cable ¢ Accessory drive belt ¢ Alternator electrical connectors ° Power steering line clip ¢ Rear alternator brace ¢ Alternator mounting bolts ¢ Alternator

INSTALLATION sen 2.2L Engines

Install or connect the following: ¢ Alternator. Torque the bolts to 37 ft lbs. (50 Nm), e Alternator electrical connectors ¢ Accessory drive belt ¢ Negative battery cable

2.4L Engines

Install or connect the following: ¢ Alternator ¢ Alternator mounting bolts. Torque the bolts to 37 ft. Ibs. (50 Nm). Rear alternator brace Power steering line Clip Alternator electrical connectors Accessory drive belt Negative battery cable

Ignition Timing ADJUSTMENT SE Ne

ET

Ny Ignition timing is controlled by the Powertrain Control Module (PCM). No adjus tment is necessary or possible.

GENERAL MOTORS CORPORATION CAVALIER * SUNFIRE RA

EIS

SES STEPPE LE IETS SEISI

BEDE TERETE OSE

Engine Assembly REMOVAL & INSTALLATION 2.2L Engine

WITH MANUAL TRANSMISSION 1. Before servicing the vehicle, refer to e precautions in the beginning of this secion. 2. Relieve the fuel system pressure. 3. Drain the cooling system. 4. Remove or disconnect the following: Both battery cables Throttle body air inlet duct Upper radiator hose Vacuum hose from the power brake booster e Idle Air Control (IAC) valve electrical connector e Alternator electrical connectors e Throttle Position (TPS) sensor electrical connector Manifold Absolute Pressure (MAP) sensor electrical connector EVAP emission solenoid electrical connection Fuel injector electrical connectors Exhaust Gas Recirculation (EGR) valve electrical connector Engine Coolant Temperature (ECT) sender electrical connector Oxygen (02S) sensor electrical connector Engine grounds electrical connection Accessory drive belt

EES LE

LS

LIT PEE

SL STF

I

LSI

STUN SE

Shift control cable Coolant surge tank Vacuum line near the master cylinder 5. Install an engine support fixture. Lower radiator hose Wheels Wheel well splash shields Exhaust pipe from the manifold Engine mount strut Wheel Speed Sensor (WSS) electrical connection Ball joints from the steering knuckles Tie rod ends from the steering knuckles Brake lines from the suspension support Air conditioning compressor. DO NOT disconnect the lines.

Ignition Control Module (ICM) electrical connector Vehicle Speed Sensor (VSS) electrical connector Cooling fan electrical connector Starter electrical connector Oil pressure sensor electrical connector Power steering lines from the rack and pinion Intermediate shaft Accelerator and cruise control cables Rack and pinion bolts Suspension support extension brace Stabilizer bar Suspension support Heater hoses Halfshafts from the transmission Fuel lines Transmission mount Engine mount 6. Remove the engine support fixture. 7. Remove or disconnect the following:

GSA TIES EE SI DEI BEE SEE

I

29-3 EET EO EEL TT LETTE

Engine and transmission assembly from the vehicle Engine from the transmission To install: 8. Install or connect the following: Transaxle to the engine. Torque the bolts to 55 ft. Ibs. (75 Nm). Engine and transmission assembly to the vehicle Engine support fixture Engine mount. Torque the bolts to 49 ft. Ibs. (66 Nm). Transmission mount. Torque the bolts to 49 ft. Ibs. (66 Nm). Halfshafts Heater hoses Fuel lines Suspension support. Torque the bolts to 71 ft. Ibs. (110 Nm) plus an additional 90 degree turn. Stabilizer bar. Torque the bolts to 49 ft. Ibs. (66 Nm). Suspension support extension brace. Torque the bolts to 53 ft. Ibs. (72 Nm). Rack and pinion bolts. Torque the bolts to 89 ft. Ibs. (120 Nm). Accelerator and cruise control cables Intermediate shaft. Torque the pinch bolt to 30 ft. Ibs. (41 Nm). Power steering lines Ignition module electrical connector

VSS electrical connector Cooling fan electrical connector Starter electrical connector Oil pressure sensor electrical con-

nector A/C compressor. Torque the front bolts to 33 ft. Ibs. (45 Nm) and the rear bolt to 48 ft. Ibs. (65 Nm). Brake lines to the suspension support Tie rod ends to the steering knuckles. Torque the nuts to 7 ft. Ibs. (10 Nm) plus an additional 120 degree turn. Ball joints to the steering knuckles. Torque the nuts to 46 ft. Ibs. (62

Nm). WSS electrical connector

9300YG01

Exploded view of the upper engine mount—2.2L engine

9300YG02

Exploded view of the lower engine mount and strut—2.2L engine

Engine mount strut. Torque the bolts to 74 ft. Ibs. (100 Nm) plus an additional turn of 90 degrees. Exhaust pipe to the manifold. Torque the bolts to 26 ft. Ibs. (35 Nm). Wheel well splash shields

on Labor Guide For complete service labor times, order Nichols’ Chilt

29-4

GENERAL MOTORS CORPORATION CAVALIER ¢ SUNFIRE

1 Cylinder Block 2 Flywheel [e) Flywheel Retainer 4 Flywheel Bolt 5 Clutch Pressure Plate Bolt 6 Clutch Pressure Plate Washer % Clutch Pressure Plate 8 Clutch Disc 9 Oil Pump Drive Bolt

10 11 12 13

14 15 16 17 18 19 20 21 22 23 24

Oil Oil Oil Oil

Pump Drive Pump Drive Shaft Pump Drive Shaft Retainer Pump

Crankshaft Rear Oil Seal Crankshaft Crankshaft Bearing Crankshaft Thrust Bearing Main Bearing Cap Main Bearing Cap Crankshaft Bearing Cap Bolt Oil Pan Stud Connecting Rod Nut Oil Pan Bolt Connecting Rod Nut

25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44

Oil Pan Drain Plug Gasket Oil Pan Drain Plug Oil Pan Nut Oil Pan Oil Pan Rear Seal Crankshaft Pulley Bolt Crankshaft Pulley Hub Bolt Crankshaft Pulley Hub Bolt Washer Crankshaft Pulley Bracket Bolt Starter Motor Bracket Nut Starter Motor Bracket Nut Starter Motor Bracket Starter Motor Starter Motor Shim Starter Motor Bolt Starter Motor Bolt Crankshaft Pulley Hub Crankshaft Front Oil Seal Crankcase Front Cover Bolt 45 Crankcase Front Cover 46 Timing Chain 47 Crankshaft Sprocket 48 Camshaft Sprocket

930006

Exploded view of the crankshaft and related components—2.2 L engine

e Wheels ¢ Lower radiator hose 9. Remove the engine support fixture. 10. Install or connect the following; Coolant surge tank. Torque the

bolts to 89 inch Ibs. (10 Nm).

Shift control cable Accessory drive belt 02S electrical connector ECT sender electrical connector EGR valve electrical connector Fuel injector electrical connectors MAP sensor electrical connector TPS sensor electrical connector Alternator electrical connector IAC electrical connector Brake booster vacuum hose

¢ Upper radiator hose ¢ Throttle body air inlet duct ¢ Both battery cables 11. Refill the cooling system. 12. Start the engine and check for proper operation,

WITH AUTOMATIC TRANSMISSION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the engine oil and coolant. 3. Recover the refrigerant from the A/C system. 4. Matchmark the bolts and remove the hood. 9. Remove or disconnect the following:

Both battery cables Air cleaner assembly Brake booster vacuum line Fuel injector sight shield Accelerator and cruise control cables Engine wiring harness Cruise control module A/C line from the accumulator Accessory drive belt Coolant surge tank Upper and lower radiator hoses Fuel feed and return lines from the engine Coolant pipe assembly Wheels Wheel well splash shields Engine mount strut Torque converter dust cover Exhaust pipe from the manifold Starter motor A/C compressor and bracket Torque converter bolts Transmission-to-engine support brace Upper front engine mount Transmission-to-engine bolts Transmission from the engine 6. Lift the engine from the vehicle, To install:

7. Position the engine in the vehicle, and hand tighten the upper transmission bolts. 8. Install or connect the following: Transmission-to-engine bolts. Torque the bolts to 43 ft. Ibs. (58 Nm). Upper front engine mount. Torque the bolts to 55 ft. Ibs. (75 Nm). Transmission-to-engine brace. Torque the bolts to 71 ft. Ibs. (96 Nm). Torque converter bolts. Torque the

bolts to 46 ft. Ibs. (62 Nm). A/C compressor bracket

A/C compressor. Torque the bolts to 37 ft. Ibs. (50 Nm). Starter motor. Torque the bolts to 37 ft. Ibs. (50 Nm). Exhaust pipe to the manifold. Torque the bolts to 26 ft. Ibs. (35 Nm). Torque converter dust cover Engine mount strut. Torque the bolts to 74 ft. Ibs. (100 Nm) plus an additional turn of 90 degrees. Wheel well splash shields Wheels Coolant pipe assembly Fuel feed and return lines Upper and lower radiator hoses Coolant surge tank. Torque the

bolts to 89 inch Ibs. (10 Nm)

~

GENERAL MOTORS CORPORATION :

CAVALIER ¢ SUNFIRE

29-0

e Accessory drive belt

e e e e

A/C line to the accumulator Cruise control module Engine wiring harness Accelerator and cruise control cables e Brake booster vacuum line

Air cleaner assembly Hood. Torque the bolts to 15 ft. Ibs. (20 Nm). Battery cables 9. Evacuate and recharge the A/C sys-

em. 10. Refill the engine oil and coolant. 11. Start the engine and check for leaks. 12. Install the fuel injector sight shield. 2.4L Engine

WITH MANUAL TRANSMISSION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Discharge and recover the air conditioning refrigerant. 3. Properly drain the cooling system and engine oil. 4. Relieve the fuel system pressure. 5. Remove or disconnect the following: ¢ Both battery cables e Clutch pushrod from the pedal assembly e Heater hose at the thermostat housing Upper radiator hose Air cleaner assembly

Coolant fan Refrigerant hose assembly at the compressor Both vacuum hoses from the front of the engine Alternator electrical connector Air conditioning compressor electrical connector Fuel injector harness

9300YG03

Exploded view of the upper engine mount—2.4L engine

9300YG04

Exploded view of the lower engine mount and strut—2.4L engine

Clutch actuator line Exhaust manifold and heat shield Lower radiator hose 6. Install an engine support fixture.

Idle Air Control (IAC) electrical connector

Throttle Position (TPS) sensor electrical connector Manifold Absolute Pressure (MAP) sensor electrical connector Intake Air Temperature (IAT) sensor electrical connector Evaporative Emissions (EVAP) canister purge solenoid electrical con-

7. Remove or disconnect the following:

nector Negative battery cable from the transaxle Electronic ignition module electrical connector Engine Coolant Temperature (ECT) sensors electrical connectors Oil pressure sensor/switch electrical connector

Oxygen (02S) sensor electrical connector Crankshaft Position (CKP) sensor electrical connector Back-up lamp switch electrical connector Power brake vacuum hose from the throttle body Throttle cable and bracket Power steering pump and move it aside with the lines attached Fuel lines Shift cables

om Please visit our web Site at www.chiltonsonline.c

Coolant recovery/surge tank, move it aside with the hoses attached Engine strut mount Front wheels Right splash shield

Vehicle Speed Sensor (VSS) electrical connector Knock Sensor (KS) electrical connector Starter solenoid electrical connector Both front Anti-lock Brake System (ABS) wheel speed sensor electrical connectors Engine mount strut Transmission mount Ball joints from the steering knuckles e Suspension supports, crossmember and stabilizer shaft as an assembly Heater outlet hose from the radiator outlet pipe e° Halfshaft from the transmission and intermediate shaft Flywheel housing cover 8. Position a suitable support below the

25-6

GENERAL MOTORS CORPORATION CAVALIER ¢ SUNFIRE

a

ee

engine, then carefully lower the vehicle onto the support. 9. Raise the vehicle slowly off the engine/transaxle assembly. h pertay ba necessary to move the it | mbly rearward to yee ANS sey Glear-the Intake manifold.

e e ¢ e

Clutch actuator line Shift cables Fuel lines Power steering pump. Torque the bolts to 22 ft. Ibs. (30 Nm). Throttle cable and bracket

e Vacuum hoses to the intake mani-

fold and the brake booster

10. Remove the engine from the

¢ Back-up lamp switch electrical con-

transaxle. To install:

nector ¢ CKP sensor electrical connector * (oS electrical connector ¢ Oil pressure sensor/switch electri-

Pick WARNING

Be sure the retaining bolts are in

cal connector

their correct locations. If not, engine damage may occur.

e ECT Sensors electrical connectors e Electronic ignition module electrical connector ¢ Negative battery cable to the transaxle . EVAP canister purge solenoid electrical connector

e IAT sensor electrical connector

¢ MAP sensor electrical connector ¢ e ¢ e

TPS sensor electrical connector IAC sensor electrical connector Fuel injector harness Air conditioning compressor elec-

trical connector

11. Install or connect the following: Engine to the transaxle. Torque the mounting bolts to 55 ft. Ibs. (75

m) Engine/transaxle assembly under the vehicle, then lower the vehicle over the assembly Engine support fixture, making sure to adjust it to the previous setting Halfshafts to the transaxle Heater outlet hose to the radiator outlet pipe Suspension supports, crossmember and stabilizer shaft assembly. Torque the bolts to 53 ft. Ibs. (72 Nm) Ball joints to the steering knuckles. Torque the nuts to 44 ft. Ibs. (60 Nm) plus an additional turn of 180

degrees.

19

¢ Engine mount assembly. Torque the bolts to 46 ft. Ibs. (62 Nm). ¢ Transmission mount. Torque the bolts to 66 ft. Ibs. (90 Nm). ¢ Both front ABS wheel speed sensor

electrical connectors ¢ Starter solenoid electrical connector e

KS electrical connector

;

1 Balance Shaft Chain Cover Bolt

° VSS electrical connector

2 Balance Shaft Chain Cover

¢ Right splash shield

3 Balance Shaft Guide Adjuster Nut

e Front wheels 12. Carefull ;

y raise the vehicle off the

Support.

.

13. Install or connect the following: '

° Se ae ean Torque the Olts to 74 ft. Ibs. (100 Nm).

¢ Coolant recovery/surge tank

¢

Lower radiator hose :

¢ Exhaust manifold. Torque the nuts to 31 ft. Ibs. (42 Nm).

e

Exhaust manifold heat shield.

Torque the bolts to 19 ft. Ibs. (26 Nm).

4 Balance Shaft Chain Guide Adjuster Bolt Shaft Chain Adjuster Guide

Balance 65 Stud

7 Balance Shaft Upper Housing

8 Balance Shaft Thrust Plate Retainer Bolt 9 Balance Shaft Bearings

10 Balance Shaft Thrust Plate Retainer 11 Balance Shaft Drive

Thread.

ket Bolt-

a

21 Balance Shaft Housing Bolt Bolt

22 Oil Pan 23 Oil Pan

24 Oil Pan Gasket

25 Dowel Pin

26 Oil Pump Body

27 Gerotor

29 Oil Pump Cover to Body Bolt

13 Balance Shaft Drive Chain s

19 Balance Shaft Housing to Block Bolt

20 Balance Shaft Housing to Block Bolt

28 Oil Pump Cover

12 Balance Shaft Driven

14 Dri

17 Balance Shaft Housing Bolt

18 Balance Shaft Housing to Block Bolt

:

30 Relief Valve Pin

eet

15 Balance Shaft Driven Sprocket

16 Balance Shaft Lower Housing

i

i

i

2 shed valve sone vert 33 Relief Valve

34 Pickup Screen

9300¥G09 Exploded view of the balance shafts and related components—2.4L engine

GENERAL MOTORS CORPORATION

CAVALIER ¢ SUNFIRE

Alternator electrical connector Refrigerant hose assembly to the compressor Coolant fan Air cleaner assembly Upper radiator hose Heater hose at the thermostat housing Clutch pushrod to the pedal assembly e Both battery cables 14. Refill the transaxle and the crankcase. 15. Evacuate and recharge the air conditioning system. 16. Refill the cooling system. 17. Start the engine and check for leaks.

WITH AUTOMATIC TRANSMISSION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Matchmark the bolts and remove the hood. 3. Drain the engine coolant. 4. Recover the refrigerant. 5. Drain the engine oil. 6. Relieve the fuel system pressure. 7. Remove or disconnect the following: Air cleaner assembly Brake booster vacuum line Fuel injector sight shield Accelerator and cruise control cables Engine wiring harness Cruise control module A/C line from the accumulator Accessory drive belt Coolant surge tank Upper and lower radiator hoses Fuel feed and return lines Coolant pipe assembly Wheels Wheel well splash shields Engine mount strut Torque converter cover Exhaust pipe from the manifold Starter motor A/C compressor Torque converter bolts Transmission-to-engine brace Upper front engine mount Transmission-to-engine bolts 8. Separate the engine from the transmission and lift the engine from the vehicle. To install: 9. Position the engine in the vehicle. 10. Hand tighten the upper transmission bolts.

11. Install or connect the following: Upper front engine mount. Torque the bolts to 46 ft. Ibs. (62 Nm). Lower transmission-to-engine bolts. Torque all bolts to 55 ft. Ibs. (75 Nm). Transmission-to-engine brace. Torque the bolts to 71 ft. Ibs. (96 Nm). Torque converter bolts. Torque the bolts to 46 ft. Ibs. (62 Nm). A/C compressor. Torque the bolts to 37 ft. Ibs. (60 Nm). Starter motor. Torque the bolts to 37 ft. Ibs. (50 Nm). Exhaust pipe to the manifold. Torque the bolts to 26 ft. Ibs. (35 Nm). Torque converter cover Engine mount strut. Torque the bolts to 74 ft. Ibs. (100 Nm). Wheel well splash shields Wheels Coolant pipe assembly Fuel feed and return lines Upper and lower radiator hoses Coolant surge tank Accessory drive belt

A/C line to the accumulator Cruise control module

25-7

e Engine wiring harness e Accelerator and cruise control cables e Brake booster vacuum line e Air cleaner assembly e Both battery cables 12. Refill the crankcase and cooling system. 13. Evacuate and recharge the A/C sys-

tem. 14. Install the hood. 15. Start engine and check for leaks. 16. Install the fuel injector sight shield.

Water Pump REMOVAL & INSTALLATION 2.2L Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the cooling system. 3. Remove or disconnect the following: ¢ Negative battery cable ¢ Water pump pulley bolts, loosen ¢ Accessory drive belt e Water pump pulley e Surge tank hose

1 BOLT — 25 N-m (18 LBS. FT.) 7922YG01

L engine Exploded view of the water pump mounting—2.2

l Timing belt service is covered in Section 3 of this manua

GENERAL MOTORS CORPORATION

20-

CAVALIER ¢ SUNFIRE

e Water pump bolts, pump and gasket To install: 4, Apply a thin bead of sealer around the outer edge of the water pump gasket seating area and place the gasket on the pump. 5. Install or connect the following: Water pump. Torque the bolts to 18 ft. Ibs. (25 Nm). Water pump pulley and handtighten the bolts Surge tank hose Accessory drive belt Water pump pulley bolts. Torque the bolts to 22 ft. Ibs. (30 Nm). 6. Connect the negative battery cable. 7. Refill and bleed the cooling system. 2.4L Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the cooling system. 3. Remove or disconnect the following: Negative battery cable Oxygen (02S) sensor electrical connector Upper exhaust manifold heat shield Exhaust manifold brace-to-manifold bolt Manifold-to-exhaust pipe spring loaded bolts Both radiator outlet pipe-to-water pump cover bolts Exhaust manifold pipe

DO NOT rotate the flex coupling more than 4 degrees or damage may occur. ¢ Radiator outlet pipe from the oil pan e Brake vacuum pipe from the camshaft housing ¢ Exhaust manifold from the cylinder head

1

TIMING

CHAIN

e Front cover e Timing chain tensioner e Water pump cover and water pump

as an assembly 4. Separate the water pump from the water pump cover. To install: 5. Install or connect the following: e Water pump with a new gasket to the cover and tighten the bolts finger-tight Lubricate the splines with clean grease

e Water pump and cover assembly using new gaskets and tighten the fasteners finger-tight 6. Torque the bolts in the following sequence; a. Pump assembly-to-chain housing nuts: 19 ft. Ibs. (26 Nm). b. Pump cover-to-pump assembly: 124 inch Ibs. (14 Nm). c. Cover-to-block, bottom bolt first: 19 ft. Ibs. (26 Nm). 7. Install or connect the following: Timing chain tensioner Front cover. Torque the bolts to 97 inch Ibs. (11 Nm). Exhaust manifold with a new gasket. Torque the bolts to 31 ft. Ibs. (42 Nm). Brake vacuum pipe to the camshaft housing Radiator outlet pipe to the water pump cover. Torque the bolts to 125 inch Ibs. (14 Nm). Radiator outlet pipe to the oil pan. Torque the bolts to 18 ft. Ibs. (25 Nm). Exhaust pipe to the manifold. Tighten the exhaust pipe flange bolts evenly and gradually to avoid binding, until fully seated. Torque the bolts to 26 ft. Ibs. (5 Nm). Exhaust manifold brace to the man-

HOUSING

HOUSING

fw

TO WATER

PUMP

COVER

WATER PUMP BODY ASM.

5 GASKET, WATER PUMP BODY TO WATER PUMP COVER 6 WATER PUMP COVER

10

LOWER POSITIONS 8 BOLT (M6 X 1 X 25) 9 BOLT (M6 X 1 X 90) 10 GASKET, WATER PUMP COVER TO BLOCK BOLTS, WATER PUMP COVER TO BLOCK (2)

Cylinder Head

:

REMOVAL & INSTALLATION 2.2L Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Relieve the fuel system pressure. 3. Drain the cooling system. 4. Remove or disconnect the following: e Accessory drive belt Air cleaner outlet duct Engine mount Intake manifold Exhaust manifold Engine Coolant Temperature (ECT) sensor electrical connector Power steering pump Radiator inlet pipe Spark plug wires Rocker arm cover e» Whenever valve train components are removed, keep them in order for installation purposes.

Rocker arms and pushrods ¢ Lifters Alternator rear brace and the alternator

Two sizes of bolts are used; note the location of each.

7922YG02

Exploded view of the water pump mounting and related components—2.4L engine

the coolant level.

Power steering pump Radiator inlet pipe Ignition coil assembly Accessory bracket Spark plug wires Cylinder head bolts

2 GASKET, TIMING CHAIN NUT (3)

ifold. Torque the bolts to 41 ft. Ibs. (56 Nm). e Upper heat shield. Torque the bolts to 125 inch Ibs. (14 Nm). ¢ 02S electrical connector e Negative battery cable 8. Refill the cooling system until it comes out of the heater hose outlet; then connect the heater hose. 9. Start the engine. Run the vehicle until the thermostat opens, refill the radiator and recovery tank, then turn the engine OFF. 10. Once the vehicle has cooled, recheck

¢ Cylinder head 9. Inspect the cylinder head and block Surface for cracks, nicks, heavy scratches and flatness.

29-9

GENERAL MOTORS CORPORATION CAVALIER * SUNFIRE To install: 6. Install or connect the following: Cylinder head with a new gasket and new cylinder head bolts. Torque the long bolts, in sequence to 46 ft. Ibs. (63 Nm) and the short bolts to 43 ft. lbs. (58 Nm) plus an additional 90 degree turn on all the bolts. Lifters Pushrods and rocker arms. Torque nuts to 22 ft. Ibs. (30 Nm). Rocker arm cover. Torque the bolts to 89 inch Ibs. (10 Nm). Spark plug wires Accessory bracket Ignition coil assembly Radiator inlet pipe Power steering pump. Torque the bolts to 22 ft. lbs. (80 Nm). ECT sensor electrical connector Exhaust manifold. Torque the nuts to 118 inch Ibs. (13 Nm). Alternator. Torque the bolts to 37 ft. lbs. (60 Nm). Intake manifold. Torque the bolts to 17 ft. Ibs. (24 Nm). Engine mount. Torque the bolts to 55 ft. Ibs. (75 Nm). Air cleaner outlet duct Accessory drive belt Negative battery cable (oan efill and bleed the cooling system. 8. Start the vehicle and inspect for leaks.

1. Long bolts 2. Short bolts 3. Stud 4. Numbers on gasket indicate torque sequence

7922YG03

Cylinder head torquing sequence—2.2L engine

BOLT-

CAMSHAFT HOUSING

TO CYLINDER HEAD

ft 15 N-m (11 Ibs. ft.)

PLUS TURN 90

BOLT eegetes

CAMS!

ae

HAFT HOUSING

15 N.m (11 bbs. ft.) PLUS TURN 30°

2.4L Engine

UD. efore servicing the vehicle, refer to the prec autions in the beginning of this section. 2. R elieve the fuel system pressure. oie 1D)rain the cooling system. 4. Remove or disconnect the following: Throttle body-to-air cleaner duct Heater inlet hose Throttle body heater hose Power brake vacuum hose from throttle body Manifold Absolute Pressure (MAP) sensor electrical connector intake Air Temperature (IAT) sensor electrical connector Evaporative Emission (EVAP) canister purge solenoid Camshaft Position (CMP) sensor electrical connector Intake manifold Exhaust manifold Ignition coil assembly CMP sensor Power steering pump

TO CAMSHAFT

Me

CAMSHAFT HOUSING Ne (INTAKE SHOWN)

DOWEL PIN (2)

en

Do not use abrasive pads to clean the cylinder head or block surfaces. An abrasive pad may damage the cylinder head and/or block.

5. Install or connect the following: ¢ Cylinder head with a new gasket. Torque the new bolts 1-8 to 40 ft. lbs. (54 Nm) and bolts 9-10 to 30 ft. Ibs. (40 Nm); then, turn all bolts an additional 90 degrees (Y% turn) in sequence. Upper radiator hose to coolant outlet Intake and exhaust camshaft housings Timing chain housing. Torque the bolts to 19 ft. Ibs. (26 Nm). Fuel rail with new o-rings. Torque the bolts to 19 ft. Ibs. (26 Nm). e Vacuum lineto the fuel pressure regulator ¢ Fuel injector electrical connectors e CMP Power steering pump. Torque the bolts to 19 ft. Ibs. (26 Nm). Oil pressure switch electrical connector

Transmission fluid level indicator tube Ignition coil assembly. Torque the bolts to 11 ft. Ibs. (15 Nm) plus an additional 30 degree turn. Exhaust manifold. Torque the bolts to 31 ft. Ibs. (42 Nm).

Intake manifold. Torque the bolts to 18 ft. Ibs. (24 Nm). Upper radiator hose MAP sensor electrical connector IAT sensor electrical connector Canister purge solenoid Power brake vacuum hose Throttle body heater hose Heater inlet hose Throttle body-to-air cleaner duct 6. Refill the coolant system. 7. Connect the negative battery cable. 8. Start the engine and check for leaks.

REMOVAL & INSTALLATION e»Place the components in a rack in order to be sure they are installed in the same location.

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: ¢ Negative battery cable * Rocker arm cover(s) ° Rocker arm nuts Rocker arm pivot ball(s) ¢ Rocker arm(s) e Pushrods To install: 3. Install the pushrods. 4. Coat the bearing surfaces of the rocker arms and pivot balls with camshaft lubricant.

2.2L Engine

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Properly relieve the fuel system pressure. 3. Remove or disconnect the following: Air cleaner inlet duct Air inlet resonator and bracket Throttle and cruise control cable from the throttle body Manifold Absolute Pressure (MAP) sensor Throttle Position (TPS) sensor Idle Air Control (IAC) valve Fuel supply line Throttle body Fuel inlet pipe Intake manifold To install: 4. Install or connect the following: Intake manifold with a new gasket. Torque the bolts/nuts, in sequence, to 18 ft. Ibs. (24 Nm). Fuel inlet pipe. Torque the bolts to 18 ft. Ibs. (24 Nm). Throttle body. Torque the bolts to 89 inch Ibs. (10 Nm). e Fuel supply line e e e ¢

MAP sensor TPS sensor IAC valve Cruise control and throttle cables to the throttle body e Air inlet resonator bracket and resonator e Air cleaner inlet duct ¢ Negative battery cable

7922YG09

Intake manifold tightening sequence—

2.2L engine

GENERAL MOTORS CORPORATION

CAVALIER © SUNFIRE 25-1 1

2.4L Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Properly relieve the fuel system pressure. 3. Drain the cooling system. 4, Remove or disconnect the following: e Manifold Absolute Pressure (MAP) sensor electrical connector Intake Air Temperature (IAT) sensor electrical connector Evaporative Emission (EVAP) canister purge solenoid electrical connector Fuel injector harness Fuel regulator vacuum hose EVAP canister purge solenoid to canister vacuum hose Air cleaner duct Accelerator control cable bracket Stud-ended alternator mount bolt Exhaust Gas Recirculation (EGR) pipe from the EGR adapter Intake manifold support brace Intake manifold To install: 5. Install or connect the following: Intake manifold with a new gasket. Torque the bolts/nuts, in sequence, to 18 ft. Ibs. (24 Nm). EGR pipe to the adapter. Torque the fasteners to 19 ft. Ibs. (26 Nm). Stud-ended alternator bolt Accelerator control cable bracket Fuel injector electrical connectors

2

1

3

46C090CD0C)D0C)95 6-@

oO7

TIGHTENING SEQUENCE

STUD - 12 NeM (100 LB. IN.) INTAKE. MANIFOLD GASKET INTAKE MANIFOLD BOLT - 24 NeM (17 LB. FT.) NUT -— 24 NeM (17 LB. FT.) Be Cs GOIN)

e Vacuum hoses to the fuel regulator and EVAP canister purge solenoid e MAP sensor electrical connector e \AT sensor electrical connector e EVAP canister purge solenoid electrical connector e Air cleaner duct e Negative battery cable 6. Refill the cooling system. 7. Start the engine and inspect for leaks.

Exhaust Manifold REMOVAL & INSTALLATION 2.2L Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the cooling system. 3. Remove or disconnect the following: Negative battery cable Oxygen (02S) sensor electrical connector Accessory drive belt

Alternator Radiator inlet pipe Exhaust pipe-to-exhaust manifold bolts Oil filler tube Heater outlet hose assembly-toexhaust manifold nut Exhaust manifold To install: 4. Install or connect the following: e Exhaust manifold with new gaskets. Torque the nuts to 115 inch Ibs. (13 Nm). Heater outlet hose assembly-toexhaust manifold nut. Torque the nut to 18 ft. Ibs. (25 Nm). Oil filler tube Exhaust pipe-to-exhaust manifold bolts. Torque the bolts to 26 ft. Ibs. (35 Nm). Radiator inlet pipe Alternator. Torque the bolts to 37 ft. lbs. (50 Nm). Accessory drive belt ¢ (02S sensor electrical connector e Negative battery cable 5. Refill the cooling system. 6. Start the engine and check for exhaust leaks.

2. Remove or disconnect the following: e Negative battery cable e Oxygen (02S) sensor electrical connector e Upper heat shield e Exhaust manifold brace-to-manifold bolt e Exhaust manifold-to-oil pan nuts ->Do not bend the exhaust flex coupler more than necessary to remove it. Excessive movement will damage the flex coupler.

e Exhaust pipe from the exhaust manifold e Exhaust manifold To install: 3. Install or connect the following: e Exhaust manifold with new gaskets. Torque the nuts to 110 inch Ibs. (12 Nm), in sequence. e Heat shield. Torque the bolts to 124 inch Ibs. (14 Nm). e Exhaust manifold brace-to-manifold bolt and oil pan nuts. Torque the bolts to 41 ft. Ibs. (56 Nm) and nuts to 19 ft. Ibs. (26 Nm). e Manifold-to-flex coupler fasteners. Torque the bolts to 26 ft. Ibs. (35 Nm). e 0S sensor electrical connector e Negative battery cable 4. Start the engine and check for exhaust leaks.

TIGHTENING SEQUENCE

1. 2. 3. 4,

STUD, EXHAUST MANIFOLD GASKET, EXHAUST MANIFOLD MANIFOLD, EXHAUST NUT, EXHAUST MANIFOLD, MUST BE TIGHTENED IN SEQUENCE SHOWN TO 12.5 Nem (110 LB. IN.) 7922YG11

7922YG08

L Intake manifold torque sequence—2.4 e engin

2.4L Engine

1. Before servicing the vehicle, refer to the precautions in the beginning of this section.

Exploded view of the exhaust manifold, showing the torque sequence—2.4L engine

manual Brake service is covered in Section 4 of this

290-12

GENERAL MOTORS CORPORATION CAVALIER ¢ SUNFIRE

Camshaft and Valve Lifters

REMOVAL & INSTALLATION

6. Install or connect the following: e Rocker arm cover. Torque the bolts to 89 inch Ibs. (10 Nm). Crankshaft pulley. Torque the bolts

to 37 ft. Ibs. (60 Nm). 2.2L Engine

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the engine oil and coolant. 3. Remove or disconnect the following: Engine Accessory drive belt Alternator Power steering pump Drive belt tensioner Water pump pulley Crankshaft pulley Rocker arm cover Pushrods, by pivoting the rocker arms to the sides, keeping them in Orders. Cylinder head Valve lifters, keeping them in order Front cover Camshaft timing sprocket Timing chain Timing chain tensioner Camshaft thrust plate Camshaft Position (CMP) sensor Camshaft from the block, being sure the lobes do not contact the bearings

Water pump pulley. Torque the bolts to 22 ft. Ibs. (30 Nm). Drive belt tensioner. Torque the bolts to 37 ft. Ibs. (50 Nm). Power steering pump. Torque the bolts to 22 ft. Ibs. (30 Nm). Alternator. Torque the bolts to 37 ft. lbs. (50 Nm). e Accessory drive belt e Engine 7. Replace the oil filter and refill engine with new oil.

8. Refill the cooling system.

2.4L Engine

INTAKE CAMSHAFT 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Relieve the fuel system pressure. 3. Remove or disconnect the following: Ignition coil and module assembly ° Camshaft Position (CMP) sensor electrical connector Power steering pump. DO NOT disconnect the lines. Fuel pressure regulator vacuum line : Fuel rail Timing chain housing, DO NOT remove from the engine Intake camshaft housing cover

To install:

The camshaft lobes and journals must be adequately lubricated or engine damage could occur upon Start up. 4. Install or connect the following: Camshaft, being careful not to contact the bearings with the cam lobes CMP sensor Camshaft thrust plate. Torque the bolts to 106 inch Ibs. (12 Nm). Timing chain and sprocket. Torque the bolts —to 96 ft. Ibs. (130 Nm). Timing chain tensioner. Torque the bolts to 18 ft. Ibs. (24 Nm). Front cover. Torque the bolts to 97 inch Ibs. (11 Nm). Valve lifters Cylinder head. Torque the long bolts to 46 ft. Ibs. (63 Nm) and the short bolts to 43 ft. Ibs. (68 Nm), plus an additional 90 degree turn on all bolts. Pushrods Rocker arms 9. Adjust the valve lash after installing the engine.

my The seal must be replaced any time the housing and cover are separated.

e Camshaft housing from the cylinder head To install: 4. Install or connect the following: e Lifters into their bores

The camshaft lobes and journals must be adequately lubricated or engine damage could occur upon start up. e Camshaft e Camshaft housing with a new gasket e New intake camshaft seal lubricated with engine oil ->The timing chain sprocket dowel pin should be straight up and align with the centerline of the lifter bores. Camshaft housing cover with a new gasket. Torque the bolts, in sequence, to 11 ft. Ibs. (15 Nm) plus an additional 90 degree turn (except for the 2 rear fuel pipe-tocamshaft housing bolts). Torque the 9 rear bolts to 11 ft. Ips. (15 Nm), plus an additional 30 degree turn. Timing chain housing and the timing chain Fuel rail with new injector o-rings e Vacuum line to the fuel pressure regulator Fuel injector harness connectors Power steering pump. Torque the

bolts to 22 ft. Ibs. (30 Nm). Camshaft position sensor Ignition coil/module assembly. Torque the bolts to 11 ft. Ibs. (15 Nm) plus 30 degrees. e Negative battery cable 5 Start the engine and check for leaks.

EXHAUST CAMSHAFT 1. Before servicing the vehicle, refer tothe precautions in the beginning of this section.

BS

ET

SRP

EIS

ED SESE

EE SERGE DN A RET

2. Relieve the fuel system pressure. 3. Remove or disconnect the following: e Ignition coil/module assembly e Oil pressure switch electrical connector Transaxle fluid level indicator tube assembly, (if equipped) from exhaust camshaft cover Timing chain housing; do not remove from the engine Exhaust camshaft cover Exhaust camshaft housing by reversing of the torque sequence 4. Press the cover off the housing by threading 4 housing-to-head bolts into the camshaft housing cover tapped holes. Tighten the bolts evenly so the cover does not bind on the dowel pins. 5. Remove the camshaft housing cover. 6. Loosely install a camshaft housingto-cylinder head bolt to retain the housing during camshaft and lifter removal. ->Note the position of the chain sprocket dowel pin for reassembly.

7. Remove or disconnect the following: e Lifters e Camshaft e Camshaft housing from the cylinder head To install: 8. Install or connect the following: e Camshaft housing with a new gasket on the cylinder head with 1 bolt loosely to hold it in place e Lifters

0 WARNING The camshaft lobes and journals must be adequately lubricated or engine damage could occur upon start up.

TRENT

WAT STE

TE

LSA

PRE IS ERE

SM

e Timing chain housing Transaxle fluid level indicator tube assembly to the exhaust camshaft cover Oil pressure switch electrical connector Ignition coil/module assembly. Torque the bolts to 11 ft. Ibs. (15 Nm) plus an additional 30 degrees. e Negative battery cable 9. Start the engine and check for leaks.

Valve Lash

ADJUSTMENT All of the engines are equipped with hydraulic valve lifters. There is no adjustment.

Starter Motor

—-

:

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 e Air inlet duct e Top starter bolt ¢ Lower starter bolt e Starter electrical connectors e Starter motor To install: 3. Install or connect the following: e Starter motor. Torque the bolts to 66 ft. Ibs. (90 Nm) (for 2.4L) or 37 ft. Ips. (50 Nm) (for the 2.2 L) e Starter electrical connectors e Air inlet duct to the throttle body ¢ Negative battery cable

e Camshaft

The timing chain sprocket dowel pin should be straight up and align with the centerline of the lifter bores. ~»Apply thread locking compound to the camshaft housing cover bolt threads.

e Camshaft housing cover with a new gasket. Torque the bolts, in sequence, to 11 ft. Ibs. (15 Nm) plus an additional 90 degree turn (except for the 2 rear fuel pipe-tocamshaft housing bolts). Torque the 2 rear bolts to 11 ft. Ibs. (15 Nm), plus an additional 30 degree turn.

9306YG02

Exploded view of the starter motor—2.4L engine

on 1 of this manual For complete Engine Mechanical specifications, see Secti

25-1 4 GENERAL MOTORS CORPORATION CAVALIER ¢ SUNFIRE

To install: 4, Place a 2mm bead of RTV sealer to the oil pan sealing surface except at the rear seal mounting surface. Using a new oil pan rear seal, apply a thin coat of RTV sealer on the end down to the ears. 5. Install or connect the following: e Oil pan with a new gasket. Torque the nuts and bolts to 89 inch Ibs. (10 Nm). Engine mount strut bracket. Torque the bolts to 49 ft. Ibs. (66 Nm). Starter motor and bracket. Torque the bolts to 37 ft. Ibs. (50 Nm). Right fender splash shield Right front wheel. Torque the nuts to 100 ft. Ibs. (140 Nm). Negative battery cable 6. Refill the crankcase. 7. Start the vehicle and verify no leaks.

REMOVAL & INSTALLATION 2.2L Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the engine oil. 3. Remove or disconnect the following: e Negative battery cable e Right front wheel e Right inner fender splash shield e Starter motor and bracket e Engine mount strut bracket e Oil pan

2.4L Engine

1 SEAL

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the engine oil. 3. Drain the cooling system. 4. Remove or disconnect the following: Negative battery cable Flywheel/converter cover Right wheel Right wheel well splash shield Accessory drive belt Air conditioning compressor lower bolts Transmission-to-engine brace Engine mount strut bracket Radiator outlet pipe bolts Radiator outlet pipe from the oil pan Oil pan to the flywheel cover bolt and nut Flywheel cover stud for clearance

VIEW A

2 BOLT, 10 Nem (89 LB. IN.)

3 OIL PAN

4 NUT, OIL PAN 10 Nem (89 LB. IN.) 7922YG32

Exploded view of the oil pan mounting and related components—2.2L engine

OIL PAN BOLT (M8 X 1.25 X 22) 24 Nm (18 LB.FT.)

OIL PAN BOLT (M8 X 1.25 X 80) 24 Nm (18 LB.FT.) OIL PAN

@FRT

OIL PAN BOLT (M6 X 1.00 X 25) 12 Nm (106 LB.IN.)

OIL PAN BOLT (M6 X 1.00 X 25) 12 Nm (106 LB.IN.) OIL PAN BOLT (M8 X 1.25 X 22) 24 Nm (18 LB-FT.)

STUD END OIL PAN BOLT 26 Nm (19 LB.FT.)

OIL PAN BOLT (M8 X 1.25 X 22) 24 Nm (18 LB.FT.)

7922YG12

Oil pan fastener torque specifications—2.4L engine

e Radiator outlet pipe from the lower radiator hose and oil pan e (il level sensor connector e Oil pan To install: 5. Inspect the oil pan gasket; it is reusable if not damaged. 6. Install or connect the following: Oil pan with the gasket. Torque the M8 bolts to 18 ft. Ibs. (24 Nm) and the M6 bolts to 106 inch Ibs. (12 Nm). Oil pan to the transmission nut Oil level sensor connector Radiator outlet pipe to the lower radiator hose and oil pan Exhaust manifold brace Radiator outlet pipe. Torque the bolts to 124 inch Ibs. (14 Nm). Engine mount strut bracket. Torque the bolts to 55 ft. Ibs. (75 Nm). Transmission to the engine brace Air conditioning compressor lower bolts. Torque the bolts to 37 ft. Ibs. (50 Nm). Accessory drive belt Right splash shield Right front wheel Flywheel/converter cover Negative battery cable 7. Refill the crankcase. 8. Refill the cooling system. 9. Start the vehicle and verify no leaks.

REMOVAL & INSTALLATION —_e—_———————

2.2L Engine

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the crankcase. 3. Remove or disconnect the following: e Negative battery cable e Oil pan ¢ Oil pump and extension shaft To install:

> WARNING A plastic extension shaft retainer connects the oil pump driveshaft to the oil pump. Heat the extension Shaft retainer in hot water prior to assembly. Be sure the retainer does not crack upon installation.

4. Fill the oil pump cavities with petroleum jelly before installing the gears into the pump body. 9. Install or connect the following:

GENERAL MOTORS CORPORATION

25-1 oe

CAVALIER ¢ SUNFIRE e (il pump. Torque the bolts to 40 ft. lbs. (54 Nm).

1 mm (0.04") BRASS FEELER GAUGE >

AY,

APPLY 3 LBS. OF PRESSURE AGAINST

7922YG14

Using a feeler gauge to check the chain

tension—2.4L engine

a. Remove the oil pump cover. b. Remove the pump gear. c. Remove the sub-assembly from the balance shaft assembly d. Remove the gerotor from the oil

1 Bracket

pump housing. e. Remove the oil pump from the bal-

oe: : Bg slot esata

ance shaft housing. f. Remove the pressure relief valve. To install: 7. Lubricate the gears with clean engine

5 Shaft 6 Retainer; Heat and water soak prior to installation 7 Bolt

8 Oil pump

'

9 Cylinder block

oll 79227613

Exploded view of the oil pump mounting to engine block—2.2L engine

e Extension shaft and oi! pump. Torque the oil pump-to-bearing cap bolt to 32 ft. lps. (43 Nm) and the upper oil pump drive bolt to 18 ft. lbs. (25 Nm).

e Oil pan e Negative battery cable 6. Refill the crankcase. 7. Start the engine and check ail pressure and check for leaks.

8. Assemble the oil pump as follows: a. Place the gerotor gear into the housing. b. Fill the oil pump cavities with petroleum jelly. c. Install the pressure relief valve using a %e in. deep well socket to seat the valve. d. Connect the pump housing to the balance shaft assembly. e. Install the pump cover. 9. Install or connect the following:

e Balance shaft chain tensioner and chain «>A brass feeler gauge must be used to ensure that correct measurements are obtained. If a steel gauge is used, it will not bend to conform to the guide and will allow for incorrect measurements.

10. Adjust the chain tension as follows: a. Insert a 0.40 in. ({mm) brass feeler between the chain guide and the chain. b. Press the guide against the chain using about 3 pounds of force. c. Torque the chain tensioner fastener to 115 inch Ibs. (13 Nm). 11. Install or connect the following: e Balance shaft chain cover. Torque the nut and bolt to 115 inch Ibs. (13 Nm). e (Oil pan ¢ Negative battery cable. 12. Refill the crankcase. 13. Start the vehicle and verify oil pressure and no leaks.

Rear Main Seal

REMOVAL & INSTALLATION 2.2L 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 e Transaxle e Clutch/pressure plate assembly, if equipped with a manual transmission

2.4L Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this sec-

tion. 9. 3. 4. 5.

Disconnect the negative battery cable. Install an engine support fixture. Drain the crankcase. Remove or disconnect the following: e Oil pan ¢ Balance shaft chain cover and tensioner

e Oil pump 6. Disassemble the oil pump as follows:

s

1 Balance shaft sub assembly

y

2 Bolt 12 Nm (106 Ib. In.) 3 Oll pump sub assembly 7922YG15

Exploded view of the oil pump assembly mounting—2.4L engine

this manual For Accessory Drive Belt illustrations, see Section 1 of

95-46 SENERAL MOTORS CORPORATION CAVALIER ¢ SUNFIRE

e Flywheel e Rear main bearing seal by prying it from the engine

Timing Chain, Sprockets, Front Cover and Seal :

->Be careful not to damage or scratch the seal mounting surfaces.

REMOVAL & INSTALLATION

To install: 3. Lubricate the new rear main bearing seal with engine oil. 4. Install or connect the following: New rear main bearing seal using seal installer J-34686 until its flush with the block Flywheel Clutch/pressure plate assembly, if equipped with a manual transmission e Transaxle Negative battery cable 5. Start the engine and check for leaks.

2.2L Engine

2.4L 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 Transaxle Clutch/pressure plate assembly, if equipped with a manual transmission Flywheel Seal housing and discard the gasket Oil seal from the transaxle side of the seal housing To install: 3. Clean and inspect the gasket mounting surfaces. 4. If necessary, add silicone sealer along the oil pan-to-cylinder block mating surface. 5. Lubricate the new rear main bearing seal with engine oil. 6. Install or connect the following: ¢ New rear main bearing seal into the seal housing using installer tool J36005 until its flush with the housing. Oil seal housing with a new gasket. Torque the bolts to 106 inch Ibs. (12 Nm). Flywheel, using new bolts. Torque the bolts to 22 ft. Ibs. (30 Nm) plus an additional 45 degree turn. ¢ Clutch/pressure plate assembly, if quipped with a manual transmis-

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Negative battery cable e Accessory drive belt e Drive belt tensioner 3. Install an engine support fixture. 4. Remove or disconnect the following: e Engine mount assembly e Alternator e Power steering pump and move it aside with the lines attached ¢ Oil pan e Crankshaft pulley/hub e Front cover

9300YG05

Exploded view of the accessory drive belt tensioner mounting—2.2L engine

1. Camsheit sarecket 2, Crankshaft sprocket

2.4L Engine

3. Timing chain tensioner A. Line up timing marks on surockets

with tabs on timing chain tensioner B. Remove pin otter timing chain is installed 7922Y616

e Transaxle ¢ Negative battery cable 7. Start the engine and check for leaks.

5. Position the No. 1 piston at Top Dead Center (TDC) of the compression stroke so the camshaft and crankshaft sprockets timing marks are aligned. 6. Remove or disconnect the following: e Timing chain tensioner ¢ Camshaft sprocket and chain as an assembly e Crankshaft sprocket, using a puller To install: 7. Lubricate the timing chain with clean engine oil. 8. Install the crankshaft sprocket, press it onto the crankshaft. 9. Install the timing chain over the camshaft sprocket, then around the crankshaft sprocket. Be sure the marks on the 2 sprockets are in alignment. Lubricate the thrust surface with Molykote® or equivalent. 10. Install or connect the following: e Camshaft sprocket. Torque the bolts to 96 ft. Ibs. (130 Nm). 11. Compress the timing chain tensioner spring. Insert a cotter pin or a nail into the hole in the tensioner to retain the timing chain tensioner shoe. e Chain tensioner. Torque the bolts to 18 ft. Ibs. (24 Nm). 12. Remove the cotter pin or nail from the hole in the tensioner. e Front cover with a new gasket. Torque the bolts to 97 inch Ibs. (11 Nm). Crankshaft pulley/hub. Torque the pulley bolts to 37 ft. Ibs. (50 Nm) and the hub bolt to 77 ft. Ibs. (105 Nm). Oil pan with new gaskets. Torque the nuts and bolts to 89 inch Ibs. (10 Nm). Power steering pump. Torque the bolts to 22 ft. Ibs. (30 Nm). Alternator. Torque the bolts to 37 ft. Ibs. (50 Nm). Engine mount assembly. Torque the bolts to 55 ft. Ibs. (75 Nm). 13. Remove the engine support fixture. 14. Install or connect the following: e Accessory drive belt tensioner. Torque the bolts to 37 ft. Ibs. (50 Nm). e Accessory drive belt ¢ Negative battery cable

Align the sprocket timing marks with the alignment tabs on the tensioner during timing chain installation—2.2L engine

et is recommended that the entire procedure be reviewed before attempting to service the timing chain.

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Disconnect the negative battery cable.

GENERAL MOTORS CORPORATION

CAVALIER © SUNFIRE 25-1 7

3. Drain the cooling system. 4. Install an engine support. 5. Remove or disconnect the following: Coolant surge tank Accessory drive belt Upper fasteners from the front cover Right engine mount and bracket Right front wheel Aare shield from the right wheel we Crankshaft balancer e Front cover 6. Rotate the crankshaft clockwise, as viewed from front of engine (normal rotation), until the camshaft sprocket's timing dowel pin holes align with the holes in the timing chain housing. The mark on the crankshaft sprocket should align with the mark on the cylinder block. The crankshaft sprocket keyway should point upwards and align with the center line of the cylinder bores. This is the normal timed position. 7. Remove or disconnect the following: e Timing chain guides e>Wake sure that all of the slack in the timing chain is above the tensioner assembly.

The timing chain must be disengaged from any wear grooves in the tensioner shoe in order to remove the shoe. Slide a screwdriver blade under the timing chain while pulling the shoe outward. e Tensioner assembly 8. Mark the crankshaft sprocket and the timing chain outer surface. e Timing chain To install: 9. Install the intake camshaft sprocket. Torque the bolt to 52 ft. Ibs. (70 Nm). -> Install the Special tool J 36008-A through the holes in the camshaft sprockets and into the holes in the timing chain housing. This positions the camshafts for correct timing.

10. If the camshafts are out of position and must be rotated more than Va turn in order to install the alignment dowel pins, perform the following: a. Rotate the crankshaft 90 degrees clockwise off Top Dead Center (TDC) in order to give the valves adequate clearance to open. b. Once the camshafts are in position

and the dowels installed, rotate the crankshaft counterclockwise back to TDC.

>: WARNING Do not rotate the crankshaft clock-

wise to TDC or valve and piston damage may occur. 11. Install the timing chain over the exhaust camshaft sprocket, around the coolant pump sprocket and around the crankshaft sprocket. 12. Remove the alignment dowel pin from the intake camshaft. Using tool J 39579, rotate the intake camshaft sprocket counterclockwise enough to slide the timing chain over the intake camshaft sprocket. Release the camshaft sprocket wrench. The length of chain between the 2 camshaft sprockets will tighten. If properly timed, the intake camshaft alignment dowel pin should Slide in easily. If the dowel pin does not fully index, the camshafts are not timed correctly and the procedure must be repeated. 13. Leave the alignment dowel pins installed. 14. With slack removed from the chain between the intake camshaft sprocket and the crankshaft sprocket, the crankshaft keyway and the cylinder block mark should be aligned. If not aligned, move the chain 1 tooth forward or rearward. Remove the slack and recheck marks. 15. Reload timing chain tensioner assembly to its 0 position as follows: a. Insert the tensioner plunger assembly into the tensioner housing. b. With the tensioner plunger fully extended, turn the complete assembly upside down on a flat surface. c. Press the bottom of the tensioner housing to compress the plunger into the housing until it is seated. d. Make sure that the plunger does not extend out of the tensioner housing more than 0.07 in. (1.7mm). e. Loosely install the tensioner assembly to the timing chain housing. 16. Install or connect the following: e Tensioner shoe on the stud. e Tensioner assembly by applying hand pressure on the timing chain tensioner shoe until the locking tab seats in the stud groove. Tighten the bolts to 89 inch Ibs. (10 Nm).

17. Release the tensioner plunger by firmly pressing a flat blade tool against the plunger face. 18. Remove tool J 36008-A from the camshaft sprockets. a. Rotate crankshaft clockwise 2 full rotations. Align crankshaft keyway with mark on cylinder block and reinstall alignment dowel pins. Alignment dowel pins will slide in easily if engine is timed correctly. 19. Install or connect the following: Timing chain guides New seal lubricated with engine oil Front cover using new gaskets. Tighten the nuts and bolts to 115 inch lbs. (13 Nm). Crankshaft balancer. Torque the bolt to 129 ft. Ibs. (175 Nm) plus a 90 degree turn. Right front wheel well splash shield Wheel Right engine mount bracket. Torque the bolts to 44 ft. Ibs. (60 Nm) plus an additional 60 degree turn. Right engine mount. Torque the bolts to 55 ft. Ibs. (75 Nm). 20. Remove the engine support. 21. Install or connect the following: e Accessory drive belt e Coolant surge tank e Negative battery cable 22. Refill the cooling system and check for leaks.

Piston and Ring POSITIONING CONNECTING ROD MATCHING NUMBERS

_ ack WARNING If the timing chain tensioner plunger is not released from the installation position, engine damage will occur upon start up.

oe

7922AG51

Connecting rod and cap installation. Be sure to matchmark the cap and rod prior to disassembly—2.2L and 2.41 engines

For Tire, Wheel and Ball Joint specifications, see Section 1 of this manual

20-1

GENERAL MOTORS CORPORATION CAVALIER © SUNFIRE

7922YG21

Exploded view of the rack and pinion steering gear mounting

c. Step 3: Front upper bolts to 71 ft. lbs. (110 Nm). d. Step 4: Rear inboard bolts to 71 ft. lbs. (110 Nm). 5. Install or connect the following: ¢ Intermediate shaft. Torque the pinch bolt to 30 ft. Ibs. (41 Nm). Brake pipes to the retainers on the front suspension crossmember Tie rod ends. Torque the nuts to 44 ft. Ibs. (60 Nm), use new cotter pins. Inlet and outlet hoses to the rack and pinion. Torque the fittings to 20 ft. Ibs. (27 Nm). e Wheels ¢ Negative battery cable 6. Refill and bleed the power steering system. 7. Check and/or adjust the toe setting. 8. Road test vehicle and verify no leaks.

¢ Brake line bracket, if necessary doe ¢ Strut from the steering knuckle. Matchmark the assembly before removal.

1 2 wy)

|

R S

!

eal!

Hy

REMOVAL & INSTALLATION ——eeeoooo

Front

(2) Clamp, Stabilizer Shaft

(3) Stabilizer Shaft

1. Before servicing the vehicle, refer to

the precautions in the beginning of this section.

oe 2. Remove the upper strut-to-b ody nuts

and/or bolts.

3. Support the front crossmember with jack stands. 4. Lower the vehicle so the weight of

(:

) Bolt, Vertical Bushing

) Bushing, ; Vertical

(10) Ball Joint

si Dial iE

Lower Spring Insulator

(13) Bushing, Control Arm (14) Lower Spring insulator

Strut Nut

(15) Suspension Support

Were eh

(

Spring

(12) Control Arm

(

li

( (ie oe an up (18) Nuti ee ( 9) Nut, Strut Dampener Shaft Rate Wash (oo; Strutrut Mount Mount and and Rate Washer ( (22) Upper Spring Insulator

(21) Spring Seat

(23)

Strut Bumper and Shield

Exploded view of the front suspension

Washer

i

saihieatienpeeee

Seal (Part of 5)

sie

Assemb!

ang

decid i

sanah eet Bolt

Bolt 7922YG22

GENERAL MOTORS CORPORATION

CAVALIER ¢ SUNFIRE

The steering knuckle MUST be supported to prevent axle joint overextension. To install: 8. Install or connect the following: e Strut to the steering knuckle, aligning the matchmarks made during removal. Torque the bolts and nuts to 133 ft. Ibs. (180 Nm). e Brake line bracket e Upper strut to the body, Torque the nuts/bolts to 18 ft. Ibs. (25 Nm). 9. Remove the jack stands from under the crossmember. 10. Install the front wheel. Torque the lug nuts to 100 ft. Ibs. (140 Nm).

Shock Absorber

:

3. Raise and safely support the rear axle with jack stands. 4. Remove or disconnect the following: e Wheel e Upper mounting bolts « Lower mounting bolt e Shock absorber To install: 5. Install or connect the following: e Shock Lower mounting bolt. Torque it to 51 ft. Ibs. (70 Nm). Upper mounting bolts. Torque them to 18 ft. Ibs. (25 Nm). e Wheel Rear compartment carpet 6. Road test the vehicle.

25-29

has strut mounting holes drilled for specific vehicle lines. 4. Compress the strut approximately 12 its height after initial contact with the top cap.

Never bottom the spring or damper rod!

5. Remove the nut from the strut damper shaft and place an alignment/guiding rod on top of the damper shaft. Use the rod to guide the damper shaft straight down

Coil Spring REMOVAL & INSTALLATION

REMOVAL & INSTALLATION

Front

Rear

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Open the deck lid and position the carpet out of the way.

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove the strut from the vehicle. 3. Mount the strut assembly into a strut compressor. Note that the strut compressor

1 WRENCH 2 SOCKET 3 STRUT ASSEMBLY

3

7922YG25

—

J 34013

Use a socket and a wrench to remove the damper shaft nut spring cap while compressing the spring

vie

J34013-27

(=> J 3289-20

= NO

1 2 3 4

SHOCK, COIL-OVER NUT BOLT, UPPER STRUT (2) BOLT, AXLE 7922YG23

Exploded view of the rear shock mounting

Ww

>

STRUT ASSEMBLY INSTALL LOCKING PINS THROUGH STRUT ASSEMBLY TIGHTEN NUTS UNTIL FLUSH WITH STRUT COMPRESSOR COMPRESSOR FORCING SCREW

1 2

STRUT COMPRESSOR STRUT ASSEMBLY 7922YG26

7922YG24

View of a typical strut assembly mounted in a compressor

Install the rod to guide the damper shaft straight down through the spring cap while compressing the spring

l Timing belt service is covered in Section 3 of this manua

20-3

GENERAL MOTORS CORPORATION CAVALIER ¢ SUNFIRE

3. Compress the spring. 4, Remove the nut.

STRUT MOUNT NUT STRUT MOUNT RATE WASHER SPRING SEAT SPRING UPPER INSULATOR JOUNCE BUMPER STRUT DUST SHIELD SPRING SPRING LOWER INSULATOR —DWN OW ON Uh & — STRUT 7922YG27

Exploded view of the front strut assembly

through the spring cap while compressing the spring. Remove the components. To install: 6. Mount the strut assembly in the strut compressor, using the bottom locking pin only. 7. Install the spring over the damper and swing the assembly up so the upper locking pin can be installed. 8. Install all shields, bumpers and insulators on the spring seat. 9. Install the spring seat on top of the spring. The spring seat flat should be facing the same direction as the centerline of the strut assembly spindle. 10. Install the guiding rod and turn the forcing screw while the guiding rod centers the assembly. When the threads on the damper shaft are visible, remove the guiding rod and install the nut. tighten the nut to 02 ft. Ibs. (70 Nm) on 1998-99 models and 34 ft. Ibs. (47 Nm) on 2000-01 models. 11. Remove the strut from the compressor. 12. Install the strut to the vehicle. Rear

1. Remove the shock absorber from the vehicle. 2. Place the shock absorber in a strut compressor tool using a shock adapter.

5. Slowly release the tension on the spring. 6. Remove the spring and shock absorber from the compressor. To install: 7. Place the shock absorber in the strut compressor. 8. Slide the spring over the shock absorber. 9. Install the spring seat on top of the spring. 10. Compress the spring just until threads are showing through the spring seat. 11. Install the retaining nut. Torque the nut to 52 ft. Ibs. (70 Nm). 12. Remove the shock from the compressor. 13. Install the shock/spring assembly onto the vehicle.

Lower Ball Joint

REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section.

Care must be exercised to prevent the axle shaft joints from being overextended. 2. Remove or disconnect the following: e Front wheel ¢ Stabilizer shaft link e Wiring harness from the lower control arm ¢ Lower ball joint from the steering knuckle 3. Drill out the 3 ball joint-to-lower control arm rivets as follows: a. Use an ¥ in. (3mm) drill bit to make a pilot hole through the rivets. b. Finish drilling rivets with a % in. (13mm) drill bit. c. Remove the rivets with a punch, if necessary. 4. Remove the ball joint from the steering knuckle. To install: 5. Install or connect the following: ¢ Ball joint into the control arm ¢ 3 new nuts/bolts. Tighten the

nuts/bolts to the specifications supplied with new ball joint e Ball joint to the steering knuckle.

_

1 2 3 4 S

SERVICE BALL JOINT BALL JOINT MOUNTING NUT LOWER CONTROL ARM STEERING KNUCKLE

BOLTS

2

6 NUT — 55 N-m (41 LBS. FT.) MINIMUM TORQUE 65 N-m (48 LBS. FT.) MAXIMUM TORQUE TO INSTALL

PIN

7 PIN Exploded view of the ball joint mounting

7922YG28

GENERAL MOTORS CORPORATION CAVALIER ¢ SUNFIRE 25-31 Torque the nuts to 50 ft. Ibs. (65 Nm), use a new cotter pin. ¢ Wiring harness to the lower control

arm ¢ Stabilizer shaft link. Torque the nuts to 13 ft. Ibs. (17 Nm). e Front wheel 6. Check and/or adjust the front wheel alignment.

Lower Control Arm

REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Front wheel

e Stabilizer shaft link e Ball joint from the steering knuckle e Wiring harness from the lower control arm e Lower control arm To install: 3. Install or connect the following: e Lower control arm to the crossmember. DO NOT torque the bolts at this time. ¢ Wiring harness to the lower control arm e Ball joint to the steering knuckle. Torque the nut to 50 ft. Ibs. (65 Nm), use a new cotter pin. e Stabilizer shaft link. Torque the nut to 13 ft. Ibs. (17 Nm). e Front wheel 4. Lower the vehicle and allow it to assume proper trim height. 5. Torque the front control arm bolt to 79 ft. Ibs. (107 Nm) and the rear bolt to 81 ft. Ibs. (110 Nm) on 1998-98 models or 125 ft. lbs. (170 Nm) on 2000-01 models. 6. Check and/or adjust the front wheel alignment.

CONTROL ARM BUSHING REPLACEMENT Front Bushing 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Front wheel e Lower control arm and place it ina vise 3. Lubricate the threads of tool J-2147419 with High Pressure Lubricant J-23444-A. 4. Assemble % in. Bolt J-21474-19, Remover/Installer tool J-41397-1A, Remover/Installer tool J-41397-2A and ¥% in. Nut J-21474-18 onto the lower control arm bushing. 5. Tighten the ¥ in. Nut J-21474-18 to press the front bushing from the lower control arm. 6. Disassemble the tools. To install: 7. Lubricate the outer case of the new front bushing. 8. Insert the new front bushing into the lower control arm.

9. Assemble ¥% in. Bolt J-21474-19, Remover/Installer tool J-41397-1A, Remover/Installer tool J-41397-2A and ¥% in. Nut J-21474-18 onto the lower control arm. 10. Tighten the % in. Nut J-21474-18 to press the bushing into the lower control arm. 11. Disassemble the tools.

Rear Bushing 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Front wheel ¢ Lower control arm and place it ina vise 3. Lubricate the threads of tool J21474-27 with High Pressure Lubricant J23444-A. 4. Assemble bolt J-21474-27, Remover/Installer tool J-41211-1, Remover/Installer tool J-41211-3 and ¥% in. Nut J-21474-4. 5. Tighten the Bolt J-21474-27 to press the rear bushing from the lower control arm. 6. Disassemble the tools. J 21474 -27 J41211-1

J 4121-3

J 21474-4

J 21474-18

9306YG22

9306YG24

Removing the lower control arm front

Removing the lower control arm rear

bushing

bushing

J 21474 -27

J 21474-19

J 4i211-1

J 41397 -1A J 41397 - 2A

J 42-3

J 21474-4

9306YG25

9306YG23

9306YG21

View of the lower control arm

Installing the lower control arm front

bushing

Installing the lower control arm rear bushing

Heater Core replacement is covered in Section 2 of this manual

25-32

GENERAL MOTORS CORPORATION CAVALIER ¢ SUNFIRE

To install: 7. Insert the rear lower control arm bushing. 8. Assemble bolt J-21474-27, Remover/Installer tool J-41211-1, Remover/Installer tool J-41211-3 and 1% in. Nut J-21474-4. 9. Tighten the Nut J-21474-4 to press the rear bushing into the lower control arm. 10. Disassemble the tools.

Wheel Bearings ADJUSTMENT These vehicles are equipped with sealed hub and bearing assemblies. The hub and bearing assemblies are non-serviceable. If the assembly is damaged, the complete unit must be replaced.

4. Road test the vehicle and verify proper operation. Rear

HUB AND BEARING ASSEMBLY STEERING KNUCKLE WASHER DRIVE AXLE NUT - 260 N-m (192 LBS. FT.) HUB AND BEARING RETAINING BOLT — aQanrwn WASHER 7922YG29

Exploded view of the front hub and bearing assembly

->The top rear mounting bolt will not clear the brake shoe when removing the hub and bearing assembly. Partially remove the hub and bearing assembly prior to removing this bolt.

REMOVAL & INSTALLATION Front

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: ¢ Front wheel ¢ Halfshaft nut ¢ Brake caliper without disconnecting the fluid line ¢ Brake rotor e 3 hub/bearing assembly-to-steering knuckle bolts

1

2 3

REAR AXLE ASSEMBLY BACKING

PLATE

4

HUB AND BEARING ASSEMBLY

5>

BOLT 7922YG30

Exploded view of the rear hub and bearing assembly

¢ Hub/bearing assembly from the steering knuckle To install: 3. Install or connect the following: ¢ Hub/bearing assembly to the steering knuckle. Torque the bolts to 70 ft. Ibs. (95 Nm).

A.single-unit hub/bearing assembly is bolted to both ends of the rear axle assembly or rear knuckle assembly. The hub/bearing assembly is a sealed unit. 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: . Rear wheel Brake drum Anti-lock Brake System (ABS) wheel speed sensor electrical connector Hub/bearing assembly-to-rear axle assembly nuts/bolts

¢ Brake rotor ¢ Brake caliper e Halfshaft through hub/knuckle assembly. Torque the nut to 144 ft. lbs. (200 Nm). e Front wheel

¢ Hub/bearing assembly from the rear axle To install: 3. Install or connect the following: e Hub/bearing assembly. Torque the nuts/bolts to 44 ft. Ibs. (60 Nm). ->Position the top rear mounting bolt in the hub and bearing assembly prior to installation to the axle housing.

¢ Rear ABS wheel speed sensor wire connector e Brake drum e Rear wheel 4. Road test the vehicle.

GENERAL MOTORS CORPORATION—L/N BODY 1998-01 Chevrolet-Malibu * Oldsmobile-Cutlass DRIVE TRAIN.................. 26-22 ENGINE REPAIR................ 26-2 FUELSSYSTEM eee ecee. 26-19 PRECAUTIONS.................. 26-2 STEERING AND SUSPENSION pT 26-25

| fi ERY st aloe eae aeraete 26-25 PTTEI Re eh sce,tanh cancadecs 26-25 LST ee ae26-25 PC AMTIOL Sortie ide atte Circa,26-25 NI LCMIIFALO) aa sere ow aeeti becectec estos 26-2 installatiom Acer a) cleans 26-2 Removal ..........-. ee 26-2

Camshaft and Valve 1 GUS detent hie eetie ae 26-12 Removal & Installation............ 26-12

]01leeeee a om ier ree mee 26-2/ 70) S910

Removal & Installation............ 26-27 ae ie eee 26-23 Velie ae 26-23 ae DR

GCC OA geese onatenceeh tae 26-5 Removal & psa pee ee

26-5

ENGI ASSEIMDlWixecxrsccpersccnunsbs26-3 Removal & Installation............. 26-3 Exhaist MarthOld 2 iscstatecrtendeee 26-10 Removal & oe REA 26-10 ita Sil(ct eeepc

eaemmmerieny, Whee 26-20

Removal & Installation............ 26-20 FUGITMFCCIOIE eS eure IME clans 26-21 Removal & Installation............ 26-21 USM NIGH ete sok Weteres ee 26-20 Removal & Installation............ 26-20 Fuel System PreSSure.........e 26-19 Hel (eCUI Ghee ce RO oe 26-19 Fuel System Service Precautions........... aaa 26-19

POSHVOMIN)C: Meare cee eee renteete 26-18 Power Rack and Pinion SleerinGiGeak miter teneteee26-25 Removal & HESUUS Haye Et 26-25

Halishattometectiteia., (keno 26-23 Removal & eae Sal ed ae 26-23

Starter: OL en ene ae 26-14 Removal & Installation............ 26-14 SUnUIL, . S Aaens p eee ee e ee as 26-26 Removal & sie at head rise26-26

IOHITON HINGING Wes aaah cena. 26-2 ACIUSHTIENI Barak seas. Mints, 26-2 [ntake:Manitoldaeae iniews acer’ 26-/ Removal & ee eea Alera 26-/ lower Ball Oinien pial yeaa. Removal & Installation............ Lower Control Arm .........c-ce Control Arm Bushing REDIACCTIEING caste sectcuasezeenss Removal & yer Pome

26-28 26-28 26-29

26-29 26-29

cate beste tget:26-14 Oi P at ecace Removal & Installation............ 26-14

ern merieess 26-15 Ol PUN secon

Removal & Installation............ 26-15

eee tee. 26-18 Pisiontanc Ringwar-i

Rear Man’ Segre. eee) os 26-16 Removal & Installation............ 26-16 ROCKERANING ote erie anette 26-6 Removal & eee ba fii 26-6

Timing Chain, Sprockets, Front Cover and Seal... Removal & Installation............ Transmission Assembly.............. Removal & Jest eu Brat) ValVeashiio

eee

26-16 26-16 26-22 26-22

eee. 26-14

AGIUSUTICNt nce ceeeeeeere 26-14 W nme ceres 26-4 ats: WateP Plime 26-4 Installation.............. & Removal 26-30 Wheel BearingS......c.cccccsecee ACJUSUM@N ineetrentstcerceree 26-30 Removal & Installation............ 26-30

26-

GENERAL MOTORS CORPORATION MALIBU ¢ CUTLASS

_ PRECAUTIONS Before servicing any vehicle, please be sure to read all of the following precautions, which deal with personal safety, prevention of component damage, and important points to take into consideration when servicing a motor vehicle: e Never open, service or drain the radiator or cooling system when the engine is hot; serious burns can occur from the steam and hot coolant. * Observe all applicable safety precautions when working around fuel. Whenever servicing the fuel system, always work in a well-ventilated area. Do not allow fuel spray Or vapors to come in contact with a spark, open flame or excessive heat (a hot drop light, for example). Keep a dry chemical fire extinguisher near the work area. Always keep fuel in a container specifically designed for fuel storage; also, always properly seal fuel containers to avoid the possibility of fire or explosion. Refer to the additional fuel system precautions later in this section. ¢ Fuel injection systems often remain pressurized, even after the engine has been turned OFF. The fuel system pressure must be relieved before disconnecting any fuel lines. Failure to do so may result in fire and/or personal injury. e Brake fluid often contains polyglycol ethers and polyglycols. Avoid contact with the eyes and wash your hands thoroughly after handling brake fluid. If you do get brake fluid in your eyes, flush your eyes with clean, running water for 15 minutes. If eye irritation persists, or if you have taken

brake fluid internally, IMMEDIATELY seek medical assistance. e The EPA warns that prolonged contact with used engine oil may cause a number of skin disorders, including cancer! You should make every effort to minimize your exposure to used engine oil. Protective gloves should be worn when changing oil. Wash your hands and any other exposed skin areas aS Soon as possible after exposure to used engine oil. Soap and water, or waterless hand cleaner should be used. e All new vehicles are now equipped with an air bag system, often referred to as a Supplemental Restraint System (SRS) or Supplemental Inflatable Restraint (SIR) 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 repairs. e Always wear safety goggles when working with, or around, the air bag system. When carrying a non-deployed air bag, be sure the bag and trim cover are pointed away from your body. When placing a non-deployed air bag on a work surface, always face the bag and trim cover upward, away from the surface. This will reduce the motion of the module if it is accidentally deployed. Refer to the additional air bag system precautions later in this section.

: Alternator

REMOVAL 2.4L 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 ¢ Accessory drive belt ¢ Alternator electrical connectors ¢ Alternator 3.1L Engine

1. Before servicing the vehicle, refer to the precautions in the beginning of this section,

e Clean, high quality brake fluid from a sealed container is essential to the safe and proper operation of the brake system. You should always buy the correct type of brake fluid for your vehicle. If the brake fluid becomes contaminated, completely flush the system with new fluid. Never reuse any brake fluid. Any brake fluid that is removed from the system should be discarded. Also, do not allow any brake fluid to come in contact with a painted surface; it will damage the paint. : ¢ Never operate the engine without the proper amount and type of engine oil: doing so WILL result in severe engine damage. e Timing belt maintenance is extremely important! Many models utilize an interference-type, non-freewheeling engine. if the timing belt breaks, the valves in the cylinder head may strike the pistons, causing potentially serious (also time-consuming and expensive) engine damage. Refer to the maintenance interval charts in the front of this manual for the recommended replacement interval for the timing belt, 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 computer system(s) and may require the computer to undergo a'relearning process once the negative battery cable is reconnected. e When servicing drum brakes, only disassemble and assemble one side at a time, leaving the remaining side intact for refer-

ence.

ENGINE REPAIR

2. Remove or disconnect the following: ¢ Negative battery cable ¢ Accessory drive belt ¢ Alternator electrical connectors ¢ Power steering line clip e Alternator

INSTALLATION ate eae Se ee ES Se

3.1L Engine

1. Install or connect the following: Alternator. Torque the nuts to 22 ft. Ibs. (30 Nm) and the bolts to 37 ft, Ibs. (50 Nm). Alternator electrical connector Power steering line clip Accessory drive belt Negative battery cable

2.4L Engine

1. Install or connect the following: e Alternator electrical connectors e Alternator. Torque the nuts/bolts to 37 ft. Ibs. (50 Nm), ¢ Accessory drive belt e Negative battery cable

Ignition Timing ADJUSTMENT eet Ignition timing is controlled by the Powertrain Control Module (PCM). No adjustment is necessary or possible.

GENERAL MOTORS CORPORATION MALIBU © CUTLASS To install:

Engine Assembly

REMOVAL & INSTALLATION Be sure the retaining bolts are in their correct locations. If not, engine damage may occur.

2.4L Engine 1. Before servicing the vehicle, refer to teprecautions in the beginning of this secion. 2. Properly drain the cooling system. 3. Relieve the fuel system pressure. 4. Drain the engine oil. 5. Remove or disconnect the following: e Fuel rail assembly Air intake duct and bracket Ignition coil assembly Camshaft Position (CMP) sensor Power steering pump. DO NOT remove the lines. e Oil pressure sending switch e Cruise control assembly 6. Install an engine support fixture. e Engine mount assembly e Fuel pressure regulator vacuum line 7. Raise the engine with the engine support fixture J-hook. Engine mount bracket Accessory drive belt Front wheels Right front splash shield Crankshaft balancer Manifold Absolute Pressure (MAP) sensor electrical connector Intake Air Temperature (IAT) sensor electrical connector Exhaust Gas Recirculation (EGR) sensor electrical connector Evaporator canister electrical connector Alternator Accelerator cable and bracket Starter motor Exhaust manifold heat shield Exhaust pipe from the manifold Engine intake coolant pipe Torque converter cover Torque converter bolts Oxygen (02S) sensor

A/C compressor. DO NOT remove

the hoses Oil pan-to-bell housing bolts Transmission mount Transmission bolts 8. Install an engine lifting device and a transmission support. 9. Raise the engine slightly and separate it from the transmission to remove it from the vehicle.

10. Install or connect the following: Engine to the transaxle. Torque the bolts to 75 ft. Ibs. (100 Nm). Transmission mount. Torque the through bolt to 55 ft. Ibs. (75 Nm). Oil pan-to-bell housing bolts. Torque the bolts to 17 ft. Ibs. (23 Nm). A/C compressor. Torque the bolts to 37 ft. Ibs. (50 Nm). e 02S e Torque converter bolts. Torque the bolts to 46 ft. Ibs. (62 Nm). Torque converter cover. Torque the bolts to 115 inch Ibs. (13 Nm). e Intake coolant pipe Exhaust pipe to the manifold. Torque the bolts to 26 ft. Ibs. (35 Nm). Exhaust manifold heat shield. Torque the bolts to 124 inch Ibs. (14 Nm). Starter motor. Torque the bolts to 66 ft. Ibs. (90 Nm). Accelerator cable and bracket Alternator. Torque the bolts to 37 ft. lbs. (50 Nm). Fuel pressure regulator vacuum line Evaporator canister electrical connector EGR sensor electrical connector IAT sensor electrical connector MAP sensor electrical connector Crankshaft balancer. Torque the bolt to 129 ft. Ibs. (175 Nm). Right front splash shield Front wheels Accessory drive belt Engine mount bracket. Torque the bolts to 96 ft. Ibs. (130 Nm). Engine mount assembly. Torque the bolts to 49 ft. Ibs. (66 Nm). Cruise control assembly Oil pressure sending switch Power steering pump. Torque the bolts to 19 ft. Ibs. (26 Nm). CMP sensor Ignition coil assembly Air intake-assembly Fuel rail assembly 11. Refill the cooling system and engine oil.

26-3

12. Start the engine and check for proper operation. 3.1L Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Relieve the fuel system pressure. 3. Drain the engine coolant. 4. Remove or disconnect the following: Air cleaner assembly Hood Accessory drive belt

Coolant inlet line from the coolant Surge tank

Cruise control module Upper engine wiring harness Throttle and cruise control cables Starter motor A/C compressor. DO NOT remove the lines. Lower engine wiring harness and position aside Catalytic converter Torque converter cover Torque converter bolts Engine splash shields Transaxle-to-engine brace 2 outer transmission mounting bolts Upper and lower radiator hoses Fuel lines Brake booster vacuum line Heater hoses 5. Install an engine support fixture. 6. Remove or disconnect the following: e Engine mount ¢ Power steering pump e Transmission-to-engine bolts e Engine from the vehicle To install: 7. Install or connect the following: e Transaxle to the engine. Torque the bolts to 55 ft. Ibs. (75 Nm). e Power steering pump. Torque the bolts to 25 ft. Ibs. (34 Nm). ¢ Engine mount. Torque the bolts to

35 ft. Ibs. (47 Nm). 8. Remove the engine support fixture. 9. Install or connect the following: Heater hoses Brake booster vacuum line Fuel lines Radiator hoses Engine splash shields Torque converter bolts. Torque the

bolts to 46 ft. Ibs. (62 Nm). e¢ Torque converter cover. Torque the

bolts to 89 inch Ibs. (10 Nm).

Guide For complete service labor times, order Nichols’ Chilton Labor

26-4

GENERAL MOTORS CORPORATION MALIBU ¢ CUTLASS

Catalytic converter Lower engine wiring harness A/C compressor. Torque the bolts to 37 ft. Ibs. (50 Nm). Starter motor Throttle and cruise contro! cables Upper engine wiring harness Cruise contro! module Coolant surge tank hose Accessory drive belt Hood Air cleaner assembly 10. Refill the coolant. 11. Start the engine and check for proper operation.

Water Pump

REMOVAL & INSTALLATION 2.4L Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the cooling system. 3. Remove or disconnect the following: Negative battery cable Exhaust manifold heat shield Coolant inlet housing bolt through the exhaust manifold Oxygen (02S) sensor electrical connector Manifold-to-exhaust pipe bolts Coolant inlet housing assembly-towater pump cover bolt Coolant inlet pipe Exhaust manifold Timing chain Water pump and cover assembly 4. Separate the water pump from the cover. To install: 5. Lubricate the water pump splines with clean grease. 6. Install or connect the following: ¢ Water pump with a new gasket to the cover. Hand tighten the bolts. ¢ Water pump using new gaskets to the engine and tighten the bolts and nuts finger-tight ¢ Radiator outlet pipe O-ring, lubricated with antifreeze ¢ Radiator outlet pipe onto the water pump cover and tighten the bolts finger-tight 7. With all gaps closed, torque the bolts, in the following sequence, to the proper values: a. Pump assembly-to-chain housing nuts to 19 ft. Ibs. (26 Nm).

1 TIMING CHAIN HOUSING 2 GASKET, TIMING CHAIN HOUSING TO WATER PUMP 3 NUT (3) 4 WATER PUMP BODY ASM, 5 GASKET, WATER PUMP BODY TO WATER PUMP COVER 6 WATER PUMP COVER 7 BOLT (M6 x 1x 55) - 3 LOWER POSITIONS 8 BOLT (M6 x 1 x 25) 9 BOLT (M6 x 1 x 90) 10 GASKET, WATER PUMP COVER TO BLOCK

a 79222201

Exploded view of the water pump mounting—2.4L engine

b. Pump cover-to-pump bolts to 124

inch lbs. (14 Nm). c. Cover-to-block bottom bolt to 19 ft. Ibs. (26 Nm). d. Radiator outlet pipe assembly-topump cover bolt to 124 inch Ibs. (14 Nm). 8. Install or connect the following: Exhaust manifold with new gaskets. Torque the nuts to 12 ft. Ibs. (16 Nm). Exhaust pipe to the manifold. Torque the bolts to 26 ft. Ibs. (35 Nm). Radiator outlet pipe to the transaxle and oil pan. Torque the nuts to 19

ft. bs. (26 Nm). Timing chain and front cover Manifold heat shield 02S electrical connector

e Negative battery cable 9. Refill the cooling system until it comes out of the thermostat housing heater hose outlet; then connect the heater hose. 10. Start the engine. Run the vehicle until the thermostat opens, refill the radiator and recovery tank, then turn the engine OFF. 11. Once the vehicle has cooled, recheck the coolant level. 3.1L Engine

1. Before servicing the vehicle, refer to the precautions in the beginning of this section, 2. Drain the cooling system. 3. Remove or disconnect the following: e Negative battery cable ¢ Water pump pulley bolts, loosen ¢ Accessory drive belt

GENERAL MOTORS CORPORATION MALIBU e CUTLASS

edad

26-9

nd ada7) ) Oxry

LSA

COW

79222203

Cylinder head bolt torque sequence—2.4L engine

COOLANT GASKET

Fuel line clamp from the bracket located on top of the intake camshaft housing Fuel injector electrical connectors Fuel line rail and move it aside with the fuel lines attached Timing chains and sprockets Water pump Intake camshaft housing Exhaust camshaft housing Lifters Oil pressure switch electrical connector Upper radiator hose from the coolant outlet Coolant temperature sensor electrical connectors Cylinder head by reversin g the bolt torque sequence

PUMP

BOLT - 10 N-m (89 LBS. IN.) LOCATOR

2 ho GO

(MUST BE VERTICAL) 79222202

Exploded view of the water pump mounting—3.1L engine

e Water pump pulley ¢ Water pump bolts, pump and gasket To install: 4. Apply a thin bead of sealer around the outside edge of the water pump along the gasket sealing area. 5. Install or connect the following: ¢ Water pump with a new gasket. Torque the bolts to 89 inch Ibs. (10 Nm). Water pump pulley and fingertighten the bolts e Accessory drive belt Water pump pulley bolts and torque to 18 ft. Ibs. (24 Nm) Negative battery cable 6. Refill and bleed the cooling system. 7. Operate the engine and check for leaks.

+k WARNING

2. Relieve the fuel system pressure. 3. Drain the cooling system. 4. Remove or disconnect the following: e

Air inlet duct

Heater inlet and throttle body hoses from the water outlet Power brake vacuum hose from the throttle body

Manifold Absolute Pressure (MAP) sensor electrical connector Evaporative Emission (EVAP) purge solenoid electrical connector

Camshaft Position (CMP) sensor electrical connector Alternator stud-ended bolt e Intake manifold of "Install the stud-ended alternator bolt back onto the engine. 6. Install an engine support fixture.

7. Remove or disconnect the follow-

Cylinder Head

ing:

REMOVAL & INSTALLATION i

2.4L Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section.

Exhaust manifold Ignition coil and module assembly Power steering pump and move it aside without disconnecting the lines Vacuum line from the fuel pressure regulator

Do not use abrasive pads to clean the cylinder head or block surfaces. An abrasive pad may damage the cylinder head and block. Use a razor or scraper to clean the gasket surfaces.

To install: 8. Install the cylinder head with a new gasket. e>New replacement head bolts should be used. Coat the new cylinder head bolt threads with clean engine oil before installation.

9. Torque the new cylinder head bolts in sequence as follows: a. Step 1: Bolts 1 through 8: 40 ft. lbs. (65 Nm), b. Step 2: Bolts 9 and 10: 30 ft. Ibs. (40 Nm). c. Step 3: All 10 bolts ‘an additional 90 degree turn. 10. Install or connect the following: e Lifters e Intake and exhaust camshaft housings. Torque the long bolts to 11 ft. lbs. (15 Nm) plus an additional 90 degree turn and the short bolts to

Please visit our web site at www.chiltonsonline.com

26-

GENERAL MOTORS CORPORATION MALIBU e CUTLASS

11 ft. Ibs. (15 Nm) plus an additional 30 degree turn. Timing chains and sprockets Coolant temperature sensor electrical connector Upper radiator hose Oil pressure switch electrical connector Fuel rail on the intake manifold Fuel pressure regulator vacuum line Power steering pump. Torque the bolts to 19 ft. Ibs. (26 Nm). Ignition coil assembly Exhaust manifold 11. Remove the engine support fixture. 12. Install or connect the following: Intake manifold. Torque the bolts to 18 ft. Ibs. (24 Nm). MAP sensor electrical connector EVAP purge solenoid electrical connector

CMP sensor electrical connector Power brake vacuum hose Heater inlet and throttle body hoses Air inlet duct Negative battery cable 13. Fill all fluids to their proper levels. e>An oil and filter change is recommended.

14. Start the vehicle and check for leaks.

3.1L Engine

LEFT (FRONT) 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Relieve the fuel system pressure. 3. Drain the cooling system. 4, Remove or disconnect the following: ¢ Upper half of the air cleaner assembly ¢ Air inlet duct ¢ Exhaust crossover pipe heat shield and the crossover pipe ¢ Spark plug wires ¢ Rocker arm covers

79227204

Cylinder head bolt torque sequence—3.1L engine

e Intake plenum and lower intake manifold e Left side exhaust manifold e Oil level indicator tube e>When removing the valvetrain com-» ponents, keep them in order for installation in the same locations they were removed from.

¢ Rocker arm nuts, rocker arms, balls and pushrods e Cylinder head bolts, evenly, by reversing the torque sequence e Cylinder head To install: 5. Install or connect the following: e Cylinder head with a new gasket. Torque the bolts to 33 ft. Ibs. (45 Nm) plus an additional 90 degree turn.

Pushrods, rocker arms and balls. Torque the rocker arm nuts to 18 ft. lbs. (24 Nm). Lower intake manifold. Torque the bolts to 115 inch Ibs. (13 Nm). Upper intake plenum. Torque the bolts to 18 ft. Ibs. (24 Nm). Rocker arm covers. Torque the bolts to 89 inch Ibs. (10 Nm). Oil level indicator tube Spark plug wires Left side exhaust manifold. Torque the bolts to 12 ft. Ibs. (16 Nm). Exhaust crossover pipe. Torque the bolts to 18 ft. Ibs. (24 Nm). Crossover pipe heat shield. Torque the bolts to 89 inch Ibs. (10 Nm). Upper half of the air cleaner assembly Air inlet duct Negative battery cable 6. Refill the cooling system. e*An oil change is recommended. 7. Start the vehicle and check for leaks.

RIGHT

(REAR)

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Relieve the fuel system pressure. 3. Drain the cooling system. 4. Remove or disconnect the following: Upper half of the air cleaner assembly Throttle body air inlet duct Exhaust crossover pipe heat shield and the crossover pipe Oxygen (02S) sensor Exhaust pipe from the exhaust manifold

~

e e e e e

Right side exhaust manifold Spark plug wires Rocker arm cover Upper intake plenum Lower intake manifold

e»When removing the valvetrain components, keep them in order for installation in the same locations they were removed from.

e Rocker arms nut, rocker arms, balls and pushrods e Cylinder head bolts, evenly, by reversing the torque sequence e Cylinder head To install: 5. Install or connect the following: Cylinder head with a new gasket. Torque the bolts to 37 ft. Ibs. (50 Nm) plus an additional 90 degree turn. Pushrods, rocker arms and balls. Torque the rocker arm nuts to 18 ft. lbs. (24 Nm). Lower intake manifold. Torque the bolts to 115 inch Ibs. (13 Nm). Upper intake plenum. Torque the bolts to 18 ft. Ibs. (24 Nm). Rocker arm covers. Torque the bolts to 89 inch Ibs. (10 Nm). Spark plug wires Exhaust manifold. Torque the bolts to 12 ft. Ibs. (16 Nm). Exhaust pipe to the exhaust manifold. Torque the bolts to 26 ft. Ibs. (35 Nm). O2S sensor Exhaust crossover pipe. Torque the bolts to 18 ft. Ibs. (24 Nm). Heat shield. Torque the bolts to 89 inch Ibs. (10 Nm). Upper half of the air cleaner assembly Throttle body air inlet duct Negative battery cable 6. Refill the cooling system. 7. An oil and filter change is recommended. 8. Start the vehicle and check for leaks. Rocker Arms

REMOVAL & INSTALLATION ae 2.4L Engine

The 2.4L engine is not equipped with rocker arms. The camshafts directly actuate the valves.

GENERAL MOTORS CORPORATION

MALIBU e CUTLASS

3.1L Engine

te

LEFT SIDE (FRONT) 1. Before servicing the vehicle, refer to precautions in the beginning of this secion. 2. Disconnect the negative battery cable. 3. Partially drain the cooling system to a level below the coolant pipe. 4. Remove or disconnect the following: e Rear ignition wire harness at the upper intake manifold and at the spark plugs Coolant bypass hose clamp at the coolant tube Coolant tube from the cylinder head and move it aside Positive Crankcase Ventilation (PCV) valve from the rocker arm cover e Rocker arm cover Rocker arms and pushrods To install: >The intake pushrods are identified with yellow stripes and are 5 ¢ inches long. The exhaust pushrods are identified with green stripes and are 6 inches long.

5. Coat all valvetrain components with engine oil. 6. Install or connect the following: e Pushrods and rocker arms. Torque the rocker arm bolts to 89 inch Ibs. (10 Nm) plus an additional 30 degree turn. Rocker arm cover with a new gasket. Torque the bolts to 89 inch Ibs. (10 Nm). PCV valve Coolant tube and thermostat bypass hose. Torque the screw at the water pump to 106 inch Ibs. (12 Nm) and the nut/bolt at the cylinder head to 18 ft. Ibs. (24 Nm). Rear ignition wire harness to the upper intake manifold and the Spark plugs e Negative battery cable 7. Refill the cooling system. 8. Start the vehicle and verify no leaks.

RIGHT SIDE (REAR) 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 9. Remove or disconnect the following:

26-/

155

veh

ton

129 131 153

PUSHROD ARM, ROLLER BOUT.

ROCKER 79222205

Rocker arm components—3.1L engine

Negative battery cable Spark plug wires Power brake booster vacuum pipe from the intake plenum Accessory drive belt Alternator Ignition coil assembly Evaporative Emission (EVAP) canister purge solenoid Rocker arm cover e Rocker arms and pushrods To install: >The intake pushrods are identified with yellow stripes and are 5 e inches long. The exhaust pushrods are identified with green stripes and are 6 inches long.

3. Coat all valvetrain components with engine oil. 4. |nstall or connect the following: e Pushrods and rocker arms. Torque the bolts to 89 inch Ibs. (10 Nm) plus an additional 30 degree turn. e Rocker arm cover with a new gasket. Torque the bolts to 89 inch Ibs. (10 Nm). e Ignition coil assembly

EVAP canister purge solenoid Alternator. Torque the bolts to 18 ft. lbs. (24 Nm). Accessory drive belt Power brake booster vacuum pipe to the plenum Spark plug wires Negative battery cable

Intake Manifold REMOVAL & INSTALLATION 2.4L Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Relieve the fuel system pressure. 3. Drain the cooling system to a level below the intake manifold. 4. Remove or disconnect the following: e Air cleaner intake duct e Manifold Absolute Pressure (MAP) sensor electrical connector and vacuum line e Intake Air Temperature (IAT) sensor electrical connector

Timing belt service is covered in Section 3 of this manual

26-

GENERAL MOTORS CORPORATION MALIBU e CUTLASS

( Fuel Return Line (LSSFuel Pressure Regulator Vacuum Harness (3) Fuel Line (4) Fuel Rail (with Injectors) (5) Fuel Injector Harness

(6) Bolt, Fuel Rail to Cylinder Head (7) Bolt, Fuel Line Retainer (8) Fuel Line Retainer

(9) Fuel Line Seal (10)

Fuel Line Retainer

(11) Bolt, Fuel Line Retainer (12) Gasket, EGR Adapter (13)

EGR

Passage Cover (Export Only)

(14) Bolt, EGR Valve (15) EGR Valve (16) Gasket, EGR Valve

(17) Bolt, EGR Valve Adapter to Cylinder Head (18) Bolt, EGR

Passage Cover (Export Only)

(19) EGR Adapter

(20) Oil/Air Separator Fresh Air Tube (21) Bolt, EGR Tube to Intake Manifold

(22) Bolt, EGR Tube to EGR Adapter

(23) Throttle Cable Bracket

(24) Bolt, Throttle Body to intake Manifold (25) Throttle Body (26) Bolt, Throttle Body to Intake Manifold

Exploded view of the intake and exhaust manifolds—2.4L engine

(27) Manifold Absolute Pressure Sensor (28) MAP Sensor Vacuum Line (29) Fuel Rail Bracket (30) Bolt, Intake Manifold to Cylinder Head (31) Nut, Intake Manifold to Cylinder Head

(32) Intake Manifold (33) EGR

Pipe

(34) Bolt, Oil/Air Separator to Engine Block

(35) Oil/Air Separator (36) Oil/Air Separator Foul Air Tube

(37) Stud, Intake Manifold to Cylinder Head (38) Clamp, Oil/Air Separator Tube (39) Cylinder Head

(40) Nut, Exhaust Manifold Brace to Oil Pan Stud (41) Exhaust Manifold Brace

(42) Gasket, Exhaust Manifold (43) Bolt, Exhaust Manifold Brace to Exhaust

Manifold

(44) Nut, Exhaust Manifold to Cylinder Head (45) Stud, Exhaust Manifold to Cylinder Head

(46) Exhaust Manifold Heat Shield (47) Bolt, Exhaust Manifold Heat Shield to

ae aa, vat

(49) Oxygen

Sensor 79222206

GENERAL MOTORS CORPORATION

MALIBU ¢ CUTLASS

2

1

3

real Joal TealJanet ®

H+

7

TIGHTENING SEQUENCE

. STUD — 12 N*M (100 LB. IN.) . INTAKE MANIFOLD . INTAKE MANIFOLO

GASKET

BOLT - 24 NeM (17 LB. FT.) (17 LB. FT.)

OrRwn NUT — 24 NeM

7922YG08

Intake manifold torque sequence—2.4L engine

(1) (2) (3) (4) (5) (6) (7) (8) (9)

Evaporative Emissions (EVAP) canister purge solenoid electrical connector and vacuum line Fuel injector electrical connectors Fuel pressure regulator vacuum line Accelerator control cable bracket from the intake manifold Coolant lines from the throttle body Brake booster vacuum line Intake manifold To install: 5. Install or connect the following: Intake manifold using a new gasket. Torque the fasteners, in sequence, to 18 ft. Ibs. (24 Nm). Coolant lines to the throttle body e Brake booster vacuum line - Control cable bracket to the intake manifold

Upper Intake Manifold Bolt Thermostat Bypass Pipe Thermostat Bypass Pipe Nut

Thermostat Bypass Pipe Bolt Thermostat Bypass Pipe Screw Thermostat Bypass Hose Clamp Thermostat Bypass Hose Thermostat Bypass Hose Clamp

Coolant Outlet Bolt

(10 a= Coolant Outlet Assembly

(11) Thermostat (12) PCV Valve (13) PCV Valve Grommet (14 ~— Oil Fill Cap (15) Rocker Arm Cover Bolt (16) Rocker Arm Cover (17) Exhaust Crossover Nut (18) Exhaust Crossover Pipe

26-9

Fuel pressure regulator vacuum line Fuel injector electrical connectors EVAP canister purge solenoid electrical connector IAT sensor electrical connector MAP sensor electrical connector Air cleaner intake duct 6. Refill the cooling system. 7. Connect the negative battery cable. 3.1L Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the cooling system. 3. Relieve the fuel system pressure. 4 Remove or disconnect the following: e Upper half of the air cleaner assembly

(19) Exhaust Crossover Upper Heat Shield (20) Upper Intake Manifold Gasket (21) Upper intake Manifold Gasket

(22) EVAP Canister Purge Valve Bracket Stud (23) EVAP Canister Purge Valve Bracket Stud (24) EVAP Canister Purge Valve Bracket (25) EVAP Canister Purge Valve (26) Spark Plug Wire Support

(27) Electronic Ignition System Nut

(28) Electronic Ignition System (29) Electronic Ignition System Bolt (30) Electronic Ignition System Bolt (31) EGR Valve Pipe Assembly

(32) EGR Valve Pipe Gasket (33) EGR Valve Gasket

(34) EGR Valve Assembly Bolt (35) EGR Valve Assembly

(36) Upper Intake Manifold Stud (37) Upper Intake Manifold 79222207

nts—3.1L engine Exploded view of the upper intake and related compone

Heater Core replacement is covered in Section 2 of this manual

26-1

GENERAL MOTORS CORPORATION MALIBU ¢ CUTLASS

Brake vacuum pipe at the intake plenum Fuel pressure regulator vacuum line Spark plug wires Ignition coil assembly Evaporative Emission (EVAP) canister purge solenoid Throttle Position (TPS) sensor electrical connector Idle Air Control (IAC) valve electrical connector Fuel Injector electrical connectors Engine Coolant Temperature (ECT) sensor electrical connector Manifold Absolute Pressure (MAP) sensor electrical connector and vacuum line Camshaft Position (CMP) sensor electrical connector Vacuum modulator supply hose Control cables from the throttle body and intake plenum bracket Upper intake manifold Left and right rocker arm covers Fuel injector electrical connectors Fuel feed and return line Fuel rail with the injectors Power steering pump and move it aside without disconnecting the lines Heater inlet pipe Thermostat bypass hose Upper radiator hose at the thermostat housing Lower intake manifold bolts

Vacuum modulator supply line CMP sensor electrical connector ECT sensor electrical connector IAC valve electrical connector TPS sensor electrical connector EVAP canister purge solenoid Ignition coil assembly Spark plug wires Brake vacuum pipe at the intake plenum Accessory drive belt Brake booster vacuum line e Upper half of the air cleaner assembly : e Negative battery cable 7. Fill the cooling system.

e Lower intake manifold using a new gasket e Pushrods and rocker arms ->Be sure the pushrods are properly seated in the valve lifters and rocker arms.

Rocker arm nuts. Torque them to 18 ft. Ibs. (24 Nm). Lower intake manifold bolts, lubricated with sealant. Torque the bolts to 115 inch Ibs. (13 Nm). Upper radiator hose at the thermostat housing Thermostat bypass hose Heater inlet pipe Power steering pump. Torque the bolts to 25 ft. Ibs. (34 Nm). Fuel rail with the injectors Fuel feed and return lines Fuel injector electrical connectors Rocker arm covers. Torque the bolts to 89 inch Ibs. (10 Nm). Upper intake manifold with a new gasket. Torque the mounting bolts to 18 ft. Ibs. (24 Nm). Control cables to the throttle body MAP sensor vacuum line and electrical connector Fuel pressure regulator vacuum line

e>An engine oil and filter change is recommended.

8. Start the vehicle and verify no leaks.

Exhaust Manifold

REMOVAL & INSTALLATION 2.4L Engine

1. Before servicing the vehicle, refer to the precautions in the beginning of this section.

e>When removing the valvetrain components, keep them in order for installation in their original locations. e Rocker arm nuts, rocker arms and pushrods e Intake manifold To install: 9. Place a 0.08-0.11 inch (8-12mm) bead of RTV on each ridge, where the front and rear of the intake manifold contact the block. 6. Install or connect the following:

79222208

Lower intake manifold torque sequence— 3.1L engine

79227209

Exploded view of the exhaust manifold—2.4L engine

GENERAL MOTORS CORPORATI

Hayat:

e O25 sensor e Negative battery cable 6. Start the vehicle and verify no exhaust leaks. 3.1L Engine

LEFT SIDE (FRONT)

6 TIGHTENING SEQUENCE

1. STUD, EXHAUST MANIFOLD 2. GASKET, EXHAUST MANIFOLD 3. MANIFOLD, EXHAUST

4, NUT, EXHAUST MANIFOLD, MUST BE TIGHTENED IN SEQUENCE

SHOWN

TO

12.5 Nem (110 LB. IN.) 7922YG11

Exhaust manifold torque sequence—2.4L engine

2. Remove or disconnect the following: Negative battery cable Oxygen (02S) sensor Heat shield Exhaust manifold brace from the manifold e Exhaust manifold-to-exhaust pipe spring loaded bolts

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Partially drain the cooling system. 3. Remove or disconnect the following: e Negative battery cable e Air cleaner assembly e Throttle body duct e Exhaust crossover heat shield e Exhaust crossover pipe from the manifold Upper radiator hose from the thermostat housing e Spark plug wires Exhaust manifold heat shie (ee e Exhaust manifold To install: 4. Install or connect the following: e Exhaust manifold using a new gasket. Torque the nuts to 12 ft. Ibs. (16 Nm).

Exhaust manifold heat shield. Torque the bolts to 89 inch Ibs. (10 Nm). Spark plug wires Upper radiator hose Exhaust crossover pipe to the manifold. Torque the bolts to 18 ft. Ibs. (24 Nm). Exhaust crossover pipe heat shield. Torque the bolts to 89 inch Ibs. (10 Nim). e Throttle body duct e Air cleaner assembly e Negative battery cable 5. Fill the cooling system.

RIGHT SIDE (REAR) 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Negative battery cable Air cleaner assembly Heated Oxygen (HO2S) sensor Crossover pipe heat shield Crossover pipe Spark plug wires Exhaust manifold heat shield Exhaust manifold

>The nuts should be Icosened alternately and evenly to prevent the pipe from binding the nuts.

3. Pull down and back on the exhaust pipe to disengage it from the exhaust manifold.

> WARNING do not bend the exhaust flex coupler more than 3 degrees in any direction. Movement of more than 3 degrees will damage the flex coupler.

4. Remove the exhaust manifold. To install: 5. Install or connect the following: e Exhaust manifold using a new gasket. Torque the nuts, in sequence, to 110 inch Ibs. (13 Nm). e Exhaust manifold brace to the manifold. Tighten the bolt to 41 ft. 'bs. (56 Nm) and the nuts to 19 ft. Ibs. (26 Nm). Heat shield. Torque the bolts to 89 inch Ibs. (10 Nm). e Exhaust manifold-to-exhaust pipe bolts. Torque the bolts to 26 ft. Ibs. (35 Nm).

111. 112 113. 114 115 117. 121.

26-11

SCREW, LH EXHAUST MANIFOLD HEAT SHIELD SHIELD LH EXHAUST MANIFOLD NUT, LH EXHAUST MANIFOLD STUD, LH EXHAUST MANIFOLD MANIFOLD, LH EXHAUST GASKET, LH EXHAUST MANIFOLD HEAD, LH CYLINDER

engine Exploded view of the left-hand exhaust manifold—3.1L

Brake service is covered in Section 4 of this manual

26-1 2 GENERAL MOTORS CORPORATION MALIBU © CUTLASS To install: 3. Install or connect the following: Exhaust manifold with a new gasket. Torque the bolts to 12 ft. Ibs. (16 Nm). Exhaust manifold heat shield. Torque the bolts to 89 inch Ibs. (10 Nm). Spark plug wires Crossover pipe. Torque the bolts to 18 ft. Ibs. (24 Nm). Crossover pipe heat shield. Torque the bolts to 89 inch Ibs. (10 Nm). HO2S sensor _ Air cleaner assembly Negative battery cable

Camshaft and Valve Lifters 115 116

MANIFOLD, LEFT HAND EXHAUST STUD, EXHAUST CROSSOVER

157

MANIFOLD, RIGHT HAND EXHAUST

REMOVAL & INSTALLATION 2.4L Engine

166 CROSSOVER PIPE, EXHAUST

> Anytime the camshaft housing-to-

168 312

removed, the camshaft housing-tocylinder head gasket must be replaced.

NUT, EXHAUST CROSSOVER BOLT/SCREW, EXHAUST CROSSOVER

UPPER HEAT SHIELD

aie the

Exploded view of the exhaust crossover pipe—3.1L engine

121 153 154 155 156 157 158

HEAD, CYLINDER SHIELD, RH LOWER HEAThs SCREW, RH LOWER HEAT SHI STUD, RH EXHAUST anecrne NUT, RH EXHAUST MANIFOLD MANIFOLD, RIGHT HAND EXHAUST

ieee ae

a

ae .

SHIELD, RH UPPER HEAT

159 SCREW, RH UPPER HEAT SHIELD

160

1. Before servicing the vehicle, refer to pr ions i inni -

GASKET, RH EXHAUST MANIFOLD

196

“Ag 155

79227213

Exploded view of the right-hand exhaust manifold—3.1L engine

GENERAL MOTORS CORPORAT MALIBU yitlaes 26-1 3 2. Remove or disconnect the following: e Negative battery cable ¢ 11-pin connector from the ignition assembly cover ¢ 4 ignition assembly cover-tocamshaft housing bolts and the assembly by pulling it straight up e Connector assemblies using a spark plug boot wire remover 3. On the exhaust camshaft side, remove or disconnect the following: e Transaxle fill tube e Oil pressure switch 4. On the intake camshaft side, remove or disconnect the following: e Camshaft Position (CMP) sensor and power steering pressure switch connector Drive belt Power steering pump and move it aside with the lines attached Oil/air separator hoses from the oil fill tube, timing chain housing and intake manifold Oil/air separator with the hoses attached Vacuum line from the fuel pressure regulator Fuel injector wiring harness Fuel line clamps from the intake camshaft housing Fuel rail-to-camshaft housing bolts Fuel rail from the cylinder head and move it aside with the fuel lines attached. Timing chain and camshaft sprockets Timing chain housing bolts but do not the housing

Camshaft housing cover-tocamshaft housing bolts Camshaft housing-to-cylinder head bolts by reversing the tightening

sequence =>Leave 2 bolts loosely in place to hold the camshaft housing while separating camshaft cover from housing.

5. Push the cover off the housing by

threading 4 of the housing-to-cylinder head bolts into the tapped holes in the cam housing cover. Tighten the bolts evenly so the cover does not bind on the dowel pins. 6. Remove or disconnect the following: e Both loosely installed camshaft housing-to-cylinder head bolts e Camshaft housing cover and discard the gaskets -»Note the position of the chain sprocket dowel pin for reassembly.

e Camshaft, be careful do not damage the camshaft oil seal e Camshaft oil seal from camshaft and discard it >The oil seal must be replaced any time the housing and cover are separated. >The valve lifters must be kept in order for installation in the same locations they were removed.

e Valve lifters from the camshaft housing e Camshaft carrier from the cylinder head and discard the gasket To install:

7. Clean all gasket surfaces. 8. Install or connect the following: e New gasket on the cylinder head ¢ Camshaft housing using1 bolt loosely to hold it in place »>|f the camshaft is replaced, the valve lifters must also be replaced.

e Valve lifters in their original bores ->Lubricate the camshaft lobes, journals and lifters with camshaft and lifter prelube.

The camshaft lobes and journals must be adequately lubricated or engine damage could occur upon start up.

e Camshaft, so the timing chain sprocket dowel pin faces upward and aligns with the lifter bores centerline e New camshaft seals in the cover The seals for the intake and exhaust covers are different; be sure the correct seals are used.

9. Remove the camshaft housing securing bolt 10. Lubricate the camshaft housing-tocover bolts with thread locking compound. 11. Install or connect the following: ¢ Camshaft housing cover. Torque the long bolts to 16 ft. Ibs. (22 Nm) plus 90 degrees additional rotation and the short bolts to 16 ft. Ibs. (22 Nm) plus 30 degrees additional rotation. ¢ Timing chain housing bolts e Timing chain and sprockets » New O-rings on the fuel injectors, lubricated with engine oil

79222214

Camshaft housing bolt tightening sequence—2.4L engine

e Fuel rail. Tighten the bolts to 19 ft. lbs. (26 Nm). 12. On the intake camshaft side, install or connect the following: Fuel line clamp bolts on top of the intake camshaft housing Vacuum line to the fuel pressure regulator Fuel injector harness connector Oil/air separator Oil/air separator hoses to the oil fill tube, timing chain housing and intake manifold New oil seal into the intake camshaft housing, lubricated with oil Power steering pump pulley onto the intake camshaft ¢ Power steering pump Drive belt ¢ CMP sensor and power steering pressure switch connectors 13. On the exhaust camshaft side, install or connect the following: e Transaxle fill tube ¢ Oil pressure switch 14. Install or connect the following: ° Ignition assembly on the camshaft housing. Tighten the bolts to 13 ft. Ibs. (18 Nm). ¢ 11-pin connector to ignition assembly ¢ Negative battery cable 15. Start the vehicle and verify proper operation and no leaks. 3.1L Engine

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Relieve the fuel system pressure. e>When removing valvetrain components, marked them for installation in

1 of this manual For complete Engine Mechanical specifications, see Section

26-1

GENERAL MOTORS CORPORATION MALIBU e CUTLASS

the same location they are removed from.

3. Remove or disconnect the following: Rocker arm covers Intake manifold Rocker arms and push rods Lifter guide bolts and the guide Valve lifter(s) from the lifter bores Crankshaft balancer Front cover Timing chain and sprockets Oil pump driven gear bolt and gear Camshaft thrust plate ¢ Camshaft To install: 4. Install or connect the following: ¢ Camshaft, lubricated with camshaft lubricant Camshaft thrust plate. Torque bolts to 89 inch Ibs. (10 Nm). Oil pump driven gear. Torque the bolt to 27 ft. Ibs. (36 Nm). Timing chain and sprocket. Torque the bolt to 103 ft. Ibs. (140 Nm). Front cover. Torque the bolts to 35 ft. Ibs. (47 Nm). Crankshaft balancer. Torque the bolt to 76 ft. Ibs. (103 Nm). Valve lifters in their original locations Lifter guide. Torque the bolts to 89 inch Ibs. (10 Nm). Pushrods, rocker arms, rocker balls and rocker arm nuts. Torque the rocker arm nuts to 89 inch Ibs. (10 Nm) plus an additional 30 degrees. Intake manifold. Torque the upper and lower intake bolts to 115 inch lbs. (13 Nm). Rocker arm covers. Torque the bolts to 89 inch Ibs. (10 Nm). Negative battery cable 5. Start the engine and verity no oil leaks.

2. Remove or disconnect the following: e Negative battery cable e Air inlet duct from the throttle body e Starter bolts e Starter electrical connectors e Starter motor To install: 3. Install or connect the following: e Starter motor. Torque the bolts to 66 ft. Ibs. (90 Nm). e Starter electrical connectors e Air inlet duct to the throttle body ¢ Negative battery cable 3.1L Engine

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Negative battery cable ¢ Lower closeout panel ¢ Starter bolts ¢ Starter electrical connectors ¢ Starter motor To install: 3. Install or connect the following: ¢ Starter electrical connectors. Torque the solenoid cable to 106 inch Ibs. (12 Nm). ¢ Starter motor. Torque the bolts to 37 ft. Ibs. (60 Nm).

e Lower closeout panel e Negative battery cable

REMOVAL & INSTALLATION 2.4L Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Disconnect the negative battery cable. 3. Drain the engine oil and cooling system.

4. Install an engine support fixture. 5. Remove or disconnect the following: ¢ Engine mount and raise the engine approximately 1.5 inches (3.8cm) Flywheel dust shield Right front wheel Right inner fender splash shield Accessory drive belt Air conditioning compressor and support it aside with the lines attached Transmission-to-engine brace Radiator outlet pipe Bolt and the nut which secure the oil pan to the flywheel cover

ADJUSTMENT The 2.4L and 3.1L engines-are equipped with hydraulic valve lifters; no adjustment is necessary.

Starter Motor REMOVAL & INSTALLATION 2.4L Engine

1. Before servicing the vehicle, refer to the precautions in the beginning of this section.

1 Oil pan 2 Oil pan bolt (M8 x 1.25 x 80)

24 Nm (18 Ib. ft)

3 Oil pan bolt (M8 x 1.25 x 22)

24 Nm (18 Ib. ft) 4 Oil pan bolt (M6 x 1.00 x 25)

12 Nm (106 Ib. in.) 5 Stud end oil pan bolt 26 Nm (19 Ib. ft.)

Oil pan mounting bolt locations—2.4L engine

79227215

GENERAL MOTORS CORPORAT eet ¥canes 26-1 5 me

A

AR

SETS

SR

° Flywheel cover stud for clearance ¢ Oil pan bolts and the pan

To install: 6, Install or connect the following: e (Oil pan using a new gasket. Torque the chain housing-to-oil pan bolts 10 106 inch Ibs. (12 Nm) and the oil pan-to-block bolts to 18 ft Ibs. (24 Nm). ¢ Oil pan-to-transaxle nut. Torque the rut to 41 ft. Ibs. (56 Nm), ¢ Radiator outlet pipe

¢ Transmission-to-engine brace. lorque the bolts to 37 ft. Ibs. (50

Nm) e Air conditioning compressor. lorque the bolts to 37 ft. Ibs. (50 Nm). « Accessory drive belt ¢ Right inner fender splash shield « Right front wheel

¢ Flywheel dust shield ¢ Engine mount. Torque the bolts to 49 ft. Ips. (66 Nm)

« Negative battery cable 7, Fill the crankcase with oil, >A filter change is recommended.

8, 9. 10, 11,

Refill the crankcase, Fill the cooling system. Remove the engine support fixture. Start the engine and check for leaks.

3.1L Engine

OCD

REL

SAE

LIGETI

TT

RSE,

BE A EP PL

* Evaporator-to-accumulator A/C line Flywheel cover Engine cradle bolts Crankshaft balancer Starter motor ¢ Oil pan To install: 5, Install or connect the following: * Oil pan using a new gasket -»Apply silicone sealer to the portion of the pan that contacts the rear of the block.

* Oil pan bolts. Torque the bolts to 18 ft. Ibs. (24 Nm) and the side

bolts to 37 ft. Ibs. (50 Nm), ¢ Starter motor. Torque the bolts to 37 ft. Ibs. (50 Nm). ¢ Flywheel cover * Crankshaft balancer. Torque the bolt to 76 ft. Ibs. (103 Nm). ¢ A/C compressor. Torque the bolts to 37 ft. Ibs. (50 Nm). « Evaporator-to-accumulator line e Engine cradle bolts. Torque the bolts to 89 ft. Ibs. (120 Nm). ¢ Ball joint to the steering knuckle using a new cotter pin. Torque the nut 48 ft. Ibs. (60 Nm). ¢ Quter tie rod end. Torque the nut to 33 ft. Ips. (45 Nm), « ABS wheel speed sensor electrical connector e Inner fender splash shield

1. Before servicing the vehicle, refer to the precautions in the beginning of this section ) fyacuate and recover the A/C system. 3 Drain the engine ol! 4 Remove or disconnect the following: * Negative battery cable Accessory drive belt Upper and lower radiator hoses Right front wheel inner fender splash shield Antilock Brake System (ABS) Wheel

Sneed Sensor (WSS) electrical

connector

| SBE

NEL

EEA

ED

EER TAE ATE EEE

e Right front wheel e Accessory drive belt ¢ Upper and lower radiator hoses ¢ Negative battery cable 6. Refill the crankcase. 7. Evacuate and recharge the A/C system. 8. Start the engine and check for leaks. =» Whenever the vehicle subframe is removed or lowered, the wheel alignment should be checked.

REMOVAL & INSTALLATION 2.4L Engine Please note that the transaxle must be removed from the vehicle to service

the oil pump.

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Disconnect the negative battery cable. 3. Install an engine support fixture. 4. Drain the engine oil. 5. Remove or disconnect the following: e Qil pan e Transaxle ° Flywheel ¢ Balance shaft chain cover and chain guide Oil pump cover bolts and the cover ¢ Pump gear from the balance shaft by pulling the housing ¢ Oil pump housing from the balance shaft To install: 6. Clean all of the parts in suitable cleaning solvent. Remove all varnish sludge and dirt. 7. Lubricate the gears with clean engine oll. 8. Install or connect the following: ¢ Gerotor gear into the housing; then, fill the oil pump cavities with petroleum jelly

© Right front ball joint from the steering knuckle + Right side outer tie rod end « A/C compressor bolts and move the compressor aside

k RNING? WA Fic DO NOT disconnect the refrigerant lines or allow the compressor to hang unsupported.

79227217

79227216

Exploded view of the oil pan mounting— 3.1L engine

Exploded view of the oil pump components—2.4L engine

this manual For Accessory Drive Belt illustrations, see Section 1 of

26-1 6 GENERAL MOTORS CORPORATION MALIBU e CUTLASS

¢ Oil pump housing to the balance shaft ¢ Oil pump cover to the housing. Tighten the bolts to 40 ft. Ibs. (54 Nm). e Balance shaft chain guide and chain 9. Adjust the chain tension by performing the following procedure: a. Insert a 0.40 in. (1mm) brass feeler between the chain guide and chain.

Torque the housing-to-engine bolts to 106 inch Ibs. (12 Nm) and the oil pan-to-seal housing bolts to 106 inch Ibs. (12 Nm). ¢ Flywheel. Torque the bolts to 22 ft. lbs. (30 Nm) plus an additional 45 degree rotation. e Transaxle e Negative battery cable 8. Start the engine and check for leaks.

e>A brass feeler gauge must be used to ensure that correct measurements are obtained. If a steel gauge is used, it will not bend to conform to the guide and will allow for incorrect measurements.

b. Press the guide against the chain using about 3 Ibs. (13.3 N) of force. c. Tighten the chain tensioner fastener to 115 inch Ibs. (13 Nm). 10. Install or connect the following: e Balance shaft chain cover. Tighten the nut and bolt to 115 inch Ibs. (13 Nm). e Flywheel ¢ Transaxle e Qil pan e Negative battery cable 11. Refill the crankcase. e» A filter change is recommended.

12. Remove the engine support fixture. 13. Start the engine and verify oil pressure and no leaks. 3.1L Engine

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Disconnect the negative battery cable. 3. Drain the engine oil. 4. Remove or disconnect the following: e Oil pan ¢ Crankshaft oil deflector ¢ Oil pump and pump driveshaft To install: 9. Install or connect the following: ¢ Oil pump and pump driveshaft. Torque the bolts to 30 ft. Ibs. (41 Nm). ¢ Crankshaft oil deflector. Torque the nuts to 18 ft. Ibs. (24 Nm). ¢ Oil pan. Torque the bolts to 18 ft, Ibs. (24 Nm) and the side bolts to 37 ft. lbs. (50 Nm). ¢ Negative battery cable 6. Refill the crankcase. e>A filter change is recommended.

/. Start the engine, check the oil pressure and check for leaks.

3.1L Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Support the engine. 3. Remove or disconnect the following: e Transaxle e Flywheel e Rear main seal by prying it from the housing

Use care not to damage the crankshaft seal surface with a prytool. 79222218

Exploded view of the oil pump mounting— 3.1L engine

Rear Main Seal

REMOVAL & INSTALLATION 2.4L Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Negative battery cable ¢ Transaxle ¢ Flywheel ¢ Oil pan-to-seal housing bolts ¢ Seal housing-to-block bolts

¢ Seal housing e*The seal housing could be damaged if not properly supported during seal removal.

3. Drive the seal evenly out the transaxle Side of the seal housing using a small pry tool in the relief grooves on the crankshaft side of the seal housing. To install: 4. Press a new seal into the housing. 9. Inspect the oil pan gasket inner silicone bead for damage and repair using a silicone sealant, if necessary. 6. Lubricate the seal lip with clean engine oil. 7. Install or connect the following: * Seal housing with a new gasket,

To install: 4. Lubricate the seal bore and new seal with engine oil. 9. Install the new seal by performing the following procedure: a. Slide the new seal over the mandrel until the dust lip bottoms squarely against the tool collar. b. Align the dowel pin of the tool with the dowel pin hole in the crankshaft and attach the tool to the crankshaft. Tighten the attaching screws to 24-60 inch Ibs. (2.7-6.8 Nm). c. Tighten the T-handle of the tool to push the seal into the bore. Continue until the tool collar is flush against the block. d. Loosen the T-handle completely. Remove the attaching screws and the tool. e>Check to see that the seal is squarely

seated in the bore.

6. Install or connect the following: ¢ Flywheel e Transaxle 7. Start the engine and check for leaks.

Timing Chain, Sprockets, Front Cover and Seal

REMOVAL & INSTALLATION SE enn a Ea 2.4L Engine elt is recommended that the entire procedure be reviewed before attempting to service the timing chain.

GENERAL MOTORS CORPORATION

MALIBU e CUTLASS

1. Before servicing the vehicle, refer to eeprecautions in the beginning of this secion. 2. Disconnect the negative battery cable. 3. Drain the cooling system. 4. Install an engine support. 5. Remove or disconnect the following: Coolant surge tank Accessory drive belt Upper front cover fasteners Right engine mount and bracket

Right front wheel Lower splash shield from the right wheel house Crankshaft balancer Lower front cover fasteners Front cover 6. Rotate the crankshaft clockwise, as viewed from the front of the engine (normal rotation), until the camshaft sprocket's timing dowel pin holes align with the holes in the timing chain housing. The mark on the crankshaft sprocket should align with the mark on the cylinder block. The crankshaft sprocket keyway should point upwards and align with the center line of the cylinder bores. This is the normal timed position. 7. Remove or disconnect the following: e Timing chain guides ¢ Timing chain tensioner e Timing chain tensioner shoe

_ 2k CAUTION The tensioner piston is spring loaded and could fly out causing personal injury. e Timing chain ¢ Camshaft sprockets, using a 3 jaw puller To install: 8. Install the intake camshaft sprocket. Torque the bolt to 52 ft. Ibs. (70 Nm). ->Install the Special Tool J 36008-A through the holes in the camshaft sprockets into the holes in the timing chain housing. This positions the camshafts for correct timing. 9. If the camshafts are out of position and must be rotated more than Ye turn in order to install the alignment dowel pins, perform the following: qa. Rotate the crankshaft 90 degrees

clockwise off Top Dead Center (TDC) in order to give the valves adequate clearance to open. b. Once the camshafts are in position and the dowels instailed, rotate the

crankshaft counterclockwise back to

Do not rotate the crankshaft clock-

wise to TDC or valve and piston damage may occur. 10. Install the timing chain over the exhaust camshaft sprocket, around the coolant pump sprocket and around the crankshaft sprocket. 11. Remove the alignment dowel pin from the intake camshaft. Rotate the intake camshaft sprocket counterclockwise enough to slide the timing chain over the intake camshaft sprocket. If properly timed, the intake camshaft alignment dowel pin should Slide in easily. If the dowel pin does not fully index, the camshafts are not timed correctly and the procedure must be repeated. 12. Leave the alignment dowel pins installed. 13. With slack removed from the chain between the intake camshaft sprocket and the crankshaft sprocket, the crankshaft keyway and the cylinder block mark should be aligned. If not aligned, move the chain 1 tooth forward or rearward. Remove the slack and recheck the marks. 14. Tighten the chain housing-to-block stud. The stud is installed under the timing chain. Torque the stud to 19 ft. Ibs. (26 Nm). 15. Reload timing chain tensioner assembly to its 0 position as follows: a. Insert the tensioner plunger assembly into the tensioner housing. b. With the tensioner plunger fully extended, turn the complete assembly upside down on a flat surface. c. Press the bottom of the tensioner housing to compress the plunger into the housing until it is seated. d. Make sure that the plunger does not extend out of the tensioner housing more than 0.07 in. (1.7mm). e. Loosely install the tensioner assembly to the timing chain housing. 16. Install or connect the following: Tensioner shoe on the stud Tensioner assembly by applying hand pressure on the timing chain tensioner shoe until the locking tab seats in the stud groove. Torque the bolts to 89 inch Ibs. (10 Nm).

tok WARNING If the timing chain tensioner plunger is not released from the installation

26-1 T

position, engine damage will occur upon start up. 17. Release the tensioner plunger by firmly pressing a flat blade tool against the plunger face.

If the tensioner plunger cannot be depressed, it is not properly reset and the resetting procedure must be repeated. 18. Rotate the crankshaft clockwise 2 full rotations. Align the crankshaft keyway with the mark on the cylinder block and reinstall alignment dowel pins. The alignment dowel pins will slide in easily if engine is timed correctly. 19. Install or connect the following: Timing chain guides Front cover using new gaskets. Torque the nuts and bolts to 106 inch Ibs. (12 Nm). Crankshaft balancer. Torque the bolt to 129 ft. Ibs. (175 Nm) plus an additional 90 degree rotation. Right front lower splash shield Wheel Right engine mount bracket. Torque the bolts to 81 ft. Ibs. (110 Nm) plus an additional 90 degree rotation. Right engine mount. Torque the bolt to 49 ft. Ibs. (66 Nm). 20. Remove the engine support. 21. Install or connect the following: e Accessory drive belt ¢ Coolant surge tank e Negative battery cable 22. Refill the cooling system and check for leaks. 3.1L Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. _ Disconnect the negative battery cable. . Drain the cooling system. . Drain the engine oil. _ Recover the A/C system refrigerant. _ Install an engine support fixture. OT MD NI Po Sw _ Remove or disconnect the following: Right engine mount assembly Accessory drive belt Air cleaner assembly Throttle body tube Power steering line at the pump Alternator and bracket Right front wheel Right inner fender well splash shield

1 of this manual For Tire, Wheel and Ball Joint specifications, see Section

26-1 8 GENERAL MOTORS CORPORATION MALIBU e CUTLASS

79222220

Timing chain and sprocket timing mark alignment—3.1L engine

Right engine mount bracket Crankshaft balancer Drive belt tensioner Oil pan Crankshaft Position (CKP) sensor Coolant bypass pipe from the water pump and the intake manifold Lower radiator hose from the front cover outlet Front cover 8. Rotate the crankshaft until the timing marks on the camshaft and crankshaft sprockets are in alignment. 9. Remove or disconnect the following: ¢ Camshaft sprocket and timing chain ¢ Crankshaft sprocket ¢ Timing chain damper To install: 10. Install or connect the following: ¢ Timing chain damper. Torque the bolts to 15 ft. Ibs. (21 Nm). ¢ Crankshaft sprocket 11. Be sure the crankshaft sprocket timing mark is pointing straight up. 12. Install the timing chain over the camshaft sprocket and hold the sprocket in such a way, that the timing mark is pointing down, and the timing chain is hanging down off the sprocket. 13. Loop the timing chain under the crankshaft sprocket and install the camshaft sprocket on the camshaft. The sprocket will Only fit on the camshaft if the dowel on the camshaft aligns with the hole in the sprocket. 14. Verify se that the marks are aligned (the camshaft sprocket will be at the 6 o'clock position and the crankshaft sprocket will be in the 12 o'clock position).

15. Torque the camshaft sprocket mounting bolt to 103 ft. Ibs. (140 Nm). 16. Lubricate the timing chain components with engine oil. 17. Apply a thin bead of sealer around the gasket sealing area of the front cover. 18. Install or connect the following: ¢ Front cover with a new seal and gasket. Torque the small bolts to 15 ft. Ibs. (21 Nm) and the large bolts to 35 ft. Ibs. (47 Nm). Radiator hose to the coolant outlet Coolant bypass pipe to the water pump and intake manifold CKP sensor Oil pan. Torque the bolts to 18 ft. Ibs. (24 Nm) and the side bolts to 37 ft. Ibs. (50 Nm). Crankshaft balancer. Torque the bolt to 76 ft. Ibs. (103 Nm). Accessory drive belt tensioner. Torque the bolt to 40 ft. Ibs. (54 Nm). Right engine mount bracket. Torque the bolts to 96 ft. Ibs. (130 Nm). Right inner fender well splash shield e Wheel 19. Remove the engine support fixture. 20. Install or connect the following; Alternator. Torque the front bolt to 37 ft. Ibs. (50 Nm) and the rear bolt to 18 ft. Ibs. (24 Nm). Power steering line Throttle body tube Air cleaner assembly Accessory drive belt Negative battery cable 21. Refill the cooling system. 22. Check the engine oil level.

Piston and Ring POSITIONING CONNECTING ROD MATCHING NUMBERS

7922AG51

Connecting rod and cap installation. Be sure to matchmark the cap and rod prior to disassembly, as shown

1. PISTON 2. ORIENTATION ARROW TOWARDS FRONT OF ENGINE 3. CONNECTING ROD 4. OIL SQUIRT HOLE TOWARDS EXHAUST SIDE 5. BEARING CONNECTING ROD 6. NUT, CONNECTING ROD CAP TO CONNECTING ROD 7. CAP, CONNECTING ROD

e>An oil and filter change is recommended.

23. Start the engine and verify that there are no leaks.

OIL RING ASSEMBLY GAP

7922AG49

Piston and connecting rod assembly positioning—2.4L engine

120° TYPICAL

LOWER COMPRESSION RING GAP PISTON

FRONT OF

&

ENGINE

UPPER COMPRESSION RING GAP Piston ring end-gap spacing—2.4L engine

7922AG50

GENERAL MOTORS CORPORATION MALIBU ¢ CUTLASS 26-1 § ARROW TOWARDS FRONT OF ENGINE

\When removing the modular fuel sender from the tank, be aware that it may spring upward.

2 BODY FUEL FILTER BRACKET FUEL FILTER PWN SCREW — FULLY DRIVEN, SEATED AND NOT STRIPPED

¢ Modular fuel sender assembly

>: CAUTION When removing the modular fuel sender from the tank, be aware that the reservoir bucket is full of fuel.

¢ External fuel strainer ¢ Connector retainer from the wiring harness ¢ Fuel pump electrical connector 5. Gently release the tabs on the sides of the fuel sender at the cover assembly. Begin by squeezing the sides of the reservoir and releasing the tab opposite the fuel level sensor. Move clockwise to release the second and third tab in the same manner. 6. Remove or disconnect the following:

¢ Fuel pump/baffle assembly by rotating it counterclockwise ¢ Fuel pump by sliding the outlet away from the cover slots ¢ Fuel pump outlet seal To install: 7. Install or connect the following: ¢ Fuel pump outlet seal ¢ Fuel pump outlet by sliding it into the reservoir cover slots ¢ Fuel pump/baffle assembly onto the reservoir retainer by rotating it clockwise until seated e Lower retainer assembly by aligning the 3 sleeve tabs and pressing the retainer onto the reservoir until tabs are firmly seated

79222221

Exploded view of the fuel filter mounting

1

2 3 4 5

HOSE, PART OF FUEL SENDER

FUEL VAPOR PIPE FUEL RETURN PIPE FUEL FEED PIPE FUEL FEED PIPE NUT 27 Nem (20 LBS. FT.) HOSE, PART OF FUEL SENDER NO ABS AND FUEL SENDER HARNESS 19227222

Fuel filter mounting location and component identification

SNAP RING COVER — TAB MODULAR UNIT WIRE HARNESS - ABOVE COVER FUEL TANK TANK ISOLATION STRIPS (3) NOOPfL WD — RUBBER ISOLATOR

Exploded view of the fuel sender assembly mounting to the tank

79227223

GENERAL MOTORS CORPORATION

MALIBU ¢ CUTLASS

26-21

9306YG05

HARNESS ASSEMBLY (ABOVE COVER) - FUEL PUMP AND FUEL SENDER WIRING CONNECTOR ASSEMBLY - FUEL SENDER WIRING FUEL PIPES (3) COVER ASSEMBLY — FUEL SENDER SEAL - FUEL PUMP OUTLET SUPPORT ASSEMBLY (THREE HOLLOW SUPPORT OR GUIDE PIPES) — FUEL PUMP RESERVOIR RETAINER - FUEL PUMP RESERVOIR CONNECTOR POSITION ASSURANCE (CPA) HARNESS ASSEMBLY (BELOW COVER) - FUEL PUMP HARNESS ASSEMBLY (BELOW COVER) - FUEL LEVEL SENDER 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 STRAINER — FUEL PUMP FUEL BAFFLE (ISOLATOR CUP) — FUEL PUMP PUMP ASSEMBLY (ROLLERVANE) - FUEL OUTLET - FUEL PUMP 79227224

Exploded view of the fuel pump assembly

e Fuel pump electrical connector e Connector retainer to the wiring harness e External fuel strainer ¢ Modular fuel sender assembly ¢ Modular fuel sender assembly-tofuel tank snapring by pressing the assembly downward on 1998-99 models or lock the cam ring using Too! J-39765 on 2000-01 models e Fuel tank e Negative battery cable 8. Refill the fuel tank. 9. Pressurize the fuel system and verify no leaks.

Fuel Injector REMOVAL & INSTALLATION 2.4L Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section.

2. Relieve the fuel system pressure. 3. Remove or disconnect the following: e Air cleaner assembly ¢ Fuel pressure regulator vacuum line ¢ Camshaft Position (CMP) sensor electrical connector e Fuel injector electrical connectors e Fuel line from the fuel pressure regulator e Fuel rail e Fuel pressure regulator screw e Fuel pressure regulator from the fuel rail twisting it back and forth e Fuel injector-to-fuel rail retaining clip e Fuel injector and discard the Orings To install: 4. Install or connect the following: ¢ Fuel injector(s) with new O-rings e Fuel injector retaining clip(s) e New fuel pressure regulator O-ring, lubricated with engine oil ¢ Fuel pressure regulator to the fuel

Exploded view of the fuel rail assembly— 2.4L engine

)

i eee

9306YG06

Exploded view of the fuel injector—2.4L engine

rail. Torque the screw to 97 inch lbs. (11 Nm). e Fuel rail e Fuel line to the fuel pressure regulator e Fuel injector electrical connectors e Camshaft position sensor e Fuel pressure regulator vacuum line e Negative battery cable 5. Pressurize the fuel system and check for leaks. 3.1L Engine

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Relieve the fuel system pressure. 3. Remove or disconnect the following: e Accelerator cable from the throttle body lever and cable bracket e Upper intake manifold e Fuel feed line from the fuel rail and discard the O-ring ¢ Fuel return fine from the fuel pressure regulator e Main wiring harness connectors located near the alternator

n 1 of this manual For Maintenance Interval recommendations, see Sectio

26-22 GENERAL MOTORS CORPORATION MALIBU © CUTLASS the nylon O-ring backup to properly position the O-ring on the fuel injector so it doesn’t move when installing the fuel rail.

4. Install or connect the following: Fuel injector with new O-rings Fuel injector electrical connectors Fuel rail assembly. Torque the bolts to 7 ft. Ibs. (10 Nm). CTS electrical connector Main wiring harness connectors

Fuel return line to the fuel pressure 93062602

Exploded view of the fuel rail assembly— 3.1L engine 93062603

* Coolant Temperature Sensor (CTS) electrical connector ¢ Fuel rail assembly ¢ Fuel injector electrical connectors ¢ Fuel injector-to-fuel rail clips e Fuel injector(s) ->Be careful not to loose the O-ring backups.

Exploded view of the fuel injector—3.1L engine

To install:

->When installing new O-rings on the fuel injector, the lower position is color coded brown and the upper position is color coded black. Be sure to install

regulator using a new O-ring. Torque the fitting to 13 ft. Ibs. (17 Nm Fuel feed line to the fuel rail using a new O-ring. Torque the fitting to 13 ft. Ibs. (17 Nm). Upper intake manifold Accelerator cable to the throttle body lever and cable bracket Fuel cap and tighten it Negative battery cable 5. Pressurize the fuel system and check for leaks.

DRIVE TRAIN Transmission Assembly REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Install an Engine Support Fixture. 3. Drain the transmission. 4. Remove or disconnect the following: Negative battery cable Air cleaner assembly Front transmission mount bolts Front wheels Left and right splash shields Shift linkage from the transaxle Wiring harness connection from the transaxle Ground cables from the engine block Park Neutral Position (PNP) switch electrical connector Lower radiator and condenser Support Front transmission mount bracket Anti-lock Brake System (ABS) wheel speed sensors and electrical harnesses from the suspension supports Brake modulator assembly Vehicle Speed Sensor (VSS) Torque converter cover

Torque converter-to-flywhee! bolts Ball joints from the steering knuckles Halfshafts from the transaxle ABS module Outer tie rod ends from the Steering knuckles Pressure line from the rack and pinion Transmission fluid cooler lines Brake hose bracket from the body Intermediate shaft Transmission-to-engine bolts Transaxle from the engine To install: 9. Apply a thin film of grease on the torque converter pilot hub.

Be sure to properly seat the torque converter in the pump.

6. Install or connect the following: Transaxle. Torque the transmissionto-engine bolts to 66 ft. Ibs. (90 Nm), Intermediate shaft. Torque the pinch bolt to 15 ft. Ibs. (20 Nm). Brake hose bracket to the body Transaxle fluid cooler lines Pressure line to the rack and pinion

e Outer tie rod ends. Torque the nuts to 14 ft. Ibs. (20 Nm) plus an additional 180 degree turn. ABS module Halfshafts to the transaxle Ball joints. Torque the nuts to 48 ft. lbs. (65 Nm). Torque converter. Torque the bolts to 46 ft. Ibs. (62 Nm). Torque converter cover VSS electrical connector Brake modulator assembly Front ABS wheel speed sensors and harnesses to the suspension Support Front transmission mount bracket Lower radiator and condenser Support PNP switch electrical connector

Ground cables to the engine block Transmission electrical connections Shift cable bracket. Torque the bolt to 18 ft. Ibs. (24 Nm) and the nut to 37 ft. Ibs. (50 Nm). Air cleaner assembly Left and right splash shields Front wheels /. Remove the engine support fixture. 8. Install or connect the following: ¢ Shift linkage ¢ Negative battery cable

~

GENERAL MOTORS CORPORATION MALIBU ¢ CUTLASS 26-23 9. Refill the transmission. 10. Apply the brakes and start the engine. 11. Shift the transaxle from R to D and back to P. 12. Recheck the fluid level.

e Halfshaft from the hub/bearing assembly using a puller e Halfshaft from the transaxle To install: 3. Install the halfshaft into the transaxle by placing a tool in the joint housing groove and tapping until seated.

e Stabilizer link. Torque the nut to 13 ft. Ibs. (17 Nm). ¢ New halfshaft nut. Torque it to 284 ft. lbs. (385 Nm). e Wheel

_ CV-Joint OVERHAUL

REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Wheel ¢ Tie rod from the steering knuckle e Halfshaft hub nut and washer e Stabilizer link e Lower ball joint from the steering knuckle

(1) Drive Axle, Right Side (2) Drive Axle, Left Side (3) J 28468 or J 33008

Be careful not to damage the axle seal or dislodge the transaxle seal garter spring when installing the halfshaft. 4. Verify that the halfshaft is seated in the transaxle by grasping on the housing and pulling outward. 5. Install or connect the following: ¢ Halfshaft into the hub/bearing assembly ° Tie rod to the steering knuckle. Torque the nut to 33 ft. Ibs. (45 Nm). e Lower ball joint to the steering knuckle. Torque the nut to 48 ft. lbs. (65 Nm). e New cotter pin to the lower ball joint

Outer CV-Joint

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Front wheel Halfshaft and position it in a vise Large CV-joint boot clamp Small C\V-joint boot clamp C\V-joint boot and slide it back on the shaft Outer race from the halfshaft by spreading the outer race-to-halfShaft retaining ring Retaining ring from the halfshaft CV-joint boot from the halfshaft

(4) J 29794 (5) J 2619-01 79222225

Removing the left and right halfshafts

Retainer and Housing Assembly

10

Seal Retaining Clamp

Shaft Retaining Ring Tripot Joint Spider Assembly

11 12 13

Drive Axle Outboard Seal Seal Retaining Clamp Race Retaining Ring

Seal Retaining Clamp Tripot Trilobal Bushing

14

Chrome

15

CV Joint Inner Race

Drive Axle inboard Seal

16

CV Joint Cage

17.

CV Joint Outer Race

Spacer Ring

(1) J 28733A (2) Forcing Screw

(3) Turn Box Wrench (4) Hold Wrench 79222226

utilizRemoving the halfshaft from the hub ing the appropriate tools

Seal Retaining Clamp Axie Shaft WN DOF OWN =

Alloy Ball

Exploded view of the halfshaft assembly

1 of this manual For Tune-up, Capacities and Firing orders, seé Section

93062601

26-24

GENERAL MOTORS CORPORATION MALIBU ¢ CUTLASS

9306YG09

Crimping the small boot clamp—Outer CVjoint

9306YG11

Crimping the large boot clamp—Outer CVjoint

3. Disassemble the chrome alloy balls from the CV-joint cage as follows: a. Position a brass drift against the CV-joint cage and tap it with a hammer to tilt the cage. b. Remove the 1st chrome alloy ball from the cage. c. Tilt the cage in the opposite direction. d. Remove the opposite chrome alloy ball. é. Repeat the procedure until all 6 balls are removed. 4, Disassemble the CV-joint cage and inner race as follows: a. Pivot the cage and race 90 degrees to the center line of the outer race. b. Align the cage windows with outer race lands. C. Remove the cage from the outer race. d. Rotate the inner race upward and remove it from the cage.

To install: 5. Lubricate the parts with a light coat of grease. 6. Assemble the CV-joint cage and inner race, as follows: a. Rotate the inner race 90 degrees to” the cage centerline. b. Align the cage windows with inner race lands. c. Insert the inner race into the cage by rotating the inner race downward. d. Insert the cage/inner race into the outer race. 7. Assemble the chrome alloy balls into the CV-joint cage, as follows: a. Position a brass drift against the C\-joint cage and tap it with a hammer to tilt the cage. b. Insert the 1st chrome alloy ball into the cage. c. Tilt the cage in the opposite direction. d. Insert the opposite chrome alloy ball. e. Repeat the procedure until all 6 balls are inserted. 8. Install ¥ of the grease provided into the CV-joint. 9. Install or connect the following: ¢ Small ring clamp on the CV boot ¢ CV boot onto the halfshaft 10. Slide the small end of the CV-joint boot/clamp into place, with the seal lip in the halfshaft groove. e»Make sure the boot lies flat against the halfshaft.

11. Using a Crimp tool, a torque wrench and a breaker bar, crimp the small CV-joint boot clamp to 100 ft. Ibs. (136 Nm). 12. Install the remainder of the grease into the CV-joint boot. 13. Install or connect the following: ¢ New retaining ring on the halfshaft ¢ Outer race assembly onto the halfshaft until the ring engages the halfshaft groove e Large ring clamp on the CV boot 14. Using a Crimp tool, a torque wrench and a breaker bar, crimp the large CV-joint boot clamp to 130 ft. Ibs. (176 Nm). 15. Install the halfshaft and the front wheel.

Inner (Tri-Pod) Joint 1. Before servicing the vehicle, refer to the precautions in the beginning of this section.

9306XG14

Exploded view of the inner (tri-pod) joint

2. Remove or disconnect the following: ¢ Front wheel ¢ Halfshaft and place it in a vise ¢ Snapring from the stub shaft ¢ Small CV-joint boot clamp e Large CV-joint boot clamp ¢ CV-joint boot by sliding it away from the tri-pod joint 3. Install a Stub Shaft Removal Tool J-38868-A to the stub shaft snapring groove. 4. Using a slide hammer puller, pull the stub shaft from the tri-pod housing. 5. Remove or disconnect the following: Tri-pod housing from the tri-pod spider Inboard spacer ring slide it rearward on the shaft ¢ Outboard retaining ring ¢ Tri-pod joint spider assembly ¢ Inboard spacer ring and discard it ¢ CV-joint boot e Trilobal tri-pod bushing from the: housing To install: 6. Install or connect the following: ¢ New snapring onto the stub shaft ¢ Small boot clamp ¢ CV-joint boot 7. Using a Crimp tool, a torque wrench and a breaker bar, crimp the small CV-joint boot clamp to 100 ft. Ibs. (136 m). 8. Install or connect the following: e Inboard spacer ring slide it rearward on the shaft beyond the second groove Tri-pod joint spider assembly onto the shaft until it passes the 2nd groove Outboard retaining ring into the axle shaft groove Tri-pod joint spider assembly, slide it against the outboard retaining ring Inboard spacer ring, seat it in the groove Ya of the grease provided into the boot

GENERAL MOTORS CORPORATION

MALIBU ¢ CUTLASS

e The remaining grease into the tripod housing e Trilobal tri-pod bushing flush with the tri-pod housing face e New large seal clamp onto the CVjoint boot e Tri-pod housing, slide it over the tri-pod joint spider assembly

e CV\-joint boot/clamp, slide it into place, over the trilobal tri-pod bushing with the seal lip in the groove e>Make sure the boot lies flat against the trilobal bushing.

9. Using a Crimp tool, a torque

wrench and a breaker bar, crimp the large C\-joint boot clamp to 130 ft. Ibs. (176 Nm). 10. Check the clamp gap dimension; if it is not 0.085 in. (2.16mm), continue tightening the clamp until it is. 11. Install the halfshaft and the front wheel.

STEERING.AND SUSPENSION unnecessary SRS repairs and/or personal injury.

+ CAUTION Some vehicles are equipped with an air bag system, also known as the Supplemental Inflatable Restraint (SIR) 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.

PRECAUTIONS

1. Disconnect the negative battery cable. 2. Turn the steering wheel so the vehicle's wheels are pointing straight-ahead. 3. Turn the ignition switch to the LOCK position. 4. Remove or disconnect the following: Key AIR BAG fuse from the fuse block Left sound insulator Connector retainer clip from the yellow 2-way connector at the base of the steering column Connector retainer and yellow 2way connector from the passenger air bag lead, if equipped with a passenger's side air bag

ARMING

LS

Several precautions must be observed when handling the inflator module to avoid accidental deployment and possible personal injury. e 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.

e Place the inflator module on a bench or other surface with the bag and trim cover facing up. e With the inflator module on the bench, never place anything on or close to the module, which may be thrown in the event of an accidental deployment.

DISARMING

EEEEEEEEEEEE EE ee

1. Turn the ignition switch to the LOCK position and remove the key. 2. Install or connect the following: e Yellow 2-way connector at the base of steering column and the connector retainer clip Yellow 2-way connector at the passenger air bag lead and secure it with the connector retainer clip, if equipped with a passenger's side air bag e Left sound insulator ¢ AIR BAG fuse in the fuse block 3. Turn the ignition switch to the RUN position and verify that the AIR BAG warning lamp —flashes 7 times, then turns OFF. 4. Connect the negative battery cable.

Power Rack and Pinion Steering Gear

sete CAUTION. The Supplemental Restraint System (SRS) must be disarmed before performing service procedures around the air bag or SRS wiring. Failure to do so may cause accidental deployment of the air bag, resulting in

REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to ions in the beginning of this secprecaut the tion.

26-25

. 2. Disconnect the negative battery cable. 3. Siphon the power steering fluid from the reservoir. 4. Remove or disconnect the following: e Left front wheel e Intermediate shaft assembly e Tie rod ends from the steering knuckles e Stabilizer shaft links ¢ Steering gear mounting bolts 5. Support the rear of the support frame. 6. Remove or disconnect the following: e Transaxle-to-crossmember mounting bolt e Rear crossmember-to-body bolts e Front crossmember bolts, loosen them 7. Lower the support frame for access. 8. Remove or disconnect the following: ¢ Power steering hoses from the steering gear e Steering gear through the left wheel opening To install: 9. Install or connect the following: e Steering gear through the left wheel opening ¢ Power steering hoses to the steering gear 10. Raise the support frame. 11. Install or connect the following: Front crossmember bolts. Torque

them to 71 ft. bs. (110 Nm) plus an additional 90 degree turn. Rear crossmember bolts. Torque them to 71 ft. Ips. (110 Nm) plus an additional 90 degree turn. Transaxle mount-to-crossmember bolt. Torque it to 49 ft. Ibs. (66 Nm). Steering gear bolts. Torque them to 89 ft. Ibs. (120 Nm). Stabilizer shaft links. Torque the nuts to 13 ft. Ibs. (17 Nm). Tie rod ends to the steering knuckle. Torque the nut to 15 ft.

on Labor Guide For complete service labor times, order Nichols’ Chilt

26-26

GENERAL MOTORS CORPORATION MALIBU e CUTLASS

To install: 5. Install or connect the following: e Strut and finger-tighten the upper strut-to-chassis nuts ¢ Strut to the steering knuckle. Torque the through-bolts/nuts to 133 ft. Ibs. (180 Nm) with the reference marks aligned. e Brake line bracket to the strut. Torque the bolt to 10 ft. Ibs. (14 Nm). e Wheel 6. Torque the upper strut fasteners to 18 ft. Ibs. (24 Nm). ; 7. Check and/or adjust the front end alignment. I

Rear

9

ae ee —

[ae== . ee

\

}

|

(1) Gear Assembly, Power Steering (2) Tie Rod (3) Shaft, Front Stabilizer

(4) Frame Assembly, Drivetrain and Front Crossmember

(5) Bolt, Power Steering Gear Assembly 79222227

Exploded view of the power rack and pinion steering gear mounting

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Matchmark the strut-to-knuckle position. 3. Remove or disconnect the following: e Rear wheels e Upper strut-to-chassis nuts ¢ Strut-to-knuckle bolts e Strut To install: 4. Install or connect the following:

Ibs. (20 Nm) plus an additional 180 degree turn. ¢ Intermediate shaft. Torque the pinch bolt to 16 ft. Ibs. (22 Nm). ¢ Left front wheel ¢ Negative battery cable 12. Refill and bleed the power steering system. 13. Check and/or adjust the front end alignment.

REMOVAL & INSTALLATION 32a SE Se a ARS ly Re Front

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Support the front crossmember. 3. Matchmark the front Strut-to-steering knuckle location. 4, Remove or disconnect the following: ¢ Front wheel e Brake line bracket from the strut ¢ Strut lower mounting bracket nut and through-bolts e Upper strut-to-chassis nuts e Strut

(1) Bearing, Strut Mount (2) Nuts, Strut Mount (3) Knuckle

(4) Arm, Control

(5) Crossmember (6) Bolts, Strut Mount

(7) Spring, Strut Coil

Exploded view and component identification of the front strut

79227228

GENERAL MOTORS CORPORATION MALIBU ¢ CUTLASS 26-2/

ie Ss

A

e Strut and finger-tighten the strutto-knuckle bolts e Upper strut-to-chassis nuts. Torque the nuts to 18 ft. Ibs. (24 Nm).

a

J 34013

e> Align the matchmarks to ensure proper alignment.

e Strut-to-knuckle bolts. Torque them to 89 ft. Ibs. (120 Nm). e Rear wheels 5. Check and/or adjust the alignment.

ete

REMOVAL & INSTALLATION

1 WRENCH 2 SOCKET 3 STRUT ASSEMBLY

Front and Rear

79222232

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove the strut. 3. Mount the strut in a strut compressor. (1) Mount, Strut Upper

(3) Spring, Coil

(2) Bolt, Strut Mount

(4) Nut

Use a socket and a wrench to remove the damper shaft nut spring cap while compressing the spring

>The strut compressor has strut mounting holes drilled for specific vehicle lines.

79222229

Exploded view of the upper strut mounting

4. Compress the strut approximately V2 of its height after initial contact with the top cap.

ia

%

(1) Cap (2) Nut, Strut Mount (3) Bearing, Strut Mount

(4) Insulator, Spring (Upper)

4 2

STRUT ASSEMBLY INSTALL LOCKING PINS THROUGH STRUT ASSEMBLY 3 TIGHTEN NUTS UNTIL FLUSH WITH STRUT COMPRESSOR 4 COMPRESSOR FORCING SCREW

(1) Mount, Strut Upper (2) Spring, Coil

(3) Nuts, Strut Bolt (4) Knuckle

(5) Bolt, Strut Mount

(5) Spring, Strut Coil

(6) Insulator, Spring (Lower) (7)

(9) Shield, Strut Dust

79227231

79222230

ing Exploded view of the lower strut mount

View of the strut mounted in the compres-

sor

Strut

(8) Bumper, Jounce

Exploded view of the front strut

com Please visit our web site at www. chiltonsonline.

26-2

GENERAL MOTORS CORPORATION MALIBU e CUTLASS (1) (2) (3) (4)

i

Strut Dust Shield, Strut Spring, Strut Coil Mount, Strut Upper

(5) Washer

(6) Nut

ing rod and install the nut. Torque the nut to 34 ft. Ibs. (47 Nm). 11. Remove the assembly from the compressor. 12. Install the strut on the vehicle.

Lower Ball Joint

REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Wheel

79227234

I

ESE

TL

RI

JOINT

e Wiring harness from the control arm e Stabilizer shaft link 3. Separate the ball joint from the steering knuckle. 4. Drill out the 3 ball joint-to-lower control arm rivets. Use an ¥ in. (3mm) drill bit to make a pilot hole through the rivets; then, finish drilling the rivets with a ¥% in. (13mm) drill bit. 5. Remove the ball joint from the control arm.

Exploded view of the ball joint-to-knuckle mounting

To install: 6. Install or connect the following: ¢ Ball joint to the control arm. Torque the 3 new nuts/bolts (supplied with new ball joint) to the specifications included with the kit. ¢ Ball joint to the steering knuckle. Torque the nut to 48 ft. Ibs. (65 Nm) and install a new cotter pin. ¢ Stabilizer link to the stabilizer shaft.

Never bottom the spring or damper ET

PIN

BALL

79227235:

3

rod. SS

2

65 N-m (48 LBS. FT.) MAXIMUM TORQUE TO INSTALL

3 LOWER

e->Care must be exercised to prevent the halfshaft joints from being overextended.

Exploded view of the rear strut

1 PIN

2 NUT - 55 N-m (41 LBS. FT.) MINIMUM TORQUE

EEL

5. Remove the strut damper shaft nut and place a guiding rod on top of the damper shaft. Use the rod to guide the damper shaft straight down through the spring cap while compressing the spring. Remove the components. To install: 6. Install the bearing cap onto the strut compressor, if removed. 7. Mount the strut in the strut compressor using the bottom locking pin only. 8. Install the spring over the damper and swing the assembly up so the upper locking pin can be installed. 9. Install all shields, bumpers and insulators on the spring seat. Install the Spring seat on top of the spring. Be sure the flat on the upper spring seat is facing in the proper direction. The spring seat flat should be facing the same direction as the centerline of the strut assembly spindle. 10. Install the guiding rod and turn the forcing screw while the guiding rod centers the assembly. When the threads on the damper shaft are visible, remove the guid-

—

1 SERVICE

BALL JOINT

2 BALL JOINT MOUNTING 3 NUT

BOLTS

4 LOWER

CONTROL ARM S STEERING KNUCKLE

6 NUT — 55 N-m (41 LBS. FT.) MINIMUM TORQUE 65 N-m (48 LBS. FT.) MAXIMUM TORQUE TO INSTALL

PIN

7 PIN 79227236

Exploded view of the ball joint mounting

GENERAL MOTORS CORPORATION MALIBU ¢ CUTLASS 26-29 Torque the nut to 13 ft. Ibs. (17 Nm). e Wiring harness to the control arm e Wheel 7. Check and/or adjust the front wheel alignment.

Lower Control Arm

REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Front wheel e Stabilizer shaft link e Lower ball joint from the steering knuckle e Lower control arm-to-suspension crossmember bolts e Lower control arm To install: 3. Install or connect the following: e Lower control arm-to-suspension crossmember and hand-tighten the bolts ¢ Lower ball joint to the steering knuckle. Torque the nut to 48 ft. lbs. (65 Nm). e Stabilizer shaft link. Torque the nut to 13 ft. Ibs. (17 Nm). e Front wheel 4. Position the vehicle at curb height. 5. On 1998-99 models, torque the bolts as follows: a. Front lower contro! arm-to-suspension crossmember bolt to 79 ft. Ibs. (107 Nm). b. Rear lower contro! arm-to-suspension crossmember bolt to 74 ft. Ibs. (100 Nm).

6. On 2000-01 models, torque the bolts as follows: a. Front lower control arm-to-suspension crossmember bolt to 84 ft. Ibs. (115 Nm) plus an additional 120 degrees. b. Rear lower contro! arm-to-suspenSion crossmember bolt to 180 ft. Ibs. (245 Nm) plus an additional 180 degrees. 7. Check and/or adjust the front alignment.

CONTROL ARM BUSHING REPLACEMENT Front Bushing

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove the lower control arm and place it in a vise. 3. Lubricate the threads of Screw J21474-19 with high pressure lubricant. 4 Assemble Tools Screw J-21474-19, Remover/Installer J-41397-1A, Receiver J44397-2A and J-21474-18 onto the front control arm bushing. 5. Tighten Tool J-21474-18 until the

front bushing is pressed from the control arm. 6. Disassemble the tools. To install: 7. Lubricate the new front bushing outer casing. 8. Insert the new bushing into the control arm. 9. Assemble Tools Screw J-21474-19, Remover/Installer J-41397-1A, Receiver J44397-2A and J-21474-18 onto the front control arm bushing. 10. Tighten Screw J-21474-19 until the front bushing is pressed into the control arm. 11. Disassemble the tools. 12. Install the lower control arm. Rear Bushing 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove the lower control arm and place it in a vise. 3. Assemble Tools Screw J-21474-27, Remover/Installer J-41211-1, Receiver J-

J 21474 —-27 J 41211 —-1

J 21474-19

J 41397 —-1A J 41211-3

\ J21474—4

93062ZG07

93062605

Removing the front bushing from the lower control arm

Removing the rear bushing from the lower control arm

J 21474 -27

J 21474—-19

J 41211-1

J.41397 -1A

J 42-3

J21474-4

93062G04

Exploded view of the lower control arm and related components

93062606

Installing the front bushing to the lower control arm

93062608

Installing the rear bushing to the lower

control arm

Timing belt service is covered in Section 3 of this manual

26-3

GENERAL MOTORS CORPORATION MALIBU e CUTLASS

41211-3 and J-21474-4 onto the rear con-

trol arm bushing. 4. Tighten Tool J-21474-27 until the rear bushing is pressed from the control arm. 5. Disassemble the tools. To install:

the assembly is damaged, the complete unit must be replaced.

REMOVAL & INSTALLATION Front

6. Insert the new bushing into the control arm. 7. Assemble Tools Screw J-21474-27,

Remover/Installer J-41211-1, Receiver J44211-3 and J-21474-4 onto the rear con-

trol arm bushing. 8. Tighten Screw J-21474-4 until the rear bushing is pressed into the control arm. 9. Disassemble the tools. 10. Install the lower control arm.

Wheel Bearings

ADJUSTMENT These vehicles are equipped with sealed hub and bearing assemblies. The hub and bearing assemblies are non-serviceable. If

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Front wheel e Halfshaft nut ¢ Caliper from the steering knuckle and support it aside

“ek WARNING DO NOT allow the caliper to hang unsupported from the brake hose. e Brake rotor e 3 hub bearing-to-steering knuckle bolts e Halfshaft from the hub/bearing assembly ¢ Hub/bearing assembly

To install: 3. Install or connect the following: e Hub/bearing assembly on the haltfshaft e 3 hub/bearing-to-steering knuckle bolts. Torque the bolts to 70 ft. Ibs. (95 Nm). ; e Brake rotor e Caliper onto the steering knuckle. Torque the bolts to 38 ft. Ibs. (51 Nm). e Halfshaft nut. Torque it to 284 ft. lbs. (385 Nm). ~ ¢ Front wheel. Torque the nuts to 100 ft. Ibs. (140 Nm), Rear

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Wheel e Brake drum e 4 hub/bearing assembly-to-knuckle nuts e Anti-lock Brake System (ABS) speed sensor wire from the hub/bearing assembly e Hub/bearing assembly To install: 3. Install or connect the following: e Hub/bearing assembly ¢ ABS wheel speed sensor ¢ Hub/bearing-to-knuckle nuts. Torque the nuts to 70 ft. Ibs. (95 Nm) on 1998-99 models or 62 ft. lbs. (85 Nm) on 2000-01 models. e Brake drum ¢ Wheel. Torque the bolts to 100 ft. lbs. (140 Nm).

OW 4

HUB AND BEARING ASSEMBLY STEERING KNUCKLE WASHER

DRIVE AXLE NUT - 260 N-m (192 LBS. FT.) HUB AND BEARING RETAINING BOLT WASHER

f& nn WN 19227237

Exploded view of the front hub and bearing assembly

(1) Nut

(2) (3) (4) (5)

Knuckle, Rear Brake Assembly Hub and Bearing Assembly Bolt 79227238

Hub and bearing components

GENERAL MOTORS © CORPORATION—N-BODY 1998-01 Buick-Skylark * Oldsmobile-Achieva * Alero * Pontiac-Grand Am oe oer.27-25 DRIVEMRAIN 32.222. 27-2 ................ REPAIR ENGINE 27-22 sarees 2c 2.ccc: TEM EUELSS YO PRECAUTIONS.................. 27-2 STEERING AND SUSPENSION............:...- 27-32

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Camshaft and Valve Lifters .......... 27-14 Removal & Installation............ CITC Tsien eee net ateareencansahee. Removal & Installation............ MARINI ete ete tetar encores

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Fuel System Service Pree UO

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|

ayes 27-29

27-14 2/-28 21-28 27-36

OMT STIG AA AA eae 21-3 AGHUSITICNUA WE Ven Le. e:21-3 [mntake WAINIOHO Paes ccevet cote toe 27-11 Removal & Installation............ 21-11

97-30

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Removal & Installation........... 27-36

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EWelitTealonimeakcn mentees cet 21-24 Removal & Installation............ 21-24 se ees 21-23 FUGI PUTRI: Geert Removal & Installation............ 21-23 Fuel System Pressure... 21-22 PeWeVINGiee eee cancceecct cas 21-22

ene ee 27-30

mt as 97-8 RMMe area hen we armcsacc

Removal & Installation.............. 27-8

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VOWED aU MOU

Removal & Installation............. 27-38

Lower Control AFM...

21-39

Control Arm Bushing

E Engine ASSEMDIY .........-sseseee 21-3

Replacement :......:naassstahes. 21-39 Removal & Installation............ 21-39

F semeceme-reaagartet 21-23 seacee a cists PrN PLS 21-23 Installation........... & Removal

OU PUI Removal & Installation........... 21-18

0 Removal & Installation............. 27-3 pavers al meena ees Onl ea Va Exhaust Manifold... 27-17 Installation............ & Removal 27-13 Removal & Installation............ cere: 27-18 meee

ms 21-22 PISTON ANC ING crete auccertee

POSITIONING eet teee eee 21-22 Power Rack and Pinion SteeringiGear ieee ese 21-32 Removal & Halt te Sat 21-32 Rear alin ears este i veere 27-19 Removal & Installation............ 27-19 ROCKET Allis aac eras isaac cane 27-10 Removal & aay o fene 27-10 SHOCK-ADSOTOG Weta oeccece-catee 21-36 Removal & Installation............ 27-36 are ent 21-16 Starter: MGlOh cies. Removal & Installation............ 27-16 Ctrl ait ome eee hee ee, eae 27-34 21-34 Removal & pela hae

Timing Chain, Sprockets, Front Cover and Seal............06. 27-20 Removal & Installation............ 21-20 eee 27-37 TGCSIOM DalSucre mete Removal & Installation............ 27-31 tek eases21-25 VANSAX eat cee eee Removal & pee Aeay oily 21-25

WalWeul QS gases ates sense eames 27-16 ACIUSUMGMT: gacucee westerns 21-16 W Wale PUL eee ete eran 2t-f Removal & Installation............. 21-1 Wheel BOaginQS..vocscnct-scscscrsrcecs 27-40 iveAny time the camshaft housing-toremoved, the camshaft housing-to-

->An oil and filter change is recommended.

connector

with an automatic transaxle

cylinder head bolts are loosened or

Oil fill tube into the engine Heater inlet and throttle body heater hoses to the water outlet Power brake vacuum hose Ignition coil and module assembly 12. Remove the engine support fixture. 13. Fill all fluids to their proper levels.

fi ie nae FT (oN CLE HEA |

© Fuel rail

+ MAP sensor electrical connector

: Ween owes

e CMP sensor electrical connector e Oil switch electrical connector Exhaust manifold. Torque the nuts to 110 inch Ibs. (13 Nm). Intake manifold. Torque the bolts to 18 ft. Ibs. (24 Nm). Power steering pump. Torque the bolts to 19 ft. Ibs. (26 Nm). Throttle body air intake duct

b. Step 2: Bolts 9 and 10 to 30 ft. Ibs. (40 Nm). c. Step 3: All bolts an additional 90 degree (V4) turn. 10. Install the intake and exhaust camshaft housings and torque the bolts as follows: a. Long bolts: 11 ft. Ibs. (15 Nm) plus an additional 90 degree turn. b. Short bolts: 11 ft. Ibs. (15 Nm)

g

AN ADDITIONAL 90° WITH J 36660 2

CYLINDER HEAD

‘

3. GASKET

4 CYLINDER BLOCK

Turn the camshaft housing upside down as soon as it is removed from the cylinder head; otherwise, the lifters may fall out.

Exhaust camshaft housing Upper radiator hose Engine Coolant Temperature (ECT) sensor electrical connector Cylinder head bolts by reversing of the tightening sequence e Cylinder head

To install:

.

8. Install or connect the following:

e Cylinder head with a new gasket ¢ New cylinder head bolts lubricated with clean engine oil e the cylinder head bolts, in Torqu 9, sequence, as follows: a. Step 1: Bolts 1 through 8 to AO ft. lbs. (65 Nm).

TIGHTENING

SEQUENCE ©

6630.30. +70 le,

| engines Cylinder head bolt tightening sequence—3.1L and 3.4L

2 of this manual Heater Core replacement is covered in Section

alt 9227

Zi

GENERAL MOTORS CORPORATION—N-BODY SKYLARK ¢ ACHIEVA ¢ ALERO e GRAND AM

3. Drain the crankcase. 4. Drain the cooling system. 5. Remove or disconnect the following: Upper half of the air cleaner assembly Throttle body air inlet duct Exhaust crossover pipe heat shield Crossover pipe Spark plug wires from the spark plugs Rocker arm covers Upper intake plenum and lower intake manifold Left side exhaust manifold Oil level indicator tube e>When removing the valvetrain components, keep them in order for installation purposes. * Rocker arms and pushrods

¢ Cylinder head To install: 6. Install the cylinder head with a new gasket. 7. Torque the cylinder head bolts to 33 ft. Ibs. (45 Nm) plus an additional 90 degree turn. 8. Install or connect the following: New intake manifold gasket Pushrods and rocker arms. Torque the bolts to 89 inch Ibs. (10 Nm) plus an additional 30 degree turn. Lower intake manifold. Torque the bolts to 115 inch Ibs. (13 Nm). Upper intake plenum. Torque the bolts to 18 ft. Ibs. (25 Nm). Rocker arm covers. Torque the bolts to 89 inch Ibs. (10 Nm). Oil level indicator tube Left side exhaust manifold. Torque the nuts to 12 ft. Ibs. (16 Nm). Spark plug wires Exhaust crossover pipe. Torque the bolts to 18 ft. Ibs. (25 Nm). Crossover pipe heat shield. Torque the bolts to 89 inch Ibs. (10 Nm). Upper half of the air cleaner assembly Throttle body air inlet duct Negative battery cable 9. Refill the cooling system. 10. Refill the crankcase. eA filter change is recommended.

11. Start the engine and verify no leaks.

RIGHT (REAR) CYLINDER HEAD 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Relieve the fuel system pressure.

3. Drain the crankcase. 4 Drain the cooling system. 5. Remove or disconnect the following:

Upper half of the air cleaner assemy Throttle body air inlet duct Exhaust crossover pipe heat shield Crossover pipe Oxygen (02S) sensor electrical connector Exhaust pipe from the exhaust manifold Right side exhaust manifold Spark plug wires from the spark plugs Rocker arm covers Upper intake plenum Lower intake manifold e>\When removing the valvetrain components keep them in order for installation purposes. ¢ Rocker arms and pushrods e Cylinder head To install: 6. Install the cylinder head with a new gasket. 7. Torque the cylinder head bolts to 33 ft. Ibs. (45 Nm) plus an additional 90 degree turn. 8. Instal! or connect the following: New intake manifold gasket Pushrods and rocker arms. Torque the bolts to 89 inch Ibs. (10 Nm) plus an additional 30 degree turn. Lower intake manifold. Torque the bolts to 115 inch Ibs. (13 Nm). Upper intake plenum. Torque the bolts to 18 ft. Ibs. (25 Nm). Rocker arm covers. Torque the bolts to 89 inch Ibs. (10 Nm). Spark plug wires Exhaust manifold. Torque the nuts to 12 ft. Ibs. (16 Nm). Exhaust pipe to the exhaust manifold. Torque the nuts to 33 ft. Ibs. (45 Nm). Q2S sensor electrical connector Exhaust crossover pipe. Torque the bolts to 18 ft. Ibs. (25 Nm). Crossover pipe heat shield. Torque the nuts to 89 inch Ibs. (10 Nm). Upper half of the air cleaner assembly Throttle body air inlet duct Negative battery cable 9. Refill the cooling system. 10. Refill the crankcase. e>An oil filter change is recommended.

11. Start the engine and verify no leaks.

REMOVAL & INSTALLATION 2.4L Engine

The 2.4L engine is not equipped with rocker arms. The camshafts directly actuate the valves. 3.1L and 3.4L Engines

LEFT SIDE 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the cooling system to a level below the coolant pipe on the front of the engine. 3. Remove or disconnect the following: ¢ Negative battery cable e Spark plug wires ¢ Heater bypass pipe ¢ Positive Crankcase Ventilation (PCV) valve and hose ¢ Rocker arm cover ->Keep the pushrods in order. Intake pushrods are 5%4inches long and exhaust pushrods are 6 inches long.

e Rocker arms and pushrods install: Lubricate all the valvetrain compowith engine oil. Install or connect the following: e Pushrods and the rocker arms. Torque the bolts to 89 inch Ibs. (10 Nm) plus an additional 30 degree turn. Rocker arm cover using a new gasket. Torque the rocker cover bolts to 89 inch Ibs. (10 Nm). PCV valve and hose Heater bypass pipe. Torque the screw at the water pump to 106 inch Ibs. (12 Nm), the bolt at the cylinder head corner to 18 ft. Ibs. (25 Nm) and the nut to 18 ft. Ibs. (25 Nm). ¢ Spark plug wires ¢ Negative battery cable 6. Refill the cooling system. 7. Start the vehicle and verify no leaks.

To 4. nents 9.

RIGHT SIDE 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: ¢ Negative battery cable ¢ Spark plug wires from the Spark

N-BODY—GENERAL MOTORS CORPORATION 27-1 1 SKYLARK © ACHIEVA ¢ ALERO e GRAND AM | wrench DEX-COOL®. When adding coolant to vehicles, it is important that you use GM Goodwrench DEX-COOL (orange-colored, silicate-free) coolant. Propylene glycol is not recommended for use in GM vehicles. A 50/50 mixture of DEX-COOL and clean water will provide all the recom-

DO NOT mix DEXmended protection. .

oe

Ki

me em

5

A FINGER START ALL BOLTS

COOL with any other type of

FybRe a

B PUSH BRACE AGAINST MANIFOLD WITH FINGERS

antifreeze.

C TIGHTEN BOLTS "A" TO SPECIFICATION D TIGHTEN BOLTS “B" TO SPECIFICATION

2.4L Engine

79222309

93062ZG09

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Relieve the fuel system pressure. 3. Drain the cooling system to a level

Rocker arm components—3.1L and 3.4L

engines

plugs and the upper intake plenum wire retainer Power brake booster vacuum pipe from the intake plenum Accessory drive belt Alternator Ignition coil assembly and Evaporative Emissions (EVAP) canister purge solenoid as an assembly e Rocker arm cover

Exploded view of the intake manifold brace mounting—2.4L engine

below the intake manifold. 4. Remove or disconnect the following: e Air cleaner duct

+ Manifold Absolute Pressure (MAP)

sensor electrical connector e Intake Air Temperature (IAT) sensor electrical connector e Evaporative Emissions (EVAP) canister purge solenoid electrical connector

->Keep the pushrods in order. Intake pushrods are 5%inches long and exhaust pushrods are 6 inches long.

e Rocker arms and pushrods install: Lubricate all the valvetrain compowith engine oil. Install or connect the following: e Pushrods and the rocker arms. Torque the bolts to 89 inch Ibs. (10 Nm) plus an additional 30 degree turn. Rocker arm cover using a new gasket. Torque the rocker cover bolts to 89 inch Ibs. (10 Nm). Ignition coil and EVAP solenoid assembly Alternator. Torque the bolts to 37 ft. Ibs. (50 Nm). e Accessory drive belt Power brake booster vacuum pipe to the plenum e Spark plug wires e Negative battery cable 5 Start the vehicle and verify no leaks.

Fuel injector electrical connectors Vacuum hoses from the intake

manifold, fuel pressure regulator and EVAP canister purge solenoid

Accelerator control cable bracket

Coolant lines from the throttle body Stud-end generator mount bolt Exhaust Gas Recirculation (EGR) pipe from the EGR adapter e Intake manifold support brace e |ntake manifold

To 3. nents 4.

Intake Manifold

_

REMOVAL & INSTALLATION

99 100 103 104 105.

STUD - 11 N-m (96 LBS. IN.) INTAKE MANIFOLD GASKET INTAKE MANIFOLD BOLT - 26 N-m (19 LBS. FT.) NUT - 26 N-m (19 LBS. FT.) 79222308

These vehicles were filled at the factory

Goodwith an antifreeze/coolant called GM

.4L engine Intake manifold tightening sequence—2

4 of this manual Brake service is covered in Section

271-1 ? GENERAL MOTORS CORPORATION—N-BODY SKYLARK ¢ ACHIEVA ¢ ALERO * GRAND AM To install: 5. Install or connect the following: Intake manifold with a new gasket. Torque the fasteners in sequence to 18 ft. Ibs. (25 Nm). Intake manifold brace. Torque the bolts to 19 ft. Ibs. (26 Nm).

3.1L and 3.4L Engines 1. Before servicing the vehicle, refer to the precautions in the beginning of this section.

>The brace-to-block bolts must be tightened first, then the brace-to-manifold bolt.

EGR pipe to the EGR adapter Stud-end generator mount bolt Coolant lines to the throttle body Accelerator control cable bracket Vacuum hoses to the intake manifold, fuel pressure regulator and EVAP canister purge solenoid Electrical connectors to the fuel injectors MAP sensor electrical connector IAT sensor electrical connector EVAP canister purge solenoid electrical connector Air cleaner duct 6. Refill the cooling system.

7. Connect the negative battery cable.

A 121 143 144 145 146

2. Relieve the fuel system pressure. 3. Drain the cooling system. 4. Remove or disconnect the following: Air cleaner assembly Accessory drive belt Exhaust Gas Recirculation (EGR) valve Brake vacuum pipe at the intake plenum Fuel pressure regulator vacuum line Spark plug wires from the spark plugs and the intake plenum retainers Ignition coil assembly and the Evaporative Emissions (EVAP) canister purge solenoid as an assembly Throttle Position (TPS) sensor electrical connector Idle Air Control (IAC) sensor electrical connector Fuel injector electrical connectors

APPLY SEALANT HEAD ASSEMBLY, CYLINDER GASKET, LOWER INTAKE MANIFOLD BOLT, LOWER INTAKE BOLT, LOWER BOLT, LOWER

INTAKE MANIFOLD INTAKE MANIFOLD

144 181 182 185 184

Engine Coolant Temperature (ECT) sensor electrical connector Camshaft Position (CMP) sensor electrical connector Vacuum modulator Manifold Absolute Pressure (MAP) sensor Coolant hoses from the throttle body

Control cables from the throttle body and intake plenum bracket Upper intake plenum Fuel lines from the fuel rail and fuel line bracket Fuel rail with the injectors Inlet cooling pipe from the outlet housing Heater bypass hose from the water pump and the cylinder head Upper radiator hose at the thermostat housing Thermostat housing Both rocker arm covers Lower intake manifold e»When removing the valvetrain components, keep them in order for installation purposes.

MANIFOLD, LOWER INTAKE GASKET, UPPER INTAKE MANIFOLD MANIFOLD, UPPER INTAKE STUD, UPPER INTAKE MANIFOLD BOLT, UPPER INTAKE MANIFOLD 79227310

Exploded view of the upper and lower intake—3.1L and 3.4L engines

N-BODY—GENERAL MOTORS CORPORATION 21-1 3 SKYLARK © ACHIEVA * ALERO * GRAND AM

SOR

BesH

79227311

Lower intake manifold tightening sequence—3.1L and 3.4L engines

e Rocker arms and pushrods To install: 5. Place a 3mm bead of RTV, on each ridge, where the front and rear of the intake manifold contact the block. 6. Install or connect the following: e New intake manifold gasket e Pushrods and rocker arms. Torque the bolts to 89 inch Ibs. (10 Nm) plus an additional 30 degree turn. e Lower intake manifold. Apply sealant to the threads of the bolts and torque the bolts to 115 inch

lbs. (13 Nm).

4k

WARNING

in order to prevent oil leaks ai the intake manifold, tighten the vertical bolts before the diagonal boits. Both rocker arm covers. Torque the bolts to 89 inch Ibs. (10 Nm). Thermostat housing with a new gasket. Torque the bolts to 19 ft. lbs. (26 Nm). Upper radiator hose at thermostat housing Coolant bypass hose to the water pump and the cylinder head Coolant inlet pipe to coolant outlet housing Fuel rail with the injectors Fuel lines to the fuel rai! and fuel line bracket Upper intake manifold with a new gasket. Torque the bolts to 18 ft. Ibs. (25 Nm). Coolant hoses to the throttle body MAP sensor Vacuum modulator CMP sensor electrical connector ECT sensor electrical connector Fuel injector electrical connectors @eeeee oe IAC sensor electrical connector

TPS sensor electrical connector Ignition coil assembly and the EVAP canister purge solenoid as an assembly Spark plug wires Fuel pressure regulator vacuum line EGR valve. Torque the bolts to 22 ft. Ibs. (30 Nm). Control cables to the throttle body and intake plenum bracket Brake vacuum pipe at the intake plenum Accessory drive belt Air cleaner assembly Negative battery cable 7. Refill the cooling system. e>An engine oil and filter change is recommended.

8. Start the vehicle and verify no leaks. Exhaust Manifold

REMOVAL & INSTALLATION

9346Z2GA2

Exhaust manifold assembly torque sequence— 2.4L engine

e Exhaust manifold To install: 3. Install or connect the following: e Exhaust manifold with new gaskets. Torque the nuts, in sequence, to 110 inch Ibs. (13 Nm). e Exhaust manifold brace. Torque the bolt to 41 ft. Ibs. (56 Nm) and the nuts to 19 ft. Ibs. (26 Nm). e Exhaust pipe. Torque the bolts evenly to 26 ft. Ibs. (35 Nm). e (02S sensor electrical connector e Negative battery cable 4. Start the vehicle and verify no exhaust leaks. 3.1L and 3.4L Engines

2.4L Engine

LEFT SIDE

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Negative battery cable Oxygen (02S) sensor electrical

connector Exhaust manifold brace Exhaust manifold-to-exhaust pipe spring loaded bolts Exhaust pipe by pulling it down and back from the exhaust manifold ->Do not bend the exhaust flex coupler more than 3 degrees in any direction, for it may damage the flex coupler.

93462G01

Exploded view of the exhaust manifold assembly mounting— 2.4L engine

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Partially drain the cooling system. 3. Remove or disconnect the following: Negative battery cable Air cleaner assembly Throttle body duct Exhaust crossover heat shield Exhaust crossover pipe from the manifold Radiator hose from the thermostat housing Spark plug wires Exhaust manifold heat shield Exhaust manifold To install: 4. |nstall or connect the following: e Exhaust manifold with a new gasket. Torque the nuts to 12 ft. Ibs. (16 Nm). Exhaust manifold heat shield. Torque the nuts to 89 inch Ibs. (10 Nm). Exhaust crossover pipe. Torque the bolts to 18 ft. Ibs. (25 Nm). Crossover pipe heat shield. Torque the bolts to 89 inch Ibs. (10 Nm). Spark plug wires Radiator hose to the coolant outlet housing

on 1 of this manual For complete Engine Mechanical specifications, see Secti

27 1 4 GENERAL MOTORS CORPORATION—N-BODY m SKYLARK * ACHIEVA ¢ ALERO * GRAND AM

159 111 SCREW, LH HEAT SHIELD 112 SHIELD, LH HEAT 113 NUT, LH EXHAUST MANIFOLD 114 STUD, LH EXHAUST MANIFOLD 115 MANIFOLD, LH EXHAUST 117 GASKET, LH EXHAUST MANIFOLD 121 HEAD ASSEMBLY, CYLINDER 153 SHIELD, RH LOWER HEAT 154 SCREW, RH LOWER HEAT SHIELD 155 STUD, RH EXHAUST MANIFOLD 156 NUT, RH EXHAUST MANIFOLD 157

MANIFOLD, RH EXHAUST

158 159 160

SHIELD, RH UPPER HEAT SCREW, RH UPPER HEAT SHIELD GASKET, RH EXHAUST MANIFOLD 79222314

Exploded view of the exhaust manifold mounting—3.1L and 3.4L engines

e Air cleaner assembly ¢ Throttle body duct ¢ Negative battery cable

RIGHT SIDE 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Negative battery cable Air cleaner assembly Throttle body duct Heated Oxygen (HO2S) sensor Exhaust crossover heat shield Exhaust Gas Recirculation (EGR) pipe from the exhaust manifold Exhaust crossover pipe Exhaust manifold heat shield Transaxle oil fill tube Front exhaust pipe from the exhaust manifold Wires from the spark plugs Exhaust manifold To install: 3. Install or connect the following: ¢ Exhaust manifold with a new gasket. Torque the nuts to 12 ft. Ibs. (16 Nm). e Exhaust manifold heat shield. Torque the nuts to 89 inch Ibs. (10 Nm).

Exhaust crossover pipe to the manifold. Torque the bolts to 18 ft. Ibs. (25 Nm), Exhaust crossover pipe heat shield. Torque the bolts to 89 inch Ibs. (10 Nm). Exhaust pipe to the exhaust manifold. Torque the bolts to 33 ft. Ibs. (45 Nm). Transaxle oil level indicator and fill tube assembly

HO2S sensor EGR pipe to the exhaust manifold Exhaust crossover heat shield Throttle body duct Air cleaner assembly Negative battery cable

Camshaft and Valve Lifters REMOVAL & INSTALLATION PUES, AEN ae SN A

LS

2.4L Engine

INTAKE SIDE e Anytime the camshaft housing-tocylinder head bolts are loosened or removed, the camshaft housing-tocylinder head gasket must be replaced.

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. : 2. Remove or disconnect the following: e Negative battery cable e Ignition assembly electrical connector ¢ 4 ignition assembly-to-camshaft housing bolts and the assembly by pulling it straight up e>Use a spark plug boot wire remover to remove connector assemblies.

Camshaft Position (CMP) sensor electrical connector Power steering pump and move it aside without disconnecting the lines Vacuum line from fuel pressure regulator Fuel injector wiring harness Both fuel line-to-intake camshaft housing clamps Fuel rail-to-camshaft housing bolts Fuel rail from the cylinder head and move it aside with the fuel lines attached Timing chain and camshaft sprockets Timing chain housing bolts but do not remove from the engine

N-BODY—GENERAL MOTORS CORPORATION

SKYLARK ¢ ACHIEVA e ALERO e GRAND AM

2. Remove or disconnect the following: e Negative battery cable e gnition assembly electrical connector e 4 ignition assembly-to-camshaft housing bolts and the assembly by pulling it straight up

e Camshaft housing cover-tocamshaft housing bolts e Camshaft housing-to-cylinder head bolts by reversing of the tightening sequence e>Leave 2 bolts loosely in place to hold the camshaft housing while separating the camshaft cover from housing.

3. Press the cover off the housing by threading 4 of the housing-to-cylinder head bolts into the tapped camshaft housing cover holes. Tighten the bolts in evenly so the cover does not bind on the dowel pins. 4. Remove the camshaft housing cover and discard the gaskets. 5. Note the position of the chain sprocket dowel pin for reassembly. 6. Remove or disconnect the following: e Camshaft ¢ Camshaft oil seal from camshaft and discard it >The camshaft seal must be replaced any time the housing and cover are separated. Store the valve lifters in order so that

they may be installed in the their locations.

e Valve lifters from the camshaft housing e Camshaft carrier from the cylinder head and discard the gasket To install: 7. Clean all the gasket surfaces completely. 8. Install or connect the following: e New camshaft housing gasket e Camshaft housing =>Install 1 bolt loosely to hold the housing in place. ->|f the camshaft was replaced the valve lifters must also be rep!aced. 9. Install the lifters into their original

bores. 10. Lubricate the camshaft lobes, journals and lifters with camshaft and lifter prelube. The camshaft lobes and journals must be adequately lubricated or engine damage could occur upon start up. 11. Install or connect the following: ¢ Camshaft in its original position with the timing chain sprocket dowel pin straight up and aligned with the centerline of the lifter bores. ¢ New Green camshaft housing cover Seal

271-1 5

e>Use a spark plug boot wire remover to remove connector assemblies.

INTAKE

EXHAUST FRONT

ce) F ENGINE

bd 79222315

Camshaft housing bolt tightening sequence—2.4L engine

The seals for the intake and exhaust covers are different and the correct seals must be used.

12. Remove the bolt holding the housing in place. 13. Apply thread locking compound to the camshaft housing and cover bolt threads. 14. Install or connect the following: Camshaft housing cover. Tighten the bolts, in sequence, to 16 ft. Ibs. (22 Nm) plus an additional 90 degree turn (long bolts) and 16 ft. lbs. (22 Nm) plus an additional 30 degree turn (short bolts). Timing chain housing bolts Timing chain and sprockets New fuel injector O-ring seals lubricated with engine oil Fuel rail. Tighten the bolts to 19 ft. lbs. (26 Nm). Ignition assembly on the camshaft housing. Tighten the bolts to 11 ft. lbs. (15 Nm), plus an additional 30 degree turn. e Ignition assembly electrical connector ¢ Negative battery cable 15. Start the vehicle and verify proper operation and no leaks.

EXHAUST

SIDE

> Anytime the camshaft housing-tocylinder head bolts are loosened or removed, the camshaft housing-tocylinder head gasket must be replaced.

1. Before servicing the vehicle, refer to the precautions in the beginning of this section.

e Oil pressure switch electrical connector Transaxle fill tube Timing chain and camshaft sprockets Timing chain housing bolts but do not remove from the engine Camshaft housing cover-tocamshaft housing bolts Camshaft housing-to-cylinder head bolts by reversing of the tightening sequence =>Leave 2 bolts loosely in place to hold the camshaft housing while separating the camshaft cover from housing.

3. Press the cover off the housing by threading 4 of the housing-to-cylinder head bolts into the tapped camshaft housing cover holes. Tighten the bolts in evenly so the cover does not bind on the dowel pins. 4. Remove the camshaft housing cover and discard the gaskets. 5. Note the position of the chain sprocket dowel pin for reassembly. 6. Remove or disconnect the following: e Camshaft ¢ Camshaft oi! seal from camshaft and discard it ->The camshaft seal must be replaced any time the housing and cover are separated. ->Store the valve lifters in order so that they may be installed in the their locations.

e \Valve lifters from the camshaft housing ¢ Camshaft carrier from the cylinder head and discard the gasket To install: 7. Clean all the gasket surfaces completely. 8. Install or connect the following: ¢ New camshaft housing gasket e Camshaft housing =>Install 1 bolt loosely to hold the housing in place.

this manual For Accessory Drive Belt illustrations, see Section 1 of

2/-1

GENERAL MOTORS CORPORATION—N-BODY SKYLARK ¢ ACHIEVA @ ALERO e GRAND AM

lash is maintained automatically by hydraulic pressure in the lifters.

e>lf the camshaft was replaced the valve lifters must also be replaced.

9. Install the lifters into their original bores. 10. Lubricate the camshaft lobes, journals and lifters with camshaft and lifter prelube. The camshaft lobes and journals must be adequately lubricated or engine damage could occur upon start up. 11. Install or connect the following: e Camshaft in it original position with the timing chain sprocket dowel pin straight up and aligned with the centerline of the lifter bores. ¢ New Orange camshaft housing

When removing valvetrain components they must be marked for installation in their original location. Rocker arm covers Intake manifold Rocker arms and pushrods Lifter guides Valve lifter(s) from the bores Crankshaft balancer and front cover Timing chain and sprockets Oil pump driven gear Camshaft thrust plate Camshaft

cover seal >The seals for the intake and exhaust covers are different and the correct seals must be used.

12. Remove the bolt holding the housing in place. 13. Apply thread locking compound to the camshaft housing and cover bolt threads. 14. Install or connect the following: Camshaft housing cover. Tighten the bolts, in sequence, to 16 ft. Ibs. (22 Nm) plus an additional 90 degree turn (long bolts) and 16 ft. lbs. (22 Nm) plus an additional 30 degree turn (short bolts). Timing chain housing mounting bolts Timing chain and sprockets New fuel injector O-ring seals lubricated with engine oil Fuel rail. Tighten the bolts to 19 ft. Ibs. (26 Nm). Transaxle fill tube Oil pressure switch electrical connector Ignition assembly on the camshaft housing. Tighten the bolts to 11 ft. lbs. (15 Nm), plus an additional 30 degree turn. Ignition assembly electrical connector Negative battery cable 15. Start the vehicle and verify proper operation and no leaks. 3.1L and 3.4L Engines

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Relieve the fuel system pressure. 3. Remove or disconnect the following: ¢ Engine assembly

Avoid damaging the camshaft bearing surfaces.

To install: 4. Coat the camshaft with camshaft lubricant. 5. Install or connect the following: ¢ Camshaft Camshaft thrust plate. Torque the bolts to 89 inch Ibs. (10 Nm). Oil pump driven gear. Torque the bolt to 27 ft. Ibs. (36 Nm). Timing chain and sprocket. Torque the sprocket bolt to 103 ft. Ibs. (140 Nm). Front cover. Torque the bolts to 15 ft. Ibs. (21 Nm). Crankshaft balancer. Torque the bolt to 76 ft. Ibs. (103 Nm). 6. Lubricate the bearing surfaces with Molykote®. 7. Install or connect the following: ¢ Lifters in their original locations Lifter guides. Torque the guide bolts to 89 inch Ibs. (10 Nm). Pushrods and rocker arms. Torque the nuts to 89 inch Ibs. (10 Nm) plus an additional 30 degree turn. Intake manifold Rocker arm covers. Torque the bolts to 89 inch Ibs. (10 Nm). Engine assembly Negative battery cable 8. Adjust the valves, as required. Start the engine and verify no oil leaks.

. Valve Lash

ADJUSTMENT ie ee A

oe

The engines are equipped with hydraulic valve lifters that do not require periodic valve lash adjustment. Adjustment to zero

Starter Motor

REMOVAL & INSTALLATION 2.4L Engine

1. Before servicing the vehicle, refer to the precautions in the beginning of this section.

2. Remove or disconnect the following: e Negative battery cable e Air inlet duct from the throttle body e Upper starter bolt ¢ Lower closeout panel ¢ Lower starter bolt e Starter electrical connectors e Starter motor To install: 3. Install or connect the following: e Starter electrical connectors e Starter motor. Torque the bolts to 66 ft. Ibs. (90 Nm). ¢ Lower closeout panel e Air inlet duct to the throttle body ¢ Negative battery cable 3.1L 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 * Starter electrical connectors ¢ Starter motor To install: 3. Install or connect the following: e Starter motor. Torque the bolts to 32 ft. Ibs. (43 Nm). ¢ Starter electrical connectors e Negative battery cable 3.4L 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 ¢ Flywheel inspection cover ¢ Starter electrical connectors ¢ Starter motor To install: 3. Install or connect the following: ¢ Starter motor. Torque the bolts to

32 ft. Ibs. (43 Nm). ¢ Starter electrical connectors ¢ Flywheel inspection cover. Torque the bolts to 89 inch Ibs. (10 Nm). ¢ Negative battery cable

N-BODY—GENERAL MOTORS CORPORATION

SKYLARK ¢ ACHIEVA ¢ ALERO e GRAND AM 3.1L and 3.4L Engine

e Oil level sensor connector

e Oil pan To install:

REMOVAL & INSTALLATION

a) Inspect the oil pan gasket; it is reusable if not damaged. 6. Install or connect the following: Oil pan with the gasket. Torque the M8 bolts to 18 ft. Ibs. (24 Nm) and the M6 bolts to 106 inch Ibs. (12 Nm). Oil pan to the transmission nut Oil level sensor connector Radiator outlet pipe to the lower radiator hose and oil pan + Exhaust manifold brace

2.4L Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section.

2. Drain the engine oil. 3. Drain the cooling system. 4. Remove or disconnect the followi ing: : ees

leacatraaes

oyatihaeaakec

° She Sra arene

, ee . Act ee aie | A keer! Boe : ee Se eo abhi

° ‘ai outlet pipe trom the ol

° Hee

38 OIL PAN

ae

e

‘

To install: re! ; 5. Apply silicone sealer to the portion of the pan that contacts the rear of the di pe aT following: connect Install panor with _ «Oil Torque anew thegasket,

39A

SF rat bead slimlon =a]

ze

BeOS [p29 OAV;

oc

° hig ie eae

° Right splash shield

PSs

oy

ie

: Eherdatezyar ahanahe Heat ¥ fae uf e ue S

398 OTIS

Sar et

* Accessory drive belt

ts cover Flywheel/converter e a * Negative battery cable 7. Refill the crankcase 3 Refill the cooling system i 9. Start the vehicle and verify no leaks.

Oil pan to the flywheel cover bolt and nut e Flywheel cover stud for clearance e Radiator outlet pipe from the lower radiator hose and oil pan

Mes

cat ae : We Fae Oe Amalie OMeleeyt lator AIC li a et sate

A

|

2. Drain the engine oil. 3. Evacuate the A/C system. 4. Remove or disconnect the following: Negative battery cable Accessory drive belt Right front wheel Right splash shield Anti-lock Brake System (ABS) Wheel Speed (WSS) sensor from ieA a dle

e Engine mount strut bracket. Torque the bolts to 55 ft. Ibs. (75 Nm). e Transmission to the engine brace (50 Nm).

ae aA

e Se TA

tion.

cee Hee

* Airconditioning compressor lower bolts. Torque the bolts to 37 ft. Ibs.

Sart ¥ crane a Pe yee ae stru SE BOD 3° uve ee e

1. Before servicing the vehicle, refer to the precautions in the beginning of this sec-

° Radiator outlet pipe. Torque the

bolts to 124 inch Ibs. (14 Nm).

ey

271-17

a

YAKS S¥ DXXDOMM

398

309A BOLT, OIL PAN (M8 X 1.25 X 80)

39D

©:398

24 Nem (18 LB. FT.)

398

BOLT, OIL PAN (MB X 1.25 X 22)

39C

BOLT, OIL PAN (M6 X 1.00 X 25)

39D

BOLT, STUD END OIL PAN

rat

12 Nem (106 LB. IN.) 26 Nem (19 LB. FT.)

Oil pan mounting bolt locations—2.4L engine

SP BLOCK, ENGINE

N RETAINING 79222317

79222316

Exploded view of the oil pan mounting— 3.1L engine

of this manual For Tire, Wheel and Ball Joint specifications, see Section 1

2/-1

GENERAL MOTORS CORPORATION—N-BODY SKYLARK ¢ ACHIEVA ¢ ALERO ¢ GRAND AM

the flange bolts to 18 ft. Ibs. (25 Nm) and the side bolts to 37 ft. Ibs. (50 Nm). Starter motor. Torque the bolts to 32 ft. Ibs. (43 Nm). Flywheel cover. Torque the bolts to 89 inch Ibs. (10 Nm). Crankshaft balancer. Torque the bolt to 76 ft. Ibs. (103 Nm). Engine cradle bolts. Torque the bolts to 84 ft. Ibs. (115 Nm) plus an additional 120 degree turn. A/C compressor. Torque the bolts to 37 ft. Ibs. (50 Nm). Evaporator-to-accumulator line Ball joint. Torque the nut to 48 ft. lbs. (60 Nm). Outer tie rod end. Torque the nut to 44 ft. Ibs. (60 Nm). WSS electrical connector Wheel well splash shield Right front wheel Accessory drive belt Negative battery cable (On ill the crankcase. 8. Evacuate and recharge the A/C system. 9. Start the engine and check for leaks. e>Whenever the vehicle subframe is removed or lowered, the wheel alignment should be checked.

143 144 145 146 149 150 151

10. Check and/or adjust the front end alignment.

REMOVAL & INSTALLATION 2.4L Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Disconnect the negative battery cable. 3. Install an engine support fixture. 4, Properly drain the engine oil. 5. Remove or disconnect the following: Oil pan Balance shaft chain cover Balance shaft chain tensioner Oil pump cover Oil pump assembly from the balance shaft assembly, by pulling the housing to disconnect the pump gear from the balance shaft To install: 6. Lubricate the gears with clean engine oil. 7. Assemble the geroter gear into the housing.

e>Fill the oil pump cavities with petroleum jelly prior to installation. This seals the pump and acts like a “prime” so the pump will draw oil as soon as the engine begins to turn. This will ensure that there is oil pressure immediately on start-up and will prevent engine damage.

8. Install or connect the following: e (il pump to the balance shaft assembly. Torque the bolts to 40 ft. lps. (54 Nm). e (Oil pump cover. Torque the bolts to

40 ft. Ibs. (54 Nm). e Balance shaft chain tensioner with the bolts finger tight 9. Adjust the chain tension inserting a 0.40 in. (1mm) brass feeler, between the chain guide and the chain. e»A brass feeler gauge must be used to ensure that correct measurements are obtained. If a steel gauge is used, it will not bend to conform to the guide and will allow for incorrect measurements.

10. Press the guide against the chain using about 10 Ibs. of force. Torque the chain tensioner fastener to 115 inch Ibs. (13 Nm).

PIN, RELIEF VALVE COVER, OIL PUMP GEROTOR BODY, OIL PUMP GUIDE, RELIEF VALVE SPRING SPRING, RELIEF VALVE VALVE, RELIEF VALVE

Exploded view of the oil pump components—2.4L engine

79227318

N-BODY—GENERAL MOTORS CORPORATION

SKYLARK ¢ ACHIEVA * ALERO e GRAND AM

11. Install or connect the following: e Balance shaft chain cover. Torque the nut/bolt to 10 ft. Ibs. (13 Nm). e Qil pan. Torque the bolts to 18 ft. lbs. (24 Nm). e Negative battery cable 12. Fill the crankcase. e>An oil filter change is recommended.

13. Start the engine and verify oil pressure and no leaks. 3.1L and 3.4L Engines 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Disconnect the negative battery cable. 3. Drain the engine oil. 4 Remove or disconnect the following: e (Oil pan ¢ Oil pump and pump driveshaft To install: 5. Install or connect the following: ¢ Oil pump by engaging the oil pump driveshaft. Torque the oil pump bolts to 30 ft. Ibs. (41 Nm).

e Oil pan. Torque the bolts to 18 ft. lbs. (25 Nm). e Negative battery cable 6. Fill the crankcase. e>An oil filter change is recommended.

7. Start the engine, check the oil presSure and check for leaks.

Rear Main Seal

REMOVAL & INSTALLATION 2.4L 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 Transaxle Pressure plate and clutch disc, if equipped Flywheel Oil pan-to-seal housing bolts Seal housing Rear main seal from the housing

271-1 q

Be careful not to damage the seal housing sealing surface; damage may result in an oil leak.

To install: 3. Install the new rear main seal into the housing. 4. Inspect the oil pan gasket inner silicone bead for damage and repair using a silicone sealant, if necessary. 5. Lubricate the lip of the seal with clean engine oil. 6. Install or connect the following: e Seal housing with a new gasket. Torque the bolts to 106 inch Ibs. (12 Nm). ¢ Flywheel. Torque the bolts to 22 ft. lbs. (30 Nm) plus an additional 45 degree turn. e Clutch, pressure plate and clutch cover assembly, if equipped with a manual transaxle e Transaxle ¢ Negative battery cable 7. Start the engine and check for leaks. 3.1L and 3.4L Engines 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Support the engine. 3. Remove or disconnect the following: e Transaxle e Flywheel e Rear main seal using a prytool

Be careful not to damage the crankshaft sealing surface.

34 N-m (25 LBS. FT.) OlL PUMP OIL PUMP

DRIVE

41 N-m (30 LBS. FT.)

—WN

79222319

To install: 4. Lubricate the seal and bore with engine oil. 5. Install the new seal by sliding it over the mandrel until the dust lip bottoms squarely against the tool collar. 6. Align the dowel pin of the tool with the dowel pin hole in the crankshaft and attach the tool to the crankshaft. Tighten the attaching screws to 24-60 inch Ibs. (2.7-6.8 Nm). 7. Tighten the tool T-handle to press the seal into the bore until the tool collar Is flush against the engine. 8. Remove the installation tool.

.1L and 3.4L engines Exploded view of the oil pump mounting—3

this manual For Wheel Alignment specifications, see Section 1 of

21-2

GENERAL MOTORS CORPORATION—N-BODY SKYLARK ¢ ACHIEVA ¢ ALERO e GRAND AM

e>\lake sure that the seal is squarely seated in the bore.

9. Install or connect the following: ¢ Flywheel. Tighten the flywheel-tocrankshaft bolts to 52 ft. Ibs. (71 Nm). e Transaxle 10. Start the engine and check for leaks.

Timing Chain, Sprockets, Front Cover and Seal

REMOVAL & INSTALLATION

2.4L Engine eit is recommended that the entire procedure be reviewed before attempting to service the timing chain.

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the cooling system. 3. Remove or disconnect the following: ¢ Negative battery cable ¢ Coolant surge tank e Accessory drive belt e Alternator 4. Install an engine support. 9. Remove or disconnect the following: Upper cover fasteners Front cover vent hose Right engine mount and bracket Right front wheel Right lower splash shield Crankshaft balancer Lower cover fasteners Front cover 6. Rotate the crankshaft clockwise, as viewed from front of engine (normal rotation) until the camshaft sprocket's timing dowel pin holes align with the timing chain housing holes. The crankshaft sprocket mark should align with the engine mark. The crankshaft sprocket keyway should point upward and align with the cylinder bores centerline. This is the normal timed position. 7. Remove the timing chain guides. 8. Remove the timing chain tensioner. e>Be sure all the slack in the timing chain is above the tensioner assembly when removing it.

The tensioner plunger is spring loaded and could fly out causing personal injury. SEES

9. Remove or disconnect the following: e Timing chain e Camshaft sprockets To install: 10. Install or connect the following: e Camshaft sprockets. Torque the bolts to 52 ft. Ibs. (70 Nm). e Camshaft sprocket alignment pin through the camshaft sprockets holes into the timing chain housing holes to position the camshafts for timing. 11. Ifthe camshafts are out of position and must be rotated more than Yeturn in order to install the alignment dowel pins, perform the following: a. Rotated the crankshaft 90 degrees clockwise off Top Dead Center (TDC) in order to give the valves adequate clearance to open. b. Once the camshafts are positioned and the dowels installed, rotate the crankshaft counterclockwise back to TDC.

+t WARNING Do not rotate the crankshaft clockwise to TDC or valve and piston damage may occur. 12. Install the timing chain over the exhaust camshaft sprocket, around the idler sprocket and around the crankshaft sprocket. 13. Remove the alignment dowel pin from the intake camshaft. Using a dowel pin remover tool, rotate the intake camshaft sprocket counterclockwise enough to slide the timing chain over the intake camshaft sprocket. Release the camshaft sprocket wrench. The length of chain between the 2 camshaft sprockets will tighten.

17. Reload the timing chain tensioner as follows: a. Forma keeper from heavy gauge wire. b. Slightly, compress the shoe plunger and insert a small screwdriver into the access hole. c. Release the ratchet pawl and compress the plunger completely into the hole. d. Insert the keeper between the access hole and the blade. 18. Install or connect the following: e Tensioner assembly to the chain housing. Torque the bolts to 89 inch Ibs. (10 Nm). e»Recheck plunger assembly installation. It is correctly installed when the long end is toward the crankshaft.

e Tensioner shoe and retainer. Torque the bolts to 89 inch Ibs. (10 Nm). 19. Remove the alignment dowel pins. Rotate crankshaft clockwise 2 full rotations. Align the crankshaft timing mark with mark on cylinder block and reinstall alignment dowel pins. Alignment dowel pins will slide in easily if engine is timed correctly.

If the engine is not correctly timed, severe engine damage could occur. tab dahRenaratal dale ses tee bby poke

e>\f properly timed, the intake camshaft alignment dowel pin should Slide in easily. If the dowel pin does not fully index, the camshafts are not timed correctly and the procedure must be repeated.

14. Leave the alignment dowel pins installed. 15. With slack removed from chain between intake camshaft sprocket and crankshaft sprocket, the timing marks on the Crankshaft and the cylinder block should be aligned. If marks are not aligned, move the chain 1 tooth forward or rearward, remove Slack and recheck the marks. 16. Tighten the chain housing to engine stud. The stud is installed under the timing chain. Torque it to 19 ft. Ibs. (26 Nm)

2. Timing chain

3. Timing chain tensioner

4. S. 6. 7. 8.

R.H. timing chain guide LH. timing chain guide Upper timing chain guide Exhaust camshaft sprocket Intake camshaft sprocket 79227321

Timing chain and sprocket alignment positions—2.4L DOHC engine

N-BODY—GENERAL MOTORS CORPORATION 21-21 SKYLARK @ ACHIEVA ¢ ALERO e GRAND AM 20. Install or connect the following: e Timing chain guides e New Seal into the front cover by lubricating the seal lip and tapping it into place Front cover and gaskets. Torque the nuts and bolts to 106 inch Ibs. (12 Nm). Crankshaft balancer. Torque the bolt to 129 ft. Ibs. (175 Nm). Right front lower splash shield Front wheel. Torque the nuts to 100 ft. Ibs. (140 Nm). Right engine mount bracket. Torque the bolts to 81 ft. Ibs. (110 Nm) plus an additional 90 degree turn. Right engine mount. Torque the bolt to 49 ft. Ibs. (60 Nm).

e Upper cover vent hose 21. Remove the engine support. 22. Install or connect the following: e Alternator. Torque the bolts to 37 ft. lbs. (60 Nm). e Accessory drive belt e Coolant surge tank ¢ Negative battery cable 23. Refill the cooling system. 24. Start the engine and check for leaks. 3.1L and 3.4L Engines

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Disconnect the negative battery cable. 3. Drain the cooling system. 4. Drain the engine oil. 5. Discharge and recover the A/C refrigerant. 6. Install an engine support fixture. 7. Remove or disconnect the following: Front engine mount and bracket Accessory drive belt Air cleaner assembly Air intake duct 2 upper air conditioning compressor mounting bolts Power steering pump Alternator and bracket Right front wheel Right wheel well splash shield Crankshaft balancer Drive belt tensioner Right Wheel Speed sensor (WSS) harness at the Suspension support

Lower ball joint Stabilizer bar from the control arm and suspension support Suspension support A/C compressor-to-oil pan bolts Oil filter and adapter Starter motor Oil pan Crankshaft Position (CKP) sensor Lower front cover bolts Coolant bypass hose Upper radiator hose Engine front cover 8. Place the number one piston at Top Dead Center (TDC). 9. Remove or disconnect the following: e Camshaft sprocket e Timing chain e Crankshaft sprocket To install: 10. Install the crankshaft sprocket. ->Be sure the timing mark on the crankshaft sprocket is pointing toward the mark on the chain damper.

11. Place the timing chain over the camshaft sprocket and hold the sprocket so the timing mark is pointing down and the timing chain is hanging off the sprocket. 12. Loop the timing chain under the crankshaft sprocket and install the camshaft sprocket on the camshaft. 13. Verify that the marks are aligned; the

93002301

Be sure to align the damper mark (1) with the crankshaft mark (2) and the damper mark (3) with the camshaft sprocket mark (4)—3.1L and 3.4L engines

camshaft sprocket will be at the 6 o'clock position and the crankshaft sprocket at the 12 o'clock position. >The No. 1 piston will be at TDC and the No. 4 piston will also be at TDC but on the compression stroke.

14. Torque the camshaft sprocket bolt to 103 ft. Ibs. (140 Nm). 15. Install or connect the following: Front cover, using a new gasket and seal. Torque the small bolts to 15 ft. Ibs. (21 Nm) and the long bolts to 35 ft. Ibs. (47 Nm). Upper radiator hose Coolant bypass hose CKP sensor Oil pan. Torque the bolts to 18 ft. lbs. (25 Nm). Starter motor. Torque the bolts to 32 ft. Ibs. (43 Nm). Oil filter adapter and filter A/C compressor-to-oil pan bolts. Torque the bolts to 37 ft. Ibs. (50 Nm). Suspension support. Torque the bolts to 61 ft. Ibs. (82 Nm). Stabilizer bar. Torque the bolts to 13 ft. Ibs. (17 Nm). Ball joint. Torque the nuts to 41 ft. lbs. (55 Nm). WSS electrical connector Drive belt tensioner. Torque the bolts to 33 ft. Ibs. (45 Nm). Crankshaft balancer. Torque the bolt to 76 ft. Ibs. (103 Nm). Right wheel well splash shield Right front wheel Alternator. Torque the front bolt to 37 ft. Ips. (50 Nm) and the rear bolt to 18 ft. Ibs. (25 Nm). 2 upper air conditioning compressor mounting bolts. Torque the bolts to 37 ft. Ibs. (50 Nm). Power steering pump. Torque the bolts to 25 ft. Ibs. (34 Nm). Air intake duct Air cleaner assembly Accessory drive belt Front engine mount and bracket. Torque the 8mm bolts to 15 ft. Ibs. (20 Nm) and the 12mm bolts to 30 ft. Ibs. (40 Nm). Negative battery cable 16. Evacuate and recharge the A/C system. 17. Refill the engine oil and coolant. 18. Start the engine and check for leaks.

on 1 of this manual For Maintenance Interval recommendations, see Secti

GENERAL MOTORS CORPORATION—N-BODY

21-2

SKYLARK ¢ ACHIEVA @

Piston and Ring

1. PISTON 2. ORIENTATION ARROW TOWARDS FRONT OF ENGINE 3. CONNECTING ROD 4. OIL SQUIRT HOLE TOWARDS EXHAUST SIDE 5. BEARING CONNECTING ROD 6. NUT, CONNECTING ROD CAP TO CONNECTING ROD 7. CAP, CONNECTING ROD

POSITIONING CONNECTING ROD MATCHING NUMBERS

7922AG49

Piston and connecting rod assembly positioning—2.4L engine

ga

7922AG51

Connecting rod and cap installation. Be sure to matchmark the cap and rod prior to disassembly, as shown—All engines

OIL RING

ASSEMBLY GAP

120° TYPICAL LOWER COMPRESSION RING GAP PISTON

FRONT OF

&

ENGINE

NGINE LEFT B.

c

ENGINE FRONT

C.

=>

ARROW TOWARDS FRONT OF ENGINE


The washer and nut must be installed on the outboard side.

9 Install the control arm.

Wheel Bearings

ADJUSTMENT

Installing the front bushing to the lower control arm

To install: 7. Lubricate the new front bushing outer casing. 8. Insert the new bushing into the control arm. 9, Assemble a bushing driver/installer set onto the front control. 10. Tighten the screw until the front bushing is pressed into the control arm. 11. Disassemble the tools. 12. Install the lower control arm.

d. Install J 21474-18 (3/8 inch) nut onto the J21474-19 (3/8 inch) bolt.

These vehicles are equipped with sealed hub and bearing assemblies. The hub and bearing assemblies are non-serviceable. If the assembly is damaged, the complete unit must be replaced.

REMOVAL & INSTALLATION Front J 21474-18

os

J 21474-19

93462602

Removing the rear control arm bushings

1. Before servicing the vehicle, refer to the precautions in the beginning of this section.

2. Remove or disconnect the following:

J 21474—19 J 29376 —7

J 29376 —1 eo J 29376 — 4 J 21474 -—18 93462603

Installing the rear control arm bushings

N-BODY—GENERAL MOTOR SKYLARK © ACHIEVA e Seer

21-41

e Front wheel e Halfshaft nut and washer e Caliper from the steering knuckle and supportitaside

DO NOT allow the caliper to hang unsupported from the brake hose. e Brake rotor e 3 hub/bearing assembly bolts e Halfshaft from the hub/bearing assembly e Hub/bearing assembly To install: 3. Install or connect the following: Hub/bearing assembly onto the halfshaft, making sure the splines engage smoothly

Hub/bearing assembly to the steering knuckle. Torque the bolts to 70 ft. lbs. (95 Nm). Brake rotor Caliper onto the steering knuckle. Torque the bolts to 38 ft. Ibs. (51 Nm). Halfshaft nut. Torque the hub nut to 74 ft. Ibs. (100 Nm) plus an additional 40 degree turn for 1998 models, or to 284 ft. Ibs. (385 Nm), for 1999-01 models. Front wheel. Torque the nuts to 100 ft. lbs. (140 Nm).

HUB AND BEARING ASSEMBLY STEERING KNUCKLE WASHER DRIVE AXLE NUT — 260 N-m (192 LBS. FT.) HUB AND BEARING RETAINING BOLT ana WASHER WN nf 79222340

Exploded view of the front hub/bearing assembly

S

Rear

2

ars

co

3

DRUM BRAKE 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Wheel e Brake drum e 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.

BOLT

= IND Gl! fe CH

REAR AXLE ASSEMBLY BACKING PLATE HUB AND BEARING ASSEMBLY LOCKNUT

Hub and bearing components

79 227341

e Anti-lock Brake System (ABS) speed sensor wire from the hub/bearing assembly e Hub/bearing assembly To install: 3. Install or connect the following: e Hub/bearing assembly on the knuckle ¢ ABS wheel speed sensor

For Wheel Alignment specifications, see Section 1 of this manual

2/- 4?

GENERAL MOTORS CORPORATION—N-BODY SKYLARK ¢ ACHIEVA ¢ ALERO e GRAND AM

Hub/bearing nuts. Torque the nuts

to 44 ft. Ibs. (60 Nm). Brake drum

e Wheel. Torque the nuts to 100 ft. lbs. (140 Nm).

DISC BRAKE 1. Before servicing the vehicle, refer to the precautions in the beginning of this section.

2. Remove or disconnect the following: Wheel Brake rotor Parking brake cable from the lever Wheel Speed Sensor (WSS) electrical connector Hub/bearing assembly bolts from the knuckle Torx® bolts from the rear of the hub/bearing assembly Hub/bearing assembly from the backing plate

93002304

Rear wheel bearing assembly with disc brakes—1999-01 models

To install: 3. Install or connect the following: e Hub/bearing assembly to the backing plate. Tighten the Torx®bolts to 89 inch Ibs. (10 Nm). e Hub/bearing assembly on the knuckle. Torque the bolts to 70 ft.

lbs. (95 Nm) on 1999 models or 62 ft. Ibs. (85 Nm) on 2000-01 models. WSS electrical connector Parking brake cable to the lever Brake rotor Wheel assembly

GENERAL MOTORS CORPORATION—V-BODY 1998-01 Cadillac-Catera DRIVE TRAIN............0..... 28-13

F

ENGINE REPAIR ................ 28-2 FUEISSYSTEM i. rece. 28-12 PRECAUTIONS.................. 28-2 STEERING AND

Front Crankshaft Seal .....c.ccsueseud 28-8 Removal & Installation... 28-8 UE AIT ese stator aShiva etsaaah28-12 Removal & Installation............ 28-12

SUSPENSION................. 28715" A

Ful lnecior eae ee

P

ee

28-13

Removal & Installation............ 28-13

LET SE laa tite Mal Ae a le eee 28-15 DEPSaERIDINU Mere. case pancascters: 28-15 PACOON ON Sa eet conga cetaten 28-15 BECO UNE catia cetatiatyreaslycoer 28-15 POD OR RRR cc cic SaaS cps Ei ces 28-2 HISTALT ALO Ms Stecsceedexevsctens zcsemees 28-2

28-14 28-14 28-11 28-11

Rear Main Sealer

20-11

R

3 8 Pin

ae

98-12 Do210 28-12 28-12

Removal & Installation............ 28-11 Recirculating Ball Power SLCC Gaia ane aie enemoe. 28-15 Removal & Tee Sache ahh 28-15

28-12

Shock Absorber.......... iterate 28-17

PAITISHE ay ered ea an Guster 28-8

Removal & Installation... 98-6

Removal & Installation........... 28-17

2erte

~ LowerBall Joint. aaeat oe 28-19

Transmission Assembly................ 28-13

aes eee eek Met ener 28-14

Lower Control APM uuu... 28-19

Ren OV alnetnteeye is cl.amen28-2 Axle Shaft, Bearing and Seal........28-14 Removal & Installation............ 28-14 C

Removal & Installation............ 28-8

Oot Spires tec

Removal & Installation........... 28-17

OU

Inner & Outer Joint.............-. 28-14 PVNesEAC sox. tuze) eperinscvcesoseans 28-4 Removal & See sah ea

28-4

FURL PUI reine Removal & Installation............ Fuel System Pressure... Relieving@eke so cenaamy Fuel System Service Se DB ctis gh de Wan 295

PINiONoea lec: Are 2) rear Removal & Installation............ Piston*annd RING Wan seeat en cre POSIIOMING®, ecteeeee

| Removal & Installation............ 28-17 Ignition TIMING... ccc 29-3) = —olarter MOlOl Anan ee 28-10 Adjustment pee nh yh. 28-3 Removal & Installation............ 28-10 Intake Manifold Assembly.............. 20-6). SttuLh ee aren Pocurtain 28-1/ i

Removal & Installation............ 28-19

Control Arm Bushing Replacement .....:...tsscsssesestee 28-20

Tb ihe

Exhaust Manifold... imac

OHNE) aman

Removal & Installation............. 28-7

28-19

As Ie ae Sle

Engine Assembly ......c..0eene Sey

Removal & Installation............. 28-3

RY a

Removal & Be

Removal & Installation........... 28-10

de a

28-10

Removal & Installation............ 28-10

ake

Removal & st

T

Rei 28-13

Valve LASP .ssssssstsstseiserneenese ang Adjustment... iif soa ea A tna as78-4 Water Punt eae

Uren eal RU

Eee

Wheel Bearing .......ssssseesssseen ia

ACJUSIMEME.....sssseseter seers

‘

Removal & Installation......... 28-20

28-2

ula ERA

MOTORS CORPORATION—V-BODY

dr

PRECAUTIONS Before servicing any vehicle, please be sure to read all of the following precautions, which deal with personal safety, prevention of component damage, and important points to take into consideration when servicing a motor vehicle: ¢ Never open, service or drain the radiator or cooling system when the engine is hot, serious burns can occur from the steam and hot coolant. e Observe all applicable safety precautions when working around fuel. Whenever servicing the fuel system, always work in a well-ventilated area. Do not allow fuel spray or vapors to come in contact with a spark, open flame or excessive heat (a hot drop light, for example). Keep a dry chemical fire extinguisher near the work area. Always keep fuel in a container specifically designed for fuel storage; also, always properly seal fuel containers to avoid the possibility of fire or explosion. Refer to the additional fuel system precautions later in this section. e Fuel injection systems often remain pressurized, even after the engine has been turned OFF. The fuel system pressure must be relieved before disconnecting any fuel lines. Failure to do so may result in fire and/or personal injury. e Brake fluid often contains polyglycol ethers and polyglycols. Avoid contact with the eyes and wash your hands thoroughly after handling brake fluid. If you do get brake fluid in your eyes, flush your eyes with clean, running water for 15 minutes. If

eye irritation persists, or if you have taken brake fluid internally, seek medical assistance IMMEDIATELY. e The EPA warns that prolonged contact with used engine oil may cause a number of skin disorders, including cancer! You should make every effort to minimize your exposure to used engine oil. Protective gloves should be worn when changing oil. Wash your hands and any other exposed skin areas as soon as possible after exposure to used engine oil. Soap and water, or waterless hand cleaner should be used. « All new vehicles are now 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 repairs. e Always wear safety goggles when working with, or around, the air bag system. When carrying a non-deployed air bag, be sure the bag and trim cover are pointed away from your body. When placing a nondeployed air bag on a work surface, always face the bag and trim cover upward, away from the surface. This will reduce the motion of the module if it is accidentally deployed. Refer to the additional air bag system precautions later in this section. e Clean, high quality brake fluid from a sealed container is essential to the safe and

proper operation of the brake system. You should always buy the correct type of brake fluid for your vehicle. If the brake fluid becomes contaminated, completely flush the system with new fluid. Never reuse any brake fluid. Any brake fluid that is removed from the system should be discarded. Also, do not allow any brake fluid to come in contact with a painted surface; it will damage the paint. e Never operate the engine without the proper amount and type of engine oil; doing so WILL result in severe engine damage. ¢ Timing belt maintenance is extremely important! Many models utilize an interference-type, non-freewheeling engine. If the timing belt breaks, the valves in the cylinder head may strike the pistons, causing potentially serious (also time-consuming and expensive) engine damage. Refer to the maintenance interval charts in the front of this manual for the recommended replacement interval for the timing belt, and to the timing belt section for belt replacement and inspection. e Disconnecting the negative battery cable on some vehicles may interfere with the functions of the on-board computer system(s) and may require the computer to undergo a relearning process once the negative battery cable is reconnected.

e When servicing drum brakes, only disassemble and assemble one side at a time, leaving the remaining side intact for reference.

ENGINE REPAIR e>Disconnecting the negative battery cable on some vehicles may interfere with the operation of the on board computer system. The computer may undergo a relearning process once the negative battery cable is reconnected.

Alternator

|

REMOVAL 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Negative battery cable e |ntake air resonator e Drive belt ¢ Coolant heater, if equipped

e Alternator cooling duct e Alternator electrical connectors e Alternator

INSTALLATION 1. Install or connect the following: Alternator. Torque the lower nut to 26 ft. Ibs. (35 Nm) and the upper nut to 30 ft. Ibs. (40 Nm). Cooling duct Alternator electrical connectors Coolant heater, if equipped Drive belt Intake air resonator Negative battery cable 2. Perform a charging system test and verify that the system is operating properly.

Pa

(Sa

ms ia Aas

are gatas

Po UT

ee

O

—

der i A

;

93062404

Alternator mounting hardware

V-BODY—GENERAL MOTORS CUES Ignition Timing

ADJUSTMENT The 3.0L DOHC engine used in the Catera utilizes a Distributorless Ignition System (DIS). No ignition timing adjustment is possible.

Engine Assembly REMOVAL & INSTALLATION

93062402

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the cooling system. 3. Drain the engine oil. 4. Recover the A/C refrigerant. 5. Relieve the fuel system pressure. 6. Remove or disconnect the following: Battery Wiper arms Left and right air inlet grilles Hood Intake air resonator Air filter housing Red, white and black wiring harness connectors Body ground cable Power supply wires at the battery cable end Power steering hoses from the power steering pump Brake booster vacuum lines Electronic Control Module (ECM) and harness from the electrical center

Relays and wiring harness from electrical center Dox Cruise control and accelerator cables

93062401

Red, white and black harness connectors

(1)

Accelerator (1) and cruise control (2) cables

Fuel lines from the fuel rail. Use a backup wrench to prevent damage to the fuel rail. Coolant hose from the throttle body Vacuum hose from the purge valve on the engine ventilation chamber Vacuum hose from the heater control valve Coolant reservoir hose from the coolant inlet pipe Electric water pump with hoses attached Coolant hoses from the heater core Radiator Refrigerant line from the A/C compressor and compressor bracket Condenser line from the A/C condenser A/C quick-connect hose near the low pressure service valve Splash shield A/C compressor electrical connector ->Support the engine whenever the transmission is removed. The motor mounts are silicone filled and do not provide sufficient rigidity to support the engine with the transmission removed.

7. Remove the transmission from the vehicle. 8. Attach a hoist to the engine lifting eyes. Raise the engine slightly and remove the engine support fixture. 9. Remove the engine mount nuts and lift the engine out of the vehicle. Raise the engine slowly after being certain all wiring, cables and hoses have been removed. To install: 10. Install the engine. 41. Install the engine mount. Torque the upper motor mount nuts to 30 ft. Ibs. (40 Nm). Torque the lower nuts to 41 ft. Ibs. (55 Nm).

NA

ATERA

28-3

12. ‘Install an engine support fixture and remove the chain hoist. 13. Install or connect the following: Transmission. Torque the mounting bolts to 44 ft. Ibs. (60 Nm). A/C compressor electrical connector Splash shield and tighten securely Quick connects for the high and low pressure fittings A/C condenser line to the condenser A/C compressor line Radiator Coolant hoses to the heater core Electric water pump Coolant reservoir hose to the coolant inlet pipe Vacuum hose to the heater control valve Vacuum hose for the purge valve on the engine ventilation chamber Coolant hose to the throttle body Fuel return and supply lines. Torque the lines to 11 ft. Ibs. (15 Nm). Cruise contro! and accelerator cables to the throttle body Relays and wiring harness to the electrical center box

ECM Brake booster vacuum lines Power steering hoses to the steering pump. Torque the discharge hose fasteners to 21 ft. Ibs. (28 Nm). Power supply wires at the battery cable ends Body ground cable Red, white and black wiring harness connectors Air filter housing Intake air resonator Hood Left and right air inlet grilles Wiper arms Battery eeee#eee®# Negative battery cable 14. Fill and bleed the power steering system. 15. Refill the engine oil. ->An oil filter change is recommended.

16. Fill and bleed the coolant system. ->When refilling the coolant system add 2 crushed engine coolant supplement sealant pellets (PN 3634621) into the reservoir.

17. Recharge the A/C system and check for leaks.

For complete service labor times, order Nichols’ Chilton Labor Guide

28-4

GENERAL MOTORS CORPORATION—V-BODY CATERA

18. Start the vehicle and inspect for leaks.

Water Pump if

REMOVAL & INSTALLATION

Cr

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the coolant. 3. Remove or disconnect the following: e Negative battery cable e Intake air resonator ¢ Water pump pulley bolts, loosen only e Front timing belt cover e Water pump pulley e Water pump To install: 4. Install or connect the following: ¢ Water pump with a new O-ring. Torque the bolts to 18 ft. Ibs. (25 Nm). ¢ Water pump pulley e Front timing belt cover e Intake air resonator ¢ Negative battery cable 5. Fill the cooling system through the reservoir tank. e>When refilling the cooling system, add 2 crushed engine coolant supplement sealant pellets (PN 3634621) into the coolant reservoir.

6. Start the vehicle and inspect the coolant systems for leaks.

Yi

}

ey

GES ey.

(1) Idle Air Control (LAC) Inlet Hose (2) Resonance Chamber Guide Pin (3) Resonance Chamber Nut (4) Mass Air Flow (MAF)

Sensor

(5) Intake Air Temperature (IAT) Sensor (6) Resonance Chamber Air Intake Hose (7) Intake Plenum Air Inlet Hose 79227406

Intake air resonator and related components

93002401

Exploded view of the water pump mounting

Cylinder Head

aes

REMOVAL & INSTALLATION —__—_—_—_———

1. Before servicing the vehicle, refer to the precautions in the beginning of this section.

79227402

Before removing the timing belt, be sure to turn the crankshaf t 60 degrees BTDC to avoid valveto-piston contact and subsequent engine damage.

V-BODY—GENERAL MOTORS CORPORATION CATERA

28-9

2. Drain the engine coolant. 3. Relieve the fuel system pressure. 4. Remove or disconnect the following: Intake plenum Intake air resonator Intake manifold and spacer Both Engine Coolant Temperature (ECT) sensor electrical connectors Coolant crossover Ignition coil assembly Camshaft cover Front timing belt cover 5. Position the crankshaft 60 degrees Before Top Dead Center (BTDC) to avoid contact between the valves and the pis-

ae [—) | ed =—

= ec! a [—

tons.

6. Remove or disconnect the following: Timing belt Timing belt tensioner bracket Four camshaft gears Water pump Rear timing belt cover Camshaft Position (CMP) sensor electrical connector Exhaust camshaft Coolant pipe/engine lift bracket from the cylinder head Oil level indicator tube Upper radiator hose from the coolant pipe Coolant pipe Exhaust manifold from the cylinder head Cylinder head

79222405

Proper head gasket installation position—right cylinder head

OBEN/TOP

To install:

e>Be sure to use new cylinder head bolts when installing the cylinder head. The old bolts have been stretched and are not reusable.

7. 8. 9. tighten

Install a new cylinder head gasket. Install the cylinder head. Install new cylinder head bolts and the bolts as follows: a. Step 1: Torque the bolts to 18 ft.

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Cylinder head torque sequence—left cylinder head

Please visit our web site at www.chiltonsonline.com

lbs. (25 Nm). b. Step 2: An additional 90 degrees. GC: Step 3: An additional 90 degrees.

d. Step 4: An additional 90 degrees. @. Step 5: An additional 15 degrees. 10. Install or connect the following: Exhaust manifold using a new gasket. Torque the nuts to 15 ft. Ibs. (20 Nm). Coolant pipe with new O-rings Oil level indicator tube Coolant pipe/engine lift bracket. Torque the bolt to 15 ft. Ibs. (20 Nm).

28-6

GENERAL MOTORS CORPORATION—V-BODY CATERA

93062402

Disconnect the accelerator and cruise control cables

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Cylinder head torque sequence—right cylinder head

Upper radiator hose to the coolant pipe Exhaust camshaft. Torque the bear-

ing cap bolts to 71 inch Ibs. (8 Nm CMP electrical connector Rear timing belt cover. Torque the bolts to 71 inch Ibs. (8 Nm). Water pump. Torque the bolts to 18 ft. Ibs. (25 Nm). Camshaft gears. Torque the bolts to 37 ft. Ibs. (60 Nm) plus a 60 degree turn, plus another 15 degree turn. Timing belt tensioner bracket. Torque the bolts to 30 ft. Ibs. (40 Nm). Timing belt Front timing belt cover. Torque the bolts to 71 inch Ibs. (8 Nm). Left camshaft cover with new Orings and gaskets. Torque the fasteners to 71 inch Ibs. (8 Nm). Ignition coil assembly Coolant crossover. Torque the bolts to 22 ft. Ibs. (30 Nm). Both ECT sensor electrical connectors Intake manifold spacer. Torque the bolts in a spiral direction, starting

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from the inside and working outward to 15 ft. Ips. (20 Nm). Intake manifold. Torque the bolts to 15 ft. Ibs. (20 Nm). Intake air resonator. Torque the nuts to 27 inch Ibs. (3 Nm). Intake plenum. Torque the bolts to 71 inch Ibs. (8 Nm). Negative battery cable

=

e Brake booster vacuum hose from the intake plenum ¢ Wiring harness channel from the plenum Switch over valve electrical connector and vacuum line Accelerator, cruise control cables and the bracket from the throttle body Throttle body control electrical connector Idle Air Control (IAC) inlet hose and electrical connector Throttle Position Sensor (TPS) electrical connection Throttle body from the intake plenum Crankcase vent tube adapter and cover from the intake plenum e Intake plenum and O-rings To install: 3. Install or connect the following: e Intake plenum with new O-rings. Torque the bolts to 71 inch Ibs. (8 Nm).

e>An oil and filter change is recommended.

11. Refill the cooling system. 12. Start the engine and inspect for leakage. 13. Inspect all fluid levels and top off, if necessary.

Intake Manifold Assembly REMOVAL & INSTALLATION eee ee Intake Plenum

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Negative battery cable e Intake plenum air inlet hoses from the throttle body

79222407

Intake plenum mounting bolt locations

V-BODY—GENERAL MOTORS CORPORATION

28-/

CATERA

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Exhaust Manifold

REMOVAL & INSTALLATION Left Side

79222408

Intake manifold mounting bolt locations

e Crankcase vent tube adapter to the intake plenum. Torque the fastener to 71 inch Ibs. (8 Nm). Throttle body to the intake plenum. Torque the fasteners to 106 inch Ibs. (12 Nm). TPS electrical connector IAC electrical connector and vacuum line Throttle body control electrical connector Accelerator and cruise control bracket and cables. Torque the bolts to 71 inch Ibs. (8 Nm). Electrical connector and vacuum hose to the intake plenum switchover valve solenoid Wiring channel to the intake plenum. Torque the bolts to 71 inch lbs. (8 Nm). Threaded brake booster vacuum hose to the intake plenum ->Be certain not to strip the threads on the brake booster vacuum hose.

e Intake plenum air inlet hoses to the throttle body e Negative battery cable 4. Start the engine and check for proper performance. Intake Manifold

1. Before servicing the vehicle, refer to the precautions in the beginning of this section.

2. Relieve the fuel system pressure. 3. Remove or disconnect the following: e Intake plenum e Fuel supply/return lines from the fuel rail by loosening the fittings e Fuel injector electrical harness connector e Fuel pressure regulator vacuum line e Intake manifold bolts -» Cover the open ports to the intake manifold spacer. Severe damage may occur if foreign material enters the engine.

e \ntake manifold To install: 4. Install or connect the following: e Intake manifold with new gaskets. Torque the bolts to 15 ft. Ibs. (20 Nm). e Fuel pressure regulator vacuum line

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the engine coolant. 3. Remove or disconnect the following: Engine assembly Exhaust manifold lower/upper heat shields Secondary Air Injection (AIR) pipe from the exhaust manifold Coolant pipe and engine lift bracket from the cylinder head Oil level indicator tube Exhaust manifold To install: 4. Install or connect the following: e Exhaust manifold with a new gasket. Torque the nuts to 1 ft. Ibs. (20 Nm). e Oil level indicator tube. Torque the bolt to 15 ft. Ibs. (20 Nm). e Engine lifting bracket and coolant pipe. Torque the bolt to 15 ft. Ibs. (20.Nm). e Air injection pipe to the exhaust manifold. Torque the bolts to 15 ft. lps. (20 Nm). e Exhaust manifold upper/lower heat shields. Torque the bolts to 71 inch lbs. (8 Nm). e Engine assembly 5. Refill the engine coolant. 6. Start the vehicle and inspect for any leaks.

Right Side 1. Before servicing the vehicle, refer to the precautions in the beginning of this section.

>The fuel injector connectors are numbered. Be sure to attach the correct connector to the proper fuel injector.

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nectors e Fuel supply/return hoses. Torque the fittings to 11 ft. Ibs. (15 Nm). e Intake plenum e Negative battery cable 5. Start the vehicle and inspect for leaks.

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Exhaust manifold heat shield bolts

Timing belt service is covered in Section 3 of this manual

28-8

GENERAL MOTORS CORPORATION—V-BODY CATERA

2. Drain the engine coolant. 3. Remove or disconnect the following: ¢ Transmission assembly ¢ Coolant intake pipe 4. Remove or disconnect the following: Exhaust manifold lower heat shield Exhaust manifold lower rear nuts Exhaust manifold upper rear heat shield bolt Catalytic converter nuts from the exhaust manifold Drive belt tensioner Exhaust manifold front two nuts Exhaust manifold upper heat shield bolts

3. Drill a small shallow hole into the

steel ring of the seal. e>Use caution so as not to damage the area around and behind the seal.

4. Insert a self-tapping screw. ; 5. Using pliers, pull the front crankshaft Seal Out. To install: 6. Install or connect the following: ¢ New seal coated with grease using Seal Installer Tool (such as J35268-A) e Crankshaft gear e Timing belt

->It is not necessary to remove the upper heat shield.

¢ Secondary Air Injection (AIR) injection pipe from the exhaust manifold ¢ Exhaust manifold To install: 9. Install or connect the following: e Exhaust manifold with a new gasket. Torque the 2 upper nuts to 15 ft. Ibs. (20 Nm). AIR injection pipe to the exhaust manifold. Torque the bolts to 15 ft. lbs. (20 Nm). Upper heat shield bolts. Torque the bolts to 71 inch Ibs. (8 Nm). Exhaust manifold upper heat shield bolts. Torque the bolts to 71 inch lbs. (8 Nm). Exhaust manifold lower front nuts. Torque the nuts to 15 ft. Ibs. (20 Nm). Drive belt tensioner. Torque the bolts to 30 ft. Ibs. (40 Nm). Catalytic converter nuts. Torque the nuts to 15 ft. Ibs. (20 Nm). e Exhaust = manifold lower rear nuts. Torque the nuts to 15 ft. Ibs. (20 Nm), ¢ Exhaust +manifold lower heat shield, Torque the bolts to 71 inch Ibs. (8 Nm). ¢ Coolant intake pipe. Torque the bolts to 15 ft. Ibs. (20 Nm). Transmission assembly 6. Refill the engine coolant. 7. Start the vehicle and inspect for leaks.

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 e Intake plenum e Intake air resonator ¢ Camshaft cover ¢ Front timing belt cover ¢ Timing belt

J 42069—1

3. Rotate the crankshaft 60 degrees counterclockwise Before Top Dead Center (BTDC) to prevent valve/piston contact. 4. Use a Camshaft Locking tool to hold the camshaft gears in place and loosen the camshaft gear bolt. 5. Remove the locking tool from the gears. 6. Remove the camshaft gear(s). ->Be certain that the camshaft is not under load from the lifters.

7. Gradually loosen the camshaft bearing cap bolts sequentially, starting in the center and working outward in a spiral. Note the identification marks on the caps. 8. Remove the camshaft from the cylinder head. To install: 9. Lubricate the camshaft lobes, lifters and bearing journals with camshaft lubri-

cant. 10. Install the camshaft to the cylinder head. 11. To reduce the lifter load, position the pin on the front of the camshaft as follows: ¢ 1 clock position: right exhaust camshaft ¢ 11 o'clock position: right intake camshaft

J 42069 -2

Front Crankshaft Seal

REMOVAL & INSTALLATION a IS a Ee et eS ier. 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove the timing belt and crankshaft gear.

79227409

Camshaft gear holding tools must be installed before attempting to remove the gears from the

camshafts

V-BODY—GENERAL MOTORS CORPORATION CATERA

L5

L6

L7

L8

28-9

79227410

The camshaft bearing caps have identification marks stamped on the side

e 12 o'clock position: left exhaust camshaft e 7 oclock position: left intake camshaft 12. Place a small amount of Locktite® on the edge of the front bearing cap to ensure a good seal between the cap and surface of the cylinder head. Do not allow the sealer to get into the oil journal of the cap.

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L3

L2 79222411

Camshaft bearing cap locations-right cylinder head

The bearing caps must be installed in their original positions. 13. Install or connect the following: e Camshaft bearing caps. Torque the bolts in sequence starting in the center and working outwards to 71 inch Ibs. (8 Nm). e New camshaft seal lubricated with engine oil «> Make certain that the camshaft seal

is fully seated.

e Camshaft gear. Tighten the new bolt to 37 ft. Ibs. (60 Nm), plus a 60 degree turn, plus a 15 degree turn.

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A new camshaft gear bolt must be installed. The required tightening method will stretch the bolt making the original bolt unusable. Timing belt and adjust as needed Front timing belt cover. Torque the bolts to 71 inch Ibs. (8 Nm). Camshaft cover. Torque the bolts to 71 inch Ibs. (8 Nm). Intake plenum. Torque the bolts to 71 inch Ibs. (8 Nm). Intake air resonator

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Camshaft bearing cap locations—teft cylinder head

Heater Core replacement is covered in Section 2 of this manual

28-1

eee CATER

MOTORS CORPORATION—V-BODY

e Negative battery cable 14. Start the vehicle and verify the engine is running properly.

Valve Lash

ADJUSTMENT >The valve lash is non-adjustable.

Starter Motor

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

¢ e e e

Starter electrical connectors Right hand catalytic converter Right side engine mount nuts Intake air resonator to the throttle body ducts

3. Install an Engine Support Fixture to the right side of the engine. 4. Raise the right side of the engine approximately 1.5 inches (38mm) to gain access to the starter motor bolts. 5. Remove or disconnect the following: e Engine mount from the bracket and cradle ¢ Engine mount bracket bolts and reposition the bracket ¢ Starter motor To install: 6. Install or connect the following: ¢ Starter motor. Torque the bolts to 44 ft. Ibs. (60 Nm). ¢ Engine mount to the bracket and front crossmember. Torque the bolts to 30 ft. Ibs. (40 Nm). 7. Lower the engine into position and make certain that the mount locator tab is fully seated in the front crossmember slot.

8. Remove the special tools from the engine. 9. Install or connect the following: Engine mount nuts. Torque the upper nut to 30 ft. Ibs. (40 Nm) and the lower nut to 41 ft. Ibs. (655 Nm). Intake air resonator to the throttle body ducts Catalytic converter. Torque the bolt to 25 ft. Ibs. (34 Nm) and the nuts to 18 ft. Ibs. (25 Nm). Starter electrical connectors. Torque the battery cable nut to 115 inch Ibs. (13 Nm) and the starter solenoid nut to 35 inch Ibs. (4 Nm). Negative battery cable

REMOVAL & INSTALLATION Lower

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the engine oil. 3. Remove or disconnect the following: ¢ Negative battery cable e Splash shield ¢ Oil level sensor wiring C-clip from the oil pan housing Qil level sensor electrical connector ¢ Oil pan from the oil pan housing To install: 4. Clean the oil pan and housing sealing surfaces with a non-abrasive cleaner. 9. Install or connect the following: Oil level sensor wire connector to the oil pan housing C-clip Oil pan with a new gasket. Torque the bolts to 71 inch Ibs. (8 Nm). Oil level sensor electrical connector Splash shield. Torque the bolts until they are fully seated. Negative battery cable 6. Refill the engine oil. 7. Start the vehicle and check for leaks. Upper

93062405

Remove the starter motor and bolts

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: ¢ Negative battery cable ¢ Lower oil pan ¢ Engine mount lower nuts e A/C compressor hose strap from the oil pan ¢ Transmission bolts from the oil pan

e All but the 4 corner bolts from the oil pan e Propeller shaft 3. Support the propeller shaft out of the

way. 4 Remove or disconnect the following: e Catalytic converter e Idler arm bolts and lower the relay rod out of the way 5. Install an engine support fixture and raise the engine slightly to allow removal of the oil pan. 6. Remove or disconnect the following: e Remaining oil pan bolts ¢ (il intake pipe ¢ Oil pan from the vehicle To install: 7. Apply a bead of silicone sealer in the bottom of the upper oil pan groove. 8. Install a new rubber seal into the groove in the pan. 9. Apply a 3 mm (0.12 in) bead of silicone sealant on the OUTSIDE edge of the seal, at the front of the upper oil pan and apply an identical bead on the INSIDE edge of the seal at the rear of the upper oil pan. The beads will overlap at the middle of the upper oil pan. 10. Install or connect the following: ¢ Upper oil pan * Oil intake pipe. Torque the bolt to 71 inch Ibs. (8 Nm). e Four oil pan corner bolts finger tight 11. Lower the engine into place. 12. Install or connect the following: Remaining oil pan bolts. Torque the bolts to 11 ft. Ibs. (15 Nm). Transmission-to-oil pan bolts. Torque the bolts to 30 ft. Ibs. (40 Nm). Idler arm bolts. Torque the bolts to 44 ft. bs. (60 Nm). Catalytic converter. Torque the nuts to 18 ft. Ibs. (25 Nm). Propeller shaft. Torque the bolts to 70 ft. Ibs. (95 Nm). A/C compressor hose strap. Torque the bolt to 71 inch Ibs. (8 Nm). Engine mount lower nuts. Torque the nuts to 41 ft. Ibs. (55 Nm) Lower oil pan 13. Refill the engine oil.

REMOVAL & INSTALLATION SE nen a eee 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the engine oil.

V-BODY—GENERAL MOTORS bodman eon 28-1 1 ing pump bracket. Torque the fasteners to 30 ft. Ibs. (40 Nm). A/C compressor. Torque the bolts to 30 ft. Ibs. (40 Nm). Rear timing belt cover. Torque the bolts to 71 inch lbs. (8 Nm), Timing belt Front timing belt cover. Torque the bolts to 71 inch Ibs. (8 Nm). Intake plenum. Torque the bolts to 71 inch Ibs. (8 Nm).

79222414

Oil pump mounting bolt locations

3. Drain the engine coolant. 4. Discharge and recover the A/C sys-

tem. 5. Remove or disconnect the following: Negative battery cable Intake air resonator Front timing belt cover Intake plenum Timing belt Rear timing belt cover

A/C compressor A/C compressor and power steering pump bracket and position it out of the way of the oil pump housing Lower alternator mounting bolt and loosen the upper mounting bolt then, position the alternator aside Lower and upper oil pans Crankshaft drive gear Oil pump Front main oil seal and collar To install: 6. Coat the pump side of the oil pump gasket with a thin layer of sealant. Do not cover or restrict the gasket openings with sealant. 7. Install or connect the following: Oil pump collar New front main oil seal Oil pump with a new gasket by aligning the guide pins. Torque the bolts to 9 ft. Ibs. (12 Nm). Crankshaft gear. Torque the bolt to 184 ft. Ibs. (250 Nm) pius an additional 60 degree turn. Upper oil pan. Torque the bolts to 11 ft. Ibs. (15 Nm). Lower oil pan. Torque the bolts to 71 inch Ibs. (8 Nm). Alternator. Torque the upper and lower bolts to 30 ft. Ibs. (40 Nm). 8. Re-tighten the oil pumo bolts to 15 ft. Ibs. (20 Nm). 9. Install or connect the following:

e A/C compressor and power steer-

10. 11. 12. 13.

Intake air resonator Negative battery cable Fill the engine oil. Fill the coolant. Recharge the A/C system. Start the vehicle and checks for leaks.

Rear Main Seal 79222417

REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Negative battery cable. e Flywheel 3. Center punch the steel ring of the rear main seal. 4. Drill a small hole into the steel ring. «> Make certain not to damage any engine components on the opposite side of the seal.

Press the rear main seal into position using a threaded seal installer like J 42067

e Rear main oil seal using an Oil Seal Installer tool J 42067 e Flywheel. Torque the new bolts to 48 ft. Ibs. (65 Nm), plus a 30 degree turn, plus a 15 degree turn. e Negative battery cable

Piston and Ring POSITIONING

5. Install a small self tapping screw. 6. Remove the rear main oil seal. To install: 7. Clean all sealing surfaces with a nonabrasive cleaner. 8. Install or connect the following: e New seal lubricated with chassis

grease

(1) (2) (3) (4) (5)

Ist Compression Ring End Gap Location 2nd Compression Ring End Gap Location Oil Control Ring Upper Ring End Gap Location Oil Control Ring Spacer End Gap Location Oil Control Ring Lower Ring End Gap Location

7922AG55

79222416

Thread a self-tapping screw into the metal part of the seal and remove the seal

Piston ring end-gap spacing—GM 3.0L engine

Brake service is covered in Section 4 of this manual

28-1 2 east MOTORS CORPORATION—V-BODY CATER

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Fuel System Service Precautions Safety is the most important factor when performing not only fuel system maintenance but any type of maintenance. Failure to conduct maintenance and repairs in a Safe manner may result in serious personal injury or death. Maintenance and testing of the vehicle's fuel system components can be accomplished safely and effectively by adhering to the following rules and guidelines. ¢ To avoid the possibility of fire and personal injury, always disconnect the negative battery cable unless the repair or test procedure requires that battery voltage be applied. e Always relieve the fuel system pressure prior to disconnecting any fuel system component (injector, fuel rail, pressure regulator, etc.), fitting or fuel line connection. Exercise extreme caution whenever relieving fuel system pressure, to avoid exposing skin, face and eyes to fuel spray. Please be advised that fuel under pressure may penetrate the skin or any part of the body that it contacts. ¢ Always place a shop towel or cloth

around the fitting or connection prior to loosening to absorb any excess fuel due to spillage. Ensure that all fuel spillage (should it occur) is quickly removed from engine surfaces. Ensure that all fuel soaked Cloths or towels are deposited into a suitable waste container. + Always keep a dry chemical (Class B) fire extinguisher near the work area. * Do not allow fuel spray or fuel vapors to come into contact with a spark or open flame. e Always use a backup wrench when loosening and tightening fuel line connection fittings. This will prevent unnecessary stress and torsion to fuel line piping. Always follow the proper torque specifications. ¢ Always replace worn fuel fitting Orings with new. Do not substitute fuel hose or equivalent, where fuel pipe is installed.

Fuel System Pressure RELIEVING Bada da hein ee Ladle Ba atte Ae 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Loosen the fuel filler cap to relieve the tank pressure.

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3. Remove or disconnect the follow-

¢ Negative battery cable ¢ Intake manifold top cover 4. Install a Fuel Pressure Gauge to the fuel pressure fitting. Wrap a shop towel around the fitting while installing the gauge. 5. Connect a bleed hose into an approved container and open the valve to bleed the system. 6. Close the valve and disconnect the gauge. 7. Drain any remaining fuel from the gauge into the approved container.

REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Loosen the fuel filler cap to relieve pressure in the tank. 3. Relieve the fuel system pressure. 4. Remove or disconnect the following: ¢ Fuel feed and return lines e Fuel filter from the bracket To install: 9. Clean the bolts and fittings on both fuel lines. 6. Install or connect the following: e Filter in the retaining strap making certain that the flow is in the proper direction ¢ Both fuel lines. Torque the fittings to 18 ft. Ibs. (25 Nm). ¢ Fuel filter bracket mounting bolt. Torque the bolt to 13 ft. Ibs. (18 Nim). ° Fuel filler cap 7. Crank the engine for a few seconds and check for leakage.

REMOVAL & INSTALLATION Ce ee AIRE Ee sie a

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e Spring loaded clamp around the tank boot e Tank boot from the housing >The fuel pump assembly may spring up from its position. The reservoir bucket on the assembly is full of fuel. Tip the assembly slightly so the float is not damaged during removal.

Fuel sender locking nut from the tank using a Fuel Tank Sender Wrench (J 42219) Fuel pump electrical connectors Fuel tank connection cover Hose from the pump Fuel pump from the tank by pushing the tabs inward Locking ring by pushing the tabs in and pushing the locking ring from the housing simultaneously Fuel pump from the housing Lip seal from the cover by sliding it downward, past the reservoir and over the float arm and discard it 5. Drain the remaining fuel from the reservoir into an approved container. To install: 6. Install or connect the following: ¢ New lip seal lubricated with engine Oil Fuel pump into the housing Locking ring into the housing New fuel inlet screen Fuel pump assembly into the tank Fuel line to the pump using a new clamp Fuel pump electrical connectors Fuel tank connection cover Fuel sender locking nut. Torque the nut to 37 ft. Ibs. (60 Nm).

yd Dice

1. 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 following: ¢ Fuel tank e Fuel tank pressure sensor ¢ Fuel tank connection cover electrical connector

(1) Fuel pump (2) Fuel gauge float arm (3) Fuel reservoir 79227419

Fuel pump module components

V-BODY—GENERAL MOTORS SUAAU SS

SS

Fuel tank boot to the housing Fuel tank pressure sensor. Torque the fastener to 18 inch Ibs. (4 Nm). Air reference hose to the pressure sensor Fuel feed and return lines using new clamps Fuel tank pressure sensor and connection cover electrical connectors Fuel tank to the vehicle. Torque the bolts to 22 ft. Ibs. (30 Nm). Negative battery cable 7. Refill the fuel tank. 8. Start the vehicle and inspect for leaks.

Fuel Injector REMOVAL & INSTALLATION

2k: CAUTION Remove the fuel rail assembly carefully to prevent damage to the injec-

: —

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 Shift linkage from the transmission Propeller shaft coupling bolts Propeller shaft coupling from the drive flange Access holes plugs from the oil pan and bell housing -> Mark the flywheel to the torque converter to ease the installation procedure.

Flywheel-to-torque converter bolts Oil cooler inlet and outlet pipes Oxygen (02S) sensor connections Catalytic converters Transmission housing-to-oil pan bolts 3. Support the transmission. 4. Remove or disconnect the following: e Transmission crossmember to mount nuts

SS

SSS

tor electrical connector terminals and Spray tips. Support the fuel rail after it is removed in order to avoid damaging the fuel rail components. Cap the fittings and plug the holes when servicing the fuel system to prevent debris from entering open ports. Fuel injection systems often remain presSurized, even after the engine has been turned OFF. The fuel system pressure must be relieved before disconnecting any fuel lines. Failure to do so may result in fire and/or personal injury. 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Relieve fuel system pressure. 3. Remove or disconnect the following: e Intake plenum Fuel rail supply and return lines from the fuel rail Fuel injector electrical connectors Harness from the fuel rail Fuel rail attaching bolts from the intake manifold Fuel pressure regulator vacuum lines

DRIVETRAIN

Transmission Assembly

¢ ¢ ¢ ¢ °

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Transmission crossmember Vent hose Electrical connector from the transmission control selector switch Electrical connector from the adapter case Electrical connector from the main case Electrical connector from the transmission speed sensor 5. Support the front of the engine. 6. Lower the transmission to gain access to the upper housing bolts. 7. Remove the upper transmission housing bolts. 8. Carefully remove the transmission from the vehicle. To install:

tk WARNING The transmission fluid cooler and lines must be flushed out prior to installing a new or reconditioned transmission. 9. Apply thread locking compound to the transmission-to-engine mounting bolts. 10. Install or connect the following: e Transmission. Torque the transmis-

MN carera 20" 10d

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¢ Fuel rail assembly e Injectors from the fuel rail and discard the O-rings To install: 4. Install or connect the following: New O-rings lubricated with clean engine oil onto the fuel injectors Fuel injectors with new retaining clips Fuel rail to the intake manifold. Torque the bolt to 71 inch Ibs. (8 Nm). Fuel pressure regulator vacuum line Fuel injector electrical connectors Harness to the fuel rail Fuel supply/return lines to the fuel rail. Torque the fasteners to 11 ft. lbs. (15 Nm). Fuel line bracket. Torque the bolts to 37 ft. Ibs. (60 Nm). Intake plenum. Torque the bolts to 71 inch Ibs. (8 Nm). Negative battery cable 5. Crank the engine several times to pressurize the system. 6. Check for leaks and repair, if necessary.

| sion-to-engine bolts to 44 ft. Ibs. (60 Nm). Electrical connector to the transmission control selector switch Electrical connector to the adapter case Electrical connector to the main case Electrical connector to the speed Sensor Vent hose Crossmember. Torque the bolts to 33 ft. Ibs. (45 Nm). Crossmember-to-mount and torque the nuts to 15 ft. Ibs. (20 Nm) 11. Remove the transmission support. 12. Install or connect the following: Transmission housing-to-oil pan bolts and torque the bolts to 15 ft. lbs. (20 Nm) Catalytic converters. Torque the bolts to 18 ft. Ibs. (25 Nm). 02S connectors Oil cooler inlet and outlet pipes to the center pipes Torque converter to the flywheel by aligning the matchmarks. Torque the new bolts to 22 ft. Ibs. (30 Nm).

For complete Engine Mechanical specifications, see Section 7 of this manual

28-1 4 GENERAL MOTORS CORPORATION—V-BODY CATERA

->Be sure the torque converter weld nuts are flush with the flywheel.

¢ Oil pan access hole plugs ¢ Bell housing access hole plugs e Propeller shaft coupling-to-drive flange an torque the bolts to 70 ft. lbs. (95 Nm) e Shift linkage to the transmission e Negative battery cable 13. Adjust the shift lever rod as follows: a. Place the shift control lever in the P position. b. Loosen the adjusting bolt on the rod. c. Hold the selector lever on the transmission toward the rear stop to eliminate any free-play. d. Tighten the adjusting bolt to 71 inch Ibs. (8 Nm). 14. Refill the transmission. Tighten the plug to 33 ft. Ibs. (45 Nm). 15. Start the vehicle and check for leaks. Be sure the vehicle will only start in the P and N positions.

Axle Shaft, Bearing and Seal REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Place the gear selector in N. 3. Remove or disconnect the following: e Rear wheel ¢ Drive axle flange bolts e Outer end of the drive axle from the

wheel bearing/hub inner flange e>Make certain that the drive axle separator tool is properly aligned to the differential and drive axle. The tool is clearly marked “Differential Side”. If

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79227421

Pry the halfshaft out of the differential

installed incorrectly, damage to the Anti-lock Brake System (ABS) sensor reluctor ring is possible.

4. Remove the axle shaft. 5. Use a suitable pry tool to remove the axle seal from the differential. To install: 6. Use a Seal Installation Tool (such as J 26234) to install the new seal. 7. Lubricate the splines of the halfshaft and the sealing surfaces with differential oll. 8. Install or connect the following: e Axle shaft into the differential bore by aligning the splines e>lf necessary use a soft faced tool, such as a rubber mallet, to seat the halfshaft fully in the differential bore.

Outer end of the axle shaft into the wheel bearing/hub inner flange. Torque the bolts to 37 ft. Ibs. (50 Nm) plus an additional 67 degree turn. ¢ Rear wheel 9. Road test the vehicle.

INNER & OUTER JOINT RRS ESOL Willi CAPRA

79227420

Prevent the outer hub from turning by installing a tool such as Hub Holding Tool

J 42066

8. Remove the CV joint retaining ring. 9. Remove the CV boot.

2a 53

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Disconnect the negative battery cable. 3, Remove the axle shaft and place it in a Vise. 4. Remove the large boot retaining clamp. ©. Remove the small boot retaining clamp. 6. Slide the boot up the shaft away from the joint, /. With a brass drift and a hammer tap on the inner race of the cross grove.

>The joint is not serviceable, if damaged it must be replaced.

To install: 10. Pack the CV joint with % of the grease provided in the service kit. 11. Install new small and large boot retaining clamps on the ends of the boot 12. Install a new boot on the halfshaft. 13. Install a new joint retaining ring onto the halfshaft. 14. Place halfshaft into a shop press and press the joint into place. 15. Slide the CV boot over the joint . 16. Using a crimping tool a breaker bar and a torque wrench, torque the small retaining clamp to 100 ft. Ibs. (140 Nm). 17. Place the remaining grease into the CV boot. 18. Using a crimping tool a breaker bar and a torque wrench, torque the large retaining clamp to 130 ft. Ibs. (176 Nm). 19. Install the halfshaft in the vehicle.

REMOVAL & INSTALLATION —_—_—_—_—_—_—_—_————

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Plate the transmission in N. 3. Remove or disconnect the following: e Underbody heat shields ¢ Bolts from the propeller shaft center bearing bracket ¢ Propeller shaft from the front and rear propeller shaft couplings ¢ Rear propeller shaft coupling 4. Mark the position of the gear yoke, gear and nut for correct bearing pre-load. 5. Remove or disconnect the following: e Drive pinion flange nut * Drive pinion flange using a gear puller ¢ Pinion seal from the rear axle housing by using a blunt chisel to drive the seal out To install: 6. Apply lubricant to the outer diameter of the gear yoke and the outer lip of the new Seal. 7. Install or connect the following: ¢ New seal lubricated with chassis grease ¢ Drive pinion flange

¢ Drive pinion gear nut and handtighten

V-BODY—GENERAL MOTORS CORPORATION

CATERA

8. Tighten the nut to the position marked in the removal procedure. Tighten

the nut an additional 0.062 inch (1.59mm). 9. Install or connect the following: e Rear propeller shaft coupling e Propeller shaft center bearing

|

bracket. Torque the bolts to 15 ft. Ibs. (20 Nm). ¢ Propeller shaft to the rear coupling. Torque the bolts to 70 ft. Ibs. (95 Nm). ¢ Propeller shaft to the front cou-

28-1 5

pling. Torque the bolts to 70 ft. Ibs. (95 Nm), e Underbody heat shields. Torque the bolts to 18 inch Ibs. (2 Nm). 10. Road test the vehicle.

STEERING AND SUSPENSION

oe Recirculating Ball Power

+ CAUTION These vehicles are equipped with an air bag system, known as a Supplemental Inflatable Restraint (SIR) 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 repairs.

PRECAUTIONS Several precautions must be observed when handling the inflator module to avoid accidental deployment and possible personal injury. e 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. e Place the inflator module on a bench or other surface with the bag and trim cover facing up. e With the inflator module on the bench, never place anything on or close to the module which may be thrown in the event of an accidental deployment.

lf major electrical or mechanical repairs are being performed on the vehicle, including painting, body part replacement or welding, the SDM module must first be disarmed.

REARMING 1. Turn the steering wheel so that the wheels are pointing straight ahead. 2. Turn the ignition switch to the LOCK position and remove the key. 3. Reconnect the negative battery cable. 4, Wait at least 1minute for the capacitors to recharge. 5. While staying away from the inflator modules, turn the key to the RUN position. The air bag warning lamp should turn ON for 3-4 seconds, then turn OFF.

Steering Gear REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Center the front wheels, then turn the ignition key to the LOCK position. 3, Drain the coolant.

4. Evacuate the A/C system. 5, Siphon the power steering fluid from the reservoir. 6. Siphon the brake fluid from the reservoir. 7. Remove or disconnect the following: e Negative battery cable e Windshield wiper assembly e 3 body harness electrical connectors

DISARMING 1. Turn the steering wheel to align the wheels in the straight-ahead position. 9. Turn the ignition switch to the LOCK ee position and remove the key. rs in capacito the until 3. Wait 1 minute (SDM) Module ic Diagnost and the Sensing discharge. 4. Disconnect the negative battery cable.

79222422

Body harness electrical connector locations (1)

For Accessory Drive Belt illustrations, see Section 1 of this manual

28-1 fs]GENERAL MOTORS ican

79222423

Matchmark the coupler to the steering gear before removing the coupler bolts (1)

Electronic Control Module (ECM) from the electrical box Upper radiator hose Evaporative line extension bolt Power steering fluid reservoir and bracket Brake booster vacuum connection from the intake plenum Brake pipes from the master cylinder Electrical connector from the master cylinder reservoir cap Sound insulator 8. Matchmark the steering coupler and input shaft of the steering gear.

Do not allow the steering wheel to rotate when the steering gear coupler is disconnected. Use a locking devise to secure the steering wheel in place. Damage to the SIR coil in the Steering column may occur. 9. Remove or disconnect the following: ¢ Steering coupler bolts from the coupler. Spread the clamp and pull the steering shaft upward and away from the steering gear connection. ¢ Brake pedal from the power brake

booster link rod by removing the retaining clip from the pin and driving the pin out of the linkage rod Instrument panel drivers side knee bolster energy absorber Relay panel. Move the fuse and relay panel away from the brake booster. Brake booster nuts from the inward side of the cowling Brake booster and master cylinder as one unit A/C evaporator line quick connect fitting Power steering hoses from the steering gear Electronic Brake Traction Control Module (EBTCM) Heat shield upper fastening bolt Pitman arm washer and nut. Mark the alignment of the pitman arm to the steering gear for ease of installation. Pitman arm using a suitable puller Lower heat shield mounting nuts Steering gear lower washers, bolts and nuts Heat Shield Electrical connector from the power steering fluid flow control valve actuator Upper steering gear shims and bolt ° Steering gear To install: 10. Find the center of travel of the steering gear by turning the stubshaft and counting the number of turns from lock-tolock. Divide the total number in half and turn the stub shaft from either lock position by this amount. Finally align the mark on the stub shaft to the “V” mark on the steering gear. 11. Install or connect the following:

79222425

79227424

Steering gear mounting bolt locations

Align the mark on the stub shaft with the “V” mark on the steering gear mounting bolt locations

Steering gear Steering gear shims and bolt. Torque the bolt snugly at this time. Do not tighten the bolt to proper specification at this time. Electrical connector to the power steering flow control valve actuator Heat shield with the upper mounting bolt. Torque the bolt to 71 inch lbs. (8 Nm). Lower steering gear washers, bolts and nuts. Torque all fasteners to 30 ft. Ibs. (40 Nm). Heat shield lower mounting bolt. Torque the bolt to 11 ft. Ibs. (15 Nm). Pitman arm to the steering gear. Make certain that the steering gear shaft protector is in place. Pitman arm washer and nut. Torque the fastener to 118 ft. Ibs. (160 Nm). EBTCM assembly Inlet and outlet hoses to the steering gear. Torque the hoses to 21 ft.

lbs. (28 Nm). A/C evaporator line quick connect with a new O-ring lubricated with mineral oil Vacuum booster/master cylinder assembly. Make certain the vacuum booster nuts are facing the inward side of the cowl. Torque

the fasteners to 15 ft. Ibs. (20 Nm). Fuse and relay panels and tighten the fasteners securely Drivers side instrument panel knee bolster energy absorber Brake pedal to the power booster by driving the pin into the linkage rod Retaining clip to the pin

Steering coupler to the gear by aligning the matchmarks Coupler bolts. Torque the bolts to 16 ft. Ibs. (22 Nm). Sound insulator Brake pipes to the master cylinder. Torque the fasteners to 12 ft. Ibs. (16 Nm). Electrical connector to the master cylinder reservoir cap Brake booster vacuum connection to the intake plenum Power steering fluid reservoir and clamp. Torque the clamp to 62 inch Ibs. (7 Nm). New O-ring lubricated with mineral oil to the A/C evaporator line extension Evaporator line to the cowl.

V-BODY—GENERAL MOTORS BOL OBATION 28-1 T SSS

Torque the bolt to 15 ft. Ibs. (20 Nm). ¢ Upper radiator hose ¢ ECM to the electrical box ¢ Body harness electrical connectors ¢ Wiper assembly e Negative battery cable 12. Fill and bleed the brake fluid. 13. Fill and bleed the power steering system. 14. Fill the coolant system. 15. Recharge the A/C system. 16. Start the vehicle and check all fluid system for leaks. 17. Check all fluid levels and top off, if necessary. 18. Road test the vehicle. 19. Bleed the systems again, if necesSary.

until after camber corrections have been made.

e Stabilizer shaft link to the strut.

Torque the nut to 48 ft. Ibs. (65 Nm). Before installing the bolts for the caliper, run an M12 x 1.5 tap through the holes and coat the new bolts with a thread locking compound.

4 5. bolts 6.

REMOVAL & INSTALLATION

SSS

e Brake caliper and bracket to the steering knuckle. Torque the bracket bolts to 70 ft. Ibs. (95 Nm) plus a 37 degree turn. e Brake flex hose to the strut and retain it with the clip e WSS wiring to the strut e Brake wear indicator wires to the strut e Front wheel Adjust the wheel alignment. Torque the steering knuckle-to-strut to 52 ft. Ibs. (70 Nm). Road test the vehicle.

Shock Absorber

Front

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Front wheel e Wheel Speed Sensor (WSS) wiring from the strut Brake wear indicator wires from the strut e Brake flex hose clip from the strut Brake caliper and bracket from the steering knuckle

e Stabilizer shaft link Lower strut mounting bolts from the steering knuckle

e>|t may be necessary to support the lower control arm for ease of installation of the lower nut.

e ALC air line connection to the shock 5. Position the rear seats in their proper position. 6. Road test the vehicle and verify a smooth ride.

REMOVAL & INSTALLATION REMOVAL & INSTALLATION Rear

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Position the rear seat backs forward to allow access to the upper shock absorber mounting. 3. Remove or disconnect the following: e Protective cap and nut from shock tower e Upper mounting nut, washer and grommet

» Upper support plate protective cap

¢ Upper support plate Strut from the wheel well To install: 3. Install or connect the following: e Strut into the strut tower ¢ Upper support plate and nut. Torque the nut to 41 ft. Ibs. (55 Nm). e Cap to the upper support nut e Steering knuckle to the strut e New bolts for the steering knuckle. Torque the lower bal! joint pinch bolt to 74 ft. Ibs. (100 Nm). ->The steering knuckle-to-strut bolts will not be tightened to specifications

e Automatic Level Control (ALC) air line connection from the shock ¢ Lower shock mounting bolt e Shock absorber To install: 4. Install or connect the following: e Lower rubber mounting grommet and washer Shock into the tower Upper shock mounting grommet, washer and nut. Torque the nut 15 ft. lbs. (20 Nm). Protective cap to the shock tower Lower shock mounting bolt. Torque the bolt 81 ft. Ibs. (110 Nm).

79227426

Air line connection to the shock absorber

for Automatic Level Control (ALC)

Front

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove the strut from the vehicle. 3. Using a Strut Compressor Holding tool J 3289-20 place the strut in a Compressor tool J 34013-A along with an Adapter J 3413-88 4. Remove or disconnect the following: e Compress the spring e Upper bearing support nut e Bearing and plate assembly 5. Decompress the spring. 6. Remove or disconnect the following: ¢ Upper spring support plate e Upper insulator e Strut bumper e Cover from the strut e Spring from the strut ¢ Lower insulator from the strut To install: 7. Before servicing the vehicle, refer to the precautions in the beginning of this section. ¢ Lower insulator to the strut e Spring on the strut e Upper spring support plate

For Tire, Wheel and Ball Joint specifications, see Section 1 of this manual

—V-BODY 98-18 GENERAL MOTORS CORPORATION—V-BOD e Upper insulator e Strut bumper e Cover 8. Align the spring between the upper and lower rubber isolation rings. 9.. Compress the spring. 10. Install or connect the following: e Bearing and plate assembly e Upper bearing support nut. Torque the nut to 52 ft. Ibs. (70 Nm). 11. Release the tension from the spring. 12. Remove the strut compressor tools from the strut. 13. Install the strut to the vehicle. 14. Road test the vehicle and verify a smooth ride and no abnormal noises from the strut and spring. (1) (2) (3) (4) (5)

Upper Support Plate Nut Upper Support Plate Upper Bearing Support Nut Bearing and Bearing Plate Assembly Upper Spring Support Plate

Rear

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Retainers from the lower control arms Brake pipes from the lower control arms without disconnect the brake fitting Stabilizer shaft link bolts Stabilizer shaft link from the lower control arms Rubber exhaust insulators from the hangers. Support the exhaust system so no damage occurs to the pipes or gaskets. Rear wheel speed sensor electrical connections Shock lower mounting bolt after properly supporting the lower control arms Support from the lower control arms and place on the rear differential Rear axle cradle mounts to the body bolts 3. Lower the rear differential so that coil Spring can be removed. 4. Remove or disconnect the following: ¢ Rear springs with the seats on the spring

(6) Upper Insulator (7) Strut Bumper (8) Strut Cover

(9) Strut (10) Lower Insulator

(11) Spring 79222427

Exploded view of the strut assembly

79222428

Be sure to compress the coil spring before removing the upper bearing support nut

¢ Seats from the spring To install: 9. Install or connect the following: e Seats to the spring ¢ Rear springs to the lower control arm and body. Make certain that the spring leg is aligned properly. ¢ Protective shields * Rear differential with the cradle mounting bolts. Torque the bolts to 48 ft. Ibs. (65 Nm).

V-BODY—GENERAL MOTORS CORO bAON 28-1 8] ¢ Shock absorber. Torque the bolt to 81 ft. Ibs. (110 Nm). e Rear wheel speed sensor electrical connections e Rubber exhaust insulators to the hangers e Stabilizer shaft link to the lower control arm. Torque the bolts to 15 ft. Ibs. (20 Nm). e Brake pipes to the lower control arm and secure with the retainers 6. Check and/or adjust the rear toe.

e Vertical bolt and hand-tighten at

this time e Horizontal bolt by inserting it from the rear side of the vehicle. Torque all bolts to 103 ft. Ibs. (140 Nm).

79222431

The replacement ball joint will be bolted to the lower control arm with the bolts supplied in the kit

e>Be certain that the lower control arm is in the horizontal position before tightening the bolts to prevent the bushings from binding.

Steering knuckle to the lower control arm ball stud. Torque the bolt to 74 ft. Ibs. (100 Nm). Steering knuckle to the strut with new bolts. Hand tighten the bolts at this time. Stabilizer shaft link to the shaft. Torque the nut to 48 ft. Ibs. (65 Nm). Outer tie rod to the steering knuckle New outer tie rod nut. Torque the nut 44 ft. Ibs. (60 Nm).

e Front wheel 6. Check and/or adjust the front end alignment.

Lower Ball Joint

REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Front wheel e Lower control arm 3. Using a 0.5 inch (13mm) drill, drill out the 3 rivet heads that attach the ball stud to the lower control arm. 4. Remove the ball stud from the lower control arm. To install: 5. Install or connect the following: e Ball stud to the lower control arm e Bolts through the upper side of the lower control arm. Torque the new bolts to 26 ft. Ibs. (35 Nm). e Lower control arm

Lower Control Arm REMOVAL & INSTALLATION Front

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the follow-ing: e Front wheel e Brake pad wear indicator rubber sleeve e Wheel Speed Sensor (WSS) e Brake hose from the strut bracket e Brake caliper from the steering knuckle ->Do not open the hydraulic brake system.

e Outer tie rod from the steering knuckle e Stabilizer shaft nut from the shaft e Steering knuckle from the strut

79222430

Drill out the rivets to remove the ball joint from the lower control arm

¢ Lower control arm ball stud pinch bolt e Steering knuckle from the lower control arm ball stud. The rotor and wheel hub will remain attached. 3. Loosen the lower control arm horizontal/vertical bolts. 4. Remove or disconnect the following: e Horizontal bolts Vertical bolts by rotating the lower control arm from the support bracket e Lower control arm To install: 5. Install or connect the following: ¢ Lower control arm into the support bracket

e>Clean the bolt holes for the brake caliper by running a M12 x 105 tap through the holes. Use new bolts for the caliper to steering knuckle connection after applying a thread locking compound.

e Caliper to the steering knuckle. Torque the new bolts to 70 ft. Ibs. (95 Nm) plus a 37 degree turn. e Brake hose to the strut bracket with a new clip e WSS. Torque the bolt to 71 inch lbs. (8 Nm). e Brake pad wear indicator sleeve to the strut e Front wheel 6. Adjust the wheel alignment and tighten the lower strut mounting bolts to 52 ft. Ibs. (70 Nm). 7. Road test the vehicle. Rear

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 9. Remove or disconnect the following: e Wheel Driveshaft from the rear wheel hub flange Brake pipe from the lower control arm e Brake caliper e Brake rotor Parking brake cable from the actuator bracket Rear hub and flange

l For Wheel Alignment specifications, see Section 1 of this manua

28-20

Hanetbide MOTORS CORPORATION—V-BODY

Wheel bearing Brake backing plate Exhaust system from the rubber mounts Rear outer tie rod from the rear control arm Stabilizer shaft link connection at the lower control arm

Rear axle cradle mounting bolts e>Make certain that the rear differen-

tial is properly supported.

Lower shock mounting bolts Rear coil spring Underbody heat shield Propeller shaft center bearing bracket bolts Rear support flange bolts Rear support bushing bolt Lower control arm To install: 3. Install or connect the following: ¢ Lower control arm. Torque the bolts to 74 ft. Ibs. (100 Nm). Rear support bushing bolt. Torque the bolt to 92 ft. Ibs. (125 Nm). Rear support flange bolts. Torque the bolts to 48 ft. Ibs. (65 Nm). Propeller shaft center bearing bracket. Torque the bolts to 15 ft. Ibs. (20 Nm). Underbody heat shield. Torque the bolts to 18 inch Ibs. (2 Nm). Rear coil spring Rear axle cradle mount. Torque the body bolts to 48 ft. Ibs. (65 Nm). Shock absorber. Torque the lower mount bolt to 81 ft. Ibs. (110 Nm). Stabilizer shaft link to the lower control arm. Torque the bolt to 15 ft. Ibs. (20 Nm). Outer tie rod. Torque the nut to 44 ft. Ibs. (60 Nm). Exhaust system to the rubber mounts Brake backing plate Wheel bearing Hub and flange Parking brake cable and route it through the bracket in the rear lower control arm Brake rotor and set screw. Torque the screw to 35 inch Ibs. (4 Nm), Brake caliper. Torque the bolts to 09 ft. Ibs. (80 Nm). Brake pipe and clip to the lower control arm Driveshaft. Torque the bolts to 37 ft. Ibs. (50 Nm) plus an additional 70 degree turn. © Wheel 4. Check and/or adjust the rear toe.

CONTROL ARM BUSHING REPLACEMENT Front

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove the control arm from the vehicle. 3. Press the bushings from the control arm. To install: 4. Press the new bushings into the control arm. 5. Install the control arm in the vehicle. Rear

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following; ¢ Wheel e Rear axle lower control arm * Collar for the inboard and outboard lower control arm bushings by cutting it off 3. Press the bushings out of the contro! arm. To install: 4. Press the inboard side bushing into the control arm with the collar toward the rear differential. 5. Press the outboard side bushing into the control arm. 6. Install or connect the following: ¢ Lower control arm e Wheel

79227429

Cut-away view of the hub/wheel bearing assembly and steering knuckle

To install: 3. Install or connect the following: Bearing onto the spindle and press the outer bearing ring into the hub Hub nut. Torque the nut to 236 ft. lbs. (320 Nm). Dust cap to the hub Brake rotor and setscrew. Torque

the screw to 35 inch Ibs. (4 Nm). Brake caliper to the steering knuckle after cleaning the bolt holes with an M12 x 1.5 tap and Coating the new bolts with a thread locking compound. Torque the bolts to 70 ft. Ibs. (95 Nm), plus a 37 degree turn. Brake hose to the strut bracket with a retaining clip Brake pad wear indicator wire to the strut

Wheel Bearings

ADJUSTMENT rr

ge

The wheel bearings are not adjustable,

REMOVAL & INSTALLATION SSPSL n RSS Lah Front

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: ¢ Front wheel e Brake pad wear indicator wire from the strut bracket Brake hose from the strut bracket Caliper bolts from the steering knuckle ¢ Brake caliper. The brake system should remain closed, Brake rotor and setscrew Dust cap from the hub Hub with the bearing Bearing by pressing it from the hub

Front wheel 4. Road test the vehicle. 9. Check and/or adjust the front end alignment. Rear

e» Several special tools are necessary to remove the rear wheel bearing from the knuckle. The tools required are as follows:

J 36660 Torque angle meter J 42066 Holding tool J 42094-1 Holding Fixture J 42094-2 Spacer J 42094-3 Threaded Driver J 42094-4 Threaded Arbor J 42094-5 Ball Head J 42094-6 Bearing Remover J 42094-7 Threaded spacer pin J 42094-8 Bearing Installer J 42094-9 Hub Installer J 42094-10 Thrust Bearing J 42072 Triple Hex Head (10mm) deep socket The tool numbers mentioned are Kent-

V-BODY—GENERAL MOTORS CORPORATION

CATERA

Moore tools used by GM. Equivalent tools

2. Remove the rear wheel.

e Brake pipe and retaining clip from

may be available from other sources. i Before servicing the vehicle, refer to

3. Remove the outer tie rod from the knuckle.

the precautions in the beginning of this section.

4. Use a Holding tool J 42066 and a 0.5 inch breaker bar to counter hold the rear wheel hub. . 5. Remove or disconnect the following:

the lower control arm e Rear brake caliper and support it aside e Set screw and brake rotor

e Three of the four brake backing plate bolts approximately 9 revolutions by installing a deep well socket Rear wheel hub nut by installing a

e Driveshaft from the rear hub

79227434

Damage to the wheel bearing seal is possible while pressing out the rear wheel hub. Inspect the seal and replace if needed.

79227437

10. Remove the wheel bearing retaining ring. 11. Attach a Bearing Remover J42094-6 to the end of the threaded driver. 12. Turn the driver in a clockwise manner to press out the wheel bearing. To install: 13. Install or connect the following: ¢ Wheel Bearing Installer Tool J 42094-8 through the wheel bearing and on to the threaded driver Wheel bearing until fully seated by turning the threaded driver Wheel bearing retaining ring Hub Installer Tool J 42094-9 on the shaft of the threaded driver. Make Certain that the rear wheel hub installer is on the inner ring of the wheel bearing 14. Attach the Holding Fixture to a Threaded Spacer Pin J 42094-7 and remove the anchoring bolts from the threaded arbor. 15. Install or connect the following: ¢ Rear wheel hub into the driver and make certain the driver is seated properly on the wheel bearing. If not centered properly, it may cause

the hub to bind Wheel hub into the wheel bearing by holding the driver and turning the arbor clockwise. When fully seated, remove the tools 16. Connect the Threaded ArborJ 42094-4, Threaded DriverJ42094-3, Holding Fixture J 42094-1, SpacerJ 42094-2, and Thrust Bearing J 42094-10 to the wheel flange with the halfshaft mounting bolts. 17. Install or connect the following: ¢ Hub to the flange and make certain that the splines are aligned properly ¢ Flange fully onto the hub by turning the arbor clockwise while

79227438

ies TIA

|= INUIT —_~

Set up the special tools as shown to install the flange on the hub

counter holding it with the driver 18. Remove the thrust bearing, arbor and driver while leaving the holding fixture and Spacer attached to the hub. 19. Install the rear wheel hub nut. Torque the nut 221 ft. Ibs. (300 Nm). 20. Remove the spacer and holding fixture from the hub. 21. Install or connect the following: e Retaining washer to the hub ¢ Backing plate bolts. Torque the bolts to 37 ft. Ibs. (60 Nm) plus a 40 degree turn.

79227439

Brake rotor and set screw. Torque the screw to 35 inch Ibs. (4 Nm). Brake caliper. Torque the bolts to 99 ft. Ibs. (80 Nm). Brake pipe to the lower control arm and secure it with a clip Driveshaft to the hub flange. Torque the bolts to 37 ft. Ibs. (50 Nm) plus an additional 70 degree turn. Tie rod end. Torque the nut to 44 ft. lbs. (60 Nm). Rear wheel

GENERAL MOTORS CORPORATION—W-BODY 1998-01 Buick-Century * Regal * Chevrolet-Impala * Lumina * Monte Carlo Oldsmobile-Intrigue * Pontiac-Grand Prix DRIVE TRAIN.................. 29-34 ENGINE REPAIR ................ 29-2 FUER SYSTEM eich. kk 29-32 PRECAUTIONS.................. 29-2 STEERING AND SUSPENSION a era ia 29-38

DN ICISEUI rant Ulneated bec haateres29-38 1 OIATT iio eee eee Rea SRINY Ae 29-38 Si eee 29-38 Ber AM ONS a nas ss ke ccssz nner 29PAIPCHUPALEL ee neat ep ance wtauis«ease 29-2 REG eee ee 29-3 Removal............ Seis 29-2 Camshaft and Valve Lifters .......... 29-20 Removal & Installation............ 29-20

G Olly OUNCES

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29-41

Removal & Installation............ 29-41 eR Aah29-36 ER(OUTS Nae Rehan OPED CAV PS ct coca 29-36 CORT VER Ceec

Cylinder Had ci.) tn. scsaeenaessemsenee 29-8

Removal & ego Pe ae 29-8

DISTIDUITON... ceessao>e eeiiurratre 29-2

Engine ASSEMDIy ........2-:seeeeeee 29-3

Removal & Installation.............. 29-3 PYFAUSE IANIIOIG «.ccccsceceeeeerseseoe-x- 29-16 Removal & Baer - eee 29-16 Front Crankshaft Seal .............+. 29-19 Removal & Installation............ 29-19

FUel Filtegein, cori cosh, et Aybeunale 29-32 Removal & Installation............ 29-32 Fuelilinjecho leer cite ie ities 29-33 Removal & Installation............ 29-33 FLUC PUR peers. Crammeiaces. 2 29-32 Removal & Installation............ 29-32 Fuel SystemPressurey ss asc... 29-32 RENOVA Memes teaches cmies 29-32 Fuel System Service Precautions........... vniaiReRS 29-32

ee Sate 29-35 REUSE Rose RR Removal & per Nee 29-35

aayiigeree WIiMiMle eae cere recoccute: 29-3 cctieh 29-3 ACJUSUMIEI iets, Snctersstttans eracta.29-13 (atakea Miaoheey. (rere pe Se 29-13 Removal & ee

Lower Ballons eae 29-42 Removal & Installation............ 29-42 Lower Control Arn! 28 s.cecs.s2-.. 29-43

Control Arm Bushing ee ne29-43 PEDIACCINGI cts ceuteeere 4} 29-43 ne op ub Ween & Removal iy anette teatoca 29-22 CHa erate Removal & Installation............ 29-22

PUM

Cee eer ee teresa: 29-24

Removal & eran hiss beret29-24

PISTOMPANCe allMUteee ear teues peers: 29-31 PGSIIGINII Mites arereeerenrenecees= 29-31

Power Rack and Pinion

SteeringGeatn ewe cemiviee: 29-39 Removal & eal 2 ae 29-39 Rear MaineSealnern tale ie Removal & Installation............ ROCKer ATTISte we ech aes een Removal & eeiae 4,3 Ose

29-26 29-26 29-11 29-11

et ome: 29-22 Clare WOU eee 29-22 ........... Installation. & Removal 29-40 eacaanre, orto a hes ee aTE)aug 29-40 ........... Installation. & Removal

SUDCheGANG leans tueeheceetanartte 29-12

Removal & See thee 29-12

Timing Chain, Sprockets, Front Cover and Seal...........:.068 Removal & Installation............ Transaxle ASsemDIy ce. uertieie. Removal & Peer Rha

29-2/ 29-27 29-34 29-34

tee eens29-22 Walve Laskin. ath eta NGIUSUMCI ieee teeters ae 29-22 W ice29-7 Water PURO tc ceeaetenescesaten Removal & Installation... 29-7 Whee liBearinGSwzraneexaceeate.: 29-43

once ts29-43 ACHUSIMentteremecer Removal & Installation............ 29-43

29-2

CENTLY =Raa PERE

ATION—W-BODY

LUnANE e MONTE CARLO ¢ INTRIGUE e GRAND PRIX

. PRECAUTIONS Before servicing any vehicle, please be Sure to read all of the following precautions, which deal with personal safety, prevention of component damage, and important points to take into consideration when servicing a motor vehicle: ¢ Never open, service or drain the radiator or cooling system when the engine is hot; serious burns can occur from the steam and hot coolant. Observe all applicable safety precautions when working around fuel. Whenever servicing the fuel system, always work in a well-ventilated area. Do not allow fuel spray Or vapors to come in contact with a spark, open flame or excessive heat (a hot drop light, for example). Keep a dry chemical fire extinguisher near the work area. Always keep fuel in a container specifically designed for fuel storage; also, always properly seal fuel containers to avoid the possibility of fire or explosion. Refer to the additional fuel system precautions later in this section. * Fuel injection systems often remain pressurized, even after the engine has been turned OFF. The fuel system pressure must be relieved before disconnecting any fuel lines. Failure to do so may result in fire and/or personal injury. ¢ Brake fluid often contains polyglycol ethers and polyglycols. Avoid contact with the eyes and wash your hands thoroughly after handling brake fluid. If you do get brake fluid in your eyes, flush your eyes with clean, running water for 15 minutes. If

eye irritation persists, or if you have taken brake fluid internally, seek medical assistance IMMEDIATELY. e The EPA warns that prolonged contact with used engine oil may cause a number of skin disorders, including cancer! You should make every effort to minimize your exposure to used engine oil. Protective gloves should be worn when changing oil. Wash your hands and any other exposed Skin areas as soon as possible after expoSure to used engine oil. Soap and water, or waterless hand cleaner should be used. e All new vehicles are now 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 repairs. ° Always wear safety goggles when working with, or around, the air bag system. When carrying a non-deployed air bag, be sure the bag and trim cover are pointed away from your body. When placing a nondeployed air bag on a work surface, always face the bag and trim cover upward, away from the surface. This will reduce the motion of the module if it is accidentally deployed. Refer to the additional air bag system precautions later in this section. Clean, high quality brake fluid from a sealed container is essential to the safe and

proper operation of the brake system. You should always buy the correct type of brake fluid for your vehicle. If the brake fluid becomes contaminated, completely flush the system with new fluid. Never reuse any brake fluid. Any brake fluid that is removed from the system should be discarded. Also, do not allow any brake fluid to come in contact with a painted surface; it will damage the paint. ¢ Never operate the engine without the proper amount and type of engine oil: doing so WILL result in severe engine damage. ¢ Timing belt maintenance is extremely important! Many models utilize an interference-type, non-freewheeling engine. If the timing belt breaks, the valves in the cylinder head may strike the pistons, causing potentially serious (also time-consuming and expensive) engine damage. Refer to the maintenance interval charts in the front of this manual for the recommended replacement interval for the timing belt, and to the timing belt section for belt replacement and inspection. e Disconnecting the negative battery cable on some vehicles may interfere with the functions of the on-board computer system(s) and may require the computer to undergo a relearning process once the negative battery cable is reconnected. e When servicing drum brakes, only disassemble and assemble one side at a time, leaving the remaining side intact for reference.

ENGINE REPAIR Distributor The engines in this section all utilize a Distributorless Ignition System (DIS).

Alternator REMOVAL 3.1L 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 ¢ Drive belt from the alternator * Coolant recovery reservoir and place it away from the alternator ¢ Alternator electrical connector ¢ Alternator bolts and the alternator

3.4L 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 Engine compartment cross brace Accessory drive belt Coolant recovery reservoir and place it aside Alternator bolts Alternator electrical connector ¢ Alternator

3.5L Engine

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the cooling system.

3. Remove or disconnect the following: Battery and tray Drive belt Engine cooling fan assembly Thermostat housing and radiator hose Qutboard/inboard alternator bolts Idler pulley bolt and pulley Alternator electrical connectors Alternator bolts and the alternator 3.8L 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 ¢ Drive belt ¢ Alternator electrical connectors e Rear alternator brace ¢ Alternator bolts and the alternator

W-BODY—GENERAL MOT

CENTURY ¢ REGAL ¢ IMPALA @ LUMINA INSTALLATION 3.1L Engine Install or connect the following: Alternator e Alternator output BAT terminal and torque the nut to 15 ft. lbs. (20 Nm) Protective boot from the output terminal Electrical connector Alternator bolts and torque them to 37 ft. Ibs. (60 Nm) Coolant recovery reservoir Drive belt Negative battery cable 3.4L Engine Install or connect the following: Alternator e Alternator output BAT wire and torque the nut to 15 ft. Ibs. (20 Nm) Alternator electrical connector Alternator bolts and torque them to 37 ft. Ibs. (60 Nm) Coolant recovery reservoir Drive belt Negative battery cable

BENGE eel DERE

e Engine cooling fan assembly e Drive belt e Battery tray and torque the bolts to 44 inch Ibs. (5 Nm) e Battery 2. Refill the cooling system. 3.8L Engine 1. Install or connect the following: Alternator e Alternator bolts and torque them to 37 ft. Ibs. (50 Nm) Alternator electrical connectors and torque the positive battery terminal to 15 ft. Ibs. (20 Nm) Rear alternator brace and torque the bolts to 37 ft. Ibs. (50 Nm) e Accessory drive belt ¢ Negative battery cable

Ignition Timing

.

ADJUSTMENT The ignition timing is not adjustable.

_Engine Assembly

:

REMOVAL & INSTALLATION

3.5L Engine

EEE

i

1. Install or connect the following: e Alternator e Alternator electrical connectors. Torque the positive battery terminal to 15 ft. Ibs. (20 Nm). Idler pulley and torque the bolt to 37 ft. Ips. (50 Nm) Alternator bolts and torque them to 37 ft. Ips. (50 Nm) Thermostat housing with radiator hose and torque the bolts to 80 inch Ibs. (9 Nm)

9306VG01

View of the alternator—3.5L engine

3.1L Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the engine coolant. 3. Drain the engine oil. 4 Relieve the fuel system pressure. 5. Remove or disconnect the following: Negative battery cable Hood Throttle body air inlet duct Air cleaner Engine mount struts Drive belt Knock Sensor (KS) electrical connector Heated Oxygen (HO2S) sensor electrical connector Camshaft Position (CMP) sensor electrical connector Crankshaft Position (CKP) sensor electrical connector Manifold Air Pressure (MAP) sensor electrical connector e

Exhaust Gas Recirculation (EGR) valve electrical connector

RAADIERRE

29-3

Evaporative (EVAP) emissions canister purge solenoid valve Throttle Position (TPS) sensor electrical connector Idle Air Control (IAC) valve electrical connector Starter motor electrical connector Alternator electrical connector Ignition coil electrical connector Wiring harness ground connections Two body wiring harness-to-engine harness connectors Oil filter Catalytic converter pipe from the rear exhaust manifold Engine mount lower nuts Torque converter cover A/C compressor Right side splash shield Torque converter bolts Transaxle brace Radiator outlet hose from the engine Accelerator and cruise control cables Heater inlet and outlet hoses Vacuum hoses from the upper intake manifold Fuel feed and return hoses Power steering pump and reposition e Radiator inlet and outlet hoses 6. Attach an engine lifting device. 7. Remove the transmission-to-engine bolts. 8. Remove the engine from the vehicle. To install: 9. Install or connect the following: e Engine to the vehicle e Transmission-to-engine bolts and torque them to 56 ft. Ibs. (75 Nm) 10, Remove the engine lifting device. Power steering pump and torque the bolts to 25 ft. Ibs. (34 Nm) Power steering lines to the pump and torque the fasteners to 20 ft. lbs. (27 Nm) Radiator inlet hose Heater inlet and outlet hoses Fuel feed and return hoses Vacuum hoses to the upper intake manifold >in order to avoid possible injury or vehicle damage, always replace the accelerator control cable with a NEW cable whenever you remove the engine from the vehicle.

Chilton Labor Guide For complete service labor times, order Nichols’

29-

RATION—W-BODY

CEATRS REGAINSTAPAENLOBINA e MONTE CARLO ¢ INTRIGUE ¢ GRAND PRIX

11. Remove the trim panel under the left instrument panel and detach the throttle cable from the top of the pedal then squeeze the retainer and push the cable through the bulkhead to remove it. 12. Install or connect the following: New accelerator cable Cruise control cable Radiator outlet hose Transmission brace and torque the transmission bolts to 32 ft. Ibs. (43 Nm) and the engine bolts to 46 ft. lbs. (63 Nm) Right side splash shield and torque the fasteners to 44 inch Ibs. (5 Nm) Torque converter bolts and torque them to 47 ft. Ibs. (63 Nm) A/C compressor and torque the bolts to 37 ft. Ibs. (60 Nm) Starter motor and torque the bolts to 32 ft. Ibs. (43 Nm) Torque converter cover and torque the bolts to 89 inch Ibs. (10 Nm) Engine mount lower nuts and torque them to 32 ft. Ibs. (43 Nm) Catalytic converter pipe to the rear exhaust manifold and torque the fasteners to 26 ft. Ibs. (35 Nm) Oil Filter Two body wiring to engine harness Wiring harness grounds Ignition coil electrical connector Alternator electrical connector A/C compressor electrical connector

13. 14. 15. repair

Starter motor electrical connector IAC valve electrical connector TPS sensor electrical connector EVAP canister purge solenoid valve electrical connector EGR valve electrical connector MAP sensor electrical connector CKP sensor electrical connector CMP sensor electrical connector HOzsensor electrical connector KS sensor electrical connector Drive belt Engine mount struts and torque the fasteners to 35 ft. Ibs. (48 Nm) Hood and torque the bolts to 18 ft. lbs. (25 Nm) Throttle body air inlet duct Air cleaner Negative battery cable Fill the engine with clean oil. Fill the coolant system. Start the vehicle and check for leaks, if necessary.

Heater inlet and outlet hoses Radiator inlet hose

3.4L Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section.

2. 3. 4. 5.

Drain the cooling system. Drain the engine oil. Relieve the fuel system pressure. Remove or disconnect the following: Hood Cross vehicle brace Engine mount struts Drive belt Brake booster vacuum hose Heated Oxygen (HO2S) sensor electrical connector Secondary Air Injection (AIR) check valve electrical connector Exhaust Gas Recirculation (EGR) valve electrical connector Evaporative Emissions (EVAP) canister purge solenoid valve electrical connector Throttle Position (TPS) sensor electrical connector Idle Air Control (IAC) valve electrical connector Alternator electrical connector Ignition coil electrical connector Wiring harness grounds Two engine wiring harness connectors Lower radiator air baffle Engine splash shields Oil filter Vehicle Speed (VSS) sensor electrical connector Oil level sensor electrical connector Oil pressure switch electrical connector

Engine block heater (if equipped) Knock (KS) sensor electrical connector Crankshaft Position (CKP) sensor A/C compressor electrical connector

Catalytic converter Engine mount lower nuts Torque converter cover Starter motor A/C compressor without disconnecting the lines Torque converter bolts Transaxle brace Radiator outlet hose Accelerator and cruise control cables Vacuum hoses from the upper intake manifold Fuel feed and return hoses Power steering pump without dis-

connecting the hoses

6. Attach an engine lifting device. 7. Remove the transmission bolts. 8. Remove the engine from the vehicle.

To install: 9. Install or connect the following: Engine to the transaxle and torque the bolts to 55 ft. Ibs. (75 Nm) Radiator inlet hose Heater inlet and outlet hoses Power steering pump and torque the bolts to 25 ft. tbs. (34 Nm) Fuel feed and return hoses Vacuum hoses to the upper intake manifold e>in order to avoid possible injury or vehicle damage, always replace the accelerator control cable with a NEW cable whenever you remove the engine from the vehicle.

10. Remove the trim panel under the left instrument panel and detach the throttie cable from the top of the pedal then squeeze the retainer and push the cable through the bulkhead to remove it. 11. Install or connect the following: New accelerator cable Cruise contro! cable Radiator outlet hose Transmission brace and torque the transmission bolts to 32 ft. Ibs. (43 Nm) and the engine bolts to 46 ft. lbs. (63 Nm) Torque converter-to-flywheel bolts and torque them to 47 ft. Ibs. (63 Nm) A/C compressor and torque the bolts to 37 ft. Ibs. (50 Nm) Starter motor and torque the bolts to 32 ft. Ibs. (43 Nm) Torque converter cover and torque the bolts to 89 inch Ibs. (10 Nm) Engine mount lower nuts and torque them to 32 ft. Ibs. (43 Nm) Catalytic converter and torque the nuts to 24 ft. Ibs. (32 Nm) New oil filter VSS electrical connector Qil level sensor electrical connector Qil pressure switch electrical connector Engine block heater electrical connector KS electrical connector HO28 electrical connector CKP sensor electrical connector A/C compressor electrical connector Wiring harness grounds

W-BODY—GENERAL MOTOR

CENTURY ¢ REGAL ¢ IMPALA e LUMINA @ MONTE CARLO @ ERCUBER RANGER Lower radiator air baffle and torque the bolts to 15 ft. Ibs. (20 Nm) Engine splash shield and torque the fasteners to 18 inch Ibs. (2 Nm) AIR check valve solenoid electrical connector EGR valve electrical connector EVAP canister purge solenoid valve electrical connector TPS electrical connector IAC valve electrical connector Alternator electrical connector Ignition coil electrical connector Wiring harness grounds Engine wiring harness connectors Drive belt Engine mount strut and torque the bolt to 35 ft. Ibs. (48 Nm) Throttle body air inlet duct Cross vehicle brace and torque the

nuts to 29 ft. lbs. (40 Nm) Hood and torque the bolts to 18 ft. lbs. (25 Nm) Negative battery cable 12. Fill the engine oil. 13. Fill the engine coolant. 14. Inspect the transmission fluid level and top off if necessary. 15. Turn the ignition to the ON position several times to pressurize the fuel system. 16. Start the engine and inspect for any leaks, repair if necessary. 17. Check and top off the fluid levels if required. 3.5L Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Relieve the fuel system pressure. 3. Drain the engine oil. 4. Drain the engine cooling system. 5. Remove or disconnect the following: Drive belt Fuel injector sight shield Power steering pump and move it aside Air intake duct from the throttle body Engine mount strut from the bracket Fuel lines from the fuel supply rail Fuel vapor line Throttle and cruise control cables with the bracket from the throttle body Range selector cable from the Park/Neutral Position (PNP) switch

e Brake booster vacuum hose from the engine Air conditioning vacuum hose from the engine Wiring harness from the engine and transaxle Radiator inlet hose from the engine Transaxle fluid cooler lines from the radiator Thermostat housing Surge tank inlet hose Heater hoses from the engine Lower radiator air deflector Secondary Air Injection (AIR) pipe from the AIR inlet valve Battery cables from the retainers Radiator outlet hose from the engine Alternator A/C compressor, move it aside without disconnecting the lines Torque converter cover Starter motor Flexplate-to-torque converter bolts Catalytic converter from the rear exhaust manifold Lower transaxle-to-engine bolts Front wheels and splash shields Fog lamp electrical connectors Wheel Speed Sensor (WSS) harness from the lower control arms Tie rod ends from the steering knuckles Lower ball joints from the steering knuckles e Halfshafts Intermediate shaft from the steering rack

Secure the front of the vehicle to the lift. The vehicle may become unstable as the engine/transaxle assembly is removed from the vehicle. 6. Position a frame table under the vehicle. 7. Lower the vehicle so the frame is resting on the frame table. 8. Remove the frame-to-chassis bolts.

>: WARNING

29-9

93002501

Engine mount bracket bolt tightening sequence—3.5L engine

10. Remove or disconnect the following: ¢ Remove the engine mount bracket bolts e Remove the transmission brace e Remove the engine from the transaxle To install: 11. Install or connect the following: e Transaxle to the engine and torque the bolts to 55 ft. Ibs. (75 Nm) e Transaxle brace and torque the bolts to 32 ft. Ibs. (43 Nm) e Engine mount bracket to the front of the engine and torque the bolts to 43 ft. Ibs. (58 Nm) e Engine/transaxle assembly under the vehicle 12. Coat the sub-frame bushings with rubber lubricant. 13. Lower the vehicle onto the assembly. Align the sub-frame on the vehicle using 2 bolts or drill bits, % inches thick by 8 inches long through the alignment holes on the right side of the frame. 14. Install new frame-to-body bolts and torque them to 133 ft. Ibs. (180 Nm) starting with the rear bolts and then the front bolts 15. Raise the vehicle and remove the frame table. 16. Install or connect the following: e Intermediate shaft to the steering rack and torque the pinch bolt to 35 ft. Ibs. (48 Nm) =>Be sure the shaft is fully seated on the stub before installing the pinch bolt.

Do not damage the air conditioning compressor or lines when removing the frame from the vehicle.

9. Lift the vehicle from the engine/transaxle assembly.

Please visit our web site at www.chiltonsonline.com

e Halfshafts ¢ Lower bail joints and torque the nuts to 40 ft. Ibs. (60 Nm) * Tie rod ends and torque the nuts to 92 ft. Ips. (30 Nm) plus an additional 120 degree turn

29-6

RATION—W-BODY

anaite rCHie BPR SLEM IN ¢ MONTE CARLO ¢ INTRIGUE e GRAND PRIX

WSS wiring harness to the lower control arm Splash shields Front wheels Fog lamp electrical connectors Catalytic converter to the rear exhaust manifold and torque the nuts to 53 inch Ibs. (6 Nm) Flexplate-to-torque converter by aligning the matchmarks and torque the bolts to 47 ft. Ibs. (63 Nm) Starter motor and torque the bolts to 37 ft. Ibs. (50 Nm) Torque converter cover and torque the bolts to 89 inch Ibs. (10 Nm) A/C compressor and torque the bolts to 37 ft. Ibs. (560 Nm) Alternator and torque the bolts to 37 ft. Ibs. (50 Nm) Lower radiator hose to the engine Battery cables in the retainers AIR pipe Lower radiator air deflector and torque the bolts to 15 ft. Ibs. (20 Nm) Thermostat housing and torque the bolts to 80 inch Ibs. (9 Nm) Heater hoses Surge tank hose Transaxle fluid cooler lines to the radiator Upper radiator hose to the engine Wiring harness connectors to the engine/transaxle A/C vacuum hose to the engine Brake booster hose to the engine Shifter cable to the transaxle PNP switch ein order to avoid possible injury or vehicle damage, always use a new accelerator cable when replacing the engine assembly.

17. Remove the trim panel under the lett instrument panel and detach the throttle cable from the top of the pedal then squeeze the retainer and push the cable through the bulkhead to remove it. 18. Install or connect the following: New throttle cable Cruise control cable to the throttle body Fuel vapor line Fuel lines to the supply rail Engine mount strut and torque the bolt to 35 ft. Ibs. (48 Nm) Air duct to the throttle body Power steering pump and torque the bolts to 25 ft. Ibs. (34 Nm)

e Fuel injector shield and torque the bolts to 27 inch Ibs. (3 Nm) e Drive belt ¢ Negative battery cable 19. Refill the cooling system. 20. Install a new oil filter and refill the engine with new oil. 21. Start the engine and check for leaks, repair if necessary. 3.8L Engine

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Relieve the fuel system pressure. 3. Drain the cooling system. 4. Drain the engine oil. 5. Remove or disconnect the following: Hood Fuel injector sight shield Throttle body air inlet duct Air cleaner Radiator inlet/outlet hoses A/C compressor without disconnecting the lines Starter motor wiring harness Accelerator and cruise control cables Wiring harness from the top of the engine Fuel lines from the fuel rail Fuel vapor line Power brake booster vacuum hose A/C vacuum hose Heater hoses Engine mount struts from the brackets Power steering pump and move it aside Torque converter cover Starter motor Flywheel-to-torque converter bolts Engine mount lower nuts Transaxle brace Catalytic converter pipe from the rear exhaust manifold Lower transaxle to engine bolts 6. Lower the vehicle and install a suitable engine lifting device. 7. Remove the upper transaxle to engine bolts, 8. Remove the engine from the vehicle. To install: 9. Install the engine to the vehicle. 10. Torque the transmission-to-engine bolts to 59 ft. Ibs. (75 Nm). 11. Remove the engine lifting device. 12. Install or connect the following:

e Catalytic converter to the rear exhaust manifold. Torque the nuts to 26 ft. Ibs. (35 Nm). Transaxle brace and torque the transaxle bolts to 32 ft. Ibs. (43 Nm) and the engine bolts to 46 ft. “ Ibs. (63 Nm) Engine mount lower nuts and torque them to 35 ft. Ibs. (47 Nm) Flywheel-to-torque converter bolts

and torque them to 47 ft. Ibs. (63 Nm) Starter motor and torque the bolts to 32 ft. Ibs. (43 Nm) Torque converter cover and torque the bolts to 89 inch Ibs. (10 Nm) Power steering pump and torque the bolt to 25 ft. Ibs. (34 Nm) Engine mount struts and torque the bolts to 35 ft. Ibs. (48 Nm) Heater hoses

A/C vacuum hose Power brake booster vacuum hose Fuel vapor line Fuel lines Wiring harness to the top of the engine ein order to avoid possible injury or vehicle damage, always replace the accelerator control cable with a NEW cable whenever you remove the engine from the vehicle.

13. Remove the trim panel under the left instrument panel and detach the throttle

Cable from the top of the pedal then squeeze the retainer and push the cable through the bulkhead to remove it. 14. Install or connect the following: New throttle cable Cruise control cable to the throttle body Starter motor wiring harness

A/C compressor and torque the bolts to 23 ft. Ibs. (31 Nm) and the nuts to 74 ft. Ibs. (100 Nm) Inlet and outlet radiator hoses Throttle body air inlet duct Air cleaner Hood and torque the bolts to 20 ft. Ibs. (27 Nm) Fuel injector sight shield ¢ Negative battery cable 15. Fill the engine with new oil.

e>A filter change is recommended.

16. Fill the cooling system. 17. Start the engine and check for leaks, repair if necessary.

W-BODY—GENERAL MOTOR

CENTURY © REGAL ¢ IMPALA ¢ LUMINA e MONTE CARLO ¢ A

EA RAMBALe

29-/

Water Pump REMOVAL & INSTALLATION 3.1L and 3.4L Engines

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the cooling system. 3. Remove or disconnect the following: e Negative battery cable e Accessory drive belt guard e Water pump pulley bolts, loosen e Accessory drive belt e Water pump pulley e Water pump To install: 4. Install or connect the following: ¢ Water pump with a new gasket and torque the bolts to 89 inch Ibs. (10 Nm) e Water pump pulley and torque the bolts to 18 ft. Ibs. (25 Nm) e Accessory drive belt e Drive belt guard

5. Fill the cooling system. 6. Start the engine and check for leaks, repair if necessary.

wre Be sure to install the 5 long water pump bolts in the correct locations—3.5L engine

e |dler pulley and torque the bolt to 115 inch Ibs. (13 Nm) e Drive belt e Surge tank hose 5. Refill the cooling system. 6. Start the engine and check for leaks. 3.8L Engines

99007503

tion.

Water pump mounting—3.5L engine

2. Drain the engine coolant.

3. Remove or disconnect the following: e Surge tank outlet hose ¢ Water pump pulley

get ole GASKET

=»The water pump is attached

ARG an ees

Oley dues a

79241601

F ;

-

to the

engine with both long and short bolts, be sure to note their locations. e Water pump To install: 4. Install or connect the following:

Water pump assembly mounting—3.1L and 3.4L engines

j

sae 1. Before servicing the vehicle, refer to

¢ Water pump using a new gasket and torque the bolts to 124 inch

tion.

+ Water pump pulley and torque the

the precautions in the beginning of this sec-

9. Partially drain the cooling system.

.

3. Removeordisconnect the following: ¢ Negative battery cable. e Drive belt ¢ Water pump pulley

¢ Drive belt e |dler pulley 2

1. Before servicing the vehicle, refer to the precautions in the beginning of this sec-

Ibs. (14. Nm)

.

Power steering pump and move it e aside

Saeeeun To fe

ie

P

4. Install or connect the following: e Water pump using a new gasket and torque the long bolts to 15 ft. lbs. (20 Nm) plus a 40 degree turn

and the short bolts to 11 ft. Ibs. (15 Nm) plus an additional 80 degree turn

* Water pump pulley and torque the

bolts to 18 ft. Ibs. (25 Nm)

l Timing belt service is covered in Section 3 of this manua

bolts to 115 inch Ibs. (13 Nm)

29-8

RPORATION—W-BODY

ener REGAL IMEA bate e MONTE CARLO ¢ INTRIGUE ¢ GRAND PRIX ¢ Cylinder head bolts evenly e Cylinder head and discard the gasket To install: 6. Install the cylinder head with a new

79222504

Exploded view of the water pump assem-

bly mounting—3.8L engine

e Power steering pump and torque

the bolts to 25 ft. Ibs. (34 Nm) ¢ Drive belt ¢ Negative battery cable 9. Fill the cooling system. 6. Start the vehicle and check for leaks, repair if necessary.

Cylinder Head REMOVAL & INSTALLATION 3.1L and 3.4L Engines

LEFT (FRONT) CYLINDER HEAD 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Relieve the fuel system pressure. 3. Drain the engine oil. 4. Drain the cooling system. 5. Remove or disconnect the following: Upper half of the air cleaner

Throttle body air inlet duct Upper intake manifold Spark plug wires from the spark plugs Rocker arm covers Lower intake manifold Rocker arm bolt, rocker arms, balls and pushrods Exhaust crossover pipe Engine mount strut bracket from the cylinder head Left side exhaust manifold Oil level indicator tube

93462GA9

Tighten the cylinder head bolts using the following sequence—31L and 3.4L engines

gasket. 7. Apply thread sealer to the head bolts. 8. Tighten the cylinder head bolts to 37 ft. Ibs. (50 Nm) plus an additional 90 degree turn. 9. Install or connect the following:

e Left side exhaust manifold and torque the nuts to 12 ft. Ibs. (16 Nm) Oil level indicator tube Engine mount strut bracket and torque the bolts to 52 ft. Ibs. (70 Nm) Exhaust crossover pipe and torque the nuts to 18 ft. Ibs. (25 Nm) Exhaust crossover pipe heat shield and torque the bolts to 89 inch lbs. (10 Nm) Pushrods, rocker arms, balls and bolts and tighten the bolts to 89 inch Ibs. (10 Nm) plus an additional 30 degree turn Lower intake manifold and torque the bolts to 115 inch Ibs. (13 Nm) Upper intake plenum and torque the bolts to 18 ft. Ibs. (25 Nm) Rocker arm cover and torque the bolts to 89 inch Ibs. (10 Nm) Spark the plug wires Upper half of the air cleaner assembly Throttle body air inlet duct Negative battery cable 10. Refill the cooling system. 11. Refill the engine with clean oil. e>A filter change is also recommended.

12, Start the engine and check for leaks, repair if necessary.

RIGHT (REAR) CYLINDER HEAD 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Relieve the fuel system pressure. 3. Drain the engine oil. 4. Drain the cooling system, 9. Remove or disconnect the following: Upper half of the air cleaner Throttle body air inlet duct Upper intake plenum Lower intake manifold Spark plug wires from the Spark plugs Rocker arm covers Exhaust crossover pipe heat shield

e e ¢ e ¢

Crossover pipe Right side exhaust manifold Fuel line bracket Alternator and bracket Rocker arms bolt, rocker arms, balls and pushrods \e Cylinder head bolts evenly e Cylinder head To install: 6. Install the cylinder head with a new gasket. 7. Apply thread sealer to the head bolts. 8. Tighten the cylinder head bolts to 37 ft. Ibs. (50 Nm) plus an additional 90 degree turn. 9. Install or connect the following: Pushrods, rocker arms, balls and rocker arm bolts and tighten the bolts to 89 inch Ibs. (10 Nm) plus an additional 30 degrees Exhaust manifold and torque the nuts to 12 ft. Ibs. (16 Nm) Alternator bracket and torque the bolts to 37 ft. Ibs. (50 Nm) Alternator and torque the bolts to 37 ft. Ibs. (50 Nm) Rocker arm cover and torque the bolts to 89 inch Ibs. (10 Nm) Spark plug wires Exhaust crossover pipe and torque the nuts to 18 ft. Ibs. (25 Nm) Exhaust crossover pipe heat shield and torque the bolts to 89 inch Ibs. (10 Nm) Pushrods, rocker arms, balls and bolts and tighten the bolts to 89 inch Ibs. (10 Nm) plus an additional 30 degree turn Lower intake manifold and torque the bolts to 115 inch Ibs. (13 Nm) Upper intake plenum and torque the bolts to 18 ft. Ibs. (25 Nm) Upper half of the air cleaner assembly Throttle body air inlet duct Negative battery cable 10. Refill the cooling system. 11. Refill the engine with clean oil. An oil filter change is recommended. 12. Start the engine and check for leaks, repair if necessary, 3.5L Engine

FRONT 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the engine oil. 3. Drain the cooling system, 4. Remove or disconnect the following:

W-BODY—GENERAL MOTOR

CENTURY ¢ REGAL ¢ IMPALA e LUMINA e MONTE CARLO

29-9

EC RRIIEALY

Be

e |ntake manifold and torque the bolts to 62 inch Ibs. (7 Nm) e New oil filter e Negative battery cable 13. Refill the engine with clean oil. 14. Refill the cooling system. 15. Start the engine and check for leaks, repair if necessary. REAR Le oe

s206V6At Front cylinder head bolt torque

e Camshafts and torque the bearing cap bolts to 71 inch Ibs. (8 Nm) plus an additional 22 degree turn

Negative battery cable Intake manifold Water outlet housing Engine mount strut bracket Coolant crossover pipe

e Primary camshaft drive chain e Camshaft cover and torque the bolts to 80 inch Ibs. (9 Nm)

e Exhaust manifold and torque the

e Front exhaust manifold

bolts to 18 ft. Ibs. (25 Nm)

e Camshaft cover

5. Install a holding tool on the camshafts to hold them in position. 6. Remove or disconnect the following: e Camshaft primary chain ¢ Camshafts from the front cylinder head

¢ Rocker arms and valve lifters

¢ Coolant crossover pipe and torque the bolts to 18 ft. Ibs. (25 Nm) e Engine mount strut bracket and torque the bolts to 37 ft. Ibs. (50 Nm)

e Water outlet housing and torque the

het

oe

a

Drain the engine oll.

_

engine

sequence—3.5L engine

e e ¢ e *

Camshaft holding fixture J-42038—3.5L

1. Before servicing the vehicle, refer to the precautions in the beginning of this sec3. Drain the cooling system. 4. Remove or disconnect the following: e Negative battery cable ; aliickemen ere ->Do not remove the rear exhaust manifold. Detach it from the cylinder head and the connection from the front mani-

fold; then, move it aside. ¢ Exhaust manifold

« Coolant crossover pipe ¢ Camshaft cover 5. Install a holding tool on the camshafts to hold them in position. 6. Remove or disconnect the following: ¢ Primary camshaft drive chain

© Camshafts

bolts to 80 inch Ibs. (9 Nm)

=>Be sure to keep the arms and lifters in order so they can be installed the their original locations.

¢ M6 bolts from the front of the cylinder head ¢ M11 cylinder head bolts and discard ¢ Cylinder head To install: 7. Be sure the dowels are securely mounted in the engine block. 8. Install or connect the following: e New gasket e Cylinder head e New M11 bolts ¢ M6 bolts in the front of the cylinder head

9. Torque the M11 bolts in sequence to: p22ft. Ibs. (30 Nm). a. Ste1:

=

oe

d. Step 4: 60 degree turn. 10. Torque the long M6 bolt to 22 ft. Ibs. (30 Nm). 11. Torque both shorter M6 bolts to 106 inch Ibs. (12 Nm). 49. \nstall or connect the following: « Lifters and rocker arms in their original positions

6

a

A

Ke) =O} sf] Va Q SH i

Al

i

,

Cale ty. > a

va

z

4

1

e Rear cylinder head bolt torque sequence—3.5L engin

2 of this manual Heater Core replacement is covered in Section

5

29-1 0 Santee REGKU

ATION—W-BODY

PARA GLAMIH e MONTE CARLO ¢ INTRIGUE ¢ GRAND PRIX

e Rocker arms and valve lifters

e>Keep the valve train parts in order so they can be installed in their original positions.

e Engine Coolant Temperature (ECT) sensor from the cylinder head ¢ M6 bolts from the front of the cylinder head, note the location of the longer bolt e M11 cylinder head bolts and discard the bolts e Cylinder head To install: 7. Be sure the dowels are securely mounted in the engine block. 8. Install or connect the following: e New gasket e Cylinder head ¢ New M11 bolts ¢ M6 bolts in the front of the cylinder head 9. Torque the M11 bolts in sequence as follows: a. Step 1: 22 ft. Ibs. (30 Nm). b. Step 2: 60 degree turn. c. Step 3: 60 degree turn. d. Step 4: 60 degree turn. 10. Torque the long M6 bolt to 22 ft. Ibs. (30 Nm). 11. Torque both short M6 bolts to 106 inch Ibs. (12 Nm). 12. Install or connect the following: ECT sensor and torque the fastener to 15 ft. Ibs. (20 Nm) Lifters and rocker arms in their Original positions Camshafts and torque the bearing Cap bolts to 71 inch Ibs. (8 Nm) plus an additional 22 degree turn Primary camshaft drive chain Camshaft cover and torque the bolts to 80 inch Ibs. (9 Nm) Coolant crossover pipe and torque the bolts to 18 ft. Ibs. (25 Nm) Exhaust manifold and torque the bolts to18 ft. Ibs. (25 Nm) Intake manifold and torque the bolts to 62 inch Ibs. (7 Nm) New oil filter ¢ Negative battery cable 13. Refill the engine with clean oil, 14. Refill the cooling system. 15. Start the engine and check for leaks, repair if necessary, 3.8L Engine

LEFT SIDE 1. Before servicing the vehicle, refer to the precautions in the beginning of this section.

79222507

Cylinder head bolt torque sequence—3.8L engine

2. Relieve the fuel system pressure. 3. Drain the cooling system. 4. Remove or disconnect the following: e Fuel injector sight shield ¢ Throttle body air inlet duct Right and left engine mount strut brackets Fuel lines from the fuel rail Upper intake manifold Lower intake manifold Left exhaust manifold Rocker arm cover Rocker arms and pushrods Cylinder head bolts Cylinder head To install: 9. Install the new cylinder head gasket with the arrow pointing to the front of the engine. 6. Install the cylinder head. 7. Install NEW cylinder head bolts. Torque the bolts in sequence, as follows: a. Step 1: 37 ft. Ibs. (50 Nm). b. Step 2: Plus 120 degree turn. C. Step 3: Rotate the 4 center bolts an additional 30 degrees. 8. Install or connect the following: Push rods and rocker arms Rocker arm cover and torque the bolts to 89 inch Ibs. (10 Nm) Left exhaust manifold and torque the bolts to 22 ft. Ibs. (30 Nm) Lower intake manifold and torque the bolts to 11 ft. Ibs. (15 Nm) Upper intake manifold and torque the bolts to 89 inch Ibs. (10 Nm)

e Left and right engine mount strut brackets and torque the bolts to 37 ft. Ibs. (50 Nm) e Throttle body air inlet duct ¢ Fuel injector sight shield and torque the bolts to 27 inch Ibs. (3 Nm) ¢ Negative battery cable 9. Refill the cooling system. 10. Start the engine and check for leaks.

RIGHT SIDE 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Relieve the fuel system pressure, 3. Drain the cooling system. 4. Remove or disconnect the following: ¢ Throttle body air inlet duct ¢ Fuel injector sight shield ¢ Accessory drive belt ¢ Alternator ¢ Catalytic converter from the exhaust manifold ¢ Engine mount struts 9. Place the transmission in neutral and rotate the engine forward for access. 6. Remove or disconnect the following: Drive belt tensioner Power steering pump without disconnecting the lines Heater hoses from the engine Spark plug wires Oxygen (02S) sensor electrical connector Throttle and cruise control cables

W-BODY—GENERAL MOT

ERARENOIPAL 29-1 1

CENTURY ¢ REGAL ¢ IMPALA ¢ LUMINA ¢ MONTE CARLO ¢ REE Fuel lines from the fuel rail Fuel rail

Exhaust Gas Recirculation (EGR) valve heat shield EGR valve EGR valve outlet pipe EGR valve adapter Upper intake manifold Lower intake manifold Exhaust crossover pipe Right exhaust manifold Rocker arm cover Rocker arms and pushrods Cylinder head To install: 7. Install a new cylinder head gasket with the arrow pointing to the front of the engine. 8. Install the cylinder head and secure with NEW head bolts. Torque the bolts, in Sequence, as follows: a. Step 1: 37 ft. Ibs. (50 Nm). b. Step 2: Plus a 120 degree turn. c. Step 3: Rotate the 4 center bolts an additional 30 degrees. 9. Install or connect the following: Push rods and rocker arms Rocker arm cover and torque the bolts to 89 inch Ibs. (10 Nm) Right exhaust manifold and torque the bolts to 22 ft. Ibs. (30 Nm)

Exhaust crossover pipe and torque the nuts to 18 ft. Ibs. (25 Nm) Lower intake manifold and torque the bolts to 11 ft. Ibs. (15 Nm) Upper intake manifold and torque the bolts to 89 inch Ibs. (10 Nm) EGR valve adapter and torque the bolts to 37 ft. Ibs. (50 Nm) EGR valve outlet pipe and torque the bolts to 21 ft. Ibs. (29 Nm) EGR valve and torque the nuts to 21 ft. Ips. (29 Nm) EGR valve heat shield and torque the bolts to 89 inch Ibs. (10 Nm) Fuel rail Fuel lines to the fuel rail Throttle and cruise control cables 09S electrical connector Spark plugs and torque them to 20 ft. Ibs. (27 Nm)

Spark plug wires Heater hoses Power steering pump and torque the bolts to 25 ft. Ibs. (34 Nm) + Drive belt tensioner and torque the bolts to 37 ft. Ibs. (50 Nm) ully return the engine to its Caref 40. proper position.

11. Place the transmission in park. 12. Install or connect the following: Throttle body air inlet duct Engine mount struts and torque the bolts to 35 ft. Ibs. (48 Nm) Catalytic converter and torque the bolts to 26 ft. Ibs. (85 Nm) Alternator and torque the bolts to 37 ft. Ibs. (60 Nm) Accessory drive belt Fuel injector sight shield Negative battery cable 13. Refill the cooling system. 14. Start the engine and check for leaks.

REMOVAL & INSTALLATION 3.1L and 3.4L Engines

LEFT SIDE 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Disconnect the negative battery cable. 3. Drain the cooling system. 4. Remove or disconnect the following: ¢ Spark plug wires Engine mount strut Secondary Air Injection (AIR) check valve pipe, if equipped Thermostat bypass hose and pipe Positive Crankcase Ventilation (PCV) valve from the rocker arm cover Rocker arm cover =>Keep the pushrods in order. Intake pushrods are 5% inches long and exhaust pushrods are 6 inches long.

e Rocker arm bolts e Rocker arms e Pushrods To install: 5. Lubricate all the valvetrain components with engine oil. 6. Install or connect the following: ¢ Pushrods and the rocker arms and tighten the bolts to 89 inch Ibs. (10 Nm) plus an additional 30 degree turn on 3.1L engines or 14 ft. Ibs. (19 Nm) plus 30 degrees on 3.4L engines e Rocker arm cover using a new gasket and tighten the rocker cover bolts to 89 inch Ibs. (10 Nm) e PCV valve to the rocker arm cover ¢ Coolant tube with the thermostat

bypass hose and tighten the bolt to 98 inch lbs. (11 Nm) and the nut to 18 ft. Ibs. (25 Nm) e AIR check valve pipe and torque the adapters to 22 ft. Ibs. (30 Nm) e Engine mount strut and torque the bolt to 35 ft. Ibs. (48 Nm) e Spark plug wires e Negative battery cable 7. Refill the cooling system. 8. Start the vehicle and verify no leaks.

RIGHT SIDE 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Negative battery cable Accessory drive belt Alternator Alternator Bracket Spark plug wires Ignition coil and Evaporative (EVAP) emissions canister purge solenoid as an assembly Power brake booster vacuum pipe from the intake plenum e Rocker arm cover ¢ Rocker arm bolts, balls, rocker arms and pushrods To install: 3. Lubricate all the valve train components with engine oil. 4. Install or connect the following: ¢ Pushrods and the rocker arms and tighten the bolts to 89 inch Ibs. (10 Nm) plus an additional 30 degree turn on 3.1L engines or 14 ft. Ibs. (19 Nm) plus 30 degrees on 3.4L engines e Rocker arm cover using a new gas-

93062609

Rocker arm components—3.1L and 3.4L engines

manual Brake service is covered in Section 4 of this

ATION—W-BODY 2 9-7 2 BENTUY= REGALSIMPALAS LEMINA ¢ MONTE CARLO ¢ INTRIGUE ¢ GRAND PRIX e Right side spark plug wires e Fuel injector sight shield bracket e Rocker arm cover >The rocker arms, pushrods, pedestals and bolts must be kept in order for installation in the same locations they were removed from.

¢ Rocker arm bolts, pedestals, rocker arms and pushrods To install: 4. Seat the pushrod in the lifter and install the rocker arm, pedestal and mounting bolt. Tighten the mounting bolt to 11 ft.

79222508

Rocker arm mounting—3.1L engine

ket and tighten the rocker cover bolts to 89 inch Ibs. (10 Nm) Power brake booster vacuum pipe to the plenum EVAP solenoid and ignition coil assembly Spark plug wires Alternator bracket and torque the

bolts to 37 ft. Ibs. (50 Nm) Alternator and torque the bolts to 37 ft. Ibs. (50 Nm) Accessory drive belt Negative battery cable 5. Start the vehicle and verify no leaks. 3.5L Engine Refer to the camshaft removal and installation procedure for rocker arm service.

3.8L Engine

The rocker arm bolts have been permanently stretched during installation. New bolts must be used each time the rocker arm assemblies are removed. A

LEFT SIDE (FRONT) ROCKER ARMS 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Negative battery cable Engine lift bracket from the exhaust manifold studs Fuel injector sight shield Engine mount strut bracket Spark plug wires Spark plug wire cover from the valve rocker arm cover Rocker arm cover ->The rocker arms, pushrods, pedestals and bolts must be kept in order for installation in the same locations they were removed from.

e Rocker arm bolts, pedestals, rocker arms and pushrods

79227509

Exploded view of the rocker arm, pushrod and pushrod guide plate assembly—3.8L engine

To install: 3. Apply thread locking compound to the rocker arm bolts. 4. Install or connect the following: e Pushrod in the lifter e¢ Rocker arm, pedestal and mounting bolt and tighten the mounting bolt to 11 ft. Ibs. (15 Nm) plus an additional 90 degrees Rocker arm cover with a new gasket and torque the mounting bolts to 89 inch Ibs. (10 Nm) Spark plug wire cover to the rocker arm cover Spark plug wires Engine mount strut bracket and torque the bolt to 75 ft. Ibs. (102 Nm) Fuel injector sight shield Engine lift bracket to the exhaust manifold and torque the bolt to 22 ft. Ibs. (30 Nm) Negative battery cable 5. Start the vehicle and check for leaks, repair if necessary.

RIGHT SIDE (REAR) ROCKER ARMS 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Negative battery cable e Fuel injector sight shield ¢ Accessory drive belt ¢ Alternator ¢ Drive belt tensioner e Engine mount struts ¢ Throttle body air inlet duct 3. Rotate the engine forward for proper access. ¢ Evaporative (EVAP) emissions purge solenoid and brace

Ibs. (15 Nm) plus an additional 90 degrees. 5. Install or connect the following: * Rocker arm cover using a new gasket and torque the bolts to 89 inch lbs. (10 Nm) ¢ Fuel injector sight shield bracket and torque the bolts to 22 ft. Ibs. (30 Nm) ¢ EVAP purge solenoid and brace e Right side spark plug wires 6. Return the engine back to its original position. ¢ Throttle body air inlet duct e Engine mount struts and torque the bolt to 35 ft. Ibs. (48 Nm) ¢ Drive belt tensioner and torque the bolts to 37 ft. Ibs. (50 Nm) e Alternator and torque the bolt to 37 ft. Ibs. (50 Nm) ¢ Fuel injector sight shield e Negative battery cable 7. Start the vehicle and check for leaks, repair if necessary.

Super Charger REMOVAL & INSTALLATION —— ee 3.8L (VIN 1) Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Relieve the fuel system pressure. 3. Remove or disconnect the following: Fuel injector sight shield Exhaust Gas Recirculation (EGR) valve heat shield Supercharger drive belt Right side spark plug wires from the ignition module Alternator brace Fuel injector electrical connectors Manifold Absolute Pressure (MAP) sensor bracket Fuel lines Fuel rail with the injectors

W-BODY—GENERAL M

CENTURY ¢ REGAL e IMPALA ¢ LUMINA ¢ MONTE ARLOS Be UES RRND PAIK 29-1 3 e Spark plug wires e Supercharger drive belt e EGR valve heat shield e Fuel injector sight shield e Negative battery cable 5. Start the engine and ensure proper operation. Intake Manifold

REMOVAL & INSTALLATION 3.1L and 3.4L Engines 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Relieve the fuel system pressure. 3. Drain the cooling system. 4. Remove or disconnect the following: e Intake Air Temperature (IAT) sensor electrical connector ¢ Throttle body air inlet duct e Throttle and cruise control cables with bracket e Throttle Position (TPS) sensor electrical connector e Idle Air Control (IAC) valve electri-

Sipe?

cal connector

Supercharger bolt locations—3.8L (VIN 1) engine

Boost control solenoid Electrical and vacuum connections as necessary e Throttle and cruise control cables with the bracket e Throttle body air inlet duct e Supercharger To install: 4. Install or connect the following: e Supercharger with new a new gasket and O-rings and torque the bolts to 17 ft. Ibs. (23 Nm) Throttle body air inlet duct Throttle and cruise control cables with the bracket and torque the bolts to 142 inch Ibs. (16 Nm) Electrical and vacuum connectors Boost control solenoid and torque the nut to 72 inch Ibs. (8 Nm) Fuel rail with fuel injectors and torque the hold-down bolts to 7 ft. Ibs. (10 Nm) and the stud to 18 ft. lbs. (25 Nm) Fuel |i Maes « MAP sensor bracket ¢ Fuel injector electrical connectors » Alternator brace and torque the bolt and nut to 37 ft. Ibs. (50 Nm)

Rape SEALANT 121 HEAD ASSEMBLY, CYLINDER 143 GASKET, LOWER INTAKE MANIFOLD 144 BOLT, LOWER INTAKE 145 BOLT, LOWER INTAKE MANIFOLD 146 BOLT, LOWER INTAKE MANIFOLD

144 181 182 183 184

MANIFOLD, LOWER INTAKE GASKET, UPPER INTAKE MANIFOLD MANIFOLD, UPPER INTAKE STUD, UPPER INTAKE MANIFOLD BOLT, UPPER INTAKE MANIFOLD

3.4L engines Lower intake manifold torque sequence—3.1L and

on 1 of this manual For complete Engine Mechanical specifications, see Secti

nes

ATION—W-BODY 29-14 CernysREGALSiMPALA >LUMINA'® MONTE CARLO » INTRIGUE » GRAND PRIX Camshaft Position (CMP) sensor wiring harness from the intake Spark plug wires from the intake Thermostat bypass hoses from the throttle body Rear alternator brace Vacuum lines from the upper intake manifold Manifold Absolute Pressure (MAP) sensor Exhaust Gas Recirculation (EGR) valve Spark plug wires Ignition contro! module Upper intake manifold Engine Coolant Temperature (ECT) sensor electrical connector Fuel injector electrical connectors Fuel lines from the fuel rail and fuel line bracket Fuel rail with the injectors Power steering pump and move it aside without disconnecting the lines Coolant inlet pipe from the coolant outlet housing Coolant bypass hose Upper radiator hose at thermostat housing Both rocker arm covers Lower intake manifold bolts e>\Nhen removing the valvetrain components, keep them in order for installation purposes.

¢ Rocker arm bolts, rocker arms and pushrods ¢ Intake manifold To install: 5. Place a 3mm bead of RTV, on each ridge, where the front and rear of the intake manifold contact the block. 6. Install or connect the following: e Intake manifold gasket e Pushrods and rocker arms ¢ Rocker arm bolts and torque the bolts to 89 inch Ibs. (10 Nm) plus an additional 30 degree turn

In order to prevent oil leaks, tighten the vertical bolts before the diagonal bolts. SES

SNES

¢ Lower intake manifold and torque the bolts to 115 inch Ibs. (13 Nm) Both rocker arm covers and torque the bolts to 89 inch Ibs. (10 Nm) Thermostat bypass hose Upper radiator hose Heater inlet pipe and heater hose to the lower intake

Power steering pump and torque the bolts to 25 ft. Ibs. (34 Nm) Fuel fail with the injectors Fuel feed and return lines Fuel injector electrical connectors ECT sensor electrical connector Upper intake manifold using a new gasket and torque the bolts to 18 ft. lbs. (25 Nm) MAP sensor Ignition control module EGR valve Spark plug wires Vacuum lines Rear alternator brace and torque the pivot bolt to 37 ft. Ibs. (50 Nm) and the nut to 18 ft. Ibs. (25 Nm) Thermostat bypass pipe coolant hoses to the throttle body TPS sensor electrical connector IAC valve electrical connector Throttle and cruise control cables with the bracket and torque the bolts to 115 inch Ibs. (13 Nm) and the nuts to 89 inch Ibs. (10 Nm) Throttle body air inlet duct IAT sensor electrical connector Negative battery cable 7. Refill the cooling system. e*An engine oil and filter change is recommended. 8. Start the vehicle and check for leaks, repair if necessary.

3.5L Engine

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Partially drain the engine coolant. 3. Remove or disconnect the following: ¢ Negative battery cable Throttle body air inlet duct Fuel injector sight shield Throttle and cruise control cables from the throttle body with the bracket Coolant hoses from the throttle body Fuel lines from the fuel supply rail Fuel vapor line from the Evaporative Emission (EVAP) canister purge solenoid Brake booster vacuum hose Air conditioning vacuum hose from the engine Surge tank inlet pipe retainer from the fuel supply rail Fuel injector electrical connectors Throttle Position Sensor (TPS) electrical connectors

Idle Air Control (IAC) valve electrical connector EVAP canister purge solenoid connector

Manifold Absolute Pressure (MAP) sensor connector Wiring harness channels from the camshaft covers Vacuum tube from the fuel pressure regulator Positive Crankcase Ventilation (PCV) valve and both feed tubes Exhaust Gas Recirculation (EGR) valve outlet pipe-

Fuel supply rail with injectors ->Disengage the snap-lock retainers by pushing toward the camshaft covers and lifting.

¢ Throttle body coolant hose e Intake manifold The manifold-to-cylinder head seals are reusable unless cut or damaged.

To install: 4. Install or connect the following: ¢ New intake manifold-to-cylinder head seals Intake manifold and torque the bolts, in a circular pattern, starting from the center to 62 inch Ibs. (7 Nm) Throttle body heater hose New O-rings on the fuel injectors Fuel supply rail with injectors

EGR pipe and torque the intake manifold bolt to 89 inch Ibs. (10 Nm) and the coolant crossover bolt to 18 ft. Ibs. (24 Nm) PCV valve and related tubing Brake booster vacuum hose Fuel pressure regulator vacuum hose Air conditioning vacuum hose

eS 93002506

Intake manifold assembly—3.5L engine

W-BODY—GENERAL MOT

CENTURY © REGAL ¢ IMPALA e LUMINA e MONTE athe TTBIGUEGREADIERTE 29-1 0 oe wiring harness with channel 0 the camshaft covers and torque the bolts to 89 inch Ibs. (10 Nim) Surge tank pipe retainer to the fuel Supply rail TPS electrical connector IAC electrical connector EVAP solenoid electrical connector MAP sensor electrical connector Fuel injector electrical connectors Coolant hoses to the throttle body Throttle and cruise control cables to the throttle body Fuel lines to the fuel supply rail Fuel vapor line to the purge solenoid Fuel injector sight shield Throttle body air inlet duct Negative battery cable 5. Refill the cooling system. 6.. Start the engine and check for leaks, repair if necessary.

1

3

?

3.8L Engine—Not Equipped With A

79222511

Supercharger

There are 2 bolts hidden beneath the upper intake manifold. These bolts are

located in the right front and left rear corners of the lower intake manifold. It is necessary to remove the upper

intake manifold to service the lower

intake manifold.

1. Before servicing the vehicle, refer to

Always tighten the lower intake manifold bolts in sequence—3.8L (VIN 1 and K) engines

¢ Throttle cables from the throttle body lever e Throttle body support bracket

e Drive belt tensioner e EGR valve outlet pipe e Upper radiator hose

e Manifold Absolute Pressure (MAP)

e Engine Coolant Temperature (ECT)

¢ Upper intake plenum

e Lower intake manifold

sensor electrical connector

sensor electrical connector

the precautions in the beginning of this section. 2. Relieve the fuel system pressure. 3. Drain the cooling system. 4. Remove or disconnect the following: Negative battery cable Fuel injector sight shield and air inlet duct Spark plug wires from the right side of the engine Evaporative emissions (EVAP) canister purge solenoid electrical con-

nector Fuel feed and return lines

Vacuum lines from the throttle body

Q

Accessory drive belt Alternator and bracket Fuel injector electrical connectors Fuel pressure regulator vacuum line Fuel rail hold down bolts Fuel rail with injectors Brake booster hose from the manifold

Exhaust Gas Recirculation (EGR) valve heat shield

hy 79227512

K) engines Upper intake manifold bolt tightening sequence—3.8L (VIN 1 and

l For Accessory Drive Belt illustrations, see Section 1 of this manua

29-1

eae

Soe

To install: 5. Install or connect the following: e New intake manifold gaskets Intake manifold and torque the

6. 7. 8. repair

bolts, in sequence, to 11 ft. Ibs. (15 Nm) ECT sensor electrical connector _ Upper radiator hose EGR valve outlet pipe Drive belt tensioner and torque the bolts to 37 ft. Ibs. (50 Nm) Intake plenum using a new gasket and torque the bolts, in sequence, to 89 inch Ibs. (10 Nm) MAP sensor electrical connector Throttle body support bracket Throttle cables to the throttle body lever EGR heat shield Brake booster vacuum hose Fuel rail assembly and torque the bolts to 84 inch Ibs. (10 Nm) Fuel pressure regulator vacuum line Fuel injector electrical connectors Alternator bracket and torque the nut and bolt to 37 ft. Ibs. (60 Nm) Alternator and torque the bolts to 37 ft. Ibs. (50 Nm) Accessory drive belt Vacuum lines to the throttle body Fuel feed and return lines EVAP canister purge solenoid electrical connector Spark plug wires to the rear bank spark plugs Air inlet duct Fuel injector sight shield Negative battery cable Pressurize the fuel system. Refill and bleed the cooling system. Start the vehicle and check for leaks, if necessary.

3.8L Engine—Equipped With A Supercharger 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Relieve the fuel system pressure. 3. Drain the cooling system. 4. Remove or disconnect the following: Negative battery cable Exhaust Gas Recirculation (EGR) valve heat shield Supercharger drive belt Right side spark plug wires Alternator rear brace Fuel injector electrical connectors Manifold Absolute Pressure (MAP) sensor and bracket

RATION—W-BODY

aa erteel ¢ MONTE CARLO ¢ INTRIGUE ¢ GRAND PRIX Fuel feed and return lines Fuel rail with the injectors Boost control solenoid Cruise control and throttle cables Air inlet duct Supercharger Upper radiator hose Thermostat housing EGR tube Temperature sensor electrical connector Intake manifold To install: 5. Install or connect the following: Intake manifold with new gaskets and torque the bolts to 11 ft. Ibs. (15 Nm) Temperature sensor electrical connector EGR tube Thermostat housing with a new gasket and torque the bolts to 20 ft. lbs. (27 Nm) Upper radiator hose Supercharger with new gaskets and torque the bolts to 17 ft. Ibs. (23 Nm) Air inlet duct Cruise control and throttle cables Boost control solenoid and torque the bolts to 72 inch Ibs. (8 Nm) Fuel rail and torque the hold down bolts to 7 ft. Ibs. (10 Nm) Fuel feed and return lines MAP sensor and bracket Fuel injector electrical connectors Alternator rear brace and torque the bolts to 37 ft. Ibs. (50 Nm) Spark plug wires Supercharger drive belt EGR valve heat shield Fuel injector sight shield Negative battery cable 6. Fill the cooling system. 7. Start the engine and check for leaks.

Exhaust Manifold REMOVAL & INSTALLATION 3.1L Engine

LEFT SIDE 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: ¢ Negative battery cable ¢ Throttle body air inlet duct ¢ Right engine mount strut bracket ¢ Crossover pipe heat shield

79227513

Exploded view of the left exhaust manifold mounting-3.1L engine

Crossover pipe nuts to the left exhaust manifold Exhaust manifold heat shield Exhaust manifold

To install: 3. Install or connect the following: Exhaust manifold with a new gasket and torque the nuts to 12 ft. Ibs. (16 Nm) Exhaust manifold heat shield and

torque the nuts to 89 inch Ibs. (10 Nm) Exhaust crossover pipe to the manifold and torque the bolt to 18 ft. Ibs. (25 Nm) Crossover pipe heat shield and torque the bolt to 89 inch Ibs. (10

Nm) Left side engine mount strut bracket and torque the bolt to 37 ft. lbs. (60 Nm) Throttle body air inlet duct Negative battery cable

RIGHT SIDE 1. Before servicing the vehicle, refer to the precautions in the beginning of this section.

2. Remove or disconnect the following: Negative battery cable Throttle body air inlet duct Exhaust crossover pipe heat shield Exhaust crossover pipe-to-right exhaust manifold nuts Heated Oxygen (HO2S) sensor electrical connector Catalytic converter pipe from the exhaust manifold Exhaust Gas Recirculation (EGR) pipe from the exhaust manifold Exhaust manifold heat shields Exhaust manifold

To install: 3. Install or connect the following: ¢ Exhaust manifold with a new gasket

W-BODY—GENERAL

CENTURY ¢ REGAL @ IMPALA e LUMINA ¢ MONTE rated I RIGUESACRANIHERIX and torque the bolts to 12 ft. Ibs. (16 Nm) Exhaust manifold heat shield and torque the bolts to 89 inch Ibs. (10 Nm) Crossover pipe and torque the bolts to 18 ft. Ibs. (25 Nm) Crossover pipe heat shield and torque the bolts to 89 inch Ibs. (10 Nm) Thermostat bypass pipe Ignition wires to the front spark plugs AIR pipe, if equipped Negative battery cable Throttle body air inlet duct Air cleaner

79222514

Exploded view of the right exhaust manifold mounting—3.1L engine

and torque the nuts to 12 ft. Ibs.

(16 Nm) Exhaust manifold heat shields and torque the bolts to 89 inch Ibs. (10 Nm) EGR pipe to the exhaust manifold and torque the bolt to 22 ft. Ibs. (30 Nm) Catalytic converter pipe with a new gasket and torque the nuts to 26 ft. lbs. (35 Nm), HO2S sensor electrical connector Exhaust crossover pipe and torque the bolts to 18 ft. Ibs. (25 Nm) Exhaust crossover pipe heat shield and torque the bolts to 89 inch Ibs.

(10 Nm) Throttle body air inlet duct Negative battery cable 3.4L Engine

LEFT SIDE 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following:

Negative battery cable Air cleaner Throttle body air inlet duct Ignition wires to the front spark plugs Secondary Air Injection (AIR) pipe, if equipped Thermostat bypass pipe Exhaust crossover pipe heat shield Exhaust crossover pipe nuts to the left exhaust manifold Exhaust manifold heat shield Exhaust manifold

To install: 3. Install or connect the following:

Exhaust manifold with a new gasket

4 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 section.

2. Remove or disconnect the following: Negative battery cable Throttle body air inlet duct Secondary Air Injection (AIR) pipe, if equipped Exhaust crossover heat shield Exhaust crossover pipe from the manifold Heated Oxygen (HO2S) sensor electrical connector Catalytic converter from the manifold Exhaust Gas Recirculation (EGR) valve from the intake manifold Exhaust manifold heat shields Exhaust manifold To install: 3. Install or connect the following: Exhaust manifold with a new gasket and torque the nuts to 12 ft. Ibs.

(16 Nm) Exhaust manifold heat shields and torque the bolts to 89 inch Ibs. (10 Nm) EGR valve and torque the bolts to

22 ft. Ibs. (30 Nm) Catalytic converter and torque the nuts to 24 ft. Ibs. (32 Nm) HO2S electrical connector Crossover pipe to the manifold and torque the bolts to 18 ft. Ibs. (25 Nm) Crossover pipe heat shield and torque the bolts to 89 inch Ibs. (10

Nm)

29-17

AIR pipe and torque the bolt to 15 ft. Ibs. (20 Nm), if equipped Throttle body air inlet duct Negative battery cable 4. Start the vehicle and check for leaks,

repair if necessary. 3.5L Engine

LEFT 1. Before servicing the vehicle, refer to the precautions in the beginning of this section.

2. Drain the cooling system. 3. Remove or disconnect the following: Negative battery cable Fuel injector sight shield Engine mount strut and bracket Cooling fans Upper and lower radiator hoses Transaxle oil cooler lines from the radiator Radiator Alternator Exhaust manifold heat shield Oil level indicator tube Secondary Air Injection (AIR) control valve assembly from the engine mount strut bracket Exhaust manifold-to-crossover pipe Studs Exhaust manifold To install: 4. Install or connect the following: Manifold to the crossover pipe using a new gasket and torque the studs to 18 ft. Ibs. (25 Nm) Exhaust manifold with a new gasket and torque the bolts to 18 ft. Ibs. (25 Nm) AIR valve and torque the pipe nut to 44 ft. Ibs. (60 Nm) and the bolt to 80 inch Ibs. (9 Nm) Oil level indicator tube and torque the bolt to 80 inch Ibs. (9 Nm) Exhaust manifold heat shield and torque the bolts to 80 inch Ibs. (9 Nm) Alternator and torque the bolts to 37 ft. Ibs. (60 Nm) Radiator and torque the bolts to 89 inch Ibs. (10 Nm) Transaxle oll cooler lines and torque the fitting to 17 ft. Ibs. (23 Nm) Upper and lower radiator hoses Cooling fans and torque the bolts to 89 inch Ibs. (10 Nm) Engine mount strut bracket and

For Tire, Wheel and Ball Joint specifications, see Section 1 of this manual

29-1

ATION—W-BODY Secs

re

tin e MONTE CARLO ¢ INTRIGUE e GRAND PRIX

torque the bolts to 37 ft. Ibs. (50 Nm) e Engine mount strut and torque the bolts to 35 ft. Ibs. (48 Nm) e Fuel injector sight shield and torque the nuts to 27 inch Ibs. (3 Nm) e Negative battery cable 5. Fill the cooling system. 6. Start the vehicle and check for leaks, repair if necessary.

RIGHT 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Relieve the fuel system pressure. 3. Drain the cooling system. 4, Remove or disconnect the following: Negative battery cable Fuel injector cover Air intake duct Engine mount strut Fuel lines from the supply rail Cruise control and accelerator cables from the throttle body Transaxle selector range cable and cable brackets Transaxle shift cable from the shift module Brake booster vacuum hose from the engine Wiring harness connectors from the engine and transaxle Upper radiator hose Transaxle oil cooler lines from the radiator Surge tank inlet hose Heater hoses from the engine Lower radiator air deflector Battery cables from the retainers Lower radiator hose A/C compressor without disconnecting the lines and move it aside Starter wiring Catalytic converter from the manifold Front wheels and splash shields Wheel speed sensor (WSS) wiring from the lower control arms Tie rod ends from the steering knuckles Lower ball joints from the knuckles Halfshafts Intermediate shaft from the steering rack 5. Secure the vehicle to the lift in preparation for engine removal. 6. Position an engine/frame support table under the vehicle and lower the vehicle to meet the table. 7. Remove or disconnect the following:

93002507

Exploded view of the right exhaust manifold—3.5L engine

Frame-to-body bolts Crossover pipe from the front manifold Exhaust Gas Recirculation (EGR) pipe from the crossover pipe Right exhaust manifold from the engine To install: 8. Install or connect the following: e Right exhaust manifold with a new gasket and torque the bolts to 18 ft. lbs. (25 Nm) e Crossover pipe to the front exhaust manifold and torque the bolts to 18 ft. Ibs. (25 Nm) e EGR pipe to the crossover pipe and torque the pipe nut to 44 ft. Ibs. (60 Nm) 9. Position the engine/transaxle assembly under the vehicle. 10. Coat the sub-frame bushings with rubber lubricant. 11. Lower the vehicle onto the assembly. Align the sub-frame on the vehicle using 2 bolts or drill bits, % inches thick by 8 inches long through the alignment holes on the right side of the frame. 12. Install new frame-to-body bolts. Torque the bolts to 133 ft. Ibs. (180 Nm) starting with the rear bolts and then the front bolts. 13. Raise the vehicle and remove the frame table. 14. Install or connect the following: e Intermediate shaft to the steering rack and torque the bolts to 35 ft. lbs. (48 Nm) e*Be sure the shaft is fully seated on the stub before installing the pinch bolt.

¢ Halfshafts ¢ Ball joints and torque the nuts to 40 ft. Ibs. (55 Nm) ¢ Tie rod ends and torque the nuts to 22 ft. Ibs. (30 Nm) plus an additional 120 degree turn

WSS wiring harness Splash shields and front wheels Catalytic converter and torque the nuts to 53 inch Ibs. (6 Nm) Starter wiring A/C compressor and torque the bolts to 37 ft. Ibs. (50 Nm) Lower radiator hose Battery cables in their retainers Lower radiator air deflector and torque the bolts to 15 ft. Ibs. (20 Nm) 15. Remove the straps securing the vehicle to the lift. Heater hoses Surge tank hose Transaxle oi! cooler lines to the radiator and torque the fittings to 17 ft. Ibs. (23 Nm) Upper radiator hose Wiring harness connectors to the engine and transaxle Transaxle shift cable to the shift module and bracket Transaxle range selector cable Cruise control and accelerator cables to the throttle body Fuel lines to the supply rail Engine mount strut and torque the bolts to 35 ft. Ibs. (48 Nm) Air inlet duct e Fuel injector sight shield Negative battery cable 16. Refill the cooling system. 17. Start the engine and check for leaks, repair if necessary.

3.8L Engines

LEFT SIDE 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Negative battery cable Fuel injector sight shield Engine mount struts Exhaust crossover from the manifold Spark plug wires from the plugs Oil level indicator tube Exhaust manifold heat shield Engine lift hook Exhaust manifold To install: 3. Install or connect the following: Exhaust manifold with a new gasket and torque the bolts to 22 ft. Ibs. (30 Nm) Engine lift hook and torque the bolts to 22 ft. Ibs. (30 Nm) Exhaust manifold heat shield and torque the bolts to 15 ft. Ibs. (20 Nm).

™

CENTURY © REGAL

W-BODY—GENERAL M

IMPALA ¢ LUMINA © MONTE NRL TIGER EAN in 29-1 i] Oil level indicator tube and torque the nut to 14 ft. Ibs. (19 Nm) Spark plug wires Exhaust crossover and torque the bolts to 15 ft. Ibs. (20 Nm) Engine mount struts and torque the bolts to 35 ft. Ibs. (48 Nm) Fuel injector sight shield e Negative battery cable 4. Start the vehicle and check for leaks, repair if necessary.

RIGHT SIDE 1 LEFT (FRONT) EXHAUST MANIFOLD 2 STUD 30 Nem (22 LB. FT) 3 BOLT 30 Nem (22 LB. FT) 7922XG30

Exploded view of the left exhaust manifold mounting—3.8L engine

1

EXHAUST

CROSSOVER

PIPE

(30. Nm)

2 BOLT 20 Nem (15 LB. FT.)

e 02S electrical connector

3. STUD 20 Nem (15 LB. FT.) SEAL

a

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Negative battery cable Fuel injector sight shield Exhaust crossover pipe from the manifold Exhaust Gas Recirculation (EGR) adapter pipe from the manifold Catalytic converter Spark plug wires from the plugs Engine lift bracket Fuel injector sight shield bracket Oxygen Sensor (02S) electrical connector Exhaust manifold To install: 3. Install or connect the following: Exhaust manifold with a new gasket and torque the bolts to 22 ft. !bs.

Se

e Fuel injector sight shield bracket and torque the bolts to 22 ft. Ibs. (30 Nm) . a

Exploded view of the crossover pipe mounting—3.8L engine

ee a va the

Spark plug wires Catalytic converter and torque the bolts to 26 ft. Ibs. (85 Nm) EGR adapter pipe and torque the bolt to 21 ft. Ibs. (29 Nm) Exhaust crossover pipe and torque the bolts to 13 ft. Ibs. (18 Nm) ¢ Fuel injector sight shield e Negative battery cable 4. Start the vehicle and check for leaks, repair if necessary.

- Front Crankshaft Seal

=

REMOVAL & INSTALLATION 1

_]—$—$——

RIGHT (REAR) EXHAUST MANIFOLD

Except 3.5L Engines

2 STUD 30 Nem (22 LB. FT.)

7922XG29

Exploded view of the right exhaust manifold mounting—3.8L engine

1. Before the vehicle, refer to the UIOIe servicing ee precautions in the beginning of this section.

For Wheel Alignment specifications, see Section 1 of this manual

29-20

ATION—W-BODY

cane FLATS ERE TOMI ¢ MONTE CARLO ¢ INTRIGUE e GRAND PRIX 5. Install or connect the following:

Camshatt Camshaft thrust plate and torque the bolts to 89 inch Ibs. (10 Nm) Oil pump driven gear and torque the bolt to 27 ft. Ibs. (36 Nm) Timing chain and sprocket and torque the bolt to 103 ft. Ibs. (140 Nm) e Front cover and torque the small bolts to 15 ft. Ibs. (21 Nm), the medium bolts to 35 ft. Ibs. (47 Nm) and the large bolts to 41 ft. Ibs. (55

9346GV05 9346VG22

Installing the front crankshaft seal— except 3.5L engines

2. Remove the crankshaft balancer using an appropriate puller. 3. Pry the front crankshaft seal out. To install: 4. Coat the new seal with engine oil to ease installation. 5. Install the front crankshaft seal using seal installer J-35468 on 3.1L and 3.4L engines. On 3.8L engines use tool J 35354. Make sure that the crankshaft front oil seal lip faces the engine. 6. Make sure the seal is flush with the engine when installed. e Crankshaft balancer and torque the bolt to 76 ft. Ibs. (103 Nm) 3.5L Engines

The installed depth of the seal (1) should protrude 1-2 mm (0.039-0.078 in.) from the front cover—3.5L engine

Nm)

7. Thread the installation tool in the crankshaft. Ensure you engage at least ten threads of the tool before pressing the seal in place. 8. Push the seal into position by tightening the nut on the installation tool until the mandrel bottoms out on the crankshaft sprocket. 9. Check the installed depth of the seal, which should protrude 1-2 mm (0.0390.078 in.), from the front cover. 10. Install the crankshaft balancer to 37 ft. lbs. (650 Nm) plus an additional 125 degrees.

Installation of a new camshaft or a wear pattern on the old valve lifter will require the replacement of the camshaft and lifters together. If camshaft replacement is not necessary, be sure to install the used valve lifters in their original position. 7. Install or connect the following: Lifters in their original locations Lifter guide and torque guide bolts

to 89 inch Ibs. (10 Nm) Pushrods, rocker arms, balls and

Camshaft and Valve Lifters

REMOVAL & INSTALLATION

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove the crankshaft balancer using an appropriate puller. 3. Pry the front crankshaft seal out. To install: 4. Coat the new seal with engine oil to ease installation. 5. Place the front seal onto the mandrel of the installation tool J-42041. 6. Slide the mandrel onto the screw of the installation tool.

:

e Crankshaft balancer and torque the bolt to 76 ft. Ibs. (103 Nm) 6. Lubricate the bearing surfaces with Molykote®.

3.1L and 3.4L Engines 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Relieve the fuel system pressure. 3. Remove or disconnect the following: Engine assembly Rocker arm covers Intake manifold Rocker arm bolts, balls, rocker arms and pushrods Lifter guide bolts and the guide Valve lifters from the bores Crankshaft balancer Front cover Timing chain and sprockets Oil pump driven gear Camshaft thrust plate Camshaft

bolts and torque the nuts to 89 inch lbs. (10 Nm) plus an additional 30 degree turn Intake manifold and torque the lower manifold bolts to 115 inch lbs. (13 Nm) and the upper manifold bolts to 18 ft. Ibs. (25 Nm) Rocker arm covers and torque the bolts to 89 inch Ibs. (10 Nm) Engine assembly Negative battery cable e>The only time valve adjustment in needed is if there was a valve job performed or the rocker studs have been replaced with an adjustable rocker arm stud. The rocker arm stud installed from the factory should be shouldered and not need any adjustment.

8. Start the engine and check for leaks, repair if necessary. 3.5L Engine

Avoid damaging the camshaft bearing surfaces. EE

9346VG04

Remove the front oil seal, using a suitable prying tool

I

SE

To install: 4. Coat the camshaft with assembly lubricant.

ES

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the cooling system. 3. Remove or disconnect the following: ¢ Negative battery cable ¢ Fuel injector sight shield

W-BODY—GENERAL M

CENTURY © REGAL ¢ IMPALA ¢ LUMINA « MONTE ARISTON THIGUECIERENTTOHR 29-21 e Thermostat housing for clearance when installing the camshaft Holding Fixture ¢ Camshaft cover 4. Rotate the crankshaft so the camshaft flats are parallel to the camshaft’ sealing surface, then install a camshaft holding fixture. 5. Remove the camshaft sprocket bolts. 6. Install a timing chain/sprocket holding fixture J 42042. 7. Evenly slide the camshaft sprocket and chain from the camshafts onto the holding tool.

1. 2. 3. 4.

Left intake Left exhaust Right intake Right exhaust

al tT TlPit a

>The camshaft bearing caps are marked. Be sure the raised portion of the cap faces the outside of the engine. They must always be installed in their original positions.

8. Remove or disconnect the following: ‘e Camshaft bearing caps e Camshaft holding fixture e Camshafts

93002508

;

!

}

Vie

=

=

Conor 4 93002511

Camshaft identification—3.5L engine

To install: 9. Coat the rocker arms with engine oil and place them in their original positions. Be sure to install the rounded end on the lash adjuster and the flat end on the tip of the valve.

Camshaft holding fixture installed on the camshafts—3.5L engine

i

10. Install or connect the following: e Camshafts, lubricated with engine oil, with the sprocket drive pin notch located at the top Bearing caps and torque the bolts to 71 inch Ibs. (8 Nm) plus an additional 22 degree turn camshaft Holding Fixture tool onto the camshaft(s) at the rear of the cylinder head «>Use the camshaft flats to turn the camshaft.

11. Compress the secondary timing

chain tensioner by hand and insert a wire into the access hole to lock it in place. 12. Slide the camshaft sprockets/timing chain off the tool and onto the camshafts. Be sure to align the drive pins. 13. Remove the timing chain/sprocket holder from the front of the cylinder head. Torque the sprocket bolts to 18 ft. Ibs. (25 Nm); then, an additional 45 degree turn. 14. Remove the wire from the chain tensioner and allow the tensioner to apply pressure to the chain. 15. Remove the camshaft holding fixture. 16. Install or connect the following: e Camshaft cover and torque the bolts to 80 inch Ibs. (9 Nm) e Thermostat housing, if removed e Fuel injector sight shield and torque the nuts to 27 inch Ibs. (3 Nm) e Negative battery cable 17. Refill the cooling system. 18. Start the vehicle and check for leaks, repair if necessary. 3.8L Engine

93002509

Timing chain/sprocket holding fixture installed on the cylinder head; use the flats on the camshaft if rotation is necessary for installation of the holding tool—

Before installation, compress the tensioner and lock it in place with a piece of

3.5L engine

wire—3.5L engine

93002510

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Discharge the A/C system. 3. Drain the cooling system. 4. Remove or disconnect the following: e Negative battery cable e Radiator with the air conditioning condenser assembly e Rocker arm cover

For Maintenance Interval recommendations, see Section 1 of this manual

ATION—W-BODY

29-22

CeNTUaY

AEaRLS PAERIOLMNA e MONTE CARLO ¢ INTRIGUE

GRAND PRIX

Valve.Lash

ADJUSTMENT The valve clearance cannot be adjusted on these engines.

Starter Motor

REMOVAL & INSTALLATION

79227517

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Negative battery cable e Radiator lower air deflector e Torque converter cover e Electrical connections from the starter e Starter motor

The timing marks should face each other if the chain and gears are installed properly—3.8L engine

e Valve lifters e Front cover ¢ Camshaft sprocket and timing chain e Camshaft thrust plate 5. Remove the camshaft assembly, as follows: a. Step 1:Install 12-20 x 6 inch bolt in the camshaft front bolt hole b. Step 2:Carefully rotate and pull the camshaft assembly out of the bear-

11 ft. Ibs. (15 Nm)

3.1L and 3.4L Engines

93062615

Exploded view of the starter—3.1L and 3.4L engines

Front cover and torque the bolts to 15 ft. Ibs. (20 Nm) plus an additional 40 degree turn Valve lifters Rocker arm cover and torque the bolts to 89 inch Ibs. (10 Nm) Radiator with the air conditioning condenser and torque the bolts to

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the engine oil. 3. Remove or disconnect the following: ¢ Negative battery cable e Engine mount struts ¢ Drive belt

¢ A/C compressor mounting bolts and reposition the compressor 4. Install an engine support fixture. 9. Remove or disconnect the following: ¢ Catalytic converter from the right exhaust manifold * Oil level sensor electrical connection

18 ft. Ibs. (25 Nm) Negative battery cable 8. Evacuate and recharge the A/C system.

9. Refill the cooling system. 10. Start the engine and check for leaks, repair if necessary.

To install: 3. Install or connect the following: e Starter motor and torque the bolts to 32 ft. Ibs. (43 Nm) on all models except Intrigue. On Intrigue models, tighten the bolts to 37 ft. Ibs. (50 Nm). e Starter solenoid BAT terminal e Starter solenoid S terminal e Torque converter cover and torque the bolts to 89 inch Ibs. (10 Nm) Radiator lower air deflector and torque the bolts to 15 ft. Ibs. (20 Nm) e Negative battery cable

REMOVAL & INSTALLATION

ings. 6. Inspect the camshaft for damage and replace if necessary. To install: 7. Install or connect the following: Camshaft lubricated with assembly lubricant Thrust plate and torque the bolts to

93062617

Exploded view of the starter—3.8L engine

93062616

Exploded view of the starter—3.5L engine

Starter motor Transaxle brace from the oil pan Transaxle mount lower nuts Engine mount lower nuts 6. Raise the engine to gain access to the oil pan.

W-BODY—GENERAL MOT

CENTURY ¢ REGAL e IMPALA ¢ LUMINA * MONTE CARLO e RCI

93462G02

Exploded view of the oil pan side bolts— 3.1L and 3.4L engines

e Transaxle brace to the oil pan and torque the bolts to 46 ft. Ibs. (63 Nm) ¢ Starter motor and torque the bolts to 32 ft. Ibs. (43 Nm) e Oil level sensor electrical connection e Catalytic converter to the rear manifold and torque the nuts to 26 ft. lbs. (35 Nm) 13. Remove the engine support fixture. e A/C compressor and torque the bolts to 37 ft. lbs. (60 Nm) e Drive belt e Engine mount struts and torque the bolts to 35 ft. Ibs. (48 Nm) e Negative battery cable 14. Fill the engine with new oil.

READERS 29-23

93002513

Use a straight-edge to align the rear of the oil pan to the rear of the engine—3.5L engine

15. Start the vehicle and check for leaks, repair if necessary.

3.5L Engine

93462603

Exploded view of the oil pan retaining bolts—3.1L and 3.4L engines

7. Remove the engine mount from the oil pan. 8. Remove the oil pan. To install: 9. Apply a small amount of sealer on both sides of the rear main bearing cap between the gasket and the engine. 10. Install or connect the following: e Oil pan with a new gasket and torque the retaining bolts to 18 ft. lbs. (25 Nm) e Front and rear oil pan bolts and torque the bolts to 37 ft. Ibs. (50 Nm) ¢ Engine mount and bracket to the oil pan and torque the bolts to 43 ft. lbs. (68 Nm) 11. Lower the engine into position. 12. Install or connect the following: e Engine mount lower nuts and torque the nuts to 32 ft. Ibs. (43 Nm) e Transaxle mount lower nuts and torque the nuts to 35 ft. Ibs. (47 Nm)

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the engine oil. 3. Remove ordisconnect the following: e Negative battery cable ¢ Oil filter cap and filter e Oil level sensor electrical connector e Transaxle brace e Oil pan To install: 4. Install or connect the following: ¢ Oil pan with a new gasket, Do not tighten the bolts ° Transaxle brace on the engine block only and torque the bolts to 18 ft.

lbs. (25 Nm)

93002512

93002514

Oi! pan mounting bolt tightening sequence—3.5L engine

e Brace-to-oil pan bolts, loosely install them 5. Align the rear of the oil pan flush with the rear of the engine block. Use a straight edge for reference. 6. Press the front of the oil pan against the transaxle brace; then, torque the braceto-oil pan bolts to 18 ft. Ibs. (25 Nm). Be sure to keep the rear of the pan flush with the rear of the engine. 7. Torque the oil pan bolts in sequence to 18 ft. Ibs. (25 Nm). 8. Torque the brace-to-transaxle bolts to 32 ft. Ibs. (43 Nm). 9. Install or connect the following: ¢ Oil level sensor electrical connection ¢ Drain plug and torque it to 15 ft. lbs. (20 m) e New oil filter and torque the cap to 18 ft. Ibs. (25 Nm) e Negative battery cable 10. Refill the engine with clean oil. 11. Start the vehicle and check for leaks, repair if necessary.

Exploded view of the oi! pan—3.5L engine

For Tune-up, Capacities and Firing orders, see Section 1 of this manual

29-24

GENERAL MOTORS CORPORATION—W-BODY

CENTURY @ REGAL ¢ IMPALA ¢ LUMINA ¢ MONTE CARLO ¢ INTRIGUE ¢ GRAND PRIX

3.8L Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the engine oil. 3. Remove or disconnect the following: e Negative battery cable e Throttle body air inlet duct e Engine mount struts e Accessory drive belt 4. Install an engine support fixture. Catalytic converter from the right exhaust manifold Right front wheel Right side splash shield

Oil filter and discard A/C compressor bracket and reposition the compressor Power steering oil cooler pipe brackets from the frame Engine mount bracket bolts Lower engine mount nuts Torque converter cover Oil level sensor electrical connector Oil level sensor 5. Raise the vehicle and place a support under the frame. ¢ Right side frame bolts and loosen the left side bolts e Engine mount and bracket e Oil pan ¢ Qil pump pipe and screen To install: 6. Install or connect the following: ¢ New oil pan gasket and the oil pump pipe and screen assembly and torque the bolts to 11 ft. Ibs. (15 Nm) Do not over tighten the oil pan bolts or damage to the pan may occur.

93062618

Exploded view of the oil pan mounting— 3.8L engine

Oil pan and torque the bolts to 125 inch Ibs. (14 Nm) Engine mount and bracket and torque the bolts to 50 ft. Ibs. (68 Nm) New right side frame bolts and torque all the bolts to 133 ft. Ibs. (180 Nm) Lower engine mount and torque the nuts to 35 ft. Ibs. (47 Nm) Oil level sensor and torque the fastener to 15 ft. Ibs. (20 Nm) Oil level wire connector Torque converter cover and torque the bolts to 89 inch Ibs. (10 Nm) Power steering oil cooler pipe brackets to the frame A/C compressor and torque the upper bolt to 37 ft. Ibs. (50 Nm) and the lower bolt to 59 ft. Ibs. (80 Nm) New oil filter Drain plug and torque the plug to 22 ft. Ibs. (30 Nm) Splash shield Right front wheel Catalytic converter pipe to the right exhaust manifold and torque the bolts to 26 ft. Ibs. (35 Nm) 7. Remove the engine support fixture.

e Drive belt e Engine mount struts to the engine and torque the bolts to 41 ft. Ibs. (56 Nm) e Throttle body air inlet duct s« Negative battery cable 8. Fill the engine with new oil. 9. Start the vehicle and check for leaks, repair if necessary. 10. Road test the vehicle, check the front end alignment and adjust if necessary.

REMOVAL & INSTALLATION 3.1L and 3.4L Engines

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the engine oil. 3. Remove or disconnect the following: e Negative battery cable e Qil pan e Bolt attaching the oil pump to the rear crankshaft bearing cap e Oil pump and driveshaft

OIL PUMP BOLT

w“p,

OIL PUMP DRIVE ROD

ENGINE BLOCK 79227519

Oil pump and driveshaft components—3.1L and 3.4L engines

CENTURY ¢ REGAL To install:

e>Rotate the driveshaft as required to obtain the proper engagement with the oil pump drive unit.

4. Install or connect the following: ¢ Oil pump and driveshaft and torque the bolt to 30 ft. Ibs. (41 Nm) e Qil pan e Negative battery cable 5. Fill the engine with new oil. 6. Start the vehicle arid check for leaks, repair if necessary.

3.5L Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the engine oil. 3. Remove or disconnect the following: e Negative battery cable e Front cover e Rocker arm covers 4. Install camshaft holding fixtures J

W-BODY—GENERAL MOTOR

IMPALA ¢ LUMINA * MONTE CARLO e ITBIGUE aCRANDIEHIK 29-25 42038 on both sets of camshafts. Turn the hex portion of the camshaft to align them for tool installation. When installed, the flats on the rear of the camshafts will be parallel with the camshaft cover sealing surface.

5. Remove or disconnect the following: Oil pan Oil pump pipe and screen Primary chain tensioner Primary chain from the drive sprocket

Oil pump by sliding it off the crankshaft To install: 6. Pack the oil pump housing with white petroleum jelly to insure priming. 7. Align the oil pump sprocket with the crankshaft and install the pump on the engine until a positive stop is felt. When installed properly, the sprocket will protrude Slightly from the oil pump and the face of the sprocket will be behind the machined step in the crankshaft. 8. Install or connect the following: e Qil pump and torque the bolts to 18 ft. lbs. (25 Nm) e Primary chain on the sprocket ->Be sure to maintain correct timing.

e Chain tensioner e Oil pump pipe with the screen and

torque the nut and bolt to 89 inch lbs. (10 Nm) ¢ Oil pan and torque the bolts to 18 ft. Ibs. (25 Nm) 9. Remove the camshaft holding tools. 10. Install or connect the following: e Camshaft covers and torque the bolts to 80 inch Ibs. (99 Nm) e Engine front cover and torque the bolts to 124 inch Ibs. (14 Nm) e Negative battery cable 11. Fill the engine with new oil. 12. Start the vehicle and check for leaks, repair if necessary. 3.8L Engines 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the engine oil. 3. Remove or disconnect the following: e Negative battery cable e Front cover e (il pump cover e (Oil pump gear set To install: 4. Lubricate the oil pump gears with petroleum jelly and install the gears into the housing. 5. Pack the gear cavity with petroleum jelly after the gears have been installed. 6. Install or connect the following:

97 inch Ids. (11 Nm) Oil pump cover Pump outer gear

Pump inner gear Front cover cal ih ede 93002515

The oil pump is mounted on the front of the engine and driven by the crankshaft— 3.5L engine

93002516

Correct position of the crankshaft sprocket when the oil pump is installed correctly— 3.5L engine

Oil pump assembly—3.8L engine

For complete service labor times, order Nichols’ Chilton Labor Guide

29-26

RATION—W-BODY

SOHNE RESALE Aa LOMIHA e MONTE CARLO ¢ INTRIGUE ¢ GRAND PRIX 8. Place a small amount of gasket maker to the crankcase split line across the end of the upper and lower crankcase seal. 9. Coat the outer diameter of the block with clean engine oil. 10. Clean the outer diameter of the flywheel flange with a lint-free cloth.

e Oil pump cover and torque the screws to 98 inch Ibs. (11 Nm) e Front cover e Negative battery cable 7. Fill the engine oil. A new oil filter is recommended. 8. Start the vehicle and check for leaks, repair if necessary.

+ CAUTION

Rear Main Seal |

Do not apply any oil on the green coating of the new seal.

93002517

REMOVAL & INSTALLATION

Use the guide holes in Tool J 42841 to install the screws in the seal—3.5L engine

Except 3.5L Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Negative battery cable e Transmission e Flexplate e Rear main seal by prying it out To install: 3. Lubricate the lip and the outer edge of the new seal with clean engine oil. 4. Install or connect the following: e Position the new seal on the mandrel until the back of the seal is flush against the collar of the tool e Seal installer tool to the rear of the crankshaft with the 2 mounting bolts. Turn the handle until the seal is seated in the rear of the engine. Remove the installer tool e Flexplate e Transmission e Negative battery cable 5. Start the vehicle and check for leaks, repair if necessary.

e Negative battery cable e Transaxle e Engine flywheel 3. Place Rear Seal Remover Tool J 42841 on the crankshaft with retaining bolts. 4. Install eight one-inch self starting screws through the guide holes of the tool. Tighten the screws. 5. Install the two retaining bolts. 6. Install a center forcing screw into the removal tool and pull the seal off the end of the crankshaft. To install: 7. Clean debris from the crankshaft rear seal drain. The seal may leak if the drain is not properly cleaned.

11. Loosen the center bolt of the seal installer tool until the hub protrudes past the outer plate (approximately inch). 12. Install or connect the following: e Three mounting bolts into the crankshaft flange until the tool is fully seated on the crankshaft e New seal by tightening the center bolt until the tool bottoms out against the crankshaft 13. Remove the removal/installer tool and make certain the seal is installed properly 14. Install or connect the following: e Flywheel. Torque the bolts to 11 ft. lbs. (15 Nm) plus an additional 50 degrees with a torque angle meter. e Transaxle e Negative battery cable

79222522

Carefully pry the seal from the bore without damaging the crankshaft seal surface

3.5L Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following:

mn 93062619

Install a center forcing screw into the removal tool—3.5L engine

W-BODY—GENERAL MOT

CENTURY ¢ REGAL ¢ IMPALA ¢ LUMINA ¢ MONTE alin TANS 15. Top off the engine oil if needed. 16. Start the vehicle and check for leaks, repair if necessary.

Timing Chain, Sprockets, Front Cover and Seal REMOVAL & INSTALLATION 3.1L and 3.4L Engines 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the cooling system. 3. Drain the engine oil. 4. Remove or disconnect the following: Negative battery cable

Coolant reservoir Accessory drive belt Crankshaft balancer Drive belt tensioner Power steering pump, DO NOT disconnect the lines Thermostat bypass pipe from the front cover Upper radiator hose Water pump pulley Lower Crankshaft Position (CKP) sensor Front cover 5. Rotate the crankshaft until the timing

marks on the camshaft and crankshaft sprockets are in alignment (facing each

_ other). e Camshaft sprocket bolt, sprocket and timing chain e Crankshaft sprocket e Timing chain damper bolts and damper, if necessary To install: 6. Install or connect the following: e Timing chain damper (if removed) and torque the bolts to 15 ft. Ibs. (21 Nm) e Crankshaft sprocket ->Be sure the timing mark on the crankshaft sprocket is pointing toward the mark on the chain damper.

e Timing chain over the camshaft sprocket 7. Loop the timing chain under the crankshaft sprocket and install the camshaft sprocket on the camshaft. 8. Verify that the marks are aligned; the camshaft sprocket will be at the 6 o'clock position and the crankshaft sprocket at the 12 o'clock position. ->The No. 1 piston will be at Top Dead Center (TDC) and the No. 4 piston will also be at TDC but on the compression stroke.

9. Tighten the camshaft sprocket bolt to 103 ft. Ibs. (140 Nm). 10. Lubricate the timing chain components with engine oil. 11. Install or connect the following: ¢ New front cover seal Front cover using a new gasket and torque the small bolts to 15 ft. Ibs. (21 Nm) and the large bolts to 35 ft. lps. (47 Nm) Water pump pulley and torque the bolts to 18 ft. Ibs. (25 Nm) Upper radiator hose Thermostat bypass pipe Power steering pump and torque the bolts to 25 ft. Ibs. (34 Nm) Drive belt tensioner and torque the bolt to 37 ft. Ibs. (50 Nm)

93002301

Be sure to align the damper mark (1) with the crankshaft mark (2) and the damper mark (3) with the camshaft sprocket mark (4)—3.1L and 3.4L engines

CKP sensor Crankshaft balancer and torque the bolt to 76 ft. Ibs. (103 Nm) Accessory drive belt Coolant reservoir Negative battery cable 12. Refill the fluids. 13. Start the engine and check for leaks, repair if necessary.

:

oH Gea 29-2/

3.5L Engine

PRIMARY

CHAIN

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the engine oil. 3. Drain the cooling system. 4. Disconnect the negative battery cable. 5. Remove the camshaft covers. 6. Rotate the crankshaft so the No. 1 piston is at Top Dead Center (TDC) and the flats on the rear of the camshafts are parallel with the camshaft cover sealing surface. 7. Install camshaft holding fixtures on both sets of camshafts. Turn the hex portion of the camshaft to align them for tool installation. e>\Nhen installed, the flats on the rear of the camshafts will be parallel with the camshaft cover sealing surface.

8. Remove or disconnect the following: Right diagonal brace Battery and tray Coolant reservoir Underhood accessory wiring junction block, move it aside Drive belt Power steering pump pulley Idler pulley and belt tensioner Water pump pulley Water pump drive belt shield Water pump 9. Support the engine cradle. 10. Remove the right side engine cradle bolts. 11. Lower the cradle. 12. Remove or disconnect the following: Crankshaft balancer Front cover Engine lift bracket from the front of the engine Camshaft Position (CMP) sensor Sprocket bolt from the exhaust camshaft on the right cylinder head to allow for clearance of the chain guide Four chain guide access plugs from the cylinder heads ->Note that each plug has an O-ring.

e Primary chain tensioner =>Remove the lower bolt allowing the tensioner to swing down and expand.

Please visit our web site at www.chiltonsonline.com

e Primary chain tensioner shoe, by removing the bolt, pushing the guide downward slightly and

29-28

GENERAL MOTORS CORPORATION—W-BODY CENTURY @ REGAL ¢ IMPALA ¢ LUMINA * MONTE CARLO e INTRIGUE ¢ GRAND PRIX

1

15. Install the timing chain on the sprockets. 16. Center the mark on the left intake camshaft sprocket between the 2 painted links. 17. Verify that all of the timing marks are aligned. 18. Install the primary chain tensioner shoe. Torque the bolt to 22 ft. Ibs. (30 Nm). 19. Compress the primary chain tensioner using the following sub-steps: a. Step 1:Rotate the ratchet release lever counterclockwise and hold it. b. Step 2:Press the tensioner shoe in and hold it. c. Step 3:Release the ratchet lever and slowly release the pressure on the shoe. d. Step 4:Insert a pin through the hole in the lever as the lever moves to the first click. The ratchet should hold the shoe in the compressed position.

2

->Be sure the lever on the tensioner is facing you when installed.

20. Install or connect the following: e Primary chain tensioner and torque the bolts to 18 ft. Ibs. (25 Nm): then, remove the chain tensioner pin e Four chain guide access plugs and torque the plugs to 44 inch Ibs. (5 Nm)

4 o

2

93002519

Shoe

93002520

Compressing the primary chain tensioner—3.5L engine

pulling it up through the cylinder head e Primary chain from the right camshaft, allowing it to fall into the oil pump area e Primary chain To install: 13. Rotate the crankshaft so the No. 1 piston is at Top Dead Center (TDC) and the mark on the crankshaft is at the 4 o'clock position. 14. Rotate the balance shaft so the timing mark is at the 5 o'clock position.

er VON ‘@) as BESET °

=

Ql] 93002521

e>Be sure the painted links are facing the front of the engine.

Apply RTV sealant to the 3 areas indicated before installing the front cover and gasket—3.5L engine

W-BODY—GENERAL MOT

CENTURY ¢ REGAL e IMPALA ¢ LUMINA ¢ MONTE PARLOIG AYES ¢ Front engine lift bracket and torque the hex head bolt to 37 ft. Ibs. (50 Nm) and the internal drive bolt to 18 ft. Ibs. (25 Nm) e CMP sensor and torque the bolts to 80 inch Ibs. (9 Nm) 21. Remove the camshaft holding tools. 22. Install the rocker arm covers. Torque the bolts to 80 inch Ibs. (9 Nm). 23. Place a small bead of RTV sealant on the 3 areas indicated in the diagram. 24. Install or connect the following: e Front cover with a new gasket and torque the bolts to 124 inch Ibs. (14 Nm) and the coolant drain plug to 89 inch Ibs. (10 Nm) e Crankshaft balancer and torque the bolt to 37 ft. Ibs. (60 Nm) plus an additional 120 degree turn 25. Raise the engine cradle and install new bolts loosely. 26. Coat the sub-frame bushings with rubber lubricant. 27. Lower the vehicle onto the assembly. Align the sub-frame on the vehicle using 2 bolts or drill bits, 34 inches thick by 8 inches long through the alignment holes on the right side of the frame. 28. Install or connect the following: e New frame-to-body bolts and torque the bolts to 133 ft. Ibs. (180 Nm) Water pump with a new gasket and torque the bolts to 124 inch Ibs. (14 Nm) Water pump pulley and torque the bolts to 106 inch Ibs. (12 Nm) Belt tensioner and torque the bolt to 37 ft. Ibs. (50 Nm) Power steering pump pulley Drive belt Underhood accessory wiring junction Coolant reservoir and torque the nuts to 30 inch Ibs. (3 Nm) Battery and tray Right diagonal brace and torque the bolts to 35 ft. Ibs. (47 Nm) @ Camshaft covers and torque the bolts to 80 inch Ibs. (9 Nm) Negative battery cable 99. Refill the engine cooling system. 30. Refill the engine with new oil. 31. Start the vehicle and check for leaks, repair if necessary.

SECONDARY TIMING CHAIN 4. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the cooling system.

93002522

Correct sprocket alignment for secondary

timing chain—3.5L engine

3. Remove or disconnect the following: e Negative battery cable e Thermostat housing for clearance (when working on the front cylinder head) e Rocker arm cover and install a Camshaft Holding Fixture e Camshaft position (CMP) sensor e Camshaft sprocket bolts 4. Install the timing chain/sprocket holding fixture on the cylinder head. 5. Evenly slide the secondary drive chain and sprockets off the camshafts. To install: 6. Install the secondary timing chain on with the drive pins at the 12 sprockets, the o'clock positions. 7. Install the sprockets/chain assembly onto the camshafts, with the chain properly aligned on the tensioner. 8. Remove the sprocket holding fixture from the cylinder head. 9. Install the sprocket bolts and torque the bolts to 18 ft. Ibs. (25 Nm) plus an additional 45 degree turn. 10. Remove the camshaft holding fixture. 11. Install or connect the following: e Rocker arm cover and torque the bolts to 80 inch Ibs. (9 Nm) ¢ Thermostat housing (if removed) and torque the bolts to 80 inch Ibs. (9 Nm) ¢ CMP sensor and torque the bolts to 80 inch Ibs. (9 Nm) e Negative battery cable 12. Refill the cooling system. 43. Start the vehicle and check for leaks, repair if necessary. 3.8L Engines 1. Before servicing the vehicle, refer to the precautions in the beginning of this section.

RRAN BRT 29-29

2. Drain the coolant system. 3. Drain the engine oil. 4. Install an Engine Support Fixture. 5. Raise the engine so that the weight is removed from the engine mount. 6. Remove or disconnect the following: Negative battery cable Accessory drive belt(s) Drive belt tensioner Crankshaft balancer Crankshaft Position (CKP) sensor shield Engine mount bracket Front oil pan-to-front cover bolts Oil filter Lower radiator hose Water pump pulley

CKP sensor Front cover 7. Rotate the crankshaft until the timing mark on the camshaft sprocket is aligned with the crankshaft sprocket timing mark. Timing chain damper assembly e Camshaft sprocket bolt e Camshaft sprocket with the timing chain e Crankshaft sprocket To install:

8. Install the crankshaft sprocket. e>|t may be necessary to use a gear installer to fully seat the gear. Be sure the timing mark on the crankshaft gear is pointing straight up.

9. Install the camshaft gear with the timing chain. «Hold the sprocket with the timing mark facing downward and the chain hanging down off the sprocket; then, loop the chain under the crankshaft : sprocket.

10. If the marks are not in alignment perform the following: a. Step 1:Remove the camshaft sprocket and timing chain. b. Step 2:Install the camshaft sprocket onto the camshaft and rotate the camshaft until the camshaft and crankshaft marks are aligned. c. Step 3:Remove the camshaft sprocket. d. Step 4:Reinstall the assembly. 41. Install or connect the following: ¢ Camshaft sprocket bolt and torque the bolt to 74 ft. lbs. (100 Nm) plus an additional 90 degree turn ¢ Timing chain damper and torque the mounting bolts to 16 ft. Ibs. (22 Nm)

manual Timing belt service is covered in Section 3 of this

29-3

GENERAL MOTORS CORPORATION—W-BODY

CENTURY ¢ REGAL ¢ IMPALA ¢ LUMINA e MONTE CARLO e INTRIGUE e GRAND PRIX

e Front cover seal lubricated with engine oil, using the appropriate seal driver New front cover gasket Front cover and torque the bolts to 15 ft. Ibs. (20 Nm) plus an additional 40 degree turn Oil pan-to-front cover bolts and torque the bolts to 125 inch Ibs. (14 Nm) CKP sensor and torque the bolts to 21 ft. Ibs. (28 Nm) CKP sensor shield Engine mount bracket and torque the bolts to 65 ft. Ibs. (87

Nm)

12. 13. 14. 15. repair

Water pump pulley and torque the bolts to 115 inch Ibs. (13 Nm) Lower radiator hose Oil filter Crankshaft balancer and torque the bolt to 111 ft. Ibs. (150 Nm) plus an additional 75 degree turn Belt tensioner and torque the bolts to 37 ft. Ibs. (60 Nm) Accessory drive belt Negative battery cable Remove the engine support fixture. Refill the cooling system. Refill the engine oil. Start the engine and check for leaks, if necessary.

(1) Flywheel Bolt Flywheel Crankshaft Rear Oil Seal Oil Pan Gasket (Includes Baffle) CEOS Gi ) Engine Oil Pan 6) Oil Level Sensor Ni) Oil Pan Bolt

) Oil Pan Drain Plug ) Wiake sure the boot lies flat against the trilobal bushing.

8. Position the CV-joint boot so it measures 4.9 in. (125mm). 9. Using the Crimp Too! J-35910, a torque wrench and a breaker bar, crimp the large CV-joint boot clamp to 130 ft. Ibs. (176 Nm). 10. Install or connect the following: e Halfshaft e Front wheel

outer race.

9306XG20

Tilting the cage—Outer CV-joint

Outer Joint

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Front wheel Halfshaft Swage ring using a hand grinder Large boot clamp, cut and discard it ¢ CV-joint boot, slide it away from the CV-joint CV-joint assembly by spreading the inner race-to-axle shaft retaining ring ears using Snapring Pliers Tool J-8059 ° CV-joint boot from the axle shaft and discard it 3. Disassemble the chrome alloy balls from the CV-joint cage as follows: a. Position a brass drift against the CV-joint cage and tap it with a hammer to tilt the cage. b. Chrome alloy ball from the cage. c. Tilt the cage in the opposite direction. d. Remove the opposite chrome alloy ball. e. Repeat the procedure until all 6 balls are removed.

c. Remove the cage from the outer race. d. Rotate the inner race upward and remove it from the cage. 5. Throughly clean and inspect all parts. To install: 6. Lubricate the parts with a light coat of grease. 7. Assemble the CV-joint cage and inner race, as follows: a. Rotate the inner race 90 degrees to the cage centerline. b. Align the cage windows with inner race lands. c. Insert the inner race into the cage by rotating the inner race downward. d. Insert the cage/inner race into the

9306XG21

View the cage and inner race—Outer CVjoint

Position edge of seal here

9306XG22

8. Assemble the chrome alloy balls into the CV-joint cage, as follows: a. Position a brass drift against the CV-joint cage and tap it with a hammer to tilt the cage. b. Insert the 1st chrome alloy ball into the cage. c. Tilt the cage in the opposite direction. d. Insert the opposite chrome alloy ball. e. Repeat the procedure until all 6 balls are inserted. 9. Install or connect the following: e 1% kit grease into the CV-joint boot e kit grease into the CV-joint ¢ Swage ring clamp e CV-joint boot ¢ C\V-joint onto the axle shaft until the retaining ring seats into the groove 10. Position the CV-joint boot seal into the axle shaft’s joint seal groove and align the swage ring clamp on the boot. 11. Secure the swage ring clamp as follows: a. Mount the lower half of tool J41048 in a vise. b. Position the outboard of the halfshaft in the tool. c. Position the upper end of tool J44048 onto the lower half.

Positioning the boot—Outer CV-joint

4. Disassemble the CV-joint cage and inner race as follows: a. Pivot the cage and race 90 degrees to the center line of the outer race. b. Align the cage windows with outer race lands.

Make sure that there are no pinch points on the inboard seal. d. Insert both bolts and tighten by hand until snug.

this manual For Accessory Drive Belt illustrations, see Section 1 of

29-38

ee

TEA

RPORATION—W-BODY

RAEAES LOIN ¢ MONTE CARLO ¢ INTRIGUE ¢ GRAND PRIX

e. Tighten each bolt 180 degree (2) turn at a time, alternating between the bolts, until both sides are bottomed. f. Remove the tool. 12. Install or connect the following: e New large seal clamp onto the CVjoint boot

e CV-joint boot/clamp, slide it into place, over the outer race with the Seal lip in the groove Make sure the boot lies flat against the outer race.

torque wrench and a breaker bar, crimp the large CV-joint boot clamp to 130 ft. Ibs. (176 Nm). 14. Install or connect the following: e Halfshaft e Front wheel

13. Using the Crimp Tool J-35910, a

STEERING AND SUSPENSION ing column. 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 the right side sound insulator. 7. Detach the CPA and yellow 2-way SIR connector at the base of the steering wheel. The passenger's side air bag is now disabled.

ARMING After necessary repairs are made, reenable the air bag system as follows: 1. Be sure the ignition is locked and the key is removed.

2. Attach the yellow 2-way Supplemental Inflatable Restraint (SIR) connector and CPA at the base of the steering wheel. 3. Install the right side sound insulator. 4. Attach the yellow 2-way SIR connector and Connector Position Assurance (CPA) at the multi-use bracket at the base of the column. 5. Install the left side sound insulator. 6. Install the AIR BAG fuse. 7. Turn the ignition switch to the RUN position and verify the AIR BAG light flashes 7 times, then shuts off.

PRECAUTIONS Several precautions must be observed when handling the inflator module to avoid accidental deployment and possible personal injury. e 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. e Place the inflator module on a bench or other surface with the bag and trim cover facing up. e With the inflator module on the bench, never place anything on or close to the module which may be thrown in the event of an accidental deployment.

CONNECTOR, SIR BRACKET, MULTIUSE MODULE CONNECTOR POSITION ASSURANCE run CONNECTOR, STEERING COLUMN WIRING HARNESS

(CPA)

7922XG21

SRS 2-way connector location—driver’s side

DISARMING 1. Turn the steering wheel so the vehicle wheels are pointing straight-ahead. 2. Turn the ignition key to the LOCK position and remove the key. 3. Remove the AIR BAG fuse from the fuse block. 4, Remove the left side sound insulator. 9. Detach the Connector Position Assurance (CPA) and yellow 2-way Supplemental Inflatable Restraint (SIR) connector at the multi-use bracket near the base of the steer-

1 MODULE, INFLATOR 2

BRACKET, MULTIUSE

3 CONNECTOR, SIR 7922XG22

SRS 2-way connector location—passenger’s side

W-BODY—GENERAL MOTORS CORPORATION. 29-39 CENTURY ¢ REGAL ¢ IMPALA ¢ LUMINA ¢ MONTE CARLO ¢ INTRIGUE ¢ GRAND PRIX Power Rack and Pinion Steering Gear

e» Set the steering shaft so that the block tooth on the upper steering shaft is at the 12 o’clock position. The wheels should be straight ahead. Set the ignition key lock to the LOCK position. Failure to follow these procedures could result in damage to the SIR coil assembly.

e Negative battery cable e Front wheels

>: CAUTION REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following:

Failure to disconnect the intermediate shaft from the rack and pinion stub shaft may result in damage to the steering gear. This damage may cause a loss of steering control and may cause personal injury.

TIE ROD ENO JAM NUT TIE ROD INNER BUSHING STUB SHAFT STEERING GEAR

3. Remove or disconnect the follow-

ing:

2)

FRAME

i

WEES

C] JA

MOUNT

WH OWFf On

9

Sy)

BOLT

10

NUT

i)

‘Seale

12 13 14 15 16

NUT COTTER PIN KNUCKLE STRUT ASSEMBLY BOLT, STEERING GEAR HEAT SHIELD SHIELD, STEERING GEAR HEAT

3

=):

J rid

3.4L ONLY

mounting Common rack and pinion steering gear

1 of this manual For Tire, Wheel and Ball Joint specifications, see Section

29-4

RATION—W-BODY

CENTURY sTEREST HEALS AURIINA ¢ MONTE CARLO ¢ INTRIGUE ¢ GRAND PRIX

e Intermediate steering shaft lower pinch bolt from the steering gear stub shaft e Intermediate steering shaft e Both tie rod ends from the steering knuckles 4. Support the frame at the center

rear. ->DO NOT lower the frame too far. Engine components near the firewall may be damaged. 5. Remove or disconnect the follow-

ing:

Frame bolts from the rear of the frame. Lower the frame slightly Power steering pressure line from the steering gear Power steering return hose Magnasteer Variable Assist electrical connector from the power steering gear assembly, if equipped Steering gear mounting bolts Power steering gear through the left wheel opening To install: 6. Install or connect the following: e Power steering gear through the left wheel opening Mounting bolts and torque them to 59 ft. Ibs. (80 Nm) Magnasteer Variable Assist electrical connector to the power Steering gear assembly, if equipped Power steering lines with new 0rings to the steering gear. Torque the fasteners to 20 ft. Ibs. (27 Nm). e Power steering return hose 7. Raise the rear frame to its original position. 8. Install or connect the following: ¢ New rear frame bolts and torque them to 133 ft. Ibs. (180 Nm) e Tie rod ends to the steering knuckles and torque the nuts to 22 ft. Ibs. (30 Nm) e Intermediate steering shaft to the steering gear stub shaft and torque the lower pinch bolt to 35 ft. Ibs. (48 Nm) e Front wheels ¢ Negative battery cable 9. Fill and bleed the power steering system. 10. Start the vehicle and check for leaks, repair if necessary. 11. Check the front end alignment and adjust as needed.

REMOVAL & INSTALLATION Front Strut

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Scribe the strut to the steering knuckle for proper installation. 3. Remove or disconnect the following: e Front wheel e Three upper strut nuts e Lower strut bolts e Strut To install: 4. Install or connect the following: e Strut e Three upper strut nuts and torque them to 30 ft. Ibs. (41 Nm) on all models except Impala or 24 ft. Ibs. (33 Nm) on Impala models. e Lower strut bolts 5. Align the strut to the scribe mark on the steering knuckle. Torque the lower bolts to 90 ft. Ibs. (123 Nm). 6. Install the front wheel. 7. Road test the vehicle and check the front end alignment, adjust if necessary. Front Strut Cartridge ~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.

> CAUTION DO NOT service the strut cartridge unless the weight of the vehicle is on the suspension. The weight of the vehicle keeps the coil spring compressed. Otherwise the released coil spring could result in personal injury. SE

SE SS

ES

ES

Sa

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Scribe the strut cover to body to assure proper camber adjustment. 3. Remove or disconnect the following: e Wheel Strut cover by removing the three cover nuts Strut shaft nut by using a No. 50 Torx® bit Strut mount insulator by prying with a flat bladed tool Strut bumper

4. Install a Strut Alignment tool in the correct position and compress the strut into the cartridge. 5. Remove or disconnect the following: e Strut closure nut by unscrewing the closure nut using a Strut Cap Nut wrench e Strut cartridge 6. Remove any oil in the strut housing using a suction pump. To install: 7. Install or connect the following: e Self-contained replacement cartridge into the strut housing e Strut cartridge closure nut and torque it to 82 ft. Ibs. (110 Nm) e Compress the shaft into the cartridge with a strut alignment tool e Strut bumper 8. Raise the strut and remove the alignment rod. ~ 9. Install the strut mount insulator as follows: a. Step 1:Use a soap solution to lubricate the bushing for ease of installation. b. Step 2:If necessary, install an alignment rod tool after the bushing is partially installed and position the strut as required to assist in the bushing installation. 10. Install or connect the following: ¢ Strut shaft nut using the No. 50 Torx® bit tighten it to 59 ft. Ibs. (80 Nm)

—_

A

NO

5TORX BIT

Strut closure nut removal 79222537

Strut shaft nut removal

79227532

Strut closure nut removal

W-BODY—GENERAL M

CENTURY © REGAL ©IMPALA ¢ LUMINA ¢ MONTE CARLOS’ INTRIGUE? GRANDPak 29-41 1

To install: 5. Install or connect the following:

e Strut e Strut to knuckle bolts and torque the bolts to 90 ft. Ibs. (122 Nm) e Stabilizer shaft link to the strut e Rear tire and wheel e Three strut to body mount nuts and torque them to 30 ft. Ibs. (41 Nm) 6. Road test the vehicle and adjust the rear wheel alignment if needed.

LUMINA

(1) Front Stabilizer Shaft Insulator Clamp Bolt/screw (2) Front Stabilizer Shaft Link Nut

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Negative battery cable e Wheel e Brake hose bracket at the strut Strut mount to body nuts Strut/stabilizer shaft bracket from the knuckle

(9) Front Stabilizer Shaft Link]

e Strut

(10) Front Lower Control Arm

To install:

(11) Front Lower Control Arm Bolt/screw

(3) Front Suspension Strut Mount Nut

(4) Front Suspension Spring

(12) Front Lower Cotrol Arm Nut

(6) Strut To Knuckle Nut

(14) Front Stabilizer Shaft Insulator

(7) Front Steering Knuckle

(16) Front Stabilizer Shaft Clamp

ae

°

(15) Front Stabilizer Shaft

(8) Strut To Knuckle Bolt/screw

;

:

3. Install or connect the following:

(13) Frame

(5) Front Suspension Strut

Strut mount-to

79221530

knuckle

Exploded view of the front suspension without replaceable strut cartridge

e Strut-to-knuckle bolts and nuts.

yuu the nuts to 82 ft. Ibs. (112 m) Brake hose bracket

© Strut cover while aligning scribe marks and torque the bolts to 24 ft. Ibs. (33 Nm)

Wheel

11. A 4-wheel alignment is recom-

-

mended after any steering/suspension

:

Coil Spring

repairs are performed. Rear Strut

REMOVAL & INSTALLATION

EXCEPT LUMINA

;

1. Before servicing the vehicle, refer to the precautions in the beginning of this sec-

tion.

2. Remove or disconnect the following:

ante Le Equipped With A Front trut Cartridge

1. Before servicing the vehicle, refer to

the precautions in the beginning of this sec-

e Negative battery cable

tion.

e Three strut to body nuts

(3) Front Spring

ice tein

.

(4) Front Spring Seat

(5) Front Suspension Strut Bumper 79222531

Knuckle and strut assembly with replaceable strut cartridge

2. Remove the strut from the vehicle.

3. Mount the strut assembly into a strut

e Rear tire and wheel

Eee

body nuts and

tighten to 37 ft. Ibs. (50 Nm) e Strut/stabilizer shaft bracket to the

° Stabilizer shaft link from the strut 3. Scribe the strut to the knuckle. The knuckle must be retained after the strut to knuckle bolts have been

compressor. Note that the strut compressor has strut mounting holes drilled for specific vehicle lines. _ 4. Compress the strut approximately “2

ball joint or drive axle if the knuckle is

Cap.

not retained.

fick WARNING

its height after initial contact with the top

removed. Damage may occur to the

f

4. Remove or disconnect the following: e Strut to knuckle bolts e Strut :

‘

: be bottom the spring or damper .

For Wheel Alignment specifications, see Section 1 of this manual

ATION—W-BODY

29-42

CENTany =WORLC IEMA LORIINA ¢ MONTE CARLO ¢ INTRIGUE ¢ GRAND PRIX ; 2 3 4 6

5

Models Equipped With A Front Strut Cartridge

7 8

=

NR

w

>

9

STRUT ASSEMBLY INSTALL LOCKING PINS THROUGH STRUT ASSEMBLY TIGHTEN NUTS UNTIL FLUSH WITH STRUT COMPRESSOR COMPRESSOR FORCING SCREW

10 7922YG24

View of a typical strut assembly mounted in a compressor

1 2 3 4 3 6 7 8 9 10

1 2 3

STRUT MOUNT NUT STRUT MOUNT RATE WASHER SPRING SEAT SPRING UPPER INSULATOR JOUNCE BUMPER STRUT DUST SHIELD SPRING SPRING LOWER INSULATOR STRUT 7922YG27

WRENCH SOCKET STRUT ASSEMBLY

forcing screw while the guiding rod centers the assembly. When the threads on the damper shaft are visible, remove the guiding rod and install the nut. tighten the nut to 63 ft. Ibs. (85 Nm) on all models except Impala models or 52 ft. Ibs. (70 Nm), for a front strut or 55 ft. Ibs. (75 Nm) (for a rear strut) 11. Remove the strut from the compresSor. 12. Install the strut to the vehicle.

Exploded view of the front strut assembly

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove the strut assembly from the vehicle.

+k CAUTION Do not over compress the coil spring. Only compress the spring until it comes away from the seat.

3. Compress the coil spring approximately Yainch (13mm) using a spring compressor. 4. Remove or disconnect the following: ¢ Strut rod nut with the proper socket while not allowing the rod to rod to rotate. Discard the nut 5. Relieve the spring tension and remove the spring. To install: ¢ Spring to the strut and make certain that the upper and lower seats are positioned correctly ¢ Strut rod nut and torque to 63 ft. lbs. (85 Nm) ° Strut

7922YG25

Use a socket and a wrench to remove the damper shaft nut spring cap while compressing the spring

J34013-27

1 2

STRUT COMPRESSOR STRUT ASSEMBLY

7922YG26

Install the rod to guide the damper shaft Straight down through the spring cap while compressing the spring

5. Remove the nut from the strut damper shaft and place an alignment/guiding rod on top of the damper shaft. Use the rod to guide the damper shaft straight down through the spring cap while compressing the spring. Remove the components. To install: 6. Mount the strut assembly in the strut compressor, using the bottom locking pin only. 7. Install the spring over the damper and swing the assembly up so the upper locking pin can be installed. 8. Install all shields, bumpers and insulators on the spring seat. 9. Install the spring seat on top of the spring. The spring seat flat should be facing the same direction as the centerline of the strut assembly spindle. 10. Install the guiding rod and turn the

Lower Ball Joint

REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove the wheel. 3. Remove the lower control arm from the vehicle. 4. Remove the ball joint from the lower contro! arm by drilling out the 4 rivets retaining the ball joint to the control arm. Use an ¥ in. drill bit to make a pilot hole through the rivets. Finish drilling the rivets using a Yin. drill bit. 9. Remove the ball joint. To install: 6. Install or connect the following:

~.

W-BODY—GENERAL MO

CENTURY ¢ REGAL ¢ IMPALA ¢ LUMINA ¢ MONTE CARLO SD RTHCUE EREATIELIK 29-43 ¢ Ball joint to the control arm ¢ Bolts with the heads facing down and torque them to 50 ft. Ibs. (68 Nm) e Lower control arm to the vehicle e Wheel eA 4-wheel alignment is recommended after any steering/suspension repairs are performed.

Lower Control Arm REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Front wheel Antilock Brake System (ABS) wheel speed sensor connector and jumper harness from the retainer

Stabilizer shaft link Cotter pin from the ball stud and loosen the nut 3. Install a ball joint removal tool over the ball joint and lower contro! arm. Rotate the ball stud nut counterclockwise to separate the ball stud from the steering knuckle. 4. Remove the lower control arm. To install: 5. Install the lower control arm and bolts. Do not tighten the nuts at this time.

models tighten the control arm-toframe nuts to 52 ft. Ibs. (70 Nm). e Front wheel

CONTROL ARM BUSHING REPLACEMENT 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. ee Remove or disconnect the following: e Front wheel e Lower control arm 3. Lubricate the threads of a bushing driver with high pressure lubricant. 4. Assemble the tool onto the control arm bushing. 5. Tighten the tool until the bushing is pressed from the control arm. 6. Disassemble the tools. To install: 7. Lubricate the new bushing outer casing. 8. Install a new bushing into the control arm. 9. Assemble a bushing driver/installer set onto the control arm.

=>Align the ball stud cotter pin hole parallel to the knuckle to ease the cotter pin installation.

6. Install or connect the following: e Ball stud to the knuckle and torque the nut to 40 ft. Ibs. (65 Nm) on Monte Carlo, Grand Prix, Century and Regal models. On Impala models, tighten to 15 ft. Ibs. (20 Nm) plus an additional 120 degrees on Impala models. On Lumina models tighten to 63 ft. lbs. (85 Nm). New cotter pin and bend the ends. Make certain the ends do not make contact with the ABS wheel speed sensor Stabilizer shaft link ABS wheel speed sensor wire harness to the retainer clips ABS wheel speed sensor connector e Lower control arm nuts and torque them to 83 ft. lbs. (113 Nm) on all models except Lumina. On Lumina

J 21474 -18

9306ZG05

Removing the bushing from the lower control arm

J 21474—-19

J 41397 -1A

9306ZG06

Installing the bushing to the lower control arm

10. Tighten the screw until the bushing is pressed into the control arm. 11. Disassemble the tools. 12. Install or connect the following: e Lower control arm e Front wheel

Wheel Bearings ADJUSTMENT The wheel bearings are not adjustable. If a wheel bearing is out of specification, it must be replaced. Using a dial indicator, check for looseness. If it exceeds 0.005 in. (0.127mm) on drum or disc brakes the bearing wear is excessive and the hub and bearing should be replaced.

REMOVAL & INSTALLATION Front

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Front wheel ¢ Wheel Speed Sensor (WSS) electrical connector e Brake caliper and bracket e Rotor e Driveshaft nut 3. Install a front hub removal tool to the wheel bearing/hub assembly with three wheel nuts. Use the tool to push the driveshaft out of the wheel bearing/hub. 4. Remove the wheel bearing/hub assembly and discard the bolts. To install: 5. Install or connect the following: Wheel bearing/hub assembly using new bolts and torque them to 96 ft. lbs. (130 Nm) New drive shaft nut and torque it to 118 ft. lbs. (160 Nm) on all except Impala models or 159 ft. Ibs. (215 Nm) on Impala models Brake.rotor Front caliper with the bracket and torque the bracket bolts to 137 ft. lbs. (185 Nm) and the caliper mounting bolts to 63 ft. Ibs. (85 Nm) e WSS electrical connector e Front wheel Rear

The rear wheel bearing/hub is integrated into one unit. The unit is non-serviceable. If the hub or bearing is damaged, the com-

this manual For Maintenance Interval recommendations, see Section 1 of

29-44

GENERAL MOTORS CORPORATION—W-BODY

CENTURY ¢ REGAL e IMPALA e LUMINA ¢ MONTE CARLO @ INTRIGUE ¢ GRAND PRIX

plete hub and bearing unit must be replaced. 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Rear wheel e Brake drum, if equipped e Rear caliper and bracket, if equipped e Brake rotor, if equipped e Antilock Brake System (ABS) Wheel

Speed Sensor (WSS) electrical connector e Rear wheel hub to knuckle bolts e Parking brake lever bracket and parking brake actuator e Rear wheel hub from the knuckle To install: 3. Install or connect the following: e Parking Brake lever bracket and actuator e Hub and bearing assembly and torque the bolts to 55 ft. Ibs. (75 Nm)

e WSS electrical connector e Brake rotor, if equipped e Brake caliper with the bracket and torque the bracket bolts to 92 ft. lbs. (125 Nm) and the caliper bolts to 32 ft. Ibs. (44 Nm), if equipped e Brake drum, if equipped e Rear wheel 4. A 4 wheel alignment is recommended after any steering/suspension repairs have been performed.

1 KNUCKLE ASSEMBLY, REAR SUSPENSION 2 HUB AND BEARING ASSEMBLY 3 BOLT/SCREW, WHEEL 79222535

:

The rear hub/bearing assembly is bolted to the knuckle

Parking brake lever bracket (1) and parking brake actuator (2)

93062623

GENERAL MOTORS CORPORATION—Y-BODY 1998-01

Chevrolet-Corvette DRIVE TRAIN.................. 30-18 ENGINE REPAIR................ 30-2 FUEL SYSTEM ................ 30-16 PRECAUTIONS.................. 30-2 STEERING AND SUSPENGSIONG: 20. ..cci. 0.5:30-28

Removal & Installation............ 30-17 Fue Pinaforecss 30-16 Removal & Installation............ 30-16 Fuel System PreSSUre ........cceeee 30-16 Relievitiqe eee ae ok 30-16 Fuel System Service

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30-23 30-23 30-23 30-23

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Intake Manifold... ccceeeeen 30-7 Removal & Installation.............. 30-7

30-22

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Removal & Installation............. 30-3

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Timing Chain, Sprockets, Front Cover and Seal..............0.. 30-13 Removal & Installation............ 30-13 Transmission Assembly ...........+. 30-18 Removal & Installation............ 30-18 TaNSVEFS@ SPFiNG....cceceeecee 30-30 Removal & poet sen 30-30

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30-2 ee

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GENERAL MOTORS CORPORATION—Y-BODY CORVETTE TERE.

ERG IS TSS

: Before servicing any vehicle, please be sure to read all of the following precautions, which deal with personal safety, prevention of component damage, and important points to take into consideration when servicing a motor vehicle: e Never open, service or drain the radiator or cooling system when the engine is hot; serious burns can occur from the steam and hot coolant. ¢ Observe all applicable safety precautions when working around fuel. Whenever servicing the fuel system, always work in a well-ventilated area. Do not allow fuel spray or vapors to come in contact with a spark, open flame or excessive heat (a hot drop light, for example). Keep a dry chemical fire extinguisher near the work area. Always keep fuel in a container specifically designed for fuel storage; also, always properly seal fuel containers to avoid the possibility of fire or explosion. Refer to the additional fuel system precautions later in this section. Fuel injection systems often remain pressurized, even after the engine has been turned OFF. The fuel system pressure must be relieved before disconnecting any fuel lines. Failure to do so may result in fire and/or personal injury. ¢ Brake fluid often contains polyglycol ethers and polyglycols. Avoid contact with the eyes and wash your hands thoroughly after handling brake fluid. If you do get brake fluid in your eyes, flush your eyes with clean, running water for 15 minutes. If

|

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Distributor All 5.7L (VIN G) engines use a Direct Ignition System.

Alternator

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PRECAUTIONS eye irritation persists, or if you have taken brake fluid internally, seek medical assistance IMMEDIATELY. e The EPA warns that prolonged contact with used engine oil may cause a number of skin disorders, including cancer! You should make every effort to minimize your exposure to used engine oil. Protective gloves should be worn when changing oll. Wash your hands and any other exposed skin areas as soon as possible after exposure to used engine oil. Soap and water, or waterless hand cleaner should be used. e All new vehicles are now 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 repairs. ¢ Always wear safety goggles when working with, or around, the air bag system. When carrying a non-deployed air bag, be sure the bag and trim cover are pointed away from your body. When placing a nondeployed air bag on a work surface, always face the bag and trim cover upward, away from the surface. This will reduce the motion of the module if it is accidentally deployed. Refer to the additional air bag system precautions later in this section. ¢ Clean, high quality brake fluid froma sealed container is essential to the safe and

ENGINE REPAIR

proper operation of the brake system. You should always buy the correct type of brake fluid for your vehicle. If the brake fluid becomes contaminated, completely flush the system with new fluid. Never reuse any brake fluid. Any brake fluid that is removed from the system should be discarded. Also, do not allow any brake fluid to come in contact with a painted surface; it will damage the paint. e Never operate the engine without the proper amount and type of engine oil: doing so WILL result in severe engine damage. e Timing belt maintenance is extremely important! Many models utilize an interference-type, non-freewheeling engine. If the timing belt breaks, the valves in the cylinder head may strike the pistons, causing potentially Serious (also time-consuming and expensive) engine damage. Refer to the maintenance interval charts in the front of this manual for the recommended replacement interval for the timing belt, and to the timing belt section for belt replacement and inspection. e Disconnecting the negative battery cable on some vehicles may interfere with the functions of the on-board computer system(s) and may require the computer to undergo a relearning process once the negative battery cable is reconnected. e When servicing drum brakes, only disassemble and assemble one side at a time, leaving the remaining side intact for reference.

‘

To install: 3. Install or connect the following: ¢ Alternator e Alternator mounting bolts and torque them to 37 ft. Ibs. (50 Nm)

e Alternator rear mounting bracket and torque the bolts to 37 ft. Ibs. (50 Nm) ¢ Drive belt ¢ Regulator connector and battery to

REMOVAL 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: ¢ Negative battery cable e¢ Regulator connector and battery to alternator terminal from the rear of the alternator Accessory drive belt Rear mounting bracket Alternator mounting bolts Alternator

AS EEL

93062624

Exploded view of the alternator—5.7L engine

Y-BODY—GENERAL MOTORS OE

VETTE

alternator terminals and torque the alternator terminal nut to 10 inch lbs. (13 Nm) e Negative battery cable

Engine Assembly REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. The following tools will be required in addition to the basic hand tools: e Transverse spring compressor and adapters e Ball joint separator e Engine support table e Driveshaft support strap e Fuel pressure gauge 2. Relieve the fuel system pressure. 3. Drain the cooling system. 4. Drain the engine oil. 5. Evacuate the A/C system. 6. Remove or disconnect the following:

Intake Air Temperature (IAT) sensor electrical connector

Mass Air Flow (MAF) sensor electrical connector Air intake duct and air cleaner Upper radiator support Radiator Electronic Brake Control Traction Module/Brake Pressure Modulator

Valve (EBTCM/BPMV) and bracket Brake pipes Accessory drive belt Fuel line from the connector at the front of the dash e>Cap and plug all openings for the fuel system to prevent contaminants from entering the system. Fuel rail covers e Fuel line at the fuel rail

Radiator hoses from the water DUMP Heater hoses from the water pump Fuel injector electrical connectors Ignition coil main harness connector

Sew

BS

Pedy E44

Chl

‘i

J 33432-A 79222602

the front transverse spring—5.7L (VIN G) Use a compressor such as J 33432-A to compress

30-3

Evaporative Emission (EVAP) solenoid electrical connector Electric throttle motor electrical connector Throttle Position Sensor (TPS) electrical connector Engine Coolant Temperature (ECT) sensor electrical connector A/C compressor electrical connec-. tor Alternator electrical connectors Alternator Brake booster vacuum hose Intermediate shaft to steering gear bolt Intermediate shaft from the steering gear Secondary Air Injection (AIR) hose from the left exhaust manifold Both front wheels Heated Oxygen (HO2S) sensor connectors from the intermediate exhaust pipes Intermediate exhaust pipes Close-out panel Starter motor electrical connectors Starter motor Oil level sensor connector Crankshaft Position (CKP) sensor electrical connector A/C compressor hose assembly Engine oil temperature sensor electrical connector Left Heated Oxygen (HO2S) sensor 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 crossmember, if equipped Electronic Variable Orifice (EVO) connector clips from the crossmember, if equipped Real Time Damping (RTD) connector clips from the crossmember, if equipped Shock absorber lower mounting bolts Front transverse leaf spring Automatic transmission cooler pipes at the flywheel housing junction Automatic transmission cooler pipe clamps from the engine oil pan Automatic transmission cooler pipe from the radiator

engine

Guide For complete service labor times, order Nichols’ Chilton Labor

30-4

GENERAL MOTORS CORPORATION—Y-BODY CORVETTE

ck CAUTION Failure to use the minimum fastener length specified will prevent the proper retention of the propeller shaft during assembly. 7. For vehicles with an automatic transmission, perform the following steps: a. Remove the two plug bolts in the driveline support assembly. b. Install an M10 x 55 bolt, or longer, in each plug location. Torque the bearing support bolts to 26 ft. Ibs. (35 Nm). 8. On vehicles with automatic transmission, remove the bell housing inspection cover, then turn the flywheel hub collar to access the bolt and loosen it. 9. Remove the engine flywheel housing access plug. 10. Rotate the automatic transmission collar so that the bolt is facing down. 11. Loosen the bolt 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. 79222603

On automatic transmission vehicles, remove the plugs from the driveline support assembly and install 2 M10 x 1.5 bolts into the plug holes

79222604

Loosen the bolt on the flywheel hub collar after turning it for access

>: CAUTION Never use a driveline support tool to support the weight of the engine assembly.

13. If equipped with a manual transmission, perform the following steps: a. Unclip the clutch actuator hose from the engine flywheel housing ctip. b. Using a hydraulic clutch line separator tool, 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. 14. Support the engine and crossmember assembly. 15. Remove or disconnect the following: Front 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 strap from the rear of the left cylinder head Engine oil pressure sensor electrical connector Camshaft Position (CMP) sensor electrical connector Manifold Absolute Pressure (MAP) sensor electrical connector

Y-BODY—GENERAL MOTORS CORPORATION CORVETTE

J 42203 79227605

Install a Driveline Support tool J 42203 to the under cover flange

e Knock Sensor (KS) electrical connector ¢ Front driveline support assembly bolts e Engine from the driveline, by placing a flat blade tool between edge of the driveline and the flywheel housing 16. Pull the engine away from the propeller shaft. 17. Raise the vehicle off of the engine and crossmember. _ 18. Remove the engine mount-to-crossmember nuts. 19. Remove the engine from the crossmember. To install: 20. Install the engine on the crossmember and torque the nuts to 40 ft. Ibs. (54 Nm). 21. Lower the vehicle onto the engine/crossmember assembly. 92. \nstall or connect the following: ¢ Power steering pump and reservoir on the engine and torque the bolts to 18 ft. Ibs. (25 Nm) e Ground strap to the rear of the left cylinder head and torque the bolt to 24 ft. Ibs. (32 Nm) e Engine oil pressure sensor electrical connector

CMP sensor electrical connector MAP sensor electrical connector KS electrical connector Install or connect the following: Front driveline support bolts and torque them to 37 ft. Ibs. (50 Nm) Air tube and bracket and torque the bolt to 37 ft. Ibs. (50 Nm) New crossmember nuts and torque them to 81 ft. Ibs. (110 Nm) Flywheel housing bolts and torque them to 37 ft. Ibs. (60 Nm) Clutch actuator hose to the flywheel housing (if equipped) Master cylinder hose to the clutch actuator hose (if equipped) Wire harness to the rear of the engine 23. Remove the driveline support tool. 24. Remove the M10 x 55mm bolts from the driveline support assembly. ¢ Two plugs in the driveline support assembly after removing the M10 x 55 bolts and torque them to 37 ft. Ibs. (50 Nm) e Automatic transmission oil cooler pipes at the flywheel housing junction and torque them to 20 ft. Ibs. (27 Nm) (if equipped) e Automatic transmission cooler pipes to the front and rear of the oil pan

Please visit our web site at www.chiltonsonline.com

30-9

Front transverse spring and torque the bolts to 46 ft. Ibs. (62 Nm) Shock absorber lower mounting nuts and torque them to 21 ft. Ibs. (28 Nm) Front stabilizer shaft and torque the bolts to 53 ft. Ibs. (72 Nm) ABS electrical connector EVO electrical connector RTD electrical connector Tie rods to the steering knuckle and - torque the nuts to 33 ft. Ibs. (45 Nm). Radiator Cooling fan assembly to the radiator and attach the electrical connectors to the fans Ground wires to the left side of the engine HO2S sensor connectors Engine oil temperature sensor connector A/C compressor hoses to the compressor A/C compressor line retaining bolt and torque it to 26 ft. Ibs. (35 Nm) CKP sensor electrical connector Oil level sensor electrical connector Wire harness ground wires to the right side of the engine Starter motor and torque the bolts to 37 ft. Ibs. (50 Nm) Driveline close out panel and torque the bolts to 106 inch Ibs. (12 Nm) Intermediate exhaust pipe and hangers and torque the bolts to 37 ft. Ibs. (560 Nm) and the nuts to 15 ft. Ibs. (20 Nm) Front wheels Automatic transmission cooler pipes to the radiator (if equipped) and torque the fittings to 26 ft. Ibs. (35 Nm) AIR hose to the left exhaust manifold Intermediate steering shaft to the steering gear and torque the bolt to 35 ft. Ibs. (48 Nm) Brake booster vacuum hose Alternator bracket and torque the bolts to 37 ft. Ibs. (50 Nm) Alternator and torque the bolts to 37 ft. Ibs. (60 Nm) Alternator connectors and torque the nuts to 10 ft. Ibs. (13 Nm) Fuel injector electrical connectors Ignition coil main electrical connectors

30-6

GENERAL MOTORS CORPORATION—Y-BODY CORVETTE

EVAP solenoid electrical connectors Throttle motor electrical connector ECT sensor electrical connector TPS electrical connector A/C compressor electrical connector Heater hoses to the water pump Radiator hoses to the water pump Fuel line to the fuel rail Fuel rail covers Drive belt EBTCM/BPMV bracket and torque the bolts to 20 ft. Ibs. (27 Nm) EBTCM/BPMV to the bracket and torque the nuts to 89 inch Ibs. (10 Nm) Upper radiator hose Upper radiator support Air cleaner and air intake duct IAT sensor electrical connector MAF sensor electrical connector Negative battery cable 25. Fill the engine with new oil. 26. Fill the cooling system. 2/7. Evacuate and recharge the A/C system. 28. On vehicles with an automatic transmission, start the engine and allow it to idle for 10 minutes. Torque the hub collar bolt to 96 ft. Ibs. (130 Nm) and install the flywheel inspection plug. 29. A wheel alignment is recommended when the engine and crossmember have been removed from the vehicle. 30. Check the vehicle for leaks and repair if necessary.

Water Pump REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the cooling system. 3. Remove or disconnect the following: ¢ Negative battery cable e Intake Air Temperature (IAT) sensor electrical connector Mass Air Flow (MAF) sensor electrical connector e Air intake duct Accessory drive belt e Inlet and outlet hoses from the water pump e Heater hoses from the water pump ¢ Water pump pulley bolts and pulley (if equipped) Six water pump retaining bolts Water pump

79222608

Exploded view of the water pump mounting assembly—5.7L engine

To install: 4. Install or connect the following: New gasket with the tabs facing up Water pump. Torque the bolts to 11 ft. lbs. (15 Nm) and then to 22 ft. lbs. (30 Nm). Water pump pulley (if equipped). Torque the bolts to 89 inch Ibs. (10 Nm) and then to 18 ft. Ibs. (25 Nm). Heater hoses to the water pump Radiator inlet and outlet hoses to the water pump Accessory drive belt Air intake duct MAF sensor electrical connector IAT sensor electrical connector Negative battery cable 9. Fill the cooling system. 6. Start the vehicle and check for leaks, repair if necessary.

Cylinder Head REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the engine coolant. 3. Relieve the fuel system pressure. 4. Remove or disconnect the following: ¢ Negative battery cable ¢ Rocker arm cover ¢ Exhaust manifold from the cylinder head Intake manifold Vapor vent pipe Power steering pump pulley, if removing the left side

¢ Power steering pump and reposition it, if removing the left side ¢ Power steering pump bracket, if removing the left side e Ground wire bolt from the rear of the cylinder head, if removing the left side e Cylinder head To install: e>New M11 cylinder head bolts must be used when installing the cylinder head assembly.

5. Install the new cylinder head gasket onto the locating pins. 6. Place the cylinder head on the engine and tighten the bolts in sequence to:

a. M11 bolts: 22 ft. Ibs. (30 Nm). b. M11 bolts: plus 90 degrees. C. M11 bolts 1-8: plus 90 degrees. d. M11 bolts 9-10: plus 50 degrees. e. M8 bolts (11-15): 22 ft. Ibs. (30 Nm). 7. Install or connect the following: Ground wire to the rear of the cylinder head and torque the bolt to 24 ft. Ibs. (32 Nm), if removed Power steering pump bracket and torque the bolts to 37 ft. Ibs. (50 Nm) , if removed Power steering pump and torque the bolts to 18 ft. Ibs. (25 Nm), if removed Power steering pump pulley, if removed Exhaust manifold and torque the

bolts, in sequence, to 11 ft. Ibs. (15 Nm), then to 18 ft. Ibs. (25 Nm) Valve rocker arm cover and torque

>

Y-BODY—GENERAL MOTORS SLE.

OR VETTE

30-7

9. With the engine in this position, tighten the exhaust valve rocker arm bolts on cylinders No. 1, 2, 7 and 8 to 22 ft. Ibs. (30 Nm), then, tighten the intake valve rocker arm bolts on cylinders No. 1, 3, 4 and 5 to 22 ft. Ibs. (30 Nm). 10. Rotate the crankshaft 1 revolution (360 degrees). 11. With the engine in this position, tighten the exhaust valve rocker arm bolts on cylinders No. 3, 4, 5 and 6 to 22 ft. Ibs. (30 Nm), then, tighten the intake valve rocker arm bolts on cylinders No. 2, 6, 7 and 8 to 22 ft. Ibs. (30 Nm). 12. Install the rocker arm cover using a new gasket and torque the bolts to 106 inch lbs. (12 Nm). 13. Negative battery cable. 14. Start the vehicle and check for leaks, repair if necessary.

‘Intake Manifold 79222611

—

REMOVAL & INSTALLATION

Be sure the tab on the edge of the gasket is closer to the front of the engine when installed

12

>The intake manifold, throttle body, fuel injectors and rail may be removed from the engine as an assembly.

14

79222612

Cylinder head bolt torque sequence—5.7L engine

the bolts to 106 inch Ibs. (12 Nm) e Intake manifold and torque the bolts in sequence to 44 inch Ibs. (5 Nm) then to 89 inch Ibs. 910 Nr) vent pipe and torque the bolt Vapor e to 106 inch Ibs. (12 Nm) e Negative battery cable 8. Fill the cooling system. 9. Start the vehicle and check for leaks, repair if necessary.

Rocker Arms — REMOVAL & INSTALLATION

a

=>Aiways keep the rocker arms and pushrods in order so they can he installed in their original positions. 1. Before servicing the vehicle, refer to

the precautions in the beginning of this section. 2. Relieve the fuel system pressure. 3. Remove or disconnect the following: e Rocker arm cover e Rocker arm ¢ Rocker arm, push rods and pedestals e Rocker arm pivot support, if necesSary To install: 4. \f removed, install the rocker arm pivot support. 5. Lubricate the rocker arms and pushrods with clean engine oil. 6. Lubricate the flange and washer surface of the rocker arm mounting bolts. 7. Install the rocker arms but do not tighten the bolts at this time. 8. Rotate the crankshaft so the No. 1 piston is at Top Dead Center (TDC).

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the cooling system. 3. Relieve the fuel system pressure. 4. Remove or disconnect the following: Intake Air Temperature (IAT) sensor electrical connector Mass Air Flow (MAF) sensor electrical connector Air intake duct Fuel line from the fuel rail Vacuum ventilation hose Fuel injector electrical connectors Throttle Position Sensor (TPS) electrical connector Knock Sensor (KS) connector KS jumper pigtail from the fuel rail stop bracket Positive Crankcase Ventilation (PCV) valve pipes from the rocker arm covers PCV tube from the throttle body Engine cooling air bleed hose from the throttle body Throttle body heater outlet hose e |ntake manifold and fuel stop bracket To install: 5. Apply a 0.20 in. (5mm) bead of threadlock to the threads of the intake manifold bolts.

Timing belt service is covered in Section 3 of this manual

30-8

GENERAL MOTORS CORPORATION—Y-BODY CORVETTE

9346ZGB1

Intake manifold torque sequence—d.7L engine

> CAUTION The fuel rail stop bracket must be installed on the intake manifold in its original position. Failure to reinstall this part may result in fuel spray Causing personal injury.

6. Install or connect the following: e Intake manifold with a new gasket e Fuel stop bracket e Intake manifold bolts and torque the bolts first to 44 inch Ibs. (5 Nm) in the sequence shown, then

make a second pass and tighten the bolts to 89 inch Ibs. (10 Nm) Throttle body heater outlet hose Engine coolant air bleed hose PCV tube PCV valve pipes KS sensor jumper pigtail KS electrical connector TPS electrical connector Fuel injector electrical connectors Vacuum vent hose Fuel line Air intake duct IAT sensor electrical connector MAF sensor electrical connector Negative battery cable 7. Fill the cooling system. 8. Start the vehicle and check for leaks, repair if necessary.

Exhaust Manifold

REMOVAL & INSTALLATION Left Side 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Relieve the fuel system pressure. 3. Remove or disconnect the following:

Negative battery cable e Left hand intermediate pipe flange nuts from the exhaust manifold studs Heated Oxygen (HO2S) sensor Alternator electrical connector Engine Coolant Temperature (ECT) sensor electrical connector Accessory drive belt Alternator Secondary Air Injection (AIR) hose from the check valve AIR pipe from the exhaust manifold and reposition it AIR pipe retainer from the rear of the cylinder head and reposition it e Spark plug wires e Spark plugs . e Exhaust manifold To install: 4. Apply threadlock to the threads of the bolts. 5. Install the exhaust manifold using a new gasket. 6. Beginning with the center 2 bolts, torque the bolts to 11 ft. Ibs. (15 Nm) alternating from side-to-side until all the bolts are tight. Torque the bolts again in the same sequence to 18 ft. Ibs. (25 Nm). 7. Bend over the exposed portion of the gasket at the rear of the cylinder head. 8. Install or connect the following: Spark plugs and torque them to 11 ft. Ibs. (15 Nm) Spark plug wires AIR pipe retainer bolt to the rear of the cylinder head and torque the bolt to 15 ft. Ibs. (20 Nm) AIR pipe with a new gasket and torque the bolts to 15 ft. Ibs. (20 Nm) AIR hose to the check valve and torque it to 15 ft. Ibs. (20 Nm) Alternator and torque the bolts to 37 ft. Ibs. (50 Nm) Accessory drive belt Alternator electrical connector ECT sensor electrical connectors HO2S sensor and torque it to 30 ft. lbs. (42 Nm) Fuel lines Intermediate pipe flange-to-exhaust manifold nuts and torque them to 15 ft. Ibs. (20 Nm) Negative battery cable 9. Start the vehicle and check for leaks, repair if necessary.

Right Side 79227613

Be sure to reinstall the fuel stop bracket when installing the intake manifold

1. Before servicing the vehicle, refer to the precautions in the beginning of this section.

Y-BODY—GENERAL MOTORS CORPORATION CORVETTE

30-9

e AIR pipe using a new gasket and torque the bolts to 15 ft. Ibs. (20 Nm) :

e HOS sensor in the manifold and torque it to 30 ft. Ibs. (42 Nm) e Intermediate pipe flange-to-exhaust manifold nuts and torque them to

15 ft. Ibs. (20 Nm) e Negative battery cable 8. Start the vehicle and check for leaks, repair if necessary.

REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the cooling system. 3. Relieve the fuel system pressure. 4. Remove or disconnect the following: Fuel lines from the fuel rail Rocker arm covers Rocker arms and pushrods Both cylinder heads Valve lifter guides and the lifters Radiator

93062625

Exploded view of the exhaust manifold—5.7L engine

2. Remove or disconnect the following: e Negative battery cable e Right side intermediate exhaust pipe nuts from the manifold studs Heated Oxygen (HO2S) sensor Secondary Air Injection (AIR) pipe from the exhaust manifold Spark plug wires Spark plugs Oil level indicator and tube Exhaust manifold To install: 3. Apply threadlock to the threads of the bolts. 4. Install the exhaust manifold using a new gasket. 5. Beginning with the center 2 bolts, tighten the bolts to 11 ft. Ibs. (15 Nm) alternating from side-to-side until all the bolts are tight. Then, tighten the bolts again in the same sequence to 18 ft. Ibs. (25 Nm). 6. Bend over the exposed portion of the gasket at the rear of the cylinder head. 7. Install or connect the following: Oil Jevel indicator tube and torque

=

the bolt to 12 ft. Ibs. (16 Nm)

e Spark plugs and torque them to 11 ft. Ibs. (15 Nm) e Spark plug wires

handle Install three M8—-1.25 x 100mm long bolts into the camshaft to use as a

Heater Core replacement is covered in Section 2 of this manual

ae

30-1 0 GENERAL MOTORS CORPORATION—Y-BODY CORVETTE

pS

e e e e e

Engine front cover Oil pan Oil pump Camshaft sprocket and timing chain Camshaft Position (CMP) sensor bolt and sensor e Camshaft retainer plate

All camshaft bearings are the same diameter, extreme care must be taken during camshaft removal or installation to avoid damaging them. 5. Install 3 M8 x 100mm long bolts in the front of the camshaft to use as a handle. 6. Carefully remove the camshaft from the engine, be sure not to damage the camshaft bearings. To install: 7. Lubricate the camshaft with clean engine oil. 8. Install or connect the following: Three M8-1.25 x 100mm long bolts in the front of the camshaft to use as a handle Camshaft into the engine and remove the 3 bolts Camshaft retainer using a new gasket and torque the bolts to 18 ft. lbs. (25 Nm) CMP sensor with a new O-ring and torque the bolt to 18 ft. Ibs. (25 Nm) Timing chain and sprocket and torque the sprocket bolts to 26 ft. lbs. (35 Nm) Oil pump and torque the bolts to 18 ft. Ibs. (25 Nm) Oil pan with a new gasket and torque the bolts pan-to-rear cover bolts to 106 inch Ibs. (12 Nm) and the remaining bolts to 18 ff. Ibs. (25 Nm) ¢ Front cover with a new gasket and torque the bolts to 18 ft. Ibs. (25 Nm) ¢ Radiator ¢ Valve lifters and lifter guides and torque the bolts to 106 inch Ibs. (12 Nm) e Cylinder heads Pushrods and rocker arms ¢ Rocker arm covers with new gaskets and torque the bolts to 106 inch Ibs. (12 Nm) Fuel lines to the fuel rail ¢ Negative battery cable 9. Refill the cooling system. 10. Start the engine and check for leaks, repair if necessary.

Valve Lash

fold nuts to 15 ft. Ibs. (20 Nm) and all other bolts to 37 ft. Ibs. (50 Nm)

:

e Negative battery cable

ADJUSTMENT The rocker arms on the 5.7L (VIN G) engine are bolted into position so that no adjustment is possible. If the valves are noisy, suspect low oil pressure or worn valve train components. polis

REMOVAL & INSTALLATION

REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the engine oil. 3. Remove disconnect Secativéor Baty cible the following:

om 1. Before servicing the vehicle, refer to the precautions in the beginning of this sec-

Alternator Washer reservoir Engine Coolant Temperature (ECT)

tion.

sensor electrical connector

|

2. Removeor disconnect the following:

Headlamp electrical connector

Negative battery cable

Tie rods from the steering linkage

Dae electrical connectors Starter Starter bolts . Starter motor To install:

Damping (RTD) sensor Real if equipped links,Time

3. Install or connect the following: e Starter motor and torque the bolts to 37 ft. Ibs. (50 Nm) e Starter electrical connectors e Intermediate exhaust pipe and torque intermediate pipe-to-mani-

e Stabilizer shaft e Intermediate shaft from the steering gear Electronic Brake Control Module/Brake Pressure Modulator

Valve (EBCM/BPMV) bracket and reposition Power steering gear

93062626

Exploded view of the starter assembly—5.7L engine

Y-BODY—GENERAL MOTORS CORPORATION CORVETTE

30-11

93462G01

Separate the upper (1) and lower (3) oil

pans

e Lower shock absorber mounting bolts Transverse leaf spring using a suitable compressor Lower control arm bolts from the Suspension crossmember Engine mount lower nuts Wheel Speed Sensor (WSS) wiring harness from the crossmember e Brake line from the crossmember 4. Support the suspension crossmember. e Crossmember mounting nuts e Front crossmember e Oil filter Automatic transmission cooler line front and rear retaining clamp bolts (if equipped) Engine flywheel housing-to-oil pan bolts Engine flywheel close out bolts Engine oil level sensor Engine oil temperature sensor electrical connector Oil pan assembly « Lower oil pan bolts and separate the pans (if necessary)

79222629

Apply seatant to the areas where the front and rear covers attach to the engine block—5.7L engine

=>To remove the oil pan gasket it is necessary to drill out 3 rivets securing it to the pan.

To install: 5. If separated, connect the upper and lower oil pans with a new gasket and torque the bolts to 106 inch Ibs. (12 Nm). 6. Apply 20.20 in. (5mm) bead of RIV sealant directly on the tabs of the front and rear cover gaskets that extend onto the oil pan mounting surface. 7. Install or connect the following: ¢ New gasket on the oil pan. It is not necessary to rivet the new gasket on the oil pan.

79222630

Exploded view of the oil pan mounting—5.7L engine

Brake service is covered in Section 4 of this manual

30-1 2 GENERAL MOTORS CORPORATION—Y-BODY CORVETTE

e Qil pan and hand tighten the bolts e Oil pan-to-engine bolts and torque them to 18 ft. Ibs. (25 Nm) e Oil pan-to-front cover bolts and torque them to 18ft. Ibs. (25 Nm) e (il pan-to-rear cover bolts and torque them to 106 inch Ibs. (12 Nm) e Flywheel housing bolts and torque them to 37 ft. Ibs. (50 Nm)

Left and right close outs and bolts and torque the bolts to 106 inch Ibs. (12 Nm)

¢ Front headlamp electrical connector ¢ Negative battery cable 9. Fill the engine with new oil. 10. Start the vehicle and check for leaks, repair if necessary. 11. Check and adjust the front end alignment. 12. Torque the lower control arm bolts to 125 ft. Ibs. (170 Nm).

,

|

ROW PUNIBS (og ES

F eis sensor and torque it to 26 ft. Ibs. (35 Nm)

1. Before servicing the vehicle, refer tothe precautions in the beginning of this section.

¢ Automatic transmission cooler pipe front retaining clamp bolt and torque it to 106 inch Ibs. (12 Nm) ¢ Automatic transmission cooler pipe rear retaining clamp bolt and

2. Drain the engine oll. 3. Drain the cooling system. Baht 4. Removeordisconnect a CHT ‘ ee battery cable * Engine front cover

Deo and the nut to 18 ft. Ibs.

Se

torque it to 22 inch Ibs. (3 Nm) Oil filter and torque it to 22 ft. Ibs. (30 Nm) Oil drain plug and torque it to 18 ft. lbs. (25 Nm) 8. Raise the suspension crossmember into position. e Crossmember mounting nuts and torque them to 81 ft. Ibs. (110 Nm) Engine mount lower nuts and torque them to 48 ft. Ibs. (65 Nm) WSS wiring harness to the crossmember Brake line to the crossmember Transverse leaf spring

m

© Oil pan ° Engine front cover

6. 7. 8. repair

+ Negative battery cable Fill the engine with new oil. Fill the cooling system. Start the vehicle and check for leaks, if necessary.

\

Lower control arm to the cross-

b

member, DO NOT torque the bolts at this time

Lower shock absorber mounting

e

bolts and torque them to 21 ft. Ibs. (28 Nm) Power steering gear and torque the bolts to 74 ft. Ibs. (100 Nm) EBCM/BPMV bracket and torque the bolts to 20 ft. Ibs. (27 Nm) Intermediate shaft and torque the pinch bolt to 25 ft. Ibs. (35 Nm) Outer tie rods and torque the nuts to 18 ft. Ibs. (25 Nm) plus an additional 180 degree turn RTD sensor electrical connector, if equipped Stabilizer shaft and torque the link nuts to 53 ft. Ibs. (72 Nm) and the Clamp bolts to 43 ft. Ibs. (58 Nm) Alternator and torque the bolts to 37 ft. Ibs. (50 Nm) Washer reservoir and torque the

nuts to 66 inch Ibs. (7.5 Nm)

ECT sensor electrical connector

|

¢ Oil pump screen with a new O-ring and torque the bolt to 106 inch Ibs.

¢ Engine oil temperature sensor elec-

ay pheee eos

¢ Oil pan “ Oil pump screen : Oil pump To install: O Install or connect the following: ¢ Oil pump and torque the bolts to 18 ft. Ibs. (25 Nm) Be sure the crankshaft sprocket and oil pump drive gear are aligned properly.

sera}

ee: Oil pump assembly mounting—5.7L engine

or

Y-BODY—GENERAL MOTORS CORPORATION

CORVETTE

3 0 -1 3

Rear Main Seal

REMOVAL & INSTALLATION e>The rear main seal is a 1-piece unit. It can be removed or installed without removing the oil pan or crankshaft.

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Transmission

e Clutch and pressure plate, if equipped with a manual transmission e Flywheel inspection cover e Flywheel 3. Using a pry tool, carefully pry the old seal out. 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 oil. 6. Install or connect the following: e Seal, using a seal installer e Flywheel and torque the bolts in sequence to 15 ft. Ibs. (20 Nm) then to 37 ft. Ibs. (50 Nm) and finally to 74 ft. Ibs. (100 Nm) ¢ Flywheel inspection cover and torque the bolts 18 ft. Ibs. (25 Nm)

9346ZG02

Flywheel torque sequence

e Clutch and pressure plate if equipped with a manual transmission e Transmission 7. Start the vehicle and check for leaks,

repair if necessary.

Timing Chain, Sprockets, Front Cover and Seal REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the cooling system. 3. Drain the engine oil. 4. Remove or disconnect the following: e Negative battery cable e Engine front cover e Oil pan ¢ Oil pump 5. Rotate the crankshaft until the timing marks are aligned. The marks should face each other. Remove the camshaft sprocket bolts.

Installer

->Do not turn the crankshaft after the timing chain has been removed. Damage to the pistons or valves may occur.

79222634

the crankshaft Use a seal installer to press the seal on

6. Remove or disconnect the following: e Camshaft sprocket and timing chain e Crankshaft sprocket using a suitable puller To install: 7. Be sure the timing mark on the crankshaft sprocket is at the 12 o'clock position. If not rotate the crankshaft to the correct position.

manual For complete Engine Mechanical specifications, see Section 1 of this

30-1 4 GENERAL MOTORS CORPORATION—Y-BODY CORVETTE

J 41558

J 41816 —2

J 8433-1 79222638

A puller is needed to remove the crankshaft sprocket

8. Install or connect the following: Crankshaft sprocket with a Crankshaft Balancer and Sprocket Installer tool Timing chain on the camshaft sprocket. Timing chain and sprocket assembly so the timing marks are aligned and torque the camshaft sprocket bolts to 26 ft. Ibs. (35 Nm) Oil pump and torque the bolts to 18 ft. Ibs. (25 Nm) Oil pan with a new gasket Front cover with a new gasket and seal and hand tighten the bolts at this time 9. Install the oil pan to cover bolts and hand-tighten them at this time. Make certain that the front cover is properly aligned and torque the oil pan-to-front cover bolts to 18 ft. Ibs. (25 Nm) then the remaining bolts to 18 ft. Ibs. (25 Nm). 10. Connect the negative battery cable. 11. Fill the cooling system. 12. Fill the engine with new oil. 13. Start the vehicle and check for leaks, repair if necessary.

J 41665—1 93462GB2

Timing chain alignment—5.7L engine

79227639

Be sure to install the crankshaft sprocket properly

Y-BODY—GENERAL MOTORS CORPORATI

Savors 30-1 5

Piston and Ring

—

Q

Ga

POSITIONING

ENGINE RIGHT

ENGINE FRONT

ENGINE LEFT Pesmncmms emai

C cornea

a=

AD

B omen

esse

2. Upper compression piston ring

A. Oil ring spacer gap

3. Lower compression piston ring

B. Oil ring rail gaps

C ond ehd

4. Oil contro! piston ring .

.

.

°

5. Oil control ring spring w/spacer

relerin

compression

D. Top Seo

a

a

ee

7922AG43

7922AG42

Piston ring positioning—5.7L engine

Piston ring end-gap spacing—5.7L engine

WOTE: LARGE CHAMFERS ON CONNECTING RODS MUST FACE CRANKSHAFT COUNTERWEIGHTS.

1, 2. 3. 4. 5. 6. 7.

Piston Connecting Connecting Connecting Connecting Connecting Crankshatt

rod LH

rod rod rod rod

bearing RH bearing cap bearing cap bolt 7922AG44

engine Piston and connecting rod positioning—5.7L

For Accessory Drive Belt illustrations, see Section 1 of this manual

30-1 6 GENERAL MOTORS CORPORATION—Y-BODY CORVETTE

ue

Fuel System Service Precautions Safety is the most important factor when performing not only fuel system maintenance but any type of maintenance. Failure to conduct maintenance and repairs in a Safe manner may result in serious personal injury or death. Maintenance and testing of the vehicle's fuel system components can be accomplished safely and effectively by adhering to the following rules and guidelines. e To avoid the possibility of fire and personal injury, always disconnect the negative battery cable unless the repair or test procedure requires that battery voltage be applied. e Always relieve the fuel system pressure prior to disconnecting any fuel system component (injector, fuel rail, pressure regulator, etc.), fitting or fuel line connection. Exercise extreme caution whenever relieving fuel system pressure, to avoid exposing skin, face and eyes to fuel spray. Please be advised that fuel under pressure may penetrate the skin or any part of the body that it contacts. e Always place a shop towel or cloth around the fitting or connection prior to loosening to absorb any excess fuel due to spillage. Ensure that all fuel spillage (should it occur) is quickly removed from engine surfaces. Ensure that all fuel soaked cloths or towels are deposited into a suitable waste container. ¢ Always keep a dry chemical (Class B) fire extinguisher near the work area. ¢ Do not allow fuel spray or fuel vapors to come into contact with a spark or open flame. e Always use a back-up wrench when loosening and tightening fuel line connection fittings. This will prevent unnecessary Stress and torsion to fuel line piping. Always follow the proper torque specifications. ¢ Always replace worn fuel fitting Orings with new. Do not substitute fuel hose or equivalent, 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. Disconnect the negative battery cable. 3. Loosen the fuel filler cap to relieve the tank pressure.

4. Remove the left fuel rail cover. 5. Wrap a shop towel around the fuel pressure valve fitting (located on the side or end of the fuel rail assembly) to catch any fuel spray and connect a fuel pressure gauge. 6. Place the bleed hose into a suitable container, then open the valve to bleed the fuel system pressure. 7. Close the valve and disconnect the fuel gauge. Drain any remaining fuel from the gauge into the bleed container.

REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Relieve the fuel system pressure. 3. Clean the filter connections, then depress the locking tabs and detach the quick-connect fittings from the filter. 4. Remove or disconnect the following: Rear stabilizer bar from the rear cradle Intermediate pipe-to-muffler bolts and lower the left muffler Fuel feed and return quick connect fittings from the fuel filter Fuel filter/pressure regulator bracket mount nut Fuel feed pipe from the outlet side of the fuel filter/pressure regulator Fuel filter/pressure regulator and bracket Fuel system ground strap ¢ Fuel filter/pressure regulator from the bracket To install: 9. Install or connect the following: New plastic quick connector retainers on the inlet and outlet tubes e Fuel filter/pressure regulator into the bracket e mE= fq>) system ground strap e Fuel feed pipe to the outlet side of the fuel filter/pressure regulator ¢ Fuel filter/pressure regulator and bracket to the mounting stud and torque the nut to 40 inch Ibs. (4.5 ¢ Fuel return and feed quick connect fittings Muffler and torque the hanger nuts to 12 ft. Ibs. (16 Nm) and the intermediate pipe bolts to 37 ft. Ibs. (50 Nm)

e Stabilizer shaft and torque the nuts to 70 ft. Ibs. (95 Nm) 6. Connect the negative battery cable. 7. Turn the ignition switch ON for 2 seconds, then OFF for 10 seconds. Turn the ignition switch back ON and inspect for leaks.

REMOVAL & INSTALLATION These models have 2 fuel tanks (right and left). The fuel pump is part of the fuel sender assembly in the left fuel tank. The right fuel tank contains a fuel sender assembly with a siphon jet pump which supplies fuel to the left tank through the fuel sender feed pipe. Although there are 2 sending units, the removal and installation procedure is the same for both. 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Properly relieve the fuel system pressure. 3. Drain the fuel tank(s). 4. Remove or disconnect the following: e Both rear wheels e Fuel tank shield(s) 5. Clean.the area around the fuel sender assembly. 6. Mark each fuel line to help identify them during installation. 7. Remove or disconnect the following: Quick connect fittings from the fuel sender Fuel sender electrical connector Fuel tank strap and properly support the fuel tank Fuel sender attaching bolts and discard them

93462G03

These models have 2 fuel tanks connected by a fuel sender feed pipe

Y-BODY—GENERAL MOTORS CORPORATION

CORVETTE

3 0 -1 T

¢ Float arm retaining clip and the float arm (left side sender only) ¢ Fuel sender and gasket To install: e» Always install a new fuel strainer before installing the fuel sender assembly. A strainer that has been exposed to fuel will not unfold completely and may interfere with the full travel of the float arm.

8. Install a new gasket on the fuel sender.

Do not damage the float arm during installation. 9. Fold the long strainer over itself and hold the strainer in this position. 10. Pinch both strainers upward toward each other. 11. Install the float arm through the fuel tank opening with the folded strainers. ->It may be necessary to rotate the sender for proper installation.

12. Look into the fuel tank opening and make certain that the long strainer is visible. If it is not visible, rotate the fuel sender until the strainer is free 13. Align the fuel sender gasket tab with the fuel sender cover mark and align the cover mark with the fuel tank mark. 14. Install the new break away head attaching bolts to the fuel sender and hand tighten them.

79227641

Tighten the fuel pump mounting bolts in the sequence shown—5.7L engine

"2 CAUTION - The upper hex head portion of the fuel sender attaching bolts is designed to shear off the lower section of the bolt when the proper torque is reached. Do not tighten the bolts after the head is sheared off.

15. Tighten the new break away attaching bolts in sequence until the hex head shears off of the lower section. 16. Install or connect the following: Fuel feed and return pipes Fuel sender electrical connector Fuel tank strap and torque the boits to 18 ft. Ibs. (25 Nm) Fuel tank shield and torque the bolts to 18 ft. Ibs. (25 Nm) Both rear wheels Negative battery cable

79222640

Fold the strainer on itself 3 times so it will fit into the opening in the fuel tank

17. Fill the fuel tank and install the fuel filler cap. 18. Turn the ignition ON for 2 seconds, OFF for 10 seconds, then ON again and inspect the system for leaks.

Fuel Injector REMOVAL & INSTALLATION ee

1. Before servicing the vehicle, refer to the precautions in the beginning of this section.

2. Relieve the fuel system pressure. 3. Remove or disconnect the following: e Both fuel rail covers e Fuel feed hose from the fuel rail ¢ Fuel injector electrical connectors ¢ Fuel rail mounting bolts e Fuel rail 4. Spread the injector clip to release the injector from the fuel rail. 5. Fuel injector by spreading the retaining clip.

For Tire, Wheel and Ball Joint specifications, see Section 1 of this manual

30-1 8 GENERAL MOTORS CORPORATION—Y-BODY CORVETTE

To install:

->The fuel injector is stamped with a part number identification, manufacturing date, week code and plant number. Make certain the correct injector is ordered when replacing them.

6. Lubricate the new injector seals with clean oil. 7. Install or connect the following: e New O-ring seals on the injectors e New retainer clip on the injector

|

e Fuel injector into the fuel rail socket

2 CAUTION The fuel rail stop bracket must be installed onto the engine. The bracket serves as protection for the fuel rail in the event of a frontal crash. If the bracket is not installed, fuel could spray possibly causing a fire and personal injury.

Fuel rail and ground strap to the intake manifold and torque the fuel rail attaching bolts to 89 inch Ibs. (10 Nm) Electrical connectors to the injectors Fuel feed hose to the fuel rail Negative battery cable Left and right fuel rail covers 8. Turn the ignition ON for 2 seconds, OFF for 10 seconds, then ON again and inspect the system for leaks.

DRIVE TRAIN

Transmission Assembly REMOVAL & INSTALLATION

e Right side muffler and tie the left side muffler to the underbody e Driveline tunnel closeout panel e Rear bell housing access plug and matchmark the flexplate to the torque converter

Automatic

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Disconnect the negative battery cable. 3. Shift the transmission into N. 4, Remove or disconnect the following: e Rear wheels e Intermediate exhaust pipe

e Flexplate-to-torque converter bolts e 2 plug bolts from the front of the driveline support assembly 5. Install two M10 x 1.5 x 55mm or longer bolts into the bolt holes. Torque the bolts to 26 ft. Ibs. (85 Nm). These bolts must remain installed until instructed to remove them in order to maintain the position of the input shaft bearing.

6. Remove or disconnect the following: Engine flywheel housing access lu Propeller shaft hub clamp bolt e Shift cable bracket nuts e Shift control cable from the shift lever Rear transverse spring and support the lower control arms e Outer tie rod ends from the knuckle e Shock absorber lower mounting bolts Lower ball joints from the knuckles 7. Install a transmission support fixture to the transmission. e Wiring harness and brake pipe clip retainers from the rear crossmember Lower transmission-to-differential nut Transaxle mount-to-rear cross-

o>

>

member nut Rear crossmember retaining nuts while supporting the crossmember Crossmember e Transaxle mount bracket 8. Separate the axle shafts from the differential and tie them to the underbody. 9. Release the retainer securing the wiring harness from the “L” shaped brackets along the driveline support and move the harness out of the way. 10. Lower the driveline slightly and tilt it to gain access to the electrical connectors.

11. Remove or disconnect the following: Vehicle Speed Sensor (VSS) electrical connector Wire harness retainer from the differential rear cover stud Wire harness retainer clip from the top of the differential Transmission harness 20 way connector 79222642

Remove the inspection plug, then remove the flexplate-to-torque converter bolts

Park Neutral Position (PNP) switch electrical connectors

Y-BODY—GENERAL MOTORS CORPORATION

CORVETTE

79222643

Remove the plugs and install two M10 x 1.5 x 55mm or longer bolts into the bolt holes to secure the bearing—5.7L engine

79222644

loosen it—5.7L engine Rotate the flywheel to gain access to the clamp bolt, then

3 0 -1 !)

e Bolt securing the wire harness to the left side of the case 12. Lower the driveline and angle it while observing the top rear of the differential and the lowest part of the rear compartment floor panel. The engine Positive Crankcase Ventilation (PCV) pipes will most likely contact the dash panel. Make certain not to damage the dash. 13. Remove or disconnect the following: e Wire harness from the retainer along the top of transmission e Transmission rear oil cooler pipes from the junction fittings at the flywheel housing e 5 driveline to flywheel housing bolts after supporting the rear of the engine 14. Bend the wiring harness bracket away from the driveline, toward the tunnel wall to have access to remove the driveline. 15. Separate the driveline from the engine by prying them apart with a flat blade tool. 16. Lower the driveline and tilt it away from the engine until the input shaft clears the flywheel housing. 17. Remove or disconnect the following: e Driveline e Transmission oil cooler rear pipes from the fittings e Transmission to driveline bolts ¢ Separate the transmission from the driveline with a flat blade tool 18. Using a lifting device, place the 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 Differential-to-transmission bolts Differential from the transmission To install: 19. Install or connect the following: e Differential to the transmission and torque the bolts to 37 ft. Ibs. (50 Nm) e Transmission to the driveline support and torque the bolts to 37 ft. Ibs. (60 Nm — e Rear transmission oil cooler fittings to the transmission and torque the fittings to 30 ft. Ibs. (40 Nm) 20. Using a chain hoist, place the assembly on a transmission jack. 21. Carefully raise the assembly into the

For Wheel Alignment specifications, see Section 1 of this manual

30-20

GENERAL MOTORS CORPORATION—Y-BODY CORVETTE

2. Remove or disconnect the following: Negative battery cable Both rear wheels Folding top stowage compartment lid extension panel (on convertible ‘ models) Traction control/ride contro! switch Console retaining nut covers Console retaining nuts Accessory plug electrical connector Fuel door release electrical connector Console 79227645

Transmission-to-differential mounting bolt locations—5.7L engine

vehicle while placing the wiring harness loosely into the harness retaining slots. 22. Align the assembly for installation into the engine. The driveline will slide into the rear of the engine as long as the angles are the same. 23. Install or connect the following: Driveline assembly in the vehicle. Reposition the wiring harness bracket to align with the appropriate hole in the driveline assembly. Driveline support-to-flywheel housing bolts and torque them to 37 ft. lbs. (50 Nm) Oil cooler lines and torque the fittings to 20 ft. Ibs. (27 Nm) Wiring harness to the left side of the transmission and torque the

bolt to 22 inch Ibs. (2.5 Nm) PNP switch electrical connector Transmission harness 20 way connector Wiring harness clip to the top of the differential VSS electrical connector 24. Raise the transmission to installation height. Axle shafts Transmission mount to the crossmember and torque the nuts to 37 ft. Ibs. (50 Nm) Suspension crossmember and torque the nuts to 81 ft. Ibs. (110 Nm) Lower transmission-to-differential nut and torque it to 37 ft. Ibs. (50 Nm) Wiring harness and brake pipe clip retainers to the crossmember Lower ball joints to the suspension knuckles and torque the nuts to 52 ft. Ibs. (70 Nm) Shock absorber lower mounting bolts and torque them to 162 ft. lbs. (220 Nm) Outer tie rod ends to the knuckles

and torque the nuts to 15 ft. Ibs. plus an additional 160 degrees Rear transverse spring and torque the bolts to 46 ft. Ibs. (62 Nm) Wiring harness into the “L” shaped brackets Transmission cable and bracket and torque the nuts to 15 ft. Ibs. (20 Nm) Transmission flexplate to the torque converter using the matchmarks made during removal and torque the bolts to 47 ft. Ibs. (63 Nm) Rear bell housing access plug Propeller shaft hub bolt until it is finger tight 29. Remove the two M10 x 55mm bolts from the input shaft front bearing. 26. Install or connect the following: ¢ 2 plug bolts to the driveline support assembly and torque the bolts to 37 ft. Ibs. (50 Nm) Driveline tunnel closeout panel and torque the bolts to 89 inch Ibs. (10 Nm) Right hand muffler assembly Intermediate pipe and torque the bolts to 37 ft. Ibs. (50 Nm) Both rear wheels ¢ Negative battery cable 27. Start the vehicle and allow it to reach normal operating temperature. Turn the engine OFF. Allow the engine to cool to ambient temperature, then tighten the flywheel hub collar bolt to 96 ft. Ibs. (130 Nm). 28. Install the bell housing inspection plug. 29. Flush the automatic transmission oil cooler. 30. A front end alignment is recommended when the crossmember is removed. Manual

1. Before servicing the vehicle, refer to the precautions in the beginning of this section.

Shift contro! knob button Shift control knob retainer Shift control knob Shift contro! boot by grabbing both sides and pulling it in toward the lever e Ashtray Trim plate grill Retaining screws located behind the grill and behind the ashtray Instrument panel accessory trim plate Shift contro! closeout boot retaining nuts and boot Shift rod clamp bolt Shift control mounting bolts Shift control assembly Courtesy lamp @e'@@ 36 6 Left side lower closeout panel while guiding the courtesy lamp through the hole

Clutch master cylinder pushrod retainer and the pushrod from the pedal Clutch actuator cylinder hose from the retainer clip Clutch actuator hose from the master cylinder hose Rear wheels Intermediate exhaust pipe and secure the mufflers out of the way Driveline closeout panel Rear transverse spring

Outer tie rod ends Lower shock absorber bolts Lower ball joints 3. Support the transmission Wiring harness and brake lines from the suspension crossmember Lower transmission-to-differential nut Transmission mount-to-crossmember nuts Rear suspension crossmember nuts Transmission mount and bracket from the differential Axle shafts from the differential and position them out of the way Wiring harness from the driveline support assembly

Y-BODY—GENERAL MOTORS CORPORATION

CORVETTE

VA 79222646

Insert a flat bladed tool between the shifter bracket and brake liner retainer before lowering the transmission assembly—5.7L engine

3 0 -21

e Reverse lockout solenoid electrical connector e Gear select (skip shift) solenoid electrical connector e Transmission fluid temperature sensor electrical connector (if equipped) 6. Support the rear of the engine e Driveline support-to-bell housing bolts e Driveline support assembly out of the bell housing while moving the assembly rearward 7. Carefully lower the assembly away from the vehicle while simultaneously adjusting the angle. 8. Attach a chain hoist to the assembly, then remove it from the jack and place it on a workbench. 9. Remove or disconnect the following: e Driveline support-to-transmission mounting bolts. Carefully pry the driveline assembly away from the transmission while guiding the shift rod through the opening in the driveline support Transmission shift rod from the transmission Transmission-to-differential mounting bolts and separate the differential from the transmission To install: 10. Install or connect the following: ¢ Differential to the transmission and torque the bolts to 37 ft. Ibs. (50 Nm) e Transmission shift rod e Driveline support to the transmission and torque the bolts to 37 ft.

~

=

Race

79222647

Driveline support-to-transmission mounting—5.7L engine

e Harness clip from the top of the differential ese bs Ps

WARNING

Do not lower the top rear portion of the differential past the bottom of the storage compartment or the PCV pipe will hit the dash panel possibly causing damage.

4 Lower the transmission enough to remove the wiring harness from the top of the assembly. 5. Remove or disconnect the following: e Vehicle Speed Sensor (VSS) electrical connector e Backup lamp switch electrical connector

lbs. (50 Nm) 11. To aid in later installation place a rubber band around the shift rod then tape the shift rod to the driveline support assembly. 12. Place the assembly on the transmission jack with a chain hoist. 13. Begin to raise the assembly into the vehicle while loosely installing the wiring harness along the driveline assembly retaining slots. 14. Have an assistant guide the front of the driveline support to the bell housing. 15. Be sure the driveline assembly is at the same angle as the engine before trying to install it. 16. Install or connect the following: e Input propeller shaft into the clutch disc e Wiring harness bracket to align

this manual For Maintenance Interval recommendations, see Section 1 of

3 0 -22

GENERAL MOTORS CORPORATION—Y-BODY CORVETTE

79222649

Pull the shift rod up to break the tape and hook the rubber band on the rear stud— 5.7L engine

79227648

Place a rubber band on the shift rod, then tape the rod to the driveline support assembly—5.7L engine

with the appropriate hole in the driveline assembly Driveline support-to-flywheel housing bolts and torque them to 37 ft.

lbs. (50 Nm) Wiring harness to the retainer on the top of the transmission and attach the connectors Transmission fluid temperature sensor electrical connector (if equipped) Gear select/skip shift solenoid electrical connector Reverse lockout solenoid electrical connector Backup lamp switch electrical connector Wiring harness to the top of the differential VSS electrical connector Axle shafts in the differential Transmission mount on the differential and torque the bolts to 37 ft. lbs. (50 Nm) Rear Suspension crossmember and torque the nuts to 81 ft. Ibs. (110 Nm) Transmission mount-to-crossmember nuts and torque them to 37 ft. lbs. (50 Nm)

Lower transmission-to-differential nut and torque it to 37 ft. Ibs. (50 Nm) Wiring harness and brake line retainers to the crossmember Lower ball joints and torque the nuts to 52 ft. Ibs. (70 Nm) Shock absorber lower mounting bolts and torque them to 162 ft. lbs. (220 Nm) Outer tie rod ends and torque the nuts to 15 ft. Ibs. (20 Nm) plus an additional 160 degrees Transverse spring and torque the mounting bolts to 46 ft. Ibs. (62 Nm)

e Clutch master cylinder pushrod retainer e Left lower closeout panel e Courtesy lamp 17. Pull up the shift rod to break the tape and hook the rubber band on the rear stud on the top of the driveline tunnel. e Shift control assembly and torque the bolts to 22 ft. Ibs. (30 Nm) e Shift control closeout boot and torque the nuts to 106 inch Ibs. (12 Nm) e Instrument panel accessory trim plate e Shift control boot e Shift control knob e Shift contro! knob retainer and button e Console ¢ Fuel door release electrical-connector e Accessory plug electrical connector ¢ Console retaining nuts and torque

them to 89 inch Ibs. (10 Nm) ¢ Console retaining nut covers ¢ Traction control/ride control switch ¢ Folding top stowage compartment lid extension panel e Rear wheels ¢ Negative battery cable 18. Bleed the clutch system.

ADJUSTMENT

Clutch actuator hose to the master

LS

cylinder hose

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove the flywheel inspection cover. 3. Have an assistant depress the clutch pedal until the tension is released from the stepped adjusting ring. 4. Using 2 screwdrivers, rotate the Stepped adjusting ring counterclockwise until fully adjusted out. 9. Continue to hold them in this position and have the assistant release the clutch pedal.

Clutch actuator hose to the retaining clip Driveline tunnel closeout panel and torque the bolts to 89 inch Ibs. (10 Nm) Muffler assemblies Intermediate exhaust pipe and torque the bolts to 37 ft. Ibs. (50 Nm) Rear wheels Clutch master cylinder pushrod to the clutch pedal

Y-BODY—GENERAL MOTORS CORPORATION CORVETTE 30-23

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. 3. Raise and safely support the vehicle with an assistant in it. 4 Remove the intermediate exhaust pipe. 5. Remove the driveline tunnel cover. 6. Have the assistant depress and hold the clutch pedal down. 7. Loosen the bleeder screw on the actuator cylinder to release the air, then tighten the screw.

kk WARNING Do not allow the clutch pedal to be released until the bleeder screw is closed or air will be drawn into the system.

79222652

Rotate the stepped adjusting ring counterclockwise to compress the springs

6. Remove the screwdrivers. 7. Install the inspection cover. Torque the bolts to 18 ft. bs. (25 Nm).

REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the followPing:

§

79222650

Clutch assembly torque sequence

Negative battery cable Exhaust system Driveline support and transmission as an assembly Flywheel inspection cover Pressure plate bolts. It will be necessary to rotate the flywheel to access all the bolts Pressure plate and disc To install: 3. Install or connect the following: e Clutch disc and pressure plate on the flywheel e Clutch disc alignment tool through the disc to keep it in place e Pressure plate bolts finger-tight. Turn the flywheel to access all the bolt holes 4. Torque the bolts in the sequence shown, using 3 steps to 52 ft. Ibs. (70 Nm). e Inspection cover and torque the bolts to 18 ft. Ibs. (25 Nm) e Driveline support and transmission assembly e Exhaust system ¢ Negative battery cable 5. Bleed the clutch system.

8. Repeat the prior two steps until the air has been purged from the system. Check the master cylinder fluid level and refill as needed. 9. Install the driveline tunnel cover. 10. Install the intermediate exhaust pipe. 11. Lower the vehicle.

REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Apply the parking brake. 3. Remove or disconnect the following: Wheel Axle nut Rear transverse spring Outer tie rod end from the knuckle Antilock Brake System (ABS) Wheel Speed Sensor (WSS) electrical connector Park brake cable from the lever and bracket ->Be sure to support the halfshaft until it is removed. Do not let it hang by the CV-joint.

4. Attach a puller on the wheel studs and start to push the axle shaft into the hub

For Tune-up, Capacities and Firing orders, see Section 1 of this manual

30-24

GENERAL MOTORS CORPORATION—Y-BODY CORVETTE e Rear transverse spring and torque the bolts to 46 ft. Ibs. (62 Nm) e Halfshaft retaining nut and torque

the nut to 118 ft. Ibs. (160 Nm) e Wheel CV-Joints

OVERHAUL Inner Joint

79222653

Insert a large drift through the cooling fins to keep the hub assembly from turning while removing the retaining nut—5.7L engine

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove axle shaft. 3. Wrap a shop towel around the axle shaft. 4. Place the wheel drive shaft horizontally in a bench vise. 5. Remove the large seal retaining clamp from the CV joint seal. 6. Use a side cutter or other suitable tool and discard the clamp. 7. Remove the small seal retaining clamp from the joint seal. 8. Use a side cutter or other suitable tool and discard the clamp. 9. Separate the seal from the joint outer race at the large diameter end.

assembly. This will provide clearance for the ball joint to be separated from the knuckle assembly. 5. Remove or disconnect the following: e Ball joint from the knuckle e Axle shaft from the hub e Halfshaft assembly from the differential by inserting a suitable tool between the CV-joint and differential and prying them apart To install: 6. Install or connect the following: Halfshaft on the differential output shaft. Use light force to be sure it is fully seated Halfshaft through the hub assembly but do not install completely. This will provide clearance for installing the ball joint Ball joint to the knuckle and torque the nut to 41 ft. Ibs. (55 Nm) Halfshaft through the hub assembly completely Park brake cable to the bracket and the lever

WSS electrical connector Tie rod end to the knuckle and torque the nut to 15 ft. Ibs. (20 Nm) plus an additional 160 degrees

®

79222654

Exploded view of the halfshaft mounting—5.7L engine

Y-BODY—GENERAL MOTORS CORPORATIO

CURE RE 30-2 5

To install:

93462GB7

Remove the cage from the axle shaft-inner joint

9346ZGB3

Separate the seal from the joint outer race at the large diameter end-inner joint

10. Position the seal behind the joint face. 11. Position the wheel drive shaft vertically in the bench vise so the inner joint is up. 12. Slide the joint outer race down toward the vise. 13. Disengage the outer race retaining ring as follows: a. Insert a small flat bladed screwdriver between the retaining ring and the outer race.

b. Pry the retaining ring from the outer race. c. Position the retaining ring along the axle shaft away from the outer race. The balls may fall out of the cage and inner race when the outer race is removed. 9346Z2GB4

Remove the outer race from the axle

shaft-inner joint

9346ZGB5

Remove the snap ring from the axle

’ shaft-inner joint

oc j[=cut a

| i]

er E =fe = All traces of old grease and any contaminates must be removed.

97. Clean al parts thoroughly with clean solvent. 28. Thoroughly air dry all the parts.

Protect the wheel drive shaft boots, seals and clamps from sharp objects when servicing on or near the wheel drive shaft(s). Damage to the boot(s), the seal(s) or the clamp(s) may cause lubricant to leak from the joint and lead to increased noise and possible failure of the wheel drive shaft.

29. Wrap a shop towel around the axle shaft. 30. Place the wheel drive shaft horizontally in a bench vise. 31. Install a new small seal retaining clamp onto the wheel drive shaft. 32. Install the seal onto the axle shaft. 33. Install the cage onto the axle shaft so the smaller diameter end faces the vise. >The inner race spline relief must face away from the end of the axle shaft.

34. Install the inner race onto the axle shaft as follows: a. Engage the inner race splines onto the axle shaft splines. Be sure to install the inner race spline relief side onto the axle shaft first. b. Position a wood block squarely over the end of the inner race. c. Use a hammer to begin to drive the inner race onto the axle shaft. d. Reposition the wood block along the face of the inner race to avoid the axle shaft. e. Work evenly around the inner race and continue to drive the inner race, until you feel the inner race seat fully onto the axle shaft. 35. Inspect to be sure that the axle shaft snap ring groove is exposed. 36. Install the snap ring to the axle shaft. 37. Position the cage so the cage lands align with the inner race ball tracks. 38. Install the cage onto the inner race. 39. Position the cage windows to align with the inner race ball tracks. 40. Insert approximately 60 percent of the grease from the service kit into the outer race. 41. Position the wheel drive shaft vertically in the bench vise so the inner joint end iS Up. 42. Apply a small amount of the grease from the service kit to the cage windows and inner race ball tracks. 43. Insert the remaining grease from the service kit into the seal.

For complete service labor times, order Nichols’ Chilton Labor Guide

30-26

GENERAL MOTORS CORPORATION—Y-BODY CORVETTE

9346ZGB8

Use a hammer and a block of wood to drive the inner race onto the axle shaft-inner joint

adh

Ser

c. Slide the outer race down over the balls. 49. Position the wheel drive shaft horizontally in the bench vise. Engage the outer race retaining ring as follows: a. Slide the outer race toward the vise. b. Insert the outer race retaining ring into the groove along the outer edge of the outer race. c. Position the outer race retaining ring so the opening in the ring aligns with an outer race land (not a ball track). 50. Position the large diameter end of the seal onto the outer race. 51. Position the small seal retaining clamp onto the neck of the seal. 52. Position the seal and small retaining clamp to the axle shaft. 53. Measure the distance between the edge of the seal and the edge of the last axle shaft groove closing edge and adjust fit to 0.10 inch (2.5mm).

J 42572

9346ZGC2

Tighten the small seal retaining clamp until the base of the omega shape has a

gap width between 0.079-0.118 inch (2-3mm), with a difference in the gap width from side to side no greater than 0.016 inch (0.4mm)-inner joint

>The seal retaining clamp must not be over-tightened or under-tightened.

9346ZGB9

Insert approximately 60 percent of the grease from the service kit into the outer race—inner joint

a

2 93462ZGC1

Measure the distance between the edge of the seal and the edge of the last axle shaft groove closing edge and adjust fit to 0.10 inch (2.5mm)-inner joint

54. Crimp the small seal retaining clamp using tool J 42572. Tighten the small seal retaining clamp until the base of the omega shape has a gap width between 0.079-0.118 inch (2-3mm), with a difference in the gap width from side to side no greater than 0.016 inch (0.4mm). The clamping hold time must be no less than 2 seconds. 59. Measure the distance between the end of the seal and the end of the joint outer race and adjust the plunging motion of the joint to 8.90 inch within 0.16 inch (226mm within 4mm). 56. Position the large seal retaining clamp onto the seal. 57. Position the seal and large retaining clamp to the joint outer race. Measure the distance between the edge of the seal and the edge of the joint outer race last groove closing edge and adjust fit to 0.03 inch (0.8mm).

934626C3

Measure the distance between the end of the seal and the end of the joint outer race and adjust the plunging motion of the joint to 8.90 inch within 0.16 inch (226mm within 4mm-inner joint

4 93462604

44. Install the outer race retaining ring onto the axle shaft. 45. Position the retaining ring below the cage, toward the vise. 46. Install the balls through the cage windows to the inner race ball tracks. 47. Use the seal to keep the balls in position if necessary. 48. Install the outer race onto the axle shaft as follows: a. Be careful not to allow the grease n the outer race to leak out. b. Align the outer race ball tracks to he balls. os

>The seal must not be dimpled, stretched or out of shape in any way.

58. Inspect the seal for proper shape. If the seal is NOT shaped correctly, equalize the pressure in the seal and shape the seal properly by hand. Inspect the seal for damage. If the seal has been cut or punctured during assembly, you must discard and replace the seal. e>The seal retaining clamp must not be over-tightened or under-tightened.

59. Crimp the large seal retaining clamp using tool J 42572. Tighten the small seal

Measure the distance between the edge of the seal and the edge of the joint outer race last groove closing edge and adjust fit to 0.03 inch (0.8mm)-inner joint

retaining clamp until the base of the omega . shape has a gap width between 0.079-0.118 inch (2-3mm), with a difference in the gap width from side to side no greater than 0.016 inch (0.4mm). The clamping hold time must be no less than 2 seconds. 60. Remove the wheel drive shaft from the bench vise.

Y-BODY—GENERAL MOTORS CORPORATION

CORVETTE 30-27

61. Distribute the grease within the inner CV joint. 62. Plunge the joint back and forth four or five times. 63. Inspect the inner CV joint and wheel drive shaft for smooth operation as follows: a. Hold the wheel drive shaft vertically, with the outer joint at the bottom. b. Rotate the wheel drive shaft four or five times in a circular motion. 64. Install the axle shaft. Outer Joint

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. _ 2, Remove or disconnect the following: e Axle shaft from the vehicle * Large CV boot retaining clamp e Small CV boot retaining clamp e CV boot from thejoint

93462GC5

Separate the outer joint from the axle shaft using a hammer and wood block—outer joint

e Outer joint from the axle shaft using a hammer and wood block ¢ Axle shaft retaining ring e CV boot 3. Disassemble the chrome alloy balls from the CV-joint cage as follows: a. Position a brass drift against the CV-joint cage and tap it with a hammer to tilt the cage. b. Remove the 1st chrome alloy ball

e New retaining ring on the halfshaft e Large ring clamp on the CV boot e Outer joint onto the axle shaft 10. Compress the retaining ring using a

from the cage. c. Tilt the cage in the opposite direction. d. Remove the opposite chrome alloy

ball. e. Repeat the procedure until all 6 balls are removed. 4. Disassemble the CV-joint cage and inner race as follows: a. Pivot the cage and race 90 degrees to the center line of the outer

race. b. Align the cage windows with outer race lands. c. Remove the cage from the outer race. d. Rotate the inner race upward and remove it from the cage. To install: 5. Lubricate the parts with a light coat of grease. 6. Assemble the CV-joint cage and inner race, as follows: a. Rotate the inner race 90 degrees to the cage centerline. b. Align the cage windows with inner race lands. c. Insert the inner race into the cage by rotating the inner race downward. d. Insert the cage/inner race into the outer race. 7. Assemble the chrome alloy balls into the CV-joint cage, as follows: a. Position a brass drift against the C\V-joint cage and tap it with a hammer

93462GC7

Install the axle shaft retaining ring—outer joint

2

93462608

Measure the distance between the edge of the seal and the edge of the last axle shaft groove closing edge and adjust fit to 0.10 inch (2.5mm)

to tilt the cage. b. Insert the 1st chrome alloy ball into the cage. c. Tilt the cage in the opposite direc-

93462606

Position a brass drift against the CV-joint cage and tap it with a hammer to tilt the cage—outer joint

tion. d. Insert the opposite chrome alloy ball. e. Repeat the procedure until all 6 balls are inserted. 8. Install Yof the grease provided, into the CV-joint. 9. Install or connect the following: e Small CV boot retaining ring e CV boot on the halfshaft

93462GC9

Tighten the small seal retaining clamp until the base of the omega shape has a gap width between 0.079-0.118 inch (2-3mm), with a difference in the gap width from side to side no greater than 0.016 inch (0.4mm)-outer joint

Please visit our web site at www.chiltonsonline.com

30-28

GENERAL MOTORS CORPORATION—Y-BODY CORVETTE

J 42572

4

93462GD1

Measure the distance between the edge of the seal and the edge of the last axle shaft groove closing edge and adjust fit to 0.3 inch (8mm)—outer joint

small flat bladed tool while pushing the outer joint onto the axle shaft. 11. Seat the outer joint on the shaft using a hammer and biock of wood. 12. Install the remaining grease into the CV boot. 13. Position the CV boot and the small boot clamp. 14. Crimp the small boot clamp. 15. Position and crimp in place the large boot clamp. 16. Install the Halfshaft in the vehicle.

93462GD2

Tighten the small seal retaining clamp until the base of the omega shape has a gap width between 0.079-0.118 inch (2-3mm), with a difference in the gap width from side to side no greater than 0.016 inch (0.4mm)-outer joint

STEERING AND SUSPENSION

*< CAUTION All 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 repairs.

PRECAUTIONS Several precautions must be observed when handling the inflator module to avoid accidental deployment and possible personal injury. 1. Never carry the inflator module by the wires or connector on the underside of the module. 2. When carrying a live inflator module, hold securely with both hands, and ensure that the bag and trim cover are pointed away.

3. Place the inflator module on a bench or other surface with the bag and trim cover facing up. 4. With the inflator module on the bench, never place anything on or close to the module which may be thrown in the event of an accidental deployment.

DISARMING 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Turn the steering wheel to align the wheels in the straight-ahead position. 3. Turn the ignition switch to the LOCK position. 4. Remove the AIR BAG fuse from the fuse block. ©. Remove the left side lower trim panel, then unplug the Connector Position Assurance (CPA) device and the yellow 2-way SIR harness wire connector at the base of the steering column.

ARMING After the necessary repairs have been made, re-enable the air bag system as follows:

1. Turn the ignition switch to the LOCK position. ~ 2. Engage the yellow 2-way connector and the CPA device at the base of the steering column. 3. Install the left side lower trim panel, then install the SIR fuse to the fuse block. 4. Turn the ignition switch to the RUN position. 5. Verify the SIR indicator light flashes 7-9 times, then turns OFF. If not, inspect system for malfunction.

Power Rack and Pinion Steering Gear REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the power steering fluid. 3. Remove or disconnect the following; ¢ Negative battery cable e Brake Pressure Modulator Valve (BPMV) bracket, if equipped ¢ Both front wheels e Intermediate shaft shield

Y-BODY—GENERAL MOTORS CORPORATION

urea

30-29

79222656

Exploded view of the front shock absorber mounting—5.7L engine

79222655

Exploded view of the power steering gear mounting—5.7L engine

Intermediate shaft lower coupling from the power steering gear Power steering inlet hose from the steering gear Steering cooler pipe from the steering gear Power steering cooler Both outer tie rod ends from the knuckles Magnasteer electrical connector Stabilizer shaft from the crossmember Wire harness clips from the crossmember Brake pipe from the crossmember Steering gear mounting bolts and loosen the crossmember mounting nuts Power steering gear through the left

wheel opening To install: 4. Install or connect the following: e Steering gear to the crossmember and torque the nuts to 74 ft. Ibs. (100 Nm) 5. Torque the crossmember mounting nuts 81 ft. Ibs. (110 Nm) e Brake pipe to the crossmember e Stabilizer shaft ¢ Both outer tie rod ends to the steering knuckle and torque the nuts to 18 ft. Ibs. (25 Nm) plus and additional 180 degrees e Intermediate shaft lower steering

coupling to the steering gear and torque the bolt to 25 ft. Ibs. (34 Nm) Magnasteer electrical connector Wire harness clips to the crossmember Cooler to the crossmember Cooler pipe to the steering gear and torque the fitting to 20 ft. Ibs. (27 Nm) Inlet hose to the steering gear and torque the fitting to 20 ft. Ibs. (27 Nm) Intermediate shaft shield and torque the clamp to 32 inch Ibs. (3.5 Nm) Both front wheels Negative battery cable 6. Refill and bleed the power steering system. 7. Check and adjust the front end alignment.

Shock Absorber REMOVAL & INSTALLATION Front

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following:

e Negative battery cable e Wheel e Real Time Damper (RTD) electrical connector Upper mounting nut retainer and insulator Shock absorber lower mounting bolts Shock absorber from the upper tower 3. If equipped with heavy duty shocks (FE3) perform the following steps: a. Compress the shock absorber from the bottom upward. b. Install a shock support tool to the shock while it is compressed. c. Remove the shock from the vehicle. d. Remove the tool from the shock. 4. Remove the shock absorber. To install: 5. Install or connect the following: e Retainer and insulator to the shock absorber e Shock absorber to the upper shock tower e Upper insulator, retainer and nut and torque the nut to 19 ft. Ibs. (26 Nm) e Lower mounting bolts and torque them to 21 ft. Ibs. (28 Nm) e RID electrical connector 6. If equipped with heavy duty shocks (FE3) perform the following steps: a. Install a shock support tool to the shock absorber. b. Install the shock to the vehicle. c. Install the upper insulator, retainer and nut and torque the nut to 19 ft. Ibs. (26 Nm). d. Remove the support tool from the

Timing belt service is covered in Section 3 of this manual

30-30

GENERAL MOTORS CORPORATION—Y-BODY CORVETTE

shock and install a spring compressor to the spring. 7. Raise the lower control arm and install the shock absorber lower mounting bolts and torque them to 21 ft. Ibs. (28 Nm). a. Step 6: Remove the spring compressor tool. 8. Install or connect the following: e Wheel e Negative battery cable Rear

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Negative battery cable e Wheel e Rear position sensor electrical connector, if equipped e Lower mounting bolt e Upper mounting bolts Shock absorber from the lower control arm and shock tower Upper insulator and retainer from the shock absorber To install: 3. Install or connect the following: Upper insulator and retainer to the shock absorber, if removed

3. Measure the front spring adjuster bolt gap to ease the installation procedure and setting the proper vehicle trim height. 4. Install a spring compressor tool J 33432-A to the spring and compress it. 5. Remove or disconnect the following:

Transverse Spring REMOVAL & INSTALLATION _

Front

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Negative battery cable e Front wheels

9346ZGD3

Measure the front spring adjuster bolt gap to ease the installation procedure and setting the proper vehicle trim height—front assembly

“e Lower shock absorber mounting bolts from one of the lower control arms Stabilizer shaft link from the lower control arm Lower ball joint from the steering knuckle Cam bolts from the lower control arm after matchmarking them Lower control arm Transverse spring bolts and retainers Transverse spring and the compressor tool To install: 6. Install or connect the following: e Spring to the crossmember e New spring retainers and bolts to the crossmember and torque them to 46 ft. Ibs. (62 Nm) e Lower control arm to the crossmember e Cam bolts to the matchmarks made during the removal procedure.

Shock absorber to the shock tower and lower control arm Upper mounting bolts and torque them to 22 ft. Ibs. (30 Nm) Lower shock absorber mounting bolt and torque it to 162 ft. Ibs. (220 Nm) Rear position sensor electrical connector Wheel Negative battery cable

93062627

Exploded view of the rear shock absorber—5.7L engine

79222660

Exploded view of the front transverse spring—5.7L engine

Y-BODY—GENERAL MOTORS CORPORATION

CORVETTE

NN

Hand tighten the cam bolts at this time Lower control arm ball joint stud to the steering knuckle and torque the nut to 15 ft. Ibs. (20 Nm) plus an additional 210 degrees Shock absorber Shock absorber lower mounting bolts and torque them to 21 ft. Ibs. (28 Nm) Stabilizer shaft link to the lower control arm and torque the nut to 53 ft. Ibs. (72 Nm) 7, Remove the spring compressor tool from the transverse spring and move the

lower control arm supports. 8. Install or connect the following: e Front wheels e Negative battery cable 9. Adjust the front trim height. 10. Perform a front end alignment. 11. Torque the control arm cam bolts to 125 ft. Ibs. (170 Nm) Rear

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Negative battery cable e Rear wheels 3. Measure the transverse spring stud

height to ease the installation procedure and setting the proper vehicle trim height. 4. Install a spring compressor tool J 33432-A to the spring and compress it. 5. Remove the spring mounting bolts, Spacers and insulators from the crossmember and control arm. 6. Remove the spring from the vehicle and remove the compressor tool. To install: 7. Install or connect the following: Spring compressor to the transverse spring Spring to the vehicle Spring spacers, insulators and mounting bolts to the crossmember and torque the bolts to 46 ft. Ibs. (62 Nm) Spring to the lower control arm Lower control arm to spring bolts and insulators and release the compressor tool e Rear wheel Negative battery cable 8. Adjust the trim height and place the retainers on the control arm bolts. 9. Check and adjust the alignment, if needed.

Upper Ball Joint REMOVAL & INSTALLATION Front

9346ZGD4

Measure the transverse spring stud height to ease the installation procedure and setting the proper vehicle trim height—rear assembly

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Wheel Brake caliper Brake rotor Stabilizer shaft link from the lower control arm Wheel Speed Sensor (WSS) electrical connector Outer tie rod from the steering knuckle Upper ball joint from the control arm Steering knuckle from the vehicle 3. Press the ball joint from the steering knuckle. To install: 4. Install or connect the following: e Ball joint to the steering knuckle ¢ Upper ball joint to the control arm and torque the nut to 15 ft. Ibs. (20 Nm) plus an additional 250 degree turn

EE

30-31

ee

¢ Lower ball joint to the steering knuckle and torque the nut to 15 ft. lbs. (20 Nm) plus an additional 210 degree turn Outer tie rod to the steering knuckle and torque the nut to 18 ft. Ibs. (25 Nm) plus an additional 180 degree turn Stabilizer shaft link to the control arm and torque the nut to 53 ft. Ibs. (72 Nm) WSS electrical connector Brake rotor Brake caliper and torque the mounting bracket bolts to 125 ft.

lbs. (175 Nm) e Wheel 5. Check and adjust the front alignment. Rear

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Wheel e Wheel Speed Sensor (WSS) electrical connector Real Time Damping (RTD) position sensor, If equipped e Brake caliper e Brake rotor e Shock absorber solenoid electrical connector, if equipped Outer tie rod from the suspension knuckle Axle shaft nut Upper control arm from the knuckle Lower ball joint from the knuckle Suspension knuckle from the vehicle 3. Press the upper ball joint from the knuckle. To install: 4. Press the ball joint into the suspension knuckle. 5. Install or connect the following: e Knuckleto the vehicle ¢ Lower ball joint to the knuckle and torque the nut to 41 ft. Ibs. (55 Nm) Upper control arm to the knuckle and torque the nut to 15 ft. Ibs. (20 Nm) plus an additional 250 degree turn ©

Axle shaft nut and torque it to 118 ft. lbs. (160 Nm) Outer tie rod to the knuckle and torque the nut to 15 ft. Ibs. (20 Nm) plus an additional 160 degree turn Brake rotor

Heater Core replacement is covered in Section 2 of this manual

30-32

GENERAL MOTORS CORPORATION—Y-BODY CORVETTE

Brake caliper and torque the mounting bracket bolts to 125 ft. lbs. (175 Nm) e WSS electrical connector Shock absorber solenoid electrical connector, if equipped RTD position sensor, if equipped e Wheel 6. Check and adjust the rear wheel alignment.

Lower Ball Joint

REMOVAL & INSTALLATION Front and Rear

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove the lower control arm from the vehicle. 3. Press the ball joint from the control arm. To install: 4. Press the ball joint into the control arm. 5. Install the control arm in the vehicle.

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9346ZGD4

Ball joint removal and installation tool set-lower ball joint

Upper Control Arm REMOVAL & INSTALLATION Front

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 Real Time Damping (RTD) sensor link and support the lower control arm Upper ball joint from the upper control arm Upper contro! arm bolts and shims e Upper control arm To install: 3. Install or connect the following: Upper control arm Upper control arm shims and bolts and torque the bolts to 48 ft. Ibs. (65 Nm) Ball joint stud into the upper control arm and torque the nut to 15 ft. lbs. (20 Nm) plus an additional 250 degrees RTD sensor link Front wheel Negative battery cable 4. Check and adjust the front wheel alignment. Rear

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: ¢ Negative battery cable e Rear wheel e Wheel Speed Sensor (WSS) electrical connector ¢ Real Time Damping (RTD) position sensor link, if equipped 3. Support the lower control arm with a jack stand. ¢ Ball joint stud from the control arm ¢ Upper control arm bolts ¢ Upper control arm To install: 4. Install or connect the following: Upper control arm and torque the bolts to 81 ft. Ibs. (110 Nm) Suspension knuckle ball joint stud nut into the upper control arm. It may be necessary to use an Allen wrench to keep the ball joint stud from spinning while tightening the ball joint stud nut. Torque the nut to 15 ft. Ibs. (20 Nm) plus an additional 250 degrees WSS electrical connector RTD position sensor link, if equipped Rear wheel Negative battery cable 9. Check and adjust the rear wheel alignment.

CONTROL ARM BUSHING REPLACEMENT The manufacturer does not provide a bushing replacement procedure. The bushing is replaced when a new control arm is installed.

Lower Control Arm

REMOVAL & INSTALLATION Front

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Front wheel e Front transverse spring e Wheel Speed Sensor (WSS) electrical connector e Real Time Damping (RTD) electrical connector, if equipped 3. Support the lower control arm with a jack stand Shock absorber from the lower control arm Stabilizer shaft link from the lower control arm Ball joint stud from the knuckle Cam bolts, washers and nuts after matchmarking them Lower control arm from the vehicle To install: 4. Install or connect the following: e Lower control arm 5. Support the lower control arm with a jack stand ¢ Cam bolts to the position match marked during the removal procedure and hand tighten the bolts ¢ Lower control arm ball joint stud to the steering knuckle and torque the nut to 15 ft. Ibs. (20 Nm) plus an additional 210 degrees

79222661

Lower control arm mounting bolts—5.7L engine

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GENERAL MOTORS CORPORATION—Y-BODY 1998-01 Chevrolet-Corvette DRIVETRAIN .....kee.05 5.03. 30-18 ENGINE REPAIR................ 30-2 EUELSOV OL EME ie. cones 30-16 PRECAUTIONS.................. 30-2 STEERING AND

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30-2 oe

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GENERAL MOTORS CORPORATION—Y-BODY CORVETTE

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SANTEE

Before servicing any vehicle, please be sure to read all of the following precautions, which deal with personal safety, prevention of component damage, and important points to take into consideration when servicing a motor vehicle: e Never open, service or drain the radiator or cooling system when the engine is hot; serious burns can occur from the steam and hot coolant. e Observe all applicable safety precautions when working around fuel. Whenever servicing the fuel system, always work in a well-ventilated area. Do not allow fuel spray or vapors to come in contact with a spark, open flame or excessive heat (a hot drop light, for example). Keep a dry chemical fire extinguisher near the work area. Always keep fuel in a container specifically designed for fuel storage; also, always properly seal fuel containers to avoid the possibility of fire or explosion. Refer to the additional fuel system precautions later in this section. ¢ Fuel injection systems often remain pressurized, even after the engine has been turned OFF. The fuel system pressure must be relieved before disconnecting any fuel lines. Failure to do so may result in fire and/or personal injury. ¢ Brake fluid often contains polyglycol ethers and polyglycols. Avoid contact with the eyes and wash your hands thoroughly after handling brake fluid. If you do get brake fluid in your eyes, flush your eyes with clean, running water for 15 minutes. If

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eye irritation persists, or if you have taken brake fluid internally, seek medical assistance IMMEDIATELY. e The EPA warns that prolonged contact with used engine oil may cause a number of skin disorders, including cancer! You should make every effort to minimize your exposure to used engine oil. Protective gloves should be worn when changing oil. Wash your hands and any other exposed skin areas as soon as possible after exposure to used engine oil. Soap and water, or waterless hand cleaner should be used. e All new vehicles are now 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 repairs. ¢ Always wear safety goggles when working with, or around, the air bag system. When carrying a non-deployed air bag, be sure the bag and trim cover are pointed away from your body. When placing a nondeployed air bag on a work surface, always face the bag and trim cover upward, away from the surface. This will reduce the motion of the module if it is accidentally deployed. Refer to the additional air bag system precautions later in this section. ¢ Clean, high quality brake fluid froma sealed container is essential to the safe and

proper operation of the brake system. You should always buy the correct type of brake fluid for your vehicle. If the brake fluid becomes contaminated, completely flush the system with new fluid. Never reuse any brake fluid. Any brake fluid that is removed from the system should be discarded. Also,

do not allow any brake fluid to come in contact with a painted surface; it will damage the paint. e Never operate the engine without the proper amount and type of engine oil: doing so WILL result in severe engine damage. e Timing belt maintenance is extremely important! Many models utilize an interference-type, non-freewheeling engine. If the timing belt breaks, the valves in the cylinder head may strike the pistons, causing potentially Serious (also time-consuming and expensive) engine damage. Refer to the maintenance interval charts in the front of this manual for the recommended replacement interval for the timing belt, 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 computer system(s) and may require the computer to undergo a relearning process once the negative battery cable is reconnected. e When servicing drum brakes, only disassemble and assemble one side at a time, leaving the remaining side intact for reference.

:

To install: 3. Install or connect the following: ¢ Alternator e Alternator mounting bolts and torque them to 37 ft. Ibs. (50 Nm)

¢ Alternator rear mounting bracket and torque the bolts to 37 ft. Ibs. (50 Nm) ¢ Drive belt ¢ Regulator connector and battery to

REMOVAL 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Negative battery cable Regulator connector and battery to alternator terminal from the rear of the alternator Accessory drive belt Rear mounting bracket Alternator mounting bolts Alternator

VALE EL LEE,

PRECAUTIONS

ENGINE REPAIR

All 5.7L (VIN G) engines use a Direct Ignition System.

Alternator

OS

93062624

Exploded view of the alternator—5.7L engine

Y-BODY—GENERAL MOTORS SOREL

RVETTE

alternator terminals and torque the alternator terminal nut to 10 inch lbs. (13 Nm) e Negative battery cable

Engine Assembly

Intake Air Temperature (IAT) sensor electrical connector

Mass Air Flow (MAF) sensor electrical connector Air intake duct and air cleaner

Upper radiator support Radiator Electronic Brake Control Traction Module/Brake Pressure Modulator

REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. The following tools will be required in addition to the basic hand tools: e Transverse spring compressor and adapters e Ball joint separator e Engine support table e Driveshaft support strap e Fuel pressure gauge 2. Relieve the fuel system pressure. 3. Drain the cooling system. 4. Drain the engine oil. 5. Evacuate the A/C system. 6. Remove or disconnect the follow-

Valve (EBTCM/BPMV) and bracket Brake pipes Accessory drive belt Fuel line from the connector at the front of the dash e>Cap and plug all openings for the fuel system to prevent contaminants from entering the system.

Fuel rail covers Fuel line at the fuel rail Radiator hoses from the water pump Heater hoses from the water pump Fuel injector electrical connectors Ignition coil main harness connec-

30-3

Evaporative Emission (EVAP) solenoid electrical connector Electric throttle motor electrical connector Throttle Position Sensor (TPS) electrical connector Engine Coolant Temperature (ECT) sensor electrical connector A/C compressor electrical connector Alternator electrical connectors Alternator Brake booster vacuum hose Intermediate shaft to steering gear

bolt Intermediate shaft from the steering gear Secondary Air Injection (AIR) hose from the left exhaust manifold Both front wheels Heated Oxygen (HO2S) sensor connectors from the intermediate exhaust pipes Intermediate exhaust pipes Close-out panel Starter motor electrical connectors

Starter motor Oil level sensor connector Crankshaft Position (CKP) sensor electrical connector A/C compressor hose assembly Engine oil temperature sensor electrical connector Left Heated Oxygen (HO2S) sensor 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 crossmember, if equipped Electronic Variable Orifice (EVO)

tor

79222602

ss the front transverse spring—5.7L (VIN G) Use a compressor such as J 33432-A to compre engine

connector clips from the crossmember, if equipped Real Time Damping (RTD) connector clips from the crossmember, If equipped Shock absorber lower mounting bolts e®eeee ee® Front transverse leaf spring Automatic transmission cooler pipes at the flywheel housing junction Automatic transmission cooler pipe clamps from the engine oil pan Automatic transmission cooler pipe from the radiator

Labor Guide For complete service labor times, order Nichols’ Chilton

30-4

GENERAL MOTORS CORPORATION—Y-BODY CORVETTE

«2k CAUTION Failure to use the minimum fastener length specified will prevent the proper retention of the propeller shaft

during assembly. 7. For vehicles with an automatic transmission, perform the following steps: a. Remove the two plug bolts in the driveline support assembly. b. Install an M10 x 55 bolt, or longer, in each plug location. Torque the bearing support bolts to 26 ft. Ibs. (35 Nm). 8. On vehicles with automatic transmission, remove the bell housing inspection cover, then turn the flywheel hub collar to access the bolt and loosen it. 9. Remove the engine flywheel housing access plug. 10. Rotate the automatic transmission collar so that the bolt is facing down. 11. Loosen the bolt 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. 79227603

On automatic transmission vehicles, remove the plugs from the driveline support assembly and

install 2 M10 x 1.5 bolts into the plug holes

+ CAUTION Never use a driveline support tool to support the weight of the engine assembly. 13. If equipped with a manual transmission, perform the following steps: a. Unclip the clutch actuator hose from the engine flywheel housing clip. b. Using a hydraulic clutch line separator tool, depress the white release ring on the actuator hose and pull lightly on the master cylinder hose. Cc. Remove the flywheel housing bolts from the driveline support. 14. Support the engine and crossmember assembly. 15. Remove or disconnect the following: ¢ Front crossmember nuts BY HAND and lower the engine assembly slightly

Secondary Air Injection (AIR) tube

79222604

Loosen the bolt on the flywheel hub collar after turning it for access

bracket bolt and reposition the bracket to gain access to the ground strap Ground strap from the rear of the left cylinder head Engine oil pressure sensor electrical connector Camshaft Position (CMP) sensor electrical connector

Manifold Absolute Pressure (MAP) sensor electrical connector

Y-BODY—GENERAL MOTORS CORPORATION

CORVETTE

J 42203 79227605

Install a Driveline Support tool J 42203 to the under cover flange

e Knock Sensor (KS) electrical connector ¢ Front driveline support assembly bolts e Engine from the driveline, by placing a flat blade tool between edge of the driveline and the flywheel housing 16. Pull the engine away from the propeller shaft. 17. Raise the vehicle off of the engine and crossmember. 18. Remove the engine mount-to-cross~ member nuts. 19. Remove the engine from the crossmember. To install: 20. Install the engine on the crossmember and torque the nuts to 40 ft. Ibs. (54 Nm). 21. Lower the vehicle onto the engine/crossmember assembly. 92. Install or connect the following: ¢ Power steering pump and reservoir on the engine and torque the bolts to 18 ft. Ibs. (25 Nm) ¢ Ground strap to the rear of the left cylinder head and torque the bolt to 24 ft. Ibs. (32 Nm) e Engine oil pressure sensor electrical connector

CMP sensor electrical connector MAP sensor electrical connector KS electrical connector install or connect the following: Front driveline support bolts and torque them to 37 ft. Ibs. (50 Nm) Air tube and bracket and torque the bolt to 37 ft. Ibs. (50 Nm) New crossmember nuts and torque them to 81 ft. Ibs. (110 Nm) Flywheel housing bolts and torque them to 37 ft. Ibs. (50 Nm) Clutch actuator hose to the flywheel housing (if equipped) Master cylinder hose to the clutch actuator hose (if equipped) Wire harness to the rear of the engine 23. Remove the driveline support tool. 24. Remove the M10 x 55mm bolts from the driveline support assembly. e Two plugs in the driveline support assembly after removing the M10 x 55 bolts and torque them to 37 ft. Ibs. (50 Nm) e Automatic transmission oil cooler pipes at the flywheel housing junction and torque them to 20 ft. Ibs. (27 Nm) (if equipped) e Automatic transmission cooler pipes to the front and rear of the oil pan

Please visit our web site at www.chiltonsonline.com

30-5

Front transverse spring and torque the bolts to 46 ft. Ibs. (62 Nm) Shock absorber lower mounting nuts and torque them to 21 ft. Ibs. (28 Nm) Front stabilizer shaft and torque the bolts to 53 ft. Ibs. (72 Nm) ABS electrical connector EVO electrical connector RTD electrical connector Tie rods to the steering knuckle and torque the nuts to 33 ft. Ibs. (45 Nm). Radiator Cooling fan assembly to the radiator and attach the electrical connectors to the fans Ground wires to the left side of the engine HO2S sensor connectors Engine oil temperature sensor connector A/C compressor hoses to the compressor A/C compressor line retaining bolt and torque it to 26 ft. Ibs. (35 Nm) CKP sensor electrical connector Oil level sensor electrical connector Wire harness ground wires to the right side of the engine Starter motor and torque the bolts to 37 ft. Ibs. (60 Nm) Driveline close out panel and torque the bolts to 106 inch Ibs. (12 Nm) Intermediate exhaust pipe and hangers and torque the bolts to 37 ft. Ibs. (560 Nm) and the nuts to 15 ft. Ibs. (20 Nm) Front wheels Automatic transmission cooler pipes to the radiator (if equipped) and torque the fittings to 26 ft. Ibs. (35 Nm) AIR hose to the left exhaust manifold Intermediate steering shaft to the steering gear and torque the bolt to 35 ft. Ibs. (48 Nm) Brake booster vacuum hose Alternator bracket and torque the bolts to 37 ft. Ibs. (60 Nm) Alternator and torque the bolts to 37 ——ft. Ibs. (60 Nm) Alternator connectors and torque the nuts to 10 ft. Ibs. (13 Nm) Fuel injector electrical connectors Ignition coil main electrical connectors

30-

GENERAL MOTORS CORPORATION—Y-BODY CORVETTE

EVAP solenoid electrical connectors Throttle motor electrical connector ECT sensor electrical connector TPS electrical connector A/C compressor electrical connector Heater hoses to the water pump Radiator hoses to the water pump Fuel line to the fuel rail

Fuel rail covers Drive belt EBTCM/BPMV bracket and torque the bolts to 20 ft. Ibs. (27 Nm) EBTCM/BPMV to the bracket and torque the nuts to 89 inch Ibs. (10 Nm) Upper radiator hose Upper radiator support Air cleaner and air intake duct IAT sensor electrical connector MAF sensor electrical connector Negative battery cable 20. Fill the engine with new oil. 26. Fill the cooling system. 27. Evacuate and recharge the A/C system. 28. On vehicles with an automatic transmission, start the engine and allow it to idle for 10 minutes. Torque the hub collar bolt to 96 ft. Ibs. (130 Nm) and install the flywheel inspection plug. 29. A wheel alignment is recommended when the engine and crossmember have been removed from the vehicle. 30. Check the vehicle for leaks and repair if necessary.

Water Pump

|

REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the cooling system. 3. Remove or disconnect the following: ¢ Negative battery cable e Intake Air Temperature (IAT) sensor electrical connector Mass Air Flow (MAF) sensor electrical connector Air intake duct Accessory drive belt Inlet and outlet hoses from the water pump Heater hoses from the water pump Water pump pulley bolts and pulley (if equipped)

Six water pump retaining bolts Water pump

79222608

Exploded view of the water pump mounting assembly—5.7L engine

To install: 4. Install or connect the following: New gasket with the tabs facing up Water pump. Torque the bolts to 11 ft. lbs. (15 Nm) and then to 22 ft. lbs. (30 Nm). Water pump pulley (if equipped). Torque the bolts to 89 inch Ibs. (10 Nm) and then to 18 ft. Ibs. (25 Nm). Heater hoses to the water pump Radiator inlet and outlet hoses to the water pump Accessory drive belt Air intake duct MAF sensor electrical connector IAT sensor electrical connector Negative battery cable 9. Fill the cooling system. 6. Start the vehicle and check for leaks, repair if necessary.

Cylinder Head REMOVAL & INSTALLATION —_——————

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the engine coolant. 3. Relieve the fuel system pressure. 4. Remove or disconnect the following: ¢ Negative battery cable ¢ Rocker arm cover ¢ Exhaust manifold from the cylinder head Intake manifold Vapor vent pipe Power steering pump pulley, if removing the left side

¢ Power steering pump and reposition it, if removing the left side ¢ Power steering pump bracket, if removing the left side ¢ Ground wire bolt from the rear of the cylinder head, if removing the left side e Cylinder head To install: ->New M11 cylinder head bolts must be used when installing the cylinder head assembly.

9. Install the new cylinder head gasket onto the locating pins. 6. Place the cylinder head on the engine and tighten the bolts in sequence to: a. M11 bolts: 22 ft. Ibs. (30 Nm). b. M11 bolts: plus 90 degrees. c. M11 bolts 1-8: plus 90 degrees. d. M11 bolts 9-10: plus 50 degrees.

é. M8 bolts (11-15): 22 ft. Ibs. (30

Nm). 7. Install or connect the following: ¢ Ground wire to the rear of the cylinder head and torque the bolt to 24 ft. Ibs. (32 Nm), if removed Power steering pump bracket and torque the bolts to 37 ft. Ibs. (50 Nm) , if removed Power steering pump and torque the bolts to 18 ft. Ibs. (25 Nm) , if removed Power steering pump pulley, if removed Exhaust manifold and torque the bolts, in sequence, to 11 ft. Ibs. (15

Nm), then to 18 ft. Ibs. (25 Nm) Valve rocker arm cover and torque

-Y-BODY—GENERAL MOTORS ORR :

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OR VETTE

30-7

9, With the engine in this position, tighten the exhaust valve rocker arm bolts on cylinders No. 1, 2, 7 and 8 to 22 ft. Ibs. (30 Nm), then, tighten the intake valve rocker arm bolts on cylinders No. 1, 3, 4 and 5 to 22 ft. Ibs. (30 Nm). 10. Rotate the crankshaft 1 revolution (360 degrees). 11. With the engine in this position, tighten the exhaust valve rocker arm bolts on cylinders No. 3, 4, 5 and 6 to 22 ft. Ibs. (30 Nm), then, tighten the intake valve rocker arm bolts on cylinders No. 2, 6, 7 and 8 to 22 ft. Ibs. (30 Nm). 12. Install the rocker arm cover using a new gasket and torque the bolts to 106 inch lbs. (12 Nm). 13. Negative battery cable. 14. Start the vehicle and check for leaks, repair if necessary.

Intake Manifold 79222611

7

REMOVAL & INSTALLATION

Be sure the tab on the edge of the gasket is closer to the front of the engine when installed

>The intake manifold, throttle body, fuel injectors and rail may be removed from the engine as an assembly.

79222612

Cylinder head bolt torque sequence—5.7L engine

the bolts to 106 inch Ibs. (12 Nm) e |ntake manifold and torque the bolts in sequence to 44 inch Ibs. (5 Nm) then to 89 inch Ibs. 910 Nm) e Vapor vent pipe and torque the bolt to 106 inch Ibs. (12 Nm) ¢ Negative battery cable

8. Fill the cooling system. 9. Start the vehicle and check for leaks, repair if necessary.

REMOVAL & INSTALLATION =>Always keep the rocker arms and pushrods in order so they can be instatled in their original positions. 1. Before servicing the vehicle, refer to

the precautions in the beginning of this section. 2. Relieve the fuel system pressure. 3. Remove or disconnect the following: e Rocker arm cover e Rocker arm e Rocker arm, push rods and pedestals e Rocker arm pivot support, if necesSary To install: 4. \f removed, install the rocker arm pivot support. 5. Lubricate the rocker arms and pushrods with clean engine oil. 6. Lubricate the flange and washer surface of the rocker arm mounting bolts. 7. Install the rocker arms but do not tighten the bolts at this time. 8. Rotate the crankshaft so the No. 1 piston is at Top Dead Center (TDC).

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the cooling system. 3. Relieve the fuel system pressure. 4 Remove or disconnect the following: e Intake Air Temperature (IAT) sensor electrical connector Mass Air Flow (MAF) sensor electrical connector Air intake duct Fuel line from the fuel rail Vacuum ventilation hose Fuel injector electrical connectors Throttle Position Sensor (TPS) electrical connector Knock Sensor (KS) connector KS jumper pigtail from the fuel rail stop bracket Positive Crankcase Ventilation (PCV) valve pipes from the rocker arm covers PCV tube from the throttle body Engine cooling air bleed hose from the throttle body Throttle body heater outlet hose Intake manifold and fuel stop bracket To install: 5. Apply a 0.20 in. (mm) bead of threadlock to the threads of the intake manifold bolts.

Timing belt service is covered in Section 3 of this manual

30-

GENERAL MOTORS CORPORATION—Y-BODY CORVETTE

93462GB1

Intake manifold torque sequence—5.7L engine

test: CAUTION The fuel rail stop bracket must be installed on the intake manifold in its original position. Failure to reinstall this part may result in fuel spray Causing personal injury. 6. Install or connect the following: e Intake manifold with a new gasket e Fuel stop bracket e Intake manifold bolts and torque the bolts first to 44 inch Ibs. (5 Nm) in the sequence shown, then

make a second pass and tighten the bolts to 89 inch Ibs. (10 Nm) Throttle body heater outlet hose Engine coolant air bleed hose PCV tube PCV valve pipes KS sensor jumper pigtail KS electrical connector TPS electrical connector Fuel injector electrical connectors Vacuum vent hose Fuel line Air intake duct IAT sensor electrical connector MAF sensor electrical connector Negative battery cable 7. Fill the cooling system. 8. Start the vehicle and check for leaks, repair if necessary.

Exhaust Manifold

REMOVAL & INSTALLATION Left Side

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Relieve the fuel system pressure. 3. Remove or disconnect the following:

Negative battery cable Left hand intermediate pipe flange nuts from the exhaust manifold studs Heated Oxygen (HOS) sensor Alternator electrical connector Engine Coolant Temperature (ECT) sensor electrical connector Accessory drive belt Alternator Secondary Air Injection (AIR) hose from the check valve AIR pipe from the exhaust manifold and reposition it AIR pipe retainer from the rear of the cylinder head and reposition it Spark plug wires Spark plugs Exhaust manifold To install: 4. Apply threadlock to the threads of the bolts. 5. Install the exhaust manifold using a new gasket. 6. Beginning with the center 2 bolts, torque the bolts to 11 ft. Ibs. (15 Nm) alternating from side-to-side until all the bolts are tight. Torque the bolts again in the same sequence to 18 ft. Ibs. (25 Nm). 7. Bend over the exposed portion of the gasket at the rear of the cylinder head. 8. Install or connect the following: Spark plugs and torque them to 11 ft. Ibs. (145 Nm) Spark plug wires AIR pipe retainer bolt to the rear of the cylinder head and torque the bolt to 15 ft. Ibs. (20 Nm) AIR pipe with a new gasket and torque the bolts to 15 ft. Ibs. (20 Nm) AIR hose to the check valve and torque it to 15 ft. Ibs. (20 Nm) Alternator and torque the bolts to 37 ft. Ibs. (60 Nm) Accessory drive belt Alternator electrical connector ECT sensor electrical connectors HO2S sensor and torque it to 30 ft. lbs. (42 Nm) Fuel lines Intermediate pipe flange-to-exhaust manifold nuts and torque them to 15 ft. Ibs. (20 Nm) Negative battery cable 9. Start the vehicle and check for leaks, repair if necessary.

Right Side 79222613

Be sure to reinstall the fuel stop bracket when installing the intake manifold

1. Before servicing the vehicle, refer to the precautions in the beginning of this section.

Y-BODY—GENERAL MOTORS CORPORATION

CORVETTE

30-59

e AIR pipe using a new gasket and torque the bolts to 15 ft. Ibs. (20 Nm) e HO2S sensor in the manifold and torque it to 30 ft. Ibs. (42 Nm) e Intermediate pipe flange-to-exhaust manifold nuts and torque them to 15 ft. Ibs. (20 Nm) e Negative battery cable 8. Start the vehicle and check for leaks, repair if necessary.

REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the cooling system. 3. Relieve the fuel system pressure. 4. Remove or disconnect the following: e Fuel lines from the fuel rail e Rocker arm covers e Rocker arms and pushrods e Both cylinder heads Valve lifter guides and the lifters e Radiator

93062625

Exploded view of the exhaust manifold—5.7L engine

2. Remove or disconnect the following: e Negative battery cable e Right side intermediate exhaust pipe nuts from the manifold studs e Heated Oxygen (HO2S) sensor e Secondary Air Injection (AIR) pipe

aN

a) rs.) y oa i )

from the exhaust manifold e Spark plug wires e Spark plugs Oil level indicator and tube Exhaust manifold To install: 3. Apply threadlock to the threads of the bolts. 4. Install the exhaust manifold using a new gasket. 5. Beginning with the center 2 bolts, tighten the bolts to 11 ft. Ibs. (15 Nm) alternating from side-to-side until all the bolts are tight. Then, tighten the bolts again in the same sequence to 18 ft. Ibs. (25 Nm). 6. Bend over the exposed portion of the gasket at the rear of the cylinder head. 7. Install or connect the following: ¢ Oil level indicator tube and torque the bolt to 12 ft. Ibs. (16 Nm) e Spark plugs and torque them to 11 ft. lps. (15 Nm) e Spark plug wires

s

s

as a handle Install three M8-1.25 x 100mm long bolts into the camshaft to use

Heater Core replacement is covered in Section 2 of this manual

Dae

30-1 e e e ¢

GENERAL MOTORS CORPORATION—Y-BODY CORVETTE

Engine front cover Oil pan Oil pump Camshaft sprocket and timing chain

e Camshaft Position (CMP) sensor bolt and sensor e Camshaft retainer plate

All camshaft bearings are the same diameter, extreme care must be taken during camshaft removal or installation to avoid damaging them. 5. Install 3 M8 x 100mm long bolts in the front of the camshaft to use as a handle. 6. Carefully remove the camshaft from the engine, be sure not to damage the camshaft bearings. To install: 7. Lubricate the camshaft with clean engine oil. 8. Install or connect the following: Three M8-1.25 x 100mm long bolts in the front of the camshaft to use as a handle Camshaft into the engine and remove the 3 bolts Camshaft retainer using a new gasket and torque the bolts to 18 ft. lbs. (25 Nm) CMP sensor with a new O-ring and torque the bolt to 18 ft. Ibs. (25 Nm) Timing chain and sprocket and torque the sprocket bolts to 26 ft. lbs. (35 Nm) Oil pump and torque the bolts to 18 ft. Ibs. (25 Nm) Oil pan with a new gasket and torque the bolts pan-to-rear cover bolts to 106 inch Ibs. (12 Nm) and the remaining bolts to 18 ft. Ibs. (25 Nm) ¢ Front cover with a new gasket and

torque the bolts to 18 ft. Ibs. (25 Nm) e Radiator e Valve lifters and lifter guides and torque the bolts to 106 inch Ibs. (12 Nm) Cylinder heads Pushrods and rocker arms Rocker arm covers with new gaskets and torque the bolts to 106 inch Ibs. (12 Nm) Fuel lines to the fuel rail ¢ Negative battery cable 9. Refill the cooling system. 10. Start the engine and check for leaks, repair if necessary.

Valve Lash

fold nuts to 15 ft. Ibs. (20 Nm) and all other bolts to 37 ft. Ibs. (50 Nm) e Negative battery cable

:

ADJUSTMENT The rocker arms on the 5.7L (VIN G) engine are bolted into position so that no adjustment is possible. If the valves are noisy, suspect low oil pressure or worn valve train components.

Starter Motor

REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the engine oil. 3. Remove or disconnect the following: Negative battery cable Alternator Washer reservoir Engine Coolant Temperature (ECT) sensor electrical connector Headlamp electrical connector Tie rods from the steering linkage Real Time Damping (RTD) sensor links, if equipped Stabilizer shaft Intermediate shaft from the steering gear Electronic Brake Control Module/Brake Pressure Modulator Valve (EBCM/BPMV) bracket and

.

REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Negative battery cable e Intermediate exhaust pipe e Starter electrical connectors e Starter bolts e Starter motor To install: 3. Install or connect the following: ¢ Starter motor and torque the bolts to 37 ft. Ibs. (50 Nm) e Starter electrical connectors e Intermediate exhaust pipe and torque intermediate pipe-to-mani-

reposition

Power steering gear

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2)

93062626

Exploded view of the starter assembly—5.7L engine

Y-BODY—GENERAL MOTORS CORPORATION

CORVETTE

30-11

93462601

Separate the upper (1) and lower (3) oil

pans

Lower shock absorber mounting bolts Transverse leaf spring using a Suitable compressor Lower control arm bolts from the Suspension crossmember Engine mount lower nuts Wheel Speed Sensor (WSS) wiring harness from the crossmember e Brake line from the crossmember 4. Support the suspension crossmember. ¢ Crossmember mounting nuts e Front crossmember e Oil filter Automatic transmission cooler line front and rear retaining clamp bolts (if equipped) Engine flywheel housing-to-oil pan bolts Engine flywheel close out bolts Engine oi! level sensor Engine oil temperature sensor electrical connector Oil pan assembly Lower oil pan bolts and separate the pans (if necessary)

79222629

Apply sealant to the areas where the front and rear covers attach to the engine block—5.7L engine

=>To remove the oil pan gasket it is necessary to drill out 3 rivets securing it to the pan.

To install: 5. If separated, connect the upper and lower oil pans with a new gasket and torque the bolts to 106 inch Ibs. (12 Nm). 6. Apply a 0.20 in. (5mm) bead of RTV sealant directly on the tabs of the front and rear cover gaskets that extend onto the oil pan mounting surface. 7. Install or connect the following: ¢ New gasket on the oil pan. It is not necessary to rivet the new gasket on the oil pan.

79222630

Exploded view of the oil pan mounting—5.7L engine

Brake service is covered in Section 4 of this manual

30-1 2 GENERAL MOTORS CORPORATION—Y-BODY CORVETTE

¢ Oil pan and hand tighten the bolts Oil pan-to-engine bolts and torque them to 18 ft. Ibs. (25 Nm) Oil pan-to-front cover bolts and torque them to 18 ft. Ibs. (25 Nm) Oil pan-to-rear cover bolts and torque them to 106 inch Ibs. (12 Nm) Flywheel housing bolts and torque them to 37 ft. Ibs. (50 Nm) Left and right close outs and bolts and torque the bolts to 106 inch lbs. (12 Nm) Engine oil temperature sensor electrical connector Engine oil level sensor and torque it to 26 ft. Ibs. (85 Nm) Automatic transmission cooler pipe front retaining clamp bolt and torque it to 106 inch Ibs. (12 Nm) Automatic transmission cooler pipe rear retaining clamp bolt and torque it to 22 inch Ibs. (3 Nm) Oil filter and torque it to 22 ft. Ibs. (30 Nm) Oil drain plug and torque it to 18 ft. Ibs. (25 Nm) 8. Raise the suspension crossmember into position. e Crossmember mounting nuts and torque them to 81 ft. Ibs. (110 Nm) Engine mount lower nuts and torque them to 48 ft. Ibs. (65 Nm) WSS wiring harness to the crossmember Brake line to the crossmember Transverse leaf spring Lower control arm to the crossmember, DO NOT torque the bolts at this time Lower shock absorber mounting bolts and torque them to 21 ft. Ibs. (28 Nm) Power steering gear and torque the bolts to 74 ft. Ibs. (100 Nm) EBCM/BPMV bracket and torque the bolts to 20 ft. Ibs. (27 Nm) Intermediate shaft and torque the pinch bolt to 25 ft. Ibs. (35 Nm) Outer tie rods and torque the nuts to 18 ft. Ibs. (25 Nm) plus an additional 180 degree turn RTD sensor electrical connector, if equipped Stabilizer shaft and torque the link nuts to 53 ft. Ibs. (72 Nm) and the Clamp bolts to 43 ft. Ibs. (58 Nm) Alternator and torque the bolts to 37 ft. Ibs. (60 Nm) Washer reservoir and torque the nuts to 66 inch Ibs. (7.5 Nm) ECT sensor electrical connector

¢ Front headlamp electrical connector e Negative battery cable 9. Fill the engine with new oil. 10. Start the vehicle and check for leaks, repair if necessary. 11. Check and adjust the front end alignment. 12. Torque the lower control arm bolts to 125 ft. Ibs. (170 Nm).

REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the engine oil. 3. Drain the cooling system. 4, Remove or disconnect the following: e Negative battery cable e Engine front cover

e Oil pan e Oil pump screen e Oil pump To install: 5. Install or connect the following: ¢ Oil pump and torque the bolts to 18 ft. lbs. (25 Nm) ->Be sure the crankshaft sprocket and oil pump drive gear are aligned properly.

Oil pump screen with a new O-ring and torque the bolt to 106 inch Ibs. (12 Nm) and the nut to 18 ft. Ibs. (25 Nm) e Oil pan e Engine front cover e Negative battery cable 6. Fill the engine with new oil. 7. Fill the cooling system. 8. Start the vehicle and check for leaks, repair if necessary.

79222632

Oil pump assembly mounting—5.7L engine

Y-BODY—GENERAL MOTORS CORPORAT

gia

30-1 3

Rear Main Seal

REMOVAL & INSTALLATION ~The rear main seal is a 1-piece unit. It can be removed or installed without removing the oil pan or crankshaft.

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Transmission e Clutch and pressure plate, if equipped with a manual transmission e Flywheel inspection cover e Flywheel 3. Using a pry tool, carefully pry the old seal out. To install: 4. \nspect the crankshaft for nicks or burrs, correct as required. 5. Clean the area and coat the seal and crankshaft with engine oil. 6. Install or connect the following: e Seal, using a Seal installer e Flywheel and torque the bolts in sequence to 15 ft. Ibs. (20 Nm) then to 37 ft. Ibs. (60 Nm) and

finally to 74 ft. Ibs. (100 Nm)

¢ Flywheel inspection cover and torque the bolts 18 ft. Ibs. (25 Nm)

93462602

Flywheel torque sequence

e Clutch and pressure plate if equipped with a manual transmission e Transmission

7. Start the vehicle and check for leaks, repair if necessary.

Timing Chain, Sprockets, Front : Cover and Seal

REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section.

2. Drain the cooling system.

Installer

3. Drain the engine oil. 4, Remove or disconnect the follow-

ing: e e e e

Negative battery cable Engine front cover Oil pan Oil pump 5. Rotate the crankshaft until the timing 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. Damage to the pistons or valves may occur.

79222634

Use a seal installer to press the seal on the crankshaft

6. Remove or disconnect the following: e Camshaft sprocket and timing chain ¢ Crankshaft sprocket using a suitable puller To install: 7. Be sure the timing mark on the crankshaft sprocket is at the 12 o'clock position. If not rotate the crankshaft to the correct position.

this manual For complete Engine Mechanical specifications, see Section 1 of

30-1 4 GENERAL MOTORS CORPORATION—Y-BODY CORVETTE

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J 8433-1 79222638

A puller is needed to remove the crankshaft sprocket

8. Install or connect the following: Crankshaft sprocket with a Crankshaft Balancer and Sprocket Installer tool Timing chain on the camshaft sprocket. Timing chain and sprocket assembly so the timing marks are aligned and torque the camshaft sprocket bolts to 26 ft. Ibs. (35 Nm) Oil pump and torque the bolts to 18 ft. Ibs. (25 Nm) Oil pan with a new gasket Front cover with a new gasket and seal and hand tighten the bolts at this time 9. Install the oil pan to cover bolts and hand-tighten them at this time. Make certain that the front cover is properly aligned and torque the oil pan-to-front cover bolts to 18 ft. Ibs. (25 Nm) then the remaining bolts to 18 ft. Ibs. (25 Nm). 10. Connect the negative battery cable. 11. Fill the cooling system. 12. Fill the engine with new oil. 13. Start the vehicle and check for leaks, repair if necessary.

J 41665— 1 9346ZGB2

Timing chain alignment—5.7L engine

79227639

Be sure to install the crankshaft sprocket properly

Y-BODY—GENERAL MOTORS CORPORATI

|

Piston and Ring

Hite

Ca?

|t may be necessary to rotate the sender for proper installation.

12. Look into the fuel tank opening and make certain that the long strainer is visible. If it is not visible, rotate the fuel sender until the strainer is free 13. Align the fuel sender gasket tab with the fuel sender cover mark and align the cover mark with the fuel tank mark. 14. Install the new break away head attaching bolts to the fuel sender and hand tighten them.

- The upper hex head portion of the fuel sender attaching bolts is designed to shear off the lower section of the bolt when the proper torque is reached. Do not tighten the bolts after the head is sheared off.

15. Tighten the new break away attaching bolts in sequence until the hex head shears off of the lower section. 16. Install or connect the following: Fuel feed and return pipes Fuel sender electrical connector Fuel tank strap and torque the bolts to 18 ft. Ibs. (25 Nm) Fuel tank shield and torque the bolts to 18 ft. Ibs. (25 Nm) Both rear wheels

Negative battery cable

79222641

Tighten the fuel pump mounting bolts in the sequence shown—5.7L engine

79222640

Fold the strainer on itself 3 times so it will fit into the opening in the fuel tank

17. Fill the fuel tank and install the fuel filler cap. 18. Turn the ignition ON for 2 seconds, OFF for 10 seconds, then ON again and inspect the system for leaks.

Fuel Injector

2. Relieve the fuel system pressure. 3. Remove or disconnect the following: 6 e

Both fuel rail covers Fue feed hose from the fuel rail

e Fuel injector electrical connectors Fue rail mounting bolts Fuel rail 4. Spread the injector clip to release the injector from the fuel rail. 5. Fuel injector by spreading the retaining clip. e

.

REMOVAL & INSTALLATION

EE

1. Before servicing the vehicle, refer to the precautions in the beginning of this section.

this manual For Tire, Wheel and Ball Joint specifications, see Section 1 of

30-1

GENERAL MOTORS CORPORATION—Y-BODY CORVETTE

To install:

>The fuel injector is stamped with a part number identification, manufacturing date, week code and plant number. Make certain the correct injector is ordered when replacing them.

6. Lubricate the new injector seals with clean oil. 7. Install or connect the following: e New O-ring seals on the injectors e New retainer clip on the injector

e Fuel injector into the fuel rail socket

¢ CAUTION The fuel rail stop bracket must be installed onto the engine. The bracket serves as protection for the fuel rail in the event of a frontal crash. If the bracket is not installed, fuel could spray possibly causing a fire and personal injury.

Fuel rail and ground strap to the intake manifold and torque the fuel rail attaching bolts to 89 inch Ibs. (10 Nm) Electrical connectors to the injectors Fuel feed hose to the fuel rail Negative battery cable Left and right fuel rail covers 8. Turn the ignition ON for 2 seconds, OFF for 10 seconds, then ON again and inspect the system for leaks.

DRIVE TRAIN Transmission Assembly REMOVAL & INSTALLATION Automatic

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Disconnect the negative battery cable. 3. Shift the transmission into N. 4. Remove or disconnect the following: e Rear wheels e Intermediate exhaust pipe

e Right side muffler and tie the left side muffler to the underbody ¢ Driveline tunnel closeout panel ¢ Rear bell housing access plug and miatchmark the flexplate to the torque converter e Flexplate-to-torque converter bolts ¢ 2 plug bolts from the front of the driveline support assembly 5. Install two M10 x 1.5 x 55mm or longer bolts into the bolt holes. Torque the bolts to 26 ft. Ibs. (35 Nm). These bolts must remain installed until instructed to remove them in order to maintain the position of the input shaft bearing.

6. Remove or disconnect the following; Engine flywheel housing access

plug

Propeller shaft hub clamp bolt Shift cable bracket nuts Shift control cable from the shift lever Rear transverse spring and support the lower control arms Outer tie rod ends from the knuckle Shock absorber lower mounting bolts Lower ball joints from the knuckles 7. Install a transmission support fixture to the transmission. Wiring harness and brake pipe clip retainers from the rear crossmember Lower transmission-to-differential nut Transaxle mount-to-rear crossmember nut

Rear crossmember retaining nuts while supporting the crossmember Crossmember e Transaxle mount bracket 8. Meats the axle shafts from the differential and tie them to the underbody, 9. Release the retainer securing the wiring harness from the “L” shaped brackets along the driveline support and move the harness out of the way. 10. Lower the driveline slightly and tilt it to gain access to the electrical connec-

m)

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ae

79227642

Remove the inspection plug, then remove the flexplate-to-torque converter bolts

11. Remove or disconnect the following: Vehicle Speed Sensor (VSS) electrical connector Wire harness retainer from the differential rear cover stud Wire harness retainer clip from the top of the differential Transmission harness 20 way connector Park Neutral Position (PNP) switch electrical connectors

Y-BODY—GENERAL MOTORS CORPORATION

pura

REESE Remove the plugs and install two M10 x 1.5 x 55mm or longer bolts into the bolt holes to

secure the bearing—5.7L engine

Ge

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Ly.

30-1 g

e Bolt securing the wire harness to the left side of the case 12. Lower the driveline and angle it while observing the top rear of the differential and the lowest part of the rear compartment floor panel. The engine Positive Crankcase Ventilation (PCV) pipes will most likely contact the dash panel. Make certain not to damage the dash. 13. Remove or disconnect the following: e Wire harness from the retainer along the top of transmission e Transmission rear oil cooler pipes from the junction fittings at the flywheel housing e 5 driveline to flywheel housing bolts after supporting the rear of the engine 14. Bend the wiring harness bracket away from the driveline, toward the tunnel wall to have access to remove the driveline. 15. Separate the driveline from the engine by prying them apart with a flat blade tool. 16. Lower the driveline and tilt it away from the engine until the input shaft clears the flywheel housing. 17. Remove or disconnect the following: . Driveline os ig F ¢ Transmission oil cooler rear pipes from the fittings e Transmission to driveline bolts ¢ Separate the transmission from the driveline with a flat blade tool 18. Using a lifting device, place the assembly on a bench. Rear transmission oil cooler fittings from the transmission Transmission-to-driveline assembly support bolts e Driveline from the transmission while supporting the torque converter Differential-to-transmission bolts

PL

e Differential from the transmission

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To install:

ANY

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19. Installorconnect the following:

SSE

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WHS

¢ Differential to the transmission and

in

to37ft.Is. (50 torquethebolts

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la

79222644 it—5.7L engine Rotate the flywheel to gain access to the clamp bolt, then loosen

Nm) e Transmission to the driveline support and torque the bolts to 37 ft. lbs. (60 Nm) e Rear transmission oil cooler fittings to the transmission and torque the fittings to 30 ft. Ibs. (40 Nm) 20. Using a chain hoist, place the assembly on a transmission jack. 21. Carefully raise the assembly into the

l For Wheel Alignment specifications, see Section 1 of this manua

30-2

GENERAL MOTORS CORPORATION—Y-BODY CORVETTE

79222645

Transmission-to-differential mounting bolt locations—5.7L engine

vehicle while placing the wiring harness loosely into the harness retaining slots. 22. Align the assembly for installation into the engine. The driveline will slide into the rear of the engine as long as the angles are the same. 23. Install or connect the following: Driveline assembly in the vehicle. Reposition the wiring harness bracket to align with the appropriate hole in the driveline assembly. Driveline support-to-flywheel housing bolts and torque them to 37 ft. lbs. (50 Nm) Oil cooler lines and torque the fittings to 20 ft. Ibs. (27 Nm) Wiring harness to the left side of the transmission and torque the bolt to 22 inch Ibs. (2.5 Nm) PNP switch electrical connector Transmission harness 20 way connector Wiring harness clip to the top of the differential VSS electrical connector 24. Raise the transmission to installation

height.

e

Axle shafts Transmission mount to the crossmember and torque the nuts to 37 ft. Ibs. (50 Nm) Suspension crossmember and torque the nuts to 81 ft. Ibs. (110 Nm) Lower transmission-to-differential nut and torque it to 37 ft. Ibs. (50 Nm) Wiring harness and brake pipe clip retainers to the crossmember Lower ball joints to the suspension knuckles and torque the nuts to 52 ft. Ibs. (70 Nm) Shock absorber lower mounting bolts and torque them to 162 ft. Ibs. (220 Nm) Outer tie rod ends to the knuckles

and torque the nuts to 15 ft. Ibs. plus an additional 160 degrees Rear transverse spring and torque the bolts to 46 ft. Ibs. (62 Nm) Wiring harness into the “L” shaped brackets Transmission cable and bracket and torque the nuts to 15 ft. Ibs. (20 Nm) Transmission flexplate to the torque converter using the matchmarks made during removal and torque

the bolts to 47 ft. Ibs. (63 Nm) Rear bell housing access plug Propeller shaft hub bolt until it is finger tight 25. Remove the two M10 x 55mm bolts from the input shaft front bearing. 26. Install or connect the following: 2 plug bolts to the driveline support assembly and torque the bolts to 37 ft. Ibs. (60 Nm) Driveline tunnel closeout panel and torque the bolts to 89 inch Ibs. (10 Nm) Right hand muffler assembly Intermediate pipe and torque the bolts to 37 ft. Ibs. (50 Nm) Both rear wheels Negative battery cable Zl. 9tart the vehicle and allow it to reach normal operating temperature. Turn the engine OFF. Allow the engine to cool to ambient temperature, then tighten the flywheel hub collar bolt to 96 ft. Ibs. (130 Nm). 28. Install the bell housing inspection plug. 29. Flush the automatic transmission oil cooler.

30. A front end alignment is recommended when the crossmember is removed. Manual

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 Both rear wheels Folding top stowage compartment lid extension panel (on convertible models) Traction control/ride control switch Console retaining nut covers Console retaining nuts Accessory plug electrical connector Fuel door release electrical connector Console Shift control knob button

Shift control knob retainer Shift contro! knob Shift contro! boot by grabbing both sides and pulling it in toward the lever e Ashtray Trim plate grill Retaining screws located behind the grill and behind the ashtray Instrument panel accessory trim plate Shift control closeout boot retaining nuts and boot Shift rod clamp bolt Shift control! mounting bolts Shift control assembly Courtesy lamp Left side lower closeout panel while guiding the courtesy lamp through the hole Clutch master cylinder pushrod retainer and the pushrod from the pedal Clutch actuator cylinder hose from the retainer clip Clutch actuator hose from the master cylinder hose Rear wheels Intermediate exhaust pipe and secure the mufflers out of the way Driveline closeout panel Rear transverse spring Outer tie rod ends Lower shock absorber bolts Lower ball joints 3. Support the transmission Wiring harness and brake lines from the suspension crossmember Lower transmission-to-differential nut Transmission mount-to-crossmember nuts Rear Suspension crossmember nuts Transmission mount and bracket from the differential Axle shafts from the differential and position them out of the way Wiring harness from the driveline support assembly

Y-BODY—GENERAL MOTORS CORPORATION

CORVETTE 30-21

e Reverse lockout solenoid electrical connector e Gear select (skip shift) solenoid electrical connector e Transmission fluid temperature sensor electrical connector (if equipped) 6. Support the rear of the engine ¢ Driveline support-to-bell housing bolts Driveline support assembly out of the bell housing while moving the assembly rearward 7. Carefully lower the assembly away from the vehicle while simultaneously adjusting the angle. 8. Attach a chain hoist to the assembly, then remove it from the jack and place it on a workbench. 9. Remove or disconnect the following: ¢ Driveline support-to-transmission mounting bolts. Carefully pry the driveline assembly away from the transmission while guiding the shift rod through the opening in the driveline support e Transmission shift rod from the

79227646

transmission

the Insert a flat bladed tool between the shifter bracket and brake liner retainer before lowering transmission assembly—5.7L engine

Transmission-to-differential mounting bolts and separate the differential from the transmission To install: 10. Install or connect the following: ¢ Differential to the transmission and torque the bolts to 37 ft. Ibs. (50 Nm) e Transmission shift rod e Driveline support to the transmis-

=

sion and torque the bolts to 37 ft.

Ibs. (50 Nm)

0 en RE — Sata SN >.

ea *)

11. To aid in later installation place a AS

pe Driveline support-to-transmission mounting—5.7L engine e Harness clip from the top of the differential

5. Remove or disconnect the follow-

ck WARNING

: of portion rear top the lower not Do differential past the bottom of the the i BiOrage compartment of eee Hee will hit the dash panel possibly cals;

ing damage.

4. Lower the transmission enough to remove the wiring harness from the top of the assembly.

ing: ae

e

Vehicle Speed Sensor (Vo) élec | trical connector

-

¢ Backup lamp switch electrical connector

rubber band around the shift rod then tape the shift rod to the driveline support assembly. 12. Place the assembly on the transmission jack with a chain hoist. 13, Begin to raise the assembly into the vehicle while loosely installing the wiring harness along the driveline assembly retaining slots. ee Have an assistant guide the front of the driveline support to the bell housing. 15. Be sure the driveline assembly is at

the same angle as the engine before trying to install it. following: 16. i Install or connect the ee Input propeller shaft into the ciutc disc ¢ Wiring harness bracket to align

Neen

n 1 of this manual For Maintenance Interval recommendations, see Sectio

30-22 GENERAL converte

MOTORS CORPORATION—Y-BODY

79222649

Pull the shift rod up to break the tape and

hook the rubber band on the rear stud— 5.7L engine

79222648

Place a rubber band on the shift rod, then tape the rod to the driveline support assembly—5.7L engine

with the appropriate hole in the driveline assembly Driveline support-to-flywheel housing bolts and torque them to 37 ft. lbs. (50 Nm) Wiring harness to the retainer on the top of the transmission and attach the connectors Transmission fluid temperature sensor electrical connector (if equipped) Gear select/skip shift solenoid electrical connector Reverse lockout solenoid electrical connector Backup lamp switch electrical connector Wiring harness to the top of the differential VSS electrical connector Axle shafts in the differential Transmission mount on the differential and torque the bolts to 37 ft. lbs. (50 Nm) Rear suspension crossmember and torque the nuts to 81 ft. Ibs. (110 Nm) Transmission mount-to-crossmember nuts and torque them to 37 ft. lbs. (50 Nm)

Lower transmission-to-differential nut and torque it to 37 ft. Ibs. (50 Nm) Wiring harness and brake line retainers to the crossmember Lower ball joints and torque the nuts to $2 ft. Ibs. (70 Nm) Shock absorber lower mounting bolts and torque them to 162 ft. lbs. (220 Nm) Outer tie rod ends and torque the nuts to 15 ft. Ibs. (20 Nm) plus an additional 160 degrees Transverse spring and torque the mounting bolts to 46 ft. Ibs. (62 Nm) Clutch actuator hose to the master cylinder hose Clutch actuator hose to the retaining clip Driveline tunnel closeout panel and torque the bolts to 89 inch Ibs. (10 Nm) Muffler assemblies Intermediate exhaust pipe and torque the bolts to 37 ft. Ibs. (50 Nm) Rear wheels Clutch master cylinder pushrod to the clutch pedal

e Clutch master cylinder pushrod retainer e Left lower closeout panel e Courtesy lamp 17. Pull up the shift rod to break the tape and hook the rubber band on the rear stud on the top of the driveline tunnel. e¢ Shift control assembly and torque the bolts to 22 ft. Ibs. (30 Nm) e Shift control closeout boot and torque the nuts to 106 inch Ibs. (12 Nm) e Instrument panel accessory trim plate ¢ Shift contro! boot e¢ Shift contro! knob e Shift contro! knob retainer and button e Console ¢ Fuel door release electrical connector ¢ Accessory plug electrical connector ¢ Console retaining nuts and torque them to 89 inch Ibs. (10 Nm) ¢ Console retaining nut covers ¢ Traction control/ride control switch ¢ Folding top stowage compartment lid extension panel e Rear wheels Negative battery cable 18. Bleed the clutch system.

ADJUSTMENT a

ee

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove the flywheel inspection cover. 3. Have an assistant depress the clutch pedal until the tension is released from the Stepped adjusting ring. 4. Using 2 screwdrivers, rotate the Stepped adjusting ring counterclockwise until fully adjusted out.

5. Continue to hold them in this position and have the assistant release the Clutch pedal.

Y-BODY—GENERAL MOTORS CORPORATION

CORVETTE

30-23

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. 3. Raise and safely support the vehicle with an assistant in it. 4 Remove the intermediate exhaust pipe. 5. Remove the driveline tunnel cover. 6. Have the assistant depress and hold the clutch pedal down. 7. Loosen the bleeder screw on the actuator cylinder to release the air, then tighten the screw.

WARNING Do not allow the clutch pedal to be released until the bleeder screw is closed or air will be drawn into the system.

79222652

Rotate the stepped adjusting ring counterclockwise to compress the springs

6. Remove the screwdrivers. 7. Install the inspection cover. Torque the bolts to 18 ft. Ibs. (25 Nm).

REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the follow~ ing:

cs)

79222650

Clutch assembly torque sequence

Negative battery cable Exhaust system Driveline support and transmission as an assembly Flywheel inspection cover Pressure plate bolts. It will be necessary to rotate the flywheel to access all the bolts Pressure plate and disc To install: 3. Install or connect the following: e Clutch disc and pressure plate on the flywheel ¢ Clutch disc alignment tool through the disc to keep it in place e Pressure plate bolts finger-tight. Turn the flywheel to access all the bolt holes 4. Torque the bolts in the sequence shown, using 3 steps to 52 ft. Ibs. (70 Nm). e Inspection cover and torque the bolts to 18 ft. Ibs. (25 Nm) e Driveline support and transmission assembly e Exhaust system e Negative battery cable 5. Bleed the clutch system.

8. Repeat the prior two steps until the air has been purged from the system. Check the master cylinder fluid level and refill as needed. 9. Install the driveline tunnel cover. 10. Install the intermediate exhaust pipe. 11. Lower the vehicle.

REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Apply the parking brake. 3. Remove or disconnect the following: Wheel Axle nut Rear transverse spring Outer tie rod end from the knuckle eee @ Antilock Brake System (ABS) Wheel Speed Sensor (WSS) electrical connector Park brake cable from the lever and bracket «>Be sure to support the halfshaft until it is removed. Do not let it hang by the CV-joint.

4. Attach a puller on the wheel studs and start to push the axle shaft into the hub

For Tune-up, Capacities and Firing orders, see Section 1 of this manual

30-24

GENERAL MOTORS CORPORATION—Y-BODY CORVETTE

e Rear transverse spring and torque the bolts to 46 ft. Ibs. (62 Nm) e Halfshaft retaining nut and torque the nut to 118 ft. Ibs. (160 Nm) e Wheel

CV-Joints

OVERHAUL Inner Joint

79222653

Insert a large drift through the cooling fins to keep the hub assembly from turning while removing the retaining nut—5.7L engine

assembly. This will provide clearance for the ball joint to be separated from the knuckle assembly. 5. Remove or disconnect the following: e Ball joint from the knuckle e Axle shaft from the hub ¢ Halfshaft assembly from the differential by inserting a suitable tool between the CV-joint and differential and prying them apart To install: 6. Install or connect the following: Halfshaft on the differential output shaft. Use light force to be sure it is fully seated ¢ Halfshaft through the hub assembly but do not install completely. This will provide clearance for installing the ball joint ¢ Ball joint to the knuckle and torque thefap) nut to 41 ft. Ibs. (55 Nm) e Halfshaft through the hub assembly completely Park brake cable to the bracket and the lever WSS electrical connector Tie rod end to the knuckle and torque the nut to 15 ft. Ibs. (20 Nm) plus an additional 160 degrees

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove axle shaft. 3. Wrap a shop towel around the axle shaft. 4. Place the wheel drive shaft horizontally in a bench vise. 5. Remove the large seal retaining clamp from the CV joint seal. 6. Use a side cutter or other suitable tool and discard the clamp. 7. Remove the small seal retaining clamp from the joint seal. 8. Use a side cutter or other suitable tool and discard the clamp. 9. Separate the seal from the joint outer race at the large diameter end.

79227654

Exploded view of the halfshaft mounting—5.7L engine

Y-BODY—GENERAL MOTORS CORPORATION

CORVETTE

30-25

To install: ->Protect the wheel drive shaft boots, seals and clamps from sharp objects when servicing on or near the wheel drive shaft(s). Damage to the boot(s), 9346Z2GB7

Remove the cage from the axle shaft-inner joint

93462GB3

Separate the seal from the joint outer race

at the large diameter end-inner joint

10. Position the seal behind the joint face. 11. Position the wheel drive shaft vertically in the bench vise so the inner joint is up. 12. Slide the joint outer race down toward the vise. 13. Disengage the outer race retaining ring as follows: a. Insert a small flat bladed screwdriver between the retaining ring and the outer race. b. Pry the retaining ring from the outer race. c. Position the retaining ring along the axle shaft away from the outer race. >The balls may fall out of the cage and inner race when the outer race is removed.

9346ZGB4

Remove the outer race from the axle

shaft-inner joint

9346ZGB5

_

Remove the snap ring from the axle shaft-inner joint

9346ZGB6

Remove the inner race from the axle shaft using a three jaw puller-inner joint

14, Remove the outer race from the axle shaft as follows: a. Use the seal to catch any balls which are not retained by grease. b. Lift the outer race off the axle shaft. 15. Remove any remaining balls from the cage and inner race. 16. Remove any balls caught by the seal. 17. Position the wheel drive shaft horizontally in the bench vise. 18. Remove the outer race retaining ring from the axle shaft. 19. Remove the snap ring from the axle shaft. 20. Align the cage lands with the inner race ball tracks. 21. Reposition the cage along the axle shaft away from the inner race. 22. Wipe the grease from the inner race. 23. Remove the inner race from the axle shaft using a three jaw puller. 94. Remove the cage from the axle shaft. 95. Remove the seal from the axle shaft. 26. Remove the wheel drive shaft from the bench vise. e>All traces of old grease and any contaminates must be removed.

97. Clean al parts thoroughly with clean solvent. 98, Thoroughly air dry all the parts.

the seal(s) or the clamp(s) may cause lubricant to leak from the joint and lead to increased noise and possible failure of the wheel drive shaft.

29. Wrap a shop towel around the axle shaft. 30. Place the wheel drive shaft horizontally in a bench vise. 31. Install a new small seal retaining clamp onto the wheel drive shaft. 32. Install the seal onto the axle shaft. 33. Install the cage onto the axle shaft so the smaller diameter end faces the vise. >The inner race spline relief must face away from the end of the axle shaft.

34. Install the inner race onto the axle shaft as follows: a. Engage the inner race splines onto the axle shaft splines. Be sure to install the inner race spline relief side onto the axle shaft first. b. Position a wood block squarely over the end of the inner race. c. Use a hammer to begin to drive the inner race onto the axle shaft. d. Reposition the wood block along the face of the inner race to avoid the axle shaft. e. Work evenly around the inner race and continue to drive the inner race, until you feel the inner race seat fully onto the axle shaft. 35. Inspect to be sure that the axle shaft snap ring groove is exposed. 36. Install the snap ring to the axle shaft. 37. Position the cage so the cage lands align with the inner race ball tracks. 38. Install the cage onto the inner race. 39. Position the cage windows to align with the inner race ball tracks. 40. Insert approximately 60 percent of the grease from the service kit into the outer race. 41. Position the wheel drive shaft vertically in the bench vise so the inner joint end iS Up. 42. Apply a small amount of the grease from the service kit to the cage windows and inner race ball tracks. 43. Insert the remaining grease from the service kit into the seal.

For complete service labor times, order Nichols’ Chilton Labor Guide

30-2

GENERAL MOTORS CORPORATION—Y-BODY CORVETTE

9346ZGB8

Use a hammer and a block of wood to drive the inner race onto the axle shaft-inner joint

Ao

Cee

c. Slide the outer race down over the balls. 49. Position the wheel drive shaft horizontally in the bench vise. Engage the outer race retaining ring as follows: a. Slide the outer race toward the vise. b. Insert the outer race retaining ring into the groove along the outer edge of the outer race. c. Position the outer race retaining ring so the opening in the ring aligns with an outer race land (not a ball track). 50. Position the large diameter end of the seal onto the outer race. 51. Position the small seal retaining clamp onto the neck of the seal. 52. Position the seal and small retaining clamp to the axle shaft. 53. Measure the distance between the edge of the seal and the edge of the last axle shaft groove closing edge and adjust fit to 0.10 inch (2.5mm).

J 42572

9346ZGC2

Tighten the small seal retaining clamp until the base of the omega shape has a gap width between 0.079-0.118 inch (2-3mm), with a difference in the gap width from side to side no greater than

0.016 inch (0.4mm)-inner joint

e>The seal retaining clamp must not be over-tightened or under-tightened.

9346ZGB9

Insert approximately 60 percent of the grease from the service kit into the outer race—inner joint

aa

2 93462GC1

Measure the distance between the edge of the seal and the edge of the last axle shaft groove closing edge and adjust fit to 0.10 inch (2.5mm)-inner joint

44. Install the outer race retaining ring onto the axle shaft. 45. Position the retaining ring below the cage, toward the vise. 46. Install the balls through the cage windows to the inner race ball tracks. 47. Use the seal to keep the balls in position if necessary. 48. Install the outer race onto the axle shaft as follows: a. Be careful not to allow the grease in the outer race to leak out. b. Align the outer race ball tracks to the balls.

54. Crimp the small seal retaining clamp using tool J 42572. Tighten the small seal retaining clamp until the base of the omega shape has a gap width between 0.079-0.118 inch (2-3mm), with a difference in the gap width from side to side no greater than 0.016 inch (0.4mm). The clamping hold time must be no less than 2 seconds. 59. Measure the distance between the end of the seal and the end of the joint outer race and adjust the plunging motion of the joint to 8.90 inch within 0.16 inch (226mm within 4mm). 96. Position the large seal retaining clamp onto the seal. o/. Position the seal and large retaining Clamp to the joint outer race. Measure the distance between the edge of the seal and the edge of the joint outer race last groove Closing edge and adjust fit to 0.03 inch (0.8mm). e>The seal must not be dimpled, Stretched or out of shape in any way.

98. Inspect the seal for proper shape. If the seal is NOT shaped correctly, equalize the pressure in the seal and shape the seal properly by hand. Inspect the seal for damage. If the seal has been cut or punctured during assembly, you must discard and replace the seal. e>The seal retaining clamp must not be over-tightened or under-tightened.

99. Crimp the large seal retaining clamp using tool J 42572. Tighten the small seal

9346ZGC3

Measure the distance between the end of the seal and the end of the joint outer race and adjust the plunging motion of the joint

to 8.90-inch within 0.16 inch (226mm within 4mm-inner joint

4 93462GC4

Measure the distance between the edge of the seal and the edge of the joint outer race last groove closing edge and adjust fit to 0.03 inch (0.8mm)-inner joint

retaining clamp until the base of the omega shape has a gap width between 0.079-0.118 inch (2-3mm), with a difference in the gap width from side to side no greater than 0.016 inch (0.4mm). The Clamping hold time must be no less than 2 seconds, 60. Remove the wheel drive shaft from the bench vise.

»

Y-BODY—GENERAL MOTORS CORPORATION

CORVETTE

61. Distribute the grease within the inner CV joint. 62. Plunge the joint back and forth four Or five times. 63. Inspect the inner CV joint and wheel drive shaft for smooth operation as follows: a. Hold the wheel drive shaft vertically, with the outer joint at the bottom. b. Rotate the wheel drive shaft four or five times in a circular motion. 64. Install the axle shaft. Outer Joint 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. . 2. Remove or disconnect the following: e Axle shaft from the vehicle e Large CV boot retaining clamp e Small CV boot retaining clamp e CV boot from the joint

9346ZGC5

Separate the outer joint from the axle shaft using a hammer and wood block—outer joint

e Quter joint from the axle shaft using a hammer and wood block e Axle shaft retaining ring e CV boot 3. Disassemble the chrome alloy balls from the CV-joint cage as follows: a. Position a brass drift against the C\-joint cage and tap it with a hammer to tilt the cage. b. Remove the 1st chrome alloy ball from the cage. c. Tilt the cage in the opposite direction. d. Remove the opposite chrome alloy ball. e. Repeat the procedure until all 6 balls are removed. 4. Disassemble the CV-joint cage and inner race as follows: a. Pivot the cage and race 90 degrees to the center line of the outer race. b. Align the cage windows with outer race lands. c. Remove the cage from the outer race. d. Rotate the inner race upward and remove it from the cage. To install: 5. Lubricate the parts with a light coat of grease. 6. Assemble the CV-joint cage and inner race, as follows: a. Rotate the inner race 90 degrees to the cage centerline. b. Align the cage windows with inner race lands. c. Insert the inner race into the cage by rotating the inner race downward. d. Insert the cage/inner race into the

3 0 -21

e New retaining ring on the halfshaft e Large ring clamp on the CV boot e Quter joint onto the axle shaft 10. Compress the retaining ring using a

93462ZGC7

Install the axle shaft retaining ring—outer

joint

2

93462608

Measure the distance between the edge of the seal and the edge of the last axle shaft groove closing edge and adjust fit to 0.10

inch (2.5mm)

J 42572

outer race. 7. Assemble the chrome alloy balls into

93462606

Position a brass drift against the CV-joint cage and tap it with a hammer to tilt the cage-outer joint

the C\V-joint cage, as follows: a. Position a brass drift against the C\-joint cage and tap it with a hammer to tilt the cage. b. Insert the 1st chrome alloy ball into the cage. c. Tilt the cage in the opposite direction. d. Insert the opposite chrome alloy ball. e. Repeat the procedure until all 6 balls are inserted. 8. Install Yeof the grease provided, into the C\V-joint. 9. Install or connect the following: e Small CV boot retaining ring ¢ CV boot on the halfshatt

9346ZGC9

Tighten the small seal retaining clamp until the base of the omega shape has a gap width between 0.079-0.118 inch (2-3mm), with a difference in the gap width from side to side no greater than 0.016 inch (0.4mm)-outer joint

Please visit our web site at www.chiltonsonline.com

30-2

GENERAL MOTORS CORPORATION—Y-BODY CORVETTE

J 42572

;

93462GD1

Measure the distance between the edge of the seal and the edge of the last axle shaft groove closing edge and adjust fit to 0.3

inch (8mm)—outer joint

small flat bladed tool while pushing the outer joint onto the axle shaft. 11. Seat the outer joint on the shaft using a hammer and block of wood. 12. Install the remaining grease into the CV boot. 13. Position the CV boot and the small boot clamp. 14. Crimp the small boot clamp. 15. Position and crimp in place the large boot clamp. 16. Install the Halfshaft in the vehicle.

9346ZGD2

Tighten the small seal retaining clamp until the base of the omega shape has a gap width between 0.079-0.118 inch (2-3mm), with a difference in the gap width from side to side no greater than 0.016 inch (0.4mm) -outer joint

STEERING AND SUSPENSION

*¢ CAUTION All 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 repairs. A Speescbeenesnattsomessensenanes

PRECAUTIONS a

Several precautions must be observed when handling the inflator module to avoid accidental deployment and possible personal injury. 1. Never carry the inflator module by the wires or connector on the underside of the module. 2. When carrying a live inflator module, hold securely with both hands, and ensure that the bag and trim cover are pointed away.

3. Place the inflator module on a bench or other surface with the bag and trim cover facing up. 4. With the inflator module on the bench, never place anything on or close to the module which may be thrown in the event of an accidental deployment.

DISARMING SS

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Turn the steering wheel to align the wheels in the straight-ahead position. 3. Turn the ignition switch to the LOCK position. 4. Remove the AIR BAG fuse from the fuse block. 9. Remove the left side lower trim panel, then unplug the Connector Position Assurance (CPA) device and the yellow 2-way SIR harness wire connector at the base of the steering column.

ARMING After the necessary repairs have been made, re-enable the air bag system as follows:

1. Turn the ignition switch to the LOCK position. ~ 2. Engage the yellow 2-way connector and the CPA device at the base of the steering column. 3. Install the left side lower trim panel, then install the SIR fuse to the fuse block. 4. Turn the ignition switch to the RUN position.

9. Verify the SIR indicator light flashes 7-9 times, then turns OFF. If not, inspect system for malfunction.

Power Rack and Pinion Steering Gear REMOVAL & INSTALLATION SERRE i vsssors s2s 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the power steering fluid. 3. Remove or disconnect the following: ¢ Negative battery cable e Brake Pressure Modulator Valve (BPMV) bracket, if equipped ¢ Both front wheels e Intermediate shaft shield

Y-BODY—GENERAL MOTORS CORPORATI

oaetere 30-2 g

79222656

Exploded view of the front shock absorber mounting—5.7L engine

79227655

Exploded view of the power steering gear mounting—o.7L engine

Intermediate shaft lower coupling from the power steering gear Power steering inlet hose from the Steering gear Steering cooler pipe from the steering gear Power steering cooler Both outer tie rod ends from the knuckles Magnasteer electrical connector Stabilizer shaft from the crossmember Wire harness clips from the crossmember Brake pipe from the crossmember Steering gear mounting bolts and loosen the crossmember mounting nuts Power steering gear through the left wheel opening To install: 4. \nstall or connect the following: e Steering gear to the crossmember and torque the nuts to 74 ft. Ibs. (100 Nm) 5. Torque the crossmember mounting nuts 81 ft. Ibs. (110 Nm) + Brake pipe to the crossmember

e Stabilizer shaft ¢ Both outer tie rod ends to the steering knuckle and torque the nuts to 18 ft. Ibs. (25 Nm) plus and additional 180 degrees e Intermediate shaft lower steering

coupling to the steering gear and torque the bolt to 25 ft. Ibs. (34 Nm) Magnasteer electrical connector Wire harness clips to the crossmember Cooler to the crossmember Cooler pipe to the steering gear and torque the fitting to 20 ft. Ibs. (27 Nm) Inlet hose to the steering gear and torque the fitting to 20 ft. Ibs. (27 Nm) Intermediate shaft shield and torque the clamp to 32 inch Ibs. (3.5 Nm) Both front wheels Negative battery cable 6. Refill and bleed the power steering system. 7. Check and adjust the front end alignment.

‘Shock Absorber

—

ae

REMOVAL & INSTALLATION i

Front

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2 Remove or disconnect the follow-

ing:

e Negative battery cable e Wheel e Real Time Damper (RTD) electrical connector Upper mounting nut retainer and insulator Shock absorber lower mounting bolts Shock absorber from the upper tower 3. If equipped with heavy duty shocks (FE3) perform the following steps: a. Compress the shock absorber from the bottom upward. b. Install a shock support tool to the shock while it is compressed. c. Remove the shock from the vehicle. d. Remove the tool from the shock. 4 Remove the shock absorber. To install: 5. Install or connect the following: e Retainer and insulator to the shock absorber e Shock absorber to the upper shock tower e Upper insulator, retainer and nut and torque the nut to 19 ft. Ibs. (26 Nm) e Lower mounting bolts and torque them to 21 ft. Ibs. (28 Nm) e RTD electrical connector 6. If equipped with heavy duty shocks (FE3) perform the following steps: a. Install a shock support tool to the shock absorber. b. Install the shock to the vehicle. c. Install the upper insulator, retainer and nut and torque the nut to 19 ft. Ibs. (26 Nm). d. Remove the support tool from the

Timing belt service is covered in Section 3 of this manual

30-30

GENERAL MOTORS CORPORATION—Y-BODY CORVETTE

shock and install a spring compressor to the spring. 7. Raise the lower control arm and install the shock absorber lower mounting bolts and torque them to 21 ft. Ibs. (28 Nm). a. Step 6: Remove the spring compressor tool. 8. Install or connect the following:

e Wheel e Negative battery cable Rear

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Negative battery cable Wheel Rear position sensor electrical connector, if equipped Lower mounting bolt Upper mounting bolts Shock absorber from the lower control arm and shock tower Upper insulator and retainer from the shock absorber To install: 3. Install or connect the following: Upper insulator and retainer to the shock absorber, if removed Shock absorber to the shock tower and lower control arm Upper mounting bolts and torque them to 22 ft. Ibs. (30 Nm) Lower shock absorber mounting bolt and torque it to 162 ft. Ibs. (220 Nm) Rear position sensor electrical connector Wheel Negative battery cable

Transverse Spring REMOVAL & INSTALLATION Front

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Negative battery cable e Front wheels

} 9346Z2GD3

Measure the front spring adjuster bolt gap to ease the installation procedure and setting the proper vehicle trim height—front assembly

:

3. Measure the front spring adjuster bolt gap to ease the installation procedure and setting the proper vehicle trim height. 4. Install a spring compressor tool J 33432-A to the spring and compress it. 5. Remove or disconnect the following: ‘e Lower shock absorber mounting bolts from one of the lower control arms Stabilizer shaft link from the lower control arm Lower ball joint from the steering knuckle Cam bolts from the lower control arm after matchmarking them Lower control arm Transverse spring bolts and retainers Transverse spring and the compressor tool To install: 6. Install or connect the following: e Spring to the crossmember e New spring retainers and bolts to the crossmember and torque them to 46 ft. Ibs. (62 Nm) e Lower control arm to the crossmember ¢ Cam bolts to the matchmarks made during the removal procedure.

Ne

(ie

93062G27

Exploded view of the rear shock absorber—5.7L engine

79227660

Exploded view of the front transverse spring—5.7L engine

Y-BODY—GENERAL MOTORS CORPORATION

CORVETTE

Hand tighten the cam bolts at this time Lower control arm ball joint stud to the steering knuckle and torque the nut to 15 ft. Ibs. (20 Nm) plus an additional 210 degrees Shock absorber Shock absorber lower mounting bolts and torque them to 21 ft. Ibs. (28 Nm) Stabilizer shaft link to the lower control arm and torque the nut to 53 ft. Ibs. (72 Nm) 7. Remove the spring compressor tool from the transverse spring and move the lower control arm supports. 8. Install or connect the following: e Front wheels e Negative battery cable 9. Adjust the front trim height. 10. Perform a front end alignment. 11. Torque the control arm cam bolts to 125 ft. Ibs. (170 Nm) Rear

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Negative battery cable e Rear wheels 3. Measure the transverse spring stud

height to ease the installation procedure and setting the proper vehicle trim height. 4. Install a spring compressor tool J 33432-A to the spring and compress it. 5. Remove the spring mounting bolts, spacers and insulators from the crossmember and control arm. 6. Remove the spring from the vehicle and remove the compressor tool. To install: 7. Install or connect the following: Spring compressor to the transverse spring Spring to the vehicle Spring spacers, insulators and mounting bolts to the crossmember and torque the bolts to 46 ft. Ibs. (62 Nm) Spring to the lower control arm Lower control arm to spring bolts and insulators and release the compressor tool Rear wheel Negative battery cable 8. Adjust the trim height and place the retainers on the control arm bolts. 9. Check and adjust the alignment, if needed.

Upper Ball Joint REMOVAL & INSTALLATION Front

9346ZGD4

Measure the transverse spring stud height to ease the installation procedure and set-

ting the proper vehicle trim height—rear assembly

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Wheel Brake caliper Brake rotor Stabilizer shaft link from the lower control arm Wheel Speed Sensor (WSS) electrical connector Outer tie rod from the steering knuckle Upper ball joint from the control arm e Steering knuckle from the vehicle Oo Pestthe ball joint from the steering knuckle. To install: 4. Install or connect the following: e Ball joint to the steering knuckle Upper ball joint to the control arm and torque the nut to 15 ft. Ibs. (20 Nm) plus an additional 250 degree turn

3 0 -31

e Lower ball joint to the steering knuckle and torque the nut to 15 ft. lbs. (20 Nm) plus an additional 210 degree turn Outer tie rod to the steering knuckle and torque the nut to 18 ft. Ibs. (25 Nm) plus an additional 180 degree turn Stabilizer shaft link to the control arm and torque the nut to 53 ft. Ibs. (72 Nm) WSS electrical connector Brake rotor Brake caliper and torque the mounting bracket bolts to 125 ft. lbs. (175 Nm) e Wheel 5. Check and adjust the front alignment. Rear

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Wheel e Wheel Speed Sensor (WSS) electrical connector Real Time Damping (RTD) position sensor, if equipped e Brake caliper * Brake rotor ¢ Shock absorber solenoid electrical connector, if equipped Outer tie rod from the suspension knuckle Axle shaft nut Upper contro! arm from the knuckle Lower ball joint from the knuckle Suspension knuckle from the vehicle 3. Press the upper ball joint from the knuckle. To install: 4 Press the ball joint into the suspension knuckle. 5. Install or connect the following: e Knuckle to the vehicle e Lower ball joint to the knuckle and torque the nut to 41 ft. Ibs. (55 Nm) Upper control arm to the knuckle and torque the nut to 15 ft. Ibs. (20 Nm) plus an additional 250 degree turn Axle shaft nut and torque it to 118 ft. lbs. (160 Nm)

Outer tie rod to the knuckle and torque the nut to 15 ft. Ibs. (20 Nm) plus an additional 160 degree turn e Brake rotor

Heater Core replacement is covered in Section 2 of this manual

30-32

GENERAL MOTORS CORPORATION—Y-BODY CORVETTE

Brake caliper and torque the mounting bracket bolts to 125 ft. lbs. (175 Nm) WSS electrical connector Shock absorber solenoid electrical connector, if equipped RTD position sensor, if equipped Wheel 6. Check and adjust the rear wheel alignment.

Lower Ball Joint

REMOVAL & INSTALLATION Front and Rear

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove the lower control arm from the vehicle. 3. Press the ball joint from the control arm. To install: 4. Press the ball joint into the control arm. 5. Install the control arm in the vehicle.

93462GD4

Ball joint removal and installation tool set—lower ball joint

Upper Control Arm REMOVAL & INSTALLATION Front

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 Real Time Damping (RTD) sensor link and support the lower control arm Upper ball joint from the upper control arm Upper control arm bolts and shims Upper control arm To install: 3. Install or connect the following: Upper control arm Upper control arm shims and bolts and torque the bolts to 48 ft. Ibs. (65 Nm) Ball joint stud into the upper control arm and torque the nut to 15 ft. lbs. (20 Nm) plus an additional 250 degrees RTD sensor link Front wheel Negative battery cable 4. Check and adjust the front wheel alignment. Rear

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Negative battery cable e Rear wheel ¢ Wheel Speed Sensor (WSS) electrical connector e Real Time Damping (RTD) position sensor link, if equipped 3. Support the lower control arm with a jack stand. ¢ Ball joint stud from the control arm ¢ Upper control arm bolts ¢ Upper control arm To install: 4. Install or connect the following: ¢ Upper control arm and torque the bolts to 81 ft. Ibs. (110 Nm) Suspension knuckle ball joint stud nut into the upper control arm. It may be necessary to use an Allen wrench to keep the ball joint stud from spinning while tightening the ball joint stud nut. Torque the nut to 15 ft. Ibs. (20 Nm) plus an additional 250 degrees WSS electrical connector RTD position sensor link, if equipped e Rear wheel ¢ Negative battery cable 5. Check and adjust the rear wheel alignment.

CONTROL ARM BUSHING REPLACEMENT The manufacturer does not provide a bushing replacement procedure. The bushing is replaced when a new control arm is installed.

Lower Control Arm

:

REMOVAL & INSTALLATION Front

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Front wheel e Front transverse spring e Wheel Speed Sensor (WSS) electrical connector e Real Time Damping (RTD) electrical connector, if equipped 3. Support the lower control arm with a jack stand e Shock absorber from the lower control arm Stabilizer shaft link from the lower control arm e¢ Ball joint stud from the knuckle ¢ Cam bolts, washers and nuts after matchmarking them Lower control arm from the vehicle To install: 4. Install or connect the following: ¢ Lower control arm 5. Support the lower control arm with a jack stand ¢ Cam bolts to the position match marked during the removal procedure and hand tighten the bolts ¢ Lower control arm ball joint stud to the steering knuckle and torque the nut to 15 ft. Ibs. (20 Nm) plus an additional 210 degrees

79227661

Lower control arm mounting bolts—5.7L engine

Y-BODY—GENERAL MOTORS SUE

UE ORVETTE

Stabilizer shaft link to the lower control arm and torque the nut to 53 ft. Ibs. (72 Nm) Transverse spring and remove Shock absorber lower mounting bolts and torque them to 21 ft. Ibs. (28 Nm) RTD electrical connector, if equipped WSS electrical connector Front wheel Negative battery cable 6. Perform a front wheel alignment. 7. Tighten the lower control arm nuts to 125 ft. Ibs. (170 Nm).

CONTROL ARM BUSHING REPLACEMENT The manufacturer does not provide a bushing replacement procedure. The bushing is replaced when a new control arm is installed.

Wheel Bearings ADJUSTMENT No periodic wheel bearing adjustment is necessary. The wheel bearings are a sealed unit that must be replaced if loose or noisy.

REMOVAL & INSTALLATION

Rear

1. Before servicing the vehicle, refer to the precautions in the beginning of this sec-

Front

tion.

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Negative battery cable e Front wheel e Wheel Speed Sensor (WSS) electrical connector

2. Remove or disconnect the following: Negative battery cable Rear wheel

Transverse spring from the lower control arm Shock absorber from the lower control arm Lower ball joint stud nut from the knuckle Stabilizer shaft link from the lower control arm Cam bolts, washers and nuts after matchmarking them Lower control arm from the vehicle

30-33

Brake caliper Brake rotor Stabilizer shaft link from the lower control arm and support the lower control arm Separate the outer tie rod ball stud from the steering knuckle Lower ball joint stud from the Steering knuckle Wheel hub mounting bolts Wheel hub/bearing assembly from the knuckle To install: 3. Install or connect the following: Hub/bearing assembly to the steering knuckle. Make certain that the speed sensor cable connection is facing rearward and torque the mounting bolts to 96 ft. Ibs. (130 Nm) Lower control arm ball stud to the Steering knuckle and torque the nut to 55 ft. Ibs. (75 Nm) Outer tie rod to the steering knuckle and torque the nut to 33 ft. Ibs. (45 Nm) WSS electrical connector

To install: 3. Install or connect the following: 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 ft. lbs. (20 Nm) plus an additional 210 degrees

Stabilizer shaft link to the lower control arm and torque the link nut to 53 ft. Ibs. (72 Nm) Shock absorber lower mounting bolts and torque the bolts to 162 ft. lbs. (220 Nm) Transverse spring to the lower control arm Rear wheel Negative battery cable 4. Perform a rear wheel alignment. 5. Torque the lower control arm front cam bolt to 107 ft. Ibs. (145 Nm) and the rear cam bolt to 70 ft. Ibs. (95 Nm).

79222657

engine Exploded view of the front hub/wheel bearing and knuckle assembly—5.7L

Brake service is covered in Section 4 of this manual

30-34

GENERAL MOTORS CORPORATION—Y-BODY CORVETTE

Stabilizer shaft link to the lower control arm and torque the nut to 55 ft. Ibs. (75 Nm) Brake rotor Brake caliper and torque the bracket mounting bolts to 126 ft. lbs. (175 Nm) Front wheel Negative battery cable Rear

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Negative battery cable e Rear wheel Wheel Speed Sensor (WSS) electrical connector Real Time Damping (RTD) position sensor link, if equipped Brake caliper Brake rotor Shock absorber solenoid electrical connector, if equipped Outer tie rod end from the suspension knuckle

79222658

Exploded view of the rear hub/wheel bearing and knuckle assembly—5.7L engine

e Axle nut e Separate the upper control arm from the suspension knuckle e Steering knuckle from the lower control arm ball joint stud e Suspension knuckle e Hub/bearing bolts e Hub/bearing from the knuckle To install: 3. Install or connect the following: e Hub/bearing assembly to the steering knuckle. Make certain that the

speed sensor cable connection is facing rearward and torque the hub mounting bolts to 96 ft. Ibs. (130 Nm) Upper control arm to the steering knuckle and torque the bolt to 49 ft. lbs. (65 Nm) Lower control arm ball stud to the suspension knuckle and torque the nut to 55 ft. Ibs. (75 Nm) Axle nut and torque it to 118 ft. Ibs. (160 Nm) Outer tie rod ball stud to the steering knuckle and torque the nut to 33 ft. Ibs. (45 Nm) Brake rotor Brake caliper and torque the mounting bracket bolts to 125 ft. lbs. (175 Nm)

WSS electrical connector Shock absorber solenoid electrical connector RTD position.sensor link, if equipped Rear wheel Negative battery cable

GEO/CHEVROLET 1998-01 Metro * Prizm DRIVE TRAIN.................. 31-19 ENGINE REPAIR ................ 31-2 FUESYSTEM@ re es31-17 PRECAUTIONS..-.....-....:..-. 31-2 STEERING AND SUSPENSION as ski 31-27

EXhausteVAniiGtt.< Gamer Stee 31-10 Removal & Installation............ 31-10

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Halistiatie ee eee iid er 31-23 Removal & Installation............ 31-23

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31-12 31-12 31-21 31-22 31-22

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Removal & Installation............ 31-32 LA ey a ae eee 31-24 DTSEL Ce Se ener tnee apc 31-24

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31-7

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Front Crankshaft Seal... Removal & Installation............ Fuel Filters 28 70> Bae eters Removal & Installation...

31-11 31-11 31-17 31-17

Removal & Installation... 31-18 Removal & Installation............ 31-17

Fuel System Pressure ...........0 31-17 Relieving........... err

31-17

Hydraulic Clutch System............. 31-23 Bleeding............. ees 31-23 LQTMPON IIe he eee ae hee 31-3 AQHUSTIMENL Dot cee unt meets c.31-3

Removal & Installation... 31-14 Oi) Pump Deere Orne anime 31-14 Removal & Installation............ 31-14

PIStONOU RINGS

ctor tere nce, 31-16

Positioning ....... arn

31-16

Rack and Pinion Steering Gear ....31-28 Removal & Installation............ 31-28 Rear Mainoedliacte. ace semeete 31-15 Removal & Installation... 31-15 Rocker Arms/Shafts .....c.ccccecee 31-9 Removal & Pea eros 31-9 Starter VO ienehemes 31-14 Removal & Installation............ 31-14 Sitti etal atic ncaa acts iret tame 31-30

Removal & Installation............ 31-30 Timing Chain, Sprockets, Front Cover & Seal... 31-15 Removal & Installation............ 31-15

Intake ManiGld 2s sa caeeercct.: 31-9 Removal & psiaralion Ba eee 31-9

Transaxle ASS@MDIY .......... eee 319

LGWETD ALLIS ede, leet bes 31-33 Removal & Installation............ 31-33 Cower Control AMM .ccceceer seas 31-33

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31-2 SS

GEO/CHEVROLET METRO ¢SG PRIZM TSR

TSS

DT

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EE

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EL

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PRECAUTIONS Before servicing any vehicle, please be sure to read all of the following precautions, which deal with personal safety, prevention of component damage, and important points to take into consideration when servicing a motor vehicle: e Never open, service or drain the radiator or cooling system when the engine is hot; serious burns can occur from the steam and hot coolant. e Observe all applicable safety precautions when working around fuel. Whenever servicing the fuel system, always work in a well-ventilated area. Do not allow fuel spray or vapors to come in contact with a spark, open flame or excessive heat (a hot drop light, for example). Keep a dry chemical fire extinguisher near the work area. Always keep fuel in a container specifically designed for fuel storage; also, always properly seal fuel containers to avoid the possibility of fire or explosion. Refer to the additional fuel system precautions later in this section. ¢ Fuel injection systems often remain pressurized, even after the engine has been turned OFF. The fuel system pressure must be relieved before disconnecting any fuel lines. Failure to do so may result in fire and/or personal injury. ¢ Brake fluid often contains polyglycol ethers and polyglycols. Avoid contact with the eyes and wash your hands thoroughly after handling brake fluid. If you do get brake fluid in your eyes, flush your eyes with clean, running water for 15 minutes. If

eye irritation persists, or if you have taken brake fluid internally, IMMEDIATELY seek medical assistance. e The EPA warns that prolonged contact with used engine oil may cause a number of skin disorders, including cancer! You should make every effort to minimize your exposure to used engine oil. Protective gloves should be worn when changing oil. Wash your hands and any other exposed skin areas as soon as possible after exposure to used engine oil. Soap and water, or waterless hand cleaner should be used. e All new vehicles are now 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 repairs. ¢ Always wear safety goggles when working with, or around, the air bag system. When carrying a non-deployed air bag, be sure the bag and trim cover are pointed away from your body. When placing a nondeployed air bag on a work surface, always face the bag and trim cover upward, away from the surface. This will reduce the motion of the module if it is accidentally deployed. Refer to the additional air bag system precautions later in this section. ¢ Clean, high quality brake fluid from a sealed container is essential to the safe and

proper operation of the brake system. You should always buy the correct type of brake fluid for your vehicle. If the brake fluid becomes contaminated, completely flush the system with new fluid. Never reuse any brake fluid. Any brake fluid that is removed from the system should be discarded. Also, do not allow any brake fluid to come in contact with a painted surface; it will damage the paint. e Never operate the engine without the proper amount and type of engine oil; doing so WILL result in severe engine damage. ¢ Timing belt maintenance is extremely important! Many models utilize an interference-type, non-freewheeling engine. If the timing belt breaks, the valves in the cylinder head may strike the pistons, causing potentially serious (also time-consuming and expensive) engine damage. Refer to the maintenance interval charts in the front of this manual for the recommended replacement interval for the timing belt, and to the timing belt section for belt replacement and inspection. e Disconnecting the negative battery cable on some vehicles may interfere with the functions of the on-board computer system(s) and may require the computer to undergo a relearning process once the negative battery cable is reconnected. e When servicing drum brakes, only disassemble and assemble one side at a time, leaving the remaining side intact for reference.

ENGINE REPAIR Distributor

By

anit

REMOVAL 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the followng: ¢ Negative battery cable ¢ Distributor electrical connector ¢ Spark plug wires from the distributor cap Distributor cap 3. Mark the position of the distributor rotor in relation to the distributor body and mark the position of the distributor body in relation to the cylinder head. 4. Remove the distributor hold-down bolts.

5. Remove the distributor from the

engine.

INSTALLATION Timing Not Disturbed 1. Align the reference marks made during removal. Position the distributor carefully and be sure the drive gear engages properly within the slot. 2. Install or connect the following: ¢ Hold-down bolts but do not tighten ¢ Distributor electrical connector ¢ Spark plug wires ¢ Distributor cap ¢ Negative battery cable _ 3. Check and/or adjust the ignition timing. 4. Tighten the distributor hold-down bolts to 11 ft. Ibs. (15 Nm).

Timing Disturbed

1. Remove the No. 1 spark plug. 2. Place a thumb over the spark plug hole. Have someone rotate the engine by hand using a wrench on the crankshaft pulley, until compression is felt. 3. Align the timing mark on the crankshaft pulley with the 0 degrees mark on the timing scale attached to the front of the engine. This places the engine at Top Dead Center (TDC) on the compression stroke. 4. Turn the distributor shaft until the rotor points to the No. 1 spark plug tower on the cap. 9. Install or connect the following: ¢ Distributor, by aligning the distributor housing-to-cylinder head marks made during the removal procedure

GEO/CHEVROLET METRO « PRIZM

31-3

93066228

Exploded view of the alternator—Metro and Prizm models

1. Distributor 2. Distributor mounting bolts 79222701

Be sure to tighten the distributor mounting bolts to prevent the timing from changing—Prizm

e Spark plug wires and electrical wires e Distributor cap e Negative battery cable 6. Check and/or adjust ignition timing. 7. Tighten the distributor hold-down bolts to 11 ft. Ibs. (15 Nm).

Alternator

.

ae

REMOVAL Metro

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: ¢ Negative battery cable e Air cleaner assembly e Alternator electrical connectors e Accessory drive belt e Upper and lower mounting bolts e Alternator Prizm

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Negative battery cable e Accessory drive belt e Alternator electrical connectors e Alternator

INSTALLATION Metro

Install or connect the following: e Alternator and the bolts, do not tighten the bolts at this time

e Accessory drive belt and adjust as necessary e Alternator electrical connectors, then torque the alternator bolts to 17 ft. Ibs. (23 Nm) e Air cleaner assembly e Negative battery cable Prizm

1. Install the alternator and hand-tighten the bolts. 2. Install the alternator belt and adjust the tension until a deflection of 0.24-0.31 inch (6-8mm) deflection with 22 Ibs. (10 kg) of pressure exerted when installing a used belt. On a new belt the belt deflection should be 0.20-0.27 inch (5—7mm) with 22 lbs. (10 kg) of pressure exerted. 3. Install or connect the following: e Alternator bolts to 17 ft. Ibs. (23 Nm) e Alternator electrical connectors ¢ Accessory drive belt e Negative battery cable

Ignition Timing ADJUSTMENT =>The ignition timing on the Prizm is not adjustable. Metro

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 9. Run the engine until it reaches normal operating temperature. Stop the engine, but keep the ignition switch in the ON position for approximately 5 seconds. Start the engine again. 3. Run the engine at 2000 RPM for approximately 5 minutes. After 5 minutes, allow it to run at idle speed. 4. Be sure all accessories are turned OFF.

A. Blank (cavity 1) B. Diagnostic request terminal

(cavity 2) C. Diagnostic output terminal

(cavity 3) D. Ground terminal(cavity 4)

E. Test switch terminal(cavity 5) F. Duty check terminal(cavity 6) 1. Duty check DLC 2. Jumper 79222702

Jumping terminals in the 6 terminal DLC—Metro models

5. Fully engage the parking brake. 6. Be sure the shift lever is placed in the NEUTRAL or PARK depending on transaxle type. 7. Connect a tachometer to the negative terminal of the ignition coil. Connect a timing light to the No. 1 spark plug wire. Check the engine idle speed and adjust, if needed. 8. Refer to the vehicle emission control information label (located under the hood) for ignition timing specifications. 9. Remove the cap from the diagnostic check connector, located next to the ignition coil or left side strut tower and insert a fused jumper wire between appropriate the terminals. 10. On 4 terminal connectors, hold the connector with the locking tab at the top and jump the lower 2 terminals (€ and D). 11. On 6 terminal connectors, hold the connector with the locking tab at the top and jump the 2 terminals at the lower left (D and E). 12. Loosen the distributor hold-down bolt and rotate the distributor until the correct timing marks are aligned. 13. Tighten the distributor hold-down bolt to 11-15 ft. Ibs. (15-20 Nm) and recheck the timing. Be sure the timing advances according to engine speed. 14, Remove the diagnostic check jumper. Remove the timing light and tachometer.

Guide For complete service labor times, order Nichols’ Chilton Labor

31-4

GEO/CHEVROLET METRO ¢ PRIZM

Prizm

Engine Coolant Temperature (ECT)

Engine Assembly

«>If the ignition timing is out of specification, a possible engine electrical failure may have occurred. The following procedure may be used to check the timing:

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Warm the engine to normal operating temperature. Turn all electrical accessories OFF. 3. Connect a tachometer or engine scan tool and check the engine idle speed and be sure it is 650-750 rpm. 4. Connect a timing light. Remove the cap on the Data Link Connector (DLC). Using a fused jumper wire, connect terminals E1 and TE1. 5. Start the engine and check timing. With the jumper wire connected, the timing should be at 10 degrees Before Top Dead Center (BTDC). 6. Remove the jumper wire from the DLC and reinstall the cap. 7. Shut the engine OFF and disconnect all test equipment.

REMOVAL & INSTALLATION

sensor electrical connector Coolant Temperature Sending unit electrical connector

Throttle Position Sensor (TPS) Metro

electrical connector

7.0L ENGINE

valve electrical connector

Exhaust Gas Recirculation (EGR)

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Properly relieve the fuel system pressure. 3. Drain the cooling system. 4. Drain the engine oil. 5. Drain the transmission fluid, if equipped with an automatic transmisson. 6. Remove or disconnect the following: e Hood after scribing the hood hinge to the hood Air cleaner Coil wire from the distributor Radiator and cooling fan assembly Evaporative emissions (EVAP) purge solenoid electrical connector e Distributor electrical connector

Idle Speed Control (ISC) motor electrical connector Intake manifold ground wires

Manifold Absolute Pressure (MAP) sensor electrical connector

Heated Oxygen (HO2S) sensor electrical connector — Throttle Body Injection (TBI) unit electrical connector

Early Fuel Evaporation (EFE) heater electrical connector, if equipped Oil pressure switch electrical connector Alternator connectors Starter solenoid electrical connec-

tor

A/C compressor clutch coil electrical connector, if equipped EVAP canister vacuum hose MAP sensor vacuum hose Brake booster hose Accelerator cable from the throttle body Clutch cable, if equipped Gear select cable for automatic transmissions Speedometer cable Heater inlet and outlet hoses Fuel feed and return hoses 7. Support the engine. ¢ Exhaust pipe from the manifold Gearshift control shaft and extension rod from the transmission Backup lamp switch electrical connector

Crankshaft Position (CKP) sensor electrical connector Both halfshafts

e>It is not necessary to disconnect the halfshaft from the knuckle.

e A/C compressor without discon-

+B E1 FP TE1 Ww 600

SYSTEM VOLTAGE GROUND TERMINAL FUEL PUMP TERMINAL DIAGNOSTIC REQUEST TERMINAL MALFUNCTION INDICATOR LAMP (MIL) TERMINAL DATA LINK CONNECTOR (DLC) (UNDER HOOD) 79222703

DLC pin locations—Prizm models

necting the hoses ¢ Power steering hoses from the pump, if equipped 8. Attach a lifting device to the engine. ¢ Left side transmission mount e Right side and rear engine mount ¢ Engine/transmission assembly To install: 9. Install or connect the following: ¢ Engine/transmission assembly ¢ Left transmission mount and torque the nut to 41 ft. Ibs. (55 Nm)

GEO/CHEVROLET

METRO e PRIZM

ra

e Right and rear engine mounts and torque the bolts to 41 ft. Ibs. (55 Nm) 10. Remove the engine lifting device and properly support the engine assembly. e Exhaust pipe to the manifold and torque the bolts to 33 ft. Ibs. (45 Nm) Gearshift control shaft and extension Backup lamp switch Halfshafts Power steering hoses to the pump A/C compressor and torque the bolts to 37 ft. Ibs. (50 Nm) Speedometer cable Gear select cable, if equipped Clutch cable, if equipped Accelerator cable Heater inlet/outlet hoses Engine vacuum lines Alternator and torque the bolts to 17 ft. Ibs. (23 Nm) Fuel return and feed lines Distributor electrical connector Starter solenoid electrical connector CKP sensor electrical connector MAP sensor electrical connector EVAP purge solenoid electrical connector ECT sensor connectors Coolant temperature sending unit electrical connector TPS electrical connector EGR valve electrical connector ISC motor electrical connector Fuel injector connectors HO2S sensor connector Intake manifold ground wires EFE heater electrical connector Oil pressure switch electrical connector Alternator electrical connector

A/C Compressor clutch coil electrical connector, if equipped Starter solenoid electrical connector MAP sensor electrical connector EVAP canister vacuum hose Map sensor vacuum hose Brake booster vacuum hose Accelerator cable

Clutch cable, if equipped Speedometer cable Radiator and cooling fan and torque the bolts to 89 inch Ibs. (10 Nm) Air cleaner assembly

e Hood and torque the bolts to 20 ft. lbs. (27 Nm) e Negative battery cable 11. Adjust the clutch pedal free-play, gear select cable and accelerator cable play, if equipped. 12. Fill the engine with clean oil. 13. Fill the cooling system. 14. Fill the transmission. 15, Fill the power steering reservoir. 16. Start the engine and check for leaks, repair if necessary.

7.3L ENGINE 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Properly relieve the fuel system pressure. 3. Drain the cooling system. 4. Evacuate and recover the A/C system. 5. Drain the engine oil. 6. Drain the transmission fluid. 7. Remove or disconnect the following: Positive and negative battery cables Hood Radiator and cooling fan assembly Air cleaner assembly Engine Coolant Temperature (ECT) sensor electrical connector Throttle Position (TPS) sensor electrical connector Evaporative emissions (EVAP) purge solenoid electrical connector Camshaft Position (CMP) sensor electrical connector Crankshaft Position (CKP) sensor electrical connector Idle Speed Control (ISC) motor electrical connector Heated Oxygen (HO2S) sensor electrical connector Fuel injector electrical connectors Manifold Absolute Pressure (MAP) sensor electrical connector Power steering pump pressure switch electrical connector, if equipped Oil pressure switch electrical connector A/C compressor clutch electrical connector, if equipped Park/Neutral Position (PNP) switch electrical connector Ignition coil connectors Alternator electrical connector Starter solenoid electrical connector

oT -5

e Backup lamp switch electrical connector

Vehicle Speed (VSS) sensor electrical connector Direct clutch and second brake solenoid electrical connector Brake booster hose Accelerator cable Clutch cable, if equipped Shift select cable, if equipped Speedometer cable Heater inlet and outlet hoses Fuel feed and return hoses 8. Install and engine support fixture. Right side engine mount Left transmission mount Rear engine mount Exhaust pipe from the manifold Gearshift control shaft and extension rod, if equipped Both halfshafts Power steering pump, if equipped A/C compressor, if equipped 9. Place an engine table under the vehicle. 10. Remove the engine support fixture. 11. Raise the vehicle from the engine/transmission assembly. To install: 12. Place the engine/transmission assembly on the table, under the vehicle. 13. Lower the vehicle onto the engine/transmission. 14. Install or connect the following: Left transmission mount and torque the bolts to 41 ft. Ibs. (55 Nm) Right side engine mount and torque the bolts to 41 ft. Ibs. (55 Nm) Rear engine mount and torque the bolts to 41 ft. Ibs. (65 Nm) Power steering pump and torque the bolts to 25 ft. Ibs. (35 Nm) A/C compressor and torque the bolts to 18 ft. Ibs. (25 Nm) Both halfshafts Gearshift control shaft and extension rod Exhaust pipe to the manifold and torque the bolts to 37 ft. Ibs. (50 Nm)

Please visit our web site at www.chiltonsonline.com

15. Remove the engine support fixture. Fuel —feed and return hoses Heater inlet and outlet hoses Accelerator cable Clutch cable, if equipped Shift select cable, if equipped Speedometer cable Brake booster hose

31- 6

GEO/CHEVROLET METRO ¢ PRIZM Drive belt tensioner, if equipped

ECT sensor electrical connector TPS sensor electrical connector EVAP purge solenoid electrical connector CMP sensor electrical connector CKP sensor electrical connector ISC motor electrical connector HOS sensor electrical connector Fuel injector electrical connectors MAP sensor electrical connector Power steering pump pressure switch electrical connector, if equipped Oil pressure switch electrical connector

with manual transmission Accelerator cable

Intake Air Temperature (IAT) sensor electrical connector Air cleaner assembly

Upper radiator hose Windshield washer reservoir

Oxygen (O2S) sensor Engine wiring harness and place aside Lower radiator hose from the thermostat housing

Splash shields Both halfshafts Starter motor electrical connectors Starter motor Torque converter bolts, if equipped with an automatic transmission Power steering pump, do not disconnect the hoses Exhaust pipe from the manifold Transmission-to-engine bolts Manifold Absolute Pressure (MAP) sensor hose Brake booster hose MAP sensor Data Link Connector (DLC) and

A/C compressor clutch electrical connector, if equipped PNP switch electrical connector Ignition coil connectors Alternator electrical connector Starter solenoid electrical connector Backup lamp switch electrical connector VSS sensor electrical connector Direct clutch and second brake solenoid electrical connector Radiator and cooling fan assembly

and torque the bolts to 89 inch Ibs. (10 Nm) Air cleaner assembly

A/C pressure switch wiring harnesses Ground wires from the intake manifold and fenders Heater inlet and outlet hoses Fuel feed and return hoses Shift select cable 8. Attach an engine hoist to the engine. 9. Remove or disconnect the follow-

Hood ¢ Positive and negative battery cables 16. “Fil the cooling system. ate Fill the engine oil. 18. Evacuate and recharge the A/C sys-

tem. 1; Fill the transmission fluid. 20. Start the engine and check for proper operation. Prizm

ls Before servicing the vehicle, refer to the precautions in the beginning of this section.

2: Properly relieve the fuel system

pressure. 3. 4. ws 6.

Drain the cooling system Drain the engine oil. Drain the transmission fluid. Evacuate the A/C system, if equipped. 7. Remove or disconnect the following: Hood after scribing the hood hinge to the hood Ignition coil electrical connectors Accessory drive belt A/C compressor, if equipped Alternator Crankshaft pulley, if equipped with manual transmission

ing: e Front and rear transmission mounts e Right engine mount

¢ Engine assembly To install: 10. Install or connect the following:

Engine reflae Engine-to-transmission bolts and torque them to 47 ft. Ibs. (64 Nm) Right side engine mount and torque the bolts to 40 ft. Ibs. (54 Nm) Front and rear transmission mounts and torque the front mount bolts to 47 ft. Ibs. (64 Nm) and the through-bolt to 64 ft. Ibs. (87 Nm). Torque the rear transmission nuts to 42 ft. Ibs. (52 Nm) and the through-bolt to 64 ft. Ibs. (87 Nm). 11. Remove the engine hoist and support the engine. Both halfshafts Front exhaust pipe and torque the bolts to 46 ft. Ibs. (62 Nm)

02S sensor and torque the nuts to 32 ft. Ibs. (40 Nm) Power steering pump and torque the bolts to 27 ft. Ibs. (37 Nm) Torque converter bolts and tighten them to 26 ft. Ibs. (35 Nm) Starter motor and torque the bolts to 22 ft. Ibs. (30 Nm) Engine splash shields and torque the bolts to 89 inch Ibs. (10 Nm) Lower radiator hose Engine wiring harness Alternator and torque the bolts to 17 ft. Ibs. (23 Nm) _ Windshield washer reservoir and torque the bolts to 89 inch Ibs. (10 Nm)

Upper radiator hose Air cleaner assembly and torque the bolts to 89 inch Ibs. (10 Nm) IAT sensor electrical connector Accelerator cable to the throttle lever Accessory drive belt A/C compressor and torque the bolts to 18 ft. Ibs. (25 Nm) Alternator and torque the upper bolt to 18 ft. Ibs. (25 Nm) and the lower bolt to 40 ft. Ibs. (64 Nm) Drive belt tensioner (if equipped with manual transmission) and

torque the bolt to 51 ft. Ibs. (69 Nm) and the nut to 21 ft. Ibs. (29 Nm). Crankshaft pulley, if equipped with manual transmission, and toque the

bolt to 105 ft. Ibs. (142 Nm) Ignition coil electrical connectors Shift cable Fuel return hose eee e @ Fuel feed pipe to the fuel rail, using new gaskets and torque the bolt to 22 ft. Ibs. (29 Nm) Heater inlet and outlet hoses Engine ground wires to the intake manifold and fender Radiator and cooling fan and torque the bolts to 9 ft. Ibs. (13 Nm) Hood and torque the bolts to 20 ft. lbs. (27 Nm) Negative battery cable 12. Adjust the clutch pedal free-play, gear select cable and accelerator cable play, if equipped. 13. Recharge the A/C system. 14. Fill the engine with clean oil, 15. Fill the cooling system. 16. Fill the transmission. 17. Fill the power steering reservoir. 18. Start the engine and check for leaks, repair if necessary.

y Water Pump REMOVAL & INSTALLATION Metro

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the cooling system. 3. Remove or disconnect the following: Negative battery cable Air cleaner assembly A/C compressor suction pipe bracket, if equipped Water pump pulley bolts, loosen but do not remove the bolts Right side lower splash shield

A/C compressor drive belt, if equipped Lower alternator cover plate Water pump/alternator drive belt Crankshaft pulley Water pump pulley Timing belt Oil level indicator tube Upper alternator bracket from the water pump Water pump bolts and nuts Water pump To install: 4. Install or connect the following: e Water pump with a new gasket and torque the bolts to 115 inch Ibs. (13 Nm) New rubber seals Upper alternator adjusting bracket and torque the bolt to 17 ft. Ibs. (23 Nm) Oil level indicator tube Timing belt

Crankshaft pulley and torque the bolts to 12 ft. Ibs. (16 Nm) Water pump/alternator drive belt Lower alternator cover plate and torque the bolts to 89 inch Ibs. (10 Nm) A/C compressor drive belt, if equipped Right side lower splash shield Water pump pulley and torque the bolts to 18 ft. Ibs. (24 Nm) 5. Adjust the water pump drive belt tension and torque the alternator adjustment bolt to 17 ft. Ibs. (23 Nm). ¢ A/C compressor suction pipe bracket, if equipped e Air cleaner assembly e Negative battery cable 6. Refill the cooling system. 7. Start the engine and check for leaks, repair if necessary. Prizm

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the engine coolant. 3. Remove or disconnect the following: e Negative battery cable e Accessory drive belt e Right side lower splash shield e Water pump bolts e Water pump To install: 4. Install or connect the following: e Water pump with a new O-ring and torque the bolts to 8 ft. Ibs. (11 Nm) e Right side lower splash shield e Accessory drive belt e Negative battery cable 5. Fill the cooling system.

GEO/CHEVROLET METRO ¢ PRIZM

6. Start the vehicle and check for leaks, repair if necessary.

Cylinder Head

:

REMOVAL & INSTALLATION Metro

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Negative battery cable Intake manifold Exhaust manifold Rocker arm cover Timing belt and tensioner Camshaft Valve lifters Distributor Cylinder head bolts Cylinder head To install: 3. Install or connect the following: e Cylinder head with a new gasket and torque the bolts in 3 even

79222709

Cylinder head torque sequence—1.OL engine

[4] waTer Pump 79222704

To ensure a tight seal, be sure gasket surfaces are properly prepared—Metro

31-7

93462GD7

Cylinder head torque sequence—1.3L engine

Timing belt service is covered in Section 3 of this manual

31-8

GEO/CHEVROLET METRO ¢ PRIZM

A CRANKSHAFT PULLEY SIDE 6053 CYLINDER HEAD GASKET 79222708

Cylinder head gasket positioning—1.0L engine

1. Cylinder head gasket 2. Cylinder block 79222799

Cylinder head gasket positioning—1.3L engine

stages, in sequence, to 54 ft. Ibs. (73 Nm) on 1.0L engines or 49 ft. lbs. (68 Nm) on 1.3L engines Valve lifters

Camshaft Rocker arm cover and torque the bolts to 44 inch Ibs. (5 Nm) Timing belt and tensioner Distributor Intake manifold and torque the bolts to 17 ft. Ibs. (23 Nm) Exhaust manifold and torque the bolts to 17 ft. Ibs. (23 Nm) Negative battery cable 4. Start the engine and allow it to reach normal operating temperature. Check for leaks and adjust the ignition timing, if necessary. Prizm

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Properly relieve the fuel system pressure, 3. Drain the engine coolant. 4. Drain the engine oil. 9. Remove or disconnect the following: ¢ Negative battery cable ¢ Washer tank and pump ¢ Accessory drive belt

93062638

Cylinder head bolt torque sequence—Prizm

Alternator Accelerator cable from the throttle body Intake Air Temperature (IAT) sensor electrical connector Air cleaner hose Throttle Position (TPS) sensor electrical connector Idle Air Control (IAC) valve electrical connector Manifold Absolute Pressure (MAP) sensor electrical connector Coolant bypass hoses Fuel injector electrical connectors Fuel injector harness from the intake manifold Intake manifold support bracket Oxygen (02S) sensor Exhaust pipe from the manifold 6. Install an engine support fixture. A/C receiver pinch clamp and move the receiver aside Right side engine mount Ignition coil connectors Fuel line at the fuel rail Spark plug wires Ignition coils Fuel rail Ground wires from the cylinder head Heater hose from the cylinder head Water bypass pipe Camshaft Position (CMP) sensor Engine Coolant Temperature (ECT) sensor Positive Crankcase Ventilation (PCV) valve and hoses Rocker arm cover 7. Set the No. 1 piston to Top Dead Center (TDC) and align the camshaft timing sprockets. 8. Remove or disconnect the following: ¢ Power steering oil pressure switch connector ¢ Right side lower engine splash shield ¢ Power steering pump

Crankshaft pulley Crankshaft Position (CKP) sensor Drive belt tensioner Right side engine mount bracket Timing chain tensioner Timing chain cover Crank sensor reluctor Timing chain slipper Crankshaft sprocket Timing chain Camshaft sprockets Camshaft bearing caps Camshafts Valve lifters Intake manifold Exhaust manifold Cylinder head To install: 9. Install the cylinder head with a new gasket. 10. Torque the cylinder head bolts in the following sequence: a. 18ft. Ibs. (25 Nm). b. 36 ft. Ibs. (49 Nm). C. Plus an additional 90 degrees. 11. Install or connect the following: ¢ Camshafts and torque the bearing cap bolts to 10 ft. lbs. (13 Nm) Camshaft sprockets and torque the bolts to 40 ft. Ibs. (55 Nm) Timing chain Timing chain cover and torque the bolts to 14 ft. Ibs. (18 Nm) Crankshaft pulley and torque the bolt to 105 ft. Ibs. (142 Nm) Rocker arm cover and torque the bolts to 89 inch Ibs. (10 Nm) ECT sensor Camshaft sensor and torque the bolt to 11 ft. Ibs. (15 Nm) Water bypass pipe and torque the bolt to 11 ft. Ibs. (15 Nm) Heater hoses Ground wires to the cylinder head and torque the bolts to 11 ff. Ibs. (15 Nm)

GEO/CHEVROLET METRO ¢ PRIZM Fuel rail and torque the bolts to 10 ft. Ibs. (14 Nm) Fuel line to the rail Ignition coils and torque the bolts to 10 ft. Ibs. (14 Nm) Right side engine mount and torque the bolts to 40 ft. Ibs. (54 Nm) A/C receiver pinch clamp 12. Remove the engine support fixture. e Exhaust manifold support bracket and torque the bolt to 26 ft. Ibs. (35 Nm) Exhaust pipe with a new gasket and torque the bolts to 46 ft. Ibs. (62 Nm) Ozsensor and torque the nuts to 30 ft. Ibs. (41 Nm) Fuel injector harness brackets Vacuum hoses Intake manifold support bracket and torque the bolts to 37 ft. Ibs. (50 Nm) Fuel injector harness to the intake manifold and torque the bolts to 106 inch Ibs. (12 Nm) Upper radiator hose Fuel injector connectors Coolant bypass hoses MAP sensor electrical connector IAC valve electrical connector TPS sensor electrical connector IAT sensor electrical connector Accelerator cable to the throttle body Alternator and torque the bolts to 17 ft. Ibs. (23 Nm) Washer pump and torque the bolt to 89 inch Ibs. (10 Nm) Accessory drive belt Negative battery cable 13. Fill the engine with new oil. 14. Fill and bleed the cooling system. 15. Start the vehicle and check for leaks, repair if necessary. Road test and check for proper operation.

2. Remove or disconnect the following: e Both battery cables Battery Rocker arm cover Timing belt Camshaft sprocket Camshaft Position (CMP) sensor Camshaft Rocker shaft retaining bolts. Lift out the exhaust and intake rocker arm shafts, with the springs and rocker arms attached. If necessary, remove the rocker arms, washers and springs from the rocker shafts. Note the order in which the components are removed; they must be re-assembled in the same order and position.

1. Before servicing the vehicle, refer to the precautions in the beginning of this section.

REMOVAL & INSTALLATION Metro

7.0L ENGINE 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Relieve the fuel system pressure. 3. Drain the cooling system. 4 Remove or disconnect the following: Air cleaner Engine Coolant Temperature (ECT) sensor electrical connector ECT sending unit connector Throttle Position (TPS) sensor electrical connector Exhaust Gas Recirculation (EGR) valve electrical connector Idle Speed Control (ISC) motor electrical connector Ground wires from the intake manifold e Throttle body electrical connector e Manifold Absolute Pressure (MAP) sensor electrical connector e Early Fuel Evaporative (EFE) heater electrical connector, if equipped

e Fuel feed and return hoses from the throttle body e Coolant hoses from the throttle body

(11 Nm). e Camshaft ¢ CMP sensor and torque the bolts to 97 inch Ibs. (11 Nm)

¢ EGR Modulator

¢ Camshaft sprocket and torque the

¢ EGR valve

bolt to 43 ft. Ibs. (60 Nm)

ee ms a

e}

REMOVAL & INSTALLATION

1.3L Engine

Intake Manifold

To install: 3. If disassembled earlier, assemble the springs, washers and rocker arms on to the rocker shafts. 4. |nstall or connect the following: e Lubricate the rocker arms and shafts with clean engine oil. Position the intake and exhaust rocker arm shafts in their original positions and torque the bolts, in the correct sequence, to 97 inch Ibs.

i) Pa

The 1.0L and 1.8L engines do not use rocker arms/shafts, the camshaft directly actuates the valves.

¢ Rocker arm cover and torque the bolts to 44 inch Ibs. (5 Nm) e Battery e Both battery cables

>The intake and exhaust rocker arm shafts are NOT the same. Both can be distinguished by looking at the ends of the shafts, which are different. Install the intake rocker arm shaft with the stepped end toward the distributor side.

Rocker Arms/Shafts

CS

@

31-9

ia al

oO

6

6) 79222712

Rocker arm shaft retaining bolts tightening sequence—1.3L engines

Heater Core replacement is covered in Section 2 of this manual

pif ee Evaporative Emissions (EVAP) can-

Wiring harness from the retaining clamps Fuel feed and return hoses Coolant hoses from the throttle body Brake booster hose Canister purge hose Accelerator cable Intake manifold bolts Intake manifold

ister vacuum hose MAP sensor hose from the intake manifold Brake booster vacuum hose Positive Crankcase Ventilation

(PCV) vacuum hose Accelerator cable from the thrott g

body Intake manifold/throttle body unit To install: 5. Install or connect the following: Intake manifold with a new gasket and torque the bolts to 17 ft. Ibs.

To install: 5. Install or connect the following: Intake manifold with a new gasket

and torque the nuts and bolts to 17 ft. Ibs. (23 Nm) Canister purge hose Brake booster hose Coolant hoses Fuel feed and return hoses Wiring harness to the retaining clamps Ground wires to the intake manifold Fuel injector electrical connectors MAP sensor electrical connector TPS sensor electrical connector IAC valve electrical connector EVAP canister purge valve electrical

(23 Nm)

PCV hose EVAP canister vacuum hose MAP sensor vacuum hose Brake booster vacuum hose Coolant hoses Fuel feed and return hoses ECT sensor electrical connector Coolant temperature sending unit electrical connector EFE heater electrical connector, if equipped ECT switch electrical connector TPS sensor electrical connector

EGR solenoid valve electrical connector ISC motor electrical connector Ground wires to the intake manifold Throttle body electrical connector Wiring harness to the retaining clamps Accelerator cable to the throttle body and adjust as needed Air cleaner assembly Negative battery cable 6. Fill the cooling system. 7. Start the vehicle and check for leaks, repair if necessary.

7.3L ENGINE 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Relieve the fuel systern pressure. 3. Drain the cooling system. 4. Remove or disconnect the following: Air cleaner Ground wires from the intake manifold es Fuel injector electrical connectors Manifold Absolute Pressure (MAP) sensor electrical connector e Throttle Position (TPS) sensor — electrical connector Idle Air Control (IAC) valve electrical connector Evaporative Emissions (EVAP) canister purge valve electrical connector

connector Accelerator cable Air cleaner assembly Negative battery cable 6. Fill the cooling system. 7. Start the vehicle and check for leaks, repair as necessary.

Prizm

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Relieve the fuel system pressure. 3. Drain the cooling system. 4. Remove or disconnect the following: Accelerator cable from the throttle body Throttle valve cable from the throttle body, if equipped Intake Air Temperature (IAT) sensor electrical connector Air cleaner assembly Throttle Position (TPS) sensor electrical connector Idle Air Control (IAC) valve electrical connector Manifold Absolute Pressure (MAP) sensor electrical connector Coolant bypass hoses Fuel injector electrical connectors Wiring harness from the intake manifold

e Intake manifold support bracket e Upper radiator hose and support bracket e Brake booster vacuum hose e Fuel feed and return hoses

¢ Intake manifold To install: 5. Install or connect the following: Intake manifold with a new gasket and torque the bolts to 13 ft. Ibs. (18 Nm) Brake booster vacuum hose Fuel inlet pipe to the fuel rail and torque the fitting to 22 ft. Ibs. (29 Nm) Fuel return hose Intake manifold support bracket and torque the bolts to 13 ft. Ibs. (18 Nm) Upper radiator hose and support bracket and torque the bolt to 13 ft. lbs. (18 Nm) Engine wire harness to the intake manifold and torque the bolt to 9 ft. lbs. (13 Nm) Fuel injector connectors to the fuel injectors Coolant bypass hoses MAP sensor electrical connector IAC valve electrical connector TPS sensor electrical connector Air cleaner assembly IAT sensor electrical connector Accelerator cable and torque the bolts to 98 inch Ibs. (11 Nm) Throttle valve cable, if equipped and torque the bolts to 11 ft. Ibs. (15 Nm) Negative battery cable 6. Fill the cooling system. 7. Start the vehicle and check for leaks, repair if necessary.

Exhaust Manifold REMOVAL & INSTALLATION ee

. eee

Metro

7.0L 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 pipe from the exhaust manifold e Heated Oxygen (HO2S) sensor e Exhaust manifold heat shield e Exhaust manifold

oui Orn To install: 3. Install or connect the following: ¢ Exhaust manifold with a new gasket and torque the bolts to 17 ft. Ibs. (23 Nm) e Exhaust manifold heat shield and torque the bolts to 11 ft. Ibs. (15 Nm) e Front pipe to the exhaust manifold with a new seal and torque the bolts to 33 ft. Ibs. (45 Nm) e HO2S and torque the bolts to 33 ft. lbs. (45 Nm) e Negative battery cable 4. Start the vehicle and check for exhaust leaks, repair if necessary.

7.3L ENGINE 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Negative battery cable Front pipe from the exhaust manifold e Exhaust manifold stiffener bracket e Oxygen (02S) sensor electrical connector Exhaust manifold heat shield e Low side A/C line bracket and position aside, if equipped e Exhaust manifold To install: 3. Install or connect the following: e Exhaust manifold with a new gasket and torque the bolts to 24 ft. Ibs. (32 Nm) Exhaust manifold heat shield and torque the bolts to 11 ft. Ibs. (15 Nm) Low side A/C line bracket, if equipped and torque the bolts to 11 ft. Ibs. (15 Nm) e Exhaust manifold stiffener bracket and torque the boits to 37 ft. Ibs. (50 Nm) Front pipe and torque the bolts to 37 ft. Ibs. (50 Nm) 02S electrical connector Negative battery cable Prizm

1. Before servicing the vehicle, reier to the precautions in the beginning of this section. 2. Remove or disconnect the following: ¢ Negative battery cable

Heated Oxygen (HO2S) sensor and sub-oxygen sensor Front exhaust pipe from the exhaust manifold Exhaust manifold support bracket Exhaust manifold upper heat shield Exhaust manifold Lower heat shield from the exhaust manifold, if necessary To install: 3. Install or connect the following: e Lower heat shield, if removed, and torque the bolts to 11 ft. Ibs. (15 Nm) Exhaust manifold with a new gasket and torque the bolts to 36 ft. Ibs. (48 Nm) Exhaust manifold upper heat shield and torque the bolts to 11 ft. Ibs. (15 Nm) Exhaust manifold support bracket and torque the bolts to 24 ft. Ibs. (32 Nm) Front pipe to the exhaust manifold and torque the bolts to 46 ft. Ibs. (62 Nm) HOssensor and torque the fasteners to 30 ft. Ibs. (41 Nm) e Negative battery cable 4. Start the vehicle and check for exhaust leaks, repair if necessary.

Front Crankshaft Seal REMOVAL & INSTALLATION Metro

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the engine oil. 3. Remove or disconnect the following: Negative battery cable Air cleaner assembly Right side engine splash shield Lower alternator cover Accessory drive belt Crankshaft pulley Ons @7.0. © 6‘oF, Water pump pulley Timing belt cover 4. Rotate the Crankshaft to align the timing marks. e Timing belt e Crankshaft oil seal To install: 5. Lubricate the lip of the new seal with clean engine oil.

79222713

To prevent damage to the lip of the seal use an oil seal protector as shown—Metro

6. Install or connect the following: New oil seal Timing belt and torque the tensioner bolt to 20 ft. Ibs. (27 Nm) Timing belt cover and torque the bolts to 97 inch Ibs. (11 Nm) Water pump pulley and torque the bolts to 18 ft. Ibs. (24 Nm) Crankshaft pulley and torque the bolts to 12 ft. Ibs. (16 Nm) Accessory drive belt Alternator cover plate and torque the bolts to 49 inch Ibs. (5.5 Nm) Right side splash shield Air cleaner assembly e Negative battery cable 7. Fill the engine with new oil. 8. Start the vehicle and check for leaks, repair if necessary. Prizm

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Negative battery cable e Accessory drive belt e Right side splash shield e Crankshaft pulley e Crankshaft front seal To install: 3. Apply clean engine oil to the new oil seal and lubricate the lip of the oil seal with multi-purpose grease. 4. Install or connect the following: e New oil seal using a seal driver e Crankshaft pulley and torque the bolt to 105 ft. Ibs. (142 Nm) e Right side splash shield e Accessory drive belt e Negative battery cable 5. Start the vehicle and check for leaks, repair if necessary.

Brake service is covered in Section 4 of this manual

ai-12 See Camshaft

“

REMOVAL & INSTALLATION Metro A - Indicates pages from timing belt

7.0L 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 Rocker arm cover Distributor and housing Timing belt Camshaft timing belt sprocket. Lock the camshaft with a 0.39 in. (10mm) rod inserted into the hole in the camshaft, before loosening the sprocket retaining bolt.

B - Indicates direction to timing belt 79222715

Directional markings for the camshaft bearing caps—Metro with 1.0L engine

79222716

The mating surface of the cylinder head and cover must not be damaged during this procedure. Place a clean shop cloth between the rod and mating surfaces and use care not to bump the rod when loosening. 3. Turn the crankshaft until the crankshaft sprocket timing mark is 60 degrees to the left of the arrow mark on the oil pump case. 4. Remove or disconnect the following: ¢ Camshaft caps from the cylinder head ¢ Camshaft e Valve lifters To install: 5. Pour engine oil through the camshaft journal oil holes and check that engine oil comes out from the oil holes in the valve lifter bores. 6. Install the valve lifters in their original positions, if being re-used. 7. Install the camshaft in the cylinder

Torque sequence for the camshaft bearing cap bolts—Metro with 1.0L engine

head. After applying engine oil to the camshaft journal and all around the cam, position the camshaft so the camshaft timing sprocket pin hole in the camshaft is at the lower position. 8. Apply clean engine oil to the sliding surface of each bearing cap against the camshaft journal. 9. Apply silicone sealant to the mating Surface of the No. 1 and No. 3 bearing cap, which will mate with the cylinder head. 10. There are marks provided on each camshaft bearing cap indicating the position and direction for installation. Install the bearing cap as indicated by the marks. e»Camshaft bearing cap No. 1 is installed first. It retains the camshaft in the proper position and thrust direction.

11. Apply clean engine oil to the retaining bolts and torque them to 97 inch lbs. (11 Nm).

12. Install or connect the following: Camshaft oil seal after applying engine oil to the seal lip Camshaft sprocket and torque the bolt to 44 ft. Ibs. (60 Nm) Valve cover using a new gasket and torque the bolts to 44 inch Ibs. (5 Nm) Distributor housing Distributor Timing belt Negative battery cable 13. Start the engine and check the ignition timing. Adjust the timing as necessary. e»When the engine is started, if air is trapped in the Hydraulic Valve Lash (HVL) adjuster, the valve may make a tapping sound when the engine is operated. In such a case, run the engine at 2000 rpm until the air is purged and the tapping sound ceases.

7.3L 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 ¢ Rocker arm cover e Timing belt ¢ Camshaft timing belt pulley ¢ Camshaft Position (CMP) sensor and housing 3. Loosen all valve adjusting screws to allow the rocker arms to move freely. ¢ Camshaft housings ¢ Camshaft To install: 4. Apply clean engine oil to the camshaft, oil journals and the oil seal. 9. Install or connect the following: e Camshaft ¢ Camshaft housings and torque the bolts in sequence to 97 inch Ibs. (11 Nm) ¢ New camshaft oil seal

CRANKSHAFT KEY

iSa

CRANKSHAFT TIMING GEAR

79227714

Position the crankshaft as shown before removing the camshaft—Metro with 1.0L engines

Camshaft housing torque sequence

9346XGB1

SENETRO «Pain O 1-10

eS

e Camshaft timing sprocket and torque the bolt to 43 ft. Ibs. (60 Nm) e Timing belt 6. Perform the following steps to adjust the valve lash. a. Set the number one cylinder to top dead center. b. Ensure the camshaft is in proper phase. c. Adjust valves 1, 2, 8, and 6. d. Rotate the crankshaft one revolution (360°). e. Adjust valves 3, 4, 7, and 5. 7. Install or connect the following: ¢ CMP sensor housing and torque the bolts to 97 inch Ibs. (11 Nm) e CMP sensor e Rocker arm cover and torque the bolts to 97 inch Ibs. (11 Nm) e Negative battery cable Prizm

e>The procedure is the same for the exhaust camshaft and the intake camshaft.

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Negative battery cable Timing chain Camshaft sprocket Camshaft bearing cap bolts, in sequence, by starting at the ends and working towards the center of the camshaft e Camshaft from the cylinder head To install: 3. Install or connect the following: e Camshaft to the cylinder head e Camshaft bearing caps in their proper location and direction and torque the bolts in sequence to 10

SSS

ft. lbs. (13 Nm). Torque the front bearing cap bolts to 17 ft. Ibs. (23 Nm). ¢ Sprocket to the camshaft and torque the bolt to 40 ft. Ibs. (55 Nm) e Timing chain e Negative battery cable 4. Check the valve clearance and adjust if necessary.

Valve Lash

:

ADJUSTMENT 1.0L Metro

Lash adjusters, located between the camshaft and valve stems, are used to adjust the valve clearance to 0 lash automatically at all times. Adjustment is not required or possible. Prizm and 1.3L Metro

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove the negative battery cable. 3. Disconnect the ignition wires. 4, Remove the rocker arm cover. 5. Turn the crankshaft until the piston in No. 1 cylinder is at Top Dead Center (TDC) on the compression stroke. Align the groove in the crankshaft pulley with the 0 mark on the timing belt cover. Be sure the camshaft gears are aligned. 6. The intake valve clearance should be 0.006—-0.010 in. (0.15—0.25mm) and the exhaust valve clearance should be 0.010—-0.014 in. (0.25-0.35mm). 7. Using a feeler gauge, measure the clearance between the camshaft and valve

J99871-1 J 39871-2

79222724

9306230

Camshaft bearing cap tightening sequence—Prizm

Using the valve clearance adjustment tool

SSS

lifter shim at the No. 1 cylinder intake and exhaust valves, the No. 2 cylinder intake valves and the No. 3 cylinder exhaust valves. Record the clearance measurements for all valves that are not within specification, in order to determine the required replacement shims. 8. Rotate the crankshaft pulley1 full turn (360 degrees) and check the clearance at the No. 2 cylinder exhaust valves, the No. 3 cylinder intake valves and the No. 4 cylinder intake and exhaust valves. Record the clearance measurements for all valves that are not within specification, in order to determine the required replacement shims. 9. For valves requiring adjustment, proceed as follows: a. Be sure the base of the camshaft lobe is directly over the valve (camshaft lobe pointing away from the valve). b. Insert tool J-3987-1 between the camshaft and lifter adjustment shim, to compress the valve spring and push the lifter down. c. Insert tool J-39871-2 between the camshaft and the lifter, to hold the lifter away from the camshaft. Position the bottom edge of the tool on the lifter. d: Using a small screwdriver and a magnet, remove the adjustment shim from the top of the lifter. e. Use the micrometer to measure the thickness of the removed shim. Determine the thickness of the new shim using the formula below. For the purposes of the following formula, T = Thickness of the shim removed: A = Valve clearance measured; N = Thickness of the required new shim. 10. For the intake camshaft valves: N = T + A—0.008 in. (0.20mm). 11. For the exhaust camshaft valves: N = T + A—0.010 in. (0.25mm). a. Select a shim closest to the calculated thickness. Shims are available in 16 sizes, in increments of 0.002 in. (0.050mm), from 0.1004 in. (2.55mm) to 0.1299 in. (3.30mm). b. Install the shim on the valve lifter and remove tool J-39871-2. Recheck the valve clearance. 12. Install the rocker arm cover, using a new gasket and torque the nuts to 53 inch lbs. (6 Nm). 13. Connect the ignition wires. 14. Connect the negative battery cable. 15. Run the engine and check operation.

set to hold the lifter

For complete Engine Mechanical specifications, see Section 1 of this manual

Bi-ia oa Starter Motor

REMOVAL & INSTALLATION Metro

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Negative battery cable e Starter solenoid electrical connectors

e Starter motor To install: 3. Install or connect the following: e Starter motor and torque the bolts to 17 ft. Ibs. (23 Nm) e Starter solenoid electrical connectors ¢ Negative battery cable Prizm

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: ¢ Negative battery cable e Upper mounting bolt e Right side splash shield ¢ Starter motor electrical connectors e Starter motor To install: 3. Install or connect the following: e Starter motor and torque the bolts to 27 ft. Ibs. (37 Nm) ¢ Starter motor electrical connectors ¢ Right side splash shield ¢ Negative battery cable

93062631

Exploded view of the oil pan and strainer—Metro

5. Clean the oil pan and oil pump strainer. To install: 6. Install or connect the following: New oil pump strainer seal e Oil pump strainer to the cylinder block and torque the bolts to 97 inch Ibs. (11 Nm) Oil pan to the cylinder block after applying a continuous bead of sealant around the oil pan. Torque the bolts to 97 inch Ibs. (11 Nm) Starting in the center and working outward. CKP sensor Flywheel inspection cover Front pipe to the exhaust manifold Center pipe to the front pipe Catalytic converter Negative battery cable 7. Fill the engine with new oil. 8. Start the vehicle and check for leaks, repair if necessary. Prizm

REMOVAL & INSTALLATION Metro

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the engine oil. 3. Remove or disconnect the following: ¢ Negative battery cable ¢ Front pipe from the exhaust manifold and separate it from the center/resonator pipe ¢ Catalytic converter ¢ Crankshaft Position (CKP) sensor ¢ Flywheel inspection cover e Oil pan ¢ Qil pump strainer and bracket 4. Clean the mating surface of the oil pan and the cylinder block.

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the engine oil. 3. Remove or disconnect the following: ¢ Negative battery cable e Right side lower splash shield ¢ Flywheel inspection cover (if equipped with manual transmission) ¢ Qil pan To install: 4. Install or connect the following: ¢ Oil pan with a new gasket and torque the bolts to 97 inch Ibs. (11 Nm) starting in the center and working outward * Flywheel inspection cover, if removed e Right side lower splash shield ¢ Negative battery cable

SECTION A-A

SECTION B-B

DO

6.0mm (0.24")

E

SILICONE SEALER

669

SECTION C-C

OIL PAN 79222725

To ensure a leak-free seal, apply sealer as shown—Prizm 1.8L engine

5. Start the vehicle and check for leaks, repair if necessary.

REMOVAL & INSTALLATION Metro

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the engine oil. 3. Remove or disconnect the following: Negative battery cable Oil pan Timing belt and tensioner A/C compressor, if equipped and lock the crankshaft ¢ Timing belt guide ¢ Oil pump and discard the gasket ¢ Rotor plate pins from the oi! pump

Long

Bells 79222727

Oil pump mounting bolt identification— Metro

ere To install: 4. Install or connect the following: ¢ Rotor plate pins to the oil pump ¢ Oil seal over the crankshaft and make certain that the lip is not turned out Apply Loctite® sealant to the threads of the short mounting bolts and install the oil pump. Torque the bolts to 97 inch Ibs. (11 Nm). Rubber seal between the oil pump and the water pump Timing belt guide and lock the crankshaft A/c compressor and bracket, if equipped e Qil pan Timing belt and tensioner Guide tube to the oil pump. Torque the bolt to 97 inch Ibs. (11 Nm). Negative battery cable 5. Fill the engine with new oil. 6. Start the vehicle and check for leaks, repair if necessary. Prizm

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the engine oil. 3. Remove or disconnect the following: e Negative battery cable e Timing chain e Oil pump To install: 4. Install or connect the following: ¢ Oil pump with a new gasket and torque the bolts to 97 inch Ibs. (11 Nm) ¢ Timing chain ¢ Negative battery cable 5. Fill the engine with new oil. 6. Start the vehicle and check for leaks, repair if necessary.

9346XGB2

Oi! pump—Prizm

Rear Main Seal

REMOVAL & INSTALLATION Metro

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Negative battery cable e Transmission from the vehicle e Pressure plate and clutch disc, for manual transmission 3. Matchmark the flywheel-to-engine position. e Flywheel from the crankshaft e Crankshaft position (CKP) sensor e Oil pan e Rear crankshaft seal housing e Rear crankshaft seal To install: 4. Lubricate the inside and outside edges of the rear crankshaft seal. 5. Install or connect the following: e Rear crankshaft seal housing with a new seal and torque the bolts to 97 inch lbs. (11 Nm) e Oil pan and torque the bolts to 97 inch Ibs. (11 Nm) e CKP sensor and torque the bolt to 97 inch Ibs. (11 Nm) 6. Apply Loctite® sealant to the flywheel retaining bolt threads. ¢ Flywheel and torque the bolts to 55 ft. ps. (75 Nm) e Pressure plate and clutch disc, for manual transmission e Transmission e Negative battery cable 7. Check the oil level and top off if necessary. 8. Start the vehicle and check for leaks, repair if necessary.

To install: 4. Lubricate the lip of the new rear oil Seal. 5. Install or connect the following: e Rear oil Seal and tap it into place e Flywheel and torque the bolts to 67 ft. Ibs. (83 Nm) e Pressure plate and clutch disc, for manual transmission e Transmission e Negative battery cable 6. Check the oil level and top off, if necessary. 7. Start the vehicle and check for leaks, repair if necessary.

Timing Chain, Sprockets, Front Cover & Seal REMOVAL & INSTALLATION Prizm

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: 3. Drain the cooling system. Negative battery cable Windshield washer reservoir Drive belt Alternator and install an engine Support fixture Right side engine mount Cylinder head cover

Prizm

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: ¢ Negative battery cable e Transmission e Pressure plate and clutch disc, for manual transmission 3. Matchmark the flywheel-to-engine position. e Flywheel from the crankshaft e Rear crankshaft seal

93062632

Exploded view of the timing chain and sprockets—1.8L Prizm

For Accessory Drive Belt illustrations, see Section 1 of this manual

Bid See 4. Set the No. 1 piston to the Top Dead Center (TDC) position on the compression Stroke and align the camshaft timing sprockets. 5. Remove or disconnect the following: Power steering oil pressure switch connector Power steering pump Crankshaft pulley Crankshaft Position (CKP) sensor Drive belt tensioner Timing chain cover Crankshaft sensor reluctor Timing chain damper and shoe Crankshaft sprocket Timing chain Front seal Camshaft sprocket bolt Camshaft sprocket To install: 6. Install or connect the following: ¢ Camshaft sprocket. Use a wrench to turn the camshafts to align the timing marks Crankshaft bolt and turn it until the keyway faces upward. When aligned properly, torque the sprocket bolts to 33 ft. Ibs. (44 Nm). Front seal and tap it into position until the surface is flush against the retainer edge Timing chain Crankshaft timing sprocket Timing chain shoe and torque the bolts to 89 inch Ibs. (10 Nm) Timing chain damper and torque the bolt to 14 ft. Ibs. (18 Nm) Crankshaft sensor reluctor and make certain that the F is facing outward Timing chain cover after applying a sealant to the mating surface. Torque the 10mm bolts to 89 inch Ibs. (10 Nm) and the 12mm bolts to 14 ft. Ibs. (18 Nm). Install the timing chain tensioner by depressing the plunger and applying the hook to the pin. Torque the bolts to 89 inch Ibs. (10 Nm). Right side engine mounting bracket and torque the bolts to 40 ft. Ibs. (54 Nm)

C&D

9346Z2GD8

Use a wrench to turn the camshafts to align the timing marks—Prism

Drive belt tensioner and torque the bolt to 51 ft. Ibs. (69 Nm) and the nut to 21 ft. Ibs. (29 Nm) CKP sensor and torque the bolt to 106 inch Ibs. (12 Nm) Crankshaft pulley and torque the pulley to 105 ft. Ibs. (142 Nm) Power steering pump and torque the bolts to 32 ft. Ibs. (43 Nm) ¢ Power steering oil pressure switch 7. Rotate the crankshaft clockwise 1 revolution and verify that the plunger on the timing chain tensioner has released. If the plunger does not release perform the following steps: a. Step 1: Press the timing chain dampener into the tensioner. b. Step 2: Release the hook from the pin. C. Step 3: Verify proper timing chain alignment after the plunger is released. 8. Install or connect the following: e Cylinder head cover e Right side engine mount and insulator. Torque the bolts to 40 ft. Ibs. (54 Nm). ¢ Alternator 9. Remove the engine support fixture, 10. Install or connect the following: ¢ Windshield washer reservoir ¢ Negative battery cable 11. Fill the cooling system. 12. Start the vehicle and check for leaks, repair if necessary,

A “R"OR“T MARK B OIL RING

C UPPER COMPRESSION RING 0 LOWER COMPRESSION RING 7922AG40

Chevrolet 1.0L, 1.3L and 1.8L engines— piston ring positioning

B C O E F

PISTON ARROW MARK H F FIRST RING END GAP SECOND RING END GAP G INTAKE SIDE OIL RING END GAPS H EXHAUST SIDE OIL RING SPACER GAP 7922AG39

Chevrolet 1.0L, 1.3L and 1.8L engines— piston ring end-gap Spacing

=) CRANKSHAFT PULLEY SIDE

A. Arrow mark

B. Oil hole (oil hole should come on intake side)

1. Piston

2. Connecting rod

Piston & Ring POSITIONING PR ALLL

ee

7922AG41

Si it) FY,

Chevrolet 1.0L, 1.3L and 1.8L engines— piston and connecting rod assembly positioning

eee BM |

FUEL SYSTEM 7. Disconnect the negative battery cable. 8. Continue with the required service procedure(s).

Fuel System Pressure RELIEVING 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove the fuel filler cap. 3. On Metro, perform the following: a. Remove the control relay box cover from the relay box. b. Disconnect the fuel pump relay from the relay box connector. 4. Remove the circuit opening relay above the left side lower kick panel. 5. Attempt to start the engine, if it starts, let it run until the engine stalls due to lack of fuel. 6. Engage the starter for a few seconds to assure relief of remaining fuel pressure.

629

RELAY BOX

630

FUEL PUMP RELAY 79222728

View of the relay box showing the location of the fuel pump relay—Metro

79222729

Leave the circuit opening relay unplugged during fuel system servicing—Prizm

REMOVAL & INSTALLATION The fuel filter is an integral part of the fuel sender assembly which is located in the fuel tank. The fuel filter does not require replacement at regular intervals.

REMOVAL & INSTALLATION Metro

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Properly relieve the fuel system pressure. 3. Drain the fuel tank by pumping the fuel out through the filler neck into a suitable container. 4. Remove or disconnect the following: Rear seat cushion Fuel pump electrical connector Muffler and exhaust pipe assembly Fuel filler hose Fuel feed and return clamps and hoses from the pump Fuel tank from the vehicle Screws from the pump assembly Fuel sender assembly 5. Disassemble the fuel sending unit by removing or disconnecting the following: « Fuel level sensor by depressing the tab Lower assembly end cap Fuel pump cushion Fuel sender sub assembly electrical connectors Fuel pump from the sender assembly Fuel tube and 2 grommets from the fuel sender sub assembly 6. The sender sub assembly contains filter and must be serviced as an fuel the assembly. To install: 7. Install or connect the following: e Fuel tube and 2 new grommets from the fuel sender sub assembly e Fuel pump to the sender assembly

;

7

,

e Fuel sender sub assembly electrical connectors New fuel pump cushion Lower assembly end cap Fuel level sensor Fuel sender assembly with a new gasket in the fuel tank and torque the screws to 89 inch Ibs. (10 Nm) Fuel feed and return hoses and clamps on the fuel pump Fuel sender electrical connectors Fuel tank and torque the bolts to 18 ft. lbs. (25 Nm) Fuel filler hose Muffler and exhaust pipe assembly and torque the bolts to 26 ft. Ibs. (35 Nm) Rear seat cushion Negative battery cable 8. Refill the fuel tank. 9. Turn the ignition key ON and allow the fuel system to pressurize. 10. Start the engine and check for leaks, repair if necessary. Prizm

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Properly relieve the fuel system pressure. 3. Drain the fuel tank into a suitable container. 4. Remove or disconnect the following: e Rear seat cushion to gain access to the service panel e Access panel e Fuel sender electrical connectors

FUEL PUMP

ar

CONNECTION

FUEL PUMP

FUEL PUMP HOSE

ee

as ELECTRICAL

CONNECTOR 79222732

Remove the fuel pump and the sender assembly from the fuel tank slowly to keep from splashing fuel—Prizm

on 1 of this manual For Tire, Wheel and Ball Joint specifications, see Secti

ie

93062633

Remove the fuel injector from the Throttle Body Unit (TBI)—Metro

1. 2. 3. 4.

Fuel Fuel Fuel Fuel

To install: 4. Install or connect the following: e New O-rings coated with clean engine oil to the injector e Injector into the TBI unit ¢ Fuel injector cover e Air cleaner stud bracket and torque the bolts to 89 inch Ibs. (10 Nm) ¢ Fuel injector electrical connector ¢ Negative battery cable 5. Turn the ignition ON to pressurize the fuel system. 6. Check for fuel leaks and repair if necessary.

level sensor and guage unit Filter Pump pump electrical connector 9346XGB3

Exploded view of the fuel sender assembly unit

¢ Fuel line retaining clip ¢ Fuel line ¢ Fuel sender from the tank 5. Disassemble the Fuel sender assembly by removing or disconnecting the following: e End cap Fuel pressure regulator Fuel pump strainer retaining clip Fuel pump strainer Fuel sender assembly housing from the fuel level sensor and gauge unit Fuel pump electrical connector Fuel pump from the fuel filter Fuel filter from the fuel level sensor and gauge unit To install: 6. Install or connect the following: New fuel filter to the fuel level sensor and gauge unit ¢ Fuel pump into the fuel filter ¢ Fuel pump electrical connector ¢ Fuel pump assembly to the fuel level sensor and gauge unit Fuel pressure regulator Fuel pump strainer End cap Fuel sender assembly to the tank using a new gasket and torque the bolts to 35 inch Ibs. (4 Nm)

7.3L ENGINE e Fuel line and retaining clip ¢ Fuel sender electrical connector e Negative battery cable 7. Refill the fuel tank. 8. Turn the ignition ON to pressurize the fuel system. 9. Check for fuel leaks and repair if necessary. 10. Install the service access panel and rear seat cushion.

Fuel Injector REMOVAL & INSTALLATION

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Metro

7.0L ENGINE 1, Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Properly relieve the fuel system presSure, 3. Remove or disconnect the following: e Air cleaner assembly ¢ Air cleaner stud bracket from the Throttle Body Injection (TBI) unit ¢ Fuel injector cover ¢ Fuel injector electrical connectors ¢ Fuel injector

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Properly relieve the fuel system pressure. 3. Remove or disconnect the following: Positive Crankcase Ventilation (PCV) hose from the intake Intake manifold brace ¢ Fuel injector electrical connectors e Fuel pressure regulator vacuum hose ¢ Fuel feed and return lines ¢ Fuel rail ¢ Fuel injectors To install: 4. Install or connect the following: e New O-rings and grommets on the fuel injectors * Fuel injectors to the fuel rail ¢ Fuel rail and torque the bolts to 17 ft. Ibs. (23 Nm) Fuel feed and return lines e Fuel injector electrical connectors ¢ Fuel pressure regulator vacuum hose Intake manifold brace and torque the bolts to 22 ft. Ibs. (30 Nm)

e PCV hose Negative battery cable

seyuntss 31-19 5. Turn the ignition ON to pressurize the fuel system. 6. Check for fuel leaks and repair if necessary. Prizm

1. Before servicing the vehicle, refer to Heprecautions in the beginning of this secion. 2. Remove the engine cover. 3. Properly relieve the fuel system presSure. | 4. Remove or disconnect the following:

To 5. rings 6.

Fuel feed hose quick connect coupling cover Fuel feed hose Throttle Valve (TV) cable and bracket, if equipped Fuel injector electrical connectors Fuel rail from the cylinder head Fuel injectors from the fuel rail install: Apply clean engine oil to the new Oand grommets. Install or connect the following: e New O-rings and grommets to the fuel injectors

e Fuel injectors to the fuel rail e Fuel rail to the cylinder head and torque the bolts to 13 ft. Ibs. (18.5 Nm) e TV cable and bracket and torque the bolts to 77 inch lbs. (9 Nm) e Fuel feed hose quick connect fitting e Fuel feed hose coupling cover e Fuel injector electrical connectors e Negative battery cable 7. Turn the ignition ON to pressurize the fuel system. 8. Check for fuel leaks and repair if necessary.

:

DRIVE TRAIN e Bolts from the rear transmission

Transaxle Assembly

mount e Left side mounting bracket bolts e Right side case-to-engine mounting bolts e Transmission through the left side of the engine compartment and make certain that the input shaft

REMOVAL & INSTALLATION Manual

METRO 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the transmission fluid. 3. Remove or disconnect the following: Negative battery cable Both front wheels Backup lamp switch electrical connector Clutch release lever from the clutch release shaft Clutch cable bracket and move it aside Negative battery cable and hanger from the transmission Gearshift guide case bolts and set the engine wire harness and bracket aside Speedometer cable Starter motor Two right side upper case-toengine bolts 4. Install an engine support fixture. e Both drive axles after properly supporting the transmission e Flywheel cover ¢ Control joint shaft through bolt and separate the control shaft from the control joint © Gearshift control lever guide plate and separate the extension rod from the lever guide plate 5. Support the transmission.

clears the clutch pressure plate To install: 6. Install or connect the following: Transmission to the engine and torque the bolts to 44 ft. Ibs. (60 Nm) Left side mounting bracket and torque the bolts to 44 ft. Ibs. (60 Nm) Rear transmission through bolt and torque it to 44 ft. Ibs. (60 Nm) Starter motor and torque the bolts to 21 ft. Ibs. (28 Nm) Extension rod to the mounting stud on the transmission and torque the nut to 29 ft. Ibs. (40 Nm) Extension rod to the gearshift control lever guide plate and torque the bolts to 89 inch Ibs. (10 Nm) Gearshift control shaft and joint and torque the joint through bolt to 15 ft. Ibs. (20 Nm) Flywheel cover and torque the bolts to 15 ft. Ibs. (20 Nm) Both driveshafts

7. Remove the transmission support. e Speedometer cable to the speedometer driven gear case ¢ Speedometer cable retaining clip e Engine wire harness and bracket to the gearshift guide case and torque the bolts to 106 inch Ibs. (12 Nm) e Negative battery cable and hanger

and torque the bolt to 106 inch Ibs. (12 Nm) ¢ Clutch cable and bracket and torque the bolts to 21 ft. Ibs. (28 Nm) e Clutch release shaft to the clutch release lever and torque the bolt to 17 ft. Ibs. (23 Nm) ¢ Backup lamp switch electrical connector e Both wheels e Negative battery cable 8. Fill the transmission with clean fluid. 9. Start the vehicle and check for leaks, repair if necessary.

PRIZM 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the transmission fluid. 3. Remove or disconnect the following: Negative battery cable Battery and tray Both front wheels Air cleaner Clutch release cylinder and line Clutch line bracket Backup switch electrical connector Vehicle Speed Sensor (VSS) electrical connectors Ground cable from the transmission Control cables from the bracket and move them to the side ¢ Upper transmission to engine bolts = _ Install an engine support fixture. e Left engine mount and bracket e Splash shields ¢ Both axle shafts e Heat insulator

manual For Wheel Alignment specifications, see Section 1 of this

31-20) SEX/UCHEVROLET METRO e PRIZM

ES

TIE

SAUL

RD

PE TS

e Front suspension crossmember ¢ Starter motor 5. Support the transaxle. ¢ Lower transmission mounting bolts e Transmission from the engine To install: 6. Install or connect the following: e Transmission to the engine and torque the lower bolts to 46 ft. Ibs. (34 Nm) and the left side bolts to 11 ft. Ibs. (23 Nm) ¢ Starter motor and torque the bolts to 29 ft. Ibs. (39 Nm) ¢ Starter electrical connectors ¢ Front suspension crossmember

and torque the bolts in the following sequence: a. Main crossmember to underbody bolts to 152 ft. Ibs. (206 Nm). b. Lower “A” frame to underbody bolt to 161 ft. Ibs. (218 Nm). c. Lower “A” frame to underbody bolts to 109 ft. Ibs. (147 Nm). d. Radiator support bolts to 45 ft. Ibs. (61 Nm). 7. Remove the transmission support. 8. Install or connect the following: e Heat insulator and torque the bolt and nut to 15 ft. Ibs. (20 Nm) ¢ Both axle shafts ¢ Both splash shields e Left engine mounting bracket and torque the bolts to 21 ft. Ibs. (28 Nm) ¢ Left transmission mount and torque the bolts to 64 ft. Ibs. (87 Nm) 9. Remove the engine support. ¢ Control cables ¢ Ground cable VSS electrical connector Backup light switch electrical connector Clutch release cylinder and line and torque the bolts to 106 inch Ibs. (12 Nm) Clutch line bracket and torque the bolts to 106 inch Ibs. (12 Nm) ¢ Both front wheels Air cleaner ¢ Battery and cables 10. Fill the transmission with clean fluid. 11. Start the vehicle and check for leaks, repair if necessary. Automatic

METRO 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the transmission fluid. 3. Remove or disconnect the following: e Negative battery cable

ASE SS

I

I PE ELT

DTS I EE

Hood Battery Transmission electrical connectors Speedometer cable Throttle Valve (TV) cable from the accelerator cable

Shift select cable from the manual select cable joint and bracket Accelerator cable from the bracket on top of the transmission case Vehicle Speed Sensor (VSS) electrical connector Shift solenoid electrical connectors Park Neutral Position (PNP) switch electrical connector Starter motor Fluid cooler hoses Upper rear transmission-to-bulkhead bolt 2 upper transmission-to-engine bolts

Negative battery cable from the transmission 4. Install an engine support fixture. Both front wheels Splash shields Control arms from the steering knuckles Both axle shafts Rear engine torque rod Fiywheel cover Flywheel-to-torque converter bolts Muffler mounting bracket from the rear of the engine Rear engine mount bracket from the transmission 5. Properly support the transmission. ¢ Left transmission mount e Remaining engine-to-transmission bolts e Transmission To install: 6. Use grease to lubricate the cup around the center of the torque converter. 7. Measure the distance between the torque converter and the edge of the transaxle housing; it should be at least 0.85 in. (21.4mm). If the distance is less than specified, the torque converter is improperly installed. Remove and reinstall it, 8. Install or connect the following; ¢ Transmission to the engine and torque the lower transaxle-toengine bolt to 40 ft. Ibs. (55 Nm) Left transmission mount and bracket and torque the bolts to 40 ft. Ibs. (55 Nm) Rear engine mount bracket to the transmission and torque the bolts to 40 ft. Ibs. (55 Nm) Rear engine mount-to-bulkhead bolt and torque it to 40 ft. Ibs. (55 Nm)

BOE

IIT

IT EEE ES OTE TDCETTE

ISSEY

Muffler mount to the rear exhaust hanger Flywheel-to-torque converter bolts and torque them to 14 ft. Ibs. (19

Nm) Flywheel inspection cover and torque the bolts to 89 inch Ibs. (10 Nm) Both driveshafts Rear engine torque rod assembly and torque the bolts to 40 ft. Ibs. (55 Nm) Control arms to the steering knuckles and torque the bolts 44 ft. Ibs. (60 Nm) Splash shields e Both front wheels 9. Remove the engine support fixture. Negative battery cable to the transmission and torque the bolt to 11 ft. Ibs. (15 Nm) Upper transmission-to-engine mounting bolts and torque them to 40 ft. Ibs. (65 Nm) Through-bolt to the rear engine mount and torque it to 40 ft. Ibs. (55 Nm) Starter motor and torque the bolts to 17 ft. Ibs. (23 Nm) Inlet and outlet fluid cooler lines with new hose clamps ¢ Speedometer cable into the gear case VSS electrical connector Shift solenoid electrical connector PNP switch electrical connector Engine wire harness bracket to the rear Of the transmission and torque the bolts 12 ft. Ibs. (16 Nm) Accelerator and shift select cables into the bracket on top of the transmission Shift select cable end to the manual select cable joint and adjust as necessary TV cable to the accelerator cable Negative battery cable 10. Fill the transmission with new oil. 11. Flush the oil cooler lines. 12. Start the engine and verify the proper gear select range. 13. Check the fluid level and adjust, as needed.

PRIZM 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the transmission fluid. 3. Remove or disconnect the following: ¢ Both battery cables e Battery and tray

eet Bice (SS

TEP

I

TVS

HEIN

TRI

Intake Air Temperature (IAT) sensor electrical connector e Air cleaner

Park Neutral Position (PNP) switch electrical connector Throttle Valve (TV) cable from the linkage and the bracket Shift select cable from the manual lever and the TV cable bracket guide e Upper transmission to engine bolts e Starter motor 4. Install an engine support fixture. ¢ Left transmission mounting bracket e Both splash shields ¢ Cooler hoses from the pipes at the transmission Both front wheels Both axle shafts Front transmission mount Rear transmission mount 6*@1ge @@Front crossmember 5. Support the transmission. ¢ Engine reinforcement brace and lower it e Flywheel access cover Flywheel-to-torque converter bolts e Lower transmission-to-engine bolts e Transmission To install: 6. Before installing the transmission assembly, perform the following: a. Apply grease around the pilot shaft at the center of the torque converter. b. Measure the distance between the outside edge of the torque converter housing and the torque converter lug. The distance should be more than 0.906 in. (23mm). If it is less than 0.906 in. (23mm), the torque converter is improperly installed. Remove and properly seat on the input shaft. 7. Install or connect the following: e Transmission and torque the two lower transmission-to-engine bolts to 47 ft. Ibs. (64 Nm) e Flywheel-to-torque converter bolts and torque them to 14 ft. Ibs. (19 Nm) e Flywheel access cover Lower engine reinforcement brace and torque the bolts to 47 ft. IDs. (64 Nm) 8 Remove the transmission support fixture. e Front suspension crossmember and torque the 10 front bolts to ee ft. Ibs. (206 Nm) and the two center bolts to 45 ft. Ibs. (61 Nm)

SE

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BTS ESTAR

AES WA 1S ATL

PRS

Rear transmission mount and torque the bolts to 42 ft. Ibs. (57 Nm) Front transmission mount and torque the bolts to 47 ft. Ibs. (64 Nm) Both driveshafts Both front wheels Left transmission mounting bracket and torque the bolts to 41 ft. Ibs. (56 Nm) Oil cooler hoses to the pipes and secure them with new clamps Both splash shields and torque the bolts to 44 inch Ibs. (5 Nm) e Starter motor and torque the bolts to 27 ft. Ibs. (37 Nm)

The differential portion of the 3speed transmission is separated from the rest of the transmission and must be drained and refilled separately. The differential cannot be drained or refilled through the transmission drain plug or filler tube. 9. On 3-speed transmission, refill the differential with 11% qts. (1.4 L) of DEXRON®III automatic transmission fluid, into the differential filler plug hole. The fluid level should be even with the bottom of the differential filler plug hole. Install the filler plug and tighten to 29 ft. Ibs. (39 Nm). 10. Install or connect the following: Left side transmission mounting bracket and torque the bolt to 41 ft. lbs. (66 Nm) Left transmission bracket reinforcement and torque the bolts to 15 ft. Ibs. (21 Nm) Upper transmission-to-engine bolts and torque them to 47 ft. Ibs. (64 Nm) TV guide cable bracket onto the transmission and torque the bolt to 71 inch Ibs. (8 Nm) Shift select cable into the bracket at the transaxle and secure with clip Shift select cable to the manual lever and torque the nut to 106 inch lbs. (12 Nm) VSS electrical connector TV cable to the throttle linkage and bracket 11. Adjust the TV cable as follows: a. Be sure the throttle valve is fully closed. b. Measure the distance between the

RL ETE ST TE LNG

OT

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PED TC BEAT

STA ESTEFEBEDE EOE

end of the outer cable boot and the end of the TV cable stopper, it should be 0-0.04 in. (0-1mm). c. If the distance is greater than specified, loosen the TV cable locknut and tighten the adjust nut until within specification. d. If the distance is less than specified, loosen the TV cable adjust nut. Torque the locknut to 71 inch Ibs. (8 Nm). 12. Install or connect the following: e Ground cable and torque the bolt to 115 inch Ibs. (13 Nm) PNP electrical connector Air cleaner and torque the bolts to 106 inch Ibs. (12 Nm) IAT electrical connector e Battery Both battery cables 13. Fill the transmission with new oil. 14. Flush the oil cooler lines. 15. Start the engine and verify the proper gear select range. 16. Check the fluid level and adjust, as needed.

ADJUSTMENT EEE

Clutch Pedal Height

Inspect the clutch pedal height. If it is not within 5.45-5.84 in. (138.4-148.4mm), adjust the pedal height as follows: 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 9. Remove the lower instrument panel and air duct. 3. Loosen the locknut. 4. Turn the stopper bolt until the pedal height is within 5.12-5.51 in.

(130-140mm). 5. Tighten the locknut and install the air duct and lower instrument panel.

Clutch Pedal Free Play

Inspect the clutch pedal free play. If it is not within 0.197-0.521 in. (5.0-15.0mm), adjust the pedal free-play as follows: 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 9. Remove the lower instrument panel and air duct. 3. Depress the pedal until resistance Is felt.

see Section 1 of this manual For Maintenance Interval recommendations,

1-22 Ea 4. Loosen the locknut.

5. Turn the pushrod until the free play is within 0.197—-0.591 in. (5.0-15.0mm).

Bi

6. Tighten the locknut and install the air duct and lower instrument panel.

733

REMOVAL & INSTALLATION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Negative battery cable

¢ Transmission assembly and matchmark the flywheel to the engine

ee rie acl Law ee

y 4 ileal: the boi fork €aring Clips and remove the

731 CLUTCH RELEASE SHAFT RETURN SPRING 732 CLUTCH RELEASE SHAFT COVER

siete ean fork and boot

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venly loosening

7 cllves \eteheeclar tne

bolts until the spring tension is re| ease d

Tosen oxoars

736 CLUTCH RELEASE BEARING

737 CLUTCH RELEASE BEARING PIN

be pec Armee ier PLATE COVER BOLTS

¢ Clutch disc To install:

i aia

3. Clean the flywheel mating surfaces

of all oil, grease and metal deposits.

4 CLUTCH COVER BOLTS

ipa

Exploded view of the clutch assembly—Metro

4. Check the diaphragm spring and pressure plate for wear or damage. If the spring or plate is excessively worn, replace the clutch cover assembly. 9. Check the pilot bearing for smooth operation. If the bearing does not spin freely, replace it. . 6. Inspect the disc, pressure plate and flywheel for damage and wear using a

1 FLYWHEEL 2 DRIVEN PLATE 3 CLUTCH COVER

le PLATE COVER

caliper to measure depth and width and a dial indicator to measure run-out. 7. The minimum clutch disc rivet head depth: 0.02 in. (0.5mm). 8. The maximum clutch disc run-out: 0.031 in. (0.8mm). 9. The maximum pressure plate spring depth: 0.024 in. (0.6mm).

10. The maximum pressure plate spring width: 0.197 in. (5.0mm). 11. The maximum flywheel run-out: 0.004 in. (0.1mm). 12. When reassembling, apply a thin Coating of multi-purpose grease to the release bearing hub and release fork contact points. Also, pack the groove inside the

5 RELEASE BEARING 6 CLUTCH FORK 7 CLUTCH FORK BALL STUD

8 FORK BOOT

Exploded view of the clutch assembly—Prizm

8 79222734

SETMEIRO «Prizm O 1-20 clutch hub with multi-purpose grease and lubricate the pivot points of the release fork. 13. Install or connect the following: e Clutch disc and clutch cover e Clutch cover bolts and torque them to 17 ft. Ibs. (23 Nm) e Release bearing, fork, and boot on the Prizm e Transmission e Negative battery cable 14. Adjust the clutch cable, if needed.

417

403

406

405

Hydraulic Clutch System BLEEDING 1. If any maintenance on the clutch system was performed or the system is suspected of containing air, bleed the system as follows: a. Fill the clutch reservoir with brake fluid. Check the reservoir level frequently and add fluid as needed. b. Connect one end of a vinyl tube to the bleeder plug on the slave cylinder and submerge the other end into a clear container half-filled with clean brake fluid. c. Slowly pump the clutch pedal several times. d. Repeat Steps 2 and 3 until all of the air bubbles are removed from the system. e. Tighten the bleeder screw to 97 inch Ibs. (11 Nm). f. Refill the master cylinder to the proper level. g. Check the system for leaks.

REMOVAL & INSTALLATION Metro

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2 Drain the transmission fluid. 3 Remove or disconnect the following: e Negative battery cable e Front wheel e Anti-lock Brake System (ABS) speed sensor from the steering knuckle, if equipped + Unstake and remove the halfshaft nut e Ball joint from the steering knuckle

403 405 406 417

DIFFERENTIAL-SIDE JOINT HOUSING RIGHT INNER DRIVE AXLE SHAFT RIGHT INNER ORIVE AXLE SUPPORT ARBOR RIGHT ORIVE AXLE ASSEMBLY 79222735

Tapping out the right inner halfshaft from the transaxle—4-door models

e>On 4-door sedan, the right side halfshaft is stabilized by a center support bearing between the transmission and the inner Tri-pod joint. It is not necessary to remove the right inner drive axle and center support bearing assembly. The right side halfshaft assembly can be separated from the center support bearing by lightly tapping with a plastic mallet.

4. Using a suitable pry tool, pry on the inboard joints of the halfshaft to detach the snapring lock. >On 4-door sedans, separate the right side halfshaft assembly from the center support bearing by tapping lightly with a plastic mallet.

¢ Halfshaft from the steering knuckle To install: 5. Inspect the C\V-joint boots for tears or deterioration and replace, if necessary. 6. Install or connect the following: e Halfshaft into the steering knuckle e Halfshaft into the transmission, Or intermediate shaft ¢ Control arm to the steering knuckle

and torque the ball stud bolt to 44 ft. Ibs. (60 Nm) e Halfshaft nut and washer and torque the fastener to 129 ft. Ibs. (175 Nm) and stake the nut e ABS speed sensor to the steering knuckle and torque the bolt to 89 inch Ibs. (10 Nm) e Front wheel e Negative battery cable 7. Fill the transmission with clean fluid. 8. Road test the vehicle. Prizm

Care must be exercised to prevent the differential-side CV-joint from being over-extended. Over-extension of the CV-joint could result in separation of internal components and possible joint failure. If the vehicle is to be lowered and moved, the front wheel bearings must be supported using a %e in. bolt, 19 in. washer, 2 in. washer and a %c in. nut, assembled through the shaft opening in the hub. Tighten the nut and bolt to 40 ft.

on 1 of this manual For Tune-up, Capacities and Firing orders, see Secti

31-24 itcnos prin Ibs. (54 Nm). If equipped with Antilock Brake Systems (ABS), use caution not to damage the ABS speed sensor ring on the wheel-side CVjoint. DO NOT pry against the ring with metal tools. If the serrations on the speed sensor ring appear damaged, replace the wheel-side CVjoint. 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 Splash shield Antilock Brake System (ABS) speed sensor, if equipped Cotter pin and lock cap from the halfshaft Halfshaft nut Tie rod end from the steering knuckle Ball joint from the control arm Outer C\-joint from the steering knuckle Inner CV-joint from the transmission by gently prying the joint out Halfshaft from the vehicle To install: 3. Inspect the CV-joint boots for tears or deterioration. Replace as necessary. 4. Inspect the front wheel bearing inner and outer oil seals for damage or deterioration. Replace as necessary. 9. Inspect the halfshaft fluid seal at the transmission for leakage or damage. Replace as necessary. 6. Install or connect the following: e Inner CV-joint into the transmission ¢ Outer C\V-joint into the steering knuckle

403

DIFFERENTIAL-SIDE JOINT HOUSING

418

TRANSAXLE ASSEMBLY

Ball joint to the control arm and torque the bolts to 105 ft. Ibs. (142 Nm) Tie rod end to the steering knuckle and torque the nut to 36 ft. Ibs. (49 Nm) New cotter pin to the tie rod end Halfshaft nut and torque it to 166 ft. lbs. (225 Nm) Lock cap onto the halfshaft and secure with a new cotter pin ABS speed sensor and torque the bolt to 71 inch Ibs. (8 Nm) Splash shield and torque the bolts to 71 inch Ibs. (8 Nm) Front wheel Negative battery cable 7. Check the wheel alignment and adjust as needed.

OVERHAUL Inner

METRO 1. Before servicing the vehicle, refer to the precautions in the beginning of this section.

2. Remove the halfshaft. 3. Place a mark on the inner joint and the halfshaft for proper assembly, prior to removal. 4. Remove or disconnect the following: e Inner and outer boot bands e Inner joint housing from the tri-pod joint spider. Place a mark on the tri-pod joint spider and the halfshaft for proper assembly, prior to removal. ¢ Snap ring from the halfshaft ¢ Tri-pod joint spider _ e CV boot To install: 5. Install or connect the following: e Inner boot ¢ Inner boot band ¢ Tri-pod joint spider aligning the marks made earlier e Snap ring on the halfshaft 6. Pack the inner joint housing with 2.8-3.5 02. (80-100 g) of the grease provided with the service kit. e Inner joint housing onto the tri-pod joint spider aligning the marks made earlier ¢ Outer boot band ¢ Halfshaft

79227736

Prying out the inner halfshaft from the transaxle—Prizm

9346ZGF1

Place a mark on the inner joint and the halfsha ft for proper assembly, prior to removal-inner joint Metro

eae aD PRISM 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove the halfshaft. 3. Remove the small side inner joint boot clamp. 4. Slide the boot towards the center of the wheel drive shaft. 5. Place index marks on the inner joint housing and the wheel drive shaft to ensure correct assembly.

6. Remove the inner joint housing from the tripot joint spider. 7. Place index marks on the tripot joint Spider and the wheel drive shaft. 8. Remove the snap ring from the wheel drive shaft. 9. Use a brass drift and a hammer to remove the tripot joint from the wheel drive shaft. Place the drift on the tripot body, not the roller. 10. Remove the tripot joint from the wheel drive shaft.

J 22912 —01

9346ZGD9

Removing the joint bands-inner joint Prism

9346ZGE2

Remove the inner joint seal using J22912-01 and a press-inner joint Prism

->Do not wash the Tri-Pot joint spider in solvent or degreaser. Washing the Tri-Pot joint spider in solvent or degreaser will remove all of the lubrication in the spider’s needle bearings. Use only a clean, dry, solvent-free rag to clean the Tri-Pot spider assembly.

11. Clean the tripot joint with a clean, dry, solvent free cloth. Inspect the tripot joint for excessive wear or damage. If any excessive wear, damage, or abnormality is found, replace the tripot joint as an assembly. 12. Remove the inner boot from the wheel drive shaft. ->Do not clean the wheel drive shaft boot(s) in solvent. Cleaning the wheel drive shaft boot(s) in degreaser or other solvents can cause the boot(s) to deteriorate. Use only a clean, dry, solvent-free cloth to clean the wheel drive shaft boot(s).

13. Clean the inner boot with a clean, dry, solvent free cloth. Inspect the inner boot for tears, damage or fatigue. Replace as necessary. 14. Inspect the dynamic dampener on the right wheel drive shaft for damage or distortion. Replace as necessary. 15. Remove the inner joint housing seal using the Bearing Puller Tool J-22912-01 and a press. To install: 16. Install the inner joint seal using a press. 17. \f the damper was removed, install the damper to the wheel drive shaft before installing the inner joint. 18. Install the damper assembly on the right side wheel drive shaft only, to the wheel drive shaft. The damper should be located on the groove on the wheel drive shaft. The damper centerline should be 16.980 inch (431mm), plus or minus 0.118 inch (3mm) from the outer joint.

93462GE3

9346ZGE1

l—inner halfshaftfor proper assembly, prior to remova Place a mark on the inner joint and the

The damper centerline should be 16.980 inch (431mm), plus or minus 0.118 inch (3mm) from the outer joint-inner joint Prism

joint Prism

Chilton Labor Guide For complete service labor times, order Nichols’

26 See 9346ZGE4

Measure the wheel drive shaft length to ensure that the boots are not stretched or excessively contracted when the wheel drive shaft is at standard length-inner joint Prism

19. Crimp the damper clamp. 20. Install the inner joint housing boot and clamps to the wheel drive shaft. Do not crimp the clamps at this time. 21. Align the index marks on the tripot joint and the wheel drive shaft.

->Place the side of the tripot joint with the bevelled splines (1) away from the transaxle.

22. Install the tripot joint onto the wheel drive shaft. 23. Install the snap ring. 24. Pack the inner joint housing with 5.8-6.4 02. (165-185 grams) of grease supplied with inner joint boot kit. 29. Align the index marks on the inner joint housing and the tripot joint. 26. Install the inner joint housing to the tripot joint. 2/. Install the inner joint boot and Clamps to the inner joint housing. 28. Measure the wheel drive shaft length to ensure that the boots are not stretched or excessively contracted when the wheel drive shaft is at standard length. 29. The right wheel drive shaft standard length is 33.756 inch (857.4mm), plus or minus 0.197 inch (5mm ). 30. The left wheel drive shaft standard length is 21.268 inch (540.2mm), plus or minus 0.197 inch (5mm ).

joint and the halfshaft for proper assembly, prior to removal. Inner and outer boot bands Snapring and outer joint housing from the halfshaft Roller ball guide snapring. Place a mark on the roller ball guide and the halfshaft for proper assembly, prior to removal. Roller ball guide from the halfshaft e Outer boot To install: 3. Install or connect the following: e Outer boot e Inner boot band e Roller ball guide aligning the mark made earlier e Roller ball guide snapring 4. Pack the double offset joint with 1.01.4 02. (30-40 g) of the grease provided in the service kit. 5. Pack the remaining grease into the outer housing. 6. Install or connect the following: ¢ Outer joint housing aligning the marks made earlier ¢ Quter housing snapring e Outer boot band e Halfshaft

PRISM 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove the halfshaft. 3. Remove the outer joint boot clamps. 4. Slide the outer joint boot towards the center of the wheel drive shaft. e>When servicing the wheel drive shaft(s), place reference marks on all components to ensure that all compo-

9346ZGE5

Remove the outer band clamps—outer joint Prism

nents are reassembled in the correct position. If the components are not reassembled in the correct position, premature wear of the joint and/or excessive driveline vibrations may occur.

5. Place index marks on the outer joint and the wheel drive shaft. ->Do not disassemble the outer joint. If any abnormality is found in the joint, or in the joint components, replace the joint as an assembly.

->Do not clean the wheel drive shaft boot(s) in solvent. Cleaning the wheel drive shaft boot(s) in degreaser or other solvents can cause the boot(s) to deteriorate. Use only a clean, dry, solvent-free cloth to clean the wheel drive

shaft boot(s). 6. Remove the outer joint from the wheel drive shaft by expanding the snap ring and pulling outward on the joint. ->When servicing the hub assembly, be careful not to damage the ABS components. If any of the ABS components

e>Use the Seal Clamp Tool J-35566 to draw the closing hooks of the clamp together, so that the clamp locks into position.

31. Crimp the clamps using the Seal Clamp Tool J-35566. 32. Check the boots for distortion or dents and correct as necessary. 33. Install the wheel halfshaft. Outer

METRO 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Halfshaft. Place a mark on the outer

Place index marks on the outer joint and the wheel drive shaft—-ou ter joint Prism

9346ZGE6

gear 81-21 LMS

Measure the wheel drive shaft length to ensure that the boots are not stretched or excessively

contracted when the wheel drive shaft is at standard length—outer joint Prism

wig the ouler joi veal uring 2 suilable teers ond 2 prets-ouler joint Prism

To instatl:

21. Expand the snap ring and slide the outer joint onto the wheel drive shaft. 22. Pack the inner joint housing with 5 8-6.4 oz. (165-185 grams) of grease supplied with inner joint boot kit. 23, Install the outer joint large boot

13,

clamp.

damage os abnormality is found, replace the gules joint as an assembly, 12, Inspect the dynamic dampener on the right wheel drive shaft for damage or distortion, Replace as necessary,

the damper centerline should he 16.960 inch (AG mom), plus or minus 0.116 inch (Aen) trom the outer joint-outer joint

wheel drive shaft.

Prism

are damaged, the ABS system may not function properly and the damaged component will need to be replaced. 7. Mount the wneel ornive shaft in a soft

jaw Vite %

Install the outer joint seal using a

suitable sleeve and 4 press. 14, If the damper was removed, install the damper to the wheel drive shaft before nstalling the outer joint. 15, Install the damper assembly on the right side wheel drive shaft only, to the

Remove the outer joint 6A4\

16, The damper should be located on the groove on the wheel drive shaft. 17, The damper centerline should be 16,980 inch (431mm), plus or minus 0.118 inch (3mm) from the outer joint. 18, Crimp the damper clamp. 19, Install the outer boot and clamps to the wheel drive shaft. Do not crimp the clamps at this time. 20. Align the index marks on the outer

9 Clean the outer boot with a clean, Ory, Solve free cloln

10), Inspect the outer boot for tears dam age OF fatigue, Replace as necessary 11, Inspect the outer joint for eYCUSSIVE wear or damage, It any excessive wear,

joint and the wheel drive shaft.

Make sure the snap sing is securely seated in the groove in the wheel drive shaft.

STEERING AND SUSPENSION PRECAUTIONS eT

CAUTION Air Fo

an All vehicles are equipped with t be dismus em syst The em, syst Bay ice on abled before performing serv steers, ent pon com em or around syst

compoing column, instrument panel Failure to nents, wiring and sensors.

procefollow safely and disabling al Air dent acci in dures could result onal pers ible poss t, Bag deploymen

em injury and unnecessary syst

repairs,

Several precautions must be observed when handling the inflator module to avoid accidental deployment and possible personal Injury. + 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

24, Measure the wheel drive shaft length to ensure that the boots are not stretched or excessively contracted when the wheel drive shaft is at standard length. 25. The right wheel drive shaft standard length is 33.756 inch (857.4mm), plus or minus 0.197 inch (5mm ). 26. The left wheel drive shaft standard length is 21.268 inch (540.2mm), plus or minus 0.197 inch (5mm ). =»Use the Seal Clamp Tool J-35566 to draw the closing hooks of the clamp together, so that the clamp locks into position.

27. Crimp the clamps using the Seal Clamp Tool J-35566. 28. Check the boots for distortion or dents and correct as necessary. 29, Install the wheel halfshaft.

¢ With the inflator module on the bench, never place anything on or close to the module which may be thrown in the event of an accidental deployment.

DISARMING nee,

LEE

Metro

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 9. Turn the steering wheel so the wheels are pointing straight-ahead. 3. Turn the ignition switch to the LOCK position and remove the Key.

facing up.

ne.com Please visit our web site at www.chiltonsonli

a1-26 Sees” Prizm

>The center sensor assembly can maintain sufficient voltage to cause deployment for up to 2 minutes after the ignition switch is turned to the LOCK position or the battery is disconnected.

1 2 3 4 5

Inflator module housing Steering wheel Rear plastic access cover SIR harness connector Connector position assurance (CPA) 79222737

Location of the SIR harness connector— Meiro

4. Remove or disconnect the following: ¢ Negative battery cable ¢ AIR BAG-IG fuse from the junction block near the base of the steering column Steering wheel side cap, Connector Position Assurance (CPA) and yellow 2-way connector for the driver's side Air Bag (inflator) module Glove box while pushing in on the Stoppers from the left and the right sides. Disconnect the yellow connector for the passenger Air Bag (inflator) module. To arm: 9. Install or connect the following: Negative battery cable Turn the ignition switch to the LOCK position and remove the key Yellow connector for the passengers side Air Bag (inflator) module and the yellow connector for the driver's air bag (inflator) module. Be sure to lock each connector with the lock lever Glove box Left side steering wheel side cap AIR BAG-IG fuse to the junction block 6. Staying away from both air bags, turn the ignition switch to the ON position and verify that the AIR BAG warning lamp flashes 7 times, then turns OFF. If the system does not operate as described, diagnoSis and repairs to the air bag system are

necessary.

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Turn the steering wheel so the front wheels are in the straight-ahead position. 3. Turn the ignition switch to LOCK. 4. Remove or disconnect the following: Negative battery cable Lower steering column trim cover IGN fuse and CIG and RADIO fuse from junction block 1 Connector Position Assurance (CPA) and disconnect the yellow 2way connector at the base of the steering column Inflatable restraint steering wheel module coil connector Glove box Unlock the passenger's side module connector and disconnect the pigtail Unlock the left and right hand side

seat module connectors and disconnect the seat modules To arm: 5. Turn the ignition switch to the LOCK position and remove the key. 6. Install or connect the following: Negative battery cable Yellow 2-way connectors for the driver's and passenger's seat modules Connectors and lock them into place with the lock levers Yellow 2-way connector to the passenger's side inflatable restraint pigtail. Connect the lock with the lever Glove box Yellow 2-way connector for the steering wheel module coil Connectors and lock them into place with the lock levers Lower steering column trim cover IGN fuse and CIG and RADIO fuse to the junction block 7. Staying away from both air bags, turn the ignition ON and verify that the AIR BAG warning lamp flashes 7 times, then turns OFF. If the system does not operate as described, diagnosis and repairs to the air bag system are necessary.

Rack and Pinion Steering Gear REMOVAL & INSTALLATION Manual

METRO

1, Junction block 1

2. ECU-B tuse 3, AG & radio tuse 4. IGN fuse 79222738

Connector view and terminal identification

of junction block 1—Prizm

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: ¢ Negative battery cable Forward section of driver's side carpet Steering shaft joint cover Loosen the steering shaft upper joint bolt but do not remove Steering shaft lower joint bolt Lower joint from the pinion Both front wheels Tie rod ends from the steering knuckles Exhaust pipe Inlet and outlet pipes Steering gear mounting bolts and brackets Steering gear from the vehicle To install: 3. Install or connect the following: * Steering gear through the front wheel opening

SEMEInO «Pai OL-29 Seamer

gc

zi

9ra

PR

TUES

ND

I

e Steering gear mounting brackets and torque the bolts to 18 ft. Ibs. (25 Nm) Inlet and outlet pipes and torque the fittings to 28.5 ft. Ibs. (40 Nm), if removed Exhaust pipe and torque the bolts to 37 ft. Ibs. (50 Nm), if removed Right and left tie rod ends to the steering knuckles and torque the nuts to 32 ft. Ibs. (43 Nm) New cotter pins Both front wheels Steering shaft to the steering gear and torque the upper and lower steering shaft joint bolts to 18 ft. lbs. (25 Nm) Steering shaft joint cover Driver's side floor carpet e Negative battery cable 4. Check and adjust the front wheel alignment.

PRIZM 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 9. The front wheels must be straight and the steering column in the LOCK position before disconnecting the intermediate shaft from the steering gear. 3. Remove or disconnect the following: e Negative battery cable Steering column upper cover Steering shaft lower coupling Outlet pipe heat shield Inlet and outlet pipes from the steering gear e Heated Oxygen (HO2S) sensor > _ Install an engine support fixture. Both splash shields Both front wheels Exhaust manifold heat shield Outer tie rods Front crossmember brace Front suspension crossmember Rear transmission mount and bracket Exhaust pipe from the exhaust manifold Steering gear boot heat shield Steering gear mounting clamps Steering gear To install: 5. Install or connect the following: e Steering gear e Steering gear clamps and torque the bolts to 52 ft. Ibs. (71 Nm) « Steering gear boot heat shield and

DBA

IPT IG

TIRE

TD

RM

SUS TN DRT

torque the bolt to 48 inch Ibs. (6 Nm) Exhaust manifold pipe and torque the bolts to 46 ft. Ibs. (62 Nm) Rear transmission mount bracket and torque the bolts to 57 ft. Ibs. (77 Nm) Rear transmission mount and torque the bolt to 64 ft. Ibs. (87 Nm) Front suspension crossmember and torque the bolts to 46 ft. Ibs.

(60 Nm) Front crossmember brace and torque the bolts to 51 ft. Ibs. (69 Nm) Outer tie rods and torque the nuts to 36 ft. Ibs. (49 Nm) Front wheels Exhaust manifold heat shield and torque the fasteners to 48 inch Ibs. (5 Nm) Both splash shields and torque the bolts to 89 inch Ibs. (10 Nm) HO2S sensor and torque the nuts to 32 ft. Ibs. (44 Nm) Inlet and outlet pipes and torque the bolts to 108 inch Ibs. (13 Nm) Inlet and outlet clips and torque the bolts to 48 inch Ibs. (6 Nm) Outlet pipe heat shield and torque the bolt to 48 inch Ibs. (5 Nm) Steering shaft lower coupling and torque the bolt to 26 ft. Ibs. (35 Nm) Steering column upper cover and torque the bolts to 48 inch Ibs. (5 Nm) Negative battery cable 6. Refill and bleed the power steering system. 7. Check and adjust the front end alignment as needed. Power

METRO 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 9 Remove or disconnect the following: e Negative battery cable ¢ Slide the driver's seat back, pull off the front part of the floor carpet on the driver's side and remove the steering shaft joint cover e Loosen the steering shaft upper joint bolt but do not remove ¢ Steering shaft lower joint bolt and

EERE

ST EBD

MASE NATO HUA,

IND

AED

SATS EA)

disconnect the lower joint from the pinion Both front wheeis Tie rod ends Exhaust pipe at the manifold Separate the shift linkage and extension rod from the transmission, for manual transmission Engine rear torque rod with the bracket from the transmission, for automatic transmission Power steering lines from the rack and pinion assembly and plug the openings to prevent system contamination e Rack and pinion from the vehicle To install: 3. Install or connect the following: Steering rack, brackets and mounting bolts to the bulkhead. When aligned properly, torque the bolts to 18 ft. Ibs. (25 Nm). Power steering lines to the rack and pinion. Torque the inlet and outlet fluid lines to 25 ft. Ibs. (85 Nm) and the remaining lines to 18 ft. lbs. (25 Nm). Shift linkage and extension rod to the manual transmission “Engine rear torque rod and bracket to the automatic transmission Front exhaust pipe to the manifold using a new seal and torque the bolts to 37 ft. Ibs. (50 Nm) Tie rod ends to the steering knuckles and torque the castle nuts to 32 ft. Ibs. (43 Nm) New cotter pins Both front wheels Lower steering shaft-to-steering gear and torque the bolts to 18 ft. lbs. (25 Nm) Upper steering shaft and torque the bolt to 18 ft. Ibs. (25 Nm) e Steering joint cover e Negative battery cable 4. Place the driver's side floor carpet back into the original position. 5. Bleed the steering system and check for leaks, repair if necessary. 6. Check and adjust the front wheel alignment.

PRIZM 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. ) The front wheels must be straight and the steering column in the LOCK position

manual Timing belt service Is covered in Section 3 of this

31-30 incrno'spizn before disconnecting the intermediate shaft from the steering gear. 3. Remove ordisconnect the following: ¢ Negative battery cable ¢ Steering column upper cover ¢ Steering shaft lower coupling

e Negative battery cable 5. Refill and bleed the power steering system. 6. Check and adjust the front end alignment as needed.

¢ Inlet and outlet pipes from the

pSte

steering gear Oxygen (02S) sensor and install an engine support fixture ¢ Both splash shields

REMOVAL & INSTALLATION SE AES Se

° ae elles heat shield

METRO

+ Front crossmember brace ¢ Front suspension crossmember,

1. Before servicing the vehicle, refer to the precautions in the beginning of this section.

e Both front wheels

transmission support, both control

e Negative battery cable e Upper strut support nuts from the tower e Front wheel e Wheel Speed Sensor (WSS) harness from the strut, if equipped

e Brake hose

Strut from the steering knuckle Strut from the vehicle To install: 3. Install or connect the following:

Front

e Strut to the vehicle and torque the eee support nuts : 21 ft. Ibs. (28

¢ Strut to steering knuckle and torque the bolts to 59 ft. Ibs. (80 Nm)

2. Remove or disconnect the following:

arms and front stabilizer shaft as a

complete unit Rear transmission mount and

bracket

oe n'y.

;

z Hill: a

Steering gear boot heat shield

or

Steering gear

// ) f=>

To install: 4. Installorconnect the following:

le

Steering gear and clamps and torque

:

torque the bolt to 48 inch Ibs. (5

Nm) Exhaust manifold pipe and torque the bolts to 46 ft. Ibs. (62 Nm) Rear transmission mount bracket

bolts to 48 inch Ibs. (5 Nm)

* Outlet pipe heat shield and torque the bolt to 48 inch Ibs. (5 Nm)

¢ Steering shaft lower coupling and

torque the bolt to 26 ft. Ibs. (35 Nm)

¢ Steering column upper cover and

torque the bolts to 48 inch Ibs. (5 Nm)

NE

| NO

5

=

8

ies Es —

bolts to 51 ft. Ibs. (69 Nm) Outer tie rods Front wheels Exhaust manifold heat shield and

torque the bolt to 48 inch Ibs. (5 Nm) Both splash shields and torque the bolts to 89 inch Ibs. (10 Nm) Ozsensor and remove the engine Support fixture Inlet and outlet pipes and torque the bolts to 108 inch Ibs. (13 Nm) Inlet and outlet clips and torque the

|

ie

Stedering gear boot heat shield and

(77 Nm) Rear transmission mount and torque the bolt to 64 ft. Ibs. (87 Nm) Front suspension crossmember, transmission support, control arms and stabilizer shaft Front crossmember and torque the

¢ DE

im |

the bolts to 52 ft. lbs. (71 Nm)

and torque the bolts to 57 ft. Ibs.

|

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Ms —=iA,

a 7 3 = tCe yyee be. a

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— 7

6

race ae

5 IEE Bide ChE a CANTHOLO AR

ee tatracke

6 WHEEL BEARING Cut-away view of the front suspension—Metro

rae

8

WHEEL

9 SWAY BAR

10

SWAY BAR LINK

11 SWAY BAR BRACKET por

SEINETRO «Priam O1-o 1 e Brake hose to the strut bracket and secure with a new eal E-ring

* WSS to the strut, if equipped and

torque the bolt to 89 inch Ibs. (10 Nm) e Front wheel e Negative battery cable 4. Check the front alignment and adjust

1, Before servicing the vehicle, refer to the

precautions in the saining of this section.

2. Properly support the front suspension crossmember. 3. Remove or disconnect the following: e Negative battery cable e Front wheel and make certain that

if necessary.

1 DUST CAP 2. STRUT ROD PISTON 3 STRUT SUPPORT 4 OUST SEAL 5 SPRING SEAT 6 UPPER INSULATOR : 9 10 11 12 13.

the weight of the vehicle is resting

PRIZM

NUT

Saaeiieer LOWER INSULATOR STRUT BRAKE LINE GASKETS BRAKE LINE—TO-CALIPER BOLT STRUT MOUNTING NUT AND BOLT

14 15 16 17 18 19 20 21 22 23 24 25

on the crossmember and not the

control arms

e Wheel Speed Sensor (WSS) electrical connector, if equipped Brake hose from the strut Strut assembly from the strut tower Lower strut bolts Strut from the vehicle

LOWER CONTROL ARM RETAINING BRACKET LOWER CONTROL ARM RETAINING BRACKET COTTER PIN BALL JOINT BALL JOINT CASTLE NUT NUT AND BOLT cL CONTROL ARM CROSSMEMBER MOUNTING BOLTS CROSSMEMBER-TO-CONTROL ARM CROSSMEMBER MOUNTING ele CROSSMEMBER MOUNTING BOLTS SUSPENSION CROSSMEMBER

BOLTS

BOLT

bly—Prizm Exploded view of the front suspension assem

this manual Heater Core replacement is covered in Section 2 of

79227739

31-32 ferno-Pam To install: 4. Install or connect the following: Strut to the lower mount and handtighten the bolts Strut to the strut tower and torque the strut tower nuts to 29 ft. Ibs. (39 Nm) and the lower mounting bolts to 203 ft. Ibs. (274 Nm) Brake hose to the strut and torque the bolt to 22 ft. Ibs. (29 Nm) WSS, if equipped and torque the bolt to 71 inch Ibs. (8 Nm) Front wheel Negative battery cable 5. Check and adjust the front end alignment. Rear

e Rear wheel e Rear seat cushions e Negative battery cable 5. Fill and bleed the brake system. 6. Check and adjust the rear wheel alignment as needed.

e Upper strut mounting fasteners e Strut from the suspension knuckle e Strut from the vehicle To install:

4. Install or connect the following: e Strut to the rear knuckle and handtighten the nuts at this time e Strut to the support and torque the nuts to 29 ft. Ibs. (39 Nm) and the knuckle bolts to 1065 ft. Ibs. (142 Nm) e Cap to the strut support e Stabilizer shaft joint, if equipped and torque the fastener to 33 ft. Ibs. (44 Nm) e WSS wire harness to the strut, if equipped e Brake hose with a new clip

REMOVAL & INSTALLATION Metro

FRONT

1. Before servicing the vehicle, refer to the precautions in the beginning of this section.

METRO 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Open the lift gate or trunk lid and reposition the trim cover from the strut tower. 3. Remove or disconnect the following: Negative battery cable Rear wheel and properly support the rear Suspension Strut from the knuckle Upper strut nuts Compress the strut and separate it from the steering knuckle e Strut from the vehicle To install: 4 Compress the strut. 5. Install or connect the following: Strut to the steering knuckle and position the alignment projection inside the opening in the knuckle Upper mounting nuts and torque them to 24 ft. Ibs. (30 Nm) Strut-to-steering knuckle bolts and torque them to 44 ft. Ibs. (60 Nm) Rear wheel e Negative battery cable 6. Reposition the rear trim cover.

Q

Ry

PRIZM 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Support the rear suspension. 3. Remove or disconnect the following: Negative battery cable Rear seat cushions Rear wheel Wheel Speed Sensor (WSS) harness from the strut, if equipped Brake hose from the strut Stabilizer shaft joint from the strut, if equipped Cap from the strut support

xe) 10

FUEL TANK BAND STRUT TOWER COVER STRUT

ROD

PISTON

STRUT ASSEMBLY REAR

LATERAL

BRAKE PIPE BRAKE DRUM NMONFWN

LINK

8 HUB ASSEMBLY 9 BRAKE ASSEMBLY NUT

10

TRAILING

ARM

12.

STABILIZER

11 FRONT LATERAL LINK SHAFT

BRACKET

13 BUSHING 14 STABILIZER SHAFT JOINT 15

STABILIZER

SHAFT 79222740

Exploded view of the rear strut assembly—Prizm

SEINETRO«PRizn O1-Oo 2. Remove or disconnect the following: e Negative battery cable e Rear wheel

e Strut 3. Mount a strut compressor tool into a holding fixture and install the strut using an adapter.

4. Compress the coil spring. 5. Remove or disconnect the following: e Strut rod piston nut and carefully release the compressed spring e Strut from the compressor tool e Strut cap, nuts, insulator and coil spring To install: 6. Install or connect the following: e Coil spring, insulator nuts and strut

ca e Mount the strut into a compressor tool and compress the coil spring

4 CAUTION © Do not over compress the spring. Excess overloading may result in tool failure and could result in bodily injury. e Strut rod piston nut and torque it to 37 ft. lbs. (60 Nm) Release the coil spring and remove the compressor tool Strut Rear wheel Negative battery cable

REAR 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Negative battery cable e Rear wheel ¢ Control rod from the knuckle

e Wheel Speed Sensor (WSS) electrical connector from the control arm, if equipped Stabilizer link from the control arm and properly support the rear suspension Knuckle from the suspension arm Coil spring from the suspension arm and upper seat To install: 3. Install or connect the following: Spring to the suspension arm with the larger diameter on the bottom Suspension arm to steering knuckle and torque the bolt to 29 ft. Ibs. (40 Nm) WSS to the control arm, if equipped Stabilizer link to the control arm and torque the nut to 18 ft. Ibs. (25 Nm) Control rod to the knuckle stud and torque the nut to 59 ft. Ibs. (80 Nm) Rear wheel e Negative battery cable Prizm

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Negative battery cable e Rear wheel e Strut 3. Mount a strut compressor tool into a holding fixture and install the strut using an adapter. 4 Compress the coil spring. 5. Remove or disconnect the following: e Strut rod piston nut and carefully release the compressed spring e Strut from the compressor tool e Strut cap, nuts, insulator and coil spring To install: 6. Install coil spring, insulator nuts and strut cap. 7. Mount the strut into a compressor tool and compress the coil spring.

st CAUTION

93062G35

Remove the coil spring from the rear suspension—Metro

Do not over compress the spring. Excess overloading may result in tool failure and could result in bodily injury.

8. Install the strut rod piston nut and torque it to 34 ft. Ibs. (47 Nm).

9. Release the coil spring and remove the compressor tool. 10. Install the strut. 11. Install the rear wheel. 12. Connect the negative battery cable. Lower Ball Joint

REMOVAL & INSTALLATION Metro

The lower ball joint is an integral part of the lower control arm assembly and is not serviceable as an individual component. If the lower ball joint is defective, the entire lower control arm must be replaced. Prizm

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Negative battery cable e Front wheel 3. Position a jack stand under the suspension crossmember. ¢ Cotter pin from the ball joint nut e. Ball joint from the steering knuckle e Ball joint from the control arm To install: 4. Install or connect the following: ¢ Ball joint to the steering knuckle and torque the new castle nut to 91

ft. Ibs. (124 Nm) New cotter pin Ball joint to the control arm and torque the bolt and nuts to 105 ft.

lbs. (142 Nm) e Front wheel ¢ Negative battery cable 5. Check the front wheel alignment and adjust as needed.

Lower Control Arm

REMOVAL & INSTALLATION ee

Metro

FRONT 1. Before servicing the vehicle, refer to s in the beginning of this secprecaution the tion. 2. Remove or disconnect the following: e Negative battery cable e Stabilizer shaft link from the control arm

Brake service is covered in Section 4 of this manual

31-34 interns Prizm e Ball joint nut e Ball joint from the steering knuckle e Control arm front mounting bracket bolts e Control arm rear mounting bracket bolts e Control arm from the vehicle To install: 3. Install or connect the following: Control arm to the vehicle Front and rear mounting brackets, do not tighten the bolts at this time Ball joint to the steering knuckle, do not tighten the nut at this time Stabilizer shaft link to the lower control arm Front wheel 4, Bounce the front end a few times to stabilize the suspension. 5. Torque the rear control arm bolts to 32 ft. Ibs. (43 Nm). 6. Torque the front control arm bolts to 66 ft. Ibs. (90 Nm). 7. Torque the ball joint nut to 44 ft. Ibs. (60 Nm). 8. Torque the stabilizer link nut to 20 ft. lbs. (28 Nm). 9. Connect the negative battery cable. 10. Check and adjust the front end alignment, if needed.

REAR 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: ¢ Coil spring ¢ Suspension arm front mounting bolts * Suspension arm rear bolt e Suspension arm from the vehicle To install: 3. Install or connect the following: e Suspension arm to the vehicle e Rear mounting bolt and torque it to 29 ft. Ibs. (40 Nm) e Front mounting bolts and torque them to 33 ft. Ibs. (45 Nm) ¢ Coil spring

. . . . .

ae3-0 (5) tor eign

7. Remove the engine support fixture and connect the negative battery cable. 8. Check and adjust the front end alignment, if needed.

REAR 9346XGB5

Disconnect the hardware as shown (1-5) in order to remove the control arm—Prizm

3. Remove or disconnect the following: e Negative battery cable e Front wheel e Suspension support brace ¢ Stabilizer shaft link, if equipped e Mounting bolts (1—5) from the lower control arm ¢ Lower control arm from the vehicle To install: 4. Install or connect the following: ¢ Lower control arm and handtighten the bolts Stabilizer shaft link to the lower control arm and hand-tighten the nut, if equipped Lower control arm bracket and torque the nut to 14 ft. Ibs. (19 Nm) Control to the steering knuckle and torque the fasteners to 105 ft. Ibs. (142 Nm) Suspension support brace and torque the nuts to 51 ft. Ibs. (69 Nm) ¢ Front wheel 5. Bounce the front end several times to stabilize the suspension. 6. Torque the bolts in the following sequence:

Prizm

FRONT If removing the left side lower control arm from a vehicle with an automatic transmission, remove the crossmember, transmission support, both lower control arms and the front stabilizer bar as a complete unit. 1. Install an engine support fixture. 2. Before servicing the vehicle, refer to the precautions in the beginning of this section.

Bolt No. 3: 129 ft. Ibs. (175 Nm). Bolt No. 1: 158 ft. Ibs. (215 Nm). Bolt No. 5: 167 ft. Ibs. (225 Nm). Bolt No. 4: 109 ft. Ibs. (147 Nm). Bolt No. 2: 91 ft. Ibs. (123 Nm). Stabilizer shaft nut to 33 ft. Ibs. (44

>The rear suspension contains a front and rear control arm.

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Negative battery cable e Both trailing arms from the suspension knuckles e Both rear suspension rear control arms 3. Support the rear suspension crossmember. e Suspension crossmember mounting bolts ¢ Both rear suspension front control arms from the crossmember To install: 4. Install or connect the following: ¢ Both rear suspension front control arms to the crossmember, do not tighten the bolts at this time e Rear suspension crossmember and torque the outer bolts to 55 ft. Ibs. (74 Nm) and the inner bolts to 14 ft. Ibs. (19 Nm) 5. Remove the crossmember support. e Both rear suspension rear control arms, do not tighten the bolts at this time ¢ Both trailing arms to the suspension knuckles, do not tighten the bolts at this time 6. Bounce the rear of the vehicle several times to stabilize the suspension. 7. Torque the trailing arm bolts to 67 ft. lbs. (91 Nm). 8. Torque the front and rear control arm bolts to 89 ft. Ibs. (125 Nm). 9. Measure the wheel alignment and adjust as necessary.

CONTROL ARM BUSHING REPLACEMENT ERR

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Metro 93062637

Install the two bolts and nut to the lower control arm—Prizm

1. Before servicing the vehicle, refer to the precautions in the beginning of this section.

SEIMETRO «Paizn_O 1~OO 2. Remove or disconnect the following: e Negative battery cable

¢ Control arm _ 3. Cut the flange off of the front bushing. e Control arm rear bushing from the control arm with Tool J 34865 e Control arm bracket e Front bushing from the control arm with Tool J 34865 To install: 4. Lubricate the circumference of the pee with soapy water to ease installaion. 5. Install or connect the following: e Center the bushing in the control arm and using tool J 34865 install the front bushing to the control arm Rear bushing to the control arm with tool J 34865 Control arm bracket. Torque the nut to 92 ft. Ibs. (125 Nm). Control arm Negative battery cable Prizm

>The lower control arm bushings are service as part of the control arm and cannot be serviced separately.

Wheel Bearings ADJUSTMENT The wheel bearings are sealed units and cannot be adjusted.

REMOVAL & INSTALLATION Front

METRO 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 Brake caliper Brake caliper bracket Brake rotor Drive axle nut

Hub/bearing from the steering

knuckle using a slide hammer 3. Inspect the wheel bearings for excessive wear, corrosion or contamination by dirt or water; replace as necessary.

To install: 4. Install or connect the following:

Hub/bearing to the steering knuckle using a piece of wood and a hammer Drive axle nut and torque it to 129 ft. bs. (175 Nm) Brake rotor Brake caliper bracket and torque the bolts to 37 ft. Ibs. (60 Nm) Brake caliper and torque the bolts to 22 ft. Ibs. (30 Nm) e Front wheel e Negative battery cable 5. Check the wheel alignment and adjust, if necessary.

PRIZM 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 Wheel Speed Sensor (WSS), if equipped Brake hose from the strut Brake caliper Brake caliper bracket Brake rotor Steering knuckle and clamp it ina soft face vise Inner seal shield from the knuckle Inner oil seal from the knuckle Wheel bearing retainer from the knuckle e Hub and brake shield from the knuckle e Outer seal 3. Press the front wheel bearing outside inner race from the knuckle. 4. Remove the wheel bearing. To install: 5. Remove the inner and outer races from the new bearing. 6. Press a new bearing into the steering knuckle. 7. Install or connect the following: e New races into the bearing e Drive the outer seal into the steering knuckle with a Hub Seal Installer tool e Brake shield to the knuckle and torque the bolts to 74 inch Ibs. (8 Nm) e Press the hub into the knuckle ¢ Front wheel bearing retainer to the knuckle e Inner seal to the knuckle 8. If equipped with Anti-lock Brake System (ABS), align the holes for the speed sensor in the inner shield and the knuckle.

9. Install or connect the following: Inner seal shield to the knuckle Steering Knuckle to the vehicle Brake rotor Brake caliper bracket and torque the bolts to 65 ft. Ibs. (88 Nm) Brake caliper and torque the bolts to 25 ft. Ibs. (34 Nm) Brake hose to the strut and torque the bolt to 22 ft. Ibs. (29 Nm) WSS, if equipped and torque the bolt to 70 inch Ibs. (8 Nm) e Front wheel e Negative battery cable 10. Check the front wheel alignment and adjust if necessary. Rear

METRO 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Negative battery cable Rear wheel Spindle nut dust cap Unstake the spindle nut and washer If not equipped with a wheel hub, tap on the brake drum/hub assembly to loosen and remove the assembly from the spindle Inner bearing from the outboard side of the assembly, using a hammer and punch eit is necessary to move the bearing spacer from side-to-side to work the punch around the perimeter of the inner bearing.

¢ Outer bearing from the inboard side of the assembly, using a hammer and punch To instail: >The outer bearing is smaller in diameter than the inner one.

3. Install or connect the following: ¢ Outer bearing in the drum/hub assembly using a Bearing Installation Tool J-34842 and driver handle J-7079-2 e Bearing spacer in the brake drum hub with the inner lip toward the outer bearing »»Be sure the bearing spacer is properly installed. The assembly will not fit on the spindle if the spacer lip is toward the inner bearing.

n 1 of this manual For complete Engine Mechanical specifications, see Sectio

31 -36

GEO/CHEVROLET METRO ¢ PRIZM

Install the inner bearing in the drum/hub assembly using a Bearing Installation Tool J-34842 and driver handle J-7079-2 Brake drum/hub assembly to the spindle Washer and a new spindle nut and torque the nut to 120 ft. Ibs. (170 Nm) if equipped with a wheel hub or to 74 ft. Ibs. (100 Nm) without a wheel hub Stake the spindle nut and install the dust cap Rear wheel Negative battery cable

PRIZM 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the follow-

ing:

Negative battery cable Rear wheel Brake drum Wheel Speed Sensor (WSS), if equipped Axle hub mounting bolts e Axle hub O-ring from the backing plate

To install: 3. Install or connect the following: New O-ring onto the backing plate Hub to the knuckle and torque the bolts to 59 ft. Ibs. (80 Nm) WSS, if equipped and torque the bolt to 70 inch Ibs. (8 Nm) Brake drum Rear wheel e Negative Battery cable 4. Check the rear wheel alignment and adjust, if necessary.

SATURN 1998-01 LW * SCi * SC2 * SL © SLi * SL2 © SW1 * SW2 DRIVE TRAIN.................. 32-38 ENGINE REPAIR................ 32-2 FUEISSYSTEM Roe set. oe 32-35 PRECAUTIONS.................. 32-2 STEERING AND SUSPENSION................. 32-50

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ERAS NU pei Make certain the alternator shield is

in place before installation.

Install or connect the following: Alternator to the cylinder block bracket and torque the bolts to 24 ft. Ibs. (32 Nm) Alternator electrical connectors Splash shield Right front wheel Accessory drive belt Negative batiery cable

2.2L Engine

Install or connect the following: e Alternator and torque the bolts to 15 ft. Ibs. (20 Nm) e Alternator electrical connectors e Accessory drive belt e Throttle body air duct e Negative battery cable 3.0L Engine

instal! or connect the following: e Alternator electrical connectors e Alternator and torque the bolts to 30 ft. Ibs. (40 Nm) e Drive belt tensioner and torque the bolts to 30 ft Ibs. (40 Nm)

~The manufacturer recommends that the engine and transmission be removed as a complete unit. Disconnect the cradle and lower the entire assembly instead of lifting the assembly out of the vehicle. Both the Single

Over Head Camshaft (SOHC) and Dual Over Head Camshaft (DOHC) engines are removed or installed in the same manner. We have found that it is often possible, however, to remove the engine or transmission alone on some models with automatic transmissions by raising it up and out of the engine compartment.

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Properly disable the Supplemental Inflatable Restraint (SIR) system. 3. Properly relieve the fuel system pressure. 4. Drain the engine coolant. 5. Drain the engine oil. 6. Remove or disconnect the following: Both battery cables Air cleaner and intake duct assembly Engine Coolant Temperature (ECT) sensor electrical connector Oxygen (02S) sensor and clip Idle Air Control (IAC) valve Ignition coil connectors Throttle Position (TPS) sensor Manifold Absolute Pressure (MAP) sensor Exhaust Gas Recirculation (EGR) solenoid Brake booster hose Ground connectors at the rear of the cylinder block Fuel injector connectors Neutral Safety Selector (NSS) switch, if equipped Valve body actuator connector, if equipped Transmission temperature sensor, if equipped Turbine speed sensor, if equipped Back-up light switch on manual transmissions

32-3

Accelerator cable Fuel pressure and return lines Drive belt Upper radiator hose and de-aeration hose A/C compressor without removing the hoses Transmission cooler lines, if equipped Automatic transmission shifter cable, if equipped Manual transmission shifter cables Hydraulic clutch actuator, if equipped Tie the radiator, condenser and fan module to the crossbar Front wheels Splash shields Brake caliper brackets and secure the calipers to the shock tower Struts from the knuckles Lower radiator hose Heater inlet and outlet hoses Steering shaft Power steering pressure switch electrical connector, if equipped Front exhaust pipe from the exhaust manifold Powertrain stiffening bracket Flywheel cover Torque converter bolts, if equipped Starter motor electrical connectors Alternator electrical connector Oil pressure sensor electrical connector Knock Sensor (KS) electrical connector Crankshaft Position (CKP) sensor electrical connector Electronic Variable Orifice (EVO) solenoid electrical connector, if equipped Vehicle Speed Sensor (VSS) electrical connector Evaporative Emissions (EVAP) purge solenoid electrical connector Powertrain Control Module (PCM) electrical connector Antilock Brake System (ABS) connectors, if equipped Brake lines from the rear of the cradle Electrical harness from the engine and position it out of the way 7. Place a block of wood between the torque strut and cradle. 8. Remove the 3 right side upper engine torque axis-to-front cover nuts and the 2 mount-to-midrail bracket nuts, allow-

For complete service labor times, order Nichols’ Chilton Labor Guide

32-

SATURN LW © SC1 ¢ SC2 ° SL* SL1 © SL2 ¢ SW1 ¢ SW2 ing the powertrain to rest on the block of wood.

93462604

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Exploded view of the cradle to body bolts—1.9L engines

9. Properly support the engine/transmission assembly. 10. Remove or disconnect the following: e 2right side front engine mount torque strut bracket-to-cradle nuts ¢ 4cradle attaching bolts Powertrain/cradle assembly from the vehicle e Spark plug wires from the ignition module Power steering pump and bracket, if equipped 11. Install an engine lifting device to the service support brackets. Front mount assembly Intake manifold support brace, DOHC engines only 3 axle shaft bracket support bolts and allow the bracket to rotate rearward Transmission attaching bolts Engine from the transmission To install: 12. Install or connect the following: Engine to the transmission and torque the lower transmission bolts to 96 ft. Ibs. (130 Nm) and the upper transmission bolts to 66 ft. lbs. (90 Nm) Front engine mount and torque the bolts to 41 ft. Ibs. (55 Nm) Engine mount torque strut bracket and torque the bolts to 52 ft. Ibs. (70 Nm) Engine strut-to-engine bracket and torque the bolts to 52 ft. Ibs. (70 Nm) Axle shaft bracket and torque the bolts to 41 ft. Ibs. (55 Nm) Starter bracket and torque the bolts to 80 inch Ibs. (9 Nm) Engine/transmission assembly to the chassis and torque the cradleto-body bolts to 151 ft. Ibs. (205 Nm) Brake lines to the cradle Steering shaft and torque the bolts to 35 ft. Ibs. (47 Nm) Starter motor electrical connectors Alternator electrical connectors Oil pressure sensor electrical connector KS sensor electrical connector CKP sensor electrical connector EVAP canister purge valve electrical connector Wiring harness PCM ground Wiring harness to the transmission/engine block and torque the fasteners to 18 ft. Ibs. (25 Nm)

SATURN

LW © SC1 ©SS SC2 © SL SL1 © SL2 © SW1 ¢ SW2 SSS

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EVO solenoid electrical connector, if equipped VSS electrical connector ABS wheel sensor electrical connectors, if equipped Front exhaust pipe to the manifold and torque the bolts to 23 ft. Ibs. (31 Nm) Exhaust pipe-to-stiffening bracket and torque the bolts to 35 ft. Ibs. (47 Nm) Exhaust pipe-to-support bracket and torque the bolts to 23 ft. Ibs. (31 Nm) Heater hoses Lower radiator hose Steering knuckle to the strut and torque the bolts to 148 ft. Ibs. (200 Nm) Brake caliper and torque the bolts to 81 ft. Ibs. (110 Nm) Hydraulic clutch slave cylinder and torque the fasteners to 19 ft. Ibs.

(25 Nm), if equipped Shift cables Transmission oil cooler lines, if equipped A/C compressor bracket and torque the bolts to 22 ft. Ibs. (30 Nm) A/C compressor and torque the front bolt to 40 ft. Ibs. (64 Nm) and the rear bolt to 22 ft. Ibs. (30 Nm) Accessory drive belt Engine mount-to-midrail bracket and torque the bolts to 37 ft. Ibs. (50 Nm) Engine mount to the front cover and torque the bolts to 37 ft. Ibs. (50 Nm) Torque converter-to-flexplate bolts and torque them to 52 ft. Ibs. (70 Nm) Dust cover and torque the fasteners to 89 inch Ibs. (10 Nm) Splash shields Both front wheels ECT sensor electrical connector 02S sensor electrical connector IAC valve electrical connector Fuel injector connectors TPS sensor electrical connectors MAP sensor electrical connector EGR valve electrical connector A/C compressor electrical connector, if equipped Brake booster vacuum hose Ground connections NSS switch connectors PNP switch connectors

32-9

SS

e Valve body actuator connector ¢ Back-up light switch connector, if equipped Temperature sensor electrical connector

¢ Accelerator cable e Fuel feed and return lines Upper radiator and de-aeration hoses e»Check the upper cooling module grommets for misalignment. The cooling module must be able to move freely.

e Air cleaner and intake duct assembly e Both battery cables 13. Fill the engine with new oil. 14. Fill the cooling system. 15. Prime the fuel system by cycling the ignition ONfor 5 seconds and OFF for 10 seconds a few times without cranking the engine. Start the engine and check for leaks. 16. Perform a short road test and check the engine again for leaks. Be sure the cooling system is filled to the surge tank FULL COLD line.

2.2L Engine

AUTOMATIC TRANSMISSION 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Properly relieve the fuel system pressure. 3. Drain the engine coolant. 4. Drain the engine oil. 5. Drain the power steering fluid. 6. Remove or disconnect the following: e Both battery cables e Battery e Main wire feed from the fuse block e Intake Air Temperature (IAT) sensor electrical connector Air cleaner and intake duct assembly Purge hose from the throttle body Purge solenoid electrical connector Rear Heated Oxygen (HO2S) sensor electrical connector e Main harness connector by the master cylinder e Alternator electrical connector e A/C pressure switch electrical connector

93462605

Remove the engine with the lifting hoist-2.2L engine

Please visit our web site at www.chiltonsonline.com

32-

SATURN

LW e SC1 * SC2 ¢ SL

Transmission electrical connectors Right front Wheel Speed Sensor (WSS) electrical connector Cowl cover Powertrain Control Module (PCM) boot from the cowl PCM electrical connectors Engine harness connectors from the fuse block Battery tray and fuse block tray Cruise control and throttle cables Brake assist vacuum line from the throttle body Fuel feed and return Evaporative Emissions (EVAP) purge hose at the solenoid Starter motor Torque converter bolts Exhaust system from the catalytic converter to the exhaust manifold A/C compressor without removing the hoses Lower engine-to-transmission bolts Heater hoses at the lower cowl Coolant reservoir hose Upper and lower radiator hoses Metal power steering line 7. Attach an engine lifting hoist to the lifting eyes. Right front engine mount while Supporting the weight of the transmission with a jack Engine mount bracket Upper transmission-to-engine bolts Engine from the vehicle To install: 8. Lower the engine into the vehicle and align it on the pins on the transmission. 9. Install or connect the following: Upper transmission bolts and hand-tighten them Engine mount bracket and torque the bolts to 66 ft. Ibs. (90 Nm) Engine mount and torque the bolts to 41 ft. Ibs. (55 Nm) 10. Remove the engine lifting device. Metal power steering line Upper and lower radiator hoses Coolant reservoir hose Lower transmission bolts and torque them to 48 ft. Ibs. (65 Nm) Torque converter bolts and torque them to 33 ft. Ibs. (45 Nm) Starter motor and torque the bolts to 37 ft. Ibs. (50 Nm) Heater hoses A/C compressor and torque the bolts to 18 ft. Ibs. (25 Nm) Accessory drive belt Exhaust from.the catalytic converter to the exhaust manifold and torque the bolts to 12 ft. Ibs. (16 Nm)

SL1 © SL2 © SW1 © SW2 11. Torque the upper bell housing bolts to 48 ft. Ibs. (65 Nm). EVAP purge solenoid electrical connector and hose Fuel feed and return lines Brake booster vacuum hose Cruise control and throttle cables Fuse block and battery trays Engine harness to the fuse block Main engine harness under the fuse block panel PCM electrical connector PCM boot to the cowl Cowl cover Main harness connector near the master cylinder Rear HO2S sensor electrical connector Purge solenoid electrical connector

Purge hose to the throttle body Air cleaner and intake duct assembly IAT sensor electrical connector Ground wire to the left fender well Main wire feed to the fuse block Battery and both cables 12. Fill the engine with coolant. 13. Fill the engine with new oil. 14. Fill the power steering fluid. 15. Prime the fuel system by cycling the ignition ON for 5 seconds and OFF for 10 seconds a few times without cranking the engine. 16. Start the engine, check for leaks, and repair if necessary.

Powertrain Control Module (PCM) boot from the front of the dash Main harness connector by the master cylinder PCM electrical connectors ‘Engine harness connectors from the fuse block Battery, tray and fuse block tray Cruise control and throttle cables Brake booster vacuum hose Control assembly rod-to-control shaft lever pinch bolt Retaining clips connecting the con-

trol shaft lever to the transmission Control shaft lever assembly Heater hoses at the lower cowl Upper and lower radiator hoses Fuel feed and return lines 7. Secure the radiator to the upper radiator support. Both front wheels Right front splash shield Left front wheel liner push pin from the frame 8. |nstall wood blocks between the transmission case and frame and the crank pulley a nd frame. Right side engine mount Left side transmission mount Exhaust system from the catalytic converter to the exhaust manifold A/C compressor without removing

the hoses Tie rods from the steering knuckles Stabilizer bar links from the struts Lower ball joints from the steering knuckles Suspension support assemblies Suspension support cage nuts from

MANUAL TRANSMISSION 1, Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Properly relieve the fuel system pressure. 3. Drain the engine coolant. 4. Drain the engine oil. 5. Drain the power steering fluid. 6. Remove or disconnect the following: Both battery cables Steering gear-to-intermediate shaft pinch bolt Main wire feed to the fuse block Ground wire on the left fender well Intake Air Temperature (IAT) sensor electrical connector Air cleaner and intake duct assembly Purge hose from the throttle body Purge solenoid electrical connector Rear Heated Oxygen (HO2S) sensor electrical connector Back-up switch electrical connector Front dash cover

the body 9. Properly support the powertrain and frame assembly. Frame-to-body attachment fasteners Powertrain/frame assembly from the vehicle To install: 10. Raise the powertrain into the vehicle. as nstall 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 ft. lbs. (100 Nm) plus 45 degrees Ball joint to the steering knuckle and torque the nuts to 74 ft. Ibs. e

(100 Nm) Stabilizer links to the struts and torque the fasteners to 50 ft. Ibs. (65 Nm)

SATURN

LW ¢ SC1 © SC2 e SL ¢ SL1 © SL2 © SW1 © SW2

32-/

IAT sensor electrical connector Ground wire to the left fender well Main wire feed to the fuse block Battery and both cables Steering gear-to-intermediate shaft and torque the pinch bolt to 22 ft. lbs. (30 Nm) 15. Fill the engine with coolant. 16. Fill the engine with new oil. 17. Fill the power steering fluid. 18. Prime the fuel system by cycling the ignition ON for 5 seconds and OFF for 10 seconds a few times without cranking the engine. 19. Start the engine, check for leaks, and repair if necessary.

3.0L Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section.

93462606

Powertrain/frame assembly with lifting table-2.2L engine

Tie rods to the steering knuckles and torque the new nuts to 46 ft. lbs. (65 Nm) Exhaust system to the exhaust manifold and torque the bolts to 12 ft. Ibs. (16 Nm) A/C compressor and torque the bolts to 18 ft. Ibs. (25 Nm) Rear HO2S sensor electrical connector Right side engine mount and torque the bolts to 41 ft. Ibs. (55 Nm) Left side transmission mount and torque the bolts to 41 ft. Ibs. (55 Nm)

42. Remove the wood blocks.

Left front wheel liner push pins Right front splash shield Both front wheels Fuel feed and return lines Upper and lower radiator hoses Heater hoses Brake booster vacuum hose Shift control rod 13. Adjust the shift control rod as follows: a. Install the shift rod into the shift

linkage assembly.

b. Rotate the transmission shift control shaft clockwise and depress the spring loaded transmission shift linkage lock pin on the case. e Pull up the shift lever boot.

d. Move the shift lever to the 5 (reverse gate) and use a 3/8 inch punch to hold it in place. €. Tighten the pinch bolt to 9 ft. Ibs. (12 Nm) plus 180 degrees 14. Install or connect the following: Cruise control and throttle cables Fuse block and battery trays Fuse block Engine harness connector to the bottom of the fuse block Fuse block PCM electrical connector PCM boot to the cow! Cowl cover EVAP purge solenoid electrical connector and hose Main harness connector near the master cylinder Transmission back-up switch electrical connector Purge hose to the throttle body Air cleaner and intake duct assembly

2. Properly relieve the fuel system pressure. 3. Drain the engine coolant. 4. Drain the engine oil. 5. Drain the power steering fluid. 6. Remove or disconnect the following: - Both battery cables Air cleaner assembly Mass Air Flow (MAF) sensor electrical connector Battery ground cable from the fuse block Transmission Control Module (TCM) main connector from under the cowl cover TCM inline connector by the brake master cylinder | A/C pressure connector Black engine harness connector from under the fuse block panel Lower weather pack connector from inside the fuse block and secure the engine harness to the engine Fuse block

Timing belt service is covered in Section 3 of this manual

Battery tray Evaporative Emissions (EVAP) purge connector Right front speed sensor connector

Front Oxygen (02S) sensor from the down pipe Transmission ground electrical connector Transmission main electrical connector Transmission shift control electrical connector Rear connector on the Engine Control Module (ECM)

32-8

SATURN

LW ¢SC1 © SC2 ¢ SL

Brake booster vacuum hose Fuel lines EVAP purge hose and solenoid Starter motor Torque converter bolts Exhaust system from the catalytic converter to the exhaust manifold Transmission nose bracket

A/C compressor without removing the hoses Heater hoses at the lower cowl Lower engine-to-transmission bolts Upper and lower radiator hoses coolant reservoir hose Metal power steering line Power steering reservoir from the radiator support 7. Attach an engine lifting device to the engine lifting eyes. e Right front engine mount and bracket e Upper transmission bolts e Engine from the vehicle To install: 8. Lower the engine into the vehicle and align it on the pins on the transmission. 9. Install or connect the following: e Upper transmission bolts and hand-tighten them e Engine mount bracket and torque the bolt to 30 ft. Ibs. (40 Nm) e Engine mount and torque the upper bolt to 30 ft. Ibs. (40 Nm) and the lower bolt to 41 ft. Ibs. (65 Nm) e Transmission nose bracket and torque the bolts to 30 ft. Ibs. (40 Nm) 10. Remove the engine lifting device. Metal power steering line Power steering reservoir to the radiator support Upper and lower radiator hoses Coolant reservoir hose Lower transmission bolts and torque them to 48 ft. Ibs. (65 Nm) Torque converter and torque them

to 48 ft. Ibs. (65 Nm) Starter motor and torque the bolts to 30 ft. Ibs. (40 Nm) Heater hoses at the lower cowl A/C compressor and torque the bolts to 30 ft. Ibs. (40 Nm) Exhaust system to the exhaust manifold and torque the nuts to 15 ft. Ibs. (20 Nm) EVAP purge solenoid and hose Fuel feed and return lines Brake booster vacuum hose ECM rear connector Transmission shift control electrical connector e Transmission ground connector

SL1 © SL2 ¢ SW1 © SW2 Transmission main connector Right front speed sensor electrical connector Front 02S sensor electrical connector

Right front speed sensor ¢ EVAP purge solenoid electrical connector 11. Torque the upper bell housing bolts to 48 ft. Ibs. (65 Nm). e Battery tray Fuse block and route the engine harness to the block Lower weather pack connector Main wire feed to the fuse block A/C pressure connector TCM inline connector TCM main connector under the cowl cover and secure it to the engine Positive main feed cable at the fuse block Battery ground cable at the wheel housing Battery and both cables Air cleaner and intake duct assembly MAF sensor electrical connector 12. Fill the engine with coolant. 13. Fill the engine with new oil. 14. Fill the power steering fluid. 15. Prime the fuel system by cycling the ignition ON for 5 seconds and OFF for 10 seconds a few times without cranking the engine. 16. Start the engine, check for leaks, and repair if necessary.

79227801

Water pump bolt torque sequence—1.9L engines

torque the bolts in a crisscross sequence to 22 ft. Ibs. (30 Nm) Water pump pulley to the hub and torque the bolts to 19 ft. Ibs. (25 Nm) Accessory drive belt Right front wheel well splash shield Right front wheel Negative battery cable 5. Fill the cooling system. 6. Start the vehicle and check for leaks, repair if necessary. 2.2L Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the cooling system. 3. Remove or disconnect the following: e Negative battery cable e Air cleaner assembly e Exhaust manifold heat shield

Water Pump REMOVAL & INSTALLATION 1.9L Engines 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the cooling system. 3. Remove or disconnect the following: Negative battery cable Accessory drive belt Right front wheel Inner wheel well splash shield Water pump pulley bolts and allow the pulley to hang freely on the water pump hub Water pump flange bolts ¢ Water pump To install: 4. Install or connect the following: ¢ Water pump with a new gasket and

93462612

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2. Drain the cooling system. 3. Remove or disconnect the following: e Negative battery cable e Air cleaner assembly e Left front wheel e Wheel well splash shield e Loosen the water pump pulley and power steering pulley bolts, but do not remove them oS. Install an engine support fixture. e Right front engine mount Accessory drive belt Release the retaining tabs on the wiring harness channel and remove the front cover Wiring harness from the channel Water pump pulley Power steering pump pulley Drive belt tensioner Front timing belt cover Water pump To install: 5. Install or connect the following: e Water pump with a new O-ring and

aus the bolts to 18 ft. Ibs. (25 m

e Front timing belt cover and torque the bolts to 71 inch lbs. (8 Nm)

Exploded view of the water pump-2.2L engine

e Thermostat housing e Water pump feed pipe ¢ Water pump sprocket access plate from the front cover 4 Install a Water Pump Holding Tool J43651. ¢ Water pump retaining bolts e Water pump To install: 5. Install or connect the following: e Water pump and torque the bolts to 18 ft. Ibs. (25 Nm) Water pump sprocket and torque the bolts to 89 inch Ibs. (10 Nm) e Water pump sprocket access plate e Water feed tube after lubricating the O-ring Thermostat housing and torque the bolts to 89 inch Ibs. (10 Nm) e Exhaust manifold heat shield Air cleaner assembly ¢ Negative battery cable 6. Fill the cooling system. 7. Start the vehicle and check for leaks, repair if necessary. 93467613

3.0L Engine

1. Before servicing the vehicle, refer to the precautions in the beginning of this section.

Timing belt cover bolt locations-3.0L engine

Heater Core replacement is covered in Section 2 of this manual

32-1

SATURN

LW ¢ SC1 ¢ SC2 ¢ SL

Drive belt tensioner and torque the bolts to 30 ft. Ibs. (40 Nm) Power steering pump and torque the bolts to 71 inch Ibs. (8 Nm) Water pump pulley’s and torque the bolts to 15 ft. Ibs. (20 Nm) Wiring harness into the channel Wiring harness channel front cover Accessory drive belt 6. Remove the engine support fixture. e Wheel well splash shield and torque the bolts to 44 inch Ibs. (5 Nm) e Front wheel e Air cleaner and intake duct e Negative battery cable 7. Fill the cooling system. 8. Start the vehicle and check for leaks, repair if necessary.

Cylinder Head REMOVAL & INSTALLATION 1.9L Engines

Only remove the cylinder head when the engine is cold. Warpage may result if the cylinder head is removed while the engine is hot. 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the cooling system 3. Drain the engine oil. 4, Properly relieve the fuel system pressure. 5. Remove or disconnect the following: Negative battery cable Air cleaner assembly Rocker cover fresh air hose Accelerator cable from the throttle body and intake manifold bracket Coolant temperature gauge electrical connector Fuel injector connectors Idle Air Control (IAC) valve electrical connector Throttle Position (TPS) sensor electrical connector A/C compressor electrical connector Manifold Absolute Pressure (MAP) sensor electrical connector Oxygen (02S) sensor electrical connector e Exhaust Gas Recirculation (EGR) solenoid

SL1 © SL2 © SW1 © SW2 A/C compressor and front bracket without removing the hoses Power steering pump without removing the lines

Right front wheel

79227802

Crankshaft gear retaining and oil pan removal tool shown—be sure to install the crankshaft tool with the flat side toward the gear

6. Reposition the wire harness out of the way. Spark plug wires Evaporative Emissions (EVAP) purge valve vacuum hose Positive Crankcase Ventilation (PCV) vacuum hose Throttle body connector Brake booster vacuum hose Upper radiator hose from the cylinder head outlet Deaeration hose from the intake manifold Heater hose from the intake manifold Fuel supply line Engine torque axis mount Accessory drive belt Drive belt tensioner Drive belt idler pulley Rocker arm cover Deaeration line from the cylinder head water outlet

Wheel well splash shield Crankshaft pulley Front exhaust pipe from the exhaust manifold Front cover 7. Install a crankshaft gear retainer tool with the flat side toward the sprocket. ¢ Front four oil pan bolts and cut the oil pan seal away from the front cover e Front cover ->Position the crankshaft 90 degrees off of Top Dead Center (TDC) to make certain that the pistons do not touch the valves during assembly.

e Timing chain, tensioner and guides e Camshaft sprocket e Loosen and uniformly remove the 10 cylinder head bolts in several passes e Cylinder head from the dowels on the engine block To install: Before installing the cylinder head, it should be cleaned and inspected for excessive wear or damage.

8. Clean the gasket mating surfaces. Be careful not to damage the aluminum components and be sure the block bolt holes are clean of any residual sealer, oil or foreign matter. 9. Using a dial gauge, check that the

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79222803

Gradually remove the cylinder head bolts in the sequence shown to prevent warping the head

LW * SC1°SC2°SLeSL1¢SL2° Avani 32-1 1

792272805

Rotate the crankshaft clockwise to 90 degrees past TDC (the crankshaft sprocket timing mark will be at 3 o’clock) to prevent valve damage during assembly

cylinder liners are flush or do not deviate more than 0.0005 in. (0.013mm). 10. Be sure the crankshaft is still 90 degrees past TDC and that the camshaft(s) are properly positioned with the dowel pin(s) at the 12 o'clock position to prevent valve damage.

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11. Install the cylinder head gasket and carefully guide the head into place over the dowels. 12. If the head bolts and/or the block were replaced, install the bolts and tighten in sequence to 48 ft. Ibs. (65 Nm) to insure proper clamp load; then, remove the bolts.

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Cylinder head bolt tightening sequence—1.9L engine

13. Coat the cylinder head bolts with clean engine oil and thread the bolts by hand until finger-tight. 14. Install the cylinder head bolts, in sequence, as follows: a. Tighten the bolts to 22 ft. Ibs. (30 m). b. Tighten the bolts to 33 ft. Ibs. (45 Nm) for SOHC engines or to 37 ft. Ibs. (50 Nm) for DOHC engines. c. Tighten each bolt an additional 90 degree turn. 15. Install the timing chain, sprockets, guides and tensioners, using the following procedure : a. Verify that the crankshaft is positioned 90 degrees clockwise past TDC. The crankshaft key way sprocket timing mark must be aligned with the cylinder block main bearing cap split line to prevent piston and valve damage. b. If required, rotate the camshaft up to No. 1 TDC position. c. Rotate the crankshaft 90 degrees counterclockwise to No. 1 TDC position. The crankshaft sprocket timing mark must align with the cylinder block timing mark. 16. Install or connect the following: Timing chain over the camshaft sprocket and under the crankshaft sprocket. Slide the camshaft sprocket onto the camshaft with the letters FRTfacing away from the cylinder head Camshaft sprocket timing pin Camshaft washer and bolt and torque the bolt to 74 ft. Ibs. (100 Nm) Fixed chain guide and torque the fastener to 19 ft. Ibs. (26 Nm). The timing chain should be snug against the fixed guide. Pivoting chain guide making certain there is clearance between the block and head and torque the bolts to 19 ft. Ibs. (26 Nm) Timing chain tensioner and torque the bolts to 168 inch Ibs. (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. Ibs. (30 Nm) and the lower center bolt to 89 inch Ibs. (10 Nm) Oil pan and torque the bolts to 80 inch Ibs. (9 Nm) Water pump pulley and torque the

Brake service is covered in Section 4 of this manual

d-12 SATURN

LW e SC1 ¢ SC2¢ SL

3

SL1 ¢ SL2 © SW1 © SW2

bolts to 19 ft. Ibs. (25 Nm) (if removed) 17. Remove the crankshaft timing gear retaining tool. 18. Apply RTV across the cylinder head and front cover T-joints and install a new rocker cover gasket Crankshaft pulley and torque the bolt to 159 ft. Ibs. (215 Nm) Rocker cover and torque the bolts

to 22 ft. Ibs. (30 Nm) Drive belt tensioner and torque the fastener to 22 ft. Ibs. (30 Nm) Drive belt idler pulley and torque the fastener to 20 ft. Ibs. (27 Nm) Accelerator linkage bracket and the throttle cable. Make certain that the cable is routed properly and is not binding and torque the bolts to 18 ft. bs. (25 Nm). Alternator and torque the bolts to 24 ft. Ibs. (32 Nm) (if removed)

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Power steering pump and torque the bolts to 22 ft. Ibs. (30 Nm) A/C compressor and torque the rear bracket bolts to 18 ft. Ibs. (25 Nm) and the front bracket bolts to 35 ft. Ibs. (47 Nm) Accessory drive belt Upper mount and torque the bracket nuts to 37 ft. Ibs. (60 Nm) and then torque the mount to cover bolts to 37 ft. Ibs. (50 Nm) Wheel well splash shield Wheel EVAP canister purge hose Throttle body vacuum harness hose PCV hose Brake booster vacuum hose Upper radiator hose Heater hose Ground wire electrical connectors O2S sensor electrical connector Fuel injector electrical connectors IAC valve electrical connector EGR valve electrical connector TPS sensor electrical connector EVAP canister purge valve connectors MAP sensor connectors Alternator electrical connectors Starter motor electrical connectors A/C compressor electrical connectors Intake manifold support bracket and torque the bolts to 22 ft. Ibs. (30 Nm) Deaeration line and torque the cylinder head nut to 80 inch Ibs. (9 Nm) and the rear lift bracket nut to 97 inch Ibs. (11 Nm) Fuel feed and return lines with new

retainers and torque the fastener to 53 inch Ibs. (6 Nm) e Air cleaner assembly e Fresh air hose e Negative battery cable 19. Fill the cooling system. 20. Fill the engine with new oil. 21. Prime the fuel system by cycling the ignition ON for 5 seconds and OFF for 10 seconds a few times without cranking the engine. 22. Start the engine, check for leaks, and repair if necessary. 2.2L Engine

Only remove the cylinder head when the engine is cold. Warpage may result if the cylinder head is removed while the engine is hot. 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the cooling system. 3. Drain the engine oil. 4. Properly relieve the fuel system pressure. 5. Remove or disconnect the following:

Negative battery cable Intake manifold Exhaust manifold flange bolts Exhaust manifold down pipe to the catalytic converter Fuel lines

A/C compressor switch electrical connector Crankcase vent hose from the camshaft cover Coolant air bleed hose Upper radiator hose from the cylinder head Ignition coil electrical connectors Knock Sensor (KS) electrical connector Engine Coolant Temperature (ECT) sensor electrical connector Fuel injector jumper harness Front Oxygen (02S) sensor electrical connector Ignition coil Power steering pump and secure it to the engine without removing the lines Camshaft cover ground strap Camshaft cover Upper timing chain guide Upper timing chain tensioner Camshaft sprocket bolts

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© 9262643

Cylinder head bolt tightening sequence—2.2L engine

WR TB Ce Stes Camshaft sprockets Plug to gain access to the fixed timing chain guide Fixed timing chain guide upper bolt only Cylinder head bolts using the

proper sequence Cylinder head ~The manufacturer recommends to perform the remaining steps to complete this procedure. It may be not be necessary to perform the remaining Steps if the timing chain can be supported without slipping or moving on the crankshaft pulley.

e Right front wheel and splash shield e Drive belt and tensioner e A/C suction line retaining clips and move the line away to allow clearance to the crankshaft pulley bolt 6. Position the crankshaft 60 degrees Before Top Dead Center (BTDC) and install a crankshaft pulley holder tool. e Crankshaft pulley e Front cover bolts except for the one blocked by the engine mount bracket e Loosen water pump bolt but do not remove it 7. Support the engine and remove the right side engine mount. Engine mount bracket Upper front cover bolt which was blocked by the mount bracket Water pump bolt Front cover Adjustable timing chain guide Fixed timing chain guide lower bolt To install: -»Set the crankshaft to 60 degrees Before Top Dead Center (BTDC) or after Top Dead Center (TDC) to prevent contact between the pistons and valves.

8. Install or connect the following: e New cylinder head gasket with the side imprinted OBENfacing up e Cylinder head and align it on the dowels New cylinder head bolts and torque them in sequence to 22 ft. Ibs. (30 Nm) plus 155 degrees Front 4 cylinder head bolts coated with Loctite® and torque them to 18 ft. Ibs. (22 Nm) 9. Position the exhaust camshaft with the offset slot in the 2 o'clock position and the intake camshaft with the offset slot in the 11 o'clock position.

Timing chain around the intake camshaft sprocket with the copper link aligned with the INTdiamond timing mark sprocket to the camshaft and align it with the offset slot New camshaft sprocket bolt but do not tighten Timing chain around the crankshaft sprocket and align the silver link to the timing mark Adjustable timing chain guide through the opening on top of the cylinder head and torque the bolt to 89 inch Ibs. (10 Nm) Timing chain around the exhaust camshaft sprocket with the silver link aligned with the offset slot. Install but do not tighten a new sprocket bolt

*-k CAUTION Make certain that all timing marks and colored links are aligned properly before proceeding to the next step. If the timing chain is not aligned properly, severe engine damage may occur. 10. Torque the intake and exhaust camshaft bolts to 63 ft. Ibs. (85 Nm) plus a 30 degree turn. 11. Install or connect the following: e Fixed timing guide and torque the bolt to 89 inch Ibs. (10 Nm) ¢ Fixed timing guide bolt access plug after applying Loctite® to the threads and torque it to 30 ft. Ibs. (40 Nm) e Timing chain tensioner and torque the bolts 44 ft. Ibs. (60 Nm) 12. Tap the top of the timing chain

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between the camshaft sprockets to engage the tensioner. Upper timing chain guide and torque the bolts to 89 inch Ibs. (10 Nm) Front cover with a new gasket and torque the bolts to 18 ft. Ibs. (25 Nm) Water pump bolt and torque it to 18 ft. Ibs. (25 Nm) Drive belt tensioner and torque the bolts to 30 ft. Ibs. (40 Nm) Engine mount bracket and torque the bolts to 66 ft. Ibs. (90 Nm) Engine mount to the side rail and torque the fasteners to 41 ft. Ibs. (55 Nm) Engine mount to the bracket and torque the bolts to 41 ft. lbs. (55 Nm) Crankshaft damper and torque the bolt to 74 ft. Ibs. (100 Nm) Accessory drive belt A/C line clamps Right wheel splash shield Right front wheel Camshaft cover and torque the bolts to 89 inch Ibs. (10 Nm) Camshaft cover ground strap and torque the bolt to 89 inch Ibs. (10 Nm) Power steering pump and torque the bolts to 18 ft. Ibs. (25 Nm) Ignition coil/module assembly and torque the bolts to 71 inch Ibs. (8 Nm) Intake manifold with a new gasket and torque the bolts to 89 inch Ibs. (10 Nm) Wiring harness to the intake manifold bracket Engine wiring harness and torque the fasteners to 89 inch Ibs. (10 Nm) All component electrical connections Upper radiator hose Crankcase ventilation hose Fuel pressure regulator hose Brake booster vacuum hose EVAP purge hose Fuel lines Fuel lines to the bracket and torque the bracket bolt to 89 inch Ibs. (10 Nm) Exhaust down pipe to the exhaust manifold and torque the bolts to 25 ft. lbs. (30 Nm) Exhaust pipe to the resonator and torque the bolts to 15 ft. Ibs. (20 Nm)

For complete Engine Mechanical specifications, see Section 1 of this manual

39-44

SATURN LW e SC1 ¢ SC2 ¢ SL

SL1 © SL2 © SW1 ¢ SW2

e Exhaust manifold heat shield and torque the bolts to 18 ft. Ibs. (25 Nm) e Air cleaner assembly e Negative battery cable 13. Fill the engine with clean oil. 14. Fill the cooling system. 15. Prime the fuel system by cycling the ignition ON for 5 seconds and OFF for 10 seconds a few times without cranking the engine. 16. Start the engine, check for leaks, and repair if necessary. 3.0L Engine

FRONT : WARNING Only remove the cylinder head when the engine is cold. Warpage may result if the cylinder head is removed while the engine is hot. 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the cooling system. 3. Drain the engine oil. 4. Properly relieve the fuel system pressure. 5. Remove or disconnect the following: Negative battery cable Air cleaner assembly Intake plenum Intake manifold Intake manifold spacer Coolant bridge Upper radiator hose from the coolant extension housing 6. Properly support the powertrain assembly. Front transmission mount through bolt Extension housing over the coolant module Oil level indicator tube Front camshaft cover Ground wires from the lift bracket Oxygen (02S) sensor electrical connector Down pipe from the exhaust manifold Front timing belt cover Timing belt Timing belt tensioner bracket Rear timing belt cover Camshaft position (CMP) sensor electrical connector Exhaust camshaft Loosen the cylinder head bolts in stages as shown

93062645

Cylinder head bolt removal for the front cylinder head-3.0L engine

e Cylinder head e Exhaust manifold from the cylinder head (if necessary) To install: 7. Install or connect the following:

e Exhaust manifold with a new gasket 6

and torque the bolts to 15 ft. Ibs. (20 Nm) ¢ New cylinder head gasket with the part number imprint facing the top of the engine

* Cylinder head

2

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93062646

Front cylinder head bolt tightening sequence—3.0L engine

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8. Torque the new cylinder head bolts,

in sequence, as follows: a. 18 ft. Ibs. (25 Nm). b. 90 degree turn. c. 90 degree turn. d. 90 degree turn. @. 15 degree turn. 9. Install or connect the following: ° Coolant pipe with new sealing rings Engine lift bracket bolt and torque it to 15 ft. Ibs. (20 Nm) Upper radiator hose to the coolant

pipe Front transmission mount through bolt Exhaust camshaft CMP sensor electrical connector Rear timing belt cover and torque the bolts to 71 inch Ibs. (8 Nm) Camshaft gears Timing belt tensioner bracket Timing belt Front timing belt cover and torque the bolts to 71 inch Ibs. (8 Nm) Down pipe to the exhaust manifold

02S electrical connector Front camshaft cover and torque the bolts to 71 inch Ibs. (8 Nm) Coolant bridge and torque the bolt to 22 ft. Ibs. (33 Nm) Intake manifold spacer and torque the bolts in a spiral direction from the inside and working out to 15 ft. lbs. (20 Nm) Intake manifold and torque the bolts to 15 ft. Ibs. (20 Nm) Intake plenum and torque the bolts to 71 inch Ibs. (8 Nm) Air cleaner assembly Negative battery cable 10. Fill the engine with clean oil. 11. Fill the cooling system. 12. Prime the fuel system by cycling the ignition ON for 5 seconds and OFF for 10 seconds a few times without cranking the engine. 13. Start the engine, check for leaks, and repair if necessary.

LW ¢ SC1 ©SC2 ¢ SL a

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the cooling system. 3. Drain the engine oil. 4. Properly relieve the fuel system pressure. 5. Remove or disconnect the following: Negative battery cable Air cleaner assembly Intake plenum Intake manifold Intake manifold spacer Coolant bridge Engine ventilation chamber Rear camshaft cover Front timing belt cover Timing belt Timing belt tensioner bracket Camshaft gears Rear timing belt cover Exhaust manifold pipe heat shield Front exhaust manifold pipe-to-rear exhaust manifold pipe fasteners e Rear exhaust manifold pipe nuts, pull the manifold pipe down and discard the gasket Exhaust Gas Recirculation (EGR)to-exhaust manifold pipe e Exhaust camshaft Cylinder head bolts Cylinder head

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e Exhaust manifold from the cylinder head To install: 6. Install or connect the following: e Exhaust manifold with a new gasket and torque the bolts to 15 ft. Ibs. (20 Nm), if removed e New cylinder head gasket with the part number imprint facing the top of the engine e Cylinder head 7. Torque the new cylinder head bolts, in sequence, as follows: a. 18 ft. Ibs. (25 Nm). b. 90 degree turn. c. 90 degree turn. d. 90 degree turn. e. 15 degree turn. 8. Install or connect the following: e Exhaust camshaft Rear timing belt cover and torque the bolts to 71 inch Ibs. (8 Nm) Camshaft gears and torque the bolts to 37 ft. Ibs. (50 Nm) plus a 60 degree turn plus another 15 degree turn Timing belt tensioner bracket and torque the bolts to 30 ft. Ibs. 940 Nm) e Timing belt Front timing belt cover and torque the bolts to 71 inch Ibs. (8 Nm) 2

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93062G78

Rear cylinder head bolt tightening sequence—3.0L engine

For Accessory Drive Belt illustrations, see Section 1 of this manual

32-1

SATURN

LW ¢ SC1 ¢ SC2 ¢ SL © SL1 © SL2 © SW1 © SW2

Rear camshaft cover and torque the bolts to71 inch Ibs. (8 Nm) Exhaust manifold pipe to the manifold Exhaust manifold pipe heat shield EGR-to-exhaust manifold pipe and torque the nut to 18 ft. Ibs. (25 Nm) Coolant bridge and torque the bolt

to 22 ft. Ibs. (33 Nm) Engine ventilation chamber and torque the bolts to 71 inch Ibs. (8 Nm) Intake manifold spacer and torque the bolts to 15 ft. Ibs. (20 Nm) Intake manifold and torque the bolts to 15 ft. Ibs. (20 Nm) Intake plenum and torque the bolts to 71 inch Ibs. (8 Nm) Air cleaner assembly Negative battery cable 9. Fill the engine with clean oil. 10. Fill the cooling system. 11. Prime the fuel system by cycling the ignition ON for 5 seconds and OFF for 10 seconds a few times without cranking the engine. 12. Start the engine, check for leaks, and repair if necessary.

Rocker Arms/Shafts

REMOVAL & INSTALLATION 1.9L and 2.2L Engines 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: ¢ Negative battery cable ¢ Spark plug wires ¢ Accessory drive belt ¢ Fresh air hose ¢ Camshaft cover ¢ Fuel injector electrical connectors 3. Install a rocker arm removal too! J43223 to the cylinder head rail. 4. Position the crankshaft at Top Dead Center (TDC) with the pip marks on the camshaft sprockets at the 12 o’clock position. 5. Rotate the crankshaft 90 degrees past TDC and remove the following rocker arm assemblies: ¢ No. 1 Intake ¢ No. 2 Intake ¢ No. 1 Exhaust ¢ No. 3 Exhaust 6. Rotate the crankshaft 360 degrees to remove the following rocker arm assemblies:

93062647

Exploded view of the valve springs compressed—-1.9L DOHC engines

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No. 2 Exhaust No. 4 Intake No. 3 Intake No. 4 Exhaust 7. Compress the valve springs. 8. Remove the rocker arm and/or valve lifters. To install: 9. Rotate the crankshaft 90 degrees past TDC and install the following rocker arm assemblies: e No. 1 Intake e No. 2 Intake e No. 1 Exhaust e No. 3 Exhaust 10. Rotate the crankshaft 360 degrees to install the following rocker arm assemblies: e No. 2 Exhaust ¢ No. 4 Intake ¢ No. 3 Intake ¢ No. 4 Exhaust 11. Remove the rocker arm tool. 12. Install or connect the following: ¢ Camshaft cover and torque the bolts to 71 inch Ibs. (8 Nm) e Fresh air hose e Accessory drive belt ¢ Fuel injector electrical connectors * Spark plug wires ¢ Negative battery cable

2. Properly relieve the fuel system pressure. 3. Drain the cooling system. 4, Remove or disconnect the following: Negative battery cable Air cleaner assembly Positive Crankcase Ventilation (PCV) valve hose Fuel line from the rail Throttle cable from the throttle

5. brake

Intake Manifold

REMOVAL & INSTALLATION 1.9L SOHC Engines

1. Before servicing the vehicle, refer to the precautions in the beginning of this section.

To 6.

body Throttle cable bracket nuts Fuel. injector electrical connectors Throttle Position (TPS) sensor electrical connectors Idle Air Control (IAC) valve electrical connectors Manifold Absolute Pressure (MAP) sensor electrical connectors Exhaust Gas Recirculation (EGR) valve electrical connectors Heater hose from the intake manifold outlet Position the wiring harness over the master cylinder. Intake manifold support bracket bolt Accessory drive belt Power steering pump without removing the lines Upper intake manifold nuts Evaporative Emissions (EVAP) canister purge valve solenoid vacuum hose Brake booster vacuum hose Lower intake manifold nuts Intake manifold install: Install or connect the following: ¢ Intake manifold with a new gasket and torque the nuts in sequence to 22 ft. Ibs. (30 Nm)

SATURN

LW ¢ SC1 ¢ SC2 © SL SL1 © SL2 © SW1 © SW2

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Intake manifold boit torque sequence—1.9L SOHC engine

Power steering pump and torque the fasteners to 27 ft. Ibs. (35 Nm) Accessory drive belt Heater hose Intake manifold support bracket bolt and torque it to 22 ft. Ibs. (30 Nm) Fuel supply and return lines Fuel line(s) in the retaining bracket and torque the mounting screw to 36 inch Ibs. (4 Nm) Throttle cable to the throttle body and accelerator cable bracket and torque the bolts to 22 ft. Ibs. (30 Nm) IAC valve electrical connector TPS sensor electrical connector MAP sensor electrical connector Fuel injector electrical connectors EGR valve electrical connector EVAP purge solenoid vacuum hose PCV valve hose Air cleaner assembly Negative battery cable 7. Fill the cooling system. 8. Prime the fuel system by cycling the ignition ON for 5 seconds and OFF for 10 seconds a few times without cranking the engine. 9. Start the engine, check for leaks, and repair if necessary.

4 Remove or disconnect the following: Negative battery cable Air cleaner fresh air hose Positive Crankcase Ventilation (PCV) valve hose Fuel line from the rail Throttle cable from the throttle body Throttle cable bracket nuts Fuel injector electrical connectors Throttle Position (TPS) sensor electrical connector Idle Air Control (IAC) valve electrical connector Manifold Absolute Pressure (MAP) sensor electrical connector

Exhaust Gas Recirculation (EGR) valve electrical connector

32-1/

Heater hose from the intake manifold outlet Power steering support brace Fuel rail EGR pipe from the cylinder head Brake booster vacuum hose Accessory drive belt Power steering pump without removing the lines Upper axis torque mount nuts and midrail bracket nuts. Allow the powertrain assembly to rest on a support fixture. Resonator and air cleaner box Intake Air Temperature (IAT) sensor electrical connector Transmission strut-to-midrail bolt and rotate the engine Intake manifold To install: 5. Install or connect the following: Intake manifold with a new gasket and torque the nuts in sequence to 22 ft. Ibs. (30 Nm) for 1998-99 1.9L DOHC engines or to 115 inch lbs. (13 Nm) for 2000-01 1.9L DOHC engines EGR pipe with a new gasket and torque the fasteners to 18 ft. Ibs.

(25 Nm) Heater hose

Fuel rail and torque the bolts to 106 inch Ibs. (12 Nm) IAC valve electrical connector TPS sensor electrical connector MAP sensor electrical connector

Fuel injector electrical connector EGR valve electrical connector

Upper Side 5

7

4

6

1.9L DOHC Engines

1. Before servicing the vehicle, refer to the precautions in the beginning of this sec-

Lower Side

tion.

2. Properly relieve the fuel system presSU fe, 3. Drain the cooling system.

79222809

Intake manifold bolt torque sequence—1998 1.9L DOHC engine

For Tire, Wheel and Ball Joint specifications, see Section 1 of this manual

32-1 § iia

SC2 ¢ SLe SL1 ° SL2 © SW1 © SW2

Upper Side 8

4 |]

5

yi

ipinleMita PaaS

eta

Lower Side 93062648

Intake manifold bolt torque sequence—1999 1.9L DOHC engine

Upper Side

5

1 4

2 fi

6

Negative battery cable Air cleaner assembly Intake Air Temperature (IAT) sensor electrical connector Throttle Position (TPS) sensor electrical connectors Idle Air Control (IAC) valve electrical connectors Manifold Absolute Pressure (MAP) sensor electrical connectors Fuel pressure regulator vacuum pipe Evaporative Emissions (EVAP) purge solenoid hose from the throttle body Throttle cable and automatic transmission downshift cable from the throttle body Throttle cable bracket nuts Brake booster vacuum hose Oil level indicator tube Throttle body Intake manifold To install: 3. Install or connect the following: Intake manifold with a new gasket and torque the nuts to 89 inch Ibs. (10 Nm) starting from the center and working outward Throttle body to the intake manifold and torque the bolts to 19 ft. Ibs. (25 Nm) Throttle cable bracket to the throttle

body studs

Lower Side 93062649

Intake manifold bolt torque sequence—2000-01 1.9L DOHC engine

EVAP canister purge solenoid vacuum hose PCV valve hose Brake booster vacuum hose Fuel rail to the manifold and torque the nut to 36 inch Ibs. (4.5 Nm) Fuel supply line to the rail and torque the bolt to 36 inch Ibs. (4 Nm) Power steering pump and torque the bolts to 28 ft. Ibs. (38 Nm) Power steering pump brace and torque the bolt to 22 ft. Ibs. (30 Nm) Accessory drive belt Transmission mount-to-frame rail and torque the bolts to 52 ft. Ibs. (70 Nm) Engine mount-to-midrail nuts and torque them to 37 ft. Ibs. (50 Nm) Air cleaner box and torque the bolts to 89 inch Ibs. (10 Nm)

Resonator IAT sensor electrical connector Throttle cable to the throttle body and support bracket and torque the

bolts to 19 ft. Ibs. (25 Nm) Intake manifold brace and torque the bolts to 58 inch Ibs. (6.5 Nm) Negative battery cable 6. Fill the cooling system. 7. Prime the fuel system by cycling the ignition ON for 5 seconds and OFF for 10 seconds a few times without cranking the engine. 8. Start the engine, check for leaks, and repair if necessary. 2.2L Engine

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following;

Oil level indicator tube and torque the fastener to 89 inch Ibs. (10 Nm) ¢ Brake booster vacuum pipe Throttle cable to the throttle body and install the support bracket. Torque the bolts to 19 ft. Ibs. (25 Nm) EVAP canister purge solenoid vacuum hose Fuel pressure regulator vacuum pipe to the throttle body IAC valve electrical connector TPS sensor electrical connector MAP sensor electrical connector Air inlet hose to the throttle body Crankcase vent hose to the camshaft cover IAT sensor electrical connector Air cleaner assembly Negative battery cable 4. Start the engine, check for leaks, and repair if necessary. 3.0L Engine

1. Before servicing the vehicle, refer to the precautions in the beginning of this section.

LW * SC1° SC2¢SL°SL1¢SL2° Seas 2. Properly relieve the fuel system presSure. 3. Remove or disconnect the following: e Negative battery cable e Air cleaner assembly e Throttle body electrical connector ¢ Fuel pressure regulator vacuum hose Both intake runners Intake plenum Fuel supply and return lines Fuel injector electrical connectors Fuel rail Intake manifold Intake manifold spacer and O-ring gaskets To install: 4. Install or connect the following: e Intake manifold spacer with new seals and torque the bolts to 15 ft. Ibs. (20 Nm) starting from the center and working outward Intake manifold with a new gasket and torque the bolts to 15 ft. Ibs. (20 Nm) Fuel rail Fuel injector electrical connectors Fuel supply and return hoses and torque the fastener to 11 ft. Ibs. (15

Nm) Intake plenum and torque the bolts to 71 inch Ibs. (8 Nm) Intake manifold runners and torque the bolts to 71 inch Ibs. (8 Nm) Negative battery cable 5. Prime the fuel system by cycling the ignition ON for 5 seconds and OFF for 10 seconds a few times without cranking the

¢ Exhaust manifold with a new gasket and torque the nuts in sequence to 16 ft. Ibs. (22 Nm) for the SOHC engine or to 150 inch Ibs. (17 Nm) for the DOHC engine

O2S sensor electrical connector

79222810

Exhaust manifold bolt torque sequence— 1.9L SOHC engines

A/C compressor and bracket and torque the front bracket-to-compressor to 40 ft. Ibs. (54 Nm) and all remaining fasteners to19 ft. Ibs. (25 Nm) Pipe-to-manifold with a new gasket and torque the fasteners ina . crosswise pattern to 23 ft. Ibs. (31 Nm) Exhaust pipe-to-engine support bracket and torque the mounting fasteners to 23 ft. Ibs. (31 Nm) e Negative battery cable 4. Start the vehicle and check for leaks, repair if necessary. 2.2L Engine

Lower Side 79227811

Exhaust manifold bolt torque sequence— 1.9L DOHC engines

the engine without removing the lines e Oxygen (02S) sensor electrical connector e Exhaust manifold To install: 3. Install or connect the following:

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Negative battery cable e Exhaust pipe from the manifold e Exhaust manifold heat shield e Oxygen (02S) sensor from the manifold e Exhaust manifold To install: 3. Install or connect the following: e Exhaust manifold with a new gasket and torque the bolts, starting from the center and working outward, to 13 ft. Ibs. (18 Nm)

engine. 6. Start the engine, check for leaks, and repair if necessary.

Exhaust Manifold ~ REMOVAL & INSTALLATION 1.9L Engines

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 9. Remove or disconnect the following: e Negative battery cable ¢ Front exhaust pipe-to-engine support bracket mounting fasteners e Pipe-to-manifold nuts and lower the pipe ¢ A/C compressor and bracket from

32-1 i)

Remove the exhaust manifold and gasket.

For Wheel Alignment specifications, see Section 1 of this manual

32-2

SATURN

LW ¢ SC1 ¢ SC2 ¢ SL

SL1 © SL2 © SW1 © SW2

e 02S sensor and torque it to 33 ft. lbs. (45 Nm) e Exhaust manifold heat shield and torque the bolts to 18 ft. Ibs. (25 Nm) e Exhaust pipe to the manifold with a new gasket and torque the nuts to 22 ft. Ibs. (30 Nm) e Negative battery cable 4. Start the vehicle and check for leaks, repair if necessary.

torque the bolt to 15 ft. Ibs. (20 Nm) 6. Lower the powertrain assembly. ¢ Front transmission mount through bolt and torque it to 41 ft. Ibs. (55 Nm) e Upper radiator hose e Negative battery cable 7. Fill the cooling system. 8. Start the vehicle and check for leaks, repair if necessary.

3.0L Engine

REAR MANIFOLD

FRONT MANIFOLD

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the cooling system. 3. Remove or disconnect the following: e Negative battery cable

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the cooling system. 3. Remove or disconnect the following: e Negative battery cable e Exhaust manifold Oxygen (02S) sensor e Upper radiator hose from the coolant extension housing 4. Install and engine support fixture. Front transmission through bolt and raise the powertrain assembly Oil level indicator tube and coolant extension tube bolt Coolant extension housing Power steering pipe bracket bolt Upper exhaust manifold nuts Front exhaust manifold pipe from the manifold Font exhaust manifold pipe from the rear exhaust manifold pipe Oil filter housing Lower exhaust manifold nuts Exhaust manifold To install: 5. Install or connect the following: Exhaust manifold with a new gasket and torque the bolts to 15 ft. Ibs. (20 Nm) Oil filter housing and torque the filter cartridge to 33 ft. Ibs. (45 Nm) Front exhaust manifold pipe and gaskets, do not tighten the bolts Front exhaust pipe to the rear exhaust pipe and torque the bolts to 15 ft. Ibs. (20 Nm) Front manifold pipe and torque the bolts to 15 ft. Ibs. (20 Nm Sr Front exhaust manifold 02S sensor and torque it to 73 ft. Ibs. (45 Nm) Power steering pipe bracket and torque the bolt to 71 inch Ibs. (8 Nm) New O-rings to the coolant extension housing Coolant extension housing and

e Oxygen (02S) sensor e Exhaust Gas Recirculation (EGR) pipe e Exhaust manifold pipe heat shield e Rear exhaust manifold pipe e Exhaust manifold To install: 4. Install or connect the following: Exhaust manifold with a new gasket and torque the bolts to 15 ft. Ibs. (20 Nm) Rear exhaust manifold pipe and torque the nuts to 25 ft. Ibs. (30 Nm) Front exhaust manifold pipe to the rear exhaust manifold pipe and torque the bolts to 15 ft. Ibs. (20 Nm) Rear exhaust manifold pipe to the resonator and torque the bolts to 15 ft. Ibs. (20 Nm) EGR pipe and torque the fasteners to 19 ft. Ibs. (25 Nm) O2S and torque it to 37 ft. Ibs. (50 Nm) Exhaust manifold heat shield and torque the bolts to 71 inch Ibs. (8 Nm) Negative battery cable 5. Start the vehicle and check for leaks, repair if necessary.

Front Crankshaft Seal

,

REPLACEMENT On the 1.9L and 2.2L engines the front crankshaft seal is located in thettiming chain front cover. Referto the timing chain procedure for information about removing the front cover and replacing the seal.

3.0L Engine

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Negative battery cable e Timing belt e Crankshaft gear 3. Drill a small pilot hole into the steel ring of the seal. 4. Screw ina Self taping screw. 5. Use pliers to pull out the oil seal.

To install:

6. Coat the lip of the new oil seal with engine oil. 7. Install the oil seal using a suitable seal installer. 8. Install the crankshaft gear and torque the bolt to 184 ft. Ibs. (250 Nm) plus an additional 45 degrees then another 15 degrees. 9. Install the timing belt. Camshaft and Lifters

REMOVAL & INSTALLATION 1.9L (SOHC) Engines 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Both battery cables Battery and tray Timing chain front cover Timing chain and camshaft sprocket Rocker arm/shaft assemblies Lifters and label or position them for assembly in their original locations 3. Drive the camshaft plug inward, then remove it from the cylinder head with a magnet. 4. Carefully pull the camshaft from the rear of the cylinder head through the oversized camshaft plug hole. Turn the camshaft back and forth slowly while withdrawing to help prevent journal or bearing damage. To install: 5. Clean and inspect all parts prior to installation. Lubricate the camshaft and carefully insert it through the hole at the rear of the cylinder head. 6. Install or connect the following; e New rear cylinder head plug coated with Loctite® 242 ¢ Valve lifters into their original bores, or if the camshaft has been replaced, install new lifters

LW * SC1 * SC2* SL SL1¢SL2¢ sWie SW? 32-21 8. Secure the support fixture using % in. bolts/blocks and align the 2 holes in each camshaft sprocket, adapter and the front support fixture. Install the 4 nuts, but do not tighten. >The steel blocks should be installed against the rearward side of the camshaft sprocket.

93462617

Remove the rocker arm/shaft assemblies

Rocker arm/shaft assemblies Timing chain and camshaft sprocket Timing chain front cover Battery and tray and torque the battery hold-down nut and screw to 80 inch Ibs. (9 Nm) Both battery cables 7. Start the engine and check for leaks, repair if necessary.

5. Position a front angled support fixture in front of the camshaft sprockets. 6. Attach the camshaft sprocket adapters to the end of each camshaft using the pilot bolts, but do not tighten the bolts. The front angled support should come between the sprocket adapters and camshaft sprockets. 7. Remove or disconnect the follow-

ing:

1.9L (DOHC) Engines ->Be careful when working around the camshaft sprockets and timing chain cover during this procedure. If a bolt or washer is accidentally dropped between the front cover and engine assembly, the cover will have to be removed for retrieval.

e Upper timing chain guide e Both front camshaft bearing caps

9. Tighten the sprocket pilot bolts to 19 ft. Ibs. (25 Nm) while holding the camshafts from turning with an open end wrench. 10. Move each camshaft sprocket off the end of the camshaft by rocking the sprocket forward or by carefully prying between the end of the camshaft and the sprocket. Then, tighten the 4 nuts and bolts with blocks from the side of the support fixture to 19 ft. lbs. (25 Nm). 11. Install the 2 bolts retaining the support fixture to the engine front cover and tighten the bolts to 89 inch Ibs. (10 Nm). Then, remove each camshaft sprocket pilot bolt while holding the camshafts with a wrench. 12. Carefully pry between the sprocket and the end of the camshaft to move the camshaft rearward. Pry only enough to

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Negative battery cable e Accessory drive belt e Spark plug wires e Positive Crankcase Ventilation (PCV) fresh air hose e Cam cover 3. Turn the crankshaft clockwise until the mark on the crankshaft pulley is in alignment with the pointer on the front cover and the No. 1 cylinder is at Top Dead Center

(TDC) of the compression stroke. Both camshaft dowel pins will be at the 12 o'clock position and the timing pin holes will be aligned when the No. 1 cylinder is at TDC. If necessary, the right wheel and splash shield can be removed to help observe the timing marks. 4. Remove the camshaft sprocket retaining bolts. Use a 7% in. (21mm) openend wrench to hold the camshaft from turning while removing the bolts.

Install the camshaft support fixture to securely hold the camshafts in position—1.9L (DOHC) engines

For Maintenance Interval recommendations, see Section 1 of this manual

32-2

SATURN

LW e SC1 © SC2 SL # SL1 © SL2 © SW1 © SW2

a

remove its end from inside the sprocket pilot otherwise camshaft or lifter damage may occu. 13. Remove or disconnect the following: e Uniformly loosen and remove the remaining camshaft bearing cap bolts. To prevent bolt/cap damage, do not use power tools and make several passes. Camshafts Pull the lifters out to remove them, always place them in the order in which they were removed and with the camshaft side facing down. Oil will drain out of the lifter if it is placed valve side down. To install: 14. Clean and inspect all parts prior to installation. Oil the camshaft and install with the IN camshaft on the intake side and EX camshaft on the exhaust side. >The dowel pin in each camshaft must be located at the 12 o'clock position during installation to prevent valve and piston damage.

15. Install or connect the following: e Lifters in their original locations e Bearing caps, except for the forward pair, in their original positions, making sure the arrows on the caps are pointing forward toward the camshaft sprockets. Lightly oil each of the cap bolts, then install and uniformly torque the bolts to 124 inch Ibs. (14 Nm). Camshaft sprocket pilot bolt in each camshaft and torque the bolts to 124 inch Ibs. (14 Nm) in order to pull the camshaft fully forward and align the sprocket support for installation of the sprocket onto the camshaft 16. Remove the 4 sprocket support bolt/blocks and nuts. 17. Install the forward bearing caps and the upper chain guide. Torque the cap bolts to 124 inch Ibs. (14 Nm). 18. Be sure the camshaft dowel pin aligns with the slot in each camshaft sprocket. Ifnecessary, rotate the camshaft slightly (1-2 degrees) and move each sprocket from the adapter onto the end of the camshaft. Fully seat each sprocket on the end of each camshaft. 19. Remove the 2 sprocket pilot bolts and adapters while using a wrench on the camshaft flats to assure the camshaft cannot move. 20. Remove the support angle fixture. 21. Install the camshaft sprocket retaining bolts and washers. Hold the camshafts and torque the bolts to 76 ft. Ibs. (103 Nm).

22. Verify all visible timing marks and holes are in alignment. Turn the crankshaft clockwise until the mark on the crankshaft pulley aligns with the mark on the front cover. Check timing by inserting %e in. drill bits through the camshaft sprocket alignment holes, into the cylinder head. If the alignment pins cannot be inserted, turn the crankshaft 360 degrees clockwise and repeat. If the pins cannot be inserted within 1-2 degrees of either TDC position, the camshafts are not properly timed. Do not Start the engine until the camshafts are timed. 23. Apply a small drop of RTV across the cylinder head and front cover T-joints. Inspect the old camshaft cover gasket and replace if damaged. Install the gasket and the camshaft cover. Torque the fasteners in proper sequence to 89 inch Ibs. (10 Nm). 24. Install or connect the following: Right splash shield and wheel, if removed to observe the timing marks PCV and fresh air hoses and the spark plug wires Accessory drive belt Negative battery cable 25. Start the engine and check for leaks, repair if necessary.

79222813

Hold the camshaft with a wrench while tightening the sprocket bolis—1.9L (DOHC) engine shown

Intake Side

Cris

e9

11 Exhaust Side 79222817

Camshaft cover bolt tightening sequence—1.9L DOHC engines

2.2L Engine ->Be very careful when working around the camshaft sprockets and timing chain cover during this procedure. Ifa bolt or washer is accidentally dropped between the front cover and engine assembly, the cover will have to be removed for retrieval.

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Negative battery cable Ignition coil Ground strap Positive Crankcase Ventilation (PCV) fresh air hose Cam cover Fuel line Wire harness bracket Power steering pump without removing the lines >To avoid valve piston contact, the No. 1 cylinder piston must be positioned at 60 degrees Before Top Dead Center (BTDC). The pistons are properly aligned when the diamond shaped hole on the intake camshaft sprocket is located at 12 o’clock.

3. Remove the upper timing chain guide and front camshaft caps. 4. Install a camshaft sprocket holding tool through the sprocket holes from the timing chain side. Align the guide pins into the slot on the support head. Torque the pins to 89 inch Ibs. (10 Nm). 5. Hold each camshaft in place with a 24mm open end wrench and remove the camshaft timing sprocket retaining bolts and washers. Discard the bolts. 6. Uniformly loosen and remove the remaining camshaft bearing caps. 7. Slide the camshaft sprockets away from the camshafts and remove the camshaft. To install: 8. Lubricate the camshaft bearing journals with clean engine oil. 9. Install both camshafts and all bearing caps except the front cap on each camshaft. 10. Torque the bearing caps uniformly, except for the front caps and the rear intake Cap, to 89 inch Ibs. (10 Nm). e>Make certain that the alignment notches are properly positioned with the notches in the camshaft sprockets before final torque is applied. Also, be sure that the timing chain is properly aligned on the fixed guide.

LW ¢ SC1°SC2°SL°SL1¢SL2¢ te

32-23

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Negative battery cable Intake plenum Air cleaner assembly Camshaft cover Front timing belt cover Timing belt ->Rotate the crankshaft counterclockwise to 60 degrees Before Top Dead — Center (BTDC) to prevent valve to piston contact. ~

93462618

Remove the camshaft and bearing caps—2.2L engine

11. Slide the camshaft sprockets and timing chain on the guide pins toward the camshafts. Rotate the camshafts with a 24mm open end wrench to align the camshaft and sprocket. 12. Install new camshaft sprocket bolts and torque them to 63 ft. Ibs. (85 Nm) plus 30 degrees. 13. Remove the camshaft sprocket holding tool. 14. Install or connect the following: Front camshaft bearing caps and torque the bolts to 89 inch Ibs. (10 Nm) Upper timing chain guide and apply Loctite® to the bolts Rear intake camshaft bearing cap and torque the bolts 19 ft. Ibs. (25 Nm) Power steering pump and torque the bolts to 19 ft. Ibs. (25 Nm) Ignition coil PCV fresh air hose Ground strap Fuel line Wire harness bracket Cam cover Negative battery cable 15. Start the vehicle and check for leaks, repair if necessary.

rear cylinder head bearing caps are marked Li-L8. ->Be very careful when working around the camshaft sprockets and timing chain cover during this procedure. If a bolt or washer is accidentally dropped between the front cover and engine assembly, the cover will have to be removed for retrieval.

3. Install a Camshaft Gear Locking Tool into the camshaft gears. 4. Remove or disconnect the following: Loosen the camshaft gear bolt, remove the holding tool Camshaft gear bolt and discard it Camshaft gear Loosen the camshaft bearing caps sequentially starting in the center and working outward in a spiral direction Camshaft bearing caps Camshatt To install: 5. Lubricate all bearing surfaces with clean engine oil. 6. Install or connect the following:

3.0L Engine

This engine is equipped with front and rear camshafts. The front camshaft bearing caps for the cylinder head are marked R1—R8 and the

93062650

Front camshaft bearing cap removal sequence-3.0L engine

For Tune-up, Capacities and Firing orders, see Section 1 of this manual

32-2

SATURN

LW ¢ SC1 © SC2 © SL

SL1 © SL2 ¢ SW1 © SW2

93062G53

Starter assembly removal—-1.9L and 2.2L engines 5

R1

R2

R3

R4 93062651

Front camshaft bearing cap installation sequence—-3.0L engine

Camshaft to the cylinder head and make sure that the pin on the exhaust camshaft is in the 12 o'clock position or that the pin on the intake camshaft is in the 7 o'clock position Camshaft bearing caps in their proper position and torque the bolts, starting in the center and working outward, to 71 inch Ibs. (8 Nm) New camshaft seal lubricated with clean engine oil Camshaft gear with a new bolt and torque the bolt to 27 ft. Ibs. (50 Nm) plus 60 degrees and an additional 15 degrees Timing belt and adjust as needed Timing belt cover Camshaft cover Intake plenum Air cleaner assembly Negative battery cable

2. Remove or disconnect the follow-

ng: e Negative battery cable -» Spray the starter solenoid electrical connectors with penetrating oil before removal.

e Starter electrical connections e Starter bolts

e Starter assembly by pulling it toward the left side of the vehi-

cle To install: 3. Install or connect the following:

¢ Starter to the flywheel housing and torque the bolts to 27 ft. Ibs. (37 Nm) e Starter electrical connectors and torque the solenoid ignition wire to 44 inch Ibs. (5 Nm) and the positive battery cable to 89 inch Ibs. (10 Nm) e Negative battery cable 3.0L Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Negative battery cable e Right front wheel e Starter electrical connections e Loosen the fastener securing the electrical harness bracket to the engine

Valve Lash

ADJUSTMENT All engines utilize hydraulic lash adjusters; no adjustment is necessary.

Starter Motor REMOVAL & INSTALLATION 1.9L and 2.2L Engines 1. Before servicing the vehicle, refer to the precautions in the beginning of this section.

93462619

Starter motor mounting-3.0L engine

LW ¢SC1°SC2°SLeSL1¢SL2¢ Ryitaste 32-25 Starter bolts

the pipe to converter bolts to.33 ft. lbs. (45 Nm) ¢ Negative battery cable 9. Fill the engine with clean oil. 10. Start the vehicle and check for leaks, repair if necessary.

° Starter assembly by pulling it toward the left side of the vehicle To install: 3. Install or connect the following: * Starter to the flywheel housing and torque the bolts to 30 ft. Ibs. (40 Nm) e Starter electrical connections and tighten the electrical harness bracket bolt ¢ Right front wheel ¢ Negative battery cable

2.2L Engine

REMOVAL & INSTALLATION 1.9L Engines 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the oil from the engine. 3. Remove or disconnect the following: e Negative battery cable e Front exhaust pipe e Front stiffening bracket e Flywheel cover e Right front wheel e Wheel well splash shield 4. Loosen the 4 front motor mount bolts approximately ¥ in. (12mm). e Oil pan bolts

79222814

Apply a 0.16 in (4mm) bead of RTV to the oil pan flange to the inner side of the bolt holes—1.9L engines

e Engine stiffening bracket e Flywheel cover e Exhaust pipe and torque the pipeto-manifold nuts in a crosswise pattern to 23 ft. Ibs. (81 Nm) and

elf equipped with a manual transaxle, an 8mm flex socket may be used to access the rear oil pan bolts located next to the flywheel.

5. Using an RTV cutter tool, separate the oil pan from the engine. Drive the tool around the pan to shear the RTV seam, then tap the pan sideways with a rubber mallet to loosen. 6. Pry the engine mount away from the engine as necessary and remove the oil pan. Be careful not to damage or score component surfaces when prying. To install: 7. Apply a 0.16 in. (4mm) bead of RTV sealer to the pan flange. Be sure the RTV Is applied to the inner side of the flange from the bolt holes. 8. Install or connect the following: ¢ (il pan and torque the bolts to 80 inch Ibs. (9 Nm) e Front engine mount bolts and torque them to 37 ft. Ibs. (50 Nm) e Right splash shield and wheel

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the engine oil. 3. Remove or disconnect the following: e Negative battery cable e Oil pan bolts 4. Using a flat blade tool, pry the oil pan from the engine block. To install: 5. Apply a 0.16 in. (4mm) bead of RTV Sealer to the pan flange. Be sure the RTV is applied to the inner side of the flange. 6. Install or connect the following: e Qil pan and torque the bolts in the proper sequence to 18 ft. Ibs. (25 Nm) e Negative battery cable 7. Fill the engine with clean oil. 8. Start the vehicle and check for leaks, repair if necessary.

3.0L Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the engine oil.

@ 1

8

2

)

15

13 10

2

7

11 93062652

Oil pan bolts torque sequence-2.2L engine

For complete service labor times, order Nichols’ Chilton Labor Guide

32-2

SATURN

LW ¢ SC1 ¢ SC2 ¢ SL® SL1 ¢ SL2 e SW1 © SW2 2. Drain the engine oil. 3. Remove or disconnect the following: Negative battery cable Right front wheel and splash shield Accessory drive belt Front crankshaft vibration damper/pulley Drive belt idler pulley Power steering pump, SOHC only Belt tensioner Camshaft cover, DOHC only Right side engine mount to front cover nuts and the engine mount to

midrail bracket nuts. Front 4 oil pan bolts Front cover bolts Drive rotor and driven rotor 4. \f necessary, remove the relief valve. Because the puller jaws will damage the relief valve sealing seat, the valve cannot be used again when removed. To install: 5. Install or connect the following: e New relief valve into the cover bore, if removed. Coat the valve with clean engine oil and tap it into the bore.

9346Z2G20

Oil pan and related components—3.0L engine

3. Remove or disconnect the following: e Negative battery cable e Nose cone bracket bolts from the oil pan ¢ Lower transmission flange-to-oil pan bolts e Qil pan bolts e» Separate the oil pan from the engine with an RTV cutter tool. Drive the tool around the pan to shear the RTV seam, then tap the pan sideways with a rubber mallet to loosen.

e Oil pan To install: 4. Apply a 0.10 in. (2mm) bead of RTV sealer to the pan flange. Be sure the RTV is applied to the inner side of the flange. 9. Install or connect the following; ¢ Oil pan and torque the bolts in the proper sequence to 11 ft. Ibs. (15 Nm) e Transmission nose cone bolts and torque them to 11 ft. Ibs. (15 Nm) ¢ Transmission-to-oil pan bolts and torque them to 11 ft. Ibs. (15 Nm) 6. Connect the negative battery cable. 7. Fill the engine with clean oil. 8. Start the vehicle and check for leaks, repair if necessary.

REMOVAL & INSTALLATION 1.9L Engines 1. Before servicing the vehicle, refer to the precautions in the beginning of this section.

o> Whenever the oil pump is installed, the assembly must be packed with petroleum jelly in order to prime the pump.

e Drive and driven rotors into the pump with the chamfer toward the front oil seal ¢ Qil pump body cover using new bolts and torque them to 97 inch lbs. (11 Nm) e New oil pressure and suction seals in the cylinder block ¢ Front oil pan bolts and torque them to 80 inch Ibs. (9 Nm)

93462621

Oil pump drive rotor and driven rotor

LW e-SC1 ° SC2°SL*SL1°SL2¢ Biase 32-21 Front cover and torque the perimeter and center bolts to 19 ft. Ibs. (25 Nm) and the lower center bolt to 89 inch Ibs. (10 Nm) Front oil pan bolts and torque them to 80 inch lbs. (9 Nm) Camshaft cover Drive belt tensioner and torque the fasteners to 26 ft. Ibs. (35 Nm) Power steering pump, if removed Drive belt and torque the pulley bolts to 33 ft. Ibs. (45 Nm)

e Right front wheel and splash shield e Accessory drive belt e Crankshaft damper pulley e Belt tensioner 4. Install an engine support fixture. e Right front engine mount e Front cover bolts and the 13mm bolt under the water pump e Front cover e Oil pump cover plate e Drive rotor and driven rotor e Pressure relief valve To install: 5. Install or connect the following:

Engine mount to midrail bracket nuts first and the engine mount to front cover nuts last and torque all nuts to 37 ft. Ibs. (50 Nm) Right front splash shield and wheel e Negative battery cable 6. Fill the engine with clean oil and replace the oil filter. 7. Start the vehicle and check for leaks, repair if necessary.

e New relief valve into the cover bore,

if removed. Coat the valve with clean engine oil and tap it into the bore. Torque the plug to 30 ft. Ibs. (40 Nm). =>Whenever the oil pump is installed, the assembly must be packed with petroleum jelly in order to prime the pump.

2.2L Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the engine oil. 3. Remove or disconnect the following: ¢ Negative battery cable e Air cleaner assembly

e Drive and driven rotors into the pump with the chamfer toward the front oil seal ¢ Oil pump body cover using new bolts and torque the bolts to 53 inch Ibs. (6 Nm) ¢ Front cover with a new oil seal and torque the perimeter and center bolts to 19 ft. Ibs. (25 Nm) and the

lower center bolt to 89 inch Ibs. (10 Nm) e Right side engine mount and torque the bolts to 41 ft. Ibs. (55 Nm) 6. Remove the engine support fixture. Drive belt tensioner and torque the bolts 37 ft. Ibs. (650 Nm) Crankshaft damper pulley and torque the bolt to 74 ft. Ibs. (100 Nm) plus 75 degrees Accessory drive belt Right front splash shield and wheel Air cleaner assembly Negative battery cable 7. Fill the engine with clean oil and replace the oil filter. 8. Start the vehicle and check for leaks, repair if necessary. 3.0L Engine 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the engine oil. 3. Drain the cooling system. 4. Remove or disconnect the followinGise nie Negative battery cable Air cleaner assembly Front timing belt cover Timing belt Rear timing belt cover

A/C compressor and power steering pump bracket and move them away from the oil pump housing Alternator bolts and move the alternator out of the way e Oil pan 5. Mount a crank hub holding tool to the crankshaft drive gear and remove the drive gear. ¢ Oil pump bolts e Oil pan housing bolts that thread into the oil pump e Oil pump e Front main oil seal and collar Pressure relief valve Oil pump cover ¢ Drive rotor and driven rotor To install: 6. Install the new relief valve into the

cover bore (if removed) and torque the plug to 30 ft. Ibs. (40 Nm). 93462622

engine Front cover and oil pump assembly—-2.2L

=>\Whenever the oil pump is installed, the new gasket must be coated with a thin bead of sealing Loctite 518°.

om Please visit our web site at www.chiltonsonline.c

32-2

SATURN

LW e SC1 ¢ SC2 © SL

SL1 © SL2 © SW1 ¢ SW2 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the engine oil. 3. Disconnect the negative battery cable. 4 Remove the oil pan. 5. Use the prying tangs provided in the carrier to remove the seal with a small suitable pry bar and hammer. Be careful not to damage the crankshaft oil seal lip contact surface. To install:

6. Clean the carrier and crankshaft with

3,10 93062654

Oil pump bolt tightening sequence-3.0L engine

7. Install or connect the following: e Drive and driven rotors into the pump with the chamfer toward the front oil seal @ Oil pump body cover using new bolts and torque them to 89 inch bs. (10 Nm) Drive gear and torque the new bolt to 184 ft. Ibs. (250 Nm) plus 45 degrees then an additional 15 degrees Oil pan and torque the bolts to 11 ft. Ibs. (15 Nm) Alternator and torque the bolts to 30 =ft. Ibs. (40 Nm) A/C compressor and power steering pump bracket. Torque the bolts to 30 ft. Ibs. (40 Nm). Rear timing belt cover—Refer to section 4 for the timing belt procedure. Drive belt idler pulley—Refer to section 4 for the timing belt procedure. Timing belt Front cover with a new oil seal Air cleaner assembly Negative battery cable 8. Fill the engine with clean oil. An oil filter replacement is also recommended. 9. Fill the cooling system. 10. Start the vehicle and check for leaks, repair if necessary.

solvent and a rag to prevent seal lip damage during installation. Check for scores or damage to the sealing surfaces. 7. Apply a light coat of clean engine oil to the seal lip and the carrier inner diameter. 8. Install a new rear main seal, using a Seal Installer tool. 9. Install the oil pan. 10. Connect the negative battery cable. 11. Fill the engine with clean oil. 12. Start the vehicle and check for leaks, repair if necessary. 2.2L Engine

Rear Main Seal REMOVAL & INSTALLATION 1.9L Engines

The Single Over Head Camshaft (SOHC) and Dual Over Head Camshaft (DOHC) engines use a 1-piece round seal mounted in a seal carrier.

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: ¢ Negative battery cable e Transmission ¢ Clutch/pressure plate assembly, if equipped with a manual transmission e Flywheel

79227818

Exploded view of the rear main seal installation—1.9L engines

LW © SC1°SC2°SLeSL1°SL2¢ aru

32-29

93462623

Rear oil seal and installation tool

J42067-2.2L engine

e Rear main bearing seal by prying it from the engine ->Be careful not to damage or scratch the seal mounting surfaces.

To install: 3. Lubricate the new rear main bearing seal with engine oil. 4. \nstall or connect the following: e New rear main seal using a Rear Main Bearing Oil Seal Installer Too! J42067 until it is flush with the block e Flywheel e Clutch/pressure plate assembly, if equipped with a manual transmission e Transmission e Negative battery cable 5. Start the engine and check for leaks, repair if necessary. 3.0L Engine

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 9. Remove or disconnect the following: e Negative battery cable e Transmission + Clutch/pressure plate assembly, if equipped with a manual transmission ¢ Flywheel 3. Center punch the steel ring of the oil Seal. 4. Drill a small hole into the steel ring. 5 Install a self-tapping screw and using pliers, pull out the rear main oil seal. «Be careful not to damage or scratch the seal mounting surfaces.

93462624

Rear main oil seal and installation tool J42067-3.0L engine

To install: ids 6. Lubricate the new rear main oil seal with engine oil. 7. Install or connect the following: e New rear main seal using a Rear Main Bearing Oil Seal Installer Tool SA9121E until it is flush with the block e Flywheel e Clutch/pressure plate assembly, if equipped with a manual transmission e Transmission e Negative battery cable 8. Start the engine and check for leaks, repair if necessary.

Timing Chain, Sprockets, Front: Cover and Seal REMOVAL & INSTALLATION eS

1.9L SOHC Engines

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the engine oil. 3. Remove or disconnect the following: e Negative battery cable e Right front wheel and splash shield

e»Place a1 in. X 1 in. X 2 in. long block of wood between the torque strut and cradle to ease removal and instaliation of the torque engine mount.

¢ 3 right side upper engine torque axis-to-front cover nuts and the 2 mount to midrail bracket nuts, allowing the powertrain to rest on the block of wood Drive belt, tensioner and pulley Power steering pump attaching bolts and set the pump to the side with the lines still attached A/C compressor from the bracket and set aside with the lines attached Camshaft cover Crankshaft damper/pulley assembly from the crankshaft 4. Install the special oil seal replacement tool SA9104E, to be sure the front crankshaft timing sprocket is held firmly in place and prevent guide damage. Install with the flat side towards the crankshaft sprocket. 5. Remove or disconnect the following: e Front 4 oil pan bolts and cut the seal away from the front cover ¢ Front cover bolts and carefully pry the cover away from the cylinder block

l Timing belt service is covered in Section 3 of this manua

32-3

SATURN

LW ¢ SC1 ¢ SC2 ¢ SL@ SL1 @ SL2 © SW1 ¢ SW2 guide first and verify the chain is Snug against the guide, then install the pivot guide. Torque the bolts to 19 ft. Ibs. (26 Nm) and verify that the pivot guide moves freely. e Timing chain tensioner and torque the

bolts to 14 ft. Ibs. (19 Nm)

79222819

Place a 1x 1x2

in. (25 x 25 x 51mm) piece of wood between the torque strut and cradle before removal of the torque engine mount—1.9L (SOHC) engines

¢ Front cover oil seal from the cover 6. Carefully rotate the crankshaft clockwise so the timing mark on the crankshaft sprocket and keyway align with the main bearing cap split line (90 degrees past Top Dead Center [TDC]). 7, Remove or disconnect the following: e¢ Timing chain guides and tensioner ¢ Camshaft sprocket bolt ¢ Timing chain and camshaft sprocket ¢ Crankshaft sprocket To install: 8. Inspect the chain for wear and damage. Check the inside diameter of the chain, it should be no more than 16.77 in. (426mm). Inspect the chain guides for wear or cracks and the timing sprockets for teeth or key wear. Replace components as necesSary. 9. Verify that the crankshaft keyway is positioned 90 degrees clockwise past TDC (keyway at 3 o'clock). The keyway should align with the split between the bearing cap and engine block. 10. Bring the camshaft up to No. 1 TDC by loosely installing the sprocket and rotating the sprocket until the timing pin can be inserted. The camshaft contains wrench flats {0 assist in turning the shaft. The dowel pin

should be at 12 o'clock when the camshaft is at TDC. 11. Install the crankshaft sprocket, then rotate the crankshaft counterclockwise 90 degrees up to No. 1 TDC (keyway at 12 o'clock). 12. Position the chain under the crankShaft sprocket and over the camshaft sprocket. The timing chain should be positioned so that 1 silver link plate aligns with the reference mark on the camshaft sprocket and the other aligns with the downward tooth (at the 6 o'clock position) on the crankshaft sprocket. The letters FRT on the camshaft sprocket must face forward, away from the cylinder head and excess chain Slack should be located on the tensioner Side of the block. 13. Install or connect the following: ¢ Timing pin to verify proper alignment of the camshaft and sprocket ¢ Camshaft sprocket and torque the sprocket bolt to 75 ft. Ibs. (102 Nm) e>Do not allow the camshaft retaining bolt to torque against the timing pin or cylinder head damage will result.

e Timing chain guides with the words FRONT facing out. Install the fixed

14. Make one final check to verify all components are properly timed, then remove all timing pins. 15. Install a new front cover oil seal using the installation tool with a press. 16. Apply a 0.08 in. (2mm) bead of RTV sealer along the vertical sealing surfaces of the front cover to the inside of the bolt holes and to the front of the oil pan. Extra sealer is necessary at the oil pan and cylinder head joints. Be sure to assemble the front cover to the engine within 3 minutes of RTV application. 17. Install or connect the following: ¢ Crankshaft sprocket retaining tool SA9104E, to align the oil pump and crankshaft during cover installation Front cover to the engine and torque the perimeter bolts starting at the center and working outwards on both sides to 19 ft. Ibs. (25 Nm) Front cover center or inner bolts and torque them to 89 inch Ibs. (10 Nm), except for the upper inside bolt, which should be tightened to 22 ft. Ibs. (30 Nm) Oil pan front bolts and torque them to 80 inch Ibs. (9 Nm) 18. After front cover installation, spray 6-12 squirts of oil through the front oil seal drain back hole to verify that it is not plugged. 19. Apply a thin film of RTV between the

79227820

Apply a 0.08 in. (2mm) bead of RTV sealer along the vertical sealing surfaces of the front cover—1.9L (SOHC) engines

LW © SC1¢SC2°SL*SL1¢SL2¢ SWiesi2 32-31 damper/pulley assembly flange and washer only; the washer and bolt head flange are designed to prevent oi! leakage. 20. Remove the crankshaft retaining tool SA9104E. 21. Install the crankshaft damper/pulley assembly and torque the bolt to 159 ft. Ibs. (215 Nm). 22. Apply a small drop of RTV across the

\G

79227822

At 90 degrees past TDC, the crankshaft sprocket keyway will align with the main bearing cap split line—1.9L (SOHC) engines

cylinder head and front cover T-joints. Inspect the old camshaft cover gasket and replace if damaged. Install the gasket and the camshaft cover and torque the fasteners uniformly to 22 ft. Ibs. (30 Nm). 23. Install or connect the following: e A/C compressor assembly and/or the power steering pump assembly e Drive belt idler pulley e Drive belt tensioner e Drive belt e Engine mount-to-midrail bracket nuts and torque them to 37 ft. Ibs. (50 Nm) ¢ 3 mount-to-front cover nuts and torque them uniformly to 37 ft. Ibs. (50 Nm) in order to prevent front cover damage e Splash shield and the wheel assembly e Negative battery cable 24. Fill the engine with clean oil. 25. Start the engine and check for leaks, repair if necessary.

79222823

No. 1 TDC—1.9L (SOHC) engines Insert a timing pin to ensure that the camshaft is at

aN 79227824

to achieve crankshaft counterclockwise 90 degrees When the camshaft is at TDC, rotate the TDC—1.9L (SOHC) engines

1.9L (DOHC) Engines 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. drain the engine oil. 3. Remove or disconnect the following: e Negative battery cable e Right front wheel and splash shield

e>Placea 1X 1X 2in. (25 X 25 X 51mm) block of wood between the torque strut and cradle to ease removal and installation of the torque engine mount.

¢ 3 right side upper engine torque axis-to-front cover nuts and the 2 rmount-to-midrail bracket nuts, allowing the powertrain to rest on the block of wood e Accessory drive belt e Drive belt tensioner and pulley e Power steering pump attaching bolts and set the pump to the side with the lines still attached e A/C compressor from the bracket and set it to the side with the lines attached e Camshaft cover e Crankshaft damper/pulley 4. Install an Oil Seal Replacement Tool SA9104E to be sure the front crankshaft timing sprocket is held firmly in place and prevent guide damage. Install with the flat side towards the crankshaft sprocket. e Front 4 oil pan bolts and cut the seal away from the front cover e Front cover bolts and carefully pry the cover away from the cylinder block e Front cover oil seal from the cover 5. Carefully rotate the crankshaft clockwise so the timing mark on the crankshaft sprocket and keyway align with the main bearing cap split line (90 degrees past Top Dead Center (TDC). e Timing guides and tensioner e Camshaft sprocket bolt e Timing chain and camshaft sprocket e Crankshaft sprocket To install: 6. Inspect the chain for wear and damage. Check the inside diameter of the chain, it should be no more than 23.15 in. (588mm). Inspect the chain guides for wear or cracks and the timing sprockets for teeth or key wear. Replace components as necessary. 7. Verify that the crankshaft keyway Is positioned 90 degrees clockwise past TDC

of this manual Heater Core replacement is covered in Section 2

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SATURN

LW ¢ SC1 ¢ SC2 @ SL @ SL1 ¢ SL2 © SW1 © SW2

(keyway at 3 o'clock). The keyway should align with the split between the bearing cap and engine block. 8. Install the crankshaft sprocket. 9. Rotate the crankshaft counterclockwise 90 degrees up to No. 1 TDC (keyway at 12 o'clock). 10. Position the chain under the crankshaft sprocket and over the camshaft sprocket. The timing chain should be positioned so that 1 silver link plate aligns with the reference mark on the camshaft sprocket and the other aligns with the downward tooth (at the 6 o’clock position) on the crankshaft sprocket. The letters FRT on the camshaft sprocket must face forward, away from the cylinder head and excess chain slack should be located on the tensioner side of the block. Torque the camshaft sprocket bolt to 75 ft. Ibs. (102 Nm). 11. Verify that the crankshaft reference mark aligns with the cylinder block mark at 12 o'clock. 12. Install or connect the following: e Timing chain fixed guide and torque the bolts to 21 ft. Ibs. (28 Nm) Pivoting chain guide and torque the bolt to 19 ft. Ibs. (26 Nm) and make certain the guide moves freely Two forward bearing caps and the upper timing chain guide and torque the retaining bolts to 124 inch lbs. (14 Nm) ¢ Timing chain tensioner and torque the bolts to 14 ft. Ibs. (19 Nm) 13. Make one final check to verify all components are properly timed, then remove all timing pins. e Seat a new front cover oil seal using the installation tool with a press

e lf the engine front cover casting or assembly is replaced, the 3 torque axis mount studs should also be replaced. Torque the new studs to 19 ft. Ibs. (25 Nm).

e>Apply a 0.08 in. (2mm) bead of RTV sealer along the vertical sealing surfaces of the front cover to the inside of the bolt holes and to the front of the oil pan. Extra sealer is necessary at the oil

fe

POOOONGS |. ps

C.K

a

— PN

Ne

79227825

Use drill bits as timing pins to verify that the camshafts are at TDC—1.9L (DOHC) engines

79222821

Apply a 0.08 in. (2mm) bead of RTV sealer along the vertical sealing surfaces of the front cover and the front of the oil

pan—1.9L (DOHC) engines

79227826

Be sure that the silver link plates and reference marks are all in alignment as shown—1.9L (DOHC) engines

LW ©SC1¢SC2°SL°SL1¢SL2¢ BNaesw2 32-39 ~ pan and cylinder head joints. Be sure to assemble the front cover to the engine within 3 minutes of RTV application.

e Crankshaft sprocket retaining tool to align the oil pump and crankshaft during cover installation Front cover to the engine and torque the perimeter bolts starting at the center and working outwards on both sides to 22 ft. Ibs. (30 Nm) Front cover center or inner bolts to 89 inch Ibs. (10 Nm) except for the upper inside bolt which should be tightened to 22 ft. Ibs. (30 Nm) 4 oil pan front bolts and torque them to 80 inch Ibs. (9 Nm) 14. After front cover installation, spray 6-12 squirts of oil through the front oil seal drain back hole to verify that it is not plugged. 15. Apply a thin film of RTV between the damper/pulley assembly flange and washer only; the washer and bolt head flange are designed to prevent oil leakage. 16. Position the crankshaft damper/pulley assembly, then secure using the wood or strap wrench (as accomplished during removal). Torque the bolt to 159 ft. Ibs. (215 Nm). 17. Apply a small drop of RTV across the cylinder head and front cover T-joints. Inspect the old camshaft cover gasket and replace if damaged. Install the gasket and the camshaft cover. Torque the fasteners uniformly to 89 inch Ibs. (10 Nm).

3. Remove or disconnect the following: Negative battery cable Front cover Camshaft cover Timing chain tensioner Upper timing chain guide Exhaust camshaft sprocket Adjustable timing chain guide Fixed timing chain guide access plug and guide Intake camshaft sprocket Timing chain through the top of the cylinder head Timing chain sprocket from the crankshaft Timing chain oiling nozzle To install: 4. Inspect the chain guides for wear and damage. Replace the guides if wear exceeds 0.045 inch (1.12mm). Inspect the timing chain shoe. Replace the shoe if wear exceeds 0.045 inch (1.12mm). 5. Install or connect the following: ¢ Timing chain sprocket to the crankshaft. Rotate the crankshaft so that the mark on the sprocket is at the 5 o'clock position. e Timing chain to the intake camshaft sprocket alignment copper link to

the “INT” diamond timing mark on the camshaft sprocket When lowering the timing chain, rotate the assembly 90 degrees to allow the chain to fall between the cylinder block bosses. Rotate the chain back so that the camshaft sprocket is facing forward.

Chain through the housing opening on top of the cylinder head. Make certain that the chain goes around both sides of the bosses Timing chain around the crankshaft sprocket and align the silver link to the timing mark Intake camshaft sprocket loosely on the camshaft and hand-tighten the new bolt Adjustable timing chain guide and torque the bolt to 89 inch Ibs. (10 Nm) Exhaust camshaft sprocket loosely on the camshaft with the timing mark on the sprocket aligned with the silver link on the chain and hand-tighten the new bolt at this time 6. Align the camshaft sprocket to

18. Remove the crankshaft retaining tool. 19. Install or connect the following: A/C compressor assembly and/or the power steering pump assembly Drive belt idler pulley Drive belt tensioner Accessory drive belt 2 engine mount-to-midrail bracket nuts and torque them to 37 ft. Ibs.

(50 Nm) 3 mount-to-front cover nuts and torque them uniformly to 37 ft. Ibs. (50 Nm) in order to prevent front cover damage

Splash shield and the wheel e Negative battery cable 90. Fill the engine with clean oil. 91. Start the engine and check for leaks, repair if necessary. 2.2L Engine

1. Before servicing the vehicle, refer to the precautions in the beginning of this seccots tion. 9. Drain the engine oil.

93062655

head-2.2L engine Remove the timing chain through the top of the cylinder

l Brake service is covered in Section 4 of this manua

39-34

SATURN LW ¢ SC1 © SC2 © SL @ SL1 @ SL2 © SW1 © SW2

camshaft and tighten the bolt using the following procedure: a. Make certain that the sprocket timing mark is at the 5 o'clock position. b. Rotate the intake camshaft using a 24mm wrench on flats of the camshaft until the sprocket to camshaft alignment notch seats. c. When Seated properly hand-tighten the bolt. d. Rotate the exhaust camshaft using a 24mm wrench on flats of the camshaft until the sprocket to camshaft alignment notch seats. e. When seated properly hand-tighten the bolt. ~ 7. Verify that all colored links are aligned with the proper marks on the camshaft and crankshaft sprockets. 8. Install or connect the following: e Fixed timing chain guide bolt-and torque it to 89 inch Ibs. (10 Nm) Fixed timing chain guide bolt access plug and torque it to 30 ft.

lbs. (40 Nm) Upper timing chain guide and torque the bolts to 89 inch Ibs. (10 Nm) Intake and exhaust camshaft sprocket bolts and torque them to 63 ft. Ibs. (85 Nm) plus 30 degrees Sealing ring and tensioner assembly and torque the tensioner bolts

ee Piston and connecting rod assembly positioning mark locations. The mark on the piston and rod bearing tang slots must

face the front of the engine—1.9L engines

93062677

Piston ring positioning—2.2L engine

to 44 ft. Ibs. (60 Nm) Timing chain oiling nozzle and torque the bolt to 89 inch Ibs. (10 Nm) Camshaft cover Front engine cover Negative battery cable 9. Fill the engine with clean oil. 10. Start the vehicle and check for leaks, repair if necessary.

4

Piston and Ring

POSITIONING

7922NG38 Both upper rings (DOHC) or the second ring (SOHC only) can be installed either way—1.9L engines

(1) (2) (3) (4)

Ist Compression 2nd Compression Oil Control Ring Oil Control Ring

(5) Oil Control

Ring End Gap Location Ring End Gap Location Upper Ring End Gap Location Spacer End Gap Location

Ring Lower Ring

E nd :

Piston ring positioning—3.0L engine

a

pe

LW © SC1*SC2°SLeSL1¢SL2¢ esi

32-35

_ FUEL SYSTEM cable. This will prevent the fuel pump from running and causing a fuel spill through the disconnected components if the ignition key is accidentally turned ON. 3. Remove the air cleaner assembly, for access. 4. Wrap a shop rag around the fuel test port fitting, located at the lower rear of the engine, then remove the cap and connect a fuel pressure gauge. 5. Install the bleed hose from the pressure gauge into an approved container and open the valve to bleed the system pressure. 6. After the pressure is bled, remove the gauge from the test port and recap it. 7. Install the air cleaner assembly. 8. After servicing the vehicle, connect the negative battery cable and prime the fuel system as follows: a. Turn the ignition ON for 5 seconds, then OFF for 10 seconds. b. Repeat the ON/OFF cycle 2 more times. c. Crank the engine until it starts. d. If the engine does not readily start, repeat sub-steps A-C. 9. Run the engine and check for leaks.

Fuel System Service Precautions Safety is the most important factor when performing not only fuel system maintenance but any type of maintenance. Failure to conduct maintenance and repairs in a Safe manner may result in serious personal injury or death. Maintenance and testing of the vehicle’s fuel system components can be accomplished safely and effectively by aula to the following rules and guideines, ¢ To avoid the possibility of fire and personal injury, always disconnect the negative battery cable unless the repair or test procedure requires that battery voltage be applied e Always relieve the fuel system pressure prior to disconnecting any fuel system component (injector, fuel rail, pressure regulator, etc.), fitting or fuel line connection. Exercise extreme caution whenever relieving fuel system pressure, to avoid exposing skin, face and eyes to fuel spray. Please be advised that fuel under pressure may penetrate the skin or any part of the body that it contacts e Always place a shop towel or cloth around the fitting or connection prior to loosening to absorb any excess fuel due to spillage. Ensure that all fuel spillage (should it occur) is quickly removed from engine surfaces. Ensure that all fuel soaked cloths or towels are deposited into a suitable waste container e Always keep a dry chemical (Class B) fire extinguisher near the work area ¢ Do not allow fuel spray or fuel vapors to come into contact with a spark or open flame e Always use a back-up wrench when loosening and tightening fuel line connection fittings. This will prevent unnecessary stress and torsion to fuel line piping e Always replace worn fuel fitting Orings with new. Do not substitute fuel hose or equivalent, where fuel pipe is installed

Fuel System Pressure

The fuel filter and fuel pressure regulator are one integral component of the new antireturn fuel injection system, and is located underneath the vehicle at the forward edge of the left side of the fuel tank.

REMOVAL & INSTALLATION 1.9L Engines

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Properly relieve the fuel system presSure. 3. Remove or disconnect the following: e Negative battery cable e Fuel filter/pressure regulator bracket screws e Fuel line bundle retaining clip on the left side of the fuel tank

Exercise extreme care when opening the retaining clip. The fuel lines must be retained in this clip; if damaged, the fuel tank assembly must be replaced, since the fitting is not serviced separately. e Evaporative Emissions (EVAP) purge line at the 90 degree quick connect fitting Outlet of the fuel filter/regulator from the support on the fuel tank bracket and remove the fuel feed line Fuel feed and return line quickconnect fittings on the fuel filter/regulator e Fuel filter

|

RELIEVING +. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Unless battery voltage is necessary for testing, disconnect the negative battery

with 2 holts-1.9L engines The fuel filter/regulator bracket is held to the frame

Section 1 of this manual For complete Engine Mechanical specifications, see

32-3

SATURN

LW ¢ SC1 ¢ SC2 e SL © SL1 © SL2 ¢ SW1 © SW2

»>It is not necessary to separate the fuel filter/regulator from the mounting bracket, since both items are serviced as an assembly.

To install: 4. Install or connect the following: e Fuel filter ¢ New fuel line retainers (3) into the female portion of the quick-connect fuel line fittings ¢ Fuel feed and return lines onto the fuel filter/regulator and snap them closed e Fuel feed, return, and EVAP purge lines into the fuel tank's retaining clip

Be sure to route the chassis fuel feed and purge lines above the parking brake cable. The parking brake cable must be firmly secured to the underbody to support the fuel and purge lines. ESSN

a REET

SET

TSR

TREE

e 90 degree EVAP purge line quickconnect fitting to the purge line and snap it closed Fuel feed outlet pipe of the fuel filter/regulator into the retaining clip on the fuel tank bracket Fuel filter/regulator bracket mounting screws and torque them to 71 inch Ibs. (8 Nm) ¢ Negative battery cable 5. Prime the fuel system as follows:

eee Wi

\

at

a. Turn the ignition ON for 5 seconds, then OFF for 10 seconds. b. Repeat the ON/OFF cycle 2 more times. c. Crank the engine until it starts. d. If it does not start, repeat the 3 above steps. 6. Start the engine and check for leaks, repair if necessary.

REMOVAL & INSTALLATION

2.2L And 3.0L Engines 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Properly relieve the fuel system presSure. 3. Remove or disconnect the following: ¢ Negative battery cable ¢ Fuel filter bracket screw ¢ Fuel feed and return lines from the filter ¢ Fuel filter from the bracket To install: 4. Install or connect the following: New fuel filter into the bracket New fuel line retainers to the female portion of the quick connect fittings Fuel feed and return lines Fuel filter bracket attaching screw and torque it to 35 inch Ibs. (4 Nm) Negative battery cable 5. Prime the fuel system as follows: a. Turn the ignition ON for 5 seconds, then OFF for 10 seconds. b. Repeat the ON/OFF cycle 2 more times.

ts

eS

(g)

c. Crank the engine until it starts. d. If it does not start, repeat the 3 above steps. 6. Start the engine and check for leaks, repair if necessary.

Ot

ae Oa

—To prevent bending of the sending unit float arm, lift the pump module up Slightly to disengage the orientation tabs in the tank. Rotate the module 90 degrees clockwise until the fuel lines are facing the 1 o'clock position.

¢ Fuel pump module from the fuel tank until the bottom of the pump module is close to the fuel tank opening ¢ Tilt the pump module approximately 45 degrees to the right hand Side of the tank and lift the pump from the fuel tank ¢ Fuel pump to tank seal and discard it To install: 4. Install or connect the following: ¢ Fuel pump module into the fuel tank by orientating the float to face the right side and tilting the module approximately 45 degrees ¢ Fuel pump into the tank and rotate the assembly 90 degrees counterClockwise to align the module tabs with the slots in the tank e>The fuel pump retaining ring cannot be properly installed if the flange loca-

SATURN LW @ SC1 © SC2 © SL © SLi ¢ SL2 © SW1 © SW2

32-3/

4. Install or connect the following: e Fuel pump feed line to the cover e Fuel pump electrical connector e Fuel pump to the new seal e Fuel pump cover lockring with Tool J-43827 ¢ Fuel lines and wiring harness e Fuel tank ¢ Negative battery cable 5. Start the vehicle and check for leaks, repair if necessary.

Fuel Injector

#

|

REMOVAL AND INSTALLATION EEUU

EE

1.9L Engines

93462625

Installing the fuel sending unit and float-1.9L engines

tor tabs are not aligned with the slots in the fuel tank.

e Retaining lockring with Tool SA9156E e Vapor line to the fuel tank vent pipe ¢ Fuel feed and return lines to the filter/pressure regulator e Fuel feed, return and EVAP canister purge line in the fuel tank retaining clip e Fuel tank e Negative battery cable 5. Start the vehicle and check for leaks, repair if necessary.

e Fuel pump tank seal and discard the seal e Fuel feed line from the bottom of the fuel pump cover with Clamp Pliers J43914 ¢ Fuel pump electrical connector

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Properly relieve the fuel system pressure. 3. Remove or disconnect the following: e Negative battery cable e Fuel rail e Fuel injector retaining clip off the ~ injector e Fuel injector e Fuel injector O-rings and discard them

2.2L and 3.0L Engines

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Properly relieve the fuel system pressure. 3 Remove or disconnect the following: Negative battery cable e Fuel tank e Fuel lines from the fuel pump module cover e Fuel pump module retaining ring with a Sending Unit Wrench,

J43827

Pull the retaining clip toward the float arm and lift up Fuel pump straight up from the fuel tank

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93062657

3.0L engines Remove the fuel pump cover lockring-2.2L and

on 1 of this manual For Accessory Drive Belt illustrations, seé Secti

32-3

SATURN

LW ¢ SC1 ¢ SC2 ¢ SL

SL1 @ SL2 © SW1 ¢ SW2 e Fuel injector to the fuel rail e Fuel rail e Negative battery cable 6. Start the vehicle and check for leaks, repair if necessary.

2.2L and 3.0L Engines

BLUE RING SOHC (L24) FUEL INJECTOR IDENTIFICATION

PINK RING DOHC (LLO) FUEL INJECTOR IDENTIFICATION 93062658

Fuel injector identification—1.9L engine

To install: |

The SOHC and DOHC fuel injectors are not interchangeable. The injectors are identified by a color coded plastic ring near the bottom of the injector. The SOHC injector has a blue ring near the O-ring that mates to the intake manifold and the DOHC has a pink ring.

4. Lubricate the new fuel injector O-ring with clean engine oil. 5. Install or connect the following: e New O-ring seals on the fuel injector e Retaining clip to the fuel injector

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Properly relieve the fuel system presSure. 3. Remove or disconnect the following: Negative battery cable Air intake tube Fuel pressure regulator hose Fuel feed line Throttle body Throttle control cable bracket Fuel injector electrical connectors Fuel rail Fuel injector retaining clip off the injector Fuel injector Fuel injector O-rings To install: 4. Lubricate the new fuel injector O-ring with clean engine oil. 5. Install or connect the following: e New O-ring seals on the fuel injector

x 93062659

Remove the retainer clip from the fuel injector—2.2L and 3.0L engines

Retaining clip to the fuel injector Fuel injector to the fuel rail Fuel rail and torque the bolts to 89 inch Ibs. (10 Nm) Fuel injector electrical connectors Throttle control cable bracket Throttle body and torque the bolts to 89 inch Ibs. (10 Nm) Fuel feed line Fuel pressure regulator hose Air intake tube Negative battery cable 6. Start the vehicle and check for leaks, repair if necessary.

DRIVE TRAIN Manual Transmission Assembly REMOVAL & INSTALLATION 1.9L Engines 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the transmission fluid. 3. Remove or disconnect the following: Both battery cables Air cleaner assembly Battery and tray Powertrain Control Module (PCM) J2 (black 28-way) harness connector. Do not disconnect the J1 (80way) connector. PCM attaching bolts and move it aside eee @ Transmission strut to midrail bracket fastener and loosen the strut to transmission fastener and move the strut aside Back-up lamp electrical connector Vehicle Speed Sensor (VSS) electrical connector, if equipped

Ground terminals from the clutch housing bolts Vent tube retaining clip Top 2 clutch housing to the engine bolts Spark plug wires from the coil towers Electronic ignition module electrical connectors Electronic ignition module Shifter cables from the arms and Clutch housing Clutch slave cylinder by rotating it Yaturn counterclockwise and pushing it into the housing 2 clutch hydraulic damper to housing fasteners and wire the actuator cylinder and damper to the upper radiator hose 4, Wire the radiator to the upper support. 9. Install an engine support bar and place the feet on athe outer edge of the shock tower. 6. Connect the bar hooks to the engine support bracke — 7. Position the stabilizer foot on the engine to the right of the dipstick tube. 8. Adjust the hooks and stabilizer to remove any looseness.

9. Remove’or disconnect the following: Both front wheels and inner splash shields Engine splash shield Engine strut cradle bracket fasteners Transmission mount-to-cradle fasteners Front exhaust pipe-to-manifold and catalytic converter fasteners Front exhaust pipe Steering gear to cradle fasteners Brake pipe bracket push pin Engine-to-transmission stiffening brace Dust cover Cotter pin from the lower ball joints Ball joint from the lower control arm with Separator Tool SA9132S Separate the left axle from the transmission and install an axle seal protector Separate the right axle from the intermediate shaft Intake bracket-to-intake manifold bolt on DOHC engines Intake bracket to intermediate shaft Support bolt

LW ® SC1 ¢ SC2 e SLe SL1¢SL2¢ nies

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Install an Engine Support too!

¢ Support bracket e Intermediate shaft from the transmission e 4cradle-to-body bolts and lower the cradle on a support dolly ¢ Bottom clutch housing bolts and install a guide bolt into the rear housing bolt hole 10. Separate the transmission from the engine. To install: 11. Place the transmission assembly securely onto a jack and position under the vehicle. Install axle seal protectors into seals on both sides. 12. Raise the transmission ‘nto the vehicle to align the input shaft to the center of the clutch. Rotate the transmission back and forth to align the input shaft splines to the clutch disc. 13. Install or connect the following: ° 2 lower clutch housing-to-engine bolts and torque them to 103 ft. lbs. (140 Nm) ¢ Axle Seal Protector tool to the inside seal and remove the transmission jack e Left side axle to the transmission. When the splines clear the seal protector, remove the tool.

e Intermediate shaft to the transmission

Intermediate shaft and torque the bolts to 40 ft. Ibs. (64 Nm) Starter bracket to the intermediate shaft and torque the bolts to 22 ft. lbs. (30 Nm) Intake manifold support bracket (on DOHC) and torque the bolts to 22 ft. bs. (30 Nm) Intake bracket to the intermediate shaft support and torque the bolt to 40 ft. Ibs. (64 Nm) e Right side axle to the intermediate shaft 14. Raise the cradle up on a support dolly and place the ball joints into the knuckles. Verify the correct positioning of the lower control arm bar studs to the knuckles, the cooling module support bushings, the engine strut bracket and the transaxle mount. 15. Insert %e in. round steel rods into the cradle-to-body alignment holes near the front cradle to body fastener holes. Guide the cradle into position making sure all mount studs are properly guided into their holes. 16. Be sure the washers are in place, then install the 2 rear cradle to body bolts. Verify proper cradle positioning and install the 2 front cradle bolts, then torque the 4 cradle bolts to 155 ft. Ibs. (210 Nm).

32-39

17. Remove the support dolly and lower the vehicle sufficiently for underhood access. Remove the engine support bar assembly. 18. Install or connect the following: Transmission strut-to-cradle bracket through-bolt and nut and torque them to 40 ft. Ibs. (64 Nm) Strut cradle bracket-to-cradle bolt and torque the it to 52 ft. Ibs. (70 Nm) Ignition module and torque the bolts to 71 inch Ibs. (8 Nm) 2 top transmission housing-toengine studs and torque them to 74 ft. Ibs. (100 Nm) VSS electrical connector Back-up lamp electrical connector Ground terminals to the clutch housing studs Vent hose clip to the housing Shifter cables to the shift arms and clutch housing Hydraulic clutch system to the clutch housing and torque the fasteners to 18 ft. Ibs. (25 Nm) Actuator to the clutch housing. Push in and rotate the actuator % _ turn

Battery tray and torque the bolts to 89 inch Ibs. (10 Nm) PCM and torque the bolts to 53 inch Ibs. (6 Nm) Connect the PCM J2 (28-way) harness Battery and hold down retainer and torque the fastener to 80 inch Ibs. (9 Nm) Air cleaner assembly Transmission lower mount-to-cradle fastener and torque it to 37 ft. lbs. (60 Nm) 2 engine strut cradle bracket-tocradle fasteners and torque them to 37 ft. Ibs. (50 Nm) Steering gear-to-cradle fasteners and torque them to 37 ft. Ibs. (50 Nm) Brake pipe-to-cradle retainer Dust cover and torque the bolts to 8 ft. Ibs. (11 Nm) Engine-to-transmission stiffening brace and torque the bolts to 40 ft. lbs. (64 Nm) Exhaust manifold pipe and torque the bolts to 23 ft. Ibs. (31 Nm) Intermediate exhaust pipe to the catalytic converter and torque the bolts to 18 ft. Ibs. (25 Nm)

Section 1 of this manual For Tire, Wheel and Ball Joint specifications, see

32-4

SATURN

LW ¢ SC1 ¢ SC2 © SL SL1 ¢ SL2 © SW1 © SW2

e Front exhaust pipe support to the stiffening bracket and torque the fasteners to 89 inch Ibs. (10 Nm) ¢ Both front wheels ¢ Both battery cables 19. Fill the transmission to the proper level. 20. Warm the engine and check the transmission fluid. Check and adjust vehicle alignment, as necessary.

2.2L and 3.0L Engines 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Drain the transmission fluid. 3. Remove or disconnect the following: ¢ Both battery cables ¢ Battery feed to the underhood fuse block Release the retaining tabs on the fuse block cover and remove it Engine 68-way electrical connector Forward lamp 68-way connector Forward lamp 2-way (white) connector Black, green and brown instrument panel 2-way connectors Fuse block from the case Engine, forward lamp and instrument panel harness from the fuse block case Case from the battery tray Battery tray and battery Loosen the pinch bolt securing the control assembly rod to the control shaft lever

transmission mount and remove the mount Frame assembly Front transmission mount Rear transmission mount Axle shafts from the transmission A/C line retaining clips and drop the A/C line down from the body 4. Lower the left side of the powertrain assembly to allow the transmission to clear the engine compartment rail. 5. Remove or disconnect the following: ¢ Left side transmission mount bracket ¢ Control shaft lever assembly pivot pin bracket 6. Properly support the powertrain assembly ¢ Remaining engine-to-transmission bolts e Transmission from the engine To install: 7. Raise the transmission into the vehicle and align the input shaft to the center of the clutch disc. 8. Install or connect the following: e Lower transmission to engine bolts and torque them to 48 ft. Ibs. (65 Nm) ¢ Control shaft lever assembly pivot pin bracket and torque the fastener

to 18 ft. Ibs. (24 Nm) e Axle shafts to the transmission.

After the splines clear the tool, remove the seal protector and snap the axle into place. 9. Remove the transmission fill plug, fill the transmission with 2 quarts of manual fluid and.install the plug. Torque the plug to 22 ft. Ibs. (30 Nm). 10. Install or connect the following: Left side transmission mount bracket and torque the bolts to 41 ft. Ibs. (65 Nm) A/C line against the body and install the retaining clips Rear transmission mount and torque the bolts to 41 ft. Ibs. (55 Nm) Front transmission mount and torque the bolts to 41 ft. Ibs. (65 Nm) Frame assembly Upper transmission to engine bolts and torque them to 48 ft. Ibs. (65 Nm) Left side transmission mount bolts using the matchmarks made during removal and torque them to 41 ft. Ibs. (65 Nm) Back-up lamp switch electrical connector Control shaft lever assembly onto the pivot pin brackets Retaining clips holding the contro! shaft lever to the transmission and frame brackets

e>The control shaft lever retaining pin has a spring loaded locking feature to keep the pin in place. The spring must be depressed before attempting to remove it.

¢ Pin retaining the control shaft lever to shift control shaft Retaining clips holding the control shaft lever to the transmission and frame brackets ¢ Control shaft lever Back-up lamp switch electrical connector ¢ Wire harness from the transmission Spring loaded locking pin from the hole on top of the transmission, if equipped ¢ Clutch hydraulic fitting from the transmission ¢ Upper transmission to engine bolts and install and engine support bar, SA9105E, and Adapter Kit J43405 Matchmark the position of the left

Remove the remaining engine to transmission bolts—2.2L and 3.0L engines

93062G62

32-41

LW e SC1 © SC2¢SL°SL1¢SL2° ene Pin to retain the control shaft lever to the shift control shaft Rotate the shift control shaft clockwise and install the shift linkage lock pin Move the shift lever to the Sth gear/reverse gate and install a% inch punch Pinch bolt securing the control assembly rod to the control shaft lever and torque it to 9 ft. Ibs. (12 Nm) plus 180 degrees Shift lever hole plug Clutch hydraulic fitting to the transmission and bleed the hydraulic system

Battery tray and torque the fasteners to 11 ft. Ibs. (15 Nm) Underhood fuse block to the battery tray and torque the fasteners to 80 inch Ibs. (9 Nm) Wire harness to the fuse case Snap the fuse block onto the hinges Engine 68-way connectors Forward lamp 68-way connectors Instrument panel 68-way connec-

2. Drain the transmission fluid. 3. Remove or disconnect the following: Both battery cables Air cleaner assembly Battery and tray Powertrain Control Module (PCM) J2 (black 28-way) harness connector. Do not disconnect the J1 (80way) connector. PCM attaching bolts and move aside Transmission strut to midrail bracket fastener and loosen the strut to transmission fastener and move the strut aside Transmission solenoid harness connector Vehicle speed and input sensor harness connectors Transmission fluid temperature sensor connector Range switch harness connector Ground terminals from the converter housing Ground wire from the range switch Spark plug wires from the coil towers

e Electronic ignition module electrical connectors e Electronic ignition module 4. Wire the radiator to the upper support. 5. Install an engine support bar and place the feet on the outer edge of the shock tower. 6. Connect the bar hooks to the engine support bracket. 7. Position the stabilizer foot on the engine to the right of the dipstick tube. 8. Adjust the hooks and stabilizer to remove any looseness. 9. Remove or disconnect the following: Both front wheels and inner splash shields e Engine splash shield Engine strut cradle bracket fasteners Transmission mount to cradle fasteners e Front exhaust pipe to manifold and catalytic converter fasteners Front exhaust pipe e Steering gear to cradle fasteners Brake pipe bracket push pin

tors

Forward 2-way (white) connector Black, green and brown 2-way connectors Snap the fuse block to the case Coolant hose to the fuse block Battery feed to the fuse block and torque the fastener to 12 inch IDs. (16 Nm) Battery tray and hold-down bracket and torque the fastener to 15 ft. Ibs. (20 Nm) Battery Fan control module to the battery hold down bracket e Both battery cables 11. Fill the transmission to the proper level. 42. Warm the engine and check the le transmission fluid. Check and adjust vehic sary. alignment, as Neces

——

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Automatic Transmission

Assembly

REMOVAL & INSTALLATION 93462626

1.9L Engines to +. Before servicing the vehicle, refer secthis of g nnin begi the the precautions in tion.

t bracket and the intermediate shaft-1.9L Remove the intak e-to-intermediate shaft suppor engines

ion 1 of this manual For Wheel Alignment specifications, seé Sect

32-4

SATURN

LW ¢ SC1 ¢ SC2 © SL ¢ SL1 © SL2 © SW1 © Sw2

Engine-to-transmission stiffening brace Dust cover Torque converter-to-flywheel bolts Ball joint from the lower control arm Separate the left axle from the transmission and install an axle seal protector Separate the right axle from the intermediate shaft Intake bracket-to-intake manifold bolt (on DOHC engines) Intake bracket-to-intermediate shaft

support bolt Support bracket Intermediate shaft from the transmission Transmission cooler lines 4 cradle to body bolts and lower the cradle on a support dolly Lower torque converter bolts Separate the transmission from the engine Shifter cable from the converter housing Transmission from the vehicle To install: 10. Flush the transmission oil cooler lines. 11. Place the transmission assembly securely onto a jack and position under the vehicle. Install axle seal protectors into seals on both sides. 12. Raise the transmission high enough to connect the shifter cable. 13. Install or connect the following: Shifter cable to the transmission gear selector lever and insert it in the converter housing 2 lower converter housing-toengine bolts and torque them to 96 ft. Ibs. (130 Nm) Axle Seal Protector tool to the inside seal and remove the transmission jack Left side axle to the transmission, When the splines clear the seal protector, remove the tool. Intermediate shaft to the transmission Intermediate shaft and torque the bolts to 40 ft. Ibs. (64 Nm) Intake manifold support bracket (on DOHC) and torque the bolts to 22 ft. Ibs. (30 Nm) Intake bracket to the intermediate shaft support and torque the bolt to 40 ft. Ibs. (54 Nm) Right side axle to the intermediate shaft Cooler lines to the transmission

14. Raise the cradle up on a support dolly and place the ball joints into the knuckles. Verify the correct positioning of the lower control arm bar studs to the knuckles, the cooling module support bushings, the engine strut bracket and the transaxle mount. 15. Insert %6 in. round steel rods into the cradle-to-body alignment holes near the front cradle to body fastener holes. Guide the cradle into position making sure all mount studs are properly guided into their holes. 16. Be sure the washers are in place, then install the 2 rear cradle to body bolts. Verify proper cradle positioning and install the 2 front cradle bolts, then torque the 4 Cradle bolts to 155 ft. Ibs. (210 Nm). 17. Remove the support dolly and lower the vehicle sufficiently for underhood access. Remove the engine support bar assembly. 18. Install or connect the following: Transmission strut-to-cradle bracket through-bolt and nut and torque them to 40 ft. Ibs. (64 Nm) Strut midrail bracket and torque the bolt to 52 ft. Ibs. (70 Nm) Ignition module and torque the bolts to 71 inch Ibs. (8 Nm) Ignition module wire connector Spark plug wires to the coil towers ->Proper orientation of the ignition module is critical to the operation of the module and the on board diagnostic system. The proper sequence is 4-1-2-3 from left to right.

¢ 2 top converter housing-to-engine Studs and torque them to 74 ft. Ibs. (100 Nm) e Transmission solenoid harness

93062G61

Electronic ignition module wire sequence 4-1-2-3-1.9L engines

connector and torque the fastener to 22 inch Ibs. (2.5 Nm) Vehicle speed and input sensor connectors Transmission fluid temperature sensor connectors Transmission range switch harness connectors Ground terminals to the top 2 converter housing bolts and torque the bolts to 19 ft. Ibs. (25 Nm) Ground wire to the neutral selector switch Adjust the control cable Air cleaner assembly Battery tray and torque the bolts to 89 inch Ibs. (10 Nm) PCM and torque the bolts to 53 inch Ibs. (6 Nm) Connect the PCM J2 (28-way) harness Battery and hold down retainer and torque the fastener to 80 inch Ibs. (9 Nm) Transmission lower mount to cradle fastener and torque it to 37 ft. Ibs. (50 Nm) 2 engine strut cradle bracket-toCradle fasteners and torque them to

37 ft. Ibs. (60 Nm)

Steering gear to cradle fasteners and torque them to 37 ft. Ibs. (50 Nm) Brake pipe to cradle retainer Torque converter to flexplate and torque the bolts to 52 ft. Ibs. (70 Nm) Dust cover and torque the bolts to 8 ft. Ibs. (11 Nm) Engine to transmission stiffening brace and torque the bolts to 40 ft, Ibs. (54 Nm) Exhaust manifold pipe and torque the bolts to 23 ft. Ibs. (31 Nm) Intermediate exhaust pipe to the Catalytic converter and torque the bolts to 18 ft. Ibs. (25 Nm) Front exhaust pipe support to the stiffening bracket and torque the fasteners to 23 ft. Ibs. (31 Nm) Lower ball joint and torque the nut to 59 ft. Ibs. (75 Nm) New cotter pins Splash shields Both front wheels Both battery cables 19. Fill the transmission to the proper level. 20. Warm the engine and check the transmission fluid. Check and adjust vehicle alignment, as necessary.

SATURN

LW ¢ SC1 © SC2 © SL © SLi © SL2 © SW1 © SW2 2.2L And 3.0L Engines 1. Before servicing the vehicle, refer to the precautions in the beginning of this section.

2. Drain the transmission fluid. 3. Remove or disconnect the following: Both battery cables Move the fan contro! module up and out of the way Battery feed to the underhood fuse block Coolant hose from the underhood fuse block Release the retaining tabs on the fuse block cover and remove it Engine 68-way electrical connector Forward lamp 68-way connector Forward lamp 2-way (white) connector Black, green and brown instrument panel 2-way connectors Fuse block from the case Engine, forward lamp and instrument panel harness from the fuse block case Case from the battery tray Battery tray and battery Control cable from the range switch lever Control cable bracket from the rear powertrain mount Transmission electrical connector and ground wire Remaining wire harness connectors from the transmission Transmission range switch electrical connector Upper engine to transmission bolts Drive belt from the alternator, for 3.0L engine Drive belt tensioner, for 3.0L engine Alternator, for 3.0L engine Output speed sensor electrical con-

2 lower engine to transmission bolts Left side transmission mount bolts 5. Slide a hydraulic lifting table under the transmission and remove the remaining mounting bolts. 6. Separate the transmission from the engine. To install: 7. With the transmission on a hydraulic lift, raise the transmission to the engine. 8. Install or connect the following: Rear wire harness bracket, for 3.0L engine Engine to transmission mounting bolts and torque them to 48 ft. Ibs. (60 Nm) Left side transmission mount bolts and torque them to 41 ft. Ibs. (55 Nm) Bottom 2 engine to transmission mounting bolts and torque them to 48 ft. Ibs. (65 Nm) Transmission oil cooler lines after lubricating them with automatic transmission fluid and torque the fasteners to 71 inch Ibs. (8 Nm) Loosely install the flex plate to torque converter bolts. When aligned properly, torque the bolts to 33 ft. Ibs. (45 Nm).

Starter motor and torque the bolts to 30 ft. Ibs. (40 Nm) Starter solenoid electrical connectors Engine to transmission bracket and torque the bolts to 26 ft. Ibs. (35 Nm) New axle shaft retaining rings on the end of the output shafts and install the axle shafts to the transmission Frame assembly Output speed sensor electrical connector and secure it to the mounting stud Alternator and torque the bolts to 30 ft. Ibs. (40 Nm), for 3.0L engine Drive belt tensioner and torque the bolts to 30 ft. Ibs. (40 Nm), for 3.0L engine Drive belt, for 3.0L engine Remaining transmission to engine mounting bolts and torque them to 48 ft. Ibs. (65 Nm) Transmission electrical connector and ground wire and torque the fasteners to 18 ft. Ibs. (25 Nm) Wire harness attachments to the

transmission side cover and torque the fasteners to 15 ft. Ibs. (20 Nm) Contro! cable mounting bracket and

nector

4. Install an Engine Support Fixture.

Pa Frame Axle shafts from the transmission

Engine to transmission bracket

Starter solenoid electrical connector

Starter motor =>The wire harness mounting bracket on the rear of the engine must be

removed on the 3.0L. Torque converter-to-flexplate bolts through the starter opening Transmission oil cooler lines

32-43

Lifting table mounting points-2.2L and 3.0L engines

n 1 of this manual For Maintenance Interval recommendations, see Sectio

32-4

SATURN

LW ¢SC1 ° SC2 ¢ SL® SL1 © SL2 ¢ SW1 © SW2

torque the bolts to 15 ft. Ibs. (20 Nm) Control cable to the range switch lever Battery tray and torque the fasteners to 11 ft. Ibs. (15 Nm) Underhood fuse block case to the battery tray. Torque the bolt to 80 inch Ibs. (9 Nm) and snap the block onto the hinges. Engine 68-way connectors Forward lamp 68-way connectors Instrument panel 68-way connectors

Forward 2-way (white) connector Black, green and brown 2-way connectors Snap the fuse block to the case Coolant hose to the fuse block Battery feed to the fuse block and torque the fastener to 12 inch Ibs. (16 Nm) Battery tray and hold-down bracket and torque the fastener to 15 ft. Ibs. (20 Nm) Battery Fan control module to the battery hold down bracket Both battery cables 9. Fill the transmission to the proper level. 10. Warm the engine and check the transmission fluid. Check and adjust vehicle alignment, as necessary.

4. Using a feeler gauge, measure the distance between the pressure plate and flywheel surfaces in order to determine clutch face thickness. Replace the clutch disc if it is not within 0.205-0.287 in. (5.2-7.3mm) for 1998-00 or to 0.18 -0.28 in. (4.65mm-—7.10mm) for 2001. 5. Remove the pressure plate-to-flywheel bolts in a progressive crisscross pattern to prevent warping the cover, then remove the pressure plate and clutch disc. 6. Inspect the pressure plate, as follows: a. Check for excessive wear, chatter marks, cracks or overheating (indicated by a blue discoloration). Black random spots on the friction surface of the pressure plate is normal. b. Check the plate for warpage using a Straightedge and a feeler gauge; the maximum allowable warpage is 0.006 in. (0.15mm). c. Replace the plate, if necessary. 7. Inspect the clutch disc, as follows: a. Check the disc face for oil or burnt spots. b. Check the disc for loose damper Springs, hub or rivets. c. Replace the disc, if necessary. 8. Check the flywheel, as follows:

a. Check the ring gear for wear or damage.

b. Check the friction surface for excessive wear, chatter marks, cracks or overheating.

c. Check flywheel thickness; the mini-

mum allowable is 1.102 in. (28mm). d. Measure flywheel run-out using a dial indicator, positioned for at least 2 flywheel revolutions. Push the crankshaft forward to take up thrust bearing clearance. Maximum flywheel run-out is 0.006 in. (0.15mm). e. Check the flywheel for warpage using a straight-edge and a feeler gauge; the maximum allowable warpage is 0.006 in. (0.15mm). f. Replace the flywheel, ifnecessary. 9. If necessary, remove the flywheel retaining bolts and remove the flywheel from the crankshaft. To install: 10. If removed, install the flywheel and torque the bolts in a crisscross sequence to 59 ft. Ibs. (80 Nm). 11. Install or connect the following: ¢ Clutch disc and pressure plate with the yellow dot on the pressure plate aligned as close as possible to the mark on the flywheel. The clutch

8

ADJUSTMENT The hydraulic clutch system is selfadjusting.

REMOVAL & INSTALLATION 1.9L Engines 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove the transmission from the vehicle. 3. Unsnap the release fork from the ball Stud, then remove the fork and bearing from the vehicle. Slide the bearing from the fork, The bearing should be checked for excessive play and for minimal bearing drag. It should be replaced if no/little drag or excessive play is found. e>The release bearing is packed with grease and should not be washed with solvent.

2 Flywheel mounting bolt tightening sequence—1 .9L engines

79222831

LW ¢ SC1°SC2°SL*SL1¢SL2¢ ain

79227832

retaining bolts—1.9L Use a proper clutch alignment tool before tightening the pressure plate engines

disc is labeled FLYWHEEL SIDE in order to help correctly position the disc. Loosely install the pressure plate bolts. Clutch alignment tool in the clutch disc and install the release bearing to the fork and torque the pressure plate bolts to 18 ft. Ibs. (25 Nm) Snap the release bearing and fork onto the ball stud Lubricate the splines of the input shaft lightly with a high temperature grease Transmission assembly Negative battery cable 2.2L and 3.0L Engines 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 9 Remove the transmission from the vehicle. 3. Check the slave cylinder release bearing minimal bearing drag. Replace the slave cylinder if little or drag is found. 4 Remove the pressure plate and clutch disc. 5. Inspect the pressure plate, as follows:

a. Check for excessive wear, chatter marks, cracks or overheating (indicated by a blue discoloration). Black random spots on the friction surface of the pressure plate is normal. b. Check the plate for warpage using a straightedge and a feeler gauge; the maximum allowable warpage is 0.006 in. (0.15mm). c. Replace the plate, if necessary. 6. Inspect the clutch disc, as follows: a. Check the disc face for oil or burnt spots. b. Check the disc for loose damper springs, hub or rivets. c. Replace the disc, if necessary. 7. Check the flywheel, as follows: qa. Check the ring gear for wear or damaqge. b. Check the friction surface for excessive wear, chatter marks, cracks or overheating. c. Check flywheel thickness; the minimum allowable is 1.102 in. (28mm). d. Measure flywheel run-out using a dial indicator, positioned for at least 2 flywheel revolutions. Push the crankshaft forward to take up thrust bearing clear-

32-45

ance. Maximum flywheel run-out is 0.006 in. (0.15mm). e. Check the flywheel for warpage using a straight-edge and a feeler gauge; the maximum allowable warpage is 0.006 in. (0.15mm). f. Replace the flywheel, if necessary. 8. If necessary, remove the flywheel retaining bolts and remove the flywheel from the crankshaft. To install: 9. Install or connect the following: Flywheel (if removed) and torque the bolts in a crisscross pattern to 39 ft. lbs. (63 Nm) plus 25 degrees e Clutch disc and pressure plate and loosely install the pressure plate bolts e Clutch alignment tool in the clutch disc, and push in until it bottoms out in the crankshaft 10. Tighten the pressure plate bolts using multiple passes of a crisscross sequence to 11 ft. Ibs. (15 Nm) and remove the alignment tool. 11. Lubricate the splines of the input shaft lightly with a high temperature grease. 12. Install the transmission assembly. 13. Connect the negative battery cable.

Hydraulic Clutch System BLEEDING LEEEEE nee

1.9L Engines

The clutch hydraulic assembly has been filled with fluid and bled of air at the factory. Do not attempt to bleed the hydraulic system. While the unit does not require periodic checking, it must be serviced, when necessary, as a complete assembly. The system is full when the reservoir is half full. Only DOT 3 brake fluid should be added to the system. If the fluid level drops, inspect the system, including the slave cylinder, for leakage. A slight wetting of the slave cylinder surface is normal. Fill the clutch master cylinder reservoir with brake fluid. Be careful not to spill brake fluid on the painted surface of the vehicle. 2.2L and 3.0L Engines

TRANSMISSION IN VEHICLE This procedure outlines how to bleed the hydraulic clutch with the transmission in the vehicle. Only DOT 3brake fluid should be added to the system.

Section 1 of this manual For Tune-up, Capacities and Firing orders, see

32-4

SATURN

LW ¢ SC1 ¢ SC2 e SL

SL1 © SL2 © SW1 © SW2

93062664

9306ZG63

Loosen the clutch bleeder screw on the hydraulic fitting

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: 3. Remove the reservoir cap and fill the reservoir with new brake fluid. 4. Install a Bleeder Adapter Too! J43915, to the reservoir and connect a pressure bleeder to the adapter. 5. Charge the pressure bleeder to 20-25 psi (138-172 kPa). 6. Attach a transparent hose over the clutch bleeder screw nipple and submerge the opposite end of the hose in a container of brake fluid. 7. Loosen the bleeder screw on the transmission hydraulic fitting. 8. Bleed the system until no air bubbles are seen in the hose. 9. Tighten the bleeder screw, 10. Check the clutch pedal for a spongy feel. If the pedal feels soft, repeat the bleeding procedure. 11. Remove the bleeder tools and top off the fluid level if necessary.

TRANSMISSION OUT OF VEHICLE This procedure outlines how to bleed the Clutch slave cylinder while the transmission

is out of the vehicle. Only DOT 3brake fluid should be added to the system. 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: 3. Connect a long piece of transparent hose to the slave cylinder fitting. 4. Depress the release bearing on the Slave cylinder towards the clutch housing and release it. 9. The release bearing will spring back, but the piston will remain depressed next to the clutch housing. 6. Fill the hose with 13.8 inches (350mm) of DOT 3 brake fluid. 7. Connect a Vacuum Pump SA9180NE with a Pressure Adapter J35555-92. to the top of the hose. 8. Apply pressure to the hose to force the brake fluid into the slave cylinder. Pressure in the gauge will increase when the Slave cylinder piston reaches the end of its travel. 9. Remove the vacuum pressure pump from the hose and depress the release bearing. Air bubbles should appear in the hose. 10. Repeat this procedure until no air bubbles are visible in the hose. 11. Drain and remove the hose,

Install a vacuum pump and pressure adapter to bleed the slave cylinder.

REMOVAL & INSTALLATION —_ee——————————

1.9L Engines 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove the wheel cover or the center: Cap for access to the halfshaft nut. Have an assistant depress the brake pedal and loosen the front halfshaft nut. 3. Remove or disconnect the following: Wheel and splash shields 2 push pins Lower shield to cradle molded-in fasteners at the cradle Drain the transmission fluid if replacing the left side halfshaft Drive axle nut and washer and discard them Lower control arm to steering knuckle cotter pin and discard it Loosen the lower control arm to Steering knuckle castle nut so that the top of the nut is even with the top of the ball stud

LW e SC1¢SC2°SL¢SL1°SL2¢ ang aie 32-4/ WARNING The outer CV-joint, if equipped with Anti-lock Brake System (ABS), contains a speed sensor ring. Use of an incorrect tool to separate the control arm from the knuckle may result in damage and loss of the ABS system. e Lower control arm from the steering knuckle by using a Lower Control Arm Separator Tool SA9132S Cotter pin and castle nut and discard them, if equipped Torque prevailing nut and discard it, if equipped Separate the tie rod end from the steering knuckle using a Tie Rod Separator Tool, SA91100C Lower contrel arm to steering knuckle castle nut Position a pry bar at the proper cradle and front stabilizer and place a cloth over the ball stud boot Separate the lower control arm from the steering knuckle and pull the knuckle away from the ball Stud While pulling the knuckle/strut away, pull the outer end of the halfshaft out of the wheel hub and properly support the halfshaft

4. For right side halfshafts, remove the halfshaft from the intermediate shaft by tapping the axle with a block of wood and hammer. Separate the halfshaft from the intermediate shaft. 5. For left side halfshafts, remove the halfshaft by installing a prybar and prying the halfshaft from the transmission. To install: ->Be careful not to damage the halfshaft oil seal when installing the halfshaft into the transmission.

6. Install or connect the following: e Transaxle Seal Protector Tool SA91112T, when installing the left side halfshaft Halfshaft into the transmission. After the splines have safely passed the oil seal, remove the protector tool Insert the inner end of the halfshaft onto the outer end of the intermediate shaft for the right side halfshaft. Push on the axle firmly to engage the retaining ring Outer end of the halfshaft into the wheel hub. Do not install any hardware at this time Lower control arm ball stud into the steering knuckle. Hand-tighten the castle nut at this time

SEAL

PROTECTOR

79222833

e the transaxle seal allow the halfshaft splines to damag Failure to use a seal protector may

e Attach the tie rod end to the steering knuckle, if equipped. Torque the nut to 33 ft. Ibs. (45 Nm) and install a new cotter pin If equipped with a torque prevailing nut, attach the tie rod to steering knuckle with a new nut. Do not allow the ball stud to turn while tightening the prevailing nut. Torque the nut to 41 ft. Ibs. (55 Nm). Axle to hub washer and new nut. Torque the nut to 148 ft. Ibs. (200 Nm). e>When tightening the axle nut, have an assistant depress the brake pedal to prevent axle rotation.

e Splash shields e Align the molded in shield fasteners with the holes in the cradle and install push pins e Wheel 7. Top off the transmission with the proper fluid. 8. Check and adjust the front end alignment as necessary. 2.2L and 3.0L Engines

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 9. Remove the wheel cover or the center cap for access to the halfshaft nut. Have an assistant depress the brake pedal and loosen the front halfshaft nut. 3. Remove or disconnect the following: e Wheel ¢ Tie rod end torque prevailing nut and discard it ° Tie rod end from the steering knuckle, using a Tie Rod Separator Too! SA91100C ¢ Lower control arm to steering knuckle =>Do not allow the steering knuckle to contact the ball stud seal. Contact may cause the seal to rip and the ball stud will need replacement.

Pull the steering knuckle/strut assembly away from the vehicle and pull the halfshaft out of the hub e Properly support the halfshait and remove the halfshaft from the transmission e Shaft retaining ring and discard It

Chilton Labor Guide For complete service labor times, order Nichols’

32-4

SATURN LW ¢ SC1 ¢ SC2 © SL

SL1 © SL2 ¢ SW1 © SW2 +t WARNING Make sure that there are no pinch points on the inboard seal.

9306ZG65

Separate the tie rod end from the steering knuckle with a Tie Rod Separator tool

To install: 4. Apply Output Shaft Lubricant 7847638, to the splines of the output shaft, if equipped with an automatic transmission. 9. Install or connect the following: ¢ New stub shaft retaining ring e Halfshaft to the transmission after installing a Seal Protector Too! SA91112T 6. Remove the seal protector tool after the splines have passed the oil seal. 7. Install or connect the following: Fully seat the halfshaft into the transmission Outer end of the halfshaft to the wheel hub with a new washer and nut Lower control arm ball stud to the Steering knuckle. Torque the fastener to 75 ft. Ibs. (100 Nm). Tie rod end to the steering knuckle. When seated properly, torque the fastener to 45 ft. Ibs. (60 Nm). Wheel Halfshaft to wheel nut. Torque the nut to 74-118 ft. Ibs. (100-160 Nm), release the nut until it turns freely and torque the nut to 15 ft. Ibs. (20 Nm) plus 90 degrees. ¢ Cotter pin 8. Top off the transmission with the proper fluid. 9. Check and adjust the front end alignment as necessary.

CV-Joints

OVERHAUL i

Inner

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Front wheel Halfshaft Swage ring using a hand grinder Large CV-joint boot clamp CV-joint boot by sliding it away from the tri-pod joint Tri-pod housing from the tri-pod spider Inboard spacer ring slide it rearward on the shaft Outboard retaining ring Tri-pod joint spider assembly Inboard spacer ring and CV-joint boot To install: 3. Install or connect the following: ° Swage ring clamp on the CV-joint boot ¢ CV-joint boot 4. Position the CV-joint boot seal into the axle shaft’s joint seal groove and align the swage ring clamp on the boot.

5. Crimp the swage ring 6. Install or connect the following: e Inboard spacer ring, slide it rearward on the shaft Tri-pod joint spider assembly onto the shaft Outboard retaining ring into the axle shaft groove Tri-pod joint spider assembly, slide it against the outboard retaining ring Inboard spacer ring, seat it in the groove Va kit grease into the boot Ya kit grease into the tri-pod housing New large seal clamp onto the CVjoint boot Tri-pod housing, slide it over the tri-pod joint spider assembly CV-joint boot/clamp, slide it into place, over the trilobal tri-pod bushing with the seal lip in the groove e» Make sure the boot lies flat against the trilobal bushing.

7. Position the CV-joint boot so it measures 4.9 in. (125mm). 8. Using a Crimp tool, a torque wrench and a breaker bar, crimp the large CV-joint boot clamp to 130 ft. Ibs. (176 Nm). 9. Install the halfshaft and the front wheel. Outer

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: ¢ Axle shaft from the vehicle

* * ¢ ¢ ¢ ¢

Large CV boot retaining clamp Small CV boot retaining clamp CV boot from the joint Axle shaft retaining ring Outer joint from the axle shaft CV boot 3. Disassemble the chrome alloy balls from the C\V-joint cage as follows: a. Position a brass drift against the CV-joint cage and tap it with a hammer to tilt the cage. b. Remove the 1st chrome alloy ball from the cage. c. Tilt the cage in the opposite direction.

LW e SC1 ¢ SC2 sit Remove the opposite chrome alloy . ? : Repeat the procedure until all 6 ; ae removed. at _ 4. Disassemble the CV-joint cage and inner ae follows: , a. Pivot the cage and race 90 egrees to the center line of the outer . . hee ¥ . Align the cage windows with outer race lands.

SL

c. Remove the cage from the outer race. d. Rotate the inner race upward and remove it from the cage. To install: 5. Lubricate the parts with a light coat of grease. 6. Assemble the CV-joint cage and inner race, as follows: a. Rotate the inner race 90 degrees to the cage centerline.

SL1 @ SL2 ° ge

32-49

b. Align the cage windows with inner race lands. c. Insert the inner race into the cage by rotating the inner race downward. d. Insert the cage/inner race into the outer race. 7. Assemble the chrome alloy balls into the CV-joint cage, as follows: a. Position a brass drift against the C\V-joint cage and tap it with a hammer to tilt the cage.

AXLE SEAL DEFLECTOR

LH-MALE

DYNAMIC DAMPERVEHICLES WITH STEEL WHEELS

W/ABS 93462628

shown, L series is similar Exploded view of axle shaft—S series

om Please visit our web site at www.chiltonsonline.c

32-9

SATURN

LW @ SC1 ¢ SC2 © SL © SL1 © SL2 © SW1 © SW2

b. Insert the 1st chrome alloy ball into the cage. c. Tilt the cage in the opposite direction. d. Insert the opposite chrome alloy ball. e. Repeat the procedure until all 6 balls are inserted. 8. Install Yeof the grease provided, into the CV-joint.

:

|

sek CAUTION All 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 repairs. aE EE A SE |

PRECAUTIONS

9. Install or connect the following: ¢ Small CV boot retaining ring CV boot on the halfshaft New retaining ring on the halfshaft Large ring clamp on the CV boot Outer joint onto the axle shaft Retaining ring into the outer race

10. Install the remaining grease into the CV boot. 11. Position the CV boot and the small boot clamp. 12. Crimp the small boot clamp. 13. Position and crimp in place the large boot clamp. 14. Install the Halfshaft in the vehicle.

STEERING AND SUSPENSION Assurance (CPA) device, then disengage the yellow 2-way SIR wiring harness connector at the base of the steering column.

ARMING +

CAUTION

4. Turn the ignition switch to the RUN position. 5. Verify the SIR indicator light flashes 7-9 times, if not, inspect the system for malfunction.

Rack and Pinion Steering Gear

After the repairs, enable the system as follows:

REMOVAL & INSTALLATION

1. Turn the ignition switch to the LOCK position. 2. Engage the yellow 2-way connector at

1.9L Engines

the base of the steering column, then install the CPA device. 3. Reinstall the Supplemental Inflatable Restraint (SIR) or AIR BAG fuse.

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Negative battery cable ¢ Both front wheels

Several precautions must be observed when handling the inflator module to avoid accidental deployment and possible personal injury. 1. Never carry the inflator module by the wires or connector on the underside of the module. 2. When carrying a live inflator module, hold securely with both hands, and ensure that the bag and trim cover are pointed away. 3. Place the inflator module on a bench or other surface with the bag and trim cover facing up. 4. With the inflator module on the bench, never place anything on or close to the module which may be thrown in the event of an accidental deployment.

DISARMING 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Align the steering wheel so the vehicle wheels are pointing in the straightahead position. 3. Turn the ignition switch to the LOCK position. 4. Remove the SIR or AIR BAG fuse from the fuse block. 9. Remove the Connector Position

The pinch bolt is located under the intermediate shaft cover—1.9L engines

79227834

LW © SC1¢SC2°SLeSL1¢SL2¢ ayieeue 32-51 To install: 3. One at a time remove and replace the frame bolts and nuts. Torque retention of the old fasteners may not be sufficient. 4. Install or connect the following: Steering gear through the left wheel opening Raise the frame assembly to the undercarriage and torque the fasteners to 66 ft. Ibs. (90 Nm) plus a 46-60 degree turn Suspension supports with new bolts and torque the bolts to 66 ft. lbs. (90 Nm) plus a 45-60 degree turn Steering gear to the frame with new bolts and torque the bolts to 35 ft. lbs. (45 Nm) plus 45-60 degrees Steering gear heat shield (on 2.2L engine with an automatic transmission) and torque the bolts to 35

79222835

Remove the steering gear-to-cradle fasteners, then remove the gear through the left fender well—1.9L engines

e Loosen the intermediate shaft cover

from the steering gear and move it aside

e Intermediate shaft pinch bolt 3. On vehicles with power steering, place a suitable container under the steering assembly. Disconnect the pressure and return lines at the steering gear and allow the system to drain. 4 Remove the steering gear to cradle fasteners.

5. Remove the steering gear through the

left fender well. To install:

6. Install or connect the following: Steering gear to cradle with new nuts and torque the nuts to 37 ft. lbs. (60 Nm) Intermediate shaft to the steering gear and torque the pinch bolt to 35 ft. lps. (47 Nm) Power steering pressure and return lines and torque the fittings to 20 ft. lbs. (28 Nm) Left side splash shield Tie rod ends to the steering knuckle and torque the castle nuts to 41 ft. lbs. (65 Nm) New cotter pins to the castle nuts Front wheels Negative battery cable 7. Check the alignment and adjust as

necessary. 8. On vehicles with power steering, bleed the power steering system.

inch Ibs. (4 Nm)

2.2L and 3.0L Engines

e Quter tie rod from the steering knuckle e Left side splash shield

Tie rod ends to the steering knuckle

1. Before servicing the vehicle, refer to the precautions in the beginning of this sec-

and torque the nut to 44 ft. Ibs. (60 Nm) Stabilizer bar links to the strut and torque the nuts to 48 ft. Ibs. (65 Nm)

tion. 2. Remove or disconnect the follow-

ing: Negative battery cable Both front wheels Intermediate shaft from the steering gear Rear exhaust manifold pipe heat shield (on 3.0L engine) Rear transmission mount through bolt Transmission mount-to-frame bolt Power steering pressure and return hoses Front wheels Right front lower splash shield Exhaust manifold pipe (on 2.2L engine with manual transmission and all 3.0L engines) Remaining rear transmission mount-to-frame bolts Tie rods from the steering knuckles Steering gear-to-frame bolts Steering gear heat shield (on 2.2L engine with automatic transmission) Stabilizer bar links from the struts

e Front suspension support assem-

blies Loosen the remaining frame to body fasteners until there is clearance to remove the steering gear Steering gear through the left side wheel opening

_ Rear transmission mount-to-frame

bolts and torque them to 44 ft. Ibs. (60 Nm) Power steering pressure and return lines and torque the fittings to 20 ft. lbs. (27 Nm) Exhaust manifold pipe (2.2L engines with a manual transmission and all 3.0L engines) to the manifold and torque the nuts to 22 ft. Ibs. (30 Nm) Exhaust manifold pipe to the exhaust pipe and torque the bolts to 15 ft. Ibs. (20 Nm) Front wheels Rear transmission mount-to-frame

bolt and torque it to 45 ft. Ibs. (60 Nm) Rear transmission mount through bolt and torque it to 66 ft. Ibs. (90 Nm) Exhaust manifold pipe heat shield (on 3.0L engine) and torque the bolts to 71 inch Ibs. (8 Nm) Intermediate shaft to the steering gear and torque the new pinch bolt to 21 ft. Ibs. (28 Nm) e Negative battery cable 5. Check the alignment and adjust if

necessary.

6. Bleed the power steering system.

l Timing belt service is covered in Section 3 of this manua

SATURN

LW ¢ SC1 © SC2 © SL

SL1 © SL2 © SW1 © SW2

POWER STEERING SYSTEM BLEEDING 1. Fill the power steering fluid reservoir. 2. Raise the front of the vehicle just sufficiently so that the drive wheels are off the ground, then safely support the vehicle. 3. Bleed the system by turning the wheels from side-to-side without hitting the stops. It may take several cycles to bleed the system. e> Maintain the reservoir at the FULL mark during this procedure.

4. Lower the vehicle. 5. Start the engine and, with the transmission in P (automatic transmission) or N (manual transmission), check the fluid level with the engine idling. If necessary, add fluid to bring the level to the FULL mark. 6. Road test the vehicle and check for proper operation. Recheck the fluid level and make sure it is at or slightly above the FULL mark after the system has stabilized at

79222836

Remove the 3 nuts to detach the top of the Strut from the body—1.9L engine

normal operating temperature.

To install: 4. Install or connect the following: e Position the strut in the vehicle and install 3 new upper mount nuts. New nuts must be used because the torque retention of the old nut may be insufficient. Torque the nuts to 21 ft. Ibs. (29 Nm). Knuckle bolts, also using new nuts. Push the bottom of the strut inward while tightening the fasteners to 126 ft. Ibs. (170 Nm) ABS wiring bracket to the strut using a new rivet. Connect the ABS wiring to the bracket and install the wiring to the speed sensor connector. Be sure the wiring is positioned as noted during removal Wheel assembly, remove the supports and lower the vehicle. ¢ Negative battery cable 5. Check and adjust the alignment if necessary.

2.2L AND 3.0L ENGINES REMOVAL & INSTALLATION Front

7.9L ENGINES 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. If equipped with an Anti-lock Brake System (ABS), disconnect the negative battery cable, then raise and support the vehicle Safely. Be sure the vehicle is at a height where underhood access is still possible. 3. Remove or disconnect the following: Front wheel Unplug and disconnect the ABS wire from the strut wiring bracket. Note the wiring position for assembly purposes, then place the ABS wiring out of the way to prevent damage. If the strut is being replaced, drill the rivet head retaining the ABS wiring bracket to the — and remove the bracket strut ¢ Loosen the 2 steering knuckle-to— Strut housing bolts, but do not remove them at this time. For reassembly purposes, matchmark the Strut position to the steering knuckle 3 upper strut-to-body nuts and discard them Place a rag over the C\-joint seal to protect it from damage, then remove the 2 steering knuckle-tostrut housing bolts Strut assembly from the vehicle

79222837

Matchmark, then remove the 2 bolts that secure the strut to the knuckle assembly— 1.9L engine

1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. lf equipped with an Anti-lock Brake System (ABS), disconnect the negative bat-

Remove the strut to body attaching nut-2.2L and 3.0L engines

93062G67

LW ¢ SC1 * SC2 ¢SLe SL1¢ SL2¢ aah

32-53

93062ZG68

3.0L engines Exploded view of the front suspension-2.2L and

tery cable, then raise and support the vehicle safely. Be sure the vehicle is at a height where underhood access is still possible. 3 Remove or disconnect the following: e Front wheel

Brake hose and ABS harness from the strut assembly « Loosen the steering knuckle to strut fasteners, but do not remove them e Stabilizer bar link to the strut assembly attaching nut and move it toward the rear of the vehicle

e Strut to body attaching nuts ¢ Place a rag over the CV-joint seal to protect it from damage, then remove the 2 steering knuckle-tostrut housing bolts

¢ Steering knuckle to strut fasteners + Strut assembly from the vehicle To install: 4. Install or connect the following: + Strut to the body and torque the new attaching nut to 40 ft. Ibs. (55 Nm) e Strut to the steering knuckle and

torque the new fasteners to 37 ft. ibs. (50 Nm) then to 66 ft. Ibs. (90 Nm) plus a 45 degree turn © Stabilizer bar link to the strut and torque the fastener to 50 ft. |bs. (65

Nm) e Brake hose and ABS wiring to the strut e Front wheel ¢ Negative battery cable 5. Check and adjust the alignment as necessary.

of this manual Heater Core replacement is covered in Section 2

32-9

SATURN

LW e SC1 ¢ SC2 ¢ SL

7.9L ENGINES 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove the rear window trim finish panel. 3. Remove or disconnect the following: e Wheel e Loosen the 2 strut to steering knuckle fasteners, but do not remove them ¢ 3 strut to body fasteners ¢ Slowly raise a hoist to support the steering knuckle and lower the strut assembly e 2 strut to steering knuckle fasteners ° Strut To install: 4. Install the strut to the vehicle and hold it in place with strut to knuckle bolts. 9. Install or connect the following: ¢ Strut to the body with new upper Support bolts and torque the bolts to 21 ft. Ibs. (29 Nm) * Strut to steering knuckle fasteners and push the bottom of the strut inward while tightening the bolts. Torque the new bolts to 126 ft. Ibs. (170 Nm). ¢ Front wheel ¢ Rear window trim panel 6. Check and adjust the alignment if necessary.

SL1 © SL2 © SW1 © SW2 2. Remove or disconnect the following: e Whee! e Inner wheelhouse liner ¢ Shock to steering knuckle attaching bolt and discard it e Upper carrier to body bolts e Loosen the lower carrier bolts until the shock can be removed

e Shock To install: 3. Install or connect the following: e Carrier to body. Torque the bolts to 40 ft. Ibs. (65 Nm). e Carrier to steering knuckle with a few bolt. Torque the bolt to 110 ft. lbs. (150 Nm) plus 30 degrees

9306ZG69

(Ge

79227837

Remove the two strut to steering knuckle fasteners—1.9L engine

eat a A

(6¢

ef,

Shock Absorber

REMOVAL & INSTALLATION a 2.2L and 3.0L Engines 1. Before servicing the vehicle, refer to the precautions in the beginning of this section.

93062670

Exploded view of the rear Suspension-2.2L and 3.0L engines

SATURN LW SC1 ¢ SC2 * SL® SL1¢ SL2 ¢ SW1 ¢ SW2

32-90

e |nner wheelhouse liner e Wheel

REMOVAL & INSTALLATION Front

1.9L ENGINES 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Strut from the vehicle Mount the strut in a bench vise, then attach a spring compressor/holding fixture; be sure that the strut component is firmly secured Compress the spring sufficiently to completely unload the upper strut mount Shaft nut while holding the strut stationary with a Torx® head socket wrench Upper spring support and inspect the rubber for cracks or deterioration Spring from the strut and inspect the spring for damage Dust shield assembly and inspect for cracks or deterioration Strut from the vise or applicable holding fixture and retract the strut shaft, checking for smooth, even resistance 3. If replacing the coil spring, carefully release the spring compressor. To install: 4 Secure the strut in the bench vise or applicable holding fixture. 5 Extend the strut shaft to the limit of its

a, ae,

79222838

Remove the strut shaft nut while the coil spring is compressed to unload the upper strut mount-1.9L engines

nut steady with an open end wrench. Tighten the fastener to 37 ft. Ibs. (60 Nm). e Release the spring compressor tool and remove the strut from the fixture e Strut assembly in the vehicle.

2.2L AND 3.0L ENGINES al Before servicing the vehicle, refer to the precautions in the beginning of this section.

oe Remove or disconnect the following:

Strut from the vehicle Place the strut into a spring compressor. Fasten the assembly with a strut to steering knuckle bolt through the lower mounting hole Compress the spring enough to completely unload the upper strut mount Strut shaft nut while holding the shaft stationary with a TORX® socket Release the spring compressor and tilt the strut outward

travel.

6. Install or connect the following: Dust shield assembly onto the strut, then install the spring with the compressor tool installed Spring isolator and the strut mount to the top of the assembly Guide the strut shaft through the upper strut mount assembly. Compress the coil until the washer and shaft nut can be installed to the end of the shaft, but do not over-compress and damage the spring Tighten the shaft to the nut using a Torx® head socket wrench and a torque wrench, while holding the

ents-2.2L and 3.0L engines Exploded view of the coil spring and related compon

manual Brake service is covered in Section 4 of this

32-9

SATURN

LW ¢ SC1 ¢ SC2 © SL

SL1 © SL2 © SW1 © SW2

Upper strut mount assembly Spring To install: 3. Install or connect the following: Strut into spring compressor Extend the strut shaft to its full travel Hollow bumper onto the strut Spring to the strut and make certain that it is properly positioned in the seat and isolator Upper spring seat and strut mount Compress the spring while guiding the strut shaft through the upper strut mount assembly. Do not over compress the spring 4. Torque the strut shaft nut to 40 ft. Ibs. (55 Nm). 5. Release the spring compressor tool. 6. Strut to the vehicle.

2.2L AND 3.0L ENGINES

Rear

1. Before servicing the vehicle, refer to the precautions in the beginning of this sec-

7.9L ENGINES 1. Before servicing the vehicle, refer to the precautions in the beginning of this section.

2. Remove or disconnect the following: Strut assembly from the vehicle Mount the strut in a bench vise, then attach a suitable spring compressor/holding fixture; be sure that the strut component is firmly secured Compress the spring sufficiently to completely unload the upper strut mount Strut shaft nut while holding the strut stationary with a Torx® head socket wrench Upper spring support and inspect the rubber for cracks or deterioration Spring from the strut and inspect the spring for damage Dust shield assembly and inspect for cracks or deterioration Strut from the vise or applicable holding fixture and retract the strut shaft, checking for smooth, even resistance 3. If replacing the coil spring, carefully release the spring compressor. To assemble: 4. Secure the strut in the bench vise, or applicable holding fixture. 9. Extend the strut shaft to the limit of its

Spring isolator and the strut mount to the top of the assembly Guide the strut shaft through the upper strut mount assembly. Compress the coil until the washer and shaft nut can be installed to the end of the shaft, but do not over-compress and damage the spring Tighten the shaft to the nut using a Torx® head socket wrench and a torque wrench, while holding the nut steady with an open-end wrench. Tighten the fastener to 37 ft. Ibs. (60 Nm). Release the spring compressor tool and remove the strut from the fixture

Strut to the vehicle

2. Remove or disconnect the following: Shock absorber assembly from the vehicle Mount the carrier assembly Spring Compressor SA9155S, in a holding fixture Mount the shock assembly to the

e Extend and retract the shock absorber and check for smooth resistance

To install: 3. Install or connect the following: Shock into a spring compressor Extend the shock to its full limit of travel Inner and outer bumpers and make certain that the springs are properly positioned in their support seats Compress the spring while guiding the shock absorber shaft through the upper mount until the washer and nut can be installed. Torque the Shaft nut to 15 ft. Ibs. (20 Nm)

CG Y

travel.

6. Ins +all or connect the following: e Dust shield assembly onto the wn—rut, then install the spring with the compressor tool installed

spring compressor using an adapter, SA9155-3 Compress the spring enough to unload the upper spring supports Shock absorber shaft nut while holding the shaft securely with a TORX® socket Release the spring compressor and remove the carrier assembly Rear suspension support and inspect the inner and outer bumpers for cracks or deterioration, replace if necessary Rear spring upper insulator

Exploded view of rear shock assembly

LW.* SC1 °SC2¢SLe°SL1¢SL2¢ Rene while holding the shaft nut with a TORX® socket. e Release the compressor tool and remove the carrier from the compressor e Shock absorber to the vehicle

2. Remove or disconnect the following: e Wheel e Lower control arm ball stud cotter

pin and discard the pin e Loosen the castle nut until it is

level with the top of the ball stud >Use caution not do damage the Antilock Braking System (ABS) speed sensor ring. If the ring is damaged a malfunction of the ABS system is possible.

Lower Ball Joint

REMOVAL & INSTALLATION 1.9L Engines The ball joint is part of the lower control arm and must be replaced as a unit. 2.2L and 3.0L Engines 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Install or connect the following: e Lower control arm from the vehicle e Rivets retaining the ball joint to the control arm using a 13 mm (% in.) drill bit e Ball joint from the control arm To install: 3. Install or connect the following: e Ball joint into the control arm e Nuts and bolts (included with new ball joint kit) as shown and torque them to 25 ft. Ibs. (35 Nm) e Control arm to the vehicle

3. Separate the lower control arm from the steering knuckle, using a Lower Control Arm Ball Stud Separator Tool SA9132S 4 Remove or disconnect the following: Lower control arm castle nut Front inner fender splash shield and remove the push pins Front section of the shield first on the left hand side and the rear section first on the right side of the vehicle Lower control arm to cradle fasteners front stabilizer bar nut at the lower control arm Lower control arm

32-57

To install: 5. Install or connect the following: ¢ Control arm to the front stabilizer bar 6. Position the end of the control arm into the cradle. Torque the bolt to 92 ft. Ibs.

(125 Nm) and the nut to 74 ft. Ibs. (100 Nm). e Control arm to front stabilizer bar nut and torque the nut to 106 ft. lbs. (144 Nm) Ball stud to the steering knuckle and torque the castle nut to 55 ft. lbs. (75 Nm) and install a new cotter pin Rear section of the shield first on the left side and the front section first on the right side of the vehicle Inner fender splash shield Align the molded in fasteners with the cradle holes and push them straight in

e Wheel 7. Check and adjust the alignment if necessary.

2.2L AND 3.0L ENGINES 1. Before servicing the vehicle, refer to the precautions in the beginning of this section.

ee st

9306Z2G74

The new ball stud is bolted into the contro! arm-—2.2L and 3.0L engines

Lower Control Arm REMOVAL & INSTALLATION Front

1.9L ENGINES

93062G71

1. Before servicing the vehicle, refer to the precautions in the beginning of this section.

engines Connect the ball stud to the steering knuckle-1.9L

Section 1 of this manual For complete Engine Mechanical specifications, see

32-9

SATURN LW ¢ SC1 © SC2 ¢ SLe SL1 © SL2 © SW1 ¢ SW2 e Stabilizer bar link to the control arm. And torque the bolt 41 ft. Ibs. (55 Nm) Backing plate and hub assembly and torque the bolts to 37 ft. Ibs. (50 Nm) plus 30 degrees Rear drum/disc and torque the bolts to 35 inch Ibs. (4 Nm): Rear brake caliper and torque the bolts to 59 ft. Ibs. (80 Nm), if equipped Parking brake cable and support bracket and torque the bolts to 71 inch lbs. (8Nm) Brake line bracket to the control arm and torque the bolts to 71 inch lbs. (8 Nm) e Rear wheel 4. Check and adjust the alignment, as needed.

LOWER CONTROL ARM BUSHING REPLACEMENT 2.2L and 3.0L Engines 93062G72

Remove the lower control arm to frame bolts-2.2L and 3.0L engines

2. Remove or disconnect the following: e Wheel ¢ Ball stud bolt ->Use caution not do damage the Antilock Braking System (ABS) speed sensor ring. If the ring is damaged a malfunction of the ABS system is possible.

¢ Separate the ball stud from the Steering knuckle by using a pry bar ¢ Lower control arm to frame bolts ¢ Lower control arm To install: 3. Install or connect the following; ¢ Control arm to the frame and torque the new bolts to 65 ft. Ibs, (90 Nm) plus 75 degrees ¢ Ball stud to steering knuckle and torque the bolt to 75 ft. Ibs. (100 Nm) e Wheel ¢ Check and adjust the alignment, if necessary. Rear

2.2L AND 3.0L ENGINES 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: e Rear wheel e Rear brake hose and bracket from the control arm

¢ Caliper, if equipped ¢ Brake drum/rotor e Antilock Braking System (ABS) sensor harness, if equipped e Hub e Parking brake cable and support Separate the backing plate from the control arm ¢ Shock absorber to control arm bolt Rear stabilizer bar link to rear control arm bolt Loosen the rear suspension upper and lower control arm to rear axle fasteners Rear axle to control arm and discard the bolts Rear upper and lower suspensions control arm bolts and discard them Rear control arm To install: 3. Install or connect the following: ¢ Control arm and install new rear axle control arm bolts. Do not tighten them at this time Upper and lower rear suspension control arm bolts Torque the rear axle control arm bolts and the upper and lower rear Suspension bolts to 65 ft. Ibs. (90 Nm) plus 30 degrees Shock absorber to rear axle control arm and torque the new bolt to 110 ft. Ibs. (150 Nm) plus 30 degrees

FRONT 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: ¢ Control arm 3. Press out the front bushing by using Tools KM-508—-3 and KM508—1. 4. Drill out the rivets retaining the ball Stud to the control arm. 5. Remove the ball stud from the control, To install: ->The new ball stud is bolted to the control arm.

6. Install or connect the following: ¢ Ball stud to the control arm and torque the new bolts to 25 ft. Ibs. (35 Nm)

93062673

Press out the control arm bushing

LW SC1 °SC2¢SL¢SL1°SL2° Resie 32-59 6. Press in the new rear axle front control arm bushing using tools KM-671, KM906-42 and KM-906-43. 7. Press in the rear axle upper and lower control arm bushings with Bushing Removal Tools KM-671, KM-906-64 and KM-906-631. e Rear axle control arm bracket. Torque the new bolt to 69 ft. Ibs. (90 Nm) plus 60 degrees

Wheel Bearings

ADJUSTMENT The wheel bearing are sealed at the factory and do not require any adjustment or maintenance.

93062674

The new ball stud is bolted into the control arm-2.2L and 3.0L engines

7. Press in the new control arm bushing using Tools KM508—1, KM508-2 and

KM508-3. ¢ Control arm to the frame and torque the new bolts to 65 ft. Ibs. (90 Nm) plus 75 degrees e Ball stud to the steering knuckle

and torque the bolts to 75 ft. Ibs. (100 Nm)

REAR 1. Before servicing the vehicle, refer to the precautions in the beginning of this section.

2. Remove or disconnect the following: e Control arm and place it in a vise e Rear axle control arm bolt and discard it 3. Press out the rear axle upper and lower control arm bushings with Bushing Removal Tools KM-671—KM-906-62— and KM-906-61. 4 Press out the rear axle control arm front bushing with Bushing Removal Tools KM-671—KM-906-41 and KM-906-44. To install: 5. Install or connect the following:

WS)9 D> NN“OS

Sy) ive and lower bushings Remove the rear axle control arm upper

REMOVAL & INSTALLATION Front

7.9L ENGINES 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. If equipped with an Antilock Braking System (ABS), disconnect the negative battery cable. 3. Loosen the front halfshaft nut, while an assistant depresses the brake pedal, then raise and support the vehicle safely. 4. Remove or disconnect the following: Wheel Brake caliper mounting bracket bolts and suspend the assembly from the strut spring with wire Loosen the strut-to-knuckle bolts, but do not remove at this time Rotor, axle nut and washer Cotter pin from the lower control arm ball joint. Back the ball joint

79222839

93062675

Tighten the hub driver screw to remove the hub while the assembly is held firmly in a vise-1.9L engine

of this manual For Accessory Drive Belt illustrations, see Section 1

32-6

SATURN

LW ¢ SC1 ¢ SC2 © SL © SL1 © SL2 © SW1 © SW2 a. If equipped, remove the ABS wheel speed sensor from the knuckle. e>Any time the hub or bearing is separated from the steering knuckle, a new bearing must be used upon assembly.

79227840

Remove the bearing retainer snapring before pressing out the bearing—-1.9L engine

79227841

Carefully press the bearing out of the knuckle after removing the snapring—1.9L engine

nut until the top of the nut is even with the top of the threads ¢ Separate the lower control arm from the steering knuckle, then remove the nut. Do not use a wedge tool or seal damage may occur >The outer CV-joint for vehicles equipped with ABS contains a speed sensor ring. Use of an incorrect tool to separate the control arm from the knuckle may result in damage and loss of the ABS system.

¢ Tie rod cotter pin and castle nut, then separate the tie rod end from the knuckle ABS wheel speed sensor electrical connector Suspend the halfshaft from the body with wire, then remove the 2 knuckle-to-strut fasteners and remove the knuckle/hub assembly from the vehicle. If difficulty is encountered, position a block of wood on the end of the halfshaft and tap on the wood with a hammer to free the hub assembly 5. Disassemble the knuckle hub assembly as follows:

6. Install Wheel Bearing Removing Tools SA9159S, to the knuckle and secure the assembly in a vise. 7. Hold the hub driver with a wrench and tighten the hub driver screw to remove the hub. If the inner bearing race is pulled out with the hub, remove the race with a bearing race remover. 8. Remove the assembly from the vise and separate the wheel hub removal tool from the knuckle. 9. Remove the bearing retainer snapring. 10. Position the knuckle in a shop press on a knuckle support tube and press the bearing from the knuckle with a small driver. To install: 11. If necessary, assemble the knuckle hub assembly as follows: a. Use a large driver and press in the new bearing until seated. b. Use the small driver and the knuckle support tube to press in the hub assembly. The small driver must be used to support the bearing inner race with its small (pilot) side facing towards the press and away from the bearing. c. Install the bearing retainer Snapring. 12. Install the ABS wheel speed sensor into the knuckle. Torque the fastener to 72 inch Ibs. (8 Nm), if equipped. e» Service knuckles may not have holes for brake dust shield mounting. The dust shield is no longer required and does not have to be reinstalled. Also, should the shield become damaged, it may be removed; there is no need to repair or replace it. But, should a shield be removed and discarded, the Shield should also be removed from the opposite side to maintain balance/symmetry.

13. Thoroughly clean and lubricate the ball joint stud threads of the lower contro! arm and tie rod end. Install the knuckle/hub assembly onto the axle shaft. Then, install the washer with a new nut, but do not tighten the nut at this time. 14. Install or connect the following: ¢ Lower control arm ball stud through the knuckle bore and install the nut, but do not tighten at this time ¢ Steering knuckle-to-strut fasteners, but do not tighten at this time

Tie rod end and nut, then torque the nut to 33 ft. Ibs. (45 Nm) and install a new cotter pin. If necessary, tighten the nut additionally, do not back off to insert the cotter pin

Push inward on the bottom of the strut and torque the knuckle fasteners to 126 ft. Ibs. (170 Nm). Torque the lower control arm ball stud nut to 55 ft. Ibs. (75 Nm), tighten additionally, if necessary, and install a new cotter pin Rotor onto the hub, then install the caliper mount bracket onto the knuckle. Tighten the mount bracket assembly bolts to 81 ft. Ibs. (110 Nm). While an assistant depresses the brake pedal, tighten the halfshaft nut to 103 ft. Ibs. (140 Nm). Wheel assembly and lower the vehicle Negative battery cable 15. Check and adjust the alignment, if necessary.

2.2L AND 3.0L ENGINES 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. If equipped with an Antilock Braking System (ABS), disconnect the negative battery cable. 3. Loosen the front halfshaft nut, while an assistant depresses the brake pedal, then raise and support the vehicle safely. 4. Remove or disconnect the following: Wheel Brake caliper mounting bracket bolts and suspend the assembly from the strut spring with wire Brake rotor and dust shield ABS sensor and bracket, if equipped

93062676

Separate the axle from the wheel hub-2.2L and 3.0L engines

LW @ SC1 ¢ SC2 © SL ¢ Loosen the strut-to-knuckle bolts, but do not remove at this time e Axle to hub nut and discard it e Tie rod end nut and discard it 5. If difficulty is encountered, position a block of wood on the end of the halfshaft and tap on the wood with a hammer to free the hub assembly. e Steering knuckle/hub assembly 6. To remove the wheel bearing proceed, as follows: a. Install Wheel Bearing Removing Tools SA9159S, to the knuckle and secure the assembly in a vise. b. Hold the hub driver with a wrench and tighten the hub driver screw to remove the hub. If the inner bearing race is pulled out with the hub, remove the race with a bearing race remover. c. Remove the assembly from the vise and separate the wheel hub removal tool from the knuckle. d. Remove the bearing retainer snapring. e. Position the knuckle in a shop press on a knuckle support tube and press the bearing from the knuckle with a small driver. To install: 7. \f necessary, assemble the knuckle hub assembly, as follows: a. Use a Suitable large driver and press in the new bearing until seated. b. Use the small driver and the knuckle support tube to press in the hub assembly. The small driver must be used to support the bearing inner race with its small (pilot) side facing towards the press and away from the bearing. c. Install the bearing retainer snap ring. 8. Thoroughly clean and lubricate the ball joint stud threads of the lower control arm and tie rod end. 9. Install or connect the following: ¢ Knuckle/hub assembly onto the axle shaft. Then, install the washer

with a new nut, but do not tighten the nut at this time Lower control arm ball stud through the knuckle bore and install the nut, but do not tighten at this time Steering knuckle-to-strut fasteners. Torque the fasteners to 40 ft. IDS. (50 Nm); then, tc 65 ft. Ibs. (90 Nm) plus 45 degrees 10. Torque the bali stud fastener to 75 ft. lbs. (100 Nm).

Tie rod end into the steering knuckle using a Linkage Installer Too! J44015. Torque the fastener to 35 ft. Ibs. (45 Nm). ABS sensor and mounting bracket, if equipped and torque the bolts to

71 inch Ibs. (8 Nm). Dust shield and torque the bolts to 35 in Ibs. (4 Nm) Rotor and screw and torque the screw to 27 inch Ibs. (3.5 Nm) Caliper mount bracket onto the knuckle and torque the bolts to 70 ft. lbs. (90 Nm) Stabilizer bar link to the strut and torque the bolts to 50 ft. Ibs. (65 Nm) Wheel e Negative battery cable 11. Depress the brake pedal and torque the axle to hub nut, in the following

sequence: e Step 1: 85 ft. Ibs. (115 Nm) to seat the bearing. e Step 2: Back the nut off e Step 3: 15 ft. Ibs. (20 Nm). « Step 4: Turn the nut an additional 90 degrees, using a torque angle gauge 12. Install the cotter pin. 13. Check and adjust the alignment Rear

1.9L ENGINES Unlike the front wheel bearings, which may be removed from the hub for replace-

SL1 ® SL2 © area

32-61

ment, the rear wheel hub and bearing assembly is not serviceable. If damaged or worn, the hub and bearing assembly must be replaced as a unit. 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Negative battery cable, if equipped with an Antilock Braking System (ABS) Rear wheel ABS speed sensor connector, if equipped Caliper assembly-to-knuckle mounting bolts and support it with a wire from the strut, then remove the rotor, if equipped with disc brakes Brake drum, if equipped with drum brakes 4 hub/bearing-to-knuckle bolts, then remove the assembly from the vehicle To install: 3. Install or connect the following: e Brake backing plate, hub/bearing assembly and retaining bolts and torque the bolts to 63 ft. Ibs. (85 ~ Nm) Brake drum or rotor and caliper assembly and torque the caliper retaining bolts to 63 ft. Ibs. (85 Nm), if equipped e ABS speed sensor connector, if equipped e Brake drum, if equipped

79222842

brake set-up shown—1.9L engine Exploded view of the rear hub/bearing assembly—drum

1 of this manual For Tire, Wheel and Ball Joint specifications, see Section

32-6

SATURN LW ¢ SC1 © SC2 ¢ SL ¢ SL1 © SL2 © SW1 © SW2

e Brake rotor, if equipped ¢ Caliper to the steering knuckle, if equipped. Torque the bolts to 63 ft. lbs. (85 Nm). ¢ Rear wheel ¢ Negative battery cable

2.2L AND 3.0L ENGINES 1. Before servicing the vehicle, refer to the precautions in the beginning of this section. 2. Remove or disconnect the following: Negative battery cable, if equipped with an Antilock Braking System (ABS)

Rear wheel Brake line to rear axle control arm attaching clip, if equipped with rear

disc brakes

;

Caliper to steering knuckle bolts and move the caliper aside, if equipped with rear disc brakes

Brake drum/rotor ABS electrical connector, if equipped Hub to control arm nuts and discard them Hub To install: 3. Install or connect the following: Hub to control arm and torque the

new nuts to 35 ft. Ibs. (50 Nm) plus 30 degrees ABS electrical connector, if equipped Brake drum/rotor attaching screw and torque the screw to 35 inch lbs. (4 Nm) Brake caliper, if equipped and torque the bolts to 59 ft. Ibs. (80 Nm) Brake line to the rear axle control arm bracket, if equipped. Torque the bolt to 71 inch Ibs. (8 Nm). Rear wheel : Negative battery cable

GLOSSARY (CRESS

PRATT

BE

BT

ED

APTS EP

SAT

PE

ETS

IE

TT SD TSN EG TEPRIS TUT

PII

MAI IDES

EDEN

A SHEDSVSI

IN ROE ATU

33-1 STORES LTE

BeSEED

GLOSSARY ABS: Anti-lock braking system. An electro-mechanical braking system which is designed to minimize or prevent wheel lock-up during braking. ABSOLUTE PRESSURE: Atmospheric (barometric) pressure plus the pressure gauge reading. ACCELERATOR PUMP: A small pump located in the carburetor that feeds fuel into the air/fuel mixture during acceleration. ACCUMULATOR: A device that controls shift quality by cushioning the shock of hydraulic oil pressure being applied to a clutch or band. ACTUATING MECHANISM: The mechanical output devices of a hydraulic system, for example, clutch pistons and band servos. ACTUATOR: The output component of a hydraulic or electronic system. ADVANCE: Setting the ignition timing so that spark occurs earlier before the piston reaches top dead center (TDC). ADAPTIVE MEMORY (ADAPTIVE STRATEGY): The learning ability of the TCM or PCM to redefine its decision-making process to provide optimum shift quality. AFTER TOP DEAD CENTER (ATDC): The point after the piston reaches the top of its travel on the compression stroke. AIR BAG: Device on the inside of the car designed to inflate on impact of crash, protecting the occupants of the car. AIR CHARGE TEMPERATURE (ACT) SENSOR: The temperature of the airflow into the engine is measured by an ACT sensor, usually located in the lower intake manifold or air cleaner. ALDL (assembly line diagnostic link): Electrical connector for scanning ECM/PCM/TCM input and output devices. AIR CLEANER: An assembly consisting of a housing, filter and any connecting ductwork. The filter element is made up of a porous paper, sometimes with a wire mesh screening, and is designed to prevent airborne particles from entering the engine through the carburetor or throttle body. AIR INJECTION: One method of reducing harmful exhaust emissions by injecting air into each of the exhaust ports of an engine. The fresh air entering the hot exhaust manifold causes any remaining fuel to be burned before it can exit the tailpipe. AIR PUMP: An emission contro! device that supplies fresh air to the exhaust manifold to aid in more completely burning exhaust gases. AIR/FUEL RATIO: The ratio of air-to-gasoline by weight in the fuel mixture drawn into the engine. ALIGNMENT RACK: A special drive-on vehicle lift apparatus/measuring device used to adjust a vehicle's toe, caster and camber angles. ALL WHEEL DRIVE: Term used to describe a full time four wheel drive power system or any other vehicle drive system that continuously delivers vehicles wagon station on primarily found is system This wheels. four all to and SUVs not utilized for significant off road use. in one ~ ALTERNATING CURRENT (AC): Electric current that flows first flow. reversing ly continual direction, then in the opposite direction, which ALTERNATOR: A device which produces AC (alternating current) battery. car the charge to is converted to DC (direct current) measure the AMMETER: An instrument, calibrated in amperes, used to ed in connect always are s Ammeter flow of an electrical current in a circuit. tested. being circuit the series with in a circuit. AMPERAGE: The total amount of current (amperes) flowing the voite increas to circuit al electric an in used device A AMPLIFIER: age of an output signal. ability of a batAMP/HR. RATING (BATTERY): Measurement of the of time. The period stated a for tery to deliver a stated amount of current battery. the better the rating, higher the amp/hr. when one volt of AMPERE: The rate of flow of electrical current present resistance. al electric of ohm one against applied is e electrical pressur similar (analouses that or ANALOG COMPUTER: Any microprocess tions. calcula its make to s gous) electrical signal of aluminum ANODIZED: A special coating applied to the surface life. service valves for extended glycol) added to the ANTIFREEZE: A substance (ethylene or propylene . weather cold in g coolant to prevent freezin

ANTI-FOAM AGENTS: Minimize fluid foaming from the whipping action encountered in the converter and planetary action. ANTI-WEAR AGENTS: Zinc agents that control wear on the gears, bushings, and thrust washers. ANTI-LOCK BRAKING SYSTEM: A supplementary system to the base hydraulic system that prevents sustained lock-up of the wheels during braking as well as automatically controlling wheel slip. ANTI-ROLL BAR: See stabilizer bar. ARC: A flow of electricity through the air between two electrodes or contact points that produces a spark. ARMATURE: A laminated, soft iron core wrapped by a wire that converts electrical energy to mechanical energy as in a motor or relay. When rotated in a magnetic field, it changes mechanical energy into electrical energy as in a generator. ATDC: After Top Dead Center. ATF: Automatic transmission fluid. ATMOSPHERIC PRESSURE: The pressure on the Earth’s surface caused by the weight of the air in the atmosphere. At sea level, this pressure is 14.7 psi at 32°F (101 kPa at 0°C). ATOMIZATION: The breaking down of a liquid into a fine mist that can be suspended in air. AUXILIARY ADD-ON COOLER: A supplemental transmission fluid cooling device that is installed in series with the heat exchanger (cooler), located inside the radiator, to provide additional support to cool the hot fluid leaving the torque converter. AUXILIARY PRESSURE: An added fluid pressure that is introduced into a regulator or balanced valve system to control valve movement. The auxiliary pressure itself can be either a fixed or a variable value. (See balanced valve; regulator valve.) AWD: All wheel drive. AXIAL FORCE: A side or end thrust force acting in or along the same plane as the power flow. AXIAL PLAY: Movement parallel to a shaft or bearing bore. AXLE CAPACITY: The maximum load-carrying capacity of the axle itself, as specified by the manufacturer. This is usually a higher number than the GAWR. AXLE RATIO: This is a number (3.07:1, 4.56:1, for example) expressing the ratio between driveshaft revolutions and wheel revolutions. A low numerical ratio allows the engine to work easier because it doesn't have to turn as fast. A high numerical ratio means that the engine has to turn more rpm's to move the wheels through the same number of turns. BACKFIRE: The sudden combustion of gases in the intake or exhaust system that results in a loud explosion. BACKLASH: The clearance or play between two parts, such as meshed gears. BACKPRESSURE: Restrictions in the exhaust system that slow the exit of exhaust gases from the combustion chamber. BAKELITE®: A heat resistant, plastic insulator material commonly used in printed circuit boards and transistorized components. BALANCED VALVE: A valve that is positioned by opposing auxiliary regulahydraulic pressures and/or spring force. Examples include mainline valve.) regulator (See valves. governor and tor, throttle, BAND: A flexible ring of steel with an inner lining of friction material. is held When tightened around the outside of a drum, a planetary member case. stationary to the transmission/transaxle races BALL BEARING: A bearing made up of hardened inner and outer roll. balls between which hardened steel on comBALL JOINT: A ball and matching socket connecting Suspensi moverotating permits It arms). control ponents (steering knuckle to lower joined. are that nts compone the between direction any in ment the change BARO (BAROMETRIC PRESSURE SENSOR): Measures altitude. in changes by caused pressure manifold intake in the SENBAROMETRIC MANIFOLD ABSOLUTE PRESSURE (BMAP)

33-2 ESR

SB

GLOSSARY RST

GBA

DEAT

PR

SN

SOR: Operates similarly to a conventional MAP sensor: reads intake manifold pressure and is also responsible for determining altitude and barometric pressure prior to engine operation. BAROMETRIC PRESSURE: (See atmospheric pressure.) BALLAST RESISTOR: A resistor in the primary ignition circuit that lowers voltage after the engine is started to reduce wear on ignition components, BATTERY: A direct current electrical storage unit, consisting of the basic active materials of lead and sulfuric acid, which converts chemical energy into electrical energy. Used to provide current for the operation of the starter as well as other equipment, such as the radio, lighting, etc. BEAD: The portion of a tire that holds it on the rim. BEARING: A friction reducing, supportive device usually located between a stationary part and a moving part. BEFORE TOP DEAD CENTER (BTDC): The point just before the piston reaches the top of its travel on the compression stroke. BELTED TIRE: Tire construction similar to bias-ply tires, but using two or more layers of reinforced belts between body plies and the tread. BEZEL: Piece of metal surrounding radio, headlights, gauges or similar components; sometimes used to hold the glass face of a gauge in the dash. BIAS-PLY TIRE: Tire construction, using body ply reinforcing cords which run at alternating angles to the center line of the tread. BI-METAL TEMPERATURE SENSOR: Any sensor or switch made of two dissimilar types of metal that bend when heated or cooled due to the different expansion rates of the alloys. These types of sensors usually function as an on/off switch. BLOCK: See Engine Block. BLOW-BY: Combustion gases, composed of water vapor and unburned fuel, that leak past the piston rings into the crankcase during normal engine operation. These gases are removed by the PCV system to prevent the buildup of harmful acids in the crankcase. BOOK TIME: See Labor Time. BOOK VALUE: The average value of a car, widely used to determine trade-in and resale value. BOOST VALVE: Used at the base of the regu ator valve to increase mainline pressure. BORE: Diameter of a cylinder. BRAKE CALIPER: The housing that fits over the brake disc. The caliper holds the brake pads, which are pressed against the discs by the caliper pistons when the brake pedal is depressed. BRAKE HORSEPOWER(BHP): The actual horsepower available at the engine flywheel as measured by a dynamometer. BRAKE FADE: Loss of braking power, usually caused by excessive heat after repeated brake applications. BRAKE HORSEPOWER: Usable horsepower of an engine measured at the crankshaft. BRAKE PAD: A brake shoe and lining assembly used with disc brakes. BRAKE PROPORTIONING VALVE: A valve on the master cylinder which restricts hydraulic brake pressure to the wheels to a specified amount, preventing wheel lock-up. BREAKAWAY: Often used by Chrysler to identify first-gear operation in D and 2 ranges. In these ranges, first-gear operation depends on a one-way roller clutch that holds on acceleration and releases (breaks away) on deceleration, resulting in a freewheeling coast-down condition. BRAKE SHOE: The backing for the brake lining. The term is, however, usually applied to the assembly of the brake backing and lining. BREAKER POINTS: A set of points inside the distributor, operated bya cam, which make and break the ignition circuit. BRINNELLING: A wear pattern identified by a series of indentations at regular intervals. This condition is caused by a lack of lube, overload situations, and/or vibrations. BTDC: Before Top Dead Center. BUMP: Sudden and forceful apply of a clutch or band. BUSHING: A liner, usually removable, for a bearing; an anti-friction liner used in place of a bearing. CALIFORNIA ENGINE: An engine certified by the EPA for use in California only; conforms to more stringent emission regulations than Federal engine.

I

EFS

DOS

EOE BE TSE NT

TE

LD

2 ET

ET

CALIPER: A hydraulically activated device in a disc brake system, which is mounted straddling the brake rotor (disc). The caliper contains at least one piston and two brake pads. Hydraulic pressure on the piston(s) forces the pads against the rotor. : CAPACITY: The quantity of electricity that can be delivered from a unit, as from a battery in ampere-hours, or output, as from a generator. CAMBER: One of the factors of wheel alignment. Viewed from the front of the car, it is the inward or outward tilt of the wheel. The top of the tire will lean outward (positive camber) or inward (negative camber). CAMSHAFT: A shaft in the engine on which are the lobes (cams) which operate the valves. The camshaft is driven by the crankshaft, via a belt, chain or gears, at one half the crankshaft speed. CAPACITOR: A device which stores an electrical charge.

CARBON MONOXIDE (CO): A colorless, odorless gas given off as a normal byproduct of combustion. It is poisonous and extremely dangerous in confined areas, building up slowly to toxic levels without warning if adequate ventilation is not available. CARBURETOR: A device, usually mounted on the intake manifold of an engine, which mixes the air and fuel in the proper proportion to allow even combustion. CASTER: The forward or rearward tilt of an imaginary line drawn through the upper ball joint and the center of the wheel. Viewed from the sides, positive caster (forward tilt) lends directional stability, while negative caster (rearward tilt) produces instability. CATALYTIC CONVERTER: A device installed in the exhaust system, like a muffler, that converts harmful byproducts of combustion into carbon dioxide and water vapor by means of a heat-producing chemical reaction. CENTRIFUGAL ADVANCE: A mechanical method of advancing the spark timing by using flyweights in the distributor that react to centrifugal force generated by the distributor shaft rotation. CENTRIFUGAL FORCE: The outward pull of a revolving object, away from the center of revolution. Centrifugal force increases with the speed of rotation. CETANE RATING: A measure of the ignition value of diesel fuel. The higher the cetane rating, the better the fuel. Diesel fuel cetane rating is roughly comparable to gasoline octane rating. CHECK VALVE: Any one-way valve installed to permit the flow of air, fuel or vacuum in one direction only. j CHOKE: The valve/plate that restricts the amount of air entering an engine on the induction stroke, thereby enriching the air/fuel ratio. CHUGGLE: Bucking or jerking condition that may be engine related and may be most noticeable when converter clutch is engaged; similar to the feel of towing a trailer. CIRCLIP: A split steel snapring that fits into a groove to hold various parts in place. CIRCUIT BREAKER: A switch which protects an electrical circuit from overload by opening the circuit when the current flow exceeds a pre-determined level. Some circuit breakers must be reset manually, while most reset automatically, CIRCUIT: Any unbroken path through which an electrical current can flow. Also used to describe fuel flow in some instances. CIRCUIT, BYPASS: Another circuit in parallel with the major circuit through which power is diverted. CIRCUIT, CLOSED: An electrical circuit in which there is no interruption of current flow. CIRCUIT, GROUND: The non-insulated portion of a complete circuit used as a common potential point. In automotive circuits, the ground is composed of metal parts, such as the engine, body sheet metal, and frame and is usually a negative potential. . CIRCUIT, HOT: That portion of a circuit not at ground potential. The hot ee is usually insulated and is connected to the positive side of the batery. . CIRCUIT, OPEN: A break or lack of contact in an electrical circuit, either intentional (switch) or unintentional (bad connection or broken wire). CIRCUIT, PARALLEL: A circuit having two or more paths for current low with common positive and negative tie points. The same voltage is applied to each load device or parallel branch. CIRCUIT, SERIES: An electrical system in which separate parts are

GLOSSARY SE

A

PS

NATE

BNE

NTRS SSS

A SSAA

I

RL

TN

ade: end to end, using one wire, to form a single path for current to Ow. CIRCUIT, SHORT: A circuit that is accidentally completed in an electrical path for which it was not intended. CLAMPING (ISOLATION) DIODES: Diodes positioned in a circuit to prevent self-induction from damaging electronic components. CLEARCOAT: A transparent layer which, when sprayed over a vehicle's paint job, adds gloss and depth as well as an additional protective coating to the finish. CLUTCH: Part of the power train used to connect/disconnect power to the rear wheels. CLUTCH, FLUID: The same as a fluid coupling. A fluid clutch or coupling performs the same function as a friction clutch by utilizing fluid friction and inertia as opposed to solid friction used by a friction clutch. (See fluid coupling.) CLUTCH, FRICTION: A coupling device that provides a means of smooth and positive engagement and disengagement of engine torque to the vehicle powertrain. Transmission of power through the clutch is accomplished by bringing one or more rotating drive members into contact with complementing driven members. COAST: Vehicle deceleration caused by engine braking conditions. COEFFICIENT OF FRICTION: The amount of surface tension between {wo contacting surfaces; identified by a scientifically calculated number. COIL: Part of the ignition system that boosts the relatively low voltage supplied by the car's electrical system to the high voltage required to fire the spark plugs. COMBINATION MANIFOLD: An assembly which includes both the intake and exhaust manifolds in one casting. COMBINATION VALVE: A device used in some fuel systems that routes fuel vapors to a charcoal storage canister instead of venting them into the atmosphere. The valve relieves fuel tank pressure and allows fresh air into the tank as the fuel level drops to prevent a vapor lock situation.

COMBUSTION CHAMBER: The part of the engine in the cylinder head where combustion takes place. COMPOUND GEAR: A gear consisting of two or more simple gears with a common shaft. COMPOUND PLANETARY: A gearset that has more than the three elements found in a simple gearset and is constructed by combining members of two planetary gearsets to create additional gear ratio possibilities. COMPRESSION CHECK: A test involving removing each spark plug and inserting a gauge. When the engine is cranked, the gauge will record a pressure reading in the individual cylinder. General operating condition can be determined from a compression check. COMPRESSION RATIO: The ratio of the volume between the piston and cylinder head when the piston is at the bottom of its stroke (bottom dead center) and when the piston is at the top of its stroke (top dead center). COMPUTER: An electronic contro! module that correlates input data according to prearranged engineered instructions; used for the management of an actuator system or systems.

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An electrical device which acts to store an electrical charge, preventing . é voltage surges. refrigerwhich in system ing condition 9M radiator-like device in the air ant gas condenses into a liquid, giving off heat. be CONDUCTOR: Any material through which an electrical current can transmitted easily. and CONNECTING ROD: The connecting link between the crankshaft iston. CONSTANT VELOCITY JOINT: Type of universal joint in a halfshaft velocity assembly in which the output shaft turns at a constant =